Zion Contracting served as the General Contractor for Project C-30401, Rehabilitation of Deepwells & Control Upgrade at the Nostrand Line in Brooklyn. This critical project aimed to restore dewatering deepwells along the Nostrand Line to a state of optimal function and upgrade the facility’s control and communication systems for improved operational efficiency and remote monitoring.

The mechanical scope of work involved extensive infrastructure upgrades, beginning with deepening three key deepwells (3701, 3702, and 3703) to a depth of 170 feet. This required removing existing well heads, screens, pipes, and other appurtenances, then filling the void spaces with clean sand, grouting the openings, and covering them with steel plates. Additional mechanical tasks included removing submersible pumps and associated discharge piping, drain lines, and valves in multiple deepwells and replacing them with new VFD-compatible submersible pumps, well heads, discharge elbows, and base plates across eight deepwells. New exhaust fans, sump pumps with level probes, high water alarm systems, and various piping and fittings were also installed, ensuring robust functionality. All eight pumps were rigorously tested at varying RPMs to document performance characteristics.

The civil and structural scope included removing and replacing critical access elements, such as eight hatch doors, six ship ladders, and reinforcing concrete. New vent shafts, enlarged hatch openings with reinforced doors, and new ladders were installed to facilitate access and improve ventilation. The scope also called for the removal of a rusted manhole cover at deepwell 3710 and installing new removable gratings with locking devices for all deepwell rooms to enhance safety and accessibility.

Electrical upgrades were substantial, involving the removal of existing service end boxes, circuit breakers, automatic transfer switches, and temporary panels. New NEMA 4X-rated stainless steel components, including service boxes, circuit breakers, and transfer switches, were installed for durability and corrosion resistance. Additional upgrades included new emergency lights, heaters with thermostats, GFCI receptacles, and rewiring for various systems, such as ventilation exhaust fans and deepwell control panels, to ensure comprehensive power and operational continuity.

The fiber optics scope entailed installing a fiber optic network connection between the Newkirk Communication Room MR-358 and the master deepwell 3701. This was part of the broader communication scope, which also involved establishing a radio communication link between deepwell 3701 and the remaining seven deepwells. Digital radios operating in the 900MHz ISM band were installed, connected via coaxial cables routed through GRS conduits for robust data transmission. Street antennas were mounted on poles to maintain line-of-sight RF paths between deepwells. A Cisco Industrial Ethernet 4000 switch was installed within the data cabinet to integrate PLC controllers, alarm monitoring, and communication devices, with a backup battery to maintain power during outages.

Architectural improvements included painting all interior surfaces, including floors, walls, ceilings, and ladders, in accordance with the architectural finish notes, and installing signage as specified in architectural drawings. Zion Contracting’s coordinated approach to these multifaceted upgrades reinforced the operational resilience of the Nostrand Line’s dewatering infrastructure and elevated the facility’s control and communication capabilities for modern transit operations.