SAVING TIME& MONEY:A CASE STUDY
OF A CUSTOMIZED FACTORY-BUILT SUBSTATION
SAVETIME
SAVEMONEY
IMPROVEQUALITY
TNMP’SDRAWINGS
OUR FACTORY
700MILES
INTRODUCTINGFACTORY-BUILT SUBSTATIONS
HOW • LESSONS LEARNED • ANALYSIS
TNMP BACKGROUND & SERVICE AREAStriving to Accommodate Growing Customers’ Needs
MOON - Prresentation Template 3
T & DMore than
9,000 Miles of Transmission
& Distribution Lines
POWERMore than243,000
Homes & Businesses
SERVES70 Communities
in Houston& Dallas-Fort Worth Area
POWERto Petroleum Customers
along Texas Gulf Coast
CONVERSION69kV to 138kV in West Texas
Large Footprint Substation
25kV Distribution Bay
6 Bays
5 – 25kV DistributionCircuit Breakers
PROJECT NEEDSStandard Meets Safety
NEED FOR AN ALTERNATIVE APPROACHProject Location Hurdles
EXTREMELY REMOTE
20 MinutesSouth of Pecos, TXResources Difficult to Mange
Pecos, TX•
Weather Constraints
High Winds
High Temps
Pecos, TX•
NEED FOR AN ALTERNATIVE APPROACHFBS Benefits
CREW MANAGEMENT• No need to manage multiple
crews at once• Substation arrives
ready to bolt into place
CREW SAFETY• Reduce risks of accidents• More controlled environment
COST SAVINGS• Little to assemble in field• Less billable hours for field
crews
TIME SAVINGS• Quick erection phase• More completed projects year-to-
year
CONSTRUCTIONQUALITY
• Marshaled materials• Welding completed
in indoor environment• Built to withstand rigors
of transportation
DESIGNITERATIONSSaving time in the field requires much attention to detail during the design phase of a project.
Good - Creative Presentation 8
CommunicationEnsure project needs
are being met
DESIGN ITERATIONPROCESS
Balancing ActNeeds vs. Shipping
Requirements & Costs
Solving the PuzzleQuadrant Approach
4 Shipments
Pacos, TX Alexandria, LA
40 Feet
Good - Creative Presentation 10
CommunicationEnsure project needs
are being met
DESIGN ITERATIONPROCESS
Balancing ActNeeds vs. Shipping
Requirements & Costs
Solving the PuzzleQuadrant Approach
4 Shipments
• Make sure sections line up• FBS can survive shipment• Steel supports needed• Built without a foundation
Good - Creative Presentation 11
2 WeekDesign Process
Convert standard design to functional FBS
CONSTRUCTION BEGINS
Dimensionsto Accuracy
Utilize 3D modeling
Integrity ChecksEnsure substation can survive
traveling down highway
12
If they can design it. We can build it.
“- Duke Taylor, FBS Manager
CONSTRUCTION & ASSEMBLY Factory-Built: 1.29.16 – 2.9.2016
Rail 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 Problems“I 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 TechServ
ANALYSIS
“We had a really positive experience and the project was very favorable on our side.” - Chris Gerety, Director of Engineering & Land Services, Texas-New Mexico Power
17
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.
4 Weeks 8 Weeks 12 Weeks 16 Weeks 20 Weeks 24 Weeks
Design 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 Complete2/9/2016
Substation Delivered2/11/2016
Substation Installed3/22/2016
10/12/2015 - 10/23/2015DIS-TRAN Design Phase
12/15/2015 - 12/22/2015TNMP Design Approval
1/29/2016 - 2/9/2016Factory Construction
2/10/2016 - 2/11/2016FBS Shipment
3/22/2016FBS Install
3/22/2016 - 5/2/2016
Standard Substation Install
Ideal Install Date*Site Issues – Foundation not yet laid
2/12/2016
All Major & Minor Parts Received
Project Timeline If Built Traditionally*
*Timeline based on project facing the same hurdles.
Customer Prepares Site Location 2/15/2016 – 3/15/2016
10/26/2015 – 11/6/2015TNMP Design Review
11/9/2015 – 12/14/2015
Construction Drawing Development
Steel & Equipment Procurements 11/13/2015 – 1/20/2016
PROJECT TIMELINE
Parallel ConstructionNot utilized due
to site issues
2 MonthDelayPROJECT SCHEDULE
NOT AN IDEAL FBS SCHEDULE If stick built, would have seen an
additional 2 month set back.
AN IDEAL FBS TIMELINE UTILIZES PARALLEL CONSTRUCTION
4 Weeks 8 Weeks 12 Weeks 16 Weeks
Major Parts Ordered
Steel RFM
Minor Parts Ordered
Factory ConstructionComplete
Substation Installed
Design Completion All Major & Minor
Parts Received
3 WeeksDesign Phase
2 WeeksCustomer Design Review
4-5 WeeksConstruction Drawing Development
1 WeekCustomer Final Design Approval
30 Days (or longer)Customer Prepares Site Location
5 DaysFactory Construction
2 DaysFBS Shipment
1-2 DaysFBS Install
Steel & Equipment Procurements 10 Weeks
IDEAL FBS TIMELINE
Contract Amount
Weekly Field Crew
Time Savings
$250K
COST 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 door’s clearance
PRE-PLAN ANEXIT STRATEGY
In the future…
“THE LOWER,THE BETTER”
• Low boy trucks instead of step decks
• Same trucks mean same shipping route
In the future…
Questions?
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