Natural gas combined-cycle energy plants often generate intense heat, especially when they power over 600,000 homes at once. This is why the new 738 megawatts West Deptford Power Plant would require the construction of a cooling system for LS Power.
The system includes pipe and pump structures designed to move water into the plant to cool the turbines. The pipes draw water from the local West Deptford greywater system to be pumped into the power plant.
Conti delivered this turnkey EPC contract to build the water supply and discharge systems that the power plant required. The team used two vertical turbine pumps with approximately 3,333 gallons per minute capacity to supply the power plant with cooling water. The pumps featured a Variable Frequency Drive System to control the volume of water to the power plant. Conti housed the pumps in a pre-engineered concrete underground pump station structure with a pre-engineered metal building that sits around an existing 72-inch corrugated metal pipe (CMP) water discharge line. To build the housing structure in the unstable soil, Conti drove 38 12-inch diameter concrete-filled pipe piles. The pipes traversed a wetland area that required drilling five feet under. Conti also provided a high-density polyethylene (HDPE) 24-inch pipeline to move the water to the power station, along with a 12-inch discharge pipe. The team installed an 8-inch electrical conduit to power the pump station and a 4-inch communication conduit for control from power plant to the pump station and vice versa.
Conti could not mobilize immediately pending the site permit, so took advantage of the down-time by scheduling material deliveries. Overall, the project was delivered on time, on schedule, and with zero safety incidents.
Conti traversed unstable soils and permitting delays to ramp up construction for the new power plant.
Containing harmful contaminants and adjacent to an urban area of Newark and the Passaic River, the site of a former manufactured coal gas plant was in need of remediation.
Over the years, the by-products of the coal gasification process (including coal and tar) had leached into the ground and contaminated both the water and soil. This concerned residents because the area was to be re-developed by the United States Army Corps of Engineers (USACE) as a public green-space for the city of Newark.
Conti was hired to restore the property and performed state of the art remediation techniques to remove Market Street’s contaminants. The team constructed three reinforced steel cofferdams at measurements of approximately 85 feet long, 365 feet long and 200 feet long. When combined with a dewatering system of shallow and more than 100-foot deep wells, piezometers and five tiers of internal bracing, the cofferdams allowed excavation to depths of 60 feet right next to the river. Conti also protected twin active gas mains with 30-inch diameters using 344 cubic yards of jet grout. Once excavated, Conti blended the contaminated soil with clean soil and cement kiln dust and transported it to thermal desorption facilities where it met strict acceptance criteria.
Conti performed 56,810 safe work hours with no lost time accidents and completed the project on schedule. The client re-developed this major riverfront site for the City of Newark and congratulated Conti for a job well done, expressing his satisfaction at having worked with such a professional team.
Named a Best Project of 2015 by Engineering News-Record, this new black start system provides immediate power regeneration in the event of an electricity outage emergency.
Touted as the cleanest fossil fuel plant in New Jersey, the West Deptford Energy Station’s black start system is LS Power’s long-anticipated upgrade to provide power to Gloucester County, New Jersey. At its construction completion in mid-2014, the plant was generating 738 megawatts of electricity, enough to power 700,000 homes.
Integrating the West Deptford Energy Station’s black start system into the existing system, the project team and the owner risked potential damage to the existing system or power outages to the entire grid. These risks are much greater than if the black start system had been built in conjunction with the energy station, which is why this project was practically unprecedented, making this a milestone project in the power world.
The team performed the design, engineering, procurement, construction, start-up, commissioning and testing of the integrated facility and system comprised of diesel-fueled internal combustion engines and installed and integrated these new systems into the gas-fired combined-cycle power generation facility. The work included installing three of the largest diesel engine driven generators Caterpillar makes in generator sound-reducing enclosures, constructing a diesel engine control system, modifying the existing facility control system and performing site improvements.
During a black start event, the power from the West Deptford Energy Station will enable other connected power plants to start.
UGI Utilities is one of the foremost providers of natural gas to communities in Pennsylvania and Maryland. Its 660,000 customers in 46 counties rely on the company’s continued service to power their homes daily.
In an effort to increase the service coverage of its natural gas pipeline distribution system in Pennsylvania, UGI contracted Conti to install new pipelines in Mechanicsburg.
Conti installed approximately 1,600 linear feet of 12-inch FBE coated 0.552-inch wall thick, high pressure steel natural gas pipe and directly buried it in a private right-of-way alongside a roadway. The team trenched the pipe across an active roadway in three locations. In all cases, the existing road pavement was saw cut and removed, and the trench was excavated for pipe installation. Once the pipe was installed, the road was backfilled and the asphalt pavement reinstalled. Conti also installed 1,174 linear feet of 12-inch Powercrete steel pipe via horizontal directional drill, 460 linear feet of which ran under wetlands, 714 of which ran under an intersection of Pennsylvania Department of Transportation state highway. Since work was performed along the side of the road, Conti implemented traffic control to ensure movement of traffic and safety for the traveling public. This included lane closures and lane shifts performed by trained traffic flagger personnel.
Once the pipeline was complete and prior to tie-in, the pipeline was pressure tested with nitrogen, and a pig was run through the line for cleaning. The line was tied-in by UGI personnel to the existing high pressure line at two locations with a hot tap.
After excavating and installing multiple pipes in residential areas and an active roadway, the project provides the Mechanicsburg community with updated gas service.
Transporting natural gas around the country requires amazing efficiency. With thousands of miles of gas pipelines intricately networked underneath America’s soils, quality gas compressor stations, which pressurize natural gas so it is capable of moving through pipelines at high speeds, are essential to gas transportation. Transco sought to build such a station in the early 1990s, which would increase productivity at huge rates.
Conti worked on an aggressive, fast-track schedule to provide Transco with a state of the art, fully-operational gas compressor station. Conti’s workforces performed a minimum of ten hours a day, six days a week to complete construction on schedule.
The team installed a 69,000 KV electrical substation generator, transformers, switchgear, grounding grids, and two 7,500 horsepower centrifugal compressor motors, in addition to the welding process and gas lines of many diameters and wall thickness. The work resulted in a capable compressor station constructed quickly and under budget.
Conti was responsible for this turnkey project and performed construction activities, scheduling, health and safety, QA/QC documentation, facility testing, finish painting, cleaning, commissioning, and equipment and systems training.
Conti broke ground and completed the project in record time thanks to strong coordination and scheduling.
Producing enough power to supply nearly 300,000 homes.
The Fairless Power Plant is a crucial electricity provider in Fairless Hills, Pennsylvania. The plant became fully operational in 2004 and is owned by Dominion Energy (DE), who sells its output to the regional and national grid. This 1200 MW combined cycle station burns natural gas fuel using four GE Frame 7FA gas turbines, two GED D-11 steam turbines, and four duct-fired heat recovery steam generators (HRSGs) equipped with Selective Catalytic Reduction (SCR) for NOx reduction to single-digit levels.
Conti self-performed logistically challenging excavation and construction of the civil foundations for all buildings of this new power plant. The project involved extensive pile driving operations, for which Conti used state-of-the-art pile driving equipment and was able to self-perform all production work.
The project included installation of steel pipe piles. Prior to installation, the team poured structural pile concrete and installed reinforcing steel pipe cages to support the piles. Due to conflicts with underground utility locations, the team pre-augured piles and performed Pile Driver Analysis (PDA) tests, including compression and lateral load tests, to confirm that piles were driven properly for the structural stability of the building foundations. Drive-fit splices for the steel pipe piles where in excess of 88 feet.
Conti’s efforts and advanced project scheduling techniques enabled the team to complete the work to specifications in just nine months.
Conti used state-of-the-art pile driving equipment and self-performed all production work for this project.
This project would return a greater portion of natural flow to the main stream of the Neuse River, providing uplift in ecological function to include increased food supply, increased velocity and improvement in successful fish migration upstream.
The original Federal project was constructed for the purpose of flood control along a segment of the Neuse River. Due to the negative impacts of flooding, particularly to agriculture, in 1941, Congress authorized the excavation of a cutoff channel approximately 6,400 feet long by-passed about 7.7 miles of the main stem of the Neuse. Within the cutoff channel, a low-head weir was constructed to divert portions of the main stem flow into the cutoff channel during higher flows. The intended effect was a reduction in flood risk along the 7.7 by-passed section of the Neuse River.
Due to environmental concerns that the reduced flow in the by-passed portion of the Neuse River is having a negative impact on riverine functionality and fish migration success. The diversion of flow into the cutoff channel reduces velocity and increases water surface area in the main stem.
Conti will perform construction of the new sheet pile weir and rip rap scour protection. Work also includes cutting the original USACE weir below grade and removing the temporary section 408 weir and construction of stone access road and incidental related work.
Overcoming many obstacles, Conti completed the last segment of this huge flood wall 30% ahead of schedule to bring New Orleans levees up to the 100-year flood protection level before the next hurricane season.
In the aftermath of Hurricane Katrina, the United States Army Corps of Engineers (USACE) set out to complete the Hurricane Storm Damage Risk Reduction System, bringing New Orleans levees up to the 100-year flood protection level. This program entailed an epic scope of engineering rarely seen to construct 350 miles of taller, stronger floodwalls. Conti delivered the last contract awarded, the Lake Pontchartrain and Vicinity 149 Project, as the final link in this network of levees.
Conti was the self-perform contractor for this milestone project which included building an enormous floodwall along the Caernarvon Canal with ties into the Mississippi River levee, the largest highway roller gate in the LPV system, a massive in-water sector gate across the canal and a railroad swing gate. The project was on a virgin swamp in an active environment with busy rail, vehicular and maritime traffic.
With zero room for error, Conti and USACE collaborated in a model partnership with local businesses to work at an extremely rapid pace. The team constructed 56 T-wall structures 30 days ahead of schedule, installed the railroad shoofly in a record-breaking 14 days and worked 24/7 for over 80% of the project to meet the June deadline in 11 months instead of 16 months, shaving off nearly 30% of the schedule. Conti also used 3D modeling to assess space conflicts in the sector gate design.
The team completed the project on budget with 182,000 work hours and zero lost time injuries, receiving numerous industry awards for excellence.
This critical project earned Conti Engineering News-Record’s Best Project of the Year, Merit Award for Civil Infrastructure, ABC New Orleans’ Award of Excellence, USACE Mississippi Valley Commander’s Coin and USACE New Orleans’ Superior Safety performance award for no lost time incidents.
The impact of the catastrophic damage caused by Hurricane Katrina in 2005 is still felt by the New Orleans region almost 10 years later.
In the aftermath of the storm, the United States Army Corps of Engineers (USACE) called for action by implementing the Hurricane and Storm Damage Risk Reduction System (HSDRRS) for 100-year flood protection. The latest installment in this program is the West Bank and Vicinity (WBV) Mississippi River Levee (MRL) 4.2 project in Plaquemines Parish from Turn Bend to Belle Chase. This project improves hurricane and flood control protection, decreasing future damage potential.
Conti constructed approximately 6,589 linear feet of new concrete floodwall stretching from Oak Road to the Belle Chase Ferry Landing. The floodwall has a final elevation of 24.5 feet. During the installation of the temporary flood protection, the existing concrete slope was degraded the team constructed four earthen ramps leading up to the floodgates. Each ramp has a “swing” or “roller” equipped with rubber seals for controlling leaks. The swing gates are hinged on one side and placed so flood water pressure will push on the gate in the direction of its swing when in the closed position. The roller gates are placed on the river side of the wall and slide into place.
Conti installed an additional 15 linear feet of new right-of-way, which is required on the protected side of the existing levee, creating roadway access for flood prevention and inspection purposes running on top of the levee adjacent to the floodwall.
Conti utilized a local workforce to complete this project. The new floodwall will meet the standards USACE set for 100-year flood control protection for the Plaquemines Parish community. This project was awarded as an ENR Texas/Louisiana Region Best Project for the team’s excellent work.
Conti’s floodwall will provide 100-year flood protection to the 23,000 residents of Plaquemines Parish.
To reduce damages from rainfall flooding in New Orleans and the surrounding parishes, the Southeast Louisiana (SELA) Drainage Program constructed new pumping stations and better drainage canals and culverts throughout the area.
Originally authorized in 1996, Congress appropriated federal funds to develop solutions to the flooding problems in Orleans, Jefferson and St. Tammany parishes in the aftermath of Hurricane Katrina in 2005. The United States Army Corps of Engineers (USACE) started working on these flood protection projects to protect against a ten-year rainfall event and reduce damages for larger events.
Conti constructed SELA-07b consisting of three 84-inch cement lined steel pipes connecting the discharge pipes from a pump station to a levee crossing and outlet structure for discharge into the Mississippi River. Work included construction and modification of existing utilities, construction of two pump stations including concrete foundations and fiberglass wet wells, pile driving, installation of waterline, mass excavation and hauling, asphalt and concrete paving, dewatering, construction of temporary retaining structures, stone and bedding construction, structural excavation, backfill and demolition.
Conti laid as much as 600 linear feet of pipe per month and coordinated with USACE, the Louisiana Department of Transportation and Development, the local utility company and Jefferson Parish to redesign the traffic configuration, temporary retaining structure (TRS) and dewatering system to improve efficiency.
The pump stations, drainage canals and culverts will divert storm water to mitigate future flooding in areas devastated by Hurricane Katrina.
The goal of this project is to achieve 100-year flood protection and to serve the Plaquemines Parish by maintaining a safe hurricane evacuation route to the northern parts of Louisiana.
The goal of this project is to achieve 100-year flood protection and to serve the Plaquemines Parish by maintaining a safe hurricane evacuation route to the northern parts of Louisiana.
The WBV-9c Project for the Hero Canal to Oakville Highway 23 Crossing is part of the Hurricane and Storm Damage Risk Reduction System (HSDRRS) implemented by the United States Army Corps of Engineers (USACE) in the New Orleans area in the aftermath of Hurricane Katrina. The HSDRRS includes the construction of many miles of floodwalls and levees for the West Bank and Vicinity of the Mississippi River.
Conti constructed two 53-foot wide swing gates across Louisiana’s busy Highway 23, a 25-foot-wide swing gate across existing active railroad tracks and T-wall floodwalls that tie in to other HSDRRS projects. The project also included work around the active highway and under the railroad, utility relocations, drainage work, fertilizing, seeding, excavation, clearing and grubbing and asphalt paving. The success of this project required Conti’s project team to execute complicated planning and coordination efforts over the course of two years on an aggressive schedule concurrently with other projects in the area to beat the flood season. The team accelerated the project schedule by using more accurate utility relocation methods and fabricating the large floodgates in its shop.
Conti regularly coordinated with the USACE and key stakeholders, including the New Orleans and Gulf Coast Railroad to maximize active rail service windows and with the Louisiana DOT to keep highway traffic lanes open during construction.
Conti provided the community with critical improvements to Louisiana’s hurricane protection system.
As America’s oldest airfield and home to the first commercial airline terminal, Newark Liberty International Airport (EWR) made aviation history when it opened in 1928.
Today it serves as a critical transportation artery for the New York City metropolitan area. As part of continual upgrades and maintenance, the Port Authority of New York and New Jersey (PANYNJ) called for upgrades to EWR’s lower level passenger arrival hall to accommodate over 35 million people each year. The agency also wanted to eliminate parking lot flooding issues.
Conti installed new underground pump stations for flood control, constructed a new bridge structure, and widened a second bridge to provide access to the new lower level of Passenger Terminal B. The team constructed three storm water pumps for evacuation of storm water, collectively capable of expelling over 45,000 gallons of water per minute from EWR’s parking lots. Conti performed shoring, dewatering, permit procurement, excavations, and sheet piling during these operations. As a part of the two-phase bridge construction, Conti poured approximately 175 cubic yards of 4,000-psi category IV Port Authority concrete for each phase, all along two bridge decks that each measured over 190 feet long.
The team handled over 300 client-driven modifications resulting from unforeseen conditions and still completed work on schedule and on budget, while keeping parking spaces and pedestrian walkways open throughout the project.
Conti’s work alleviated the frequent flood issues that plagued one of the nation’s most important airports, and also allowed for easier access for travelers.
Hundreds of flights carrying thousands of passengers fly out of Newark each day. To meet increasing demands, the Port Authority of New York and New Jersey (PANYNJ) needed to extend its main runway closest to the terminal to accommodate pilots carrying heavier loads requiring longer takeoffs.
Conti added 1,800 linear feet on runway to the current 8,200 linear foot runway. Because the concrete needed to be as strong and long lasting as possible, the team utilized a “first ever” mix design with four aggregates instead of the conventional three.
In addition to the special concrete mixture used on the runway extension, Conti took advantage of a unique slip-form process to frame the concrete. This process called for the use of a machine to drop the concrete from a conveyor between two steel guides placed 25 feet apart. The machine slowly moved down the length of the runway pouring a depth of 16 inches of material for the first layer. After the first layer was poured, Conti crews placed reinforcing mesh on top, and then applied a second four-inch concrete layer. Another crew then utilized a “rolling bridge” to smooth and finish the surface. This project was also the first time the slip-form paving had been done at Newark Liberty International Airport.
The team executed work at an active airport in a highly urban area with minimal disruption to operations, delivering the project safely and on schedule.
The US’s largest airport system was overwhelmed with customers.
As part of this vital transportation hub in the Greater New York City area, Newark Liberty International Airport (EWR) sought to reduce congestion in its A and B terminals and increase ease of access for incoming travelers. To accomplish this, the Port Authority of New York and New Jersey (PANYNJ) planned a major reconstruction effort for these airport terminals, which would include the complete reconstruction of many of the terminal’s features to accommodate greater traffic and alleviate congestion.
Conti reconstructed the roadway for each terminal including a two-lane bridge leading into the Central Terminal, which effectively increased traffic flow. In addition, Conti constructed an architectural steel and glass pedestrian walkway canopy, as well as multiple toll plazas. The team performed the work in carefully planned stages to minimize inconvenience to the public during the construction phase. Conti also installed and relocated numerous utilities, including a 36-inch saltwater line, a 24-inch storm water force main, and a 12-inch water line. The team utilized a state-of-the-art steel fabrication shop to manufacture steel for the 50,000 square foot canopy structure.
In the days following the September 11, 2001 attacks, Conti worked with the Port Authority to quickly lock down the airport and maintain security measures, such as erecting traffic barriers and requiring ID badges at all times at the airport.
Conti completed this project safely and on time while working on an active airport and overcoming delays from the September 11 attacks.
The world’s largest commercial jet is a double-deck, wide-body, four-engine mega airplane.
Having made its first flight in 2005, the huge 853-passenger Airbus 380 required a significantly larger taxiway than other aircraft, which led to the need for the Port Authority of New York and New Jersey (PANYNJ) to upgrade JFK International Airport to accommodate this enormous plane. Alterations included the relocation of Taxiway A North and South, and the rehabilitation of Taxiway B North.
Conti performed the taxiway relocation and rehabilitation to properly land the Airbus 380, all while working at a very active, high security international airport. Under this contact, Taxiway A (75 feet wide) was shifted 16 feet for a total length of over four miles.
The team placed over 90,000 cubic yards of cement-treated base and 208,000 tons of other paving materials while minimizing disruptions to airport operations. Conti batched all cement base on site from recycled millings and Lime Cement Fly Ash (LCF) base material from previous excavations into a sustainable environmentally friendly material called “econocrete”. This approach eliminated the need for 25,000 cubic yards of virgin material and 2,200 truck trips. In addition to saving PANYNJ money, Conti shaved time on the project by producing 1500 yards of the cement-treated base on site per day.
Conti also met stringent FAA runway smoothness standards for the precise quality control specifications of a maximum profile index of 15 inches/mile with no individual deviations greater than 0.4-inches in 25 LF.
Conti’s newly patented “econocrete” technology garnered huge saving for the client and surpassed sustainable goals.