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(B. LAL)Director General

INDIAN TRANSFORMER MANUFACTURERS ASSOCIATION

NEWSSEPTEMBER - OCTOBER 2017ISSUE 58

ITMAITMAITMAITMAITMAITMAITMAITMAITMAITMAITMA

Regional Half day Workshop/ Seminar on Standardization, Certification, Quality Control Order, Testing, Energy Efficiency, Reliability of Distribution Trans-formers and other related issues at Jaipur on 7th September 2017 at Hotel Fortune S e l e c t M e t r o p o l i t a n , J a i p u r, Rajasthan.

Bureau of Indian Standards (BIS) with suppor t o f Ind ian Transformer Manufacturer Association (ITMA), International Copper Association India (ICA India) has taken the initiative to spread awareness among power utilities and transformer manu-facturers to help them adopt the standard and update their technical specifications. In an attempt to facil itate sustainable development in India BIS, ICAI and ITMA today conducted a seminar on “Standardization, Certification & Quality Control Order, Testing Energy Efficiency (EE) and Reliability of Distribution Transformers”. The seminar was conducted in association with Central Electricity Authority (CEA), and Bureau of Energy Efficiency (BEE).

Distribution transformers (DT) is a vital equipment in electrical system to supply power to end consumers. Failure rate of DTs are very high in India generally to the order of 15% whereas in efficient utilities or advanced countries this is less than 1%. Reliability is an issue that has been under active consideration of policy

rest are level 1 (Star 3 of BEE Label) efficiency. However in Dec '16 on receiving Government Order through MoP notification, discontinuing previous star label 1 to 3 of BEE, effectively making star label 4 as new star label 1. The whole process got disturbed and supply of DTs got interrupted for quite some time since all tenders in process has to be retendered in line with guidelines.

He appreciated that such unique effort by ITMA, ICA India to bring Standard authority and OEMs along with users like utility allows open minded discussion and seeking resolution of problems that the industry faces. Dialogue between various stakeholders can help avoidance of ambiguity or confusion that exist while implementing new policies. Harmonization of standards between various arms of the Government like BEE and BIS is most needed.

He mentioned that DT failure cannot be attributed alone to manufacturing practice but due to varieties of reasons, be it operational or maintenance or asset management issues. Such common forum gives an opportunity to all to deliberate, discuss and resolve issues faced while rolling out ambitious program like Deendayal Upadhyaya Gramin Vidyutikaran Yojana.

Mr. R.K. Shrivastava, Managing Director Rajasthan Urja Vikas Nigam Limited (RUVNL), Govt. of Rajasthan and Chief Guest of the Seminar said in his inaugural address…It is an intensive experience to participate in this unique technical workshop and share the thoughts. Learning and applying the concepts from deliberation during the day will facilitate surely help the DISCOM in making 'Quality Power for All' at an affordable price to consumers. It is essential that we deliver every unit of electricity in a reliable & efficient way for achieving a sustained economic growth of the country. He observed that DTs are number one focus for all public representatives since it is viewed as Life Changer. For vast majority rural population transformers are considered to be blessings and while looking at larger picture one cannot forget the common man. Today every aspect of human life depends on power and rising aspiration of people have made distribution companies job more challenging to rise up to that expectation to adopt sustainable best practices to deliver EE and reliability.He mentioned three key points to be observed by the diverse stakeholders present to ensure better quality and reliability of the product.

makers aiming to supply quality power to all 24 x 7 basis. Keeping this in mind Government of India introduced quality control order for DTs as well mandating BIS certification that is ISI mark on Distribution Transformers.

The overarching objective of the seminar was to create awareness on the STANDARD – IS1180 (part-1), Certification & Quality Control of Distribution Transformers and enhance the Operational Efficiency, Incorporate Global Practices, Testing, Failure Analysis, and Improvement in Design and Performance of Distribution Transformers.

Mr. Debdas Goswami, Scientist (F) & Head BIS, Jaipur in his welcome address stated that “ DT has become a burning issue in recent times. Quality control policy is driven from highest policy makers of the country and BIS has accepted the mandate assigned. Standards are developed with national consensus under watchful eye of experts and users. On gazette notification there were flood of license application across India. But today after two years we at Jaipur have given eighty seven licenses with four more applications under active consideration in Rajasthan region, giving stability and bringing clarity. He mentioned that Rajasthan tops in number of DT Licensee followed by MP and Tamil Nadu. We must congratulate Industry facilitators like ITMA, & ICA India to facilitate in hosting this unique conference first time in the Region. We all are working towards a common national goal of providing continuous quality power supply to the consumers. Through such seminars we aim at helping industry to create awareness and upgrade their knowledge in adopting resourceful ways of preserving energy. It is essential to adopt energy efficient standards for distribution transformers as it will save total cost to consumers — ultimately saving money while serving customers 24 x 7 basis and also reducing energy consumption.”

Mr. Manas Kundu, Director - International Copper Association men-tioned in his address that , we see winds of change in Rajasthan as in many parts of India and in this city itself one can see lot of economic activities those are driven by electricity. At the same time vast rural India is targeted to be provided with access to energy for which DT is the prime mover.

We have standards those are globally one of the best in this area but still our DT failure rates and high technical losses are major areas of concern. So where are we going wrong! We the technical fraternity must ask ourselves what we can do differently to make it better from both reliability and energy efficiency point of view.

Besides EE and Reliability another key area is Repair of DTs. But the questions remains first; why the DT should fail at all being static device. The State of Rajasthan has around 1.3 million DTs and around 25% loss and these should be considered as an opportunity for all of us to put our thinking cap, act and cause change. He mentioned that EE as bottom of pyramid action based on least cost planning approach can contribute 15% of country's energy need.

Mr. Naveen Arora, Director (Technical) Jaipur Vidyut Vitaran Nigam Limited (JVVNL), Government of Rajasthan in his special address, said that “DTs are key assets for electric supply company and its helps in meeting the goal of “Electricity for All” hence the utility is looking for reliable DTs and at the same time energy efficiency too is a focus area since loss of energy is loss of money or revenue for the utility that is always trying to keep the lights on. In Rajasthan 1.25 Crore customers are served by various utilities. In Jaipur 13 lakhs DTs of various capacities both three and single phase are supplying to energy to customers.

He mentioned that JVVNL procures around 90000 DTs per year out of which 30 percent DTs are of level 2 efficiency ( Star 4 label of BEE) and

1. Utility : The stakeholders from utility sector are always handling burning issues and firefighting so such opportunities must be fully utilized to learn and apply the ideas discussed. He exhorted attentiveness of utility engineers in such seminars for better learning.

2. OEM : Standardization is very important and intention to create monopoly through small design changes etc may not support the business in long run. He exhorted that OEMs must avoid (a) Red Ocean Strategy where blood bath takes place in limited market and survival faces question mark but rather adopt (b) Blue Ocean Strategy where raise the bar through innovation in design and perfection in quality rather than creating hurdle for others. The blue ocean strategy like achieving 4 or 5 star ratings or proving your equipment lasts really long can give you winning position in market without disturbance.

3. Standardization bodies: Harmonization of standards like star rating of BEE merging with BIS standards can produce environment conducive for ease of doing business or make in India campaign taking deeper root.

He commended the role of ICA, a sustainable energy advocator, and ITMA, a progressive manufacturers association, facilitating BIS in committed ways to enhance the electricity distribution system. The implementation of higher energy efficiency transformers has sub-stantive environmental benefits too.

He wished all participants to have great time of learning, discussion and debate to come out with solutions for issues in hand.

Shri Vikas Gupta, Executive Council Member, ITMA and Proprietor, Vikas Transformers, Jaipur in his thanks giving address mentioned

“Today every unit of electricity consumed in the country is delivered through distribution transformers. As a progressive association of transformer manufacturers we at ITMA are committed to support the national energy efficiency goals to enhance the electricity distribution system and deliver power for all. The implementation of higher efficiency transformers has substantive environmental benefits. It will also facilitate advancements in manufacturers' energy saving technology while enhancing their productivity and thus lead to sustained economic growth.

He mentioned the hardship that the industry is currently going through and requested all to make constructive attempt in quick resolution of the problems due to dual certification of Distribution Transformers.

He thanked on behalf of ITMA & ICAI to each dignitaries for having spared time to be present and all participants to make the conference on overwhelming success.

ABOLISHING OFDUAL CERTIFICATION/REGISTRATION OFDTS UNDER BIS AND BEE.

The issue of dual certification of DTs has been taken up by ITMA at various forums, even at the level of Hon'ble Power Minister but without any relief. The issue has also been taken up with Hon'ble Union Minister for Commerce and Industries under “ease of doing business”the slogan of Government of India on 25th August 2017 along with the other issues viz timely payment and interest on delayed payments as discussed in the special meeting of ITMA select members on 21st August 2017.

Monitoring Committee meeting on Distribution Transformers also discussed this issue in detail and under “ease of doing business”. Chairman of the committee advised BEE to accept the same type test report for Star Label as considered by BIS while issue of BIS certification / licenceand also reduce the time period of 30 days for issue of BEE's label . ITMA shall follow up this matter with MoP and Ministry of Commerce & Industry, till it is resolved, but till then we have to continue with both the certification processes.

VALIDITY OF TYPE TEST CERTIFICATE FROM THE DATE OF ISSUE

The issue was discussed at length in the Monitoring Committee on Distribution Transformers meeting held on 22nd August 2017 under the chairman ship of Chief Engineer (DP & D) and was emphasized that the type tests should be valid till there is no change in design or major change in the technical specifications. However BIS representative informed in the meeting that at present the validity of the type test is for 5 years. Members were of the view that CEA should insist on Utilities/Discoms and other stake holders not to repeat the type test, if there is a change in design or raw material or the standards and the Utilities/Discoms should adhere to it.

PREPAREDNESS OF STAKEHOLDERS TO MANUFACTURE AND SUPPLY NEW STAR RATING 2, 3, 4 & 5 OF DISTRIBUTION TRANSFORMER AS PER NOTIFICATION DATED 16TH DECEMBER 2016.

This issue was discussed in the Monitoring Committee of Distribution Transformers on 22nd August 2017 wherein it was stated that Industry/ Discoms have accepted the new minimum star 1 labelof the MoPs Notification dated 12th December 2016. Whereas now for the implementation of next star label 2 onwards, a calendar needs to be prepared after consultation with the various stakeholders based on the proper assessment of availability of material and technology in advance. This calendar will help the stakeholders to be prepared /ready for implementation of the next higher Energy Efficiency star labels as per the notification dated 12th December 2016.

Mr. Chakrdhar, CEO of M/s. Vijai Electricals stated that they have successfully type tested (including the short circuit test ) the prototypes of the following ratings of DTs with the lowest loss figures i.e. with Star 5 with CRGO core material as per notification dated 16.12.2016 of MoP promulgating the revised star levels ( from 1 to 5 ) for the DTs from 16 KVA up to 2500 KVA rating in 11 KV class. The prototypes have been tested at NABL accredited lab, in ERDA in the month of April 2017.

warranty clause is being misused by the Discoms / Utilities for replacement of the transformers which have failed within the warranty period not due to any manufacturing defect but due to callousness of the Utilities / Discoms for not adhering to the proper installation and operation &maintenance manual for desired up keep of the transformers.

Shri Pawan Kumar Jain of KotsonsTransformersAlwar/Agra stated that this issue of warranty period was taken up with Rajasthan Discoms, where Chairman and the MD of Discoms after detailed delebrations and analysis, have reduced the Guarantee/Warranty period for Distribution Transformers from 5 years to 3 years. The authorities agreed with the argument of the association that by increasing the Guarantee/ Warranty period in the tender documents (on the analysis) the failure rate of Distribution Transformers has not come down as the staff responsible to maintenance of the Distribution Transformers as per the standard Operation and Maintenance practices, are prone to lethargy in their duty since the failed transformer during the warranty period gets repaired/replaced free of cost. However after reducing the warranty period to 3 years the failure rate of Distribution Transformers in Rajasthan, Discomshas come down and the staff is also now more attentive alert towards their duty to maintain the Distribution Transformers as per the standard Operation and Maintenance manual of the Utility/Discoms, and the transformer provides service to its designated life span.

It was suggested that we should take up the matter with CEA for impressing upon the Discoms/Utilities to keep the warranty/guarantee period as per the standard practices of 18/24 months as per the CEA's guidelines on distribution transformers of 2008. However some of the members were of the view that the warranty period is being agreed by our members in the tenders issued by with Discoms/Utilities in a bid to get orders due to which the utilities are impressing for the same. The Chair suggested that if members do not agree to the enhanced warranty period the utility may not insist for the same.

Mr. Anil Aggarwal, suggested that as Rajasthan Discoms have reduced the warranty period to 3 years, we may take up the matter with another state say UP and narrate /explain the success story of Rajasthan Discoms that by reducing the warranty period they are able to reduce the failure rate of transformers. Such a campaign shall be useful and can be extended to other states in future. It is therefore necessary that a Task Force is formulated with the following members to taking up with authorities in Uttar Pradesh (UP).

(I) 315 KVA 11/0.433 KV, CRGO Core, Cu wound. Total Losses at 75 deg C : 772 watt (max at 50% load) and 1920 Watt (max. at 100% load) (ii) 500 KVA 11/0.433 KV, CRGO Core, Cu wound. Total Losses at 75deg C : 1215 watt (max. at 50% load) and 3554 Watt (max. at 100% load ).

The above proto types were manufactured with CRGO grade 23PHD85 sourced from M/S POSCO IDPC Bawal.

Members stated that BEE has not yet issued any clarifications for the supply/execution of the orders of Distribution Transformers to EPC contractors and the private parties, placed prior to 30th June 2017.

SEPARATE STANDARDS FOR DISTRIBUTION TRANSFORMERS HAVING CRGO AND AMORPHOUS CORES.

This issue of separate standard for Distribution Transformers with material specific I.e. CRGO or Amorphous Core was discussed in the last meeting of the Special Committee of ITMA of selected members on. 21st August 2017 and the members were divided on the issue and were of the opinion that this matter should be discussed with all the members as this small select group may not be appropriate to take decision on the issue as ITMA has also members who are manufacturing DTs with amorphous metal.

Mr. Sanjay Seth from Hitachi Metals requested the chair to discuss this issue in the todays Executive Council meeting. Shri Aggarwal allowed the house to discuss the issue. Members were of the opinion that the standard should give only the parameters and should not be material specific, it would be the responsibility of the designer to select the techno-economic design with available technology and the raw material in the market to meet the requirements of the Standard. Finally after detailed deliberation it was decided that there is no need for the separate standard for Distribution Transformers based on the raw material.

STANDARDIZATION/ UNIFORMITY OF SPECIFICATIONS AT NATIONAL LEVEL

Members deliberated this issue at length and were of the opinion that the specifications for DTs should be governed by Indian Standard IS:1180 Part 1/2014 with its up to date amendments and should be followed in toto by all the Utilities/Discoms and EPC contractors more so when it is under quality control order for BIS certification as per IS:1180 Part 1/2014. DG ITMA informed the members that ITMA has already taken up this issue with CEA for uniformity of technical specifications for DTs and power transformers upto 33 KV level used in the distribution system at National level. CEA has been requested by ITMA on 25th July 2017 for convening the meeting of the stakeholders for discussing the document already in vogue for finalization and adoption at National level. It is very necessary as all the Discoms/Utilities are still floating tenders (for procurement of Dts) for projects other than DDUGJY and IPDS with different specifications not in line with IS:1180 Part 1/2014. The Chair advised the ITMA Secretariat to follow up with CEA for the early meeting of the stake holders.

WARRANTY / GUARANTEE PERIOD FOR DISTRIBUTION TRANSFORMERS.

Members mentioned that Discoms/Utilities who have been asking for the warranty/guaranty period for transformers up to 60 / 66 months in their tender documents which is too high and the members /manufacturers are adhering to the conditions in order to get the orders. But this