PCE’s team has completed many relevant projects and has a large list of satisfied clients. Below is a sampling of those clients with example projects:

City of Brownsville, TX


Mr. James McCann, Director of Engineering Brownsville, TX

(956) 983-6204 jmccann@brownsville-pub.com

Mr. James McCann was the main design contact for these projects.

PCE has designed many substations for the City of Brownsville and has performed a full transmission system protection study.

Titan 138-12.47 kV, May 1999, PCE was responsible for designing this new dedicated industrial substation to serve a new tire manufacturing plant in the city of Brownsville, Texas. The station was built for maximum reliability with dual 138 – 12.47kV LTC power transformers. The 138kV bus has four tap positions, two are for a future on-site generation plant. The others feed two transformers which are configured with automatic sectionalizing low-voltage breakers in metal-clad switchgear. Basler parallel balancing equipment and GE microprocessor relays assure continuity of service, even if a transformer fails. PCE prepared complete drawings and specifications, obtaining bids, handled bid evaluation and preparation of contract documents, project management & final inspection. PCE personnel calculated all the fault currents, designed the protective scheme, performed the relay coordination, developed the relay settings, set all the relays, performed functional testing of the protective system and placed the station in service.

City of Brownsville 138-12.47 kV system coordination project. The City of Brownsville is served by a 138 kV transmission loop that has fifteen 138-12.47 kV distribution substations tapped off the 138 kV transmission loop. The fifteen 138-12.47 kV distribution substations are relayed substations with two power transformers and eight underground feeders. PCE modeled the complete 138 kV transmission loop and the 138 – 12.47 kV distribution substations using ASPEN One Liner. After modeling the City of Brownsville power system, PCE analyzed the entire zone 1, zone 2 and zone 3 distance relay settings and verified coordination. PCE also checked that all distance relay settings conformed to the NERC loadability requirements. After checking the distance relay coordination, PCE analyzed the overcurrent relays in the fifteen distribution substations and confirmed relay coordination from the primary side transformer overcurrent relays down to the feeder overcurrent relays. PCE wrote a complete report of our findings and submitted it to the City of Brownsville.





Talquin Electric Cooperative, Quincy, FL


Mr. Bill James, Manager of Planning & Design (850) 627-7651
bjames@talquinelectric.com

Mr. James was the main design contact for the projects.

PCE has designed many substations for Talquin and has performed some smart grid upgrades.

Gretna 69 – 24.94/14.4 kV, Jan 2008. PCE was responsible for designing this new 28 MVA relayed substation with bus regulation and four underground feeder circuits, preparing complete drawings and specifications, soliciting RUS approval, obtaining bids, handling bid evaluation and preparation of contract documents, project management, final inspection and relay commissioning and protective system testing, and preparation of RUS close-out documents and as built drawings. The station was designed adjacent to an existing 69-12.47 kV energized distribution substation. The low-side bus was designed with a main and transfer bus utilizing tubular bus, hookstick switches and all welded connections. PCE personnel calculated all the fault currents, designed the protective scheme, performed the relay coordination, developed the relay settings, set all the (SEL) relays, performed functional testing of the protective system and placed the station in service.

Killearn Smart Grid Upgrade – While PCE was testing their old electrometrical relays, a faulty ABB HU relay was found. The owner made the decision to upgrade all the relays on the panel to SEL. The panel had HU’s and CO’s and was upgraded in place to new SEL 387 and SEL 351 relays with new test switches. PCE prepared all schematic drawings and point to point drawings, completed all the mounting and rewiring in the panel and interfaced the new relays with existing CT’s and breakers. Once all the wiring was completed, PCE personnel calculated all the fault currents, designed the protective scheme, performed the relay coordination, developed the relay settings, set all the (SEL) relays, performed functional testing of the protective system and placed the station in service. DNP 3.0 was used for communication back to the owner’s office.

Peace River Electric Cooperative


Mr. Paul Roberts, VP Technical Services Wauchula, FL

(863) 767-4650 Paul.Roberts@preco.coop

Mr. Roberts was the main design contact for this project.

Pine Level 230-25kV, July 2011. PCE was responsible for designing this new 56 MVA dual transformer relayed substation with feeder regulation and six feeder circuits, preparing complete drawings and specifications, soliciting RUS approval, obtaining bids, handling bid evaluation and preparation of contract documents, project management, final inspection and relay commissioning and protective system testing, and preparation of RUS close-out documents and as built drawings. PCE personnel calculated all the fault currents, designed the protective scheme, performed the relay coordination, developed the relay settings, set all the (SEL) relays, performed functional testing of the protective system and placed the station in service. The station had high side circuit switchers and secondary side MOD’s. There was a normally open tie that segregated the feeders so that each transformer fed only three feeders. The protection included differentials (SEL 587), primary side back-up overcurrents (SEL 351A) and secondary side bus overcurrent relays (SEL 351). The feeder relays were protected with SEL 351S relays. The feeder tie and other automation were controlled with a SEL 451. There was a communication link between the 351S feeder relays and the 351 bus overcurrent relay that allowed the bus overcurrent relay to trip the feeder breaker for a feeder relay failure. Using the SEL 451 logic engine we implemented an automatic transfer scheme. The SEL 451 relay was used to distinguish between a transformer fault versus substation bus faults and feeder faults. After an actual transformer fault is cleared by the high side circuit breaker, the SEL 451 relay sent an open signal to the MOD located on the secondary side of the transformer. After the faulted transformer MOD was opened, the SEL 451 sent a close signal to the tie switch so that the healthy feeders could be reenergized via the healthy transformer. The scheme also included a multi circuit trip functionality that involved communications link between the 451s the 351s and the 351Ss relays. The distribution automation throw over scheme, relay failure scheme and the multi circuit trip scheme were completely tested by PCE.



Horry Electric Cooperative, Inc.


Mr. Reed Cooper, Engineering Manager Conway, SC
(843) 369-6269 reed.cooper@horryelectric.com
Mr. Cooper was the supervisor of the main design contact. The main design contact has recently changed jobs.

PCE has designed well over a dozen substations for Horry over the last 16 years. The details are similar to the one listed below.

Collins Creek 115 – 24.94/14.4 kV, April 2011. PCE was responsible for designing this new 28 MVA relayed substation with feeder regulation and eight underground feeder circuits, preparing complete drawings and specifications, soliciting RUS approval, obtaining bids, handling bid evaluation and preparation of contract documents, project management, final inspection, and preparation of RUS close-out documents and as built drawings. The low-side bus was designed with a main and transfer bus utilizing angular bus and hookstick switches. PCE personnel calculated all the fault currents, designed the protective scheme, performed the relay coordination, developed the relay settings, set all the (Basler) relays, performed functional testing of the protective system and placed the station in service.



Rappahannock Electric Cooperative, Inc.

Mr. Sam Wilson, Director of Engineering Fredericksburg, VA


(540) 891-5846 swilson@myrec.coop

Mr. Wilson was the main design contact for these projects.

PCE has designed over 20 substations for Rappahannock over the last 16 years. Most were similar in details to the ones listed above for Horry. Below are the details of a transmission switching station completed for REC.

St. John’s Transmission Station, April 2010 (last breaker added). PCE was responsible for designing this new ring bus 115 kV transmission station (and adding new breakers as needed), preparing complete drawings and specifications, soliciting RUS approval, obtaining bids, handling bid evaluation and preparation of contract documents, project management, final inspection and relay commissioning and protective system testing, and preparation of RUS close-out documents and as built drawings. PCE also designed the new control house layout that included the AC distribution, DC distribution; batteries and all control and relay panels. PCE personnel calculated all the fault currents, designed the protective scheme, performed the relay coordination for each outgoing line, developed the relay settings, set all the (Basler & SEL) relays, performed functional testing of the protective system and placed the station in service.



Rappahannock Electric Cooperative, Inc.


Mr. Sam Wilson, Director of Engineering Fredericksburg, VA
(540) 891-5846 swilson@myrec.coop

Mr. Wilson was the main design contact for these projects.

PCE designed a new relay and control panel to be used for replacement of each of 27 breakers on the Rappahannock 35 kV transmission system. The protective scheme used included three zones of distance protection. The zone two had to have overcurrent torque control to coordinate with tap breakers that only had overcurrents. The design included control via DNP Protocol. Outputs on the main protection relay were used to control the 01 switch, a 43 Arc Flash Switch and a 43 Reclosing Disable Switch. PCE physically removed the old relay panels and installed the new panels for each breaker and interfaced with other existing panels to coordinate with those existing schemes.



Blue Bonnet Electric Cooperative


Mr. Allen Anderson, Safety Services Bastrop, TX
(512) 332-7840 allen.anderson@bluebonnet.coop

Mr. Anderson was the primary contact for this project.

PCE performed an arc flash study of the entire Blue Bonnet electric system. We modeled their 138 kV, 69 kV, 25 kV, 12 kV, 480 V and 208 V portions of their system using SKM Arc Flash and calculated the incident energies at the 25 kV, 12 kV, 480 V and 208 V portions of the system. For fault currents below 700 amps or voltages above 12 kV, the SKM Arc Flash algorithm uses the conservative Lee equations for coming up with the incident energies. Because the Lee equations are extremely conservative, we used the Arc pro program to get the incident energies for cases where the fault current was less than 700 amps for greater than 12 kV. After determining the incident energies, we determined the adequate PPE required on the 25 kV, 12 kV, 480 V and 208 V portions of the electric system.



Santee Electric Cooperative, Inc.

Mr, Adam Johnson, System Engineer Kingstree, SC
(843) 355-0667 ajohnson@Santee.org

PCE has dozens of clients where we test their batteries and relays on a periodic basis. Below is an example.

Mr. Johnson was the main contact for this project.

PCE evaluated all substation relay settings and made recommendations for modifications. We tested and calibrated all relays and batteries in 27 stations while making recommended changes. We performed functional tests of the existing protection systems and corrected numerous problems that could have resulted in mis-operation or no operation of the relay systems.



Marlboro Electric Cooperative, Inc.

Mr, Troy Coyner, Manager of Engineering Bennettsville, SC
(843) 479-3855 ext 116 tcoyner@marlboroelectric.net

PCE has dozens of clients where we have upgraded the existing relays either in place or installing new panels.

Mr. Coyner was the main contact for this project.

PCE designed a new protective scheme to replace all the electromechanical relays in Marlboro’s dedicated three transformer station for the paper mill. All the electromechanical relay were systematically removed and replaced with new microprocessor relays. We were only able to take one transformer out at a time as the plant remain in full operation while this upgrade was completed. New test switches and a breaker failure scheme were also added at the same time. All panel modifications and wiring was completed by PCE. We also calculated all the new settings, programmed and tested all the new relays and fully function tested the new scheme.



Marlboro Electric Cooperative

Mr. Troy Coyner, V.P. of Engineering and Operations, Bennettsville, S.C.
(843)-454-2865

Mr. Coyner was the main design contact for this project.

We developed both a 4 year Construction Work  plan and a “Long-Range” System Planning Report. We began with Marlboro’s existing Millsoft model  of the system. Then using data collected from the  Cooperative, Central Electric, and other sources,  developed a load forecast for the applicable time  periods for each study. This load information  was loaded into the Millsoft model, and areas in  need of improvement were identified. Then, after  consultation with the Cooperative, and taking their  standard practices into account, various options  were explored to address the problems that were found. Economic and operational considerations were considered, and the best solutions to the problems were compiled into the final report. During this process, the RUS GFR was met with to assure the approval process went smoothly. The final reports each included all supporting documentation, and maps of the proposed system changes.



Nucor Decatur Steel Mill, 500-34.5 kV Main Hot Mill Substation Upgrade (CLC)



Mr. Andy Templeman                                                       Mr. Tom Kersteins

Premier Power Maintenance                                              Nucor Steel

6525 Guio Rd.                                                                  4301 Iverson Blvd.

Indianapolis, IN 46268                                                     Trinity, AL 35673

(317) 879-0660                                                               (256) 560-4945

atemple000@aol.com                                                       Thomas.Kerstiens@nucor.com


Mr. Templeman and Mr. Kersteins were the main design contacts for this project.

Scope of work included incorporation of Power Transformer T5, 500-34.5 kV transformer into the existing main substation. Engineering included installation of precast duct banks, conduits, overhead air insulated bus work, foundation, steel structures, specifying of HV switches, etc. The contractor is Premier Power Maintenance. Design completed 2011, 2012; Presently under construction.



SCC Utilities, Los Alamos, NM — WTA 115 kV Substation (CLC)

Project consisted of a 115 kV 3-Breaker Ring Bus configuration expandable to 6 Breakers. Scopes of engineering were all inclusive including Civil, Site, Grading, Drainage, Foundations and Structural design.

Denton Municipal Electric, City of Denton, TX — Spencer 138 kV Switching Station (CLC)

This Station was designed as a 138 kV Switching Station that initially operated as a 69 kV. Scope of work included all aspects of Electrical Engineering as well as Structural Lattice Design. Engineering also included all Site, Civil, Foundation, Drainage and Retaining Wall design.

Commonwealth Edison Company, Chicago, IL — Diversey 138 kV Substation, IL (CLC)

EPC Contractor: ABB Power T&D, Inc.

Physical Substation Yard Layout; Civil, Structural, and Foundation Engineering



Nowlin & Associates, Inc., Natchitoches, LA — Phase I Environmental Assessment, Hoagland Site, Many, LA (CLC)

Project consisted of writing a comprehensive phase I environmental assessment report for a 3+ acres site in Many Louisiana. Tasks involved physically inspecting the complete site, documenting all remaining structures, researching the history of the site, conducting interviews with former & adjoining landowners and reviewing records obtained from Environmental Data Resources, Inc.



Associated Substation Engineering, Bremen, GA — Long Bay Substation, Virgin Islands Water & Power Authority, Virgin Islands (CLC)



Project consisted of a design of a 40’ x 76’ masonry control building & pile supported foundation, pile support transformer foundations layout and oil containment reservoirs with a pour-in-place concrete firewall. Structures were subjected to 155 mph wind loads and seismic zone earthquake loading. Project also had concrete incased conduit ducts subjects to HS-20 loading crossing through a precast concrete storm drainage trench. Also included was a 69-4.16 kV Auxiliary Transformer and four 69 kV overhead circuits exiting the substation.