Overview GARDNER ZEMKE was awarded the prime contract for two Lackland Air Force Base projects in excess of $ 12,000,000. The first, and largest, is the installation of two 4MW co-generation systems. The turbines weighed 80,000 lbs. each, were jacked and rolled into place in the existing generator building while the plant remained in full operation. Next we had to move in the boilers, which were mounted on a mezzanine directly over the turbines, and therefore had to be brought in through the roof. This was accomplished by the removal of a 50’ x 30’ section of the roof.

The second project is the repair of emergency power to Wilford Hall Hospital, which was a $ 1,900,000 upgrade to the medical center’s total energy plant.

Details This multifaceted project included the demolition of two existing 1500kW diesel generators, two steam boilers, and all associated ducting and cabling. The equipment was replaced with two 4MW dual fuel turbine generators and all appurtenances including new heat recovery steam boilers, evaporative coolers, lube oil coolers, exhaust and inlet stacks, and new de-aerator. Demolition included two switchgear lineups replaced with 5kV generator switchgear and 15kV paralleling switchgear. Electrical installation included 5,000 KVA transformers, unit substation, motor control centers, etc. The plant was updated with a SCADA system with automatic controls. Most of the work was performed with the plant fully operational with only brief outages. Major changes were required to the existing structure, including relocation of roof members to accommodate new equipment, erection of a new mezzanine and access grating platforms, and construction of a new addition to the soundproof control room.

This project also involved replacing three existing 300kW generators with three 600kW generators. It included the construction of a new generator building with three 600KW generators and paralleling switchgear. Also included is the expansion of the medical center’s electric room, which houses the new emergency switchgear, over 7,500’ of 250 MCM, up to 4-conductor armored cable, and 35,000’ of 500 MCM, 600V cable.