The Challenge
A 500-bed regional medical center faced critical challenges with their aging electrical distribution system. The facility's power infrastructure, installed in the 1980s, was struggling to meet modern healthcare demands. Arc flash incident energy levels exceeded 40 cal/cm² at several locations, requiring bulky PPE that hindered maintenance work. The system lacked proper coordination, increasing the risk of cascading outages. Additionally, the facility needed to add capacity for a new surgical wing without disrupting critical patient care operations.
Our Solution
We developed a comprehensive solution addressing both immediate safety concerns and long-term reliability needs. Our approach prioritized patient safety by maintaining continuous power throughout the upgrade process while systematically reducing arc flash hazards and improving system performance.
Key Components
Implementation Phases
Phase 1: Assessment and Planning (Months 1-3)
Comprehensive evaluation of existing conditions and development of detailed upgrade plan.
- •Complete electrical system documentation and single-line diagrams
- •Arc flash hazard analysis identifying high-risk locations
- •Short circuit and coordination studies
- •Equipment condition assessment reports
- •Phased implementation plan minimizing operational disruption
- •Cost estimates and project schedule
- •Risk mitigation strategies for construction
Phase 2: Critical Safety Improvements (Months 4-8)
Implementation of measures to immediately reduce arc flash hazards.
- •Installation of maintenance mode switches on main breakers
- •Zone-selective interlocking implementation
- •Updated protective relay settings for improved coordination
- •Arc flash warning labels on all electrical equipment
- •Interim safe work procedures
- •Staff training on arc flash hazards and PPE requirements
Phase 3: Equipment Upgrades (Months 9-15)
Systematic replacement of obsolete equipment with modern arc-resistant designs.
- •Replacement of main distribution switchgear with arc-resistant equipment
- •Upgrade of emergency distribution panels
- •Installation of new motor control centers
- •Expansion of emergency power system
- •Integration with existing building automation
- •Temporary power systems during equipment transitions
Phase 4: Testing and Commissioning (Months 16-18)
Comprehensive verification of system performance and staff training.
- •Acceptance testing per NETA standards
- •Updated arc flash study reflecting final configuration
- •Protective relay coordination verification
- •Emergency power system load testing
- •Transfer switch operation verification
- •Final equipment labeling and documentation
- •Operations and maintenance staff training
- •As-built drawings and O&M manuals
Results & Impact
Incident energy reduced from 40+ cal/cm² to less than 8 cal/cm² at all locations, significantly improving worker safety and reducing PPE requirements.
Achieved five-nines reliability for critical care areas through improved coordination and modern protective equipment.
Successfully added 3 MW of additional capacity to support new surgical wing and future growth.
No unplanned power interruptions to patient care areas during entire 18-month project.
Client Testimonial
"ClarkTE's expertise and meticulous planning ensured we could upgrade our critical power systems without ever compromising patient care. The arc flash mitigation has made our facility much safer for maintenance staff, and the new equipment will serve us reliably for decades."
Technical Details
Equipment Installed
- ▸2500A main switchgear with arc-resistant construction
- ▸(6) 1200A distribution panels with electronic trip breakers
- ▸(12) Motor control centers with maintenance mode switches
- ▸2 MW diesel generator with paralleling switchgear
- ▸Zone-selective interlocking system
- ▸Arc flash detection and rapid tripping system
Protection Improvements
- ▸Reduced maximum incident energy from 42 to 7.8 cal/cm²
- ▸Improved coordination selectivity from 67% to 98%
- ▸Implemented three-level selective coordination
- ▸Added ground fault protection on all feeders
- ▸Integrated fire alarm system with emergency power
Standards and Codes
- ▸NFPA 70 (National Electrical Code)
- ▸NFPA 70E (Electrical Safety)
- ▸NFPA 99 (Healthcare Facilities)
- ▸NFPA 110 (Emergency Power Systems)
- ▸IEEE 1584 (Arc Flash Calculations)
- ▸NETA ATS (Acceptance Testing)
Lessons Learned
- Early engagement with clinical staff was critical for scheduling work around patient care activities
- Temporary power systems provided essential flexibility during equipment transitions
- Phased labeling updates prevented confusion during multi-phase implementation
- Mock installations in a test area helped identify and resolve issues before field work
- Weekly coordination meetings with all trades prevented conflicts and delays
- Maintaining detailed transition procedures minimized risk during energization events
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