10 Signs Your Facility Needs a Medium Voltage Switchboard Upgrade

In a world where industries run on continuous and reliable power, even a minor electrical fault can result in costly downtime. Yet, many facilities continue to operate with outdated switchboards that silently compromise efficiency and safety.

A medium voltage switchboard is the central hub that controls, distributes, and protects power across your electrical network. Over time, wear, overloads, or technology gaps make it less reliable — and that’s when an upgrade becomes not just an option but a necessity.

If you’re wondering whether your electrical system needs a change, here are 10 clear signs it’s time to modernize your medium voltage switchboard and take control of your facility’s performance.

1. Frequent Equipment Failures or Unexpected Power Trips

When motors, pumps, or transformers keep tripping without clear causes, it’s often not the machinery — it’s the switchboard. An aging medium voltage switchboard may have worn-out contacts, corroded busbars, or faulty protective relays that can’t handle modern load fluctuations.

Frequent power interruptions not only affect productivity but also damage sensitive electronic components. Upgrading ensures stable voltage regulation and protection aligned with today’s operational demands.

2. Obsolete Protection Relays and Outdated Components

If your facility still relies on electromechanical or static relays, you’re missing out on the precision and intelligence of numerical relays. Old switchboards lack real-time monitoring and event logging, which are essential for predictive maintenance and fault analysis.

Modern medium voltage panels feature digital relays that communicate seamlessly with SCADA systems, offering faster fault detection and reduced downtime. Upgrading modernizes both performance and protection.

3. Rising Maintenance Costs and Spare Part Shortages

Are you spending more time and money finding obsolete spares? Aging low voltage switchboards and medium voltage panels often rely on components that are no longer manufactured.

A switchboard that constantly needs rewiring, cleaning, or relay replacement isn’t cost-effective. Investing in a new, type-tested medium voltage switchboard pays off by cutting maintenance costs, improving reliability, and reducing emergency repairs.

4. Increased Load Demands Beyond Design Capacity

When your plant expands or machinery upgrades, your existing switchboard might no longer support the higher power demand. Overloaded switchboards operate under constant thermal stress, leading to overheating, insulation breakdown, or arcing faults.

An upgraded medium voltage switchboard is designed to handle higher short-circuit levels and future expansions safely. It ensures smooth power distribution without compromising protection or efficiency.

5. Poor Power Quality and Voltage Fluctuations

Do your lights flicker or your drives malfunction during peak hours? That’s a red flag. Old switchboards often lack proper voltage regulation and reactive power compensation.

A modern switchboard integrates features like voltage monitoring, harmonic filtering, and reactive power management — stabilizing your network and extending equipment lifespan.

For facilities using both medium voltage panels and low voltage switchboards, balanced power quality across all voltage levels is critical for consistent performance.

6. Lack of Remote Monitoring and SCADA Integration

In the era of Industry 4.0, real-time visibility is no longer optional. Traditional switchboards operate blindly — engineers have no instant data on power health, fault status, or breaker operations.

Modern medium voltage switchboards come equipped with intelligent communication modules and SCADA integration. You can monitor load, current, and fault conditions from a central dashboard, enhancing response times and predictive maintenance capabilities.

7. Safety Non-Compliance or Audit Failures

Electrical safety standards evolve continuously. Many facilities unknowingly operate with switchboards that no longer comply with modern IEC or IS standards.

If your system has exposed live parts, inadequate interlocking, or poor fault isolation, it’s a potential safety hazard. A compliant medium voltage switchboard includes arc-flash protection, metal-enclosed compartments, and proper earthing — protecting both personnel and infrastructure.

8. Visible Signs of Wear, Corrosion, or Overheating

Sometimes, the warning signs are right in front of you — discolored cables, hot spots on panels, or a burnt smell inside the cubicle.

These are symptoms of aging conductors, deteriorated insulation, or loose terminations. Ignoring them risks short circuits and fire hazards. Upgrading to a new medium voltage panel ensures fresh insulation, better cooling, and modern thermal protection features that keep operations safe.

9. Difficulty in Expansion or System Integration

Older medium voltage switchboards were not built with modularity in mind. Adding new feeders, integrating renewable energy, or connecting automation systems often becomes a nightmare.

Modern switchboards are modular and scalable — allowing easy additions without system downtime. This flexibility is essential for industries growing into smart, energy-efficient infrastructures powered by solar, wind, or hybrid systems.

10. Energy Inefficiency and Missed Sustainability Goals

Sustainability is now a core operational goal for most industries. If your power system lacks energy monitoring or load optimization tools, you’re likely wasting electricity.

A modern medium voltage switchboard can integrate smart metering and energy management systems that track consumption, identify wastage, and optimize usage patterns.
When combined with upgraded low voltage switchboards, the result is a cleaner, greener, and more efficient power ecosystem.

Why Upgrading Now Is a Strategic Investment

Delaying a switchboard upgrade may seem cost-saving initially, but in the long run, it can lead to expensive downtime, safety incidents, and lost energy efficiency.

A state-of-the-art medium voltage switchboard offers measurable benefits:

• Improved system reliability and uptime

• Lower operating and maintenance costs

• Seamless integration with smart grids and SCADA

• Enhanced protection for assets and people

• Compliance with international standards

An upgrade transforms your switchboard from a passive distributor into an intelligent command center for your facility.

How to Plan a Successful Switchboard Upgrade

1. Conduct a Load & Condition Audit: Identify weak points, aging components, and future power requirements.

2. Engage a Qualified EPC Partner: Choose experts experienced in power systems engineering and commissioning.

3. Ensure Design Compatibility: Match your new switchboard with transformers, relays, and downstream systems.

4. Incorporate Future Readiness: Include spare feeders and modular sections for future loads or renewable integration.

5. Test Before Commissioning: Perform FAT and SAT to verify performance, safety, and system reliability.

When done right, upgrading your switchboard can redefine your facility’s energy efficiency and reliability for decades.

Empower Your Facility with Hartek Group

If your facility shows any of these 10 signs, it’s time to act. Hartek Group, one of India’s leading EPC and power infrastructure companies, specializes in designing, manufacturing, and commissioning advanced medium voltage switchboards, medium voltage panels, and low voltage switchboards tailored for industrial, commercial, and utility applications.

From modernizing legacy systems to building next-generation substations, Hartek delivers performance-driven solutions backed by engineering excellence.