Scope
Schedule
3-Years
Location
Wisconsin
Estimated Cost
$1.3M
Client
Midstream Transmission Company
Project Overview
The client needed to significantly improve power reliability at their terminal, but their existing infrastructure lacked the capacity, resilience, and configuration required to support current operations or future growth. To ensure stable power delivery, they required a new greenfield substation engineered to meet strict safety, performance, and site‑specific constraints—despite challenging soil conditions and proximity to critical facilities. To meet this need, LSC delivered a full multidisciplinary engineering and procurement effort to design and support construction of a new substation supplying 4.16 kV power to multiple distribution buildings and cross‑tie circuits. The design incorporated overhead power lines, underground cables, and cable tray systems to create a flexible and reliable distribution network. LSC’s integrated approach provided a scalable, long‑term power solution that strengthened operational performance across the terminal.
Deliverables:
- Civil Engineering
- Structural Engineering
- Electrical Engineering
- Procurement Support
- Construction Support
Project Team
Dan Kraft
Client Program Manager
Chris Kruse
Senior Structural Engineer
Kevin Jahr
Civil/Structural Engineer
Strategic, Code‑Compliant Project Planning
LSC collaborated closely with the client and project stakeholders to ensure all design decisions aligned with project goals, company standards, and site‑specific requirements. The team modeled civil improvements, structures, and electrical equipment in 3D to verify all required clearances—including switch‑operator heights, phase‑to‑phase, and phase‑to‑ground distances—were met. This upfront planning minimized rework, accelerated approvals, and established a clear foundation for a safe, reliable substation design.
Integrated Multidisciplinary Design
LSC delivered a comprehensive substation design that incorporated incoming parallel 115 kV utility lines, dead‑end bus structures, gas circuit breakers, and 20 MVA transformers feeding 6,000 A, eight‑circuit switchgear. Power distribution was engineered through cable tray systems and trenching, supported by a new station control building and 5 kV box structures.
Grounding and lightning protection were fully designed for the site and all steel structures, with specialized measures to isolate and decouple existing fiber‑optic static wires to maintain cathodic protection integrity.
Foundation Solutions for Challenging Site Conditions
Because the substation was built on a designated wetland with clay‑based soils, the site required significant imported fill—up to six feet in some areas. Anticipated settlement of at least five inches required deep foundation solutions, leading LSC to design pile caps supported on driven steel piles. This approach safeguarded long‑term structural stability and ensured the client received a resilient, future‑ready installation.