Seamless Service for Successful Station Upgrade

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Project

Manor Gate Station Upgrade

Location

Maryland

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Background

Baltimore Gas & Electric (BGE), the company that operates the entire Baltimore area gas distribution system and serves more than 650,000 customers, contracted EN Engineering to upgrade their existing Manor Gate legacy station. This station takes the transmission gas from TransCanada at 720 PSIG and lowers the pressure to 269 PSIG to feed BGE’s Beaver Dam and Notch Clift transmission lines.

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Challenges

The original BGE drawing showed 16” steel, but the pipe was 24”, so the spherical tee that was ordered for 16” did not work. A custom-made tee was ordered, which resulted in a 14-week delay. In addition, commissioning was delayed due to the frigid ambient temperature and weather forecast.

Solutions

The Manor Gate Station upgrade project included two meter runs, four regulator runs, a separator/filter, heater, odorization, controls, and fire suppression, in addition to considerable construction of buildings and concrete to house this equipment. EN Engineering took the design work from conception through completion and also provided the environmental and construction materials testing, resulting in time and cost efficiencies. The team developed accurate and detailed as-built drawings, which required minimal field changes. The construction management team was on site and eliminated time lapses for design questions during construction. Throughout the project, they focused on jobsite safety, contractor oversight, adherence to BGE standards, and cathodic protection. In addition, they interfaced with the compliance team, Certified Weld Inspector, and NACE coating inspection. Weekly meetings with the client’s senior management team assured the project was on track, and the EN Engineering team’s expertise was welcome and respected.

“EN Engineering took the design work from conception through final design and also provided the environmental and construction materials testing, resulting in time and cost efficiencies.”

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Multiple Product Areas Join Forces on Pipeline Project

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Project

New Pipeline and Injection Facilities

Location

Texas

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Background

A new midstream energy company called on EN Engineering for a wide array of services supporting a new pipeline system and injection facilities.

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Challenges

As a new company, the client had not yet developed comprehensive project procedures, so one challenge involved working together to establish new processes and standards. In addition, the project had an aggressive timeline and required the team to work at an accelerated pace.

Solutions

EN Engineering provided project management, engineering, and design services for a new pipeline system consisting of more than 70 miles of 8” and 12” diameter pipeline, as well as five new injection facilities for multiple third-party producers.

Experts from EN Engineering’s entire service portfolio came together to successfully complete the project. The pipeline design team provided oversite of the pipeline routing as well as development of engineering design details, while a facility team provided full mechanical, electrical, civil, and structural design packages, along with hydraulic and surge analysis.

Environmental experts oversaw an environmental survey and provided recommendations for both compliance measures and installation best practices along the pipeline. Several scenarios for flow modeling were evaluated by the integrity team, who also provided recommendations for emergency flow restricting device (EFRD) valves. GIS services were utilized to evaluate alternate pipeline routes and make a commercial recommendation. Designs for cathodic protection were provided by the corrosion team. Finally, procurement experts provided comprehensive support on all equipment, material, and labor contracts, from specification development to expediting and tracking deliveries.

EN Engineering also provided several specialty services, including in-house HAZOP facilitation and shop inspection services, and managed geotechnical, environmental survey, and mill inspection subcontractors. The automation team developed the control philosophy for the injection facilities and interfaced with third-party programmers and PLC integrators.

The EN Engineering team was instrumental in guiding industry best practices and helping the client develop new procedures and standardizations. In addition, they facilitated communications despite several changes in client stakeholders at critical stages during front-end loading and worked at an accelerated pace to meet project deadlines.

“Experts from EN Engineering’s entire service portfolio came together to successfully complete the project.”

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Hybrid System Upgrade Improves Performance

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Project

Hybrid System Upgrade

Location

Aberdeen Proving Ground (APG) United States Army Installation, Maryland

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Background

Our client, a company that leases and acquires Federal Government or Municipality utility infrastructures across the United States, requested assistance to upgrade their antiquated electric infrastructure to enhance system reliability and performance.

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Challenges

It was critical to keep Army mission-essential facilities in service, so the team had to reduce outage time. In addition, they had to develop a system for generating Material Take Offs (MTO) and Bill of Materials (BOM). Finally, the work was challenging because the team was working with incomplete electric asset records.

Solutions

The EN Engineering team converted the existing 4.16 kV distribution system to 13.8 kV, increasing capacity on the existing 34.5 kV and 13.8 kV systems, increasing reactive power to improve voltage profile, and implementing automated devices for fault isolation. The complex project included:

  • Upgrade of 49 linear miles of 34.5 kV, 13.8 kV, and 4.16 kV overhead electric infrastructure, including approximately 3,500 utility poles and 295,500 linear feet (LF) of fiber optic cable for Supervisory Control and Data Acquisition (SCADA) applications
  • Upgrade of 31 linear miles of 34.5 kV, 13.8 kV, and 4.16 kV underground electric infrastructure
  • Inventory of existing electric assets using Geospatial Information Systems (GIS)
  • Upgrade of approximately 400 electric services
  • Installation of 6 new substations, 2 new switching stations, 1 substation expansion, and the demolition of 25 existing substations
  • Development of 34.5 kV, 13.8 kV, secondary, and fiber optic overhead and underground construction standards, including environmental and civil site plan development

To meet the aggressive schedule, the EN Engineering project team served as the intermediary between the client, the U.S. Army, and the Maryland Department of the Environment (MDE) to coordinate and fast track MDE permit approval. The team developed detailed steps to mitigate disturbance to environmentally sensitive areas and prepared a construction sequence and switching operation plan to keep Army mission-essential facilities in service during construction.

EN Engineering conducted a comprehensive GIS inventory of existing electric assets, determining each transformer’s kVA value and secondary voltages so that the proposed transformers were accurately designed. This task involved coordination with the clients’ linemen to verify the values from a bucket truck and underground construction crews to open pad-mount transformers.

Finally, because the client did not own software to generate MTOs and BOMs, the team was faced with compiling material quantities via a time-consuming, manual process. The process of manually quantifying material across 750 design prints was inefficient and carried a high risk of error. As an alternative, the project team brilliantly used the Visual Basic for Applications (VBA) functions in Excel and MicroStation to automate the process.

While the client had not previously outsourced any design work, they called on EN Engineering to assist with this project due to the aggressive schedule parameters required to meet contract obligations with the federal government. The client continues to rely on the firm to keep the project on track and meet their contractual obligations.

“The project team brilliantly used the Visual Basic for Applications (VBA) functions in Excel and MicroStation to automate the process of compiling material quantities.”

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Power Conversion Improves Safety and Reliability

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Project

4kV Power Conversion Project

Location

Baltimore City, Maryland

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Background

The largest electric and natural gas utility in Central Maryland wanted to improve system safety and reliability by replacing outdated and unavailable 4kV equipment with 13kV equipment.

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Challenges

The project team faced several major challenges: to introduce non-standard equipment, establish a right-of-way to install it, and to minimize customer outage time.

Solutions

The EN Engineering team converted four 4kV circuits by reallocating them to local 13kV circuits. They worked on more than 200 existing and proposed utility poles, 22 proposed vaults—including submersible equipment, 4,000 linear feet (LF) of proposed concrete encased conduit construction, and 42,000 LF of underground cable installation.

To complete the project successfully, the project team coordinated with the Department of Recreation and Parks to establish a right-of-way to install non-standard equipment. Team members were instrumental in developing a solution to address the Department’s concerns with renewing their privately owned 4kV equipment. They identified all of the positive and negative risks involved with multiple design solutions and communicated their findings to the stakeholders. The Department of Recreation and Parks decided to install a step-down transformer that is not typical on the system, but provided the most cost-effective solution. Finally, the team developed construction sequences to minimize outage time for over 500 customers.

“The team developed construction sequences to minimize outage time for over 500 customers.”

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Smart Grid Reliability Enhancements

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Project

Electric Distribution Smart Grid Upgrades

Location

Maryland

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Background

Our client, the owner and operator of the gas and electric infrastructure in the Baltimore metropolitan area, called on EN Engineering to assist with a large electric distribution upgrade project and provide design services for storm hardening with the assistance of Smart Grid technology.

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Challenges

The proposed plan required overhead structures to be installed in a county park, which would have delayed the construction due to permit issues. In addition, a rare tree was rooted in the area, so a workaround had to be designed.

Solutions

EN Engineering provided design services for storm hardening to reduce supervisory control and data acquisition (SCADA) on outages, including the installation of Smart Grid technology to 40 poles of overhead electric cable and 5,090 linear feet of underground electric cable. This included an overhead recloser, fuse coordination, re-conductoring to Hendrix spacer cable, and pad-mounted equipment. The EN Engineering team prepared construction prints, communicated with the client’s project manager and engineer, conducted quality assurance/quality control reviews, and submitted all required permit application documents.

To resolve the issue of overhead structures in a county park, the team mitigated the potentially long lead time by making adjustments to the scope. The revised plan met the requirements of the client’s engineer and reused existing overhead structures to avoid work within the county park property. In addition, they avoided negative impact to a rare tree by using poles owned by a communication company.

The EN Engineering team provided technical support throughout the construction procurement process and communicated with the client’s customers and local government departments to keep all stakeholders apprised of the project’s progress. The project was completed in 2017 without any issues, on time, and on budget. Since then, seven additional projects of similar scope have been completed successfully. The client has demonstrated their confidence in the team’s communication, quality, timeliness, and ability to mitigate design and construction issues by rewarding EN Engineering with additional design projects.

“The EN Engineering team mitigated the potentially long lead time by making adjustments to the scope.”

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Successful Upgrade of Water Infrastructure

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Project

Water Main Upgrade

Location

Upper Darby, PA

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Background

The client, a leading provider of water and wastewater utility services in Pennsylvania, is currently investing over $450 million to replace and improve their water and wastewater infrastructure. They called on EN Engineering to replace a large, existing cast iron water main with ductile iron.

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Challenges

The replacement took place along a road with storm drain culvert crossings, which required detailed calculations and analysis. In addition, the road is heavily traveled and highly congested, which made field noting more difficult than usual.

Solutions

EN Engineering designed construction plans and coordinated environmental permitting for the project, which replaced the existing cast iron water main along the busy road. The replacement included approximately 7,650 feet of 8” ductile iron water main and took place along a road with two large storm drain culvert crossings, which required horizontal directional drill path calculations, analysis, and profiles. Because the road is a major transportation artery, field noting was particularly challenging.

The project was completed successfully, and the client relationship continues to expand. EN Engineering is now helping coordinate design and construction plans for future projects between the client and the local gas provider.

“The replacement took place along a road with two large storm drain culvert crossings, which required horizontal directional drill path calculations, analysis, and profiles.”

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Pipeline Replacement Through Existing Gas Corridor

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Project

Dubuque Pipeline Replacement
Location

Northern Illinois

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Background

A large natural gas distribution company required detailed engineering and design for a 30-inch, 8-mile pipeline replacement project located in northern Illinois.

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Challenges

The project posed a number of challenges. First, the pipeline was routed through an existing gas corridor in a heavily populated area. In addition, the existing 22” pipeline was replaced with a 30” pipeline, so a workaround had to be designed to accommodate this change.

Solutions

Because the pipeline was in a heavily populated area, the team worked closely with the client’s real estate group to ensure all landowner concerns were mitigated prior to construction. Additionally, proposed pipeline installation methods were adjusted to place equipment in less populated areas. The proposed pipeline was to be installed mainly within the existing local gas distribution company’s easement.

To accommodate the new 30” pipeline, the design had to take into account the existing 22” pipeline that was required to stay in service throughout construction. The designers developed a way to locate the proposed 30” pipeline within the existing easement. The replacement required precision locating by the survey and subsurface utility consultants to ensure the existing pipeline was accurately located both horizontally and vertically. Once the designers received this information, locating the proposed 30” pipeline in the easement was crucial to maintain sufficient clearances between the existing 22” pipeline and other third party utilities, while still maintaining the construction limits within the existing easement. Every effort was made to obtain additional temporary workspace where available to allow the contractors flexibility in construction for safety and cost effectiveness. The challenging 6-month project was completed on time and on budget.

“The replacement project required precision locating by the survey and subsurface utility consultants to ensure the existing pipeline was accurately located both horizontally and vertically.”

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Sample Stations Designed and Installed to Resolve Deficiencies

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Project

System design, procurement and construction support for sample stations

Location

Texas

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Background

Our client, the second largest refinery in the U.S., surveyed more than 700 existing sample stations in their various refinery units and discovered that over 400 had environmental and/or safety deficiencies. The client prioritized the stations according to the severity of the concerns and called on EN Engineering to execute engineering, design, procurement and construction for the $31 million project to replace deficient sample stations.

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Challenges

The sample stations, which were located in every production unit of the refinery, had to be replaced while the refinery was in operation, or during scheduled turnarounds. In addition, many of the sample stations were high priority and required demanding replacement deadlines. The design team demonstrated flexibility by responding to ongoing changes in priorities, turnaround schedules, operational needs, and safety concerns throughout the project.

Solutions

A dedicated team was embedded at the client’s site to work with plant personnel and executed the project from concept to installation with additional support from EN Engineering employees across the country. The team collected the necessary information and developed detailed plans to install the sample stations. The required documentation included P&IDs, data sheets, isometric drawings, installation details, operational manuals, and spare parts lists. EN Engineering also developed purchasing and tracking specifications for the procurement of each sample station and purchased $1.4 million in materials and equipment. Following procurement, the EN Engineering team provided field construction support. The project required more than 35,000 hours, and the 400 sample stations were designed, installed, and operational ahead of the challenging deadlines.

“Many of the sample stations were high priority and required demanding replacement deadlines.”

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Engineering and Environmental Design for Large Warehouse

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Project

Engineering and Environmental Design for Large Warehouse

 

Location

Harford Country, Maryland

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Background

EN Engineering provided engineering and environmental design resources to successfully obtain all approvals allowing construction of a 600,000+ square foot cross-dock warehouse distribution center.

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Challenges

The client called on EN Engineering to provide environmental design to meet stormwater requirements while also maximizing the building size.

Solutions

EN Engineering’s efficient environmental design allowed the client to maximize the useable area while avoiding and minimizing environmental constraints. The design included creative site work that met stormwater quantity and quality management requirements for a significant amount of impervious surfaces, while maximizing the building size, loading docks and truck/trailer storage. The 600,000 square foot facility includes a cross-dock warehouse, truck/trailer parking, storage and docking, employee parking, and administrative access.  The project involved successful abandonment of a County Road/ROW, offsite reforestation involving Harford County Parks and Recreation and plan adjustments as potential tenants were negotiating lease options with our client. EN Engineering also coordinated the legal, architectural, county and state approvals.

EN Engineering’s efficient environmental design allowed the client to maximize the useable area while avoiding and minimizing environmental constraints.

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Landfill Closure Meets Environmental Compliance Regulations

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Project

Landfill Closure for Steel Facility

 

Location

Ashland, Kentucky

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Background

A large steelmaking facility wanted to formally close an 11.2 acre debris landfill and retained EN Engineering to complete the closure in compliance with state regulations.

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Challenges

The existing landfill was not properly capped, and stormwater runoff was not being properly managed. The closure plan had to comply with state regulations and utilize plant process byproduct as a capping material.

Solutions

The client retained EN Engineering to provide detailed engineering services to properly complete the landfill closure. These services included surveying, civil engineering design and construction observation, all in compliance with state regulations. The deliverables included design drawings, specifications, and a construction survey layout that were monitored by EN Engineering via construction observation throughout the implementation process. The capped landfill was compliant with state environmental regulations and the stormwater runoff was properly managed, eliminating the potential for an environmental hazard. Working with EN Engineering, the client had a single source for detail design, construction management, and maintenance plan development.

Working with EN Engineering, the client had a single source for detail design, construction management, and maintenance plan development.

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