19 Main Power Switchgears

Comprehensive power distribution system based on modular technology

For the new production hall of a food plant in Lower Silesia, we carried out a project involving the installation of 19 main power switchgears. This task required detailed project preparation as well as perfect organization of the prefabrication and installation stages. The result is a complete power distribution system based on PrismaSeT cabinets, which will serve as a foundation for the plant’s further development.

Project Challenges

At the design stage, we faced several difficulties:

Lack of a complete machine layout and uncertain connection information
Changes regarding operating parameters and power supply type
Inconsistencies in information flow, multiple file versions, and extended correspondence

Closer enforcement of information delivery schedules, organized documentation flow, and clarified responsibilities proved helpful.

Our Solution

Each of the 19 cabinets was individually designed, although standardization elements were introduced that will apply at the client in the future. We used modern technological solutions proposed by Schneider Electric, subject to strict verification:

PrismaSeT – easy-to-install modular enclosures, system solution for low-voltage switchgears
Linergy busbar system from Schneider Electric – part of PrismaSeT, hybrid aluminum and copper connection providing stable power distribution up to 2000 A
Modular withdrawable devices (plug-in) – shortens service time and allows quick reconfiguration
Specialized prefabrication tools, such as copper busbar benders and torque wrenches, ensuring precise execution and safety

Prefabrication was conducted according to PN-EN 61439, and each cabinet was tested and documented in FAT protocols and cabinet passports.

Conclusions and Best Practices

This project confirmed the importance of experience and discipline in managing projects. At the design stage, precise and timely data delivery by the client and its enforcement are crucial. Supplier information should be verified by engineers and prefabricators each time. Accelerating work must not affect quality – connection verification, testing, and compliance with standards are a priority. Strategic prefabrication planning (e.g., dividing cabinets into sections, optimal circuit layout) greatly facilitates later assembly and transport. Proper tools, training, and division of responsibilities in the team are an investment that increases safety and reliability.

Results for the client

Standardization of the power distribution system across the plant with PrismaSeT,
faster service and flexibility thanks to modular plug-in solutions,
safety and compliance confirmed by PN-EN 61439, FAT protocols, and documentation,
readiness for expansion – the system designed as a base for connecting additional machines and control systems.

Summary

Thanks to our team’s experience and the use of modern technologies, we delivered a switchgear system that not only meets today’s needs but also provides a solid foundation for the plant’s future development. We also established best practices, which you can read more about in the article: “How to Prepare for Electrical Switchgear Installation? Proven Advice from Our Engineers.”

ZW Automation – Driving Future Industries.