POWERGRAMS

POWER TO ALABAMA Like changing an airplane engine in flight. That's how one Alabama Power manager described the project done with Mercedes- Benz to expand and improve its plant in Vance. In 2011, Alabama Power's Transmission team began working with Mercedes-Benz U.S. International (MBUSI) to add a third transformer to its dedicated substation. It provided about 40 megawatts of increased capacity, enabling the plant to produce its C-Class line and new 2015 GLE Coupe. This was not your typical transmission project. The modifications had to be performed during normal business hours and inside of an energized substation. Months of planning and coordination between Alabama Power and MBUSI ensured that vehicle production would not be disrupted. "It was like changing an airplane engine in midair," said Gary Gorham, Transmission Customer Service and Project Management manager. "We had to do all our work while Mercedes-Benz got its own work done." In addition to the 40-MW transformer being installed, transmission lines and relays were modified and tested. Project Manager Melinda Norris led the Alabama Power team, which included Mark Bales, Johnny Littleton, Pat Samya and Jake Warnack. The work was completed by February 2014, on time, under budget and without safety or operational incidents. And just in time to meet rising consumer demand. In 2014, Mercedes-Benz reported record- high deliveries every month worldwide. "We are consistently seeing record sales in the USA," said Dieter Zetsche, chairman of the board of management of Daimler AG and head of Mercedes-Benz Cars. The company hopes to build 300,000 vehicles annually in Vance, for nearly a 30 percent production increase at its only automotive assembly plant in North America. While MBUSI was expanding its capacity, Alabama Power discovered an opportunity to improve reliability. Service evaluations revealed that an outage could result in an extended delay on the factory floor. Alabama Power employees conducted substation modifications and a feeder reconfiguration. Upon completion, a line fault condition occurred. The plant suffered no outage or stoppage. "Your folks have been fantastic," said Randall Sagan, electrical engineer for MBUSI. "Our load had grown to the point where we had the capacity to run everything, but not if something failed. Alabama Power has greatly improved our reliability and service." "We proved that a large plant could expand while continuing to manufacture vehicles," said Larry Stokley, Alabama Power's marketing representative for Mercedes-Benz. Expansion has meant greater economic development. The Vance plant employs about 3,500 people and supports thousands of jobs in related industries. It contributes more than $1.5 billion annually to the state's economy. MBUSI announced it will hire about 200 new full-time production workers in 2015. "This is a win-win for Alabama," said Greg Barker, Marketing and Economic Development senior vice president for Alabama Power. "Mercedes-Benz has been a great partner and corporate citizen. Their continued success is good for the community." A recent tour of the plant revealed the people behind the success. Teams of workers guided auto parts through overhead assembly lines. Twenty-foot-high robot arms installed components with speed and precision. Employees rode from sector to sector on three-wheeled bicycles. Mercedes-Benz shares Alabama Power's commitment to safety and quality. Workers are authorized to slow or halt an assembly line when they see a problem. A customized alarm plays so the entire factory floor knows which line has stopped; one alarm plays the theme from "Rocky." Sagan praised Alabama Power and its workers for their expertise and collaboration. "They have been a tremendous resource for us in terms of us looking at growth and load development," said Sagan. Stokley said Mercedes-Benz thanked Alabama Power and its substation workers with a ceremony at the plant. "We don't see that very often," he said. "It's a testament to great planning and execution." By John Herr Company adds third transformer to aid Mercedes-Benz production 2 Alabama Power emloyees and contractors did extraordinary work in restoring power in Pennsylvania and Georgia last year, which earned the Edison Electric Institute's top assistance award. ON THE COVER: Transformer moved into place outside Mercedes-Benz plant in Vance. Photo by John Herr

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