Index Group

Index Group — 10 MVA Large-Scale Industrial Substation | POWERtrac

10 Megavolt-Amperes. One Vision. Bangladesh's Industrial Power at Its Most Ambitious.

Not every project tests the limits of industrial electrical engineering. This one does. The Index Group substation is among the largest and most complex industrial power infrastructure projects POWERtrac has ever delivered — a 10 MVA high-capacity installation engineered from the ground up to power one of Bangladesh's most demanding manufacturing operations. When the scale of production is this large, the power infrastructure behind it must be equally formidable.

The Scale of the Challenge

At 10 MVA, this is not a project that tolerates half-measures. Large-scale industrial facilities of this magnitude draw enormous, constantly fluctuating electrical loads across multiple production lines, utility systems, and auxiliary operations — all simultaneously, all continuously. The substation must not only deliver that power reliably, it must distribute it intelligently across the entire facility, protect every layer of the system from faults, and optimize energy consumption at every point. Designing and executing this level of infrastructure demands deep engineering expertise, meticulous planning, and zero tolerance for error.

What POWERtrac Delivered

10 MVA, 33/11 kV Power Transformer: The commanding centerpiece of this installation — a 10 MVA primary power transformer that receives high-voltage grid supply at 33 kV and steps it down to 11 kV for controlled distribution across the facility. Built for continuous heavy-load operation, this transformer forms the single most critical component ensuring the entire facility's power supply remains stable and uninterrupted around the clock.

Multiple Distribution Transformers: Rather than relying on a single step-down point, multiple distribution transformers were deployed across the facility — each serving dedicated load zones, production blocks, or utility areas. This distributed architecture reduces transmission losses, enables localized fault isolation, and gives the facility granular control over power delivery to each area of operation.

Outdoor HT Switchgear (VCB): Vacuum Circuit Breaker-based high-tension switchgear at the outdoor 33 kV level provides the primary protection and switching capability for the entire installation — ensuring fast, reliable fault clearance and safe maintenance isolation at the highest voltage level in the system.

Heavy-Duty LT Switchgear: Industrial-grade heavy-duty low-tension switchgear panels manage the final distribution of power to machinery, production lines, lighting, HVAC, and all facility utilities — built to handle the sustained high currents that come with continuous heavy manufacturing operations.

Multiple High-Capacity PFI Plants: Several high-capacity automatic Power Factor Improvement plants were deployed across the facility, each correcting reactive power in its respective load zone in real time. This distributed PFI strategy maximizes the energy efficiency of the entire installation, significantly reduces reactive energy penalties, and protects transformers and motors from the strain of poor power factor across every section of the plant.

Full System Integration & Commissioning: Every transformer, switchgear panel, protection relay, and PFI plant was integrated as a single, coordinated power system — tested for protection coordination, load balance, and operational safety before being handed over for full-scale production use.

The Result

A 10 MVA industrial power infrastructure that stands as one of POWERtrac's most significant project deliveries — scalable, highly reliable, and engineered to support the full operational intensity of one of Bangladesh's largest manufacturing facilities. The system is built not just for today's loads, but with the capacity and architecture to accommodate future expansion as the Index Group's operations continue to grow.

At this scale, power infrastructure is no longer just engineering — it is the strategic foundation on which industrial ambition is built.