PayneCrest Electric and Communications
10411 Baur Blvd
St. Louis, MO 63132
PayneCrest delivered the most technically challenging component of Ameren’s rebuild and modernization of its 450-megawatt Taum Sauk Hydroelectric Power Plant. Our design team optimized plans and installed all new electrical and control systems including 4,160-volt switchgear, 480-volt switchgear and motor control centers, panel boards, DCS (Digital Control System), protective relaying, new switchyard controls cables, communications systems, 125 VDC batteries and chargers, cables, raceway, and new instrumentation and instrumentation piping.
PayneCrest's field engineering incorporated the re-use of 6,000 feet of existing cable tray and 80,000 feet of existing galvanized rigid conduit. Additionally, PayneCrest installed 300 feet of cable tray, 12,000 feet of conduit, and 300,000 feet of power and control cable with approximately 20,000 wire terminations.
Working with an eight-month schedule in a remote area with a challenging topography at the base and summit of Proffit Mountain, PayneCrest met all of Ameren’s expectations. It managed 40,000-plus man hours with no lost-time injuries through diligent risk management. Even though the project required continuous modifications, virtually all of the project’s 20,000 terminations were delivered flawlessly. PayneCrest diligently stayed ahead of the project’s pre-functional commissioning, correcting issues related to the project’s design. As a result, the final commissioning validated the complete functionality of a highly integrated underground hydroelectric plant built on an extremely constricted site.