Electrical Questions for the GJ Sparkys

[aka Larry]

My buddy has a metal shop similar to mine. He planned to do run a 100A sub panel into the shop off the house 200A main panel. The current problem is the main panel is full.

My first question is can any of the GFCI breakers shown on the top left (see pic below) be swapped out for regular slim-line ones to free up space? In his case he has GFCI outlets in the house, so why does he need a GFCI breaker too? I don't know if this can be done per the NED, which why I'm asking.

If the GFCI breakers cannot be removed, what would be the best way to proceed? I've been told he can add a small panel beside the main panel, move two breakers from the main panel to the small panel, and wire nut the connections that are moved. Then run the new L+L+N+G feed from the new breaker in the main, through the small panel, and out to the new 100A sub panel in the shop. Is this a sound idea?

My next question is regarding the new 100A sub panel in the shop. I know the N+G cannot be bonded, but does the shop panel need it's own ground rod since it will be connected to the ground in the main 200A panel?

The panel in my shop (installed by an electrician, not me) has the ground from the main panel, plus and additional one going to a separate ground rod at the shop. Is this wrong, or just overkill?

 

[pattenp]

If you use GFCI outlets then there is no need for a GFCI breaker. One thing though, if those GFCI breakers are double pole serving a MWBC then they may not be able to be changed. Make sure the GFCI breakers are single pole serving a single circuit.

The shop does require ground rods. The ground between panels is the equipment ground and does not serve the same purpose as the grounding electrode system (rods).

You can add a subpanel by the existing panel to free up spaces. You can extend circuits to the new subpanel using wirenuts in the main panel.



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[aka Larry]

I forgot to include the pic! Here's the current panel:

 

[mrobins297aaa]

I had the exact same thing, I have a 200 amp service and wanted to add a 100 amp panel in the barn but I had no extra spaces in my 200 amp panel. So I bought two 100 amp panels, one for the barn and one I added as a sub panel to my existing.
My barn feed is on the right.
The extra spaces came in handy when I later on needed to move two more breakers for my generator inter lock circuit

 

[Crazyjake8493]

The shop does need ground rods, two actually, so it is not overkill. Unless there is a UFER ground in the shop.

The GFCI breakers are not needed if the first outlet in the circuits are GFCI, protecting all downstream outlets.

 

[aka Larry]

The shop does need ground rods, two actually, so it is not overkill.

Pretty sure my current shop only has one. What does the second one connect to?

 

[pattenp]

The two rods are connected in series along the same conductor and must be at least 6ft. apart from each other. NEC requires one rod but you must prove there is 25ohms or less resistance to earth. It's easier to just drive two rods to satisfy the ohm requirement.