5 Signs It’s Time to Modernize Your Switchgear
Why Switchgear Modernization Matters
In today’s high-demand electrical environments, reliability isn’t optional—it’s critical. Your switchgear is the heart of your power distribution system, and if it’s outdated, it could be putting your operations, safety, and bottom line at risk.
At Case Power Solutions, we help commercial, industrial, and public sector clients modernize their power infrastructure—safely and cost-effectively. If you’re unsure whether your switchgear needs attention, here are five warning signs you shouldn’t ignore.
1. Your Switchgear is Over 20 Years Old
Most switchgear systems are built to last 20–30 years. However, age doesn’t just bring wear—it also brings obsolescence. Replacement parts become harder to source, and older systems often lack the protections required by today’s standards.
Why it matters:
Aging insulation and contact points can cause failures.
Manufacturers may have discontinued critical components.
Modern loads require more advanced protection and metering.
2. You’ve Experienced Unplanned Outages
Unexplained breaker trips, brownouts, or full system failures may indicate deteriorating switchgear. Even if your team resets the breakers and gets the system running again, recurring outages are a red flag.
Potential causes:
Faulty breakers or relays
Loose bus connections or corroded terminals
Inadequate load capacity for current operations
The fix: Modernizing your system ensures reliable uptime and correct coordination across your electrical distribution.
3. Safety Concerns or Arc Flash Risks
Today’s NFPA 70E standards require proactive arc flash hazard assessments and mitigation. Older switchgear is more prone to arc flash incidents, particularly in facilities without current labeling, PPE plans, or updated protection schemes.
Modern upgrades offer:
Arc-resistant switchgear designs
Maintenance-mode relays
Ground fault and zone selective interlocking
Safer, front-access configurations
Don't wait for an accident. Ensure your facility meets modern OSHA and NFPA requirements.
4. Your Power Demands Have Grown
Has your facility expanded? Have you added new equipment, EV chargers, or solar panels? If so, your legacy switchgear may no longer handle your load requirements—or may lack flexibility for future integration.
Modern switchgear supports:
Increased amperage ratings
Smart metering and energy monitoring
Integration with battery storage, solar, or hydrogen systems
Advanced load shedding and remote management
5. You’re Spending Too Much on Maintenance
If your team is constantly troubleshooting, sourcing parts, or paying for emergency service calls, modernization can lower long-term operating costs.
Signs of a money drain:
Repeated component replacements
Long lead times for obsolete parts
High costs for emergency labor and testing
Switchgear upgrades reduce operating expenses, improve energy efficiency, and deliver a clear return on investment over time.
🛠️ What’s Involved in a Modernization?
Modernization doesn’t mean a full system tear-out. At Case Power Solutions, we offer tailored retrofit solutions including:
Circuit breaker upgrades
Protection relay retrofits (digital relays)
Bus refurbishment
Arc flash labeling and compliance
SCADA and metering integration
Infrared scanning and condition assessments
You get improved performance, lower risk, and extended life—without full replacement costs.
Is It Time to Upgrade?
If any of these signs apply to your facility, it’s time to start planning your switchgear modernization. Let our expert team help you make the right upgrade decisions, minimize downtime, and keep your operation running strong.
