Customer
AEP
Location
West Virginia
Highlights
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Wire sizing error identified before installation
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Coordination with engineering team prevented schedule impact
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Avoided over-engineering and preserved safety integrity
Proactive Oversight Resolves Wire Sizing Conflict in Substation Upgrade
The Challenge
Root Cause Analysis
- Design Oversight: Engineering prints specified a wire gauge incompatible with the lug size on the specified disconnect box.
- Legacy Planning Issues: The long delay in project execution introduced coordination gaps in equipment specifications and supply chain.
- Potential for Delay: Proceeding without verification would have led to rework, schedule disruption, or unsafe installations.
The Solution
Engineering Validation
Our team proactively reached out to the engineering lead to review the design. A joint investigation with station supervisors confirmed the incompatibility between the disconnect lugs and the specified 750 MCM wire.Voltage Drop Study and Wire Size Adjustment
A new voltage drop study was conducted. It confirmed that 500 MCM copper wire would provide adequate capacity for the station feed, ensuring both compliance and performance. The adjusted wire size was approved and integrated into the project.Maintaining Schedule and Outage Plan
This change prevented delays, allowed the contractor to maintain the outage schedule, and kept the project on track.Key Benefits
- Time & Cost Savings: Avoided costly rework and potential material waste
- Schedule Adherence: Outage window maintained with no impact to customers
- Improved Design Fidelity: Field feedback loop helped validate engineering assumptions
- Safety Assurance: Equipment was installed properly without forcing improper fits