Franchised Panel Builders
Hand Book
Gulf Countries
05
Franchised Panel Builders Hand Book
Index
Chapter
Content
PREFACE
2.
TYPICAL ORGANIZATION & FACTORY LAYOUT
3.
TENDERING
4.
ORDER PROCESS, DESIGN & ENGINEERING
5.
MATERIAL & PRODUCTION PLANNING
6.
PRODUCTION
7.
INSPECTION & QUALITY CONTROL
8.
PACKING
9.
SITE-TESTING & COMMISSIONING
10.
USEFUL INFORMATION
2
Franchised Panel Builders Hand Book – 2005
PREFACE
Schneider Electric’s strength relies in its strong Channel Partner Policy
backed up with professional expertise in dealing with Channel Networks
mainly comprising of Distributors, Franchised Panel Builders and System
Integrators. Channel Partners are true allies in our business providing “value
addition” to the business transaction between Manufacturer and Customer
and therefore need to be moulded & dedicated to our standards of Quality,
Workmanship & Service.
To maintain the lasting relationship between Schneider Electric & its
Franchised Panel Builders and in order to upkeep the image of both
Organizations a strong commitment is required from Franchised Panel
Builders in strictly following Schneider Electric standards, norms, practices &
guidelines.
This document provides basic guideline as to how Schneider Electric
Franchised Panel Builders should adapt and organize in order to present a
professional image to the Customer and differentiate themselves with other
Panel Builders in the market.
The hand book will also enable Schneider Electric’s Key Account
Responsibles to build & lead an effective Franchising activity taking into
consideration the proven & best engineering & management practices listed.
They would be in a strong position to promote Franchised Panel Builder’s
with Consultants, Contractors & End Users.
By adopting this handbook and ensuring that our Franchised Panel Builders
follow the defined processes we aim to establish uniformity amongst our
Franchisee’s and establish bench marks in the market place. We can be
confident that our Customers will better appreciate the value for money when
they procure equipment from Schneider Electric Franchised Panel Builder.
3
Franchised Panel Builders Hand Book – 2005
Franchised Equipment under present scope
OKKEN








High Dependability Switchboard targeted at large
sites (Oil & Gas, Chemical)
630A upto 6300A, 2mm thick, Form-4B
Power Distribution and Motor Control
Fixed and Withdrawable Switchboards & MCCs
Innovative, Patented solutions for different types of
Functional Units rendering extremely flexible and
safe for upgrade / maintenance
Fully Type-Tested to IEC 60439-1
Tested for Internal-Arc containment to IEC 61641
E@gle - Intelligent Motor Control Centers
Designed & Assembled by Franchised Panel Builder (Columns Supplied in Standard Kits from France)
BLOKSET






High Dependability Switchboard targeted at High
Commercial, Industrial and Infrastructure Markets
(other than Oil & Gas)
630A upto 6300A, 2mm thick, Form-4B
Power Distribution and Motor Control
Fixed and Withdrawable Switchboards & MCCs
Fully Type-Tested to IEC 60439-1
Tested for Internal-Arc containment to IEC 61641
Designed & Assembled by Franchised Panel Builder (RTW Columns supplied by Schneider Electric as per
Drawings)
PRISMA PLUS




Modular, functional system targeted at Residential
and Building Markets.
630A upto 3200A, 1.5mm thick, Form-4B
Power Distribution and Motor Control (Fixed
Version)
Fully Type-Tested to IEC 60439-1
4
Franchised Panel Builders Hand Book – 2005
Designed & Assembled by Franchised Panel Builder (Columns Supplied in Standard Kits from France)
5
Franchised Panel Builders Hand Book – 2005
CHAPTER-2
TYPICAL
ORGANIZATION
&
FACTORY
LAYOUT
6
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
Department: Switchgear Div.
Title: TYPICAL
PS-200
ORGANIZATION & FACTORY LAYOUT
Developed by: Syed Basheer
Approved by: Sunil PARKHI / Faiz AHMED
ORGANIZATION CHART
Rev-A
December 2005
GENERAL
MANAGER
SWITCHGEAR
MANAGER
SALES &
MARKETING
TENDERING
LOGISTICS &
PLANNING
DESIGN
PRODUCTION
QUALITY
ASSURANCE
QUALITY CONTROL
Sales Engineer
Estimation
Engineer-1
Design
Engineer
Purchase
Engineer
Production
Supervisor
Quality
Inspector
-
Marketing
Engineer
Estimation
Engineer-2
Draftsman
Logistics
Controller
Production
Technician
Testing
Technician
-
SEG-FPBHB/F-201
7
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
Department: Switchgear Div.
Title: TYPICAL
PS-200
ORGANIZATION & FACTORY LAYOUT
Rev-A
Approved by: Sunil PARKHI / Faiz AHMED
Developed by: Syed Basheer
December 2005
TYPICAL LAYOUT
OF A LV SWITCHGEAR
ASSEMBLY PLANT
FACTORY
LAYOUT
PACKING AREA
WAREHOUSE
9
10
TABLES ARRANGEMENT FOR ASSEMBLY & WIRING OF THE CABINETS/D.B.s
ENTRY
EXIT
BUSBAR STORAGE RACKS
CUBICLE ASSEMBLY AREA
1
DRAWING
TABLE
TESTING AREA
BUSBAR WORKING AREA
WORKSHOP
MANAGER
3
2
4
OFFICE
5
6
7
8
1 BUSBAR BENDING/CUTTING MACHINE
6 TESTING STAND
2 PUNCHING MACHINE
7 STATIC GENERATOR
3 GRINDING MACHINE
8 ENGRAVING MACHINE
4 COMBINED SHEARING/PUNCHING MACHINE
5 DRILLING MACHINE
9 WOOD PACKING MATERIALS
10 WEIGHING MACHINE
SEG-FPBHB/F-202
8
Franchised Panel Builders Hand Book – 2005
CHAPTER-3
TENDERING
9
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
Department: Tendering
Title: TENDERING
PS-300
Developed by: Syed Basheer
Rev-A
Approved by: Sunil PARKHI / Faiz AHMED
December 2005
1.0 Objective:
To describe how a Schneider Electric Franchised Panel Builder (FPB) should prepare and submit an
Offer on receipt of an enquiry from the Customer.
2.0 Scope:
To all Customer’s enquiries for Low Voltage Switchboards.
3.0 Related Documents:
RFQ Format (SEG-FPBHB/F-301)
Check-List (SEG-FPBHB/F-302)
Estimation Sheet (SEG-FPBHB/F-303)
Offer Format (SEG-FPBHB/F-304)
Discount Request Form (SEG-FPBHB/F-305)
4.0 Abbreviations:
SE-Sales engineer
TM-Tender manager
EE-Estimation engineer
DM-Design manager
DE-Design engineer (draftsman)
5.0 Procedure / Process:
Handling Customer Enquiries
 Customer enquiries are received by Sales Engineers (SE).
 SE should fill-up ‘Request For Quotation’ (RFQ) Form (SEG-FPBHB/F-301) and forward to the
Tendering Dept.
 The Tendering Manager (TM) will analyse the RFQ and check if the required items are in the
Franchised Panel builders (FPB) scope of supply.
 If it is out of the scope of supply, send a regret letter to the customer with copy to SE.
 If it is in the scope of supply, assign an Estimation Engineer (EE) for this enquiry.
10
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
Department: Tendering
Title: TENDERING
PS-300
Developed by: Syed Basheer
Rev-A
Approved by: Sunil PARKHI / Faiz AHMED
December 2005
Estimation
 EE studies the detailed specification, Single line drawings, data sheets, etc.
 EE prepares a Check-List (SEG-FPBHB/F-302) noting down the key technical points of the
specifications / customer requirement.
 If sufficient data is not available, EE obtains clarifications from Customer.
 With sufficient data available, EE starts with the Estimation / Costing. Estimation is done either
using a software or manually. For MDBs / MCC’s EE prepares a rough sketch of the Switchboard
layout in order to accurately determine the size and cost of enclosure, busbar, etc.
 For manual estimation, EE uses Estimation sheet format (SEG-FPBHB/F-303)
 In the estimation, EE evaluates cost of the following core items:
 Enclosure
 Circuit Breakers (ACB, MCCB, MCB, …)
 Motor Starters
 Instrumentation (Metering devices, CTs, PTs, Fuses, …)
 Busbars
 Etc
 Miscellaneous items (such as Hardware, Cabling, etc..) can be estimated as a percentage of
Material Cost
 Labour can be estimated as a percentage of Material Cost With the Total material Cost + Labour
known, EE adds their Profit Margin (to be decided by the management) and arrives at the Selling
Price
Offer Preparation
 EE then prepares a Techno-Commercial offer Using (SEG-FPBHB/F-304)
 It is important to note down the List of Deviations to spec in the offer.
 EE obtains signatures of relevant personnel (based on Management decision).
 EE sends the Offer to customer along with necessary documentation. One Copy of the Offer is
sent to SE and another copy filed in the Quotation File.
Job Finalization
 SE follows up the Offers submitted to the customers.
 SE declares the project on TSOP list (Target Selection of Project) based on the TSOP rules
defined by Schneider Electric.
 During negotiations with the customer, in order to obtain Special Project Discount on Schneider
Electric components, the SE should prepare a ‘Discount Request Form (SEG-FPBHB/F-305) and
send the same to concerned Sales engineer in Schneider Electric.
11
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
Department: Tendering
Title: TENDERING
PS-300
Rev-A
Approved by: Sunil PARKHI / Faiz AHMED
Developed by: Syed Basheer
December 2005
Process Flow chart:
Responsible
Comments
R e c e ip t o f c u s to m e r
E n q u ir y
Customer Enquiry by
Fax, E-mail,Post
Direct contact
C o m p le t e R F Q f o r m
F o rw a rd to T M
RFQ-Format
SEG-FPBHB/F-301
SE
A n a ly s e R F Q
Is it in o u r s c o p e
N o
S e n d re g re t
le tte r to
c u s to m e r
Y es
A s s ig n E s t im a t io n
e n g in e e r , s e n d R F Q
A c k n o w le d g e m e n t t o
S E
TM
TM
Check-list-Format
SEG-FPBHB/F-302
S t u d y d e t a ils
t e c h n ic a l &
c o m m e r c ia l s c o p e
p r e p a r e c h e c k - lis t
c la r if ic a t io n s
fro m
c u s to m e r
TM
B
A
12
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
Department: Tendering
Title: TENDERING
PS-300
Rev-A
Approved by: Sunil PARKHI / Faiz AHMED
Developed by: Syed Basheer
Responsible
December 2005
Comments
A
B
No
S u ffc ie n t d a t a to
Q u o te
EE
YES
EE
C a r r y o u t e s tim a tio n
u s in g s o ftw a r e o r
m a n u a lly
u s e e s tim a tio n s h e e t
Estimation Format
SEG-FPBHB/F-303
No
p re p a re T e c h n o c o m m r e c ia l o f f e r
EE
T M to c h e c k if
th e o ffe r is o k
TM
Offer Format
SEG-FPBHB/F-304
Yes
O b t a in a p p r o p r ia t e
s ig n a t u r e
S e n d o ffe r to c u s to m e r
c o p y to S E & Q u o ta tio n
f ile
EE
SE/EE
C
13
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
Department: Tendering
Title: TENDERING
PS-300
Developed by: Syed Basheer
Rev-A
Approved by: Sunil PARKHI / Faiz AHMED
December 2005
Responsible
Comments
C
S E f o llo w - u p o ff e r w it h
c u s to m e rs .
SE
B a s e d o n T S O P p ro c e d u re s
s e t b y S c h n e id e r
e le c t r ic , D e c la r e t h e p r o je c t
T S O P lis t
D u r in g N e g o t ia t io n s , in o r d e r t o
o b t a in s p e c ia l d is c o u n t o n
s c h n e id e r c o m p o n e n t s , s e n d
D is c o u n t r e q u e s t fo r m to
S c h n e id e r s a le s
SE
Discount Request
Format
SEG-/FPBHB/F-305
SE
14
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
Department: Tendering
Title: TENDERING
PS-300
Approved by: Sunil PARKHI / Faiz AHMED
Developed by: Syed Basheer
FPB LOGO
Date :
Country / Region
SAL Ref. No.
First Quote
Revision
Project Data :
Project Name
End User
Consultant
Main Contractor
Customer
:
:
:
:
:
Spec.
Single Line
BOM
IEC
MDB
Comments
:
Competition
:
Project Status :
SMDB
Standard
Strategic Customer :
Tender Docs.
Schematics
NEMA / ANSI
MCC
Payment Conditions :
Ref. No.
Sub Contractor :
Specification :
Scope :
December 2005
REQUEST FOR QUOTATION (RFQ)
Compiled by :
Equipment :
Rev-A
DB
CP
Non Standard (specify)
Yes
No
Budgetary
Expected Delivery Date:
Bidding Stage
Chance Of Success
Low
Job In Hand
Medium
High
Others……….. Offer Required By
:
Equipment to be offered
Blokset
Okken
Prisma Plus
Sales Managers Signature :
Date :
For Tendering Dept Use Only :
RFQ Accepted
Yes
No
Received
RFQ Rejected
Estimator
Reason(s) For Rejection :
Confirmed Quotation Date :
Quotation No.
Comments :
Signed :
Date :
Tendering Mnger
Form# SEG-FPHB/F-301
15
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
Department: Tendering
Title: TENDERING
PS-300
Rev-A
Approved by: Sunil PARKHI / Faiz AHMED
Developed by: Syed Basheer
December 2005
FPB LOGO
Customer
CHECK-LIST
Ref
Date
Rev
SPECIFICATION SNAPSHOT
Note :
Additional data to be supplied
Standards
Temperature
Atmosphere
IEC 60439-1
Ambient Air
0
BS / EN 60439-1
24hr Average
0
Duty
C Relative Humidity
%
Continuous
C Altitude
m
Discontinuous
Others
Decret 14/11/88, Relatif a la protection des personnes
Place of Installation
Sea Side
Y
N
Corrosive atmosphere
Y
N
Earthquake risk
Yes
Enclosure
No
Tropicalization
Indoor
Ventilated Room
Degree of Protection
Outdoor
Air-conditioned Room
Impact Strength
IP
Ik
Pressurized Room
Sheet Steel thickness,
mm
Special Paint
TECHNICAL DATA
Power Supply
System Parameters
Busbars
Rated operating Voltage
V
Rated Current
A
Material:
Rated Insulating Voltage
V
Short-Circuit Current
kA
Constant
Rated Impulse Withstand Voltage
kV Rated Short-time Current,1s
kA
Bare
Frequency
Hz Rated peak Withstand Current
kA
Harmonics
Aux / Control Voltage
From Busbar
V
Aux Xfmr
Tin-plated
Silver-plated
Paint
100%
50%
Earth Bar
Connections / Access
Instrumentation
Meters
Solidly grounded
TT
Incoming :
Unearthed Network
IT
Bus Duct
Earthed Neutral
TN
Outgoing
4-Wires
TN-C
Access
5-Wires
TN-S
Top
Bottom
Cable
Top
72x72
Others
Bottom
Front
96x96
Rear
Pilot Devices :
Others
22.5mm dia
Functional Unit
Internal Separation
Compartment/s
Fixed
Drawout
Form
Incoming CB
Fixed
Drawout
Form 4 Type 6
Outgoing CB
Fixed
Drawout
Assembly Classification
1
2
Manuf Quality Assurance
3
7
4
ISO-9001
ISO-9002
Remarks
Type Tested Assembly - TTA
Partially Type Tested Ass - PTTA
Form# SEG-FPHB/F-302
16
Franchised Panel Builders Hand Book – 2005
Alu
Decreasing
PVC Sleeves
Neutral
External
Earthing System
Copper
Franchised Panel Builders Hand Book
Department: Tendering
Title: TENDERING
PS-300
Rev-A
Approved by: Sunil PARKHI / Faiz AHMED
Developed by: Syed Basheer
December 2005
Date
FPB LOGO
ESTIMATION SHEET
Offer Ref
Client
Project
Swbd Ref
Sn
Reference
Item Desc
Unit List
Price
Coeff Unit Price
Disc
Net U.Price
Qty
T.Price
Remarks
1
0
0
0
2
0
0
0
3
0
0
0
4
0
0
0
5
0
0
0
6
0
0
0
7
0
0
0
8
0
0
0
9
0
0
0
10
0
0
0
11
0
0
0
12
0
0
0
13
0
0
0
14
0
0
0
15
0
0
0
16
0
0
0
17
0
0
0
18
0
0
0
19
0
0
0
20
0
0
0
21
0
0
0
22
0
0
0
23
0
0
0
24
0
0
0
25
0
0
0
26
0
0
0
27
0
0
0
28
0
0
0
29
0
0
0
30
0
0
0
31
0
0
0
32
0
0
0
33
0
0
0
34
0
0
0
0
0
0
SUMMARY OF MATERIAL COST
Material Cost
0
=S= components
Misc
2%
-
Enclosure
Labour
7%
-
Busbars
Total Matl + O/H Cost
-
Meters, CTs, Misc items,…..
Margin
20%
Total Material Cost
0
SELLING PRICE
Form# SEG-FPHB/F-303
17
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
Department: Tendering
Title: TENDERING
PS-300
Approved by: Sunil PARKHI / Faiz AHMED
Developed by: Syed Basheer
Customer:
Project:
Ref:
Date:
Rev-A
xxxxxx
xxxxxx
xxxxxx
xxxxxx
December 2005
FPB LOGO
OFFER FOR
L.V.SWITCHBOARDS
PROJECT
xxxxxxx
CUSTOMER
yyyyyyyy
CONTENTS
SN
DESCRIPTION
1.
COMMERCIAL OFFER – SPECIFIC CONDITIONS
2.
GENERAL CONDITIONS OF SALE
3.
BILL OF PRICES
4.
BLOKSET TECHNICAL SPECIFICATION
5.
TECHNICAL DETAILS
xxxx
xxxx
xxx
xxx
xxxxx
SEG-FPBHB/F-304
18
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
Department: Tendering
Title: TENDERING
PS-300
Developed by: Syed Basheer
Rev-A
Approved by: Sunil PARKHI / Faiz AHMED
December 2005
COMMERCIAL OFFER
SPECIFIC CONDITIONS
1. SCOPE OF SUPPLY
This offer consists of LV Switchgear, according to the attached Bill of Prices and the
technical part that complement one another.
2. TOTAL PRICE: EURO xxxxxx
Our prices are meant:
♦ In EURO currency of account and payment.
♦ Excluding any taxes and customs duties.
♦ Firm within the validity and delivery periods as defined hereunder.
3. PAYMENT CONDITIONS
♦ 20 % of the total price along with the order as down payment by certified cheque or
bank transfer.
♦ 80 % of the total price at the time of delivery by irrevocable and confirmed
documentary credit opened in our favour within one month from the date of order,
payable at sight upon presentation of commercial invoice and delivery note.
♦ Settlement of invoices shall not be linked to any payment due to by Purchaser a
third party (public or private).
♦ For any delay in payment, service charges for account handling shall be claimed by
Schneider Electric and paid by Purchaser at a rate of 0.5 % per month of delayed
amount.
4. VALIDITY PERIOD
This offer is valid for acceptance until the xx/xx/05.
Should extension of validity be required, please contact us.
5. DELIVERY PERIOD
The equipment will be ready for Ex Works delivery within 10 to 12 weeks from the date
of coming into force of the contract and shop drawing approval.
6. GENERAL SALES CONDITIONS
Our attached General Sales Conditions form an integral part of this offer. They shall
apply unless otherwise superseded by above specific conditions.
SEG-FPBHB/F-304
19
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
Department: Tendering
Title: TENDERING
PS-300
Rev-A
Approved by: Sunil PARKHI / Faiz AHMED
Developed by: Syed Basheer
December 2005
GENERAL CONDITIONS OF
SALE
1.
GENERAL: These conditions apply whatever the purchaser's general purchasing
conditions may be. Any departure from the conditions, stipulated in the order will only
be considered as accepted once our written consent has been accorded. The sales
contract is considered as final only after our definite acknowledgment of the order.
2.
SUBJECT AND LIMIT OF THE OFFER: The conditions of this offer apply exclusively
to supply of equipment specified in the offer, and are not binding for additional
supplies. The purchaser will in no case be allowed to put forward standards,
specifications, statutes, rules and uses not duly accepted by us.
3.
COMING INTO FORCE OF CONTRACT: The contract will be considered effective
when the following conditions are fulfilled:
♦
♦
♦
♦
Signature of the contract by two parties or acknowledgment by us of Purchase
Order.
Receipt of down payment.
Receipt of L/C covering the balance of the total equipment supply amount by us
as per agreed terms.
Should these conditions not be fulfilled within 30 days after the Contract has been
awarded, we are entitled to renegotiate the terms.
4.
VALIDITY: This offer is valid for the period specified in the Specific Conditions.
5.
PRICES:
6.
INSPECTION - TEST: Type tests will not be performed. When required, type test
certificates from similar equipment will be provided. Routine tests are always
undertaken on the equipment in our/subsidiary factories. Some of these routine tests
may be repeated during inspection at purchaser’s request. We will notify the
purchaser in writing seven (7) calendar days before the date set for inspection.
Should the purchaser or his representative fail to take inspection within a
seven (7) day period from the date for inspection, the equipment will be
considered as duly accepted and we will be entitled to proceed with packing and
delivery. In any case should the inspection be delayed for reasons outside our
control, or the duration of the inspection exceed 2 days, or technical modifications
be directed, then the delivery period will be extended accordingly. Necessary
facilities for performing the inspection (test equipment and personnel) will be made
available by us exclusive of the expenses incurred by purchaser’s representatives.
7.
PACKING : Unless otherwise specified packing is made in accordance with our
experience and practices. Only packing made by us in such conditions can involve
our responsibility. Packing is non-returnable.
8.
DELIVERY:
8.1
DELIVERY CONDITIONS: The delivery conditions stated in our offer are to be in
accordance with the Inco terms of the International Chamber of Commerce. From the
Prices indicated in the Price Schedule are firm within the validity period.
20
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
Department: Tendering
Title: TENDERING
PS-300
Developed by: Syed Basheer
Rev-A
Approved by: Sunil PARKHI / Faiz AHMED
December 2005
moment when the goods are delivered at the place agreed upon, we decline all
liabilities on our part in the event of loss, robbery or damage to the goods.
Unless otherwise agreed we reserve the right to dispatch our goods in the
event of loss, robbery or damage to the goods. Unless otherwise agreed we
reserve the right to dispatch our goods in partial deliveries.
8.2
8.3
DELIVERY PERIOD : Unless otherwise specified, the delivery time is to be
considered as ex-works (EXW) delivery. The order is not considered as final and
the delivery period does not come into force before the due completion of the
following conditions:
All information necessary to proceed with design and manufacture has been
transmitted/ forwarded to us.
The term payable at time of order, if any, has been paid or, in the event of
payment by documentary credit opened at the time of order the letter of
credit has been duly opened, and accepted by us. If despatch is delayed by
the purchaser for any reason, the goods will be stored and handled by us at
the expense of the purchaser.
VARIATIONS AND MODIFICATIONS : Should during the execution of the contract,
we be directed by notice in writing to alter, amend, omit or remove any part of the
specification, technical data or drawings, a corresponding increase or decrease in the
contractual price will be determined and the modification will be executed after
the receipt of a variation order. Due account shall be taken of any partial
execution of the contract which is rendered useless by any such variations.
Furthermore an extension of time will be granted to us. If required a manufacturing
time schedule including deadlines, after which modifications shall affect the final
delivery date, will be established by us after coming into force of contract.
9.
FORCE MAJEURE : Our responsibility could not be involved in the event of delays
in delivery due to "force majeure" or fortuitous circumstances beyond our control;
such as wars, disease, requisitions, strikes, fires, floods, cataclysms, interruptions, or
delays in the transport, or supply of raw materials, power, etc..
10.
PAYMENT : Payment shall be made in Dubai, UAE, net without discount, in
accordance with the stipulated terms of payment.
11.
RETAINED PROPERTY: It is understood that the property of the goods covered by
the contractor will not be transferred to the purchaser until complete payment of the
amount agreed upon.
12.
GUARANTEE: Our goods are guaranteed for a period of fifteen (15) months from
the delivery date or 12 months from the date of commissioning whichever comes
earlier against any defects in construction or operation arising from faulty design,
materials or workmanship. Our guarantee does not apply in the following cases:
-
Defects arising either from materials supplied by the purchaser or from a
design requested by the purchaser.
Replacements or repairs resulting from normal wear of units and machinery,
damages or injuries caused by lack of care, insufficient, inspection or
maintenance, or improper use of the goods.
Failure attributed to fortuitous circumstances or force majeure.
SEG-FPBHB/F-304
21
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
Department: Tendering
Title: TENDERING
PS-300
Rev-A
Approved by: Sunil PARKHI / Faiz AHMED
Developed by: Syed Basheer
December 2005
The guarantee consists in repairing, modifying or replacing the parts or units
recognized as defective, within the shortest time and at our expenses inclusive of
parts and labour. Our liability is limited to the obligations thus defined and we
could not be bound to pay compensation to the purchaser for incurred prejudices
such as personal injury, damage to goods other than those stipulated in the contract
or loss of profit. The guarantee legally cease if the purchaser has, under his
own initiative, undertaken modifications or repairs on our goods without our
explicit consent.
13.
13.1
CONFIDENTIALITY:
The studies, drawings and documents submitted to the purchaser remain our
property and are confidential, and the purchaser may neither make use of them for
any purpose other than stipulated in the contract nor, consciously or not, transmit
them to third party, and he binds himself to take relevant action to comply with
this.
13.2
Should the sale not be settled, the studies and documents submitted with this
tender must be handed back to us at request, within the fortnight following the
limit of validity of the offer.
14.
DISPUTES & LAW : The disputes, if any, which could not be settled by mutual
agreement shall be finally settled under the Rules of Conciliation and Arbitration of
the Chamber of Commerce by one or more arbitrators appointed in accordance
with the rules. The present offer and the relevant contract shall be construed and
governed according to the UAE Law.
15.
DIRECT OR INDIRECT LIABILITY: We can not be held responsible for any indirect
costs, such as Loss of Profit, Opportunity costs, Lack of production, due to any
damage or incident.
16.
DOCUMENTS APPROVAL: When the documents are submitted for approval to the
purchaser, he shall notify his approval or his comments within 15 (fifteen) days from
the submission date, otherwise delivery schedule will be extended accordingly.
17.
DELAYS & TERMINATION: If we are prevented from execution of the project due to
reasons beyond our control, we shall have the right to terminate the contract upon
written notice of 7 (seven) days. In such a case we shall be entitled to receive all
costs incurred upto the date of termination plus an attributable portion of the
overheads.
BILL OF PRICES
SN
QTY
U.PRICE
T.PRICE
1.
MMM
DESCRIPTION
1
XXX
XXX
2.
MMM
1
XXX
XXX
3.
MMM
1
XXX
XXX
4.
MMM
1
XXX
XXX
5.
MMM
1
XXX
XXX
TOTAL PRICE EX WORKS XXX IN EURO
XXXXXX
22
Franchised Panel Builders Hand Book – 2005
SEG-FPBHB/F-304
23
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
Department: Tendering
Title: TENDERING
PS-300
Developed by: Syed Basheer
Rev-A
Approved by: Sunil PARKHI / Faiz AHMED
December 2005
LIMIT OF SUPPLY:
This offer does not include the following supplies and services:
♦ Spare Parts
♦ Type Test repetition
♦ Labour on site such as
• Supervision of erection and installation
• Site assembly and connection
• Testing and Commissioning
♦ Remote Control and Indication
♦ Cable Termination Kits, Cable lugs and Crimping Tools
♦ AC/DC auxiliary supply
♦ Co-ordination Study
♦ As a general remark, all equipment which are not explicitly mentioned in our offer.
Scope of supply is frozen on basis of following documents:
♦ Contract SLD – Drawing Ref XXXXXXXXXXXXXX
NOTES:

Offer is based on attached Technical details of the LV Panels
24
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
Department: Tendering
Title: TENDERING
PS-300
Developed by: Syed Basheer
Rev-A
Approved by: Sunil PARKHI / Faiz AHMED
December 2005
BLOKSET TECHNICAL
SPECIFICATIONS
1
PRESENTATION
BLOKSET, a modular multi - functional system has been designed to improve reliability and
safety which:
♦ Complies with International Standards
♦ Tested according to International standards
♦ Manufactured in ISO certified facilities
BLOKSET is a fully type tested and complete system integrating Schneider Switchgear
components and composed of Standard Prefabricated components which guarantee
flexibility, quick manufacture and reliable service after delivery.
2
STANDARDS
The equipment proposed in this offer has been designed, manufactured and tested in
compliance with IEC recommendation.
♦ LV Switchgear and Controlgear Assemblies
IEC 60439 - 1
♦ Degrees of Protection provided by enclosures
IEC 60529
♦ Resistance to salt mist
IEC 68-2-11
♦ Resistance to clamp heat
IEC 68-2-30
In addition to fulfilling the above standards, Blokset has also undergone several other tests
such as :
♦ Internal Arc Confinement. - AS 3439
♦ Earthquakes - CBC ( California Building Code )
SEG-FPBHB/F-304
25
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
Department: Tendering
Title: TENDERING
PS-300
Rev-A
Approved by: Sunil PARKHI / Faiz AHMED
Developed by: Syed Basheer
3
BLOKSET UNIT AND SWITCHBOARD DESCRIPTIONS
3.1
Blokset Panel Descriptions
December 2005
The Blokset panel descriptions are presented in the Technical Leaflet reference ART.080308 Blokset range.
3.2
Sheet Metal Treatment And Painting
All the work pieces are cleaned before painting by several steps of chemical process and
finally treated by Fe Phosphate in order to protect against corrosion and get strong adhesive
result. These parts coated by Epoxy Polyester Powder which melted through treating process
at 1850 C - 2000 C will give the hardness of painting result.
To ensure the quality of the painting, the following sample test are performed
♦ Paint thickness 60-80 µm
♦ Hardness test by Perzoz pendulum ( min : 300 Second )
♦ Adherence test by Cross CUT
♦ Impact test ( 1 hg - 50 cm )
♦ Brilliancy check
♦ Bending test by Mandrel Bending
3.3 General Characteristics
Standard Manufacturing
Design System
Type Panel
Internal Separation
Degrees of Protection
Ambient Air Temperature
:
:
:
:
:
:
IEC 60439 - 1, IEC 60529
Modular
Indoor
Form 1 to Form 4b
IP31, IP42, IP54
Between -50 C up to 500 C maximum
(Average over a period of 24 hrs does not
exceed + 350 C)
Altitude
Relative Humidity
:
:
Up to 2000 m
At Max Temp. +400 C
Lower Temp. + 200 C
=Less than 50 %
=Less than 90 %
3.4 Electrical Characteristics
Rated Insulation Voltage
Rated Operational Voltage
Rated Short Time Withstand Current:
Rated peak Withstand Current
Rated Current
- Main Busbars
- Distribution Busbars
:
1000 VAC
:
690 VAC
Up to 100 kA - 1s
:
Up to 220 kA
:
:
Up to 6300A
:
Up to 3200A (except Withdrawable = 1000A)
3.5 Mechanical Characteristics
Dimension
Height (Overall)
Depth
:
:
2200 mm
600 / 1000 mm
26
Franchised Panel Builders Hand Book – 2005
Width
:
700 / 900 / 1100 mm
SEG-FPBHB/F-304
27
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
Department: Tendering
Title: TENDERING
PS-300
Developed by: Syed Basheer
Approved by: Sunil PARKHI / Faiz AHMED
Material
Enclosures
Busbars
Painting
Cable Connection Access
4
Rev-A
:
:
:
:
December 2005
Folded Metal Sheet Thickness 2 mm
TINNED Copper
Epoxy Polyester Powder
* RAL 9002 Ordinary Smooth
Bottom / Top (Front / Rear Access)
TESTS
4.1
Type-Tests
BLOKSET panels have successfully passed the following Type-Tests in accordance with IEC
60439-1 Standards.
♦ Verification of Short-Circuit withstand strength
♦ Verification of Temperature rise limits
♦ Verification of dielectric properties
♦ Verification of clearance and creepage distances
♦ Verification of effectiveness of protective circuits
♦ Verification of Mechanical operation
♦ Verification of Degree of Protection
Blokset
ype
IEC T
60439-1
Tested
Assembl
4.2
y
Routine Tests
The following Routine Tests are done in the factory in accordance with IEC 60439-1
Standards.
Inspection of the Assembly
♦ Dielectric Test
♦ Checking of protective measures and of the electrical continuity of the protective circuits
5
LIMIT OF SUPPLY
This technical offer is valid for the supply of equipment completed with documents as follows :
♦ As Built Drawing
♦ Factory Test Report
♦ Installation Guide
6
LIST OF MANUFACTURERS
♦ Switchgear & Controlgear
♦ ACB’s, MCCB’s
♦ Protective Relays
equivalent
Auxiliary Relays
♦
♦ Lamps, Push - Buttons
♦ Switches
♦ Terminals
SCHNEIDER ELECTRIC - BLOKSET
SCHNEIDER ELECTRIC - MERLIN GERIN
SCHNEIDER ELECTRIC - MERLIN GERIN or
SCHNEIDER ELECTRIC - TELEMECANIQUE
SCHNEIDER ELECTRIC - TELEMECANIQUE
SCHNEIDER ELECTRIC - TELEMECANIQUE
SCHNEIDER ELECTRIC - TELEMECANIQUE
28
Franchised Panel Builders Hand Book – 2005
♦
♦
Current Transformer
Measuring Instruments
Celsa or equivalent
Crompton or equivalent
SEG-FPBHB/F-304
29
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
TECHNICAL DETAILS
PS-300
Title: TENDERING
Developed by: Syed Basheer
Department: Tendering
Rev-A
Approved by: Sunil PARKHI / Faiz AHMED
December 2005
1. MSB-A
Incomer-1 (Mains) :
1600A 3P ACB, Drawout Motorized, NW16H1, with Micrologic 5.0A microprocessor
based control unit c/w Over-current and Short-circuit protection, 30v DC shunt trip.
Metering for Mains:
3nos Ammeters with MDI (with 3 CTs)
1 no REF Relay with 4nos Class-X CTs
10way Terminal block + Space for KWH + 3CTs
1no V/M + S/S (with busbar mounting fuses on incoming links).
3nos RYB lamps
Incomer-2 (Genr) :
1600A 4P ACB, Drawout Motorized, NW16H1, with Micrologic 5.0A microprocessor based
control unit c/w Over-current and Short-circuit protection, 30v DC shunt trip.
Metering for Genr:
3nos Ammeters with MDI (with 3 CTs)
1 no REF Relay (SEPAM 100LD) with 4nos Class-X CTs
1no V/M + S/S (with busbar mounting fuses on incoming links).
3nos RYB lamps
Note: Auto-Changeover facility to be provided between the 2 Incomers using UACONTROLLER.
Outgoing,
12nos 200A 3P MCCB, NS250H, Fixed with ext rotary handle + 200A 3P CONTACTOR
Each Contactor to have a Hand-Off-Auto selector switch
3nos (45-100)A 3P MCCB, NS100H, Fixed with ext rotary handle
Control Logic :

Voltage sensing relay senses restoration of supply either from Mains or Generator.

Each of the Contactors will be closed with a Cascaded TIME-DELAY of approx 10secs
(adj 5 to 60secs).

Necessary relays, timers, etc will be provided.
Busbars :
1600A, 4-Pole, high conductivity, hard-drawn, Tin-plated copper, fault level 85kA for 1 sec
(equivalent to 44kA for 3secs)
Design :
5-column BLOKSET modular compartmental structure conforming Form-4B to IEC 60439-1
standards. Fully Type-tested switchboard using 2mm thick sheet steel, IP42, finished to RAL
9002 paint shade.
Col-1: (700+400)w x 2200h x 1000d
Col-2, 3 : 700w x 1000h x 1000d
Col-4, 5 : (200+700)w x 2200h x 1000d
Dimensions :
4300(W) x 2200(H) x 1000(D) mm (approx)
2. LV PANEL-2
Incomer :
800A 3P ACB, Drawout Motorized, NW08H1, with Micrologic 5.0A microprocessor based
control unit c/w Over-current and Short-circuit protection, 30v DC shunt trip.
Metering for Mains:
3nos Ammeters with MDI (with 3 CTs)
30
Franchised Panel Builders Hand Book – 2005
SEG-FPBHB/F-304
31
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
Department: Tendering
Title: TENDERING
PS-300
Developed by: Syed Basheer
Rev-A
Approved by: Sunil PARKHI / Faiz AHMED
December 2005
1 no REF Relay with 4nos Class-X CTs
10way Terminal block + Space for KWH + 3CTs
1no V/M + S/S (with busbar mounting fuses on incoming links).
3nos RYB lamps
Outgoing:
2nos 300A 3P MCCB, NS400N, Fixed with ext rotary handle
2nos 250A 3P MCCB, NS250H, Fixed with ext rotary handle
4nos (63-100)A 3P MCCB, NS100H, Fixed with ext rotary handle
1nos 200A 3P MCCB, NS250H, Fixed with ext rotary handle + 200A 3P CONTACTOR +
3xSP MCB + Photocell + 3posn S/S
3nos (30-45)A 3P MCCB, NS100H, Fixed with ext rotary handle + 3nos 30A SP MCB,9kA
Busbars :
800A, 4-Pole, high conductivity, hard-drawn, Tin-plated copper, fault level 85kA for 1 sec
(equivalent to 44kA for 3secs)
Design :
3-column BLOKSET modular compartmental structure conforming Form-3B to IEC 60439-1
standards. Fully Type-tested switchboard using 2mm thick sheet steel, IP42, finished to RAL
9002 paint shade.
Col-1
: (700+400)w x 2200h x 1000d
Col-2
: 700w x 2200h x 1000d
SEG-FPBHB/F-304
Col-3
: (200+700)w x 2200h x 1000d
Dimensions :
2700(W) x 2200(H) x 1000(D) mm (approx)
32
Franchised Panel Builders Hand Book – 2005
Franchised Panel
Builders Hand Book
PB-LOGO
Title: TENDERING
Developed by: Syed Basheer
Department: Sales
Rev-A
PS-300
DISCOUNT REQUEST FORM
Approved by: Sunil PARKHI / Faiz AHMED
December 2005
PANEL BUILDER'S NAME:
Region :
Date :
Sales Manager:
Reference #
Project Name :
End User :
Consultant :
Contractor:
Project Description :
COMPETITION:
COSTING SUMMARY (mention all values in Euro)
Merlin Gerin / Square D
Telemecanique
Other Schneider (Prisma Plus, Blokset, …)
TOTAL SCHNEIDER PORTION
a1
Panel Builder's Portion
b1
Labour + Over-Heads
c1
TOTAL COST FOR PANEL BUILDER
t1 = a1+b1+c1
Panel Builder margin %
m1
Initial Selling Price for the project
s1 = t1 / (1-m1)
Target Selling Price for the project
Required reduction
DISCOUNT REQUIRED FROM =S=
Form SEG-FPBHB/F-305
33
Franchised Panel Builders Hand Book – 2005
CHAPTER-4
ORDER PROCESS
DESIGN
&
ENGINEERING
34
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
Department: Design
Title: ORDER PROCESS, DESIGN & ENGINEERING
PS-400
Developed by: Syed Basheer
Rev-A
Approved by: Sunil PARKHI / Faiz AHMED
December 2005
1.0 Objective:
To describe how a Schneider Electric Franchised Panel Builder (FPB) should process orders received
from Customers.
2.0 Scope:
To all Customer Order’s received against the Offers submitted.
3.0 Related Documents:
Contract Review form (SEG-FPBHB/F -401)
Order Acknowledgement Format (SEG-FPBHB/F -402)
Drawing format (SEG-FPBHB/F -403)
Compliance statement ( SEG-FPBHB/F -404)
Project Submittal format (SEG-FPBHB/F -405)
4.0 Abbreviations:
SE-Sales engineer
TM-Tender manager
EE-Estimation engineer
DM-Design manager
DE-Design engineer(draftsman)
5.0 Procedure / Process:
CONTRACT REVIEW
 Customer Orders are received by Sales Engineers (SE).
 SE forwards the order to the Tendering department.
 The Estimation Engineer (EE) should prepare a CONTRACT REVIEW (SEG-FPBHB/F-401)
 At this stage a detailed comparison is done between the Offer submitted and Order received.
 If discrepancies are found between the offer submitted and order received, clarifications /
amendment is sought from the customer.
 EE obtains approval of the Tendering Manager (TM) for Order acceptance. The order is then
registered in the Order register.
 TM calls for ‘Job Launching Meeting’ with all departments – Design, Planning & Logistics,
Production, Quality Control and Finance.
 Various steps of the Order Process on the Contract Review are discussed during this meeting.
 Key milestones such as:
 Receipt of Advance payment / Letter of Credit, etc.
 Submission of Drawings / Project Submittal.
 Tentative date of receipt of Drawing Approval.
 Procurement – Arranging all required items.
 Material and Production Planning schedule
 Commencement of Production.
35
Franchised Panel Builders Hand Book – 2005
 Expected date of completion – FAT dates
 Dispatch date
36
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
Department: Design
Title: ORDER PROCESS, DESIGN & ENGINEERING
PS-400
Developed by: Syed Basheer
Rev-A
Approved by: Sunil PARKHI / Faiz AHMED
December 2005
 An ‘ORDER ACKNOWLEDGEMENT’ (SEG-FPBHB/F -402) is then sent to the customer with
probable dates for Submission of Drawings, Production Schedule and Dispatch dates.
 The file is handed over to Design department.
DESIGN
 The Design Manager (DM) assigns a Design Engineer (DE) and a Draftsman for this project.
 DE and Draftsman prepare the drawings on the basis of the Contract SLD, Specifications,
Estimation and the offer submitted.
 Drawings are to be prepared as per Schneider’s Drawing format(SEG-FPBHB/F-403)
 A typical drawing should at least contain:
 Title sheet
 Revision Index sheet
 General Specification Summary
 List of Symbols used
 Front Layout / G.A. drawing should contain busbar location, cross-section,..
 Foundation layout
 Single Line Diagram
 Control Wiring Diagram, if required
 Termination schedule
 Bill of Material.
 Drawing contains the SE ‘Franchised Panel Builder’s Logo along with brand name.
 DE prepares a COMPLIANCE STATEMENT (SEG-FPBHB/F -404) to the specification.
 DE and Draftsman prepares a PROJECT SUBMITTAL Format (SEG-FPBHB/F-405) file that
should at least include:
 Company profile / brochure, ISO 9001 certificate, Project references
 ‘Franchised Panel Builder’ Valued authorization certificate from Schneider Electric.
 Drawings
 Compliance Statement
 Catalogues (at least colour print-out from Electronic files,… do not include poor quality
Xerox copies),Use data sheets
 Calculations…Short-Circuit calculations using Ecodial, if required.
 This file is reviewed by DM and submitted for Consultant / Client Approval through SE.
DRAWING APPROVAL
 DE along with SE attends technical clarification meetings with Consultant / Client.
 Drawing Approval is then received from Consultant / Client.
LOGISTICS / PRODUCTION FILES
 DE prepares files to be handed over to Logistics / Production for Material and Production
Planning.
 The Logistics file should contain detailed Bill of Material for procurement.
 Production file should contain at least the following docs:
 Approved Drawings with a stamp ‘APPROVED FOR MANUFACTURING’.
 Bill of Material
37
Franchised Panel Builders Hand Book – 2005
 Busbar fabrication drawings or list of standard busbar drawings.
 Label List
38
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
Department: Design
Title: ORDER PROCESS, DESIGN & ENGINEERING
PS-400
Rev-A
Approved by: Sunil PARKHI / Faiz AHMED
Developed by: Syed Basheer
December 2005
Process Flow chart:
Responsible
R e c e ip t o f c u s to m e r
O rd e r
Comments
SE
F o r w a r d t o t e n d e r in g d e p t . ,
E E p re p a re C O N T R A C T
R E V IE W
EE
R equest
A m e n d m e n t/
C la r if ic a t io n
fro m c u s to m e r
N o
Contract review
SEG-FPBHB/F-401
EE/SE
C h e c k if O r d e r is in lin e
w it h O f f e r
Y es
EE
O b t a in a p p r o v a l o f T M f o r
o r d e r a c c e p t a n c e R e g is te r
t h e o r d e r in o r d e r r e g is te r
TM
Y es
T M c a ll fo r jo b la u n c h in g
m e e t in g w it h a ll d e p t s
( T e n d e r in g , D e s ig n , Q C ,
P r o d u c t io n , L o g is tic s , F in . )
TM
A
39
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
Department: Design
Title: ORDER PROCESS, DESIGN & ENGINEERING
PS-400
Developed by: Syed Basheer
Rev-A
Approved by: Sunil PARKHI / Faiz AHMED
A
S e n d O rd e r
A c k n o w le d g e m e n t to
c u s t o m e r w it h P r o b a b le
M ile s t o n e s ( D a t e o f d r a w in g
s u b m is s io n , p r o d u c t io n
c o m p le t io n , F A T , d e s p a t c h )
F ile h a n d e d o v e r t o d e s ig n ,
D e s ig n m a n a g e r a llo c a t e
d e s ig n e n g r ( D E ) a n d t o s t a r t
d r a w in g p r e p a r a tio n
D E /D ra fts m a n -p re p a re
D r a w in g ( I n c lu d in g B O M )
a s p e r S c h n e id e r D r a w in g
F o rm a t
D E -p re p a re C O M P L IA N C E
STATEM EN T as per
S c h n e id e r fo r m a t
D E -p re p a re P R O J E C T
S U B M I T T A L - V e r if ie d b y
DM .
December 2005
Responsible
TM
Comments
Order Ackn
Format
SEG-FPBHB/402
DM
DE
DE
DE/DM
Drawing Format
SEG-FPBHB/403
Compliance statement
SEG-FPBHB/404
Project Submittal
SEG-FPBHB/405
B
40
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
Department: Design
Title: ORDER PROCESS, DESIGN & ENGINEERING
PS-400
Developed by: Syed Basheer
Rev-A
Approved by: Sunil PARKHI / Faiz AHMED
B
D E - S u b m it P R O J E C T
S U B M IT T A L fo r c o n s u lt a n t
C lie n t A p p r o v a l a lo n g w ith
S E
December 2005
Responsible
Comments
DE/SE
D E /S E - A tte n d c o n s u lta n t
C la r ific a tio n m e e tin g ,if
re q u ir e d
DE/SE
o b ta in A P P R O V A L O f
P r o je c t S u b m itta l
DE/SE
D E -p re p a re L O G IS T IC &
P R O D U C T IO N F ile f o r
M a te r ia l p la n n in g a n d
P r o d u c tio n
DE/SE
41
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
Department: Design
Title: ORDER PROCESS, DESIGN & ENGINEERING
PS-400
Rev-A
Approved by: Sunil PARKHI / Faiz AHMED
Developed by: Syed Basheer
December 2005
CONTRACT REVIEW
FPB LOGO
1.0
JOB DATA
1.1
CUSTOMER
:
1.2
PROJECT
:
1.3
CONSULTANT
:
1.4
MAIN CONTR./ END CLIENT
:
1.5
CUSTOMER CATEGORY
:
1.6
TENDER REFERENCE & VALIDITY
:
1.7
SALES ENG. / BRANCH
:
1.8
JOB REF / PROJ MNGR
:
1.9
ORDER RECD.
SECTION ON
BY TENDER
2.0
CONTRACTUAL DATA
2.1
P.O / LOI REF. & DATE
2.2
SCOPE
2.3
TECHNICAL CAPABILITY WITH IN =S=
2.4
CONTRACT VALUE & GROSS MARGIN(%)
2.5
DELIVERY DATE
2.6
COMING IN TO FORCE
2.7
DELIVERY TERMS / INCO TERMS
2.8
PENALTY
2.9
ADVANCE BANK GUARANTEE
1.10 ORDER HANDING OVER DATE TO PROJ
:
:
Offer
2.10
PERF. BANK GUARAN TEE
2.11
PAYMENT TERMS
2.12
VARIATIONS
:
Order
Comments
3.0
MILESTONES
3.1
DRAWING SUBM ITTAL
:
3.2
ADVANCE PAYMENT
:
3.3
DRAWING APPROV AL
:
3.4
L/C OPENING
:
3.5
FACTORY TEST W ITNESS
:
3.6
DELIVERY DATE
3.7
WARRANTY COMPLETION
:
3.8
SITE SERVICES
:
: Supervision of erection
Not applicable
15 months from date of delivery or 12 months from date of handover,
: Testing & commissioning
4.0
SCOPE OF SUPPLY
Family
Description
Qty
Price
GM%
4.1
-
TOTAL IN AED :
5.0
GENERAL
5.1
Commercial risk
:
5.3.7 Others
5.2
Technical risk
:
5.4
5.3
Special requirements agreed
:
SPEC. / DRGS
Offer and deviations
5.3.1 Equip. spec. IEC/NEMA/Other
:
P.O
Back up offers and costing sheet
5.3.2 Wire specification
:
Correspondence with Sales
5.3.3 Paint
:
Final scope of supply & prices
5.3.4 IP/form
:
5.3.5 Bus bar
:
5.3.6 Altitude
:
SIGNATURES : EM…....…..…. Date………....….
DATE: _____/_____/_____
5.5
Documents enclosed
Agreement with planning
Remarks :
TM..……………….. Date……..…………..
SIGNATURES :
PSM :…....……..……………………
POM :…..…….……..…………..
Form# SEG-FPHB/F-401
42
Franchised Panel Builders Hand Book – 2005
-
Franchised Panel Builders Hand Book
Department: Design
Title: ORDER PROCESS, DESIGN & ENGINEERING
PS-400
Developed by: Syed Basheer
Rev-A
Approved by: Sunil PARKHI / Faiz AHMED
December 2005
See details hereafter
43
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Handbook
Department: De
Title: ORDER PROCESS, DESIGN & ENGINEERING
PS-400
Developed by: Syed Basheer
Approved by: Sunil PARKHI / Faiz AHMED
LV PANEL BOARDS – SPEC REF:XXXXXXX
Sn
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Franchised Panel Builders Hand Book – 2005
Specification Clause
CO
Compliance
Franchised Panel Builders Hand Book
Department: Design
Title: ORDER PROCESS, DESIGN & ENGINEERING
PS-400
Developed by: Syed Basheer
Rev-A
Approved by: Sunil PARKHI / Faiz AHMED
OWNER
December 2005
CONSULTANT
CONTRACTOR
VENDOR
xxx
xxx
Job Ref: xxx
xxx
PROJECT SUBMITTAL
PROJECT NAME
xxx
RFQ NO:
xxx
DOCUMENT TITLE:
XXX OF 415V SWITCHGEAR
VENDOR:
FPB….XXX
P.O. BOX NO: XXX DUBAI, U.A.E
TEL: +971 4
FAX: +971 4
MAILID: nnn@sss.com
VENDOR DOCUMENT NO.:
xxx
0
Rev.
PROJECT DOC. NO.:
xxx
xxx for 415V Switchgear
Description
xx-yyy-05
Prepared
Checked
Approved
SEG-FPBHB/F-405
54
Franchised Panel Builders Hand Book – 2005
Date
CHAPTER-5
MATERIAL
&
PRODUCTION
PLANNING
55
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
Department: Logistics & Planning
Title: MATERIAL & PRODUCTION PLANNING
PS-500
Developed by: Syed Basheer
Rev-A
Approved by: Sunil PARKHI / Faiz AHMED
December 2005
1.0 Objective:
To describe how a Schneider Electric Franchised Panel Builder (FPB) should perform Material and
Production Planning during processing of customer orders.
2.0 Scope:
To all Customer Order’s under execution.
3.0 Related Documents:
Quality claim form (SEG-FPBHB/F -501)
4.0 Abbreviations
SE-Sales engineer
TM-Tender manager
EE-Estimation engineer
DM-Design manager
DE-Design engineer (draftsman)
LM-Logistics Manager
PM-Production manager
PS-Production supervisor
TN-Technicians
QCI-Quality control inspector
NCR-Non-conformity report.
5.0 Procedure / Process:
Logistics / Material & Production Planning














Logistics file is received from the Design department containing detailed Bill of Material.
Logistics Manager (LM) should include the Project in the Material Planning Schedule.
Production Manager (PM) should include the Project in the Production Planning Schedule.
Key Milestones committed to the customer are based on the ‘Job Launching Meeting’ described
in ‘Order Processing procedure …….PS-400
LM check BOM and reserve items available in ‘Stock’ for this project.
For Non-stocked items, LM should initiate Purchase Orders to suppliers – Local or Import.
All sourcing should be done only from the ‘APPROVED VENDOR’S LIST’. This list should be
validated by Schneider Electric.
LM follow-up with Suppliers for delivery of items.
LM arrange for receipt of material. Perform ‘Incoming Goods Inspection (IGI)’.
LM prepare Receipt Note only for items cleared from IGI.
For Non-Conformities noticed during IGI, LM should raise Quality Claim (NCPR – Non
Conforming Product Report) with the respective supplier.
In case of discrepancies in material received from Schneider Electric, LM should forward the
Quality Claim Form (SEG-FPBHB/F-501) to the concerned Schneider Electric SE and Quality
officer.
When all Materials are available, LM issue the items against BOM in the shop-floor.
56
Franchised Panel Builders Hand Book – 2005
 PM should allocate a rack separately for each project (with a tag) where all items related to that
project will be kept.
57
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
Department: Logistics & Planning
Title: MATERIAL & PRODUCTION PLANNING
PS-500
Rev-A
Approved by: Sunil PARKHI / Faiz AHMED
Developed by: Syed Basheer
December 2005
Process Flow chart:
Responsible
R e c e ip t o f
L o g is tic s &
P r o d u c t io n F ile s
fro m
d e s ig n
L M / P M - I n c lu d e p r o je c t in
M A T E R IA L /P R O D U C T IO N
P la n n e r c o n s id e r in g v a r io u s
M ile s t o n e s d e fin e d
LM/PM
L M - R e s e r v e ite m s
a v a ila b le
in s to c k
LM
L M - P r o c e e d w ith p u r c h a s e
o f n o n - s to c k ite m s
s e le c t s u p p lie r s f r o m v e n d o r
lis t .
LM
L M - A r r a n g e fo r R e c e ip t o f
m a te r ia l
IN C O M IN G G O O D S
IN S P E C T IO N
LM
A
Comments
B
58
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
Department: Logistics & Planning
Title: MATERIAL & PRODUCTION PLANNING
PS-500
Developed by: Syed Basheer
Rev-A
Approved by: Sunil PARKHI / Faiz AHMED
Responsible
A
December 2005
Comments
B
R a is e N C P R s e n d to
s u p p lie r .
fo r S c h n e id e r
c o m p o n e n ts
A tta c h C la im F o r m
Is th e re a n y N o n C o n fo m ity
Yes
QC
Quality Claim
Format
SEG-FPBHB/F-501
LM
NO
L M Is s u e M a te r ia l fo r
P r o d u c tio n O n M A T E R IA L
Is u u e N o te
59
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
Department: Logistics & Planning
Title: MATERIAL & PRODUCTION PLANNING
PS-500
Rev-A
Approved by: Sunil PARKHI / Faiz AHMED
Developed by: Syed Basheer
December 2005
QUALITY CLAIM FORM
TO BE COMPLETED BY CUSTOMER
Section 1
Claim Reference No.*
Customer Name:
Customer Contact:
Address: PO BOX-
* Please see INSTRUCTIONS sheet
Tel No. / Fax No:
Claim Date
E-mail address:
Non Technical Claim Catagories:- Missing Items,
Please attach supporting documents as applicable ( invoice copy, non-confirmity report, photograph etc)
Customer PO
Number
Invoice Number
& Date
POS (Line
Number)
Part Number
QTY Ordered QTY Received
Category of Claim
Technical Claim (Category:- Faulty products - Warranty claims).
In addition to documents mentioned above please provide maximum technical information for our investigation
Customer PO
Number
Invoice Number
& Date
POS (Line
Number)
Part Number
QTY
Installed /
Uninstalled
Specify Nature of Problem
Customer's signature :
.
* Claim Reference No.
XXX
Customer code. Last 3 Alphabets in Commercial Conditions Ref. No.
YY
Last 2 digits of the Calender Year. (05 for 2005)
Z
1st Alphabet of Local SE office where claim is addressed.
001
Claims for each year will start from Sr. No. 001 & then 002, 003, 004, 005 . . . . .
D-Dubai, A-Abu Dhabi, K-Kuwait, Q-Qatar, O-Oman & B-Bahrain
SEG-FPBHB/F-501
60
Franchised Panel Builders Hand Book – 2005
CHAPTER-6
PRODUCTION
61
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
Department: Production
Title: PRODUCTION
PS-600
Developed by: Syed Basheer
Rev-A
Approved by: Sunil PARKHI / Faiz AHMED
December 2005
1.0 Objective:
To describe how a Schneider Electric Franchised Panel Builder (FPB) should perform Assembly /
Production of LV Switchboards.
2.0 Scope:
To all Customer Order’s under execution.
3.0 Related Documents:
Production Files
Production Planner
Non-Conformity Report (SEG-FPBHB/F -601)
4.0 Abbreviations:
SE-Sales engineer
TM-Tender manager
EE-Estimation engineer
DM-Design manager
DE-Design engineer (draftsman)
LM-Logistics Manager,
PM-Production manager
PS-Production supervisor
TN-Technicians
QCI-Quality control inspector
NCR-Non conformity report.
5.0 Procedure / Process:
Production Planning / Job Allocation





Receive Production File from Design department.
Production Manager (PM) review Production Planner with Production Supervisor (PS).
PM instruct Production to be started based on Production Planner.
PS allocate technicians (TN) for the project.
Provide approved Drawings with stamp ‘Approved for Manufacturing’ along with BOM to
technicians.
Assembly Process
 TN obtain materials from the storage racks reserved for the particular project.
 TN start Frame Assembly, Component mounting plates, busbar supports, etc.
 Assembly to be done exactly in line with Approved Drawings received. Only authorized personnel
are allowed to make modifications on the drawings.
 Follow the guidelines provided in the relevant ASSEMBLY GUIDES.
 Busbar technicians to fabricate and assemble Busbars as per drawings.
 Standard busbar drawings are to be made available from the Design department.
 TN complete assembly of all Components, Metering instruments, CTs, etc.
 Wiring technicians complete all Power and Control wiring as per approved drawings.
62
Franchised Panel Builders Hand Book – 2005
 Complete all remaining assembly works such as internal separations, Form boxes, labels, etc.
63
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
Department: Production
Title: PRODUCTION
PS-600
Developed by: Syed Basheer
Rev-A
Approved by: Sunil PARKHI / Faiz AHMED
December 2005
Stage Inspection
 At each stage of the Assembly Process, the Quality Control Inspector (QCI) should check if the
assembly is in accordance with the approved drawings and assembly rules.
 For any Non-Conformities noticed by QCI, a Non-Conformity Report (NCR) has to be raised. PM
should be informed of the NCR. Concerned TN should rectify the Non-conformity.
 After all assembly stages are completed, the panels are offered for Final Inspection and Testing.
64
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
Department: Production
Title: PRODUCTION
PS-600
Rev-A
Approved by: Sunil PARKHI / Faiz AHMED
Developed by: Syed Basheer
December 2005
EMBED Visio.Drawing.5
Process Flow chart:
Responsible
R e c e ip t o f P R O D U C T IO N
F ile fr o m d e s ig n a n d
M a te r ia ls f r o m L o g is tic s
Comments
PM
P M - R e v ie w P r o d u c tio n P la n n e r
w it h p r o d u c tio n S u p e r v is o r
In s tru c t c o m m e n c e m e n t o f
P r o d u c tio n
PM
P S - A llo c a te te c h n ic ia n s fo r
th e p r o je c t,p r o v id e D r a w in g s
s ta m p e d A p p r o v e d fo r
M A N U F A C T U R IN G
PS
T N - O b t a in m a te r ia ls
r e s e r v e d fo r t h e p r o je c t.
S ta rt F ra m e /C o m p o n e n ts
A s s e m b ly
TN
Non-Conformity
Report Format
SEG-FPBHB/F-601
Q C - r a is e N C R
in f o r m to P M ,
A d v is e T N to r e c ify
QCI
Q C -P e rfo rm s ta g e
I n s p e c tio n ,A n y
n o n - C o n fo rm ity
YES
QCI
NO
A
65
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
Department: Production
Title: PRODUCTION
PS-600
Rev-A
Approved by: Sunil PARKHI / Faiz AHMED
Developed by: Syed Basheer
December 2005
Responsible
Comments
A
TN
T N - B u s b a r t e c h n ic ia n s t o
c a r r y o u t F a b r ic a tio n a n d
a s s e m b ly o f b u s b a r a s p e r
D r a w in g s
QCI
Q C -P e rfo rm s ta g e
In s p e c t io n , A n y
n o n - C o n fo r m ity
Q C - r a is e N C R
in fo r m to P M ,
A d v is e T N t o
r e c t if y
Yes
N o
TN
T N - C o m p le t e a s s e m b ly o f a ll
d e v ic e ( C B s ,M e te r s ,C T s ,e tc )
a s p e r d r a w in g s
QCI
Q C - r a is e N C R
in fo r m to P M ,
A d v is e T N t o
r e c tify
QCI
Q C -P e rfo rm s ta g e
In s p e c t io n , A n y
n o n - C o n fo r m ity
Yes
N O
B
66
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
Department: Production
Title: PRODUCTION
PS-600
Rev-A
Approved by: Sunil PARKHI / Faiz AHMED
Developed by: Syed Basheer
December 2005
Responsible
Comments
B
T N - E le c t r ic ia n s c o m p le t e
p o w e r a n d c o n t r o l w ir in g a s
p e r d r a w in g s
Q C -P e rfo rm s ta g e
In s p e c t io n , A n y
n o n - C o n fo r m ity
TN
Q C - r a is e N C R
in fo r m to P M ,
A d v is e T N to
r e c tify
Yes
QCI
No
T N - A s s e m b ly te c h n ic ia n s
c o m p le te m is c w o r k s u c h a s
s h o u d in g , la b e llin g
TN
Q C - r a is e N C R
in fo r m to P M ,
A d v is e T N t o r e c ify
QCI
Q C -P e rfo rm s ta g e
In s p e c t io n , A n y
n o n - C o n fo r m ity
Yes
QCI
NO
O ff e r p a n e ls f o r fin a l
I n s p e c tio n a n d te s t in g
TN
67
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
Department: Production
Title: PRODUCTION
PS-600
Developed by: Syed Basheer
FPB LOGO
Rev-A
Approved by: Sunil PARKHI / Faiz AHMED
December 2005
NON-CONFORMITY REPORT
Project Name :
Date :
Customer :
Project Ref :
Issued by :
NCR Ref :
Non-Conformity
1
2
3
4
5
6
7
QC Inspector
CORRECTIVE ACTIONS TAKEN
Acknowledged by PM
By Whom
1
2
3
4
5
6
7
SEG-FPBHB/F-601
68
Franchised Panel Builders Hand Book – 2005
CHAPTER-7
INSPECTION
&
QUALITY CONTROL
69
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
Department: Quality Control
Title: INSPECTION & QUALITY CONTROL
PS-700
Developed by: Syed Basheer
Rev-A
Approved by: Sunil PARKHI / Faiz AHMED
December 2005
1.0 Objective:
To describe how a Schneider Electric Franchised Panel Builder (FPB) should perform Quality Control
Inspection and Testing of the LV Switchboards.
2.0 Scope:
To all Customer Order’s under execution.
3.0 Related Documents:
Inspection Check-List (SEG-FPBHB/F-701)
Factory Inspection Report (SEG-FPBHB/F-702)
4.0 Abbreviations:
SE-Sales engineer
TM-Tender manager
EE-Estimation engineer,
DM-Design manager
DE-Design engineer (draftsman)
LM-Logistics Manager
PM-Production manager
PS-Production supervisor
TN-Technicians
QCI-Quality control inspector
NCR-Non-conformity report.
5.0 Procedure / Process:
Stage Inspection
 Carry out Stage Inspection at each stage of the Assembly process as described in Procedure
 “PS-600”.
 After all assembly stages are completed, the panels are offered for Final Inspection and Testing.
Final Inspection and Testing
 QCI Carry out ROUTINE TESTS as per IEC 60439-1 standards. The following minimum tests
must be performed:
 Visual inspection test – Checking of the complete switchboard in accordance with IEC
60439-1 standards and approved drawings. Checking of Integrity of Wiring, Tightness of all
joints, and Torque test on all bus connections, etc.
70
Franchised Panel Builders Hand Book – 2005
 Di-electric Test – Done using a MEGGER (verification of Insulation resistances between

phases, phase-neutral, phase-earth and neutral-earth). This test is also verified by a HIPOT test using a 2.5kV test between phases for 1min.
Mass Continuity Test – To check if there is proper earth continuity from end of the
switchboard to the other. This test can be checked either visually or by an electrical test
measuring resistance from one end to the other.
71
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
Department: Quality Control
Title: INSPECTION & QUALITY CONTROL
PS-700
Developed by: Syed Basheer
Rev-A
Approved by: Sunil PARKHI / Faiz AHMED
December 2005
 All checks should be done on the Inspection Check List format(SEG-FPBHB/F-701)
 Record all Routine Test findings in the ‘Factory Inspection Report(SEG-FPBHB/F-702)”
 For Customer FAT, make necessary arrangements to cordon-off the test area. Prepare all
documentation in advance.
As-Built Documentation
 Once the Final Tests are completed, provide ‘marked-up’ copies of drawings to the design dept to
prepare “AS-BUILT DRAWINGS”.
72
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
Department: Quality Control
Title: INSPECTION & QUALITY CONTROL
PS-700
Rev-A
Approved by: Sunil PARKHI / Faiz AHMED
Developed by: Syed Basheer
December 2005
Process Flow chart:
R e c e ip t o f C O M P L E T E D
S W IT C H B O A R D fro m
P r o d u c tio n
Responsible
Comments
QCI
Check list format
SEG-FPBHB/F-701
QCI
Factory inspection
Report format
SEG-FPBHB/F-702
Q C I-C a rry o u t s ta g e
In s p e c t io n a s d e t a ile d in
P ro c e d u re
Q C I - p e r fo r m R o u t in e t e s t s
a s p e r IE C 6 0 4 3 9 -1
S t a n d a r d , u s e c h e c k lis t
( f o r m a t ) F a c to r y I n s p e c t io n
R e p o rt
Q C - r a is e N C R
in fo r m t o P M ,
A d v ic e T N to r e c ify
QCI/TN
A n y N o n - C o n f it m it y
Y es
QCI
N O
Is c u s to m e r
FA T
R e q u ir e d
N O
SE/QCI
Y E S
A
B
73
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
Department: Quality Control
Title: INSPECTION & QUALITY CONTROL
PS-700
Developed by: Syed Basheer
Rev-A
Approved by: Sunil PARKHI / Faiz AHMED
A
Q C I-M a k e n e c e s s a ry
a rra n g e m e n ts fo r F A T
p e r f o r m R o u t in e T e s t s a s
r e q u ir e d .
Q C I-F o rw a rd M a rk e d -u p
D r a w in g t o d e s ig n t o p r e p a r e
A S - B U IL T D r a w in g s / O & M
M a n u a ls
B
December 2005
Responsible
Comments
QCI
QCI
C le a r S w itc h b o a r d f o r
P a c k in g /D e s p a t c h
74
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
Department: Quality Control
Title: INSPECTION & QUALITY CONTROL
PS-700
Approved by: Sunil PARKHI / Faiz AHMED
Developed by: Syed Basheer
December 2005
LOW VOLTAGE SWITCHGEAR
INSPECTION CHECK-LIST
FPB LOGO
C ustomer
Date
Projec t
Drawing #
Switchboard Ref
Inspec ted by
Description of Point to be checked / Inspected
Sn
Rev-A
Verification
Remarks
1 GENERAL
1a
Manufacturer of LV Switchboard
1b Type of Switchboard
1c
Dimensions of Switchboard
W
1d
1b Sheet Metal thic kness
1e Form of Separation
1f
D
mm
RAL
IP Rating
C able Entry Provision
1g Acc ess
H
mm Paint Shade
Incoming
Front
Bottom
Rear
Outgoing Bottom
Front operation, Rear C abling
1h Verify adequate labels are provided - Main / Feeders / Busbars / Danger label,..
2 BUSBARs
2a
Type-Tested Busbar System.
2b Main Horizontal Busbar Rating
Amps
* C SA (per ph)
2c
Amps
* C SA (per ph)
Vertical Busbar Rating
2d Busbar Fault Level
kA for
2e Distanc e between Busbar supports
2f
Busbar Plating
sec s
*
*
Tin-Plating
mm
Silver Plating
2g Busbar Insulation - PVC Sleeves
2h Verify if all BUSBARS are segregated from other c ompartments with IP2X separation barriers
2j
Verify if all Hardware (bolts,nuts) used is 8.8 grade and plated (cadmium)
2k Verify tightness of all J oints using TORQUE WRENC H
3 ACBs
3a
Manufacturer
Ref
3b AC B Rating
3c
Amps
No of Poles
kA Icu
3d AC B Type
Drawout
Fixed
3e AC B O peration
Manual
Motorized
3f
Shunt Trip
AC B Auxiliaries
3g AC B Trip Unit -
kA Icw
Bus-C oupler 4P (Non-Auto)
O/ L
Under-Voltage
S/ C
E/ F
Aux C ontacts
Trip Unit Ref
3h AC B Incoming Busbar Links for C able termination
3j
Inc oming mains from Xfmr - atleast 600mm space from Gland plate to term bolts
3k Aluminium gland plate for single-core cables
3l
All LIVE PARTS are adequately shrouded to prevent accidental touch / access.
3m Verify all c onnec tions and J oints using TORQUE WRENC H
4 METERING
4a
3nos Ammeters with MDI
4b 1no Voltmeter (0-500)v
4c
3 C Ts -----/ 5, C lass-1
7-posn selector switch
3nos RYB indic ation lamps with 3 control fuses
4d Space for KWH + 3C Ts + 3C F + Meter window. Separate c omp for KWH.
4e REF Relay with 4nos C lass-X C Ts -------/ 5
4f
Tapping from busbar inc links for potential wiring thro' Busbar Mounting fuse
4g C T wiring done using 2.5sqmm (1000V rated flexible) PVC cable.
4h Potential wiring done using 1.5sqmm (1000V rated flexible) PVC cable (ph colours)
75
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
Department: Quality Control
Title: INSPECTION & QUALITY CONTROL
PS-700
Approved by: Sunil PARKHI / Faiz AHMED
Developed by: Syed Basheer
December 2005
LOW VOLTAGE SWITCHGEAR
INSPECTION CHECK-LIST
FPB LOGO
C ustomer
Date
Projec t
Drawing #
Switc hboard Ref
Inspec ted by
Description of Point to be checked / Inspected
Sn
Rev-A
Verification
Remarks
5 MCCBs
5a
Manufac turer
5b
MC C B Rating/ s
5c
No of Poles
5d
MC C B Type
Ref
Amps
kA Ic u
Ic s =
% Ic u
Fixed
Plug-in
Drawout
5e M C C B O peration
Manual
Motorized
Rot Handles with door int
5f
MC C B Aux
Shunt Trip
Under-Voltage
5g
MC C B Trip Unit -
Therm-Mag upto 250A
Aux C ontac ts
Elec tronic >=300A
5h Outgoing links suffic ient for c able termination. Links a re properly supported.
5k All LIVE PARTS are adequa tely shrouded to prevent ac c idental touc h / ac c ess.
5l
Verify all c onnec tions a nd J oints using TORQUE WRENC H
6 MOTOR STARTERs
6a
Manufac turer
6b
Starter type
6c
C o-ordination
DOL (upto _____kW)
Soft Starters
6d
Eac h Starter to have
6e
E/ L Protn
Type-1
Type-2
Star-Delta (_____kW to ____kW)
VFDs
2xPil lamps
2xPush buttons
1xS/ S
A/ M with C T
6f
Verify all wiring done using c a ble lugs. Verify tightness of all c onnec tions.
6g
Verify wire numbers provided at either ends of all internal wiring.
7 SMDBs
7a
Inc oming Isolator Rating
7b
Outgoing MC C B Ratings
7c
Enc losure dimensions
7d
Busbar Rating
7e
Adequate shrouding to prevent ac c ess to live parts
A
A
Breaking C apac ity
C ross-sec tion
kA
Tin-Plating
8 FINAL DBs
8a
Inc oming Isolator Rating
8b
Outgoing MC B Ratings
A
No. of Ways
8c
Outgoing RC BO Ratings
A
8d
Busbar Rating
8e
Mounting
A
Surfac e
Breaking C apac ity
kA
mA
C ross-sec tion
Tin-Plating
Flush
9 ROUTINE TESTS (as per IEC 60439-1, BSEN 60439-1)
9a
Visual Inspec tion as above (verify c omplianc e with drawings, spec ific ations)
9b
C hec k tightness of all c onnec tions, busbar joints, etc (Torque Test)
9c
Dielec tric Test - MEGGER (500V or 1000V Megger) - Ph-Ph, Ph-N, Ph-E, N-E
Verify Megger Values a re 100 Mega Ohms or more.
9d
Dielec tric Test - INSULATION RES TEST- 2.5kV for 1min - Ph-Ph, Ph-N, Ph-E, N-E
Verify no flash-over or punc ture is observed
9e
FUNCTION TEST- Apply 415v supply. C hec k V/ M reading
Switc h-ON Inc oming AC B. Switc h-ON all outgoing MC C Bs.
Verify c ontinuity of supply in all feeders with a lamp test. Also verify Ea rth c ontinuity.
SEG-FPBHB/F-701
76
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
Department: Quality Control
Title: INSPECTION & QUALITY CONTROL
PS-700
Developed by: Syed Basheer
Rev-A
Approved by: Sunil PARKHI / Faiz AHMED
FPB LOGO
December 2005
LOW VOLTAGE SWITCHGEAR
INSPECTION CHECK-LIST
C ustomer
Date
Projec t
Drawing #
Switc hboard Ref
Inspec ted by
Description of Point to be checked / Inspected
Sn
10 COMMENTS / REMARKS
a
Verify all MC C B ratings. Ensure to provide ratings as per QP approved drawing.
b
Protection relay wiring to be completed.
c
Provide adequate cable support channels for customer cabling.
d
Perform Routine Tests after completing all pending works.
Verification
Remarks
SEG-FPBHB/F-701
77
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
Department: Quality Control
Title: INSPECTION & QUALITY CONTROL
PS-700
Rev-A
Approved by: Sunil PARKHI / Faiz AHMED
Developed by: Syed Basheer
December 2005
LOW VOLTAGE SWITCHGEAR
FACTORY INSPECTION REPORT
FPB LOGO
C ustomer
Date
Projec t
Drawing #
Switc hboard Ref
Inspec ted by
Inspection Programme:
1 Conformity Inspection
n Enclosures
n Devices
n C onductors
2 Mechanical checks
3 Earthing Continuity of exposed conductive parts
Visual
Electrical
resistance value ________ mΩ
4 Dielectric tests
Test / Injection Voltage = 2.5 kV for 1min
Test Result
:
5 Insulation tests (Megger)
Application Voltage =
Test Result
v
:
R- Y
:
MΩ
R- N
:
MΩ
R- E
:
MΩ
R- B
:
MΩ
Y- N
:
MΩ
Y- E
:
MΩ
Y -B
:
MΩ
B -N
:
MΩ
B -E
:
MΩ
6 Electrical / Function tests
N- E
:
MΩ
:
7 Comments / Remarks
a
b
c
d
e
f
g
QC Inspector
Name
Designation
Company
Date
Contractor
C onsultant
End User
:
:
:
:
SEG-FPBHB/F-702
78
Franchised Panel Builders Hand Book – 2005
CHAPTER-8
PACKING
79
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
Department: Expedition
Title: PACKING
PS-800
Rev-A
Approved by: Sunil PARKHI / Faiz AHMED
Developed by: Syed Basheer
December 2005
1.0 Objective:
To describe how a Schneider Electric Franchised Panel Builder (FPB) should proceed with
packing of the switchboard.
2.0 Scope:
To all Customer’s Low Voltage Switchboards.
3.0 Related Documents:
Assembly guides
Installation guides
4.0 Procedure / Process:
Cleaning
 Clean the switchboard prior to packing:
 Remove any dust from the inside using a vacuum cleaner – blow cleaning may cause
shavings and detritus to accumulate in an area that will subsequently be live.
 Dust the outside. If necessary, use a neutral solvent which will not damage the paint.
 Repaint, where necessary.
 Check that there are no foreign objects inside the switchboard (tools, nuts and bolts)
which could impede its proper operation.
Accessories
Include the following on the inside of the switchboard:






Any fish-plates for the busbars.
Additional mounting hardware.
Panels for installation after on-site connection: roof panel, gland plates.
A set of drawings.
The instructions for the switchgear and controlgear devices.
Check that all withdrawable or plug-in devices are inserted and locked.
Precautions:
Check that all withdrawable or plug-in devices are
inserted and locked
 Heavy equipment such as capacitor banks or
transformers may be dispatched separately. This
avoids the risk of the frame being damaged in the
event of a shock and provides for greater cubicle
stability during transport
 Large drawout circuit-breakers (Masterpact)
80
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
Department: Expedition
Title: PACKING
PS-800
Developed by: Syed Basheer
Rev-A
Approved by: Sunil PARKHI / Faiz AHMED
December 2005
 installed in the top part of a cubicle are generally delivered separately.
Packing depends on the following factors:
 switchboard weight.
 the conditions under which it will be stored
(temperature, humidity, weather, dust, shocks).
 storage duration.
 lifting techniques (fork-lift, cranes, etc.)
 transport type and conditions(lorry, container, ship,
etc.) and transit countries.
Packing must protect the front panel very effectively and bear the following, essential
indications:





fragile (glass).
not waterproof (umbrella).
position: top, bottom (arrows) and if appropriate:
centre of gravity (G).
lifting points (chains).
81
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
Department: Expedition
Title: PACKING
PS-800
Developed by: Syed Basheer
Rev-A
Approved by: Sunil PARKHI / Faiz AHMED
December 2005
Two main types of packing are generally used for packing electrical switchboards:
 overland packing: The cubicle is protected by a plastic
cover and housed in a crate.
 seaworthy packing: The cubicle, which contains
bagged desiccants, is protected by a plastic cover and
housed in a ventilated, wooden or plywood case
 Check with the transporter that packing is compatible with the lifting system in use: points
for attaching slings, skids, etc. Check with the customer that the switchboard, once
packed, can access the site (height and width of doors, etc.).
 If necessary, pack each cubicle separately and identify each package with respect to the
overall switchboard layout.
82
Franchised Panel Builders Hand Book – 2005
CHAPTER-9
SITE-TESTING
&
COMMISSIONING
83
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
Department: Quality Control
Title: SITE-TESTING & COMMISSIONING
PS-900
Developed by: Syed Basheer
1.0
Rev-A
Approved by: Sunil PARKHI / Faiz AHMED
December 2005
Objective:
To describe how a Schneider Electric Franchised Panel Builder (FPB) should prepare site- testing
and commissioning of switchboard.
2.0
Scope:
To all Customer’s Low Voltage Switchboards.
3.0
Related Documents
Switchboard file
Installation instructions
4.0
Procedure / Process:
Commissioning
In order to obtain the report required to put the switchboard in service, carry out all the checks and
tests defined in a programme approved by the customer or their representative. Tests must be carried
out by qualified and authorised personnel, using the appropriate means.
Switchboard file:
This is delivered with the switchboard and comprises:
 the cable diagrams and parts lists.
 the switchgear and controlgear instructions.
 installation instructions.
File appendices, for instance: measurement sheets and statements of conformity stating that
certain tests have been carried out at the factory and that it is not necessary to repeat them on-site
(e.g.: dielectric strength).
Inspection and test procedures and instructions.
84
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
Department: Quality Control
Title: SITE-TESTING & COMMISSIONING
PS-900
Developed by: Syed Basheer
Rev-A
Approved by: Sunil PARKHI / Faiz AHMED
December 2005
Tools:
The same tools are used as for switchboard assembly and in particular:
 A torque spanner for tightening connections to the required torque.
 A rule or gauge to check insulation clearances.
Inspection equipment In order to energize the switchboards,
the following equipment, at least, will be required:







A magneto-electric generator.
A phase tester.
A vibration tester and if necessary:
A voltage measurement device.
A current measurement device (optional).
A variable current source (AC/DC, recommended power 20 A).
A simulator with pushbuttons and lights and a measuring device
(optional).
Mechanical tests
Principle Carry out all the inspection and test operations in accordance with an on-site inspection
programme. Tests must show system conformity with the drawings, parts lists and installation
standards.
Checking mechanical connections


securing of the switchboard to the floor.
mechanical connections between cubicles.
Checking electrical connections
Bars (fish-plates): b check electrical clearances and creepage distances.
Cables: b number and cross section.
 check that any holes for passing cables through metallic panels correspond to the diameter
of the bushings or cable glands (degree of protection maintained) and that cables are not in
danger of being damaged.
 compatibility between the cable cross section or lugs and the device tunnel or terminal.
 quality of cable attachment. Cables should be secured in such a way as to support their
weight and withstand electro-magnetic forces caused by short circuits.
85
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
Department: Quality Control
Title: SITE-TESTING & COMMISSIONING
PS-900
Developed by: Syed Basheer
Rev-A
Approved by: Sunil PARKHI / Faiz AHMED
December 2005
Tightening:
 Check the cross section of the bolts and the quality of tightening for all electrical
connections, carried out
 in the factory or on-site:
 either by eye if the nuts have been marked after tightening
Electrical tests
Precautions before tests
A certain number of measures and precautions should be taken before energising the
auxiliary and power circuits:
 obey all applicable safety regulations.
 vacuum-clean dust from all the switchboards.
 remove any foreign objects which may prevent proper switchboard operation (cable or wire
off-cuts, bits of hardware, miscellaneous parts or tools).
 check the insulation of the auxiliary circuits before turning them on (use a magneto).
 inspect the auxiliary circuits on the switchboards: energise the circuits and test the various
operating sequences.
Insulation testing
Warning Before energizing the equipment, the overall insulation resistance must be measured.
If the neutral is earthed, disconnect the earthing terminals and measure the insulation.
In general, avoid making dielectric tests which have already been carried out at the factory (consult
the factory inspection report), as repeated testing may age and thus damage the insulation.
If the overall insulation value is low, heat the switchboard (using a heating element,
a light bulb or heat source) in order to remove humidity, for a period of at least 24hours.
Carry out a new insulation measurement.
Test The inspection should be carried out using an insulation measurement device, with a voltage of
at least 500 V (DC). The minimum insulation resistance value should be equal to 1000 ohms/V.
Restoring switchboard conformity
If the test has been successfully completed, reconnect any cables and earthing terminals
disconnected for the dielectric and insulation measurements. Then check the electrical continuity of
the various exposed conductive parts.
86
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
Department: Quality Control
Title: SITE-TESTING & COMMISSIONING
PS-900
Developed by: Syed Basheer
Rev-A
Approved by: Sunil PARKHI / Faiz AHMED
December 2005
Protection of persons
Electrical continuity
Presence of contact washers guaranteeing electrical continuity on all assemblies (between cubicles,
cover panels and partitioning).
 connections to the protective conductor and connections between cubicles.
 presence of earthing braid on any doors bearing devices.
 connection of the switchboard earthing circuit to the earth.
Protection against direct contact
 presence of the covers requested by the customer, in compliance with IEC 60439-1 and EN
60439-1 standards with respect to forms (2, 3 or 4). b presence of protective barriers.
Measurements may be carried out between the various exposed conductive parts of the assembly
and the protective circuit input terminal. Use a source of DC current, with an electromotive force of no
more than 12 V, but which produces a current of at least 2 A . The value of the resistance measured
in this way must not exceed 0.1 ohm. The report will note the values of the voltage and the test
current.
Degree of protection (IP)
Check that the protective elements (gasket, canopy) required to withstand the relevant external
factors have been properly fitted. Check that the openings designed for passing conductors
(intercubicle copper bars, incoming and outgoing cables) correspond to the degree of switchboard
protection, thus denying access to small animals such as rodents or snakes, etc.
Protection against indirect Contact
Check automatic disconnection of the installation at the first or second fault.
Miscellaneous inspections
Device mechanical locking:
 positive operation
 sturdy construction
 compliance with requirements
marking:
 on the switchboard,
 on power and control conductors.
appearance:
visual inspection of the outward appearance of the paintwork, checking for scratches and touching up
if necessary.
87
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
Department: Quality Control
Title: SITE-TESTING & COMMISSIONING
PS-900
Developed by: Syed Basheer
Rev-A
Approved by: Sunil PARKHI / Faiz AHMED
December 2005
Energizing the switchboard
 check that the phase sequence is the same as for the mains power supply.
 place all the switchgear devices in open position. Energize the switchboard power circuits
one by one.
Carry out operating tests:
 operating sequence,
 control, indication, measurement and protection,
 motor mechanism,
 electrical locking system.
Test report
The results of tests should be recorded in a test report.
The report will be signed by:
 the site manager.
 if appropriate, the inspector from the relevant inspection organization.
 the customer or their appointed representative.
88
Franchised Panel Builders Hand Book – 2005
CHAPTER-10
USEFUL
INFORMATION
89
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
Title: USEFUL INFORMATION
Developed by: Syed Basheer
Department: Logistics,
Production & QC
Rev-A
PS-1000
Approved by: Sunil PARKHI / Faiz AHMED
December 2005
1.0 Objective:
This chapter could help the Franchised Panel Builder locate some products and special components
which are often used during commissioning of electrical switchboards. It can also help the Franchised
Panel builder find an equivalent product on the local market. In addition to this, advise is also given
on the tooling required for mounting, monitoring, packing and shipping of LV Switchboards.
2.0 Scope:
To all Low Voltage Switchboards handled by Franchised Panel builders.
3.0 Related Documents:
Assembly guides
Installation guides
4.0
Materials and supplies
4.1 Marking varnish
Use
This varnish acts as a visual self-inspection indicator for torque
tightening.
It should preferably be applied on the nut side.
This varnish does not ensure mechanical locking.
Characteristics
Acrylic varnish
Ref: red adhesive
J.M 12 023 Bis
Other colours are available. A varnish of another colour (white) can
be used on the screws and bolts fitted when mounting fish plates on the site
Address
Ets J. Mespoulet
5, rue Des Renateaux
F-78930 Breuil Bois Robert
Tel: +33 (0)1 30 93 94 84
Fax: +33 (0)1 30 42 34 72
90
Franchised Panel Builders Hand Book – 2005
Department: Logistics,
Franchised Panel Builders Hand Book
Production & QC
Title: USEFUL INFORMATION
Developed by: Syed Basheer
Rev-A
PS-1000
Approved by: Sunil PARKHI / Faiz AHMED
December 2005
4.2 Permalite bar
Use
Flanging flat connection bars, bar hold supports.
This product is also used as a cable and flexible bar flanging support.
However, other types of material can be used for this type of application.
On installation, comply with the minimum creepage
Warning: never use graphite based pencils to mark any cut-outs or drillings.
Characteristics
Example: KM 190 Permalite type
Water absorption (thickness 4 mm) .....................2 %
Density ................................................................. 1.42 g / cm3
Temperature index............................................... 105 °C
Tracking resistance..............................................500 V
Arc resistance ......................................................120 s
Breaking stress, deflection...................................10 daN / mm2
Breaking stress, compression..............................22 daN / mm2
Most common dimensions: 40 mm, thicknesses 5 and 10 mm.
Addresses
Export Department
Rochling Permali
8, rue André Fruchard
BP 12
F-54320 Maxeville
Tel: +33 (0)3 83 34 24 24
Fax: +33 (0)3 83 32 23 18
France
Rochling Permali
2, rue de Barcelonne
F-69153 Decines
Tel: +33 (0)4 72 14 89 60
Fax: +33 (0)4 72 37 11 20
91
Franchised Panel Builders Hand Book – 2005
Franchised Panel Builders Hand Book
Title: USEFUL INFORMATION
Developed by: Syed Basheer
Approved by: Sunil PARKHI / Faiz AHMED
4.3 Insulating screen
Use
In most cases the standard components meet needs for partitioning
and protection against direct contact (forms 2.3.4 see IEC 60439.1)
However it may be advantageous to possess an insulating screen in
the following cases: cowling of Busbars, ends of connection bar
holds, branchings, transfer Busbars, distribution terminal blocks, etc.
This screen can act as a screen element when clearances between
live parts or between live parts and metal frames are less than
those laid down by standard IEC 60439.1
Characteristics
Example: F 2000 polycarbonate plate by General Electric
Self-extinguishing (DIN 53479 standard)
Specific mass....................................................... 1.24 g / cm3
Water absorption (24h of immersion) ..................0.15%
Bending temperature
Under load of 1.82 N / mm2..................................138°C
Thermal conductivity W/m°C ...............................0.20
Bending strength (at elastic limit).........................100 N / mm2
Breaking elongation .............................................80 %
Heated finger withstand .......................................950°C
Incandescent wire test at 960° (IEC 695.2.1) ......conform
This product is ideal for sawing, stamping and drilling. It can also be
bent and curved when cold. It can be welded by ultrasonics.
Addresses
General Electric Plastics France SARL
2, rue Jean-Mermoz
F- 91080 Courcouronne
Tel: +33 (0)1 60 79 69 00
Fax: +33 (0)1 60 77 56 53
Department: Logistics,
Production & QC
PS-1000
Rev-A
December 2005
Franchised Panel Builders Hand Book
Title: USEFUL INFORMATION
Developed by: Syed Basheer
Approved by: Sunil PARKHI / Faiz AHMED
4.4 Copper bar
Use
Production of main and distribution power Busbars, switchgear
connection bars, shunt bars, etc.
The vertical distribution flat Busbars should be drilled over their full
height.
Characteristics
Cu A1
Standard electrolytic copper
(minimum content)............................................. 99.9%
Metallurgical state..........................................…..h 12
Density ...........................................................….8.89g/cm3
Mechanical characteristics
Traction elastic limit........................……………25-32kgf/mm2
Relative elongation in %..................................15% min.
Resistivity (micro ohm/cm 20°c).......................1.724
Addresses
France
Gindre Composants
Route de Loyettes
BP 23 Chavanoz
F-38230 Pont De Cheruy
Tel: +33 (O)4 72 46 19 60
Fax: +33 (0)4 72.46 19 61
Export
Gindre Duchavany Orders to be sent to
31 Rue Giffard BP 23 the attention of Mr Levin
F-38231 Pont De Cheruy Tel: +33 (0)4 72 46 09 05
Cedex 5
Tel: +33 (0)4 72 46 09 00 (standard)
Fax: +33 (0)4 78 32 66 55
Department: Logistics,
Production & QC
PS-1000
Rev-A
December 2005
Franchised Panel Builders Hand Book
Title: USEFUL INFORMATION
Developed by: Syed Basheer
Department: Logistics,
Production & QC
Rev-A
PS-1000
Approved by: Sunil PARKHI / Faiz AHMED
December 2005
4.5 Standard screws and bolts
Use
All screw-on electrical and mechanical assemblies. Screws used to inter-assemble distribution bars
and for all electrical connections inside our equipment, except for connections on pads of
Masterpacts greater than or equal to 4000 A (see overleaf).
These screws MUST be tightened to the correct torque. They thus retain all their
mechanical properties in time, without material deformation, irrespective of the temperature
conditions inside the switchboard.
NB: all screws and bolts without a reference in the catalogue central warehouse must be ordered
from a local distributor or supplier.
Characteristics
Screw
Material ................................................................ steel
Quality class......................................................... 8.8
Grade ...................................................................A
Head shape..........................................................hexagonal
Screw cutting profile............................................. ISO metric
Screw end ............................................................chamfered end
Coating.................................................................Zn bichromate
Thread direction ................................................... right
Nut
Material ................................................................ steel
Quality class......................................................... 8.8
Grade ...................................................................A
Shape...................................................................hexagonal
Screw cutting profile............................................. ISO metric
Coating.................................................................Zn bichromate
Inlet chamfer ........................................................yes
Thread direction ................................................... right
Washer
Function ............................................................... braking
Shape................................................................... ribbed conical
Coating.................................................................Zn bichromate
Quality class......................................................... 8.8
Material ................................................................ steel
Manufacturing tools
Individual tools
1. Fitter’s tool box
Use
Minimum tools required to make a complete low voltage
switchboard:
Franchised
Panel Builders Hand Book
Assembly of internal components and cubicles
Title: USEFUL INFORMATION
Developed by: Syed Basheer
Approved by: Sunil PARKHI / Faiz AHMED
Department: Logistics,
Production & QC
PS-1000
Rev-A
December 2005
Production and assembly of distribution bars
Making the cabling (power and control)
Finishes
Composition
This list, which is not complete, is given by way of guidance.
Franchised Panel Builders Hand Book
Title: USEFUL INFORMATION
Developed by: Syed Basheer
Department: Logistics,
Production & QC
PS-1000
Approved by: Sunil PARKHI / Faiz AHMED
NB: in view of supplier diversity, we provide no information on references.
Group tools
Facom torque wrench
Use
Enables torque tightening of all switchboard electrical connections
and connection and adaptation of the Compact NS.
It is vital to comply with the tightening torques recommended in the
technical guides and in the technical manuals for the switchgear.
These wrenches must be regularly checked and calibrated. They
must also be checked if they are dropped, lent, etc.
As regards bolt assembly, tightening must preferably be carried out
on the nut, then once torque tightening is complete, the screws
must be marked with acrylic varnish (self-inspection) (see marking
varnish on page 8).
NB: see overleaf for the composition of the three sets of wrenches
used in our workshops as well as a list of additional tools used to
adapt the switchgear.
Rev-A
December 2005
Franchised Panel Builders Hand Book
Title: USEFUL INFORMATION
Developed by: Syed Basheer
Approved by: Sunil PARKHI / Faiz AHMED
Addresses
Manufacturer
Facom
BP 99
6 et 8 Rue Gustave Eiffel
F- 91423 Morangis
Tel: +33 (0)1 64 54 45 28
Fax: +33 (0)1 64 54 99 92
Export Department
Tel: +33 (0)1 64 54 45 28
Fax: +33 (0)1 64 54 99 92
Distributor
Jallut MSA
7 rue du Béal
ZI BP 177
F-38404 Saint Martin d’Hères Cedex
Tel: +33 (0)4 76 24 82 24
Fax: +33 (0)4 76 24 82 00
Department: Logistics,
Production & QC
PS-1000
Rev-A
December 2005
Franchised Panel Builders Hand Book
Title: USEFUL INFORMATION
DevelopedFacom
by: Syed Basheer
torque
Department: Logistics,
Production & QC
PS-1000
Approved by: Sunil PARKHI / Faiz AHMED
Rev-A
December 2005
wrench (1 to 5 Nm)
Use
Adaptation of Compact S
Franchised Panel Builders Hand Book – 2005
98
Franchised Panel Builders Hand Book
Title: USEFUL INFORMATION
Developed by: Syed Basheer
Department: Logistics,
Production & QC
PS-1000
Approved by: Sunil PARKHI / Faiz AHMED
Rev-A
December 2005
Facom torque wrench (5 to 25 Nm)
Adaptation of Compact NS
List of wrenches and accessories
Franchised Panel Builders Hand Book – 2005
99
Franchised Panel Builders Hand Book
Title: USEFUL INFORMATION
Developed by: Syed Basheer
Department: Logistics,
Production & QC
PS-1000
Approved by: Sunil PARKHI / Faiz AHMED
Rev-A
December 2005
Facom torque wrench (20 to 100 Nm)
NB: wrench with reference number MGA 970002, available from
MGAc Montmélian.
Crimping Tool
Use
Used for crimping by punching or hexagonal necking of lugs in all
low voltage switchboards.
NB: Regularly calibrate the crimping tools.
Franchised Panel Builders Hand Book – 2005
100
Franchised Panel Builders Hand Book
Title: USEFUL INFORMATION
Developed by: Syed Basheer
Department: Logistics,
Production & QC
PS-1000
Approved by: Sunil PARKHI / Faiz AHMED
Rev-A
December 2005
Description
Lug crimping tool of the XCT type (Simel).
Cross-section 4 to120 mm2.
Example: isolec 2 enclosure.
Tool fitted with a nonreturn mechanism and with a rapid advance
index.
Die capacity (mm2): 6 - 10 - 16 - 25 - 35 - 50 - 70 - 95 - 120
HP95 hydraulic crimping tool (Novopress)
HA-1ES hydraulic unit, 220V, 50/60 cyc (Novopress)
Addresses
AMP Simel
Route De Saulon
F-21220 Gev`rey Chambertin
Tel: +33 (0)3 80 58 32 00
Fax: +33 (0)3 80 34 10 15
Novopress
Scharnhorststrabe 1
D- 41460 Neuss
Federal Republic of Germany
Tel: 0 21 31 / 2 88 - 0
Fax: 0 21 31 / 2 88 - 55
Crimping tool for pre-insulated ends and lugs
Use
Crimping tool for pre-insulated ends and lugs (cross-section: 0.3 to
6.6 mm2).
Used to crimp pre-insulated ends and lugs in all low voltage
switchboards.
NB: Regularly calibrate the crimping tools.
Description
Model
n Cembre crimping tool
HP3 type supplied with a certificate of conformity
n For pre-insulated ends
Tool fitted with a nonreturn mechanism.
Check dies are properly positioned and that they match the end orlug to be crimped.
Franchised Panel Builders Hand Book – 2005
101
Department: Logistics,
Franchised Panel Builders Hand Book
Title: USEFUL INFORMATION
Developed by: Syed Basheer
Production & QC
Rev-A
PS-1000
Approved by: Sunil PARKHI / Faiz AHMED
December 2005
Address
Cembre
21, Allée du Parc de Garlande
BP 21
F- 92220 Bagneux Cedex
Tel: +33 (0)1 47 35 22 12
Fax: +33 (0)1 47 35 04 48
Installed machine base
Cutting, bending and drilling machines
Use
Set of machines required to shape switchboard Busbars.
This set can be made up of several independent machines or of a
single machine, able to carry out the various operations merely by
changing the work tool.
Use of single-function machines enables different operators to work
at the same time.
Franchised Panel Builders Hand Book – 2005
102
Franchised Panel Builders Hand Book
Title: USEFUL INFORMATION
Developed by: Syed Basheer
Department: Logistics,
Production & QC
PS-1000
Approved by: Sunil PARKHI / Faiz AHMED
Rev-A
December 2005
Description
Punching machine
Manual or hydraulic, this machine must be able to receive punches
of up to 16mm minimum diameter for 10mm thick bars.
The punching tool must be reserved for copper. Punches must be
easily interchangeable in the shortest possible time without requiring
tricky operations. Accessories must be reliable and sturdy.
NB: punches must always be in perfect working order in order to
prevent burr from forming when punching parts.
Bar cutter or bar shears
If possible provide a tool with a cutting capacity for copper Busbars
160mm wide and 10mm thick.
Provide a busbar storage rack placed upstream from the cutting
tool. This tool will be fitted up against a support equipped with
rollers. Normally placed on this rack, it enables bars to be slid up to
the cutting tool.
Bar bending press: Manual or hydraulic
Choose a tool on which it is possible to make right-angle bends as
close as possible to the edge of the bar.
The bending capacity of this press must be sufficient up to a width
of 160mm (MB) and a thickness of 10mm, and must also possess a
bending angle adjustment system.
For the bending radius, refer to the implementation guide.
NB
Busbar working and handling must preferably be performed when
the Busbars are laid flat (safety and ease of handling). Provide a
tank for recovery of the copper particles and scraps resulting from busbar
implementation. When choosing this tool, ensure that it guarantees maximum
operator safety.
Addresses
Manufacturer
Novopress Gmbh (Germany)
Scharnhorststrabe 1
D- 1460 Neuss
Federal Republic of Germany
Tel: 0 21 31 / 2 88 - 0
Fax: 0 21 31 / 2 88 – 55
Franchised Panel Builders Hand Book – 2005
103
Franchised Panel Builders Hand Book
Title: USEFUL INFORMATION
Developed by: Syed Basheer
Department: Logistics,
Production & QC
PS-1000
Approved by: Sunil PARKHI / Faiz AHMED
Rev-A
December 2005
Quality inspection tools
Dielectrometer or dielectrimeter
Use
All equipment assemblies and parts of equipment must undergo
dielectric strength testing and insulation measurement. IEC 60439.1
standard.
Description
HV generator, A 507 type (manufacturer Bouchet)
Supply voltage: 220 V
Maximum short-circuit rate:
A 507 3KV
– 1 KV range: 20 mA
– 3 KV range: 10 mA
A 507 5KV
– 2 KV range: 15 mA
– 5 KV range: 8 mA
This type of device is limited in power, it is suitable for testing parts
of equipment.
Dielectrometer MC 5 B type (Chauvin Arnoux)
Supply voltage: 220 V
Voltage adjustable from 0 to 5000 V
Megohmmeter incorporated for insulation measurements under
500 V
Maximum power available
ac: 500 VA or 200 mA on the 2500 V rating and 500 VA on the
5000 V rating
Dielectric strength test station, RMG 50 type (Sefelec)
Voltage adjustable from 0 to 5000 V
Rated current 100 mA, short-circuit 1 A
Fault detection by l type detector set at 1 mA and 10 S
Adjustable overcurrent detector
If the tested equipment is too capacitive, the device may indicate untimely faults
In this case you can either:
Split up the switchboard
Use a more powerful device.
NB Provide a filing cabinet for small equipment as well as for documentation and archiving.
Franchised Panel Builders Hand Book – 2005
104
Department: Logistics,
Franchised Panel Builders Hand Book
Production & QC
Title: USEFUL INFORMATION
Developed by: Syed Basheer
Rev-A
PS-1000
Approved by: Sunil PARKHI / Faiz AHMED
Addresses
Manufacturer
Chauvin Arnoux
190, rue du Championnet
F-75876 Paris Cedex 18
Tel: +33 (0)1 44 85 44 85
Fax: +33 (0)1 46 27 73 89
Bouchet
189 rue d’Aubervilliers
F-75886 Paris Cedex 18
Tel: +33 (0)1 40 37 00 55
Fax: +33 (0)1 40 35 01 71
Distributor
Sefelec
Parc Activités Du Mandinet
19 rue des Campanules
F-77185 Lognes
Tel: +33 (0)1 60 17 54 62
Fax: +33 (0)1 60 17 35 01
December 2005
Dielectrometer or dielectrimeter
Addresses
Multimeter
Chauvin Arnoux
190, rue du Championnet
F-75876 Paris Cedex 18
Tel: +33 (0)1 44 85 44 85
Fax: +33 (0)1 46 27 73 89
Metrix
Division de Chauvin Arnoux
6, avenue du pré Challes
F-74943 Annecy Le Vieux Cedex
Tel: +33 (0)4 50 64 22 22
Fax: +33 (0)4 50 64 22 00
Phase sequence search device
Catu
10-20 Avenue Jean-Jaurès
BP 2
F-92222 Bagneux Cedex
Tel: +33 (0)1 42 31 46 00
Fax: +33 (0)1 42 31 46 31
NB
Provide a filing cabinet for documentation
and archiving, as well as
for small equipment (multimeters,
connection devices, etc
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