Vijai Electricals Limited - Infraline
Vijai Electricals Limited - Infraline
Vijai Electricals Limited - Infraline
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<strong>Vijai</strong> <strong>Electricals</strong> <strong>Limited</strong><br />
<strong>Vijai</strong> <strong>Electricals</strong> Ltd. welcomes all distinguished dignitaries and<br />
delegates of the Power Sector at the “International Conclave on<br />
Key inputs for accelerated development of Indian Power sector<br />
for 11th Plan and beyond.”
<strong>Vijai</strong>’s Manufacturing Capabilities for Energy<br />
Efficient Transformers & Switch gear<br />
<strong>Vijai</strong> <strong>Electricals</strong> <strong>Limited</strong>
Introduction to <strong>Vijai</strong> <strong>Electricals</strong> <strong>Limited</strong><br />
Overview of <strong>Vijai</strong><br />
• Established in the year 1973<br />
• Combined aggregate growth of 52.9 % over the last 5<br />
years.<br />
• One of the first companies to introduce the concept of<br />
AMDT’s and CSP.<br />
• Has set up an overseas manufacturing facilities in Brazil<br />
and an additional facility in Uttarakhand to cater to<br />
Northern regions<br />
Hyd- July, 2007 3
A brief overview of <strong>Vijai</strong><br />
• <strong>Vijai</strong> is the one of the largest Manufacturer of Power and Distribution<br />
Transformers in India with a Sales turnover of 311 Million USD exporting<br />
to more than 25 Countires.<br />
• <strong>Vijai</strong> employs a dedicated workforce of 6000+ for manufacturing<br />
products such as Distribution and Power Transformers,Switchgears and<br />
takes part in Turnkey Projects.<br />
• Thanks to the strong commitment of the team, <strong>Vijai</strong>’s Energy Efficient<br />
Low loss AMDT State of Art manufacturing facility at Rudraram is<br />
the world largest Manufacturing unit.<br />
VISION<br />
We aim to be a prominent global player and a national leader in the<br />
field of Power Transmission and Distribution, promoting the cause of<br />
energy saving through constant innovation and customization of<br />
products, and introduction of value added solutions for our honored<br />
customers.<br />
Hyd- July, 2007 4
Hyd- July, 2007 5
Purchase Practice of many utilities.<br />
• Many utilities are only interested in lowest first Cost while evaluating<br />
offers.<br />
• In the process, they ignore.<br />
1. Losses occurred during the operation.<br />
2. Operating Cost.<br />
3. Maintenance Cost.<br />
4. Energy Savings.<br />
5. CO 2<br />
emissions.<br />
Hyd- July, 2007 6
Better Feasible Practices<br />
• Employ Capitalization factors (A&B) for evaluation of losses in mentioned<br />
in offers besides the initial cost. This ensures lower losses from Bidders.<br />
• Take the efficiency of the equipment into consideration.<br />
• Purchase Transformers which are cooler than others.<br />
• Procurement of Low Loss Higher efficiency – Amorphous Metal Distribution<br />
Transformers (AMDTs).<br />
Hyd- July, 2007 7
Facts pertaining to AMDTs<br />
• Saves huge amounts of Energy by axing the No Load Losses in a<br />
Transformer by 60 -70 %.<br />
• Over 10,00,000 Transformers in service throughout the globe.<br />
• Utilities in states of Gujarat, Maharastra, Haryana, Orissa,Andhra Pradesh<br />
and CPSU’s like PGCIL, NTPC, NHPC have already procured huge quantities<br />
of these energy savers.<br />
• Helps in reduction of green house gases due to savings in Generation.<br />
Hyd- July, 2007 8
ADVANTAGES<br />
‣ No-Load Loss is reduced by 75% as compared to that of CRGO<br />
Transformers.<br />
‣ Losses Due to non-linear loading (i.e. harmonic distortion) is reduced<br />
typically by about 570 watt for a 100 kVA transformer.<br />
‣ Less Magnetising Current.<br />
‣ Cumulative Saving of Energy Cost.<br />
‣ Total Owning Cost to Customer is much less. Reduction in fossil fuel<br />
consumption.<br />
‣ Less Temperature Rise of core.<br />
Hyd- July, 2007 9
Product Range - Transformers<br />
AMDT upto 500 kVA, 33 KV<br />
Small Power Transformer upto<br />
15 MVA, 66 KV<br />
Delta Core Transformer upto<br />
250 kVA, 11 KV<br />
1- Ø Transformer upto 3.33 MVA,33 KV<br />
Corrugated tank Transformer upto<br />
2500 kVA, 33 KV<br />
Dry Type CRT upto 8 MVA, 33 kV Class<br />
EHV Power Transformer upto<br />
500 MVA, 500 kV Class<br />
Hyd- July, 2007 10
Product Range – Switch gears<br />
Voltage Transformer till 145 KV<br />
1 Ø Current Transformer till 36 KV<br />
145 kV CT– Polymer type<br />
1 Ø Voltage Transformer till 36 KV<br />
Indoor VCB till 12 KV<br />
245 kV CT – Porcelain type<br />
145 kV CT – Porcelain type<br />
3 Ø Voltage Transformer till 12 KV<br />
Outdoor VCB till 36 KV<br />
Hyd- July, 2007 11
Switchgear Products Under Development<br />
•OUT DOOR SF6 CIRCUIT BREAKERS<br />
Live tank and Dead tank<br />
Up to 420 kV Voltage Class<br />
Up to 3150 A, 50 kA<br />
•GAS INSULATED SUBSTATIONS<br />
Up to 420 kV, 50 kA<br />
•INSTRUMENT TRANSFORMERS<br />
upto 245 kV Voltage transformers (Oil filled EMVT)<br />
upto 420 kV Current transformers (Oil filled)<br />
420 kV Current transformers (SF6 filled)<br />
•CONDENSER BUSHINGS<br />
Up to 420 kV (Oil filled)<br />
•VACUUM INTERRUPTERS<br />
Up to 36 kV, 2500 A, 40 kA<br />
Hyd- July, 2007 12
Ministry of Power. – 11 th Plan<br />
Hyd- July, 2007 13
Requirement of Major Transmission Equipment<br />
during 2007-2012<br />
HVDC bipole<br />
Projects, 2<br />
Isolators, 672<br />
500 MVA 1 ph<br />
units, 90<br />
333 MVA 1 ph<br />
units, 42<br />
Reactors 80<br />
MVAR 1 ph,<br />
174<br />
PT sets, 336<br />
765 kV bays,<br />
112<br />
Circuit<br />
Breakers, 224<br />
CT sets, 1008<br />
Equipment demand for 765 kV<br />
Hyd- July, 2007 14
Requirement of Major Transmission Equipment<br />
during 2007-2012<br />
105 MVA 1 ph<br />
units, 580<br />
80,63 &50MVA<br />
3 ph units, 370<br />
Isolators, 4399<br />
400 kV bays,<br />
846<br />
PT sets, 1396<br />
Circuit<br />
Breakers, 1523<br />
Equipment demand for 400 kV<br />
CT sets, 7614<br />
Hyd- July, 2007 15
Requirement of Major Transmission Equipment<br />
during 2007-2012<br />
50,100,100 MVA<br />
3 ph units of<br />
220/132 - 11, 740<br />
220 kV bays<br />
,3250<br />
Isolators, 13000<br />
Circuit Breakers,<br />
3250<br />
PT sets, 2960 CT sets, 9750<br />
Equipment demand for 220 kV<br />
Hyd- July, 2007 16
Transformer Demand<br />
Transformer Demand in the next 5 years.<br />
180000<br />
160000<br />
Capacity in MVA<br />
140000<br />
120000<br />
100000<br />
80000<br />
60000<br />
40000<br />
20000<br />
0<br />
2006-07 2007-08 2008-09 2009-10 2010-11 2011-12<br />
Years<br />
Total<br />
Power Transformer<br />
Distribution Transformer<br />
Source : ASIAN SECURITIES<br />
Hyd- July, 2007 17
Installed Capacity for Manufacturing<br />
T and D Equipments in <strong>Vijai</strong><br />
Hyd- July, 2007 18
Annual Installed Capacity (MVA) CRGO<br />
Transformer Plant at Hyderabad<br />
1-Phase , 450<br />
Small Power<br />
Transformer<br />
(5 MVA)<br />
900<br />
3 -Phase, 540<br />
CRGO Transformers' Capacity (MVA)<br />
Hyd- July, 2007 19
Annual Installed Capacity (MVA) for Low Loss –<br />
Energy Efficient Amorphous Metal Core<br />
Transformer Plant at Hyderabad<br />
Single Phase,<br />
3108<br />
Three Phase,<br />
5355.6<br />
Transformer capacity in MVA (Amorphous Core)<br />
Hyd- July, 2007 20
Annual Installed Capacity in <strong>Vijai</strong><br />
Haridwar Transformer<br />
Plant - MVA<br />
1-Phase , 450<br />
Small Power<br />
Transformer<br />
(5 MVA)<br />
1500<br />
3 -Phase, 540<br />
CRGO Transformers' Capacity (MVA)<br />
1-Phase,<br />
1200<br />
3 -Phase,<br />
1800<br />
Amorphous Metal Core Transformers' capacity<br />
Hyd- July, 2007 21
Summarized Annual Installed Capacity - MVA<br />
Amorphous Plant<br />
Single Phase – 3108 MVA<br />
Three Phase – 5355 MVA<br />
Sub Total – 8486 MVA<br />
CRGO Plant<br />
Single Phase –3376.8 MVA<br />
Three Phase – 3456 MVA<br />
Medium Power – 4500 MVA<br />
Cast Resin – 54 MVA<br />
Sub Total – 11386 MVA<br />
Haridwar Plant<br />
CRGO<br />
1-Phase<br />
450 MVA<br />
3 -Phase 540 MVA<br />
Medium Power 1500 MVA<br />
Amorphous<br />
1-Phase 1200 MVA<br />
3 -Phase 1800 MVA<br />
Sub total 5490 MVA<br />
EHV Large Power Transformer<br />
12000 MVA p.a<br />
Annual Capacity for Power and<br />
Distribution Transformers at a staggering<br />
37000 MVA per annum<br />
Hyd- July, 2007 22
Annual Capacity of Switch gear products<br />
Sl.No<br />
Product Name<br />
Current<br />
2008-09<br />
Future<br />
1<br />
12 kV indoor VCB<br />
1700<br />
2400<br />
12000<br />
2<br />
12 kV outdoor VCB’s<br />
with 12 KV CTs<br />
800<br />
1200<br />
6000<br />
3<br />
36 kV Outdoor VCB<br />
500<br />
600<br />
2000<br />
4<br />
INSTRUMENT<br />
TRANSFORMERS MV<br />
600<br />
2000<br />
5000<br />
5<br />
INSTRUMENT<br />
TRANSFORMERS EHV<br />
500<br />
1000<br />
2000<br />
6<br />
145 kV Live tank<br />
SF 6 breakers<br />
75<br />
150<br />
1000<br />
7<br />
245 kV Live Tank and<br />
Dead Tank<br />
SF 6 breakers<br />
40<br />
80<br />
500<br />
Hyd- July, 2007 23
Annual Capacity of Switch gear products – Contd..<br />
Sl.No<br />
Product Name<br />
Current<br />
2008-09<br />
Future<br />
8<br />
420 kV Dead Tank<br />
SF 6 breakers<br />
20<br />
40<br />
200<br />
9<br />
GIS 36 kV<br />
50 bays<br />
150 bays<br />
300 bays<br />
10<br />
GIS EHV<br />
20 bays<br />
40 bays<br />
100 bays<br />
11<br />
Vacuum interrupters<br />
2000<br />
30000<br />
60000<br />
Upto 36 KV<br />
12<br />
EHV Bushings<br />
100<br />
600<br />
1800<br />
Hyd- July, 2007 24
Infrastructure in <strong>Vijai</strong><br />
State of the art manufacturing facilities
AMDT plant<br />
Conductor plant<br />
CRGO plant<br />
Exclusive Fabrication unit for<br />
Transformer Tank and Radiators<br />
EHV plant<br />
Hyd- July, 2007 26
Upcoming facility for Switch gear<br />
Haridwar plant<br />
Brazil plant<br />
Conductor plant @<br />
Roorke<br />
Hyd- July, 2007 27
Integrated Facilities<br />
Hyd- July, 2007 28
• CORE PROCESSING FACILITY<br />
• CONDUCTOR PLANT<br />
• WINDING INSULATION MATERIAL<br />
• TANK FABRICATION FACILITY<br />
• RADIATOR MAKING FACILITY<br />
• TRANSFORMER OIL PROCESSING<br />
• ELECTRO – PORCELAIN (BUSHINGS) PLANT<br />
• TAP SWITCH MAKING<br />
• NITROGEN PLANT<br />
Hyd- July, 2007 29
BENEFITS<br />
Consistent Quality……….<br />
Competitive Pricing………<br />
Timely Delivery…………<br />
Hyd- July, 2007 30
World’s Largest AMDT plant<br />
Hyd- July, 2007 31
PLC based Core Dereeling and Spooling<br />
PLC based Automatic Core Cutting<br />
Hyd- July, 2007 32
Core loss testing<br />
Semi Automatic Winding<br />
machines<br />
Hyd- July, 2007 33
HABS system in <strong>Vijai</strong><br />
Oil filling under Vacuum<br />
Hyd- July, 2007 34
STRATEGIC ALLIANCES<br />
Hyd- July, 2007 35
Technological Tie ups.<br />
• <strong>Vijai</strong> <strong>Electricals</strong> Ltd. actively seeks and nurtures effective partnerships with likeminded<br />
companies that provide complementary services so that it can offer its<br />
customers, skilled & single-window solutions.<br />
In Past<br />
Westinghouse, USA-<br />
M & C, Germany-<br />
Daihen Corporation, Japan-<br />
Transformers.<br />
Westinghouse, USA-<br />
For Single Phase Transformers<br />
For Dry Type Cast Resin Transformers<br />
For Amorphous Metal Core<br />
For CLR/ CQR Circuit Breakers (with sister<br />
concern SEL)<br />
Present<br />
Daihen Corporation, Japan- For Large Power Transformers up to<br />
500 MVA, 500 kV Class<br />
NIIVA Russia<br />
For GIS /SF6<br />
Hyd- July, 2007 36
RISING DEMAND FOR<br />
CRGOs & AMDTS [No.s]<br />
No. of<br />
Transformers<br />
supplied (nos.)<br />
100000<br />
80000<br />
60000<br />
40000<br />
20000<br />
0<br />
97577<br />
CRGO<br />
61160<br />
66765<br />
AMDT<br />
93620<br />
2005 - 06<br />
2006 - 07<br />
Hyd- July, 2007 37
Supplies during previous financial years<br />
Total AMDTs supplied (MVA) by <strong>Vijai</strong><br />
MVA<br />
3000<br />
2500<br />
2000<br />
1500<br />
1000<br />
500<br />
533 563<br />
868<br />
1487 1468 2903<br />
2004 - 05<br />
2005 - 06<br />
2006 - 07<br />
0<br />
1 - Ph 3 - Ph<br />
Hyd- July, 2007 38
Categorical supplies<br />
Total AMDTs supplied (nos. ) by <strong>Vijai</strong><br />
60000<br />
56458<br />
No.s<br />
50000<br />
40000<br />
30000<br />
20000<br />
41120<br />
40141<br />
26624<br />
18322<br />
37162<br />
2004 - 05<br />
2005 - 06<br />
2006 - 07<br />
10000<br />
0<br />
1 - Ph 3 - Ph<br />
Hyd- July, 2007 39
Concern on Energy Efficiency Concepts across<br />
the Globe<br />
• Bureau of Energy Efficiency in India- Introduced STAR<br />
RATING based on the losses for Distribution Transformers<br />
• Intelligent Energy Europe – SEEDT(Strategies for<br />
development and diffusion of Energy Efficient Distribution<br />
Transformers)<br />
• US DOE – NEMA TP1 & TP2 Standards<br />
• World Energy Council – UK<br />
• MEPS Concept in Australia, New Zealand.<br />
Hyd- July, 2007 40
Conclusions<br />
• Power Utilities improve the Efficiency of their T & D system by reducing the<br />
line losses.<br />
• Among the various measures adopted for reduction of losses the use of Low<br />
loss Energy Efficient Transformers (Amorphous) is always easily<br />
accomplished.<br />
• “Watts Saved” are more than “Watt Generated” which can be achieved by<br />
using Energy Efficient Equipments in the networks reducing the need for<br />
more Generation . This means less fossil – fuel dependency and reduced CO 2<br />
Emissions.<br />
• The Distribution Transformers supply power and remains on line for 24 hrs a<br />
day & 365 days of the year. Being supply equipment it doesn't consume any<br />
power but the process of transformation involves certain inherent losses. In<br />
this context Amorphous Metal Core Transformers have a great advantage<br />
because they save more than 70% of the No- load losses compared to<br />
transformers with other Core material.<br />
Hyd- July, 2007 41
SUPPORT FOR QUALIFYING REQUIREMENTS FOR<br />
UPCOMING INDUSTRIES IN POWER SECTORS<br />
“The ambitious plans of the Power Sector lined up by the<br />
Ministry of Power is possible to achieve provided timely<br />
support and encouragement is extended to the Indian<br />
Industries who are investing in the Infrastructure backed by<br />
the Technological support from Collaborators( Foreign/Indian)<br />
or successful type testing in accredited laboratories along<br />
with World class Manufacturing facilities, Testing facilities with<br />
strong Quality and Management systems thereby giving equal<br />
opportunities and considerations in the Qualifying<br />
Requirements of the Utilities , PSU’s in their buying process.<br />
It is also noteworthy to relook at the Quality of the Equipment<br />
used and necessary incentives that needs to be offered to the<br />
utilities who are able to use Energy Efficient Equipments in<br />
the network and reduce losses.”<br />
Hyd- July, 2007 42
The values which drive the <strong>Vijai</strong>’s development<br />
Care for<br />
people<br />
We aim at growing personnel into responsible,<br />
accountable and performing leaders, by providing<br />
opportunities for professional development and by<br />
rewarding performance<br />
Focus on<br />
performance<br />
We are focused in identifying and capturing all<br />
value creation opportunities, focusing on efficiency,<br />
productivity and right value of our energy<br />
Invest in the<br />
community<br />
We will pursue every opportunity to reinforce our<br />
leadership position through investments and<br />
acquisitions, maintaining a socially responsible and<br />
safety oriented attitude towards the countries and<br />
our stakeholders<br />
People, Performance and Community<br />
Hyd- July, 2007 43
Let’s look at a Greener and brighter Future<br />
THANK YOU FOR YOUR ATTENTION<br />
Hyd- July, 2007 44