Z&F Consulting provided Front End Loading (FEL) 1, 2, and 3 engineering services for a new 16 MW cogeneration plant located on site at an oil refinery in Newell, West Virginia. Z&F’s role included engineering through FEL 3 and multiple rounds of construction schedules and cost estimates. The project included plans to demolish an existing building to make way for the cogeneration site, a 15 MW natural gas combustion turbine, integrating a 120,000 PPH, 300 PSI waste heat steam boiler into an existing steam system, dual gas compressors, and a 300 ton absorption chiller. The site’s existing electrical infrastructure included outdated and overloaded distribution switchgear, and the owner decided to add to Z&Fs original scope and replace the main switchgear for the entire refinery as part of the project. Z&F also worked with the local electrical utility provider and designed new interconnection safeties at the main electrical connection to allow for the export of power to the grid. One main challenge for the entire project was the site only had one full shut down planned for connection of all the new equipment and electrical infrastructure. Z&F’s design was able to work with the lead time of electrical gear and the window available for shutdown and tie in work, to allow the project to fit with the overall site schedule. Additionally, Z&F worked with the owner’s air permitting consultants throughout the project to ensure the project was able to be permitted without the use of expensive emissions controls equipment.