Fleet Electrification & EV Charging Expertise

Tasked with integrating extensive EV charging infrastructure into an active manufacturing facility, the project required meticulous site preparation, precise coordination, and technical expertise. Initial site conditions included existing underground utilities, concrete-encased conduits, and landscaping barriers, necessitating careful excavation, rerouting, and concrete work. The solution involved detailed planning, utility coordination with CPS and SAWS, and precise execution of conduit installations, transformer pads, and charger stands. Technicians installed multiple 480V and 208V chargers, switchgear, transformers, and associated electrical panels, ensuring compliance with city and CPS inspections. Despite weather delays, material sourcing issues, and complex coordination with external contractors, the project successfully delivered a fully operational EV charging system. The resulting infrastructure significantly enhances fleet electrification capabilities, aligning with sustainability initiatives and operational efficiency goals.

 This project includes the deployment of 1,500 electric vehicle (EV) charging skids and 250 power distribution skids over multiple phases. Cummings featured four different EV charging skids and two different power distribution skids to meet sizing and scalability standards. All EV charging skids are standardized around a common transformer to ensure consistent and reliable power distribution. Each EV skid is supported by 400A panels and are equipped with either a 400A or 800A disconnect, depending on load requirements. Circuit protection is managed through a combination of 100A and 16A breakers. The system is designed for flexibility, scalability, and efficient installation across all phases of the rollout. 

Amazon is the end user at 22300 Northcrest Dr, Spring, TX, where the electrical installation and commissioning of an electric vehicle (EV) charging system took place. From August 2022 through March 2023, the work included running conduits, installing medium voltage cables, transformers, CP panels, and Level 2 EV chargers. Initial tasks involved setting up temporary power and detailed job planning. Excavation and trenching were performed for transformer pads and panels, with cleaning and pumping of trenches and manholes to enable conduit and cable installations. Medium voltage cable runs of 835 feet were pulled, and 1000 kVA transformers were installed along with protective NEMA 3R shields. Several repairs of broken conduits, often caused by concrete work, required manual excavation and pipe replacement. Conduit offsets and transformer relocations were managed through change orders with precise trenching and backfilling. Grounding systems were installed with cadwelded wires, ground rods, and ground rings to ensure safety and compliance. Extensive wire pulls and terminations connected the panels to the EV chargers and transformers. Testing included megger and EPS tests on cables and terminations. Site lighting circuits were troubleshot and repaired. Safety procedures such as Job Hazard Analyses and confined space setups supported the work environment. Commissioning assistance was provided in coordination with Shermco. Punch list inspections and labeling of chargers completed the final phases. Labor hours totaled 12,304, reflecting the comprehensive scope and execution complexity over nearly seven months.

Future Energy Group LLC installed new electrical infrastructure to support dual-port Level 3 and Level 2 electric vehicle chargers at their Devine, TX site. The scope included furnishing and installing an 800A 480V NEMA 3R distribution panel, associated circuit breakers, and a 30KVA NEMA 3R transformer, along with conduit runs from utility pole to the new panels. The team coordinated utility locates and worked closely with AEP Texas for service termination and activation, ensuring compliance with all permitting requirements. During the project timeline spanning from June 2024 through February 2025, the crew addressed a schematic error involving swapped high voltage and low voltage panel setups by rerouting conduits after consultation and parts procurement, overcoming this without schedule impact. They also installed concrete pads, performed firestopping, and completed site signage installation per company environmental standards. The final phase included commissioning support, completing wiring terminations for the chargers, and field verification of equipment functionality to ready the EV charging station for operation.