Actalent Replaces Aging Equipment to Ensure the Client Can Generate and Provide Reliable Power

The Client

Our client is a southern-based utility provider serving millions of customers nationwide.

The Challenge

A distribution substation (69–46–12 kV) required protection and control infrastructure upgrades to improve reliability and functionality. The project presented several challenges that had to be addressed for successful execution: aging equipment needed replacement, the existing system relied on conflicting and nonstandard schematics, and both new and legacy equipment had to be integrated seamlessly. Additionally, although some of the new equipment differed in size from the existing components, the overall substation footprint remained fixed, requiring careful planning and precise placement of all elements.

The Actalent Solution

To address these challenges, Actalent assigned a full-time engineer for three months to support the project. During this time, the engineer researched equipment compatibility and determined the necessary configuration to ensure the new and existing systems operated seamlessly. Actalent also collaborated with equipment vendors over a two-month period to better understand the integration process and resolve any issues.

Initially, the client planned to use circuit switchers, which offer greater functionality than trans-rupters but are larger and more expensive. As the project progressed, it became clear that circuit switchers were too large for the station, requiring a shift to trans-rupters. This change necessitated additional engineering and design rework by Actalent.

At the same time, the client evaluated the use of R-MAG breakers as an alternative to traditional gas breakers. Due to their increased reliability and fewer moving parts, R-MAG breakers were ultimately selected. As a result, the internal staff, Actalent engineer, and construction crew had to familiarize themselves with the installation and operation of this newer technology.

The station’s power system operated between two SCADA cabinets, and space constraints prevented the inclusion of a centralized control house. To accommodate this, the engineering team developed a design featuring two separate control structures that could communicate with each other. For system schemes, Actalent leveraged existing standards and adapted them as needed. The engineer also defined input and output alignments and incorporated this information into the elementary diagrams.

Ultimately, the Actalent engineer replaced fuse and switch combinations, single-phase transformers, printed circuit boards (PCBs), band meters, batteries and SCADA equipment.

The Results

Actalent delivered 59 drawings—including SIA, single-line and three-line drawings—detailing two new transformer banks, feeders, trans-rupters and associated equipment. The engineer also developed a specification sheet, created two Bills of Materials (BOMs) and prepared a Shop Fabrication Request for relay control subpanels and their components.

Through this work, Actalent enabled the client to ensure reliable electric service for its customers, begin implementing R-MAG breakers and modernize the station’s design to align with current industry standards.