When electrical switchgear ages or begins to fail, businesses are often faced with a tough decision: should you refurbish the existing equipment or replace it entirely? Both options come with unique advantages and challenges, making it important to evaluate which approach best suits your operation’s needs, budget, and long-term goals.
In this guide, we’ll explore the key factors to consider when deciding whether switchgear refurbishment or replacement is the right choice for your business.
Replacement: What It Entails
Full switchgear replacement involves removing the old system and installing brand-new equipment. While this requires a higher upfront investment, it can be the best option when dealing with severely outdated or damaged systems.
Benefits of Replacement:
- Long-Term Reliability – New switchgear provides the latest technology, ensuring that your facility operates with the most reliable and efficient equipment. Replacement eliminates concerns about outdated parts or frequent failures.
- Technology Upgrades – New systems come equipped with modern advancements such as digital monitoring, increased automation, and better safety features. These upgrades help future-proof your operation and make ongoing maintenance simpler.
- Compliance with Modern Standards – Older switchgear may no longer meet current industry standards. Replacing your system ensures compliance with the latest regulations, improving both safety and operational efficiency.
Staging the integration of new gear to existing setups:
At High Power Products, we can schedule a time to come on site and get measurements of the existing gear and setup. We can then use our existing products and design custom components to integrate new gear into the setup in stages. This has been a very effective means to update medium voltage gear in stages and address the most critical updates required. This also minimizes down time, as the work is broken out into stages.
An example is an old feeder lineup that is MLO on the line side. This is a very common setup. We design a custom top hat to apply to our 15kV HPPCS ADVAC enclosure. Some custom bus components are made to tie into the existing bus of the feeders.
- Remove the existing MLO enclosure from the feeders and prep it for mating to the new HPPCS enclosure.
- Position the CS enclosure and fasten it to the existing feeders.
- Tie the new bus to the existing bus of the feeders.
- Wire in the heaters to the new controls.
- Wire the line cables to the lug pads of the new CS enclosure.
The feeder section now has protection and controls designed for the application. The controls of this system operate on a 48VDC battery system. It is changed from the PT drawer of the gear. This eliminates having to run external control power to systems that do not have current control power, as a MLO would not. The system controls now have battery back during power outages. This type of integration is accomplished in one day.
Preparation is done in engineering during the design of the new integration, so as to make for an easy install of the new HPPFS feeder enclosures.
When to Choose Replacement:
- If your equipment is obsolete or no longer supported by manufacturers.
- If frequent failures or safety issues are affecting your operations.
- If your facility needs the most current technology to remain competitive or meet regulatory standards.
Refurbishment: What It Involves
Refurbishment typically focuses on overhauling certain components of your existing switchgear while keeping the main structure intact. This process can include cleaning, replacing worn-out parts, upgrading outdated technology, and even adding new safety features. The goal is to extend the life of your equipment while improving performance and reliability.
Benefits of Refurbishment:
- Cost Savings – Refurbishing can be less expensive than purchasing new equipment. It allows you to only replace critical components, which can often restore equipment to near-new condition at a lower cost.
- Environmental Impact – Refurbishing means reusing existing structures, which reduces waste and the environmental footprint of your project. This is especially important for facilities looking to maintain sustainability goals.
When to Choose Refurbishment:
- If your switchgear is still structurally sound and only needs component updates.
- If you have budget constraints but still need to improve reliability and safety.
Key Considerations for Your Decision
1. Cost and Budget
Refurbishment generally requires less investment upfront. However, if your equipment is severely outdated, the long-term benefits of replacement—such as reduced maintenance costs and enhanced safety—may outweigh the initial savings of refurbishment.
2. Downtime and Disruption
Refurbishment can usually be completed faster, meaning less disruption to your operations. Full replacement might require a more significant shutdown, but this can be worth the temporary inconvenience for a fully modernized system.
3. Equipment Longevity
Refurbishing can extend the life of your equipment by 10 to 20 years. However, for facilities with critical electrical needs, a brand-new system may offer more reliability and a longer lifespan.
4. Sustainability
Refurbishment is typically the more environmentally friendly option, as it reduces waste by keeping most of the existing structure in place. However, new switchgear may offer better energy efficiency, which can be a long-term environmental win.
Which Option Is Right for You?
The decision to refurbish or replace your switchgear depends on various factors, including the condition of your current equipment, your operational needs, budget, and long-term goals. If your system is still structurally sound and only needs some updates, refurbishment may be your best bet. On the other hand, if your equipment is outdated or frequently failing, replacement might be the more cost-effective choice in the long run.
Final Thoughts and Next Steps
At High Power Products, we understand the importance of reliable, efficient, and safe electrical systems. Whether you’re looking to refurbish your current switchgear or need to replace it entirely, we offer tailored solutions to meet your specific needs. Our team of experts can help guide you through the decision-making process to ensure your facility remains operational and safe.
Ready to take the next step? Contact us today to request a quote and learn more about how we can assist with your switchgear needs.