Relay Retrofit
Relay Retrofits replace aging or obsolete protective relays with modern digital devices that improve reliability, safety, and system visibility.
We help you upgrade critical protection without a full system overhaul—saving time, money, and future headaches.
Benefits of Relay Retrofits
Avoid Unexpected Failures from Aging Equipment
Old relays become less reliable over time, increasing the risk of nuisance trips or failure to operate when it matters most. Retrofits help ensure consistent, accurate protection.
Improve Safety and Fault Response Times
Modern relays respond faster and offer better protection coordination, reducing incident energy and improving safety for your personnel and equipment.
Add Monitoring, Alarms, and Data Visibility
Digital relays offer communication features, event logs, and real-time data that older units simply can’t provide.
This gives your team better insight and faster response during abnormal conditions.
Use Cases
Aging Relays with Inconsistent Performance
Legacy electromechanical or early digital relays that are slow, inaccurate, or no longer reliable.
Lack of Available Replacement Parts
Discontinued relays with obsolete components can delay repairs or inflate maintenance costs.
Upgrading to Meet Modern Safety or Operational Standards
Newer relays support faster clearing times, better fault detection, and improved system protection.
Adding More Monitoring or Remote Access Capabilities
Digital relays provide metering, diagnostics, and communication for modern facilities.
Consolidating Multiple Devices into One
Modern relays often replace multiple functions; overcurrent, voltage, and communication,in one unit.
Common Applications
Medium-Voltage Switchgear Protection
Upgrading feeder or main protection relays to improve selectivity and clearing time.
Transformer Differential and Overcurrent Relays
Replacing outdated protection to better monitor internal faults and secondary loads.
Motor Protection Relays
Modern relays with thermal models and advanced trip logic for high-value motors.
Generator or Backup Power Protection
Fast, reliable protection for backup systems, with improved monitoring and logging.
Automatic Transfer Schemes
Managing emergency power transfer between utility and backup systems with zero or minimal delay.
Industries Served
Industrial Plants with Legacy Gear
Examples: Paper mills, steel manufacturing, legacy automotive facilities, etc.
Mining & Natural Resources
Examples: Mining operations, aggregate processing plants, quarries, etc.
Commercial Real Estate & Multi-Tenant Facilities
Examples: High-rise office buildings, retail centers, mixed-use residential towers, etc.
Higher Education & Government Campuses
Examples: University power plants, federal buildings, secure government labs, etc.
Mission-Critical Facilities
Examples: Hospitals, data centers, telecom facilities, etc.
Utilities & Energy
Examples: Substations, solar fields, microgrids, distributed energy facilities, etc.
Municipal Infrastructure
Examples: Transit systems, city-owned power distribution, street lighting networks, etc.
Water & Wastewater Treatment
Examples: Pump stations, lift stations, control panels, etc.
Case Studies
We don’t just talk safety, we deliver it. These case studies show how our Arc Flash expertise has made a measurable difference for facilities like yours.
FAQs
Not sure if your relays need an upgrade?
Here are a few common questions from facility managers and electrical teams about when, why, and how to retrofit your protection devices.
What is a relay retrofit?
It’s the process of replacing outdated or failing protective relays with newer, more reliable digital relays—without replacing your entire electrical system or switchgear.
How do I know if my relays need to be replaced?
Common signs include nuisance tripping, limited spare parts availability, lack of digital features, or relays over 15–20 years old.
Will a retrofit require shutting down my facility?
In most cases, only the affected equipment needs to be de-energized. We work with your schedule to minimize downtime and disruption.
What’s the difference between a retrofit and a full replacement?
A retrofit keeps your existing switchgear in place and replaces only the relay itself. A full replacement involves removing and replacing entire gear sections—much more expensive and time-intensive.
Do modern relays offer remote monitoring?
Yes. Many digital relays offer built-in communications, data logging, and alarm capabilities that can integrate with your building or SCADA system.