Petersburg coal-to-gas conversion project | CDM Smith

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Industrial plant with large smokestacks emitting steam, surrounded by equipment and a red storage building on a clear day.

Industrial plant with large smokestacks emitting steam, surrounded by equipment and a red storage building on a clear day.

Petersburg coal-to-gas conversion project

To help AES Indiana’s Petersburg power station transition from coal to cleaner natural gas, we’re providing engineering, procurement and construction to support emissions reductions and energy efficiency.

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Petersburg coal-to-gas conversion project

Client

AES Indiana

Location

Petersburg, Indiana

Practices

Construction Mechanical, Electrical and Plumbing (MEP)

Markets

Electric and Gas Utilities

Priorities

Energy and Power

Connect with an expert

Jim Calderone, PE, DBIA

Director of Design-Build

Helping AES Indiana evolve its fueling sources

To reduce carbon intensity while maintaining reliable generation, AES Indiana advanced a coal-to-natural-gas conversion at its Petersburg Generating Station. After securing regulatory approval, the utility moved forward with repowering Units 3 and 4. CDM Smith was selected to provide engineering, procurement and construction services for the balance-of-plant systems, by our long standing partner Babcock & Wilcox (B&W), helping them support a smooth transition to natural gas and long-term operational performance.

Deliver balance of plant engineering

We have completed the detailed engineering and design for the balance-of-plant modifications required to support the conversion from coal to natural gas and are currently moving into the Unit 3 Outage.

Issue construction ready designs

The team issued construction drawings and supported early design packages to advance the project from engineering into full construction.

Client

AES Indiana

Location

Petersburg, Indiana

Practices

Construction Mechanical, Electrical and Plumbing (MEP)

Markets

Electric and Gas Utilities

Priorities

Energy and Power

Connect with an expert

Jim Calderone, PE, DBIA

Director of Design-Build

Let’s Build Something Together

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Procure long lead equipment

CDM Smith procured critical long-lead equipment and materials to support schedule certainty as the project transitioned into construction. This included large gas heaters, scrubbers and process piping.

Support gas firing and NOₓ control

CDM Smith is supporting flue gas recirculation systems and associated infrastructure needed for gas firing and NOₓ reduction at the station.

With full notice to proceed received in August 2025, CDM Smith is advancing construction of the Petersburg coal-to-gas conversion project, a milestone in the plant’s repowering effort. The transition will deliver cleaner energy, cost-effective operations and a significant reduction in coal combustion at an investor-owned utility. Natural gas is planned to replace most of the fuel mix and is part of a broader strategy to enhance energy reliability and environmental performance while maintaining local workforce support. As James Calderone, our director of design-build services, explains, “Achieving this key milestone demonstrates our ability to drive the schedule forward on critical balance of plant infrastructure and support our partners with today’s vital energy projects.”

Curious to learn more?

Connect with an expert to find out how we delivered this project.

Jim Calderone, PE, DBIA

Director of Design-Build

Jim has experience in engineering, construction, and design-build for industrial and power clients, overseeing completion of all industrial design-build projects.

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