Getting electrical wiring and installations right is absolutely critical in industrial environments. Safety considerations are crucial, but so are questions of efficiency and the avoidance of costly downtime. There are also regulations and legal obligations that must be adhered to.

In this guide, we’ll be looking at some of the most important elements of the design, installation and maintenance of heavy-duty electrical systems for industrial settings, including key regulations and standards, practical issues, and what to look for when choosing a contractor.

 

What Counts as Industrial Wiring & Installations?

While they share many common components and safety requirements, there are some key differences between industrial wiring and installations and electrical systems for use in commercial and domestic settings.

The main difference comes down to a matter of scale and purpose. Commercial and domestic electrical systems tend to have light to moderate load and capacity requirements and are generally designed with the needs of the premises in mind. This means ensuring lighting, HVAC, IT systems and security requirements are all catered for.

Industrial wiring and installations need to cover these areas too, but also complex wiring and cabling systems for heavy duty machinery, equipment and infrastructure used in settings such as factories, manufacturing plants, refineries and warehouses.

This may involve higher voltages, complex distribution boards and additional elements such as industrial backup power systems for ensuring continuous operation during potential outages. Specialists like D.R Electrical can offer industrial electrical installation in the UK, as well as ongoing maintenance and industrial energy management.

Industrial Wiring and Installations

Key UK Standards & Regulations

It is crucial to comply with all relevant UK standards and regulations – not just for obvious safety considerations but also to meet legal obligations and for insurance purposes.

Industrial wiring standards in the UK are set out in BS 7671: Wiring Regulations (18th Edition).

This is the national standard for electrical installations in the UK, commonly known as ‘wiring regs’ and includes industrial wiring and installations.

Other standards that may apply in certain situations include BS 5839 for fire alarm systems, BS 62305 for lightning protection and the Health & Safety at Work Act.

Any contractor used for industrial wiring must work to these standards.

 

Major Components of an Industrial Installation

All industrial installation projects will have their own specific requirements and challenges but could include the following major components:

  • Distribution boards and switchgear: To take the incoming power feed and safely and effectively divide it into multiple circuits within the facility.
  • Power cabling: The cabling and wires that distribute power. Can include different types of fixed, flexible and armoured cable for different areas and purposes.
  • Control wiring: Provides communication and control within an electrical system via programmable logic controllers (PLCs), motor control centres (MCCs), sensor wiring and other elements.
  • Lighting and emergency lighting: Robust lighting systems for factories, warehouses and other industrial settings.
  • Earthing and bonding: Mandatory for safety of large equipment, providing a safe path for fault currents.
  • Isolation and lock-off systems: Vital for maintenance and safety as they prevent accidental startup of machinery during maintenance or repair.
  • Testing and commissioning: Can include insulation resistance tests, loop impedance and other tests to check systems and components perform to the design intent and specification.

 

Installation Project Workflow

A major industrial wiring and installation project will usually follow a workflow including the following stages:

  • Design and planning: After discussing and identifying customer needs, a thorough plan needs to be made for the entire project. This may include a site survey, load calculation, cable run planning, lighting layout and the creation of detailed blueprints outlining wiring routes, equipment placement, power distribution and grounding systems.
  • Procurement and materials: All materials that are needed to carry out the project should be sourced and procured. High-quality materials should be used with relevant compliance marks or symbols where appropriate.
  • Installation phase: This is the on-site physical execution or ‘hands-on’ part of the project. Depending on the nature and scale of the project, it may comprise many different elements, including cable laying, board assembly, equipment connection and more.
  • Testing and commissioning: Once installed, every part of the system will be thoroughly tested to ensure it works as it should. This may involve processes such as verifying protective devices, fault-current calculations and functional testing. This may be followed by a troubleshooting phase if any issues are identified.
  • Handover documentation: When the client has reviewed and accepted the installation, they will be given relevant materials, including certificates, test logs, as-built drawings, and operation and maintenance (O&M) manuals. In some cases, additional training may also be provided to client personnel on the operation and maintenance of the new systems.

 

Maintenance & Upgrades Programme

Even a properly installed industrial electrical system will require ongoing maintenance to keep it working as it should. This could include scheduled inspections, regular cleaning routines, and preventative maintenance activities. Pro-active maintenance and servicing is always better than reactive maintenance as it can head off problems before they occur, avoid downtime and be more cost-effective in the long run.

In some cases, elements of the system may need to be upgraded as parts become obsolete or less efficient than modern alternatives. Standards may also be updated to reflect safety and energy efficiency concerns.

 

Choosing an Industrial Electrical Contractor

The first thing you should look for in an industrial electrical contractor is proper accreditation. D.R. Electrical, for example, are NICEIC-approved, MCS-certified and a Paxton Gold Partner.

You should also look for experience and a proven ability to work with large and complex projects. A culture of safety-first, with the proper certification, can help provide peace of mind that the job will be done right. You should also look for a contractor that offers clear communication, documentation and after-care service.

 

The Benefits of Doing It Right

Industrial electrical installations are major projects, and it’s important to get them right from the start. The proper planning, design and installation can lead to improved uptime, efficiency and productivity. It will also increase safety and ensure compliance, with less risk of costly downtime, electrical failures or fire.

It can also provide better energy efficiency and lower running costs, and a forward-looking wiring system can be easier to expand as your operation grows.

Get in touch with D.R. Electrical for a free consultation on your industrial wiring or installation upgrade.