Design and Manufacture 

• Engineered and built new MSSBs in MECS workshop to compress lead times 

• Pre-mapped cables, lugs, terminations, and labels to streamline changeover 

• Factory fit-out and verification prior to delivery 

Installation and Sequencing 

• Weekend outage window with staged isolations to protect critical services 

• Like-for-like board footprints and gland plates to speed swap-out 

• Parallel teams working workshop and site to keep the program tight 

Controls Integration 

• Tied new boards into existing control systems and field devices 

• Re-established control loops in coordination with the client’s maintenance team 

• Updated drawings, schedules, and labelling for clarity 

Testing and Commissioning 

• Insulation and continuity testing on feeders and control wiring 

• Point-to-point verification and I O checks for all control loops 

• Functional tests under live conditions with client sign-off 

• Handover pack including as-builts, test sheets, and compliance labels 

Challenges and Solutions 

• Tight timeframe: pre-fabrication, detailed mark-ups, and shift work across the weekend 

• Live environment: sequenced changeovers to maintain supply to critical loads 

• Water damage context: controlled work zones and daily housekeeping to keep the plant safe and clear 

Outcome 

• New MSSBs installed, integrated, and commissioned within the 202 hour weekend window 

• Operations maintained without downtime or disruption 

• Clean, clearly labelled boards that simplify future maintenance and fault finding 

Client Response 

Positive feedback on planning, coordination, and the zero downtime delivery. The client’s maintenance team highlighted the smooth changeovers, clear communications, and the quality of the finished boards.