Manufactured under ISO 9001:2015 and compliant with IEC 60076, IEC 62271, and IS 1180 international engineering standards.
Precision micro-controller driven transient surge and over/under-voltage protection socket designed for heavy inductive cooling appliances, compressors, and sensitive localized control boards.
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Heavy-duty 24kV indoor fixed vacuum circuit breaker engineered with low resistance interrupter chambers, robust mechanical endurance (Class M2), and superior short-circuit interrupting capacity.
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1 to 3 core heavy-armored power cables with XLPE insulation and low-smoke zero-halogen (LSZH) fire-retardant outer sheathing for coal mines, underground conduits, and industrial feeders.
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Compact side-mounted 3-phase MV vacuum circuit breaker featuring 25kA breaking capacity, ideal for space-constrained compact secondary substations and metal-clad switchgear panels.
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Custom cross-section (25mm² to 500mm²) high-conductivity copper or EC-grade aluminum conductor cables with triple-extruded XLPE insulation and steel tape/wire armoring.
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Gapless zinc-oxide (ZnO) surge arresters engineered for superior overvoltage clamping, protecting distribution transformers and overhead lines against lightning strokes and switching surges.
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Modular factory-assembled MV switchgear incorporating VCBs, RMUs, and air/gas insulated busbars, designed for seamless integration into utility distribution networks and industrial complexes.
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Outdoor pole-mounted expulsion fuse cutouts featuring high mechanical strength porcelain/polymeric insulators and dependable fault isolation for overhead MV distribution circuits.
Send an InquiryThe global electrical power infrastructure market is undergoing a structural transition driven by grid modernization, massive renewable energy integration, and rapid industrial electrification across emerging markets. Within this evolving landscape, India has consolidated its status as a top-tier manufacturing hub for Medium Voltage (MV) power equipment, ranging from 3.6 kV to 33 kV voltage classes. Fueled by advanced metallurgy, precision copper/aluminum conductor drawing, automated foil winding, and in-house core fabrication, Indian Original Equipment Manufacturers (OEMs) provide international procurement entities with an ideal combination of rigorous engineering compliance and cost efficiency.
Leading manufacturers operating out of industrial centers such as Rajkot, Gujarat—where Synergy Transformers Pvt. Ltd. established its state-of-the-art facility in 2004—control every step of the production process under one unified Quality Management System (QMS). By managing everything internally—from raw Cold-Rolled Grain-Oriented (CRGO) steel slitting and core assembly to structural tank fabrication, automated vacuum pressure impregnation (VPI), resin casting, and routine high-voltage dielectric testing—Indian OEMs eliminate third-party supply chain bottlenecks. This vertically integrated manufacturing model ensures strict batch-to-batch consistency, complete material traceability, and exact adherence to international client specifications.
Utilizing premium grade, high-permeability CRGO silicon steel laminations cut on precision step-lap miter lines. This design reduces no-load losses, decreases magnetizing currents, and eliminates acoustic resonance in compliance with IS 1180 Level 1 & Level 2 standards.
Replacing conventional round wire with continuous copper or aluminum strip foil on Low Voltage (LV) windings. This technical approach eliminates axial short-circuit forces, reduces hot-spot thermal spikes, and extends operating lifetime during heavy load cycles.
Featuring hermetically sealed oil tanks or cast resin dry-type enclosures rated up to IP55. Built with anti-corrosive shot-blasted surface coatings designed to resist aggressive marine, desert, and chemical plant environments.
Medium voltage equipment operates under vastly different electrical and environmental conditions depending on its geographical installation site and load type. A standardized off-the-shelf equipment configuration often fails under extreme environmental stresses. Customized OEM engineering addresses these specific localized field conditions:
Renewable power plants expose step-up transformers and MV switchgear to high solar radiation, ambient temperatures exceeding 50°C, high harmonic distortion from central inverters, and frequent thermal cycling. Custom OEM units feature K-factor rated insulation, electrostatic shielding between multi-winding LV configurations, and forced-oil/forced-air (ONAF) heat exchangers.
Underground extraction networks require explosion-proof, flame-retardant MV XLPE cables and compact vacuum circuit breakers capable of withstanding heavy vibration, humidity, and conductive dust accumulation. Specialized flame-retardant low-smoke (FRLS) sheathing ensures fire safety in confined underground shafts.
Steel melting facilities generate intense mechanical shocks, rapid load swings, and frequent short-circuit conditions. OEM furnace transformers incorporate heavy-duty internal structural clamping, reinforced turn-to-turn insulation, and specialized off-circuit or on-load tap changers (OLTC) to handle extreme electrical stress.
The table below highlights the engineering envelope and design parameters available for OEM customization across global utility and industrial supply projects:
| Equipment Category | Voltage Rating Class | Insulation & Thermal Class | Applicable Standards | OEM Customization Envelope |
|---|---|---|---|---|
| Oil-Immersed Distribution Transformer | 11kV / 22kV / 33kV | Class A (Liquid-immersed, ONAN/ONAF) | IS 1180, IS 2026, IEC 60076 | Hermetically sealed / Conservator, corrugated tanks, magnetic level gauges, pressure relief valves. |
| Cast Resin Dry-Type Transformer | Up to 33kV | Class F / H (Epoxy Cast, AN/AF) | IEC 60076-11, F1 / E2 / C2 | Oil-free, flame-extinguishing, IP21 to IP55 enclosures, PT100 temperature monitoring sensors. |
| Vacuum Circuit Breaker (VCB) | 12kV / 24kV / 36kV | Vacuum Dielectric Interrupter | IEC 62271-100, IEC 62271-200 | Fixed / Drawout type, side or front mounted, motorized spring charging, anti-pumping relays. |
| Medium Voltage XLPE Power Cables | 3.6/6kV to 19/33kV | 90°C Continuous / 250°C Short-circuit | IEC 60502-2, IS 7098 (Part 2) | Single-core / 3-core, bare/tinned copper or EC aluminum, galvanized steel wire/tape armor, LSZH outer jacket. |
| Compact Secondary Substation (CSS) | 11kV to 33kV Class | SF6 / Air Insulated Busbar System | IEC 62271-202 | Kiosk enclosure, integrated Ring Main Unit (RMU), MV transformer, and LV power distribution panel. |
Evaluating an OEM supplier requires analyzing their manufacturing infrastructure and quality assurance processes. Operating out of a 103,500+ square foot facility in Rajkot, Gujarat, Synergy Transformers maintains a dedicated team of over 70 experienced power engineers and specialized technicians. Every equipment assembly line is governed by a strict quality assurance plan (QAP) to verify long-term field reliability.
Every unit undergoes complete routine testing in our certified test bay prior to dispatch. Tests include voltage ratio, vector group verification, winding resistance, insulation resistance, partial discharge, separate-source AC withstand voltage, and induced overvoltage tests.
We regularly accommodate witness testing and factory audits by international inspection bodies, including SGS, Bureau Veritas, TUV, and Intertek, ensuring full alignment with EPC contractor specifications.
Equipment exported to international markets (Middle East, Africa, Southeast Asia, South America) is protected using vacuum-sealed moisture barrier bags, desiccants, heavy wooden crates, and nitrogen-pressurized tank shipping options.
Standard distribution transformers (up to 2500 kVA) and MV circuit breakers are typically produced within 3 to 5 weeks following GA drawing approval. Custom power transformers, high-capacity furnace transformers, and integrated Compact Secondary Substations (CSS) generally require 6 to 9 weeks, depending on accessory specifications and tap-changer requirements.
Foil winding uses continuous sheet conductors across the full width of the coil, effectively eliminating axial short-circuit forces that occur during grid through-faults. This design improves heat dissipation, lowers hot-spot temperature rise, minimizes internal mechanical stress, and extends overall equipment service life in harsh electrical environments.
Yes. Our engineering department customizes technical parameters—including voltage step ratios, vector groups (e.g., Dyn11, YNd11), short-circuit impedance levels, BIL insulation ratings, surface paint thickness, and terminal bushings—to match localized grid regulations across Africa, the Middle East, South America, and Southeast Asia.
Every shipment includes a detailed technical documentation package: approved General Arrangement (GA) drawings, Schematic Wiring Diagrams, Type Test Reports (issued by accredited independent labs), Factory Routine Test Certificates, Certificate of Origin, Guaranteed Technical Particulars (GTP), and comprehensive Installation & Maintenance Manuals.
Submit your single-line diagrams (SLD), equipment specifications, or tender requirements to receive detailed engineering proposals, GA drawings, and competitive OEM pricing.
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