Enterprise data center UPS and switchgear retrofit
Live-site replacement of a legacy UPS plant and main switchgear with a modular 500 kVA N+1 system, performed without interruption to a 900 kW production load.
What we were engaged to build.
Actual ratings, devices and standards.
The service voltages, equipment ratings, protective functions and codes this project was built and tested against.
The specific electrical solutions we used.
How each design decision solved a real constraint on this project — from redundancy and coordination to protection and commissioning.
Temporary maintenance bypass for live cutover
A temporary bypass panel carried the load while the old UPS was decommissioned and the new gear landed, so the 900 kW production load never saw an interruption.
Modular N+1 with hot-swap power modules
Each 250 kVA module is field-replaceable under power, so a failed module is swapped in minutes without transferring to generator or dropping redundancy.
Lithium-ion battery with cell-level monitoring
Li-ion cabinets cut footprint by 60% versus VRLA and report per-cell voltage and temperature, flagging a weak cell long before it threatens runtime.
Static transfer under 4 ms
A 3-pole static transfer switch moves the load between UPS and bypass in under 4 ms, well within the hold-up window of modern IT power supplies.
From the build.
