Southeast Arial View of Plant

Southeast Entrance to Plant

Southeast Corner of Plant Hiding the Offending Switchgear

High Voltage Switchyard

What is it Hiding?

12,600V Isolators

WHOA! This is Actually LIVE?

Well, the inside of the plant is certainly in ship-shape condition.

Where's the back covers? You mean this is actually operated in this condition?

This looks like typical switchgear for an older plant.

This has to be changed out in a 2 day plant outage?

Transformer to be moved and office space to be used for switchgear

Extend this to where?

Client: Packaging Corporation of America, Pittsburgh, Pennsylvania Plant

Project: Upgrade existing electrical service and develop new Utility Switchyard and grounding for their 214,000 sqft production plant.

Project Scope as originally presented to Industrial Engineering.

Project would be accomplished in 2 phases. First phase was to upgrade the Utility Service and install a new 2500A main switch and distribution in a portion of the plant adjacent to the existing switchgear. This would require the use of an existing office for the electrical gear. Budget $400,000. Second phase would be to transfer all of the loads over from the old switchgear to the new switchgear. This would require splicing and extending or replacing existing feed. Budget $300,000. This would allow the project to be completed with only 1 two day outage of the plant. Partial outages would be taken to extend conduits and conductors.

After studying the project and developing preliminary construction plans, IEI proposed to put the new switchgear in the same footprint as the old gear, do it in a 2 day plant outage and do it for under the phase 1 budget.

After developing the plans in 3D modeling and confering with the client and an Electrical Contractor, the following construction drawings and scheduling were developed.

The drawings were developed in full 3D to removed the unknowns from the contractor's bid and timetable. The following schedule was developed as a recommendation to the contractor.

PRIOR TO OUTAGE:

Task 1: perform all outside work. This would include preping the area for the new HV Sectionalizing Switch and utility transformer. Arrange with utility to prepare and install a new service to the facility, including installation and connection of the sectionalizing switch, transformer and primary conductors back to where they would tie into the utility company's loop feed.

Task 2: install a new 2500A, custom designed main switch section of gear adjacent to the existing distribution switchgear, install all underground conduits and conductors and have them terminated in the transformer.

Task 3: Contractor to prepare all new distribution panels to be ready to slide into position. Switchgear cabinets to be custom built to have 3" house cleaning frame, bottom bussing, removable top rear cross bracing and extended upper cabinets to match existing plate height. New switchgear top to be notched, on site, to fit around existing conduits.

DURING OUTAGE

Task 1: Utility Company to disconnect existing HV switchyard and connect to new service.

Task 2: Contractor to test new main switch to verify its functionality and then turn off main switch.

Task 3: Contractor to sever all connections at the existing breakers and remove existing main switch, 480V and 208V switchgear sections complete. Plate, where conduits tie into existing switchgear, to be cut & left in place to keep conduits stable and lay on top of new switchgear.

Task 4: Conductors from all existing conduits to be hanging directly down towards floor.

Task 5: Contractor to slide new switchgear in place directly under existing conduits with conductors dropped into position with minimal disruption and bending of conductors (they are old and prone to cracking).

Task 6: Contractor to terminate existing 480V conductors to new breakers. No conductors should require splicing or replacement.

Task 7: Contractor to position existing 480V:208V Step down transformer and connect to new switchgear. Install rear covers on all 480V switchgear.

Task 8: Contractor to position new 208V switchgear back-to-back with new 480V switchgear and directly under the 208V conduits. Terminate all 208V conductors. Extend existing 208V conduits and conductors from far end of switchgear to new 208V switchgear.

Task 9: Energize.

POST OUTAGE:

Task 1: Contractor to remove old switchyard, install new triad ground and connect to facility ground. Restore area asphalt, etc.

 

3D layout of new electrical service