Digital switchgear curbs power losses, boosting distribution efficiency

Machine-learning models trained on continuous sensor feeds monitor parameters such as insulation integrity, partial discharges, and thermal stress, which can then predict failures weeks in advance, reducing unplanned outages and leading to the extension of equipment life by up to 30 per cent.

Digital switchgear embedded with IoT sensors and smart meters enables real-time monitoring of current, voltage, temperature, and transformer loads. This minimises power loss via optimised load balancing and predictive maintenance while preventing unauthorised access. Paired with tamper detection and automated cutoff in smart meters, these systems sharply reduce technical and non-technical losses in distribution networks in India. Piyush Garg has more to say; let us hear him.

What is the expected impact of AI and real-time data analytics on switchgear performance and lifecycle management?

With AI and real-time analytics, we anticipate a transformation in switchgear globally, enabling condition-based maintenance and dynamic asset optimisation. Machine-learning models trained on continuous sensor feeds monitor parameters such as insulation integrity, partial discharges, and thermal stress, which can then predict failures weeks in advance. This can reduce unplanned outages and extend equipment life by up to 30 percent. Real-time dashboards allow operators to rebalance loads instantly, minimising overloading and power losses. Moreover, AI-driven fault analysis accelerates root-cause diagnosis, cutting repair times and spare parts inventory. Over a switchgear’s lifecycle, these technologies can lower the total cost of ownership, enhance reliability, and support more agile, data-driven planning of replacements and upgrades for OEMs and industries.

How is switchgear reshaping sustainable, space-efficient power distribution infrastructure?

Vacuum switchgear eliminates SF₆ by utilising vacuum interrupters, which offer arc-quenching with zero greenhouse gas emissions and reduced maintenance. Its long service life and recyclable components support eco-friendly grids. Meanwhile, gas-insulated switchgear (GIS) condenses high-voltage assemblies into compact metal enclosures, vastly lowering the footprint while providing superior insulation and environmental sealing. Hybrid switchgear combines vacuum and gas technologies, minimising SF₆ volume and optimising performance and cost-effectiveness. Together, GIS and hybrid switchgear systems can significantly enhance network reliability through integrated protection and automation, enabling fault detection and isolation in circuits. Their space efficiency and modular design can alleviate urban and substation constraints, unlocking scalable, greener distribution and transmission solutions.

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The Indian switchgear market is expanding steadily and is projected to grow at a CAGR of between 6 percent and 9 percent through 2028 driven by grid modernisation, renewable energy integration, and urban infrastructure upgrades. Yet, escalating copper and steel prices, as well as ageing substation assets, stress pricing and availability. We at Balaji Switchgears understand the ongoing industry challenges; however, to revolutionise, we need to be agile and ready to move past them for the growth of our nation. Our manufacturers strategically source raw materials and are adopting modular design approaches that will help reduce raw-material intensity in their products. Combined with digital engineering and predictive-maintenance products and services, we offer cost-efficient, long-term reliability switchgear products that adapt to evolving regulations and volatile commodity markets, solidifying our position as a core player in the dynamic Indian market, resiliently and sustainably. 

How is the industry modernising legacy switchgear systems without disrupting operations or compromising cybersecurity?

Automation in switchgear facilitates remote monitoring, self-diagnostics, predictive maintenance and real-time control. This naturally boosts reliability by detecting anomalies early and improves safety through rapid fault isolation. Legacy systems pose challenges such as proprietary protocols, a lack of embedded sensors, cybersecurity vulnerabilities, and skill gaps in the workforce. The industry is addressing these issues by developing retrofit sensor kits, adopting open communication standards, and implementing modular gateway solutions that seamlessly bridge old and new equipment. Manufacturers are also offering cybersecurity frameworks and workforce training programmes to improve the quality of delivery at the end. Standardised digital platforms and scalable architectures facilitate phased upgrades, allowing utilities to modernise incrementally without disrupting existing operations securely and cost-effectively.

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