SQUARE AUTOMATION(P) LTD.

Designers & Manufacturers of Switchboards

Control Panels

1. The Company ..............................3

2. Organization Chart ..............................4

3. Manufacturing Facilities ..............................5

4. Products & Solutions ..............................7

5. Technical Specifications ..............................10

6. Salient Features of SQUARE make Panels .............................. 14

7. Our Clients & Consultants ..............................15

8. Plant & Machinery ..............................16

9. Quality Policy ..............................18

Contents

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SQUARE AUTOMATION an ISO 9001-2008 certified company is a well established Engineering organization having 3 decades of hard core engineering experience in the field of Turnkey Electrical Project execution & Designing, Manufacturing, Testing, supply, Installation, Testing and Commissioning of Electrical Panels of all types as per customer requirement and consultants specification.

The company was established 30 years ago at Mumbai and over a period of time, through hard work & due to the complete satisfactory services to our Valued Customers, has grown to 3 locations spreading over an area of 30,000 sq.ft. with all latest generation plant and machinery and in house facilities for fabrication, pre-treatment, painting, powder coating, assembly and testing to execute orders for various prestigious projects.

Factory at Mira Road, Mumbai

The Company

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Organisation Chart

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The manufacturing facilities at our Mumbai based works consists of fabrication, pre-treatment, powder coating, painting and oven baking which is the foundation for a quality control panel as per IS standards. We also have a set of assembly, wiring and testing equipments.

The fabrication shop consists of cutting, bending machines, welding machines as well as press machines. The cutting and bending of CRCA sheets is done with the CNC machines and is passed through quality check procedure to ensure that our clients gets the most elegant and accurately designed panel. The process of welding is also subjected to similar quality control so that the internal structure and rigidity of the panel is not compromised.

8 Tank Pretreatment Plant

Following painting procedure is adopted for all the Switchgear, Panel, Sheet metal fabricated enclosure & other sheet/MS metal components.

Eight tank process is used for metal treatment followed by Powder Coating or Liquid enamelled painting which is cured in the oven.

Treatment consists of -DegreasingRinsingPhosphating Rinsing/Passivation

Followed by -Powder CoatingOven Baking

Numerically Controlled

Cutting Machine

Numerically Controlled Bending Machine

Manufacturing Facilities

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Powder Coating Chamber with Turbo Cyclone Recovery Chamber

Gas Fired Oven

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Power Control Centers up to 8000 Amps, 415 Volts.

Bus Trunking for up to 6000A.

Motor Control Centers up to 5000 Amps, 415 Volts.

Synchronizing panels up to 30 MW turbine generator sets.

Control Desk, Mimic Panels, Annunciator Panels, etc.

11 KV LAPT Panels for H.T.T.G. sets.

Bus Ducts up to 6000 Amps. 415 Volts.

PLC Panels.

ACB Panels 6000A. 3MW L.T.Turbine generator sets.

Distribution panels.

Draw out PCC & MCC Panels.

Control & relay panels.

Auto Mains Failure Panels for D.G set. / Synchronizing Panels with auto load shearing.

Turbine / Generator Control Panels.

Automatic Power factor Correction panels.

D.C. Motor Starter Panels.

Stainless Steel Panels /DB’s

Rising Mains.

Products & Solutions

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This panel is our specialization with varied relays for all situations that can be observed in a plant to synchronize various sources and export the power to grid.

It comes with PLC based system to provide faster action instead of contactors.

We have also executed projects with the use of digital relays which has proved to provide the panel with more flexibility.

The panel also comes with a mimic diagram for the understanding of the entire control wiring.

This provides our client with easy training and faster commissioning of panel on site.

The durability of this panel is tested exhaustively at our integrated testing facility.

Air Circuit Breaker Panels Another specialization of our panel expertise.

We provide up to 6400A with 50KA Breaking capacity panels with single or two ACBs in parallel operation.

Sync. Schematic and parallel operation with various generating sources.

Unique Busbar arrangement to provide ventilation and durability of switchgear parts and other equipment.

Economic space saving design as well as providing value in terms of efficient distribution and safe switching of large currents.

Metering Cum Synchronizing Panel

Metering Cum Sync Panel 3 MW ACB Panels Desktype MCSP

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This panels is used in case of mains failure to switch single / multiple H.T & L.T. DG Sets.

Provides automatic changeover whenever mains fails with synchronisation and load sharing with other DG Sets.

This panel is used in varied industrial, commercial and domestic areas wherever grid supply and DG sets are in use.

The panels are supplied and commissioned with DG Sets in various airports, industries, commercial complexes and malls.

This Panel has a space saving design with PLC control for a quick changeover.

We have commissioned supply, installation, testing consisting of 3 No.s 1000KVA DG Sets with a changeover time of 1 second using PLC at Delhi airport for CAT- 3 landing power supply and 4×1000 KVA DG sets at Trivendrum Airport.

We also engineer PLC based panels using reputed make PLC. PLC panels are used in case of high end application where a series of contactors are required. We also manufacture VFD panels for various industrial application using reputed make VFD’s . VFD panels are used in area of drives with ramp-up or ramp down time with efficient utilization

power . The panels with new systems are part of a larger integrated system in which we play a role of

providing solutions and wide range of efficient panels.

1000 KVA DG Sets & AMF Panels at Mumbai Airport VFD Drive Panels

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The Power Control Center & Motor Control Centre totally enclosed dust & vermin proof modular construction, self supporting, floor mounting air insulted cubicle type for use on 415 / 440 Volts 50 Cycles AC supply.

The equipment shall be designed for operation in high ambient temperature and high humidity tropical atmosphere conditions. Means shall be provided to facilitate ease of inspection, cleaning and repair for use in installations where continuity of operation is of prime importance.

Construction:

The PCC & MCC shall be fabricated from 2mm thick CRCA sheet steel. It will be made of requisite vertical sections, which when coupled together shall form continuous dead front switchboards. The PCC & MCC shall be readily extensible on both sides by the addition of vertical sections after removal of the end covers and shall provide complete dust and damp protection, the degree of protection being not less than IP- 52 of IS:2147.

The structure of the panel is mounted on base frame of 3mm thick Sheet Steel or on base Channel Frame. The Design shall ensure that weight of the Panel is adequately supported.

Busbar:

The busbar is air insulated and made of high conductivity, high strength Aluminum alloy, complying with the requirements of Grade E91E of IS: 5082 or E.C. grade copper as required.

The Busbar is suitably braced with non-hygroscopic Epoxy/SMC supports at suitable intervals in order to withstand the dynamic forces of Short Circuit at 65KA RMS, symmetrical for one second.

Technical Specifications PCC & MCC

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Painting:

All steel work used in the construction of Power Control Centre is thoroughly cleaned to remove all rust, scales, grease and other foreign matters. This is done by treating the sheet steel by Eight Tank Process as per the IS:3618.Treatment consists of Degreasing, Rinsing, Phosphating, Rinsing, Passivation.

The sheet steel is then given a coat of highly corrosion resistant primer and then a coat of seimens grey and finally two coats of stoving synthetic enamel paint/ Powder coated to the specified shade of IS:5.

Cable Termination and Control Wiring:

Cable entries and terminals shall be provided in the switchboard to suit the number, type and size of Aluminium conductor power cables and copper conductor control cables.

Provision shall be made for top or bottom entry of cables as required. Generous size of cabling chambers shall be provided with the position of cable glands and terminals such that cables can be easily and safely terminated.

All control wiring shall be carried out with stranded copper conductor of 1.5 sq. mm section.

Wiring shall be neatly bunched, adequately supported and properly routed to allow for easy access and maintenance. Wires shall be Identified by Ferrules at each end and terminals also provided with markers.

Large clearances and creepage distances shall provided on the Busbar system to minimize the possibility of a fault as per the relevant Indian Standard. The cross section of busbars and risers for various rating is calculated approximately on the basis of 0.8 Amp Per sq.mm for Aluminium and 1.6 Amp. per sq.mm for copper.

The main busbar shall have continuous current rating throughout the length of each Power Control Centre and the neutral busbar shall have a continuous rating of at least 50% of the phase busbars. The Busbar is colour coded for identification of individual phases and neutral; Also it is insulated with insulation tape or heat shrinkable PVC Sleeves.

Busbar Assembly

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Busbar:

The busbar shall be air insulated and made of high conductivity, high strength aluminum alloy complying with the requirements of Grade E91E of IS:5082 or E.C. grade copper as required.

The Busbar shall be suitably braced with non-hygroscopic Epoxy/SMC supports at suitable intervals in order to withstand the dynamic forces of Short Circuit at 50KA RMS, Symmetrical for one sec. Large clearances and creepage distances shall be provided on the Busbar system-to minimize the possibility of a fault as per the relevant Indian Standard.

The orientation of Busbar shall be R-Y-B-N or Interleaved i.e. R-B-Y-N-R-Y-B.

The Busduct is metal clad totally enclosed dust & vermin proof air insulated for use on 415 Volts 50 Cycles AC supply.

The Busduct is designed for operation in high ambient temperatures and high humidity tropical atmospheric conditions. Means are provided to facilitate ease of inspection, cleaning and repair, for use in installations where continuity of operation is of prime importance.

Construction:

The Busduct are fabricated from 2mm thick CRCA sheet steel with Louvered covers on both sides of Busduct for proper heat dispensation, Busduct have top and bottom covers for visual inspection/maintenance. Rubber Bellows for enclosure shall be provided for avoiding DG/TG set vibration to travel into the Busduct.

The cross section of busbars for various rating are calculated approximately on the basis of 0.8 Amp. per sq.mm for Aluminium and 1.4 Amp. per sq.mm for copper.

The Busbar has a continuous current rating throughout the length of Busduct and the neutral busbar also has a continuous rating of at least 50% of the phase busbars. The Busbar is color coded for identification of individual phases and neutral. The Busbar is insulated with insulation tape or heat shrinkable PVC Sleeves or painted with Matt Black Paint.

Technical Specifications of Bus Ducts

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Painting:

All steel work used in the construction of Busduct is thoroughly cleaned to remove all rust, scales, grease and other foreign matters. This is done by treating the sheet steel by Eight Tank Process as per the IS:3618.

The sheet steel is then given a coat of highly corrosion resistant primer and then a coat of seimens grey and finally Powder Coated to the specified shade of IS:5.

End termination/Expansion Joints:

The busduct is provided 'AL/'CU' flexibles at the ends for proper alignment. After every 6 meters, of straight length portion, Expansion joints are provided for adjusting the expansion of the Busbars.

Optional Accessories:

Phase Cross over (RYBN - NBYR)

Neutral Cross Over (NRYB - RYBN)

Seal of Bushing.

Fire Proof Barrier.

Canopy for outdoor portion.

Silica Gel breather.

Space Heater with thermostat.

Wall frame Assembly.

Tests:Routine tests shall be conducted on the Busduct:

Inspection of the Busduct (physical). Dielectric Tests at High Voltage.

Insulation Test at 1000 volt.

Heat run test if required.

6000A Busduct CPRI tested

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Our panels have been tested successfully by 'Central Power Research Institute(Bhopal & Bangalore)' for 'Verification of short Circuit Strength' at 65KA for a time of 1 second as per IS 8623.

We Use Non-Hygroscopic SMC supports for Busbar for high mechanical and electrical strength.

Due to high tracking Index, our panels can withstand high values of fault current.

Our panels are cubical type with modular design for efficient and accurate distribution.

Our panels are most dynamic nature as they are fabricated, designed and painted as per customer requirement.

Our engineering skill helps us to distinguish ourselves in the way we use the allocation of resources and arrangement of panels.

We look at our customers as scope for growth and hence we standardize with them to meet high quality and accuracy needs.

Our integrated setup helps us to reduce lead time.

Our use of engraved ferrules and labels makes our panel easy to use and very easy to comprehend and train.

All Power and Control Wiring terminals are brought out through Cable Alley for easy cable termination.

We provide high quality and efficient distribution by providing Quality Assurance Plan.

We believe that the customer's need for efficient panels is our area of expertise and we excel at it.

We also have CPRI approval for 4000A, 5000A, 6000A and IP55.

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Our Major Clients & Consultants

Triveni Engg. & Industries Ltd. Bharat Diamond Bourse Airport Authority of India Sterling & Wilson Pvt. Ltd. L&T- ECC Nuclear Power Corp. of India Ltd. Mahanagar Telephone Nigam Ltd. Maharashtra State Electric Board Hindustan Petroleum Corporation Ltd. Indian Oil Corporation Ltd. Western Railway Pharmaceutical Product of India Ltd. Blue Star Ltd. ETA Engg Pvt Ltd. Sterling Wilson Electricals Ltd. Punjab Biomass Ltd. Rohini Electrical Pvt. Ltd. Sangam Multiplex Seven Hill Hospital Roshan Electrical Co. Pvt. Ltd Pravin Electricals Pvt. Ltd Godrej & Boyce Mfg. Co.Ltd

Voltas Ltd. K. Raheja Corp Bajaj Electricals Ltd. Market City Resources Ltd. Offshore Infrastructure Ltd. Sew Electricals Pvt Ltd Turnkey Electricals Engg. P Ltd Reflexions Contractors & Engg. Lavasa Corp. Ltd. Lodha Group Rustomjee Deepak Fertilisers Corp. Ltd. Essar Realty Developers Alfa Deal Pvt. Ltd. Safe Electric Co. India Bulls Real Estate Ltd. Gabrial Electrical Pvt. Ltd. Geographic's Infrastructure ABB Ltd. B N P Paribas Group. Kohinoor Constructions Group Neptune Group

Spectral Services Consultants Pvt. Ltd. John Mech-EI Technologies (P). Ltd. Kvaerner Powergas India Pvt. Ltd. TATA Consulting Services B. Mehtalia Consultants Pvt. Ltd. Pankaj Dharkar & associates Dalal Mott MacDonald Vikas Joshi & Associates Chempro Expertise Pvt. Ltd. Sunil Nayyar Consultants Pvt. Ltd. Project Engg. Services DSG Consultants Pvt. Ltd. Bhuva & Associates. Gherzi Eastern Ltd. Unique Engineering Services Chemtex Engineering of India Ltd.

ICB Contractors Pvt. Ltd. Elektromech Industrial Corpn. M. N. Dastur & Company (P) Ltd. AVANT GARDE Consultants EICS Power Service Consultants MEP Consultants Pvt. Ltd. SN Joshi Pvt. Ltd. Eskayem Consultants DFX Systems Pvt. Ltd. Structwell Consultants M & E Consultants ENM Consultants Rumi Bharucha & Associates KMR Associates Cushman & Wakefield RSP Consultants

Consultants

Clients

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1) Fabrication shop

Sr. No. Type of Machine Specification Quantity

1. NC Shearing Machine 75 tonne 1 No.

2. NC Press Brake 75 tonne 1 No.

3 Nibbling Machine 1 No.

4. Spot Welding Machine 1 No.

5. Power Press 30 tonne 1 No.

6. Drill Machine Upto 6mm 3 No.

7. Drill Machine Upto 16mm 3 Nos.

8. Hand Press 3 Nos.

9. Welding Set 4 Nos.

10. Portable Machines 12 Nos.

11. Pedestal Grinder 3 No.

12. Angle Cutter 2 No.

2) Paint Section

Sr. No. Type of machine Quantity

1. Treatment Tanks 7 Nos.

2. Powder Coating Booth with Blower 1 No.

3. Compressor 2 Nos.

4. Hoist - 2 Tonne 1 No.

5. Gas Fired Oven 1 No.

6. Mitsubishi Spray Gun Set 1 No.

Plant & Machinery

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Sr. No. Type of machine Quantity

1. 4000A Current Injection Set 1 No.

2. 5 KV H. V. Testing set (with leakage current setter) 1 No.

3. 1000V Megger 1No.

4. 500V Megger (Digital) 2 No.

5. Multimeter (Digital) 2 No.

6. Secondary Injection Test Set with DC & AC Variable voltage

supply

1 No.

7. Coat Gauge 1 No.

8. Bus Bar Conductivity meter 1 No.

9. Mili volt drop test meter 1 No.

10. Mili Ohm test meter 1 No.

11. Chemical checking instrument 1 set

12. Paint thickness checking instrument 1 set

13. Relay testing kit 1 No.

Sr. No. Type of machine Specification Quantity

1. Hydraulic Bus Bar Bending Cutting &

Punching Machine

3 No.

2. Drill Machine Up to 16mm 3 No.

3. Bend Saw For Hylam 1 No.

4. Portable Drilling Machine Up to 6mm 6 No.

5 Busbar Punching MIC 1 No.

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Our QAP procedures involve various stages as per ISO 9001:2008 standard:

We start out through visual testing which basically implies that all the components from CRCA sheets to Switchgear components and the integrity of the panel are visually observed.

Next for raw materials we test the physical and chemical properties of the metals to verify their strength and integrity.

For the purpose of pre-treatment of sheet metal, we use various processes like degreasing, rinsing, pickling, activation, phosphating and Passivation in which the pH values of the chemicals are continuously monitored.

We verify quality of powder coating through various tests like Cross cut adhesion, Pencil hardness, Sieve test and shelf life.

Fabrication is done as per dimensions and QC is measured on the basis of seamlessness of welding of the joints and the strength of the joints.

Detailed QAP is available for every stage of manufacturing.

“We believe that we can deliver superior quality and service through continual improvement and having a great partnership with our clients”.

Our quality policy includes extensive testing at our works based in Mumbai during various stages of manufacturing. This enables us to deliver high quality panels with efficient and accurate requirement for the customer.

Everything from the CRCA sheets to the final simulation of the panel is extensively tested till the panel is fail safe. The testing standards are as per IS and we adhere to this for the sole reason that our clients deserve the best kind of panels for their projects.

Quality Policy

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Standards:

The equipments shall be designed to conform to the requirements of:

(I) IS: 8623- Factory Built Assemblies of Switchgear and Control Gear.

(II) IS: 375- Marking and Arrangement for Switchgear Bus Bar etc.

(III) IS: 2147- Degree of Protection provided by enclosure for low voltage Switchgear and

Control Gear.

(IV) IS: 2516 Air Circuit Breakers of voltages not exceeding 1000V AC.

(V) IS: 4064- Fuse Switch and Switch Fuse Units for voltage not exceeding 1000V AC.

(VI) IS: 9224 HRC Fuse Links.

(VII) IS: 2705- Current Transformers.

(VIII) IS: 1248- Indicating Instruments.

(IX) IS: 6875- Control Switches & Push Buttons.

(X) IS: 4237 General requirements for switch Gear & Control Gear.

Tests:

Routine tests shall be conducted on the Panels in accordance with IS: 8623 and shall comprise:

(I) Inspection of the Panels includes inspection of wiring and electrical operational tests.

(II) Dielectric Tests at High Voltage.

(III) Insulation Test at 1000 volt.

(IV) Checking of Protective Measures and electrical continuity of the protective circuits.

(V) Relay testing and setting.

(VI) Any other type test as per clients requirement.

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MCC PanelHVAC Starter PanelDrawout Double Front

Fire Fighting PanelPCC Cum Sync PanelDrawout Single Front

VFD Panel MDBAPFC Panel Stainless Steel DB

HT & LT Turbine Generator Sets Panels

6400A Double Breaker 3MW LT ACB Panel (front view)

6400A Double Breaker 3MW LT ACB Panel (side view)

11KV. LAVT Panel

Turbine Gauge Panel

DC

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Sta

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Pan

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Metering Cum Sync Panel

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4000A & 5000A CPRI Certification

6000A Busduct & IP55 CPRI Certification

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SQUARE AUTOMATION PVT. LTD.3, Ravi Industrial Estate, Off. Mahakali Caves Road,

Andheri (East), Mumbai-400 093.Tel: +91-22-2687 3671 / 3938

Fax: +91-22-2687 3946E-mail: squareauto@gmail.com

enquiry@squareautomation.com

SQUARE AUTOMATION PVT. LTD.Plot No. S-152, W.E. Highway, Opp. Dara’s Dhaba,

Kashimira, Mira Road (East), Thane-401 104.Tel / Fax: +91-22-2845 7144 / 7261

E-mail: squareautomation@rediffmail.com