Power, control and data, engineered as one system.
HiVoltEdge designs and delivers industrial electrical panels, site installation and commissioning, PLC, SCADA and drive systems, and IIoT energy monitoring. Take one service, or hand us the whole package.
- Years of industry experience
- 10+
- Partners on every project
- 4
- Approval gates per project
- 5
One team across the boundaries where projects usually fail
Most industrial projects split the power system, the panels, the automation software and the site work between different agencies. Each works to its own drawings, and the gaps show up at commissioning: a drive that does not talk to the PLC, a panel with no spare feeders, an interlock nobody tested, drawings that no longer match the site.
HiVoltEdge works across those boundaries. Our engineers understand how a feeder, a starter, a VFD parameter and a PLC interlock affect one another, and we work for industrial plants, OEMs, EPC contractors, consultants, plant maintenance teams and procurement groups.
Vision
To be the engineering partner Indian industry trusts for electrical and automation systems that run safely, are easy to maintain and are ready for the plant’s next stage of growth.
Mission
To deliver reliable industrial electrical and automation solutions through disciplined engineering, the right choice of technology, coordinated execution, thorough testing and documentation that serves the plant for years after handover.
How we work
- Safety first
- Hazards, isolation, protection and site rules are planned before any work begins.
- Engineering clarity
- Clear requirements, drawings, interface definitions and acceptance criteria on every job.
- Practicality
- Solutions sized for the real process, operating environment and the plant’s maintenance capability.
- Integration
- Power, control, instrumentation, drives and monitoring engineered as one connected system.
- Traceability
- Drawings, settings, inspections, tests and changes recorded and handed over.
- Continuous improvement
- Commissioning feedback and operating data used to make every next system better.
Products and solutions
We engineer panels from small machine control panels to large industrial distribution assemblies. Each panel is designed as part of the plant: its protection, control logic, communication and maintenance access are worked out alongside the equipment it serves.
| Panel or system | Purpose and typical contents |
|---|---|
| HT/MV switchgear and distribution | HT incoming and transformer feeders, VCBs or RMUs with protection relays and metering, within confirmed voltage classes and authorised scope. |
| LT main distribution panel | Receives transformer or DG supply and distributes to downstream boards and loads. |
| PCC (Power Control Centre) | ACB/MCCB incomers, bus couplers, outgoing feeders, metering and protection for plant loads. |
| MCC (Motor Control Centre) | DOL, star-delta, soft-starter and VFD feeders with protection, local/remote control and status interfaces. |
| Feeder panels and distribution boards | Protection and distribution for defined circuits, utilities and equipment groups. |
| Industrial and machine control panels | Control transformers, relays, PLCs, power supplies, safety relays and terminals. |
| Motor starter panels | DOL, star-delta or other starting arrangements matched to the motor and application. |
| VFD panels | Variable-frequency drives with protection, reactors or filters, cooling and communication interfaces. |
| APFC panels | Automatic power-factor correction with capacitor steps and detuned reactors where harmonics demand. |
| PLC and instrumentation panels | PLC racks, I/O, signal isolators, network switches, SMPS and instrument terminations. |
| Custom assemblies | Panels built around a specific process, control philosophy or customer specification. |
Ratings are never assumed. Rated voltage, current, short-circuit withstand, IP rating, form of separation, cable entry and temperature-rise basis are fixed from your specification and confirmed in our technical offer. Designs reference IEC 61439 and IEC 60947, the project specification, CEA safety regulations where applicable and manufacturers’ recommendations, using your approved makes where provided.
- Components verified against the approved BOM and ratings
- Ferrules and labels that match the drawings
- Protective-device settings checked against the coordination basis
- Continuity, insulation-resistance and functional tests recorded
Fixes for the problems existing plants live with
-
Legacy PLC migration
We migrate obsolete PLC and HMI systems to current platforms, converting and documenting the logic.
Spares availability restored and a supportable, documented control system.
-
Relay logic to PLC conversion
Hard-wired relay panels replaced with PLC control while preserving proven sequences.
Fewer wiring faults, easier modification, faster troubleshooting.
-
Power-factor penalty elimination
PF and harmonics analysed, then APFC designed or upgraded with detuned reactors where required.
Reduced penalties and better use of the supply.
-
Shutdown-window retrofits
Panels and logic pre-built and pre-tested so the site changeover fits a short shutdown.
Upgrades completed with minimum production loss.
-
Undocumented panel recovery
Existing wiring traced and turned into accurate drawings and terminal schedules.
Your team regains control of its own electrical systems.
Power systems and electrification
Reliable plants start with a well-engineered power system. We design the incoming supply interface, distribution, feeders, motor loads, control power, earthing and metering, sized for your load profile, process criticality, supply conditions and expansion plans.
Engineering scope
- Load and feeder assessment, distribution arrangement and panel interfaces
- Integration of motors, pumps, fans, conveyors, process equipment and utilities
- Metering, power-quality and energy-monitoring interfaces
- Motor control and drive interfaces, local/remote modes and status feedback
- Coordination of power, control and instrumentation cabling
- Review of protection, earthing and isolation against the approved design
Every design accounts for load demand, motor starting, prospective fault level, cable capacity, voltage drop, protection selectivity, earthing, environment and the supply authority’s requirements.
Installation, erection and commissioning
The team that understands the design supervises its installation and proves it works: cable trays and routing with power, control and signal segregation, laying, glanding and termination, earthing and bonding, panel installation and field-device connections.
| Test | What it proves |
|---|---|
| Insulation resistance | No damaged or wet insulation in cables, panels and motors |
| Continuity and polarity | Correct conductor connections and core identification |
| Earth continuity and resistance | A sound protective earthing path and electrode |
| Phase sequence | Correct rotation before motors run |
| Control and interlock checks | Start/stop, local/remote, emergency stops and interlocks |
| PLC I/O loop checks | Every signal from field device to PLC to HMI |
| No-load and load trials | Current, temperature and sequence under real operation |
Industrial automation
We design, program and commission control systems in which PLCs, operator screens, drives and field instruments work as one. Because the same team understands the power panel, the logic and the field wiring, interface problems are designed out instead of discovered on site.
- Functional description and operating sequence developed with you
- I/O lists, signal types, scaling and device interfaces
- Sequences, modes, permissives, alarms and fault handling
- Communication with drives, meters, instruments and other controllers
- Testing of normal operation, abnormal states and recovery
- Troubleshooting and modification of existing PLC programs
- Operator screen hierarchy and process mimic design
- Equipment status, operating modes and permitted commands
- Alarm priorities, acknowledgement and event records
- Historical trends and production or utility reports
- Tag integration, user roles, backups and configuration documentation
- VFD selection and sizing for the load, duty cycle and environment
- Parameter configuration, ramps, limits, control mode and auto-tuning
- PLC-to-drive communication or hard-wired control
- Drive fault monitoring and diagnostics
- Energy-saving assessment on pumps and fans, based on the actual load profile
- A parameter record and backup handed over for every drive
- Field transmitter and sensor integration
- Analog signal processing, scaling and isolation
- Control-valve and actuator interfaces
- Loop checks, PID tuning and process interlocks
- Documentation of instrument tags, ranges and settings
How it fits together: a pump station
- Panel distributes and protects power.
- VFDs control pump speed to hold pressure.
- Transmitters report level and pressure to the PLC.
- PLC runs duty/standby and permissive logic.
- SCADA shows pump status, alarms and trends.
- Energy meters feed daily kWh reports.
Dry-run protection and emergency stops stay hard-wired, independent of the network.
IIoT and energy monitoring
We connect meters, controllers and sensors so your team sees energy use, equipment condition and machine status as it happens, instead of waiting for a breakdown or an electricity bill to reveal a problem.
We monitor current, voltage, power, energy, power factor and maximum demand; transformer, motor and panel temperature; run/stop, trip and utility status, running hours and start counts. Data can come from your existing PLCs, RTUs, meters and communication-capable devices.
Monitoring never sits in the safety path. Protection relays, hard-wired interlocks and emergency stops are kept out of the IIoT data path. Remote access uses network segregation, read-only data paths where possible, and your IT security rules.
- DashboardLive views, trends, alarms and management reports
- DataServer or database with defined retention, access and backup
- GatewayProtocol conversion, buffering and secure forwarding, for example MQTT
- NetworkRS-485 with Modbus RTU, Modbus TCP over industrial Ethernet
- ControlPLC, RTU or I/O module that reads and scales signals
- FieldSensors, meters, relays and equipment status signals
| Opportunity | How monitoring helps |
|---|---|
| Power-factor penalties | PF tracking and correctly sized APFC help avoid utility penalties. |
| Maximum-demand charges | Demand alerts let teams shift or stagger loads before limits are crossed. |
| Idle and unnecessary running | Run-hour and load data reveal equipment running without purpose. |
| Pumps and fans | Speed control based on measured demand instead of throttling. |
| Early fault detection | Rising temperature or current trends flag problems before breakdown. |
| ESG and energy reporting | Section-wise kWh data supports sustainability and energy-audit reporting. |
How we deliver projects
Every project follows five phases, and each phase closes with an approval gate. Nothing moves on until the previous gate is signed off, so scope, drawings and quality issues are settled before they become site problems.
Define
Requirement capture, load and process data, site assessment, scope boundaries.
Gate: scope frozen
Engineer
Concept architecture, SLDs, schematics, GA drawings, I/O lists, BOM and estimate.
Gate: drawings approved
Build
Procurement, panel assembly, PLC/HMI programming and integration testing.
Gate: inspected before dispatch
Execute
Site installation, cabling, termination, earthing and interconnections.
Gate: pre-commissioning checks complete
Hand over
Commissioning, performance runs, as-built documents, backups and training.
Gate: acceptance signed
Individual service or turnkey
Take a single defined package, such as an upgrade, a specialist task or an OEM or EPC subcontract. Or give us several disciplines under one contract and one point of responsibility, with interfaces managed within the agreed scope. Every proposal states what we execute directly, what approved subcontractors do under our supervision, and what stays with you or other agencies, such as civil work and statutory approvals.
What you receive at handover
- As-built drawings, O&M documents and open-item list
- Commented PLC program and backup
- Screen set, tag list and alarm configuration for HMI/SCADA
- A parameter record for every drive we commission
- Inspection and test reports, loop checks and commissioning checklists
Start small
- Plant electrical health check
- Visual inspection of panels, IR tests on critical feeders, earthing check and thermal scan where available. You get a prioritised report of risks and fixes.
- 30-day energy monitoring pilot
- Meters and a gateway on selected feeders with a temporary dashboard. You get real consumption, PF and demand data to plan savings.
- Power-factor and demand review
- Analysis of electricity bills, PF and maximum demand, with a plan to reduce penalties and demand charges.
- PLC and drive troubleshooting visit
- On-site diagnosis of control and drive faults: root cause, fix and updated documentation.
Ask us for project references relevant to your industry when you get in touch.
Industries served
We work to your approved vendor list, so your plant keeps its existing spares and standards.
Steel and metal processing
Motor-heavy lines, drives, harsh heat and dust.
Distribution and MCC panels, PLC/drive integration, temperature monitoring.
Cement and minerals
Long conveyor lines, crushers, dust, interlocked start-up.
High-IP MCCs, conveyor sequencing, interlocks, section-wise energy data.
Power and utilities
Auxiliary loads, critical feeders, metering.
Auxiliary distribution, feeder monitoring, alarm and event logging.
Water and wastewater
Pumping, level and flow control, remote sites.
VFD pump panels, PLC/SCADA, remote monitoring and energy dashboards.
Manufacturing and OEM machinery
Machine sequences, operator controls, short delivery cycles.
Machine panels, PLC/HMI, drive set-up and commissioning to OEM standards.
Material handling
Conveyors, transfer points, jam and fault response.
Motor control, drive coordination, PLC logic and status indication.
Process industries
Instrumentation, control loops, alarms and trends.
Instrumentation panels, PID integration, SCADA and control upgrades.
Industrial facilities and infrastructure
Utility distribution, DG integration, maintainable installations.
LT distribution, APFC, interconnections and utility monitoring.
Tell us what you need to build, fix or monitor
Whether it is a single control panel or a complete turnkey package, share your requirement and the partners will propose a practical, documented and maintainable solution.
- info@hivoltedge.in
- Website
- hivoltedge.in
- Registered office
- HiVoltEdge Power Solutions
Office 1 & 2, First Floor, Aishwarya Empire
Labhandih, Koora, Raipur
Chhattisgarh 493221 - GSTIN
- 22AATFH7559L1ZN
For a faster quote, include
- Plant, process and equipment details
- Supply voltage, load list and motor ratings
- Existing drawings, photographs and datasheets
- Operating sequence and control philosophy
- Monitoring and reporting needs
- Site location, access and shutdown window
- Required completion date and scope boundary
Factory
Our factory location is on Google Maps. Use it for directions when you visit or deliver to us.
21.23966° N, 81.41384° E
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