PROJECT REPORT
Manufacturing of an Electrical Control Panel (LV PCC/MCC)
Submitted by: Sahil Yadav
University: Deenbandu Chhotu Ram University Of Science And Technology
Training Period: 7th July 2025 – 3rd August 2025
Company: Tricolite Electrical Industries Ltd., IMT Manesar, Gurugram, Haryana
Table of Contents
Table of Contents (right-click and Update Field in Word)
Acknowledgement
I sincerely thank Tricolite Electrical Industries Ltd., IMT Manesar for the opportunity to
undergo industrial training. I am grateful to my industry mentors for technical guidance and
to my institute guide for academic support. I also appreciate the cooperation of the
Production, Quality, and EHS teams.
Declaration
I, Sahil Yadav, declare that this report is an original record of work performed by me during
industrial training at Tricolite Electrical Industries Ltd., IMT Manesar, and has not been
submitted elsewhere.
Executive Summary
This project documents the end-to-end process of manufacturing a Low Voltage (LV)
Control Panel—covering enquiry & design, material planning, sheet-metal fabrication,
busbar processing, assembly, wiring, routine testing, Factory Acceptance Testing (FAT), and
dispatch. The report also summarizes compliance to IEC 61439 and IS/IEC 60947, presents
sample calculations for busbar sizing and breaker selection, a schedule snapshot, and key
EHS practices.
1. Company Profile
Tricolite Electrical Industries Ltd. is a well-known manufacturer of custom-engineered Low
Voltage switchboards and power distribution solutions. The IMT Manesar facility supports
sheet-metal fabrication, powder coating, busbar processing, assembly lines, wiring, and
quality test benches. Applications include commercial buildings, data centers, industrial
plants, and infrastructure projects.
2. Product Overview: LV PCC/MCC
The reference product is a Form-4b Power Control Center (PCC), 4000 A, IP54, with a 65 kA,
1 s short-time withstand. It includes a draw-out ACB incomer with LSIG protection, copper
busbars, outgoing MCCB feeders, multifunction metering, CRCA enclosures, and FR/FRLS
wiring. A simplified block diagram is shown below.
Figure 1: Simplified PCC block diagram.
3. Manufacturing Process Flow
Manufacturing flows through gated stages ensuring quality and traceability: Enquiry →
Design & GA → BOM & Purchase → Sheet-Metal Fabrication → Powder Coating → Busbar
Processing → Assembly → Wiring → QA/QC → FAT → Dispatch.
Figure 2: Process flow from enquiry to dispatch.
3.1 Sheet-Metal Fabrication
Laser cutting/punching per GA drawings; bending/forming for doors, covers, and
partitions; welding and surface finishing; chemical treatment and powder coating (DFT
~60–80 μm). Dimensional checks and DFT measurements are logged as part of in-process
QC.
3.2 Busbar Processing
ETP Copper busbars are cut, drilled, and bent with minimum bend radius ≥ thickness to
limit stress. Insulation is applied using heat-shrink sleeves/shrouds with RYB color coding.
Supports use SMC/DMC with spacing justified by thermal–mechanical calculations and
short-circuit forces.
3.3 Assembly & Wiring
Devices (ACB/MCCB/contactors) are mounted with correct torque and partitioning to
maintain Form-4 separation. Control wiring uses FR/FRLS cables, numbered ferrules,
harnessing within ducts, and door bonding with earth braids. Cable alley dimensions allow
ergonomic termination and service access.
3.4 Testing & FAT
Routine tests per IEC 61439 include visual/mechanical inspection, dielectric withstand,
insulation resistance, protective circuit continuity, functional tests (interlocks/meters), and
verification of markings. FAT is performed with the customer using documented
procedures and acceptance criteria.
4. Standards & Quality Assurance
Key standards include IEC 61439 (assemblies), IS/IEC 60947 (devices), IEC 60204-1
(machinery), IS 3043 (earthing), and IS 5578/IS 11353 (color coding). Quality checkpoints
cover incoming inspection of devices/copper, coating DFT, busbar clearances/creepage,
torque logs, PE continuity, and document traceability.
5. Illustrative Calculations
Short-Circuit Basis: Assume fault level at 415 V bus = 50 kA. Incomer ACB Icu ≥ 65 kA is
chosen for margin and selectivity. Busbar Sizing: For 4000 A, using conservative current
density ~1.3–1.6 A/mm², required area is ≈ 2500–3080 mm². Three runs of 100×10 mm Cu
per phase give ~3000 mm², typically acceptable when validated against type-tested data
and temperature rise limits.
Cable Sizing: For 800 A feeders, multiple runs of 3.5C cables may be required considering
installation method, ambient temperature, grouping factors, and permissible voltage drop.
Protective settings (LSIG/LSI) are coordinated for discrimination and earth-fault coverage.
6. Project Schedule (Sample)
A representative timeline is provided for a custom PCC build. Actual durations vary based
on approvals and material lead times.
Figure 3: Illustrative Gantt-like schedule.
7. Environment, Health & Safety (EHS)
Mandatory PPE: safety helmet, shoes, gloves, and eye protection. LOTO procedures during
electrical tests; clear walkways and housekeeping; ergonomic lifts for heavy busbars;
CO₂/ABC extinguishers in designated zones; and paint booth ventilation controls. Regular
toolbox talks reinforce safe behaviors.
8. Risk Assessment (HIRA) – Excerpts
• Busbar drilling/bending → Hand injury → Guards, gloves, trained operators
• Electrical testing → Electric shock → LOTO, insulated mats, interlocked benches
• Powder coating → Inhalation/fire → Ventilation, PPE, booth SOP
• Panel lifting → Back/foot injury → Cranes, slings, team lifting
9. Bill of Materials (Snapshot)
Major items: 4000 A draw-out ACB (LSIG), MCCBs 63–800 A, ETP Cu busbars (e.g.,
3×100×10 mm/ph), multifunction meter, CTs 4000/5 A, FR/FRLS control wiring, CRCA
enclosures, earthing bars and hardware, lugs and glands.
10. Documentation Pack
Included: SLD, GA drawings, wiring schematics, terminal chart, device datasheets, routine
test reports, torque chart, as-built drawings, O&M manual, warranty terms.
Annexure A: Daily Training Diary (7th July – 3rd August 2025)
Week 1: Induction, safety briefing, plant tour, overview of panel variants (PCC/MCC/APFC).
Assisted in GA review and component familiarization.
Week 2: Observed sheet-metal fabrication and powder coating; participated in busbar
cutting/drilling with supervision; learned DFT measurement and torque logging.
Week 3: Took part in mechanical assembly and wiring harnessing; practiced ferruling and
cable routing; verified door bonding and earthing continuity.
Week 4: Supported routine testing (IR/Hi-Pot/functional), prepared FAT checklists and
documentation; compiled lessons learned and suggestions for cable alley optimization.
11. Outcomes & Learnings
The training developed practical competency in LV panel design interpretation,
manufacturing workflows, QA/QC controls, and EHS culture. It bridged classroom theory
with shop-floor execution and customer-facing FAT protocols.
12. Conclusion
The exposure at Tricolite’s IMT Manesar facility provided end-to-end understanding of
engineered LV assemblies, ensuring readiness to contribute to future projects in power
distribution and automation.
References
1. IEC 61439-1/2: Low-voltage switchgear and controlgear assemblies
2. IS/IEC 60947 series: Low-voltage switchgear devices
3. IEC 60204-1: Safety of machinery – Electrical equipment of machines
4. IS 3043: Code of practice for earthing
5. Manufacturer catalogs: ACB/MCCB, meters, CTs, cables
10. Photographs of Training & Plant Visit
Figure 1: Tricolite Company Plant View
Figure 2: Panel Assembly Section
Figure 3: Busbar Fabrication Area
Figure 4: Wiring and Harnessing Process
Figure 5: Quality Assurance and Testing
Figure 6: Completed LV Control Panel
Figure 7: Dispatch and Packaging Section
