MILLTOWN ONSITE GENERATION

L.R. Costanzo Co., Inc. completed construction of the Milltown Battery Energy Storage System, a utility-scale energy storage facility located adjacent to the Borough of Milltown electrical substation in Milltown, New Jersey. The project included installation of battery storage and power conversion equipment, reinforced concrete equipment foundations, underground duct banks and utilities, a site-wide grounding grid, fiber-optic and SCADA infrastructure, stormwater detention systems, fire protection, security fencing, and acoustical sound barriers. The completed facility provides approximately 13.17 MVA of power capacity and more than 30 MWh of energy storage, supporting the Borough’s electrical system by storing and delivering energy as needed.

• Integrating a new utility-scale battery energy storage system into an existing, operational electrical substation while maintaining system reliability
• Working within a compact site with limited space, existing infrastructure, elevation changes, required setbacks, and access requirements for maintenance and emergency response
• Coordinating extensive underground infrastructure, including medium-voltage duct banks, communications, grounding, fire protection piping, stormwater systems, and utility interconnections
• Meeting rigorous testing, protection, commissioning, and interconnection requirements before the facility could be safely energized

• Coordinated closely with engineers, equipment manufacturers, utility representatives, and the owner throughout design and construction, supported by detailed interconnection, protection, and load-flow studies
• Developed a carefully phased construction plan and utilized just-in-time deliveries and strategic material staging to minimize congestion and maintain productivity within the constrained site
• Used ground-penetrating radar, geotechnical investigations, detailed utility layouts, and direct-bore installation methods where appropriate to safely coordinate new underground systems around existing infrastructure
• Implemented a comprehensive commissioning and testing program that included relay testing, VLF cable testing, transformer acceptance testing, thermal imaging, grounding verification, communications testing, fire alarm testing, and full battery-system performance testing prior to energization