Industrial growth in Surat has accelerated rapidly in the last decade. With new manufacturing units being set up across textile, chemical, and engineering sectors, the demand for high-capacity and stable electrical infrastructure has never been higher. Many industries expanding operations face a crucial challenge:
How do you build a reliable, compliant, and cost-efficient 66 kV power system that supports future growth while minimizing downtime?
At Ashish Electrical, we specialise in end-to-end HT/LT electrical projects across Gujarat, and one of our most significant turnkey achievements has been delivering a 66 kV power solution for a leading manufacturing plant in Surat.
This detailed case study walks you through the entire process — from planning and load analysis to commissioning — showcasing how a well-planned electrical system can transform industrial productivity.
Client Overview: A Fast-Growing Surat Manufacturing Unit
The client was a mid-sized manufacturing plant located on the outskirts of Surat. Rapid production expansion had pushed their electrical load far beyond the existing 11 kV supply.
Their challenges included:
- Frequent voltage drops affecting machine performance
- Rising downtime costs
- Overloaded transformers
- Inefficient power factor leading to penalties
- Growing demand for future expansion
The company needed a high-capacity, stable, and scalable electrical infrastructure, which made the 66 kV supply line the ideal long-term solution.
They approached Ashish Electrical due to our experience in turnkey HT installations, substation development, switchyard design, and utility liaisoning across Gujarat.
Phase 1: Load Study, Feasibility Assessment & Technical Planning
Before proposing a solution, our engineering team conducted a comprehensive load study, evaluating:
- Current demand
- Expected growth over 5–10 years
- Machinery electrical ratings
- Peak-time load behaviour
- Harmonics and power factor
- Short circuit levels
- Retrofitting possibilities
Key Findings
- Current load: 8.5 MVA
- Projected load in 5 years: 14–16 MVA
- A 66 kV power source was a necessity, not a choice.
- The plant needed a double-transformer setup for redundancy & reliability.
Based on this, we designed a future-ready electrical system capable of supporting expansion without major upgrades.
Phase 2: Designing a Robust 66 kV Electrical Architecture
Our proposed solution included:
✔ 66 kV Outdoor Switchyard
- Gantry structure
- Circuit breakers
- Isolators
- Lightning arrestors
- Current & potential transformers
- Earthmat design with fault current calculations
✔ Two 66/11 kV Power Transformers (10 MVA each)
Configured in:
- N+1 redundancy mode
- Ensuring uninterrupted production
- Allowing transformer maintenance without shutdown
✔ HT Control Panels & Relay Protection Systems
We deployed:
- Numerical relays
- Over-current and earth-fault protection
- Differential protection
- SCADA-ready systems
✔ Underground XLPE Cables
High-quality XLPE cables were installed for:
- Incoming 66 kV line
- Interconnection between switchyard and control room
- LT distribution across plant workshops
✔ Grounding & Earthing System
We installed a grid-type earthing system meeting IE/IEC/CEA standards to ensure:
- Electrical safety
- Lightning protection
- Fault current dissipation
- Increased equipment lifespan
✔ Complete LT Distribution Network
Including:
- PCCs & MCCs
- APFC panels
- VFD panels
- Bus ducts
- Cable trays
- Intelligent metering systems
The design focused on:
- Maximum uptime
- Energy efficiency
- Future scalability
- Safety compliance
Phase 3: Utility Approval, Documentation & Liaisoning
Obtaining approvals for a 66 kV connection involves extensive regulatory coordination. Our liaisoning team handled:
- Load extension applications
- CEIG (Chief Electrical Inspector to Government) approvals
- Structural drawings submission
- Safety & compliance audits
- Transformer and switchyard approvals
- Metering and protection compliance
- Testing and certification
This streamlined the client’s process and cut approval time significantly.
Phase 4: Execution — From Civil Foundations to Final Cabling
The execution phase required precision, planning, and strict adherence to safety standards.
Major execution activities:
✔ Construction of 66 kV switchyard foundations
✔ Fabrication & installation of gantry structures
✔ Erection of transformers
✔ Installation of HT panels
✔ Cable trenching & laying
✔ Earthing network deployment
✔ Lighting, fencing & safety systems
✔ Indoor control room setup
✔ SCADA & monitoring system integration
We ensured:
- Zero-accident site operations
- 100% compliance with CEA and IE rules
- Fast-track execution
- Continuous coordination with plant engineering teams
Phase 5: Testing, Commissioning & Handover
Before energisation, we conducted rigorous testing, including:
✔ Transformer oil testing
✔ Relay testing using secondary injection
✔ Primary injection test
✔ Tan delta testing
✔ Insulation resistance test
✔ HV pressure testing
✔ Earth resistance measurement
✔ Load balancing test
Only after successful results, we coordinated with the utility provider for final energisation of the 66 kV line.
The system was commissioned without a single shutdown of the running plant, which was a major requirement from the client.
The Results: Measurable Impact for the Client
Within months, the new power infrastructure transformed the plant’s operational efficiency.
✔ Zero downtime from electrical overloads
Production consistency improved dramatically.
✔ A stable 66 kV power source
No more voltage fluctuations affecting sensitive machines.
✔ 20–25% improvement in overall energy efficiency
Thanks to load management + reduced losses.
✔ Significant reduction in power factor penalties
APFC system kept PF above 0.97 consistently.
✔ Prepared for next 10–15 years of expansion
The infrastructure supports load up to 20+ MVA.
✔ Better safety and compliance
Equipment lifespan increased, and electrical safety standards improved.
Why Industries in Surat Prefer Ashish Electrical for 66 kV Projects
✔ 20+ Years of Experience in HT/LT Projects
We’ve delivered dozens of 33kV and 66kV installations across Gujarat.
✔ End-to-End Turnkey Execution
From design → approvals → installation → commissioning → maintenance.
✔ CEIG-Certified Engineering Practices
Full compliance with national regulations.
✔ In-House Skilled Workforce
Engineers, liaison experts, site supervisors — no dependency on third parties.
✔ Proven Track Record with Manufacturing Plants
Specialising in textile, chemical, ceramic, engineering, food processing, and more.
✔ Fastest Approval & Commissioning Time
Because we handle documentation and utility coordination completely.
When Should You Upgrade to a 66 kV Power System?
If your industry experiences any of the following, the time to upgrade is NOW:
- Plant load above 5–7 MVA
- Frequent transformer overload
- Voltage drops affecting machinery
- Expanding manufacturing capacity
- Planning automation or robotics
- High electricity bills or penalties
- Running on dated 11 kV infrastructure
- Need for long-term scalability
A well-designed 66 kV system reduces operational cost and increases production efficiency.
Conclusion: A Reliable Power System Is the Backbone of Industrial Growth
The 66 kV power project we delivered in Surat is a perfect example of how strategic electrical infrastructure transforms a manufacturing unit’s operations. With meticulous planning, engineering precision, and adherence to the highest safety standards, Ashish Electrical delivered a future-ready, reliable, and efficient power solution.
If your industry is expanding or facing electrical limitations, our team can help design the right HT power system for your needs.
Ready to Upgrade Your Industrial Power Infrastructure?
Contact Ashish Electrical for a turnkey 66 kV, 33 kV, or HT/LT solution built for long-term performance.
📞 We handle design, approvals, installation, and commissioning — end to end.
My Company
📍 Office No-202, 3rd Floor, Exceluss Bussiness Space, Bhimrad, Althan, Surat, Gujarat-395017
📞 +91 02614611867
✉️ office.surat@ashishelectrical.com