A large Victorian manufacturing facility required a major electrical infrastructure upgrade to replace ageing distribution equipment and improve the safety, reliability and maintainability of its site electrical system.
The project involved replacement of existing distribution equipment, installation of a new main switchboard arrangement, coordination of supply isolation and reconnection requirements, and practical site works completed within a limited shutdown window.
The site needed the switchboard changeover completed during a scheduled shutdown period so production could return without unnecessary delays. Careful planning, clear sequencing and practical site execution were critical to the success of the works.
Project snapshot
- Industrial manufacturing facility in Victoria
- Switchboard upgrade completed during a planned shutdown period
- Replacement of two 400 A distribution boards
- Installation of a new 1200 A / 800 A main switchboard
- Removal of outdated HRC fuse arrangements and redundant wiring
- Coordination with electricity retailer and supply isolation requirements
- ESV approval and supply authority requirements considered as part of the project
- Four-person installation team across the shutdown period
- Changeover completed over approximately two weeks
The challenge
The existing electrical distribution arrangement included older equipment and HRC fuse infrastructure that no longer suited the facility’s operational, maintenance and compliance expectations.
The key challenge was not simply installing new switchboard equipment. The works needed to be planned so the site could be isolated, existing equipment removed, new switchboards installed, cabling and terminations completed, and the system prepared for recommissioning within the available shutdown window.
For an operating industrial site, this type of work requires careful planning around access, isolation, safety, plant availability, shutdown timing, switchboard delivery, supply authority requirements and return-to-operation expectations.
The approach
The changeover was planned around the facility’s scheduled shutdown period to reduce the impact on production. Before the shutdown, the works required confirmation of the existing installation, review of the proposed switchboard arrangement, coordination with the switchboard manufacturer, and preparation for the isolation and changeover sequence.
During the shutdown period, the works involved de-energising affected equipment, coordinating incoming supply isolation, removing redundant fuse and wiring arrangements, installing the new main switchboard and distribution boards, completing terminations, and supporting testing and commissioning activities.
The delivery approach focused on practical execution: clear sequencing, site coordination, safe isolation, efficient installation and a clean handover back to the customer’s operations team.
Key works involved
- Site review and switchboard changeover planning
- Shutdown coordination and staging of electrical works
- Isolation and de-energisation of affected distribution equipment
- Coordination of incoming mains isolation with the power supplier
- Removal of redundant HRC fuses and existing wiring arrangements
- Installation of replacement distribution boards
- Installation of new main switchboard infrastructure
- Cable disconnection, reconnection and termination works
- Testing, commissioning support and defect checks
- Handover support to assist the site’s return to operation
The outcome
The completed upgrade provided the site with a more modern electrical distribution arrangement, improved maintainability and a cleaner platform for future site electrical works.
By completing the changeover during a planned shutdown, the site avoided a more disruptive outage and was able to transition from ageing distribution equipment to upgraded switchboard infrastructure in a controlled manner.
The project highlights the importance of preparation, authority coordination, shutdown planning and practical site execution when completing critical electrical infrastructure works in a live industrial environment.
Industrial electrical works demonstrated
This type of project is directly aligned with the industrial electrical work Mobile Automation supports, particularly for customers that need switchboard works completed safely, practically and around production constraints.
- Industrial switchboard upgrades
- Main switchboard and distribution board changeovers
- Shutdown electrical works
- Site isolation and reconnection coordination
- Industrial electrical project works
- Electrical infrastructure upgrades
- Defect reduction and maintainability improvements
- Testing, commissioning and handover support
Why shutdown planning matters
Switchboard upgrades can place significant pressure on production sites because the work often affects critical electrical infrastructure. Poor planning can lead to extended outages, production delays, unclear responsibilities, missing materials or incomplete handover.
A well-planned changeover considers the full sequence of work before the shutdown begins, including switchboard supply, access, lifting or positioning requirements, cable routes, isolation points, permits, authority requirements, labour coverage, testing requirements and restart support.
For industrial customers, this type of planning can be the difference between a controlled shutdown and a costly production delay.