EPC Turn-Key Electrical Projects
End-to-end Engineering, Procurement, and Construction for high-voltage substations, cogen power plants, flameproof distilleries, and heavy industrial facilities. Powered by in-house Trisquare switchgear & POLYVION cables.
The Vertically Integrated DEC EPC Advantage
Conventional EPC projects fail due to third-party vendor delays and fragmented responsibility. DEC eliminates vendor friction by manufacturing key electrical assets in-house through group entities.
Turnkey Engineering & Design
Comprehensive electrical system engineering including single-line diagrams (SLD), short-circuit calculations, relay coordination, cable schedule optimization, and 3D substation layouts compliant with IS/IEC standards.
- Load flow & short-circuit fault analysis
- PESO & CEIG statutory compliance drawing
- State grid export protection design
In-House Manufacturing Integration
DEC group manufactures HT/LT switchgear panels through Trisquare Switchgear and high-grade armoured cables through POLYVION Cables. Guaranteed component quality and zero vendor lead-time bottlenecks.
- Trisquare VCBs, IMCCs, VFD & Synchronising Panels
- POLYVION 1.1kV to 33kV XLPE Armoured FRLS Cables
- Integrated Factory Acceptance Testing (FAT)
Site Execution & Energization
Dedicated on-site civil and electrical engineering teams manage transformer erection, outdoor switchyard structures, cable tray installation, pre-commissioning relay testing, and final CEIG energization.
- Civil foundations, gantries & outdoor switchyards
- Hi-pot, insulation & secondary injection testing
- Grid synchronization & final operational handover
DEC Landmark EPC Turn-Key Projects
Explore DEC's verified turn-key project profiles spanning high-voltage substations, hazardous ethanol distilleries, cogen power plants, and international heavy industrial facilities.
Dalmia Sugar Mill Unit-Jawaharpur 145 KLPD Grain Distillery & Cogeneration Plant Electrical Project
Dalmia Sugar Mills Unit-Jawaharpur in Sitapur, Uttar Pradesh is a major integrated sugar and bio-ethanol complex. DEC executed the complete turnkey electrical infrastructure for their 145 KLPD grain-based ethanol distillery plant and spent-wash incineration cogeneration power project.\n\nThe scope encompassed 33kV outdoor switchyard installation, IS 5571 hazardous-area flameproof (Ex-d) motor control centres for fermentation and distillation, SS304 cable tray routing through corrosive wash areas, spent-wash incineration boiler BOP electricals, and plant-wide POLYVION FRLS cable distribution.
- • 33kV Outdoor AIS Receiving Switchyard & Power Transformer Installation
- • 145 KLPD Grain Distillery & Spent-Wash Incineration Cogen Electrical Scope
- • IS 5571 Certified Flameproof (Ex-d) Switchboards for Alcohol Hazard Zones 1 & 2
Radico Khaitan 330 KLPD Greenfield Ethanol & Hazardous Area Electrification
Distillery and ethanol plants operate under stringent safety protocols due to the presence of flammable alcohol vapors (Zone 1 & Zone 2 hazardous areas classified under IS 5571). For Radico Khaitan's greenfield 330 KLPD grain-based ethanol plant in Sitapur, UP — one of India's largest single-location ethanol production plants — DEC executed the complete electrical EPC contract from 33kV grid receiving down to explosive-area motor controls. The project featured high-density flameproof (Ex-d/Ex-i) motor control centres, stainless steel SS304 cable tray networks through corrosive fermentation blocks, captive turbine synchronisation panels, and PLC/SCADA process automation interface. Through DEC's single point of accountability, all switchboards were manufactured by Trisquare and paired with POLYVION chemical-resistant FRLS cables.
- • Turnkey 33kV/11kV/415V Greenfield Substation & Power Distribution Network
- • IS 5571 Certified Flameproof (Ex-d Group IIA, IIB) Switchboards & Control Stations
- • SS304/SS316 Heavy-Duty Perforated Cable Trays through Fermentation & Wash Areas
Grainfuel Distillery 280 KLPD ZLD Greenfield Electrical & BOP Instrumentation
Modern ethanol plants in Gujarat must comply with zero liquid discharge (ZLD) environmental mandates, requiring high-precision electrical and instrumentation integration across spent-wash evaporators, decanters, and dryer units. DEC was selected by Grainfuel Distillery Pvt Ltd for their landmark 280 KLPD grain-based ethanol facility at Khoda, near Ahmedabad, Gujarat. DEC executed the project on a complete turnkey EPC basis — managing 33kV outdoor switchyard installation, plant primary power distribution, flameproof motor control centers, Balance of Plant (BOP) field instrumentation, and PLC/SCADA control integration. Supply of switchgear by Trisquare and cabling by POLYVION provided single-source reliability throughout construction.
- • 33kV Outdoor Grid Receiving Substation Erection & Power Transformer Setup
- • Flameproof (Ex-d) Motor Control Panels for Grain Milling, Fermentation & Distillation
- • ZLD Evaporator & MVR System Electrical & Field Instrumentation Package
Balrampur Chini Mills Unit-Balrampur Sugar Expansion & 330 KLPD Distillery Project
Balrampur Chini Mills Ltd (BCML) is one of India's largest integrated sugar and ethanol producers. At their flagship Balrampur unit in UP, BCML undertaken a major brownfield capacity expansion — expanding cane crushing capacity and upgrading the ethanol distillery from 160 KLPD to 330 KLPD. DEC was awarded the complete electrical upgrade package. The project involved installing high-capacity Trisquare IMCC panels, upgrading existing 11kV busducts and feeder breakers, expanding the 33kV substation yard, laying heavy POLYVION HT/LT cable routes across the sugar and distillery complexes, and integrating new mill drive VFDs without interrupting active crushing operations.
- • 11kV Feeder & Busduct Upgrades for Expanded Crushing & Distillation Loads
- • Trisquare Intelligent MCCs with Microprocessor Motor Protection Relays
- • Distillery Capacity Expansion Electrical Integration (160 KLPD to 330 KLPD)
Shree Cement 132kV Grid Export Switchyard & Grinding Unit Electrification
Cement manufacturing requires massive, uninterrupted electrical power to drive raw grinding mills, ball mills, and clinker handling infrastructure. For Shree Cement's new cement grinding facility under Shree Agra Cement Plant in Etah, UP, DEC was awarded the high-voltage 132kV grid receiving switchyard contract. Currently under active project deployment for the 2024-25 execution cycle, DEC's scope covers complete engineering design, civil foundations, structural steel lattice gantry erection, 132kV circuit breaker supply, 50 MVA step-down power transformer installation, numeric distance protection relay panels, and POLYVION high-voltage cable distribution to plant substations.
- • 132kV Outdoor AIS Grid Receiving Switchyard Turnkey Construction
- • 132kV SF6 Circuit Breakers, Isolators, Lightning Arresters & CVT Erection
- • 50 MVA 132/11kV Main Power Transformer Supply, Erection & Oil Filtration
JK Cement 132kV High Voltage Grid Substation & GU Plant Package
JK Cement Ltd is one of India's premier cement producers. To power their new greenfield Cement Grinding Unit (GU), DEC was awarded the 132kV high-voltage grid receiving substation contract — scheduled for active turnkey delivery in the 2025-2026 execution cycle. The package covers complete turnkey design, civil foundations, structural steel erection, 132kV gas-insulated/air-insulated switchgear equipment, power transformer bays, step-down 11kV distribution, Trisquare MV panels, and plant-wide POLYVION cable trenching.
- • 132kV Grid Receiving Substation Erection & Civil Foundation Engineering
- • 132kV SF6 Circuit Breakers, CT/PT Units & Busbar Protection Racks
- • Main Power Step-Down Transformer Installation & Commissioning
Jaypee Bina Thermal Power Plant Coal Handling Plant (CHP) Electrification Project
Coal Handling Plants (CHP) represent the vital fuel supply lifeline of thermal power generation facilities. Unplanned conveyor trippings or motor control failures halt coal feeding, directly threatening power generation. At Jaypee Bina Thermal Power Plant in Bina, MP, DEC executed a comprehensive electrical modification and modernization package for the plant's high-capacity Coal Handling Plant. The project involved upgrading existing 11kV/3.3kV drive switchgear, supplying Trisquare heavy-duty Motor Control Centres for crushers and conveyor drives, installing dust-proof IP65 distribution boards, and replacing main cable runs with POLYVION FRLS armoured cables.
- • 11kV & 3.3kV Medium Voltage Switchgear Modification for CHP Feeders
- • Trisquare Heavy-Duty Crusher & Conveyor Motor Control Centres (MCC)
- • Dust-Proof & Moisture-Sealed IP65 LT Distribution Boards across Conveyor Galleries
Epsilon Carbon Bellary C2GR, Zero QI & Tail Gas Power Plant Electrical Package
Epsilon Carbon Pvt Ltd is a global leader in specialty carbon black and coal tar derivative manufacturing. In their sprawling industrial complex at Bellary, Karnataka, DEC has established an extraordinary record of partnership — securing and executing four consecutive major project wins since 2022. The project scope spans the C2GR & 500 TPA production unit electrical execution (2023-24), the specialized Zero QI process unit electrical package (2023-24), the Tail Gas-Based Waste Heat Recovery Power Plant TG synchronisation package (2022-23), and the CB-II Project field instrumentation package (2024-25 ongoing).
- • C2GR & 500 TPA Specialty Unit Power Distribution & Substation Erection
- • Tail Gas Waste Heat Power Plant Generator Auto-Synchronising Panel Installation
- • Zero QI Specialty Process Unit Explosion-Resistant & Corrosion-Proof Distribution
Jindal SAW Samaghoga 66/11kV High Voltage Substation & Mill Electrification
Steel pipe manufacturing requires high-capacity electrical substations to handle severe inductive loads, heavy welding currents, and frequent motor start-stop cycles. At Jindal SAW Ltd's major manufacturing facility in Samaghoga, Kutch, Gujarat, DEC engineered and constructed the complete 66/11kV high-voltage receiving substation and plant primary power distribution network. The project covered 66kV outdoor AIS switchyard erection, 66/11kV step-down power transformers, Trisquare heavy-duty 11kV vacuum switchgear, custom Motor Control Centres for pipe rolling and seam welding mills, and heavy POLYVION XLPE armoured cables.
- • 66/11kV Outdoor Grid Receiving Substation Supply, Erection & Commissioning
- • 66kV SF6 Circuit Breakers, Motorized Line Isolators & CT/PT Towers
- • Trisquare 11kV 31.5kA Heavy-Duty Indoor Vacuum Switchgear Assembly
JK Tyre & Industries 132/6.6kV High Voltage Grid Substation & Plant Expansion
Tyre manufacturing demands zero-dip power quality. Banbury rubber mixers, curing presses, and extruders operate in continuous cycles where even brief voltage sags cause severe batch scrap. For JK Tyre & Industries Ltd's major manufacturing plant in Morena (Gwalior region), MP, DEC executed the complete 132/6.6kV high-voltage receiving substation and plant expansion electrical infrastructure. The scope included 132kV outdoor switchyard construction, 132/6.6kV 25 MVA power transformer erection, 6.6kV Trisquare medium-voltage switchboards, Banbury mixer drive MCCs, and POLYVION HT cable gallery installation.
- • 132/6.6kV Outdoor AIS Substation Erection & Civil Engineering
- • 132kV SF6 Breakers, Current Transformers & Voltage Transformers
- • 25 MVA 132/6.6kV Power Transformer Erection, Oil Filtration & Comm
Goodyear Tyres 66/2.4kV Industrial Substation & Distribution Package
Global tyre manufacturers operate under strict international EHS and engineering guidelines. At Goodyear Tyres Ltd's Ballabgarh facility in Haryana, DEC executed the complete 66/2.4kV industrial substation replacement and plant power distribution upgrade. DEC provided a turnkey solution — installing 66kV outdoor switchgear equipment, 2.4kV Trisquare medium voltage switchboards, high-torque mixer drive panels, and POLYVION XLPE armoured cables.
- • 66/2.4kV Outdoor Switchyard Supply, Civil Erection & Commissioning
- • Trisquare 2.4kV Medium Voltage Metal-Enclosed Switchgear
- • Banbury Rubber Mixer Drive Control Panels & Auxiliary Distribution
Mayfair Renewable Energy 110kV Utility Grid Export Pooling Switchyard Project
Renewable energy Independent Power Producers (IPPs) require rapid, high-integrity grid interconnection substations to export generated solar and wind power into state transmission grids. At Mayfair Renewable Energy's park in RON, Karnataka, DEC built the 110kV high-voltage grid pooling switchyard. The scope included 110kV gantry structure erection, SF6 breaker installation, 0.2S class ABT tariff metering desks, numeric distance protection relays, and 33kV POLYVION underground collector cables.
- • 110kV Outdoor AIS Pooling Switchyard Erection & Commissioning
- • 110kV SF6 Breakers, Current Transformers & Voltage Transformers
- • 0.2S Class ABT Main & Check Tariff Metering System
West Kenya Sugar Naitiri 12 MW Cogen Power Plant & Full Mill Electrification
International clients choose DEC because we combine Indian manufacturing cost advantages (in-house Trisquare switchgear and POLYVION cables) with seasoned expatriate commissioning teams capable of navigating cross-border logistics and local African energy codes. For West Kenya Sugar Company's greenfield facility in Naitiri, Kenya, DEC executed the complete turnkey electrical infrastructure for a 12 MW bagasse cogeneration power plant and sugar mill complex. The project scope encompassed containerized export of equipment from India, 33kV outdoor switchyard erection, 12 MW turbine auto-synchronising panels, mill drive MCCs, POLYVION HT cables, and Kenya Power grid evacuation licensing.
- • Containerized Logistics & Customs Export Management from India to Kenya
- • 33kV Outdoor Grid Export Switchyard Erection & Commissioning in Naitiri
- • 12 MW Steam Turbine Generator (TG) Auto-Synchronising & Protection Panels
Mufindi Paper Mill Tanzania 9000 TCD Greenfield Sugar & 2x35 MW Cogen Project
Representing one of East Africa's largest agro-industrial investments, Mufindi Paper Mill (Rai Group) is constructing a massive 9000 TCD greenfield sugar plant alongside a 70 MW (2x35 MW) steam turbine cogeneration power station in Tanzania. DEC was selected to execute the complete turnkey electrical EPC contract — scheduled across the 2025-2026 project window. DEC's scope encompasses high-voltage 132kV switchyard construction, dual 35 MW turbine auto-synchronising panels, main distribution transformers, Trisquare export switchboards, and plant-wide POLYVION HT cable infrastructure.
- • 132kV High Voltage Grid Export Switchyard Erection & Engineering in Tanzania
- • Dual 35 MW (Total 70 MW) Steam Turbine Generator Auto-Sync & Protection Panels
- • Trisquare IEC 61439 Type-Tested 11kV & 33kV Switchgear Export Supply
Suralla Power Corporation 66/110kV High Voltage Substation & Power Plant Project
Demonstrating DEC's engineering reach beyond Africa into Southeast Asia, DEC executed the turnkey 66/110kV high-voltage grid export switchyard and power plant electrical package for Suralla Power Corporation in Mindanao, Philippines (in partnership with Uttam Energy). The project involved supply and erection of 110kV outdoor switchyard gear, generator synchronisation control panels, IEC 61439 compliant Trisquare switchboards, and POLYVION HT cable networks meeting Philippine Electrical Code (PEC) standards.
- • 66/110kV Outdoor AIS Substation Supply, Erection & Grid Commissioning
- • Biomass Power Plant Generator Auto-Synchronising Panel Installation
- • IEC 61439 Type-Tested Trisquare Switchboard Containerized Export
Wonji Shoa Sugar Factory Complete Greenfield Electrical Package & Switchyard
Wonji Shoa Sugar Factory is one of East Africa's most historic sugar production facilities. As part of Ethiopia's national sugar modernization initiative, DEC executed the complete turnkey electrical infrastructure package for the greenfield expansion. The project covered 33kV substation erection, plant power distribution, Trisquare mill MCC panels, POLYVION HT cabling, and Ethiopian Electric Power (EEP) grid connection.
- • 33kV Outdoor Switchyard Supply, Civil Erection & Grid Testing
- • Trisquare Type-Tested Medium & Low Voltage Switchboards Export
- • Mill Tandem & Centrifugal Station Motor Control Centres
Olam Agri India Sugar Plant Expansion & 300 KLPD Greenfield Ethanol Project
Olam Agri India Pvt Ltd is a global agricultural conglomerate. For their major integrated agro-complex in UP, DEC was awarded the complete turnkey electrical EPC contract for sugar mill expansion alongside a greenfield 300 KLPD ethanol plant — currently under active execution in the 2024-2025 project cycle. DEC is delivering the 33kV receiving substation, IS 5571 flameproof panels for distillery zones, Trisquare IMCCs, and POLYVION armoured cables.
- • 33kV Outdoor Grid Receiving Substation Erection & Power Transformers
- • IS 5571 Flameproof (Ex-d) Distribution Panels for Ethanol Fermentation & Distillation
- • Sugar Mill Expansion 11kV Feeder Breakers & Motor Control Centres
Indian Glycols (IGL) Kashipur 132kV High Voltage Grid Substation Package
Indian Glycols Limited (IGL) is a pioneer in green chemicals and bio-based specialty chemicals. For their major chemical manufacturing site in Kashipur, Uttarakhand, DEC was awarded the 132kV turnkey grid receiving substation contract — scheduled for active 2025-2026 execution. The project scope covers 132kV AIS switchyard equipment, dual power transformer bays, Trisquare medium-voltage indoor switchgear, and heavy POLYVION cable tunnels.
- • 132kV Outdoor Grid Switchyard Turnkey Construction in Kashipur
- • 132kV SF6 Breakers, Isolators & Distance Protection Racks
- • Trisquare 11kV High-Fault Breaker Assemblies
Kinyara Sugar Uganda Turnkey Sugar Mill Electrification & Substation Package
Kinyara Sugar Ltd is one of Uganda's largest sugar producers. In partnership with Uttam Sucrotech, DEC executed the complete turnkey electrical infrastructure package for the Kinyara Sugar expansion project in Masindi, Uganda. DEC supplied containerized export-spec Trisquare switchgear, 33kV outdoor switchyard equipment, mill drive MCCs, and POLYVION XLPE cables, supported by on-site Indian commissioning engineers.
- • Containerized Export of Trisquare Switchboards & POLYVION Cables to Uganda
- • 33kV Outdoor Switchyard Erection & Transformer Commissioning
- • Mill Drive & Boiling House Motor Control Panels
Gobind Sugar Mills Sugar Mill & Distillery Power Distribution Project
Gobind Sugar Mills Ltd (Aira Lakhimpur & Lakhimpur Kheri, UP) underwent a major electrical modernization to expand cane crushing and distillery power distribution. DEC was awarded the complete electrical upgrade contract — installing 33kV switchyard bays, Trisquare HT/LT panels, mill drive MCCs, and POLYVION cables.
- • 33kV Outdoor Switchyard Modification & Grid Interconnection
- • Trisquare Medium & Low Voltage Switchboards Installation
- • Mill Drive Motor Control Panels with VFD Integration
Tirupati Sugars Limited Sugar Mill Electrification & Substation Project
Tirupati Sugars Limited in West Champaran, Bihar selected DEC for their sugar mill electrification and 33kV substation upgrade project. DEC delivered 33kV outdoor switchgear, Trisquare IMCC panels, and POLYVION armoured HT/LT cabling.
- • 33kV Outdoor Switchyard Erection
- • Trisquare Mill Motor Control Panels
- • POLYVION Armoured Cabling Network
Tehri Iron & Steel Casting Arc Furnace & Foundry Plant Electrical Project
Steel foundries present extreme electrical stress due to electric arc furnace harmonic spikes and heavy current surges. At Tehri Iron and Steel Casting Ltd in Haridwar, Uttarakhand, DEC executed the complete 33kV captive substation and furnace power distribution package.
- • 33kV Outdoor High-Fault Substation Supply & Erection
- • Arc Furnace Harmonic Filter & Capacitor Bank Integration
- • Trisquare Heavy Industrial Motor Control Panels
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6-Stage Turnkey Execution Process
From pre-bid engineering surveys to official grid energization, DEC's disciplined stage-gate methodology ensures strict quality control, schedule compliance, and safety.
Site Survey & Engineering Feasibility
Stage 01Comprehensive site geotechnical analysis, soil resistivity testing, land topography survey, maximum demand load estimation, and utility grid connectivity feasibility study.
Detailed Engineering & Statutory Approvals
Stage 02System short-circuit analysis, protection relay settings, earthing grid design, cable tray layout routing, PESO approval drawings for FLP hazardous areas, and CEIG statutory clearance filings.
In-House Equipment Manufacturing & FAT
Stage 03Manufacturing of HT/LT switchgear, IMCCs, VFD panels via Trisquare Switchgear and XLPE armoured FRLS cables via POLYVION. Factory Acceptance Testing (FAT) conducted with client engineers.
Site Civil & Structural Erection
Stage 04Outdoor switchyard civil foundations, transformer oil pit construction, gantry structure erection, cable trenching, and indoor panel room layout preparation.
Equipment Installation & HT/LT Cabling
Stage 05Placement and alignment of transformers, VCB switchgear, motor control centres, SS304/GI cable tray installation, POLYVION HT/LT cable laying, heat-shrink termination, and plant earthing.
Testing, CEIG Inspection & Grid Energization
Stage 06Comprehensive cold and hot commissioning tests, CT/PT ratio verification, numeric protection relay calibration, CEIG inspection clearance, state grid synchronisation, and client handover.
Turnkey Technical Capabilities Matrix
33kV - 220kV High Voltage Substations
Outdoor Air Insulated Switchyards (AIS) & Gas Insulated Switchyards (GIS), Power Transformers, VCB/SF6 Circuit Breakers, Isolators, Lightning Arresters, and Grid Export Metering.
IS 5571 Flameproof (FLP Ex-d) EPC
Hazardous area explosion-proof distribution for ethanol distilleries, chemical process units, and solvent extraction plants compliant with PESO and Gas Group IIA/IIB standards.
Turbine Generator (TG) Synchronisation
Multi-megawatt steam turbine generator synchronizing panels, auto load sharing desks, AVR controls, numerical protection relaying, and anti-islanding utility interfaces.
Intelligent MCCs & Process Drives
Trisquare Intelligent Motor Control Centres (IMCC) with integrated VFDs, Soft Starters, PLC SCADA communication, and central DCS marshalling panels for mill and pump automation.
POLYVION FRLS Cabling Infrastructure
Plant-wide HT & LT cable trenching, SS304/GI ladder cable tray routing through corrosive environments, heat-shrink terminations, and chemical earthing grids.
CEIG & State Utility Clearances
Complete statutory liaisoning with Chief Electrical Inspectorate to Government (CEIG), State Electricity Boards (UPPCL, MSEDCL, UBVNL), and international power utilities.
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