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Situation:

Kendall Station is a 256-megawatt combined cycle power plant built in the 1940s that has been upgraded to serve as a combined heat and power plant. As part of an EPC contract under dck worldwide’s (formerly Dick Corp.) direction, BOND was selected to serve as the civil contractor for the Station’s upgrade. BOND’s crews performed several key upgrades to the plant, including repowering old steam sets and relocating existing facilities. The project also included the relocation of underground piping and ductbanks, management of the installation of more than 600 piles, formation and placement of 8,500 CY of concrete for massive equipment foundations, and the disposal of 13,000 CY of contaminated soils. The team also installed a new fire suppression system and managed equipment deliveries and crane activities. All civil work was self-performed by BOND’s crews.

Challenges:

  • Work completed on a tight, heavily-trafficked urban site
  • Coordination of construction activity within a power plant required to be active during winter months
  • Schedule management to maintain a fast-track, 16-month schedule

Solutions:

  • Collaboration with EPC contractor, Dick Corp., to implement a badge system with training geared towards working in a live power plant
  • Rigorous safety and quality control protocols to complete utility tie-ins within the power plant
  • Development of mitigation plans to minimize disruption during equipment deliveries and maximize safety for crane activity

Results:

  • Quadrupled plant’s electricity output and reduced air emissions by 41%
  • Facilitated an electrical connection to the nearby NSTAR Station 575
  • Completed on time and within budget