PANELIZED LIGHTWEIGHT CONTROL ENCLOSURE

Abstract

The present invention relates to a panelized lightweight control enclosure, capable of being substantially manufactured before installation for housing power system devices of a power system substation. Specifically, the control enclosure is comprised of a structural frame including a plurality of vertical posts, a base, a plurality of side panels for forming the walls thereof and defining an interior space therein for housing the power system devices, and a roof for covering the interior space. The structural frame engages and provides support for the side panels and roof. To facilitate engagement between the frame, side panels and roof, the control enclosure includes a plurality of tongue-and-groove fittings. As a result, the present invention control enclosure may be constructed at and/or transported in an assembled state to an installation site. The present invention further relates to a method of making a composite material, for the panels of the control enclosure, formulated for weight reduction, strength, and resistance to cracking.

Description

RELATED APPLICATION

This application claims benefit under 35 U.S.C. §119(e) of U.S. Provisional Application Ser. No. 61/298,147, entitled “Panelized and Lightweight Control Enclosure,” filed on Jan. 25, 2010, naming Rick A. Schulz, Luis Alberto Alfredo D'Acosta Anezia, and Antonio Zaldivar Lelo de Larrea Corregidora as inventors, the complete disclosure thereof being incorporated herein by reference.

TECHNICAL FIELD

This disclosure relates to electric power control and monitoring stations. More particularly, this disclosure relates to outdoor electric power control and monitoring stations and systems for enclosing such.

BACKGROUND OF THE INVENTION

Effective electric power transmission and distribution requires equipment and devices for the control, monitoring, automation and protection of the electric power transmission or distribution systems. Examples of equipment that may be used on electric power transmission and/or distribution systems include switches, circuit breakers, capacitor banks, transformers, conductors, fuses, generators, current transformers (CTs), potential transformers (PTs), and the like. Devices may be in communication with such equipment for the monitoring, control, automation, and/or protection of the electric power system. Examples of these devices include the following: intelligent electronic devices (IEDs) such as protective relays, bay controllers, differential relays, distance relays, synchrophasor measurement units, synchrophasor measurement and control units, communications processors, synchrophasor vector processors, meters, programmable logic controllers, switches, generator relays, transformer relays, faulted circuit indicators, clocks, and the like. Devices may receive information from the equipment and act accordingly, based on the information received. Devices may also send control commands to the equipment. For example, a protective relay may be capable of receiving electric power system information (i.e. switch or breaker status from a switch or breaker, current from a CT, and/or voltage from a PT), process the gathered power system information, make a decision based on the information, and send a control command to the breaker to change status.

Power system substations are sites where several components of the electric power system converge in a single location, such as a yard. For example, a substation may be formed at the interface between an electric power transmission system and an electric power distribution system. The substation may include several step-down transformers where the relatively high-voltage from the transmission system is stepped down to the lower voltage of the distribution system. Substations may further be formed along various points of electric power transmission or distribution systems, such as where several lines of a particular system meet.

Substations often also house several devices for control, monitoring, automation and protection of an electric power transmission or distribution system. Such devices are typically mounted in panels and housed in a free-standing structure such as a building. Substation buildings may include some means of physical security such as locked doors, intruder alarm systems, and the like such that the devices are not easily accessed by unauthorized persons.

Substation buildings are permanent, often bulky, require significant amount of time to build and use large amounts of energy to maintain adequate internal environmental conditions for personnel that may be working therein. Further, substations are often placed in locations away from populated areas and may be difficult to access. Often, the need to access the devices occurs only periodically. As a result, some substation buildings are built and maintained for only a small amount of time that a person requires the benefits of the structure. Construction of such substation buildings requires transport of building materials, personnel, and equipment to the site, time in construction, and the associated costs.

Therefore, it is an object of the present invention to provide portable control enclosures, which may be used to house power system devices and equipment at a substation. Such enclosures may be manufactured, fitted with the appropriate equipment and devices (which may also be tested before the control enclosure is installed), wired, and later stored and/or installed at the appropriate location. It is specifically desirable that components of the portable control enclosure be prefabricated. Collectively, the prefabricated components may comprise a kit for assembling the control enclosure. Such a kit would not require additional construction materials and would be easily transportable. The prefabricated components may be sent to an installation site and easily configured thereon to form a control enclosure. Thus, the present invention control enclosure overcomes the problems associated with traditional, permanent building structures at substations by providing a prefabricated control enclosure.

SUMMARY OF THE INVENTION

The present invention relates to a panelized lightweight control enclosure, for housing the power system devices of a power system substation, which may be constructed, outfitted, and transported to an installation site in an assembled or unassembled state. Specifically, the control enclosure is comprised of a structural frame including a plurality of vertical posts, a base, a plurality of side panels for forming the walls thereof and defining an interior space therein for housing the power system devices, and a roof for covering the interior space. The structural frame engages and provides support for the side panels and roof. To facilitate engagement between the frame, side panels and roof, the control enclosure includes a plurality of tongue-and-groove fittings. More particularly, the control enclosure includes a plurality of tongue-shaped fittings formed on at least one of the frame, side panel and roof panel, each engaging a corresponding groove-shaped fitting formed on at least one of the frame, side panel and roof panel to form an engagement between one of the frame, side panel and roof panel. It is not required that the control enclosure be constructed at the site of the substation, or other storage site, but rather it may be transported to the site already intact and installed thereon. The present invention further relates to a method of making a composite material, for the panels of the control enclosure, formulated for weight reduction, strength, and resistance to cracking. Moreover, the present invention relates to a panelized control enclosure designed to meet the International Building Code (IBC) Live Load requirement standard for the industry.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an embodiment of the present invention portable control enclosure.

FIG. 2A is a disassembled perspective view of the embodiment of FIG. 1, showing the frame and the floor panel being installed.

FIG. 2B is a disassembled perspective view of the embodiment of FIG. 1, showing the frame and floor panel in an assembled state.

FIG. 2C is a disassembled perspective view of the embodiment of FIG. 1, showing the side panels being installed.

FIG. 2D is a disassembled perspective view of the embodiment of FIG. 1, showing the roof panels being installed.

FIG. 2E is a fully assembled perspective view of the embodiment of FIG. 1.

FIG. 2F is a disassembled perspective view of a second embodiment of the present invention portable control enclosure, showing roof supports being installed.

FIG. 2G is a disassembled perspective view of the embodiment of FIG. 2F, showing roof supports in an assembled state and the roof panels being installed.

FIG. 2H is a fully assembled perspective view of the embodiment of FIG. 2F.

FIG. 3A is a cross-sectional view of an embodiment of a fitting of a tongue-and-groove engagement.

FIG. 3B is a cross-sectional view of an embodiment of a fitting of a tongue-and-groove engagement.

FIG. 3C is a cross-sectional view of an embodiment of a fitting of a tongue-and-groove engagement.

FIG. 3D is a cross-sectional view of a corner of a control enclosure, illustrating two joints between a vertical post and two side panels.

FIG. 3E is a cross-sectional view of a joint between two side panels.

FIG. 3F is a cross-sectional view of an embodiment of a fitting of a tongue-and-groove engagement.

FIG. 3G is a cross-sectional view of a joint between two side panels.

FIG. 3H is a cross-sectional view of a joint between a side panel and a floor panel.

FIG. 4A is a cross-sectional view of an embodiment of a metal fitting piece of a tongue-and-groove engagement.

FIG. 4B is a cross-sectional view of an embodiment of a fitting of a tongue-and-groove engagement.

FIG. 4C is a cross-sectional view of a joint between a vertical post and a roof panel.

FIG. 4D is a top perspective view of a portable control enclosure.

FIG. 5A is an exploded side view of a composite side panel of an embodiment of the present invention portable control enclosure.

FIG. 5B is an exploded side view of a metal side panel of an embodiment of the present invention portable control enclosure.

FIG. 5C is another exploded side view of a metal side panel of an embodiment of the present invention portable control enclosure.

FIG. 5D is an exploded side view of a composite side panel, defining an aperture therein, of an embodiment of the present invention portable control enclosure.

FIG. 5E is an exploded side view of a metal side panel, defining an aperture therein, of an embodiment of the present invention portable control enclosure.

FIG. 6A is a front view of an embodiment of the present invention portable control enclosure.

FIG. 6B is a side view of the embodiment of FIG. 6A.

FIG. 6C is a rear view of the embodiment of FIG. 6A.

FIG. 6D is a top view of the embodiment of FIG. 6A.

FIG. 6E is a top view of the floor panel of the embodiment of FIG. 6A.

FIG. 6F is a cross-sectional view of the embodiment of FIG. 6A.

FIG. 6G is a cross-sectional view of a joint between a side panel and a roof panel.

FIG. 6H is a cross-sectional view of a joint between a side panel and a floor panel.

FIG. 6I is a cross-sectional view of a joint between two side panels and a vertical post.

FIG. 6J is a perspective view of the embodiment of FIG. 6A.

DETAILED DESCRIPTION OF THE DRAWINGS

The various embodiments of the disclosure will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout. It will be readily understood that the components of the disclosed embodiments, as generally described and illustrated in the figures herein, could be arranged and designed in a wide variety of configurations. Thus, the following detailed description of the embodiments of the systems and methods of the disclosure is not intended to limit the scope of the disclosure, as claimed, but is merely representative of possible embodiments of the disclosure.

In some cases, well-known features, structures or operations are not shown or described in detail. Furthermore, the described features, structures, or operations may be combined in any suitable manner in one or more embodiment. It will also be readily understood that the components of the embodiments as generally described and illustrated in the figures herein could be arranged and designed in a wide variety of different configurations.

As illustrated in FIGS. 1 and 2A-F, the present invention relates to a panelized control enclosure 100 that may be used for enclosing power system devices and equipment at a substation. Specifically, the panelized control enclosure 100 includes a plurality of side panels 102, each engaging each other to form the walls of the enclosure 100, thereby defining an interior space within. Additionally, the control enclosure 100 includes a floor panel 108 and at least one roof panel 106 for protecting the interior space from the environment. At least one side panel 102 may define an aperture for routing a connection from the power system devices and/or equipment housed within the chamber to the power system devices and/or equipment external to the panelized control enclosure 100. External equipment may include the following: switchgear, circuit breakers, conductors, transformers, buses, capacitor banks, reclosers, tap changers, current transformers, potential transformers, grounding mats, Rogowski coils, sensing equipment, and the like.

The control enclosure 100 further includes a structural frame 109 for supporting the side panels 102 and securing the floor 108, roof 106 and side panels 102 to each other. The frame comprises four vertical posts 110 and a base 112. The frame 109 may be constructed of metal beams, such as steel beams.

Each of the above mentioned components of the portable control enclosure may be prefabricated. Collectively, the prefabricated components may comprise a kit for assembling the control enclosure 100 at an installation site. This kit may not require additional construction materials and may be easily transportable. The prefabricated components may be sent to an installation site and easily configured thereon to form a control enclosure.

FIGS. 2A through 2E specifically illustrate the process of assembling the components detailed above to form an embodiment of the present invention panelized control enclosure 100. As shown in FIG. 2A, the vertical posts 110 of the frame are affixed to the base 112. The floor panel 108 defines corner indentations to allow the floor panel 108 to engage the four vertical posts 110 of the structural frame 109. Specifically, each corner indentation of the floor panel 108 corresponds to a vertical post 110 such that the floor panel 108, via the corner indentations, may be slid down and engage the vertical posts 110, while fitting securely onto the frame base 112. In another embodiment, the floor panel 108 may be constructed of concrete, metal, wood, or another material and may include a metal tread plate, such as a steel tread plate. Once the floor panel 108 and vertical posts 110 are securely in place, as shown in FIG. 2B, the side panels 102 may be installed. The side panels 102 may be formed from a number of pre-formed composite or metal materials. The composite material may be composed of concrete, wood, fibers and resin, polymeric, reinforced concrete or the like. The metal panels may also be corrugated.

As shown in FIG. 2B, the vertical posts 110 and frame base 112 may include tongue-and-groove fittings 104, for receiving the side panels 102. In this embodiment, the tongue-and-groove fittings 104 extend the vertical length of the vertical posts 110 and side panel 102 such that the sides of the vertical posts 110 engage the side panels 102 via the tongue-and-groove fittings 104. Each side panel 102 may also include tongue-and-groove fittings 104 for connection to each other as well as the frame 109 and roof panel 106. In this embodiment, the tongue-and-groove fittings 104 are affixed to all four sides of each side panel 102 such that the panels may engage each other, the vertical posts 110, the base 112, and the roof 106 of the enclosure. The tongue-and-groove engagements 104 are illustrated in detail in FIGS. 3A-3H.

As illustrated in FIG. 2C, the tongue-and-groove fittings 104 are installed on the base 112 and vertical posts 110 after the floor panel 108 is in place. The tongue-and-groove fittings 104 affixed to the side panels 102 are fitted into the corresponding tongue-and-groove fittings 104 affixed to the vertical posts 110. The tongue-and-groove fittings 104 allow the side panels 102 to slide downwards until the tongue-and-groove fittings 104 affixed to the base of the side panels 102 engage the corresponding tongue-and-groove fittings 104 affixed to the floor panel 108 and/or frame base 112. Alternatively, the side panels 102 may be set into the tongue-and-groove fitting 104 of the floor panel 108 and/or frame base 112 first and then slid outward to engage the tongue-and-groove fittings 104 positioned on the vertical posts 110. FIG. 2D illustrates the side panels 102 as fully extended and installed.

As further illustrated in FIG. 2D, the panelized control enclosure 100 may also include roof supports in the form of integrated non-prismatic beams in the roof panels 106. FIG. 2E illustrates the first embodiment of the panelized control enclosure 100 fully assembled.

In a second embodiment, illustrated in FIGS. 2F-2H, the roof supports may be in the form of non-integrated, angled supports 114 (i.e., triangles) situated at opposite ends of the control enclosure 100 on top of two opposing side-paneled 102 walls to define the shape and slope of the roof. The roof supports 114 in that embodiment allow the roof panels 106 to meet at an angle. As shown in FIG. 2G, the roof panels 106 are installed on top of the roof supports 114 on the two remaining side-paneled 102 walls. In both embodiments, the roof panels 106 and roof supports are affixed to the side panels 102, and each other, via tongue-and-groove fittings 104. The roof panels 106 may meet at a gradual peak in the middle, and slope downward toward the sides at a constant slope. FIG. 2H illustrates the second embodiment of the panelized control enclosure 100 fully assembled.

The tongue-and-groove fittings 104 described above are illustrated in FIGS. 3A-4C. The tongue-and-groove fittings 104 are generally comprised of individual corresponding fittings (shown at 204, 206, 208, 210, 212, 214, and 216). Each fitting joins with a corresponding fitting to form a tongue-and-groove type fitting 104, thereby forming a joint between the parts of the control enclosure 100 discussed above. The various tongue-groove type fittings are illustrated in detail in FIGS. 3A-3C, 3F, and 4A-4C. These fittings may be applied to form joints between any one of the vertical posts 110, side panels 102 or roof structures 106 of the enclosure.

For instance, as illustrated in FIG. 3D, a vertical post 110 may be connected to a side panel 102a by a tongue-and-groove fitting 104 comprised of a tongue-shaped fitting 204 and another corresponding groove-shaped fitting 206a. In the embodiment of FIG. 3D, the side panels 102a, 102b are composed of a composite material, such as concrete, and formed so as to define a groove 130a, 130b or tongue 132a, 132b, respectively, along their edges. As shown in FIG. 3D, one side panel 102b is configured to include a tongue 132b shape along its edge. The tongue 132b shape may be formed by tongue-shaped fitting 208 of FIG. 3C. The other side panel 102a is shaped to define a groove 130a along its corresponding edge. The groove 130a shape may be formed by a groove-shaped fitting similar to the groove-shaped fitting 206 of FIG. 3B. The groove-shaped fitting 206a may be affixed to the side panel 102a and the tongue-shaped fitting 208b may be affixed to the side panel 102b with sealant or welding.

The vertical post 110 may define either a groove or a tongue to facilitate engagement with the side panels through machining. Otherwise, the tongue or groove shape may be constructed to the vertical post 110 via other fittings. Specifically, the fitting 204 of FIG. 3A, including a tongue shape 132a, may be affixed to the vertical post 110. As shown in FIG. 3D, the tongue 132a of fitting 204 fits into the groove 130a of the side panel 102a to form a joint between the side panel 102a and the vertical post 110. Fittings 204 and 206 may be secured to each other with structural adhesive 138, sealant, or welding.

Furthermore, in the embodiment of FIG. 3D, the vertical post 110 engages the side panel 102b via a tongue-and-groove fitting 104 comprised of parallel rails 210 situated on the vertical post 110 forming a groove-shaped engagement and a corresponding tongue-shaped fitting 208b formed on a side panel 102b. Specifically, the tongue shape 132b may be formed by tongue-shaped fitting 208b (e.g. similar to tongue-shaped fitting 208 of FIG. 3C). The groove shape 130b may be formed by affixing two rails 210 to the vertical post 110 with sealant or welding. The space defined between the rails 210 forms a groove shape 130b. As shown in FIG. 3D, the tongue 132b of tongue-shaped fitting 208b fits into the groove 130b formed by the rails 210 to form a joint between the side panel 102b and the vertical post 110.

FIG. 3E illustrates a cross-sectional view of an embodiment of side panels 102c, 102d fitted together, via a tongue-and-groove fitting 104, to form part of a wall of the control enclosure. Specifically, one side panel 102c is shaped to define a groove 130c in its lateral edge and is fitted with a groove-shaped fitting 206c (e.g., similar to groove-shaped fitting 206 of FIG. 3B). The adjacent side panel 102d is shaped such that it includes a tongue shape 132d to engage the grooved side panel 102c. The fitting 208d (e.g., similar to fitting 208 of FIG. 3C), which has a corresponding tongue shape 132d to side panel 102d, is fitted over the lateral edge of side panel 102d and may be affixed thereto with sealant or may be welded thereto. The tongue 132d fits into the groove 130c to form a joint between the side panels 102c and 102d. The fittings 206c and 208d may be secured to each other with structural adhesive 138 or welding. In another embodiment shown in FIG. 3G, the side panel 102f is composed of a material that cannot easily define a groove or tongue. In this embodiment, the tongue-shaped fitting 212 of FIG. 3F including a pre-formed tongue shape 132 is used and applied as shown.

As illustrated in FIG. 3H, the connection between the side panel 102 and the floor panel 108 may also include a tongue-and-groove engagement 104. The floor panel 108 may be formed so as to define a groove or tongue, respectively, along its top perimeter edges to facilitate engagement with the vertical posts and the side panels. The floor panel 108 may be configured to include a tongue shape 132 along one of its edges. The tongue shape 132 may be formed by fitting 204 of FIG. 3A or fitting 212 of FIG. 3F. The side panel 102 may be formed to define a groove 130 along its corresponding bottom surface. The groove shape 130 may be formed by the fitting 206 of FIG. 3B. As shown in FIG. 3H, the tongue 132 of fitting 204 fits into the groove 130 of fitting 206 to form a joint between the floor panel 108 and the side panel 102. Fittings 202 and 206 may be secured to each other with structural adhesive 138. The fittings 204, 206 may also be welded to each other.

As described above, the engagement between the side panel 102 and the roof 106 may also include a tongue-and-groove engagement 104. As illustrated in FIGS. 4C-4D, the roof panels 106 are formed so as to define a groove or tongue, respectively, along their edges to allow for engagement with each other and the side panels 102. As specifically illustrated in FIG. 4C, a roof panel 106 may be configured to include a tongue shape 132 along one of its edges. The tongue shape 132 may be formed by fitting 214 of FIG. 4A. Moreover, fitting 214 may further provide an additional support element 170 for the roof panel. Specifically, as illustrated in FIG. 4C, the support element 170 of fitting 214 borders the outer lateral edge of the roof panel 106, which limits movement of the roof panel 106 with respect to the side panels 102 to ensure that the roof panel 106 stays in place above the side panels 102. The side panel 102 may be formed to define a groove 130 along its corresponding top surface. The groove shape 130 may be formed by the fitting 216 of FIG. 4B. The fitting 214 is affixed to the roof panel 106 and the fitting 216 may be affixed to the side panel 102 with sealant or through welding. As shown in FIGS. 4C and 4D, the tongue 132 of fitting 214 fits into the groove 130 of fitting 216 to form a joint between the roof panel 106 and the side panel 102. Fittings 214 and 216 may be secured to each other with structural adhesive 138. Additionally, the fittings 214, 216 may be welded to each other.

The fittings may be comprised of 12-gauge, ASTM 1011, HSLA Gr 55 tongue-and-grooved shaped steel. Additionally, the metal fitting pieces may be hot dipped galvanized, complying with ASTM A123/A123M.

FIGS. 5A through 5E illustrate various embodiments of side panels 102 for the panelized control enclosure 100. As discussed above, the side panels 102 may be constructed of various materials. For example, in FIGS. 5A-5E, the control enclosure 100 may include side panels 102 constructed of composite materials 120 in combination with other side panels 102 constructed of metal 122. The metal 122 side panels 102 may be formed from a light metal (i.e., 24-gauge steel with polystyrene filler) that is pre-coated in 20-yr Kynar finish. Moreover, the metal panels 122 may be corrugated. FIGS. 5B, 5C and 5E show side panels comprised of metal material 122. The composite material 120 may be a concrete, wood, fibers and resin, polymeric, reinforced concrete or the like. FIGS. 5A and 5D show side panels 102 comprised of a composite material 120. The strength of the enclosure may be customized by the select combination of metal panels and composite panels.

In one embodiment, the composite material consists of a novel concrete formula, designed for weight reduction, strength and resistance to cracking. The composite material may be selectively altered to maximize one or more of these attributes. In one embodiment, the composite material may be formed from the ingredients and in the proportions as listed in the following Table:

	Ingredient	Amount
	LW Coarse Aggregate	38	L
	Dust	38	L
	Sand	9.5	Liters
	Cement	50	Kg
	Water	19	L
	Pre-expanded mineral bead	9.5	L
	Concrete consistency regulating	400	mL
	reslump admixture
	MS Fiber (macro synthetic	200	g
	reinforcing fiber
	Acrylic resin	2	L

Moreover, in one embodiment, the composite concrete has compression strength of 2500 psi and density of 100 pcf (lb/ft³). Additionally, the concrete is reinforced with steel reinforcement comprised of wire mesh 6×6-6/6 (complying with ASTM A-185 and ASTM A-496) and with fiber reinforcement comprised of macro-synthetic reinforcing fiber (complying with ASTM C1116 0.26 lb/ft³). The formula includes fiber and wire reinforced concrete with pre-expanded mineral bead, such as Perla™ (manufactured by Fanosa, located in Sinaloa, Mexico). In one embodiment, the concrete consistency regulating reslump admixture is Sikament-100, manufactured by Sika® Corp. USA, located in Lyndhurst, N.J. Additionally, in one embodiment, the abovementioned MS fiber is Sika® Fiber MS, manufactured by Sika® Corp. USA.

As discussed above, the walls may be constructed of a number of pre-formed composite material or metal panels. In a single control enclosure, the panels may be constructed of the same or different material. That is, a single control enclosure may include a combination of metal panels and composite panels, or only metal panels, or only composite panels. The metal panels may be comprised of 12-gauge, ASTM 1011, HSLA Gr 55 tongue-and-grooved shaped steel. Additionally, the metal panels may be hot dipped galvanized, complying with ASTM A123/A123M.

The side panels 102 may comprise one of the following configurations:

Description                      Dimension
Frame: Steel HSLA 55 Gr. sheet, gauge 12, tongue and 2′-9″ × 10′-6″
groove shape
Filler: synthetic fiber and steel wire mesh reinforced
light weight concrete
Finishing: Stained and sealed concrete
Frame: Steel A-36 sheet, gauge 12, tongue and groove 2′-9″ × 10′-6″
shape
Filler: polystyrene
Finishing: pre-coated steel sheet, gauge 24
Frame: Steel HSLA 55 Gr sheet, gauge 12, tongue and 2′-9″ × 10′-6″
groove shape
Filler: synthetic fiber and steel wire mesh reinforced
light weight concrete
Finishing: Stained and sealed Concrete
Special: hole (aperture)
Frame: Steel HSLA 55 Gr sheet, gauge 12, tongue and 2′-9″ × 10′-6″
groove shape
Filler: polystyrene
Finishing: pre-coated steel sheet, gauge 26
Special: hole (aperture)

Additionally, as shown in FIGS. 5D and 5E, the side panels 102, whether composed of composite or metal material, may define an aperture 128. The aperture 128 may be a window or an access port for the devices or equipment within the control enclosure.

As shown in FIGS. 6A-6C, in a single panelized control enclosure 100, the panels may be formed of different material. That is, a single control enclosure 100 may include a combination of metal panels 122 and composite panels 120. FIG. 6A illustrates a panelized control enclosure 100 including both metal panels 122 and composite panels 120, as well as a door 118. The door 118 may be comprised of 18-gauge face sheet with 7-gauge hinge reinforcement and may be thermally insulated. Moreover, the door 118 may include a hydraulic closure and a key lock exterior handle with an interior panic bar.

The embodiment of FIG. 6A includes further an additional metal panel, the door cover 116, situated above the door 118. FIG. 6B depicts a side view of the panelized control enclosure of FIG. 6A, including composite panels and lifting yokes 148 situated on the frame base 112. FIG. 6C shows the rear of the panelized control enclosure 100, where the side panels 102 are comprised of both composite panels 120 and metal panels 122. FIG. 6D provides a top view of the panelized control enclosure 100. FIG. 6E illustrates a floor panel 108 for the control enclosure 100. The floor panel 108 may be formed from concrete, metal, wood, or another material and may include a metal tread plate 150 such as a steel tread plate. FIG. 6F illustrates a cross-sectional view of the embodiment of the panelized control enclosure 100 of FIGS. 6A-6E.

As illustrated in FIGS. 6G-61, the side panels 100, whether composed of composite material or metal, may be coated in a casing primed and finished with a top coat of Acrylic Polyurethane marine coating. Moreover, the panels 102 may be joined utilizing a 2-part methacrylic or acrylic construction adhesive and sealed with a 25-year marine sealant. The interior ceiling and side panels 102 may be comprised of plywood and/or polystyrene foam installation, sheathed with white pre-coated steel sheet, gauge 24 or plastic liner 142. FIG. 6G details the joint between the roof and the wall, and shows in detail the P.V.C. waterproofing membrane 130, adhesive 132, hot-air welded sheet 134, sealer 136, structural adhesive 138 (such as, Plexus MA310, available from ITW Plexus with a location in Rushden, UK, MAXLOK MX/T18 CART RP375 from LORD), side panel 102, roof panel 106, tongue-and-groove joint 104, polystyrene inner insulation 140, pre-coated steel sheet, gauge 24 or plastic inner liner 142, and the like. FIG. 6H illustrates a cross-sectional view of a joint between a side panel 102 and a floor panel 108, detailing the side panel 102, sealer 136, structural adhesive 138, and steel floor plate 108. FIG. 6I illustrates a top cross-sectional view of the joint between two side panels 102a, 102b and a vertical post 110 including a pre-coated steel sheet, gauge 24 or plastic liner 142.

Furthermore, as previously mentioned with respect to in FIG. 6F the panelized control enclosure 100 may include lifting yokes 148 which are installed on the frame base 112 to facilitate moving of the panelized control enclosure 100. As discussed above, it is an object of the present invention to provide a panelized control enclosure 100 that may be constructed and outfitted at a manufacturing site, and later shipped to and installed at a substation. The panelized control enclosure 100 may be stored during the time between its construction and installation. In order to move the control enclosure 100, it may be lifted onto a moving device, such as a crane, truck or train. To facilitate the lifting thereof, the panelized control enclosure 100 is fitted with lifting yokes 148. FIG. 6F illustrates the configuration of the lifting yokes 148 positioned on the base 112 of the panelized control enclosure 100.

While this invention has been described with reference to certain illustrative aspects, it will be understood that this description shall not be construed in a limiting sense. Rather, various changes and modifications can be made to the illustrative embodiments without departing from the true spirit, central characteristics and scope of the invention, including those combinations of features that are individually disclosed or claimed herein. Furthermore, it will be appreciated that any such changes and modifications will be recognized by those skilled in the art as an equivalent to one or more elements of the following claims, and shall be covered by such claims to the fullest extent permitted by law.

Claims

1. A portable panelized control enclosure for housing power system devices of a power system substation, said enclosure comprising:

a structural frame including a plurality of vertical posts and a base;

a plurality of side panels forming walls of the control enclosure and defining an interior space therein for housing the power system devices, wherein the structural frame engages and provides support for the side panels;

at least one roof structure for providing a covering for said the interior space, wherein said the frame and side panels engage and provide support for the roof panel;

a plurality of tongue-shaped fittings formed on at least one of the frame, side panel and roof panels; and

a plurality of groove-shaped fittings formed on at least one of the frame, side panel, and roof panels each engaging a corresponding tongue-shaped fitting to form an engagement between one of the frame, side panel and roof panel.

2. The portable panelized control enclosure of claim 1, wherein the panels are comprised of a combination of panels constructed of metal and panels constructed of a composite material.

3. The portable panelized control enclosure of claim 1 further including lifting yokes to facilitate transportation thereof.

4. The portable panelized control enclosure of claim 1, wherein at least one of the groove-shaped fittings is in the form of parallel rails affixed to at least one of the frame, side panel and roof panels.

5. The portable panelized control enclosure of claim 1, wherein at least one of the side panels, structural frame and roof panel are prefabricated.

6. The portable panelized control enclosure of claim 2, wherein the strength of the enclosure may be customized by the select combination of metal panels and composite panels.

7. The portable panelized control enclosure of claim 1, wherein at least one of the tongue-shaped fittings includes a pre-formed tongue.

8. The portable panelized control enclosure of claim 1, wherein at least one of the tongue-shaped fittings includes a support element adapted to limit movement of the one of the roof panels with respect to one of the side panels.

9. The portable panelized control enclosure of claim 1, wherein in the plurality of lightweight panels are composed of a composite material comprising:

about 38 liters of LW coarse aggregate,

about 38 liters of dust,

about 9.5 liters of sand,

about 50 kilograms of cement,

about 19 liters of water,

about 9.5 liters of polystyrene particle filler,

about 400 milliliters of concrete consistency regulating reslump admixture,

about 200 grams of fiber, and

about 2 liters of acrylic resin.

10. The portable panelized control enclosure of claim 9 wherein said composite material is selectively altered to have a compression strength of about 2500 psi.

11. The portable panelized control enclosure of claim 9, wherein said composite material is selectively altered to have a density of 100 pcf.

12. The portable panelized control enclosure of claim 9, wherein said composite material is reinforced with steel reinforcement comprised of wire mesh 6×6-6/6 (complying with ASTM A-185 and ASTM A-496) and with fiber reinforcement comprised of macro-synthetic reinforcing fiber (complying with ASTM C1116 0.26 lb/ft3).

13. A panelized control enclosure capable of being substantially manufactured before installation for housing power system devices of a power system substation, said enclosure comprising:

a structural frame including a plurality of vertical posts and a base;

a plurality of prefabricated side panels forming walls of the control enclosure and defining an interior space therein for housing the power system devices, wherein the structural frame engages and provides support for the side panels; and

at least one roof structure for providing a covering for said the interior space, wherein said the frame and side panels engage and provide support for the roof panel.

14. The panelized control enclosure of claim 13, wherein the panels are comprised of a combination of panels constructed of metal and panels constructed of a composite material.

15. The panelized control enclosure of claim 14, wherein the strength of the enclosure may be customized by the select combination of metal panels and composite panels.

16. The panelized control enclosure of claim 13, further including a plurality of tongue-shaped fittings formed on at least one of the frame, side panel and roof panels and a plurality of groove-shaped fittings formed on at least one of the frame, side panel, and roof panels each engaging a corresponding tongue-shaped fitting to form an engagement between one of the frame, side panel and roof panel.

17. The panelized control enclosure of claim 16, wherein at least one of the groove-shaped fittings is in the form of parallel rails affixed to at least one of the frame, side panel and roof panels.

18. The panelized control enclosure of claim 16, wherein at least one of the tongue-shaped fittings includes a pre-formed tongue.

19. The panelized control enclosure of claim 16, wherein at least one of the tongue-shaped fittings includes a support element adapted to limit movement of the one of the roof panels with respect to one of the side panels.

20. The panelized control enclosure of claim 13, wherein in the plurality of lightweight panels are composed of a composite material comprising:

about 38 liters of LW coarse aggregate,

about 38 liters of dust,

about 9.5 liters of sand,

about 50 kilograms of cement,

about 19 liters of water,

about 9.5 liters of polystyrene particle filler,

about 400 milliliters of concrete consistency regulating reslump admixture,

about 200 grams of fiber, and

about 2 liters acrylic resin.

21. The panelized control enclosure of claim 21 wherein said composite material is selectively altered to have a compression strength of about 2500 psi.

22. The panelized control enclosure of claim 21, wherein said composite material is selectively altered to have a density of 100 pcf.

23. The panelized control enclosure of claim 21, wherein said composite material is reinforced with steel reinforcement comprised of wire mesh 6×6-6/6 (complying with ASTM A-185 and ASTM A-496) and with fiber reinforcement comprised of macro-synthetic reinforcing fiber (complying with ASTM C1116 0.26 lb/ft3).