KE began the project with a comprehensive plant-wide electrical audit, documenting cable identification, terminations, and system conditions. This audit established a clear baseline and directly informed the design of the new MCC room, electrical distribution strategy, and automation replacement.
The overall project spanned approximately seven months, with KE mobilizing in mid-November 2024 and completing construction in late June 2025. A new MCC room was designed and built approximately 200 feet from the original to improve capacity, provide clear isolation points, and allow for future expansion. New MCCs were procured, installed, and commissioned as part of a shift from a plant-wide electrical approach to a system-based design. Underground conduit and cable tray infrastructure were installed well in advance of the outage to support both the new silo and long-term plant growth.
A single, highly coordinated outage occurred roughly midway through the electrical construction. While much of the silo work continued outside the outage window, this outage focused on energizing MCCs, landing cables, migrating all I/O from the old PLC to the new PLC, implementing a new FactoryTalk-based automation program, and restarting an operating facility. The outage was originally scheduled for 14 calendar days, but KE had the plant moving product again within 10 to 11 days.
The success of the outage was driven by tight coordination with Ash Grove and other trades, accurate scheduling, and clear communication. Approximately seven automation engineers were on site throughout the outage, working alongside KE’s electrical crews. The outage represented the most automation-intensive phase of the project and would not have been successful without full on-site staffing and collaboration.
Cable tray installation was completed prior to the outage. During the outage itself, KE focused on relocating and reconnecting existing cables rather than installing new tray. Full device checkout, loop testing, and permissive testing were completed to ensure safe and predictable startup. All personnel completed MSHA 48b training, and daily hazard assessments addressed mobile equipment, confined spaces, high walls, and energized work. A dedicated QAQC lead verified installations and test results before turnover.
Following startup, KE’s automation team continued to provide remote support to quickly resolve any operational issues and ensure a smooth transition to steady-state operation.
