In the ever-evolving landscape of electrical distribution equipment, the demand for medium voltage (MV) solutions is on the rise, particularly in electro-intensive industries such as data centers, oil and gas, semiconductor manufacturing and e-mobility. In addition to the rise of medium voltage applications, there is also a demand for more digitization in equipment, providing end users with increased visibility into equipment status and proactive maintenance, as well as an increased focus on sustainable solutions.

The rising demand for medium voltage in electro-intensive industries

The increase of electro-intensive industries within the U.S. market has significantly propelled the demand for medium voltage (MV) solutions. These industries, characterized by their substantial energy requirements, encompass data centers, oil and gas operations, semiconductor manufacturing and e-mobility. Each of these fields requires not only higher incoming power but also reliable, efficient distribution of power to maintain uninterrupted operations, spotlighting the critical nature of MV systems in supporting the backbone of modern infrastructure and technological advancements.

In addition to the increase of new construction of these facilities, there is also an increase of medium voltage equipment at these facilities as well as an increase of voltage and ratings required both at the incoming and through the facility. Additionally, the rise of what is referred to as the new energy landscape is also leading to increased focus on medium voltage intertwined with renewable resources. The new energy landscape consists of new forms of energy generation, storage and usage, including wind and solar generation, DC energy and micro-grids.

Specifically, data centers, semi-con and e-mobility emphasize the strong shift in energy demand, these segments are not only having historic growth, but they also seeing an increase in MV usage in their new construction projects. In the context of data centers, the exponential growth of digital data consumption and cloud services has led to major data purchasers and handlers announcing new data center development, with many projects including several phases that stretch over a decade in development. Similarly, semiconductor manufacturing, a cornerstone of the digital age, has seen an increased focus after shortages experienced in 2020, leading to the construction announcements for US-based manufacturing such as Intel’s 2022 announcement in Ohio. Additionally, the rise of e-mobility and fleet charging, underscored by the global shift towards electric vehicles being adopted at several global logistics and transportation companies such as FedEx, Amazon and facilities such as Heathrow Airport, has introduced a new dimension to the new energy landscape, further stressing the importance of resilient MV infrastructure to support charging networks and related facilities.

Digitization: The path to increased reliability and visibility

Faster access to information, quicker service and digital connectivity are not new trends for many global industries, but electrical distribution equipment may be the final frontier of digitization. The transformative power of digitization within the medium voltage landscape is revolutionizing how facility operators approach asset management and maintenance. Through the implementation of cutting-edge digital tools, the sector is witnessing an unprecedented increase in both the reliability and visibility of crucial MV equipment. Central to this advancement is the deployment of sophisticated monitoring systems that harness the potential of the Internet of Things (IoT) and cloud-based technologies. These systems provide a comprehensive view of an asset's health in real time, allowing for the early detection of irregularities that could lead to system failures.

Leveraging data analytics, end users can assess maintenance needs with remarkable accuracy, shifting from reactive to proactive maintenance cycles. This not only ensures the optimal performance of MV assets but also significantly reduces operational costs associated with unplanned downtimes, while also making maintenance procedures more efficient. The integration of digital technologies into MV solutions facilitates remote diagnostics and control, enabling maintenance teams to address issues without the need to be physically present at the site. This capability is particularly invaluable in challenging environments where access is limited or in situations that require immediate response to prevent extensive disruptions.

Moreover, the digitization of MV assets lays the foundation for a smarter power grid — one that can seamlessly adapt to changes in demand and integrate renewable energy sources more effectively. By enhancing the connectivity between various components of the power distribution network, digitization ensures that engineers have a 360-degree view of operations at all times. This interconnectedness not only bolsters the resilience of the power grid but also empowers operators to make informed decisions based on comprehensive data, thereby optimizing energy consumption and minimizing environmental impact.

As we advance further into the digital era, the role of digitization in transforming the MV sector will only grow more critical, offering innovative solutions to age-old challenges and paving the way for a more reliable, efficient and sustainable future.

Continuous health monitoring and integrated controls in MV metal-clad switchgear

The integration of continuous health monitoring and integrated controls into MV metal-clad switchgear represents a transformative leap forward in medium voltage power distribution. This innovative approach leverages the latest in sensor technology and digital analytics to provide real-time insights into the operational health of switchgear. By continuously monitoring key parameters such as temperature, humidity and critical components inside the circuit breaker itself, potential issues can be identified and addressed before they escalate into failures, ensuring uninterrupted power supply and enhancing overall system reliability.

The application of integrated controls further enhances efficiency as well as reliability by ensuring operator safety by removing allowing remote operations. This not only optimizes the performance of the switchgear but also significantly reduces the operator. As we move towards a more digitized and interconnected energy landscape, the potential of continuous health monitoring combined with predictive analytics through cloud software systems and integrated controls in maintaining and improving system integrity cannot be overstated, marking a new era in medium voltage solutions.

Sustainability as a key factor for innovation

The accelerated push towards sustainability will continue to drive innovation. The electrical distribution industry is at a critical juncture, with new regulations and sustainability standards reshaping the way companies design electrical systems, manufacture equipment and utilize MV solutions. These regulatory changes are driven by an urgent need to address climate change and reduce greenhouse gas emissions, asking all involved in the lifecycle of equipment to be cognizant and active in their sustainability initiatives.

Previously I touched on the importance digital will play in the evolution of switchgear, and one facet that will be heavily influenced by digital technologies will be enabling sustainable practices. Through sophisticated data analytics, IoT and other digital tools, industries can gain unprecedented insights into their operations, identifying areas for improvement in energy efficiency, resource management and waste reduction. This digital layer not only enhances operational transparency but also empowers businesses to implement more sustainable practices with greater precision and impact. It can allow them to be more efficient about their equipment usage and ensure it is operating at its peak performance, as well as provide insight into potential wear that could risk the integrity of the breaker itself. By enabling more preventive action around the maintenance of equipment, end users can decrease the chance of premature equipment replacement.

As the global focus intensifies on reducing greenhouse gas emissions and combating climate change, the medium voltage (MV) industry faces a significant challenge due to the widespread use of sulfur hexafluoride (SF6) in gas-insulated switchgear (GIS). Known for its excellent insulating and arc-quenching properties, SF6 has been a cornerstone in the development of MV infrastructure. However, its classification as a potent greenhouse gas, with a global warming potential thousands of times greater than that of carbon dioxide, has spurred a concerted effort to find sustainable alternatives. This endeavor is not just driven by regulatory pressures, including stringent emissions targets and potential bans on SF6, but also by a collective industry commitment to environmental stewardship.

Innovators and engineers across the sector are now actively exploring and developing SF6-free technologies that promise comparable or even enhanced performance without environmental drawbacks. These alternatives include air-insulated switchgear (AIS) that employs vacuum technology and solid insulation materials to eliminate the need for SF6. The transition to SF6-free solutions reflects a broader industry shift towards sustainability, aligning with global environmental goals and consumer expectations for more eco-friendly energy solutions.

However, the dichotomy between the environmental implications of SF6 and the operational benefits of SF6 GIS necessitates a balanced approach, exploring innovative solutions that can deliver the reliability and efficiency of SF6 GIS without its environmental drawbacks. As the industry grapples with this challenge, the quest for sustainable, high-performance alternatives to SF6 in GIS applications becomes increasingly crucial, driving research and development efforts across the sector.

Rethinking manufacturing

In the realm of industrial operations, the pivot towards sustainable manufacturing processes is not just an environmental imperative but a strategic business decision. This shift reflects a comprehensive approach to minimizing the ecological footprint of production while bolstering efficiency and future-proofing businesses against evolving regulatory landscapes. In this transition, the focus extends beyond mere compliance to a proactive embrace of eco-friendly practices that transform every facet of manufacturing, from raw material sourcing to end-product delivery.

Central to this sustainable overhaul is the optimization of material usage. By critically assessing and redesigning production lines, industries can significantly reduce waste, thereby conserving resources and mitigating the environmental impact of their operations. This entails not only the prudent selection and use of raw materials but also the adoption of manufacturing technologies that enhance material efficiency. The integration of advanced automation and precision engineering tools enables industries to achieve tighter control over their processes, minimizing excess and optimizing the use of resources.

Moreover, the adoption of green packaging solutions represents another vital aspect of sustainable manufacturing. Moving away from single-use plastics and non-recyclable materials to biodegradable, recycled and recyclable options not only reduces the environmental toll of packaging but also aligns with the growing consumer demand for sustainable products. This transition, while challenging, offers a compelling opportunity for industries to lead in innovation and sustainability.

As industries embark on this journey towards sustainable manufacturing, the benefits extend beyond environmental conservation. They encompass improved operational efficiency and reduced costs. This comprehensive approach to sustainability in manufacturing processes underscores a commitment to innovation, efficiency and environmental stewardship that will define the industrial leaders of tomorrow.