Fort Campbell Microgrid and Power Plant

The natural gas generation plant and microgrid system provide energy resilience for critical airfield flightline operational facilities.

Location

Kentucky, USA
Tennessee, USA

Project Value

$19,142,177

Project Status

Completed

Fort Campbell, a major U.S. Army installation in Kentucky, required a reliable and resilient energy system to support its essential airfield operations and mission-critical facilities. Through the Energy Resilience and Conservation Investment Program (ERCIP), the U.S. Army Corps of Engineers awarded a $19 million design-build contract to provide a new microgrid and a 6-MW on-site natural gas power generation plant.

Our team was selected to lead the design effort, developing a system capable of operating in both continuous and islanded modes. The solution enables Fort Campbell to maintain full functionality for more than 14 days without relying on the public utility grid, ensuring uninterrupted power for radar and air traffic control towers, airfield lighting, aircraft hangars, fueling stations and operations centers.

Generation plant voltage

12,470

Days of full functionality off-grid

14

On-site natural gas power plant

6-MW

Designing for integration and control

We designed the generation plant around three containerized INNIO Jenbacher JGC 612 GS-N natural gas generators with black start capability. These units are supported by new switchgear, transformers, electrical distribution systems, radiators, advanced protection and control features. Optimization programming, auto-switching and protective relays were integrated to ensure seamless transitions between grid-connected and off-grid operations.

To enable secure and reliable communications, we developed a telecommunications system that includes an 8-port Ethernet switch, Niagara 4 JACE controller and SEL-735 power meter. These components were integrated with Fort Campbell’s existing RNEC network and configured to communicate with the Utility Monitoring and Control System and the Tennessee Valley Authority (TVA) via fiber optic connections.

The microgrid ties into City Light and Power, the installation’s privatized utility provider, requiring enhancements to the supervisory control and data acquisition (SCADA) system and sectionalization strategies to isolate critical loads. Communication between generator controllers and switchgear was achieved through a combination of Ethernet protocols and hard-wired feedback systems.

The solution enables Fort Campbell to maintain full functionality for up to 14 days without relying on the public utility grid.

Securing the system and navigating complexity

Cybersecurity was a key consideration throughout the design process. To meet evolving federal standards and obtain government approvals for interconnection, we partnered with a Huntsville-based cybersecurity consultant. Their expertise ensured compliance with CMMC 2.0 and helped safeguard the integrity of the microgrid system.

As one of the first ERCIP projects involving a privatized base utility system, the Fort Campbell initiative required extensive coordination with stakeholders. Our team worked closely with all parties to navigate uncharted processes and deliver a successful outcome.

Delivering a comprehensive solution

We self-performed 95% of the design work, delivering 100% Issued for construction plans and specifications across civil, architectural, structural, mechanical, electrical, geotechnical and mapping disciplines. Our scope also included field investigations, grounding studies, load flow and short circuit analysis, relay coordination, arc flash analysis and environmental permitting support.

The completed system operates at 12,470 volts in a 3-phase, 4-wire configuration and includes interior and exterior lighting, mechanical ventilation and integrated metering systems. The Fort Campbell microgrid and power plant project stands as a model of secure, resilient infrastructure supporting national defense operations.