Updating Electrical Wiring in Older Industrial Buildings

Introduction

Updating and maintaining electrical wiring in older industrial buildings is crucial for safety, efficiency, and staying compliant with modern electrical codes. However, this can be a complex and expensive undertaking that requires careful planning and execution. In this article, I will provide an in-depth guide on major considerations when updating electrical systems in dated industrial facilities.

Assessing the Existing Electrical System

The first step is thoroughly evaluating the current electrical system. This includes:

• Electrical load analysis - Determine the types of equipment, their power demands and if the existing infrastructure can handle current and future loads. Overloaded circuits are a fire hazard.

• Wiring conditions - Inspect for damaged or frayed wiring insulation, improper terminations, undersized wiring for loads, and other violations of electrical code. Outdated wiring can't safely handle modern power needs.

• Grounding evaluation - Check that all equipment and conduits are properly grounded. Faulty grounding puts workers at risk of shocks.

• Mapping the system - Document the layout of panels, circuits, wiring runs and electrical rooms. This provides a blueprint for planning upgrades.

• Safety & compliance audit - Assess for lighting issues, lack of GFCI outlets near water sources, inadequate smoke/fire detection, and other safety hazards.

Thorough assessment determines what needs repair, replacement or expansion for a safe and sufficient electrical system. I would consult a qualified electrical engineer for large industrial buildings.

Upgrading Service Capacity

Industrial facilities often need upgraded electrical service to meet modern power demands. This may involve:

• Install higher amperage breakers in the main service panel if allowed by the utility company.

• Replace outdated service entry wires with new conductors sized for increased loads.

• Install additional service panels to add circuit capacity and segregate critical equipment.

• For major capacity increases, work with the utility to upgrade the incoming service wires and meter socket.

• Add surge protection devices and other modifications to meet current electrical code.

Proper service upgrades prevent overloading, ensure reliable power to all equipment, and improve safety. Load calculations by an engineer guide required capacity.

Replacing Outdated Wiring

Beyond the main service, systematically upgrading old wiring throughout the building is a key task:

• Replace aged branch circuit wiring with new copper wiring that meets load demands. Rewire entire circuits from panels to endpoints.

• Remove knob and tube wiring - this outdated method is a fire hazard.

• Eliminate unsafe aluminum wiring and replace with copper. Use copalum crimp connectors if copper is cost prohibitive.

• Replace damaged wiring and undersized conductors for modern loads. Use 10 AWG or larger wire for 20A+ branch circuits.

• Reroute wiring through new conduit for physical protection and heat dissipation. Use flexible conduits for adjustments.

• Provide dedicated neutral wires for all circuits as per modern code. Shared neutrals are unsafe.

Systematic rewiring ensures reliable power distribution and safety. I would hire a licensed electrician for this complex task.

Additional Safety Upgrades

Beyond wiring, industrial electrical upgrades should include:

• Overcurrent protection - Install circuit breakers or fuses sized appropriately for each circuit's wire gauge and load. This prevents dangerous overheating.

• Grounding - Verify all equipment is grounded via third prong plugs or wires to ground bus bars. Upgrade grounding system if needed.

• GFCI protection - Install GFCI outlets near wet areas like bathrooms. This prevents lethal shocks.

• Smoke/CO detectors - Add detectors in all occupied areas and rooms with major electrical equipment. Integrate with fire alarm system.

• Lighting - Ensure adequate illumination in work areas and emergency lighting for egress. Upgrade fixtures to efficient LEDs.

• Signage - Post safety signage like arc flash hazards, high voltage warnings, panel directories and emergency procedures.

• Firestopping - Seal penetrations in firewalls with fireproof caulk to slow fire spread.

These measures, along with proper wiring, are essential for a safe industrial electrical system. I would have upgrades inspected for code compliance.

Managing Costs

Electrical upgrades in aging industrial buildings can be very costly. Here are tips to reduce expenses:

• Do upgrades in phases based on priority, starting with safety issues and overloaded circuits.

• Scout for utility rebates - many offer incentives for energy efficient upgrades.

• Consider lower cost conductors like aluminum or copper-clad aluminum wire where allowed. Get engineer approval.

• Rewire selectively - replace only damaged or insufficient wiring, don't automatically rewire everything.

• Purchase reconditioned breakers and panels to save costs. Have a supplier inspect and guarantee performance.

• Compare contractor bids - get quotes from several reputable electrical contractors before selecting one.

• Time projects - coordinate electrical work with other planned renovations to reduce costs.

With good planning and cost management, critical electrical upgrades can be executed without breaking the bank.

Maintaining the Upgraded System

Once electrical systems are updated, I would institute an ongoing maintenance program:

• Perform infrared scans to identify hot spots in wiring and connections needing repair. Do annually.

• Conduct power quality audits to troubleshoot issues like harmonics, low power factor, and voltage fluctuations.

• Continually update documentation on electrical systems, panels and wiring as modifications are made.

• Clean electrical rooms regularly to prevent dust buildup on equipment.

• Lubricate panel door hinges, breaker handles and other moving parts per manufacturer specifications.

• Inspect wiring in hazardous areas annually - look for damage, corrosion, overheating.

• Test GFCIs and smoke detectors monthly to verify functionality.

• Check grounding via earth resistance tests yearly.

Proactive maintenance ensures an upgraded electrical system will continue providing safe and reliable power over the long run. I would make it standard operating procedure.

Summary

Updating outdated and insufficient electrical systems in old industrial buildings is a complex but vitally important undertaking. Careful assessment provides the blueprint for required upgrades. Systematic wiring and service capacity improvements tailored to current and future needs are essential, as are additional safety features. With good planning, phased upgrades, and ongoing maintenance, industrial electrical systems can be modernized in a safe and cost-effective manner over time. A qualified electrical engineer and licensed electrician are critical partners for navigating significant upgrades smoothly and successfully.