Burlington 69kv Interconnection and Substation
Carr & Duff was selected as the design-build contractor to construct a 69kv – 12.47kv 15MVA substation and 69kv utility interconnection to the sub-transmission grid. The project was the first customer owned 69kv sub-transmission substation interconnected to the local utility’s system. The new substation was constructed to support a 1.05 million square-foot national retailer’s distribution facility on a 72-acre site in Logan Township, NJ.
C&D began the project with site civil grading and concrete construction of foundations and equipment pads. A transformer retention pad and blast wall were constructed, as well as 48” diameter caissons drilled and poured to a depth of 25 feet to support the dead-end structure.
After site work and the ground grid was completed, C&D crews began installing the steel supports and other equipment. A dead-end structure was constructed with provisions for a 72.5kv hook-operated bypass switch and a 72.5kv manual operated vertical break disconnect switch.
C&D was also responsible for assisting with the design, procurement and installation of the customer 15kv infrastructure from the new substation to the building. The facility had five separate radial feeders to four outdoor 15kv switches and padmount transformers as well as one indoor 15kv switch and unit substation. C&D was responsible for installation of duct banks, 15kv cabling, terminations, equipment installations and start-up and commissioning of the equipment.
The 69kv – 12.47kv 15MVA transformer, SF6 breaker, PTs, Automatic Transfer Switch, battery cabinet, low voltage power center and relay cabinet all arrived in the summer of 2023. C&D crews made quick work of assembly and installations – to hit a target of end of November 1st, 2023, energizing date with the utility.
C&D was also responsible for design assist, procurement and installation of the 15kv primary service switchgear installation ahead of the radial feeders. Working with the owner’s construction group for their future generator plans, C&D was able to design and install custom 15kv duplex switchgear with relay protection and operational controls. The gear was also constructed with an extra future section of isolated switchgear and distribution tap boxes, for ease and safety the future generator expansion installations. C&D was responsible for design-assist and installation of all the telemetry, relay protection and functional controls of the substation equipment. SEL relays were interconnected with fiber-topic cabling installed by C&D.
The $6.1 million dollar design-build 69kv interconnection and substation project was completed on-time, safely and much to the satisfaction of the construction management team.
