Do you provide electrical design for industrial plants and factories?

Yes. Electro Solutions provides electrical design consultancy for factories, production units and plant buildings, including load calculations, HT/LT distribution, SLDs, cable schedules, BOQ and working drawings.

Can you plan motor loads and process equipment demand?

Yes. Motor loads, utility loads and process equipment requirements can be included when machine lists, equipment ratings or expected demand information is available.

Do you include transformer, DG and substation planning?

Yes. Industrial packages can include transformer sizing, DG coordination, substation planning, panel schedules and distribution drawings based on the project requirement.

What documents are included for industrial tendering?

A typical industrial package includes the connected load and demand summary, single-line diagrams, transformer and DG sizing, power and lighting layouts, earthing and lightning protection layouts, cable schedules, tender-ready BOQ, technical specifications and working drawings.

Will the design comply with Indian standards and utility board requirements?

Yes. Industrial designs are prepared against IS 732, IS 3043 for earthing, NBC 2016 and SP 30, and we also follow ECBC 2017 and IEC 60364 where they apply. CEA guidelines and the Indian Electricity Rules are built into the design basis from the start, and the package is tailored to the local DISCOM so load sanction and energization do not stall on documentation.

What technical studies do you carry out to confirm system stability?

Where the project needs it, we run ETAP-based load flow and short-circuit studies, and size cables to control voltage drop across large plant distribution. Load flow confirms equipment is sized for peak demand; short-circuit analysis sets the breaking capacity of switchgear; arc flash analysis defines PPE and safety boundaries for operators.

How does the design allow for future factory expansion and added machine loads?

Distribution architecture, transformer and panel capacities are planned with headroom so additional machine loads can be integrated later without a full redesign.

What is the difference between connected load and maximum demand?

Connected load is the total of all installed equipment ratings. Maximum demand is the actual peak drawn at any one time, which is always lower because equipment does not run together. The gap between them is handled with demand and diversity factors, and it decides your transformer size.

How does power factor correction affect industrial load calculations?

Improving the power factor reduces reactive power (kVAR) demand. That lowers the total kVA on the transformer, so existing capacity goes further and monthly utility penalties come down.

How is the maximum demand calculated for a complex industrial or commercial facility?

We calculate maximum demand by multiplying the total connected load by a diversity factor, which accounts for the fact that not all machines run at full capacity simultaneously. We then verify this against the specific duty cycles of the industrial equipment.

What are the financial and operational risks of under-sizing or over-sizing my power equipment?

Under-sizing leads to frequent power trips, overheating, and potential equipment burnout. Over-sizing results in unnecessary capital expenditure and poor efficiency, often leading to a low power factor that can attract penalties from the electricity board.

Industrial & Plants

Industrial Plant Electrical Design Consultant

Electro Solutions works as electrical design consultants and engineering consultants for industrial projects such as factories, production units and plant buildings, covering HT/LT power distribution, motor loads, transformer and DG backup, substation planning, cable schedules, BOQ and working drawings, as a design-only firm with 20 years of Indian practice.

Discuss a Plant Project Call 082183 69807

Industrial electrical design for loads, motors and uptime

Industrial projects need electrical planning that reflects production loads, process equipment, utilities, stores, admin areas, transformer capacity, DG backup and cable routes. The design must be readable for both contractors and future plant teams.

Electro Solutions prepares connected load and demand assumptions, HT/LT distribution, SLDs, transformer and DG planning, cable sizing, cable schedules, power layouts, lighting layouts, earthing, lightning protection, BOQ, specifications and working drawings for factories, production units and plant buildings.

Machine and motor load planning
HT/LT distribution, SLDs and cable schedules
Transformer, DG, earthing and tender documentation

Industrial project references

Industrial references include AVA Handfab in Partapur Meerut, Brassex India in Moradabad, Stanford Sports in Meerut, Sareen Sports on Mawana Road Meerut, AL-Faheem Meatex in Meerut, Supracraft Industries in Bhiwadi and Everest Food Industries in Meerut.

The public project archive uses representative names and broad work categories so visitors can judge fit without exposing private drawings, plant capacities or commercial information. For any specific factory or production facility, the design basis should come from the current machine list, utility loads and site information.

Review electrical design services · View industrial projects · Preliminary Electrical Design Report Consultant for Commercial Project · Expert Electrical Tender Document Consultant for Commercial Projects · Electrical Design Consultant in Gurgaon for Commercial Projects · Electrical Design Consultant in Dehradun for Commercial Projects · Electrical Design Peer Review and Value Engineering · Professional Electrical BOQ Preparation for Tender · Electrical Consultants in Ghaziabad for Industrial and Commercial Proj · Electrical Consultants in Moradabad for Industrial & Commercial Projec · Hotel and Banquet Hall Electrical Design Consultancy · Electrical Consultants in Noida for Commercial & Industrial Projects · Expert Electrical Consultants in Uttar Pradesh for Industrial Projects · Expert Electrical Consultants in Meerut for Commercial Projects · Electrical Earthing and Lightning Protection Design Services · Understanding the Difference Between LT and HT Panel Design · Commercial building electrical design · Government and public building electrical design · Start with plant load details

Inputs that help plant electrical planning

A useful industrial enquiry should include architectural layouts, production area notes, machine names, equipment ratings, quantity, duty pattern, utility loads, HVAC or compressor needs, admin areas, stores, expected demand and whether DG backup or substation planning is part of the scope.

If those details are not complete yet, Electro Solutions can still review the project stage and explain the missing inputs before a final design basis is prepared. The industrial blog note explains the machine and utility information that owners should prepare before electrical design starts.

Industrial design inputs article · Electrical design process · About Electro Solutions · Contact Electro Solutions

Project references in this sector (25)

Public project names, locations and the broad scope of electrical design work handled on each. Names and locations are public; drawings, load figures and client documents remain confidential.

Stanford Sports, Meerut (HT/LT Design, Motor Load, Working Drawings)
Arihant Prakashan, Meerut (Power Layout, Lighting, Working Drawings)
Brassex India, Moradabad (HT/LT Design, Cable Schedule, BOQ)
Sareen Sports, Mawana Road, Meerut (HT/LT Design, Motor Load, Cable Schedule)
National Sports, Gagol Road, Meerut (Power Distribution, BOQ, Working Drawings)
AVA Handfab, Partapur, Meerut (HT/LT Distribution, Substation Planning, Cable Schedule)
AL-Faheem Meatex Pvt. Ltd, Meerut (Power Layout, DG Integration, BOQ)
Supracraft Industries, Bhiwadi (HT/LT Design, Cable Schedule, Documentation)
Everest Food Industries, Meerut (Power Distribution, DG Coordination, BOQ)
PJ Foods, Rampur (Distribution Design, Cable Schedule, Working Drawings)
MAC Bearings, Bhiwadi (HT/LT Design, Motor Load, Cable Schedule)
ICD (Concore), Dadri (Power Distribution, Substation Planning, BOQ)
Nageen Prakashan, Meerut (Distribution Design, BOQ, Documentation)
Goldland Exports, Moradabad (Power Distribution, Working Drawings, Documentation)
Springfit Mattresses, Gejha, Meerut (Power Distribution, BOQ, Documentation)
SAS International, Gejha, Meerut (HT/LT Design, Cable Schedule, BOQ)
Sidwal Industries, Sector-69, Faridabad (Power Layout, Substation Planning, Working Drawings)
Yujin Industries, Sector-69, Faridabad (HT/LT Design, Motor Load, BOQ)
CK Enterprises, Meerut (Power Layout, BOQ, Documentation)
Modern Plastics, Meerut (Power Distribution, Cable Schedule, BOQ)
Wazirchand & Company, Moradabad (HT/LT Design, Working Drawings, BOQ)
AtoZ Industries, Moradabad (Power Layout, Cable Schedule, Documentation)
Brassex Unit-2, Moradabad (HT/LT Design, Cable Schedule, BOQ)
Arvind Prakashan, Meerut (Power Layout, Lighting, Working Drawings)
Arihant Prakashan New Plant, Meerut (HT/LT Design, Cable Schedule, BOQ)

Browse the full project archive · Discuss a project

Building-Scale Electrical Substation Engineering

The scope of a substation design consultant begins with the Design Basis Report (DBR), defining load requirements and utility constraints. We then progress through load flow analysis, equipment sizing, and the creation of Single Line Diagrams (SLDs). The process concludes with detailed layout drawings, technical specifications, and Good for Construction (GFC) drawings that allow contractors to execute the installation precisely.

We provide neutral, design-only expertise for 11kV and 33kV HT/LT substations. Because we do not manufacture panels or supply equipment, our specifications prioritize owner cost-efficiency over vendor commissions, preventing vendor lock-in during the procurement phase.

Power System Studies: We perform Load Flow, Short Circuit, Arc Flash, and Harmonics analysis to validate stability before implementation. Technical Documentation: Precise specifications for transformers, switchgear, and busbars to ensure tender-ready BOQs. Protection & Safety: Earthing and lightning protection layouts coordinated with the building's civil plan to meet safety codes. Regulatory Alignment: Every design adheres strictly to Indian Standards (IS), IEC, and NBC regulations.

Our experience spans diverse critical environments. For instance, at Sharda Hospital (Greater Noida) and Mahant Indresh Hospital (Dehradun), we managed HT/LT design and critical power distribution to ensure stability for patient-care areas. With 20 years of practice, we bridge the gap between complex engineering and practical Indian regulatory compliance.

By separating design from supply, we provide the technical specifications and working drawings needed for competitive bidding, which typically reduces overall project costs.

National-scale industrial electrical design for large plants

Electro Solutions handles large-scale industrial loads, with 15 MVA delivered on its largest single project to date rather than as a ceiling, and has designed over 1 crore square feet of industrial and commercial space. Since 2006 we have provided design-only consultancy for over 500 projects across India, focusing on high-capacity HT/LT distribution and complex load planning for manufacturing plants.

We operate as a pure design consultancy. Because we do not engage in electrical contracting, panel manufacturing, or supply, we provide unbiased technical specifications and BOQs. This ensures that our electrical design services are focused solely on the owner's technical requirements and long-term operational efficiency.

Our approach ensures compliance with the National Building Code (NBC 2016) and IS 732 for wiring installations. For plants like Brassex India in Moradabad or AVA Handfab in Meerut, we focus on precise HT/LT distribution, cable schedules, and substation planning to maximise uptime for critical machine loads.

We provide tender-ready BOQs and working drawings that contractors can price accurately. Our deliverables include detailed single-line diagrams, cable sizing based on IS 694 or IS 7098, and earthing layouts following IS 3043. We coordinate these designs with architects and PMCs through intermittent site visits.

From motor load planning for Stanford Sports in Meerut to power distribution for National Sports in Meerut, we manage the entire design lifecycle. We size transformers and DG sets to ensure no-break transitions for critical loads, grounding every layout in the National Electrical Code of India (SP 30).

How industrial load calculation and transformer sizing is done

Connected load is the sum of every equipment nameplate rating on site. Maximum demand is the highest load actually drawn at any one time, and it is always lower, because production, utility and admin sections do not peak together. The bridge between the two is a demand factor and a diversity factor applied section by section, and getting that judgement right is what decides whether the transformer is correctly sized.

For transformer capacity we group machinery into critical and non-critical categories, add the maximum demand of each group to arrive at total kVA, and carry a margin for future growth agreed with the owner rather than a fixed rule of thumb. That prevents both overloading and the wasted capital of an oversized unit that never runs near its rating.

The errors that cost the most are ignoring the starting current of large motors, and applying generic demand factors instead of analysing the actual plant cycle. At AVA Handfab (Partapur, Meerut), substation planning was set against real motor loads so the transformer carries peak starting demand without voltage dips on the rest of the plant.

The working method is consistent: aggregate loads by plant section, apply diversity factors so the main distribution board is not over-sized, calculate power factor correction to reduce kVA demand and avoid utility penalties, then size cables on both voltage drop and current carrying capacity so the schedule holds up during execution.

In Uttar Pradesh, utility board approvals expect load data that stands up to scrutiny. The tender-ready BOQ and working drawings map those calculations to what will actually be built, which is what prevents contractor disputes later. At Brassex India (Moradabad) the cable schedule and HT/LT design were aligned to actual maximum demand to keep material cost down without eroding safety margin.

Precision Transformer and DG Sizing for Industrial Uptime

To determine the exact kVA rating, we calculate the total connected load and apply a diversity factor to find the maximum demand. We then add a safety margin, typically 20 percent, to account for future growth and peak surges, ensuring the transformer and DG set handle the actual load without overheating.

We distinguish between connected load, which is the sum of all equipment ratings, and maximum demand, which is the actual peak power used. For projects like Brassex India (Moradabad), we use diversity factors to ensure the system is not over-sized, which wastes capital, or under-sized, which leads to frequent trips.

Backup load planning differs from primary sizing. We identify critical loads that must remain live during outages. For AVA Handfab (Partapur, Meerut), we coordinated the DG sizing with the substation planning to ensure a no-break transition for essential machinery, following SP 30 and NBC 2016 guidelines.

Sizing equipment in isolation is a risk. We integrate transformer capacity with detailed cable sizing and cable schedule preparation to prevent voltage drops. This holistic approach prevents the operational risk of equipment failure due to undersized cabling, even if the transformer is correctly rated.

Over-sizing leads to poor power factors and higher fixed costs, while under-sizing causes capacity overloads and equipment damage. With 20 years of practice, we provide unbiased design-only recommendations, meaning our kVA ratings are based on engineering data rather than equipment vendor commissions.

About Electro Solutions

Electro Solutions is a Meerut-based electrical consultancy founded in 2006 by Mr. Deepak Tyagi. The firm is positioned for building-scale projects, with 500+ completed projects, 1 crore+ sq. ft. designed, and public references across healthcare, industrial, commercial, educational, public-sector and hospitality environments.

Working as a design-only consultancy, Electro Solutions delivers load planning, HT/LT distribution, lighting and power layouts, earthing, BOQ and tender-ready documentation that architects, PMCs and owners use for approval, procurement and site execution.

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