Factory built substation case study

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SAVING TIME & MONEY:

SAVING TIME& MONEY:A CASE STUDY OF A CUSTOMIZED FACTORY-BUILT SUBSTATION

SAVETIME

SAVEMONEY

IMPROVEQUALITY

TNMPSDRAWINGSOUR FACTORY700MILESINTRODUCTINGFACTORY-BUILT SUBSTATIONSHOW LESSONS LEARNED ANALYSIS

TNMP BACKGROUND & SERVICE AREAStriving to Accommodate Growing Customers NeedsMOON - Prresentation Template3

T & DMore than9,000 Miles of Transmission & Distribution LinesPOWERMore than243,000Homes & BusinessesSERVES70 Communities in Houston& Dallas-Fort Worth AreaPOWERto Petroleum Customersalong Texas Gulf CoastCONVERSION69kV to 138kV in West TexasLarge Footprint Substation

3

25kV Distribution Bay6 Bays5 25kV DistributionCircuit Breakers

PROJECT NEEDSStandard Meets Safety

NEED FOR AN ALTERNATIVE APPROACHProject Location HurdlesEXTREMELY REMOTE20 MinutesSouth of Pecos, TXResources Difficult to Mangeq

Pecos, TXWeather ConstraintsHigh WindsHigh Temps

Pecos, TX

5

NEED FOR AN ALTERNATIVE APPROACHFBS Benefits

CREW MANAGEMENTNo need to manage multiple crews at onceSubstation arrives ready to bolt into placeCREW SAFETYReduce risks of accidentsMore controlled environmentCOST SAVINGSLittle to assemble in fieldLess billable hours for field crewsTIME SAVINGSQuick erection phaseMore completed projects year-to-yearCONSTRUCTIONQUALITYMarshaled materialsWelding completedin indoor environmentBuilt to withstand rigorsof transportation

DESIGNITERATIONS

Saving time in the field requires much attention to detail during the design phase of a project.

Good - Creative Presentation8CommunicationEnsure project needs are being metDESIGN ITERATIONPROCESSBalancing ActNeeds vs. Shipping Requirements & CostsSolving the PuzzleQuadrant Approach4 Shipments

Pacos, TXAlexandria, LA

40 Feet

Make sure sections line upFBS can survive shipmentSteel supports neededBuilt without a foundation

Good - Creative Presentation10CommunicationEnsure project needs are being metDESIGN ITERATIONPROCESSBalancing ActNeeds vs. Shipping Requirements & CostsSolving the PuzzleQuadrant Approach4 Shipments

Pacos, TXAlexandria, LA

40 Feet

Make sure sections line upFBS can survive shipmentSteel supports neededBuilt without a foundation

Good - Creative Presentation112 WeekDesign ProcessConvert standard design to functional FBSCONSTRUCTION BEGINS

Dimensionsto AccuracyUtilize 3D modelingIntegrity ChecksEnsure substation can survive traveling down highway

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If they can design it. We can build it.

- Duke Taylor, FBS Manager

CONSTRUCTION & ASSEMBLY Factory-Built: 1.29.16 2.9.2016Rail SystemSystem used to temporarily mount substation on to the factory floor to hold base plates and columns during construction.

Support SteelDesigned and used to keep partial assemblies stabilized. Steel supports in place throughout the factory-built construction phase.

5 Day DelayProblem with switches provided by switch manufacturer.

Factory Construction Completed in 10 Days

FBS Shipment & DeliveryTook 1 day to ship & 3 hours to unload. FBS Shipment: 2.10.16 2.11.16

1 Month Assembly DelaySite issues prohibited TNMP from beginning foundation work during the design phase of project. TNMP Installed Without Question or ProblemsI had never seen anything like that before. We always have had to do everything on the job site. But it was perfect. Joe Sandifer, Safety Inspector for TechServTitle HereCupcake ipsum dolor sit amet. Sweet chupa chups cheesecake sugar plum. Sesame snapsTitle HereCupcake ipsum dolor sit amet. Sweet chupa chups cheesecake sugar plum. Sesame snaps

ANALYSISWe had a really positive experience and the project was very favorable on our side. - Chris Gerety, Director of Engineering & Land Services, Texas-New Mexico Power17

Time SavingsProject timeline comparison of FBS vs. stick built substation& review of ideal parallel construction process.Cost SavingsBased on Time Savings Assessment, the elimination of material shortages & the eradication of alignment issues & weather delays.

Today4 Weeks8 Weeks12 Weeks16 Weeks20 Weeks24 WeeksDesign Completion10/25/2015

Major Parts Ordered11/11/2015

Steel Ordered11/13/2015

Minor Parts Ordered12/7/2015

Steel Received1/4/2016

1/20/2016

Factory Construction Complete2/9/2016Substation Delivered2/11/2016Substation Installed3/22/2016

10 days

10/12/2015 - 10/23/2015DIS-TRAN Design Phase

37 days

6 days

12/15/2015 - 12/22/2015TNMP Design Approval

8 days

1/29/2016 - 2/9/2016Factory Construction

2 days

2/10/2016 - 2/11/2016FBS Shipment

1 day

3/22/2016FBS Install

30 days

3/22/2016 - 5/2/2016Standard Substation InstallIdeal Install Date*Site Issues Foundation not yet laid

2/12/2016All Major & Minor Parts Received

Project Timeline If Built Traditionally**Timeline based on project facing the same hurdles.

Customer Prepares Site Location2/15/2016 3/15/2016

10/26/2015 11/6/2015TNMP Design Review

11/9/2015 12/14/2015Construction Drawing Development

Steel & Equipment Procurements11/13/2015 1/20/2016PROJECT TIMELINE

Parallel ConstructionNot utilized dueto site issues2 MonthDelay

PROJECT SCHEDULENOT AN IDEAL FBS SCHEDULE

If stick built, would have seen an additional 2 month set back.

AN IDEAL FBS TIMELINE UTILIZES PARALLEL CONSTRUCTION

Today4 Weeks8 Weeks12 Weeks16 WeeksMajor Parts Ordered

Steel RFM

Minor Parts Ordered

Factory ConstructionComplete

Substation Installed

Design Completion

All Major & Minor Parts Received

21 days

3 WeeksDesign Phase

10 days

2 WeeksCustomer Design Review

35 days

4-5 WeeksConstruction Drawing Development

5 days

1 WeekCustomer Final Design Approval

30 days

30 Days (or longer)Customer Prepares Site Location

5 days

5 DaysFactory Construction

2 days

2 DaysFBS Shipment

0 days

1-2 DaysFBS InstallSteel & Equipment Procurements10 Weeks

IDEALFBS TIMELINE

Contract AmountWeekly Field CrewTime Savings

$250KCOST SAVINGS

Construction Labor Savings

$18K

6weeks

$80K

LESSONS LEARNEDPreparing for the Next FBS

Center of Gravity needed for each shipment, not entire substation

Factor factory doors clearance

PRE-PLAN ANEXIT STRATEGY

In the future

THE LOWER,THE BETTER

Low boy trucks instead of step decks

Same trucks mean same shipping routeIn the future

Questions?

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