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A Guide to the Electrical Substation Design Process
January 24, 2022 | Blog

Whether you're retrofitting or building a substation, following a well-defined process is essential to ensure electrical and operational integrity. The substation design process involves engineering, planning, and construction elements that directly impact system reliability, safety, and future scalability.
You need experts like Keentel Engineering by your side. We bring over 30 years of experience in electrical substation design and layout for utilities, developers, and IPPs. Our team ensures every project aligns with best practices in substation planning, energy efficiency, and regulatory compliance.
Step-by-Step Substation Design Workflow
1. Switching Station Selection
The first step in substation engineering design is identifying the appropriate switching station configuration. While switching stations do not transform voltage, they are crucial for routing power safely and enabling grid flexibility.
At this stage, our engineers assess the best type of bus (e.g., ring bus or breaker-and-a-half), control systems, and disconnect switches. Choosing the right switching station directly influences future substation expansion design and maintenance capability.
2. Preliminary Layout and Site Planning
Next, we create a
substation layout plan showing all critical infrastructure components—equipment pads, buswork, fencing, driveway access, and grounding. This layout is the foundation of successful
substation construction and future-proof scalability.
Our planning phase includes:
- Evaluating transmission voltage class (e.g., 69kV, 138kV, or 230kV)
- Aligning with substation civil design standards
- Planning space for a substation control building
- Integrating paths for future feeder bays or transformer additions
3. Detailed Substation Planning
This stage formalizes:
- Component placement and interconnection
- Site-specific milestones and substation project development
- Budget allocation for electrical substation building design
- Real estate acquisition and permitting requirements
- Power flow studies to size transformers and protection systems
We also conduct load flow studies and analyze protective device coordination to ensure the electrical engineering design process supports operational safety and future demands.
4. Procurement & Equipment Selection
Keentel advises clients during the equipment procurement stage. From high-voltage transformers to SCADA-ready relays, each component must meet project specs, withstand environmental stress, and comply with IEEE/NESC standards.
We focus on:
- Smart grid compatibility
- Interoperability for substation design build projects
- Efficient electrical substation construction timelines
5. Design Execution & Construction Management
Our engineers develop detailed schematics, 3D models, and site-specific construction packages. Keentel also assists with:
- Routing of electrical cabling and conduit
- Ground grid modeling
- Control house configuration
- NERC compliance review
The entire substation design and construction process is managed under QA/QC protocols to ensure alignment with substation design standards and operational safety.
Why Keentel Engineering?
We specialize in:
- Utility substation design
- Primary substation design
- SCADA system integration
- Substation building layout optimization
- EPC-level substation projects
We are trusted partners for substation design engineers, utility developers, and grid planners across North America.
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Contact us today for help with substation projects—greenfield or brownfield.
FAQ: Substation Design Process
Q1: What is the first step in substation design?
Selecting the switching station and defining bus configuration based on transmission system needs.
Q2: What are the key components in substation planning?
Layout plan, protection coordination, SCADA integration, civil permits, and budget alignment.
Q3: How long does substation design take?
Typically 4–9 months depending on complexity, permitting, and grid interconnection needs.
Q4: What’s included in the electrical substation construction package?
Schematics, grounding plan, control house layout, equipment specs, compliance documentation.
Q5: Does Keentel offer substation EPC support?
Yes—we support end-to-end substation EPC design build projects with in-house design and QA/QC.

About the Author:
Sonny Patel P.E. EC
IEEE Senior Member
In 1995, Sandip (Sonny) R. Patel earned his Electrical Engineering degree from the University of Illinois, specializing in Electrical Engineering . But degrees don’t build legacies—action does. For three decades, he’s been shaping the future of engineering, not just as a licensed Professional Engineer across multiple states (Florida, California, New York, West Virginia, and Minnesota), but as a doer. A builder. A leader. Not just an engineer. A Licensed Electrical Contractor in Florida with an Unlimited EC license. Not just an executive. The founder and CEO of KEENTEL LLC—where expertise meets execution. Three decades. Multiple states. Endless impact.
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About the Author:
Sonny Patel P.E. EC
IEEE Senior Member
In 1995, Sandip (Sonny) R. Patel earned his Electrical Engineering degree from the University of Illinois, specializing in Electrical Engineering . But degrees don’t build legacies—action does. For three decades, he’s been shaping the future of engineering, not just as a licensed Professional Engineer across multiple states (Florida, California, New York, West Virginia, and Minnesota), but as a doer. A builder. A leader. Not just an engineer. A Licensed Electrical Contractor in Florida with an Unlimited EC license. Not just an executive. The founder and CEO of KEENTEL LLC—where expertise meets execution. Three decades. Multiple states. Endless impact.
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