Case Studies

Over the 30-plus years of providing excellence in engineering, we have completed thousands of projects ranging from small simple installations to large complex projects.  Utilizing both AutoCAD and MicroStation, Tangibl Consulting successfully provided our clients with professional quality documentation.  We also have completed hundreds of power studies utilizing both SKM Power Tools and eTAP Software, in addition to power studies we also provide lighting design utilizing Visual Lighting Software.  We are posting only a few Case and Power Studies, please contact Tangibl Consulting, we would very much appreciate a chance to discuss your project. 

34.5kV Switchgear and Power Distribution

Newspaper Printing Facility, Southeast Pennsylvania
Tangibl Consulting was retained by the owner for peer review of the design of their new printing facility. The new facility will be fed from the local utility at 34.5kV.  Tangibl Consulting and its predecessor companies have provided professional engineering and construction services to this client at their other facilities since the 1980s.  The scope of work included 34.5kV service entrance equipment, oil-filled 2500kVA padmount-type transformers and 480V distribution equipment. Tangibl Consulting recommended the use of particular types of equipment, as well as managing the relationship with the local utility company. One of the client’s facilities already had a 34.5kV three-phase, four-wire distribution system, with air-insulated switchgear at the utility service entrance point as well as at other points on the system.  Since the construction of their original facility, medium-voltage switching and protection technology had evolved from large and bulky air-insulated-only designs to more compact SF6 designs incorporating microprocessor technology for fault protection.  The equipment was also unique in that it incorporated a load-break switch with a grounding position that virtually eliminated the need to handle cable elbows and tees after initial installation. In addition to reviewing the design and specification documents for the owner, Tangibl Consulting researched the past performance of the utility supply circuit in cooperation with the serving utility.  Although history suggested good performance based on outages, there is no record of sags and swells.  We then investigated the feasibility of a 2500kVA front-end UPS for the client. Given the sensitivity of the new facility’s printing presses to external sources of voltage sag, swell and harmonics, we recommended that the infrastructure for the UPS, including its controls, wiring and battery banks in an outdoor enclosure, be installed now.  Given the sensitivity of the press controls and the experience of our other clients in the power quality area, the client concurred with our recommendation.

34.5kV Switchgear and Power Distribution

Solid Waste Facility, Southeast Pennsylvania

Tangibl Consulting successfully completed the design of a 34.5kV electrical power distribution system at a very large solid waste facility.  This facility, located in southeastern Pennsylvania, is one of the largest landfills in the United States, and is regulated by the Pennsylvania Department of Environmental Protection (PA DEP). Tangibl Consulting and its predecessor companies have provided professional engineering and construction services to this client at these facilities since the 1980’s.  The scope of work included aerial as well as underground distribution, SF6 switchgear, oil-filled padmount-type transformers and 480V distribution equipment.

The facility already had a 34.5kV three-phase, four-wire distribution system, with air-insulated switchgear at the utility service entrance point as well as at other points on the system.  Since the construction of the original system, medium-voltage switching and protection technology had evolved from large and bulky air-insulated-only designs to more compact SF6 designs incorporating microprocessor technology for fault protection.  The equipment was also unique in that it incorporated a load-break switch with a grounding position that virtually eliminated the need to handle cable elbows and tees after initial installation.

In addition to providing the design and specification documents for the installation contractor, the client assigned the pre-purchase of major equipment to Tangibl.  We administered the entire procurement process, from quotation evaluation against specification to contract negotiation, administration and expediting.  The equipment was commissioned and installed on time and within budget.

Harmonic Analysis and Design/Build

Plastics Manufacturing Facility, Bucks County, Pennsylvania

Tangibl Consulting successfully completed the turnkey installation of an electrical power distribution system at a specialty plastics manufacturing facility.  This case study is an example of how we collected data on current and voltage distortion, identified the source of the problem, and made recommendations for the client’s original facility.  As a result of our ability to identify and mitigate the problem, the client awarded us the electrical power and control design and installation for their new, expanded facilities.

The original facility’s major load was four (4) plastic extrusion lines that, when operated simultaneously, produced voltage and current distortion levels in excess of IEEE 519 standards.  The local utility had adopted this standard as the upper limit for the facility’s service. After analyzing the data collected onsite, we recommended installation of passive harmonic filters and isolation transformers.  The client acted upon our recommendation, which provided a temporary solution to excess harmonic distortion.

Growth in the client’s customer base required that the facility be relocated and expanded to ten (10) extrusion lines.  The relocation/expansion design involved re-using some of the original passive harmonic filters and isolation transformers, as well as ten (10) new harmonic-canceling transformers.  Alternate distortion mitigation methods were considered, but given the technology available and the facility requirements, we recommended this as the best solution to the problem.  Power factor, which had also been a problem at the original facility, was also addressed in the new design. The facility’s present voltage distortion does not exceed 1% total harmonic distortion (THD), with the current distortion below 4% THD on most days.  Additionally, the facility’s power factor operates within the limits prescribed in local utility’s tariff.

MV/LV Power Distribution, Controls and Communications

Hazardous Wastewater Treatment Facility, Bucks County, Pennsylvania
As part of an Engineer-Procure-Construct (EPC) team selected by our client, Tangibl Consulting successfully completed the design of the power, control and communications system for an innovative hazardous wastewater treatment facility in southeastern Pennsylvania.  This facility, the first of its kind in the United States to integrate both membrane-type reverse osmosis (R/O) and thermal-evaporator treatment technologies, was mandated by the Pennsylvania Department of Environmental Protection (PA DEP).  The plant’s treatment process was specifically designed to satisfy more stringent regulatory standards for discharge color into the Delaware River. Tangibl Consulting and its predecessor companies have provided professional engineering and construction services since the 1980’s to this client, who entrusted us with this complex project.  Our scope included a large medium-voltage (MV) and low voltage (LV) electrical power distribution system, a supervisory control and data acquisition (SCADA) system for process control, and a communications system for voice, data acquisition and secured remote access.  Major components and systems included underground MV distribution, air interrupter switchgear, LV standby generation, oil-filled padmount-type transformers, 480V distribution equipment, building heating ventilation and air conditioning (HVAC), light and power, a programmable logic controller (PLC) based SCADA system, and a local Wi-Fi system that allows for process control using portable tablets. The facility was designed and constructed in the geographic center of the existing treatment/process infrastructure, which had to remain in service during the project.  The existing LV distribution network was modified with filters to accommodate the large amount of new high harmonic loads.  The SCADA system was custom designed to successfully integrate numerous U.S. and European proprietary process controller platforms supporting each portion of the treatment process. In addition to providing the design and specification documents for the project, the client assigned the management of electrical construction and pre-purchase of major equipment to Tangibl Consulting.  We administered the entire electrical construction and procurement process, from quotation evaluation against specification, to contract negotiation, administration, expediting, subcontractor selection, and project management.  The project was commissioned and installed on time and within budget. After commissioning, Tangibl Consulting was selected by the client to continue to provide engineering and technical services in support of advanced technology upgrades at the facility.

Power Studies

Steel Manufacturer, Mid-Atlantic Area

Power system load flow only study for the 69 kV, 13.8kV, and 480 Volt furnace distribution systems.  The load flow study involved 50 buses with ten different operating conditions. 

Waste Water Treatment Plant, Southeast Pennsylvania

Power system study including short circuit, coordination and flash hazard studies for the 13.2 kV and 480 Volt distribution systems in the plant. The short circuit and flash hazard studies involved 235 buses with six different operating conditions; the coordination study involved 75 coordination curve plots.

Water / Well Pump Station, Southeast Pennsylvania

Power system study including short circuit, coordination and flash hazard studies for the 480 Volt distribution systems for the pump station.  The short circuit and flash hazard studies involved 30 buses with three different operating conditions; the coordination study involved 10 coordination curve plots.

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