Substations & Renewable Energy Expertise

Harnessing West Texas wind at utility scale, this project included the new construction of a 345kV to 34.5kV substation to support the 151.2 MW Old Settler Wind Farm in Floyd County. The wind farm features 63 GE 2.4 MW turbines and ties directly into the ERCOT grid via the 345kV White River Substation along the CREZ Silverton-to-Cottonwood transmission line. Electrical scope included full substation development, transmission interconnection, and integration of medium voltage systems to deliver clean energy from turbine to grid with seamless reliability.

Energizing 640 acres of clean power, this high-voltage install included a prefabricated control room and the full EPC of a 161kV to 34.5kV substation to support the 80MW River Bend Solar Project. Scope also included installation, terminations, and commissioning of a short slack span to the TVA switchyard.

Tesla, Inc. undertook comprehensive electrical installations at its Austin, TX facility, focusing on the Melt Center substations and control rooms. The scope included prefabrication and installation of cable racks and trays across multiple zones, running conduit and cables varying in size and type, and installing electrical equipment such as panels, AHUs, VFDs, and substation gear. The work progressed from July to December 2024, involving coordination with crane and construction schedules, moving materials and tools, and executing medium voltage cable pulls between substations. Challenges such as boom lift malfunctions, access constraints around plumbing and scaffolding, and safety at elevated work heights were managed through equipment repairs, adjusted installation approaches, and use of large boom and scissor lifts. Punch list items like securing bolts and bonding corrections were systematically addressed. Quality control was maintained through torque and megger testing, inspections using CX Alloy software, and coordination with Tesla to meet commissioning requirements. The team adapted to scope changes, including reassignment of large cable pulls to other contractors, ensuring continuous progress. Throughout, emphasis on bonding and grounding compliance, safety, and housekeeping supported a structured and safe installation process, culminating in the successful electrical setup of the facility's critical production systems.

CS Energy undertook extensive electrical installations at their Fort Stockton substation, located at 874 E 42nd Ln, TX. The work commenced with site orientation, safety training, and thorough review of project documentation to ensure alignment with design specifications. Construction Innovations provided contracting services, performing trench duct installations, conduit layouts, and foundation drilling and pouring across the site including transformer pads, piers, and breaker supports. The installation process involved fitting medium and high voltage cables through various sized conduits, erecting steel structures for low and high voltage skids, and mounting crucial equipment such as switches, insulators, and surge arrestors. Coordination with Texas New Mexico Power (TNMP) ensured proper metering setups and commissioning. Challenges such as conduit fitting adjustments, material delays, equipment damage, and complex relay troubleshooting for a 138 kV motorized switch were systematically addressed through collaborative problem-solving and schedule optimization. After rigorous functional testing and Lockout Tagout procedures, the team successfully energized the 138 kV primary side and associated breakers. The effort concluded with comprehensive site cleanup, documentation updates, and demobilization. The project spanned over five months from September 2024 to February 2025, integrating precise electrical infrastructure with foundational civil works in a high voltage substation environment.

Targa Resources Operating, LLC saw the necessity of robust electrical infrastructure at the Odessa site along Interstate 20. Saulsbury Industries was tasked with installing key substation equipment including power poles, reclosure and air switches, wiring, control boxes, and insulators. The process began with procuring materials and coordinating safe digs with 811 to protect underground utilities. Installation progressed systematically starting with poles, switches, and wiring between key points, utilizing a bucket truck for elevated pole work. A notable challenge was awaiting specific adapters required to terminate connections on the reclosure switch, which Saulsbury addressed by advancing other installation steps to prevent delay. Across several months, diligent effort ensured successful installation of all components and wiring to complete the substation electrical system. Coordination and material pickup at multiple intervals supported steady progress. The work adhered to necessary safety notifications and involved detailed terminations scheduled pending part arrivals. This installation supported Targa's electrical distribution reliability at their Odessa facilities, enabling continued energy operations.