Value Delivered
Forest Electric New Jersey (Forest NJ) led the design and construction of a new medium-voltage electrical distribution system at a 100-acre campus in New Jersey. Forest NJ provided the project team with the electrical design and engineering expertise required to replace two existing 26kV substations, six miles of underground duct bank conduits, and 54 miles of medium-voltage feeder cable—all without causing a major impact on the operations of the pharmaceutical company’s headquarters.
We coordinated power outages, road closures, and site logistics with the plant’s usual operation, in order to provide a seamless transition from existing to new power equipment. The team was able to install new equipment and duct banks within, or in close proximity to, the electrical system’s existing equipment while minimizing shutdown time, which helped to maximize the client’s cost-savings. Forest NJ’s advanced value engineering services also allowed the project to meet strict budgetary requirements.
Client Objectives
Merck was planning an extensive electrical infrastructure upgrade and needed an electrical engineering team with the construction capabilities and industry know-how to design a new electrical distribution system and manage a complicated project involving various construction, utility, and energy companies.
Solutions
The project overcame a variety of electrical engineering and construction management challenges while simultaneously adhering to some of the highest labor and environmental safety standards. Utilizing an integrated project team approach, Forest NJ spearheaded the installation of the new grid while coordinating efforts among the general contractor, DPR Construction, an onsite cogeneration plant operated by Atlantic Power, and Public Service Electric & Gas (PSE&G).
The project’s impeccable safety record consisted of over 114,000 man-hours without a
single “days away, restricted or transferred” (DART) incident. Additionally, during the
installation of new conduit duct banks through sensitive wetland areas, Forest Electric
demonstrated a commitment to environmental stewardship by taking care of the area’s
delicate ecosystem.
During the project, Forest Electric delivered the following:
- Electrical design and value engineering
- Integrated project team approach to construction management
- Replacement of two 26kV substations, six miles of duct bank conduits, and 54 miles of medium-voltage feeder cable
- 26kV and 5kV protection relay, campus power management, and building management systems
- Fire alarm and security systems
- Interfacing between local utility and onsite co-generation plant
- Installation in environmentally sensitive wetland
- Minimal plant shutdown time
- 114,000 man-hours worked without a DART incident
Client Background
Merck is an American multinational pharmaceutical company and one of the largest pharmaceutical companies in the world.