Multiple EPC Substation Projects

Location: New Jersey

Client: Public Service Electric & Gas

Completion Date: Ongoing

To facilitate aggressive project schedules, Public Service Electric & Gas (PSE&G) has selected Burns & McDonnell as engineer-procure-construct (EPC) contractor. Burns & McDonnell is engaged in a number of PSE&G EPC projects and is using an approach that cuts months from the typical project cycle. Other services provided for PSE&G include parallel scoping, preliminary design, detailed engineering, procurement and construction activities. The Burns & McDonnell EPC approach has resulted in on-time schedules, working around critical outage windows. Burns & McDonnell works closely with PSE&G to prequalify and select subcontractors and suppliers.

  • Engineering
  • Procurement
  • Construction management

Recent PSE&G EPC projects include:

Essex Switching Station

At Essex Switching Station, Burns & McDonnell is working on a 138-kV reactor bypass project to increase system transfer capability. Due to space constraints, single-phase candlestick power circuit breakers were installed immediately adjacent to 138-kV series reactors. A helical pile system with spread footer foundations helps mitigate poor soils, clearance issues and limited outage times. Each new breaker was installed, wired, connected and commissioned in one week.

Burlington Substation

Due to an upcoming generation facility demolition project containing substation controls, an existing 26-kV substation protection and controls system that services 18 feeders, transformers and tie breakers required replacement. Burns & McDonnell provided a single-piece, 16-foot by 50-foot control enclosure, complete with relay panels and AC/DC systems. Abandoned transformer pads used required close coordination with the enclosure manufacturer. New trench cable was installed throughout the substation as the backbone of the raceway system from the enclosure to existing breakers, instrument transformers and station service equipment.

Branchburg Switching Station

With existing, derated transformer banks and increasing transfer capacity demands, two banks of 500-kV/230-kV autotransformers were scheduled for replacement. Working with PSE&G and its transformer vendors, Burns & McDonnell designed, procured and installed all adjacent facilities to support the replacement project. Each bank was allowed a five-week outage. Within that timeframe, Burns & McDonnell worked nights, weekends and holidays to complete the project on time. Services included removing existing transformers from the pads, removing existing rock, adding containment liners, adding new conduit and grounding, modifying jacking pads, assembling new unit sets, installing new rock, making high-voltage connections, terminating low-voltage cables, upgrading the protection system, and testing and commissioning all components.

In conjunction with the transformer replacement projects to increase capacity of Branchburg Switching Station, Burns & McDonnell upgraded the 230-kV ring bus configuration to handle this additional capacity. The bus ring was upgraded to meet a substantial 4000A continuous and 50kA short-circuit rating. Burns & McDonnell designed, procured and installed all new equipment required, including the replacement of five circuit breakers, 14 disconnect switches, coupling capacitor voltage transformers, surge arresters, bus, insulators and other high-voltage equipment.

Burns & McDonnell also expanded the 230-kV ring bus configuration to handle an additional line position and split an existing capacitor bank from its existing line position. Burns & McDonnell designed, procured and installed all new equipment required, including two new circuit breakers, 11 disconnect switches at three different locations, coupling capacitor voltage transformers, surge arresters, bus, insulators and other high-voltage equipment. Burns & McDonnell also upgraded the relaying for nine line positions and one capacitor bank for four substations to accommodate new transmission line routing.

New Freedom Switching Station

Working with PSE&G and its transformer vendors, Burns & McDonnell designed, procured and installed all adjacent facilities to support the addition of a fourth transformer bank. The scope of work included installing three single-phase, 500-kV/230-kV autotransformers; adding a new bay with two 500-kV circuit breakers in the 500-kV yard; adding one 230-kV circuit breaker in an existing bay in the 230-kV yard; replacing two over-burdened, 230-kV circuit breakers; replacing a new station, light, power transformer, switchgear, 500-kV and 230-kV A-frames, and oil containment for the new bank; and replacing and adding relays to support the new bank and breakers.

Miscellaneous Projects

Other PSE&G EPC projects include breaker, switch and circuit switcher replacements; line terminal upgrades; and other retrofit and new construction.