Power Utility Substation Controls

For more than 25 years, the Wunderlich-Malec team has been building custom utility power distribution protective relay and control panels. Our stringent quality procedures allow us to meet the demanding requirements of the utility power industry, and our engineering and manufacturing facility in Winslow, Maine gives us the capability to produce modular control and power engineered assemblies. We have delivered multi-million dollar projects on time and with the highest quality to leading utilities and international power equipment manufacturers. We also provide modular control houses, fabricated with all systems and components installed and tested at our plant and delivered by rail or truck for final installation in your utility substation.

Substation Protection Panel Design & Fabrication

Wunderlich-Malec will engineer and provide a complete panel designed from a set of 3-line drawings, or we can use drawings provided by our clients. The panels can be custom cabinets with fronts to match your existing panel line-up. We handle complete delivery of the finished panels directly to your location or substation.

We have experience with a variety of utility and industrial power distribution panels, including:

• relay protection panels
• transformer protection panels
• substation control panels
• service station switchgear

Metal-Clad Switchgear

Wunderlich Malec can provide metal-clad switchgear packages and modular enclosures for leading switchgear manufacturers—completely fabricated, factory tested and delivered to your site.

Modular Prefabricated Building Structures

Modular unit in construction within the fabrication area of the Wunderlich-Malec manufacturing facility.

Wunderlich-Malec can provide modular prefabricated building structures—complete with relay and protection systems—for any application. These modular structures eliminate field installation and wiring of highly sophisticated and critical equipment, significantly reducing costs and improving project schedules.  We have successfully completed and delivered an extensive variety of these projects, demonstrating the scope and capabilities of our manufacturing plant.

In addition, to reduce your risk and eliminate field rework on the project, Wunderlich–Malec can provide full engineering support and will functionally test your equipment and systems: 

• Buildings with complete systems installed are engineered, constructed and fully tested before being delivered to the construction site.  Wunderlich-Malec will even write the formal Functional or Factory Acceptance Test (FAT) Plan for your approval to ensure the project is complete and functional before leaving our factory.

	Panels and modular units are crated when required to provide protection against the toughest environmental conditions.

• These buildings are structurally designed to carry the equipment load for shipping and site placement.  Our experienced riggers and personnel then deliver the buildings to your site and locate them on slabs or pilings.
• Buildings can be environmentally controlled, secure and built to meet the uniqueness of the site.
• Modular units complete with all systems—including battery banks and charger, protection and control panels, termination panels, interconnection assemblies, fiber optic and LAN systems, HVAC, lighting, wiring diagrams, interconnects, DCS/SCADA/HMI and systems programming—can be delivered to your site, tested and ready to connect.

A view inside of a modular unit with battery area, lighting, and environmental controls.		Work-in-Process (WIP) control wiring inside modular unit.		Moving modular unit in preparation for shipping.

Prefabricated Building Single Units

	Modular design with 12-week delivery.

• 12’ H X 16’W X 40 L
• Includes engineering, design and certification
• AC distribution panels
• DC distribution panels
• Relay protection and control panels
• (21 Units)
• Battery system backup
• Roof designed for 120 psf

Prefabricated Building Dual Split Units

Modular unit with two sections. The sections were delivered by Wunderlich-Malec truck to the substation and then joined at the site.		Delivery of the first section of the modular unit.		The dual-section modular unit has a brick facade to match the surrounding neighborhood buildings. Brick was installed at the factory.

		Dual-Section Brick Veneer Modular Unit 12’ H X 12’W X 45 L Includes engineering, design and certification AC distribution panels DC distribution panels Relay protection and control panels (17 Units) Battery system primary and backup
Modular design with 12-week delivery.

Multi-Section Modular Unit

Four (4)-Section Modular Unit

• 11’ 6” H  X  48’ W  X  64’ L
• Includes engineering, design and certification
• AC distribution panels
• DC distribution panels
• Relay protection and control panels
• (50 Units)
• Battery system primary and backup
• Step down transformer
• Each Section is 12’ W X 64’ L

First section's raised floor with walls and ceiling being installed at Wunderlich-Malec facility.		Two sections completed.

Proven Capability

Power Utility Control & SCADA Systems

Wunderlich-Malec provides utility control and SCADA systems and will program and support the installation of remote automated monitoring and control Transmission and Distribution (T&D) Station control systems. These systems provide communication between the dispatch centers and remote T&D substations. The equipment for switchgear line-ups, equipment IEDs and the PLC system are located at the sub-station. Local HMI systems and protocol converter systems consist of standard SCADA systems, and the PLC system is installed in a single enclosure with the HMI. A completed system provides T&D relay and automated switching control to the entire substation.

Our quality procedures and methodology easily meet the electronic file records and signature requirements of 21 CFR Part 11 as required by the FDA. Our Quality Program also includes a client-approved Factory Acceptance Test (FAT) Plan test at our facility, as well as an additional client-approved Site Acceptance Test (SAT) Plan at the final job location.