EPR Magazine April 2015 by I-Tech Media Pvt Ltd

editorial Gas it up Has ‘achche din’ come to the Indian power sector yet? The latest initiatives from the power ministry are seem to be well-directed in this way and experts feel ‘achche din’ are certainly on the anvil! www.eprmagazine.com

I-Tech Media Pvt Ltd, 15/2, 2nd Floor, Chandroday Co-Op Society, Swastik Park, CST Road, Chembur, Mumbai - 400071. (India) Tel.: +91-22-32682214 / 15 GROUP EDITOR* Subhajit Roy Email: editor@eprmagazine.com EDITORIAL Dibyendu RoyChowdhury Shahzad Bagwan ADVERTISING Sanjay Poojary Email: sanjay@i-techmedia.com Call: +91-9975097047 SUBSCRIPTION subscribe@eprmagazine.com Telephone: +91-22-3268 2214/15 *responsible for selection of news under PRB Act

After years of struggle to meet demand-supply gap, the Indian power sector heaves a sigh of relief. Undeniably, the coal-based power plants were cruising through the most difficult phase, as coal block allocations were cancelled due to ‘coal gate’ unearthed. The same was in the case of gas-based power sector. About 10,000 MW of power capacities was lying idle due to lack of domestic availability of gas and high prices of imports. On a major move, with an aim to deal with shortage of fuel for coal-based power plants, the government has unlocked the potential through successful, transparent bidding of 34 coal mines. These mines are part of the 204 coal blocks whose allocation was cancelled by the Supreme Court in last year September after holding their allotment as illegal and arbitrary. Also, to revive and improve utilisation of the stranded gas-based power generation capacity in India, the government has recently approved a mechanism that envisages importing Regasified Liquified Natural Gas (RLNG) for power generation. In addition, the government’s decision of providing subsidy directly to the distribution companies for purchasing gas-based power is likely to be a game changer. With this move, electricity generation in the country expected to get enhanced by around 79 billion units, valued at about ` 42,000 crore. Let’s hope that ‘achche din’ starts rolling. Hope you’ll enjoy reading their experiences. Please do send me your comments at editor@eprmagazine.com

Printed and published by Subhajit Roy on behalf of I-Tech Media Pvt Ltd. and printed at Print, Process Offset Printers, B-23, Royal Industrial Estate, 5-B, Wadala, Mumbai-400031 and published from I-Tech Media Pvt Ltd. 1, Gayatri, Karumari Amman, Chheda Nagar, Chembur (West), Mumbai - 400089. Editor: Subhajit Roy All rights reserved. While all efforts are made to ensure that the information published is correct, Electrical & Power Review holds no responsibility for any unlikely errors that might occur. The information on products and services / technology on offer is being provided for the reference of readers. However, readers are cautioned to make inquiries and take their decisions on purchase or investment after consulting experts on the subject. Electrical & Power Review holds no responsibility for any decision taken by readers on the basis of information provided herein. Tel.: +91-22-32682214/15, +91-9821667357

APRIL 2015

Electrical & Power Review

Cover Story

Transformer market with a transforming future A detailed analysis on why the transformer industry is surely going to shine brighter

EPR PERSONALITY

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India, US joining hands for smarter energy Russell L. Conklin, US representative to ISGAN, talks about the positivity of the bilateral cooperation between India and the US

Dependability for successful smart energy deployments: Schomberg Richard Schomberg, Smart Grid System Committee Chairman, IEC, talks on the international roadmap for smart grid

Tech View

Innovation in distribution transformers for more energy conservation, protection

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Alstom helping smart city become smarter Laurent Schmitt, VP - Smart Grid Solutions, Alstom, shares how they integrate all kinds of power generation

Industry Analysis

Making wires and cables market success story

An analysis on how the wires and cables market is likely to show double digit growth for next 5 years ApRil 2015

Maintenance of transmission lines An article about preventive and predictive maintenance techniques in cold line and hot line conditions

One-on-one

Polycab targets export-focused expansion Inder Jaisinghani, Chairman and MD, Polycab Group, talks about the current scenario of cables and wires market

Marriage between what to do and what society needs Vinod Raphael, Country Business Head, Omron Electronic & Mechanical Components Division, shares how they are helping clients achieve what they want

A technical overview about the energysaving options by use of amorphous core transformers along with techno-economic solutions

Interview

Guest Column

Innovation

Thermal management for LEDs

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Power Update

An analysis on how ICs with smart over temperature protection help in increasing lifetime of LED lighting systems

Power Brand Trading Zone Electrical & Power Review

POWER UPDATE

Trina Solar receives UAS certificate from TUV Rheinland

Isolux Corsan completes first EPC project for Power Grid

Trina Solar Limited providing photovoltaic (“PV”) modules, solutions and services, has recently announced that its state key laboratory testing Center became the first testing center in the solar industry to receive the Power Measurement Uncertainty Assessment Service (“UAS”) Certificate from TUV Rheinland. This certificate validates the accuracy of on-site power measurements recorded at the Trina Solar state key laboratory testing center, following the certification all products assessed by the company’s state key laboratory testing center will carry a TUV Rheinland certification mark.

Isolux Corsan India, the Indian subsidiary of the European infrastructure company operating in the domestic sector, has announced that it has completed its first High Voltage Transmission line EPC project for Power Grid Corporation of India Limited (PGCIL). Isolux Corsan had undertaken the complete engineering, procurement and construction of 163.6 km of 765 kv single circuit transmission line on the PuneSolapur section in the state of Maharashtra. This line is a crucial link to the One Grid project of the Government of India, being executed by Power Grid Corporation of India Limited (PGCIL).

Trina Solar received the Power Measurement UAS Certificate from TUV Rheinland after seven months of continuous tracking, identifying key influencing factors, technique optimisation and rigorous on-site training. This certification proves that the procedures, test equipment and staff capabilities employed during the process of power output measurement at Trina Solar’s state key laboratory testing center are in accordance with stringent International Electro-technical Commission (IEC) standard as well as TUV Rheinland strict assessment criteria. The certification provides clear guidance to PV manufacturers and buyers on the power rating of PV modules, provides transparent information about the performance, and minimise measurement uncertainty of PV module output. It also helps manufacturers improve the accuracy of measurements and reduce measurement errors.

The project is set to unify the southern and western regions which will improve the process of distribution of electricity as and when the Krishnapatnam Ultra Mega Power Plant commences. Despite serious operational challenges like inhospitable terrain, land acquisition and inclement weather the project was completed within the stipulated timeframe. Speaking on the successful completion of the project, Jose Ruiz Hernandez, Managing Director, Isolux Corsan India said, “The new Government has taken up the agenda of bolstering India’s infrastructure which is crucial to the country’s economic growth. We, as a serious professional organisation in the space, want to be committed in accomplishing the task.” Isolux Corsan is the first Spanish company specialising in building major infrastructure to win an infrastructure concession in India and is also executing two more projects from PGCIL in Karnataka, and Uttarakhand.

CII signs MoU with Siemens and Hitachi The MoUs were signed by Chandrajit Banerjee, Director General, CII with Sunil Mathur, CEO and Managing Director, Siemens Ltd and Ichiro Iino, Managing Director, Hitachi India Ltd in the presence of Amitabh Kant, Secretary, Department of Industrial Policy & Promotion (DIPP) and HE Takeshi Yagi, ambassador of Japan.

The Confederation of the Indian Industry signed two separate Memoranda of Understandings (MoUs) with Siemens Ltd and Hitachi India Ltd to spearhead the conceptualisation and implementation of pilot projects in Smart Cities.

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CII has set up a “National Mission on Smart Cities” under the Chairmanship of Ravi Parthasarathy, Chairman, IL&FS and the objective of this Mission is to play the role of a facilitator and a thought leader to assist the government in the process of the development of 100 Smart Cities by 2022. The MoUs are

part of the implementation strategy to take forward the Cities initiative. Since a Smart City initiative in any city would entail a host of sub components including transportation, responsive public services, infrastructure for employment, ICT, etc, it would be beyond the scope of any one organisation to deliver seamlessly across these requirements. The National Mission on Smart Cities has therefore decided to create industryled consortia, which could render the full range of services for the development of a Smart City, in which Siemens Ltd and Hitachi India Ltd have consented to be the lead industry partner for the German and Japanese consortium.

Electrical & Power Review

POWER UPDATE

Crompton bags 3 orders to supply LED products Crompton has won three prestigious orders from Energy Efficiency Services Ltd. (EESL), a joint venture set up by the Power Ministry comprising of four public sector undertakings - NTPC, PFC, REC and Power Grid, for the implementation of energy efficiency projects in the country. Laurent Demortier, CEO and Crompton was the only player from Managing Director, CG the entire lighting industry to qualify for all three orders for energy efficient LED lamps from EESL, as per their technical and commercial requirements. According to the order, Crompton will supply close to 4 million LED lamps to EESL for its different projects, the first of which was launched in Andhra Pradesh to distribute 7W LED lamps to consumers at an affordable price, followed by the project in Delhi. The move is part of the government`s plan to boost energy efficiency through widespread use of Light Emitting Diode (LED) technology-based lighting solutions in the country. This will enable the government to offset power deficit in the country through energy conservation. Commenting on this win, Avantha Group Company CG`s CEO and Managing Director, Laurent Demortier, said: “We are honoured to receive this opportunity from the Power Ministry to partner with EESL and look forward to working with them in driving energy

conservation and efficiency in the country. Our strategy to localise the production and increasing the scale of manufacturing has been the key lever for our success in this highly competitive market.”

Praj, Gevo ink pact for RE technology Pune-based Praj Industries Ltd has signed a MoU to become a Gevo licensee for producing renewable isobutanol at sugar based ethanol plants. Under the MOU, Praj will undertake to license up to 250 million gallons of isobutanol capacity for sugar-based ethanol plants over the next 10 years. Gevo will market the isobutanol produced by Praj’s sub-licensees. Praj will also contribute process engineering and equipment services to expand isobutanol capacity at Gevo’s plant in Luverne, Minnesota, as well as to improve yields and optimise energy consumption at the facility. “Praj has conducted significant diligence on Gevo’s corn starchbased isobutanol technology and we believe in the technology,” said Pramod Chaudhari, Executive Chairman of Praj. “Isobutanol has a substantial market opportunity given that isobutanol is a high performance biofuel that can solve many of the issues of first generation biofuels. It is also a step closer to a true biorefinery model wherein a number of specialty chemicals and bio-products can be produced using isobutanol as a feedstock. We look forward to creating a new opportunity for first generation sugar-based ethanol plant owners, as well as accelerating the use of second generation cellulosic feedstocks to produce isobutanol to make an advanced biofuel.”

Sembcorp’s power plant commences its first phase Sembcorp Industries (Sembcorp) has announced that its first power project in India for Thermal Powertech Corporation India (TPCIL) has successfully commenced commercial operation with the completion of its first 660-megawatt unit. The 1,320-megawatt coal-fired power plant comprises two units of 660 megawatts each, with the second unit expected to begin commercial operation in the third quarter of 2015. With the completion of this first unit, the plant has already begun supplying power to the states of Andhra Pradesh and

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Telangana, helping to meet the increasing power demand in the southern region and supporting its economic growth. TPCIL has already secured power purchase agreements for 900 megawatts or almost 70 per cent of the plant’s capacity, of which 500 megawatts will be sold under a 25-year agreement with the Andhra Pradesh and Telangana Power Distribution Companies.

conventional coal-fired power plants, and is located in the coastal town of Krishnapatnam, Nellore, in Andhra Pradesh.

The US $1.5 billion investment power plant power utilises supercritical technology, which allows for enhanced efficiency and reduced emissions compared to other

The company is also developing its second thermal power project in India, which is a 1,320-megawatt coal-fired power plant expected for completion by 2016.

Sembcorp owns 65per cent stake in TPCIL through its wholly-owned subsidiary, Sembcorp Utilities, while Gayatri Energy Ventures, a wholly-owned subsidiary of Gayatri Projects, owns the remaining 35 per cent.

Electrical & Power Review

POWER UPDATE

Indsur expands to new markets eyeing “Make in India” initiative

natural gas pipeline system that will cross the Arabian Sea, can be completed within 48 months and worth $ 5.6 billion with 4% variation.

Indsur Global Ltd, manufacturers of Power Infrastructure Castings, has tied up with reputed Global Industrial Group (GIG) of Russia, a Power insulator manufacturer, for long term supply of castings. The initial commitment is for an order valued at $ 10 mn, which will be supplied in the next eighteen months. The supplies would commence from April. The contract was agreed upon and signed between Yaakov Denis, CEO, GIG Group and Amit Lodha, Director, Indsur Group, during former’s visit to India recently. It is important to note that prior to the arrangement, GIG Group was sourcing its supplies from China.

In this regard, the company’s CMD Ajay Kumar recently gave a detail oriented first level presentation to Petroleum Minister Dharmendra Pradhan in New Delhi. “A dual sized, single, pipeline from the Oman coast near Ra’s Al Jifan would be linked to DUQAM onshore and from Al DUQAM to the Indian coast at Gujarat via a mid-line re-compression station situated on the Qualhat Seamount (Murray ridge),” he said.

Commenting on the occasion, S.M. Lodha, Chairman, Indsur Group said, “We at Indsur have always believed in raising the bar when it comes to scale quality and cost efficiency. In doing so, we have become a supplier of choice to marquee global companies. The tie-up with GIG Group is yet another step that proves our commitment to sustained value creation for our stakeholders as well as for the nation.” He further added, “We are proud to advocate and Support the PM’s call for “Make in India” and are fully committed towards establishing India at the forefront of preferred sourcing destinations, globally. In last few years, we are proud to have successfully promoted “Make in India” brand quiet aggressively in European countries and against Chinese competition.

Fox Petroleum proposes Oman-India pipeline Fox Petroleum Ltd has proposed the Indian government to build the Oman –India Multi Purpose Pipeline (OIMPP) with 100 per cent investment from foreign funding. According to the company, the project – a deepwater, transnational,

During his presentation, Mr Kumar said, “Since India has serious security concerns with regard to pipeline projects over land, a deep sea pipeline is probably the most promising option. This 1,600-km OIMPP project intends to transport 8 tcft (trillion cubic feet) of natural gas to India over a period of 20 years. The pipeline is planned to be about 1,300 km long in phase one and 300 km more to connect Mumbai, laid at a depth of 3,400 metres below the seabed.”

Trina Solar to supply 48 MW of Solar Modules to ACME India Trina Solar Limited, provider of photovoltaic (“PV”) modules, solutions and services, has signed an agreement to supply 48MW of solar modules to ACME Cleantech Solutions Ltd (“ACME”). The new agreement brings the total sales of solar modules to ACME to 70 MW. According to the agreement, approximately 1, 88,000 Pieces of Honey modules TSM-PC05A will be installed on two ground-mounted solar power plants in India. The installations are expected to provide an annual output of 81.6 GWh. The shipment will be completed in the first quarter of this year.

Tata Power commissions unit 1 of Dagachhu hydro project in Bhutan Tata Power has commissioned 63 MW sized unit 1 of its 126 MW Dagachhu Hydro Power Corporation (DHPC) in Bhutan. The project is in line with Tata Power’s commitment to commission 120 MW of new Hydro Power Project this year as part of the centenary year celebration theme of Invisible Goodness, and is the first cross border project registered under UNFCCC’s Clean Development Mechanism (CDM). The Dagachhu project is a joint venture initiative between Tata Power (and Druk Green Power Corporation, owned by Royal Government of Bhutan (RGoB), and National Pension and Provident Fund of Bhutan.

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With the commissioning of the project, Tata Power’s total hydro generation capacity stands at 513 MW and overall capacity at 8,684 MW.

The Dagachhu project is the first cross-border CDM project that has led to other projects being cleared under the Clean Development Mechanism.

The Dagachhu Project is 126 MW (2X63 MW) run of river hydro project located in Dagana Dzongkhag, Bhutan.

The main promoter, ADB, has agreed to finance the 118 MW Nikachhu project and also expand on ADB’s involvement in Bhutan’s hydropower sector.

The commercial flow of energy generated from the Dagachhu project to India officially started at 00:30 hours in the morning (Bhutan time) on 21st February. The test run for the second unit of 63 MW will also be immediately started and expected to be completed soon.

This commissioning of the project marks a significant milestone on the 35th birth anniversary of the king of Bhutan and also Tata Power’s centenary year celebration of commissioning of its first hydro-unit in 1915 at Khopoli.

Electrical & Power Review

OPEN FORUM Imports have captured about 43 per cent of the market for electrical equipment in India. How are imports affecting the Indian electrical equipment market?

High time to impose duties on cheap imports There is a need to curb cheap, imported and low-quality electrical components which are forcing good quality domestic manufacturers to cut corners. We, as a nation, need to invest into innovation and latest technology. Itâ&#x20AC;&#x2122;s high time for the government to take steps by imposing duties on cheap, low-quality imports. - Himanshu Sharma; Sales Head - Industries & Contractors; OEMs, Railway, Hydrocarbon, Generation and SAARC; Energy Products Division; Raychem RPG

Indian manufacturers are well equipped We still need to watch out for the high rate of imports of EHV transformers, reactors, cables and insulators, which harm domestic production. Indian manufacturers are well equipped and have the capacity to manufacture these products. - Sunil Misra, Director General, IEEMA

APRIL 2015

Electrical & Power Review

OPEN FORUM

Imports are having a negative impact The electrical equipment sector in India comprises of more than 1,000 manufacturers and suppliers (organised segment), of which approximately 80 per cent are SMEs. Indian manufacturers have sufficient capacity to meet the domestic requirement of electrical equipment (both power generation as well as power transmission and distribution equipment). Imports, primarily cheaper electrical equipment, are having a negative impact on the domestic electrical industry. The low-capacity utilisation of the domestic manufacturers severely impacts business performance, hurting their top lines and bottom lines. Additionally, the cheaper imports of electrical equipment has resulted in poor quality equipment being used, severely impacting the performance of power plants. There are few instances of power plants of Independent Power Producers (IPP) with Chinese BTG equipment, where there have been component failures. Due to the absence of local servicing workshops of the Chinese BTG suppliers, equipment had to be sent back to China for repairs, adding logistics cost of transporting the equipment to China from India, resulting in power generation plants being shutdown. - Amol Kotwal, Director, Energy and Environment Practice, Frost & Sullivan

Innovation or development is really not taking place In terms of imports, we have not gone into our own basic R&Ds. Whatever government efforts have taken so far on the R&D, innovation or development is really not taking place. There is also a fad on discussing that imports are hurting us, but can we take care of the basics to underline the imports? - Rajiv Agrawal, Secretary, Indian Captive Power Producers Association

Electrical & Power Review

APRIL 2015

EPR PERSONALITY

India, US joining hands for smarter energy “The US and India have a very active energy dialogue which has been around since 2005,” remarks Russell L. Conklin, U.S. Representative to the International Smart Grid Action Network The International Smart Grid Action Network (ISGAN) brings together 25 countries from across five continents, including India and the United States, to advance the development and deployment of smarter, cleaner electricity grids around the world. It aims to improve global understanding of the value offered by smarter, cleaner electricity grids, to facilitate international peer-to-peer knowledge exchange and to share the latest on emerging best practices and tools. In an exclusive interview with Subhajit Roy, the U.S. representative to ISGAN, Russell L. Conklin shares how bilateral cooperation between India and the United States can help India become smarter in smart grid. How will the U.S. be a part of the smart grid initiative in India?

Both India and the United States are strongly interested in sharing knowledge on smarter grid technologies that can bring value for their electricity customers and citizens. The U.S. and Indian governments have a very active Energy Dialogue, which has been around since 2005. Under the Energy Dialogue’s Power and Energy Efficiency Working Group and similar arrangements, we are beginning to see progress on smart grids. This got a big boost at last year’s summit between India’s PM and the U.S. President, where there were a number of announcements on the energy sector that will be vital for smart grid progress. But the announcements are just the beginning, of course. Now we are in the more challenging work phases focused on how to implement this cooperation to effectively leverage each other’s knowledge and interests as well as the many

opportunities for the development of smart grids in India. We are focusing a lot on U.S. developed tools, models and frameworks. Many of these were developed by our public and private sector knowledge partners to satisfy the demands of the massive deployment of smart grid technologies under our 2009 stimulus bill. We want know what value we got as a nation from making these investments in smart grid infrastructure. But our frameworks also reflect what we think are the emerging trends in smart grids, such as transactive energy. I believe there is a tremendous value in the tools that we’ve developed, both domestically and for our international partners. Even if the tools do not translate perfectly to the Indian technical, regulatory and market situations, the principles and processes we used to develop them may hold value for India going forward. What are the market volumes you are projecting?

There have been some analyses done on what the total investment is going to be for fully modernising grids in the U.S., and this is on order of $300 billion to $900 billion over the next few decades. To put that in perspective, the stimulus bill had about $4.5 billion in grid modernisation funds, which leveraged a commensurate amount of private sector funds. So, it’s clear that this was just the beginning and much more investment will be needed to make our grids fully modern. Right now, there is a lot of work focused on fully understanding the costs of smart grids versus the benefits, especially how to define and capture the value Continued to 18

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Electrical & Power Review

EPR PERSONALITY

Dependability for successful Smart Energy deployments: Schomberg “Around the world, the dependability will be the next big challenge for smart energy, because dependability is like security or privacy which has to be built in by design from the very beginning,” says Richard Schomberg, Smart Grid System Committee Chairman, International Electrotechnical Commission (IEC) As the demand of reliable power supply is on the rise across the globe, smart grid deployments are universally pursued. On the sidelines of ISGW 2015, Richard Schomberg speaks to Subhajit Roy and talks on the international roadmap for smart grid and the role India can play. How do you look at the roadmap for India as the smart grid and smart city initiatives are concerned?

There are so many different things we can do. And also, each time the question is that how we are going to finance this. First of all, it is crucial to identify and decide on some targets to be reached. At many places around the world, people have been testing and developing many things but not really knowing what to reach. Then it is necessary to design some transition scenarios involving all the stakeholders in order to create conditions so that the very first steps get engaged. These transition scenarios can be very specific to the priorities of each country or region, but they are expecting to use the same global portfolio of solutions. The India Smart Grid Forum has elaborated a clear roadmap mid-2013, and the government of India gets involved at the highest level to decide on simple but powerful targets to provide the crucial 24X7 power, and the deployment of 150 GW of renewable generation and the 100 smart cities. There are four success factors that are extremely powerful for India. In India people are able to do things you cannot imagine doing as quickly in any other part of the world. India has the benefit of not to take care too much about

the legacy unlike many parts of the world where people have to build from existing assets whether it’s for electric systems or smart cities. In India people can work naturally in English which definitely allows accessing quickly the world experience on smart grids, what works and what doesn’t work. This will also facilitate the crucial training of the needed new workforce. Also India has an incredible talent pool to develop software. India has the mindset of integration, and smart grid and smart cities challenges are all about integration. For all these reasons, I think that real deployments will happen on a large scale in India even though it may take some time. You are in talks with the Indian authorities and Indian industry for a long time; how optimistic are you about the developments?

Relating to the smart cities and smart grids, there is a need to get things jump started. With the discussions, I have had with the authorities there is a real understanding of what it is about. A real consciousness of where might be the challenges to actually start doing anything, while staying well connected to the realities. When we start to pile up a lot of technologies, we are talking about integration, because we are looking for some value by connecting many parts. We are talking about huge number of intelligent nodes, operating in real time and tightly coupled. Therefore system engineering needs to be applied and the dependability has to be designed from day one. Dependability is the characteristic by which one can depend on the system. A lot of smart grid programmes have been started by deploying smart meters. Continued to 18

Electrical & Power Review

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EPR PERSONALITY Interview with Richard Schomberg Continued from 17 f

They have been deployed and operated for some time, and suddenly there was the concern about the security as soon as it was understood that there is a “connectdisconnect” switch on the meters. Hackers could take control of the metering infrastructure and trigger a blackout. And later on, the privacy issues started to be raised, as soon as people understood what the data allows to know about the users. Around the world, the dependability will be the next big challenge, because it is like security or privacy which has to be by design from the very beginning, because it simply cannot be added after the facts. This is something that can really be worked on. How do we manage this? We don’t see too many people talking about this. The vendor community, of course, might not be inclined to open up on this kind of discussion as it can be more frightening than enticing to do something. But I don’t say we shouldn’t do anything about this; we need to help decision makers making risk informed decisions to proactively invest in projects. This challenge is not specific to India per say, but to any very Interview with Russell L. Conklin Continued from 16 f

streams provided by integration of the many technologies under the umbrella of smart grid. We are finding that utilities are uncovering many benefits that they may not have anticipated before the technology was deployed out in the field. Taking these benefit streams into account is very important because there is still a lot of smart grid technology development, deployment and investment yet to come. It is going to be multi-decadal effort to create the kind of resilient, reliable, robust, cost-effective, secure, and flexible energy systems that we want to have ultimately.

large scale complex system design and deployment. We need to evaluate the lessons learned from pilot projects...

Of course, but the issue is which data and information can be accessed! Usually success stories are well documented and very often embellished, but who wants to document what has not been a success or even be a failure? All large corporations have their hard learnt lessons. It is all about trusted relations between the players; they don’t publish or spread data or information outside that could be misused. In fact it is possible to access valuable information with peer to peer interactions. The India Smart Grid Forum is very active and very well connected worldwide. I think it is providing to India a unique capability to promote India success stories but also to benefit from the worldwide experience. How will you be a part of the advent of smart grid?

Large utilities need to procure huge number of equipment on an open market from many different vendors in competition for

For smart cities and smart grid, which are the core areas you will be focussing on?

but may not be the right solution for every case. It is really looking at your local circumstances, meaning your customer base, market and regulatory structure, and installed infrastructure, all measured against your strategic objectives. Is your goal to have reliable electricity service? Are you facing a lot of extreme weather, where grid resilience becomes a principal challenge? Or are you dealing with issues regarding aging assets? If you identify the right suite of technologies for your situation, are there policies or maybe institutional structures that will not allow you to achieve your objectives? You need to address all of these facets together – technology, policy, regulation, institutions – to create a true, integrated smart grid.

I think technology integration. It is always dangerous to think that smart grids involve only one or two kinds of technologies. For a variety of reasons, a lot of people focus first on smart meters at the distribution level or on transmission infrastructure. Those are good solutions in many cases

Even so, technology has and will continue to be a driver, because it unlocks new possibilities. Right now, we are in a period of innovation for smart grids. Many of the technologies we need for them have already been invented. As happened when

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innovation and performance. For example ERDF the distribution utility in France is procuring annually €3 billion for business as usual to maintain the quality of service. The industrial strategy is to be able to use standards in order to organise a fair ecosystem in competition that can understand your needs and provide you with the solutions for today but most importantly for tomorrow. As in charge of industrial strategy for smart energy at a large utility, this is why I invest in the world standard development Will you be setting up a business unit in India?

I am here to promote sustainable development and advancing the use of standards to support industrial strategies which is a strategic key at the scale of India to make things happen. This has been understood by the Indian Government and the India Smart Grid Forum. It is critical that India keeps assigning to the international standards development key resources and representatives to support its goals, serve its major initiatives, and maximise its success rate. n

other new technologies were invented, we are now in the innovation period to try to figure out how to apply and, more importantly, to integrate these technologies in smart systems and, along with that, to create business models to make them economically viable. Throughout history, the technology inventors have often not been the innovators, who are the ones that make the technology work in the real world, in real markets. The inventor of the transistor was not the company that marketed it to the world. The inventors of the graphical user interface were not the ones who made it the norm for every computer and smart phone. So innovation and integration are interesting topics for me, especially given the complexity of smart grids and the way they cut across technology, regulation, and economics. Who will be the innovators for smart grids? I think there are many opportunities for the U.S. and India to collaborate on this. n

Electrical & Power Review

Cover Story

Transformer market with a transforming future

With new policies as well as ‘Make In India’ initiative, the transformer industry is surely going to shine brighter The global electrical equipment market is expected to increase from a cumulative size of more than $3 trillion (200815) to $ 6.8 trillion (2016-30), and transformers market is expected to have more than 30 per cent share. There has been an overall growth in most segments of the electrical equipment industry — transformers — due to the high demand from central and state power utilities. Growing transformer market The transformer market in India has been in a sound state for a few years now. “The market is further anticipated to witness sound healthy growth rates and empowering demand for the impending years,” believes Anil Kadam, Senior Manager - Solution Architect (Utility Segment), Schneider Electric India. “The government initiatives alongside the need of substitution of transformers introduced in the previous years are relied upon to drive development in the Indian transformers market. Schneider

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Electric India is a well-established manufacturer having capabilities to develop all type of transformers up to the 800 kV and 1,200 kV levels.” Anil Kumar Aggarwal, Chairman and Managing Director, PME Power Solutions (India) Ltd., also feels the same. He explains, “Transformer industry is completely geared up with latest innovations and technologies for manufacture of transformer of highest ratings, i.e. 1,500 MVA at 765 KV voltage class. The industry is capable of catering the demand or requirement of domestic market besides 50 per cent of the export requirements.” Industrial and commercial segment growth and transformers market The transformer industry is totally dependent on the load growth in the industrial and commercial sectors. “One cannot lose sight of growth in agriculture and domestic sectors, as

transformer industry caters to the later sector 30 per cent of the power utilised in the country,” says Mr Aggarwal. “At present, the installed capacity of the power generation is about 2,60,000 MW with maximum demand of 1,80,000 MW. The main hurdle in the growth of the sector is the availability of power in the country.”

Energy-efficient transformer can be manufactured in India to meet international requirements.

Anil Kadam, Senior Manager - Solution Architect (Utility Segment), Schneider Electric India

Electrical & Power Review

Cover Story For the past couple of decades, power planning had a great setback, as the planed schemes could not be completed in time and has only been accomplished not more than 50 per cent of the target. There is, now, ray of hope with the installation of the new government, since tangible progress in getting clearances of various power projects have been observed. Mr Aggarwal adds, “Recently, each of four UMPPs of 4,000 MW has been cleared for execution, still India has a long way to go in harnessing the resources in respect of fuel for supply both locally and import coupled with giving impetus to the renewal energy particularly solar energy for which the government has elaborate programme to add to 20,000 MW grid connected solar power by 2022. Unless sufficient power is injected in the system which itself needs equal augmentation to supply power to industry and to all other sectors. It is pointed out that the growth of railways is also tremendous in the coming years together with industrialisation and development of smart cities along the freight corridors earmarked by the government.” He also adds there is a tremendous scope of growth of transformer industry which has a crucial raw material problem. “As a president of ITMA, we have been striving hard with the Indian Government to arrange establishment of plants for manufacturing CRGO so that the dependence of industry on the import of CRGO is done away with,” remarks Mr

The industry is capable of catering the demand or requirement of domestic market besides 50 per cent of the export requirements.

Anil Kumar Aggarwal, CMD, PME Power Solutions (India) Ltd.

Electrical & Power Review

Aggarwal. “Transformer industry in India is already spending foreign exchange of $ 5,000 crore and equal amount for rotating machines industry, i.e. motors and generation, which uses CRNGO. About 50 per cent of its requirement is hardly produced or manufactured in India.” Addressing growing concern about imports Imports have captured about 43 per cent of the market for electrical equipment in India, and the transformer market is definitely facing some stiff competition from outside as cheaper imports from China and Korea have majorly impacted the industry. “This is a serious matter of concern as direct impact on small- and medium-sized transformer manufacturers,” opines Mr Kadam. “However, the government’s continued efforts to revive the power and the infrastructure sector augur very well for the transformers industry as both these sectors would need strong electrification which shall help the local players maintain a healthy growth rate.” Mr Aggarwal also echoes the same opinion. According to him, “It is a serious concern for the growth of electrical industry in India. At present, electrical industry contributes only 1 per cent of the global requirement which is going to be seriously affected if import is not stopped and virtually threatens the industrial growth. The Government of India has to device ways and means to stop the import by imposing the anti-dumping duties as well as provide incentives to the Indian industry so that the industry is at levelplaying field with the importers. It is understood that some measures are already in process with the government for implementation within the framework of WTO agreement.” Technological trends in the market The transformer business in India has grown rapidly in terms of technological advancements and now developed engineering base that prompts excellent completed items. Mr Kadam believes

that Indian players have a proven innovation and ability to manufacture a array of power transformers, distribution transformers and different sorts of special transformers for furnace, traction, converter duty and so on. Today, around 85 per cent of the transformers introduced in the Indian power network are of indigenous source. Energy-efficient transformer can be manufactured in India to meet international requirements. Research and development in transformer industry is a rigorous process for the transformer industry to adopt most modern trends and technologies in design and manufacture of transformers. “ITMA in a bid to update the technological advances globally arranges international conference on transformers, where experts from all over the world participate and interact with our engineers for adoption of new technology so that the transformers manufactured in India are acceptable in international market,” opines Mr Aggarwal. Mission 2012-2022 The Indian Electrical Equipment Industry Mission Plan 2012-2022 has planned to make India the country of choice for the production of electrical equipment and reach an output of $100 billion by balancing exports and imports. No doubt the next 5 years would be extremely crucial for the Indian electrical equipment industry as it prepares to meet the rapidly rising domestic demand. “Quality products at reasonable prices are the key differentiator in any market, and the transformer industry should continue to focus on R&D so that it can keep delivering superior products to its customers,” says Mr Kadam. However, the Modi Government is well aware about the present market scenario. With the innovative “Make in India” campaign as well as manufacturingfriendly Union Budget, the electrical equipment industry is surely going to shine. APRIL 2015

TECH VIEW

Innovation in distribution transformers for more energy conservation, protection A technical overview about the energy-saving options by use of amorphous core transformers along with techno-economic solutions technology upgradation, obsolete equipment, design deficiencies, oversizing of equipment, use of inefficient controls and so forth.

Electrical energy is the most popular form of energy being used as the main driving force in industrial units and power stations due to its versatility, easy to use and less pollution. The electrical energy is easily transferred from one voltage level circuit to another voltage level circuit by transformers which are static electrical equipment. These equipment are robust and sturdy which do not have any moving parts. Transformers require least maintenance compared to other electrical equipment. Due to the advancement in transformer core technology, new low loss transformers introduced. The transmission and distribution loss accounts for about 29 per cent of the total energy generated. In India, the T&D losses are on higher side compared to other developed countries due to lack of operational optimisation of equipment, ageing of equipment, hesitation in

The losses in transformers account for 3.6 per cent of total auxiliary power in a typical 210 MW plant and are in the range of 5 per cent to 16 per cent in process industries. Thus, due to acute shortage in power, it is essential to conserve the energy through minimising the transformer losses by design upgradation, use of low loss material, improved secondary load power factor, minimising the voltage and load unbalance, suppressing the harmonics and use of better quality of oil. The distribution transformer failure rate varies widely in different distribution companies. In BESCOM the average DTR failure rate is 8.27 per cent and is higher compared to other distribution companies of developed countries. The failure of distribution transformers is mainly due to exposed to changing weather conditions, lightning, due to lengthy LT lines prone to faults, and clashing of loosely strung LV lines, among others. Amorphous core transformers The iron losses in transformers form about 0.15 2.0 1.8 1.6

M: Magnetisation

Iron Loss, W/kg

1.4

Fig 1: Atomic arrangement of core material

1.2 CRGO Core

1.0 0.8 0.6 0.4

Amorphous Core

0.2 0.0

Fig 2: Magnetisation curve

APRIL 2015

1.0

1.1

1.2

1.4 1.5 1.3 Flux density, tesla

1.6

1.7

1.8

Fig 3: Variation of Iron loss with flux density

Electrical & Power Review

TECH VIEW per cent of total power transferred and 11.3 per cent of transformer losses. The iron losses account for 1.77-3.85 per cent of total input energy in an industry. These losses are mainly due to eddy current and hysteresis losses. In order to reduce these both iron losses, new amorphous cores are developed for transformers. Since the eddy current losses are proportional to square of thickness of laminations, the thickness of laminations of amorphous cores will be of the about 0.025 mm which is about 1/10th of laminations of silicon steel. This causes reduction of eddy current losses considerably.

The CSP system protects the transformer from lightning, secondary faults, severe overloads, provides visual warning of uneconomical loading conditions and protects the distribution system from line “lock-out” in the event of a transformer failure. For secondary fault and overload protection, the circuit breaker is mounted inside of the transformer and it is connected between the secondary winding and the secondary bushings, such that, the load current and fault current flows through the circuit breaker. For line “lock-out”, it is connected between the incoming high voltage lead from the bushing and the high voltage line.

Fig 4: View of Amorphous core transformer installed in field.

The overall reduction in iron losses (combination of both hysteresis and eddy current losses) in amorphous core transformer will reduced by 1/5th that of iron losses in silicon steel cores.

Primary fuse For a general distribution system, DISCOMs use a HG fuse on primary side of a distribution transformer for system protection which has following disadvantages:

The amorphous core has higher electrical resistance, i.e. 130 -cm which is almost triple of silicon steel cores (50 -cm). This higher resistance of amorphous core helps in reduction of eddy losses in core, i.e. when magnetic flux flows, eddy current flows to negate the flux.

• It is exposed to atmosphere which may mechanically weaken due to exposure to rain and adverse environmental conditions. • Vulnerable to tampering by consumers • Prone to replacing with non-standard fuse wires

Completely self protected (CSP) transformers The failure rate of distribution transformers in rural areas is more compared to urban areas. Wide variation in ambient conditions and loading pattern cause undesirable breathing and ingress of moisture which allow oxygen to come in contact with transformer oil. The moisture weakens the dielectric strength of oil that forms sludge which will restrict the natural circulation of oil inside transformer and also this sludge deposit of winding. Due to restriction in oil circulation cause increase in oil temperature and final winding temperature that may lead to failure of windings.

The purpose of this expulsion fuse is to protect the part of the electrical distribution system, which is ahead of the transformer from faults which occur inside of the distribution

Surge arrestor

Rating (kVA)

No Load Loss (W)

Load Loss (W)

Fig 6: View of CSP Transformer

Electrical & Power Review

Efficiency (per cent)

Impedance (per cent)

AMIT

SiFe-IT

AMIT

SiFe-IT

AMIT

SiFe-IT

AMIT

SiFe-IT

250

160

570

3200

4000

98.7

98.2

4.50

500

250

900

4800

6550

99.0

98.53

4.50

630

260

1000

5200

8000

99.1

98.54

4.75

750

365

1250

6050

9000

99.2

98.65

4.75

1000

450

1500

7650

11800

99.2

98.68

5.00

Table 2: Performance results of amorphous core and silicon steel core transformers

Circuit breaker operating handle

Signal light indicator HT fuse link

Fig 5: View of Amorphous core transformer installed in field.

55% free space for oil exansion

Fig 7: View of CSP Transformer installed in

Type/grade, mm

Thickness

Core loss at flux density of 1.7 T, W/kg

0.27

1.22

MOH

0.30

1.01

ZH 100

0.27

0.96

ZDKH

0.23

0.84

Metal glass alloy SA1

0.025

0.31

Table 1: The core losses for different grades of transformer cores

APRIL 2015

TECH VIEW

Fig 8: View of CSP Transformer installed in field.

transformer. If a fault occurs in the windings or some other part of the transformer, it will cause abnormally large currents to flow and the flow of these currents will cause the fuse to melt, open and clear the circuit. In this way, the fault is limited only to those customers who are served by this particular transformer and service is maintained on the rest of the system. When this type of fault exists, the transformer is no longer usable and must be removed from service for repair. Any fault ahead of the transformer will not be seen by any of the transformerâ&#x20AC;&#x2122;s internal protective devices and will have to be cleared by some other protective device upstream from the transformer. Secondary circuit breaker In the case of cyclic loads (containing peaks and valleys) where peak load is of relatively short duration, Transformers considerably smaller than the peak loads can be safely installed without any rapid loss of transformer life due to over load. The CSP circuit breaker will permit the transformer to function within cyclic loads up to the point where the amount and duration of the peak load begins to cause significant loss of transformer life. Surge arrester The surge arrester is installed to protect the transformer from lightning strikes. As the mounting of surge arrester closer to the transformer, the shorter will be the ground lead connection between the arrester and the transformer. The shorter connection will reduce the surge induced voltage stress on transformer winding. The mounting of surge arrester on the transformer tank, the ground lead length is effectively zero that help maximum protection. Dry type of transformers In dry-type transformers, air is used as the cooling and dielectric medium. Most

APRIL 2015

Fig 9: Conventional oil filled transformer with oil leakages in field.

are manufactured with vacuum pressure impregnation in polyester or silicone varnish. In oil-filled transformers, the cooling and dielectric media is a fluid which remains in a liquid state during the operation of the transformer. Dry type transformers can be located closer to the load unlike oil transformers which require special location and civil construction for safety reasons. Locating the transformers near the loads may lead to savings in cable costs and reduced electrical losses. Oil type transformers may require periodic sampling of the oil and more exhaustive maintenance procedures. However, though dry type transformers are advantageous, they are limited by size and voltage rating. Higher MVA ratings and voltage ratings may require the use of oil transformers alone. For outdoor applications, oil filled transformers are cheaper than dry types. Conclusion Transformers play a major role in power transmission and distribution system because the generator terminal voltage will be less due to constraints in insulation cost and transmission voltage will be high to curtail T&D loss. Since transformers are in the circuit all the time and iron losses will be continuously occurring, use of amorphous core transformers will reduce the iron losses by about 70 â&#x20AC;&#x201C; 75 per cent which helps in reduction of T&D losses considerably. Authored byâ&#x20AC;&#x201D; Rajashekar P. Mandi, Energy Efficiency & Renewable Energy Division, Central Power Research Institute (Bangalore) And Dr Udaykumar R. Yaragatti Dept. of Electrical & Electronic Engineering, National Institute of Technology (Surathkal) Electrical & Power Review

Interview

Alstom helping smart city become smarter “Alstom is a strong leader in IT and automation technologies for energy and transportation infrastructure and thus well-positioned in that space [smart city],” remarks Laurent Schmitt, Vice President, Smart Grid Solutions, Alstom Alstom is very active in global and local smart city projects. The organisation has built up a strong expertise and technological knowhow through many eco-city demonstration projects. In a conversation with EPR, Laurent Schmitt shares how Alstom successfully brings the knowledge and capacity to integrate all kinds of power generation. Alstom in developing smart cities A smart city is a concept of transversal optimisation to deliver energy, water, transportation, public health and safety, and other key services to empower cities to run better and control critical infrastructure operations while providing a clean, economic and safe environment to the people. For Alstom, it’s more than just a proof-of-concept. Alstom is very active in global and local smart city projects, building up a strong expertise and technological know-how through many eco-city demonstration projects that are under implementation worldwide such as Philadelphia, Las Vegas in the US, Dublin or Rotterdam in Europe. Alstom grid innovation is helping bridge the gap between existing technology and the rapidly evolving digital era with new information and telecommunication technologies. Alstom also brings the knowledge and capacity to integrate all kinds of power generation — renewable, thermal and storage — which translates into significant environmental, social, technological and economic savings for the cities. Helping smart city become smarter Alstom is a strong leader in IT and Electrical & Power Review

automation technologies for energy and transportation infrastructure and thus well-positioned in that space. It has already designed a reference smart city architecture, which can be used as a backbone for rapid smart city deployment. Alstom has the expertise in key smart grid technologies to reach the end consumer or the smart city, through partnerships. This strategy positions Alstom across the entire energy value chain from power generation to end consumer. Its different solutions are: • Real-time two-way information technology system • Energy storage capacity at city level, with integrated dynamic forecasting and communication technologies to store or incorporate renewable energy into the grid and help balance overall demand to production • Intermittent renewable energy integration on the city electrical grid: wind, solar, thermal • Distributed generation integration: connecting multiple renewable energy power plants and integrating islanding solutions (becoming autonomous) • Enabling use of plug-in electric vehicles therefore providing additional storage services.

Supporting smart city projects Alstom has the ability to improve urban energy management at the distribution level with ICT (information and communication technologies) and its leading software to optimise the use of electrical infrastructures and energy:

• Smart distribution grid — production, consumption and storage • Equipment and resources optimising energy efficiency, electricity consumption monitoring and cost savings • Common software architecture and open data monitoring and analysis platform • Multi-criteria visualisation (weather forecasts, end-user consumption, local clean energy generation)

Mission ‘100 smart cities’ In order to achieve 100 smart cities by 2020, the infrastructure including power, transportation, and water supply of these cities should be created in such a manner that it supports the population growth for the next five to six decades rather than addressing the immediate requirement. Further, the model should be flexible and allow for capacity addition in a quick time and without too much construction and associated hindrances. All the appliances should be energy efficient to ensure minimal power usage while facilities should be created to recycle water to the extent possible. Every single unit — whether its water or power — should be accounted for to curb transmission and distribution losses and pilferage. The road map should also ensure that all the stakeholders involved in generation and distribution of essential services should get the right price to put an end to the subsidy culture. APRIL 2015

Industry Analysis

Making wires and cables market success story An analysis on how the wires and cables market is likely to show double digit growth for next 5 years

The new government, the new policies, the “Make In India’ initiative, and a mission to make India the choice for the production of electrical equipment and reach an output of $100 billion by balancing exports and imports, the wires and cables market is in a such position from where success is just a step away. Growing wires and cables market The industrial and commercial segment is an important aspect for the growth of wires and cables market. “Wire and cable business growth is linked to power and infrastructure segment growth,” remarks Anil Krishna, Vice President, Borouge (India) Pvt. Ltd. “With auctioning of coal blocks to power producers, the sector is likely to show double digit growth for next 3-4 years.” Industrial production grew at the rate of 3.2 per cent YoY in the past 3 months which seems to be on a lower side, considering the sentiments shown by SENSEX recently. “Current sentiments and capital market movement speak volumes of growth destined to hit India in years to come,” explains Himanshu Sharma, Sales Head - Industries & Contractors; OEMs, Railway, Hydrocarbon, Generation and SAARC; Energy Products Division; Raychem RPG. “The government will ensure to turn the recent cyclical recovery into a sustained boom. We are benefiting hugely from a worldwide slump in energy prices. Consumer-price inflation has come down to 5.1 per cent

APRIL 2015

and current account deficit has shrunk with rupee being stable even under pressures.” With this Raychem is bound to get good capital for structural reforms for which people of India have given powerful mandate to Modi Government. “I am sure next 5 years will be a transformational era and we should see industrial segment growing at an average of more than 7 per cent,” opines Mr Sharma. “With this we should see a rebound in cable industry in Q3-Q4 of FY16 at the rate of more than 15 per cent YoY.” However, Nikhil Gupta, Executive Director - Cables, KEC International Ltd., sounds little cautious. His reason is that large part growth across manufacturing and infrastructure sector has been subdued. He adds, “Market sentiments have improved largely due to falling commodity prices but we are yet to see a turnaround. At the same time, the government has promised investment in railways, ports, smart cities renewable generation and distribution amongst others. This bodes well for cables market and we can expect it to grow annually at 10-12 per cent.” Concern of growing imports Imports have captured about 43 per cent of the market for electrical components in India. No doubt, it is a matter of serious concern. Wire and cable business is different than electrical component

business, and imports come due to global competition in big power generation and distribution projects. “For highvoltage cables, Indian manufacturers need government support perhaps in the form of duty exemption on imported raw material as there is no local supplier,” remarks Mr Krishna. “However, for lowvoltage cables, India has adequate capacity and expertise.” The time has come for the industry to raise the quality standards so that end users should prefer local products rather than cheap imports. According to Mr Gupta, “Imports have historically been higher in power equipment space, but cables import was around $800 million in 2014 while market is around $5 billion which places it at 18 per cent. Moreover, most of the

For high-voltage cables, Indian manufacturers need government support perhaps in the form of duty exemption on imported raw material as there is no local supplier.

Anil Krishna, Vice President, Borouge (India) Pvt. Ltd.

Electrical & Power Review

Industry Analysis imports have been in wire space apart from specialized cables coming from Thailand, Korea and Germany.”

of ultra-mega power projects. For solar and wind energy sectors, special highvoltage DC cables are required too.

Raychem tends to gain with global competition coming in by benchmarking and ensuring competitive productivity levels. “Low cost of imported equipment ensures decent ROI and low initial investments,” explains Mr Sharma.

Mr Gupta believes that producing good quality cables that meet standards is a challenge in India and focus will need to be lean manufacturing and tighter process control. He adds, “In EHV cables, we recently manufactured 220 kV, 2,000-sq.-mm. cable which is largest ever in India. As power requirements of urban areas increase, there will be demand for such large size cables to deliver bulk power reliably.”

Many big players like ABB and Siemens are now localising their electrical components to remain competitive in the market which in turn is helping domestic industry. Technological trends in the market The market is moving towards smart solutions and reducing human intervention. According to Mr Sharma, “The convergence of efforts towards minimising human errors and controlled energy consumption will emerge into new products which will revolutionise electrical industry. The government’s efforts towards renewable energy are taking centre stage and bound to become a success.” While talking about the technological trends, Mr Krishna says that with growing energy demand and urbanisation, there is urgent need to overhaul India’s power distribution system. He also discuss about moving towards underground cables for safety and security reasons. Demand for high-voltage cables is picking up with growing energy demand and coming up

Market sentiments have improved largely due to falling commodity prices but we are yet to see a turnaround.

Nikhil Gupta, Executive Director - Cables, KEC International Ltd

Electrical & Power Review

Taking businesses to next level What is the prime factor to take any business to the next level? Raychem RPG firmly believes in providing innovative products embedded in solution based value propositions. Mr Sharma says, “We initiated comprehensive sales training programme for the team to equip them to understand and deliver value propositions in marketplace. We also ramped up our services team with latest tools and training to enhance customer experience. There is a process in place through which we promptly brainstorm voice of the customer and come out with value-based propositions.” In order to bolster growth, Borouge has set up a LDPE plant of 3.5-lakh tonnes which is the base resin to make XLPE grades needed for cable insulation. With capacity to produce more than 1.5-lakh tonnes of cable grades, Borouge will be one of the major players in Asia for cable business. For KEC International, next growth will come from EHV and from new products. In EHV, the company has already 220kV KEMA type test certificate and is well positioned to cater to the increasing demand. At the same time, KEC International is looking to innovate and introduce customised products to suit local requirements. Mission 2012-2022 The Indian Government has made an ambitious plan. According to their Indian

Low cost of imported equipment ensures decent ROI and low initial investments.

Himanshu Sharma, Energy Products Division, Raychem RPG

Electrical Equipment Industry Mission Plan 2012-2022, the government has planned to make India the country of choice for the production of electrical equipment and reach an output of $100 billion by balancing exports and imports. “For this we have to see how far government is able to implement the industry friendly policy,” says Mr Krishna. “Starting from making land and infrastructure available for industry to be set up, single window clearances, labour law reforms, taxation policy all needs to be updated to meet global competition. In a democratic country like India, implementation and execution is always a challenge.” For “Make in India” initiative to succeed, as Mr Gupta describes, the government must make it easier for people to do business here and the decisions must be fast-tracked. He adds, “We must match the speed of development in other fastgrowing economies like China and hence push has to be towards competitiveness and global benchmarking.” Mr Sharma seems very optimistic and talks about innovation and believes that innovation has to play a big role in achieving exports target of $23 billion by 2022 as we must get first mover advantage to reap benefits in this competitive industry. The government should also support or rather subsidise innovation in power sector to make the Indian power industry a super success story. APRIL 2015

Guest Column

Maintenance of transmission lines This article covers information about the health diagnostic methods, as well as about preventive and predictive maintenance techniques in cold line and in hot line conditions Maintenance of transmission lines The transmission lines play a very important role in transmitting the huge quantum of electrical power generated at various generating stations to the whole area of the country from one end to other end over a distance of several hundreds of kilometers. By such transmission it is possible to distribute the power to the various types of customers through substations, at lowest possible line losses. For uninterrupted power supply it is essential to maintain the transmission lines in trim and healthy condition.

maintenance • Cold line maintenance • Deteriorated tower stub strengthening • Live Line Maintenance techniques  Live line maintenance by hot stick method.  Bare hand technique for system maintenance.  Hot line washing.

Ground patrolling is carried out by Inspection of the line, by walk down survey, and thorough patrolling by climbing on the tower through internal

body of the tower and observing the line components keeping safe body clearance. While visual inspection thermo- scanning, digital photograph of the components and corona detection by Daycor camera is carried out. • • • • • •

Tower foundation Tower earthing Nut-bolts Tower members Anti climbing devices Number plates, phase plate, danger boards • Clearances, as required by IE Rules • 1956 for Ground / river /canal /dam/

Fig 1: Thermovision report of dead end of 220 KV line 92.1 0C 30

For preventive and predictive maintenance of transmission lines following methods are applied. • Regular (monkey) thorough line patrolling with digital photography of the line components is carried out. • Thermo-graphic scanning for detecting Hot spots. • Punctured insulator detection by electric field measurement. • Punctured insulator detection by voltage measurement method. • Corona-Detection by Decor camera. • Resistance measurement of electric joint in live line condition (CRM). • Tower footing earth resistance measurement.

Various

techniques APRIL 2015

for

EHV

line

50 40 20 0.0 0C

IR Text Comment

Value

Tower No.

062

Phase

B Phase

Ckt. No.

End

Eklahare End

Object Distance

30 Mtr

Ambient Temp.

35.8

Humidity

60%

Load at the time

440 Amp.

Defects

Conductor seems damaged inside dead end joint

Recommendation

Dead end joint needs replacement Conductor seems damaged inside dead end joint

Object

Value

Emissivity

0.96

Label

Value

R: max

92.10c

LIO 1: max

92.10c

ARO1:

92.1 c 0

IR01 101 .

50 0

Line 101

M in 54.90C

Max 92.10C

Cursor -

Observation Conductor in Dead end needs replacement on priority

Electrical & Power Review

Guest Column length bands of x-rays, ultra violate rays. Visible light, infra red rays and microwaves as shown in Fig 2.

Fig 3: CRM instrument

• • • • •

• • • • • • • •

Modern health diagnostic methods for EHV lines Thermo-vision scanning: By Thermovision scanning hot spots on the line live components can be detected. Electromagnetic spectrum having wave X-rays UV(corona) VL

1 nm

240nm

280nm

400nm

700nm

MICR0

1mm(1x106nm)

(1 m=103mm= 106 am = 109nm=1012am) Angstrom=1000nm

Fig 2: Wave length bands

Electrical & Power Review

It measures the voltage drop, the line current, and the calculated resistance is displayed. The ratio of the resistance of the joint (Rj) and the reference resistance of equal length of the conductor (Rc) indicates the condition of the joint. The value Rj / Rc should be < 1 for healthy joint. The ratio > 3 is serious, needs urgent replacement.

Fig 4: CRM of dead end joint

Fig 5: PID using positron instrument by RPL crew File Log/Lin

Punctured insulator detection using positron instrument by electric field measurement (PID): The positron instrument detects punctured insulator in the string by measuring the electric field across the insulator. The electric field across the punctured insulator is less as compared to healthy insulator.

inear

E field (KV/m)

• • • •

structure/ Buildings / Road/ Tree/ Railway/ HT- LT lines/ telephone line crossing, etc. are checked Broken disc insulator Flashover disc insulator Contaminated disc insulator Split pins / cotter pins/ W pin/ hangers Conductor and earth wire hardware (tension and suspension hardware, mid span joint) Conductor condition Jumper condition Repair sleeve Sag and ground clearance Tack welding to the nuts and bolts of tower Tower members missing Armouring, suspension clamp, split pin Conductor spacer Vibration dampers for conductor and earth wire Earth wire fittings flexible earth bond, jumper Mid span joint and repair sleeve Bird guard Conductor and conductor fittings Armour rod, suspension hardware Insulator and insulator fittings, hanger, eye bolt, yoke plate, nut- bolts Corona measurement Thermo-vision scanning.

Measurement of resistance of electric joint in live line condition (CRM): The sophisticated instrument (live line micro ohm meter) is designed to be attached directly to an energised EHV line through a hot stick and directly reads the resistance in micro ohms. Live line Micro ohm meter is designed to store up to 9 sets of readings.

100 90807060504030- 1 20- 5 10C 1

1 0

1 0 0

1 0 0 0 0

1 0 0

Session : 2009_3_06 16_31_26.PRN 12 strings

Punctured insulator detection by voltage measurement method using Ritz’s instrument:

1 0 0 0 0

147 1 0 0

220 KV AKOLA TO BANDERA D/C LINE CKT1

2 0f 12

100

Forward 2008/03/06 PTESTER IR2 Backward t=48 seconds

1 0 0 0 0

Insulator number B PH LOC.NO 232 CP

Fig 6: PID graph & IR values of the defective string taken after string replacement

The Ritz’s instrument detects punctured insulator in the string by measuring the voltage across the insulator. The voltage across the punctured insulator is zero. Coronagraphy by Daycor camera: When voltage on an electrical conductor exceeds threshold value, the air around it begins to ionise to form a blue or purple glow and produces hissing noise. Corona is the polarisation of air molecules due to energy on high voltage. Electromagnetic spectrum having wave length bands of x-rays, ultra violate rays. Visible light, infra red rays and Micro waves as shown in Fig 9.

Fig 7: PID by voltage measurement method with Ritz’s instrument

Tower footing earth resistance: Tower footing earth resistance is measured by the instrument earth tester. The limit for the tower footing earth resistance is 10 ohms. After seeing the modern health diagnostic methods for EHV lines let us APRIL 2015

1 0 0 0 0

BADNERA

Guest Column

Fig 8: Corona detected on 400 KV insulator string

X-rays UV(corona) VL

240nm

1 nm

280nm

400nm

700nm

MICR0

1mm(1x106nm)

(1 m=103mm= 106 am = 109nm=1012am) Angstrom=1000nm

Fig 9: Wave length bands

see the various techniques for EHV line maintenance as below.

In hot stick method the works are carried out by using hot line tools.

Cold line maintenance In the cold line method the maintenance is carried out by availing outage on the line. The works of replacement of defective insulator strings, tightening loose nuts and bolts of the joints, cold line Insulator washing etc. and defects noticed in the thorough line patrolling are rectified, however since there is interruption in the line, there is huge revenue loss and customer’s dissatisfaction, which are the main disadvantages of cold line maintenance. Therefore hot line (live line) maintenance is highly preferable and adopted where ever possible.

Bare hand technique for system maintenance It is based on faraday’s principle. Therefore, when a lineman is shielded in Faraday’s cage wearing Conductive Suit and it gets bonded to an energised conductor, he can work on the conductor and associated hard ware without shock or discomfort.

Live line maintenance Advantages of hot line technique

Fig 10: Replacement of 132 Kv suspension string by hot stick method

•

• Fig 11: Live line string replacement through bare hand technique at 400 Kv line by RPL crew

•

Fig 12: Hot line insulator washing for 400 Kv line

APRIL 2015

• No outage, so no interruption to consumers • No revenue loss • Problem is attended immediately, loose nut-bolts can be tightened by hot line technique and breakdown is avoided. Hence no interruption • Emergency outage is avoided • Contaminated disc insulators can be cleaned by hot line washing, so flashover of disc insulators resulting in to break-down can be avoided Punctured insulator can be detected with hot stick attached to punctured insulator detecting instrument either by Electric field measurement method or by Voltage measurement method. The punctured insulator can be replaced in live line Hot spots noticed during thermo graphic scanning can be attended by hot stick method or by bare hand technique as preventive maintenance Defective jumper can be relieved from the danger of breakdown by providing parallel jumper and emergency is avoided Very less man-power and very less time is required as compared to cold line method.

Live line maintenance by hot stick method

Hot line tools The tools required for hot line work are made as per IEC 60832, 60895 and 61478. • Tool head required to operate (heat treated aluminium alloy which is used in aero plane) • Hot sticks on which the tool is fitted were previously made of wooden handles, but they were heavy. Now epoxy glass handles are used • Engineers and the line men should be trained and authorised for hot line work. Training centres in India are at, Bengaluru (Karnataka) and Gangawal (Punjab) • Conductive suit, hand gloves, socks (woven from thin stainless steel wires and special type of fibers), boots and static belts are also manufactured on above principle • Hot line ladder and swivel sticks (manufactured from epoxy-glass) and adjustable ladder hook. Strain sticks, insulating cradle, tie sticks, roller link sticks, suspension, gin poles, cum along clamps, strain carrier sticks, double string dead end insulator toll, yoke plates, nylon and poly propylene rope, etc. • Ladder monitor kit: To detect micro ampere leakage through the ladder, this monitor kit is connected before it is placed into use and periodical readings are taken during work progress to ensure safe working condition.

Hot line washing The insulators of lines and equipment are contaminated due to dust, bird droppings, chemical pollution, industrial Electrical & Power Review

Guest Column pollution, saline weather, smoke due to vehicle exhaust, agricultural burning, volcanic ash etc. The contaminated insulators are susceptible for flashover during humid atmosphere, Drizzling, dew or foggy weather etc. hence need to be cleaned. The contaminated insulators can be cleaned by hot line washing method for lines including 400 Kv level. • When de-mineralised water jet at very high pressure (300 to 800 psi) is released in the air, the water particles split due to air resistance and so the water path is not continuous, offering the sufficient electrical resistivity more than 30,000 ohm - cm. For better cleaning high pressure compact stream is maintained. • Probe system can be used for continuous monitoring of water conductivity. A light or audible warning and pump throttle control can be integrated in to monitor circuit. • For hot line washing water used should have conductivity less than 200 micro mhos per CC to avoid leakage current. • The high pressure water jet is created by electric motor pump or diesel engine operated pump.

Stub strengthening Since, the transmission line towers are working in agricultural fields, industrial

Fig 13: Stub strengthening by MRF PU speciality coating system by RPL

Electrical & Power Review

areas, sea shore areas etc. and the tower foundation is embedded in ground, the tower stubs get heavily rusted in life span of about 10-15 years. The major causes for deterioration are wet, marshy soil around tower stubs on account of rain and drain water, watering of crops by cultivators, chemical reaction due to fertilisers and chemicals, in the farms as well as in industrial areas. It is necessary to inspect the tower stubs condition if those are deteriorated and such towers are likely to fall in stormy weather. Hence, the deteriorated tower stubs need to be repaired and strengthened. Tower Stub strengthening process • The area around the tower leg is cleaned • Area of one meter wide and one meter deep is excavated around the leg so as to make a room for the process • Chimney concrete of the tower stub is broken by vibro hammer • The rusted portion of the stub is thoroughly cleaned using power tools • Phospating is done to avoid corrosion. This helps to get perfect etching • Two nos M.S. angle of the same size as the stub, which are pre-treated in the factory for anti-rusting and notching is done for perfect fitting • The angles are welded with specialised welding procedure • Then the welded surfaces are thoroughly cleaned by MRF cleaning agent and protected from rusting by applying special MRF anticorrosive solution • Anti-corrosive, low viscosity epoxy resin is filled up in the cavity in between old and new stub angles • Then after the whole joint is sealed by specialized MRF putty to make the surface plain and leak proof and MRF special paint is applied • Joint is wrapped with glass wool, fibre mesh clothing giving extra protection to the stub.

• In re-concreting process homogeneous jointing of old and new concrete, special bonding agent which is a specific epoxy adhesive is applied over the surface of the old concrete before final concreting is started • Advanced machines like needle vibrator for re-concreting process are used • In the concrete special fibre mesh fibre is mixed which gets uniformly dispersed in the concrete as millions of fibres in every cubic metre • For achieving perfect waterproofing of newly cast sub concrete, special 100 per cent MRF PU paint is applied • The concrete is cured by using a curing catalyst for avoiding excess watering • The concrete portion and the tower leg are painted • And finally the remaining pit portion around the concrete is backfilled with soil by compacting the layers • Thus finally a strong waterproof and anti-rust structure is developed for the tower stub which avoids possibility of tower collapsing due to corroded stub and ensures long and healthy life for the tower lines. Authored by__

Sudhir S. Kulkarni, Technical Director, RPL. The author is Technical Director in Ramelex Pvt. Ltd, Pune since last 11 years. He retired as Superintending Engineer (EHV), MSEB-Pune. Ramelex Pvt. Ltd. is a company founded by Mr. Ram B Jogdand, Chairman and Managing Director in the year 1990. The company provides services in the field of line and substation, construction and maintenance, health diagnostic methods and preventive and predictive maintenance activities in cold line as well as in Hot line techniques. It also manufactures electric power connectors and conductor accessories and insulator hardware up to 400 Kv level for ACSR, AAAC as well as for HTLS conductors.

APRIL 2015

One-on-one

Polycab targets export-focused expansion “The key focus area for us is the oil and gas sector, specifically in the MENA region, which has tremendous growth potential,” says Inder Jaisinghani, Chairman and MD, Polycab Group

With a turnover of ` 4,500 crores during last fiscal, Polycab is one of the leading cables and wires players in India. In an exclusive interview with EPR, Inder Jaisinghani discusses a broad range of topics that includes current market scenario and Polycab’s growth strategies.

and switchgear units in Bhiwandi and Nasik in Maharashtra and also LED light unit in Bhiwandi. To enhance our distribution capacities we have recently set up four warehouses at Bhiwandi, Rewari, Bengaluru and Kolkata.

The electric wires and cables market is expected to witness rapid growth in the coming years. What are your strategies in gaining more market share? Polycab is a ` 4,500 crores group at present and expects to be a ` 10,000 crores group within the next five years. At present we are at an interesting stage of evolution. We are blending some outstanding professionals into the company to augment the tremendous entrepreneurial success.

What about enhancing export opportunities and setting up of facility outside India? Our export market is poised to grow every year by 40 to 50 per cent. The key focus area for us is the oil and gas sector, specifically in the MENA region, which has tremendous growth potential. Due to the complexity of the cables required and also quality of the cables being of prime importance, it is the ideal platform for Polycab to capture the oil and gas markets. Our focus is on markets such as GCC, UAE and Africa.

To achieve more market share we are implementing on few strategies which include capacity expansion, hiring more professional, enhancing our distribution networks and increasing our exports. Could you brief us on the latest development at Polycab? Currently we are in the process of entering new segments such as optical fibre cables, solar power cables, and rubber cables. We are also expanding our B2C portfolio such as premium range decorative fans, LED lights, conduit pipes, switches and switchgears for housing sector. We have recently established a fan manufacturing facility at Roorkie, switch

At present, we do not have any plans to set up facility outside India. What are the challenges the sector is facing? The cable industry’s growth is relatively proportional to the country’s overall economic growth. The current situation is slightly murky. Political uncertainty, lack of decision making, hesitation in launching the next stage of economic reforms, commodity price fluctuations and pressures on the forex front are all contributory factors to a sluggish industrial growth. Power generation plants which are a major driver of our growth are on hold. Continued to 34

APRIL 2015

Electrical & Power Review

One-on-one

Marriage between what to do and what society needs “Our focus will be at the metering side at first, wherein we will try to focus on our strong products such as AC Latching relays and sensing solutions for optimal energy management and reduction of power losses,” says Vinod Raphael, Country Business Head, Omron Electronic & Mechanical Components Division, India

Omron is focussing on India, creating new solutions and products for the energy market by integrating its different business units. The sensing company has also decided to contribute in minimising the power losses with its sensing technology and solutions. In an exclusive interview with Subhajit Roy, Vinod Raphael shares how Omron is bridging between what it wants to do and what the society needs. How do you look at the opportunities for Omron’s business regards to the smart grid initiative? Our corporate philosophy is to work for the benefit of the society and people. All our products, concepts and solutions are based on how it can benefit to the society. That is the reason why Omron has chosen the energy markets. We understand that at the macro level, there is big gap between the demand and supply of power. When you go in the micro level, it is not exactly the issue with the demand and supply alone; a lot of losses happen on the transmission and distribution side too. We have both sensing and control technology, so we try to conceptualise the concept in which both our strong points (i.e. sensing and control) can help to make new products. This, we feel, can eventually help the government and the distribution companies to reduce the power losses. We are working on a very small portion of smart grids, as we know smart grid is a big infrastructure altogether. Our focus

will be at the metering side at first. As far as the market is concerned, I think everyone knows that the smart grid and smart meters market is set to grow hugely. It’s the beginning at the moment, but I think the government is very ambitious with its plans. It’s said that by 2027, all the households in India will have smart meters. The market is huge, and our solutions will benefit the power issues of the society. That is the reason there is marriage between what Omron wants to do and what the society needs. Will your particular focus be on making smart meters? We do not make smart meters, but we make products which fit into smart meters such as AC power latching relays, sensors and switches. Omron is a company which has diversified interests with a lot of different kinds of solutions and products. At the end of the day, we are a company driven by market need. We identify this as the starting point of what to do first, but in the long run Omron as a corporate will look to the total energy market in India. We work towards combining business units and divisions to come out with products and solutions to support the market. In the Indian energy sectors, the core challenges are the aging infrastructure, cost and reliability. In which core areas, are you going to focus on the larger aspect? Omron has been known as a technology innovator in Japan where we started. We want to work as the market- in approach Continued to 34

Electrical & Power Review

APRIL 2015

One-on-one Interview with Vinod Raphael Continued from 33 f

rather than product- out of approach. First we gather what is the requirement of the society and what is the requirement of the customer and then we create anything that suits the market based on our fundamental technologies. It’s a bit early to say what kind of things we will do, because the market itself is in premature stage. As things move on, we will utilise this particular opportunity of getting into the market with some sensing solutions and then look for expansion. We will gather more information on the core issues and will go ahead step-by-step. With the help of our advanced R&D centre in Keihanna (Japan), we have been able to create solutions and products based on the society needs. Are you more focussed on the Indian market, sensing the opportunities in the market, or trying to create a kind of synergy for smart grids and smart cities? Omron has a 10-year long-term plan from 2011 to 2020 called as the value generation plan. The major focus of this plan is to generate value. There is a basic difference between how to generate value and how to create products. Emerging countries are top priority, and when we talk about emerging countries, India is at top of the list for Omron. Moreover, India’s good relationship with

Japan generates optimism for us and, hopefully, will prove very helpful. Is there any major investment plans for the Indian market? In terms of investment, it may not be feasible to divulge much as of now, however, as just mentioned India is indeed a very important destination in the value generation plan of Omron. We aim to expand the business and generate value and serve the Indian society needs effectively. When can we expect your new products for the smart metering? We are in the process and will be able to come out with the solutions very soon. We are not just talking about the products; our idea is to make product and solutions. Just to reiterate, we are focussing on India for creating new solutions and products for the energy market by integrating our different business units.

Amidst all these challenges, pushing the idea of smart grids and smart cities will benefit in the long run to the societies. How to balance these two things? In terms of spending, policies and so forth are huge challenges. There will be soft implementations in the next few years with the pilot projects which we have implemented. But in the full scale, we will take some time, so the market will expand very rapidly by 2018-19 for smart grids. To share your article or case study in this section, write us at editor@eprmagazine.com Next issue focus: l Power equipment l lighting l Cables l Pumps & valves l Concentrated solar power Vol 3

How will the market shape up? As far as the smart grid is concerned, from the business point of view, we are very optimistic. But in realistic point of view, there are a lot of challenges as India as a country lacks fundamental infrastructure. We have problems of education, poverty, sanitisation and basic amenities with other challenges.

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Interview with Inder Jaisinghani Continued from 32 f

From the time metals used by cable manufacturers have come under the label of commodity trading, it has been an exercise of guarded operations for them. This is due to their shift in focus from their core competency, which is manufacturing, to managing unwanted risk factors in purchase of basic raw materials such as copper and aluminium. Despite all these challenges, we are of the strong opinion that there is sufficient headroom for our company to prosper despite the gloomy market scenario. All one requires is the right market strategy in place and agile decision making in terms of the right investments in production

APRIL 2015

capacity, product range, people and distribution channels. Despite a slowdown all around the industry, Polycab achieved a turnover of ` 4,500 crore in last fiscal. How did it happen? At Polycab we always had a foresight about the market scenario and its probable impact on our industry. We achieved a turnover of ` 4,500 crore in last fiscal despite slowdown because we offered widest range of cables and with ready stocks. With multiple stocking points in India we have shortest delivery time of high quality cables vis-à-vis our competitors.

How do you look at the recent status of standardisation as far as electric wires and cables industry in India is concerned? Standardisation and stringent rules will help to weed out the temporary fly-by-night operators in the sector. We at Polycab use latest world-class machineries and quality raw materials to ensure high quality wires and cables. We have always strived to provide best quality at the most affordable price and it is achieved through our state-of-theart plants. Electrical & Power Review

Power Brand

Infineon’s OptiMOS 5 delivers efficiency, power density for voltage regulator solutions

Infineon’s OptiMOS 25V and 30V product family

Infineon Technologies AG introduced the OptiMOS 5 25V and 30V product family, the next generation of Power MOSFETs in standard discrete packages, a new class of power stages named Power Block, and in an integrated power stage, DrMOS 5x5. Together with Infineon’s driver and digital controller products the company delivers full system solutions for applications such as server, client, datacom or telecom. Megatrends such as cloud computing, Internet of Things and social media drive an ever increasing demand for computing power in modern society. This is accompanied by a boost in energy consumption which, in return, triggers the need for energy efficiency within the power conversion chain. The newly introduced OptiMOS 25V and 30V product family offers benchmark solutions with efficiency improvements of around 1 per cent across the whole load range compared to its previous generation, exceeding 95 per cent peak efficiency in a typical server voltage regulator design. This improved performance is based for example on the reduction of switching losses (Qswitch) by 50 per cent compared to the previous OptiMOS technology. Thus, the company claims, implementing the new OptiMOS25V would lead to energy savings of 26.3 kWh per year for a single 130 W server CPU working 365 days. “Adding 50,000 servers working in a server farm on average this would amount to savings of 2.6 GWh per year,” it said. New packaging technology The launch of the OptiMOS25V and 30V product family is accompanied by the introduction of a new packaging technology offering a further reduction in PCB area consumption. It is used in the Power Block product family and in the integrated powerstageDrMOS 5x5 and offers a source down low-side MOSFET for improved thermal performance, Electrical & Power Review

DrMOS 5x5 by Infineon

with a reduction by 50 per cent of the thermal resistance in comparison to standard package solution, such as SuperSO8. Infineon’s Power Block is a leadless SMD package comprising the low-side and high-side MOSFET of a synchronous DC/DC converter into a 5.0x6.0 sq.mm. package outline. With Power Block, customers can shrink their designs up to 85 per cent by replacing two separate discrete packages, such as SuperSO8 or SO-8. Both, the small package outline and the interconnection of the two MOSFETs within the package minimize the loop inductance for best system performance. OptiMOS 5 25V is also used in an integrated power stage, combining DrMOS 5x5, driver and two MOSFETs, for total area consumption on the PCB equal to 25 sq.mm. The integrated driver plus MOSFETs solution results in a shorter design time and is easy to design-in. Additionally, the dovetailed power stage includes a high accurate temperature sense of +/-5 C (compared to +/-10 C of an external one) which enables higher system reliability and performance. Offering complete system solution “With the significant reduction in switching losses, the OptiMOS 5 products allow engineers to operate their designs at higher switching frequencies, reduce energy consumption and save overall system costs. Together with our digital IC and driver family we offer a broad range of complete solutions for DC/DC voltage regulation applications, where DrMOS 5x5 and Power Block products are the designers` choice for highest efficiency in industry standard footprints,” stated Richard Kuncic, Vice President and General Manager Power Management and Multimarket at Infineon Technologies. For more details, visit www.infineon.com APRIL 2015

Innovation

Thermal management for LEDs LED driver ICs with smart over temperature protection help in increasing lifetime and optimizing system cost of LED lighting systems frame elements. If this heat transfer system has design or manufacturing flaws, or the system experiences extremely high temperature conditions the LEDs, the driver IC or other heat sensitive components like electrolytic capacitors can be damaged. The patent pending smart thermal management technology included in the latest LED driver ICs can help protect the system from thermal failure resulting in improved LED system designs. LED lifetime depends on temperature High-quality LEDs are in general robust devices that can operate in excess of 100,000 hours, when properly operated. The lifetime of LEDs is directly related to the junction temperature to which they are exposed, increasing temperatures can reduce the operating lifetime significantly. LEDs offer an enormous potential to save energy and enhance the quality of light in indoor and outdoor lighting applications. In addition, LEDs enable a service free, long lifetime of lighting fixtures which allow a significant advantage for total cost of ownership calculations. In order to benefit from the long lifetime of LED lighting fixtures, it has to be considered that the LED lifetime is a function of the LED junction temperature. The fact that LEDs enable new compact lighting designs increases even more the necessity of putting high emphasis on thermal management of LED lighting solutions. System manufacturers are addressing thermal challenges by designing systems with appropriate heat sinks, high-thermal conductivity enclosures and other advanced thermal design techniques. Generally, these manufacturers do not consider the LED driver IC as a control component in the thermal system. The use of an LED driver IC with intelligent over temperature protection provides an additional control mechanism that can increase the lifetime of LED light sources significantly, ensuring the rated lifetime and reducing the incidence of defective products. Depending on the lighting manufacturer and application, useful lifetime for LED lighting products range from about 20,000 hours to more than 50,000 hours compared to less than 2,000 hours for incandescent bulbs. The intelligent thermal protection helps also reduce system cost by enabling system integrators to design the heat sink with lower safety margin. Despite the very high efficiency of LEDs compared to other light sources, a large portion of the energy used to drive LEDs is converted to heat. Unlike other light sources like incandescent bulbs, LEDs generate little or no infrared radiation. Thatâ&#x20AC;&#x2122;s why the generated heat must be conducted from the LED die to the underlying circuit board and heat sinks, housings or luminaries

APRIL 2015

Different approaches for thermal protection The thermal design is often focused on the heat sink and PCB design, while the opportunities for thermal management by the LED driver IC and driving circuit are not considered. Intelligent over temperature protection by the LED driver IC can increase the lifetime of LED light sources significantly. Temperature protection with LED driver ICs can be implemented in a variety of ways. Some LED driver devices include a sense pin to which an external temperature sensor may be attached. Different temperature sensing devices, including diodes, onchip sensors, positive temperature coefficient (PTC) or negative temperature coefficient (NTC) thermistors can be used in LED lighting applications to protect the LEDs from overheating. NTC thermistors are often the preferred choice for temperature sensing and control in many of these applications, primarily because of their small package sizes and attractive price/performance ratio. But accuracy, response time and thermal gradient depend on the way the NTC thermistor is mounted. Once the temperature is accurately sensed, the response to over temperature must be considered. The typical response is to trigger an abrupt turn off of the current to the LEDs when a critical temperature has been detected. These devices then can â&#x20AC;&#x153;restartâ&#x20AC;? when the temperature is reduced or wait until a power cycle to restart. Smart over temperature protection implemented at the LED driver IC Infineon Technologies has a granted patent which describes a circuit arrangement of a power supply unit for LED current control including a temperature sensor and a trigger circuit to provide a temperature dependent LED output current to protect the LEDs from overheating. Electrical & Power Review

Innovation Vs RTadj

Leveraging the key idea of the above mentioned patent to use the LED driver IC as a thermal sensor Infineon Technologies has developed pending patent technology to protect the LEDs with a slope dimming characteristic and adjustable trigger temperature for the start of thermal protection to overcome the limitations of conventional LED system designs. The new technology was implemented in the recently announced ILD6150 and ILD6070 DC/DC hysteretic buck LED driver with high side current sensing.

2) Protection of LED lifetime by slope dimming mechanism Reducing the LED average current with an integrated slope dimming mechanism protects the lifetime of the LEDs by reducing their junction temperature. The protection circuit should ideally result in LED power deliver that has a smooth protection characteristic as a hard switching may lead to flickering. If a light source driven by the new LED drivers is exposed to a higher temperature condition than foreseen in the thermal design the driver ICs will reduce the average current of the LED continuously in a slope dimming characteristic, not abruptly. 3) Optimisation between lifetime and cost for thermal system by adjusting the triggering point for thermal protection Luminary manufacturers can adjust the temperature that the protection engages by selecting the value of a low cost external resistor according to the end customer and application needs. 4) Maintaining light colour during thermal protection due to PWM dimming method Dimming by generating an internal PWM signal during thermal protection ensures that the light colour doesnâ&#x20AC;&#x2122;t change. Since the light colour remains practically unchanged it might not be visible to end users that the LED system is in thermal protection mode. The integrated temperature protection circuit will start to reduce the LED current by internal PWM modulation once the certain temperature trigger point of the slope characteristic of the IC is exceeded. New LED driver generation The new driver generation implementing the described smart thermal protection technology consists of hysteretic buck LED Electrical & Power Review

VSTAB

PWM Cpwm

VREF

Rsense OTP

OCP

Exposed pad to be connected to GND

Cpwm is optional for soft start

Fig 1: Application circuit with the new ILD6070 driver: The current reduction is triggered at a threshold of the solder point temperature of the LED driver IC which is adjustable using an external resistor connected to the Tadj pin VCC C

Rsense

1) Saving system cost by using the driver IC as a thermal sensor for thermal protection The driver IC can be used as a reference temperature to determine the LED temperature in systems where the driver is thermally coupled to the LEDs. This saves cost of NTC, additional wiring and connector pins. In addition the design for thermal protection is simplified.

UVLO

LED1

GND IC1 EN 1 1 8 Tadj EN PWM 2 2 7 VS PWM R2 GND3 3 6 Vsense GND GND4 4 5

Zener

GND

The implementation of the specific smart temperature protection provides the following key benefits to LED system integrators which will be elaborated in more detail:

Schottky Diode

LED2 L

Vswitch

ILD 6070 NTC Thermistor

GND

GND GND

GND

Fig 2: Depending on the application the new driver ICs can use both internal temperature protection and external NTC for thermal protection

driver ICs for driving high power LEDs in general lighting applications. With a wide range of supply voltages, they are suitable for various LED applications. A multifunctional PWM input signal allows dimming of the LEDs with an analog DC voltage or an external PWM signal. Summary A key challenge in implementing high-quality, durable LED lighting systems is managing the heat emitted from the LED components and electronics. Luminary designers are advised to consider other ways than only the heat sink design in order to manage the high thermal load at the PCB. With the patent pending smart thermal management technology described here and used in the latest LED driver generation, the lifetime and cost of LED designs can be significantly improved. Authored byâ&#x20AC;&#x201D;

Bernd Pflaum - Principal Engineer (for concept and development of linear LED driver ICs and switching regulator ICs) Infineon Technologies AG Hakan Yilmazer - Senior Manager (and global head of Application Marketing for Lighting) Infineon Technologies AG. APRIL 2015

K N Neelkant appointed as Executive VP and President of IB Unit, CG Avantha Group Company CG has appointed K.N. Neelkant as Executive Vice President and President of Industrial Business Unit. Neelkant will also be a member of CG’s executive committee. He will be taking over the reins of the Industrial business of CG from Anil Raina. Mr Neelkant brings with him 20 years of experience in strategy formulation and deployment, project management, supply chain management and manufacturing across sectors including infrastructure, power transmission and distribution and engineering. In addition to his role as the head of the Industrial Business Unit, he will supervise CG’s EPD business in India and the company’s distribution franchise in Jalgaon, Maharashtra.

Gamesa Country Head appointed as Vice Chairman, CII Chennai Chapter Ramesh Kymal, Chairman and Managing Director, Gamesa India has recently been elected as Vice Chairman of CII Tamil Nadu State Council for the year 2015-16. An active member of CII, Mr Kymal has held several senior posts across CII bodies assuming various roles and responsibilities in furthering the body’s goals and objectives. He is the Chairman of Energy and Sustainability Sub-Committee, CII Southern Region and also the Chairman of Renewable Energy Council of CII Godrej Green Business Centre. He has also held the role of Chairman, Indian Wind Turbine Manufacturers Association (IWTMA) from 2011-2014. In addition to the new responsibilities, he will be executing as the Vice Chairman of CII Chennai Chapter. With over 25 years of experience in the renewable energy industry, Mr Kymal is a mechanical engineer with specialisation in operational research and statistical quality control.

APRIL 2015

Electrical & Power Review

PEOPLE Daniel Bentley appointed as New Sales and Distribution Director for Asia Perkins has appointed Daniel (Dan) Bentley as the new sales and distribution director for the Asia-Pacific region, following Jaz Gill’s move to the post of global marketing director. Dan, who has already spent time talking to and meeting Perkins Generator Original Equipment Manufacturers (GOEMs) in India, is responsible for engines sales in the region and the development of the aftermarket business. Since 1994, Dan has held a number of roles which have focused on its customers and their requirements from its electric power and industrial products.

Shekhar Dutt is new Director General of SPDA Solar Power Developers Association (SPDA), the national association representing India’s upcoming solar power generators and developers, has announced the appointment of Shekhar Dutt as the Director General, with effect from March 2015. At SPDA, Mr Dutt will be responsible for promoting the organisational vision of increasing the focus on solar energy generation and advocating sustainable development. He will be at the forefront of drafting the industrial policies and proposals and share his invaluable expertise on various governmental and corporate initiatives. He will also provide guidance to the team for developing the enabling policy framework and regulatory regime for the solar sector. Commenting on his appointment, Mr Dutt said, “I am happy to be associated with SPDA. It will be my endeavor to contribute towards the association’s objective of promoting solar energy as a solution for India’s energy security needs and developing this nascent sector.”

Electrical & Power Review

APRIL 2015

Trade Zone

t o h s ap

n S t rke

IEX & PXIL Price and Volume Day Ahead Market-Feb’15 Delivery day

"IEX Avg MCP (Rs./kWh)"

"PXIL Avg MCP (Rs./kWh)"

"IEX MCV (MWh)"

"PXIL MCV (MWh)"

Delivery day

"IEX Avg MCP (Rs./kWh)"

"PXIL Avg MCP (Rs./kWh)"

"IEX MCV (MWh)"

"PXIL MCV (MWh)"

1-Feb-15

2.53

2.75

76,982

1,417

15-Feb-15

2.70

2.75

73,485

962

2-Feb-15

2.75

2.71

80,608

1,469

16-Feb-15

2.83

3.07

72,434

1,032

3-Feb-15

3.13

2.71

76,190

1,321

17-Feb-15

3.48

3.00

62,585

829

4-Feb-15

3.06

3.14

78,573

1,102

18-Feb-15

3.26

3.34

67,785

978

5-Feb-15

3.06

3.17

77,324

1,195

19-Feb-15

3.42

3.08

62,822

1,021

6-Feb-15

3.06

2.88

77,308

1,792

20-Feb-15

3.11

3.23

66,567

750

7-Feb-15

3.14

2.90

74,360

1,901

21-Feb-15

2.93

3.06

69,211

986

8-Feb-15

2.68

2.57

70,970

1,523

22-Feb-15

2.42

3.08

66,473

819

9-Feb-15

3.11

2.75

74,377

2,040

23-Feb-15

2.58

3.04

67,681

620

10-Feb-15

2.89

76,283

1,654

24-Feb-15

2.65

2.98

78,525

864

11-Feb-15

2.70

2.67

75,510

1,451

25-Feb-15

2.89

3.21

71,479

1,236

12-Feb-15

2.53

2.57

74,923

1,608

26-Feb-15

2.69

3.20

74,527

810

13-Feb-15

2.63

2.36

75,647

1,410

27-Feb-15

2.56

3.28

69,848

1,060

14-Feb-15

2.49

2.52

64,421

958

28-Feb-15

2.50

3.45

71,273

906

IEX & PXIL Price & Volume in Day Ahead Market-Feb'15 IEX & PXIL Price & Volume in Day Ahead Market-Feb'15 IEX MCV PXIL MCV IEX Avg MCP PXIL Avg MCP

90,000

(MWh) IEX MCV (MWh)

90,000 80,000

(MWh) PXIL MCV (MWh)

(Rs./kWh) IEX Avg MCP (Rs./kWh)

4.00

(Rs./kWh) PXIL Avg MCP (Rs./kWh)

4.00 3.50 3.50 3.00

70,000 60,000

3.00 2.50

60,000 50,000

2.50 2.00

50,000 40,000

2.00 1.50

40,000 30,000

1.50 1.00

30,000 20,000

1.00 0.50

20,000 10,000 4-Feb-15

7-Feb-15

10-Feb-15

13-Feb-15

16-Feb-15

19-Feb-15

22-Feb-15

25-Feb-15

0.50 0.00 28-Feb-150.00

4-Feb-15

7-Feb-15

10-Feb-15

13-Feb-15

16-Feb-15

19-Feb-15

22-Feb-15

25-Feb-15

28-Feb-15

10,000 0 0 1-Feb-15 1-Feb-15

Average Daily MCV : IEX- 72,435 MWH | PXI- 1,204 MWh Average Daily MCV : IEX- 72,435 MWH | PXI- 1,204 MWh

MCPMCP (Rs/kWh) (Rs/kWh)

Cleared Cleared Volume Volume (MWh) (MWh)

80,000 70,000

APRIL 2015

| |

Average Daily MCP : IEX- 2.85 kWH | PXI- 2.94 kWh Average Daily MCP : IEX- 2.85 kWH | PXI- 2.94 kWh

Source: IEX

Electrical & Power Review

Trade Zone

Mar

ket

Snap

shot

IEX Non-solar REC Trade Details

IEX Non Solar REC Trade Details

100

8,994

4,342,307

8,994

1,500

Oct'14

36,411

4,766,941

36,411

Nov'14

93,100

4,946,763

93,100

Dec'14

177,960

5,313,974

177,960

1,500Mar'14

Jan'15

393,081

6,720,193

393,081

1,500

Feb'15

345,184

6,025,638

345,184

1,500

345,184 177,960 6,025,638 345,184

393,081 6,720,193 393,081 177,960

177,960

36,411

345,184 6,025,638 345,184

400

0 Mar'14

393,081 6,720,193 393,081

5,313,974

93,100 5,313,974 4,946,763

93,100 4,766,941 4,946,763 93,100 36,411

4,342,307

4,766,941

36,411

400

800

Apr'14

May'14

June'14

July'14

Aug'14

July'14

Sep'14

Aug'14

Oct'14

Nov'14

Sep'14

Dec'14

Oct'14

Jan'15

Nov'14

Feb'15

Dec'14

Jan'15

Feb'15

Cleared Price (Rs/REC)

987,764

100

Sep'14

800

688,581

1,000

1,600

1,200 1,200

10,000

1,500

1,000

1,600

Cleared Price (Rs/REC)

10,000

36,411

15,736

Cleared Price (Rs/REC)

8,994

3,949,016

4,342,307

15,736

8,994 8,994

Aug'14

100,000

3,949,016

4,241,244

8,994

13,609

1,000,000

3,949,016

July'14

50,743 100,000 1,500 13,609 1,500

15,736

3,166,863

15,736

50,743

15,736

June'14

Cleared Volume

15,736

16,1421,000,000 1,500 10,000,000

4,241,244 4,241,244

3,615,695

13,609

16,142

Cleared Volume

Sale Bid

13,609

May'14

Buy Bid

13,609 13,609

16,798 1,500 10,000,000

3,166,863 50,743 3,166,863

2,924,976

50,743

16,798

50,743

1,500

16,142 3,615,695 16,142 50,743

Apr'14

16,142 2,924,976 3,615,695

361,842

16,142

2,893,896

16,798

361,842

16,798

Mar'14

Sale Bid

IEX Non Solar REC Trade Details

93,100

Buy Bid

177,960

Cleared Price (Rs/ REC) 2,924,976 2,893,896

Cleared Volume

361,842 16,798

Sale Bid

16,798 361,842

Buy Bid

361,842 2,893,896 361,842

Month

IEX Solar REC Trade Details

688,581

30,650

Mar'14 3,500

Feb'15

26,726

987,764

26,726

3,500

100

10 9,300

3,000

26,726

30,650

235,972

987,764

688,581

6,000

6,00

3,00

10 1

12,0

9,00

Cleared Price (Rs/REC)

30,650

26,726

Jan'15

12,000

366

9,300 1

366

30,650

235,972

30,650

235,972

245

366

245

Dec'14

366

245

232

241,063

366

245

Nov'14

232 245

232

264

187,483

232

Oct'14

1,000

264

9,300

264

367 264

161,260

367

264

367

Sep'14

367

9,300 1,000

498

367

498

150,091

26,726

241,063

241,063187,483

161,260

Cleared Price (Rs/REC) 187,483

161,260

Cleared Volume

9,000

498 498

367

636

Aug'14

10,000

636

498

9,300

Sale Bid

636

179,581

636

498

100

Cleared Volume

100,000

July'14

Electrical & Power Review

9,300

7,211

9,300 10,000

469

636

469

147,026

Sale Bid

IEX Solar REC Trade Details

Buy Bid

469

636

100,000

469

June'14

9,3001,000,000

823

823 1,000,0009,300 469

823

147,937 178,986

8237,211

823 469

8237,211

Apr'14 May'14

Buy Bid

150,091

9,300

150,091

7,211

179,581179,581

131,759

147,026

7,211

147,026

Mar'14

IEX Solar REC Trade Details

178,986

Cleared Price (Rs/ REC) 178,986

Cleared Volume

147,937

Sale Bid

131,759 147,937

Buy Bid

131,759

Month

0 Mar'14

Apr'14

May'14

June'14

July'14

Aug'14

Sep'14

Aug'14

Oct'14

Sep'14

Nov'14

Oct'14

Dec'14

Jan'15

Nov'14

Feb'15

Dec'14

APRIL 2015

0 Jan'15

Feb'15

ADVERTISERS INDEX Central Power Research Institute .............................. BC East India Udyog Pvt Ltd .............................................. 5

OBO Bettermann India Pvt Ltd ..................................... 7 PME Power Solutions (India) Ltd ............................. IFC

Electrotherm India Ltd .................................................. 9 Indian Oil Corporation Ltd ............................................ 3 Megger (India) Pvt Ltd .............................................. IBC

Ramelex Pvt Ltd ......................................................... 11 Sivananda Electronics................................................. 19

Megger India offers precision instrument capacitance and dissipation factor test set CDAX 605 is a capacitance and dissipation factor test set to be used with an external power source/ generator. It is a precision instrument using a combination of bridge and direct (vector) measurements and is capable of measuring capacitive, resistive and inductive loads.

voltage level pending on the rating of the equipment, the power source and the capacitor. The unit will accept a test current up to 5 A from the insulation under test which can be increased by using an external current transformer.

CDAX 605 is designed for laboratory, production line or field testing of electrical equipment insulation and insulating materials as well as e.g. calibration of CCVTs and other ratio devices. A test set with unique high accuracy for the most demanding applications.

These two quantities can be measured as a receiving material quality control, during assembly and verification of electrical apparatus, at the time of installation or as a part of a maintenance program after the equipment is placed in service. The test is non-destructive and is used for verification, trending and comparison.

In determining the quality of highvoltage equipment insulation, power frequency capacitance and dissipation factor are among the most frequently measured insulating characteristics.

CDAX605 is a measurement instrument that is used with an AC power source and a standard capacitor to form a complete measurement setup. Testing can be performed at almost any

ApRil 2015

Traditional bridge methods can only measure and compare capacitive currents and since calibrated standard capacitors are typically available in the 100 to 1,000 pF range, precision measurements on e.g. CCVTs and other devices with a high ratio are difficult to perform. With the new technology in CDAX605, the input voltage to the device can be measured with a traditional reference capacitor while the secondary low voltage can be measured with a calibrated resistive divider that can be designed to give appropriate measurement current. Electrical & Power Review

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