Switchgear industry gears up for innovations

The demand for advanced, high-performance switchgear technologies is rising and will continue for years to come.

With the rise of electricity demand, the government is promoting clean energy and local manufacturing. The switchgear industry is not untouched by the impact of the ongoing advancements in the power sector. Policies like Make in India, regulations such as BIS Certification for electrical components, and major investments in solar, wind and smart grid upgrades are driving demand for high-performance, sustainable switchgear products. This shift creates opportunities for OEMs and all related switchgear sector partners.

Let us analyse the switchgear industry, where innovation and growth have taken centre stage. Industry experts share their thoughts with EPR, providing insights into the industry.

Advanced switchgear technologies

The country is at a turning point with energy transition shaping a more inclusive and sustainable future. And so the demand for advanced, high-performance switchgear technologies is rising and will continue for years to come. The industry is experiencing a race for innovation. The accelerating integration of renewable energy sources such as solar and wind is reshaping the design, operation and power systems. Unlike conventional generation, renewable power flows can be highly variable and bidirectional. This variability is driving the industry to adopt more advanced and adaptable switchgear solutions.

Rakesh Dwivedi, Head of High Voltage Products at Hitachi Energy India Limited, shares, “Companies are racing to develop solutions that ensure grid stability and operational efficiency and environmental benefits. Digital switchgears are revolutionising the management of networks.” The integration of IoT and cloud-based platforms will facilitate remote monitoring, predictive maintenance and early fault detection. This will ultimately minimise downtime and improve reliability.

Modular switchgear monitoring and point-on-wave switching technologies are also coming into light, which is again a new thing. The features of scalable operations and reinforced microgrids help in the distribution of renewable energy across diverse geographies. High Voltage Direct Current (HVDC) systems are another cornerstone of this transformation. They facilitate the transmission of bulk renewable power from regions with abundant renewable energy to distant load centres, which offer operators greater control and flexibility. Rakesh adds, “In space-constrained environments, offshore wind platforms, gas-insulated switchgear (GIS) and hybrid GIS are compact and efficient solutions for substation expansion.

One major shift is the mandatory requirement for four-quadrant power measurement in modern systems. With bidirectional energy flows and dynamic tariff structures, switchgear must now precisely monitor active and reactive power in both directions. This demands devices capable of high-speed, accurate measurements integrated into advanced control architectures.

Dr Suraj Pardeshi, Sr Technical Lead from elnfochips, believes that traditional switchgear, largely electromechanical, struggles to meet these demands. He emphasises, “Today’s electronic, smart and communicable switchgear replaces mechanical control mechanisms with microprocessor-based systems which enable faster response times, complex logic execution and remote operability. The integration of IoT and AI allows real-time monitoring, predictive maintenance and optimised energy management that reduces downtime and improves grid stability.”

The design philosophy of switchgear is changing. Modern switchgears are compact, modular and scalable to meet the needs of space-constrained urban substations and renewable integration points. This modularity allows for easier upgrades, flexibility in configuration and faster deployment, which is necessary for keeping pace with expanding renewable installations.

Speaking of OEMs and panel builders, a necessary part of the switchgear industry, Piyush Garg, Managing Director at Balaji Switchgear, notes that the shift to renewables is changing the way OEMs, panel builders, and end users think about switchgears. Shifting from reliability and safety to intelligence, adaptability, and environmental sustainability.

Solar and wind bring variability for customers seeking solutions that can manage load, offer remote diagnosis, and integrate into upgraded energy management systems. Balaji Switchgear has been working closely with clients to provide smarter, compact switchgear solutions that are ready for the new demands while also future-proofing their systems & not just supplying products.

Piyush Garg said, ‘We have been at the forefront of digital switchgear implementation for years now.’ For us, it is about supplying products and implementing smarter systems for clients. With remote monitoring, predictive diagnostics, or IoT-enabled panels, we are helping OEMs and panel builders to upgrade with ease. Our goal is to simplify digitalisation and add value in India’s complex grid with renewables and decentralised loads by promoting systems that respond and adapt.

Market condition

Speaking of market conditions, the switchgear sector is enjoying robust growth in India. The government’s ambitious target to achieve 500 GW of non-fossil fuel-based energy capacity by 2030 necessitates a power infrastructure for advanced switchgear technologies. Flagship initiatives like ‘Make in India’ and ‘Atmanirbhar Bharat’ are strengthening domestic manufacturing and reducing import dependency. This, in turn, is fostering innovation in the switchgear ecosystem. These policies support self-sufficiency and the development of next-generation, sustainable technologies tailored to the energy landscape of the country. The rapid modernisation in the railway, airport and port sectors is increasing demand for advanced electrical infrastructure. This trend is accelerating the adoption of SF6-free switchgear solutions, which enhance grid stability and reduce environmental impact.

Rakesh Dwivedi notes, “India’s goal of becoming a developed economy by 2047 is promoting sustainable infrastructure investments, especially in low-GWP alternatives to SF6 and digital switchgear systems for efficient real-time grid management.” He further says that in line with these national goals, Hitachi Energy is contributing through innovative and eco-efficient switchgear solutions that support energy security and environmental stewardship.

Adding to it, Piyush Garg shares that manufacturers are working towards integrating switchgears with AI innovation to read data, spot trouble, and alert you before it becomes a problem for the system and the entire production line. He says, “We are working to offer RE-compatible gears that are built for a clean, future-proof and sustainable India.” With the government’s push towards renewable energy, power grids will soon be RE-dominated. Companies such as Balaji Switchgear provide RE-compatible gears designed for a clean, future-proof and sustainable India.

Unified Network Management System

A robust communication network is the backbone of a modern power grid, and the Unified Network Management System (N-UNMS) can change the game in this space. N-UNMS can improve the efficiency and responsiveness of switchgear operations across India’s grid by providing a centralised platform for data collection, monitoring and intelligent analytics. It can also enable operators to access real-time data across the grid from switchgear and transformers to other critical infrastructure. This comprehensive visibility can allow swift fault isolation, reduce downtime and facilitate more agile decision-making.

Commenting on this system recently approved by POWERGRID, Rakesh Dwivedi says, “N-UNMS capabilities go beyond reduced downtime and fault management. It uses intelligent analytics to detect early signs of equipment stress or failure, enabling predictive maintenance and ensuring uninterrupted grid performance. Operators can schedule interventions proactively, improving system reliability and extending asset life.” The platform can keep vital parameters checked like power flow, voltage and current. Rakesh adds that by turning this data into actionable insights, it can help utilities fine-tune grid performance and cut energy losses. In practice, this means they can work smarter, react faster, and ensure a power supply that’s reliable and sustainable.

The N-UNMS is built around Intelligent Electronic Devices (IEDs) for switchgear, which play a central role in advancing grid operations. Unlike conventional SCADA systems, IEDs provide higher bandwidth, reliability and security for power networks. Highlighting major benefits of N-UNMS Dr Suraj Pardeshi shares, “Modernisation of switchgear is guided by international IEC standards, with IEC 61850 enabling substation automation and the IEC 60870-5 series supporting monitoring and control. Fast and secure communication between IEDs is achieved through GOOSE and SMV protocols, while IEC 60870-5-104 over TCP/IP facilitates telecontrol and remote data acquisition.”

Condition-based maintenance (CBM) is another key element of the N-UNMS, improving the dependability of switchgear by relying on real-time data from sensors installed in components such as circuit breakers, transformers and lightning arresters. This approach allows early detection of faults and supports predictive maintenance practices, which in turn strengthen grid stability and continuity of supply.

SF₆-free switchgear solution

The country’s projected peak demand of 388 GW by FY32 is a clear signal for the transmission and distribution network to scale rapidly and intelligently. As the grid expands, managing the variability of renewable energy and the unpredictability of consumption patterns becomes complex. To meet these challenges, the industry is embracing smart and SF6-free switchgear technologies that improve reliability, efficiency and sustainability.

Automation and digitalisation are leading this revolution. Today’s smart switchgear systems come up with advanced monitoring and control capabilities. This enables operators to collect real-time data, remotely operate equipment and respond to grid disturbances within seconds. These features are important to maintaining grid stability in a high-demand renewables-driven environment.

The shift away from SF6, a potent greenhouse gas with global warming potential (GWP) of up to 23,400, is gaining momentum. Speaking on this, Rakesh Dwivedi says, “The traditional high-voltage switchgear, which relies on SF6, is being replaced with low-GWP gas alternatives. These solutions meet all technical and safety standards while maintaining the same compact footprint of conventional equipment, making it ideal for rural and urban space-constrained installations.”

SF6-free switchgear technologies are more resilient to grids and support the country’s vision of a sustainable, energy-driven future. The transition to eco-friendly technology is also important. Non-SF6 (sulphur hexafluoride) switchgear eliminates the use of potent greenhouse gases and is helping India align with its low-carbon and climate goals.

Conclusion

In essence, the rise of renewables is influencing the evolution of switchgear. The switchgear industry is moving from passive, mechanical protection devices to intelligent, adaptive and highly integrated systems that form a critical part of the smart grid ecosystem. Such advancements are laying the foundation for a more resilient grid. This is accelerating the integration of renewables, propelling India on the path to a cleaner energy future. The future of robust power systems will be decided by the industry’s willingness to adopt and optimise advanced switchgear technologies.

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Quotes:

Rakesh Dwivedi, Head, High Voltage Products- Hitachi Energy India Ltd

Companies are racing to develop solutions that ensure grid stability, operational efficiency, and environmental benefits. Digital switchgears are revolutionising the management of networks.”

Dr Suraj Pardeshi, Sr. Technical Lead – elnfochips 

“Modernisation of switchgear is guided by international IEC standards, with IEC 61850 enabling substation automation and the IEC 60870-5 series supporting monitoring and control.”

Piyush Garg, Managing Director- Balaji Switchgear

“We are working to offer RE-compatible gears that are built for a clean, future-proof and sustainable India.”