Ensuring Safety and Reliability: Electrical System Overhaul at Polymer Solutions Group

Polymer Solutions Group (PSG), formerly known as Flow Polymers, has been a longtime customer of Harrington Electric Co. As an innovative manufacturer of proprietary and custom polymer additives, dispersions, and release agents, PSG operates in a highly specialized and potentially flammable work environment, handling asphalt-based products and loading materials from railroad cars. Keeping their electrical infrastructure safe and reliable is critical to their operations.

Harrington Electric Co. first worked with PSG to install a 600-amp chiller. Since then, the company has consistently trusted our team with their electrical needs. When a fire damaged PSG’s silos and critical processes, we were there to assist in the rebuilding efforts. More recently, when their manufacturing facility—constructed sometime in the 1930s or 1940s—experienced an electrical failure, they turned to us once again.

The facility’s main electrical gear, originally installed in 1943, had become the backbone of the entire manufacturing and office operation. The busway system, which distributed power throughout the facility, had the potential to be unsafe due to its age and condition. With no means of monitoring ground faults or having arc flash mitigation capabilities, it was clear that an upgrade was necessary.

“Our objective was to replace the aging infrastructure with modern electrical gear that enhances safety and reliability,” says Jerry Strand, Project Manager at Harrington Electric Co. “We put together a strategic plan to surgically remove the old system and install a new one with minimal disruption to operations.”

The project, which began in April, 2024 and is set for completion by July, 2025, is now two-thirds complete. The team is methodically transferring power from the 1943 gear to a newer 4000-amp system installed in 2007. This transition includes decommissioning, shutting down, cutting apart, and removing the old gear to create a safer environment. The new electrical distribution panel board, rated at 4000 amps at 480 volts, provides PSG with ample capacity to meet its operational demands. It also incorporates advanced ground fault detection technology that can automatically shut down the system if an issue is detected, preventing potential electrocution hazards.

“Our biggest challenge has been coordinating the work while keeping PSG’s production running smoothly,” Strand explains. “We’ve structured the project into four phases, carefully planning strategic shutdowns to avoid interruptions. In fact, we’ve reached a point where the office staff barely notices our work, which is a testament to our careful execution.”

Harrington Electric Co.’s expert team, led by Rich Drum and supported by Albert Madson, Frank Medancic, and Rob Lee, has been working diligently on-site. With just two or three technicians on-site at any given time, the team has successfully executed precise shutdown phases while ensuring PSG’s operations remain uninterrupted.

The new electrical gear is installed in rooms adjoining the huge factory floor, away from the primary production area. The team has knocked out brick walls to run new conduit, ensuring a seamless integration of the updated system. Once the transition is complete, the old gear will be dismantled and scrapped by PSG’s ownership.

Given the facility’s dusty environment, Harrington Electric Co. has also recommended that PSG implement a routine preventive maintenance schedule, including regular system cleaning to prevent airborne contaminants from affecting electrical performance.

Harrington Electric Co. is proud to support PSG in modernizing its electrical infrastructure. By replacing an 80-year-old system with state-of-the-art technology, we are ensuring a safer, more reliable, and more efficient operation for the future.