Published by On Load Gears
In the fast-evolving power distribution and transmission landscape, switchgears remain a foundational component ensuring system integrity, operational control, and fault resilience. At On Load Gears, we don’t just manufacture switchgears—we engineer them with precision, purpose, and a deep understanding of the Indian and global power ecosystem.
This article takes a deep dive into the technical and process-centric foundation of our switchgear portfolio, highlighting the advanced engineering practices and rigorous quality assurance protocols that define our products.
What Makes Switchgears Critical in Power Systems?
Switchgears serve three fundamental purposes:
- Control the flow of electricity
- Protect systems from overloads and faults
- Isolate faulty sections without disrupting the rest of the network
At voltages like 11 kV and 33 kV, reliability, breaking capacity, mechanical endurance, and insulation coordination are non-negotiables—and that’s where our product excellence shines.
Our Switchgear Product Portfolio
We offer a comprehensive range of medium-voltage switchgears built to meet the demands of utility, industrial, and commercial infrastructures:
1. Porcelain-Clad Outdoor VCBs (11 kV & 33 kV)
- Designed for harsh outdoor environments
- Encapsulated in porcelain to ensure pollution resistance and weather durability
- Breaking Capacity: Up to 26.3 kA
- Applications: Substations, power grids, renewable energy tie-ins
2. Metal-Clad Indoor VCB Panels
- Modular, compact, and safe for confined electrical rooms
- Integrated with interlocks and pressure relief systems
- Rated Voltage: 11 kV / 33 kV
- Customizable for control panels, metering, and remote operation
3. Vacuum Load Break Switches (LBS)
- Ideal for isolating and interrupting load currents up to 630 A
- Vacuum technology eliminates arc flash risks
- Compact footprint for Ring Main Units and pole-mount substations
4. Solenoid-Operated Capacitor Switches (15 kV)
- High-speed switching without restrikes or transients
- Used for capacitor banks in large-scale industries and power factor correction systems
Engineering Process and Manufacturing Excellence
Our switchgear manufacturing follows precision-guided stages that ensure product reliability, safety, and longevity:
1. Design Engineering
- Conducted in-house by a dedicated R&D team with expertise in high-voltage systems
- Finite Element Analysis (FEA) and electromagnetic simulations guide mechanical and electrical design
- Customization based on IEC/IS standards and specific client requirements
2. Material Selection
- Vacuum interrupters sourced from globally reputed suppliers (with internal QA certification)
- High-creepage insulation materials for polluted environments
- Stainless steel / hot-dip galvanized structures for corrosion resistance
3. Assembly and Integration
- All switchgear units are assembled in a controlled environment using precision jigs and fixtures
- Mechanical interlocks, earthing mechanisms, and arc shutters are tested for alignment and function
4. Testing and Quality Assurance
Every unit undergoes:
- High-voltage withstand test (up to 75 kV for 33 kV units)
- Partial Discharge (PD) test to ensure insulation integrity
- Mechanical endurance up to 10,000 operations
- Short-time withstand current test per IEC 62271
5. Client-Specific FAT and SAT
- Factory Acceptance Test (FAT) tailored to client protocols
- On-site commissioning support and Site Acceptance Testing (SAT) assistance as required
Compliance and Standards
Our switchgear solutions comply with:
- IEC 62271-100 (High-voltage circuit breakers)
- IS 13118 (VCBs for indoor use)
- IEC 62271-200 (Metal-clad switchgear)
- Custom testing per customer specs, CPRI, and NABL-accredited labs
Long-Term Reliability and Maintenance
- Modular construction allows for easy retrofit or replacement of breakers and switches
- Vacuum technology ensures contact wear is minimal, enabling up to 20 years of operation
- Minimal lubrication requirements and no SF₆ gases make our switchgear eco-friendly and maintenance-light
Industries We Serve
- Power Utilities & DISCOMs
- Large Manufacturing Plants (cement, steel, textiles)
- Metro Rail and Airports
- Commercial Buildings & Data Centers
- Renewable Energy Parks
Why On Load Gears?
- 30+ years of manufacturing legacy in high-voltage power equipment
- Fully equipped in-house testing facility and QA lab
- Trusted by leading EPCs, utilities, and infrastructure developers
- Dedicated post-sales service and support network
Final Word
At On Load Gears, we combine innovation, precision, and engineering depth to manufacture switchgear systems that perform under pressure—ensuring grid stability, equipment protection, and human safety in every installation.
To explore our complete switchgear lineup or request a consultation, visit https://onloadgears.com/