Updating Obsolete Electrical Wiring in Industrial Facilities

Upgrading electrical systems in industrial facilities is an important task that should not be overlooked. As facilities age, electrical wiring and components inevitably become outdated and can pose major safety and operational risks if left unaddressed. In this article, I will provide an in-depth look at the key considerations, costs, and process for updating obsolete electrical wiring in industrial settings.

Why Electrical Upgrades Are Necessary

There are several reasons why industrial facilities need to periodically update their electrical systems:

Safety

• Older electrical systems often lack modern safety features like ground fault circuit interrupters (GFCIs) and arc fault circuit interrupters (AFCIs) that detect dangerous conditions and cut power to prevent fires, electrocution, and other hazards. Upgrading provides an extra layer of protection for workers.

Reliability

• Outdated wiring and components are more prone to failures, shorts, and power fluctuations that can lead to downtime and disrupt operations. Newer systems are designed for reliability and resilience.

Efficiency

• Electrical code has evolved to support more energy efficient equipment and practices. Upgrading allows facilities to reduce energy waste and costs.

Load Capacity

• Sometimes electrical demand has expanded beyond the capabilities of old systems. Upgrades are needed to provide sufficient power capacity.

Compliance

• Older installations likely do not comply with modern electrical code. Upgrades are necessary to meet current standards and pass inspections.

Planning the Upgrade Project

Careful planning is required for a smooth electrical upgrade project:

Full Facility Assessment

• A qualified electrical contractor should conduct a detailed assessment of the facility's current systems to identify problem areas and determine the scope of required upgrades.

Prioritizing Updates

• Focus first on upgrades that address immediate safety hazards, load issues, or regulatory noncompliance. Other improvements can be phased in over time if needed.

Budgeting

• Get accurate cost estimates for equipment, labor, and disruption to operations during the upgrade. Secure appropriate funding.

Scheduling

• Plan work during lower demand or shutdown periods to minimize impact on operations. Stage tasks carefully.

Contingency Planning

• Identify possible points of failure and have contingency plans ready for issues like power outages during the upgrade.

Selection of Electrical Contractor

• Choose a contractor thoroughly vetted for proper licensing, expertise, experience, and capability to execute the project.

Electrical Upgrade Methodology

The general process for upgrading industrial electrical wiring will involve:

1. Install New Electrical Panel(s)

• A new main panel and any subpanels will likely need to be installed to increase capacity. Select panels compatible with new wiring.

2. Run Conduit and Wiring

• Conduit provides protected pathways for running new wiring through the facility. Use rigid galvanized conduit for industrial settings.

3. Replace Outlets and Switches

• Upgrade to modern outlets, switches, and covers as needed to match the increased system capacity.

4. Install New Hardware

• Replace outdated breaker boxes, transformers, and other aging electrical hardware for optimal performance.

5. Connect and Test

• Safely connect the new wiring to equipment. Thoroughly test for faults before going live. Verify grounding and bonding.

6. Commission and Certify

• Commission the upgraded system. Have inspector certify that installation complies with all electrical codes and standards.

7. Provide Documentation

• Obtain full documentation of the upgrade with diagrams, manuals, warranties, and certificates for the facility's records.

Key Electrical Components to Upgrade

Some of the main electrical elements to evaluate for replacement during an industrial upgrade include:

• Circuit breakers - Outdated breakers pose fire and shock risks. Current limiting breakers improve safety.

• Switchgear - New switchgear provides better reliability, safety mechanisms, and connectivity.

• Transformers - Replace inefficient or undersized transformers to optimize power distribution.

• Surge protectors - Modern surge protection reduces damage to equipment from voltage spikes.

• Lighting - Upgrade lighting fixtures, controls and wiring for improved efficiency and control.

• Emergency systems - Ensure EXIT signs, egress lighting, and backup power systems are up to current code.

• Wiring - Replace outdated wiring not rated for capacity demands. Use copper for optimal safety and efficiency.

Key Factors That Impact Upgrade Costs

Some major factors that influence the costs of an electrical upgrade include:

• Scope of work - More extensive upgrades cost more. Prioritize critical needs first.

• Labor rates - Prevailing electrician wage rates in your region impact labor costs.

• Materials - Type of wiring, conduit, panels, and hardware specs impact material costs.

• Facility size and configuration - Wiring runs needed for large and complex builds cost more.

• Permitting and inspection fees - Local fees apply for permits and inspections.

• Utility work - Upgrades to incoming electric service and metering add cost.

• Abatement - Removal of hazardous materials like asbestos adds cost.

• Operational disruption - Lost revenue during shutdowns factors into overall cost.

Helpful Tips for the Upgrade Process

Some helpful tips for smoothly upgrading obsolete electrical in industrial facilities include:

• Get input from operations staff to understand pain points with existing systems.

• Address any environmental hazards like lead paint or asbestos to avoid delays.

• Label all circuits to simplify installation of new wiring.

• Consider long-term expansion needs not just immediate requirements.

• Research utility incentives - some offer rebates for electrical upgrades.

• Keep careful documentation of all changes for future reference.

• Monitor contractor work closely for safety and quality control.

• Train maintenance staff on the new systems.

• Dispose of old wiring and equipment properly.

Conclusion

While upgrading electrical systems in industrial facilities represents a major undertaking, the benefits for safety, reliability, efficiency, and compliance make the investment very worthwhile. Careful planning and execution of the upgrade using the methodology and tips provided can help organizations modernize their electrical infrastructure in a streamlined fashion and provide performance gains for years to come through their updated systems.