Sterling Generators Pvt. Ltd. Regional Offices Mumbai 10th Floor, Universal Majestic Building, P.L. Lokhande Marg, Chembur (W), Mumbai 400 043. Tel: 022 25526100, Fax: 022 25526200 Email: panelsales.mumbai@sterlinggenerators.com Noida C-56/38, Institutional Area, Sec-62, Noida - 201301. Tel: +91 120 4071000 Email: panelsales.delhi@sterlinggenerators.com Kolkata 3rd Floor, Benfish IT Tower, Plot G. N. 31, Sector V, Salt Lake City, Kolkata 700 091. Tel: 033 30118100, Fax: 033 30118159 Email: dgkolkata@sterlingwilsonpowergen.com / panelsales.delhi@sterlinggenerators.com Bangalore 4A/14, 4th Main, Chikka Adugodi New Extension, Thavarekere Main Road, Bengaluru 560 029. Tel: 080 67178601-09, Fax: 080 67178675 Email: dgbangalore@sterlingwilsonpowergen.com / panelsales.mumbai@sterlinggenerators.com Corp Office: 10th Floor, Universal Majestic Building, P.L. Lokhande Marg, Chembur (W), Mumbai 400 043. Tel: 022 25526100 Fax: 022 25526200, Email: panelsales.mumbai@sterlinggenerators.com / dgmumbai@sterlingwilsonpowergen.com Regd. Off: B-2, Bussa Udyog Bhavan, T.J. Road, Sewari (W), Mumbai 400 015. Factory: Sterling Generators Pvt. Ltd., Survey No. 59, 343/1, Village Kala, Kherdi Khanvel, Silvassa - 396 230. (U.T. of Dadra & Nagar Haveli)
Our group Our strength / partners Our Strength: Only non-switchgear Panel manufacturing company having all India foot print. Our Technolgy Partners for MV and LV Switchboards Our regional office in all major locations equipped with all specialties including design & after sales adds to client comfort & reliance. Being part of a major group adds to financial strength which enables us to execute any size of order. Complete in-house facility and pool of expert & qualified engineers makes us technically more strong and modern manufacturing facilities like pneumatic assembly line makes us more efficient. Product Basket General Application Panels Power Control Centre Double Bus Bar panels Motor Control Centres (Manual/ Intelligent) HT Panels 6.6/11/33KV Distribution & Meter Boards Automatic Capacitor panels (Conventional/Thyristor Based) Captive Power Control, Synchronization & Load Management Panels with SCADA Control Desks & Mimic panels Control & Relay panels Outdoor Feeder pillars Drive panels Bus Ducts ShapoorjiPallonji Sterling and Wilson Powergen Fabrication Components production on highly precision CNC Turret punch and press break & bending machines from AMADA Japan, complete online programing. Pre-Treatment through Hot Phosphate process using fourteen Tank with online temperature monitoring of Degreasing, Phosphating and Passivation tanks. Independent Laboratory to monitor Pre-Treatment, Painting process and quality of powder coating. Our design engineers adopt established engineering practices for selection of components including busbar & enclosure designing. Shapoorji Pallonji is one of India s oldest and most respected construction groups, operating for over 145 years. With a group turnover of over USD 2 Billion, the company has its operations spread across India, Middle- East, Africa and the Caribbean. Following ISO standards for Design & Build & EPC, its construction activities include power plants, industries, luxury hotels, refineries, atomic energy establishments, airports, educational institutions, commercial and residential buildings, complexes and prestigious palaces, skyscrapers, villas and stadiums. The Mistry family that owns SP is also the largest private stakeholder (18.5%) of TATA Sons Limited, the holding company of the TATA group. Sterling and Wilson Sterling and Wilson was established in 1927 as Wilson Electric Works. Sterling and Wilson was formed in 1973. Between the years 1973-1993, the company has primarily focused on various projects in the Middle-east before becoming an active player in the Indian market. Having executed over 1500 high-value projects since then, Sterling and Wilson has evolved as India's leading MEP (Mechanical, Electrical & Plumbing) services company that has a pan-india presence. With excellent project management capabilities, 200 in-house design engineers, the company is today 2300 employees strong and has another 3500 personnel on contract. Sterling and Wilson today is a bankable name for clients all across the business segment. Sterling and Wilson Powergen Pvt. Ltd., is headquartered in Mumbai and has its regional & branch offices spread across 18 cities in India. It is managed by the best minds in the industry that bring in a solution based approach towards its customers in the field of diesel based captive power generation. Today SWPPL is known for its endearing project management skills and service capabilities that help them provide round the clock support across India, Middle-east and Africa with tailor-made solutions. Sterling and Wilson Co-Gen Solutions Sterling and Wilson Co-Gen offers highly optimized gas based Combined Heat and Power (CHP) turn-key solutions for commercial buildings and process industries, providing reliable and quality power requirement in the most cost effective manner. Sterling and Wilson with leading OEMs like MTU and Kawasaki, offers world renowned power generation equipments - Gas Engines & Turbines, reducing the carbon foot print of industries and establishments by mitigating their impact on the environment. Sterling Generators To keep pace with the time Sterling and Wilson started a process of backward integration by setting up a modern manufacturing facility for DG Sets and LT & MV Switchboards at Silvasa in the year 2005. The manufacturing unit is equipped with all modern computerized machines to produce the quality products with speed & accuracy. Complete job planning & management through online monitoring and planning software. Each and every stage starting from order booking to final dispatch is being monitored and controlled through the software. Fully bolted construction ensures complete flexibility while with standardization 250 combinations of Panels can be made from just 47 standard components. Achievments: Achieved booking turnover of approx. `100Cr in 6th year of operation which is fastest rise in the industry. Executed single order worth `20Cr for US based Pharma Major Hospira Healthcare in 6 months record time. Our panel type tested for 100KA fault level with ACB inside. Panel type tested for form of separation 4B and Seismic Zone-IV & V. Designed, manufactured and commissioned complete power management & SCADA solution for 66MVA DG Based captive plant at Delhi Airport terminal T-3. With our quality, service and dedication we have won the confidence of customers like TOI, Vodafone, Tata Motors, Coca Cola, Boeing, Hospira, USV, Dr. Reddy s Lab, TCS, Ford Motors, Berger Paints, Bharat Electronics, NBCC, F1 to name a few. Only Indian company, who has designed, manufactured and successfully tested EMI/EMC compliant panels for defence establishments. Special Products SG Solar Compact Sub-Station EMI/EMC Compliant Panels TTA Panels Draw-out MCC 2 3
Manufacturing Facilities Manufacturing Facilities Fabrication All sheet metal processing like shearing, bending, punching, etc. are being done on world-class highly accurate CNC Machines. Sheet is directly sourced from the manufacturer to maintain product quality. The basic skeleton of the panel i.e. frames are C sections made of folded sheet metal. These frames are provided with holes at a pitch of 75mm, which makes the panel fully modular in construction. Busbar Assembly High conductivity electrical grade Aluminium/Copper conductor (as specified) is directly sourced from manufacturers to ensure quality. All busbars are thoroughly cleaned before panel assembly. Cutting, punching and bending is done on hydraulic/electric machines to achieve the desired angle and smooth edges. After cutting & bending, the busbars are covered with heat shrinkable PVC sleeves and then it is kept inside a baking oven with moving bed to shrink fit the sleeves on the busbars. Painting Procedure All the fabricated parts are painted with polyester based powder for long lasting corrosion free life. Powder coating booth is equipped with robotic gun for uniform coating of the surface. Afterwards powder coated components goes into the oven for baking on an automated conveyor system at a pre-set speed for optimum result. Fourteen tank pre-treatment processes are adopted for surface cleaning of all fabricated sheet metal parts before powder coating. The pre-treatment consists of: Knock-out De-greasing De-greasing De-rusting Activation Phosphating Passivation Dryer 1 Dryer 2 Detailed process is as under: Degreasing: This is basically a metal cleaning process where removal of grease, oil, lubricants, oxide films, heat treatment scales, etc. is undertaken before protective coating. Rinsing: After degreasing a rinsing process is carried out to completely wash out the degreasing chemical from the metallic surface. De-Rusting: This process is carried out to remove heavy rust and soil in the tank using mixed acid at room temperature for about 10-15 minutes. This procedure is capable of removing the traces of rust. After this process another round of rinsing is done. Activation: After rinsing the surface of the sheet metal, it is activated with proper Zn & Mn phosphate coating at ambient temperature. Phosphating: It is a process that produces a smooth, compact, uniform zinc-nickel phosphate coating. Conducted at room temperature, the dip duration is around 20 minutes. After this process another round of rinsing is done. Passivation: In order to obtain maximum corrosion resistance over phosphate coating, it is necessary to apply a post treatment in order to seal the pores. A chromate rinse is carried out at room temperature to facilitate this effect. Water Drying: Components are dried in a hot air chamber. The metal is powder painted within 24 hours of the final process. This surface treatment process is being adopted for all the sheet metal components made up of sheet thickness up to 3mm. For components above 3mm or ISMC channels shot blasting process is being used for surface cleaning. For best results we ensure: Oven calibration at regular intervals & online temperature monitoring to ensure consistent curing. Pre-Treatment bath made up from Pre-Treated ground water through our in-house RO plant. Independent painting laboratory to monitor pre-treatment and paint process Following major tests Scratch test. Cupping & impact test. Salt spray test for corrosion resistance. Powder Coating Plant Busbar Sleeving Oven CNC Punching Shot Blasting Facility CNC Bending Busbar Bending Pre-treatment Process 4 5
LT Panels HT Panels Rated current upto 6300A Fault level upto 100kA for 1 Sec Construction of Panel: 2A/2B/3A/3B/4A/4B Seismic zone IV & V certified Degree of Protection: IP 42 / IP 52 / IP 54 / IP 65 Bus bar: Aluminium or Copper Interleaved design of Main bus bar for ratings above 3200A Panels are functionally Color coded for easy identification of feeders TRF I/C- Blue, DG I/C- Orange, Bu Coupler- Off White, O/G Feeders- Siemens Grey RAL-7032 Voltage Rating 6.6KV/11 KV / 22KV / 33 KV Current Rating 6.6KV/11 KV- up to 3150A 22KV / 33 KV 1250A Fault level 11KV Panels - 20 KA / 26.3 KA / 31.5KA / 40kA for 3 sec 33 KV panels 31.5 KA for 3 Sec Internal Arc Tested Degree of Protection: Indoor Panel IP 4X Outdoor Panel IP 55 Overall dimensions: For 11kV (26.3KA) - Width: 600mm; Height: 2350mm; Depth: 1500mm For 11kV (40KA) - Width: 800mm; Height: 2350mm; Depth: 1500mm For 33kV (31.5KA) - Width: 1000mm; Height: 2700mm; Depth: 2100mm Conforms to IS & IEC Standards and is fully Type Tested. Solar CSS Compact enclosure housing inverter transfomer and RMU Available ratings are 1.26 MW, 1.75 MW & 2.0 MW High efficiency Grid-tie Inverters Low auxiliary power consumption Reactive power compensation also during the night time Active power limitation Low harmonic output current (<3%) High efficiency low loss transformer Highly reliable RMU from ABB Best in-class LT switchboard from Sterling Generators Remote monitoring through industrial type data communication option Compact and easy to maintain Integrated and flexible DC input cabinet Minimum onsite civil work Modular construction. Easy to transport Plug and play arrangement leads to less onsite execution time Thermally insulated high strength enclosure 6 7
TTA Panels Strategic tie up with M/s ABB for ArTuK Boards Compliance with IEC 61439 Rated Current upto 4000A Rated Service Voltage - upto 690V Rated Insulation Voltage: upto 1000V Rated Impulse withstand Voltage 8KV Rated Short time withstand Current - 105kA( 1S) & 50KA (3S) Construction of Panel: 2/ 3A / 3B / 4 Enclosure made up of Alu. Zinc Degree of protection: IP 31 / IP41 / IP 54/ IP 65 Bus bar: Copper or Aluminium Quality Manamgement SGPL is an ISO 9001 : 2008, DIN EN ISO 14001 : 2009 & BS OHSAS 18001 : 2007 certified company. Type Test Certifications LT Panels Panels type tested for short circuit levels of 50, 65, 75 & 100kA Panel type tested for 100KA with breaker in ON position Verification of temperature rise test Degree of protection IP:54/55 Verification of dielectric properties Verification of effectiveness of protective circuit Panels type tested for seismic zone-iv & V Form 4B construction HT Panels 11 KV panels type tested for short circuit level 26.3kA for 3 sec, & 33KV Panel at 31.5KA for 3 sec Panels type tested for degree of protection IP-4x Panel type tested for lightening impulse withstand test for 75kV & 195 KV Verification of temperature rise test Dry power frequency voltage withstand test Testing Equipment Conductivity meter Milli-Volt Test for checking joint resistance 4000A, Primary Injection set for Verification of Temperature Rise Primary injection kit for verification CT ratio Secondary - Injection Test kit for testing of Meters, Relays CT Polarity Testing kit 5KV High Voltage testing kit for LT Panels 80KV High Voltage testing set for HT Panels Megger for insulation resistance testing 2.5KV Earth Leakage tester Power Analyzer Draw Out MCC Rated current upto 4000A, Fault current upto 50KA for 1 Sec Degree of Protection- IP53 Fully compartmentalized design with Single & Double front configuration Three operating position of Service, Test & Isolate with locking facility in all positions Gravity operated safety shutters to cover live bus bars when trollies are removed All equal sized Draw-out units are fully interchangeable Safety shutters provide against accidental contact from vertical busbars Latest design of our Draw-out enclosure provide maintenance free vertical busbars without joint Self-aligning and disconnecting power and control contact Racking screw arrangement with telescopic rails system provide safe and smooth movement of trolley Modular construction with wide choice of compartment sizes with min size of 225 mm and max size of 900mm Hinged auxiliary doors inside main compartment door used for convenient mounting of control & indicating equipment Fully covered vertical bus bar chamber Draw-out contacts available from 32 amp to 630 amp 8 9
Our Clients Our Footprint Installations Ahmedabad Aurangabad Ludhiana Baddi, HP. Bangalore Baddi, HP Bhubaneshwar Bhuj Chennai Coimbatore Gwalior Cochin Gwalior Guwahati Bhuj Goa Hyderabad Vadodara Raipur Indore Jaipur Aurangabad Kolhapur Kolkata Kolhapur Lucknow Ludhiana Nagpur New Delhi Patna Pune Ranchi Surat Applications Tiruvananthapuram Head Office Installations Factory Tiruvananthapuram Vadodara Vizag Mumbai Silvassa Russia Nigeria International presence Abu Dhabi Dubai Lagos, Africa Nepal Nigeria Qatar Russia Saudi Arabia 10