DB Replacement and Rewire 

The existing board had reached end of life, so it was replaced with a new DB suited to the site’s current needs and future reliability. The team removed redundant equipment, re-terminated circuits, and rewired as required to bring the installation up to current electrical standards. 

Live Site Staging and Continuity 

To avoid downtime, the upgrade was staged and sequenced around the station’s operating needs. Loads were managed carefully so critical services stayed online, including fuel pumps, lighting, and tills. The crew coordinated each cutover to reduce risk and maintain continuous operation. 

Labelling, Testing, and Handover 

All cabling and circuits were clearly labelled, dressed neatly, and organised for safe access and easier future maintenance. Testing and verification were completed as part of commissioning to confirm correct operation before final handover. 

Project Challenges and Solutions 

Zero Downtime Requirement 

A busy service station is not the place for trial-and-error. The upgrade required detailed planning and tight on-site coordination to complete the changeover without interrupting trade. 

Working In a Live Retail Environment 

With staff and customers moving through the site, the team maintained a controlled work area and coordinated tasks carefully to complete the upgrade safely while the station remained open. 

Client Response 

The client was pleased the service station could keep trading throughout the upgrade, with pumps, lighting, and tills staying online the whole time. They also called out the clean finish and clear labelling in the new DB, which makes the setup safer and much easier to maintain going forward.