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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Self-Optimized Grid Improvement

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Project

Recloser Design for Self-Healing Networks

Location

Cincinnati, Ohio

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Background

One of the largest electric power holding companies in the U.S. is undertaking an initiative to upgrade systems across their service area to implement Smart Grid technology. They are building self-healing networks to help isolate outages and reinstate power more quickly for customers who are outside of the problem area. They enlisted EN Engineering to design reclosers to replace manual switches on the networks.

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Challenges

Once in the field, the team encountered constructability issues between the master plan and a few of the construction locations.

Solutions

After the client identified locations on their network for recloser placements, the EN Engineering team inspected the pole locations to determine their accessibility, condition, and clearance. They worked with the client to resolve location issues for several poles and recommended alternative locations. To resolve constructability issues, the team identified problematic poles, provided the client with options for more optimal locations, and successfully relocated the poles. Finally, the team developed construction drawings and estimates for labor and materials for each recloser.

Over the next two years, EN Engineering will design more than 200 reclosers in the Cincinnati region. The team effectively manages the demanding workflow and communication with the client by maintaining a detailed spreadsheet and sharing it with the client weekly. The EN Engineering team’s knowledge and experience with Smart Grid technology contributed to the success of the project and has led to expansion in other regions of the country. EN Engineering is now providing recloser design services for the client’s North Carolina service areas.

“The EN Engineering team’s knowledge and experience with Smart Grid technology contributed to the success of the project.”

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Powering Up the First U.S. Offshore Wind Farm

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Project

Offshore Wind Generation

Location

Rhode Island

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Background

EN Engineering was called on to provide project management, owner’s engineer, and outage planning services for the first commercial offshore wind farm in the United States, located three miles off the shore of Rhode Island. Construction of the five turbine, 30-million-watt project began in 2015, and in late summer 2016 five Alstom Haliade 150-6-MW turbines were erected. The project interconnects to the client’s 34.5 kV sub-transmission system and supplies power to Block Island and the mainland. Our client is the interconnecting utility and the owner/operator of the facilities.

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Challenges

Because there were no precedents for this type of project, challenges included gaining new experience with permitting, constructing, and commissioning. In addition, EN Engineering facilitated communication among all of the stakeholders, including state and federal authorities. Finally, several severe weather events impacted the timeline of the project.

Solutions

EN Engineering worked with the client to design substations on the island and mainland, modify a third substation to receive the output of the project, install 13 miles of submarine cable from the island to the mainland, and install an additional five miles of underground cable to connect to the transmission grid. The EN Engineering team provided overall coordination of construction schedules between the client and other entities and also facilitated communication between parties. In addition, the team developed outage management and energization plans and schedules, developed switching protocol for the 34.5 kV cable system, and reviewed equipment and cable specifications. 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.

“EN Engineering provided project management, outage planning services, and served as owner’s engineer for the first commercial offshore wind farm in the United States.”

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Submersible Transformer Replacements Provide Improved Access and Reliability

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Project

Submersible Transformer Replacement Program

Location

Ohio/Kentucky

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Background

The client wanted to eliminate all submersible transformers on their distribution system to allow improved access to equipment and replace aged equipment. A total of 500 underground facilities were to be converted to above ground pad-mounts. EN Engineering replaced all primary and secondary cables, along with the terminal poles associated with these locations.

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Challenges

This program took place in upscale, older neighborhoods that were unaccustomed to seeing traditional pad-mount transformers. It was critical to educate customers on the improvement in reliability associated with the new transformers and to work closely with the customer and county to select transformer locations that would minimize visual intrusion while maintaining the electrical improvements desired. In addition, the project provided the opportunity to evaluate and identify looping and reliability opportunities for these neighborhoods.

Solutions

EN Engineering independently ran this new program and provided critical client communication. The team was responsible for planning, detailed design, cost estimating, permit package preparation, easement research, acquisition identification and construction support. More than 250 transformers and 25 miles worth of cabling were targeted for replacement over the course of a three-year construction cycle. The primary, secondary and associated service cabling was also replaced and additional looping was targeted. Our designers were responsible for doing the scoping, detailed design and construction support for all sites associated with these replacements.

It was critical to educate customers on the improvement in reliability and safety associated with the new transformers.

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Design, Demolition, and Installation of Replacement Flare Stacks

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Project

Design, Demolition, and Installation of Replacement Flare Stacks

 

Location

Kentucky

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Background

Our client requested a detailed engineering design package for the installation of replacement flare stacks for two vessels for their steel manufacturing plant.

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Challenges 

The client had two, 20-year-old flare stacks with internal corrosion from the process environment, and the stacks had begun to lean. A temporary solution was needed to enable continued operation until the flare stacks could be replaced. The client also requested a full-service solution for the design and off-site fabrication of flare stacks for two vessels. In addition, the client requested a plan for demolition and installation of the new stacks and on-site supervision of the project.

Solutions

EN Engineering provided detailed design for temporary support for the existing stacks, allowing them to remain in operation until new stacks could be designed, constructed, and installed. EN Engineering also prepared a detailed engineering design package for the installation of the two replacement flare stacks. As a benefit to the client, the new stacks were redesigned with silencers, which were relocated to the roof to grant easier maintenance access. New platforms were designed to aid in access to flow control and flare equipment. The EN Engineering team provided 24/7 staffing to supervise both demolition and installation. The stack replacement was completed on schedule and under budget with no safety incidents.

“The engineering was under budget and on schedule. The quality was excellent. Everything fit just right, and there was no rework.” – Client Project Manager

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