Retrofitting vs. Replacing Ageing LV Switchgear: A Guide for UK Plant Managers
In the fast-paced world of UK manufacturing and infrastructure, the heartbeat of any facility is its electrical distribution system. However, for many plant managers across the country, the equipment currently in service is reaching a critical milestone.
As systems age, the question of whether to invest in a complete overhaul or breathe new life into existing frames arises. At A&T Enclosures, we have spent more than 30 years helping engineers navigate these complex decisions and understand that the decision between retrofitting or replacing low voltage switchgear is not merely a financial calculation; it is a balance of safety, future capacity planning, and operational continuity.
So, here’s what you need to know to make an informed decision.
Assess the Health of Your Legacy Systems
The first step in any decision is a thorough audit of your current assets.
Many legacy boards in UK plants are built like tanks, featuring robust copper busbars that remain in excellent condition even after decades of use. However, the moving parts, such as the circuit breakers, contactors, and protection relays, often tell a different story.
When we consult with facility managers, we look for red flag indicators. The most common ones are a lack of spare parts for obsolete breakers, excessive heat signatures during thermal imaging, or a failure to meet modern arc-flash safety protocols.
If the core structure is sound, a retrofit may be the most sustainable path forward.
The Case for Retrofitting: Speed and Sustainability
Retrofitting involves replacing outdated internal components with modern, high-performance equivalents while keeping the original busbars and housing intact. This approach is often favoured in sectors such as water treatment or food production, where downtime must be kept to a minimum.
By retrofitting, you can integrate the latest digital monitoring and energy-saving technologies without extensive civil works or cable rerouting. It is a cost-effective way to extend the life of your assets by another 10 to 15 years. Furthermore, it is a greener choice, reducing the carbon footprint associated with manufacturing and transporting entirely new steel structures.
When Is a Full Replacement Non-Negotiable?
Despite the benefits of retrofitting, there are times when a full replacement is the only responsible choice. If your facility has expanded and the current fault rating of your board is no longer sufficient to handle the increased load, a retrofit cannot address the underlying physics.
A new installation allows you to take advantage of the latest engineering breakthroughs in footprint optimisation and environmental protection. For instance, if your plant environment has become harsher over time due to new chemical processes or increased moisture, upgrading to modern IP rated electrical enclosures in the UK ensures that your sensitive electronics are protected against ingress in a way that older cabinets simply cannot match.
Furthermore, a full replacement ensures that your entire assembly is verified to the latest BS EN 61439 standards from the ground up. This provides a level of legal and operational zero-risk that is highly valued in high-stakes industries like rail and power distribution.
Making the Right Choice for Your Facility
Ultimately, the choice depends on your long-term goals. If you need a quick safety upgrade with minimal disruption, a retrofit is a powerful tool. However, if you are looking to future-proof your site for the next 25 years with integrated smart-grid technology, a new low voltage switchgear installation is a superior investment.
Are you still confused? Do you need expert help to navigate this important decision? Contact A&T without hesitation.