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Transforming Tesla
Overview
Tesla’s Fremont plant, which was acquired from Toyota, along with additional facilities in Palo Alto and Sunnyvale, forms a large complex dedicated to research, development, and sales operations. Each major plant is divided into smaller units, leading to a complex distribution system. When Mozart joined the team, Tesla was facing significant challenges in understanding and revising the electrical infrastructure across approximately 35 to 40 primary and secondary double-ended and single-ended unit substations within these facilities.
Challenge
The complexity of Tesla’s electrical distribution system meant that gathering accurate information for a comprehensive study could take weeks if not months. Their decentralized approach has created gaps in crucial knowledge about substations, which could expose the system to risks related to short circuit ratings, breaker coordination, and existing Arc Flash energy.
Approach
Mozart’s task was to quickly map and analyze Tesla’s substation infrastructure. His approach significantly differed from traditional methods due to his unique qualifications and expertise.
Expertise
Mozart is a proficient electrical engineer and mission-critical designer, specializing in data centers, hospitals, and microelectronics. This expertise enables him to navigate complex electrical systems quickly and accurately.
One-Line Diagram Analysis
Mozart conducted a comprehensive site investigation, documenting all existing components with a primary focus on circuit breakers, distribution panels, transformers, and other relevant equipment to assess any major issues. He personally modeled the substations using the latest version of SKM Power Tools for Windows (PTW32), which streamlined the process and reduced costs by eliminating the need for large data entry teams.
Performed a Power Study
To ensure the power system operated without issues, Mozart documented all missing relevant information, including circuit breakers and other critical distribution equipment.
Coordination & Arc Flash Studies
He conducted coordination studies to ensure the proper selection of all relevant equipment and performed arc flash studies to determine incident energy levels and safety requirements.
Regulatory Communication
Mozart was adept at communicating with regulatory authorities, ensuring compliance in a timely manner.
Unique Efficiency
Unlike traditional engineering firms, Mozart’s innovative approach eliminates the inefficiencies of the conventional multi-role method.
Streamlined Process
In a typical setup, companies hire data entry personnel to collect information about the system, while a separate professional engineer is responsible for generating the report. Additionally, inspectors with limited expertise may be assigned to verify the optimization detailed in the report. This segmented approach divides authority and knowledge, creating gaps that can lead to errors and suboptimal outcomes, such as schedule delays, which are critical for clients.
Single Expert Authority
Mozart’s proficiency allows him to oversee the entire process, from site investigation to the final report, ensuring consistency, thoroughness, and optimization throughout.
Results
Mozart completed the analysis of 45 substations within a year—a task that typically takes two to three years for most companies. His meticulous modeling process and deep expertise allowed him to swiftly uncover and address issues.
Safety Improvements
By recommending the upgrade of 1000 amp panels to be protected by 1300 or 1400 amp circuit breakers, Mozart significantly reduced the risk of catastrophic failures and potential explosions.
Cost Savings
His efficient process not only sped up project timelines but also lowered costs. While typical fees for such comprehensive studies could amount to several hundred thousand dollars, Mozart’s approach kept costs at $35,000.
Regulatory Compliance
Mozart’s ability to quickly conform to OSHPD’s strict requirements ensured that Tesla’s facilities could continue operations without prolonged permitting delays or downtime.
Safety Compliance
Protect Equipment
Improve Reliability
Eliminate Downtime
Key Advantage
Mozart’s unique blend of skills as an electrical engineer and mission-critical designer forms the basis of his fast and effective approach. His specialized knowledge in data centers, hospitals, and microelectronics enables him to tackle complex issues with precision and speed. This dual expertise allows him to identify and solve problems that others might overlook or take significantly longer to address.
Conclusion
Mozart’s innovative approach to evaluating substations, combined with his exceptional expertise in primary and mission-critical power studies, allowed Tesla to optimize its electrical infrastructure quickly, cost-effectively, and safely. His work ensured not only compliance with regulations but also significantly improved the operational reliability of Tesla’s plants. With his unique skills as both an electrical engineer and a mission-critical designer, Mozart stands out in his field, consistently delivering outstanding results in record time. By consolidating roles typically spread across multiple positions in other firms, he minimizes inefficiencies and achieves a higher level of optimization and authority in his work.
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–EUGENE H. SAKAI, AIA, STUDIO S SQUARED ARCHITECTURE
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