Electrical Fault Study & Switchgear Design for High-Density Data Center - San Jose, CA

Image Credit: Canva

Category: Computer Server Manufacturing / Data Center

Overall Area: 70,000 ft²

Services Provided: Electrical Engineering

Completion Date: 2025

Owner: Confidential (Data Center Client)

Contractor: RC Power

Project Description

For a 70,000-square-foot server manufacturing and data processing facility in San Jose, a main switchboard upgrade prompted the need for precise fault current evaluation and design intervention. Pragmatic PE was engaged by RC Power to deliver advanced electrical engineering support focused on short-circuit safety and system reliability.

Scope of Work

Pragmatic PE was tasked with assessing the electrical distribution system to determine the suitability of existing equipment following the installation of a new 4000A switchboard. Our responsibilities included:

• Conducting thorough site surveys to inspect existing panels, breakers, and distribution connections.

• Creating as-built single-line diagrams based on verified onsite conditions.

• Performing a full short circuit and available fault current (AFC) analysis using SKM Systems Analysis software.

• Calculating voltage drop and confirming Title 24 compliance for all affected distribution equipment.

• Identifying components with insufficient Short Circuit Current Ratings (SCCR) or Ampere Interrupting Capacity (AIC).

• Recommending cost-effective, code-compliant upgrade options to mitigate identified risks.

• Providing NRCC Electrical Distribution Title 24 documentation as required.

Challenges & Solutions

The core challenge was integrating a 4000A switchboard into an existing system without compromising safety or compliance. To address potential overcurrent risks, we:

• Modeled load impacts under both current and future demand scenarios.

• Recommended targeted switchgear upgrades and coordination improvements to reduce fault current exposure.

• Provided multiple solution pathways—balancing cost, schedule, and reliability—for client consideration.

Results & Impact

Pragmatic PE delivered a technically sound, solution-oriented engineering report that empowered the contractor and client to proceed with their upgrade safely and confidently. Our work:

• Enabled seamless integration of high-capacity switchgear.

• Ensured compliance with California Title 24 energy standards.

• Protected critical infrastructure with optimized electrical distribution planning.

• Strengthened client trust in our data center expertise for future upgrade projects.