1. Requirement Analysis & Design
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Client requirements, load data, and applications are studied.
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Engineers design panel layouts using CAD software (like AutoCAD Electrical or EPLAN).
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Component selection (MCBs, MCCBs, contactors, relays, PLCs, VFDs) is finalized.
2. Material Procurement
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Enclosures (MS/SS/Aluminum), busbars (Copper/Aluminum), switchgears, terminals, wiring accessories, etc., are sourced.
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All materials are quality checked upon receipt.
3. Fabrication & Painting
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The panel enclosure is fabricated by cutting, bending, and welding metal sheets.
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Holes are made for components, cable entry, ventilation, etc.
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Then it’s powder-coated or painted for corrosion resistance and proper finish.
4. Busbar Assembly
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Busbars are cut, drilled, and mounted as per the design.
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Heat-shrink sleeves or color codes are applied (R-Y-B and neutral/earth).
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Insulation, spacing, and support clamps are ensured as per IS/IEC standards.
5. Component Mounting
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All electrical components (breakers, relays, meters, VFDs, PLCs) are fixed on mounting plates or DIN rails.
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Proper spacing and alignment are maintained for safety and maintenance.
6. Internal Wiring
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Control and power wiring is done using color-coded wires.
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Ferrules, cable tags, lugs, and sleeves are applied for identification.
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Wiring is routed neatly through cable ducts.
7. Testing & Quality Check
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High-voltage (Hi-pot), insulation resistance (IR), and continuity tests are performed.
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Control logic is tested if PLC/automation is involved.
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Panel is energized to check functionality, safety, and tripping features.
8. Labeling & Documentation
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Component labeling, terminal tags, panel nameplate, and schematic drawings are added.
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A user manual with wiring diagrams is prepared.
9. Final Inspection & Dispatch
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Final QA is done.
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Panel is packed securely and dispatched to the site for installation.