Medium Voltage Service Emergency Repair

Project Name:

Medium Voltage Service Emergency Repair

Project Location:

Norris City, Illinois

Disciplines Involved:

Electrical, Civil, Structural

LeanTrak was contacted to assist in the forensic investigation of a medium voltage switchgear failure. LeanTrak deployed a specialist to the site to work with the local technicians, contractor, and regional leadership to determine the cause, get the problem corrected, and get the pipeline back on line.

It was determined that a combination of leaky top bushings and failed space heaters allowed moisture to build up inside the gear. This eventually caused a phase-to-ground fault on the main bus.

The top bushings were reset and resealed. The space heaters were fixed and new 5 kV bus pieces were fabricated and installed. The electro-mechanical relays were replaced with multilin 750 that allowed trip speeds to be increased to reduce the arc flash potential from category 4 to a category 2. The pipeline was back in service within a few days.

LeanTrak began work immediately on a longer term solution to remove the top entry bushings and aluminum tube bus, and replace with a fabricated copper outdoor bus assembly. This required a new steel structure to support the new bus assembly. LeanTrak was on-site for the bus replacement work. The pipeline was down for a 36-hour period while the bus work was completed.

The client’s personnel, the contractors, and LeanTrak personnel worked together as a team to execute this project successfully.

References are available upon request.

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Station Electrical Upgrade

Project Name:

Station Electrical Upgrade

Project Location:

Scott City, Missouri

Disciplines Involved:

Electrical, Instrument and Controls, Civil and Structural, and Project Management

LeanTrak performed a site electrical safety audit focused on area classification and grounding. The audit revealed a significant number of hazards.  The client determined that a complete electrical upgrade would be the most economical approach to correcting the hazards.

LeanTrak was hired to develop the project’s scope of work and definitive cost estimate. LeanTrak personnel worked closely with the local area folks to ensure a complete understanding of the site’s current installation.

LeanTrak managed the project through construction and commissioning. As-builts, equipment manuals, and final closeout documents were completed in less than 30 days after construction.  The project was completed on time and under budget.

The project involved a new 12,470V substation and low voltage distribution system. A new power electrical center (PEC) building was installed with a new main cable tray system throughout the station.  All station loads were re-fed and all station instruments and controls were taken to a new PLC panel.  Power, control, and instrument wire and cable from the north and south tank farms were intercepted with large, stainless steel terminal boxes.

The client’s personnel, the contractors, and LeanTrak personnel worked together as a team to execute this project successfully.

References are available upon request.

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Station Pipeline Upgrade

Project Name:

Station Pipeline Upgrade

Project Location:

Michigan

Disciplines Involved:

Mechanical, Civil, Controls, and Project Management

Our client has a facility that serves as storage of propane and butane for one of their refineries. In order to increase seasonal flexibility with butane logistics, a new pipeline connection was proposed.  An independent pipeline company has a mainline that passes directly adjacent to the client’s facility.  The client proposed a new pipeline be installed from their manifold to connect their existing butane delivery and receipt system to the independent company’s mainline.

Fast track plans were formulated to construct a 1,400′ long by 6″ diameter, below grade, butane pipeline within the client’s facility located in Michigan.

LeanTrak was contracted to develop construction documents for the installation of the new DOT regulated pipeline. To take advantage of favorable market conditions, the client’s normal front end engineering was combined with detailed design to insure construction could be completed while not adversely impacting sound project decision making.  While some details such as final tie-in locations were being determined, LeanTrak staff focused on the main route, performing field investigations, meeting with stakeholders and reviewing historical data.  Constant communication insured that capital expenditures would not be sunk as the final details were worked out between our client and the independent pipeline company.

Early construction releases insured materials could be ordered quickly and contractor’s given adequate information for manpower scheduling. High quality design packages led to a successful fast track installation, completed to meet the client’s objectives and within budget.

The client’s personnel, the contractors, and LeanTrak staff worked together as a team to execute this project successfully.

References are available upon request.


    Pipeline Integrity Management

    Project Name:

    Pipeline Integrity Management

    Project Location:

    Various

    Disciplines Involved:

    Mechanical

    LeanTrak provides a wide range of services to clients required to maintain a robust pipeline integrity management plan as regulated by the Pipeline and Hazardous Materials Safety Administration (PHMSA). Two examples are outlined below:

    Reassessment Planning

    A pipeline operator’s pipelines are required to be reassessed on a regulated timeline depending on a number of risk factors associated with the integrity and safety of each specific pipeline. The reassessment task is complex, requiring pipeline data review for items including internal and external corrosion, third party damage risk, geology, pipe age and fabrication and operating conditions.  Further complicating the reassessment process is the evolving inline inspection tool technology and current regulatory emphasis. LeanTrak provides data analysis, risk reviews, tool technology reviews and knowledge of the client’s integrity program standards to develop pipeline reassessment plans.  LeanTrak documents every step of the process, providing the client with all required records mandated by PHMSA rules.

    Audit Preparation

    PHMSA annually audits pipeline operators for compliance with the regulations for integrity management. Usually, a pipeline operator is notified of an upcoming audit with instructions on the audit’s focus.  LeanTrak provides audit preparations, including data gathering, records review, regulated drawing reviews and historical tool run data.  LeanTrak prepares an audit spreadsheet for each pipeline segment to be audited that insures all data has been quality checked and is ready for the auditor’s review.  After an audit, LeanTrak prepares an after-action report that serves to ensure that future audit preparation incorporates lessons learned. LeanTrak has performed successful audit preparation services for over 100 pipeline segments during the past three years.

    References are available upon request.