Challenge

A large chemical client initiated an onsite program to replace several 480V motor control centers (MCCs) due to equipment obsolescence and unsafe existing conditions. Valdes Architecture & Engineering (Valdes) was engaged to execute front-end engineering (FEL) efforts to support upgrades to electrical rooms with new MCC lineups, improved motor controls, segregated power for non-motor feeds, and enhanced environmental control infrastructure to support long-term equipment reliability. Mechanical and structural leads were engaged from the outset to evaluate room modifications, HVAC requirements, utility routing impacts, and fire protection compliance to ensure a fully coordinated facilities upgrade.

Solution

Valdes delivered a full electrical, mechanical, and structural FEL design package. A load identification analysis confirmed proper equipment sizing, while new cable systems were engineered to accommodate relocated substations. Existing MCCs were itemized against their respective loads to support new feeder routing and integration of power factor correction equipment. Distribution was reconfigured across fifteen MCCs to balance load between substations and increase operational efficiency.

To support equipment longevity and compliance, mechanical engineering scope included walkdowns of the new MCC room, HVAC load calculations, and development of conditioning and ventilation requirements. The team reviewed existing utility and process piping to determine reroute needs for new MCC and PDP equipment, coordinated with vendors to secure budgetary pricing, and generated datasheets and preliminary equipment specifications. Mechanical staff prepared detailed HVAC layouts, equipment schedules, general notes, and performed a full NFPA and FM Global code review to determine fire protection requirements. A preliminary fire protection plan was developed, accompanied by modification sketches for documentation. Concurrently, structural engineering defined wall, door, and support steel modifications for proper room separation and supported integration of new HVAC equipment through foundation and framing assessments.

Impact

The FEL effort positioned the client to execute a multi-year replacement strategy with minimal operational disruption. Valdes identified electrical distribution improvements, including harmonic filtering for VFD-converted motors, and collaborated closely with construction teams to phase cutovers within tight outage windows. Mechanical and structural integration ensured that future MCC rooms will support equipment loads, airflow needs, code-compliant fire protection, and safe maintainability. Detailed engineering will follow, with the full replacement program expected to progress over the next decade to modernize site distribution capability.

Services

Structural

Mechanical

Electrical

Project Management

Project Controls