It’s no secret that, around the world, the power grid is anchored by aging substations, transmission lines and communications networks. Even though they were built decades ago, these systems are being asked to support new demands like electrification, AI, renewable energy and EV charging—all without interrupting service. But existing infrastructure wasn’t designed for these kinds of operating conditions.
Whether your next project is about expanding system capacity to support new loads, or upgrading what’s in place to maintain current operations, legacy assets must be able to carry critical services as new infrastructure is brought online.
No matter if you’re planning a single substation retrofit or a multi‑year system‑wide modernization program, upgrades must be planned and executed so the grid keeps operating safely and reliably at all times with few and controlled disruptions. (You might be able to feel the impact of every change, but your customers shouldn’t.)
In that sense, grid modernization is a lot like trying to change the tires on a car as it speeds down the road at 200 mph. The system has to keep moving, keep customers connected and keep meeting strict safety and reliability standards, all while core components are replaced, new technologies are added and the underlying network architecture evolves.
Keep momentum going
How can you reduce risk without slowing progress to a crawl as you modernize critical infrastructure? Start by following these recommendations for grid modernization.
How to de-risk grid modernization
These core principles should shape every aspect of grid modernization, from high‑level architecture to day‑to‑day implementation.
1. Avoid disruption by keeping systems running
Legacy infrastructure is so embedded in daily operations that replacing it overnight with a new, state-of-the-art platform is impossible.
Legacy protocols and equipment aren’t going away any time soon, so the communications and networking layer—even when it’s a mix of old and new technologies—has to be able to:
- Carry legacy and packet‑based traffic
- Support mixed topologies
- Allow incremental migration instead of risky forklift cutovers
- Integrate with existing protection and control schemes
- Provide clear monitoring and diagnostics so issues are caught early
When you’re upgrading assets that can’t go offline, a parallel‑systems approach is desired. Instead of tearing out System A and dropping in System B, utility companies must stand up the new environment alongside the old one, validating performance and protection schemes along the way, and then migrate traffic or functions in controlled phases. That way, if something unexpected surfaces during grid modernization, there’s a clear rollback path.
One question to guide decisions
You can pressure-test every decision by asking: How will this choice promote better, faster, stronger and more scalable power generation over time?
To make better decisions, prioritize partners and solutions that offer long product lifecycles, a clear migration path and the flexibility to evolve as the grid—and your needs—change. The right partner can help you balance the comfort level of today’s operational reality with a forward-thinking vision for tomorrow.
3. Standardize designs
Repeatable designs, prefabricated panels and cabinets, and standardized layouts offer many benefits to utility companies during grid modernization and upgrades:
- Reduced engineering time
- Shorter construction schedules
- Simplified commissioning
- Easy component swapping with less disruption
- Faster scaling as needs grow
- More predictable material planning and inventory management
- Easier training and onboarding for operations and maintenance teams
- Greater performance consistency and compliance across sites
When line, substation and telecom designs follow certain standards and design parameters that can be repeated, the result is delivery with consistent time, cost and risk reductions. Plus, you can learn from each build and apply those lessons to the next project you execute, because they all share the same underlying design framework.
For example, digital substations use standardized, Ethernet‑based communications like IEC 61850 instead of hardwired point‑to‑point connections. This makes it easier to:
- Make protection and control modular
- Replicate proven designs across multiple sites
- Adapt to new devices or applications without having to re‑engineer
4. Follow a clear plan for grid upgrades
New technology, modularity and standards only work when they’re backed by a disciplined and de-risked way of executing upgrades.
A blueprint for grid upgrade projects
Keep projects structured, predictable and easier to repeat.
- Upfront engineering and documentation: Define clear requirements, acceptance criteria and designs so everyone understands what “success” looks like before work begins.
- Building and testing in a controlled environment (factory assessment testing, or FAT): Before anything moves to the field, the solution should be engineered, built and tested offsite so issues can be found early.
- Structured installation: Once equipment ships and installation begins, every step needs to be tracked (what’s been installed where, what’s been tested, what’s ready to be migrated, etc.)
- Site acceptance testing (SAT): Confirm that the new system behaves as expected in the real environment. Only then can functions and traffic be migrated to put the new platform fully into service.
- Phased cutover with a clear rollback plan: Move services over in stages, preserving a safe path back to the previous system if something unexpected occurs.
- Training and handover: Prepare operations and maintenance teams to run and support the new environment by making sure they have documentation and training that reflect the final system.
Throughout the grid modernization process, coordination between telecom, protection and control, and operations is critical so network infrastructure meets real‑world requirements.
Modernize utility operations with confidence
Grid modernization is about not only choosing the right technology but also about having a partner that understands how to apply that technology in ways that reduce risk and make upgrades practical, approachable and easy to repeat.
That’s where Belden comes in. Our complete connection solutions, combined with our experts, help utilities modernize without sacrificing reliability.
We can also help you weave modularity and standardization into your designs and deployment practices, helping you create repeatable building blocks for substations and communications sites. Those building blocks can be reused and refined across projects, cutting engineering time and startup effort while improving consistency from site to site.
We work alongside utilities, integrators and even standards groups to turn high‑level goals into practical designs. This can mean advising on network architectures that align with internal standards, helping select products that fit long‑term roadmaps or supporting lab and field testing.
Belden can help you do your work better, faster and more consistently, without losing sight of the reliability your utility company is measured by every day.
Learn more about our energy solutions.