Modernization of 2.4kV to 38kV Electrical Distribution Switchgear lineups:
Functional Separation and Remote Command as the Future Standard
1. Current Installation Conditions
Existing power cables: Power conductors are already installed and operational, although originally designed under outdated standards.
Defined switchgear and control panel locations: Physical spaces for equipment placement are fixed and cannot be expanded.
Limited physical space: New installations must strictly adapt to the available space without structural modifications.
2. New Installation Requirements
Arc flash hazards: Modern installations must minimize arc flash risks, ensuring operator and equipment safety.
Updated technical standards: Current regulations (IEEE, ANSI, NFPA, IEC) require higher safety levels, functional separation, smart monitoring, and remote operation capabilities.
New protection philosophies: Clear functional separation must be established between:
– Protection: Independent, high-speed protection relays.
– Switching: Medium-voltage switchgear dedicated to electrical isolation and energy flow management.
– Control and monitoring: Remote control panels, separated a safe distance from power sections.
Advances in communication technologies: Implementation of industrial Ethernet, IEC 61850 protocols, and redundant network architectures is often needed.
Advances in electrical measurement: Precision metering of voltage, current, active/reactive power, and power quality indicators must be integrated.
3. Equipment Replacement Strategy
Minimal downtime: Replacement activities must be completed in the shortest time possible to minimize operational disruptions.
Maximized reuse of existing infrastructure: Reuse of existing cables, ducts, and panel locations is preferred when technically and safely viable.
Extended service life: New equipment must guarantee long-term operational reliability, maintainability, and changing technology.
Personnel safety priority: Systems must protect operators and energy users, with integrated fault detection, arc flash mitigation, and remote command features.
Investment optimization: Capital expenditure and downtime costs must be minimized through efficient project execution.
Additionally, remote command systems must incorporate cybersecurity measures to protect critical infrastructure, ensuring compliance with standards such as IEC 62443 and NERC CIP. Network redundancy, secure authentication protocols, and intrusion detection systems must be implemented to guarantee continuous operation and protect against emerging digital threats.
4. Conclusion
Considering technical, physical, and economic constraints, the future of 2.4kV to 38kV electrical distribution lineups is clear:
Safe and efficient operation can only be achieved through full functional separation of protection, switching, and control, combined with complete remote operation capability.
Modern electrical distribution systems must incorporate:
– Metal Clad switchgear with remote operation capability.
– Independent, configurable relay panels with self-supervision features.
– Low-voltage control panels installed in secure, accessible areas.
Modern switchgear designs must also be flexible enough to integrate distributed energy resources (DER) such as solar, energy storage systems, and microgrids, enhancing the overall resilience and sustainability of electrical networks.
This new architecture reduces risks, ensures compliance with current standards, extends the system’s useful life by allowing for eventual expansion to include new services or protection or control requirements that would be developed in spaces separate from the power systems, and creates a resilient and sustainable operating model for decades to come.
