Confidential Coal Boiler Replacement Project

Though we were initially brought in to supplement an existing CM's staff, our client quickly recognized our expertise and asked us to take the entire project over by May 2020, which, at that point, was four months behind schedule.

• Phase 1 consisted of the demolition of existing coal boilers and infrastructure supporting them. Three of the existing boilers remained online to meet the demands of the active pharmaceutical site. Next, two new 3,500 horsepower natural gas boilers were installed along with supporting infrastructure to meet EPA requirements.
• Phase 2 was supplying the two new gas boilers and one existing boiler with a backup fuel source to combat the risk of a natural gas shortage. The project installed three 20,000-gallon diesel storage tanks and all associated project controls, piping, leak detection, and required civil and structural upgrades.
• Phase 3 was decommissioning the remaining three coil boilers once the installation of the two new gas boilers was complete, tested, verified, and accepted by operations.

Our team eventually grew to one project director and three project managers, who quickly learned our client's policies and procedures and were then able to showcase our value-add services in several ways:

• CSM Group re-sequenced and consolidated the existing project schedule, which showed completion in April 2021. Through proper scheduling, sequencing, logic, and resource management, CSM Group reduced the duration of the schedule by approximately four months, and the system began commissioning sequences in November 2021.
• CSM Group provided constructibility and value engineering ideas related to piping routes throughout the process, which avoided a six-figure expenditure and long lead times for structural steel supports.
• CSM Group reviewed all CO/CRs for the project and, in one case, produced a savings of $287,000 on a steel fabrication/erection Change Order by managing the same scope on a Time and Materials basis.
• The costs for CSM Group's services were offset entirely by the price and schedule savings we provided through our experienced management.

This project received our client's most prestigious award across their global network in 2021 for its impact on the business and successful execution.