Electrical Project

Case Study: Electrical Repair and System Upgrade for Greenfield Manufacturing Plant

Client: Greenfield Manufacturing Plant
Location: Mississauga, ON
Project Type: Electrical System Repair and Upgrade
Completion Date: August 2023

Overview

Greenfield Manufacturing Plant, a large industrial facility, experienced repeated electrical system failures that caused operational downtime and posed safety risks. The client needed a reliable solution to address outdated wiring, overloaded circuits, and inconsistent power distribution across the facility. Midwest Services Canada was hired to assess the electrical system, repair the immediate issues, and upgrade the system to meet modern safety and efficiency standards.

Challenges

• Aging Infrastructure: The plant’s electrical wiring and panel boards were outdated, causing frequent circuit trips and power disruptions, especially during peak operational hours.
• Safety Hazards: There were multiple instances of overheating circuits, which posed a fire hazard and needed to be addressed urgently.
• Minimizing Downtime: The repair and upgrade had to be completed with minimal disruption to plant operations, as every hour of downtime resulted in significant losses.

Solutions

Midwest Services Canada provided a thorough and efficient electrical repair and upgrade, ensuring safety, compliance, and minimal operational disruption:

1. Comprehensive System Inspection: Our team conducted a detailed inspection of the plant’s electrical system to identify the causes of the power failures. We found that outdated wiring, overloaded circuits, and inefficient power distribution were the primary issues.
2. Emergency Electrical Repairs: To immediately reduce the safety risks, we replaced the overheating circuits and repaired faulty wiring, restoring safe and stable power to critical areas of the plant.
3. Electrical Panel Upgrades: We upgraded the main electrical panel and subpanels, improving the plant’s ability to handle the power load from modern machinery and equipment. This also reduced the frequency of circuit trips and allowed for future expansion.
4. Rewiring and Circuit Redistribution: We replaced old wiring throughout the facility, installing new copper wiring that met modern safety standards. Additionally, we redistributed power across multiple circuits to balance the load more effectively, preventing future overloading.
5. Energy Efficiency Solutions: As part of the upgrade, we installed energy-efficient lighting and motion sensors to reduce power consumption in non-critical areas of the plant. This helped the facility lower its overall energy costs while improving operational efficiency.
6. Work Phasing: The repair and upgrade work were conducted in phases, targeting specific sections of the plant during scheduled maintenance hours. This minimized disruption and allowed most plant operations to continue as usual.

Results

• Improved Safety and Reliability: The electrical repairs eliminated the risk of overheating circuits and fire hazards, and the system’s reliability improved significantly, with no power disruptions since the upgrade.
• Increased Efficiency: The plant’s upgraded electrical system handled the increased power demand more efficiently, reducing downtime by 95% and allowing the plant to run at full capacity during peak hours.
• Energy Cost Savings: The installation of energy-efficient lighting and better power distribution resulted in a 15% reduction in the plant’s monthly energy costs.
• Seamless Operations: By phasing the repair and upgrade work, Midwest Services Canada minimized downtime, ensuring that the plant could continue operating during the project.

Client Testimonial

“Midwest Services Canada went above and beyond to repair and upgrade our electrical system. Their team worked around our schedule to keep downtime to a minimum, and the improvements they made have increased our efficiency and safety. We no longer have to worry about power outages, and our energy costs have gone down. We highly recommend their services.”
— Michael T., Operations Manager at Greenfield Manufacturing Plant

Key Takeaways

• Safety First: Midwest Services Canada’s prompt response and thorough electrical repairs eliminated safety risks and prevented potential fire hazards.
• Efficiency Gains: The upgraded electrical system significantly improved power distribution, reducing downtime and energy costs.
• Client-Focused Approach: By carefully scheduling the work in phases, Midwest Services Canada minimized operational disruption, allowing the plant to maintain production throughout the project.