Switchboard surgery at Sydney high-rise

When a high-rise commercial and retail building in Sydney’s CBD needed to upgrade its switchboards, the contractors involved knew they were in for a challenging task.

The project, at 580 George St, above Town Hall Station, entailed replacing three main switchboards, nine main distribution boards and 22 smaller boards, as well as modifying existing tenant distribution boards across the building’s 30 levels — all without disrupting tenant activity.

Electrical contractor Fredon partnered with Australian switchboard manufacturer Fuji SMBE Macquarie to carry out the work.

“This job was a bit like taking out the brain, nervous system and heart, while keeping the patient alive as new ones are put in,” said Tim Botskor, Senior Project Manager, Client Services Group – NSW, at Fredon Electrical.

“We worked closely with Fuji SMBE Macquarie in the pre-design phase, which was essential in ensuring full Standards compliance, and making sure the job could be completed in stages, in tight spaces, and with minimal disruptions.”

The team also worked closely with ER&D, a specialist electrical engineering consultancy that provides end-to-end design and project management services across the commercial, industrial and retail sectors.

Fuji SMBE Macquarie Director Peter Silsby said that the project was able to be delivered in a short timeframe due to all three companies working well together.

“We’ve worked with both Fredon and ER&D on a number of projects over many years, which means we are all on the same page when it comes to delivering the best outcomes to the end client,” he said.

Early in the design phase, prior to the project being awarded, ER&D worked with SMBE to develop concept designs.

“This early collaboration was essential to ensure the switchboards would fit within the physical space and the rigid staging constraints, allowing for a staged replacement without impacting normal building operations,” said Ben van Dyk, Project Engineer, ER&D.

“Fuji SMBE Macquarie provided us with different switchboard systems tailored to the unique constraints of each switchroom. This flexibility was critical in overcoming the spatial and staging constraint, leading to successful project delivery.”

Limited time and space

Fredon was given just four Ausgrid shutdown windows for the entire project, so careful planning was essential.

“The client advised us of the shutdown windows, so the switchboards were specifically designed to fit these constraints, and be able to be cut over in sections, not all at once. Fuji SMBE Macquarie were heavily involved in this process, with their expertise proving highly valuable,” Botskor said.

Not only was space limited, but every floor was different, so modifying the tenants’ existing switchboards could not follow a template for each upgrade.

“We had to modify the tenant boards while they were still online, and customise this process for every floor of the building,” Botskor said.

“Different measurements, different requirements, different boards. We then had to stage connection points and integrate the control network. Fuji SMBE Macquarie is highly experienced in this area and helped make it all work seamlessly.”

Shared history at heart of project success

Fredon’s long history of collaboration with Fuji SMBE Macquarie was instrumental to this project’s success, Botskor said.

“Fuji SMBE Macquarie has been highly accommodating with design options, and works with us to meet ambitious lead times and project deadlines set out by end customers. They truly go above and beyond, and this is the type of supplier we like to build long-term partnerships with,” he said.

“The Fuji SMBE Macquarie team works through problems with us, and often we find they are looking at things from a different perspective and identify potential issues we have not seen, so they can be addressed before they even arise.”

3D tech improves visibility

“Fuji SMBE Macquarie also use 3D models where we can see all components from all angles, which is particularly valuable for our team,” Botskor said.

“We work in high-risk, highly technical environments, where safety and compliance are essential. The Fuji SMBE Macquarie team are the ultimate professionals in this area, and we plan to continue this long and productive relationship.”

Images courtesy of Fuji SMBE Macquarie.