West Fremont 138-kV Substation

Location: Fremont, Ohio

Client: First Energy Corp.

Completion Date: 2004

Burns & McDonnell performed substation engineering, procurement, and construction for the new West Fremont 138-kV substation.  This substation was a 15-breaker, 10-position breaker-and-a-half scheme, for a new combined cycle power plant for Calpine Corporation in Fremont, Ohio.

  • Engineering
  • Procurement
  • Construction Commissioning
  • Construction Management

Burns & McDonnell worked with First Energy at the conception of the project to develop a new 138-kV layout, which would maximize the space available for the substation. The layout established became the new FE standard for 138-kV breaker-and-a-half stations.


Burns & McDonnell was responsible for all phases of design including foundations, raceway, grounding, control building, one lines, schematics and wiring diagrams. The project involved the complete design, procurement and construction of the substation. Burns & McDonnell was involved with reviewing vendor drawings and incorporating final vendor drawings into the construction packages. The line and bus protection included SEL-321, SEL-311B, SEL-311C, SEL-501, SEL-387, PVD, and KAB relays. Burns & McDonnell also developed detailed schematics and wiring diagrams for the entire project.


Burns & McDonnell coordinated all construction activities with Calpine and provided regular updates on progress to First Energy. The project was completed in 6 months and the first lines were energized on schedule.