Customer:
Metropolitain Washington Airports Authority
1 Aviation Circle
Washington DC 20001
Cynergy was awarded a contract for $3,949,259.00 in April 2022 for the replacement of one existing substation, installing concrete pads, bollards, rigid steel conduits, stainless steel pull boxes, structural steel supports, grounding systems, intercept and extend existing 15kV cables, and demolish existing associated 15kV feeders.
The nature of the installation being on Airport property involved a great deal of scheduling due to the feeders supplying power to essential buildings that were affected. Confined space permits and lock out/tag out procedures were also paramount to successful completion of the project.
Principle features of the project were:
· Install 15kV pad-mounted switchgear
· Install 480/277V outdoor rated NEMA 3R switchgear
· Install 3750KVA cast-coil type outdoor transformer
· Install 5,000A outdoor copper bus between transformer and 480V switchgear
· Intercept and extend existing 15kV cables from manholes to equipment
· Provide 15kV terminations
· Provide 15kV 900-amp dead-break elbows and junctions in manholes
· Provide grounding, identification tags and arc-proof tape in manholes
· Provide a short circuit, coordination, and arc-flash study
· Provide third party NETA testing on cables and all new equipment
· Demolition of existing concrete pads, concrete pavement, and electrical switchgear
· Installation of an electrical handhole
· Installation of 480V cabling
· Provide pavement markings
The facility had to remain operational 24/7 during construction. All service outages had to be limited to off hours coordinated and approved by the owner. A detailed construction sequence was developed and had to be approved by the owner before any outage could begin. The project required all outages to be performed during work hours that would not interfere with the building occupants. The logistics of the project were difficult at best. There were complex rigging requirements to install the new equipment. Phased outages were required for the extension of 15kV feeders.
The original design required a large pull box located over the outdoor switchgear and conduit entries though the top of the switchgear. Cynergy suggested a design change to remove the large overhead pull box and install pad-mounted stainless steel pull boxes with underground duct-bank to the switchgear. This change will allow future maintenance on the secondary feeders without ladders, the design meets OSHA regulations and maintains the weather integrity of the outdoor switchgear.
All work was performed by qualified and certified high voltage technicians. All technicians go through annual OSHA training for confined space, lock-out/tag-out, electrical safe work practice, ARC flash and many other certifications. Cynergy owns and operates an APS75 diesel driven underground hydraulic cable trailer. The trailer is designed specifically to install underground cable and has industry leading features like anti-twist rope, rotating modular extension arm and an advanced electronic information system for monitoring and documenting vital pulling functions. Cynergy is one of few contractors that is a certified MVPower Contractor by TE Energy (Raychem). Any products installed by MVPower Certified Contractors, using Raychem 5-35KV medium voltage splice and termination power cable accessories, provide a twenty (20) years warranty after installation. To become a certified MVPower Contractor extensive training and validation for products used by all technicians were performed. All technicians are also certified by the National Cable Splicing Board which certification is designed to assure personnel handling medium voltage cables and components are properly trained. In the medium voltage service industry, you will inevitably come across unusual cable or uncommon applications/requests from customers. Cynergy has the staff to tackle unusual or difficult applications, older cables, and customized product applications.
Commissioning and field testing were a large component in the project. Third party testing was provided for all medium voltage switchgear, 15kV breakers, grounding grids and 15kV cables. Factory field services were provided for the hands-on training, classroom training and operation and maintenance manuals were provided for all operational systems. Other items provided by Cynergy were an arc flash, short circuit & coordination study, new concrete pads, traffic bollards, asphalt paving, parking lot stripping, concrete trench drains, structural steel supports, scheduling, quality control, safety and security were important elements of the entire project. The project was completed ahead of schedule.
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