Updating Obsolete Wiring in Industrial Facilities

Industrial facilities often rely on electrical wiring and systems that were installed decades ago. Over time, this obsolete wiring can become unsafe and insufficient for modern needs. Upgrading and updating industrial wiring is crucial for operational safety, efficiency, and supporting new technology.

Assessing the Current Industrial Electrical System

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

• Surveying wiring diagrams, electrical plans, and infrastructure records to understand installed systems and history.

• Inspecting wiring, conduits, breaker panels, transformers, and other components for damage, corrosion, insulation breakdown, or code violations.

• Load testing circuits to ensure they can handle modern power requirements for lighting, equipment, computers, etc.

• Evaluating grounding, surge protection, and fire safety systems.

• Checking for modifications, additions, or removals that may have compromised the original system design.

Proper assessment highlights deficiencies, risks, and areas needing upgrade. It also gives a baseline to calculate upgrade costs and plan the project.

Key Reasons to Upgrade Industrial Electrical Systems

Upgrading industrial electrical systems provides:

• Increased safety: Eliminating obsolete or damaged wiring and components reduces fire and electrocution risks. Modern systems have better circuit protection and safety systems.

• Improved reliability: New wiring, breakers, connectors, and other components greatly reduce downtime from electrical faults or failures.

• Higher efficiency: Upgraded wiring, lighting, and components cut energy consumption. This saves on utility costs.

• Added capacity: New systems support larger equipment loads and increased computing needs. This facilitates expansions.

• Regulatory compliance: Modern wiring and components meet current electrical codes and standards. This is critical for obtaining insurance and passing inspections.

• Better analytics: Smart systems provide data to optimize electrical usage, maintenance, and inventory.

Planning the Electrical Upgrade Project

Careful planning ensures a smooth wiring upgrade project. Key steps include:

• Schedule during lower occupancy or production periods to minimize downtime.

• Procure necessary wiring, conduits, panels, breakers, disconnects, and other materials well in advance.

• File permits and arrange inspections by the local building department.

• Hire qualified electrical contractors experienced with industrial systems.

• Design new wiring layouts, capacities, and components to support current and future electrical loads.

• Plan temporary power arrangements to keep critical operations running during the upgrade.

• Establish safety protocols, like lockout/tagout procedures, to protect workers.

• Manage costs through careful budgeting, getting quotes, and applying for rebates on energy-efficient upgrades.

Thorough planning is essential for minimizing facility downtime and electrical hazards during system upgrades.

Implementing the Wiring Upgrade Project

The upgrade project involves:

• Disconnecting and safely removing old wiring, conduit, breaker panels, and obsolete components.

• Installing new conduit, wiring, transformers, panels, disconnects, and other equipment.

• Terminating wires properly at panels and devices, ensuring a secure, failure-resistant connection.

• Connecting new systems to existing circuits where applicable.

• Testing all new wiring under load to verify it meets design specs and electrical code.

• Retrofitting lighting, equipment, and other electrical usages to integrate with the new system.

• Labeling all wiring and components clearly for safety and maintenance.

• Documenting the new electrical system thoroughly in diagrams and manuals.

The contractor should provide close project oversight and quality control throughout the implementation process. All work must be inspected.

Benefits of a Modern Industrial Electrical System

Upgrading obsolete wiring yields substantial benefits:

• Enhanced safety: Reduces workplace injuries or fatalities due to electrical fire or shock.

• Greater reliability: Minimizes costly downtime from electrical failures.

• Improved efficiency: Cuts utility costs by 10% or more.

• Added capacity: Supports expanding production and computing needs.

• Regulatory compliance: Meets insurance and legal requirements for safety and codes.

• Increased property value: Electrical upgrades make industrial properties more valuable.

• Tax incentives: Electrical upgrades may qualify for energy efficiency tax credits or property tax rebates.

• Better analytics: Provides data to optimize and monitor electrical usage.

Modernizing antiquated industrial wiring requires a strategic approach but yields major rewards. A coordinated assessment, planning, and implementation process allows aging electrical systems to be upgraded efficiently and economically.