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Explore Switchgear & the Value of A Custom Switchgear Manufacturer

Definition & Overview

All electrical systems require a power source (or sources) and electro-power conversion/utilization. Between these two, electrical power distribution is required in a safe and efficient manner. Electrical switchgear is an essential element of this distribution. Modern metal-clad switchgear has evolved with available new technologies, but many characteristics remain consistent. The following is a summary of industry common applications and an attempt to explain what is included in the solutions.

Here is a short table of contents to jump to exactly what you’re looking for:

  1. Switchgear Overview
  2. Historical Evolution of Switchgear
  3. The Function of Switchgear
  4. Switchgear Recap
  5. Spike Electric Switchgear Solutions


Switchgear Solutions: Empowering Electrical Safety and Efficiency

Components of Switchgear

As stated in the opening paragraph, modern electrical power utilization systems are designed to distribute energy to smaller utilization loads with a centralized power supply (normally at distribution level voltages of 9kV or higher) of adequate capacity to power the total need. A user of that power, often, is tasked with safely distributing this power once the service entrance from a utility is established. The most common method of creating such a interconnect point is a metal enclosed, industrially fabricated enclosure that includes at minimum, the following:

  • Conductors – commonly three phase conductors and possibly a neutral depending on the power system configuration. Conductors serve as the “roadway” for the flow of large levels of electrical current.
  • Electrical insulators/insulation – anything that constitutes a separation of the electrical conductors from anything that is not at the same voltage potential as the conductors. Insulation is effectively the “guardrails” to the conductors.
  • Circuit isolators – mechanical devices that allow the electrical power to be isolated from the source effectively stopping the flow of electrical power.

Inside the Housing of Electrical Switchgear like that which Spike Electric Controls produces.

Often included in switchgear, are components that allow unsupervised and automated protection from failures in the electrical distribution system such as:

  • Instrument transformers – electrical power sensing devices that reduce utilization levels of voltage and current to safely monitored thresholds, normally 120VAC and 5A signals that are interpreted by relays and meters to indicate the state of the utilization power.
  • Circuit protectors – additional power sensing devices that may or may not, work with the instrument transformers to prevent the electrical distribution system from damage to the system insulation (short-circuit (phase to phase) or phase to ground). Examples are circuit breakers, current interrupting fuses, and load-break switches (manual and electrically operated).
  • Protective relays – devices that interpret the power system operation (often utilizing the outputs of the instrument transformers) and based on those inputs, output signals to alarm personnel or operate the circuit isolators to safely isolate faults or overloads.
  • Metering – allows for monitoring the power system operation.
    Control power transformer(s) – allow for an efficient means of providing electrical power to the devices that are associated with the operation of the switchgear components.
  • Power transformers – unit substations, typically dry-type fan cooled.
    The benefit of using switchgear as the repository of many of these components is the efficiency of manufacture and installation, protection against external influences that can harm electrical distribution systems, and protection of personnel and property from the inherent hazards of high voltage power with respect to physical damage during faults.

Enclosure Integrity and Composition

Switchgear enclosure designs can be provided with variable degrees of protection against intrusion of outside contaminants and thus, can be provided for outdoor or indoor applications. All switchgear must allow for the entry and exit of power conductors as well as any external communications or control circuit conductors. Internal designs can serve to maximize the flexibility of end users for the routing of these external systems with respect to required cooling clearances and working space while maintaining enclosure integrity. Switchgear enclosures can be connected (close-coupled) to transformer enclosures, motor control centers (MCC), large motor control (variable speed drives or soft starter) cabinets, and panel boards. Exterior surfaces can be powder coat painted steel, stainless steel, or aluminum. Structural rigidity can be varied with the gauge or thickness of the material and the fastening means of the supports and sheathing. While enclosure integrity has an inherent protection element, this can be enhanced by achieving design classification of being arc-resistant meaning that any arc explosion created within the containment of the switchgear will be prevented from escaping the enclosure and harming personnel or other equipment.

Electrical Rating: Voltage

The electrical service readiness of switchgear is defined by the design application rating with respect to the operating voltage and maximum continuous current that needs to be distributed (frequency rating is also a determinant but mainly secondary regarding application). The voltage rating of switchgear determines the required dielectric properties of the non-conductive elements of the design that can be efficiently manufactured for the intended use to minimize cost and complexity. For instance, low voltage power systems (less than 690VAC) use smaller insulation mediums than those classified as medium voltage (690VAC up to 70kV). These design variations result in the voltage classification of the switchgear powerline. Industry standard levels for switchgear in North America are typically identified as 480V or 600V for low voltage and 5kV, 15kV, 25kV, and 38kV for medium voltage designs when oxidizing (naturally occurring) air is the primary insulating medium. With air insulation, phase to phase, and phase to ground separation distances are the primary determination of the insulation classification. It should be noted that the voltage rating (referred to as the Power Frequency Withstand Rating) of the switchgear design often differs from the operating voltage of the user. The rated voltage of the switchgear must always exceed the intended operating voltage for which it is applied to ensure reliable operation and the prevention of flashover phase or ground faults. For instance, if the operating voltage is 12.47kV, the switchgear rating will be 15kV. Additionally, switchgear designs will incorporate a Basic Impulse Level or BIL rating, that describes the insulation level viability to withstand overvoltage conditions associated with lightning strikes.

Electrical Rating: Current

The electrical service readiness of switchgear is defined by the design application rating with respect to the operating voltage and maximum continuous current Like the voltage rating of a switchgear design, the current rating of the conductors should be optimized to limit cost and physical size of the system. The current carrying conductors in any electrical power distribution are subject to the laws of physics and thermodynamics. The ampere rating of a switchgear design is determined by the allowable heat-rise of the conductor and the mechanical stresses exhibited between the conductors during normal and faulted conditions. The continuous current rating is the maximum allowable heat level that will not cause the conductors (or insulation) of the system to be damaged with respect to their mechanical (or dielectric) strength. The same conductors, through sizing, spacing, and bracing, must exhibit sufficient mechanical strength to withstand fault currents that can exceed ten times the continuous current capability of the design. This constitutes what is known as the maximum allowable short circuit rating of the switchgear system. Both current ratings are influenced by the power delivery application that is required for end use. Consequently, current ratings are largely driven by the cost and technical limitations of maximizing the application operating voltage level. Current rating requirements can be minimized by using the higher system voltage rating.

Manufacturing Standardization

The mechanical and electrical rating thresholds are determined by standards that are developed by industry users and manufacturers to ensure confidence in performance and safety. In North America, in accordance with OSHA and NFPA regulations, ANSI/IEEE standards, consolidated in articles C37.20, specify the quality assurance and application appropriateness of mass-produced switchgear and switchgear components. IEC standards cover switchgear industries globally and many of the two governing standards have been harmonized. OSHA qualifies National Regulatory Testing Laboratories, NRTL’s such as UL, to ensure compliance from users and providers. Federal, state, and local municipalities then ensure end-users utilize qualified products. While allowing manufacture standardization in components and assembly, these standards are designed to enhance user confidence that compliant designs are reliable and thus, if applied correctly, perform to limit damage to personnel and property.

Electrical Switchgear like that which Spike Electric Controls produces.

Switchgear can be described as any free-standing enclosure that serves as an enclosed distribution system of electrical power. Designs are often a compromise of minimizing cost and complexities of that process to provide an essential solution for harnessing electrical energy and safely converting it to another process such as mechanical or thermal. When applied appropriately, switchgear is often a silent or invisible component of automated systems that function as intended and serve as a silent sentinel to protect personnel and property from harm.

Importance in Power Systems

Switchgear’s importance in electrical infrastructures cannot be overstated. It offers protection against potential hazards such as power surges and electrical overloads, which are critical in both commercial and industrial settings. Reliable and uninterrupted power is a necessity in today’s world, and Switchgear plays a central role in achieving this. While Switchgear may operate silently behind the scenes, its contribution to the smooth functioning of power systems is undeniable. It is a crucial component, ensuring the safety and reliability of electrical networks.

A Shield Against Electrical Threats

  • Protecting Against Power Surges and Overloads: Switchgear’s robust design can withstand immense power surges and unexpected overloads, diverting the surge and effectively isolating the affected area, preventing widespread damage and potential outages.
  • Safeguarding Critical Electrical Equipment: Switchgear safeguards expensive electrical equipment, such as transformers, motors, and generators, from damage caused by power surges, short circuits, and other electrical faults. This protection extends the lifespan of these assets and reduces the need for costly repairs or replacements.
  • Preventing Electrical Arc Faults: Switchgear’s arc-resistant design minimizes the risk of electrical arc faults, potentially catastrophic events that can cause severe injuries, property damage, and widespread outages.
  • Enhancing Personnel Safety: Switchgear’s protective features, such as grounding, compartmentalization, and interlocking mechanisms, safeguard personnel from electrical hazards, preventing injuries and ensuring a safe working environment.

The Cornerstone of Modern Power Infrastructure

  • Enabling Efficient Power Distribution: Switchgear forms the backbone of modern power infrastructure, enabling efficient power distribution and control. Its presence allows for the precise regulation of voltage and current, ensuring that power reaches its intended destination with minimal loss.
  • Ensuring Uninterrupted Power Supply: Switchgear plays a pivotal role in ensuring reliable and uninterrupted power supply, a necessity for businesses, industries, and critical infrastructure facilities. By preventing disruptions, Switchgear safeguards operations and minimizes downtime.
  • Facilitating System Maintenance: Switchgear’s isolation capabilities allow for safe and efficient maintenance of electrical systems, reducing the risk of accidents and ensuring optimal performance.
  • Enhancing System Reliability: Switchgear’s ability to isolate and protect faulty sections of the electrical system prevents widespread outages and ensures that power continues to flow to critical areas. This uninterrupted operation minimizes downtime and maintains business continuity.

Historical Evolution of Switchgear

The evolution of Switchgear reflects the advancements in electrical technology. From the early days of simple designs to today’s sophisticated, digitally integrated systems, Switchgear has seen a remarkable transformation. This evolution mirrors the increasing demands and complexities of electrical distribution in various sectors, highlighting the need for more advanced and reliable power management solutions.

Early History

  • Late 19th Century: With the advent of commercial electrical power systems, devices to control and protect these systems became necessary. Early forms of Switchgear were simple knife switches mounted on insulating panels of marble or asbestos.
  • Early 20th Century: Oil-filled Switchgear appeared. These used oil as an arc-quenching medium and were more reliable than earlier air-insulated switches.

Key Developments and Companies

  • 1920s-1930s: The development of metal-enclosed Switchgear. Companies like Westinghouse and General Electric in the United States were instrumental in advancing the technology of Switchgear.
  • 1950s: The introduction of vacuum and SF6 (sulfur hexafluoride) as arc extinguishing media marked significant advancements. SF6 is still widely used today due to its effectiveness and relative environmental safety compared to earlier oil-based systems.
  • 1960s-1970s: The emergence of Gas Insulated Switchgear (GIS). European companies, including ABB and Siemens, played a significant role in developing GIS technology. GIS was advantageous in terms of space-saving and reliability, especially for high-voltage applications.
  • 1980s-1990s: The advent of digital and microprocessor-based control systems revolutionized Switchgear. This era saw the integration of advanced protection, control, and monitoring technologies.
  • 2000s-Present: The focus has shifted to sustainability, with developments in eco-friendly Switchgear using alternatives to SF6 gas, which is a potent greenhouse gas. Companies like Schneider Electric, ABB, and Eaton have been involved in these developments.

Modern Evolution

  • Smart Switchgear: Integration with smart grid technology, offering advanced features like remote monitoring and control.
  • Modular and Compact Designs: Emphasis on space-saving and flexible designs for modern electrical infrastructure needs.
  • Eco-Friendly Innovations: Efforts to find sustainable alternatives to SF6 gas and other environmentally harmful components.

Global Influence

The development and evolution of Switchgear have been a global effort, with significant contributions from companies and researchers in the United States, Europe, and Asia. Each region has contributed to both technological advancements and the adoption of international standards, shaping the Switchgear we know today.

Here is a break down of the timelines through history of the evolution of Switchgear:

Early History of Switchgear

Event Year
Benjamin Franklin experiments with electrical conductors and insulation materials Late 18th century
Humphry Davy develops the first arc lamp Early 19th century
Development of the first Switchgear devices, which were simple switches and fuses Early 19th century

Early 20th Century Advancements

Event Year
Hugh Cooper develops the first oil circuit breaker 1903
Development of more sophisticated Switchgear, including metal-clad Switchgear and air-blast circuit breakers Early 20th century

Late 20th Century and Beyond

Event Year
Switchgear technology continues to evolve, driven by the increasing complexity of electrical systems and the demand for greater safety and reliability Late 20th century and beyond
Modern Switchgear incorporates advanced technologies such as digital control systems, microprocessor-based relays, and fiber optic communication Late 20th century and beyond

Timeline of Companies that Revolutionized Switchgear




Westinghouse Electric & Manufacturing Company


Develops the first commercial alternating current (AC) Switchgear.

Hugh Cooper


Develops the first oil circuit breaker.

General Electric (GE)


Introduces the first metal-clad Switchgear.



Develops the first air-blast circuit breaker.

Brown Boveri & Cie (BBC)


Develops the first vacuum circuit breaker.



Introduces the first gas-insulated Switchgear (GIS).

Westinghouse Electric


Develops the first microprocessor-based relays.

ABB (Asea Brown Boveri)


Introduces the first fiber optic communication systems for Switchgear.

GE and Siemens


Develop advanced digital control systems for Switchgear.


The Function of Switchgear 

Imagine your facilities electrical system is like a busy city road network, with electricity traveling like cars on roads to different rooms and devices. Now, think of Switchgear as the traffic control system for this network. It’s like a powerful police officer who can direct traffic, block roads during an accident, or open new routes when needed. This “officer” ensures that electricity flows smoothly to where it’s needed, and more importantly, jumps into action to prevent accidents, like electrical overloads or short circuits.

In simpler terms, Switchgear is a key component in electrical systems that controls, protects, and regulates the flow of electricity. Here’s how it works and why it’s helpful:

  1. Traffic Director (Control): Switchgear directs the flow of electricity, turning it on or off as needed. Just like traffic lights control the flow of cars, Switchgear can switch power to different parts of a building or system.
  2. Accident Preventer (Protection): If there’s an “accident” like an electrical fault (a sudden, unexpected surge of electricity), Switchgear acts like an emergency responder. It quickly cuts off the power in that “road” or circuit to prevent damage to the electrical network and keep everyone safe.
  3. Efficiency Monitor (Regulation): Switchgear also keeps an eye on how much electricity is flowing and where. It’s like a traffic manager ensuring that no road (or circuit) is overloaded and that everything runs smoothly and efficiently.
  4. Adaptable and Responsive: Modern Switchgear can be very sophisticated, capable of not just reacting to problems but also anticipating and adjusting to changing electrical demands, just like a smart traffic system that adapts to changing road conditions.

In essence, Switchgear is the unsung hero in the background, ensuring that the electricity in our homes, offices, and factories is managed safely and efficiently. It’s like having a highly skilled traffic control team making sure that the complex network of electrical “roads” runs without a hitch, keeping the lights on and machines running while protecting us from potential electrical hazards.

Role in Managing Electrical Overload

Switchgear systems are specifically engineered to handle predetermined amounts of electricity. When the current exceeds these limits, the Switchgear acts as a safeguard, protecting the wiring and connected devices from overheating and potential damage. This protective mechanism is essential for preventing system failures and hazardous conditions like fires. The special designed circuit breakers within the system are there to turn on and off the flow of electricity when needed. 

Type of Breaker

Voltage Range

Switchgear Type


Protection Functions

IEEE Rating

Molded Case Circuit Breaker (MCCB)

Up to 600V


A compact circuit breaker commonly used in low-voltage applications.

Magnetic trip (LSI) for short circuits, thermal trip (LS) for overloads, ground fault protection (GFI), arc fault protection (AFCI).


Solid-State Circuit Breaker (SSCB)

Up to 600V


A technologically advanced circuit breaker utilizing electronics for sophisticated protection.

Microprocessor-based protection, communication capabilities, adjustable protection settings.


Vacuum Circuit Breaker (VCB)

4160V to 34.5kV


A high-voltage circuit breaker known for its compact size and excellent insulating properties.

Overcurrent relays, overvoltage relays, differential relays.


Gas-Insulated Switchgear (GIS)

4160V to 34.5kV


A high-voltage circuit breaker system utilizing SF6 gas as an insulating medium.

Digital protection relays, integrated protection schemes, fiber optic communication.


Note: Molded Case Breakers can be seen within the Switchgear Controls system, but SSCB breakers will be used as the feeders.

Protective Mechanism Against Voltage Surges

In scenarios of electrical surges, such as a lighting strike of fault within the system, Switchgear is designed to automatically interrupt the power flow. This protective action is crucial for preserving the integrity of the electrical infrastructure, ensuring its longevity and reliability. Some components within  the Switchgear system to help with these types of voltage surges.

Protective Mechanism


Surge Arresters

Divert high-voltage surges to ground, protecting sensitive equipment from damage.


Melt under excessive current conditions, interrupting the flow of power and protecting downstream equipment from damage.

Circuit Breakers

Detect a wider range of fault conditions, including overcurrents, short circuits, and ground faults, and can be reset after tripping.

Metal-Oxide Varistors (MOVs)

Exhibit non-linear resistance, allowing current to flow freely under normal conditions but diverting surge current to ground when subjected to a surge.

Spark Gaps

Conduct surge current to ground when a surge occurs, ionizing the air between two electrodes.

Transient Voltage Suppression (TVS) Diodes

Conduct current in both directions, allowing them to divert both positive and negative surges to ground.

Overvoltage Relays

Monitor the voltage level and trip the circuit breaker if it exceeds a predetermined threshold.

Directional Relays

Protect against ground faults and other fault conditions in specific directions within the electrical system.

Distance Relays

Measure the impedance between the relay and the fault location to determine the distance to the fault and trip the nearest circuit breaker.

Differential Relays

Compare the current entering and exiting a transformer or other equipment to detect internal faults and trip the circuit breaker.

Ground Fault Relays

Monitor the current flowing in the neutral conductor and trip the circuit breaker if the neutral current exceeds a predetermined threshold.

Arc Fault Detection and Protection (AFDP) Systems

Monitor the electrical waveform for patterns that are indicative of arcing faults and trip the circuit breaker.

Integrated Protection Systems

Incorporate multiple protection relays that work together to provide comprehensive protection.

Components of Switchgear

Switchgear is a critical component of the electrical power system, responsible for controlling, protecting, and isolating electrical circuits. It houses various devices that work together to ensure the safe and reliable distribution of electricity. Here’s a detailed breakdown of the key components of Switchgear:

  1. Switches

Switches are the fundamental elements of Switchgear, responsible for making and breaking electrical connections. They are mechanical devices that physically move to establish or interrupt the flow of current in a circuit. Switches come in various forms, including:

  • Isolator switches: These switches provide complete isolation of a circuit, ensuring that no current can flow through it during maintenance or repairs.
  • Disconnecting switches: Similar to isolator switches, disconnecting switches isolate a circuit but are designed for infrequent operation.
  • Load break switches: These switches are capable of breaking current while under load, making them suitable for switching energized circuits.
  1. Fuses

Fuses are safety devices that protect electrical circuits from overcurrent, a condition where excessive current flows through the circuit, potentially causing damage or fire. Fuses consist of a thin strand of conductive material, such as zinc or copper, that melts when subjected to excessive current, interrupting the circuit and preventing further damage.

  1. Isolators

Isolators are specialized switches that are specifically designed to ensure that a circuit is completely de-energized before maintenance or servicing can be performed. They provide a visible disconnect point, allowing technicians to verify that the circuit is dead before working on it. Isolators are typically rated for full load current and are capable of breaking the circuit under fault conditions.

  1. Relays

Relays are electrically operated switches that control high-power devices with a small input signal. They act as intermediaries between a low-power control circuit and a high-power circuit, allowing for precise control of electrical equipment. Relays operate based on various principles, including electromagnetic, solid-state, and microprocessor-based mechanisms.

  1. Circuit Breakers

Circuit breakers are automatically operated electrical switches designed to protect an electrical circuit from damage caused by excess current. They function similarly to fuses but offer more sophisticated protection and can be reset after tripping. Circuit breakers are designed to detect various fault conditions, including overcurrent, short circuits, and ground faults, and to quickly interrupt the circuit to prevent damage.

  1. Lightning Arresters

Lightning arresters, also known as surge arresters, are devices used to protect electrical systems from lightning damage. They provide a low-impedance path for high-voltage surges, such as those caused by lightning strikes, to safely dissipate to ground, safeguarding sensitive equipment from damage. Lightning arresters are typically installed at the entry points of electrical systems, such as power lines and transformers.

  1. Busbars

Busbars are the backbone of Switchgear, providing a conductive path for the distribution of electricity. They are typically made of copper or aluminum and are designed to withstand high currents and temperatures. Busbars are arranged in a variety of configurations to meet the specific requirements of the Switchgear.

  1. Specialty Designed Metal Enclosure

Switchgear enclosures are specially designed to withstand the harsh electrical environment and protect the internal components from external factors such as dust, moisture, and mechanical impact. The enclosure is typically made of metal, such as aluminum or stainless steel, and may incorporate features like ventilation, grounding, and fireproofing.

  1. Arc-Resistant Switchgear

Arc-resistant Switchgear is designed to minimize the effects of electrical arcs, which are high-energy discharges that can cause severe damage to equipment and pose a safety hazard. Arc-resistant Switchgear incorporates various features to contain and extinguish arcs, such as:

  • Arc chutes: These are specially designed channels that guide the arc away from sensitive components and towards grounding points.
  • Pellicles: These are thin, insulating barriers that help to break up the arc and prevent it from spreading.
  • Arc flash mitigation systems: These systems utilize sensors, detectors, and suppression devices to detect and suppress arc flashes, reducing the risk of injury and property damage.
  1. Instrument transformers

    These transformers convert high-voltage and high-current signals to lower levels for monitoring and control purposes.

  2. Control panels
    These panels house the control circuitry and instrumentation that allow for the operation and monitoring of the Switchgear.


  3. Communication systems
    These systems enable real-time data exchange between the Switchgear and other components of the power grid, facilitating remote monitoring and control.


  4. Protective relays
    Protection relays in switchgear systems are essential for monitoring electrical parameters like current and voltage to ensure safe operation. They detect faults such as overcurrent’s or short circuits by observing deviations from normal conditions. Upon detecting a fault, the relay evaluates whether to trigger a circuit breaker based on predefined settings. The primary action of a protection relay is to send a trip signal to a breaker, isolating the faulty section to prevent damage. Different types of relays, including overcurrent, differential, and earth fault relays, cater to specific protection needs. These relays are coordinated within the system to minimize disruption by only isolating the affected area. Modern digital relays offer advanced features like communication capabilities and self-diagnostics, enhancing the safety and efficiency of electrical power systems.

Protection Relays in Switchgear Systems:

Protection relays in a switchgear system play a crucial role in ensuring the safety and reliability of electrical power systems. Here’s a basic overview of how they work

Monitoring Electrical Parameters

  • Protection relays continuously monitor various electrical parameters such as current, voltage, frequency, and phase angle.
  • They are designed to detect abnormal or fault conditions like overcurrent, undercurrent, overvoltage, undervoltage, frequency deviations, and phase imbalances.

Detection of Faults

  • When a fault occurs (like a short circuit or an overload), the electrical parameters deviate from their normal operating ranges.
  • The relay detects these deviations. For example, an overcurrent relay will activate if the current exceeds a predefined threshold.

Decision Making

  • Once a fault is detected, the relay decides whether to initiate a trip command based on its settings and the nature of the fault.
  • Relays can be programmed with certain ‘set points’ or ‘tripping characteristics’ that determine their response to different conditions.

Initiating Action

  • If the relay determines that the fault is harmful or potentially damaging, it sends a trip signal to a circuit breaker.
  • This trip signal instructs the circuit breaker to open and isolate the faulty section of the network.

Types of Protection Relays

  • Overcurrent Relays: Respond to excessive current.
  • Differential Relays: Compare the difference in current between two points; commonly used in transformer protection.
  • Distance Relays: Measure the impedance to a fault and are typically used in transmission line protection.
  • Earth Fault Relays: Detect faults involving the earth.


  • Protection relays are coordinated in a system to ensure that only the nearest breaker to the fault opens, minimizing the disruption to the electrical network.
  • This coordination is achieved by setting time delays and sensitivity levels appropriately.

Advanced Features

  • Modern relays are digital and have advanced features like communication capabilities, self-diagnostics, and data logging.
  • They can be integrated into wider control systems for efficient monitoring and management.

Application in Switchgear

  • In switchgear, these relays are integral components that ensure the system operates safely and efficiently.
  • They protect equipment like transformers, generators, motors, and transmission lines from damage due to electrical faults.
  • The reliability of these relays is critical for the overall safety of the electrical power system.

Protection relays, therefore, are essential for detecting faults and preventing damage to electrical equipment, ensuring the stability and reliability of the power system.

Function and Importance of Each Component

Each component in a Switchgear system plays a critical role. For example, circuit breakers and fuses act as protective devices against overcurrent, preventing potential hazards. Isolators and relays facilitate the safe operation and control of electrical circuits, while lightning arresters protect the system from external electrical disturbances.

Classification of Switchgear by Voltage

Electrical Switchgear like that which Spike Electric Controls produces being Tested or Measured.

High-Voltage Switchgear (Above 38kV)

These are designed for managing high power levels and are typically used in substations and power transmission systems. They feature enhanced safety measures, given the high risks involved with handling such high voltages.

Medium-Voltage Switchgear (1KV to 38kV)

Commonly found in commercial buildings, industrial plants, and medium-sized power plants, medium-voltage Switchgear balances power handling with safety. They are crucial in applications like motor control centers, feeder circuits, and distribution transformers.

Low-Voltage Switchgear (Up to 1kV)

These are more common and used in smaller-scale applications, such as residential buildings and small commercial establishments. They play a key role in protecting and controlling lower voltage power systems.

Types of Insulating Media in Switchgear


Commonly used due to its cost-effectiveness but has a lower dielectric strength.

  • Pros: Cost-effective and readily available, non-toxic, environmentally friendly, no risk of leakage or contamination.
  • Cons: Low dielectric strength requires larger equipment, susceptible to environmental influences like humidity and temperature.

Fluid (including oil)

Offers better insulation and cooling, suitable for systems prone to overheating. Oil is known for its high dielectric strength.

  • Pros: Better insulating properties than air, cooling benefits, oil has high dielectric strength.
  • Cons: Potential environmental and health hazards in case of leaks, regular maintenance and leak monitoring needed.

Gas (e.g., Sulfur Hexafluoride)

Pressurized gasses like Sulfur Hexafluoride provide superior dielectric strength and are used in compact Switchgear designs.

  • Pros: Higher dielectric strength than air, non-flammable, chemically stable.
  • Cons: More expensive than air, special handling and safety precautions due to greenhouse gas potential.

Solid (e.g., resins)

Materials like resins offer excellent dielectric strength and are resistant to chemical and thermal deterioration.

  • Pros: High dielectric strength enables compact designs, resistant to deterioration, consistent performance over a wide temperature range.
  • Cons: More expensive, less flexible in application due to rigid nature.

Operational Mechanics of Switchgear

Electrical Switchgear like that which Spike Electric Controls produces with Danger High Voltage warnings.


Process of Interrupting Power Flow

Switchgear operates by detecting fault conditions, such as overcurrents or short circuits, and promptly interrupting the power flow. This interruption is crucial for preventing damage to the electrical system and ensuring safety.

Application in De-energizing Equipment for Maintenance

Beyond protection, Switchgear is vital for safely de-energizing equipment to allow for maintenance and fault clearing. This ensures that maintenance personnel can work safely without risks associated with live circuits.

Switchgear in Different Industrial Applications

A Technician about to Access Electrical Switchgear like that which Spike Electric Controls produces.

Use in Motors, Feeder Circuits, and Power-Distribution Transformers

Switchgear is extensively used in various industrial applications, such as controlling large motors, managing feeder circuits, and in the power-distribution transformers of industrial plants and large commercial buildings. Its ability to control and protect these components is crucial for the smooth operation of these systems.

Applications Across Various Industries

The versatility of Switchgear makes it indispensable across a multitude of sectors, including manufacturing, energy production, utility services, and healthcare facilities. Its adaptability to different voltage requirements and configurations allows for its widespread use in diverse settings.

Advanced Technologies in Switchgear Design

Innovations in Safety Features

Contemporary Switchgear designs incorporate cutting-edge safety features, such as fault detection algorithms, predictive maintenance capabilities, and enhanced control mechanisms. These advancements significantly improve the safety and reliability of electrical systems.

Integration with Digital Control Systems

The integration of digital technologies in Switchgear, such as IoT connectivity and smart monitoring systems, allows for real-time data analysis and remote management. This digitalization enables predictive maintenance, improved energy efficiency, and better overall management of electrical systems.

Emerging Trends and Future of Switchgear

Sustainability and Efficiency

Looking forward, the Switchgear industry is moving towards more sustainable and energy-efficient solutions. This includes the development of Switchgear that integrates renewable energy sources, reduces carbon footprint, and enhances operational efficiency.

Smart Grid and IoT Integration

The future of Switchgear also lies in its integration with smart grid technology and IoT devices. This integration is expected to revolutionize Switchgear functionality, offering enhanced monitoring, predictive maintenance, and better adaptability to changing power demands.


Line of Electrical Switchgear like that which Spike Electric Controls produces with locks on them.

Importance and Evolution of Switchgear

Switchgear has evolved significantly over the years, becoming an indispensable part of modern electrical infrastructures. Its role in ensuring the safety and efficiency of power systems is more crucial than ever.

Future Outlook

With ongoing technological advancements, Switchgear is set to become even more integral in the rapidly changing landscape of power distribution. Its adaptation to new challenges and innovations will continue to play a pivotal role in ensuring safe and efficient electrical systems.

Understanding the Standards and Ratings for Switchgear

Switchgear development is largely under the purview of manufacturers, allowing them to innovate and tailor their products. However, to ensure safety, reliability, and compatibility, this development must align with certain industry standards, unless alternative designs have been tested and proven effective.

Key Standards Governing Switchgear:

  • IEEE (Institute of Electrical and Electronics Engineers): Provides comprehensive standards (such as IEEE C37 series) for different voltage levels of Switchgear, focusing on safety, design, and performance.
  • IEC (International Electrotechnical Commission): Offers international standards like IEC 62271 for high-voltage Switchgear and IEC 61439 for low-voltage assemblies, ensuring global interoperability and safety.
  • ANSI (American National Standards Institute): Develops standards (ANSI C37 series) that cover a range of Switchgear applications, emphasizing specifications for safe and efficient operation.
  • NEMA (National Electrical Manufacturers Association): Sets guidelines (such as NEMA SG-5 for power Switchgear assemblies) for design, production, and testing, ensuring quality and consistency in the U.S. market.

Additional Codes and Standards:

  • NEC (National Electrical Code): A part of NFPA 70, the NEC outlines safe electrical installation practices, including those for Switchgear, to prevent electrical hazards.
  • NFPA (National Fire Protection Association): NFPA 70E focuses on electrical safety in the workplace, while NFPA 79 deals with electrical standards for industrial machinery, both impacting Switchgear use and safety.
  • UL (Underwriters Laboratories): UL standards (such as UL 1558) provide safety-related certifications for Switchgear, ensuring the products meet rigorous safety and reliability criteria.

Importance of Standards:

  • Safety and Reliability: Adhering to these standards ensures that Switchgear operates safely under various conditions, minimizing the risk of electrical hazards.
  • Interoperability and Compatibility: Standards like those from the IEC promote global compatibility, making it easier to integrate Switchgear from different manufacturers.
  • Innovation within Boundaries: While manufacturers are free to innovate, these standards provide a framework to ensure that new developments don’t compromise on safety and performance.
  • Regulatory Compliance: Compliance with these standards is often legally required, making it crucial for manufacturers to adhere to them.

Our Low Voltage Switchgear

Spike Electric Low Voltage Switchgear is the new generation low voltage Switchgear platform, incorporating the best of both worlds: cutting-edge SACE® Emax® 2 air circuit breaker with SACE Emax 2 Ekip trip unit technology, integrated into the proven AKD Switchgear platform, once again, demonstrating the innovation and reliability end users expect from Spike Electric. 

Spike Electric Low Voltage Switchgear is manufactured in an ISO 9001 certified Spike facility and built to rigorous standards. 

Spike Electric Low Voltage Switchgear meets the demands of industrial, utility and commercial applications. It is designed and tested in accordance with the latest IEEE C37.20.1 standard, CAN/CSA-C22.2 No. 31, and UL 1558 standards (file no. E76012). Spike Electric Low Voltage Switchgear has been conformance-tested to ANSI C37.51. Any equipment requiring UL 1558 or CSA labeling will be provided with a cUL label. (A cUL label is a third-party certification that indicates the Switchgear is compliant to both ANSI/IEEE and CSA standards.) 

ANSI/IEEE standards require that Switchgear operates at the ratings of devices installed. Switchgear short circuit ratings are based on two 30-cycle withstand tests with 15-second interval between the two tests, performed at 15 percent power factor and 635 Vac maximum. In addition ANSI/IEEE Switchgear thermally qualifies the design through testing, which is inclusive of the UL 1066 Power Air Circuit Breaker. In contrast, switchboards only provide a single 3-cycle withstand test at 20 percent power factor and 600 Vac maximum and do not require thermally tested solutions inclusive of UL1066 or UL489 breakers. 

Spike Electric Low Voltage Switchgear Switchgear is available with the following ratings: 

  • 600 Vac nominal, 635 Vac maximum 
  • 10000 amps AC main bus/6000 amps breaker max. 
  • 50/60 Hz 

100 kA symmetrical short circuit

    Our Metal-Clad Medium Voltage Switchgear

    At Spike Electric Controls, we specialize in the design and manufacture of state-of-the-art Metal-Clad Medium Voltage Switchgear, adhering to the highest industry standards. Our commitment to delivering cutting-edge Metal-Clad Switchgear solutions ensures reliability, efficiency, and safety in diverse industrial and commercial settings.

    Compliant with IEEE C37.20.2 Standards for Metal-Clad Switchgear

    Spike Electric Medium Voltage Switchgear is manufactured in an ISO 9001 certified Spike facility and built to rigorous standards. Our Metal-Clad Medium Voltage Switchgear aligns with the stringent requirements of IEEE C37.20.2, marking our commitment to quality and technical excellence. Key features of our Metal-Clad Switchgear include:

    • Optimal Voltage Range: Our Metal-Clad Switchgear operates efficiently across a voltage range of 4.60 kV to 38 kV, making it suitable for a variety of medium voltage applications.
    • Versatile Current Ratings: Addressing various power demands, our Metal-Clad Switchgear offers main bus continuous current ratings of 1200 A, 2000 A, 3000 A, and 4000 A. This versatility ensures compatibility with diverse electrical load requirements.
    • Safety-Centric Metal-Clad Design: The Metal-Clad construction of our Medium Voltage Switchgear enhances safety and durability. Its compartmentalized structure isolates vital components like instrumentation and connection points, providing added protection and ease of maintenance.
    • Grounded Metal Barriers for Enhanced Protection: Our Metal-Clad Switchgear incorporates grounded metal barriers in each compartment, reinforcing safety against electrical faults and contributing to the longevity and reliability of your power systems.

    At Spike Electric Controls, our focus is on pioneering solutions in the realm of Metal-Clad Medium Voltage Switchgear. We are dedicated to providing products that meet the evolving needs of our customers, ensuring their electrical systems operate with unparalleled efficiency and safety.

    Our Medium Voltage Load Interrupter Switches

    Spike Electric Controls is proud to present our range of Medium Voltage Load Interrupter Switches, expertly crafted to align with the pivotal IEEE C37.20.3 standards. Our commitment to innovation and quality is evident in every Load Interrupter Switch we produce, providing reliable and efficient solutions for your power management needs.

    Adherence to IEEE C37.20.3 Standards

    Spike Electric Medium Voltage Load Interrupter Switches is manufactured in an ISO 9001 certified Spike facility and built to rigorous standards. Our Medium Voltage Load Interrupter Switches are engineered with precision to comply with the critical specifications of IEEE C37.20.3. This commitment ensures the highest standards of safety and functionality in our products. Key features of our Load Interrupter Switches include:

    • Broad Voltage Range Compatibility: Our switches are designed to operate effectively across a wide voltage spectrum, from 2.4 kV to 38 kV. This versatility makes them suitable for a diverse range of applications in various settings.
    • Load Ratings for Diverse Requirements: To cater to different power system demands, our Medium Voltage Load Interrupter Switches come with load ratings of 600 A and 1200 A, ensuring compatibility with various electrical loads and operational requirements.
    • Designed for Excellence: Each of our Medium Voltage Load Interrupter Switches is not just compliant with IEEE C37.20.3 standards but strives to exceed them. This focus on surpassing the established benchmarks ensures our switches offer enhanced performance and reliability.

    At Spike Electric Controls, we understand the critical role that Medium Voltage Load Interrupter Switches play in the safety and efficiency of electrical systems. Our commitment to quality and innovation drives us to deliver products that not only meet but exceed industry standards and customer expectations.

    Our 4160V – 15kV  Arc-Resistant Switchgear

    At Spike Electric Controls, we are at the forefront of delivering Arc-Resistant Switchgear, engineered to provide the highest level of safety in electrical power systems. Our Arc-Resistant Switchgear is designed to effectively manage and contain internal arcing faults, ensuring the utmost protection for both equipment and personnel.

    Compliant with IEEE C37.20.7 Standards

    Our commitment to safety and quality is underscored by our adherence to the stringent requirements of IEEE C37.20.7. This standard is a benchmark for testing metal-enclosed Switchgear, and our products are rigorously tested to meet these criteria. Key features of our Arc-Resistant Switchgear include:

    • Testing Under IEEE C37.20.7 Guidelines: Our Arc-Resistant Switchgear undergoes comprehensive testing as per IEEE C37.20.7, ensuring it can withstand internal arcing faults effectively. This testing is crucial for certifying the Switchgear’s capability to handle challenging fault conditions.
    • Rated for Up to 15 kV: Designed to be robust and reliable, our Arc-Resistant Switchgear is rated for applications up to 15 kV. This makes it suitable for a wide range of medium voltage applications where enhanced safety measures are paramount.
    • Metal-Enclosed for Added Safety: The metal-enclosed design of our Arc-Resistant Switchgear not only provides superior protection from internal arcs but also ensures durability and longevity of the equipment.

    Spike Electric Controls: Synonymous with Reliability and Safety

    At Spike Electric Controls, we understand the critical importance of safety in electrical power management. Our Arc-Resistant Switchgear is a testament to our dedication to providing solutions that prioritize the safety of your operations and personnel. Explore the world of enhanced electrical safety with Spike Electric Controls’ Arc-Resistant Switchgear. Contact us to find out more about our range of Switchgear solutions and how we can help safeguard your electrical infrastructure. Choose Spike Electric Controls for Switchgear solutions where safety and reliability are non-negotiable.

    Our 4160V – 15kV Safe Sync Medium Voltage Automatic Transfer Switch

    Seamless Power Transition with Our Advanced Medium Voltage Transfer Switch

    Spike Electric Controls 4160V – 15kV Safe Sync Medium Voltage Automatic Transfer Switch, a pioneering solution in the realm of power continuity and reliability. This state-of-the-art transfer switch is meticulously designed to ensure seamless power transition in medium voltage applications, enhancing both safety and efficiency in your power management system.

    Built to Metal Clad Switchgear Standards and UL 1008A

    Our commitment to excellence is reflected in the robust design and construction of the Safe Sync Medium Voltage Automatic Transfer Switch, which adheres to the highest industry standards:

    • Metal Clad Switchgear Standard Compliance: Aligning with the Metal Clad IEEE Switchgear standards, our transfer switch ensures superior protection and reliability. This compliance guarantees that the switch is built to handle the demanding requirements of medium voltage power systems, providing enhanced safety and operational excellence.
    • UL 1008A Listing: The Safe Sync Medium Voltage Automatic Transfer Switch is UL listed for UL 1008A, signifying its adherence to stringent safety and quality guidelines. This UL listing is a testament to the switch’s reliability and performance in critical power applications.

    Key Features of the 4160V – 15kV Safe Sync Medium Voltage Automatic Transfer Switch

    • Voltage Range: Optimally designed for medium voltage applications, our transfer switch operates effectively within the 4160V to 15kV range, catering to a broad spectrum of power system needs.
    • Automatic Operation: Engineered for automatic operation, the switch seamlessly transitions power sources without manual intervention, ensuring continuous power supply and minimizing downtime in case of power outages.
    • Safe Synchronization: The Safe Sync feature ensures that the Switchgear synchronizes safely between power sources, reducing the risk of power surges or interruptions during the transfer process.


    Spike Electric Controls: Your Trusted Partner for Power Solutions

    At Spike Electric Controls, we are dedicated to innovating solutions that elevate the standards of electrical power management. Our 4160V – 15kV Safe Sync Medium Voltage Automatic Transfer Switch is a reflection of our commitment to delivering products that combine safety, efficiency, and reliability. Experience the advanced capabilities of the Safe Sync Medium Voltage Automatic Transfer Switch. Contact Spike Electric Controls to learn more about how this product can enhance the resilience and efficiency of your power systems. Trust us to empower your operations with cutting-edge electrical solutions.

    Understanding 38kV Switchgear:

    In the world of electrical power distribution and control, switchgear plays a pivotal role in managing, protecting, and isolating electrical circuits. Among the various types of switchgear used across industries, the 38kV switchgear stands out for its capacity to handle high-voltage applications with remarkable efficiency and safety. Here’s what you need to know about 38kV switchgear, a key player in the management of electrical power systems.

    The Heart of High-Voltage Electrical Systems

    38kV switchgear is designed to operate with systems that have voltage levels up to 38 kilovolts (kV) RMS. This type of switchgear is essential in environments where robust electrical control and protection are needed, such as in utility substations, industrial plants, and large data center complexes. The term “38kV” not only refers to the maximum voltage level the switchgear can handle but also indicates its suitability for systems operating at common voltages like 35kV and 34.5kV, making it a versatile solution in the high-voltage spectrum.

    Built on Solid Standards

    Adhering to the IEEE Standard, 38kV switchgear meets rigorous standards ensuring safety, reliability, and performance. This adherence guarantees that the switchgear can withstand the electrical and mechanical stresses of high-voltage applications, including:

    • Rated Maximum Voltage: The switchgear’s maximum voltage capability of 38kV RMS signifies its ability to handle the electrical power of systems operating at or below this voltage, accommodating common voltages such as 35kV and 34.5kV within its operational scope.
    • Power Frequency Withstand: With a power frequency withstand rating of 80kV RMS, the 38kV switchgear is tested to endure continuous operational voltages, ensuring reliability under normal conditions.
    • Lightning Impulse Withstand (BIL): The BIL rating of 150kV Peak is particularly crucial. It indicates the switchgear’s ability to protect against transient voltages—such as lightning strikes and switching surges—providing a high level of insulation and safeguarding the electrical system from sudden voltage spikes.

    The Core of System Protection

    38kV switchgear encompasses various components, including circuit breakers, disconnect switches, and control instrumentation, all housed within a metal-clad enclosure. This metal-clad design ensures compartmentalization and grounded barriers for enhanced safety and ease of maintenance. Features like automatic shutters and insulation cover the primary circuit components, significantly mitigating the risk of electrical faults.

    Customization and Flexibility

    While the foundational standards set the stage, 38kV switchgear offers a range of customization options to fit specific operational needs. From the integration of advanced protective relays to adaptations for unique system voltages, the switchgear can be tailored to various applications, ensuring that each setup is optimized for performance and safety.

    Ensuring Reliability and Safety in High-Stakes Environments

    38kV switchgear is integral to maintaining the integrity of high-voltage electrical systems. By controlling the flow of electrical power, protecting against overloads, and allowing for safe maintenance practices, this type of switchgear ensures that electrical systems operate smoothly, efficiently, and safely, even under the most demanding conditions.

    Whether it’s powering a large industrial complex, supporting critical infrastructure, or managing utility distribution networks, 38kV switchgear is at the heart of high-voltage electrical systems, offering unmatched reliability and protection.

    Understanding 27kV Switchgear:

    27kV switchgear is an essential component in the landscape of electrical power distribution, offering a blend of safety, efficiency, and reliability for medium-voltage applications. Designed to manage, protect, and isolate electrical circuits, 27kV switchgear stands as a cornerstone in electrical systems where precise control over medium voltages is paramount. Here’s a closer look at what 27kV switchgear is and why it’s crucial for managing electrical power in various settings.

    Tailored for Medium-Voltage Excellence

    27kV switchgear is engineered to operate within systems having a voltage up to 27 kilovolts (kV) RMS, making it an ideal solution for a wide range of industrial, commercial, and utility applications. Its design caters to systems operating at common medium voltages like 24kV and 20kV, thereby providing a versatile and effective solution for controlling electrical power in these ranges.

    Adherence to Rigorous Standards

    Following the IEEE Standard guidelines, 27kV switchgear is built to meet stringent standards that ensure every unit’s safety, reliability, and operational integrity. This includes:

    • Rated Maximum Voltage: At 27kV RMS, the switchgear is designed to comfortably handle and effectively manage the distribution of electrical power for systems operating at or below this voltage level. This encompasses commonly used voltages such as 24kV and 20kV, providing flexibility and reliability in a variety of applications.
    • Power Frequency Withstand: With a rating of 60kV RMS, 27kV switchgear demonstrates its capability to withstand the operational voltages without succumbing to electrical stress, ensuring consistent performance under standard conditions.
    • Lightning Impulse Withstand (BIL): A BIL rating of 125kV Peak underscores the switchgear’s resilience against transient voltages. This level of protection is crucial for guarding the system against external surges, such as those caused by lightning strikes, and internal voltage spikes, ensuring the longevity and reliability of the electrical infrastructure.

    The Critical Role in Electrical Systems

    Equipped with advanced components like circuit breakers and control instrumentation, all housed within a secure metal-clad enclosure, 27kV switchgear offers comprehensive protection and control. This setup facilitates not only the effective distribution of electrical power but also ensures system safety through fault isolation and rapid response capabilities.

    Customizable for Specific Needs

    The modular nature of 27kV switchgear allows for extensive customization, enabling it to meet the unique demands of various electrical systems. Whether adapting to specific voltage requirements, integrating protective devices, or accommodating unique operational conditions, 27kV switchgear can be tailored to ensure optimal functionality and alignment with system requirements.

    A Pillar of Medium-Voltage Distribution

    27kV switchgear is pivotal in the efficient and safe distribution of electrical power in medium-voltage systems. Its capacity to manage electrical loads, protect against circuit overloads, and enable safe maintenance and testing activities makes it an indispensable component of modern electrical infrastructure.

    From supporting vital industrial processes to ensuring the reliability of commercial power systems and beyond, 27kV switchgear plays a key role in maintaining the stability and safety of electrical distribution networks, embodying the principles of versatility, reliability, and safety.

    Understanding 15kV Switchgear:

    15kV switchgear represents a crucial component in medium-voltage electrical power systems, offering a robust solution for managing, protecting, and isolating electrical circuits. Tailored to operate efficiently within systems of up to 15 kilovolts (kV) RMS, this type of switchgear is pivotal in a myriad of applications, ranging from industrial operations to utility distribution networks. Here’s an insightful look into what 15kV switchgear is and its significance in the electrical landscape.

    Designed for Medium-Voltage Mastery

    15kV switchgear is engineered to handle systems with voltage levels up to 15kV RMS, making it a versatile player in the medium-voltage arena. It’s especially suited for commonly used voltages such as 11kV and 13.8kV, offering a reliable platform for electrical power distribution and control in these ranges.

    A Testament to Rigorous Standards

    Aligning with the stringent IEEE Standard, 15kV switchgear adheres to critical standards ensuring its capability to manage medium-voltage power with utmost reliability and safety. Key ratings include:

    • Rated Maximum Voltage: The 15kV RMS rating signifies the switchgear’s aptitude in handling and distributing electrical power for systems operating at or below this threshold, including the prevalent 11kV and 13.8kV systems, with efficiency and reliability.
    • Power Frequency Withstand: A rating of 36kV RMS showcases the switchgear’s resilience under operational voltages, confirming its ability to sustain electrical performance without compromise under standard conditions.
    • Lightning Impulse Withstand (BIL): With a BIL of 95kV Peak, the switchgear is fortified against transient voltages, protecting the system from external and internal electrical surges. This level of insulation is critical for safeguarding the system’s integrity against lightning strikes and switching surges, thus ensuring operational continuity and reliability.

    Core to Electrical System Safety and Efficiency

    15kV switchgear incorporates state-of-the-art components like circuit breakers, disconnect switches, and advanced control systems within a secure, metal-clad enclosure. This comprehensive setup not only facilitates efficient electrical power distribution but also ensures enhanced safety through immediate fault isolation and responsive control mechanisms.

    Versatility Through Customization

    The modular design of 15kV switchgear allows for extensive customization to cater to specific operational needs and system requirements. Whether it’s adjusting to unique voltage needs, incorporating specialized protective devices, or meeting particular environmental conditions, 15kV switchgear can be precisely configured to deliver optimal performance and meet exacting standards.

    Pillar of Medium-Voltage Distribution

    15kV switchgear is indispensable in the distribution and control of electrical power within medium-voltage networks. Its capability to efficiently manage electrical loads, safeguard against overloads, and facilitate safe maintenance procedures positions it as a foundational element in modern electrical infrastructure.

    From powering essential industrial processes to ensuring the reliability of utility and commercial power systems, 15kV switchgear underpins the stability and safety of medium-voltage electrical distribution, exemplifying the principles of efficiency, reliability, and protection.

    Understanding 8.25kV Switchgear:

    8.25kV switchgear is designed as a crucial component in medium-voltage electrical systems, adept at managing, protecting, and controlling electrical power flow with precision and safety. Engineered to accommodate systems operating up to 8.25 kilovolts (kV) RMS, this switchgear variant is particularly suited for settings requiring an intermediary voltage level, offering a bespoke solution for specialized electrical distribution and control needs.

    Engineered for Specialized Applications

    8.25kV switchgear offers a perfect fit for applications where standard medium-voltage ranges, such as 6.6kV or 5kV, are not required or where system specifications dictate a lower voltage level for efficiency or safety reasons. It bridges the gap between low-voltage and higher medium-voltage systems, providing a tailored approach to power distribution that enhances system compatibility and operational efficiency.

    Adherence to Exacting Standards

    In line with the comprehensive IEEE Standard, the 8.25kV switchgear stands on a foundation of strict standards that guarantee its ability to deliver exceptional performance while upholding the highest safety measures. These standards include:

    • Rated Maximum Voltage: At 8.25kV RMS, this switchgear is specifically designed to function seamlessly within electrical systems operating at this voltage, ensuring reliable power distribution and control without exceeding operational thresholds.
    • Power Frequency Withstand: The power frequency withstand rating of 36kV RMS underlines the switchgear’s capacity to endure normal operating voltages, affirming its durability and reliability under typical service conditions.
    • Lightning Impulse Withstand (BIL): A BIL rating of 95kV Peak indicates robust protection against transient voltage events. This critical feature shields the electrical infrastructure from potential damage due to lightning strikes and switching surges, thereby maintaining system integrity and continuity.

    Integral to Specialized Electrical Systems

    The 8.25kV switchgear incorporates advanced technological components within a metal-clad enclosure, including circuit breakers and disconnect switches, complemented by sophisticated control systems. This integrated approach not only ensures effective power distribution and safety but also enables quick isolation of faults and responsive system adjustments.

    Customization for Unique Needs

    Reflecting the versatile nature of electrical systems, 8.25kV switchgear is designed with modularity and adaptability in mind, allowing for extensive customization. This ensures that each setup is optimally configured to address specific voltage requirements, environmental conditions, and protective needs, enhancing system performance and safety.

    A Versatile Solution in Medium-Voltage Distribution

    8.25kV switchgear is invaluable in specialized medium-voltage electrical networks, supporting a wide array of applications with its unique voltage level. It provides a tailored solution that fits specific operational needs, exemplifying efficiency, reliability, and safety in electrical power distribution and control.

    Whether serving niche industrial applications, augmenting utility distribution networks, or meeting specific commercial power requirements, 8.25kV switchgear plays a pivotal role in the effective and safe management of electrical power, embodying the essence of precision-engineered power distribution solutions.

    Understanding 4.76kV Switchgear:

    4.76kV switchgear represents a fundamental component in the electrical distribution framework, especially tailored for low-to-medium voltage applications. Engineered to facilitate control, protection, and isolation of electrical circuits, 4.76kV switchgear plays a pivotal role in enhancing operational efficiency and safety within a wide array of electrical systems.

    Bridging Low and Medium Voltage Requirements

    Designed to operate seamlessly at voltages up to 4.76 kilovolts (kV) RMS, 4.76kV switchgear serves a critical function across various voltage levels, including 1.2kV, 2.4kV, 3.3kV, 4.16kV, and up to 4.76kV. Its adaptability makes it an ideal choice for a broad spectrum of installations, from industrial facilities and commercial complexes to utility substations, embodying a versatile solution that caters to a diverse range of electrical power distribution needs.

    Ensuring Safety and Performance Through Standards

    Adhering to the rigorous IEEE Standard, 4.76kV switchgear meets and exceeds established criteria for safety, reliability, and performance, including:

    • Rated Maximum Voltage: With a 4.76kV RMS rating, this switchgear is designed for optimal operation within electrical systems functioning at or below this level, facilitating reliable power distribution and control across common lower voltage applications.
    • Power Frequency Withstand: A power frequency withstand rating of 19kV RMS underscores the switchgear’s capability to maintain structural integrity and operational reliability under normal voltage conditions, ensuring the system’s resilience.
    • Lightning Impulse Withstand (BIL): With a BIL rating of 60kV Peak, the switchgear offers formidable protection against transient voltage disturbances. This critical protection mechanism is essential for safeguarding the electrical infrastructure against potential damages from external surges, including lightning strikes, thereby enhancing system durability and continuity.

    A Linchpin in Electrical Distribution

    Incorporating leading-edge components such as circuit breakers, disconnect switches, and advanced monitoring systems within a robust, metal-clad enclosure, 4.76kV switchgear ensures comprehensive control and safety. This integration not only supports efficient electrical power distribution but also enables swift fault detection and isolation, fostering responsive system management.

    Tailored Solutions for Diverse Applications

    4.76kV switchgear’s modular design and customizable features allow it to meet specific requirements and operational challenges, ensuring that each configuration is precisely suited to the application it serves. Whether adjusting to unique environmental conditions, accommodating specific voltage levels, or integrating protective measures, 4.76kV switchgear can be meticulously tailored, affirming its role as a highly adaptable power distribution solution.

    The Foundation of Reliable Power Distribution

    Occupying a critical position in the electrical distribution hierarchy, 4.76kV switchgear underpins the reliability and safety of low-to-medium voltage networks. Its ability to efficiently manage electrical loads, coupled with robust protection against overloads and faults, makes it an indispensable asset in ensuring the smooth operation of electrical systems.

    From powering essential industrial processes to maintaining the operational integrity of commercial and utility power systems, 4.76kV switchgear exemplifies the essence of precision and reliability in electrical power distribution and control, marking a key milestone in the journey toward optimized and safe electrical infrastructure.

    Common Voltages in Medium Voltage Metal Clad Switchgear

    Medium Voltage (MV) Metal Clad Switchgear serves as a pivotal element in electrical distribution systems, bridging the gap between high-voltage transmission lines and the low-voltage needs of end users. This equipment is essential for the safe and efficient distribution of electricity across various sectors, including industrial, commercial, and utility networks.

    MV Metal Clad Switchgear is designed to operate within a range of voltage levels, each suited to specific applications based on power requirements, distance, and efficiency considerations. Here’s a breakdown of the most common voltages and their typical uses:

    • 1,200V to 5kV Range: This voltage spectrum is particularly favored in heavy industrial settings where large motors and drives are prevalent. It supports high-power applications where efficiency and space considerations render lower voltages impractical.
    • 6.6kV to 15kV Range: Widely utilized in both industrial and utility applications, voltages within this range are chosen for their balance between equipment size and power capacity. They are common in sectors such as mining, marine, and large-scale commercial facilities.
    • Above 15kV: Voltages exceeding 15kV up to 38kV cater to extensive industrial complexes and utility distribution networks. These higher voltages facilitate power transmission over longer distances with minimal losses, optimizing the reach and efficiency of power distribution networks.

    Each voltage level within the MV range is chosen based on specific requirements of the application, including the nature of the electrical load, the geographical layout of the distribution network, and the operational environment. By selecting the appropriate voltage for a given application, engineers can ensure that electrical systems are both safe and efficient, minimizing losses and maximizing performance.

    Rated Maximum Voltage (kV rms) Common Applications Power Frequency Withstand (kV rms) Lightning Impulse Withstand (BIL) (kV peak)
    1,200V (1.2kV) Heavy industrial applications for large motors and drives. 19 60
    2,400V (2.4kV) Industrial and commercial distribution, large HVAC systems, pumping stations. 19 60
    3,300V (3.3kV) Mining industry, heavy industrial applications, especially underground. 19 60
    4,160V (4.16kV) Industrial plants, power generation, utility distribution. 19 60
    4,760V (4.76kV) Industrial and utility distribution. 19 60
    5kV (5,000V) Large industrial applications, manufacturing facilities, oil and gas plants. 36 95
    6.6kV (6,600V) Heavy industry with large electric motors, marine and mining sectors. 36 95
    11kV (11,000V) Primary urban and rural power distribution, large industrial supply. 36 95
    13.2kV (13,200V) North American distribution networks, medium to large industrial consumers. 36 95
    13.8kV (13,800V) Utility distribution in urban/industrial settings, large facility distribution. 36 95
    15kV (15,000V) Similar to 13.8kV, for utility distribution and in large industrial plants. 36 95
    15.5kV (15,500V) Certain distribution networks, slightly above standard MV range. 60 125
    22kV (22,000V) Regional power distribution to bridge high-voltage transmission and local MV distribution. 60 125
    24.9kV (24,900V) Primary utility distribution in North America, urban and rural areas. 60 125
    25kV (25,000V) Railway electrification, especially for high-speed rail networks. 60 125
    27kV (27,000V) Specialized industrial applications, higher load utility distribution. 60 125
    33kV (33,000V) Regional utility distribution, rural/suburban areas. 80 150
    34.5kV (34,500V) Industrial complexes, utility distribution in North America. 80 150
    35kV (35,000V) Large industrial applications, utility distribution networks. 80 150
    36kV (36,000V) Specialized utility and industrial settings. 80 150
    38kV (38,000V) Regional utility distribution, large industrial plants/data centers. 80 150

    American-Made Excellence: Our Commitment to the Build America Buy America Act

    At Spike Electric, we take pride in manufacturing switchgear solutions that are not just at the forefront of technological innovation but also deeply rooted in our commitment to American manufacturing excellence. Under the Build America Buy America Act, a policy aimed at bolstering American industry by requiring federally funded infrastructure projects to use American-made products, we stand as a leading provider of switchgear solutions that meet and exceed these requirements​ (U.S. Department of Commerce)​​ (The Department of Energy’s​​ (Rural Development)​.

    Why Choose American-Made Switchgear?

    Quality and Reliability: Our switchgear solutions are engineered, designed, and manufactured within the United States, ensuring they adhere to the highest standards of quality and reliability. The BABA Act emphasizes the use of American-made iron, steel, manufactured products, and construction materials, a standard that Spike Electric not only meets but proudly champions​ (U.S. Department of Commerce)​​ (The Department of Energy’s​.

    Supporting Local Economies: By choosing our American-made switchgear, you’re not just getting a superior product; you’re also supporting the American economy, safeguarding local jobs, and contributing to a sustainable manufacturing sector that’s vital for the nation’s infrastructure​ (Rural Development)​.

    Compliance and Standards: Spike Electric’s adherence to the BABA Act ensures that our products are not just made in America but also embody the spirit of American innovation and craftsmanship. Our switchgear solutions comply with the rigorous standards set forth by the IEEE, ANSI, and UL, guaranteeing that you receive products that are safe, efficient, and ready to meet the demands of both today and tomorrow​ (U.S. Department of Commerce)​​ (The Department of Energy’s​​ (Rural Development)​.

    Our Pledge to You

    In line with the Build America Buy America Act, Spike Electric is dedicated to providing infrastructure projects across the nation with switchgear solutions that are built on the foundation of American excellence. Whether you’re involved in utility, industrial, or commercial projects, our commitment to manufacturing in the United States ensures that you receive products characterized by unparalleled quality, reliability, and performance.

    Choose Spike Electric for your switchgear needs and experience the difference that American-made quality brings to your projects.

    Cole Attaway - Spike Electric

    Cole Attaway


    Robert Hodson Headshot - Spike Electric

    Robert Hudson


    About Spike Electric Controls

    Spike Electric Controls, based in the vibrant city of Houston, Texas, is a globally recognized custom engineering manufacturer, dedicated to providing exceptional electrical gear for the energy sector. Our specialty lies in the rapid production of complex and integrated systems for power distribution and control assemblies, designed to address the critical needs of our clients. Our product range, from the straightforward “Switchrack” to the more intricate “Medium Voltage Switchgear”, is crafted by our team of seasoned and expert professionals, who are committed to meeting your specific application and design requisites. 

    At the core of our operations, safety takes precedence. By relocating assembly processes from busy job sites to our secure, controlled facility, we substantially reduce the risk of injury for our clients. This move also contributes to the heightened quality of our quick ship products, which are delivered complete and accompanied by comprehensive quality assurance documentation. The advantages of our rapid delivery service are numerous, leading to decreased downtime and increased operational efficiencies.

    Clients benefit from our all-encompassing, integrated service approach. This approach encompasses consulting, solving technical issues, innovating solutions for outdated equipment, meticulous management of your custom-engineered solutions, field startup support, and constant emergency assistance.

    Spike solutions are known for minimizing unplanned downtime, decreasing the necessity for overtime, and boosting operational efficiencies. With a vast array of facilities and expertise, Spike Electric Controls is well-equipped to manage your electrical product needs. We take pride in our in-house full metal fabrication shop, which allows us to make any necessary modifications or engineer structures needed for your orders. Our climate-controlled, ISO 9001 Certified panel wiring facility is where our team focuses on building quality products. We are committed to delivering optimal value to our customers by producing products and systems that operate with the highest safety standards and provide the utmost efficiency in operation and design. Our track record of repeat customers and longstanding relationships is a testament to our commitment to quality and service. We pride ourselves on being more than a supplier — we are a trusted partner in our clients' success.

    Spike Electric operates 24 hours a day, six days a week. In 2021, we chose to close on Sundays to give our team a day for rest and worship. Nonetheless, we are always prepared to assist our customers with any urgent needs, offering support whenever it's most crucial.

    The team at Spike Electric has been on point with all documentation, equipment turnarounds and schedule delivery dates within our fast-paced and tight schedule. I’m looking forward to working with this great team again on future projects around the Houston area and possibly nationwide.

    – Clyde (Buster) Kellar, MMR Constructors, Inc.

    In 41 years in the electrical industry I have never see a company deliver fully built equipment as quickly as Spike Electric. 20 sections of motor control, 114 fully wired buckets, & the switchboards delivered in less than 5 days. With their support we got the Seabrook Odfjell tank farm back up and running ahead of schedule.

    – Jason Redmon, Project Manager MMR Constructors, Inc.

    Spike engineered and delivered a complete hazardous location switch rack in less than 3 weeks for a urgent project. Their team offered a wealth of knowledge and always react with a sense of urgency.

    – Kodey Henderson EE PE, Mangan Engineering

    Spike’s team recently helped me deliver 26 explosion proof switch racks for Exxon in 6 weeks. The quality of engineering and the product delivered was far superior to any other manufacturer I have worked with in the past. I always enjoy working with this group, they always have integrity when they tell me something’s going to get done I can trust it will happen.

    – Allen Moravits, West Texas Area Manager, Saber Power Systems