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ro[ect at a g|ance

The proposed unit will have highly modernized in-house fabrication facility for
manufacturing any type of cubicle or structure as per any specific requirement. Apart
from this, there will be standardized panels of all type including PCC, MCC, draw out or
non-draw out type, single or double front type. This will help in maintaining quality and
prompt deliveries. The fabrication shop will be equipped with semi-automatic nibbling
machines, power presses and specialized machines and tooling for bending, notching,
etc.

There will be a paint shop where both Stoving Enameled Spray paint as well as Powder
Coating facility will be available. The pre-treatment of structure will be carried out at
elaborate tank treatment plant where each panel will undergo a strict quality check at
every stage to ensure the proper results as per the relevant S. The Powder Coating
facility will have a spray chamber which has the capacity to accommodate two full sized
panel sections simultaneously for spraying. Drying and baking will be done in electric or
diesel fired ovens.
.

Busbar bending, shearing, and punching will be done by hydraulic machines, which
ensure accuracy and at the same time ensure that the electrical properties of the
busbars will not altered. Wiring and fitting will be done as per standardized procedures
to ensure maximum reliability .

Quality will be ensured by rigid and stringent checks carried out on the bought out raw
materials, components including switchgears, breakers, various equipments and
accessories in accordance with the standardized quality plan/manual, before accepting
them for production line.







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,anufactur|ng rocess

All types of Low Tension (LT) Electrical Distribution Panels will be manufactured as per
relevant S Standard/against customer's specification and supply orders. These
Electrical Panels are compact, modular and are made of sheet steel design to provide a
low tension sub-logic system. They will customized to suit the specific requirement of
the project to ensure highest reliability and ease of maintenance. Our manufacturing
process comprises of following steps:
O Designing
O Fabrication
O Pre- treatment & Painting
O Assembling
O Wiring, Terminals & Hardware
O n-house testing

A) Des|gn|ng
The unit will have in-house facility to design any type of electrical custom-built assembly
as required by our valued customer. The design team will be well experienced and
qualified to take any assignment. Designing is the key to success to get any supply
order which reflects into a growth of an organization. Designing of any electrical custom
built-assembly will be completed in the following steps:

O Design Planning
O Design nput
O Design Output
O Design Control Sheet
O Design Review
O Design Verification
O Design Validation
O Design Changes

Once the design is accepted and approved internally by the concerned
departments and externally by the customer, the same will be released for
fabrication.

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) Iabr|cat|on

The unit will fabricated out of 14 gauge MS sheets and will be of welded or bolted
construction. The base is made of 10 gauge channel with removable gland plate on top
and holes for grouting at the bottom. Fabrication facility will be spread over 4000sq.ft
area and includes state-of-the art shearing and bending machines. There will be semi-
automatic nibbling and notching machines to have any type of cut-outs required in the
enclosures. There will be a comprehensive tooling division to ensure any type of
specialized or customized fabrication works.

O Unique features of our pre-treatment and paint shop
O Large size tanks
O Phosphoric acid based pre-treatment chemicals
O Boilers for adequate heating of tanks.
O Powder Painting booth of Thermax make
O Electrostatic guns for uniformity of paint coating (used from 2 sides).
O Electric hoist for better object movement.
O Diesel Fired and Electric Heated Baking Oven
O Air compressor with moisture and oil preventing filters

Fabrication:
t is the first stage of production process and will be performed inside the factory
premises. Fabrication will be done according to work order drawings using suitable
machines viz. hydraulic shearing, power press, press brake, notching and electric
welding machines. Completion of fabrication will be followed by inspection done by QC
nspection Team as per the quality plan.






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) retreatment and a|nt|ng
The second stage is the pre-treatment of the product. This activity ensures that the
metal surface is free from traces of oil, grease and rust and a very thin layer of iron
phosphate is deposited before it is painted for good adhesion of paint. Pre-treatment will
be done by following a process of dipping in tanks by help of electric hoist of capacity
running over the tanks.

!ainting:
After the completition of pre-treatment process, the product will be ready to be painted.
This activity is performed to cover the metal surface with non-rusting material and to
give the desired shade and finish to the product. We have a facility for both liquid paint
as well as powder coat paint. As a standard practice we provide powder coat paint,
whereas liquid paint is available on demand/special application.


i) Liquid !ainting: :

After pre-treatment of the enclosure and parts, primer coat comprising of
Red Oxide or Zinc Chromate will be applied by spray gun. Primer coat
enhances adhesion and prevents rust formation. Then it will be baked an
oven at a temperature of 120C. Metal putty will be used wherever
required for obtaining smooth surface of component, thereafter a coat of
surfacer is applied. Water emery paper is used, if required and two coats
of final paint is applied using spray gun, followed by baking in oven at
120C.

ii). !owder Coat !ainting :

After pre-treatment and cleaning of the enclosure and parts with, powder
will be sprayed with the help of powder spray gun. The powder sticks to
the panel surface due to the electrostatic charge. The spray gun helps to
deposit a uniform coat of paint to a thickness of 50-70 microns. Thereafter,
it is baked an oven at a temperature of 120C or as recommended by the
powder manufacturer. The temperature and duration of curing varies from
shade to shade and manufacturer.


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D) Assemb||ng

!aneI joining and base channeI fitting
O Door channel fitting
O Door gas kitting
O Door fitting, adjustment and lock fitting
O Top plate and bottom plate fitting.
O Lifting hook fitting
usbar:
The unit will make switchboards incorporate 3-phase, 4-wire, 50 Hz suitably rated
Electrolytic Copper or Aluminum bus bars which are air insulated. The bus bars are
mounted on SMC/DMC supports providing spacing as per S guidelines. Hylum sheet
brackets by counter-sunk screws and specially designed acrylic sheets shrouding are
provided in order to provide protection to the operator. Busbar fitting includes
O Busbar support fitting
O Busbar preparation, sleeving and fitting.
O Fitting of earth Busbar / Earthing bolt

To facilitate earthing, a G.. bar 50 x 6mm or 25 x 6mm size is provided at the bottom of
each panel. These bars are painted in green shade for identification, with sufficient
unpainted space spared for earthing connections. Also, earthing stickers are fixed on
the outside of the panel from where the connection is to be taken.

Component Fitting:
O Drilling and taping
O Mounting plate fitting
O Components fitting
O Terminal channel fitting
O MCB channel fitting.
O PVC duct fitting
O Name plates fitting.


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Feeder Name Plates (white font on blue background) as per the feeder descriptions are
fixed over each feeder, and similar name plates are also provided on the front of the
panel board. Black anodized or white acrylic, engraved name plate can also be provided
on request.

The switchgear is offered in single and two tier arrangements. More than two Air Circuit
breakers are not incorporated in a vertical section in view of the undesirable
temperature rise and also from the point of view of convenient cable terminations

Wiring, TerminaIs & Hardware
Wiring of equipment is carried out inside the factory premises with insulated, flexible
copper conductors. Selection of colour and size of control wiring, identification of control
wires by PVC ferrules is done according to work order drawings. Size of the conductors
is selected as per current ratings of various feeders. The control wiring including that of
indicating lights and measuring instruments such as voltmeters etc. is done using
flexible copper cable. While those for CT and ammeters are carried out. Wiring also has
marker ferrules with red, yellow, or blue and colored PVC sleevers at both ends to
indicate numbers and phase color coding. The wiring is routed and bunched neatly and
support on slotted angles or routed in PVC channels as required. nspection by our QC
nspection Team is done to ensure wiring quality.

TerminaI & Hardware
Terminal & Hardware For terminating control inter-connections, suitable terminals are
provided for equipment. These are suitably numbered to ensure proper connections and
to facilitate ease of maintenance.
All other hardware accessories such as lugs, glands, locks, etc are used as per our
strict quality control measures.







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F In-house Testing
After assembly each switch Board, LT Panel and Bus Duct is thoroughly tested.
Suitable tests are carried out to ensure continuity of operation. n-house tests cover the
following:
O Wiring Continuity Test
O nsulation Resistance Test
O Earth Continuity Test
O Earth Resistivity Test
O Testing of Polarity of non-linked Single Pole Switches
O Operation checks












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ost of the ro[ect
1oLal cosL of Lhe pro[ecL wlll lnclude followlng
AmounL (8s)
i). Shed (1500 Sq. Ft.) 3, 00, 000.00
ii) Machinery (As per Annexure) 9, 59,000.00
) Furniture 80,000.00
V) Stock of Raw Material 11, 37,000.00
Total 24, 76,000.00


Sources of Finance
i). Capital 40,000.00
ii) Bank Loan 24, 00,000.00
iii). Sundry Creditors 36,000.00
24,76,000.00















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nnexure

Particulars of Machinery Qty. Amount(Rs.)
Ball Press 1 250,000.00
Compressor 3 261,000.00
Weeding Machine 2 40,000.00
Cutter Machine 2 24,000.00
Grider Machine 2 30,000.00
Drill Machine 2 24,000.00
Other Tools

20,000.00
CRC Sheet

80,000.00
Paint

30,000.00
Transfers Machine 2 50,000.00
Angle Cutter 2 34,000.00
Spot Weeding Machine 2 50,000.00
Clamping Machine 2 36,000.00
Weight Machine 1 30,000.00
Total

959,000.00







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nnexure

naIysis of Workforce Requirement

Sr
No
Department No of Workers
1. Designing 2
2. Fabrication 4
3. Painting 2
4. Assembling 2
5. Administration 2