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Project Tortilla Chip - Austin Switchyard

AUSTIN, TX

 

 

 

The deployment of advanced control modules in high-capacity environments is essential for optimizing operations and ensuring reliable performance. In this project near Austin, Texas, Cummings Electrical installed three control modules for a 100MW switchyard showcased innovative solutions to complex challenges, particularly in thermal management and logistics. This initiative not only demonstrated Cummings' technical expertise and commitment to quality but also contributed to enhanced equipment reliability and client satisfaction.

Scope of Work

The project involved deploying three control modules for a 100MW switchyard near Austin, Texas. The team focused on optimizing HVAC systems with underfloor cooling and hot aisle containment to manage heat from server racks and electrical equipment. Each control room, measuring 76’x16’x12.5’, was constructed in two segments of 38’x16’ and assembled on-site by the Cummings Integrated Manufacturing Service Team. The modules weighed between 77,000 and 89,000 lbs., presenting challenges during transport. Rigorous factory acceptance testing (FAT) was conducted prior to commissioning.

Challenges & Solutions

Thermal management in high-load environments was a significant challenge. Cummings optimized the HVAC systems to address heat generation from equipment. To ease transport and assembly, the modules were split into 38-foot sections. Experienced personnel ensured proper reassembly on-site. Assurance testing was conducted under tight timelines through a dual-phase approach, with both factory and on-site testing to quickly resolve issues.

Start Date
October 2022

Completion Date
September 2023

Unites & Phases
3 Units over 1 Phase 

Prefab Product
Electrical Switchyard Control Room 

Vertical
Substations & Renewable Energy


Results

The project successfully deployed three operational control modules on time. The HVAC design enabled effective thermal regulation, enhancing equipment lifespan. The modular approach reduced construction time and logistics complexity, ensuring high reliability. The project met all benchmarks, reflecting positively on Cummings' capabilities and resulting in high client satisfaction.

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