1-1SALIENT DETAILS

Name of the company : STAHLLFORM TECHNIK PVT. LTD. (ISO Accredited)
Address : 30A, Phase-1,Sipcot Industrial Complex, Hosur- 635 126, Tamil Nadu.
Type of Company : Private Limited

Type of Products : All types of Panel Boards , Accessories for LT, Bus Ducts, Mandatory Electrical Safety Products, Energy Saver Panel
Plant Capacity : Rs.200 Lakhs worth Electrical panels and Bus ducts per month

ISO 9001:2008 CERTIFICATE

 

3

TEST CERTIFICATES

4

5

RANGE OF PRODUCTS

POWER CONTROL CENTRES

MOTOR CONTROL CENTRES

POWER FACTOR CORRECTION CAPACITOR PANELS

CONTROL & RELAY PANELS

AUTO I MANUAL SYNCHRONIZING PANELS

CONTROL DESK & MIMIC PANELS

BUS DUCTS & RISING MAINS

VFD PANELS

SOFT STARTER PANELS

ENERGY SAVING PANELS

FULLY DRAW OUT MCC PANELS

RECENT ORDER EXECUTED

 

S.NO PROJECT ITEM
1 Changpond Technologies Ltd. Sipcot IT Park ,Siruseri, Chennai – 600 103 PMCC,APFCP, BUSDUCT,RISING MAINS, etc.
2 Chemplast Sanmar Ltd.,Karikal Project(Ethylene storage fire fighting facilities) PMCC
3 Calci Tech India Ltd. Hosur- 635 126 PMCC,SUB MAIN BOARDS ,APFC
4 Chemplast Sanmar Ltd., Hosur- 635 126 PMCC
5 Luk India Pvt. Ltd. Hosur- 635 126 PCC
6 Genau Extrusions      Ltd. Hosur- 635 126 PCC, APFCP, BUSBAR TRUNKING
7 Chemplast Sanmar Ltd.,Karikal project(4000kl caustic storage facilities in karikal) PMCC
8 Chemplast Sanmar Ltd., Mettur Dam – Plant Ill project PMCC
9 Biocon Park Bangalore MCC, PDB
10 Calcitech India Ltd. Hosur PMCC
11 Luk India Ltd. Hosur PMCC
12 V.B Medicare Ltd (Bioplus) Hosur MPCC, MCC, BUSDUCT
13 Subha Shri Bio Energy Ltd, Thiruchengodu PMCC, APFCP
14 Bhararth Heavy Electricals Ltd, Hydrabad BUSDUCTS ,BUSBAR TRUNKING
15 Om Sakthi Narayani Siddar Peedam, Vellore SSB
16 Airport Authority of lndia,Calicut. N.E PANEL, CAPACITOR PANEL
17 V.B Medicare Ltd, Bangalore MPCC,APFCR
18 Synergy, Bangalore PCC,MCC and PDB
19 V.A. TECH WABAG LTD Kerala Water Authority PMCC, MCC, MLDB, ASDB.
20 DMW CNC Solutions India (P) Ltd Perundurai MAIN MV PANEL,APFCR PANEL , FGB,RGB PANELS
 

21

 

Diesel Machinery works Perundurai

SSB EXISTING 1&2, SSB EXISTING HALL
 

22

 

BSNL Sankarapuram

 

MAIN MV PANEL

 

23

 

Sygenta Bio Sciences Goa.

MAIN LT PANELS ATTACHEMENT PANEL
 

24

 

CK Airtech India (P)Ltd. Hosur

 

STARTER PANELS

 

25

 

Preludesys Solutions India (P) Ltd. Chennai

 

LT PANEL BOARDS

 

26

 

TTK LIG Ltd Pondichery

 

BUSDUCTS

 

27

 

Kongu Engineering College Perundurai

 

CAPACITOR PANELS

 

28

 

Crescent Engeering Bhavani

OUTDOOR TYPE PANELS , BUSTUCTS,TRANSFORMER BOX
 

29

 

Aro Granite Industries Ltd Hosur

 

STP MCC PANEL

 

30

 

Yekediar Farms (P) Ltd Chennai

MLDB, ESSENTIAL, LIFT PANELS
 

31

 

Rasi Seeds Pvt Ltd Attur Salem

 

MCC 1,2&3

 

32

 

Bharat Petroleum pvt Ltd Mangalore

 

MCC PANEL,ROV PANEL

 

33

 

Bharat petroleum pvt Ltd Cherralapally

 

MCC 1A ,APFC PANEL

 

 

34

 

 

Cauvery Medical Center Bangalore

MAIN LT

PANELS,DISTRIBUTION BOARDS, STREET LIGHTING BOARDS.

 

35

 

Vaizak Cricket Stadium

 

Change over panel

 

36

 

Spices Board, Guntur

 

Main M.V Panel, Sub Panels

 

37

 

BSNL, Mysore

Main M.V Panel,APFCR Panel

LIST OF IN-HOUSE TESTING FACILITIES

 

S.NO

 

EQUIPMENT

 

RATING

 

APPLICATION

 

1

 

High Voltage Tester

 

0-10KV, 0-

03mA

 

For Testing of High Voltage withstanding capacity of Panels (Power & Control circuits)

 

2

 

Secondary Current Injection Kit

 

0-5A, 10

 

For Testing of Ampere Meter, Relays etc.

 

3

 

Conductivity Meter

 

10-108%

 

For Measurement of Conductivity of AI and CU. Busbars

 

4

 

Relay Testing Kit (Portable)

 

0-230V AC, 10

For Testing of various Relays Viz.. ON,UN,O/C,E/F relays , MCB, MCCBs Thermal 0/L etc.
 

5

 

Mobile Test Bench

 

0-415V Variable

AC/DC

 

For Panel Testing

 

6

 

Mill volt Drop Test Bench

 

0-100V DC

 

Millivolt Drop Test of Busbar joints

 

7

 

Megger (Battery

operated)

 

0-1000M’O,

500V DC

 

For Measurement of Insulation Resistance value

 

8

 

Multi Meter

 

Digital

 

For Measurement of AC/ DC Voltages, Current, Resistance etc.

 

9

 

Tong Tester (Multimeter)

 

Digital

 

For Service Engineers, Site work

 

10

 

Dial Vernier Caliper

 

0-200mm

 

For Measurements of Thickness of Busbars, Sheet Steel etc.

 

11

 

Torque Wrench

 

0-125KGNM

 

For Testing of Hardware Tightness

 

12

 

Filler Gauge

 

For Bus bar joints Gap checks

 

13

 

Alco Meter (Paint Coat Gauge)

 

0-1000 Micron

 

For Measurements of Paint thickness

 

14

 

Digital PH Meter

 

0.01-14PH

 

For Measurement of PH of 9 Tank Process

medium

 

15

 

Sycro Meter

 

0-15ml

 

For Testing of Accelerator in Phosphating Bath

PAINTING PROCEDURE

Following is the painting procedure (9-tank process for base treatment , followed by Powder Coating and curing in a LPG oven)
adopted for all the Switchboards , Panels, sheet Metal fabricated enclosures and other sheet! MS metal components.

Procedure consists of the following steps:

De-greasing :

This is basically a metal cleaning process prior to the protective coating (Tank-1) where removal of grease, oil, soils, lubricating,
drawing components, oxide films , heat treatment scales etc. Take place. A proprietary degreaser called “METRITE SAG SP that
effectively cleans steel surface without undesirable consequences is made use of. A through action with quickness and effectiveness
is achieved by air agitation method in the bottom of the tank containing “METRITE SAG SP”. Degreasing is followed by a
rinsing process in Tank No.2. (Rinse -I)

De- rusting:

After rinsing in the tank ,this process of ‘De-rusting’ is carried out in the 3rd tank for removal of heavy rust and soil, using an acidic
solution (“METRITE AH-SP “) .at Room temperature for about 10- 15 minutes..After de­ rusting rinsing is carried out again inTank
No.4 & Tank No.5 (Rinse – 11 & Rinse – Ill).

Activation:

After rinsing in the tank, the surface of sheet steel components is activated for subsequent Zn   phosphate
coating at ambient temperature inTank No.6.Activation chemicalis called “METRITE DSM”

Phosphating :

Phosphating produces a smooth , compact, uniform zinc phosphate coating. It is a Room temperature process and the special
grade solution used in this VII th tank is called “METRITE ZLP 30”.The dip duration is around 20 minutes. The degreased,
derusted (and thoroughly rinsed) components are dipped in this solution for about 5 -20 minutes;after this components are rinsed
thoroughly inwater kept inTank No.8.

Sealing  (Passivation):

In order to obtain maximum corrosion resistance of the phosphate coatings, it is necessary to seal the pores. This is realized through a
chromate rinse carried out at Room temperature using a commercia l grade solution called “METRITE AH – 50   in Tank No.9.

Powder coating and drying:

The final and important  powder coating is carried out subsequent ly within 24 hours using the custom­
made powder coating chamber and equipment , followed by drying in hot air chamber.

PRELUDE

11

MAKE PCC /MCC PANELS

Stahllform’s PCC panels have been successfully tested at Central Power Research Institute, Bangalore for “Verification of
Short Circuit Strength” at 50KA as per IS:8623.

Salient features of the panels:

• Use of non-hygroscopic SMC supports for Bus bar for adequate mechanical and electrical strength to
withstand specified full current.

• Panels are totally enclosed, dust proof and vermin proof, and fully compartmentalized, cubicle design
and modular construction. The covers and doors are well gasket with neoprene rubber gaskets so as to
obtain dust proof enclosure .

• The panels are manufactured with separate Bus bar chamber isolated from Unitfeeder chambers and
Cable Alleys. This provides extra safety for working personnel.

• The panels are made of 2mm thick CRCA sheet steel for robust construction. The doors are provided
with concealed hinges for better aesthetic appearances.

• All sheet metal work is processed using imported & accurate shearing and Press Brake machines,
resulting in desired accuracy.

• Optimized design and size of Panels, compartments, Bus bar Chamber and Cable alley.

• The panels are treated for de-greasing, de-rusting, Phosphating and Passivation by adopting Nine
Tank process as per the Indian Standard Specification before powder coating with epoxy based powder.

• All Control and Power wiring terminals are brought out in the Cable Alley for easy cable termination.

• All Power and Control wiring is done using numbered ferrules of proper size and quality at both ends for
identification.The wiring is neatly bunched and kept inthe PVC trunking and closed by a cover for a clear wiring.

• All Bus bars are insulated with heat shrinkable PVC sleeves and all the live parts are shrouded to avoid accidental contact.

• All live parts are properly shrouded using FRP sheets in order to avoid accidental contact with live parts during
maintenance and facilitate simultaneous inspection.

• Systematic adherence to “Quality Assurance Plan”to ensure top class quality.

TECHNICAL SPECIFICATIONS FOR STAHLLFORM  MAKE POWER /

MOTOR CONTROL CENTRES

Technical Specifications:

The Power and Motor Control Centers are metal clad totally enclosed dust and vermin proof modular
construction, self supporting, floor mounting, air insulated cubicle type for use on 415 Volts 50 Cycles AC supply.

Construction:

The Power and Motor Control Centers is fabricated using 2mm thick CRCA sheet steel. These are made of
requisite vertical sections, which when coupled together shall from continuous dead front switch boards.
The Power & Motor Control Centers are readily extensible on both sides by the addition of vertical sections
after removal of the end covers and provide complete dust and damp protection,the degree of protection
being not less than IP-52ofiS:2147

The structure of the panel is mounted on the base frame of3mm thick Sheet steel. The design shall ensure that
weight of the components is adequately supported.

Bus bars:

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

The bus bar is suitably braced with non-hygroscopic SMC supports at suitable intervals in order to withstand
the dynamic forces of Short Circuit at 50KA RMS, symmetrical for 1 sec. large clearances and creepage distances
are provided on the bus bar system to minimize the possibility of a fault as per the relevant Indian Standard.

The cross section of bus bars and risersfor various rating is calculated  on the basis of 0.8Amp. Per sq. mm for
Aluminium and 1.6Amp .Per sq.mm for Copper.The main bus bar shall have continuous current rating throughout
the length of each Power I Motor Control Centre and the neutral bus bar shall have a continuous rating of at least
50% of the phase bus bars.

The bus bar is color coded for identification of individual phases and neutral. The bus bar is insulated with heat
shrinkable PVC sleeves.

Surface Treatment:

All steel work used in the construction of Bus duct are thoroughly cleaned to remove all rust, scales, grease and
other foreign matters.This is done by treating the sheet steel through the Nine Tank Process that involves de-greasing,
de-rusting, activation,Phosphating ,scaling and  drying as per the IS:3618

The sheet steel structure is then powder coated with epoxy based powder with specified shade as per
national / International standards.

Cable Termination And Control Wiring:

Cable entries and terminals are provided in the switchboard to suit the number, type and size of Aluminium
conductor power cables and copper conductor control cables. Provision will be made for Top or Bottom entry
of cables as required. Generous size of cabling chambers are provided with the position of cable glands and terminals
such that cables can be easily and safely terminated.

All control wiring is carried out with stranded copper conductor of 1.5 sq. mm for Control and Potential circuits.
2.5 sq.mm wires are used for CTs and current circuits.

Wiring shall be neatly bunched and provided in the PVC troughs with a cover. Adequate support is provided
and properly routed to allow for easy access and maintenance. Wires are  identified by ferrules at each end.

Tests:

Following routine inspection and tests are conducted on the Power I Motor Control Centre in accordance with
IS:8623.

Inspection of the Power I Motor Control Centre including inspection of wiring and electrical operational tests ,
where ever necessary. Dielectric Tests at High Voltage. Insulation Test at 1000 Volts.
Checking of Protective Measures and electrical continuity of the protective circuits.

Applicable Standards:

Switchboards are designed to conform to the requirements of the following Standards:

IS8623    Factory BuiltAssemblies of Switchgear and Control gear.
IS375    Marking andArrangement for Switchgear Bus bar etc.
IS4237    General requirements for Switch gear & Control gear.
IS 2147    Degree of Protection provided by enclosure for Low Voltage Switch gear & Control gear.
IS2516    Air Circuit Breakers of voltages not exceeding 1OOOV AC
IS4064    Fuse Switch and Switch Fuse units for voltage not exceeding
1000VAC    IS9224    H.R.C.Fuse Links
IS2705    Current Transformers
IS 1248    Indicating Instruments
IS722    A.C. Electric Meters
IS 3231    Electrical Relays for Power System Protection
IS6875    Control Switches & Push Buttons
IS 10118    Code of Practice for Selection, Installation and Maintenance of Switch gear and Control gear
IS 13947    Low Voltage Switch gear and Control gear- Contactors &
(Part-4)    Motor Starters

In the absence of specific Indian Standard Specifications , International Electro-mechanical Committee Specifications are followed.

TECHNICAL SPECIFICATION FOR STAHLLFORM MAKE BUSDUCTS & RISING MAINS
General Specification:

The Bus duct & Rising Main are metal clad, totally enclosed non-segregated type, dust & vermin proof air
insulated for use on 415 Volts, 50 Cycles AC supply.

The Bus duct & Rising Main are designed for operation in high ambient temperature and high humidity tropical
atmospheric conditions. This facilitates ease of inspection, cleaning and repair,for use in installations where
continuity of operation is of prime importance.

Construction:

The Bus duct & Rising Mains are fabricated from 2mm thick CRCA sheet metal,with louvered covers on both
sides of Bus duct & Rising Mains for adequate heat dissipation. Bus duct & Rising Main have top and bottom
covers for visual inspection I maintenance.

Rubber I Cotton Bellows for enclosure are provided for avoiding DG/TR set vibration affecting the Bus duct I
Rising Main.

Bus bars:

The bus bars are air insulated and made of high conductivity, high strength aluminum alloy complying with
the requirements of Grade E91E of IS:5082 or E.C.grade aluminum I copper as per the Customer requirements.

The Bus bars are suitably braced with non-hygroscopic SMC supports at suitable intervals in order to withstand
the dynamic forces of Short Circuit at 50KA RMS, symmetrical for 1 sec. Large clearance s and creepage distances
are provided on the Bus bar system as per the relevant Indian Standard, .to minimize the possibility of a fault

The orientation of Bus bar shall be N-R-Y-B or inter-leaved i.e. R-Y-B-N.

The cross sections of bus bars for various rating are calculated on the basis of 0.8 Amp. Per sq. mm for Aluminum
and 211.6Amp. Per sq. mm for copper.

The bus bars shall have continuous current rating throughout the length of Bus duct & Rising Main and the neutral
bus bar shall have a continuous current rating of at least 50% of the phase bus bars.The Bus bars are color coded
for identification of individual phases and neutral. The Bus bar shall be insulated with heat shrinkab le PVC sleeves .

Finishing:

All steel work used in the construction of Bus duct & Rising Main are powder coated (subsequent to the 9-tank process
of pre-treatment) with epoxy based powder with specified shade as per national I international standards.

End Termination I Expansion Joints:

Bus duct I Rising Main shall be provided with AI I Cu flexib le at the ends for proper alignment. After every 6 Meters
of straight length portion, expansion joints shall be provided for accommodating the expans ion of the Bus bars.

Optional Accessories (For Bus ducts):

i.    Phase Cross over (RYBN – NBYR)

ii.    Neutral Cross over (NRYB- RYBN)

iii.    Seal of Bushing

iv.    Fire Proof Barrier

v.    Canopy for outdoor portion

vi.    Silica gel breather

vii.    Wallframe Assembly.

Inspection & Testing :

Following routine tests are conducted on the Bus duct:

•    Inspection of the Bus duct (Physical Measurement)

•    Verification of Phase sequence

•    Tightness of Joints

•    Dielectric Tests at HighVoltage.

•    Insulation Resistance at 1000 Volts.

PHOTO GALLERY

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