Extreme Weather Response – Washington, D.C.

The Challenge: Expedited Delivery of Critical Power Connectivity Solutions

A critical substation outside of Washington, D.C., was scheduled for a 72-hour window to complete a breaker replacement on a 230kV bus. If the work wasn’t finished in time, the utility faced fines of $10,000 per day. With less than 36 hours remaining, the contractor realized they lacked enough 3” bus connectors to meet the original design specifications. This unexpected shortage put the project timeline in jeopardy.

The urgency of the situation escalated as a strong storm cell brought heavy rain over the weekend, with a major hurricane expected to make landfall soon after. Initial forecasts predicted a Category 4 storm would directly hit the beltway area, leading to a state of emergency for the entire District of Columbia just two days after the project’s deadline. Completing the installation amidst these challenging conditions was critical to avoid financial penalties and ensure the substation’s operational readiness.

The Execution: Rapid Response and Efficient Delivery

DMC Power’s Territory Manager and engineering team quickly mobilized to address the urgent needs of the contractor. With strong communication and a collaborative approach, they facilitated rapid design modifications, enabling timely approval and execution of the project requirements.

  • On-Site Customer Service: Between on-site trainings and regular job site check-ins, our Territory Manager’s familiarity with the project allowed them to quickly guarantee DMC Power could help this client meet their deadline.
  • Operational Agility: Due to the long-standing relationship with the contractor as well as the utility’s engineering department, the coordination required to approve the design modification was able to occur without delays caused by paperwork or payment that could be finalized after this emergency.
  • Strategic Deployment: DMC Power has strategically located facilities across North America with a vast variety of connector sizes and configurations on the shelf and ready to ship. While final design modifications were being made, our Territory Manager drove to our facility to pack and stage the connectors and tooling ahead of a 6:30 a.m. the next day.
  • Client Collaboration: The designs were updated, and logistics coordinated to perfection with the contractor.  Ahead of delivery, a brief training was conducted with the 6-man crew. When the Swage Tooling and Bus connectors arrived onsite, they were able to get right to work.
  • Expedited Design Adjustments: Leveraging our established partnership, we secured swift approval for design modifications, cutting through typical administrative delays.
  • Reliable Supply Chain: DMC Power’s US-based supply chain and strategically located part depots ensured quick access to critical materials, supporting project needs without delay.
  • On-Site Training: Comprehensive Swage Connection System training was provided for the 6-man crew, enabling immediate implementation of the swage tooling and connectors upon arrival.


PLK1850D56B
3.5" Center Formed Terminal		 PLK1150D56
3.5" 90° Transverse Pad Tee

The Results: Delivering Excellence under Challenging Conditions

DMC Power’s agile response and efficient coordination helped meet the tight project deadline, delivering long-term benefits that can be applied across similar critical infrastructure projects. The success of this response demonstrated how our solutions can adapt to urgent needs while maintaining quality and reliability.

Accelerated Project Timeline: The project was completed ahead of schedule, enabling the utility to re-energize the substation before the hurricane, minimizing prolonged outages and avoiding significant fines.

Enhanced Installation Efficiency: The DMC Power Swage Connection System reduced the overall installation time, enabling the crew to work efficiently and safely, even during the inclement weather.

Proactive Risk Management: DMC Power’s comprehensive risk management planning and quick response to unforeseen challenges ensured project continuity in adverse conditions.

Scalable Operational Framework: The communication and logistics strategies employed in this project are part of DMC Power's scalable operational framework, allowing us to adapt quickly to various project demands and client needs across diverse environments.

Strengthened Client Trust: DMC Power's ability to provide reliable solutions under pressure reinforced the contractor’s trust of this long-standing partnership.

"As of close of business today, the 230kv bus has been modified to maintain a new phase to ground clearance of 86”. As some of you may know, there were some material incompatibility issues that arose yesterday. We scrambled yesterday to get new DMC Power fittings and tooling for the existing bus. I would like to thank DMC Power, [Contractor] and [Utility], and my crew onsite for coming together, and going above and beyond, to get this work done safely over the rainy weekend." - Foreman, E&I Division

DMC Power’s rapid response, strategic planning, and efficient execution enabled the contractor to complete critical substation work within a compressed timeframe and under challenging conditions. This success not only prevented costly delays but also highlighted the importance of engineering support in achieving rapid, reliable solutions.

For tailored support, reach out to a DMC Power Territory Manager today!