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Retrofit vs Full Switchgear Replacement Retrofit vs Maintain existing breakers
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Country/territory
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Industry Segment
Number of Switchgear panels
70
Voltage system
Civil works -types of installation
Tooltip
  • Easy : Assuming a straightforward installation with minimal site preparation, easy access, and no significant obstacles.
  • Medium : Assuming moderate site preparation, some access challenges, and the need for additional support structures or minor modifications
  • Hard : Assuming extensive site preparation, significant access challenges, major modifications, and possibly dealing with existing infrastructure.
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Medium
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Savings Outcome
Total saving
Tooltip
Total saving is an average estimate based on full turnkey project costs, excluding typical unexpected cost of switchgear replacement (e.g MV cables..)
Savings compared to the full switchgear
Capex saving
Tooltip
In addition to the total CAPEX savings from the retrofit, retrofitting allows capital expenditure to be distributed over multiple years according to budget availability — unlike full replacement, which requires a one-time upfront investment.

Equipment costs saving
Tooltip
It's considered only the materials cost saving

Installation & commissioning and civil works
Tooltip
Retrofit can be installed and commissioned within an hour, minimizing shutdown time. It requires no civil works or MV/LV recabling — unlike full switchgear replacement, which involves extended downtime and might impacts plant production planning.

Dismantling and materials disposal
Tooltip
Dismantling a full panel involves 600–800 kg more material than just a circuit breaker, with higher costs and environmental impact. Durable raw materials like copper and steel often have much longer service life. ABB also supports proper end-of-life handling for old equipment.
Environmental saving
Tooltip
Retrofit is a low environmental impact modernization solution compared to full switchgear replacement. This is supported by EPDs published for key products and retrofit solutions. Contact ABB for more details.
Saving of raw materials (kg)
Tooltip
Retrofit preserves the switchgear frame — mainly copper and steel — which has a long service life. Full replacement would dispose of these high carbon footprint materials prematurely. ABB also supports proper end-of-life handling.

kg CO2eq.
Tooltip
The amount of CO₂eq represents the total climate impact of a product in its life-time, expressed as an equivalent amount of CO₂. The data shown is calculated using Type III EPDs (Environmental Product Declarations), certified and published by ABB for its products.
~ km driven with a small petrol
Tooltip
The value is calculated consider the following conversion factors Greenhouse gas reporting: conversion factors 2024 - GOV.UK

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Disclaimer: The calculator only provides an estimate and is provided for illustrative purposes only
Tooltip
The calculator does not necessarily reflect all potential variables and site information needed to assess the change and savings related to the service of the switchgears. Calculations are provided on an "as is" basis and ABB makes no representation, guarantee or warranty, expressed or implied, as to the accuracy, correctness or completeness of the calculations, ABB is not liable for any losses or damages, error or omissions (including losses or damages, error or omissions by third parties) arising from any use of this calculator and/or reliance on the calculations provided, information or content on this website, including but not limited to any direct, indirect, incidental, exemplary, punitive, special or consequential.
Input Input
Results Results
Enter the details
Country/territory
Currency
Industry Segment
Number of panels
70
Voltage system
Hourly cost of unplanned shutdown ()
Tooltip
Unplanned shutdowns due to failure can lead to major economic loss, reputational damage, and safety risks. While MV and LV breaker failure rates are typically low, the risk increases significantly after 15–20 years in service — peaking around 40 years — especially without proper maintenance or in non-standard environmental conditions.

Please enter Hourly cost of unplanned shutdown

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Time to restore the power after a shutdown (hours)
Tooltip
This is the typical time required to restore power after a failure. Having recommended spare parts available can significantly reduce recovery time.
4
Switchgears average ages
20
Spare parts availability
Tooltip
Contact ABB to assess the recommended spare parts to keep on hand, helping reduce downtime and speed up recovery in case of failure.
Maintenance strategy
Tooltip
More details on proper maintenance procedures can be found in ABB’s SWAPs tool https://new.abb.com/medium-voltage/service/maintenance/swaps
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Savings outcome
Opex saving
Tooltip
The calculation considers savings in maintenance costs, reduced repair needs, shorter maintenance time, and the risk of unplanned shutdowns. This risk is multiplied by the expected restoration time and the likelihood of failure occurring.

Operational saving per year
ROI = years

Return of investment (ROI) Retrofit
Tooltip
The Return of Investment in years
Reduction of risk of unplanned shutdown
Tooltip
This is a statistical calculation based on ABB data and international publications. It's also important to assess the potential consequences for operators and the economic impact. This provides an initial evaluation to determine whether the risk is
tolerable or if corrective actions are needed. Further risk reduction can be achieved by adding ABB monitoring and diagnostic solutions.
Probability of failure of existing system:
Tooltip
  • Very Unlikely= Very unlikely, but within technical possibility in the next 30 years
  • Rare= Rare, but possible within next 20 years
  • Low Frequency = Possible once within next 10-15 years
  • Likely = May occur in the next 5 years
  • Very Frequent/Critical = Expected within 1–3 years
Very Unlikely Rare Low Frequency Likely Very Frequent
Probability of failure adopting retrofit:
Tooltip
To further reduce the risk of failure, please contact ABB for monitoring and diagnostics options. To eliminate any risk for the operator, ask about the availability of remote operation solutions
Very Unlikely Rare Low Frequency Likely Very Frequent

Do you have questions or would like to discuss the results with us?

Would you like a copy of the results to share by email?

Disclaimer: The calculator only provides an estimate and is provided for illustrative purposes only
Tooltip
The calculator does not necessarily reflect all potential variables and site information needed to assess the change and savings related to the service of the switchgears. Calculations are provided on an "as is" basis and ABB makes no representation, guarantee or warranty, expressed or implied, as to the accuracy, correctness or completeness of the calculations, ABB is not liable for any losses or damages, error or omissions (including losses or damages, error or omissions by third parties) arising from any use of this calculator and/or reliance on the calculations provided, information or content on this website, including but not limited to any direct, indirect, incidental, exemplary, punitive, special or consequential.
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