Stored energy: Turnkey substation battery building project
Energy management: Oldcastle Precast provides turnkey battery building and fire wall for live high-voltage substation.
Power management: Oldcastle Precast has completed the turnkey substation battery building project located at Boeing’s “Customer Owned” Main High-Voltage Substation, West Jordan, Utah. The substation battery building accommodates battery power to a redundant 138-12.47 kV, 20MVA, 3-phase, three wire grounded 60-Hz substation for Boeing’s West Jordan manufacturing facility.
As a project-managed, turnkey contract, Oldcastle Precast’s project scope included the design, construction, outfitting, and installation of a new, 350-square-foot, substation battery building with redundant (A&B) 125VDC battery, as well as TruFire Walls for fire and explosion protection for the redundant 12.47kV Plant utility power source.
The work included manufacturing a high-seismic and ballistic proof, drop-in battery building that has fire rated walls, capacity to regulate and monitor inside environment up to 77 degrees, capabilities to contain acid spills, resistance to high salt "air" spray and ability to withstand hurricane force winds.
In addition, the fully outfitted building had a raised floor, defined conduit and water pop-up location, with a 125VDC (maintenance capable fully redundant) uninterruptable station service power supply, and Dual 125VDC, 400Amp-Hour DC Battery, in 2 Step Seismic Rack. All OEM equipment required was installed by Oldcastle Precast’s experienced teams and fully factory tested prior to dispatch. Outfitting off-site kept the complex engineering work out of the critical path and away from Boeing’s operational site.
“The best and least expensive option for Boeing’s LIVE substation was to drop-in a fully assembled concrete enclosure,” stated Engineer Ray Glenn, Casne Engineering. “The safety procedures for getting unqualified, non-electrical workers, working around high voltage, are daunting. The Oldcastle Precast battery building was not only a high quality built, walk-in, enclosure, but it also reduced the construction schedule (Dual Path) and improved safety by not having non-qualified personnel inside a "LIVE” substation environment.”
Tyson DeVere of SML-LLC Salt Lake City, manufacturers’ representative for Oldcastle Enclosure Solutions commented, “Working in a “LIVE” substation is always interesting, and presents unique logistical and safety challenges, but Oldcastle Precast installed the drop-in, 125VDC Dual Battery Building and DC Power was transferred, without affecting customer service. The process went seamlessly.”
Mike Aime, Wasatch Electric job foreman stated, “On the day of the Battery enclosure install, the installation couldn’t have been easier and smoother. Everything came together and fit perfectly.”
In addition to the battery building, Oldcastle Enclosure Solutions, contracted by Wasatch Electric, supplied their TruFire Wall system (Refractory Concrete Fire Wall). Refractory firewalls are built for large hydrocarbon pool fires (ASTM E1529) that can occur when transformer cooling oil ignites and burns at 2150ºF (1180ºC) with a heat flux of 50,000 Btu/ft2.h. “Fire walls” that comply with IBC are not designed for the temperatures encountered during an actual transformer fire. TruFire Wall has been tested to these standards by an independent testing laboratory.
The TruFire Wall system consisted of 24’-0’’-tall by 20’-0’’-wide refractory concrete fire wall columns, panels, hot-dip galvanized column base plates, base plate thermal covers, and dry mix refractory grout for base connections. The slide-in panels are relatively lightweight and grooved columns minimize manufacturing and installation costs without compromising thermal or mechanical performance.
Project successes were dual path construction, improved quality, no contractor change orders, defined points of interface, on-time delivery, scheduled outages, and seamless cutover transition due to dual battery system and TruFire Walls.
Wasatch Electric was the general contractor for the Boeing Project.
About Oldcastle Precast:
Oldcastle Precast is the clear choice for building products and services for North American Infrastructure projects. The company is a leading provider of engineered product solutions nationwide to a number of market sectors including Energy, Communications, Water, Transportation, and Building Structures.