Types of Power Switchgear Conversions and Their Applications
— Understanding What Can Be Upgraded and Why It Matters
Modern electrical systems are expected to operate safely, reliably, and efficiently despite aging infrastructure and increasing load demands. For many facilities, however, the core of their power distribution system — the switchgear — may be several decades old. Fully replacing it can be costly, disruptive, and often unnecessary. That’s where switchgear conversions come into play.
At GONGSHUN, we specialize in upgrading outdated switchgear to meet today’s safety, regulatory, and performance standards. In this article, we break down the most common types of switchgear conversions, their ideal applications, and how they can reduce risk, save cost, and extend equipment life.
What Is a Switchgear Conversion?
A switchgear conversion involves upgrading critical components of an existing electrical distribution system without replacing the entire lineup. Guided by engineering standards like IEEE C37.59, these conversions ensure that the modified system maintains — or even exceeds — its original ratings for performance, insulation, arc resistance, and short-circuit withstand.
Rather than tearing out entire structures, conversions often focus on key parts: breakers, relays, insulation systems, panels, and controls. When done correctly, they can add 10 to 20+ years of life to existing equipment.
1. Circuit Breaker Retrofits
One of the most common and cost-effective upgrades involves replacing outdated or unsupported breakers that are no longer manufactured or do not meet modern performance expectations.
What it involves:
- Replacing air-magnetic or oil circuit breakers with vacuum or SF6 circuit breakers, offering faster fault clearing and better arc suppression
- Designing and installing cradle adapters or compartment kits to fit new breakers into existing switchgear frames
- Upgrading secondary disconnects, racking mechanisms, and shutters to match the modern breaker design
- Evaluating and upgrading auxiliary contacts and wiring for compatibility with new relays and control systems
Benefits:
- Enhanced electrical and mechanical reliability
- Improved arc flash protection due to faster interruption technology
- Reduced maintenance — no oil or gas handling required
- Easier access to spare parts for long-term support
🛠️ Technical Note: Vacuum circuit breakers are ideal for medium-voltage systems and require little maintenance. SF6 breakers offer high interrupting capacity but must be handled responsibly due to environmental concerns. Retrofit designs must preserve original short-circuit ratings and coordination settings per ANSI/IEEE guidelines.
Best for: Structurally sound switchgear with outdated breakers in factories, utilities, water plants, campuses, and commercial buildings.
2. Arc-Resistant Switchgear Conversions
Arc flash incidents are among the most severe hazards in power distribution. Converting traditional switchgear to arc-resistant designs can significantly improve operator safety, but requires precise engineering and certified components.
What it involves:
- Partnering with a certified switchgear manufacturer like GONGSHUN
- Adding tested arc venting paths and pressure relief systems
- Installing internal steel barriers, sealed compartments, and arc containment ducts
- Integrating remote racking systems and controls to allow safe operation outside the arc flash boundary
- Coordinating UFES (Ultra-Fast Earthing Switch) devices with relays to quickly extinguish faults
⚠️ Safety Note: Equipment can only be legally labeled “arc-resistant” if it has been type-tested by a Nationally Recognized Testing Laboratory (NRTL) such as UL or Intertek. Engineers or testing firms alone cannot certify arc resistance without partnering with an approved manufacturer.
Benefits:
- Maximum safety improvement via certified arc containment
- Compliance with modern arc flash standards (NFPA 70E, IEEE 1584, ANSI C37.20.7)
- Reduced PPE requirements and lower risk to personnel
Best for: Medium- and high-voltage systems with high incident energy levels or elevated operator risk (e.g., utilities, refineries, data centers, heavy industry).
3. Relay and Protection Upgrades
Upgrading relay protection is a strategic way to enhance safety, reliability, and system intelligence. Older electromechanical and early solid-state relays lack the speed, precision, and flexibility of modern digital relays.
What it involves:
- Replacing legacy relays with microprocessor-based digital relays
- Reprogramming and rewiring for advanced protection logic, coordination, and event recording
- Integrating with SCADA, EMS, or standalone monitoring systems
- Coordinating UFES systems to minimize arc flash energy during faults
- Ensuring all upgrades comply with updated IEEE, ANSI, and NFPA standards, including updated short-circuit studies
GONGSHUN Advantage: We handle all mechanical and electrical integration in-house, including custom sheet metal fabrication for relay panels, door modifications, and remote operation interfaces. We provide full CAD documentation, ensuring a precise and visualized installation plan — no third-party outsourcing required.
Benefits:
- Faster and more precise fault detection and clearing
- Improved system diagnostics and event tracking
- Adaptable logic for evolving power loads
- Lower incident energy exposure with coordinated protection
Best for: Facilities aiming to improve fault protection, diagnostics, automation, and arc flash safety — including utilities, industrial operations, and mission-critical systems.
4. LV to MV Switchgear Conversions
As facility demand grows, low-voltage switchgear may no longer meet safety or capacity needs. Converting to medium-voltage (MV) systems offers a robust upgrade path.
What it involves:
- Removing or modifying LV gear to support MV-rated components
- Installing MV circuit breakers, CTs, PTs, and protection relays to ANSI/IEEE specs
- Meeting MV insulation, phase spacing, and clearance requirements
- Implementing arc flash mitigation strategies using UFES and relay coordination
- Conducting detailed space planning to meet MV system ventilation and footprint guidelines
📐 Consultation Note: These projects require thorough engineering and layout planning. GONGSHUN provides full in-house design, layout, and fabrication services, reducing delays and project risks.
Benefits:
- Higher system capacity to support larger infrastructure
- Better fault protection and reliability at scale
- Future-proofed architecture for expansion
Best for: Growing plants, data centers, or utilities modernizing from legacy LV gear to modern MV systems.
5. Compartment Adapter Conversions
Older switchgear often varies significantly in size and breaker mounting configurations. Custom adapters allow modern devices to be installed safely into existing compartments.
What it involves:
- Designing custom structural adapters for legacy frames
- Reinforcing enclosures to meet mechanical strength and safety codes
- Maintaining mechanical interlocks and grounding continuity
- Ensuring compatibility of doors, hinges, and operator access
GONGSHUN Advantage: We design and fabricate all adapter kits in-house, with structural analysis and CAD verification for exact fitment. No need to wait on third-party metal shops.
Benefits:
- Preserves the existing switchgear cabinet
- Avoids major demolition or site welding
- Shorter lead times through in-house production
- Ensures mechanical integrity and regulatory compliance
Best for: Unsupported OEM gear where breakers or relays must be upgraded without replacing the entire assembly.
6. Control Panel & Operator Interface Upgrades
Today’s operators expect intuitive, safe, and informative controls. Panel upgrades improve interaction, safety, and visibility.
What it involves:
- Replacing analog meters with digital displays or HMIs
- Installing updated buttons, switches, and indicator lights
- Adding remote racking controls or touchscreen interfaces
Benefits:
- Clearer information and safer operations
- Easier diagnostics and troubleshooting
- Compatible with modern communication protocols
Best for: Facilities seeking to improve user interfaces without complete system replacement.
How to Choose the Right Conversion
Factors to consider:
- Condition and age of the existing gear
- Spare part availability
- Arc flash risk and exposure level
- Compliance with UL, NEC, OSHA, and IEEE
- Expansion needs or load changes
At GONGSHUN, we begin with a site inspection and full engineering review to determine what can be reused and what should be upgraded — providing the most cost-effective and safe path forward.
Why Convert Instead of Replace?
| Comparison | Conversion | Full Replacement |
|---|---|---|
| Cost | 30–70% savings | Full investment |
| Downtime | Minimal | Extended |
| Project Timeline | Faster | Longer |
| Infrastructure Impact | Reuses structure | Requires demolition |
| Regulatory Compliance | Achievable | Achievable |
✅ Conversions are strategic investments, not shortcuts.
FAQs
Q: What is a switchgear conversion?
A: It’s an upgrade that improves performance and safety by replacing outdated components while keeping the main structure.
Q: Can old switchgear be upgraded?
A: Yes. Most legacy gear can be modernized with new breakers, relays, and control components.
Q: Why convert instead of replace?
A: It saves cost, reduces downtime, and avoids full system tear-out while achieving compliance and performance improvements.
Q: What types of conversions are available?
A: Breaker retrofits, arc-resistant upgrades, relay replacements, adapter kits, and LV-to-MV upgrades are common.
Q: Who should perform conversions?
A: Only qualified manufacturers or service providers with UL/IEEE/NRTL compliance expertise and design experience.
Final Word
Switchgear conversions allow you to modernize power infrastructure without the high cost and disruption of full replacement. But successful upgrades require deep engineering knowledge, precision execution, and a strong commitment to safety.
That’s where GONGSHUN comes in. We don’t just replace parts — we engineer lasting, intelligent solutions.
Professiona Switchgear supplier and manufacturer
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