Industrial Wiring for the Forgotten 1990s Factory

Introduction

As the sole electrician tasked with upgrading the wiring in our decades-old factory, I knew I had my work cut out for me. The building had originally been constructed in the 1990s and many of the electrical systems were in dire need of replacement. In this article, I'll walk through the full process I followed to rewire the factory from start to finish. My goal is to provide a comprehensive guide covering all aspects of industrial electrical work so that others maintaining aging infrastructure can learn from my experience.

Assessment of Existing Systems

Before doing any upgrades, my first task was to carefully assess the existing electrical systems throughout the factory. This involved:

• Inspecting the main electrical service panel and all subpanels: I checked for any damaged breakers, fuses, or bus bars. I also verified that all wiring lugs and connections were tight and corrosion-free.

• Testing circuits for faults: I used a multimeter to check for shorts, grounds, and unacceptable voltage drops in all circuits. This helped identify any damaged wiring or devices.

• Evaluating wire and cable conditions: I visually inspected all exposed cables and conduits for damage, deterioration, or violations of code requirements. Safety was my top concern.

• Documenting everything: I created detailed notes, diagrams, and photos to thoroughly document the existing systems prior to modifications. This was crucial for staying organized.

Creating an Upgrade Plan

With a solid understanding of the current electrical system's condition, I was able to develop a comprehensive plan for upgrades and new installation:

• Service capacity analysis: Based on the factory's equipment needs, I calculated the appropriate service size and identified upgrades needed to the main panel.

• Load calculations: I analyzed the voltage drop and load requirements for all circuits to specify proper wire sizes, overcurrent protection, and installation methods.

• Equipment selection: I researched and selected suitable new devices like motor controllers, disconnects, switches, and outlets to install.

• Code review: I extensively reviewed NEC and local codes to ensure the design met all requirements for industrial facilities. Safety was the top priority.

• Developing diagrams: I created detailed wiring diagrams showing all circuits, wire sizing, and connections for the upgraded electrical system.

Installation of New Industrial Wiring

With the overhaul plan finalized, I began the process of bringing the factory's electrical system up to modern standards:

Running Conduit

• I installed new galvanized rigid metal conduit throughout the factory to house wiring for lighting, outlets, equipment, etc. This offered excellent physical protection and made wiring upgrades easier.

Pulling Wire

• Based on my load calculations, I pulled the appropriately sized THHN wiring through the conduit runs. For large feeders, I used wire pullers to safely pull multiple conductors through long runs.

Terminations

• I securely terminated all wires using insulated lugs, splices, and connectors. Proper terminations ensure reliable continuity and prevent shorts or fires. I adhered to torque specs.

Installing New Industrial Equipment

• I safely de-energized circuits and removed outdated equipment like motor starters and disconnects. New devices were installed per code and manufacturer specifications.

Testing and Inspection

• Once installation was complete, I tested all circuits for proper function and shorts/grounds. Everything was meticulously inspected against NEC requirements prior to energization.

Results of the Electrical Overhaul

After months of diligent work, the factory was fully rewired to modern, code-compliant standards. The upgrades provided:

• Increased power capacity to run larger equipment loads

• A safe, reliable electrical system with new overload and fault protection

• Energy efficiency gains from proper wire and equipment sizing

• Code compliance for both NEC and local requirements

• Documentation and labeling for maintainability

• Room for future expansion with increased service size

By following structured electrical engineering and installation best practices, I was able to completely revitalize the decades-old factory's wiring. The owners now have a modern power distribution system that will support their needs for years to come.

Key Lessons Learned

Upgrading old industrial wiring requires meticulous planning and execution. Based on challenges I faced in this project, I recommend the following:

• Allow ample time for assessment - don't rush into upgrades blindly

• Carefully track all changes to the existing system via diagrams and photos

• Use quality materials and follow best practices - don't cut corners

• Confirm all code requirements and work permits early on

• Expect the unexpected! Be ready to adapt your plans as needed

• Leverage experienced electricians if the project is beyond your skill level

Following these guidelines will help ensure a successful, code-compliant industrial electrical overhaul. Let me know if you have any other questions!