Confidential Client
Midwest USA
Power & Energy
Overview
A global food & beverage manufacturer plays a critical role in supporting large-scale food production and distribution, requiring reliable utilities and infrastructure to maintain operations. As part of a facility expansion initiative, the client introduced a new wastewater treatment plant (WWTP), requiring upgraded substation electrical infrastructure to support safe, efficient operations.
To meet this need, Nexus Engineering Group was engaged to provide execute-level engineering services for the design of a new overhead feeder to connect the WWTP to the existing substation. The project focused on expanding the facility’s electrical infrastructure by delivering a 12.47 kV overhead feeder design to support reliable power delivery between Substation #2 and the new treatment facility.
Nexus’ water wastage project scope included conductor engineering, routing and modeling, relay coordination, and preparation of construction-ready deliverables. The goal was to provide a complete, coordinated design that aligned with existing infrastructure while supporting the client’s long-term operational needs.
Challenge
This water wastage project presented several technical and coordination challenges that required careful planning and integration:
Integration with Existing Infrastructure
The new overhead feeder needed to tie into existing substation electrical infrastructure and previously designed pole structures. This required the team to work within constraints established by prior engineering efforts while ensuring compatibility with the new circuit design.
Coordination Across Multiple Engineering Inputs
Portions of the supporting pole structures and underground duct bank systems were designed by others, requiring Nexus to coordinate closely with third-party designs and assumptions. The team had to ensure alignment without direct control over all design elements.
Efficient Use of Existing Design Data
The project relied on an existing PLS-CADD 3D model developed for a previous project. Nexus needed to update and integrate new routing and conductor design into this model while maintaining accuracy and consistency with available survey and LiDAR data.
Balancing Constructability and Performance
Designing a new medium-voltage overhead feeder route within an active industrial environment required balancing electrical performance, constructability, and physical routing constraints—ensuring the design met capacity requirements while remaining practical for installation.
Solution
Nexus addressed these challenges through a coordinated, multi-disciplinary approach that combined electrical engineering and transmission line design expertise.
The team leveraged the existing PLS-CADD model as a baseline and updated it to reflect the new circuit routing and conductor design. Through detailed modeling, Nexus evaluated conductor sizing, sag-tension requirements, and system clearances to ensure compliance with applicable standards and reliable long-term performance.
In parallel, Nexus performed power system analysis—including short circuit and overcurrent coordination—to develop relay setting sheets for both the substation feeder breaker and WWTP systems. This ensured proper system protection and operational reliability across the expanded electrical infrastructure.
The team also developed comprehensive construction deliverables, including plan and profile drawings, staking tables, sag charts, and technical specifications. Direct-embed foundation design was completed using geotechnical data provided by the client, ensuring structural integrity of the new pole line.
By integrating engineering, modeling, and coordination into a single delivery effort, Nexus provided a streamlined communication path and reduced the need for the client to coordinate separate design vendors. This approach enabled efficient execution and ensured a consistent, high-quality design solution.
Services Provided
- 12.47 kV overhead feeder design and conductor engineering
- Distribution line routing, modeling, and alignment updates (PLS-CADD)
- Conductor sizing and sag-tension analysis
- NESC/RUS-based clearance verification
- Plan and profile drawings, staking tables, and sag charts
- Direct-embed foundation design
- Technical specifications and construction deliverables
- Power system modeling and relay setting development
- Electrical coordination and project management support
Project Director
