Project Overview

Investigated aging electrical service entrance equipment at a process and distribution facility in Hartford, CT, to assess its condition and reliability. The evaluation revealed that the existing switchgear was obsolete, had inoperable breakers, and posed significant risks due to its limited serviceability. The facility relied on two double-ended switchboards fed from redundant utility services and transformers, with portable generator connections. Given space constraints and the need to minimize downtime, the solution was a rooftop e-house with integrated switchgear, allowing for installation and commissioning before power cutover.

Role & Responsibilities

🔹 Electrical System Evaluation – Assessed existing service entrance equipment and determined its limitations due to age, failure risks, and obsolescence.
🔹 Redundant Power & Cutover Strategy – Designed and implemented a phased installation approach to transition power with minimal service disruption. New overhead feeders replaced existing underslab runs before de-energization.
🔹 Power System Studies – Conducted arc flash studies, power system analysis, and breaker setting adjustments for selective coordination.
🔹 Rooftop E-House Integration – Coordinated with the e-house manufacturer and structural engineers to modify the building structure and support rooftop switchgear installation.
🔹 Field Documentation & Site Coordination – Performed multiple site visits to document feeder paths, breaker conditions, and cable routing, ensuring an accurate and executable construction plan.

Key Challenges & Solutions

🔹 Minimizing Downtime While Replacing Critical Electrical Infrastructure – The facility required continuous operations, making prolonged shutdowns unacceptable.
✔ Solution: Designed a rooftop e-house approach, allowing the new switchgear to be installed, wired, and tested before phased cutover, ensuring uninterrupted operations.

🔹 Tightly Packed Plant Space for Existing Equipment – The electrical room was congested with mechanical and process equipment, limiting options for in-place upgrades.
✔ Solution: Relocated the switchgear to a rooftop e-house, freeing up valuable plant space and simplifying future maintenance access.

🔹 Detailed Field Investigations to Avoid Costly Surprises – The complexity of the existing infrastructure required thorough planning to prevent unforeseen construction delays.
✔ Solution: Conducted meticulous documentation of existing conditions, including feeder routing and breaker configurations, to provide a clear and executable construction strategy.

Outcome & Impact

✅ Eliminated downtime risks – The e-house installation enabled seamless cutover, maintaining operational continuity.
✅ Increased system reliability – Upgraded switchgear improved maintainability, selective coordination, and future serviceability.
✅ Strategic cost control – Careful planning and phased execution kept project costs in check while achieving a modernized and code-compliant electrical system.

Let’s Talk About Your Project

Need an experienced engineering partner to assess aging electrical infrastructure and minimize downtime risks? Let’s connect to discuss how NLS can support your next upgrade.

Process & Distribution Facility Electrical Upgrade

(Hartford, CT)