CASE STUDY

INDUSTRIAL POWER INTEGRATION

THE CHALLENGE

Industrial Power Distribution & Electrical Infrastructure for a Roofing Materials Manufacturing Plant.

Connecting Complex Electrical Infrastructure Across a New Manufacturing Facility

A roofing materials manufacturer developing a plant in Texas required a coordinated electrical power distribution infrastructure to support its manufacturing operations. National Service Alliance (NSA) became involved in March 2025, joining a project that was already underway. NSA was tasked with supporting the plant’s electrical infrastructure through initial power studies and analysis, switchgear procurement, and the engineering and routing of extensive cable tray systems.

The challenge extended beyond electrical design. NSA’s scope required coordinating electrical distribution connections across approximately six major plant areas and interfacing with equipment from a dozen different manufacturers.

With project information evolving, equipment details arriving at different stages, and project management transitioning mid-project, NSA faced the challenge of developing the electrical connections needed to bring the facility’s systems together.

THE EXECUTION

Coordinating the Details Behind the Power Infrastructure

NSA entered the project after key decisions regarding equipment manufacturers, equipment types, and the plant floor layout had already been established. As a result, NSA’s role centered on executing its defined engineering and procurement responsibilities while coordinating with the broader project team.

The cable distribution design required information from numerous equipment manufacturers, with documentation, technical details, and project requirements that continued to evolve throughout execution.

NSA’s work involved navigating these coordination challenges while developing the routing and support systems necessary to connect the facility’s electrical infrastructure.

the project status

Advancing Toward Construction & Final Engineering Deliverables

At the time of the project update, the cable tray routing work was in its final stages, while construction of the plant was in its initial stages. Final Issued for Construction (IFC) drawings were scheduled for submission in July 2026, with additional project support anticipated as construction and commissioning activities progressed and requirements evolved. The ultimate operational impact of NSA’s work will become clearer as the facility advances toward completion.

NSA'S SOLUTION

Engineering the Connection Between Power Distribution and Production

NSA supported three critical areas of the project, helping to establish the electrical infrastructure required to distribute power throughout the facility.

Power Studies & Grid Interface Analysis

NSA worked with the customer and CenterPoint Energy to perform the initial power studies and analysis required for the plant’s interface with the utility grid. This scope also included developing the specifications for the switchgear to be procured for the project.

Switchgear & Power Distribution Procurement

NSA supplied the incoming power switchgear for the facility, along with various additional switchboards and electrical panels distributed throughout the plant. NSA’s supply-chain relationships supported the procurement scope.

Cable Tray Design & Routing

NSA designed the cable tray routing and support infrastructure connecting the switchgear room to panel rooms and various points of use throughout the plant. The distribution layout accommodated multiple cable types, including power cables, variable frequency drive (VFD) cables, and control cables, serving the facility’s major operational areas.

NSA'S CAPABILITIES IN ACTION

This project demonstrates NSA’s ability to support complex industrial electrical infrastructure through:

Electrical power studies and grid interface analysis
Switchgear specifications and procurement
Switchboards and power distribution equipment
Electrical cable tray design and routing
Integration planning across multiple equipment manufacturers
Engineering coordination for large-scale industrial facilities

CONCLUSION

| Grid-to-Plant Integration

POWERING COMPLEX INDUSTRIAL OPERATIONS

There were very strict constraints that Centerpoint imposed and NSA was able architect a solution and provided top tier documentation that not only satisfied Centerpoint, but Centerpoint engineers/representatives have stated that “they are so impressed that they are going to use that as their gold standard as a point of reference”.

The PM representing the client said that they were able to come in and conduct a thorough inspection of the installation completed by others and also sorted out a wiring issue that allowed the control testing of the breaker interlocks to remain on track.

This action not only demonstrated committed to customer success, but also highlighted another core value of being a problem solver.