Case Study | Project Tortilla Chip Switchyard

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.