In the Spring of 2011, an IEA customer, and national Data Center, was experiencing reliability problems with its electrical switchgear. Data Center management contacted IEA to discuss possible solutions to the problem. IEA identified three open-transition Automatic Transfer Switches (ATS) as the source of the problem. Due to the design of the open transition ATS equipment, it was possible to disconnect from the utility but never connect to the emergency power source, causing an outage.

IEA recommended that all three ATS units (one 1,600 amp, one 2,500 amp, and one 4,000 amp) be replaced with new closed-transition switches.

Problem: It was believed by Data Center management that it was not possible to remove the three units without having to take an extended facility power outage, which was not acceptable (the facility had been in continuous operation for nearly 20 years and could not be shut down without incurring extraordinary cost and jeopardizing national customer operations)

Challenge: Replace three transfer switches without having an interruption of power to the facility.

Solution: IEA developed a plan utilizing a combination of generator power and custom built temporary switchgear, power could be maintained throughout the three-week, three-phase installation.

IEA detailed equipment specifications, scope of work, and the detailed work instruction required to complete the installation. Each ATS had to be custom-built to fit into the footprint of the old equipment. This involved measuring existing bus structures and then duplicating them to within a fraction of an inch. Standard ATS units were ordered and then modified by the manufacturer to achieve the necessary geometry. In addition, specific controls were required to coordinate operation of the three ATSs with 3 standby diesel generators, including a priority load management system designed to protect critical facility loads. IEA supervised each phase of construction, coordinating with customer management representatives and presenting project results at regular customer meetings.

IEA drafted and supervised the execution of complicated post-installation testing procedures required to verify specialized ATS operational characteristics.

Result: Almost 10 months from concept to completion and the project was completed on time, under-budget, and with zero impact to customer operations. The reliability of the new equipment has been excellent.