MV Switchgear Design for Cost, Safety & Compliance

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

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.

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Testing costs, junction temperature rises, and outdated materials.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.

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.