Industrial electrical revamping and retrofit
We revamp existing industrial electrical systems by upgrading switchgear, substations, feeders, protection and auxiliary systems, integrating new equipment with assets that can remain in service and planning the work around operating requirements.
From initial surveys and engineering through testing and recommissioning.
Revamping existing systems does not always mean replacing everything
An industrial plant can remain in operation for decades, undergoing expansions, process changes, equipment replacements and successive maintenance interventions.
When a component becomes obsolete or part of the distribution system no longer meets plant requirements, complete replacement is not necessarily the only solution.
Revamping may involve complete replacement of a section, retrofit of new equipment into existing structures, or a combination of both approaches.
LAMAEL assesses the actual plant condition, technical constraints and operating requirements to determine which elements can be retained, which must be adapted and which should be replaced.
Obsolescence and recurring failures
Discontinued protection devices and equipment, unavailable spare parts, recurring faults or components whose reliability no longer meets plant requirements.
Higher power demand and new loads
Plant expansions, new machinery and process changes may require new feeders, circuits, switchgear or a revised distribution architecture.
Protection and network configuration
A plant modification may require a new assessment of short-circuit levels, selectivity, back-up protection and protection coordination.
Plant evolution over time
In installations that have operated for many years, the actual configuration often no longer fully matches the available drawings. Site surveys therefore become an integral part of the project.
The starting point is understanding the plant as it actually exists
A revamping project is engineered from what is actually installed in the field, not solely from available documentation.
Preliminary activities include review of client documentation and an on-site survey to verify correspondence, identify critical issues and define the conditions under which the modification can be executed.
Document review
Electrical schematics, layouts, cable lists and equipment documentation are compared with the actual installed configuration.
Site surveys
Equipment, dimensions, connections, routes and available spaces are surveyed to assess the feasibility of proposed solutions.
Reconstruction of existing connections
Where documentation is incomplete, LAMAEL can reconstruct existing schematics and connections, including individual cable identification and tracing where required.
Identification of critical issues
The survey identifies existing conditions that could interfere with the new work so they can be addressed before execution begins.
Scope of an industrial electrical revamping project
The scope is defined according to existing plant condition and the technical objective of the project.
LV/MV switchgear, Power Centers, MCCs and motor panels
LAMAEL works on distribution, command and control switchgear through complete replacement or integration of new equipment into existing enclosures where technically feasible.
Activities may include engineering, enclosure work, busbars, protection and control equipment, auxiliary circuits, wiring, installation and testing.
MV/LV substations, transformers and feeders
Work may involve substation architecture, MV and LV switchgear, distribution feeders, transformer connections and infrastructure required by the new configuration.
LAMAEL also performs transformer maintenance, testing, disconnection, handling, replacement and installation. Supply of the transformer itself is not directly included in this service.
MV and LV feeders are modified or replaced when required by the new configuration, power demand or condition of the existing installation.
Electrical protection
Revamping can include replacement of obsolete protection devices and reassessment of system coordination.
Where required, short-circuit, selectivity and back-up calculations are developed, including trip-curve checks and definition of protection settings.
UPS, rectifiers, batteries and auxiliary systems
The project may include DC systems, UPS, rectifiers, batteries and associated distribution and control switchboards.
For battery systems, LAMAEL also has dedicated equipment for controlled discharge testing and individual cell-voltage monitoring.
Field instrumentation
Experience in E&I maintenance allows the revamping scope to include instrument replacement, signal and control cabling, circuit checks, loop checks, signal simulation, non-fiscal calibration and troubleshooting.
For automation systems, LAMAEL provides installation, wiring and connections to PLC, DCS and supervisory systems according to project scope.
Explore E&I maintenance →Earthing systems
New switchgear, equipment, structures and loads are integrated with the existing earthing system, including required extensions and equipotential bonding, with continuity verification.
Revamping engineering and design
Modifying an existing plant requires simultaneous verification of the new configuration and compatibility with assets that will remain in service.
LAMAEL develops the engineering required to define the project in-house and can also manage the engineering, assembly and installation of electrical switchgear.
Surveys, reconstruction of as-built conditions and definition of modifications are part of industrial electrical engineering.
Electrical sizing and calculations
- Feeder sizing
- Cable current-carrying capacity checks
- Voltage-drop calculations
- Short-circuit current calculations
- Protection coordination checks
- Selectivity and back-up studies
- Cable protection and let-through energy verification
Calculations and checks are also developed using software tools provided by major electrical equipment manufacturers.
Switchgear engineering
Engineering may include single-line and functional diagrams, auxiliary circuits, terminal blocks, cable lists, layouts, bills of materials, interlocking logic and documentation required for assembly and testing.
LAMAEL can also directly manage switchgear assembly and wiring and procure components through its supply network.
LV/MV switchgear engineering and assembly →Integration of new equipment into existing systems
When the switchboard or enclosure can be retained, the mechanical and electrical adaptations required for new components are engineered.
Feasibility is assessed case by case considering available space, existing-system characteristics, required performance, material condition, equipment compatibility and safety requirements.
Revamping on operating plants
In power plants, production facilities and process plants, the challenge is not only deciding what to modify, but how to execute the work without compromising systems that must remain operational.
For this reason, the work sequence is developed together with the technical solution.
Assessment of operating constraints
Critical loads, available redundancies, isolation conditions, shutdown windows and activities that can be performed while the plant remains operational are identified.
Preparation before shutdown
Where possible, new switchgear, feeders, supports, wiring and infrastructure are prepared in advance while the existing plant remains in service.
Definition of migration phases
Loads are grouped and transfer sequences coordinated with operations and maintenance. Depending on plant architecture, isolations, redundancies, temporary connections or temporary power supplies may be used.
Work within available shutdown windows
Activities requiring plant unavailability are concentrated within agreed windows, with advance preparation to reduce shutdown duration.
Testing before transfer
Electrical, circuit and functional checks are completed on the relevant section before energization.
Progressive recommissioning
Start-up follows the defined sequence, checking controls, protection, signals and load behavior before each work phase is closed.
The objective is not to promise zero downtime in every situation, but to engineer the project around operational continuity from the outset and limit outages to those technically necessary.
Working within complex industrial sites
Revamping is frequently carried out in operating plants, where electrical work must also account for safety, access, process and coordination constraints.
Work permits and safe isolation
Activities are organized in accordance with site procedures, isolation conditions and required safe-work methods, including LOTO procedures where applicable.
Work interfaces
Scheduling and work sequences account for simultaneous activities, area accessibility and interfaces with operations, maintenance and other contractors.
Electrical work and hazardous areas
Teams are assigned according to the work and site requirements, including personnel trained for electrical work and, where required, ATEX environments.
Shutdowns and planned activities
When revamping must be integrated into a full or partial shutdown, preparation, materials, prefabrication and preliminary testing are planned so that only activities truly requiring plant unavailability are performed during the shutdown window.
Testing, pre-commissioning and commissioning
Replacement or modification of part of the plant concludes with a verification sequence appropriate to the equipment, voltage level and project scope.
LAMAEL has the expertise and test equipment to directly perform a wide range of testing, acceptance and commissioning activities.
Explore specialist technical services →Switchgear, feeders and circuits
- Continuity
- Insulation
- Phase-sequence verification
- Circuit checks
- Connection and torque checks
- Thermography
- Auxiliary circuit testing
- Local and remote command verification
- Interlock testing
- Signal and indication checks
Protection systems
- Protection-setting verification
- Trip testing
- Primary and secondary injection testing
- Protection relay testing
- Trip-curve verification
- Functional checks of the protection system
Medium voltage and transformers
The test program may include MV cable testing, VLF and tan-delta tests, as well as tests on existing transformers such as insulation, turns ratio and winding resistance.
Auxiliary systems and instrumentation
UPS, rectifiers and batteries are tested according to their characteristics and required duty.
Instrumentation activities can include loop checks, signal simulation, I/O checks, calibration and functional testing through start-up support.
Testing is defined according to the project, client specifications and actual plant conditions.
A modified plant must also be properly documented
On an existing plant, document updating is part of the revamping scope.
The objective is to return not only a modified and tested plant, but also documentation consistent with what was actually built.
- Updated single-line diagrams
- Functional and multi-line diagrams
- Layouts and plans
- Terminal-block drawings
- Cable lists and identification
- Equipment lists
- As-built drawings
- Instrument test reports
- Acceptance-test reports
- Protection-setting data and reports
- Equipment certificates and documentation
- Switchgear technical file
- Operation and maintenance manuals
- Declarations and conformity documentation required for the specific work
Experience on existing electrical systems
From engineering to maintenance of the upgraded plant
Experience in both installation and continuous E&I maintenance allows revamping to be approached with accessibility, maintainability and future operating behavior in mind.
Revamping is therefore not treated as separate engineering, supply and installation stages, but as a modification that must integrate with existing infrastructure and remain manageable throughout its operating life.
Explore E&I maintenanceIndustrial electrical revamping FAQs
When is revamping preferable to complete replacement?
The choice depends on existing conditions and the required modification. A switchboard or part of the infrastructure can be retained when its enclosure, connections and electrical characteristics are compatible with new equipment. In other cases, obsolescence, material condition, higher power demand or architectural changes make complete replacement preferable. The assessment is made after a site survey.
Can revamping be carried out while the plant remains in operation?
In many industrial environments, revamping is specifically engineered around operational continuity. New feeders and equipment can be prepared in advance and loads transferred according to an agreed sequence. Whether the plant can remain in service still depends on its architecture, available redundancies and safety conditions; some phases may require shutdown windows.
Can new equipment be installed in existing switchboards?
Yes, where technically feasible. Before retrofit, the enclosure condition and characteristics, available space, busbars, connections, required performance and compatibility of the new equipment are checked. If adaptation cannot provide a technically suitable solution, replacement of the section or switchboard is evaluated.
What if the electrical drawings no longer match the plant?
This is common in plants modified over many years of operation. LAMAEL compares documentation with field conditions and can reconstruct missing or outdated connections and schematics. In more complex cases, individual cable identification and tracing may be required before the modification is engineered.
What tests are performed before recommissioning?
The program depends on the type of installation. It can include continuity and insulation tests, circuit checks, interlocks and controls, protection testing, primary or secondary injection, MV cable and transformer tests, auxiliary-system checks and instrumentation loop checks. Where required, electrical tests are followed by pre-commissioning, SAT, commissioning and start-up support.
Can revamping cover both MV and LV systems?
Yes. Projects may include MV substations and switchgear, Power Centers and LV distribution, MCC and motor-control panels, transformers, MV/LV feeders, protection systems, auxiliaries and instrumentation. Scope is defined according to the existing configuration and technical objective of the modification.
Do you need to upgrade or renew an existing electrical system?
Share the available documentation, current plant condition and requirement with our technical team.
We can assess the revamping scope, required preliminary checks and execution methods compatible with site operating conditions.
Request a technical discussion