Substation Construction to Support Renewable Energy via an On-shore Wind Farm

A Midwestern power company serving multiple states through nearly 30,000 miles of power lines and 13,000 miles of natural gas systems, is in a quest to provide 100% renewable energy to their customers. Wind energy is a growing power source for our client and now accounts for more than 60% of their generation capacity.

To help support their growing renewable energy portfolio, PFES managed a $17M substation construction project for our client which included the installation of a new interconnection substation and a new collector substation for a large onshore wind farm.

As part of the project, two 34.5kV-345kV 200MVA transformers and a 345kV ring bus with three breakers were installed, coordinated with the adjoining utility, and upgraded line relaying at the remote end substations.

Our Approach

PFES managed the project’s scope from the initiation phase through the contractor’s design of the interconnection substation, the collector substation, and the remote end line relaying. We also oversaw substation construction and construction of the remote ends as well as directed substation terminations. Additionally, we handled construction means and methods, approvals, weekly team reporting, monthly project reporting, project executive leadership meetings, maintenance, and closeout of the project files.

The project was successful with the implementation of field observations which were used to confirm compliance with design specification and construction installation standards, and the project achieved the required In-Service Date (ISD) without any safety accidents and/or injuries.

Major Project Tasks:

• Created project estimates, and budget and applied for funding
• Coordinated with the client and utility
• Ensured adherence to the project schedule
• Replaced line terminals and upgraded relaying at the remote end substation
• Buried fiber optic cable for relay and SCADA communication
• For the interconnection substation:
• Design and site preparation for the ground grid, yard rock, and security fencing in the yard
• Below-grade control ducts, manhole systems, foundations, etc.
• All substation structures and equipment including bus supports, dead-end structures, switch stands, disconnect switches, instrument transformers, arresters, lightning masts, shield wires, and circuit breakers
• 345kV three-breaker ring bus with connections to two substations
• 345kV SSVT for station service
• Control enclosure for indoor systems and equipment
• Install relaying, SCADA, and communication equipment
• For the collector substation:
• Design and site preparation for the ground grid, yard rock, and security fencing in the yard for the collector substation
• Below-grade control ducts, manhole systems, foundations, etc.
• All substation structures and equipment including bus supports, dead-end structures, switch stands, disconnect switches, instrument transformers, arresters, lightning masts, shield wires, capacitor banks, and circuit breakers
• Two 34.5kV 18-unit switchgear
• Two 34.5kV-345kV transformers
• Two 345kV circuit breakers

Critical Success Factors:

• Completing the project by In-Service Date (ISD) accommodates the interconnection customer’s request to MISO for one interconnection point and complies with the MISO interconnection process
• Fulfilling requirements in the Generator Interconnection Agreement with the interconnection customer and providing reliable service
• Executing the work described in the project scope without any significant additions
• Ensuring all work is performed safely, following proper switching procedures and safety guidelines
• Completing the work without any environmental incidents or unintended outages, by the schedule and within the authorized expenditures

The Perfect Partner for Substation Construction

Our team consists of industry heavyweights who bring substantial expertise to our clients. We collaborate with you to minimize risk and uncertainty in your capital projects, ensuring timely delivery of initiatives that provide significant cost savings while adhering to industry and safety standards.

At PFES, our Capital Projects services are the cornerstone of our mission to deliver strategic consulting that achieves powerful results. Contact us today to find out how we can help.