Energy / Power

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SSOE is providing design and engineering services for constructing a new greenfield solar cell manufacturing facility for a solar client. The project, once complete, will span approximately 1 million SF and will be designed to produce 5 GW of solar cell manufacturing per year.

Our team supported the client throughout the site selection and acquisition process, preparing a site due diligence report analyzing environmental, utility, zoning, site development, and permitting constraints. Our services also included master planning and early site development plans, including mass grading and stormwater management plans and specifications.

As part of the project, SSOE has worked closely with a Chinese Design Institute to assist in localizing the client’s technology used overseas to ensure compliance with all U.S. codes and standards. This involved extensive evaluation of the design basis, hazardous chemical usages and storage volumes, egress requirements, and modular construction methodologies. In this analysis, SSOE was able to optimize the facility layout to suit a uniform structural layout, fostering a modular concept for the cleanroom space of the production building.

Additionally, SSOE spent the early stages of the Schematic Design focusing on the most critical and highest value systems within the design. Through discrete analyses of the cleanroom classification, water purification, recycling, wastewater strategy, and process utilities, our team refined these concepts to provide more cost certainty to the client and the contracting community.

Our team also concentrated design efforts on critical path items, such as early earthwork packages, preliminary structural design including steel mill orders, and major facility equipment specifications to facilitate early procurement for long-lead items. As such, SSOE and the client have maintained the overall project schedule and the anticipated start of production timelines.

Construction on the project is expected to begin later this year with production beginning at the end of 2026.

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In addition to safety improvements, SSOE’s upgrades also improved product distribution and reduced downtime.

SSOE completed multiple projects for the Marathon Load Rack Program. This program was charged with improving safety and optimizing truck loading across their facilities by eliminating potential fall hazards. The Detroit Load Rack was one of the larger projects completed due to the extent of piping and electrical changes implemented.

The scope included the design of new platforms, gangways, stairs, safety cages, load arms, and piping. The safety-enhanced version of Marathon’s load rack included improved controls and safety interlocks, as well as improved lighting. The operator interface was redesigned to assure that safety interlocks and protocol for loading are satisfied prior to the start of loading. To ensure safety and ergonomics, many of the hand-operated valves were replaced with actuated valves. SSOE also integrated the control of the hydraulic gangway as part of the load rack controls. Hydraulically actuated gangways were installed to prevent injuries related to strain and poor ergonomics. In some areas, SSOE added stairs or extended platforms to create an optimal distance between the operator and the fill point.

SSOE’s experience with asphalt piping and electrical systems extends far beyond addressing safety issues, providing the added benefit of increased efficiency at this facility. Redesigned piping at loading stations improved product distribution. Reconfigured controls ensured that only affected lane(s) would shut down in the event of a problem, resulting in less downtime. The features integrated were part of a standard used throughout Marathon’s facilities so that workers can now safely operate equipment at any location.

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SSOE’s efforts, along with other design consultants, will save $100 million a year through sustainable features.

When the National Nuclear Security Administration (NNSA) decided to develop a new site with multiple facilities, SSOE was enlisted to lead design efforts for all Mechanical, Electrical, Pluming (MEP) and structural systems. With a large multidiscipline team in place and innovative use of 3D BIM design, SSOE played an integral role to the success of the project.

Mandated by Kansas City’s Responsive Infrastructure, Manufacturing and Sourcing (KCRIMS) transformation plan, the project was implemented to protect some of the nation’s most premier security assets. The new complex incorporates five buildings, featuring manufacturing spaces, laboratories, office spaces, and warehouses. SSOE led all MEP and structural design efforts for the campus buildings and provided structural and MEP design for a central utility plant, which included a chilled water system, cooling tower system, hot water boiler system, and a compressed air system. SSOE’s scope also included the electrical design of medium and low voltage power, lighting, auxiliary, grounding, and outbuilding systems.

The new campus, which manufactures non-nuclear mechanical, electronic and engineered materials for national defense systems, was developed to replace outdated facilities. SSOE’s efforts enabled the client to upgrade from an outdated complex into a 21st century Nuclear Security Enterprise.

SSOE followed sustainable design principles in an effort to reduce environmental waste, maintenance and energy costs. The efforts from the design team and their consultants will result in saving the client more than $100 million each year and qualified the project for LEED® Gold certification.

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Dover Light & Power, with whom SSOE has a 20+ year relationship, called upon our firm to design a fiber optic backbone loop around the City of Dover, Ohio. The fiber optic cable used was a multimode type, with the loop consisting of 48 and 96 stranded fiber cable. The fiber optic loop is approximately 10 miles in length.

Initially, the fiber optic system was utilized by the electric department for relaying and Supervisory Control and Data Acquisition (SCADA) communications. SSOE then designed a governmental and educational wireless Wide Area Network (WAN). The governmental WAN connects the department networks and provides data and voice communications between various city buildings and offices. The educational WAN provides data, voice, and video communications for the city’s public and private school systems.

The backbone system can be used in the future for cable TV, telephone, and internet services.

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SSOE has deep experience across many manufacturing sectors. The following are examples of GE Power & Water industrial / manufacturing project experience:

  • Punchline Process Improvement
  • Asphalt Distribution System Analysis
  • Powerhouse Backup Fuel Study
  • Storage Tank Building Demolition
  • 160 PSIG Steam Stress Analysis
  • 400 PSIG Steam Stress Analysis
  • De-Superheater Stress Analysis
  • Stress Analysis HPS Steam Main

Punchline Process Improvement (2013)
Schenectady, New York

SSOE performed process analysis for the purpose of increasing product quality and throughput in the following punchline functional areas: stamping, deburring, final coating, and curing operation. Recommendations and costs were provided for replacement and improvement of the existing manufacturing equipment. The project included manufacturing flow diagrams and equipment selections.

Asphalt Distribution System Analysis (2012)
Schenectady, New York

SSOE performed various engineering services for an existing asphalt distribution system in the plant’s bar shop. The project included fluid flow analysis, pipe stress analysis, pipe support system redesign and reconfiguration, project scheduling, and estimates.

Powerhouse Backup Fuel Study (2012)
Schenectady, New York

SSOE developed a study investigating various fuel options for various fuel alternates for an existing 400 PSIG steam plant. The investigation included comparison of propane air mix, natural gas, and #2 and #6 fuel oils. SSOE performed preliminary design services to help develop proof of concept. The firm also performed energy and cost analysis calculations for proof for funding.

Storage Tank Building Demolition (2012)
Schenectady, New York

SSOE provided a demolition design package for an existing abandoned asphalt storage tank and mixer. The project design included demolition and rework required for segregation from the building’s steam and electrical systems. The design required development of system understanding to minimize interruption to existing manufacturing operations. The project included design, project scheduling, and estimation services.

160 PSIG Steam Stress Analysis (2011)
Schenectady, New York

SSOE performed stress analysis per ASME B31.3 for an existing 160 PSIG system to accommodate operational temperature increase. The firm investigated field conditions to verify existing valve classes and piping infrastructure. SSOE mitigated resulting stresses through system modifications and upgrades of existing components.

400 PSIG Steam Stress Analysis (2011)
Schenectady, New York

SSOE performed stress analysis per ASME B31.3 for an existing 400 PSIG system to redesign the damaged support system. The firm provided analysis with a new recommended support scheme.

De-Superheater Stress Analysis (2012)
Schenectady, New York

SSOE performed stress analysis for a new steam loop for de-superheating per ASME B31.3. The firm worked with GE to simplify system design to expansion joints and minimize impact to the 80-year-old boiler house.

Stress Analysis HPS Steam Main (2011)
Schenectady, New York

SSOE completed an analysis of an existing 600 PSIG / 750 F superheated steam piping, 14″ line size, to confirm adequate flexibility prior to modifications performed during shutdown. Autopipe software package was used to perform the analysis and recommendations were provided back to pipe fitters prior to work.

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Creative design planning saved floor space and enabled uninterrupted operations during early phases of construction.

In 2013, SSOE provided comprehensive design services for a wheelbox upgrade for General Electric’s Steam Turbine Test Laboratory in Schenectady, New York. A leading manufacturer of critical high-speed rotating equipment for the power generation industry, GE Power & Water uses the test laboratory to perform vibration testing of turbine wheels.

One of GE’s major test systems, the wheelbox is a large evacuated chamber in which turbines are run through a range of operating speeds to determine bucket vibration response.

Wheelbox 2 SmallFor this project, SSOE performed the design for removing an existing 4,000 HP induction motor located in the Building 262 (B-262) wheelbox drive pit. Our design included removal of associated control and power control equipment and the eddy current clutch. SSOE also provided detailed design to support installation of the new 5,000 HP induction motor with associated new VFD and new isolation transformer. Modifications to existing switchgear, new motor power feed cabling to the switchgear, oil system connections, control system and vibration monitoring system, including associated wiring, were also part of the scope.

Working within an aggressive project schedule, SSOE addressed a number of project challenges, such as floor space limitations and the client’s need for uninterrupted use of existing systems and equipment during the early phases of construction. Creative repurposing of existing space, namely installing the new VFD on the mezzanine above the lab, helped us work within space limitations. Relocating system connection points and modifying system designs to allow for later installation enabled the client to use the existing equipment to complete current ongoing testing.

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SSOE was awarded a nationwide, five-year IDIQ contract for A/E services related to master planning for over 12 million SF of the EPA’s environmental and analytical laboratory and support facilities. This included coordination with EPA program and regional offices to incorporate their missions and strategic goals into specific master plans.

SSOE has completed the following tasks for the EPA:

Research Triangle Park (RTP), North Carolina
The RTP EPA Research and Administration Facility consists of approximately 1.4 million SF of laboratory, vivarium, office, and special use space.

SSOE has performed the following tasks at this site:

  • Facility master plan
  • Programming and planning to relocate the EPA Division now located off-site into the RTP facility
  • Energy reduction strategies
  • Evaluation of sustainability opportunities

Chapel Hill, North Carolina
SSOE completed an engineering study to provide recommendations for energy reduction strategies and HVAC improvements.

Narragansett, Rhode Island; Athens, Georgia; and Corvallis, Oregon
SSOE provided master planning services to address the renovation of the existing 40 year-old laboratory buildings, strategies to meet/exceed EPAct and EISA criteria, and a “green” strategy for restructuring the site.

Las Vegas, Nevada
SSOE developed a POR and Design Intent documents for a new two-story, 40,000 SF leased laboratory / office building. This building will house the offices and laboratories of the EPA’s Radiation and Indoor Environments National Laboratory currently located at the University of Las Vegas.

Houston, Texas
SSOE developed the POR for a new EPA Region 6 build-to-suit 10 acre campus, including a 90,000 SF laboratory building and support facilities.

Edison, New Jersey
SSOE developed a POR for a new 400,000 SF, state-of-the-art Environmental Science Center. The new facility consolidates the Edison EPA’s program into one building, replacing the aging, inadequate existing facilities.

Fort Meade, Maryland
SSOE completed a conceptual design for modifications of the EPA Environmental Science Center to allow for chemical warfare agents testing as requested by the Department of Homeland Security.

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On April 16, 2013, a Silicon Valley power substation was attacked by a sniper. Shots were fired into the radiators and conservators of 17 transformers, causing the equipment to leak 52,000 gallons of oil, disabling the yard and interrupting service to customers. Prior to this attack, communication lines were deliberately severed near the site to delay local law enforcement’s response time. As a result, $15.4 million in damages were reported by the utility company, with 27 days spent repairing the substation to bring it back online.

In light of this attack, critical utility service providers are now compelled by the Utility Commission, the North American Electric Reliability Corporation (NERC), and the Federal Energy Regulatory Commission (FERC) to reduce the vulnerability of critical sites through the enactment of the Critical Infrastructure Protection Reliability Standard 014 (CIP-014). To comply with these guidelines, a large electrical utility provider partnered with SSOE and a well known security equipment supplier to design and implement site hardening strategies at its Tier 1 critical sites.

An overall programmatic approach was established, including the definition of hardening objectives, identification of site threats and vulnerabilities, development of recommendations for hardening protocols, and identification of technology sources. SSOE provided project management and engineer of record services for plan implementation by creating detailed design packages with coordinated designs from civil, structural, electrical, and data / fire / security disciplines.

In compliance with safety protocols, SSOE worked with the client’s transmission group in providing all engineering and construction support for the implementation of the following security measures:

  • Electronic access control systems
  • Complete video surveillance
  • Multiple layers of perimeter intrusion detection
  • Anti-climb and anti-cut perimeter fencing
  • Vehicle rated barriers, ditches, bollards, and gates
  • Landscape modifications for visual block
  • Intrusion detection system triggered alarm based lighting
  • Ballistic protection and detection around major assets
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Through the utilization of laser scanning, SSOE was able to gather site information while spending a limited amount of time in the field. This reduction in required field time created approximately $100,000 in project savings for DTE.

DTE Energy sought an engineering alliance partner to efficiently and effectively deliver its Belle River Mills (BRM) Compressor Station Mechanical Drawing As-Built Legacy Program, meeting their delivery deadlines for confirming and updating existing mechanical drawings to reflect current conditions. SSOE was engaged as the partner of choice for this program, having successfully demonstrated its proposed project team’s ability to provide top quality deliverables, while thinking outside the box to maximize value for the client.

In order to provide the best possible value solution, SSOE partnered with an image servicing subcontractor to utilize 3D laser scanning to scan the BRM site at project kickoff. The scans were then used to remotely verify dimensions and locate missing items. An additional, short site visit was required to field investigate a handful of areas that were too congested and detailed to capture on the 3D laser scan. However, utilizing laser scanning reduced the required time for on-site walk downs from months to less than a day. This reduction in on-site staff equated to approximately $100,000 in savings for DTE.

Cost savings are not the only benefit realized through the use of laser scanning. By reducing staff time spent in the field, the risk of injury also decreased. Additionally, laser scans also increase the accuracy of combined drawing sets. Over the years, minor alterations have the potential to create match line errors. SSOE’s process in updating drawings allows measurements to be referenced to a single datum at the site, eliminating errors occurring between drawings.

Ultimately, SSOE met the client’s required deliverables. These requirements include redlines conforming to DTE’s complex drafting field data collection procedure, finalized CAD drawings, and high resolution photography for areas of changes, all while meeting DTE’s standards and procedures.

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Tight coordination of the procurement process prevented potential schedule delays and cost increases due to a scarcity of available parts.

Increasing demand for gas in areas served by an obsolete pipeline prompted Consumers Energy to engage SSOE’s engineering and procurement services to upgrade and replace the line. The project included developing multiple iterations of the routing plan to avoid  recreational areas. SSOE assisted in obtaining permits from the township and various other agencies. The approved route added two miles to the line, making the 24-inch pipe 11 miles in length. SSOE also designed a temporary bypass to maintain gas service while the 2.5-year project was completed.

The project also involved significant changes to the existing metering stations. One station was demolished and replaced, while the other was upgraded and remodeled. A separation wall was installed to provide safety in the event of a gas leak. SSOE developed renderings of the stations and designed landscaping to create a residential character to these buildings, allowing them to blend into their surroundings.

Procurement proved to be challenging due to the extent of supplies and materials that had to be pre-purchased and the difficulty of obtaining the needed parts. SSOE responded to the challenge with careful tracking and tight coordination of the procurement process.

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SSOE applied significant value engineering to the preliminary schematic project design. Through design innovations, utilization of specialists in blast resistant design, and other ideas, Husky realized more than $7 million in savings.

In an effort to improve safety and communication at their Lima Refinery, Husky embarked on a plan to relocate all non-essential personnel away from blast risk zones to a centralized location outside the battery limits of the production facility. They called upon SSOE’s extensive refinery expertise and familiarity with blast resistant structures to design their new control building. SSOE provided full architecture and engineering for the 250,000 SF, two-story structure, which consists of a central control room, laboratory, warehouse, maintenance shops, vehicle repair center, and unit personnel housing.

Due to it’s proximity to plant production operations, the facility was designed to resist a substantial blast over-pressure while maintaining an open and architecturally appealing structure. SSOE collaborated with the owner, specialized design consultants, constructors, and material systems providers to provide a functioning structure that is fully code compliant, protects its occupants from hazards, and allows for the operation and controlled shutdown of systems should an event occur. This collaboration and the application of specific design techniques resulted in a $3 million reduction in the cost of the structural frame alone.

As part of the project, SSOE customized the fire alarm, access control, data cabling, and raceway systems including the specialized protection needs of potentially hazardous operations. SSOE’s Data, Fire, and Security (DFS) team also designed an electronically secure enclosed area featuring anti-passback technology within the access control system.

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Met the client’s aggressive schedule, enabling them to submit their grant proposal on time.

With the next step in their growth (and a major expansion) on the line, Xunlight looked to SSOE to provide the Department of Energy (DOE) with an extensive review of their planned expansion from an initial 25 MW plant to a full scale 100 MW production facility.

This review included:

  • PV cell manufacturing and module assembly processes
  • Facilities and site requirements
  • Chemical handling and safety requirements
  • Production cost estimating
  • Permitting review
  • NEPA assessment assistance

The challenge was to provide a very rapid assessment of Xunlight’s scale-up plan that would also be thorough enough to ensure the DOE’s review process would be smooth and quick. With extensive resources in both industrial process and facilities, SSOE was able to instantly assign a team of multi-disciplined experts to fast-track the process.

The successful technical review that resulted was a product of a proactive and responsive client as well as deep technical resources that allowed a fast-track review by “A-team” experts for each discipline. SSOE’s extensive experience in integrating facility and process design and large project execution produced findings that satisfied Xunlight’s specialized needs.

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Reduced engineering schedule by 30%, saving GLE $60,000 a day.

Glacial Lakes Energy (GLE), a manufacturer of corn-based ethanol, underwent a capacity increase to more than double their existing capability. SSOE provided full engineering, design, procurement, fabrication, erection, and commissioning support. We coordinated with GLE, the contractor, and the process provider to successfully complete a fast-track, turnkey project which increased GLE’s existing ethanol production to 100 million gallons per year.

SSOE utilized staff in its Shanghai, China office to provide 24-hour project support, which reduced the engineering schedule by 30% and helped bring the facility to full production capacity in just 11 months. Also, as a result of the accelerated schedule, the client recognized a sizable profit. GLE saved $60,000 per day, which equaled approximately $1.8 million in profit per month.

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On the merits of SSOE’s broad experience with chemical / energy projects and front-end process design, Secure Energy enlisted SSOE to help it develop a coal gasification system at its Decatur, Illinois plant.

SSOE served as the lead process engineering firm and integrated the various technologies required for the process into the plant. The firm was responsible for modeling and design of the process areas as well as scheduling and cost estimating for the overall engineering effort. With a minimal number of coal gasification units working in the U.S., SSOE developed a mathematical model of the chemical processes involved in transforming coal into synthetic natural gas and utilized the first gasifiers brought into the country by the client’s technology provider.

Running at full operational capacity, the gasification units convert 1.4 million tons of coal annually to 21 billion cubic feet of pipeline quality synthetic natural gas. The gas is supplied to the interstate natural gas pipeline network.

The client’s coal gasification transition was sparked by loan guarantees from the U.S. Department of Energy’s Energy Policy Act of 2005 designed to spur the deployment of alternative energy technology projects.

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SSOE provided on-site assistance at the fist beta site unit which has prepared this company for additional installations and further enhancements to the turbine and balance of system design.

Wind Energy Corporation executed a multiphase project at two separate locations. SSOE provided design and application engineering services for a new vertical axis wind turbine. In the first phase of the retrofit project, SSOE optimized the design of the turbine unit, its structural supports, and power electronics integration. In addition, the project scope included the complete integration of the prototype vertical axis wind sail system. SSOE also provided inverter specification, electrical permit drawings, and controls system development.

As part of SSOE’s Value Promise, SSOE provided on-site assistance at the first beta site unit, which prepared this company for additional installations and further enhancements to the turbine and balance of system design.

For the second phase of the project, SSOE delivered product development support which required multidiscipline team coordination. This effort included control and transmission development, inverter specifications, and system integration for planned installations – executed by our electrical controls team. SSOE’s structural team provided specifications for tower mounting and building integration. By utilizing a planned installation project delivery method, SSOE delivered the project on schedule, which was based on timelines and critical milestones.

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