Industrial Manufacturing Facility

Project at a glance

Scope delivered

• MV service & distribution. 35kV class primary service from Oncor, indoor metal-clad MV switchgear per ANSI C37.20.2, and dual 5,000kVA unit substations distributing 480V three-phase through main-tie-main switchgear. Microprocessor relay protection (SEL platform), arc-flash analysis per IEEE 1584, and protection coordination across the plant distribution system.
• MCC lineups. Eight motor control centers distributed across production zones, comprising 280 motor starters serving production line motors, conveyor drives, and utility motors. Square D Model 6 platform with SCADA-integrated metering and remote monitoring.
• VFD installations. 38 VFDs on production motors requiring variable-speed control (Allen-Bradley PowerFlex platform), sized for application duty cycle with motor protection and integration with the plant PLC network. Harmonic mitigation at point of common coupling per IEEE 519.
• PLC & SCADA. Plant-wide PLC integration on Allen-Bradley ControlLogix, with FactoryTalk SCADA tied to production line HMIs. EtherNet/IP network across MCCs, VFDs, and process instrumentation. Coordination with the OEM process equipment integrators on field bus interfaces.
• Process equipment hookup. Power and control hookups for 14 major production tools, plus compressed air, chiller plant, cooling tower, and process water system motors. Equipment grounding per IEEE 1100 for sensitive electronics, conditioned power for instrumentation.
• Hazardous-location electrical. Class I Div 2 area electrical in the solvent storage and handling zones per NEC Article 500. Explosion-proof fixtures, sealing fittings at boundary penetrations, and intrinsically safe instrumentation circuits.
• Lighting & controls. High-bay LED lighting across production zones (240 lux average at floor), networked controls with occupancy sensing and zone scheduling, ASHRAE 90.1 compliance documentation.
• Life safety. Fire alarm power, emergency lighting per NFPA 101, exit signage, and a 750kW diesel generator with ATS sized for full life-safety load plus essential production controls.

The challenge

The owner’s operations team was committed to first-product output 22 months from NTP. The electrical scope included long-lead MV switchgear (52-week lead time at the time of release) plus prefabricated MCCs that needed to be on the building shell floor before mechanical and process piping installation began.

We engaged the utility transmission planning group during schematic design, modeled the plant load against the available primary service capacity, and produced a service-entrance design that could be approved early in the project. MV switchgear was released during DD with the owner’s approval, ahead of CD issuance. The eight MCCs were specified, ordered, and prefabricated off-site in a coordinated sequence with the building schedule.

The outcome

Energization completed on schedule. Production startup began on the contracted date with full plant electrical capacity available. First-product output occurred within the owner’s target window. Closeout including arc-flash labeling, as-built drawings, and operator training delivered to the owner’s operations team during the commissioning phase.