Current Projects

Project: Lake Texoma Pump Station Improvements
Date: July 2016

Since 2009, NTMWD hasn’t pumped raw water from Lake Texoma. Five Star Electric, working with T-Star Engineering and Northeast Power Solutions, has assisted with increasing pumping capacities from Lake Texoma thru the installation of a SVC-Static VAR Compensator. Medium Voltage Dynamic VAR Compensation Systems greatly improves substation or plant power quality. Their main goal is to resolve power issues such as voltage “Flicker” and “Sag” due to weak power supplies or motor starting.

An SVC (Static VAR Compensator) is placed on an entire bus, and compensates for all loads on that bus – including multiple motors of different sizes. Like a VFD, it remains online constantly, correcting for all load changes, not just motor starts. After installation of the pump station the motor or load curves were off, thus not allowing the motors to start. The solution Five Star Electric offered was to stiffen the system. Using the equipment that was currently installed and adding a 1500 kVAR capacitor banks to the system when starting to reduce the magnetizing current drawn from the Utility. The medium voltage metal enclosed SVC are an economic, compact and easy to maintain source of reactive power.  The Static VAR Compensator are customer built to the requirements desired and shipped fully tested, assembled and ready for interconnections. They contain all switching, protection and all control.

Adding the SVC has assisted NTMWD in increasing pumping capacity from Lake Texoma to allow greater flexibility in the pipeline operation.

Project: VFD with VFD bypass
Date: June 2015

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Five Star Electric (FSE) prides itself on being a turnkey integrator; we’re proud to work with mechanical contractors who represent many different VFD manufacturers.  Since HVAC is critical business in Texas, it’s necessary to have reliable systems.  Some VFD packages require a mechanical bypass to ensure the air handler continues to run and not all VFD manufacturers are capable of configuring a customer specific application.  If a special enclosure is needed (NEMA 4X, 12, 3R, etc.), FSE is able to take a customer supplied VFD and integrate per the customer specification.

The following application was designed for a local high school, where the contractor had to supply VFD’s with a VFD bypass.  This is an unusual request since most bypass systems are mechanical. The operation required FSE to engineer a solution for VFD #1 to automatically switch to VFD #2 when #1 fails.  The project required redundant 3hp, 10hp, and 25hp.  The 3hp required a 36”x36”16 NEMA 4X 304SS enclosure, 10hp 42”x36”x12” NEMA 12, and 25hp 60”x36”X16” NEMA 12.  Additionally, a rush turnaround time for this particular project was needed in order to maintain extremely critical construction schedules.  FSE utilized its FASTRAX program to take this custom project from inception to delivery in less than 6 weeks.  Most large manufacturers fail to provide the flexibility to make something like this happen in such a limited amount of time; but FSE remains extremely flexible despite its growth, and will always take the extra steps to get the job done.  Our customers always come first.  This has been, and will remain to be, our business model.

Project: Irrigation Pump Skid
Date: February 2015

Five Star Electric (FSE) is proud to have an integral role in upgrading the irrigation pump control system for a local theme park in San Antonio, Texas. FSE is providing a turn-key solution to make the system more efficient in order to reduce overall operating expense.  Due to the size of the process and proximity of the park, it is critical for this application to work seamlessly on its own.  The system consists of five VFD’s (10HP, 25HP, 50HP, 75HP, 100HP) which will significantly reduce the energy costs required to operate the system compared to the original full voltage starters being replaced.  In addition to the VFD’s, FSE will also be automating the process to be more self-containing.

Five Star Electric (FSE) manufactured all the VFD’s and PAC Control Panel at their San Antonio Texas Plant.  FSE Service group will be providing all the installation and commissioning services, in addition to customer support for the entire system.

Project: Phillips 66 Corporate Headquarters VFD Project
Date: January 2015

Five Star Electric is proud to announce we have partnered with Siemens Energy to provide the Variable Frequency Drive Package for the Phillips 66 Corporate Campus Headquarters.  The Sinamics G120 series was selected for its robust features including an across the line bypass with each VFD.  In addition, Five Star Electric is providing a VFD harmonic analysis complying with IEEE 519 1992.  Five Star Service will perform all commissioning/startup in addition to an onsite Harmonic Verification Study.

Phillips 66 announced plans to move forward with building a new corporate headquarters in west Houston. The project slated for 14 acres in the West chase District could encompass 1.2 million square feet of space in multiple buildings. Plans include a parking garage, cafeteria, fitness center, coffee shop and conference center. The project will also have a running track on the roof of a garage, a soccer field and multiple dining options.

The facility will house all of the company’s 1,800 Houston-area employees once construction is finished. The architect is St. Louis-based HOK.

Project: Rentech
Date: July 2014

IA automation for Acid Plant and Cogen, Cyber Security PCS Access Control Infrastructure and Advantage Upgrade with Foxboro by Schneider Electric

Five Star Electric and Invensys by Schneider Electric are performing DCS upgrades including SAP I/A support, software upgrade, project services, commissioning, FoxView to InFusion View, and an upgrade and modernization with a new DCS for their existing Acid Plant. Availability of the ACID plant is an important requirement for this project. Our responsibility included system definition configuration, control strategy configuration and process displays. Also included is hardware, software including a Galaxy upgrade to FCS4.x, application configuration programming, FAT Testing, and site services for power-on and commissioning/start-up support.

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Project: City of Houston Siemens/Robicon
Date: June 2014

Five Star Electric and Siemens are providing equipment, software services and complex documentation for the East Water Plant Low Lift Pump addition. Conforming to the size and performance needs for the City of Houston were key concerns. Documentation, testing, training, field testing and commissioning are also complex that could only be completed by our partner and Five Star Electric.

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Project: Tarrant Regional Water District – Waxahachie Pump Station, Waxahachie Texas
Date: March 2014

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TRWD is a major supplier of raw water to the City of Fort Worth Texas. The goal of the project was to install two new VFD’s at the Waxahachie pump station in Waxahachie Texas. When completed the station will have five Medium Voltage Perfect Harmony VFD’s operating on their 90” pipeline. This phase of the project consisted of adding two new 5000HP, 4160V Synchronous Variable Speed Drives. Each VFD consisted of an Input Disconnect Switch, 100kva CPT, Brushless Synchronous Exciter and one 5000HP, 4160 volt Gen 3e Siemens Perfect Harmony VFD. Each VFD was configured with cell bypass. The challenge was matching the same design criteria as the existing VFD’s that were installed 10 years ago. Siemens and Five Star Electric were able to provide a complete solution that was engineered, manufactured, delivered and commissioned to meet the customer’s expedited schedule

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Project: Southwest Research Institute – Immersion Heater Test Stand
Date: March 2014

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San Antonio, Texas
Application: Class I, Div II, Groups A,B,C,D Immersion Heater Control Panel
Equipment Description: Triplex Immersion Heater Control Panel suitable for Hazardous Locations. Panel is equipped with Type Z purge system and listed in compliance with UL 508A/NFPA 496. Test Stand Heaters are controlled from safe area via remote switch box.

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Project: Public Works San Antonio River Walk – Storm Water DCS ADVANTAGE Upgrade Project
Date: December 2013

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San Antonio, Texas, United States
Five Star Electric is teaming up with Invensys/Foxboro to provide an integrated solution for the City of San Antonio River Walk Storm Water DCS Upgrade Project.

The San Antonio Department of Public Works selected Invensys/Foxboro to upgrade and provide maintenance to the existing Automated Flood Monitoring System at the San Antonio Tunnel System, San Pedro Tunnel System, Olmos Dam and the Marina facility

Goals that were achieved:

Reduced site reliance on daily maintenance and operations personnel for inadvertent manual control intervention by providing ‘active’ critical alarming to Maintenance Shop and Main Operations to remedy any critical situation requiring immediate manual intervention or other and including remote paging. Invensys/Foxboro utilized redundant controllers (fault tolerant or redundant-ready) at the “Riverwalk” and “Remote” sites which minimizes downtime for the installation. Also provided was web based monitoring of the Control Center Operations (HMI, etc.) without direct control capabilities.

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Project: Temple Lift Station
Date: May 2013

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Temple, Texas
Application: Triplex Pump System

Equipment Description: Siemens Motor Control Center Including QTY. (3) Siemens-Micromaster MM440 6-Pulse Variable Frequency Drives with integrated RFI Filtration.

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Project: City of Galveston, Lift Station No. 1
Date: March 2013

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Galveston, Texas
Application: Quadraplex Lift Station Pump System

Equipment Description: Siemens Motor Control Center Including QTY. (2) Siemens-Robicon W-Series 6-Pulse Variable Frequency Drives with integrated Harmonic Filtration. System is configured for 4 motor simultaneous operation via full voltage start and/or VFD control.

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Project: Galveston Main Wastewater Treatment Plant
Date: June 2012

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Galveston, Texas
2011 Be Inspired Award Winner – Innovation in Water and Wastewater Treatment Plants Five Star is teaming up with Invensys/Foxboro to provide an integrated solution for the Plant Automation/Instrumentation control system.

Located on a barrier island off the Texas Gulf coast, Galveston was devastated by Hurricane Ike in 2008. The extended storm surge caused a major portion of the public wastewater facilities including the 10-million-gallon-per-day Main Wastewater Treatment Plant to fail to function. Design of the $75.4 million project to rebuild the plant was completed in less than a year to help ensure federal block grant funding eligibility.

The scope included modifying screening structures; rebuilding an influent lift station as a submersible pump station; rebuilding the grit-removal system; replacing aeration basins, air diffusers, and blowers with a sequencing batch reactor; converting the disinfection system to ultraviolet disinfection; constructing an intermediate pump station; and modifying the solids dewatering building.

CDM constructed a 3D/4D model of the seven facilities using original drawings and field surveys. Intelligent modeling drove the integrated design process from front-end engineering and design through phased construction. ProjectWise facilitated management of more than 8,800 documents for 162 team members in 22 offices. Using 3D/4D models shortened client and regulatory review time by 25 percent and reduced design time by 30 percent.

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Project: Hess Oil – Tioga ND Facility
Date: February 2012

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Hess Oil is a major Oil and Gas Producer in the United States. This specific project was located in Tioga North Dakota and is directly related to the Bakken Shale gas formation. The project included the installation of eight large reciprocating compressors. Five Star Electric was able to provide a complete solution including two 3750HP, two 3850HP, two 6500HP and two 6700HP 6.6kv perfect harmony VFD’s for this installation. The VFD’s were installed with input disconnects, cell bypass and air to air heat exchangers to dissipate the heat in the control room.

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Project: City of Galveston, Jamaica Beach Elevated Storage Tank Pump Station
Date: March 2011

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Galveston, Texas
Application: Booster Pump System

Equipment Description: Siemens Motor Control Center with 800 Amp Manual Transfer Switch configuration. Includes QTY. (3) 150Hp Siemens-Robicon W-Series 18-Pulse Variable Frequency Drives configured with application specific controls.

Comments: VFD Cabinets customized to meet critical space limitations within the base of the Elevated Storage Tank in which they were installed.

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Project: City of Houston, 69th Street Waste Water Treatment Plant Phase 2
Date: October 2010

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Houston, Texas
Application: Waste Water Treatment Plant – Return Activated Sludge (RAS) Pumps

Equipment Description: QTY. (12) 150Hp Siemens-Robicon W-Series 18-Pulse Variable Frequency Drives configured with application specific controls. VFD’s configured into NEMA 4X 316 Stainless Steel cabinets with 316SS air conditioners.

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Project: City of Galveston, 30th Street Pump Station
Date: January 2010

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Galveston, Texas
Application: Water Treatment Plant – Process Monitoring and Control System (PCMS)

Equipment Description: Invensys Foxboro A2rd Control System/SCADA with Redundant T2550 Control Processors, Redundant I/0, and Redundant Fiber Optic Communications.

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Project: Bexar Metropolitan Water District, Stein Tract Tank Pump Station
Date: March 2008

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San Antonio, Texas
Application: Well Pump System – Transfer Pumps

Equipment Description: Siemens Motor Control Center. Includes QTY. (2) 20Hp Siemens-Robicon 454GT-Series 6-Pulse Variable Frequency Drives configured with application specific controls and tamper-proof operator interface.

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Project: Coastal Water Authority, Trinity River Pump Station
Date: June 2006

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Houston, Texas
Application: Raw Water Distribution Plant – Process Monitoring and Control System (PCMS)

Equipment Description: Invensys Foxboro A2rd Control System/SCADA with Redundant T940X Control Processors.

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Project: Coastal Water Authority, Lynchburg Pump Station
Date: December 2005

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Houston, Texas
Application: Raw Water Distribution Plant – Process Monitoring and Control System (PCMS)

Equipment Description: Invensys Foxboro A2rd Control System/SCADA with Redundant T940X Control Processors, and Redundant Fiber Optic Communications.

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