Documente Academic
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Issue: 1
` 25/-
Bimonthly, Chennai
Chairman
Mr. Madhusudan Khemka
Managing Director
Regen Powertech Pvt. Ltd., Chennai
Vice Chairman
Mr. Chintan Shah
President & Head, (SBD)
Suzlon Energy Limited, Pune
Issue: 1
Contents
Page No.
Yesheen Vibhakar, Head, SCM Operational Excellence, Suzlon Energy Limited, Pune
Honorary Secretary
Mr. Devansh Jain
Director, Inox Wind Limited, Noida
Executive Members
Secretary General
Mr. D.V. Giri, IWTMA, Chennai
16
Steve Sawyer, Secretary General, Global Wind Energy Council, Brussels, Belgium
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23
Srikaanth Sarangapani
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Rajanish Saxena, Assistant Vice President- Sourcing, Regen Powertech Private Limited
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37
Sri Abhijit Kulkarni, General Manager, SKF INdia Ltd. and IWTMA Team
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40
Dear Readers,
The visit of the President of United States of America,
Mr. Barack Obama, is a momentous occasion to the
country as the Chief Guest at the 66th Republic Day
Celebration on 26th January 2015. More importantly,
the major agenda was on furthering cooperation
in Renewable Energy. Readers are aware that the
Government of India has now set a target of 60 GW
Wind Power by 2022.
The Government while sensing the laudable targets of 100 GW of Solar and 60 GW of Wind, Ministry of New and
Renewable Energy (MNRE) is organizing a two days conference and three days exhibition titled RE-Invest in New
Delhi from February 15-17, 2015. It is a matter of pride that the Honble Prime Minister of India is inaugurating the
RE-Invest on February 15, 2015 at Vigyan Bhawan, New Delhi.
The wind industry is committed to meet the laudable targets Make it Happen with our support and pledge to
the Prime Ministers Make in India Campaign. The wind sector has already achieved 70% localization and fully
committed to the National Offset Policy of Government of India.
Rightly so, this issue is dedicated to Supply Chain Management, which is the backbone to this Capital Good
Industry where components are tailor made to different technologies. The technological innovation is an on-going
process and this has resulted in higher Plant Load Factors (PLF) and Capacity Utilization Factors (CUF) in operating
wind farms in low and medium wind regime.
The industry is thankful to the various ministries viz., Ministry of Finance, Ministry of Power, Ministry of New
and Renewable Energy, Ministry of Environment, Forest and Climate Change to address various opportunities and
challenges. We, in IWTMA, believe that once the land reforms are available for easy accessibility to land, ambitious
programme of PGCIL for evacuation and continuity of proactive policies of the Government will make this silent
non-polluting wind power unstoppable to achieve the energy security for the country.
Finally, on behalf of IWTMA, I wish the readers and their families a Happy Holi and a Year of Prosperity.
We encourage you to enjoy reading this issue and equally look forward to your valuable feedback.
Madhusudan Khemka
Chairman
2.
9.
question.
3.
4.
2. USA
5.
3. South Africa
4. Egypt
first in NE Brazil.
6.
Japanese
wind
to
get
some
post-Fukushima
5. Germany
momentum.
7.
8.
6. India
7. Vietnam
8. Mexico
9. Ghana
10. Brazil
Post Commissioning
Fulfil
the
equipment
warranty
obligations,
OMS (Operations & Maintenance Services), spares and
consumables, component servicing. It also extends well
after the serial life of the product to ensure supply of
parts and components for the lifecycle of the product.
Design Phase
This phase is where the concept and the boundary conditions
on what is likely to follow gets largely determined.
The sites where wind power plants are erected are also called
wind farms, generally in multiples of 50 MW capacities.
The wind power plant consists of two key parts: The PE
(Power Evacuation) and WTG (Wind Turbine Generator)
(also referred as WEC (Wind Energy Convertor) in some
regions). The better and more accessible wind sites got
consumed in the early phase of wind energy movement
which started a couple of decades ago for India. The
sites which are less accessible/ remote or have lesser wind
environmental
and
Thank You,
www.indianwindpower.com
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3rd Wrapper
4th Wrapper
SKF
13
20-21
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Procurement
A turbine is made out of multiple components, e.g. from
steel towers to high-tech components. Yet, 70% of the
total cost of a wind turbine comes from 7 main elements:
blades, tower, gearbox, generator, nacelle and power and
control systems (pitch and yaw), and transformer.
10
Inventory Management
Let us say, the inventory management for wind energy
business is different. While this can be said for most of
the businesses, the combination of project management
with engineering manufacturing process with both highly
interlinked makes a case for such a statement.
The challenges of the forecasting for wind energy projects
as explained above and due to complexity involved during
project execution stage in Indian scenario, wind energy
Industry is facing very crucial issue of working capital
management and it adds to difficulty of the business that
this remains highly expensive with reference to global
comparisons.
Delayed project execution due to n no of issues like
clearance from government authorities, land procurement
cycle, timely execution of activities like road construction,
evacuation capacities at particular state electricity board,
local issues and many other factors which are the main
causes of delays and which is affecting the cash flow cycle
and therefore the material flow.
On a broader lever at project, we can have mismatch
of time and major sub-assemblies with repercussions on
manufacturing and then back end manufacturing and
similarly corresponding impact of supply chain disturbances
on manufacturing and then onto the project execution
making it double whammy so as to say.
So the concepts like just in time are in fact very
expensive when perspective is restricted to a limited part
of the supply chain. The need for wind energy supply
chain is to consider at any point of time and envisage at
different points of time in future, what would be the best
inventory position considering the whole of the supply
chain. The efficiencies can be brought in only when there
is comprehensive view and decisions are taken virtually
every day based on emerging scenarios.
So the key is as near JIT as possible, but with entire
supply chain in view.
11
12
Bonfiglioli is a leading provider of complete packages for the wind industry that
seamlessly control energy generation, from rotor blade positioning with a pitch drive
to nacelle orientation with a yaw drive. Working closely with customers, Bonfiglioli
designs and manufactures a series of specialized wind turbine gearboxes and inverters
that deliver reliable, superior performance.
Introduction
As on January 2015, the cumulative installed capacity of
wind power in India has crossed 22 GW. However, the
annual wind power development in the recent past has
suffered due to several factors. Lack of stable & long-term
policy environment, inadequate RPO enforcement
mechanism, slow pace of infrastructure planning and
eco-system development for wind power evacuation and
grid integration and frequent changes in rules governing
market off-take arrangements are some of the factors
responsible for the current state of uncertainty surrounding
the investment in the wind sector. The National Wind
Mission steered by the MNRE seeks to address some of
these challenges and aims to accomplish cumulative
capacity to cross 100 GW by end of 13th Plan (by 2022).
In this article, three critical issues that would greatly
influence the future Wind capacity addition plans have
been discussed namely, (a) evacuation planning, (b)
implementation framework for scheduling & forecasting
and (c) RPO compliance, monitoring & enforcement.
14
Conclusion
In order to upscale large scale deployment of wind
installations, apart from focusing on supply side measures,
the National Wind Mission should also lay emphasis
on demand side intervention measures. In this context,
regulatory institutions should consider following key
priorities (a) encourage state participation in planning
& development of wind resource based transmission
evacuation infrastructure, (b) develop institutional capacity
for management of wind intermittency and bringing
clarity in scheduling framework and (c) develop adequate
institutional capacity for RPO compliance monitoring and
reporting framework and to ensure timely enforcement of
RPO targets.
(Note: Views expressed in the article are Authors personal
views and need not necessarily represent views of the
organization.)
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1. Project Execution
Supply chain needs to be given importance,
marked by standardization and selecting right
suppliers with proven record. Quality is equally
important as cost.
As wind power projects are necessarily to be
time bound, high degree of accuracy at the time
of project planning is must keeping in mind to
facilitate least amount of down time for trouble
free operation over a 20 year period.
What is not well taken care in the initial project
execution can be seen in falling apart of
equipment, adding down time. These stoppages
are additional to what can be due to Turbines.
There are chances of these deficiencies causing
additional repair / replacement costs to the
investor.
2. Turbine Manufacturing
Procurement
decisions
during
Turbine
manufacturing also depend on the Technology
provider. Scenarios under different arrangements
can be:
** Joint Venture The Buyer may need to
procure from the partner, if the part/
component/equipment is made at the
partners end, for distribution to all the
subsidiaries or associates. This throws some
challenges to the local buyer in terms of
continuously negotiating deliveries, prices
and dealing regularly with quality issues.
16
4. Product Development
The role of Supply Chain in the Product Development
phase of a new turbine model is very critical. The
business entity may already be a turbine manufacturer
or it could be a new investor entering the turbine
business. In the first case, the manufacturer is already
familiar with supply sources for various parts required
for this new model that is under design, development
and prototype construction. In the second case,
the design house generally drives the selection
and process, or the new team brings in all the old
17
Supply Issues
Availability of turbine components easily, across the world,
is generally an issue. This could be due to the mismatch
between demand and availability. Market variations
over the years also cause supply issues in India. Some
commodity component suppliers such as for castings
and forgings depend only partially on the wind turbine
business. Component manufacturers cannot depend
only on wind turbine manufacturers because of the low
volumes and high variants. Over the last decade many
suppliers had geared up with huge investments, banking
on the upbeat mood in the market, but suffered for want
of orders. Obtaining localized parts of the right quality in
higher volumes is always a challenge. Partnership between
Prime Minister Shri Narendra Modi makes Strong Pitch for Clean Energy at G20 Summit
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Prime Minister Shri Narendra Modi has pitched for a global effort at G20 summit in Brisbane, Australia to
make clean energy available to all through concerted actions, which can be a major economic opportunity for
all countries across the globe. Seeking collective R&D effort and collaboration in the direction of having clean
energy path. Modi urged the leaders of big economies to set up a global virtual centre for clean energy
research and development, with adequate public funding, which will fund collaborative projects in diverse
sources of clean energy, smart grids and energy efficiency.
IREDA, US Exim Bank Ink $1 Billion Pact for Clean Energy Projects
Indian Renewable Energy Development Agency (IREDA), a body under the Ministry of New and Renewable
Energy, has signed a preliminary agreement with US Exim Bank for a $1 billion loan from the American entity
to undertake development activities in the clean energy sector. A Memorandum of Understanding (MoU) has
been signed between IREDA and US Exim Bank with respect to cooperation in clean energy investment.
People approach, opinion and expectation on multiMegawatt turbines had gone a sea change in decade
period but the harassment at the hands of check post, RTO,
sales tax, police, toll gate, highway robberies and stealing
of diesel, tyres, money, miscreants damaging the vehicles
etc. are increased in greater phenomenon, which prevents
the reputed transporters to enter in to the transportation
of wind turbine super ODC components within India.
Today in India the transportation policy and guidelines are
framed by the Central Government but the interpretation
of Central Government guidelines and implementation
are rests with the respective State Governments. This
arrangement enables the State Governments to generate
direct revenue but contributes delay in free vehicles
movements across India. This especially affects the wind
Industry super ODC Components very badly.
Today in India to operate commercial vehicle the owner/
company has to apply mother tax (handled by State
Government) for quarterly, half-yearly or annually and to
operate within India need to apply for National Permit
(valid for 5 years and handled by Central Government) and
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22
Submission of Documents
Company Profile,
ISO System
Technical
documentation,
Documentation
Manufacturing
Facility Evaluation
Information
as mentioned in
Design Evaluation
document
requirement
(if applicable)
Accept
No
Type
No
Accept
Agreements with Indian Certification Body for
Certification & Type Testing
RLMM Processing Fee
Conduct of RLMM meeting by
Indian Certification Body
Inclusion in RLMM list
Process flow of inclusion of new company in Revised List of Models and Manufacturers of
wind turbine and requirements for entering agreement with Indian Certification Body
Approach
This article puts focus on the requirements of Indian Certification Type Approval
Pro-visional Scheme-2000 (TAPS-2000) for WTG system in India and describes
23
Design Evaluation
Certification body evaluates WT type is designed and
documented in conformity with the design assumption,
standard and technical requirements.
Following documentation are required for this purpose:
Wind Turbine description
Detailed technical specifications including the make,
model and source of major components
Environmental condition & wind turbine design class
Control and Protection system
Load and Load cases including details of Design Load
Cases (DLCs)
Foundation design
Measurement Load Cases (MLCs)
Manufacturing, Installation and maintenance plan
Safety and function test
Scope of TAPS
24
PTC Cat. I
PTC Cat . II
Partial Design
Evaluation/Review of
Type Certificate
Partial Design
Evaluation / Review of
Type Certificate
Manufacturing System
Evaluation
Manufacturing System
Evaluation
Manufacturing System
Evaluation
Provisional type
Testing
Review of Foundation
Design Requirements
Review of Foundation
Design Evaluation
(optional)
Review of Foundation
Design Requirements
Type Characteristics
Measurement (optional)
Foundation Design
Evaluation (optional)
Foundation Design
Evaluation (optional)
Timely
coordination
with
certification
body,
measurement
agencies
and reply to their technical
queries.
Design Evaluation
Certificate
Type Characteristics
Measurement
(optional)
Importance / Significance
of Type Certification
The following modules are modified in new IEC 6140022 Ed. 1: Wind Turbines Part 22 Conformity testing and
certification.
Type Certification
3. Project Certification
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26
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*Amount in LAKHS
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60.00
O&M charges
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CEIG Approvals
Approximately.
0.50
TNEB Cost
Approximately.
30.00
3 .5 Acres
30.00
Line Cost
2 KM maximum
30.00
10
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Others
30.00
1.5 Acres
15.00
2.52
Approximately.
TOTAL
13
25.00
225.00
50.00
250.00
28
Key to success
** Speed to fulfill what customer wants
** Customer satisfaction (delight comes next)
Focus Customer
Derived benefits
** Shareholders delight
It is an ideal theoretical concept which each organization
needs to customize with no standard thumb rules.
** Take decisions
Now lets try to run through this little bit of science which
we could apply to make better use of our common sense!
The Concept
Like a relay race
Everyone is buyer for someone & customer for
someone
Every stage carries out value addition or else why
should the stage exist?
Starts with obtaining order from final customer
Ranges from end customer to first supplier and the
environment
29
Construction
and
and
30
inspection,
** Annual electrical
calibration
Categories of Purchases/Contracts
There are following categories of purchases and contracts
in wind turbine installations:
1. Off the shelf readymade item
2. Item from existing range of supplies from a supplier
with little modifications
3. Design given by buyer and item manufactured by
supplier tailor made item
4. Application given by buyer and design, manufacturing
and supplies made by supplier
5. Raw material purchases
6. Commodity purchases copper, steel, cement
7. Project specific purchases include subcontracting
Power Evacuation
** Sub Station (layout is usually given by wind
turbine company)
** EHV, HV lines
** Unit Transformer yards
Foundation
Erection and Commissioning
31
32
Conclusion
It is evident that supply chain in wind industry has its own
pros and cons but it is no different than any other industry
at macro level. Same rules apply here too. The only need is
to have accurate forecasts and adherence to commitments
made.
Proactive Government Policy can Double Wind Energy Market Instantly: Gamesa
Spanish energy major company Gamesa has pointed out that a proactive government policy on wind energy
could instantly double the market for wind energy generation, from 2500 MW to 5000 MW, in the country.
The market leader in wind turbine manufacturing in the country is also planning to invest over 100 million
Euros in India in the next five years. Gamesa Groups Executive Chairman Ignacio Martin said to reporters while
inaugurating a new production line for their 2 MW turbine in Mamandur near Chennai that it was a good sign
that the new government has landed a much needed political stability for sustained growth in the country. But
a proactive government policy is needed if the sector is to expand to its full potential.
34
27647.26
Thermal (Coal+Gas+Diesel)
21885.74
Nuclear
559.32
Hydro
772.00
4430.20
Wind Resource
Topography & Climate
State brief :
Gujarat is located on the west coast of India surrounded by
the Arabian Sea in the West, Rajasthan in the North and
North-East, Madhya Pradesh in the East and Maharashtra in
the South and South East. It is situated between 201' and
247' north latitudes and 684' and 744'east longitudes.
The state has the longest coastline of about 1600 km. The
state has three distinct geographical regions a corridor,
which is the industrial mainland; a peninsula, known as
Saurashtra, and Kutch, which is partly desert and partly
marshland. Gujarat has varied climatic conditions. The
north-western part is mostly dry due to the desert areas
while the southern region is moist due to heavy rainfall
during the monsoon season. The southern districts receive
maximum rainfall, making it suitable for vegetation. The
northern region is dry because of the adjoining desert. The
Arabian Sea and the Gulf of Cambay make the weather
pleasant. Areas like Kutch, Jamnagar, Panchmahals and
Mehsana fall in the rain shadow region and thus receive
little rainfall. The overall climate of the state is extreme due
to the variation in topography.
10609 MW at 50m
Hub Height
35071 MW at 80m
Hub Height
Total Nos of
established Wind
Monitoring stations
and data recorded by
CWET
81
Number of operational
CWET wind monitoring
stations recording data
13
Jamnagar, Kutch,
Porbandar, Rajkot,
Bhavnagar
35
17.84
Banking
(for captive)
Reactive Power
Charges
# 2nd (after
Tamilnadu)
Green Statistics
Renewable
Purchase
Obligation
Prevailing
APPC Rate
CDM Sharing
Feed in Tariff
(Sale to EB)
Third Party
Sale of Power
HT Industrial/
Commercial
Tariff (for
captive)
PPA Tenure
Wheeling
charges
Electricity Duty
(for captive)
36
Rs 2.64/kWh
First year generator will get full 100%
and thereafter 10% incremental
sharing yearly till sixth year when both
Generator & DISCOM will share on a
50:50 basis.
All wind projects to submit day ahead
schedule to SLDC and share real time
data with SLDC
Private Utilities
Torrent Power
Open Access
Charges
Cross subsidy
Charges
Scheduling of
Wind power
Miscellaneous Factoids
Project
Commencement
Year
37
2003
38
Photo Feature
Launch of
Indian Wind Energy Alliance
Hon.
Minister
of
State
with
Independent
Charge
for
Power,
Coal and New & Renewable Energy
Sri Piyush Goyal (in centre) being
received by Sri Sumant Sinha, Chairman,
IWEA and Sri Madhusudan Khemka,
Vice Chairman of IWEA and Chairman of
IWTMA
39
Inox Wind is a fully integrated player in the wind energy market with state of the art manufacturing
plants near Ahmedabad (Gujarat) for Blades & Tubular Towers and at Una (Himachal Pradesh)
for Hubs & Nacelles. Inox Wind manufactures the key components to ensure high quality, most
advanced technology, reliability and cost competitiveness. Inox WTGs are designed for low wind
speed sites of India.
Mr. Devansh Jain is Director of Inox Wind Limited since April 25, 2009. He has work experience
in various management positions across the Inox Group, which he has been spear heading the
company since its inception in FY 2010. The company successfully started its turbine, blade and
tower manufacturing units in 2010 and is already amongst the leading and fastest growing wind
turbine manufacturers in the country. Under his supervision, INOX Wind Limited has obtained an ISO
9001:2008, ISO 14001:2004, OHSAS 18001 and ISO 3834 certification for its management systems
pertaining to manufacturing, installation, commissioning and O&M of wind turbines. INOX Wind
WTGs are C-WET (part of MNRE) approved and Type Certified by TUV Sud. Mr. Jain has completed
a double major degree in Economics and Business Administration from Carnegie Mellon University,
Pittsburgh, USA.
Engineers at Work
Workshop where
Nacelles get prepared
Printed by R.R. Bharath and published by Dr. Rishi Muni Dwivedi on behalf of Indian Wind Turbine Manufacturers Association
and printed at Ace Data Prinexcel Private Limited, 3/304 F, (SF No. 676/4B), Kulathur Road, Off NH 47 Bye Pass Road,
Neelambur, Coimbatore 641062 and published at Indian Wind Turbine Manufacturers Association, Fourth Floor, Samson Towers,
No. 403 L, Pantheon Road, Egmore, Chennai 600 008.
Editor: Dr. Rishi Muni Dwivedi
40
87
87
Samson Tower, 403L, Pantheon Road, Egmore, Chennai 600 008. Tel: +91 44 3023 0200, Fax: +91 44 30230298/99.
Email: marketing@regenpowertech.com
www.regenpowertech.com
Chennai: +91 98401 61228, Delhi: +91 98112 27535, Mumbai: +91 98190 63836
Factories :
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Udaipur: NH-76 Udaipur Chittorgarh Road, Village Bhatewar, Tehsil Vallabh Nagar, Dist.Udaipur (Rajasthan),
Pincode: 313601, Opp. Sir Padampath Singhnia University.
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