Vijai Electricals Limited - Infraline

Vijai Electricals Limited
Vijai Electricals Ltd. welcomes all distinguished dignitaries and
delegates of the Power Sector at the “International Conclave on
Key inputs for accelerated development of Indian Power sector
for 11th Plan and beyond.”

Vijai’s Manufacturing Capabilities for Energy
Efficient Transformers & Switch gear
Vijai Electricals Limited

Introduction to Vijai Electricals Limited
Overview of Vijai
• Established in the year 1973
• Combined aggregate growth of 52.9 % over the last 5
years.
• One of the first companies to introduce the concept of
AMDT’s and CSP.
• Has set up an overseas manufacturing facilities in Brazil
and an additional facility in Uttarakhand to cater to
Northern regions
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A brief overview of Vijai
• Vijai is the one of the largest Manufacturer of Power and Distribution
Transformers in India with a Sales turnover of 311 Million USD exporting
to more than 25 Countires.
• Vijai employs a dedicated workforce of 6000+ for manufacturing
products such as Distribution and Power Transformers,Switchgears and
takes part in Turnkey Projects.
• Thanks to the strong commitment of the team, Vijai’s Energy Efficient
Low loss AMDT State of Art manufacturing facility at Rudraram is
the world largest Manufacturing unit.
VISION
We aim to be a prominent global player and a national leader in the
field of Power Transmission and Distribution, promoting the cause of
energy saving through constant innovation and customization of
products, and introduction of value added solutions for our honored
customers.
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Purchase Practice of many utilities.
• Many utilities are only interested in lowest first Cost while evaluating
offers.
• In the process, they ignore.
1. Losses occurred during the operation.
2. Operating Cost.
3. Maintenance Cost.
4. Energy Savings.
5. CO 2
emissions.
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Better Feasible Practices
• Employ Capitalization factors (A&B) for evaluation of losses in mentioned
in offers besides the initial cost. This ensures lower losses from Bidders.
• Take the efficiency of the equipment into consideration.
• Purchase Transformers which are cooler than others.
• Procurement of Low Loss Higher efficiency – Amorphous Metal Distribution
Transformers (AMDTs).
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Facts pertaining to AMDTs
• Saves huge amounts of Energy by axing the No Load Losses in a
Transformer by 60 -70 %.
• Over 10,00,000 Transformers in service throughout the globe.
• Utilities in states of Gujarat, Maharastra, Haryana, Orissa,Andhra Pradesh
and CPSU’s like PGCIL, NTPC, NHPC have already procured huge quantities
of these energy savers.
• Helps in reduction of green house gases due to savings in Generation.
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ADVANTAGES
‣ No-Load Loss is reduced by 75% as compared to that of CRGO
Transformers.
‣ Losses Due to non-linear loading (i.e. harmonic distortion) is reduced
typically by about 570 watt for a 100 kVA transformer.
‣ Less Magnetising Current.
‣ Cumulative Saving of Energy Cost.
‣ Total Owning Cost to Customer is much less. Reduction in fossil fuel
consumption.
‣ Less Temperature Rise of core.
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Product Range - Transformers
AMDT upto 500 kVA, 33 KV
Small Power Transformer upto
15 MVA, 66 KV
Delta Core Transformer upto
250 kVA, 11 KV
1- Ø Transformer upto 3.33 MVA,33 KV
Corrugated tank Transformer upto
2500 kVA, 33 KV
Dry Type CRT upto 8 MVA, 33 kV Class
EHV Power Transformer upto
500 MVA, 500 kV Class
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Product Range – Switch gears
Voltage Transformer till 145 KV
1 Ø Current Transformer till 36 KV
145 kV CT– Polymer type
1 Ø Voltage Transformer till 36 KV
Indoor VCB till 12 KV
245 kV CT – Porcelain type
145 kV CT – Porcelain type
3 Ø Voltage Transformer till 12 KV
Outdoor VCB till 36 KV
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Switchgear Products Under Development
•OUT DOOR SF6 CIRCUIT BREAKERS
Live tank and Dead tank
Up to 420 kV Voltage Class
Up to 3150 A, 50 kA
•GAS INSULATED SUBSTATIONS
Up to 420 kV, 50 kA
•INSTRUMENT TRANSFORMERS
upto 245 kV Voltage transformers (Oil filled EMVT)
upto 420 kV Current transformers (Oil filled)
420 kV Current transformers (SF6 filled)
•CONDENSER BUSHINGS
Up to 420 kV (Oil filled)
•VACUUM INTERRUPTERS
Up to 36 kV, 2500 A, 40 kA
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Ministry of Power. – 11 th Plan
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Requirement of Major Transmission Equipment
during 2007-2012
HVDC bipole
Projects, 2
Isolators, 672
500 MVA 1 ph
units, 90
333 MVA 1 ph
units, 42
Reactors 80
MVAR 1 ph,
174
PT sets, 336
765 kV bays,
112
Circuit
Breakers, 224
CT sets, 1008
Equipment demand for 765 kV
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Requirement of Major Transmission Equipment
during 2007-2012
105 MVA 1 ph
units, 580
80,63 &50MVA
3 ph units, 370
Isolators, 4399
400 kV bays,
846
PT sets, 1396
Circuit
Breakers, 1523
Equipment demand for 400 kV
CT sets, 7614
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Requirement of Major Transmission Equipment
during 2007-2012
50,100,100 MVA
3 ph units of
220/132 - 11, 740
220 kV bays
,3250
Isolators, 13000
Circuit Breakers,
3250
PT sets, 2960 CT sets, 9750
Equipment demand for 220 kV
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Transformer Demand
Transformer Demand in the next 5 years.
180000
160000
Capacity in MVA
140000
120000
100000
80000
60000
40000
20000
0
2006-07 2007-08 2008-09 2009-10 2010-11 2011-12
Years
Total
Power Transformer
Distribution Transformer
Source : ASIAN SECURITIES
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Installed Capacity for Manufacturing
T and D Equipments in Vijai
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Annual Installed Capacity (MVA) CRGO
Transformer Plant at Hyderabad
1-Phase , 450
Small Power
Transformer
(5 MVA)
900
3 -Phase, 540
CRGO Transformers' Capacity (MVA)
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Annual Installed Capacity (MVA) for Low Loss –
Energy Efficient Amorphous Metal Core
Transformer Plant at Hyderabad
Single Phase,
3108
Three Phase,
5355.6
Transformer capacity in MVA (Amorphous Core)
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Annual Installed Capacity in Vijai
Haridwar Transformer
Plant - MVA
1-Phase , 450
Small Power
Transformer
(5 MVA)
1500
3 -Phase, 540
CRGO Transformers' Capacity (MVA)
1-Phase,
1200
3 -Phase,
1800
Amorphous Metal Core Transformers' capacity
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Summarized Annual Installed Capacity - MVA
Amorphous Plant
Single Phase – 3108 MVA
Three Phase – 5355 MVA
Sub Total – 8486 MVA
CRGO Plant
Single Phase –3376.8 MVA
Three Phase – 3456 MVA
Medium Power – 4500 MVA
Cast Resin – 54 MVA
Sub Total – 11386 MVA
Haridwar Plant
CRGO
1-Phase
450 MVA
3 -Phase 540 MVA
Medium Power 1500 MVA
Amorphous
1-Phase 1200 MVA
3 -Phase 1800 MVA
Sub total 5490 MVA
EHV Large Power Transformer
12000 MVA p.a
Annual Capacity for Power and
Distribution Transformers at a staggering
37000 MVA per annum
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Annual Capacity of Switch gear products
Sl.No
Product Name
Current
2008-09
Future
1
12 kV indoor VCB
1700
2400
12000
2
12 kV outdoor VCB’s
with 12 KV CTs
800
1200
6000
3
36 kV Outdoor VCB
500
600
2000
4
INSTRUMENT
TRANSFORMERS MV
600
2000
5000
5
INSTRUMENT
TRANSFORMERS EHV
500
1000
2000
6
145 kV Live tank
SF 6 breakers
75
150
1000
7
245 kV Live Tank and
Dead Tank
SF 6 breakers
40
80
500
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Annual Capacity of Switch gear products – Contd..
Sl.No
Product Name
Current
2008-09
Future
8
420 kV Dead Tank
SF 6 breakers
20
40
200
9
GIS 36 kV
50 bays
150 bays
300 bays
10
GIS EHV
20 bays
40 bays
100 bays
11
Vacuum interrupters
2000
30000
60000
Upto 36 KV
12
EHV Bushings
100
600
1800
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Infrastructure in Vijai
State of the art manufacturing facilities

AMDT plant
Conductor plant
CRGO plant
Exclusive Fabrication unit for
Transformer Tank and Radiators
EHV plant
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Upcoming facility for Switch gear
Haridwar plant
Brazil plant
Conductor plant @
Roorke
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Integrated Facilities
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• CORE PROCESSING FACILITY
• CONDUCTOR PLANT
• WINDING INSULATION MATERIAL
• TANK FABRICATION FACILITY
• RADIATOR MAKING FACILITY
• TRANSFORMER OIL PROCESSING
• ELECTRO – PORCELAIN (BUSHINGS) PLANT
• TAP SWITCH MAKING
• NITROGEN PLANT
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BENEFITS
Consistent Quality……….
Competitive Pricing………
Timely Delivery…………
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World’s Largest AMDT plant
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PLC based Core Dereeling and Spooling
PLC based Automatic Core Cutting
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Core loss testing
Semi Automatic Winding
machines
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HABS system in Vijai
Oil filling under Vacuum
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STRATEGIC ALLIANCES
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Technological Tie ups.
• Vijai Electricals Ltd. actively seeks and nurtures effective partnerships with likeminded
companies that provide complementary services so that it can offer its
customers, skilled & single-window solutions.
In Past
Westinghouse, USA-
M & C, Germany-
Daihen Corporation, Japan-
Transformers.
Westinghouse, USA-
For Single Phase Transformers
For Dry Type Cast Resin Transformers
For Amorphous Metal Core
For CLR/ CQR Circuit Breakers (with sister
concern SEL)
Present
Daihen Corporation, Japan- For Large Power Transformers up to
500 MVA, 500 kV Class
NIIVA Russia
For GIS /SF6
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RISING DEMAND FOR
CRGOs & AMDTS [No.s]
No. of
Transformers
supplied (nos.)
100000
80000
60000
40000
20000
0
97577
CRGO
61160
66765
AMDT
93620
2005 - 06
2006 - 07
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Supplies during previous financial years
Total AMDTs supplied (MVA) by Vijai
MVA
3000
2500
2000
1500
1000
500
533 563
868
1487 1468 2903
2004 - 05
2005 - 06
2006 - 07
0
1 - Ph 3 - Ph
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Categorical supplies
Total AMDTs supplied (nos. ) by Vijai
60000
56458
No.s
50000
40000
30000
20000
41120
40141
26624
18322
37162
2004 - 05
2005 - 06
2006 - 07
10000
0
1 - Ph 3 - Ph
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Concern on Energy Efficiency Concepts across
the Globe
• Bureau of Energy Efficiency in India- Introduced STAR
RATING based on the losses for Distribution Transformers
• Intelligent Energy Europe – SEEDT(Strategies for
development and diffusion of Energy Efficient Distribution
Transformers)
• US DOE – NEMA TP1 & TP2 Standards
• World Energy Council – UK
• MEPS Concept in Australia, New Zealand.
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Conclusions
• Power Utilities improve the Efficiency of their T & D system by reducing the
line losses.
• Among the various measures adopted for reduction of losses the use of Low
loss Energy Efficient Transformers (Amorphous) is always easily
accomplished.
• “Watts Saved” are more than “Watt Generated” which can be achieved by
using Energy Efficient Equipments in the networks reducing the need for
more Generation . This means less fossil – fuel dependency and reduced CO 2
Emissions.
• The Distribution Transformers supply power and remains on line for 24 hrs a
day & 365 days of the year. Being supply equipment it doesn't consume any
power but the process of transformation involves certain inherent losses. In
this context Amorphous Metal Core Transformers have a great advantage
because they save more than 70% of the No- load losses compared to
transformers with other Core material.
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SUPPORT FOR QUALIFYING REQUIREMENTS FOR
UPCOMING INDUSTRIES IN POWER SECTORS
“The ambitious plans of the Power Sector lined up by the
Ministry of Power is possible to achieve provided timely
support and encouragement is extended to the Indian
Industries who are investing in the Infrastructure backed by
the Technological support from Collaborators( Foreign/Indian)
or successful type testing in accredited laboratories along
with World class Manufacturing facilities, Testing facilities with
strong Quality and Management systems thereby giving equal
opportunities and considerations in the Qualifying
Requirements of the Utilities , PSU’s in their buying process.
It is also noteworthy to relook at the Quality of the Equipment
used and necessary incentives that needs to be offered to the
utilities who are able to use Energy Efficient Equipments in
the network and reduce losses.”
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The values which drive the Vijai’s development
Care for
people
We aim at growing personnel into responsible,
accountable and performing leaders, by providing
opportunities for professional development and by
rewarding performance
Focus on
performance
We are focused in identifying and capturing all
value creation opportunities, focusing on efficiency,
productivity and right value of our energy
Invest in the
community
We will pursue every opportunity to reinforce our
leadership position through investments and
acquisitions, maintaining a socially responsible and
safety oriented attitude towards the countries and
our stakeholders
People, Performance and Community
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Let’s look at a Greener and brighter Future
THANK YOU FOR YOUR ATTENTION
Hyd- July, 2007 44