Case Study Snapshot
A defense contractor required a turnkey power solution for a network of classified facilities on a remote island base. Following extensive storm damage, Total Energy Solutions (TES) delivered a fully integrated system encompassing 14 Cummins generators (20–500 kW), automatic transfer switches, Clark fire pumps and Convault ballistic-rated fuel tanks, all engineered to meet stringent Buy American Act and military submittal standards. Despite remote-island logistics, monsoon conditions and complex permitting, the 22-month project was completed on schedule, providing reliable, compliant backup power across multiple mission-critical sites.
Project Scope
In the aftermath of Typhoon Mawar in May 2023, a military base on a remote island in the Pacific required resilient backup power for critical operations, including communications, air traffic control and fire suppression across top-secret facilities and restricted access support sites. The defense contractor collaborated with TES and Power Temp Systems (PTS) to design and deliver a unified, base-wide solution. The project encompassed 14 generator installations and associated automatic transfer switch (ATS) systems ranging from 20 kW to 500 kW. Each site required unique engineering due to classified operations and military security standards. All components were reviewed for compliance with the Buy American Act, requiring detailed documentation of all American manufactured mechanical hardware and electrical components. The submittal process alone totaled thousands of specification sheets, completed over 2.5 weeks by a dedicated documentation team.
Integrated Solution
Spanning more than a dozen secure facilities, the project integrated multiple power and safety systems designed to maintain continuous operation under demanding military conditions.
- Hangar for top-secret drone operations: 2,000 A (amps) main distribution panel and 600 A automatic transfer switch, with Square D transformers and sub-panels from PTS
- Main fuel supply: Cummins 450 kW generator with 1,000 A automatic transfer switch to power aircraft refueling systems
- Lift station: 60 kW Cummins generator with 400 A automatic transfer switch for water and sewage lift operations
- Air traffic control tower: 100 kW Cummins generator with 400 A automatic transfer switch ensuring continuous communications and flight safety
- Restricted-access hangar: Two Clark fire pump engines for critical fire suppression systems
- Support facility: Remote satellite and radar site powered by a Clark fire pump engine
- Fire station: 600 A Cummins automatic transfer switch and 1,000-gallon Convault ballistic-rated, concrete-encased fuel tank
- Beacon tower: 20 kW Cummins generator with 125 A automatic transfer switch to maintain the essential airfield navigation beacon
- Secure aviation operations facility: 1,200 A automatic transfer switch and 4,000-gallon Convault fuel tank with integrated pumps and controls to support unmanned aerial systems
- Recreation and support facility: 1,600 A automatic transfer switch ensuring continuous power for base personnel and administrative services
TES served as the primary integrator for the technical execution, providing Cummins generators and automatic transfer switches, while PTS supplied distribution systems and switchboards. TES also managed conduit installation (¾” to 4”), foundation pouring and electrical outage permitting amid the Air Force base’s tight operational schedule. Electrical crews removed obsolete wiring and installed new pipe and controls across multiple zones, coordinating crane lifts and on-site concrete pours under live-base restrictions.
Every system was engineered for resilience, redundancy and compliance with the Buy American Act, meeting the military’s rigorous standards for performance and documentation.
Implementation and Timeline
- December 2023: Site assessment and scoping across all mission- critical buildings
- April 2024: Initial mobilization and decommissioning; electrical planning and design validation by TES’ master electrician
- February-August 2025: Sequential installation and commissioning visits (four in total) to execute, test and certify each facility
- October 2025: Final commissioning and turnover of all systems
Despite island-wide logistical constraints and frequent monsoon conditions, four earthquakes and tropical heat reaching 95°F, TES maintained schedule integrity through adaptive planning, meticulous resource management and supply chain support from U.S. operations and local enterprises.
Outcomes
√ Resilient power infrastructure: Fully redundant backup systems enabling the Air Force base to maintain operations amid monthly power outages
√ Buy American Act compliance: Complete adherence through exhaustive documentation of U.S.-manufactured materials
√ Safety and reliability: Installation quality verified by both our customer (the military operational support company) and its defense contractor, meeting stringent military inspection standards
√ Exceptional client satisfaction: Clear communication, milestone reporting and earned trust, requiring minimal customer oversight
√ Enterprise collaboration: Exemplified the strength of TES’ alliance with PTS, reinforcing integrated delivery capabilities across remote and classified environments
This multi-million-dollar engagement demonstrates the ability of TES to deliver complex, turnkey power systems for mission-critical applications under extreme logistical and environmental conditions.
Total Energy Solutions delivers certainty where it matters most: for capital-intensive, safety-critical and schedule-driven operations across classified facilities, chemicals, refineries, LNG terminals, data centers and other infrastructure where downtime isn’t an option. Learn more about Total Energy Solutions’ integrated solutions for the world’s most demanding operations at TotalEnergySolutions.com
