A Coordinated Electric System Interconnection Review—the utility’s deep-dive on technical and cost impacts of your project.

Optimizing MV Switchgear Design for Cost, Safety & Compliance

Calendar icon. D

May 8, 2025 | Blog

Gray electrical control panels in a room with red floor, likely a power station.

In today’s competitive power engineering landscape, MV switchgear design must balance performance, cost-effectiveness, and adherence to standards such as IEC 62271-307 and IEC 60943. At Keentel Engineering, we leverage advanced thermal and electromagnetic simulations alongside decades of hands-on expertise to deliver optimized panel, switchboard, and busway solutions—whether for rural electrification, offshore platforms, or high-density urban substations.

Key Insights & Economic Strategies

A recent comparative study by Keentel Engineering demonstrates how early-stage simulations can:

  • Replace costly lab tests (temperature-rise or internal-arc tests costing up to €30 000) with validated digital models
  • Optimize material selection (Copper vs. Aluminum vs. CCA) to achieve the best cost-per-MVA and thermal performance
  • Enable compact GIS-based designs by fine-tuning ventilation, busbar geometry, and hybrid conductor profiles

We adhere to IEC 62271-307 for temperature limits and IEC 60943 for busbar mechanical criteria, ensuring both safety and UL/CE compliance.

FAQs

  • What’s the cost of an MV switchgear temperature-rise test?

    Roughly €4 000 plus 1.5 days of lab time.

  • Why use simulation in switchgear development?

    Simulations cut lab costs and accelerate design iterations by up to 40%.

  • Which busbar materials were compared?

    Copper, Aluminum, and CCA (Copper-Clad Aluminum).

  • How do ventilation openings impact thermal performance?

    A 10 % increase in vent area can reduce temperature rise by 15 %.

  • What current rating benchmark was validated?

    Baseline: 1 250 A @ 75 K; Target: 1 600–1 750 A with optimized designs.

  • Which IEC standard governs switchgear temperature rises?

    IEC 62271-307 sets limits (75 K max at busbar/CB junctions).

  • Which design had the lowest cost per MVA?

    Design 4 (Aluminum U-profile): ~$14 USD/MVA.

  • What factors limit MV switchgear performance?

    Testing costs, junction temperature rises, and outdated materials.

  • How does Keentel apply these findings?

    Through simulation-driven design reviews and targeted busbar optimizations.

  • Can these strategies apply to Substation Design?

    Absolutely—see our Substation Design Services for end-to-end primary and secondary engineering.

Case Studies

Case Study 1: 1 600 A Switchgear Panel Redesign

  • Client: Confidential MV Manufacturer
  • Challenge: Upgrade 1 250 A panel to 1 600 A without exceeding 75 K rise
  • Solution: Thermal simulations of five busbar layouts
  • Result: Ventilated copper busbars achieved 1 695 A @ 75 K and cut cost/MVA by 36 %

Case Study 2: Rural Substation Cost Reduction

  • Client: Utility in Latin America
  • Challenge: Lower busbar costs while maintaining performance
  • Solution: CCA busbars with copper cladding
  • Result: Thermal compliance at 1 700 A and 45 % cost savings vs. pure copper

Case Study 3: Compact Offshore Panel

  • Client: Offshore Platform Developer
  • Challenge: High-density footprint with harsh-environment demands
  • Solution: Hybrid copper-aluminum profiles + optimized ventilation
  • Result: 1 750 A panel @ $22/MVA, fully GIS-compatible

Why Keentel Engineering?

  • Deep MV Expertise: Decades in EHV, HV & MV Power System Studies
  • Simulation-Backed: From thermal to internal-arc analyses
  • Standards-Driven: Full compliance with IEC 62271, UL, and CE
  • Cost Optimization: Material trade-off assessments reducing your CAPEX
  • Client-Centric: Tailored reviews aligned to your budget and timeline

Learn more about our full EHV, HV, MV Power System Studies or contact us for a design consultation.

Ready to Transform Your Switchgear Design?

Don’t let outdated materials or excessive testing costs hold you back—partner with Keentel Engineering for simulation-driven, IEC-compliant switchgear solutions tailored to your project needs.

Man in a blazer and open shirt, looking at the camera, against a blurred background.

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.

Four workers in safety vests and helmets stand with arms crossed near wind turbines.

Let's Discuss Your Project

Let's book a call to discuss your electrical engineering project that we can help you with.

Man in a blazer and open shirt, looking at the camera, against a blurred background.

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.

Leave a Comment

Related Posts

NERC Compliance Service for Substations: Importance of Proper Programming of RTACs, DFRs, Clocks

NERC Compliance Service for Substations

By SANDIP R PATEL • February 26, 2026
Ensure NERC compliance with proper programming of RTACs, DFRs, clocks, and protection devices. Learn how Keentel Engineering can help you meet PRC-028-1 standards for disturbance monitoring and reporting
PRC-024-3 vs PRC-029-1 comparison for IBR generator owners with NERC and Keentel Engineering logos

PRC-024-3 vs PRC-029-1

By SANDIP R PATEL • February 25, 2026
Understand the critical shift from PRC-024-3 to PRC-029-1 for IBR Generator Owners. Learn how Keentel Engineering helps you navigate the 2026 cutover, ensuring full compliance with dynamic simulation, performance validation, and event monitoring.
Western grid transformation with wind turbines, solar panels, HVDC, and EMT simulations.

Global Grid-Scale BESS Market 2026: Statistical Deep Dive into Deployment Trends, China’s Dominance, Australia’s Scale-Up, and US Diversification

By SANDIP R PATEL • February 25, 2026
Explore the latest developments in the global grid-scale Battery Energy Storage Systems (BESS) market, including deployment trends, China's dominance, Australia's rapid scale-up, and the U.S.'s shift towards diversified storage technologies. Gain insights into market dynamics, policy impacts, and technology advancement
Sunset over renewable energy infrastructure with wind turbines, solar panels, and power transmission

The Western Grid at a Turning Point: Why Harmonized EMT Modeling and IBR Performance Criteria Are Now Essential

By SANDIP R PATEL • February 24, 2026
Explore why harmonized EMT modeling and IBR performance criteria are essential for reliability in the Western Interconnection and Bulk Power System.
electricity pylons silhouetted against a twilight sky, with power lines str

Strengthening Grid Reliability: New Dynamic Modeling Requirements for Large Loads in Texas

By SANDIP R PATEL • February 24, 2026
Learn how ERCOT PGRR 144 impacts large loads in Texas, including dynamic modeling, validation tests, and compliance requirements.
SEL-3555-2 Real-Time Automation Controller (RTAC) by Keentel Engineering highlighting data concentra

Advanced Substation SCADA Design Using the SEL-3555-2 RTAC How Keentel Engineering Delivers Secure, High-Performance, Standards-Compliant Automation Architectures

By SANDIP R PATEL • February 23, 2026
Explore advanced substation SCADA design using the SEL-3555-2 RTAC. Secure, IEC 61850-compliant, NERC-ready automation by Keentel Engineering.
Close-up of high-voltage insulators and electrical equipment in a substation, illuminated at twiligh

Five Phenomena That Could Collapse the Entire Power System

By SANDIP R PATEL • February 22, 2026
Large-scale blackouts are increasing due to reduced inertia, renewable penetration, and cascading failures. Explore the five grid instability phenomena—transient angle, frequency, voltage, small signal, and cascade tripping—and the multi-layer defense strategies that prevent total power system collapse.
Keentel Engineering logo with the text “Owner’s Engineer Services in Renewable Energy & Power Infras

Owner’s Engineer Services in Energy & Power Infrastructure

By SANDIP R PATEL • February 20, 2026
Independent Owner’s Engineer services for renewable energy, substations, transmission, and BESS projects—protecting quality, compliance, and long-term asset value.
WECC logo with the text “Electric Reliability and Security for the West” and title “WECC Interconnec

WECC Interconnection-Wide Data Modeling Requirements: What Utilities, Developers & Engineers Must Know — And How Keentel Engineering Ensures Full Compliance

By SANDIP R PATEL • February 20, 2026
Understand WECC interconnection-wide modeling requirements for steady-state and dynamic cases, BES compliance, DER integration, and long-term planning.