Replacing outdated medium voltage systems to ensure safe, continuous production
A Belgium customer in the petrochemical sector contacted us with the request to replace a severely outdated medium voltage installation. The risk of failures and unplanned downtime was increasing daily, and their requirement was clear: renew the switchgear with minimal disruption to operations, ensured by clear communication between all stakeholders.
Our solution focused on delivering a safe and reliable system through engineering excellence and close coordination with the client and contractors.
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Full inventory of existing installation and cable routing
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Load flow and short-circuit studies
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Specification and vendor selection in alignment with petrochemical safety and quality standards
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Detailed electrical design in collaboration with the client and supplier
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Electrical construction drawings, material and cable lists, and work instructions with photos
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SCADA integration for real-time monitoring and remote control
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Phased execution plan with temporary bypasses to maintain production
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Extensive FAT (Factory Acceptance Test) and SAT (Site Acceptance Test)
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Construction supervision and deviation management
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On-schedule, surprise-free delivery of the new MV system
The challenge
Ensuring reliability and safety in a live oil refinery environment
The outdated medium voltage switchgear posed growing risks to safety and uptime. The challenge was to modernize the system without halting production, while maintaining compliance with the strict technical, safety, and quality standards of the petrochemical industry.
Our approach
From obsolete infrastructure to operational excellence
We began with a comprehensive technical survey, including an inventory of the existing installation, cable routes, and electrical studies to support the new design. Together with the customer, we selected a vendor that met all technical, safety, and quality benchmarks.
To prepare the project for execution, Contec:
- Delivered clear and actionable documentation for the E&I contractor, including drawings, material lists, and photos
- Developed a phased implementation plan with bypasses to ensure uninterrupted production
- Integrated the new installation into the SCADA environment
- Conducted FAT and SAT to verify safety, reliability, and functionality
- Provided hands-on construction supervision, identifying and resolving on-site deviations in real time
Thanks to close follow-up and coordination, the new medium voltage installation was delivered on schedule and without surprises.
With this successful revamp, Contec proves its value as a partner for complex energy infrastructure projects. Our technical expertise and rigorous execution ensured the customer now benefits from a safe, reliable, and future-ready MV installation, guaranteeing production continuity well into the future.
