Powering progress: India’s substation and switchgear surge

Rising electricity demand, green energy targets and digital innovations drive India’s growing need for modern substations and intelligent switchgear systems.

 


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India: India’s power sector is undergoing a rapid evolution to address increasing electricity needs, enable renewable integration, and upgrade outdated grid infrastructure. Backed by government policies, major investments and emerging technologies, the country is significantly expanding its transmission and distribution systems. At the heart of this transformation are substations and switchgear, which are essential for delivering power safely, efficiently, and reliably.

Infrastructure growth and system overview

India’s high voltage infrastructure includes AC substations ranging from 132 kV to 765 kV, and HVDC substations from ±320kV to ±800 kV. By April 2025, AC substation capacity surpassed 1,317 GVA at 220 kV and above, growing at a CAGR of nearly 6 %. HVDC capacity reached 33,500 MW over the same period.

Switchgear systems are segmented into low (up to 1 kV), medium (6.6 kV and above) and high voltage (up to 1,200 kV) types. While LV switchgear is commonly used in buildings and industry, MV and HV switchgear serve as the control points between transmission and distribution systems. These are crucial for maintaining network stability and are available in air-insulated, gas-insulated, or hybrid designs.

Market drivers and key developments

Electricity demand is rising, driven by industrial growth, urbanization, and climate-related consumption spikes. Emerging applications such as data centers and EV charging hubs are also increasing grid loads. The per capita electricity consumption is expected to rise from 1,331 kWh (2022–23) to over 1,700 kWh by 2031–32.

To meet this surge, India’s transmission plan includes thousands of new circuit kilometers and hundreds of substations. Policy shifts have also made it easier to locate and develop new facilities, reducing land acquisition hurdles and fast-tracking project execution.

Initiatives like the Green Energy Corridor aim to connect 20 GW of renewable power by 2026 through new intra-state lines and substations. In addition, the RDSS programe is boosting distribution capacity with over 2,300 substations already sanctioned and thousands of transformers under installation.

Technology trends

Innovation is shaping the future of substations and switchgear. Hybrid substations offer compact, modular designs suitable for space-constrained areas. Digital substations improve safety, control and cost-efficiency by leveraging automation and intelligent devices.

On the switchgear side, smart systems with sensors and microprocessors offer predictive maintenance and enhanced energy savings. GIS and hybrid GIS solutions reduce footprint and boost reliability, while vacuum switchgear provides an eco-friendly alternative to SF6-based systems.

Challenges and outlook

Safety remains a concern due to high voltages and equipment complexity. Failures can lead to severe outages and risks to human life. Regular monitoring and adherence to new safety regulations are key to preventing accidents.

Environmental sustainability is also rising in importance. Modern substations now aim to minimize resource use and avoid pollutant leakage, supporting greener operations.

As electricity consumption continues to climb, and renewable projects expand, the demand for advanced substations and switchgear is set to grow. Backed by government support and digital innovation, this segment will be a cornerstone of India’s power sector transformation.

Source: Power Line