Power Construction

The Grasslands Substation project called on E-J Electric to provide the complete "above grade" electrical package. The work within this scope included the rigging and placement of switchgear, a complete 3000A/4500A bus duct system, installation and termination of all control and power cables, placement and wiring of all control room equipment, (2) 500kVA station power transformers, complete fire alarm system, complete public address/paging system and completion of two 138kV/13.8kV transformer bays which included welding of cable bus, installation and adjustment of circuit switchers and circuit interrupters and all 125VDC control devices.

The station was completed on an aggressive schedule, made challenging by one of the areas most severe winters. This was the first time that Consolidated Edison Co. contracted this complete scope of work.

When 345,000 volt Con Edison cables required repair and replacement, E-J Electric Installation received the call from Pirelli, a leading international manufacturer of high voltage cable. They needed a contractor who had the ability to provide experienced electricians and the corporate agility that such a complex project demanded. The project called for using liquid nitrogen to freeze both ends of a 10" pipe filled with insulating oil, cutting out pipe sections replacing and splicing the cable. With the new 345kV cable in place, testing was performed and the cable returned to service. Delays were "not an option".

E-J prepared, at 7 World Trade Center, the space for the Con Ed utility substation including five 138kV transformers. The work consisted of providing temporary service of 4,000 amps for initial and future phases of construction. E-J also installed nine miles of conduit for medium-voltage and high-voltage distribution duct banks and installed 8-ft by 8-ft horizontal ground plates with cad-welded conductors as well as ground rods, to provide complete building lightning protection and grounding system. All grounding was tested to exacting Con Edison "Fall of Potential" specifications.

Installation of (6) 27kV vaults and network compartments servicing Brooklyn Army Terminal including (3) 2500kVA transformers with associated collector bus, network protectors, switchgear and feeders, ventilation control and alarm systems.

The upgrade of this existing active 13.2kV Con Ed Substation consisted of receiving, rigging and setting new sections of 13.2kV switchgear, making bus ties between existing and new switchgear and performing welding of switchgear enclosures as required. The work was performed on a 24-hour/day basis during Con Ed shutdown and was completed ahead of schedule.

The project included 3,600 LF of 138kV transmission line from the Astoria Energy 500MW Power Plant to the Consolidated Edison Astoria East Substation.

The line consisted of 4 spans of double-circuit 1590 MCM ACSR overhead transmission line conductor on tubular steel towers and 1,700 LF of 12 - 2000 MCM solid die-electric cable (2 cables per phase) double-circuit encased 138kV underground transmission.

Both the overhead line and duct have provisions for a future circuit to be added.

A notable feature were the side by side 108' tall transition towers where the overhead conductor was terminated and connected to the underground cable using 12 G&W oil-filled 138kV potheads.

The work at the NYPA500 project included the erection, installation, and testing of (2) 200MVA GSU, (1) 234MVA GSU, and (2) auxiliary transformers, in addition to the installation and testing of (1) isolation transformer and (3) excitation transformers.

Dead end and PT structures along with associated 138kV switches were constructed to connect two of the three GSU transformers to the overhead transmission lines fed from the Astoria West substation. For design diversity a pothead structure, along with the associated switches, was assembled to connect the third GSU to an underground 138kV feed which was also derived from the Astoria West ring bus.

The low side of these GSU transformers utilized a field welded 18kV Isophase bus to make the necessary connections to the combustion turbine, and steam turbine generators as well as the auxiliary transformers. Power from the auxiliary transformers was delivered to the 4160V switchgear via a 5kV cable bus.

E-J Electric was the prime contractor for the complete structural, mechanical and electrical installation for the thirteen acre site's main power distribution including Con Edison utility vaults.

The installation required routing 27kV Con Edison feeders underground to (4) 2000kVA transformers feeding network protectors bussed directly to 480 Volt switchgear.

The distribution across the site is a 480 Volt system via ductbanks and manholes. The longest feeds utilized (2) 5kV unit substations in a step-up step-down configuration.

E-J's installation included dual 5kV building utility feeds, site lighting, communications and power feeds as well as feeds for airplane ground power units for the entire site including Cargo Building, future Cargo Building and surrounding airside work. The work also included ten manholes throughout the site.

At NRG we replaced a 138kV to 13.8kV transformer. In off peak a transformer shorted out and destroyed all 13.8 feeders and switchgear to Unit #12 G.T. We installed two 100kw transformers because the original was too small and they couldn't get one large enough. Because of this we also installed 138kV bus structure to tie the hi side of the transformers together. We installed all new duct work and medium voltage cable from 13.8 collector buses back to each of four generator turbines. The job was accomplished in approximately 4 1/2 weeks. Also in this time frame our Subcontractor T. Moriarity & Sons built a containment around the new units. All new relay wiring and conduits to transformers and collector bus back to relay house. In the relay house an extensive amount of rewiring had to be done to accommodate two transformers instead of one unit.

The Jamaica Bay Peaking Facility, located South of Jamaica Airport, serves the Long Island Power Authority grid as an additional energy source during high­ energy draw situations. Located on the same site, this plant runs in conjunction with the Bayswater Peaking facility constructed by E-J during the summer of 2002.

E-J also performed the installation of 15kV transmission yard equipment and interface to the Long Island Power Authority (LIPA) transmission lines. The design included bus duct from the station transformer into the transmission yard tower bus disconnect and the associated controls of the SCADA system.

Installed two sections of 15kV switchgear to existing switchgear lineups in switchyard. This job was completed around the clock during a reduced outage.

Replaced Con Edison provided 2500kVA (13.8kV primary/ 120/208V secondary) transformer at United Nations headquarters. Provided 100 ton crane to hoist existing transformer out and hoist the new transformer into the sub-grade vault on United Nations property. The work was complicated by the location (off property on 1st Avenue) of the Con Edison truck delivering and taking away the transformers. Project involved disconnecting and re-connecting primary and secondary conductors as well as performing required "Hi-Potential" testing to Con Edison specifications. Surface grating was removed, modified and re-installed to accommodate the new installation. All work was performed "off-hours" and coordinated to avoid any conflict with ongoing United Nations operations.

This project was part of the overall redevelopment of the American Airlines Terminal at JFK International Airport. E-J's scope was the primary service to all 5 substations on the site. In Concourse "C" E-J did all the distribution and entire building fitout. The complete 5kV site work included power to Concourse C and the main terminal. At Concourse C the installation consisted of the S&C 5kV switch, transformers, network protectors, collector bus and (2) 5000 Amp 480 Volt services as well as the installation of Taxi Way Lighting and Control.

Tight sites for construction projects are not uncommon in New York. More often than not, project teams rise to the challenge. But when that site is landlocked by subway stations on three sides and a landmark theater on another, no room is left for Con Edison vaults below the sidewalks. The project team decided to put the vaults on the 3rd floor of the new, $150 million, 38-story, 575-foot-high, 1.1 million square foot building.

E-J Electric’s team built a complete Con Edison Spot Network within the vaults. This network consists of four 4100-480/277Volt power transformers (with expansion capabilities to six), network protectors and collector bus. E-J ran 5kV power conductors, within concrete-encased five-inch rigid metal conduits that sweep up from behind street level to the 3rd floor.

To deliver base building power E-J installed a lineup of four, 6000Amp service switchgear arrays, feeding four duct risers (one for every nine floors), with tap-offs to transformers. To compensate for the voltage drop experienced at higher floor levels, the bus duct runs are rated at both 4000A and 5000A.

A 1500 watt- rated standby diesel generator provides power for emergency lighting circuits and other vital loads, if utility-supplied power to the building is ever lost.

Combining creativity with technology, a unique façade lighting installation provides dramatic visual identification to this Times Square office tower. E-J Electric also installed an UL-listed lighting protection system for the office tower.