Case Study | Project Pony Express Fleet Electrification

Scope of Work

The project encompassed the deployment of 1,500 electric vehicle (EV) charging skids and 250 power distribution skids across multiple phases. Cummings designed and manufactured four different EV charging skid configurations and two distinct power distribution skid models to meet various sizing and scalability requirements. A key design feature was the standardization of all EV charging skids around a common transformer, which ensured reliable and consistent power distribution across all units. Each EV charging skid was supported by 400A panels and was equipped with a 400A or 800A disconnect, depending on the specific load requirements at each installation site. Circuit protection for the system was managed with a combination of 100A and 16A breakers. The overall system was designed with an emphasis on flexibility, scalability, and ease of installation to accommodate the ongoing phases of the rollout.

Challenges & Solutions

Cummings Electrical faced several challenges deploying EV charging and power distribution skids across multiple phases and locations, particularly in ensuring scalability, standardization, and load flexibility. To address these issues, they designed modular and scalable systems with a standard transformer for standardized power distribution, making replication easier. The skids were configured to support various power requirements, enabling customization for specific site needs. Pre-integrating components prioritized installation efficiency, which minimized operational downtime during the deployment of 1,500 charging skids and 250 distribution skids. Additionally, the systems were equipped with 100A and 16A breakers to ensure compliance with stringent electrical standards, maintaining safety and reliability across different locations.

Results

The project was successfully deployed in multiple phases, with 1,500 EV charging skids and 250 power distribution skids installed across various locations. By standardizing the design around a common transformer and offering flexible power distribution solutions, Cummings ensured the system's scalability, which could easily adapt to different site conditions and power load requirements. The pre-integrated design of the skids allowed for faster installation, minimizing downtime and improving overall deployment efficiency. Additionally, the use of customizable disconnects, circuit breakers, and load flexibility provided a robust and safe system that met the varying needs of each deployment location. The project was completed on schedule, and the client received a highly reliable and scalable solution that would continue to support the growth of the EV charging infrastructure in the future.