Quad Plus recommended a paid equipment survey, analysis, and arc flash study to determine the condition of the equipment and its viability. The review would also look for opportunities to make changes to improve efficiency, reliability, and safety. The customer agreed to the survey and was pleased with the Quad Plus proposal as it specifically addressed the needs of the facility rather than applying the more costly one-size-fits-all approach taken by the other vendors.
Quad Plus worked closely with the customer to create a plan that would minimize out-of-service time. All systems identified for replacement were chosen based on future updates across the facility to allow consistency from line to line. For example, all SCRs are the same size, but used in multiples for more capacity when it becomes necessary. MCC replacements were chosen for higher NEMA ratings due to their location in the manufacturing area, and cabinets mounted on the manufacturing floor were sealed and fitted with internal forced-air cooling using air/water heat exchangers that are serviced by available water sources within the plant.
New parts, cabinets, and cable runs were prepared in advance and staged in parallel with existing systems to expedite replacement once systems were shut down. At shutdown, outmoded and end-of-life components were removed and cabinets cleaned for reuse wherever possible. Prefabricated systems were installed in existing cabinets, and doors replaced to support the new equipment. In other areas, new cabinets were installed and LV breakers added to equipment feeds to reduce the potential incident energy exposure of 163 Cal/cm2 to an acceptable level of 5 Cal/cm2 under fault conditions. The existing MV breaker was also configured with a pendant system that allows for remote closure from a safe distance with minimal PPE.