Manufacturing Process & Technical Standards

From concept to execution: An in-depth look at production stages and quality assurance at TPS Electrical

The Manufacturing Roadmap of a Standard Switchgear

1. Consultation & Engineering Design

Following technical consultation and requirements analysis, detailed schematics are drafted using specialized software such as EPLAN and AutoCAD Electrical.

2. Enclosure Fabrication

Cold-rolled steel sheets of standard thickness (1.5 to 2.5 mm) are CNC punched, bent, and welded into a robust panel framework.

3. Surface Pretreatment & Degreasing

Parts undergo a multi-stage chemical wash (degreasing and phosphating) to prepare the metal surface for optimal coating adhesion.

4. Electrostatic Powder Coating

Thermoset powder paint (RAL 7032 or 7035) is electrostatically applied and cured in baking ovens for maximum corrosion resistance and durability.

5. Electrical Component Assembly

Major components (circuit breakers, fuses, contactors) from certified brands are mounted on mounting plates and frames according to layout drawings.

6. Busbar Fabrication & Installation

Electrolytic copper busbars are calculated, cut, bent, and punched to current ratings and installed respecting standard clearance distances.

7. Wiring & Terminal Numbering

Control and power circuit wiring is routed neatly inside ducts with standard color coding, heat-shrink markers, and ferrule terminals.

8. Quality Control & Testing (QC / FAT)

Prior to dispatch, functional operation, insulation resistance (Megger), circuit continuity, and high-voltage dielectric (Hi-Pot) tests are carried out.

Compliance with International Standards

Quality and safety are inseparable pillars at TPS Electrical. All manufactured switchgear panels are designed and produced in strict accordance with the latest international IEC standards to deliver unmatched reliability and efficiency for your facility.

IEC 61439 Standard

The core standard for low-voltage switchgear assemblies defining strict design verification, construction, and testing requirements.
IEC 60529 Standard (IP Code)

Specifies the ingress protection rating of enclosures against dust, foreign objects, and water penetration (e.g., IP54, IP65).
IEC 62262 Standard (IK Code)

Defines the degree of protection provided by enclosures against external mechanical impacts (e.g., IK10).

Electrical Switchgear Technical Standards

Final testing and quality assurance adhering to IEC standards

Design & Manufacturing Workflow at TPS Electrical

From preliminary site assessment to final testing and commissioning

Project Assessment

Evaluating equipment lists, starting methods, site requirements, and operating conditions.

Engineering Design

Drafting Single-Line Diagrams (SLD), power & control schematics, and general arrangement (GA) drawings.

Component Sourcing

Selecting certified circuit breakers, contactors, protection relays, VFD drives, and automation gear.

Assembly & Wiring

Fabricating enclosures, component mounting, copper busbar arrangement, and power/control wiring.

Testing & Delivery

Rigorous QC, FAT functional checks, documentation prep, and readying panels for final handover.

Why Choose TPS Electrical for Switchgear Solutions?

Engineered Precision

Custom-engineered panels designed precisely around your project’s real-world specifications.

Custom Fabrication

Tailored panel dimensions, feeder configurations, and component selection to match exact requirements.

Quality Control

Comprehensive assembly audits, wire-by-wire inspection, and strict FAT performance testing.

Technical Support

Full on-site commissioning, operator handover, and long-term technical lifecycle support.