Past Projects

Since its inception, Vanalt has performed over a hundred power and signal projects on active transit systems. These systems have included subways and high-speed lines with 3rd rail; trolleys, street cars, and light rail lines with DC trolley wire or catenary systems; regional rail lines with 12kV heavy rail catenary, and work on Amtrak’s Northeast Corridor. Vanalt has installed trolley wires, simple catenary, complex catenary, catenary structures, signal systems, automatic train control systems, communications systems, power feeders, and other work in these different electrified rail transit environments.

Below are just a few examples of our past projects:

SEPTA Fairmount Substation

From 2007 to 2009, Vanalt constructed a new 25Hz traction power substation as part of SEPTA’s Regional Rail Substation Improvements Program to replace or reconstruct traction power substations which had aged well beyond their useful and reliable life. The Fairmount substation was the first of these facilities built under this program, and it replaced the 70-year-old Callow Hill substation. In addition to being the prime electrical contractor, Vanalt was also the coordinating contractor, responsible for the coordination, scheduling, safety, and quality assurance of all contractors on the work site.

Major items included in this project were provision of a 60 Hz substation for house power, 125V DC back-up system including battery bank and chargers, two 25HZ, 36KV/12KV, 5MVA liquid filled autotransformers, two 25HZ, 46KV, 2000A outdoor breakers, new 25HZ, 24KV and 12KV Switchgear complete with state-of-the-art microprocessor-based relays, and Supervisory Control and Data Acquisition (SCADA) system with local and remote human-machine interfaces.

2007002 - Fairmount Elliots

2007002 - Fairmount Roof Skyline

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2007002 - Fairmount Elliots

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SEPTA 30th Street Switching Station

This project was to provide a new switching station to replace the existing former Amtrak SUB 1A. In addition to being the prime electrical contractor, Vanalt was also the coordinating contractor, responsible for the coordination, scheduling, safety, and quality assurance of all contractors on the work site.

Major items included in this project were the provision of a 60 Hz substation for house power, 125V DC back-up system including battery bank and chargers, 25HZ 12KV Switchgear with sixteen 1200 amp and eight 2000-amp breakers. Controlling the breakers is a state-of-the-art microprocessor-based relay and automation system, SCADA controls and indication, and local and remote human-machine interfaces.

As part of the traction power feeders and distribution, Vanalt installed numerous high voltage switches on the roof of the switching station and on structures throughout the site. Vanalt relocated existing aerial circuits, installed aerial feeder wires and approximately nine miles of 25KV power cables in underground duct-banks. In addition, a 2400V 200Hz Motor Alternator system was provided to power SEPTA’s signal system.

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Amtrak Hamilton Substation

The Amtrak Hamilton Substation Project was for the construction of a new 25Hz, 138kV to 12kV traction power substation with four 4.5MVA transformers. This substation was an addition to Amtrak’s existing Traction Power system to provide increased capacity along segments of the Northeast Corridor as part of their High-Speed Rail Improvement Program.

Vanalt was the prime contractor. Major work elements of the project included extensive civil construction, installation of four 4.5MVA 25 Hz step down transformers, nine 12KV 25 Hz traction power trolley circuit breakers, one 6.9 KV 200 Hz signal power circuit breaker, more than 40 medium and high voltage disconnect switches, all new gantry and take-off steel structures, in-house installation of over 100 caisson foundations, aerial feeder and bus work, ground grid and low voltage cable trough, conduits and wiring. All the major equipment is monitored and controlled via a prefabricated control building also provided and installed by Vanalt.

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SEPTA Jenkintown Substation

This project was the complete replacement of the existing 80-year-old Jenkintown Traction Power Substation. In addition to being the prime electrical contractor, Vanalt was also the coordinating contractor, responsible for the coordination, scheduling, safety, and quality assurance of all contractors on the work site.

The original design called for a large nine-section prefabricated substation building to house 25Hz 12KV and 24KV metal clad air insulated switchgear line-ups. Due to the size and spacing requirements of the specified switchgear, the overall building would have been an extremely tight fit in the available space for the substation. Vanalt presented a value-engineering proposal to SEPTA to replace the specified switchgear with Gas Insulated Switchgear (GIS). Vanalt took on a design-build role and made numerous other changes to provide a better project. The revised design reduced the footprint of the building and platforms to one fifth of the original size. This created a much better substation layout, provided space for future expansion, and saved SEPTA more than $1.2 million dollars.

Along with the substation building, major work elements of the project performed by Vanalt included installation of two 25HZ, 36KV/12KV, 5MVA liquid filled autotransformers, two 2-pole 46KV circuit breakers, 18 medium voltage disconnect switches, two new take-off steel structures, modification of existing steel structures, aerial feeder and bus work, 25KV & 46KV insulated cable to connect the switchgear to the take-off structures, new fiber optic communications cable and equipment, ground grid, and low voltage cable trough, conduits, and wiring.

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Amtrak Metuchen Substation

Vanalt was the prime contractor for the rehabilitation and expansion of an active Step-up Yard at PSE&G’s facility in Edison, NJ. The purpose of this substation is to take 25Hz 13.2KV power from the new static frequency converters and step it up to 138KV to feed Amtrak’s Northeast Corridor Transmission System.

Major work elements of the project included installation of four 20/24MVA 25 Hz step-up transformers, nine 15KV 25 Hz 5000A traction power generator circuit breakers, 28 medium and high voltage disconnect switches, new gantry and take-off steel structures, aerial feeder and bus work, ground grid, cable trough, conduits, and control wiring. All the major equipment is monitored and controlled via a prefabricated control building provided and installed by Vanalt. The scope of the contract also included extensive civil work, the installation of 138KV cables from the substation to the Northeast Corridor, and the removal of existing aerial circuits and structures.

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SEPTA Lenni Substation

Vanalt was the prime contractor for the design-build rehabilitation of an existing 80-year-old traction power substation fed from a 138KV transmission line. Work was performed while the substation remained operational, and required complex staging in order to safely renovate the entire facility while continuously powering the railroad.

Major electrical work elements of the project included installation of a new control house, two 4.5MVA 25Hz step-down transformers, three 12KV 25Hz trolley circuit breakers, 14 medium and high voltage disconnect switches, aerial feeder and bus work, a full site ground grid, cable trough, conduits, and power and control wiring. Other work performed by Vanalt included lighting, communication and security systems, structural steel, new aerial walkways, fall protection systems, and demolition of existing transformers, other equipment, and circuits. Activities performed by Vanalt’s subcontractors included civil work, foundation repairs, new foundations, preparation and painting of existing structures, fencing, demolition of the existing control and battery building, and repairs of cribwalls.

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SEPTA Substation Contract 1

This project was the first of SEPTA’s multi-location substation rehabilitation projects. The project was for the design-build reconstruction of three existing Traction Power Substations along SEPTA’s West Trenton Line. Again, Vanalt partnered with Gannett Fleming, to progress the 50% design documents received with the contract to 100% final design.

Construction at each of these sites was performed in an operating substation yard and staged to allow construction to proceed safely while half or more of the yard remained energized. In addition to the challenges affecting the medium and high voltage portionsThis project was the first of SEPTA’s multi-location substation rehabilitation projects. Vanalt was prime contractor for the design-build reconstruction of three existing Traction Power Substations along SEPTA’s West Trenton Line. Work at each location required complex staging to safely renovate the entire facility while continuously powering the railroad. In addition to the challenges affecting the medium and high voltage portions of the work, these sites required equipment to be connected to existing, new, and temporary circuits to enable control and protection schemes to remain fully functional as each site transitioned from all existing equipment connected to existing controls, to all new/final equipment connected, controlled, and protected by the new control circuits. Electrical and subcontracted civil and other work was similar to that performed on Vanalt’s other substation projects. of the work, these sites required equipment to be connected to existing, new, and temporary circuits, to enable control and protection schemes to always remain fully functional as each site transitioned from all existing equipment connected to existing controls, to all new/final equipment connected, controlled, and protected by the new control circuits.

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SEPTA Substation Contract 2

This was the second straight multi-location rehabilitation contract awarded to Vanalt. Vanalt was prime contractor for the design-build reconstruction of Two Traction Power Substations and two Traction Power Switching Stations on multiple SEPTA lines. Work at three locations required complex staging to safely renovate each facility while continuously powering the railroad. In addition to the challenges affecting the medium and high voltage portions of the work, these sites required equipment to be connected to existing, new, and temporary circuits to enable control and protection schemes to remain fully functional as each site transitioned from all existing equipment connected to existing controls, to all new/final equipment connected, controlled, and protected by the new control circuits. Electrical and subcontracted civil and other work was similar to that performed on Vanalt’s other substation projects.

The project was progressed at multiple locations concurrently and was completed approximately six months ahead of schedule and under budget. Vanalt was awarded the 2023 NECA National Project Excellence Award for Transit & Infrastructure and the NECA Penn-Del-Jersey Project Excellence Award winner for Design Build for its work on this project.

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PATCO 11th St

Vanalt was the electrical subcontractor to Railroad Construction Company for the track and signal renovation of 11th Street Interlocking, adjacent to PATCO’s 12th-13th St. Station in Philadelphia. Vanalt performed new signal and traction power work, plus temporary work in support of the GC’s activities to ensure that the system was tested and operational at the end of each work shift. Work included protection of existing cables, modification to signal circuits, installation of new signal and power cables, rail bonding, new switch machine rod layouts, lighting, and other work.

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SEPTA NHSL Bridgeport Viaduct

Vanalt was the electrical subcontractor to Railworks Corporation for the renovation of tracks and systems on a large viaduct over the Schuylkill River for the Norristown High Speed Line. The work was performed during a 120-day shutdown between Bridgeport Station and the Norristown Transportation Center terminus. Vanalt demoed all existing electrical cables and equipment, installed new work including under-bridge cable tray, signal cables, power cables, 3rd Rail connectors, signal devices, rail bonding, new track switch machines, and snow-melters.

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SEPTA Fern Rock Yard Reconstruction

The Fern Rock Yard Reconstruction involved the renewal of over 16,570 feet of track and 37 track switches. Railworks, the prime contractor, awarded Vanalt a subcontract to perform the signal and traction power work on the project. Vanalt’s work involved removing and replacing portions of the train yard Signal System, replacing the switch machines for the track switches, and a complete replacement of the DC 3rd Rail Traction Power Feeder System including new underground ductbanks, feeder cables, and third rail connections. Other work performed by Vanalt included installation of new DC switches, negative return cables, and rail bonding.

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DRPA Ben Franklin Bridge

Railroad Construction Company Inc. in joint venture with Iron Bridge Constructors was the prime contractor for this huge project involving the removal and replacement of railroad tracks and structural supports, painting, and systems reconstruction for the PATCO transit line across the Benjamin Franklin Bridge. As a subcontractor, in a joint venture with Beach Electric, we performed all electrical, signal and communications work on the project. Our work included the removal of about 13 miles of exposed 2”, 3”, 4”, and 5” conduits and their replacement with PVC coated steel conduits, removal and replacement of over 30 miles of cables for 35kv traction power substation interconnect feeders, 4.16kv bridge power feeders, 2.4kv signal power feeders, lighting feeders, and signal circuits. Major train control work included the removal and replacement of signal equipment, cases, and switch machines. Additionally, we undertook the design and installation of a new redundant fiber-optic communication backbone and demolition of the old communications system. Work was performed and tested during track outages in support of the track contractor’s activities. In addition, the performance of all those involved enabled the GC to receive incentive payments for early completion of outage work.

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SEPTA Market Street Elevated Reconstructions

When SEPTA undertook an over $700 million, ten-year complete reconstruction of the Market Elevated, they divided the undertaking into multiple sections. Vanalt was selected as the electrical subcontractor on two portions of the project. Because of the challenges and size of these two sections of the overall project, both prime contractors were joint ventures: (Neshaminy Construction and Granite Construction on one, and Buckley & Co., and Neshaminy Construction on the other). With over 150,000 individual trips per day on the Market-Frankford Line, it was imperative for SEPTA to minimize the disruption to service. Therefore, work requiring train outages was performed during limited shutdowns of two days, nine days, or sixteen days depending on the extent of work involved. Each shutdown involved the complete demolition of a section of the elevated and the full reconstruction and testing of all guideways, tracks, third rail, power systems, and signal systems for both tracks. Overall, about thirty shutdowns were performed. Due to the extensive coordination and planning, and high performance of all contractors and subcontractors, all milestones were achieved, and transit service was resumed on-time after each shutdown.

At the start of each of these outages, Vanalt worked with SEPTA to shut down all power and apply grounds and run-around bonding to ensure the safety of workers on the project. Once that was accomplished, Vanalt’s crews worked rapidly to remove the four 2000 KCM negative return cables through each section, disconnect and remove electrical equipment, signal equipment and cables. Once this work was completed, the GC and its other subs were able to demolish the section of up to 450 feet and begin building the new guideway or station. Approaching the end of each outage, electrical work proceeded as available. Finally, after the GC and track contractor completed their work, Vanalt reinstalled all remaining electrical, signal, and traction power equipment and cables, and replaced the four 2000 KCM negative return cables through each section.

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SEPTA Media – Sharon Hill Line Resectionalization of Traction Power

Vanalt was the prime contractor on this project to sectionalize traction power feeders on the 101 & 102 trolley lines. Vanalt’s work included the addition of over 15 miles of aerial feeder cable circuits, and new motor-operated switches along the wayside and at traction power substations. Service was maintained on the lines throughout construction. After completion, SEPTA was able to provide single track service during maintenance power outages with fewer service interruptions.

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Frazer Yard Shop & Yard Expansion – Ph. 1

As a subcontractor to C. Abbonizio Contractors, Vanalt was responsible for the design-build construction of catenary, lighting, and other systems for a new three-track expansion to the storage yard at the Frazer Shop & Maintenance Facility in Malvern, PA. Vanalt’s work included new structural steel portal and cantilever structures, an overhead catenary system, aerial bonding and lighting cables, and a cable trough system for future use. The work was performed in an active commuter rail yard and required close coordination with SEPTA for procedures, clearances, protection, outages and access.

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NJ Transit – North Jersey Light Rail Projects

From 1998 through 2006, Vanalt, in Joint Venture with Daidone Electric of Newark, New Jersey, completed several NJ Transit light rail projects. These projects included:

Newark City Subway OCS Replacement

Complete removal of the existing above-ground trolley wire and replacement with simple catenary systems.

Hudson-Bergen Light Rail

New signal, power, and catenary systems on several segments of a brand-new light rail line from Bayone to Weehawken, NJ. Work was performed as part of a DBOM (Design Build Operate Maintain) project for 21st Century Rail Corporation.

Newark City Subway – Bloomfield Yard Extension

Design and Installation of new OCS catenary system for a new rail storage yard and maintenance building in Bloomfield, NJ.

Newark City Subway – Newark-Elizabeth Rail Link

Installation of a new OCS catenary system for the extension of the Newark City Subway to the NJT Broad Street Station.

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PATCO Linden

Most of the DRPA’s PATCO high speed line already utilized reverse-signal and SCADA, but the signaling system from Linden Interlocking to Lindenwold dated back to 1969 and it had no SCADA to indicate or control power, switching or signaling. This installation gave the DRPA more efficient and safer movement of trains between yard storage and revenue service by improving and extending automatic train control and dispatcher indication and control.

Vanalt installed a Central Instrument Location, a supporting track circuit case, and all cabling to signals, switches, track circuits, switch heaters, third rail disconnects and impedance bonds.

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NJ Transit Positive Train Control

Work included installation of 112 radio sites, including antennas, huts, cases, poles and associated wiring. Some locations required integration into existing NJT facilities. Sites were located throughout NJT’s vast railroad territory in New Jersey and New York. Vanalt’s timely completion of its work was critical in NJT meeting a major installation milestone by the end of 2018.

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