CASE STUDY
FULLY REDUNDANT E-HOUSE
THE CHALLENGE
Fully Redundant E-House for Dredge Boost Pump Application (500HP)
Our customer needed a portable, turnkey MCC (Motor Control Center) solution that could be deployed in the field with minimal additional installation effort.
National Service Alliance was asked to design and deliver a self-contained, motor control solution capable of:
- Housing and operating two 500HP Active Front End (AFE) VFDs.
- Providing reliable power distribution via a 2000A switchboard.
- Integrating PLC-based control and monitoring
- Maintaining proper environmental conditions through HVAC systems.
- Deliver a fully assembled, tested, and ready-to-deploy unit.
Delivery: Kermit, TX
CLIENT OVERVIEW
- Industry: Oil & Gas
- Focus: Leading provider of proppant and logistics services to the oil and gas industry within the Permian Basin.
SOLUTION & RESULTS
NSA’s approach delivers several key results and impacts:
- Reduced Field Installation Time & Cost
By fully assembling, wiring, and testing the system before shipment, NSA minimizes on-site labor, commissioning time, and associated costs. - Improved Reliability & Quality Assurance
Factory testing of power, controls, and communications ensures that the system arrives fully validated and operational, reducing startup risk. - Enhanced Mobility & Flexibility
The containerized design provides a portable MCC solution, enabling rapid deployment to different locations as operational needs change. - Integrated, Turnkey Solution
NSA eliminated the need for multiple vendors by delivering a complete package (power, control, cooling, and enclosure) in a single system. - Scalability & Engineering Support
NSA accounted for uncertainties (e.g., missing motor data) and built in flexibility for engineering review and future adjustments, ensuring long-term applicability.
NSA'S SOLUTION
NSA proposed and delivered a custom-engineered, modified 10’ x 8’ shipping container designed as a mobile MCC package.
This solution was designed as a plug-and-play, factory-tested system to minimize field work.
- Electrical Power & Control
- Two (2) 500HP AFE VFDs (Rockwell PowerFlex 755T)
- One (1) 2000A main switchboard with feeder breakers
- Integrated Rockwell ControlLogix PLC system with full I/O capability
- Marshalling panel for clean field connections and troubleshooting
- Mechanical & Environmental
- Fully Redundant HVAC systems, wall mounted and fully commissioned.
- Insulated and finished interior for environmental control
- LED lighting (interior and exterior)
- Container Modifications
- Custom entry door and emergency escape hatch
- Cable penetrations via MCTs for clean routing
- Finished interior with 18-gauge white sheeting.
- Testing & Commissioning
- Full power-up and functional testing at 480V
- I/O verification testing
- PLC-to-VFD communication validation
- V/Hz functional testing of each VFD
- Fully assembled and commissioned prior to shipment.
OVERALL SYSTEM
The system is a fully integrated, containerized Mobile Motor Control Center (MCC) designed to provide power distribution, motor control, and automation in a single, self-contained unit.
At its core, the system takes incoming 480V, 3-phase power and distributes it through a 2000A main switchboard, which feeds two 500HP Active Front End (AFE) Variable Frequency Drives (VFDs) as well as auxiliary loads such as HVAC and lighting. The VFDs are responsible for efficiently controlling motor speed and performance, while also improving power quality through active front end technology.
A Rockwell ControlLogix PLC system serves as the control backbone, managing inputs and outputs, enabling communication with the VFDs, and providing overall system monitoring and control. The PLC and marshalling panel are designed to allow for clean field integration, simplified troubleshooting, and future expandability.
All components are housed in a custom-modified, insulated shipping container, which functions as both a protective enclosure and a mobile platform. The container is equipped with dual high-capacity HVAC systems to maintain proper operating temperatures, along with lighting, cable entry provisions, and safety features such as an emergency escape hatch.
The entire system is fully redundant, factory assembled, wired, and tested prior to shipment, ensuring that it arrives on site as a ready-to-deploy, plug-and-play solution. This significantly reduces field installation time and commissioning risk while providing a consistent, high-quality build.
In summary, the system is a portable, turnkey electrical and control solution that integrates power distribution, motor control, automation, and environmental management into a single, deployable asset.
CONCLUSION
Integrated Turnkey Solution with Enhanced Mobility and Flexibility
NSA delivered a fully integrated, containerized Mobile Motor Control Center (MCC) engineered for performance, reliability, and rapid deployment. This turnkey solution combines high-efficiency 500HP Active Front End VFD technology, robust 2000A power distribution, and advanced Rockwell ControlLogix automation within a compact, climate-controlled enclosure.
Designed for demanding industrial applications, the system is factory-assembled, fully tested, and ready for immediate operation, significantly reducing installation time, field labor, and project risk. The inclusion of dual high-capacity HVAC systems, intelligent control architecture, and a rugged modified shipping container ensures consistent, reliable performance across a wide range of operating environments.
The NSA advantage lies in its ability to deliver true turnkey integration backed by deep engineering expertise and in-house execution. By combining electrical, controls, and mechanical integration into a single scope, NSA eliminates coordination gaps between vendors, shortens project schedules, and ensures accountability from design through commissioning. NSA’s rigorous factory acceptance testing, standardized build practices, and attention to serviceability provide customers with a solution that is not only ready to deploy, but also easier to maintain and scale over time.
With its plug-and-play design, mobility, and scalable architecture, NSA’s Mobile MCC solution offers a flexible, cost-effective platform that accelerates deployment while maintaining the highest standards of quality, performance, and reliability.