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6 Key Considerations To Optimally Modernise Your Switchgear

6 Key Considerations To Optimally Modernise Your Switchgear

All electrical equipment and its components have a defined operational lifespan. For most switchgear, this averages around 20 years. However, with proper maintenance and care, one can further maximise the service life of a switchgear beyond this timeline. This is akin to how diligent generator maintenance can keep backup power systems operational for extended periods.

Beyond routine maintenance, modernisation through retrofitting plays a critical role in extending the usability and efficiency of switchgear. Retrofitting involves upgrading essential components with newer, more advanced technologies and replacing non-functional elements such as signage, decals, or operator instructions. This process not only enhances the functionality of the switchgear but also ensures it meets modern safety and operational standards.

While certain components, like protective relays or bus bars, may remain relatively unaffected by technological advancements, innovations in other areas can significantly improve safety, efficiency, and functionality. If you are planning a switchgear modernisation project, it’s essential to carefully evaluate several factors to ensure a successful outcome. Here are six key considerations to guide you through the process:

1. Conducting a Thorough Site Assessment

The first step in any switchgear modernisation project is a detailed site assessment. This phase involves gathering comprehensive information about the equipment’s current condition and identifying specific needs for the retrofit. Key activities during this stage include:

  • Collecting service history records, equipment photos, and manufacturer manuals.
  • Consulting with operational teams to understand how the switchgear is currently performing and identifying any recurring issues.
  • Assessing the minimum requirements and maximum potential upgrades to determine an appropriate scope of work.
  • Developing an installation plan that aligns with operational schedules, cost constraints, and desired timeframes.

By obtaining a holistic understanding of the switchgear’s condition and operational demands, engineers can create a modernisation plan that is both effective and cost-efficient.

2. Determining the Level of Retrofit Required

The extent of modernisation required for your switchgear will depend on its current state and your operational needs. Different levels of retrofitting have varying implications for safety, cost, potential downtime, and project timelines. These levels can be broadly categorised as follows:

  • Individual parts replacement: This involves replacing specific obsolete components. It is the least invasive option and typically has minimal downtime.
  • Major component replacement: In this scenario, an entire set of components, such as a programmable logic controller (PLC), is replaced. This process usually takes between two to six weeks from assessment to completion.
  • Control system overhaul: This level involves replacing all obsolete controls while retaining the switchgear’s “power envelope” (e.g., bus, breakers, power cables, and sheet metal). This is the most common type of switchgear modernisation and typically requires 8-12 weeks to complete from the initial assessment.
  • Total replacement: If the site assessment concludes that the existing switchgear is beyond salvage, a full replacement may be necessary. This rare and extensive process can take up to 20 weeks from assessment to completion.

It’s important to note that these timelines include the design and acquisition of components. Actual downtime is limited to the installation phase unless the equipment poses an immediate safety risk.

3. Component Obsolescence

A critical aspect of switchgear modernisation is the replacement of obsolete components. These upgrades can range from addressing active safety risks, so replacement is necessary to enhancing functionality with newer technologies, which is more of a nice-to-have upgrade. Some examples include upgrading single-function meters to multi-function devices, integrating separate governor controllers or import-export controls into unified systems, and replacing filament indicating lamps with energy-efficient LED alternatives.

Ideally, this should also include substituting components no longer in production, such as certain protective relays, or PLCs without factory support. Upgrading obsolete components not only improves reliability but also ensures that your switchgear meets current industry standards and remains serviceable in the long term.

4. Costs

Cost is a significant consideration for any retrofit or refurbishment project, just like with electric motor rewinds or overhauling, for instance. In switchgear modernisation, it’s crucial to weigh both the immediate project costs and the potential hidden costs of not upgrading. Failure to modernise switchgear can lead to the inability to transition effectively to backup power during mains power outages, resulting in downtime and lost productivity. Moreover, there will be an increased safety risk for employees due to outdated or malfunctioning components and the potential for the surrounding equipment to sustain extensive damage in the event of a failure.

5. Ensuring Regulatory Compliance

Adhering to regulatory standards is a fundamental aspect of switchgear modernisation. Compliance not only ensures the safety of employees and equipment but also reduces the risk of legal and financial liabilities arising from negligence. Standards governing switchgear often include general requirements for electrical safety as well as specific obligations for critical loads and emergency response times. Facilities like healthcare centres, for instance, must meet stringent regulations to ensure uninterrupted power during emergencies. Understanding and integrating these requirements into the modernisation process is essential for achieving a compliant and future-ready system.

6. Appearance

Switchgear modernisation should also address the physical appearance and safety features of the equipment. For starters, insufficient or outdated signage and safety measures can pose challenges during inspections or routine maintenance. Upgrades should include professional signage, updated safety notices, and enhancements to physical features. Reducing excessive wiring, consolidating functions, or adding locking mechanisms to restrict access are examples of improvements that not only enhance safety but also streamline operations.

Conclusion

Modernising your switchgear is a crucial investment in the safety, efficiency, and reliability of your electrical infrastructure. To ensure the project’s success, organisations must address the key considerations outlined above and as they ensure a seamless transition to a more advanced and capable system. Remember, proactive modernisation not only extends the lifespan of your switchgear but also prepares your facility to meet future challenges with confidence.