A team was constructed consisting of Gettle (electrical contractor), Lehigh Cement, M+S (engineer),SSL, ESS Metron, Benshaw, and Virginia Transformer for this project. SSL coordinated weekly project meetings and worked with all parties to deliver a successful project on time. The substation was energized in December 2017.
SSL was contacted by MC Dean to provide suggestions and solutions for an existing motor control center for DC Water located underground in downtown Washington DC. The existing MCC had been out of service for many years and the controls were obsolete. It was desired to keep the existing MCC structure, but replace the main, tie, main as well as the feeder breakers for 4 pumps. A tight schedule was required to bring the pump station back online in 3 months.
SSL worked onsite to make measurements of the existing gear and review the required interface with the new control system that was being added onsite. SSL designed a new control schematic for the existing pump starters. These pump starters were built by one of its partners, Benshaw to the specified dimensions and required cable lengths to fit into the existing MCC section. SSL also worked with another partner - Park Detroit to provide retrofit breakers to upgrade the main and tie breakers. An outage was taken to perform all work on schedule. The control wire was completely replaced by SSL, all breakers and breaker handles were replaced. Finally a system startup was performed to test the control logic, DRLO the existing bus, and startup all pumps. The project was completed on time in August 2018 .
Job name: SEPTA South Substation
Location: Philadelphia, PA
Completion Date: September 2017
SEPTA South Substation, a company in South Philadelphia, contacted us about a new project for a skidded Substation. SEPTA needed this substation to provide power to charge 25 new electric buses. This substation was needed in less than three months to meet their installation schedule and arrival time for these new buses. SSL visited the site to perform an assessment to help determine proper sizing, location, and dimensions for the new substation. SSL coordinated a skidded substation provided by ESS Metron to meet the tight delivery schedule and to meet the utility requirements. The substation has been delivered and is awaiting the arrival of the new electric buses.
Job name: Techmer PFCC
Customer: Techmer /Willier Electric
Location: New Castle, DE
Completion Date: August 2017
SSL was contacted by Techmer in DE, about their incoming utility transformer that was being overloaded. SSL reviewed the application with the local utility as well as with Techmer’s engineering department to determine the cause of the problem. It was noted that due to the significant motor load feeding from the transformer, and the significant AC and DC drive load, that the overall power factor for the system was hovering between .65 and .75.
SSL worked with Power Survey, who specializes in power quality solutions. We reviewed the previous utility bills and discussed plans for any future expansion. Based on the conversations and analysis, a 600 kVAR automatic power factor correction bank was chosen for the application with steps in increments of 50kVAR. Since the system had significant non-linear loads (such as DC drives and AC drives), SSL worked to size a power factor correction bank that was detuned to the 3.78thharmonic. By detuning the PFCC bank, the system will avoid any possible resonance or overheating. The power factor correction bank was installed in August 2017, and the power factor has improved to .97 or greater.
Job name: Veolia Water RVSS Upgrade
Customer: Graybar / Veolia Water
Location: Wilmington, DE
Completion Date: March 2017
Veolia has existing full voltage starters installed for many years. These control blowers in their waste water facility. They have had recent issues with motor failures and maintenance issues on the driven equipment, so the suggestion was made to upgrade to an RVSS. The existing controls had been modified several times over the last 40 years. SSL visited the site to perform an assessment of the existing controls as well as determine the proper sizing and mounting locations for the new RVSS. The RVSS system was designed to fit into the existing space and utilize much of the existing, wiring, and controls. SSL also removed and cleaned up any wiring that was unnecessary or no longer in use, to provide ease in future troubleshooting. The system was upgraded in less than a month and is currently operational.
name: Neshaminy Water Treatment Plant
Customer: Aqua Water
Location: Neshaminy, PA
Completion Date: February 2017
Aqua Water recently had a plant expansion for its Neshaminy plant. This plant expansion required the addition of (2) 2750 kVA substation transformers. SSL received the inquiry and worked with our partner, Virginia Transformer, to select the proper transformers, rating, efficiency level and transformer configuration. The project had a short leadtime, which required an expedited shipping schedule to meet the customer’s requirements. The project scope called for a substation style transformer with a nitrogen preservation system. The decision to go with Virginia Transformer as the transformer provider was easy as Virginia Transformer could meet the customer’s delivery schedule. SSL provided an onsite scope review with the customer prior to placing the order and helped with the onboard drawing review to meet the expedited shipping schedule. Finally, SSL was onsite to observe the offloading of the (2) transformers.
Job name: Jones
Falls Pumping Station
Customer: Team Service
Location: Baltimore, MD
Completion Date: September 2016
Baltimore City installed (4) low voltage clean power VFD’s. These were custom 18 pulse VFD’s which utilized (2) 18 pulse transformers and (2) 400 HP VFD’s operating in parallel. The VFD’s had a failure one evening and the original manufacturer was not willing to service without having the VFD’s sent back to the factory. Team Service contacted SSL to look at the existing application and make suggestions to the design. SSL visityed the site with Team Service and performed a comprehensive review of the existing application. SSL worked with Benshaw to provide a more reliable solution, while utilizing some of the existing components of the original VFD. It was determined that a better solution would be to remove the existing (2) paralleled VFD’s and replace the system with a new 18 pulse rectifier and a new 800 HP VFD for the application. The VFD system was designed to fit into the existing space and utilized much of the existing, wiring, controls, and cooling.
Job name: CSX Switchgear Upgrades
Customer: Team Service / CSX
Location: Baltimore, MD
Completion Date: July 2016
We were contacted by Team Service and CSX to review an existing switchgear line up at the Curtis Bay Pier location. The existing gear was 1950’s vintage gear utilizing GE Magna Blast vertical lift breakers. Using a collaborative approach, SSL presented several solutions, including gear replacement and refurbishing the existing gear. After reviewing all options, the team decided to upgrade the existing gear. This would eliminate the need for costly removal of existing gear, permitting, and heavy rigging while allowing for a quicker time for completion. After receiving the notice to proceed a complete gear inspection was completed, identifying the existing controls, site specific measurements, and condition of existing components. SSL worked with our partner AETA to provide (5) new relay panels with SEL relays to replace the existing controls, along with generating a complete set of new schematics. SSL integrated retrofit vertical lift breakers to replace the existing Magna Blast breakers, refurbished the existing lifting motors and lifting elevators and performed the installation over the July 4thshutdown. The project was completed in July of 2016.
Job name: Johnson Controls 115KV Substation
Customer: IB Abel, Inc. & Schaedler Yesco Distribution
Location: York, PA
Completion Date: May 2016
We were contacted by a number of local electrical contractors to supply the components in a 115KV substation for Johnson Controls’ new testing facility in York, PA. After reviewing the bid documents, we found that this opportunity meshed well with our strengths. We put together a comprehensive scope letter followed by a detailed bill of material highlighting the responsibilities each of our manufacturers would cover. Our scope of work included substation engineering services by ARM EnerTech, packaged substation equipment (including steel structures, prefabricated bus, gang operated switches, surge arresters, insulators, & foundation design) by DisTran Packaged Substations, (2) SF6 circuit breakers by Siemens, (2) 10/11.2/12.5/14MVA transformers by CG Power Systems, and 15KV switchgear housed inside a Power Distribution Center by ESS Metron. After multiple productive follow up meetings with the awarded contractor, IB Abel, we were successful in securing orders for each manufacturer involved. The project was completed in mid-2016.
Job name: P998 Drydock 8
Customer: Helix Electric
Location: Norfolk, VA
Completion Date: March 2016
SSL took a comprehensive look at harsh environment projects located in coastal areas in the Mid-Atlantic, and we targeted this project as a great opportunity. Our expansive stainless steel, ANSI C57.12.29 rated product line, as well as expertise on products and interconnections involved in past complex projects, allowed us to offer value to project bidders that competing firms could not. We were effective in securing orders for our manufacturers on the electrical equipment, and we are currently working with Helix Electric to support this project with our project management team. The scope of our project offering on this particular project includes the following: structures, surge arresters and insulators by DisTran Packaged Substations; stainless steel ANSI C57.12.29 power cast coil substation transformers by JST USA; 38KV and 15KV metal-clad switchgear in ANSI C57.12.29 stainless steel power distribution centers (PDC's) and custom shore power units by ESS Metron; skidded uni substations using primary stainless steel ANSI C57.12.29 power liquid filled substation transformers by CG Power Systems USA and stainless steel ANSI C57.12.29, 200k AIC rated low voltage switchgear by ESS Metron, single phase padmount transformers; relay programming and testing. SSL continues to manage all expectations and points of ownership between our participating manufacturers, thereby providing Helix Electric with a single point of contact for any questions that arise.
One of our manufacturers asked us for assistance in a project outside of our territory. After reviewing the scope of the project, we decided not only to pursue a portion of the project through a single avenue but to cover every base and go ‘all in’. With no contacts and no knowledge of the Los Angeles County local market, we decided that our expertise on the products and interconnections of this complex project would position us to lend great value to the project bidders. We were successful in securing orders for our manufacturers on the electrical equipment and currently are working with Southern Contracting to support this project with our project management team. The scope of our product offering on this particular project includes the following: structures, group operated switches, surge arresters, insulators, aerial bus and connections, and grounding by DisTran Packaged Substations; SF6 dead tank circuit breakers, 40MVA power transformers, and station power liquid filled padmount transformers by CG Power Systems USA; 15KV metal-clad switchgear in power distribution centers (PDCs) with a SCADA integration substation system utilizing Schweitzer relays by ESS Metron; 15KV non-segregated busway tie between PDCs by Park Detroit. SSL continues to manage all expectations and points of ownership between our participating manufacturers, thereby providing Southern Contracting with a single point of contact for any questions that arise. Final energization was complete in July 2014.
In follow up to a previous successful project where we provided 6.6KV drawout metal-clad switchgear for NASA, we were contacted about another project at the same facility retrofitting (3) existing substations. This job was a perfect fit for our engineering and manufacturer capabilities as the scope of the project involved 2.3KV stainless steel primary load interrupter switches, liquid filled substation style transformers, stainless steel UL 891 switchboards, and an engineering study for a short circuit, coordination, and arc flash study. We were successful in securing orders for our manufacturers on the electrical equipment. After securing the order, a field site survey was performed to ascertain existing field conditions including stub-up points, dimensional restrictions, clearances, wire lengths, existing breaker settings and any potential issues. Working closely with our manufacturers, we designed retrofit substations to fit into the existing field conditions rather than using "standard” designs that would be difficult and costly to install. SSL managed all expectations and points of ownership between our participating manufacturers thereby providing GGR Construction with a single point of contact for any questions that could arise. The substations were successfully installed over a single weekend. To assure a successful installation, SSL provided onsite representation to clarify any possible issues or remediation. The units were successfully installed in December 2013.
Jobname: United Airlines Wide Body Hanger at Dulles International Airport
Customer: Graybar Electrical Company & Chesapeake Electrical Systems
Location: Dulles, VA
Completion Date: August 2013
One of our local distribution partners, Graybar Electric Company Inc., contacted us on a project opportunity where Schneider Electric could not meet the requirements of the project, knowing that we could offer an engineered solution to their customer’s custom application. This particular project required an outdoor NEMA 4 enclosed substation. After reviewing the plan documents and specifications with the electrical contractor, Chesapeake Electrical Systems Inc., SSL issued several RFI’s to present different outdoor enclosure offerings to the consulting engineer with pros & cons for each option. After several meetings and conference calls with the contractor, consulting engineer, distributor and the authority having jurisdiction, Metropolitan Washington Airport Authority (MWAA), it was determined that the best solution would be a power distribution center (PDC) to house the low voltage switchgear manufactured on a skid-mounted unit substation with medium voltage low profile pad mounted switchgear and a liquid filled padmount transformer connected to the PDC via cable tray. This solution saved a great deal of installation time and field labor in addition to providing the contractor with a pre-wired engineered assembly tested and shipped from a single source.
This project scope consisted of upgrading two existing PATCO 5KV substations located in the subway in Center City Philadelphia. Due to space restrictions in the electrical room and the inability to rig new equipment into place, the consulting engineer proposed to retrofit the existing 5KV substation transformer enclosure and secondary power distribution enclosure with new core & coils and interiors while increasing both the KVA rating of the transformer and ampacity of the switchgear. SSL asked to visit the jobsite, so that we could "roll up our sleeves” and take measurements of the existing equipment to see if the retrofit was possible. SSL was able to determine that custom MGM core and coils would fit the available space in the existing transformer enclosure and custom East Coast Panelboard secondary switchgear could be designed to mount in the existing switchgear enclosures. SSL was able to provide technical expertise in all aspects and products on this project from the initial field measurements and conception to the final design and support.
When the project came out to bid in February 2012, SSL attended the pre-bid meeting to get a comprehensive understanding of the project scope. Our product offering for this project consisted of the following equipment: a double ended unit substation utilizing PCI’s medium voltage metal enclosed load interrupter switches and JST’s UL approved cast coil transformers, an MGM distribution dry transformer, an ASCO automatic transfer switch, and other low voltage distribution equipment all housed within a power distribution center (PDC). We worked closely with the bidding contractors to provide them with a clear understanding of our complete equipment package and provided value engineering options with cost evaluations. SSL was able to secure the customer’s confidence by providing an overall complete material & start-up package using our various manufacturers while maintaining a competitive edge by allowing the material to be purchased with each individual manufacturer. The customer had no issue in writing multiple purchase orders as SSL stayed involved in all aspects of the project by ensuring the successful close coupling connection between the PCI load interrupter switches and the JST cast resin encapsulated transformers, providing project management of all components, and remaining intimately involved in the factory witness testing, field start-up and post shipment support.
A representative of a manufacturer contacted us for a quick turnaround for a 15KV PP&L main metal enclosed load interrupter switch with a utility primary metering cubicle after the contractor determined it was required as part of their contract. At the time of quotation, none of our manufacturers were listed on PP&L’s existing pre-approved vendor list for this product. However, we had direct contact with personnel within PP&L’s engineering group to facilitate product approval. Park Detroit was able to provide a quotation for equipment to be manufactured within 3 weeks of approval and was able to provide approval drawings within 2 days. With a manufacturer willing and able to turn around the required engineering documentation to immediately assist PP&L in their approval process, we gained PP&L approval within a day of submitting the drawings to them and had a release for shipment soon thereafter. A little over 3 weeks later, the equipment was installed, inspected and energized and the contractor was able to maintain his project schedule commitment. After successful completion of the project, SSL worked with PP&L to have Park Detroit listed on PP&L’s pre-approved vendor list.
We were contacted by Samson Electrical Supply Company in September of 2011 to supply the new components to an above ground 34.5KV substation required to expand the existing 34.5KV substation. The original project drawings were disregarded due to the utility company not allowing construction while the substation was energized. SSL met with the contractor, Travis Inc., and literally proposed a design concept on a napkin. An additional hurdle to the substation renovation was an energization deadline of February 2013 (5 months from design conception). SSL quickly coordinated various meetings with DisTran Packaged Substations to communicate the intent, scope, pricing, and delivery requirements. The scope of work included: steel structures, hardware, ground platforms, insulators, bus pipe and bus support clamps, field supervision and design engineering. The equipment arrived onsite in January 2013 and was installed the following week, thereby surpassing the end user’s expectation.
We received the request for proposal from Yonkers Electric Contracting Corporation in early August of 2011. The scope of the contractor’s work for the project included purchasing, installing, rigging, and commissioning a new outdoor 2000KVA unit substation into existing jobsite conditions. The construction timeline was the compelling issue on this project. The project was awarded in late August 2011 and was to be installed and commissioned by December 2011. We worked with the contractor, consulting engineer, and end user to review the plan documents and equipment leadtimes in order to come up with a solution that would meet the intent of the specification and the project timeline. In the end, we supplied a new 2000KVA substation transformer by Sunbelt Transformer and a 1600A NEMA 3R outdoor non-walk-in switchgear lineup by Park Detroit. Drawings for approval were completed within 1 week and approved the following week. The equipment arrived onsite as required by the customer and SSL assisted in the commissioning and training process to complete our support of the project in order to meet the required completion date.