Saving Time & Money: A Case Study Of A Customized Factory-Built Substation

1. SAVING TIME
& MONEY:
A CASE STUDY
OF A CUSTOMIZED
FACTORY-BUILT SUBSTATION
SAVE
TIME
SAVE
MONEY
IMPROVE
QUALITY

2. TNMP’S
DRAWINGS
OUR
FACTORY
700
MILES
INTRODUCTING
FACTORY-BUILT SUBSTATIONS
HOW • LESSONS LEARNED • ANALYSIS

3. TNMP BACKGROUND & SERVICE AREA
Striving to Accommodate Growing Customers’ Needs
MOON - Prresentation Template 3
T & D
More than
9,000 Miles
of Transmission
& Distribution Lines
POWER
More than
243,000
Homes & Businesses
SERVES
70 Communities
in Houston
& Dallas-Fort Worth Area
POWER
to Petroleum Customers
along Texas Gulf Coast
CONVERSION
69kV to 138kV
in West Texas
Large Footprint Substation

4. 25kV Distribution Bay
6 Bays
5 – 25kV Distribution
Circuit Breakers
PROJECT NEEDS
Standard Meets Safety

5. NEED FOR AN ALTERNATIVE APPROACH
Project Location Hurdles
EXTREMELY REMOTE
20 Minutes
South of Pecos, TX
Resources Difficult to Mange
Pecos, TX•
Weather Constraints
High Winds
High Temps
Pecos, TX•

6. NEED FOR AN ALTERNATIVE APPROACH
FBS 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
CONSTRUCTION
QUALITY
• Marshaled materials
• Welding completed
in indoor environment
• Built to withstand rigor
of transportation

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

8. Good - Creative Presentation 8
Communication
Ensure project needs
are being met
DESIGN ITERATION
PROCESS
Balancing Act
Needs vs. Shipping
Requirements & Costs
Solving the Puzzle
Quadrant Approach
4 Shipments
Pacos, TX Alexandria, LA
40 Feet

10. Good - Creative Presentation 10
Communication
Ensure project needs
are being met
DESIGN ITERATION
PROCESS
Balancing Act
Needs vs. Shipping
Requirements & Costs
Solving the Puzzle
Quadrant Approach
4 Shipments
• Make sure sections line up
• FBS can survive shipment
• Steel supports needed
• Built without a foundation

11. Good - Creative Presentation 11
2 Week
Design Process
Convert standard design
to functional FBS
CONSTRUCTION
BEGINS
Dimensions
to Accuracy
Utilize 3D modeling
Integrity Checks
Ensure substation can survive
traveling down highway

12. 12

13. If they can design it.
We can build it.
“
- Duke Taylor, FBS Manager

14. CONSTRUCTION & ASSEMBLY
Factory-Built: 1.29.16 – 2.9.2016
Rail System
System used to temporarily mount
substation on to the factory floor to
hold base plates and columns
during construction.
Support Steel
Designed and used to keep partial
assemblies stabilized. Steel
supports in place throughout the
factory-built construction phase.

15. 5 Day Delay
Problem with switches provided
by switch manufacturer.
Factory Construction Completed in 10 Days
FBS Shipment & Delivery
Took 1 day to ship & 3 hours to unload.
FBS Shipment: 2.10.16 – 2.11.16

16. 1 Month Assembly Delay
Site 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

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

18. 4 Weeks 8 Weeks 12 Weeks 16 Weeks 20 Weeks 24 Weeks
Design Completion
10/25/2015
Major Parts Ordered
11/11/2015
Steel Ordered
11/13/2015
Minor Parts Ordered
12/7/2015
Steel Received
1/4/2016
1/20/2016
Factory Construction Complete
2/9/2016
Substation Delivered
2/11/2016
Substation
Installed
3/22/2016
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 - 5/2/2016Standard 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 – 12/14/2015Construction Drawing Development
Steel & Equipment Procurements 11/13/2015 – 1/20/2016
PROJECT TIMELINE

19. Parallel
Construction
Not utilized due
to site issues
2 Month
Delay
PROJECT 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

20. 4 Weeks 8 Weeks 12 Weeks 16 Weeks
Major Parts Ordered
Steel RFM
Minor Parts Ordered
Factory
Construction
Complete
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

21. Contract Amount
Weekly Field Crew
Time Savings
$250K
COST
SAVINGS
Construction Labor Savings
$18K
6
weeks
$80K

22. LESSONS LEARNED
Preparing for the Next FBS

23. • Center of Gravity needed for
each shipment, not entire
substation
• Factor factory door’s clearance
PRE-PLAN AN
EXIT STRATEGY
In the future…

24. “THE LOWER,
THE BETTER”
• Low boy trucks instead of
step decks
• Same trucks mean same
shipping route
In the future…

25. Questions?