Switchgear Modernization Solutions

Improve Power System Reliability

and Lower Life-Cycle Costs
Presented by:

Doug Robling, U.S. Services Division

When considering whether to replace or continue to maintain

existing equipment, there are a number of factors to consider.
Operating environment
Availability of spare parts

Impact of downtime
Cost of ongoing
maintenance

Need to increase fault or

continuous current rating
Desire to upgrade to
current technology

Two cost-effective
modernization solutions
are available to upgrade
your existing equipment
to current technology and
save time and money.
Direct Replacement
Retrofill

Utilizing the existing

equipment structure
and footprint saves
time and money.

Installing new switchgear, which is

usually smaller than the older or
obsolete equipment it is replacing,
requires that existing conduit above
and below the equipment be moved.
This is a time-consuming and costly
process.

Direct Replacement: Circuit breakers are designed to fit into the

existing cubicle with little-to-no modification to the switchgear cell.
Reduces downtime since there
is minimal (if any) outage on
the equipment bus

Designs are available for any

manufacturers low-voltage
(LV) or medium-voltage (MV)
switchgear
- LV: MasterpactTM circuit breaker
- MV: MagnumTM circuit breaker

Above:
Masterpact Circuit Breaker
Right:
Magnum Circuit Breakers

Low Voltage Direct Replacement

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A new circuit breaker element, truck

and carriage assembly are installed in
existing switchgear

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The interior of existing cells are not

modified; adapter cradle designs are
available for most manufacturers
brands of switchgear

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A Masterpact circuit breaker fits into

the adapter cradle and directly
replaces the existing circuit breaker

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Interfaces with the existing structure

and maintains safety interlocks
inherent with the original design

Masterpact Circuit Breakers: The Latest in Circuit Breaker Technology

High ampere interrupting (AIR) and short-time current ratings

ModbusTM communication protocol, field-installable

devices, including sensor plugs and accessories
Minimal maintenance requirements

Draw-out circuit breakers with three racking positions

and status indicator on cradle
Draw-out or fixed mount, 3- or 4-pole construction

Integral ground-fault protection for equipment

Masterpact Circuit Breakers

and MicroLogic Trip Units

Protective relaying functions

Zone-selective interlocking, which can reduce damage in the event of a detected fault

Full nuclear certification including V&V or software and radiation

Medium Voltage
Direct Replacement
A new circuit breaker element,
truck and carriage assembly are
installed in existing switchgear
Interfaces with the existing
structure and maintains safety
interlocks inherent with the
original design
The interior of the existing cell
is not modified
Designs are available, utilizing
the Magnum circuit breaker, to
directly roll-in to the existing cell

Magnum MV Circuit Breakers

Available in 5 kV 15 kV; upgraded MVA ratings available
Low maintenance vacuum and SF6 arc interruption technology

Meets the requirements of ANSI/IEEE C37.59 standards

High dielectric strength, moisture resistant primary insulation
Nuclear certification available
No arc by-product ventilated into the compartment
Reduced power consumption of the control components
Optional capabilities
- Increased arc fault current interruption capacity
- Relay upgrade, improved accuracy and repeatability
and shorter interrupting time
- Power monitoring and communication
- Ground and test devices available
- Remote racking solutions available

The operating
mechanism
on Magnum MV
circuit breakers
is simple to inspect
and maintain

Retrofill Solution
The existing switchgear cell and bus are
modified to accept a new circuit breaker.
New operating and racking mechanisms for
circuit breakers
Typically requires more labor and downtime
that a direct replacement solution
Both direct replacement and retrofill
solutions feature new cubicle doors
Available for any manufacturers switchgear
Above: LV retrofill Below: MV retrofill, often used in lieu of the direct
replacement option for larger devices, such as main breakers and tie breakers.

Benefits of Modernizing Existing Switchgear

Reduced costs for switchgear upgrades
- New circuit breakers are installed in existing switchgear
- Original footprint is left intact, saving time and money

Less downtime for installation

- Downtime is minimized compared to demolishing and
replacing existing equipment

Enhanced equipment reliability

- New circuit breakers undergo complete factory testing
and are backed by our standard equipment warranty

Reduced maintenance and operating costs

- New, easy-to-maintain operating mechanism
- Reduced need for difficult to obtain spare parts

Any brand
Any industry
Any time

Additional options to
extend equipment life
include:

Trip Unit Retrofits for LV Circuit Breakers

A retrofit upgrades the trip unit on low voltage circuit
breakers to current standards of over-current and
ground fault protection
- Existing trip units are replaced with a solid-state design

LV Trip Unit Retrofits

- Fused vacuum contactors conversions are also available for

most LV circuit breakers

MV Contactor Conversions

MV Contactor
Conversions

Available for all brands of 5kV 15kV circuit breakers,

- Upgrades equipment to current technology: vacuum or SF 6
- 400 amp or 700 amp

Circuit Breaker
Reconditioning

Increases electrical system capacity through better

coordination using fuses
Extends circuit breaker life cycle to 100,000+ operations

Reconditioning: A cost-effective option to

extend the life of existing equipment.
All circuit breakers need periodic
maintenance and testing
- Maintenance of operating mechanism and
current-carrying parts
- Cleaning and re-lubrication of pivot points

Upon completion, the reconditioned circuit

breaker performs to manufacturers original
specifications
While not a modernization solution,
reconditioning circuit breakers will:
- Reduce unplanned downtime
- Improve reliability
- Extend equipment life

Questions Answers