Sai Electricals Wishes You A Very Happy & Prosperous New Year 2016 To All.

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Sai Electricals Wishes You A Very Happy Merry Christmas And New Year To All.

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In case any enquiry feel free to contact us at info@saielectricals.com

Listing of blogs on Transformer

Dear Sir,

Transformer experts at Sai Electricals have been releasing blogs on various topics for transformers. The blogs mainly cover following topics-

1.  Installation and Maintenance.

2. Protection of Transformers.

3. Standards and Energy Efficiency of Transformers.

4. Essentials and Selection Criteria of Transformers.

5. Corrugated Transformers and Compact Sub Stations.

We give here below links for all the blogs published by Sai Electricals to enable you to acquire your desired information.

1.   Installation and Maintenance.

 1.1    Site Instructions for Transformers (Part 1)

 1.2    Site Instructions for Transformers (Part 2)

1.3    SiteInstructions for Transformers (Part 3)

1.4    SiteInstructions for Transformers (Part 4)

1.5    SiteInstructions for Transformers (Part 5)

1.6    Maintenanceof the Transformer

1.7    Failures in Transformers

2.   Protection of Transformers.

2.1    Transformer Protection (Part-1)

2.2    Transformer ProtectionBest Practices

2.3    Transformer Protection (Part-2)

2.4    On-LineCondition Monitoring of Transformer

3.   Standards and Energy Efficiency of Transformers.

3.1    Revision InIs 1180: Highlighted Points (Part I)

3.2    Revision InIs 1180: Highlighted Points (Part II)

3.3    Revision InIs 1180: Summary Points (Part III)

3.4    Method ofReducing Energy Bills through Energy Efficient Transformers

3.5    ECBCTransformers Guidelines

4.   Essentials and Selection Criteria of Transformers.

4.1    Selection ofRight Transformers (Part 1)

4.2    PowerTransformer:Essential Asset of an Electrical System(Part-1)

 4.3   PowerTransformer:Essential Asset of an Electrical System(Part-2)

5.   Corrugated Transformers and Compact Sub Stations.

5.1    CorrugatedTransformers: Benefits & Application

In case any enquiry free feel to contact us at info@saielectricals.com or visit our website www.saielectricals.com

SAI ELECTRICALS WISHES HAPPY AND PROSPEROUS DIWALI TO ALL ENJOY WITH YOUR FAMILY AND FRIENDS.

Diwali is the festival of lights may this divine festival removes all darkness from your life.... forever.

May on this Dhanteras goddess lakshmi bless you with happiness good health and wealth.

On this auspicious day of dussehra... I wish you every happiness and the fulfillment of all your dreams.

Wishing you a very auspicious and delightful navratri. Subh Navratri.

May the spirit of truth and non-violence be with us in this Gandhi Jayanti. Best Wishes on Gandhi Jayanti…

Heartfelt Wishes to our friends and followers on this joyful occasion of Eid Al-Azha.

ZERO DEFECT AND ZERO EFFECT

Recently our Prime Minister Mr. Narendra Modi has been given a new slogan to our nation, "Don't compromise on two points “Zero Defect” and “Zero Effect".

Now Let's think about this quote deeply we conclude that making our product which has 'zero defect' so that it does not come back (get rejected) from the market and 'zero effect' so that the manufacturing does not have an bad & worst effect on our environment".

To achieve “Zero Defect” we have implemented the following:

A) Quality circles:

1) for identifying problems and providing solutions by Implementation of following:

2) Preparing cause and effect diagram

3) Pareto Analysis

4) Check sheets

5) Inter departmental customer satisfaction

B) Implementation of 5 S across plant.

C) Implementation of LEAN MANUFACTURING to reduce the wastages 

1) We are member of Lean manufacturing council under MSME Ministry Government of India.

2) Implemented ISO 9001 Quality System.

3) This initiative has reduced our wastages and delays by implementation of line balancing.

D) Use of computer aided design for reliable and defect free product.

Our Motto is:

“GREEN PRODUCT FROM GREEN PLANT FOR GREEN ENVIRONMENT”

A) We have reduced the carbon foot prints by using solar energy for oil processing and natural gas for heating ovens.

B) Water Harvesting.

C) No industrial waste is being drained out in environment.

D) By automated design using CAD we have been able to design products with lesser materials to reduce carbon foot prints.

E)   Power conditioning product i.e. Servo Voltage Stabilizer, Lighting, Isolation & Harmonic Offset Transformers and also manufacturing energy saving transformers as per Bureau of Energy Efficiency guidelines.

In case any enquiry free feel to contact us at info@saielectricals.com or visit our website www.saielectricals.com

Sai Electricals wishing you all very happy janmasthmi. Makhan chor bless you all with happiness and joyful.

Sai Electricals wish you “HAPPY RAKSHA BANDHAN” and I pray to God for your prosperous life.

SITE INSTRUCTIONS FOR TRANSFORMERS (PART 5)

After successful installation it is very important to take care of the various safety measures during operation of transformer. Transformer ageing is very much depends upon various stresses like electrical i.e. loading patterns, surges & spikes, voltage & frequency variations, short circuit forces, over fluxing harmonic, mechanical, chemical and environmental factors which will affect the insulation of transformer and deteriorate the insulation this deterioration will affect the performance of transformer and reliability of equipment got reduced. Besides of theses stresses faults like partial discharge, electrical arcs, or hot spots generally deteriorate the condition of transformer in quick progression. Hence early detection of these faults is very important for saving transformer from any catastrophic failure.

Now a day’s various methods are available with us through which we can monitor and record the real time data for various parameters which are having a great impact on transformer performance, some of the parameters are as follows:

1) Internal Parameters

a) H2 PPM Level

b) Ambient Temperature

c) Oil Temperature

d) Winding Temperature Rise

2) External Parameters

a) Voltage & Current on all three phases.

b) Active/ Reactive Apparent Energy & Power

c) Maximum Demand/ Demand Forecasting

d) Time Bound & Stamped Data for KVAH/KWH/KVAR

With strict monitoring, accurate diagnostics of above parameters the following would be achieved effectively:

• Asset economic loading conditions identification and assessment for maximum practicable operating efficiency.

• Premature failures risk minimization.

• Life estimation and timely asset replacement/ retiring planning.

• Asset life extension by implementing correct operational and cost effective maintenance strategies

• Improvement in the system performance ensuring good reliability as well as plant availability.

• Minimization of the long-term operational cost.

• Cost saving by eliminating the unplanned maintenance.

• Minimizing the outage period.

• Relocation/ retirement planning.

• In time procurement of spare parts to get competitive rates.

• To enhance the overall reliability of the system

• Accurate risk assessment.

For recording and monitoring the real time date for above parameters we can take the help of online condition monitoring system for transformer, the typical schematic diagram is as below:

Above system are available with powerful software and having the various features some of them are as below:

Connectivity

Available through MODBUS, RS 485 & GSM/CDMA (Though Modem)

Inbuilt Software

Available & Suitable for Planning Preventive Maintenance Schedules, Asset Life Extension, Load Management and fault Monitoring

Data Storage

Data can be stored in graphical forms as well as time stamped forms

Suitable for all Voltage Class Transformers.

As we can see from above that online condition monitoring system are available with inbuilt software through which we can analyze the data and can plan our various activities which will help us in enhancing the life of transformer as well as reliability of equipment. With the help of above system we can observe 255nos. of transformer at a time. It will also benefit the end user to have power supply without interruption, in particular the industrial sector. It will reduce the risks to human kind and the environmental damages.

In case any enquiry feel free to contact us at:info@saielectricals.com

WHY Meerut is vibrant enough to become a smart city

By Girish Kumar

Keeping in view the aspirations of modern citizens, in todays world any city with a populations of 1.5 to 2.0 millions people will require smart city to live a life of Vibrancy. A smart city that is equipped with basic infrastructure to give high quality of life, a clean and sustainable environment through application of some smart solutions. Assured water and electricity supply, sanitation and solid waste management, efficient urban mobility and public transport, robust IT connectivity, e-governance and citizen participation, safety and security of citizens.Assured water and electricity supply, sanitation and solid waste management, efficient urban mobility and public transport, robust IT connectivity, e-governance and citizen participation, safety and security of citizens.

Meerut is the second largest city in National Capital region only after Delhi. Meerut could be one of the smart cities of India.

The city Meerut feels pride to stand fifth on the vibrancy index, declared by the US based financial company Morgan Stanley in the 2011 survey done on 200 cities of India. After examining it on their prescribed parameters the company adjudged its position ahead of Delhi and Mumbai in terms of investment and economic growth.

The Walled city Meerut has shown its existence from ancient period of Lord Rama and thereafter Kuru dynasty of Mahabharta which had privilege of having close association with Lord Krishna. The city also has pride of having some of the archeological site like Alamgirpur which existed parallel to Harrapa and Mohanjodaro. It also spearheaded the first war of Independence against British Raj in 1857.

SMART ENVIRONMENT

Besides being second largest city in National Capital Region (NCR) it also spearheaded the green revolution in the region in 1970s turning the region into an ‘agriculture belt’. The bumper crop of Sugarcane and potato year after year has paved the way of setting up many sugar mills and food processing plants in the region.

The trade of frozen meat flourished in the region in past one decade and many of international brands of frozen meat belong to this city which has been earning a good amount of foreign currency for country`s exchequer.

SMART ECONOMY

The city also has earned name in the manufacturing of sports goods especially world`s top cricket brand SG, SS and BDM have originated from this walled city. Engineering industry is another emerging commerce in the city. Known for its fine work of scissors manufacturing it has earned certification of geographic indicator patent in the name of 'MEERUT SCISSORS'. This for the first time that traditional manufacturing activity has earned GI Patent in India.

Original special taste of ‘Rewari and Gajak’ which is now choice of millions across the globe. 

SMART PEOPLE

Education and language play a significant role in the development of a city and Meerut is quite fortunate in the way that even after experiencing brunt of many communal riots in past people of different communities have shown their zeal to live and advance on the path of development together.

City peoples` die hard’ attitude also makes it a fit case to put it in a path of development for better future of their coming generation and country as well.

With more than three dozen engineering colleges and over 70 public schools the city has emerged as hub of education. This has given the city youngsters who are well versed in English language which helps in connecting them with rest of the world and easy access to information on internet. The city also has advantage of having four universities including one agriculture university and two medical colleges.

Its skilled artisans are a major demographic advantage for engineering industry while industrialists and entrepreneurs enjoy a cordial relationship which is evident by the fact that the city has experience no ‘labour unrest’ in past fifteen years.

It is a virgin place for industrial development and 12% of its land is available for industrial use along with the advantage of low cost as compared to other places of NCR. Seeing the potential of development GAILGAS Ltd. has made its elaborate setup in the district in order to provide clean and green piped gas fuel to industries for better development of the area. Food proccesssing industries have advantage of low cost of inputs in terms of fuel as well as agriculture produce.

SMART LIVING

The people and the culture of Meerut has promoted harmony and balance between the science and technology of the modern world we live in and the beauty and purity of the natural world that surrounds us. The city is resource rich in terms of the quality of soil available for growing organic agricultural food as also this becomes possible because of the availability of less contaminated Ganga water. 

SMART MOBILITY

In a quest to develop the city as new center of development the city is likely to get share of infrastructure projects of over Rs 20,000 crore in coming years These projects include Meerut Delhi express way, Rapid Rail Transit System, Bulandshahr- Meerut express way, Western Peripheral Expressway, Eastern Peripheral Expressway, Upper Ganga Expressway, Airport, Delhi Mumbai Freight Corridor, Amritsar Howrah freight Corridor etc.

Meerut stands thorough on the five pillars of a smart city which are smart economy, smart people, smart environment, smart mobility and smart living. All that we need is smart governance.

(The author is an entrepreneur Graduated from IIT, Kanpur, entrepreneur and activily associated with Industrial Association like CII, IIA, FISME, ITMA AND MIDFo)

In case any enquiry feel free to contact us at:info@saielectricals.com

ENERGY SAVING UNDER PRESENT POWER SCEANARIO

India has 16% of world’s population, but less than 1% of the world’s energy resources. There is a huge difference in the demand and availability of energy. The total installed capacity is 207006MW and the present peak demand is 217000MW. However this peak demand has not taken into account energy generated through alternate sources. Hence the peak demand may be 10% higher if alternate sources are factored in. The real challenge for the power sector is to narrow this gap. This can be done by increasing the installed capacity but it requires high CAPEX. The second option is to narrow the gap through energy saving or energy conservation.

There is a huge potential to save energy in various sectors i.e. Industrial, Agriculture and domestic. Energy conservation can be achieved by both, a promotional and a regulatory role. Promotional role includes awareness, education, training, demonstration etc. Regulatory role includes energy audits, deciding the norms of energy and implementation of standards through act of parliament.

Some areas of energy conservation are as below:

Supply Side

A) Improving existing thermal power station performance

B) Grid Management

C) Reducing losses in transmission and distribution system

Demand Side

Energy saving initiations can be taken in the following sectors. It is estimated that these initiatives can save upto 20% energy i.e. it can totally end the demand supply gap.

A) Industrial Sector

B) Domestic Sector

C) Commercial Sector

D) Agriculture Sector

Now let us talk about the Energy Conservation on Demand side as most of us are concerned with Demand side. Energy used in Ind., Domestic & Comm. sector plays a vital role in whole energy scenario. Energy saving can be promoted by educating the consumer for using the good quality power i.e. by improving the voltage profile, improving the power factor of system, balance power supply Etc.

When our installed equipment does not get optimum voltage, it consumes excessive energy. This energy wastage is, however, invisible & goes unnoticed. But this poor quality power will have a great impact on our energy bills as well as our costly equipment could be damaged due to this voltage fluctuation. Besides voltage fluctuations and imbalance of phase voltage is also an important factor of energy loss. Unbalancing between the ph. voltages generate problems like heating motors and wiring and hence, increased energy consumption etc.

Electric utilities aim to provide service to customers at a specific voltage level, for example, 220V or 240V, but service voltage to customers will in fact vary along the length of a conductor of a distribution feeder. Since there is no law and local practice, actual service voltage exceeds the tolerance band such as ±5% or ±10%. In order to maintain voltage within tolerance under changing load conditions, various types of devices are traditionally employed by the consumers themselves. In India fluctuations in input power supply are common and frequent and input voltage practically varies between 300 to 480V. If we are able to optimize this fluctuation we can save the energy as well as life and reliability of our installed equipments. Now from below example we can see that how voltage optimization contributes towards energy saving:

Resistive element of load: V = I x R (Where V = Voltage, I = Current & R = Load)

With constant load, reduction in voltage will correspondingly reduce current.

For example a 5% reduction in the voltage at the motor will result a 5% reduction in current.

Now Suppose P1= V x I

After reducing the voltage & current by 5% than P2 = 0.95V x 0.95I = 0.9025VI

So we can conclude that reducing the input voltage by 5% will reduce consumed power by 10%.

This builds up a strong case to maintain optimum voltage at demand side by using SERVO VOLTAGE STABILIZER.

Government has also recognized this fact and is providing 80% depreciation on this product as a energy saving equipment.

In case any enquiry feel free to contact us at:info@saielectricals.com

TRANSFORMER PROTECTION

All we know that a transformer works as a heart of an electrical system. As a critical and an expensive component of the power systems, transformers play an important role in power delivery and the integrity of the power system network as a whole. Each Transformer have a specified limits of operation beyond which the loss of transformer life can occur. If subjected to adverse conditions there can be a heavy damage to the system and system equipment, besides intolerable interruption of service to the customers. Since the lead time for repair and replacement of transformers is usually very long, therefore limiting the damage to faulted transformers is the foremost objective of transformer protection.

Due to transformer failure direct and indirect impacts is there, which are as below;

Direct impact: The direct economic impact of repairing or replacing the transformer in terms of money.

Indirect impact: After transformer failure supply to the customer got interrupted due to which production loss will occur which will affect the economy of nation.

Transformer Failure:

There are various Environmental Conditions due to which transformer operation got affected and loss of transformer life will occur, further the risk of a transformer failure is two-dimensional: the frequency of failure and the severity of failure. Most often transformer failures are a result of "insulation failure". This category includes inadequate or defective installation, insulation deterioration, and short circuits, as opposed to exterior surges such as lightning and line faults.

Failures in transformers can be classified into

•  Winding failures resulting from short circuits (turn-turn faults, phase-phase faults,    phase-ground, open winding)
•  Core faults (core insulation failure, shorted laminations)
•  Terminal failures (open leads, loose connections, short circuits)
•  On-load tap changer failures (mechanical, electrical, short circuit, overheating)
•  Abnormal operating conditions (overfluxing, overloading, overvoltage)
•  External faults

Besides of above there are some other causes of transformer failure which may include.

Overloading: Transformers that experience a sustained loading that exceeds the nameplate capacity often face failure due to overloading.

Line Surge: Failure caused by switching surges, voltage spikes, line faults/flashovers, and other T&D abnormalities suggests that more attention should be given to surge protection, or the adequacy of coil clamping and short circuit strength.

Loose Connections: Loose connections, improper mating of dissimilar metals, improper torquing of bolted connections etc can also lead to failures in transformers.

Oil Contamination: Oil contamination resulting in sludging, carbon tracking and humidity in the  oil can often result in transformer failure.

Design/Manufacturing Errors: This includes conditions such as: loose or unsupported leads, loose blocking, poor brazing, inadequate core insulation, inferior short circuit strength, and foreign objects left in the tank.

Improper Maintenance/Operation: Inadequate or improper maintenance and operation are a major cause of transformer failures. It includes disconnected or improperly set controls, loss of coolant, accumulation of dirt & oil, and corrosion.

External Factors: Several external factors like floods, fire explosions, lightening and moisture can be established as the causes of the failure as well.

TRANSFORMER PROTECTION BEST PRACTICES

• Transformer failures and safety hazards can be avoided or minimized by ensuring that the conductors and equipment are properly sized, protected and adequately grounded. Incorrect installation of transformers can result in fires from improper protection, as well as electric shock from inadequate grounding.
• Once the transformer is placed, the tank must be permanently grounded with a correctly sized and properly installed permanent ground.
•  Access should be restricted to the transformer liquid-filled compartment in conditions of excessive humidity or rain.
• Dry air should be continuously pumped into the gas space if humidity exceeds 70%.
• Transformer should be given protection against rain such that no water gets inside.
•  All equipment used in the handling of the fluid (hoses, pumps, etc.) should be clean and dry. If the insulating liquid for inspection is drawn out, its level should not go below the top of windings.
• Sufficient gas pressure must be maintained to allow a positive pressure of 1 psi to 2 psi at all times (even at low amb.temp.) when liquid-filled transformers are stored outside.
• Final inspection of the transformer is essential before it is energized. All electrical connections, bushings, draw lead connections should be checked.
• Upon loading the transformer it should be kept under observation during the first few hours of operation. All temperatures and pressures should be checked in the transformer tank during the first week of operation.
• Surge arresters must be installed and connected to the transformer bushing / terminals with the shortest possible leads to protect the equipment from line switching surges and lightning.

    In case any enquiry feel free to contact us at:info@saielectricals.com

HOW TO IMPROVE THE POWERFACTOR OF AN SYSTEM

In continuation of our previous blog, it is proved that improved power factor can improve the system efficiency and we can get the best output by improving the power factor.

Now the question arises that how we can improve the power factor of our system, we have studied that sources of reactive power i.e. inductive loads decreases power factor, some of the loads are as below:

a)      Transformers

b)      Induction Motors

c)       Induction Generators

d)      High Intensity Discharge (HID) Lighting

Similarly consumers of reactive power through which we can improve the power factor are as follows:

a)      Capacitors

b)      Synchronous Generators

c)       Synchronous Motors

Installation of capacitors or Automatic Power factor Control panel (APFC) are best option to improve the power factor of an electrical system. Installing of APFC i.e. capacitor bank decreases the magnitude of reactive power (KVAR), thus increasing the power factor.

Reactive power (KVAR), caused by inductive loads, always acts at a 90 Degree angle to working power i.e. KW

Inductive and capacitance react at 180 Degrees to each other. Capacitors store KVAR and release energy to opposing the reactive energy caused by the inductive loads. The presence of both a capacitor and inductor in the same circuit results in the continuous alternating transfer of energy between the two, thus when the circuit is balanced, all the energy released by the inductor is absorbed by the capacitor. 

Above capacitor banks or APFC panels is provided with power factor controller which monitors the actual power factor and orders the connection or disconnection of capacitors in order to obtain the required power factor. Connection is usually provided by contactors.

 Advantage

• Elimination of low power factor penalty levied by electrical supply authorities and avail the incentives as per Electricity   board.

• Reduced kVA demand charges

• Prevention of leading power factor in an installation.

 Salient features

• Panel design which allows easy handling by the user.

• Switchgear used such as contactors, Switch disconnects or, fuses, MCCB’s etc. conform to the latest Indian and International Standards.

In case any enquiry feel free to contact us at: info@saielectricals.com

IMPORTANCE OF POWER FACTOR IN AN ELECTRICAL SYSYTEM

To know the importance of power factor in an electrical system, first of all we should have the knowledge of some basic terms which are used in an electrical system i.e actual power, reactive power etc.. In an electrical system the power flow has two components, one flow from source to load and able to perform the work at load known as KW or actual power, and the other one is the reactive power which cannot perform any work and it is generated due to the delay between voltage and current known as phase angle. There are one another term is apparent power which are the sum of actual power & reactive power, It is denoted as KVAR. So that we can say that

Apparent Power = Actual Power + Reactive Power

Total KVA = KW + KVAR

Power factor = KW / KVA = KW / (KW+KVAR)

In an ideal system KVAR would be very small and KW and KVA would be almost equal, so we are trying to design an electrical system with power factor 1 than only we are able to get the maximum output from a system. This phenomenon can also be shown as power triangle as below:

Where Cos Ɵ  is power factor angle i.e. Cos Ɵ = KW/KVA

Reasons of Lower Power Factor:

Since power factor is defined as the ratio of KW to KVA, we see that low power factor results when KW is small in relation to KVA. Now the question arises what causes a large KVAR in a system? The answer is…inductive loads.

Inductive loads (which are sources of Reactive Power) include:

􀂉 Transformers

􀂉 Induction motors

􀂉 Induction generators (wind mill generators)

􀂉 High intensity discharge (HID) lighting

These inductive loads constitute a major portion of the power consumed in industrial complexes. Reactive power (KVAR) required by inductive loads increases the amount of apparent power (KVA) in our distribution system. This increase in reactive and apparent power results in a larger angle θ (measured between KW and KVA). Recall that, as θ increases, cosine θ (or power factor) decreases. So, inductive loads (with large KVAR) result in low power factor.

So there are several reasons due to which, we have to improve our system power factor, some of the benefits are as below:

1) Lower Utility Charges :

a. Reducing Peak KW billing demand

Inductive loads require reactive power, which caused low power factor. This increase in required reactive power (KVAR) causes an increase in required apparent power (KVA), which is what the utility is supplying. So, a facility’s low power factor causes the utility to have to increase its generation and transmission capacity in order to handle this extra demand. By raising power factor, we use less KVAR. This results in less KW, which will help in savings of the utility.

b. Eliminating the power factor penalty

Utilities usually charge customers an additional fee when their power factor is less. Thus, we can avoid this additional fee by increasing our power factor. Now a day’s utilities start the billing in KVAH instead of KWH, this is another reason due to which controlling of power factor is essential.

2) Increased System Capacity and Reduced System Losses in our Electrical System

By adding capacitors (KVAR generators) to the system, the power factor is improved and the KW capacity of the system is increased.

For example, a 1,000 KVA transformer with an 80% power factor provides 800 KW (600 KVAR) of power to the main bus.

1000 KVA = (800 KW)2 + ( ? KVAR)2

KVAR = 600

By increasing the power factor to 90%, more KW can be supplied for the same amount of KVA.

1000 KVA = (900 KW)2 + ( ? KVAR)2

KVAR = 436

The KW capacity of the system increases to 900 KW and the utility supplies only 436 KVAR. Uncorrected power factor causes power system losses in our distribution system. By improving our power factor, these losses can be reduced. With the current rise in the cost of energy, increased efficiency is very desirable, and with lower system losses, we are also able to add additional load to your system.

In case any enquiry feel free to contact us at: info@saielectricals.com