Complete Lifecycle Support for Your Critical Distribution Equipment
Switchgear is the critical junction point where power is controlled, protected, and distributed throughout your facility. Switchgear failures account for 35% of all substation outages, with average replacement costs exceeding $500,000.
Proper maintenance, testing, and expert service extend switchgear life from 30 to 50+ years while preventing catastrophic failures that halt operations.
Switchgear services encompass the complete lifecycle support for medium voltage (1-38kV) and high voltage (>38kV) switchgear systems. These services include:
Installation & Commissioning
New switchgear acceptance testing and startup
Preventive Maintenance
Scheduled inspections and testing programs
Diagnostic Testing
IR thermography, partial discharge, contact resistance
Emergency Repairs
24/7 response for critical failures
Services cover all switchgear types: metal-clad, metal-enclosed, pad-mounted, arc-resistant, gas-insulated (GIS), and manufacturers including ABB, Eaton, GE, Schneider Electric, S&C, and Siemens.
Switchgear failures cause immediate, facility-wide power loss. Unlike transformers or breakers that can sometimes be bypassed temporarily, switchgear failure means complete shutdown. Proper maintenance prevents failures that average 48-72 hours of downtime during emergency replacement.
Real Example:
Manufacturing facility deferred switchgear maintenance for 8 years to save costs. A vacuum breaker failed during a normal switching operation, causing arc flash that destroyed the entire switchgear lineup. Total downtime: 11 days waiting for replacement equipment. Lost production: $3.3M. Equipment replacement: $680K. Lawsuit from injured operator: $1.8M. Cost of maintenance program: $15K/year.
NFPA 70B and NETA MTS recommend maintenance intervals based on switchgear type and environment. OSHA 1910.303 requires equipment to be maintained in safe condition. Insurance carriers increasingly require documented maintenance programs as coverage conditions.
Well-maintained switchgear operates reliably for 40-50 years. Neglected equipment fails at 20-25 years. With switchgear replacement costs of $500K-$2M, proper maintenance providing 20+ years of additional service life generates enormous ROI.
Maintenance testing identifies developing problems—overheating connections, degrading insulation, worn mechanism components—before catastrophic failure. Planned repairs during scheduled outages cost 10-20x less than emergency replacements.
Bus connections and breaker contacts deteriorate over time from thermal cycling, oxidation, and mechanical wear. High-resistance connections overheat, causing insulation damage and eventual failure. Thermographic inspection and contact resistance testing identify these issues before failure.
Insulation systems degrade from electrical stress, moisture, contamination, and thermal aging. Insulation resistance testing, power factor testing, and partial discharge measurements detect degradation before breakdown occurs. Early detection allows planned replacement versus catastrophic failure.
Operating mechanisms, interlocks, and auxiliary switches wear with repeated operations. Worn components cause slow breaker operation, failed trips, or inability to close. Preventive maintenance includes lubrication, adjustment, and replacement before failure affects protection system performance.
Dust, moisture, chemicals, and pests accumulate in switchgear over years of operation. Contamination creates tracking paths that cause flashovers, corrodes connections, and interferes with mechanisms. Regular cleaning prevents contamination-related failures common in industrial environments.
Older switchgear faces parts obsolescence as manufacturers discontinue support. Maintenance programs identify components requiring spare parts while still available. Strategic replacement planning prevents emergency situations where parts simply don't exist.
Best Practice: Implement condition-based maintenance using thermography and testing data to optimize service intervals based on actual equipment condition.
Typical Duration: Comprehensive switchgear maintenance requires 3-5 day outage depending on lineup size. Annual thermography can be performed energized in 2-4 hours.
$500K-$2M
Emergency switchgear replacement cost
$15K-$35K
Comprehensive maintenance service cost
15-60x
ROI from preventing ONE failure
Provides maintenance intervals and procedures for switchgear based on voltage, environment, and criticality.
Defines specific test procedures and acceptance criteria for switchgear maintenance testing.
Covers design, testing, and maintenance requirements for metal-enclosed switchgear, pad-mounted equipment, and arc-resistant switchgear.
Mandates equipment be maintained in safe condition appropriate for the intended use.
Proactive maintenance prevents catastrophic failures and extends equipment life decades beyond the alternative.
📧 support@clarkte.com | ☎️ +1 (617) 396-4632 | 📍 Boston, MA