SQUARE
AUTOMATION
PRIVATE LIMITED
An ISO 9001:2008 Company
 An
ISO 9001:2008 CERTIFIED COMPANY and
established Engineering organization.
 Having
4 decades of engineering experience
in the field of turnkey electrical project
execution & execution, manufacturing,
testing, supply, installation, testing &
commissioning of electrical panels of all types.
 The
company has competent, well-qualified &
experienced engineers in the field working
towards achieving perfection.
THE COMPANY.
 We
strictly follow QUALITY MANAGEMENT
system that is in line with ISO 9001:2008
standards
 We
are also in the approval list of all
reputed & major electrical services
consultants of INDIA.
QUALITY ASSURANCE
THE FACTORY VIEW
PRODUCTS & SOLUTIONS…..
 Power
 Bus
control centres upto 8000 Amps,415 Volts
trunking for upto 6400A.
 Motor
control centres upto 4000 Amps,415 Volts
 Synchronizing
GENERATOR.
 Control
 PLC
 ACB
panels upto 6 Mw TURBINE
desk,mimic panels,Annuciator Panels etc.
Panels
Panels upto 3 MW L.T Turbine generator.
 Distribution
panels like PDB’s & MDB’s.
PRODUCTS & SOLUTIONS…..
 Double
 Dual
Front Panels.
Speed Starter Panels.
 Draw
out Panels.
 LAVT
& NGR Panels.
MANUFACTURING FACILITIES
CUTTING & BENDING
o
Cutting of sheets is done through
NC shearing machine.
o
Capacity of the machine is 75 Tons.
o
Bending is done through CNC
machine.
o
Capacity for the same is 80 Tons.
o
Settable parameters on the
machine provides standardization of
large projects.
o
Uniformity in the bend without
compromising linearity of the bend.
o
Overall reduction in lead time.
WELDING
o
CO2 Welding include a
copper extrusion along with
CO2 tank and mode of
operation.
o
More accurate weld points.
o
Integrity of fabricated shell
increased.
o
Durability of the welded joint
also improved by 10%
o
Panel Aesthetic also
improved at jointing structure
ESSENTIAL FABRICATION TOOLS
Hand Press
1 No.
Pillar Drilling Machine
7 No.
Power Operated Hack Saw
3 No.
Manual Shearing Machine
2 No.
Hand Drilling Machine
10 No.
Tapping Machine
2 No.
Grinding Machine
8 No.
Blower
2 No.
Weighing Machine
1 No.
Hydraulic Crimping Machine
1 No.
Bus Bar Bending Machine
2 No.
Bus Bar Punching Machine
2 No.
8-TANK PROCESS
o
Degreasing: Removing oil, grease, dirt.
o
Water Rinsing: Neutral degreasing
agents are washed for 15 minutes.
o
De-scaling: Removal of black scales and
rust from the surface.
o
De-rusting: Removal of rusted surface
using cold type solvent.
o
Water Rinsing: Clear reminants of above
acid with water bath for 4 minutes.
o
o
o
o
Zinc Phosphating: Once the rusted material is
removed, it is coated with a layer to prevent further
corrosion and provide durability.
Water Rinse: To prevent blistering on the surface, it
is dipped in a water bath.
Passivation: Final neutralizing rinsing for providing
corrosion resistance.
Even after the above process, the sheets are dried
and coated with phosphate primer to make it
humidity resistant.
POWDER COATING BOOTH
o
It is done through electrostatic
technique.
o
Mitsuba electrostatic spray gun
with powder paints for a one
shot painting process and no
blistering on the surface.
o
Paint used is RAL 7032 for all
panels.
o
A thickness of 70 microns is
maintained using micron meter.
o
We also us gas recovery and
cyclone pump for recycling of
powder granules.
GAS FIRED OVEN
o
After the painting curing is done
in the oven.
o
Temperature is maintained at
180oC to polymerize the paint .
o
The baking ensures the longevity
of the paint on the panel.
o
The time for this is about 12
minutes.
ASSEMBLY AREA
o
Multi-Tier assembly shop
for simultaneous
production.
o
IS practices used for
assembly of components,
bus bars and wiring to
ensure no re-work at site.
o
Separate teams for fitting
of components and bus
bar as well as wiring.
o
Repeated tasks like
ferruling are automated
using ferruling machine.
TESTING PRACTICES
o
Physical Test: The panel
dimensions and tightness of bus
bar joints as well as wiring
tightness are checked.
o
HV Dielectric Test: Phases are
shorted and 2.5KV is injected into
the system for 1 minute.
o
Megger Test: The meggering for
the panel is done before and
after the HV test. Megger rated
at 1KV
o
Operational Test: The panel is
then energized and control logic
is tested as per logic diagram.
ESSENTIAL TESTING TOOLS
5 KV HV Testing Kit
2 No.
5 KV Megger
5 No.
1 KV Megger
5 No.
Milli – Volt Drop Measuring Kit
2 No.
Continuity Tester
2 No.
Tong Tester
2 No.
Polarity Tester
2 No.
Earth Resistance Kit
2 No.
Conductivity Meter
2 No.
Current Injection Test Kit
1 No.
Multimeter
5 No.
DESIGN & DEVELOPMENTS
o
Designing is done through a dedicated
design department using ‘E-Plan Electric
P8’.
o
Standardization of Drawings for easy
referencing.
o
Macro programming for eliminating
repeated tasks and reducing revisions in
drawings
o
Innovation intensive structuring which
helps in identifying patterns.
o
Updates of new technology available
from global site.
o
Cross referencing in control logic made
easy
o
o
No latency in report generation.
We have also upgrade ‘E-Plan’ to the
latest version for incorporation of more
databases and further standardisation
QAP (QUALITY ASSURANCE PROGRAM)
AS PER QMS (QUALITY MANAGEMENT SYSTEM) FOR ISO – 9001: 2008
WE CARRYOUT QUALITY CHECK PROCEDURES FOR THE FOLLOWING
o
FABRICATION
o
7-TANK PROCESS
o
ASSEMBLY
o
PAINTING
o
INTERNAL TESTING
o
LUG CRIMPING
WE ARE PROVIDING THE SNAPSHOT FOR THE SAME IN THE FOLLOWING
SLIDES.
FABRICATION
SAPL-QR/INI/ FABRICATION
PROJECT NAME:
DATE OF STARTING:
PANEL NAME:
DATE OF FINISHING
REF: DRG:
SR NO.
DESCRIPTION
TYPE OF TEST
Sheet Metal / Angles
1
2
3
4
Sheet steel used for CRCA or MS
CRCA Sheet used for door 2 mm / 1.6 mm thick
CRCA Sheet used for Partician 2 mm / 1.6 mm thick
Angle used for Frame ,Support & Rigidness / load
bearing switchgear (i.e. ACB)
Vernier
Vernier
Visual/ Measurement
Fabrication check for frame against approved drawing
1
2
3
4
5
6
7
8
9
10
Overall Dimension (Height x width x depth)
Right angle for the Frame & Doors check
Proper welding joints check at every Joints & corners
Mounting Hole for Fixing mounting plate with Frame
Compartment holes
Vertical Partician with proper Grommate Hole check
Earthing Busbar cut out given through & through partician to
Partician and Both the end.
Proper support Arrangments given for Fixing Terminal
Channels.
Proper support for clamping I/C & O/G in cable Alley.
Proper support for clamping I/C & O/G in ACB Section
In wire way proper channel support given & check.
Measurement
Right Angle
Visual
Visual
Visual
Visual
Visual
Visual
Visual
Visual
RESULT FOUND
7-TANK PROCESS
SAPL-QR/INI/8TANK PROCESS
PROJECT NAME:-
DATE OF STARTING:-
PANEL NAME:-
DATE OF FINISHING
REFERENCE:SR NO. FABRICATED
TANK-1
TANK-2
TANK3
TANK4
TANK5
TANK6
TANK7
TANK8
ITEM
DEGREASING
WATER RINSE
DERUSTING
WATER RINSE
ACTIVATION
PHOSPHATING
WATER RINSE
PASSIVATION
25 TO 35 MIN
METRIT SAG
10 TO 14 ML
TIME DUR
FROM
TO
1
SEC-1
2
SEC-2
3
SEC-3
4
SEC-4
5
DOORS
6
PLATES
7
BASE
8
ANGLE
9
CHANNEL
1 MIN
25 TO 35 MIN
METRIT DSM
1 TO 2 ML
TIME DURATION
TIME DURATION
FROM
TO
FROM
TO
1 MIN
1 TO 2 MIN
25 TO 35 MIN
METRIT DSM
METRIT ZLP
1 TO 2 ML
27 TO 33 ML
TIME DURATION TIME DURATION TIME DURATION
FROM
TO
FROM
TO
FROM
TO
CHECKED BY
APPROVED BY
1 MIN
1 TO 2 MIN
METRIT PASSIVATE
3 TO 5 ML
TIME DURATION
TIME DURATION
FROM
TO
FROM
CLEARED FOR
ASSEMBLY
SAPL-QR/INI/ASSEMBLING
PROJECT NAME:-
DATE OF STARTING:-
PANEL NAME:-
DATE OF FINISHING
REFERENCE:SR NO. DESCRIPTION
A. PANEL ASSEMBLY
1 Painted Surface assembly
2 Earth washer 2Nos. Minimum per frame coupling
3 Gasketing between frame of doors
4 Frame fixing nut/bolt size
5 All nut/bolt to be with plain washer and spring washer
TYPE OF TEST
VISUAL
VISUAL
VISUAL
VISUAL
VISUAL
B. BUSBARS
Busbar Material
Size of the busbars
3 HBB Size
4 VBB Size
5 Earth Bus Size
6 Support Type And Size
7 Joints Holes
8 PVC Sleeving
9 Earth Bus Terminal Size
10 LIVE Bus Bar Shrouding Arrangement
11 Busbar Joints Nut/Bolt Size
12 Busbar Hole provision to connect Cables at site
13 Tightness Of Connections/Joints
14 Hardware on O/G Busbar
1
DWG
2
DWG
INCOMING/STAR DELTA/DOL/CAP/SFU
Switch gear Rating
2 Mounting arrangements
3 Wire Size
4 Grommet for Wires
5 Tightness Of the Wire
DWG
DWG
DWG
DWG
VISUAL
VISUAL
DWG
VISUAL
VISUAL
DWG
VISUAL
VISUAL
C.
1
DWG
VISUAL
DATA SHEET
VISUAL
VISUAL
RESULT FOUND
REMARK
PAINTING
SAPL-QR/INI/ PAINTING
PROJECT NAME:
DATE OF STARTING:
PANEL NAME:
DATE OF FINISHING
REF: DRG:
SR NO.
DESCRIPTION
TYPE OF TEST
1
Appearance of the sections
Visual
2
Thickness of the Paint
Micronmeter
3
Adhesive quality of Paint
Scratch Test
4
Shade of the Paint
Shade Test
5
Acid Resistance
Corrosion Resistance Test
CHECKED BY
APPROVED BY
RESULT FOUND
REMARK
CLEARED FOR ASSEMBLY
INTERNAL TESTING
SAPL-QR/INI/INTERNAL TEST
PROJECT NAME:-
DATE OF STARTING:-
PANEL NAME:-
DATE OF FINISHING
REFERENCE:SR NO.DESCRIPTION
A. DIMENSIONAL TEST
1 Width
2 Height
3 Depth
B.
BOM TEST
C.
1
OPERATIONAL TEST
2
3
4
5
D.
1
2
3
4
5
6
7
8
9
E.
1
Check the control wiring
Check Output Voltage
Check Function as per Control logic
Check Indicating Lamps
Check Meter Setting
TYPE OF TEST
VISUAL
VISUAL
VISUAL
DWG
CONTINUITY TEST
MULTIMETER
DWG
VISUAL
MANUAL
MEGGER TEST before HV
R-Y
R-B
R-N
Y-B
Y-N
B-N
R-E
Y-E
B-E
HV TEST
2.5KV HV Injection For 1min.
MEGGER
MEGGER
MEGGER
MEGGER
MEGGER
MEGGER
MEGGER
MEGGER
MEGGER
HV KIT
RESULT FOUND
REMARK
LUG CRIMPING
SAPL-QR/INI/LUG CRIMPING REPORT
PROJECT NAME;
DATE:
PANEL NAME;
REFRENCE:
SR.NO.
TYPE OF LUG
TOOL USED
CRIMPING
APPROVED BY:
DATE:
RESULT FOUND
CHECK BY
NEW PANEL DESIGNS
o
In the past years we have
improved our skill set and executed
various types of panels as well .
o
A PCC panel with double busbar
arrangement as shown on the right.
o
We have also executed large
no.of HVAC automation projects
as well.
o
Dual speed Starter Panel with PLC
Logic for high speed and low
speed operation.
o
o
PLC based panel
We have also provided panels for
TATA Project in Mundra in which we
have provided panels for
excitation of actuators and
dampers.
NEW PANEL DESIGNS
o
We have also executed PCC panels
with length of 30m for IT Projects,
Hospital , Commercial and Power
Projects with multiple incomers DG
sets interlocks and programmed
functions through PLC system.
o
Also PLC Based DG synchronizing
Panel with multiple DG Sets/ TG sets .
o
We have Designed and executed
Double front Draw-out Panel PCC
cum MCC for Power Plants.
o
We have also expanded are
expertise to the HT side by providing
LAVT(Lightning Arrestor Voltage
Transformer) Panels and NGR(Neutral
Grounding Resistor) Panels.
FUTURE DEVELOPMENTS





Flexible bus bar for reduction in panel sizes
and reducing link work as well as efficient
transmission.
Standardization of panel enclosures as per
bolted construction schemes.
Development of wireless control logic for
reducing control wiring and providing more
mobility and status recognition of panel by
the use of trans receivers and Wi-Fi devices.
Automation of 8-tank process using crane
automation with infrared technology.
iMCC/iPCC panels with the use of HMI for
Remote Management.
1000 KVA DGSETS & AMF
PANELS AT MUMBAI AIRPORT
PROJECT SNAPSHOTS
VFD DRIVE PANELS FOR
BHARAT DIAMOND BOURSE
SYNCHRONIZING PANEL FOR
NAVDURGA, GUJRAT PROJECT
INTERNAL LAYOUT FOR THE
SYNC. PANEL
LIGHTINING ARRESTOR AND VOLTAGE TRANSFORMER
PANEL (LAVT)
DC MOTOR STARTER AND ACDB PANEL
5000A ACB PANEL
3MW ACB PANEL
DOUBLE FRONT DRAWOUT PMCC PANEL FOR DEEPAK
FERTILIZER
PCC PANEL FOR VELOCITY ARCADE MALL @ RAIPUR
NEPTUNE MAGNETO MALL PCC PANEL
MCC & LDB PANEL FOR IT PROJECTS
CONTROL PANEL WITH PLC & AC DRIVES FOR
AUTOMATION PROJECTS
INSIDE VIEW OF CONTROL PANEL WITH PLC & AC
DRIVES FOR AUTOMATION PROJECTS
TYPICAL MCC PANEL FOR BUILDING AND INDUSTRIAL
SEGMENT.
SALIENT FEATURES OF “SQUARE”
MAKE PANELS

Our panels have been tested successfully by
“central power research institute”for “verification
of short circuit strength” at 65 KA for a time of 1
sec as per IS 8623

For high mechanical &electrical strength we use
NON-HYGROSCOPIC SMC supports for Busbar.

Detailed analysis of each feeder.

Clear indication of status and identification of
feeders.

Our estimates are accurate and price
competitive.

Durability for more than 20 years. Install and
forget.
QUALITY POLICY
 It
includes extensive testing at our works
based in Mumbai during various stages
of manufacturing
 Our
QAP procedures involve various
stages as per ISO 9001:2008
“WE BELIEVE THAT WE CAN DELIVER
SUPERIOR QUALITY & SERVICE
THROUGH CONTINUAL IMPROVEMENT
&HAVING GREAT PARTNERSHIP WITH
OUR CLIENTS”
Corporate Office:
SQUARE AUTOMATION PVT LTD
3,Ravi industrial estate,
THANK YOU.
Off Mahakali caves road,
Andheri(E),
Mumbai-400093
Tel:+91-22-26873671/3938
Fax:+91-22-2687 3946
Email: squareauto@gmail.com
Website: www.squareautomation.com
Works:
SQUARE AUTOMATION PVT LTD
Plot No.S-152,
W.E.Highway,opp.Dara’s Dhaba,
Kashimira,Mira road(E),Thane-401104