Bus duct Manufacturers in India | Powergear

Based at Chennai, India Powergear Limited is one of the leading bus duct manufacturers in India. Control panels. switchgear, high voltage substations are also part of their portfolio.

BUSDUCT

Isolated – Phase Busducts
Isolated Phase Busduct is a custom designed Busbar system enclosed in an aluminum duct forming the interconnection between Generator and Generator Transformer through Generator Circuit Breaker. Taps are taken to Unit Auxiliary Transformer, LAVT cubicle, Excitation Cubicle etc.

The Design & Construction of IPB are such that it reduces the short circuit forces to a very minimum, theoretically zero and also prevents the electromagnetic interference with a neighboring steel structure. This system ensures high reliability of the inter connection, which is one of the most vital and critical element in the successful operation of the Generating station. Powergear has 35 years of experience in designing and supplying such a highly reliable equipment for hundreds of Generators in about 20 countries throughout the world.

The IPB system consists of the following associated equipment:

Air Pressurization Equipment
Forced Air Cooling system, if required
Hot Air blower system
Various metering and protection CTs
GCB, LAVT, NG & Excitation cubicles
Galvanized Steel Structure for support of Busducts and GCB

The ratings under manufacture are:

Voltage rating up to 36KV
Continuous current rating up to 50kA
Short time current up to 800 kA –/200KA(rms)
The type testings are done up to the maximum testing capacity available in CPRI India or KEMA, HOLLAND.

Powergear also Supplies as per customer requirement associated equipment such as:

Hot air blower system
Air pressurization system
Forced Air Cooling System
Current Transformer
PTSP cubicle
NG cubicle
Support Steel Structure

Segregated Phase Busducts

Segregated Phase Busducts is a metallic enclosure housing busbar of all the three phases. The three phases are segregated from one another using Aluminum or Insulating barrier. The SPB is being used for interconnection between Transformer & Switchgear or Transformer to Transformer or Switchgear to Switchgear in Power Plants or in Heavy Industries.

Ratings under manufacture:

Voltage upto 15kv
Continuous current rating upto 5000Amps
Short time rating upto 65kA (rms)

Non – segregated phase Busducts

Non-Segregated Phase Busducts is the same as SPB mentioned above without phase barrier. These are generally used for low voltage application for interconnection between LV equipment like Transformers, Switchgears etc. For long length of low voltage NSPB, the voltage drop is very significant and hence special designs are being made to reduce the voltage drop to keep it as minimum as possible.

Ratings

Rated current range up to 5000A
Rated voltage range up to 415 V
Short time rating upto 65kA

CUBICLES AND PANELS

Generator Circuit Breaker Compartment

The Generator circuit breaker (GCB) compartment provides on-line isolation in the main power circuit between the generator and generator transformer using a vacuum or SF6 draw-out circuit breaker. Metal enclosed switchgear compartment houses both control and protection system components. Powergear has also designed mobile cubicles housing line side and neutral side bus bars along with Generator Circuit Breaker and corresponding equipment for metering and protection. Mobile GCB cubicles are mounted on a trailer and can be used for short term mobile power plants.

Features

Fully compartmentalized
Draw out and fixed types
Vacuum or SF6 circuit breaker for disconnection during fault condition
Non Draw-out and Draw-out type Potential Transformers
Operating aisle (if required)
Power connection by Busducts or by cables
Fire protection system (if required)
Off-load isolators and Earth switches
Aluminium or Copper conductors with Silver plated joints
Forced air-cooled option for higher current rating
Houses Current Transformers, Potential Transformers, Surge Arresters, Surge Capacitors etc.

Ratings

Voltages up to 24 kV
Continuous current up to 10,000 Amps
Multiple short circuit ratings as required
BIL up to 125 kV

Generator Line & Neutral Terminal Cubicles
Generator Line side cubicle houses the generator line side busbar systems along with corresponding protection and monitoring equipments. The metering / protection PTs and surge protection equipment are also housed inside the cubicle.

Similarly, Generator Neutral side cubicle also house houses neutral side and star formation bus systems, integrated with neutral grounding equipment along with monitoring and protection systems.

These cubicles are mounted on the frame of the generator and have suitable interface with Generator on one side and the Generator Busduct on the other side.

In some cases, both these line and neutral side cubicle are mounted in one large cubicle and this cubicle is mounted on the flange of the generator frame having interface with Generator Terminal on one side and Generator Busduct on the other.

These cubicles are also provided with hydrogen detectors (In the case of hydrogen cooled Generator) and PD sensors as per customer requirement.

Ratings

Voltage range upto 24 kV
Continuous current range upto 14000 Amps
Short time current rating upto – 250000 A

Specialised Custom Built – HV/MV/LV Cubicles

These cubicles are designed and manufactured according to the needs and specification of the customer to match the special / unique requirement.These cubicles made up of aluminium or steel sheet containing different types of Electrical Equipments like:

Busbar system
Metering and protection system
Draw-out / Non draw-out GCB
Draw-out / Non draw-out potential Transformer
Unit Auxiliary Transformer
DC Excitation Panel
Batteries and Battery charges
Climate Control systems
HMI

The construction is compartmentalised, compact and with operating aisle if required by customer.
Some of the specialised custom built cubicles are:

Generator Auxiliary compartment having Generator circuit breaker, Excitation transformer, D.C Rectifier Panel, Unit Auxiliary transformer, etc.
Mobile Power station cubicles
Excitation cubicle
Load commutated Inverter cubicle
Solar cubicles

Ratings

Voltages up to 15 kV
Continuous current up to 10,000 Amps
Short time rating upto 100kA

E-house

E-house is a prefabricated metal enclosed building housing various control equipments such as Generator Protection Panel, Turbine Protection Panel, Fire Management & suppression systems, Motor Control Centres, Vibration Monitoring systems, Batteries & Battery charges, climate control system etc. These cubicles are skid mounted, preassembled and climate controlled for use in power plant / manufacturing plants / oil and gas / marine industries. This walk-in cubicle is designed to form a nerve-centre of control of various plant

Advantages

Avoidance of Erection and Commissioning of individual cubicles at site and hence saving lot of time.
Elimination of wiring problem at site and hence commissioning time is reduced.
Less Civil works
Ease of installation
Possibility of outdoor installation
Centralised Control
Overall Economy

Motor Control Centers / Control Panels

Draw – out, internal arc withstand type of MCC and Control & Relay panels as per IEC or any other International standards are in the Manufacturing range.

Features

Pressurized air pumping system
Forced cooling
Possibility of fault is minimum
Operation at extreme ambient conditions
Insulated and ventilated enclosure
Walk-in aisle for operating personnel
Operation at extreme ambient conditions

Ratings

Rated current range up to 250000 A
Rated voltage range up to 24 KV

Short Time Current Disconnectors

Motorised high short time current withstand disconnectors are manufactured for use as Earthing | line disconnectors. The Dynamic Braking switch is required at Hydel station to reduce the run-down time of the Generator. This is achieved by shorting the stator phase terminals of the generator (once the unit is tripped) by means of Dynamic Braking Switch after the Excitation is removed. This 3-pole Switch is housed inside Aluminum Cubicle enclosure and rated for short time current.

Features

High operating reliability
Simple maintenance and Inspection
Simple and Reliable driving mechanism
Operated both Motor and Manual
Operation by specialized Motor, and there by smooth operation
Tested in accordance with the IEC

Installation Services by Powergear, the leading bus duct manufacturers in India.

Powergear leads the way not only in Busduct supply but in installation also. The high standards delivered over the years has moved PGL into the world arena and today its busducts installation work spans many countries.

High Voltage Substations

Powergear designs and builds HVSS upto 230KV and has proven expertise in right from foundation to commissioning. Some of the equipments are outsourced from very reliable suppliers.

These sub stations may be for Distribution purpose or switchyard for any Generating Stations.

Sub-stations in power distribution require top-notch installation expertise to work at optimum levels. Powergear is equipped to supply and install sub-station. Powergear has vast experience in the field and proven expertise in installing a range of sub-stations upto 230 kV.

RENEWABLE EQUIPMENTS by Powergear, the leading bus duct manufacturers in India.

Wind Tower
Powergear manufactures Wind towers in association with Gestamp Windsteel of Spain. Wind Towers are steel fabricated structures on which Nacelle and Blades are mounted. These are 80 to 100m in length and are conical with maximum diameter of 5m at bottom. Wind towers are split into 3 or 4 sections based on design and transported to site in specially designed trailers.

Wind Components
Powergear is a provider of electrical, mechanical and fabricated components to the wind industry with the motto of Cheaper, Faster & Better. Some of the components are manufactured in-house and some are procured from suppliers across the world to have highest quality, just in time and at the best possible cost.The components list is given below:

Cables & Wires
Wind bus
Cable Tray Systems
Conduit & Fittings
Enclosures & Boxes
Lighting kits
Safety switches
Copper braids
Fastners
Platforms
Door Assemblies
Door Frames
Trays
Mechanical fittings
Structural Products
Stickers

EPCM (Engineering, Procurement and Construction Management) by Powergear, the leading bus duct manufacturers in India.

Power Gear has been in the power industry for the past 30 Years. This provides an excellent platform to be a pioneer in the solar industry. The technical team has the experience of installing several On-Grid and Off-Grid solar power plants in the past few years. The marketing team has had interactions with several high profile clients thus bringing us up in the solar domain. Power Gear through its huge reputation have also joined hands with solar module manufacturers in other countries to offer better services to the clients at very competitive rates. Through the 4 manufacturing facilities in India, Power Gear limited also manufacture the AC side components of a solar power plant.

Research and developmental activities in the field of CPV and solar tracking are being pursued.

Solar EPC Consultancy
Solar AC side Products
Research & Development
Power Gear have entered the Solar EPC Business using the Technical and marketing team who have more than a decade experience in Solar in India.The following EPC services are provided to the customers.

Site survey at your land and Technological feasibility of solar power at your site
Initial and Detailed design in DC, AC, Structural and Civil for the client
Complete EPCM for concept to commissioning for a MW size solar plant
Operation & Maintenance support for a Power Plant

ELECTRO PLATING by Powergear, the leading bus duct manufacturers in India.

Electro Plating
Electro plating services are done in one of our group companies, who has one of the largest specialized electro plating facilities in Southern India with focus on Silver, Tin, Nickel and Zinc plating on Copper and Aluminum surface. Some of the products plated at our facility include copper tubes, Aluminum and Copper busbars, terminals, flats, plates among others. The facility has capabilities to handle large jobs of aluminium / copper fabricated parts, upto 3 Mtr Long Copper and Aluminum Busbars and up to 1100 OD Aluminum busbars.

The Plating services are:

Silver Electroplating on Copper Components
Silver Electroplating on Aluminum Components
TIN Electroplating on Copper Components
TIN Electroplating on Aluminum Components
Zinc Electroplating
Nickel Electroplating

Facility:
Fully Automated Plant
In – House LAB
Full fledged Effluent Treatment Plant ( ETP) strictly according to Government Regulation.
The electroplated components are supplied and/or used in equipment supplied to several leading companies such as General Electric, ABB, Siemens, Alstom, Areva, Melco in India, Canada, USA and China.

Components

Since inception in 1979, Powergear has provided electrical, mechanical and fabricated components for the power industry. Some of the components are manufactured in-house and other components are procured from suppliers across the world inorder to provide the components with the highest quality, just in-time at the best possible cost.

Our procurement team motto: Cheaper, Faster, Better

We Provide: