DESIGN ENGINEER – ELECTRICAL SWITCHGEAR (US MARKET)

Client:

Switchgear Manufacturer Company

Requirement:

Our client was tasked to design a 4000A switchgear system with utility power from a transformer and emergency power from four generators. The system needed to sync utility and emergency power, control and synchronize all generators, and fit into a single, space-constrained enclosure.

TekMinds Solution:

• Developed a custom enclosure to integrate breakers, disconnects, modules, transformer, and switches within limited space.
• Deepsea Module for main synchronization and SEL relay for generator protection and control.
• Developed a wiring schematic to sync both utility and emergency power along with all four generators.
• Detailed control scheme with precise numbering and terminal points.
• Adhered to NEMA standards for enclosure, wiring, and busbar spacing.

Impact:

The client received full approval for the custom enclosure and schematics, leading to 12 additional custom switchgear projects. Satisfied with TekMinds’ detailed work, the client is now considering MV switchgear solutions with us.

Client:

Critical Infrastructure Facility

Requirement:

The client needed a reliable EPO system to ensure safe and efficient shutdown of critical equipment (UPS, CRAC units, transfer fans, etc.) during emergencies. The system had to integrate with the building’s fire alarm, Clean Agent Control, and Preaction Systems to coordinate responses without disrupting fire suppression mechanisms.

TekMinds Solution:

1. Emergency Push Buttons: Designed wiring for immediate shutdown of critical equipment.
2. Control Relay Logic: Integrated multi-poled relays for automatic shutdown upon signals from fire and safety systems.
3. Dual Power Configuration: Created interlocked relay wiring for redundancy and continuous functionality.
4. Pilot Lights Monitoring: Added indicators for power availability, emergency activation, and system status.
5. Pilot Light Test System: Included a testing feature to ensure proper functionality during maintenance.

Impact:

• Improved Coordination: Seamless interaction between EPO and safety systems.
• Enhanced Safety: Reliable and rapid shutdown of critical equipment.
• Simplified Maintenance: Easy troubleshooting with pilot light testing.

The detailed design and documentation delivered a tailored, efficient EPO system meeting the client’s
operational needs

Client:

Panelboard Manufacturer

Requirement:

The client required a Motor Control Center (MCC) capable of managing multiple industrial motors and providing centralized control and protection. The design specifications included a 1200A main breaker, modular sections mounted back-to-back, with a combination of motor starters.

TekMinds Solution:

TekMinds designed a custom Motor Control Center (MCC) solution that addressed the client’s specific requirements for managing multiple industrial motors, providing centralized control and protection. The solution included:

• Optimized the MCC layout for easy maintenance and efficient use of floor space.
• Incorporated a range of motor starters (Size 5 to Size 1 CFVNR), ensuring precise motor control across various loads.
• Provided detailed elevation diagrams for seamless installation and troubleshooting.
• Delivered precise power and control wiring diagrams with flexibility for future expansions.

Impact:

By delivering precise, easy-to-follow drawings, TekMinds helped the client reduce installation time, leading to faster project completion. This success enabled the client to secure more MCC contracts and build a strong reputation for high-quality, customized solutions. With over 30 successful MCC projects, TekMinds’ reliable, flexible solutions enhanced operational efficiency and supported long-term business growth.

Client:

Panelboard Manufacturer

Requirement:

Design a layout and one-line drawing for a Siemens P5 panelboard, including both main breakers and branch breakers. Provide cable termination details for cable entry into the system.

TekMinds Solution:

• Developed a detailed layout and one-line as per client requirement.
• Provided precise cable termination details for CTs (current transformers) and connections to the main breaker.
• Ensured the optimal fit for three 500MCM cables in the panel.
• Searched and selected compatible lugs for the main breaker, allowing three cables (500MCM each) to be terminated per pole.

Impact:

The client received full approval for the panel, with particular praise for the cable termination design.

TekMinds’ expertise in designing custom and assembled panelboards ensures smooth approvals and seamless integration into client projects.

Client:

Control Panel Manufacturer

Requirement:

Design a multi-starter panel to operate a 125HP industrial pump, two blowers, a lube pump, and a liner wash pump. The client required automation, system protection, and a single enclosure to house all components.

TekMinds Solution:

• Developed a comprehensive BOM with calculated amperages for all motor starters.
• Incorporated a soft starter for the main 125HP pump and FVNR (Full Voltage Non-Reversing) starters for the remaining motors.
• Designed a custom enclosure to optimize space and accommodate all components.
• Automated the system using control relays which were receiving signals from PLC.
• Enhanced pump protection with disconnects and starters controlled by switches and remote signals.
• Provided detailed layout and wiring schematics with clear tagging for every component.

Impact:

The client received full approval for the panel, impressed by its compact design and advanced automation. This success led to multiple additional projects for industrial control panels, strengthening our partnership.

Client:

Control Panel Manufacturer

Requirement:

The client’s requirements included the design of a safe, efficient, and cost-effective Spiderbox featuring a contactor, TJB connector, and remote access for secure control and seamless power distribution.

TekMinds Solution:

• Designed a detailed wiring schematic for the Spiderbox, ensuring seamless power flow from the Camlocks through the breaker, contactor, and ultimately to the TJB connector. Every aspect of the TJB connector was meticulously analysed and wired to align with the client’s specific requirements and expectations
• Configured PLC contacts to enable remote functionality for precise control of the TJB connector.
• Integrated a 24VDC power supply derived from the 3-phase system to power the display.

Impact:

Empowered by the product’s innovative safety and efficient design, the client unlocked opportunities for multiple new projects. Client delivered the project on time enabling them to achieve greater success in their competitive market.

Client:

Control Panel Manufacturer

Requirement:

The client requested the development of a lighting control panel with features to effortlessly schedule lighting. They required a solution for commercial use that would automatically turn off lights in predefined areas when not needed and vice versa. Additionally, the client sought both manual and automated control options to meet their specific needs.

TekMinds Solution:

• • We developed a layout that included all the bulky components to be adjusted in the enclosure with optimal placement and no over-heating issue ensure the ventilation in the panel.
  • The control scheme included a Main breaker, lighting contactor, branch breakers, a SPD, a photocell and other components for control scheme.
  • The wiring schematic was developed with lighting contactor’s coil to be designed to work on Hand operation (LC coil is energized as soon as gets supply from main breaker) and Auto operation (LC coil is controlled by a photocell, energizing only when light is not detected). The contactor then supplies power to branch breakers.

Impact:

The client successfully secured the bid and was awarded the project promptly. The project was completed within a remarkably short timeframe and dispatched ahead of schedule.

The control scheme varies based on the specific requirements of the task. Tekminds specializes in customizing lighting control panels to meet the unique needs of each client.

Client:

Control Panel Manufacturer

Client Requirement:

Our client needed a custom-designed ground fault monitoring panel to improve electrical system safety and reliability. The panel had to detect ground faults quickly and accurately, with clear visual fault indications hrough LED indicators.

TekMinds Solution:

TekMinds engineered a ground fault monitoring panel utilizing the ground fault monitor. The solution included:

• Precise fault detection: The monitor ensures accurate and timely detection of ground faults.
• Clear visual indication: LED indicators provide immediate visual confirmation of fault conditions.

Impact:

The high-quality ground fault monitoring panel provided by TekMinds led to increased sales for the client. The solution’s reliability and advanced features helped the client secure multiple orders, boosting their market reputation and driving further business growth.

Client:

Manufacturing Plant

Requirement:

The client, a manufacturing plant, required a control system to optimize the operation of their oil pump and crusher motors. The oil pump motor was crucial for providing adequate lubrication to the crusher motor, both before and after its operation. The crusher motor, in turn, required precise control, contingent on the status of the oil pump motor to ensure efficient and reliable performance.

TekMinds Solution:

Our engineering team designed a control system that incorporated the following features:

• Timer Relays: Implemented On-Delay and Off-Delay timer relays to ensure the oil pump motor has a 3- minute pre-lube time before the crusher motor engages and a 6-minute post-lube time after the crusher motor disengages, providing adequate lubrication.
• Control Logic: Developed a control logic to coordinate the start/stop sequences of the motors, optimizing their operation and preventing premature wear.

By carefully synchronizing the operation of the oil pump and crusher motors, we ensured optimal lubrication and
efficient energy consumption.

Impact:

By implementing our solution, the client achieved:

• Improved Equipment Reliability: Reduced downtime and increased equipment lifespan.
• Enhanced Operational Efficiency: Optimized the production process and maximized output.
• Increased Safety: Mitigated the risk of accidents and equipment damage.
• Cost Savings: Lowered maintenance costs and improved overall productivity.

Through our expertise and innovative approach, we provided the client with a reliable and efficient control system
that met their specific needs

Client:

C&I Solar Project Developer

REQUIREMENT

The customer requires a ClawOS generated report to determine the most suitable racking system for their project.

TEKMINDS’ SOLUTION

Following steps are required to generate the clawOS report:

• • Create PV Layout: We design a customized photovoltaic layout in AutoCAD based on project requirements.
  • Generate .Json File: Convert the layout into a ClawOS-compatible .json file using the PanelClaw AutoCAD extension.
  • Upload to ClawOS: Submit the .json file on ClawOS to process the design data.
  • Provide the Report: Deliver the ClawOS-generated report, which includes insights on the best racking system and design optimizations for your project.

Impact:

Using the ClawOS-generated report, Client was able to save significant time in designing this and coordinating it with the OEM. We also made comparisons with other OEMs for BOM pricings so that the client could have an informed decision on which racking manufacturer to go with.

Client:

C&I Solar Project Developer

Requirement:

The client needed a 30% Coordination Set that required a detailed site plan and a comprehensive Single Line Diagram (SLD) to ensure clarity and alignment during the early stages of the project.

TekMinds Solution:

We delivered a comprehensive and efficient design solution of 97.49 kW DC / 83.30 kW AC solar system, tailored to the client’s specific requirements. The 30% coordination set includes:

A.   Detailed Site Plan Development

• Reviewed Client-Provided Construction Documents:
  Analysed construction documents to assess the site layout, structural details, and ensure optimal use of space while meeting safety requirements.
• Created a Precise and Optimized Site Plan:
  Designed a layout featuring PV arrays, strategically placed to maximize energy generation while adhering to safety and fire code setbacks.
• Mapped All Major Components:
  Identified and documented the locations of key components, including inverters, pull boxes, disconnects, and the interconnection point, providing clear guidance for the installation team.
• Integrated with Existing Equipment:
  Aligned the PV system layout with existing infrastructure such as utility transformers, panelboards, and generators, ensuring seamless utility coordination.

B. Single Line Diagram (SLD)

• Developed a detailed SLD showcasing the electrical flow of a 97.49 kW DC / 83.30 kW solar system.
• Illustrated connections between PV arrays, inverters, combiner panels, disconnects, and the utility interconnection point at 480Y/277V.
• Highlighted key safety features, including lockable disconnects and compliance with UL and NEC standards.
• Provided clear annotations for equipment specifications, voltage, and current ratings to guide installation and utility coordination.

Impact:

Our impactful designs and attention to detail earned the client’s trust, leading to an ongoing partnership where we now provide Issued for Construction (IFC) sets for their projects. This progression reflects our commitment to quality and meeting client expectations.

Client:

C&I Solar Project Developer

REQUIREMENT

The customer requires a feasibility report to assess the suitability of the site for solar installation.

TEKMINDS’ SOLUTION

The feasibility report we provide covers:

• • Wetlands and Environmental Impact: Using environmental databases and mapping tools, we identify nearby streams and wetlands, ensuring your project complies with ecological regulations.
  • Topographic Analysis: Leveraging GIS platforms and topographic resources, we generate precise contour maps (10 ft intervals) to design optimal layouts for your solar panels.
  • Soil Suitability: Soil reports from government and private databases help us evaluate the land’s structural stability, guaranteeing a solid foundation for your solar infrastructure.
  • Utility Easement Review: By referencing utility providers’ mapping systems, we assess proximity to electrical transmission lines, making grid connection straightforward and efficient.
  • Flood Zone Verification: Partnering with authoritative platforms like FEMA Flood Maps, we confirm that your site is safe from flood risks, protecting your investment from environmental hazards.
  • Zoning Information
    We assess local zoning regulations and land-use policies to ensure your project complies with legal requirements, avoiding potential delays or restrictions.

Impact:

In the early stages of your project, this detailed data offers clarity on site viability, ensuring you have the confidence to move forward or adjust plans as needed. Our site analysis minimizes risks, saving time and resources by highlighting potential challenges upfront.

Client:

C&I Solar Project Developer

REQUIREMENT

The client needed a IFC set of the same project. It includes Site Plan, PV String Map, UL 3741 Plan, Cable Scheduling, Single Line Diagram (SLD) and Placards to ensure clarity and alignment during the construction of the project.

TEKMINDS’ SOLUTION

We delivered a IFC set tailored to the client’s specific requirements. The IFC set includes:

• Site Plan: A detailed layout of the PV arrays and system components, ensuring accurate installation and integration with the existing infrastructure.
• PV Stringing Map: A clear diagram showing the wiring connections and string configuration for the PV arrays.
• UL 3741 Plan: A safety plan detailing the rapid shutdown procedures for the PV system in case of an emergency.
• Single Line Diagram (SLD): A visual representation of the electrical connections and flow, highlighting key components of the system.
• Cable Scheduling: A detailed wiring schedule designed in compliance with NEC codes, outlining cables and their connections to ensure proper electrical flow and adherence to safety standards.
• Placards: Electrical placards and labels for system identification, safety, and code compliance.

Impact:

Our IFC set ensured strict compliance with NEC standards and regulatory requirements, ultimately contributing to a streamlined installation and a successful project outcome. This thorough preparation also reinforced the client’s trust in our ability to deliver high-quality, accurate design solutions.

Client:

C&I EPC Contractor

Task Description:

Client was tasked to produce a detailed 30% plan set of a 957.95 KW DC / 760 KW AC Solar Power Plant, which contains the Overall Site Aerial Plan, Electrical One-line Diagram, Cables and Conduits Schedule, and Electrical Take-Off that includes the cable lengths of PV Strings, DC PV Combiners, Inverters, LV AC Panels, Switchgears to Transformers, and Transformers to MV AC Panels.

Client Provided Documents:

• Site Survey Reports
• Markups and Guidelines
• Data Sheets

Tekminds Solution:

1. Major Equipment Placement:
   Apart from marking the obstacles, existing electrical infrastructure, Tekminds designed the whole solar electrical infrastructure from selecting the equipment like solar panels, inverters, roof mounting racks, switchgear, transformers and cables to PV Placement, DC Combiners Placement, Inverter Placement, AC LV Panels Placement, Cable Trenches, DC PV Strings Cables Placement, DC Combiners Cables Placement, AC Inverters Cables Placement, AC Panels and Switchgear Cables Placement.
2. Electrical Single-line Drawing:
   Tekminds developed Electrical Single Line drawing for the flow of electrical construction of solar power plant. Also, illustrated connections between PV arrays, inverters, combiner panels, disconnects, transformers, auxiliaries, and existing grid side.
3. Electrical Take-Off:
   Apart from the summary of major equipment like solar panels, inverters, roof mounting racks, Tekminds calculated the cables lengths and sized them according to the NEC guidelines and specifications. Also, conduits, ducts, raceways, ray trays were sized according to the cables placement and size.

Impact:

1. Electrical Take Off helped client to calculate an accurate cost of the solar power plant, which will improve their financial analysis.
2. The 30% detailed designed plan set will be used for proposal or bidding purpose.
3. Later on more detailed layouts will be formed for the stamping and construction purposes.