Aerospace & Defence Switchboard Replacement Project

Location: Portsmouth.
Contractor: Capri Mechanical Services Ltd.
Industry: Aerospace / Defence.

Project Overview
This project involved the replacement of multiple ageing System 4 electrical switchboards originally supplied by us approximately 30–40 years ago. Due to the critical nature of the site, works were carefully planned to minimise downtime and ensure a seamless changeover.

Scope of Works

• Removal of existing System 4 switchboard.

• Supply and installation of new front and rear access .switchboards

• Configuration:

  • Form 4 Type 2 – Front Access.

  • Form 4 Type 6 – Rear Access.

• Integration of:

  • Schneider ACBs and MCCBs.

  • Rayleigh multifunction power meters.

• Detailed site surveys and design coordination to ensure the new switchboards aligned as closely as possible with existing cable positions.

• Design allowances enabling the contractor to re-terminate existing cables up to 300mm sq (4-core).

Installation & Programme

• Both panels were removed on the August Bank Holiday Saturday.

• Full installation, testing, and commissioning completed.

• Power restored and fully operational by Monday afternoon.

• This installation formed 2 of the 3 panels successfully installed during the same weekend shutdown.

Key Challenges & Solutions

• Restricted outage window: Achieved through detailed pre-planning and off-site design work.

• Legacy cabling constraints: Addressed by precise alignment of new switchboards and tailored termination allowances.

• Critical operational environment: Delivered with zero unplanned downtime.

Outcome
The project was delivered safely, on time, and within the limited shutdown window, providing the client with modern, compliant switchgear while maintaining continuity of operations in a high-reliability aerospace and defence facility.