Energizing NGL Hub in 5 Months with High-Voltage EPC Solution

Project overview

Greenfield y-grade NGL pumping station
1,200-ft, 138-kV transmission line
138-kV/4,160-V, 7.5-MVA temporary substation
138-kV/4,160-V permanent substation
Relay panels + PDC building
Two-phase execution

Scope of work

Engineering + design
Procurement
Project management
Fabrication
Construction

Project summary

Losing energization source for new NGL hub

A greenfield pumping station in South Texas required a high-voltage transmission line and dedicated substation to pump y-grade natural gas liquids (NGLs) at the site along a statewide pipeline. After unexpected setbacks to the electrification plan, the operator sought an expedited, full-EPC solution for the power infrastructure.

Prioritizing temporary substation + balancing stakeholders

To get the pumping station energized without delay, the Audubon power team split the project into two phases—first prioritizing a 138-kV/4,160-V, 7.5-MVA temporary mobile substation and a 1,200-ft, 138-kV transmission line. Detailed engineering and design focused on precision and efficiency, while also negotiating the requirements of multiple entities. With outside governance over an adjacent distribution line and access to the pipeline system, civil engineering became crucial. We collaborated with all stakeholders on their concerns and expectations to get the power infrastructure designed and permitted within a narrow set of competing parameters.

Reusing resources + overcoming unavailable supply

Audubon also handled all procurement and construction activities. We effectively managed material lead times and equipment delivery and ensured on-time installation of the substation and transmission line. To save time and cost, we utilized the site’s previously abandoned transmission poles and retrofitted them to meet current design standards. Our commitment to the project schedule was especially evident when the site’s third-party energy meter became undeliverable—our team went above and beyond to source available materials, redesign it, and build it without sacrificing quality, compliance, or performance.

Powering on with EPC agility

Audubon applied ingenuity and flexibility to achieve the operator’s startup schedule—delivering the phase-one transmission line and temporary substation in just 5 months from project award to energization. With the facility fully energized, our EPC team was able to begin engineering phase two’s permanent substation, alongside engineering and fabrication of the site’s relay panels and power distribution center (PDC) building, without delaying pumping operations. The final 138-kV/4,160-V substation is set for completion within 15 months of the project award.

The new substation and transmission line rebuild prove what can be done when superior engineering meets project dedication. Our team’s flexibility, problem-solving, and EPC execution made all the difference. With reliable power, the pumping station will surely deliver critical energy resources for the long term.

Jules Marks
Project Manager, Audubon Companies