Switchgear is an important element in the power distribution of electrical systems. It has multiple applicability and can be found in industrial facilities, commercial properties, civil infrastructure, or residential areas. It can control, protect, and isolate electrical equipment, especially during electrical faults such as overloads and short circuits, to ensure that the systems can run safely and reliably.
However, when mistakes are made during the design, selection, panel manufacturing, installation, maintenance, or operation phases, the consequences can be significant, leading to equipment damage, fire hazards, or even loss of life.
To help you keep your systems safe and efficient, we've outlined some of the most common switchgear mistakes and offered clear, actionable strategies to prevent them.
1. Overloading the System
Mistake: Overloading of switchgear can affect the inherent safety of the entire power network. Exceeding load capacity may lead to overheating and equipment malfunction.
How to Avoid It:
● Calculate actual loads accurately before design and installation.
● Include buffer capacity for future expansion.
● Use load-monitoring devices to detect early signs of stress.
2. Not Considering Environmental Conditions
Mistake: Engineering switchgear without factoring in the specific environmental stresses it will face, such as temperature extremes, humidity, salinity, or airborne contaminants, can lead to early degradation or failure.
How to Avoid It:
● Conduct a thorough site environment analysis during the design phase.
● Select materials and components (e.g., corrosion-resistant metals, tropicalised control circuits) suited for the local environment.
● Design enclosures and ventilation systems that preemptively address likely stressors like heat, dust, or moisture.
3. Using Incorrect Spare Parts
Mistake: Replacing components with unauthorised or incompatible parts may affect the system's performance and safety.
How to Avoid It:
● Only use replacement parts that are identical to the ones originally specified for the system.
● Work with trusted suppliers and avoid low-quality aftermarket alternatives.
● Maintain an inventory of critical spare parts for emergencies.
4. Outdated Equipment Still in Use
Mistake: Holding on to ageing switchgear no longer meets modern safety standards is a gamble with serious risks.
How to Avoid It:
● Conduct routine audits of switchgear systems.
● Replace or upgrade equipment that shows signs of wear or is no longer compliant.
● Consider the life cycle cost over upfront savings when planning upgrades.
5. Poor Grounding Practices
Mistake: Improper or absent grounding can result in fault currents that may affect equipment performance and system integrity.
How to Avoid It:
● Follow national standards and local regulations for grounding.
● Test grounding systems regularly.
● Make sure to work with tools and materials suited to the exact requirements of the system in use.
6. Lack of Proper Documentation
Mistake: In many facilities, especially older ones, documentation is either missing or outdated. This causes confusion during fault-finding or upgrades.
How to Avoid It:
● Maintain updated single-line diagrams and panel schedules.
● Document all modifications and repairs.
● Store documents in both digital and physical formats.
7. Poor Ventilation
Mistake: Switchgear generates heat during operation. Without proper ventilation, that heat builds up, leading to insulation degradation and component failure.
How to Avoid It:
● Install switchgear in well-ventilated environments.
● Use fans, louvres, or HVAC systems if necessary.
● Make it a habit to clean vents and air passages often so the air can move freely.
8. Skipping Pre-Commissioning Checks
Mistake: Rushing to initiate switchgear systems without pre-commissioning checks may lead to failures that could have been easily prevented.
How to Avoid It:
● Before putting the system into service, conduct insulation checks, measure the contact resistance, and test relays to make sure everything is working properly.
● Verify all connections, labels, and settings.
● Have a qualified engineer sign off before activating the system.
9. Inadequate Maintenance
Mistake: Components of switchgear are vulnerable to ageing and wear-out effects during their operational life. In addition, inadequate maintenance leads to overheating, arc faults, and ultimate breakdowns of the system.
How to Avoid It:
● Establish a routine maintenance schedule.
● Check the insulation condition, secure any loose connections, and routinely test the protective relays.
● Keep a record of all maintenance activities.
10. Failure to De-Energise Before Maintenance
Mistake: Performing maintenance while the switchgear is still energised is extremely hazardous and can lead to serious injury or death.
How to Avoid It:
● Always shut off power and lockout/tagout before servicing.
● Verify zero energy state using proper testing tools.
● Train personnel in safety procedures and risk assessments.
11. Inadequate Training of Staff
Mistake: Even with the best equipment, untrained or under-trained staff can make errors that put both personnel and infrastructure at risk.
How to Avoid It:
● Set up regular sessions to teach staff the correct and safe ways to operate and maintain equipment.
● Make sure employees handling high-voltage systems have the necessary certifications.
● Conduct refresher courses and safety drills.
● Emphasise the importance of switchgear training during onboarding and throughout an employee's tenure.
12. Neglecting Arc Flash Risk Assessments
Mistake: Failing to conduct arc flash analysis can leave staff unprotected during faults, risking severe injury.
How to Avoid It:
● Perform arc flash studies during design and update them regularly.
● Clearly label switchgear with arc flash boundaries.
● Equip personnel with arc-rated PPE and training.
13. Not Conducting Post-Incident Reviews
Mistake: When an incident occurs, many organisations address only the surface issue and fail to investigate the root cause. This can result in repeated mistakes and additional risks.
How to Avoid It:
● Perform a thorough root cause analysis after every incident.
● Use findings to update safety protocols and training content.
● Communicate learning across teams to prevent future occurrences.
14. Ignoring Manufacturer Guidelines
Mistake: One of the most frequent and often overlooked errors is neglecting to follow the manufacturer's instructions. Skipping installation, switchgear training, operating procedures, or regular maintenance guidelines can put the whole system at risk.
How to Avoid It:
● Be sure to carefully go through the instructions manual before starting the installation.
● Train the technicians thoroughly to meet equipment-specific requirements.
● Keep documentation accessible for future reference.
Avoiding these common mistakes isn't just about protecting your equipment; it's about safeguarding people, minimising downtime, and maintaining uninterrupted operations. Achieving a resilient switchgear system starts with thoughtful design, expert training, and regular maintenance.
At Lauritz Knudsen Electrical & Automation, our low-voltage switchgear solutions are engineered to meet the highest standards of safety, efficiency, and durability. Designed for optimal performance in low-voltage distribution, our range includes ACBs, MCBs, MCCBs, among others — all built to eliminate risks like overloads, short circuits, and premature failures. Whether you need technical guidance, professional training, or a fully integrated switchgear solution, we're here to strengthen industrial operations and ensure safety at every step.
Get in touch today to build a switchgear system that performs without compromise!
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