IPB Switch Failure & Refurbishment Project Success: Turning the ‘Can’t be done’ into DONE in just 20 Days

Refurbishment Case Study

Hearing ‘that can’t be done’ isn’t a phrase that EBI shies away from. In fact, EBI leads the industry with the highest level of experience, quality, and knowledge when it comes to successfully completing complex bus duct projects. When other electrical contractors say, ‘it can’t be done,’ EBI rolls up their sleeves and puts their 44 years of bus duct experience to work.

During the recent holiday season, EBI’s emergency response team received a call from a Pennsylvania generating station who experienced a post-holiday nightmare after the plant encountered an isolated phase bus (IPB) switch failure. After facilitating a planning call to assess the situation in detail, EBI mobilized a crew and arrived onsite to perform a thorough walk-down assessment and repair recommendation analysis.

After initial review, the project’s complexity was compounded by several key factors: 1) The damaged switch was obsolete, eliminating the possibility of a simple fix; 2) Partial drawings for the IPB and switch did not call out specific material types nor tolerances for any of the parts; 3) Exact insulator replacements for the obsolete switch were not available. Despite the challenges, EBI’s crew kicked into high gear. By the next day, the damaged switch had been dismantled and shipped to EBI’s facility where the comprehensive assessment, reverse engineering process, and refurbishment began.

EBI utilized their extensive in-house technical knowledge and expertise of bus duct components of all OEM’s, both current and obsolete, to completely re-construct the replacement switch enclosure, insulators, and associated parts. Unlike other electrical contractors, EBI’s best-in-class, in-house stock supply of all required materials, including: aluminum, standoff/support insulators, along with copper for switch bars and contact surfaces, allowed for the expedited turnaround that was essential to the project’s success. Upon refurbishment completion, the switch was re-packaged and shipped back to the plant where EBI performed the re-installation.

Due to the emergent nature and limited information available, other electrical contractors and OEM’s were not capable of taking on the project and guaranteeing results. EBI took on the challenge when no one else would touch it and successfully completed the scope within 20 business days of when the initial emergency call came in. The exemplary turn-around time EBI was able to provide allowed the plant to return back online in a fraction of the lead time compared to ordering new OEM replacements.

If your plant experiences a forced outage due to a transformer, isophase, non-seg or cable bus failure, call EBI first. Our 24/7 toll-free number at 1-877-297-0616. For more information on how EBI can put their 44 years of bus duct expertise to work for you, contact us today at [email protected].