How to Rewire Your Factory to Meet Code and Avoid Shutdowns

Introduction

Upgrading an older factory to meet modern electrical codes can be a daunting task, but it is crucially important for safety and continued operation. Rewiring a factory is a complex endeavor that requires careful planning, expertise, and diligent oversight. However, with the right approach, it can be accomplished smoothly and cost-effectively. In this article, I will provide an in-depth guide on how to rewire your factory to meet code and avoid shutdowns.

Assess Your Current Electrical System

The first step is to thoroughly assess your factory's current electrical system.

• I hire a licensed electrician to conduct a full evaluation of the existing wiring, components, and equipment.

• The electrician provides me with a detailed report identifying any deficiencies, risks, and areas that need to be upgraded.

• I review the findings to understand where my factory stands in relation to current local and national electrical codes.

• I pay special attention to the age and condition of wiring, grounding systems, overcurrent protection devices, and electrical panels.

• Older factories often have outdated wiring that is insufficient for modern power loads.

Create a Rewiring Plan

With a clear picture of my factory's electrical status, I work with the electrician to develop a rewiring plan and timeline.

• The plan prioritizes rewiring the most outdated and hazardous sections first.

• It also includes adding new circuits and panels to meet increased power demands.

• I consult the factory's operations team to minimize downtime and production impact.

• The plan factors in equipment that may need rewiring like HVAC systems, machinery, and lights.

• Permit applications are submitted and contractors hired to complete the work.

Upgrade Main Service and Panels

Rewiring starts with upgrading the main service and electrical panels:

• The service entrance wires and main panel may need replacing if undersized or in poor condition.

• New grounding electrodes may be added if the existing grounding does not meet code.

• I install new main disconnect switches and overcurrent protection devices.

• Old fuse boxes are replaced with circuit breaker panels with ample capacity.

• New panels are added to eliminate long wiring runs and overloads.

Install New Wiring and Devices

With upgraded main systems in place, rewiring the factory itself begins:

• Old wires are removed and replaced with new wires meeting current code size and insulation standards.

• Wiring methods are updated from outdated open knob-and-tube wiring to safer and code-compliant methods.

• Devices like switches, receptacles, and light fixtures are also replaced.

• GFCI and AFCI protection is added where required by code to prevent shocks and arc faults.

• Lighting systems are overhauled with modern energy efficient fixtures.

Incorporate Other Electrical Improvements

The factory rewiring presents opportunities to enhance the electrical system:

• I install new emergency lighting and exit signs with battery backups.

• Wiring for future equipment upgrades or expansions is added.

• Higher capacity wires are used in certain areas for planned additions.

• Separate circuits are run for any sensitive electronics or computers.

• Lightning and surge protection safeguards are put in place.

Have Follow-Up Inspections

Once the rewiring is complete, I schedule thorough inspections and testing:

• The local building department inspects the new installation for code compliance.

• The electrician performs insulation resistance, ground continuity, and load testing to ensure safety.

• All new circuits are carefully checked and labeled at distribution panels.

• Problems are quickly corrected until the installation passes all inspections and tests.

• I keep detailed documentation of all inspections, approvals, and testing.

Maintain and Upgrade Wisely

To keep my factory's new electrical system in excellent shape, I establish regular maintenance and commit to future upgrades:

• Qualified electricians perform preventative maintenance on equipment and wiring.

• I budget for system upgrades as codes evolve over time.

• Electrical rooms and panels are kept clean, dry, and accessible.

• Workers are trained to spot and report any electrical issues.

• The system is reassessed at least every 10 years and upgraded accordingly.

Proper rewiring and vigilant maintenance helps ensure my factory operates efficiently while avoiding costly unplanned shutdowns. Although complex, a factory-wide electrical overhaul is a smart investment in productivity, safety, and regulatory compliance. With close cross-departmental cooperation, the process can be executed smoothly.