Industry Solution
Industrial Factory Power Distribution Solutions
Turnkey MV/LV power distribution systems for factories, processing plants, and industrial parks — from utility intake to production line power.
Industrial facilities demand power distribution systems that are not just reliable — they must be resilient, scalable, and safe under 24/7 operation. A typical factory's electrical infrastructure includes medium-voltage (MV) intake from the utility, main step-down transformers, low-voltage (LV) main switchboards, motor control centers (MCC), power factor correction (PFC), and distribution to production lines, HVAC, lighting, and auxiliary systems.
Ziyao Power provides complete industrial power distribution packages engineered to your factory's specific needs. We combine our core products — dry-type and oil-immersed transformers, LV withdrawable switchgear (GCS), MV metal-clad switchgear (KYN28), and capacitor banks — into a single, pre-engineered system. All equipment is factory-tested together, reducing on-site integration risks.
Our industrial solutions serve textile mills, food processing plants, steel fabrication, automotive assembly, pharmaceutical facilities, cement plants, and general manufacturing. We understand the harsh operating conditions — dust, heat, vibration, corrosive atmospheres — and configure equipment accordingly with appropriate IP ratings, protective coatings, and thermal management.
Factory Capacity Expansion
Growing manufacturing sectors in emerging markets require new or upgraded electrical infrastructure. Transformer and switchgear capacity must scale with production lines.
Energy Efficiency Mandates
Industry regulations and ESG requirements demand high-efficiency transformers (IEC ES1/ES2), automatic PFC to avoid utility penalties, and energy monitoring systems.
Reliability & Uptime
Unplanned downtime costs manufacturers $50,000–$500,000 per hour. Redundant transformer configurations (N+1), auto-transfer schemes, and robust switchgear are essential.
Motor Control Demands
Industrial plants have hundreds of motors — pumps, compressors, conveyors, fans. Proper MCC design with intelligent motor protection relays and VFD integration is critical.
Harmonic Mitigation
VFD-driven motors, UPS systems, and electric furnaces generate harmonics. Industrial distribution systems need passive or active harmonic filtering to maintain power quality.
Safety & Arc Flash Protection
Industrial electrical rooms require arc-flash-rated switchgear, proper protection coordination, and compliance with NFPA 70E and IEC 61641 for personnel safety.
Oil-Immersed Main Transformers
S22-MHeavy-duty S22-M transformers for outdoor factory substations. High overload capacity, ONAN/ONAF cooling options, and robust tank construction for industrial environments.
Available in redundant N+1 configuration with auto-changeover scheme.
View S22-M Series →LV Withdrawable Switchgear (Main)
GCSGCS-series main LV switchboards with draw-out ACBs, full instrumentation, and Form 4 segregation for maximum operator safety.
Motor Control Center (MCC)
MCCIntelligent MCC panels with withdrawable motor starters, VFD integration, and communication-ready motor protection relays for production line power.
Power Factor Correction
PFCAutomatic capacitor banks with detuned reactors for harmonic-rich industrial environments. Maintain PF > 0.95 to avoid utility penalties.
Textile & Garment
Stable voltage for spinning/weaving machines. Harmonic filtering for VFD-controlled looms. Fire-safe indoor substations.
Food & Beverage Processing
Washdown-rated electrical rooms. Redundant transformer supply. PFC for refrigeration compressor loads.
Steel & Metal Fabrication
Heavy-duty transformers for arc furnaces. High-breaking-capacity LV panels. Harmonic filtering for electric welding.
Automotive Assembly
Clean, stable power for robotic assembly lines. MCC with intelligent motor protection. UPS-backed control power.
Pharmaceutical
Redundant (2N) transformer configuration. Dry-type for clean environments. Detailed power quality monitoring for GMP compliance.
Cement & Mining Processing
Dust-protected (IP54+) electrical rooms. Oversized transformer capacity for crusher/grinder motor starting. Rugged construction.
Reference: 5MVA Factory Electrical Distribution System
Typical single-line configuration for a medium-sized factory with 5MVA connected load, redundant transformer supply, main LV switchgear, MCC, and PFC. Reference design based on industrial best practice — not a specific customer project.
| Equipment | Qty | Specification |
|---|---|---|
| MV Intake RMU | 1 set | 12kV, 630A, 3-way SF6 RMU, utility metering compartment |
| Main Transformers | 2 | S22-M 3150kVA each (N+1 redundant), 11/0.4kV, Dyn11, ONAN |
| LV Main Switchboard | 1 set | GCS, 400V, 5000A, 80kA, Form 4b, bus coupler + 2 incomers |
| Motor Control Center (MCC-1) | 1 set | 12-way withdrawable, 37kW–250kW, soft starters |
| Motor Control Center (MCC-2) | 1 set | 24-way fixed/withdrawable, 0.75kW–30kW, DOL |
| Capacitor Bank | 1 set | Automatic PFC 1200kVAR, 12-step, 7% detuned reactors |
| Sub-Distribution Panels | 8 units | TPN DBs, 200A–630A, for lighting, HVAC, auxiliaries |
| Energy Management System | 1 system | Multi-function meters, data logger, Modbus TCP to BMS |
Q: How do you size transformers for a factory?
We calculate based on total connected load × diversity factor (typically 0.6–0.8) + 20% future expansion. Motor starting currents (typically 6× FLC for DOL) must be considered. We recommend N+1 transformer configuration for critical 24/7 operations.
Q: Can you supply complete pre-wired switchboards?
Yes. Our GCS LV switchboards, MCCs, and capacitor banks are fully assembled, wired, and factory-tested. We provide full FAT (Factory Acceptance Test) reports. On-site work is limited to cable termination and final commissioning — saving weeks of installation time.
Q: Do you provide arc-flash studies and protection coordination?
We perform protection coordination studies and arc flash hazard analysis using ETAP or equivalent software. Our switchgear is arc-tested to IEC 61641 and we provide detailed settings schedules for all protection relays.
Q: What is the typical delivery time for an industrial package?
Standard production: 8–10 weeks for transformer + switchgear packages. Express manufacturing available at 6 weeks with surcharge. We can stage deliveries to match your construction schedule — transformers first, switchgear 2–3 weeks later.
Q: Do you offer turnkey installation and commissioning?
We provide factory-trained commissioning engineers for on-site supervision, testing, and handover. For turnkey EPC (design + supply + install + commission), we work with local electrical contractors under our supervision. This service is available in Middle East, Africa, and Asian markets.
Power Your Factory with IEC-Certified Equipment
Share your factory single-line diagram or load list — we'll engineer a complete power distribution package with competitive pricing and delivery schedule.