Location: Hillsboro, North Dakota
Client: American Crystal Sugar Company (ACSC)
Facility Type: Sugar processing and steam generation plant
Project Background
American Crystal Sugar Company (ACSC) operates multiple large-scale sugar processing facilities across the Red River Valley. Steam generation is a critical utility within the plant, supporting evaporation, crystallization, and other core processing operations. Reliable boiler performance is essential to maintaining production throughput during the processing campaign.
During inspection and maintenance planning, the facility identified deterioration and wear within one of the boiler economizers. The economizer recovers heat from boiler exhaust gases to preheat feedwater, improving efficiency and reducing fuel consumption. Due to age and service conditions, the unit required replacement prior to campaign startup to prevent efficiency loss or potential failure during production.
Because the project involved pressure-related equipment, tight outage timing, and coordination with boiler inspectors, the facility required a contractor with qualified welding procedures, experienced boilermakers, and documented repair capabilities. NorMinn Industrial was selected to support the economizer replacement.
Project Challenge
The economizer replacement presented several challenges:
- The work had to be completed during a scheduled outage window.
- Removal required working in elevated and restricted boiler house areas.
- The component was large and heavy, requiring engineered rigging.
- Installation required precision fit-up to existing boiler connections.
- Welding and connections had to meet code and inspection requirements.
- Startup deadlines were fixed ahead of the processing campaign.
Improper installation or delayed completion could impact boiler startup and delay plant operations. The project required careful coordination with plant maintenance, engineering, and authorized inspectors.
Project Solution
NorMinn Industrial mobilized a crew of experienced boilermakers, pipefitters, and certified welders to complete the economizer replacement.
Scope of work included:
- Isolation and preparation of the boiler system.
- Removal of the existing economizer assembly.
- Structural modifications and support adjustments.
- Rigging and placement of the new economizer.
- Precision alignment and connection to existing piping.
- Code-compliant welding procedures.
- Coordination with inspection personnel.
- Final tie-ins and preparation for startup.
NorMinn developed a rigging and installation plan to safely remove the existing unit and install the replacement within the confined boiler structure. The crew worked closely with plant personnel to maintain the schedule and inspection requirements.
All welding and installation activities were performed using qualified procedures and documented to support inspection and plant startup.
Project Result
The economizer replacement was completed within the scheduled outage, and the boiler was returned to service for the processing campaign.
Project outcomes:
- Safe project execution.
- Successful inspection and acceptance.
- Boiler startup on schedule.
- Restored heat recovery efficiency.
- Reduced risk of in-season equipment failure.
Following startup, the boiler operated as intended with proper feedwater heating and improved reliability heading into the production campaign.
How NorMinn Achieved the Result
NorMinn’s success was driven by:
- Experienced boilermaker crews.
- Qualified welding procedures.
- Coordination with inspectors and plant maintenance.
- Detailed outage planning.
- Rigging and heavy installation experience.
- Strong safety practices.
This project demonstrated NorMinn Industrial’s capability to perform work on critical steam system components where reliability and schedule adherence are essential.