How to extend the service life of high and low voltage switchgear?

High and low voltage switchgear is inevitably prone to malfunctions after prolonged operation. If these issues are not addressed promptly, it will undoubtedly affect their service life. Extending the service life of high and low voltage switchgear hinges on systematic preventive maintenance, standardized operation, and timely technical upgrades. The following are specific methods and measures:

I. Strengthening Daily Operation Management and Monitoring

Regular Inspections:

Check for abnormal sounds (such as discharge sounds), unusual odors, and hot spots.

Observe whether instrument readings are normal and indicator lights are functioning properly.

Check the cabinet for condensation, corrosion, and dust accumulation.

 

Environmental Control:

Maintain good ventilation and dryness in the power distribution room, keeping the temperature below 40℃ and relative humidity ≤80%.

Install air conditioners, dehumidifiers, or heaters to prevent condensation that can lead to insulation degradation or corrosion.

Prevent corrosive gases and dust from entering; use sealed designs or protective filters when necessary.

 

Load Management:

Avoid prolonged overload operation; regularly use an infrared thermal imager to check the temperature of connectors, busbars, and other components.

Balance the three-phase load to prevent unbalanced loads from causing localized overheating.

 

II. Regular Maintenance and Servicing

Power Outage Inspection (at least once a year):

Clean insulating components: Use a vacuum cleaner and soft cloth to remove dust; stubborn stains can be wiped with anhydrous ethanol.

Tighten connection points: Use a torque wrench to tighten busbars and cable connectors to prevent increased contact resistance and overheating.

Check mechanism operation: Operate the circuit breaker and disconnect switch multiple times to ensure smooth opening and closing, and lubricate the transmission mechanism (using special lubricating grease).

Verify protection devices: Test the settings and operating logic of relay protection and integrated protection devices to ensure reliability.

 

Maintenance of key components:

Circuit breaker: Check contact wear and arc chamber condition according to the instruction manual, and replace worn parts.

Contactor/Relay: Check for contact burning and ensure good coil insulation.

Insulating components: Check for cracks and tracking marks on post insulators, bushings, etc., and measure insulation resistance if necessary.

 

III. Technological Transformation and Upgrading

Updating Obsolete Components:

Replacing outdated or underperforming components (such as old relays and electromagnetic mechanisms).

Upgrading to intelligent circuit breakers and digital protection devices to improve reliability and support condition monitoring.

 

Enhancing Protection Capabilities:

Installing anti-condensation devices (such as temperature and humidity controllers + heaters).

Applying anti-corrosion treatment to cabinets in humid environments (e.g., applying protective coatings).

 

Intelligent Transformation:

Installing online monitoring systems to monitor parameters such as temperature, current, and partial discharge in real time, enabling predictive maintenance.

 

IV. Standardized Operation and Training

Strictly adhere to operating procedures:

Do not operate disconnect switches under load.

Strictly follow the "tagging and locking" procedure during power outage maintenance.

Personnel Training:

Provide regular training for operation and maintenance personnel to improve their fault identification and troubleshooting capabilities.

 

V. Full Lifecycle Management

Establish records: Document the switchgear's factory specifications, maintenance records, and fault handling information.

Condition Assessment: Conduct comprehensive assessments of equipment that has been in operation for more than 10 years and develop plans for replacement or major overhaul.

 

Common problems and targeted solutions

Problem Description	Possible causes	Measures to extend lifespan
Cabinet corrosion	Humid environment, corrosive gases	Improve ventilation, install dehumidifiers, and apply anti-corrosion coatings.
Overheating of connectors	Loosening, oxidation	Regularly tighten fasteners, apply conductive paste, and perform infrared temperature measurements.
Reduced insulation	Dust accumulation, condensation	Regularly clean and reinforce moisture-proof sealing.
Mechanism jamming	Dry lubricant, component wear	Regularly lubricate and replace worn parts.

 

Summary

 

The key to extending the service life of switchgear is "prevention first, maintenance second." Through a good operating environment, standardized inspection and maintenance, and timely technical upgrades, the service life of switchgear can typically be extended from the designed 10-15 years to over 20 years, while significantly reducing the failure rate.In short, proper daily maintenance and inspection of high and low voltage switchgear are essential to ensure its normal operation and even extend its service life.

Shaanxi Huadian offers a range of low and high-voltage switchgear solutions, from standardized designs to applications in special environments. We provide flexible configurations to precisely match your project requirements. We strictly adhere to national standards and international electrical codes, using core components from renowned domestic and international brands, and maintaining meticulous attention to detail throughout the manufacturing process. We have established a service system covering the entire project lifecycle, with 24/7 technical support. Please contact us if you are interested：pannie@hdswitchgear.com.