GLOW

tamasoma jyotirgamaya
From Darkness to Light
Brihadarankya Upanishad

Volume VII, Issue 02,

MAY-AUG 2010

Global Footprint
Spreading Wings Solar Power: Impact of Metallic Overview of Technological
Across the Globe The Reliable Source Particles in a GIS & Progress in Indian Electric
of Energy its Mitigation Power Grid

inspired by tomorrow
02 | CELEBRATIONS

EMCO Foundation Enters

Third Glorious Year…
We have the vision… we have the path
Started with Vision: “To transform lives through sustainable
development involving stakeholders”
Moving forward with focus on: Education (Yashasvi, Shiksha,
Parivartan), Environment (Amrut, Ankur) & Health (Jeevan)

Some path-breaking social endeavours and accomplishments

EDUCATION

AKSHAR
YASHASVI: Scholarship to SSC
=
meritorious students from Thane and
Jalgaon Municipal Schools, covering
142 students for their further
education.
SHIKSHA: Community Development
=
– Education for Slum children;
benefited so far more than 4000
children in the age group of 6-14
years.
PARIVARTAN: Soft Skills
=
Development Programme for
Municipal School children of 8th to
10th standard students of Thane and
Jalgaon; covered 2000 children and Yashasvi: SSC Topper-2008 from TMC School, Thane receiving
scholarship award from our Chairman
adding 4500 this year.

Yashasvi: SSC Topper-2010 from TMC School, Uniform distribution to Jalgaon Mun. Corp. School Parivartan: TMC Ex-Commissioner Mr Nandkumar
Thane receiving scholarship award from Students by Dr Narendra Jadhav, Member - Planning Jantre awarding Appreciation Certificate to
our Managing Director Commission, Govt of India & Mrs Ratna Jain TMC School Students

GLOW | May-Aug 2010

 03 | CELEBRATIONS Contd...

“ No enterprise could ever have grown

and created wealth without the society ’s
solid backing; hence we need to express
our gratefulness and contribute
to its well-being.
”
- Rajesh S. Jain
Chairman

ENVIRONMENT

AMRUT ANKUR
Commenced ‘Integrated Tree Plantation and
Watershed Development’ Distribution of Seeds.
programme in Bilwadi, Planted 600 trees and
near Jalgaon, aiming adding 110 more this
benefit to 500 families. year.

Amrut: Nala Survey by EF Team under ‘Integrated Watershed

Development’ Programme at Bilwadi, Jalgoan

Mr Ashok Khivsara, Trustee - Maharana Pratap School, Jalgaon,

planting tree during inaugural function of Parivartan programme Ankur: Tree plantation by TMC School students

HEALTH

JEEVAN
Organized Blood Donation
Camps in Thane, Jalgoan,
Vadodara and Dadra. Collected
700 units of blood and donated
to the society. Jeevan: Blood donation camp at EF Managing Trustee Mr Ramaswamy giving
Meters Plant, Dadra away blood donation certificate

www.emcoindia.com GLOW | May-Aug 2010

 Contents
“Science is neither limited by time
nor by space; It belongs to the
world, and is of no country and
of no age.”
- Sir Humphrey Davy

05 Spreading Wings
Across the Globe 11 Impact of Metallic Particles
in a GIS and its Mitigation

Editorial Committee

Meenakshi Jain
M.L. Jain
06 News Highlights 13 Changing Power Scenario

Co-ordinators
Solar Power:

07
Vijay Nakhate - Thane
Pravin Maskar - Thane
The Reliable Source
of Energy 14 Customer Delight

Bhagwat Patil - Jalgaon

Puneet Shukla - Dadra

09 Creative Forum 15 From the Heart

Please send us your

‘ GLOW’ is published in suggestion/feedback at:
Thane for EMCO Limited.
For private circulation only. 10 Happenings
glow@emcoindia.com

GLOW | May-Aug 2010

 EMCO STORY - XIX | 05

‘AAMCHI EMCO’

Spreading Wings Across the Globe

- Editorial Committee

A
s ‘Aamchi EMCO’ was growing strongly in
domestic markets across various Divisions, it was
decided also to make efforts to sell our products
in demanding markets around the world. In this scenario
a need was felt for exploring new markets and becoming
a global player with an objective of achieving sustained
growth and profitability. The strategy was to have a good
geographical mix of customers rather than dependence
on one single market.
It was in South Africa we got our first foothold in 1997.
Soon other African countries, the Middle East Market,
especially Oman and markets in Europe and US opened
for EMCO and in 2001 a full-fledged International
Division took its shape offering single point access to all
global customers for its products and solutions.
By 2004, the International Division became the visible
arm of Emco in global markets. In this year, we
expanded the export product range from Transformers
to Meters.
The ensuing years were hectic for EMCO and
from 2001-2010 we participated with complete
preparedness and with full force in more than 30
exhibitions in Germany, Spain, Dubai, Italy, Malaysia,
South Africa, USA, Iran, Kuwait, Vietnam, Indonesia,
Thailand etc. With that the second phase of follow–up
visits after these exhibitions and years of hard work we
got pre-qualified to compete in tenders from various
Utilities and bagged repeat orders from most major
Utilities and EPC Contractors in our focus markets.
Participation in these exhibitions and face to face
meetings with numerous customers with varied needs
offered our team an opportunity to learn about the
needs of the markets. This exposure and subsequent
interaction also improved our product basket and
enhanced our exacting quality standards.
In 2008 we expanded our operation on the global
arena by collaborating with Edison Power South Africa
for the supply of transformers in the African continent
and also dispatched our first transformer to Latin
America. In spite of the global meltdown in early 2008
we continued our march forward with our strategy of
focusing on the emerging markets. In 2009 we supplied
our first 330kV transformer to Nigeria, coupled with our
regular supplies to Africa and Middle East in the 220kV
class segment.
Today a large number of transformers are installed and
successfully put in to operation in more than 43
countries across five continents including Americas,
Europe, Middle East, Africa and Asia Pacific. EMCO's
International Division is today pre-qualified with all the
major Utilities around the world and our years of hard
work has been recognized with EMCO receiving the
‘Best Export Performance Award’ from TMA for the fifth
consecutive year in 2009. EMCO has become an
established name in the international markets with

A brief account of the landmark events chronicled below reflects pattern of our business growth in the
international market.
1997 Business Development Group forays in to export business
1998 Export of Transformers to Bangladesh and Ghana
2001 Business Development Group christened as International Division; export of first transformer to USA
2002 Export of Furnace Transformers to Europe
2003 Company accorded 'Star Export House” status by DGFT, Government of India
2004 Received 'Export Performance Award 2003' from TMA, Thane
2005 First time export of Meters – beginning with Africa and Germany; Received US$ 5.5 Million single order
for transformers from Syrian Utility
2006 Received 'Export Performance Award 2005' from TMA, Thane
2007 Export of first 220 kV transformer to Africa
2008 Collaboration with Edison Power to supply transformers in South Africa and becomes the only Company in
India to be pre-qualified in Saudi Arabia. Exports 165 MVA transformers to Iraq and 120 MVA transformers
to Iran
2009 Export of first 330 kV class transformer to Africa. Supplied transformers to Panama Canal Authority and get
pre-qualified with Petronas, Malaysia
2010 Receives pre-qualification from Nigeria for supply of Substation

www.emcoindia.com GLOW | May-Aug 2010

06 | EMCO STORY - XIX

offices in multiple locations outside India and partners
spread across the globe.
Today EMCO has garnered the experience and
expertise for supplying transformers that meets various
international standards like IEC, ANSI, DIN, SANS. Our
customer list encompasses the major Utilities across the
globe.
It has been a very good learning curve to make
products to suit varied requirements and different
standards. As we have sold our products to more than
43 countries, it has added a valuable positive
dimension to our character. It has increased our
confidence multifold. We also have a large population
of Transformers in Oman with more than 200 Units
operating satisfactorily. For the year 2008-09 exports
contributed 14% of our overall revenue.
is commendable. We shall not hesitate to recommend
EMCO any day, anywhere. We appreciate you.”
- S.O. Udeh, Nigeria
< “A big leap forward in the manufacturing of
transformers regarding all the aspects. All the best for
the future.”
- Roger Ehnstrom, Finland
< “Thanks for your hospitality and taking great care of
us. Great Company, neat, organized and best
practices implemented. Great Job & Great Team!
Thank you for the experience.”
- Adrienn Cser, Italy
< “Factory is very well organized, clean. Security and
health is preserved. Testing procedures and
knowledge of engineering is very good. Thank you
for your staff and equipment.”
- Fernando Alcarraz, Uruguay

Towards our endeavor to achieve 30% of our revenues
from exports, we are also looking at selected
opportunities in Projects business and we have already
been pre-qualified by certain prestigious utilities. In any
business, key to long-term success is customer
satisfaction. Our company always tries to go that extra
mile to ensure delighted customers. We reproduce here
below a few quotes from our esteemed customers which
bear clear testimony to how they perceive EMCO as a
brand name.
“EMCO is by all standards a great Power Transformer
Manufacturer. The quality and standards of work is
commendable. The hospitality of the company and staff
‘Aamchi EMCO’ has over the last 13 years
demonstrated its business acumen with focus on
customer delight to support and build sustainable
business relationship in international arena.
Global business is very dynamic, competitive and
exacting. International markets have also been volatile
due to changes in the macro economic situation. Only
players with long term vision, great product quality, full
commitment and competitiveness can survive in this
situation. EMCO Management is committed to build on
this strength to further expand its footprint in the global
market and ensure success for years to come.

News Highlights

Performance Certificate
The prestigious Type Test Certificate from KEMA, The Netherlands,
for our 315 MVA, 220 kV Generator Step Up Transformer, one of
the largest ratings in the world for short-circuit performance.

Order Received
EMCO received a very prestigious order for supply of 4,872 Nos. of
‘Meter-Cum-Protection Box’, a newly developed product for a very
strong EPC Contractor.

Conferences
< Mr. Chetan Adalja participated in ‘CIGRE India Session’-
A national conference on ‘Latest Technological Developments &
Installations in Power Sector’, organised by CIGRE India & CBIP
at CBIP, New Delhi during 28-30 July 2010.
< Mr. Neeraj Yadav & Mr. Chetan Adalja, participated in
International Council on Large Electric Systems (CIGRE 2010)
held at Paris in August 2010. Mr. Chetan presented a technical
paper at Poster Session of SC A2 on Transformers.

GLOW | May-Aug 2010


SOLAR POWER: THE RELIABLE SOURCE OF ENERGY
- Dr. Annamalai Karthigeyan
M
any ancient civilizations worshiped the sun as great
force of life. Around 1350 BC, Egyptians worshiped
the sun as the only god. In ancient Greek
mythology, the sun god Helios drove his chariot across the
sky every day and floated back across the ocean at night in
the golden cup. In Hinduism, Surya the sun god is driven by a
seven-horsed Chariot depicting the seven days of the week.
We look at the sun every day as a ray of hope not without
substance.
Solar Energy the Ultimate Long Term Power Solution
Solar energy is renewable and there is no danger of
running out. Other energy sources such as coal and oil are
burned and used up to produce power. Geothermal, wind
and biomass power are also renewable forms of energy. The
sun which drives other sources such as winds and water by
warming some part of the world more than others that affect
the air that surrounds our planet and also heating the oceans
creating clouds and rain a never ending water cycle. World's
fossil fuels - coal, oil and natural gas which come from the
fossilized remains of prehistoric plants and animals could
have never existed without sun. Fig. 1 depicts present and the
possible future scenario of power contribution by solar
energy. Presently cumulative solar energy production
accounts for less than 0.01% of total Global Primary Energy
demand.
Greenhouse Effect
The increase of the average temperature of Earth's near-
surface air is called Global Warming. A number of indicators
suggest that this is due to greenhouse effect which results
from human activity such as fossil fuel burning and
deforestation. It has been estimated that CO2 is the major
greenhouse gas which contributes to the rise in temperature.
Greenhouse effect itself occurs when short wave solar
radiation heats the surface of the Earth, and the energy is
radiated back as heat through the earth atmosphere. A lot of
thermal radiations are absorbed by water vapor and CO2,
www.emcoindia.com
SOLAR POWER | 07
which in turn radiate it, thus heating the atmosphere. This is
what keeps the earth habitable. Without the greenhouse
effect overnight temperatures would plunge and the average
surface temperature would be about minus 18oC, about the
same as on the moon, which lacks the shroud of our
atmosphere. The particular problem arises in a particular
band of solar radiation where water vapor is a weak
absorber of radiation and where the Earth's thermal
radiation is greatest. Increased concentrations of CO2 and
other radiative gases here mean that less heat is lost to space
from the Earth's lower
atmosphere, and tempera-
tures at the Earth's surface are
therefore likely to increase.
But the greenhouse gases
have some residence time
in the atmosphere. For
example, methane has about
an eleven-year residence
time and CO2 has longer
time. So it is understandable,
why the world talk of reducing
the carbon dioxide emission
due to change in climate and
that business-as-usual in the
Fig. 1: Sources of Energy energy sector is not an option
any more.
Advantages of Solar Power
The fuel is free. There is more than sufficient solar radiation
available around the world. Solar Photovoltaic is a simple,
low risk technology. For power companies and their
customers, Photovoltaics has the advantage of providing
relatively quick and modular deployment. In environmental
terms, there are no emissions of carbon dioxide - the main
gas responsible for global climate change.
Solar Power Systems
The solar power systems discussed here are different from
the ones where the sun rays are used for hot water system in a
house, swimming pool, etc. Solar power systems based on
Photovoltaics and solar thermal by Concentrating Solar
Power (CSP) is briefly presented in this article.
Solar Photovoltaics
Photovoltaics (PV) is an elegant but expensive technology.
The most important parts of a PV system are the cells which
form the basic building blocks. This cell can be considered
as two terminal device which conducts like a diode in the
dark and generates a photovoltage when charged by the
sun, they are packaged into modules generating DC current
and converted suitably using inverters for everyday use.
Crystalline Silicon Solar Cells
About 87 per cent of the PV installations in 2009 are
powered by crystalline silicon (c-Si) solar cells. This
GLOW | May-Aug 2010
08 | SOLAR POWER

technology is widely available, well understood. Efficiencies grid solar power are mainly in the telecommunications field,
of more than 20% have been obtained with silicon cells in the especially to link remote rural areas to the rest of the country.
laboratory, but typical commercial c-Si cells are 10-17 per Other applications include traffic signals, marine navigation
cent efficient. aids, security phones, weather or pollution monitors, remote
Solar Cell Efficiency (ç) lighting, highway signs and waste water treatment plants.
Stand-alone (off-grid) PV systems contain a battery
connected to the PV array via a charge controller which
protects the battery from over charge or discharge. An
inverter is required to convert the DC power to AC if
required.
Grid Connected PV Systems
It is the most popular type of PV system for homes and
The efficiency of a solar cell is one of its most important businesses in the developed world. Connection to the local
characteristics of the device. Efficiency of the solar cell or electricity network allows any excess power produced to be
module is defined as electrical power produced by the cell or sold to the utility. Electricity is then imported from the network
module (Pm) to the ratio of incident light power (Solar outside daylight hours. An inverter is used to convert the DC
radiations strikes the earth with 1000 Wm-2 under standard power produced by the system to AC power for running
condition). normal electrical equipment. Most installations today are on
Thin Film Solar Cells rooftops, but larger field-based installations in megawatts
100.0% Thin film market share (MW) range are becoming common.
90.0%
in 2009 was around Solar Thermal Generation (CSP)
80.0%
19%. The modules are
70.0%

60.0%
constructed by deposit-
50.0% ing extremely thin layers
40.0% of photosensitive mate-
30.0% rials on a low cost
20.0%
backing such as glass,
10.0%
stainless steel or plastic.
0.0%
2008 2009 2010
This results in lower
Crystalline CdTe Thin Film Thin Film Others production costs com-
pared to the more
material intensive crystalline technology even though the
efficiencies are inferior to crystalline solar cells . Three types
of thin film modules, such as amorphous Silicon
(a-Si), Copper Indium diselenide (CIS, CIGS) and Cadmium
Telluride (CdTe) are commercially available presently.
Concentrator Photovoltaic Systems (CPV) The basic concept of CSP is relatively simple. CSP devices
Concentrator systems offer an effective, practical way to concentrate energy from the sun's rays to heat a receiver to
keep solar cell conversion efficiencies high while keeping high temperatures. This heat is transformed first into
semiconductor material costs down using relatively mechanical energy (by turbines or other engines) and then
inexpensive optics such as mirrors or lenses to ’concentrate’ into electricity. CSP is a proven technology. At present, there
or focus light from a relatively broad collection area onto a are four main CSP technology families, which can be
much smaller area of active semiconductor material. Since categorized by the way they focus the sun's rays and the
CPV systems work by focusing sunlight onto a targeted area, technology used to receive the sun's energy. It can be built in
they must be pointed directly at the sun and require trackers a range of sizes, from a few MW up to several hundred MW.
that follow the sun's trajectory throughout the day. These are
As of early 2010, the global stock of CSP plants neared
the main drawbacks of these systems. CPV modules reduce
the amount of PV material (Si/III-V compounds) used by as 1 GW capacity and is expected to contribute 5% of the
little as 2-5 times to 100-1000 times. annual global electricity production in 2050 in this scenario.
Types of PV Systems Conclusion
Stand alone/Off grid PV Systems Despite widespread interest and support for solar systems
all over the world, lot of efforts are on to make cost and
PV provides vital power for communities in the developing
world who have no access to mains electricity. Among the performance attractive to make solar power competitive with
uses are for domestic lighting, solar lanterns, TV sets, water electricity from conventional sources. Sun is much closure to
pumping, refrigerators and providing lighting for shops, us than any other star and hold our earth and other planets
health centers or small market places. Industrial uses for off by gravity would always be our reliable source of life.

GLOW | May-Aug 2010

 CREATIVE FORUM | 09

MCO
y Co nt est at E
phy Da
hotogra
World P
Creative Forum
10 Tips to Stay Positive in Negative Situations
Though it's not easy, it's important to stay positive in negative
situations. Beat the negative situations by staying positive. Here are
10 tips on how to do it; pick the ones that work for you:
1. Never respond when you are not calm. If you are not sure, take
time to calm yourself down first.
2. Take a deep breath as a first step to calm yourself down.
3. Speak in gentle tone to reduce the tension of the situation.
4. Realize that you can find opportunities in negative situations.
Albert Einstein said: “In the middle of every difficulty lies
opportunity.”
’:
t EMCO
5. If you make mistakes, be open to admit it. B e s t M oment a s t a nd
theme o
f ‘My "Even I
6. If you make mistakes, remember this quote by George Bernard On the o f E M CO says ca n 't ..?”
rance coite
main ent every Em
Shaw: “A life spent making mistakes is not only more honorable, but Tree at year s .. . w h y
inner
alue for st
Prize W
more useful than a life spent doing nothing.” for my v ave, 1
- P.S. D
7. If you can, listen to motivational audio program to feed positive
thoughts into your mind.
8. Talk to a positive friend who can encourage you. DççF&
9. Remember your favorite quotes to give you inspiration and
motivation. This is one reason why you should have quote of the
DççF&mççþçÇ kçÀç³ç çÆuçnÓ
day. DççF&mççþçÇ kçÀmçí çÆuçnÓ
10. Look at the negative situations as your training sessions for real DççF&mççþçÇ HçájlççÇuç SJç{í
life. The higher you climb in life, the worse the negative situations
would be, so you'd better be prepared for them. Mçyo vççnçÇlç kçÀçíþí
- Jitendra Dashrathi DççF&JçjlççÇ çÆuçnçÇC³ççFlçHçlç
vççnçÇ cççPçí J³ççÆkçwlçcçlJç cççííþí
pççÇJçvç ní Mçílç DççF& cnCçpçí çÆJçnçÇj
Humour pççÇJçvç nçÇ vççÌkçÀç lçj DççF& cnCçpçí lççÇj
pççÇJçvç nçÇ MççUç lçj DççF& cnCçpçí HççìçÇ
pççÇJçvç ní kçÀçcç®ç kçÀçcç lçj DççF& cnCçpçí mçáfçÇ
DççF& cnCçpçí cçbçÆojç®çç Gb®ç kçÀUmç
DççF& cnCçpçí DçbiçCççlççÇuç HççÆJç$ç lçáUmç
DççF& cnCçpçí Yçpçvççlç içáCçiçáCççJççÇ DçMççÇ mçblçJççCççÇ
DççF& cnCçpçí JççUJçbìçlç H³ççJçb Dçmçb þb[iççj HççCççÇ
DççF& cnCçpçí DççjlççÇlç JççpçJççJççÇ
DçMççÇ uç³çyç× ìçUçÇ
DççF& cnCçpçí Jçíovçívçblçj®ççÇ
mçJçç&lç HççÆnuççÇ DççjçíUçÇ...
- mçboçÇHç cçiçj

A two year-old Octopus Paul, the so-called Octopus Oracle, has
become the superstar of this FIFA World Cup with his right predictions!
What lies behind you and what lies in front of you,
pales in comparison to what lies inside of you.
Every morning on an empty stomach make it a
habit to drink 2 teaspoons of honey with warm
water and a half spoon of lemon extract... this
acts universally as a best blood purifier and also
HEALTH TIPS a good drink to keep the cholesterol and your
weight under control.

www.emcoindia.com GLOW | May-Aug 2010

10 | HAPPENINGS

Happenings

Welcome: Our Vice-Chairman Mr. Shailesh Jain & CEO for Transmission
Inspiration: Our MD Mr. Ajay Dhagat sharing a word of wisdom with our
Line Business Mr. Deepak Khandelwal welcoming Director (Projects)
2010 batch of Eklavyas
PGCIL, Mr. Jha & GM (CMG) Mr. Jain at our Corporate Office, Thane

Chairing a Session: Our Vice-President Mr. M.L. Jain chairing CIGRE Customer Visit: Inspection Team from Italy at our Transformer facility,
India Session at CBIP, New Delhi Jalgaon

HTS Transformer

Industrial Visit: Faculties & Students from MIT College of Engineering, Apex Meet: PRC Members from CEA, CPRI & EMCO at our Jalgaon
Pune at our Transformer facility, Thane Plant

Skill Enhancement: Training of Shop-floor Emcoites on ‘Brazing’ at Thane Independence Day: Celebrated at our Jalgaon Plant

GLOW | May-Aug 2010


Impact of Metallic Particles in
a Gas Insulated Substation and
its Mitigation
Dr. B.P. Singh, Ex-General Manager, BHEL
Principal, St Martin’s Engineering College, Dhulapally, Secunderabad
G
as Insulated Substations (GIS)
are finding increasing
demand in Metropolitan
Cities and Hydro-Power stations. It has
found greater acceptability with power
generating companies and utilities due
to several advantages it offers over
conventional Air Insulated Substations
(AIS). The major advantages are their
compactness, protection against
lightning, reduced maintenance, free
from disturbance due to switching and
lightning surges, noiseless operation,
immunity to explosion, flame-resistant
and minimum interference. The
volume occupied by GIS at EHV levels
is far less than that of AIS. Since all the
live parts are enclosed within GIS
chamber, safety against high voltage
provides an added advantage. A GIS
consists of several main components,
e.g. Circuit Breaker, Bus Enclosure,
C u r r e n t Tr a n s f o r m e r, Vo l t a g e
Transformer, Disconnector, Earthing,
Switch and current carrying moving
contact.
Fig 1: Typical GIS configuration
The inner live part of the GIS is
supported by specially designed
insulator of epoxy, filled with alumina.
The space between the live conductor
and bus enclosure is filled with Sulphur
Hexafluoride (SF6) gas at a specified
www.emcoindia.com
pressure. The pressure of gas is chosen
on the basis of manufacturer design.
However, the pressure in circuit breaker
arcing chamber is maintained much
higher than that of rest of the
components of substation.
While, there are several advantages
associated with GIS, there are two
specific disadvantages which relate to
very fast transients during disconnector
operation and existence of small
metallic particles within the space
between live part and rounded
enclosure. These particles move in the
interspace region and may give rise to
partial or full discharges leading to
failure of the GIS.
This article deals with the particle
movement in the electric field arising
due to power frequency voltage of the
system. This presents the mathematical
treatment of the particle movement
within the duct considering several
parameters like particle material,
shape, size, gas pressure, drag force
and random motion for a typical bus
duct of a GIS of EHV class. It also
presents experimental result of partial
discharges due to loosely held free
metal particles.
Source of particles and mechanism
of movement
Even though SF6 exhibits very high
dielectric strength, the withstand
voltage of SF6 within the GIS is
drastically reduced due to the
presence of particles or defects like:
1. Free particles on the inner surface
of the enclosure,
2. Protrusion on the high voltage
(HV) bus,
3. Protrusion on the inner surface of
the enclosure, and
4. Narrow gaps between the spacer
and the electrode due to imperfect
casting and or imperfect mechanical
machining, which may lead to high
electrical stress and thus micro
GUEST ARTICLE | 11
electrical discharges.
Free conducting particles create one
of the most onerous conditions in GIS.
These free conducting particles may
have any shape or size, may be
spherical or filamentary (wire like) or in
the form of fine dust. Particles may be
free to move or rest on to the surfaces.
They could be of conducting material
or insulating material. Particles of
insulating materials are not so harmful,
since they have little effect on the
breakdown properties of gases. The
wire-like particles made of conducting
material are more harmful.
The components of a GIS are
manufactured with any of the
combination of materials, e.g.
aluminum, steel, copper, silver, nickel
etc. The likely causes of existence of
particle contamination are debris left
from the manufacturing and assembly
process, movement of the central
conductor under load cycling,
mechanical abrasion, and vibration
during shipment. Even with a very high
level of quality control, it appears that
a certain level of particulate
contamination is unavoidable. In
addition, the arcing in the circuit
breaker (CB) may erode a part of
graphite or copper which can settle at
random locations inside the chamber.
Several authors have reported
investigations on movement of
particles in GIS. However, the presence
of atmospheric dust containing
conducting particles, especially on the
cathode, reduces the breakdown
voltage. Conducting particles placed
in a uniform AC field lift-off at a certain
voltage. As the voltage is raised, the
particles assume a bouncing state
reaching a height determined by the
applied voltage. With a further
increase in voltage, the bounce height
and the corona current increase until
breakdown occurs. The lift-off voltage
is independent of the pressure of gas.
After the onset of bouncing, the offset
GLOW | May-Aug 2010
12 | GUEST ARTICLE
voltage is approx. 30% lower than the
lift-off voltage.
Some of the methods for conducting
particle control and de-activation are:
< Electrostatic trapping,
< Use of adhesive coatings to
immobilize the particles,
< Discharging of conducting particles
through radiation,
< Coating conducting particles with
insulating films.
Understanding the dynamics of a
metallic particle in a coaxial electrode
system, i.e. bus duct or bus enclosure
which forms major portion of GIS, is of
vital importance for determining the
effect of metallic contamination in a
GIS. If the motion pattern of a metallic
particle is known, the probability of
particle crossing a coaxial gap and
causing a flashover can be estimated.
The lift-off field for a particle on the
surface of an electrode and its
subsequent motion can be determined
by a set of equations.
A conducting particle in motion in an
external electric field will be subjected
to a collective influence of several
forces. In order to understand the
mechanism of movement a basic bus
duct as shown in Fig.1 can be
considered. It shows a typical
horizontal bus duct with a conical type
support insulator. The space between
the cylindrical HV electrode and
enclosure is filled with SF6 gas at pre-
specified pressure.
SF6 Gas
High Voltage Metallic Particle
Conductor
Fig 1: Model of a bus duct with co axial enclosure
Theory of Particle Movement
Under an applied electric field a
conducting particle acquires a charge
and lifts off from its resting position on
the enclosure when the electrostatic
force from the field becomes equal to
the gravity force. The charge acquired
by a particle resting at the inner surface
of the enclosure is given by
GLOW | May-Aug 2010
where, Qnet is the charge on the particle for power frequency voltage it can be
until the next impact with the eclusure; 1 is seen from Fig. 2 that the particle
the particle length; r is the particle radius; reached 43 mm from the bottom of
E(t0) is the ambient electrical field at t=t0. chamber during one of its flight. Such
movement occasionally gives rise to
Considering the electrostatic,
discharges between the particle and
gravitational and drag force and gas
the HV electrode causing explosive
pressure, the movement of a particle is
evaporation and ionization of metal
given by
where,
leading to breakdown.
V Sinùt is the supply voltage on the
Partial Discharge due to particle
inner electrode, r0 is the enclosure
radius; ri is the inner conductor radius; Particles exhibit different behaviour
y(t) is the position of the particle which under different conditions. If a particle
is the vertical distance from the surface is resting loosely on the inner surface of
of the enclosure towards the inner the chamber then partial discharge will
electrode; y is the velocity of the exhibit a pattern as shown in Fig 3. The
particle; µ is the viscosity of the fluid; r is simulation was carried out with a single
wire like particle.
the particle radius; ñg is the gas density;
l is the particle length; Kd(y) is a
drag coefficient; m=mass of the
particle; y= displacement in vertical
direction; Fe= Electrostatic force;
g = gravitational constant.
Movement of Particle in the bus duct of
a 245 kV GIS
Metallic particles move randomly in a
horizontally mounted GIS/GITL system
due to the electrode surface roughness
and particle irregularities. Under 50 Hz
AC voltage, the particle can cross the Fig 3: PD pattern for a loosely held particle
gap at a sufficiently high voltage level. The magnitude of PD depends on the
However, the particle may remain in
applied voltage, the shape of the
mid-gap or hover near the central
Spacer particle and gas pressure.
electrode for several voltage cycles.
Particle movement plays a crucial role Conclusion
in determining the insulation behavior The article describes the components
Grounded
Enclosure of GIS/GITL systems. of GIS and its merit over conventional
Results AIS. The mechanism of formation of
Particle Movement due to various forces conducting particles and mathematical
Using the above equations the expression required for determining its
movement has been discussed. Results
movement of typical wire like
aluminiunm particle of 10 mm long with regard to movement of an
and 0.5 mm diameter was examined aluminum wire in a typical EHV class
GIS is presented. Experimental result
with regard to partial discharges for
loosely held particles and protrusion
have been depicted.
Fig 2: Movement of aluminum particle
(10 mm/0.5 mm) in a 245 kV GIS bus duct
 TECHNICAL ARTICLE | 13

Overview of Technological Progress in Part Two

Indian Electric Power Grid

Changing Power Scenario

Mata Prasad, FNAE
Advisor to Chairman, EMCO

Part One of the article published in the Jan-Apr 2010 issue of the Glow covered a brief overview of the changing global
power scenario. Dwelling up on the technological changes, the challenges in system developments and the technology
developments, the article ended with introductory remarks on distributed generation and its spin-off values.
Taking forward the progress on the distributed generation, covering DG technologies in different countries and its impact
on network, the author introduces Electrical Engineering Innovation in Power System in this issue.

Distributed Generation (DG) and its impact on Network The latest awakening in such energy parks as DG, wind and
solar farm has boosted the plans for accelerating the
The following gives listing of promising DG technologies for development of various forms of DG. Without energy, there
application in developing countries: can be little economic development, clean water, refrigerated
= Micro-turbines foods and medicines, no telephones, radio/TV or the most
= Fuel cells basic forms of sustainability. Many rural areas are still very
= Wind power remote or too poor to support energy systems that are
= Solar power connected to the electricity grid. Many developing countries
= IC Reciprocating engines face population growth that far exceeds the planned rates of
= Small Hydro-electric grid connection. As such many will either remain without
power energy or forced to migrate to urban areas where the
= Hybrid power with more infrastructure is already over burdened.
than one type of
generator In general, many technical influences of increasing share of
= Micro-grid DG may be observed in different countries depending upon
= Other enabling the amount of DG and the kind of generators used as well as
technologies on the structure of the system. For example, the subsidies and
attractive power supply rates for energy from DG, especially
Examples of DG show the wind farms and solar cells will lead to high increase of such
emphasis by Governments to provide electric power to power plants and special problems in the conventional
remote communities: systems. Network expansion planning is directly affected
when a large number of DGs can only be connected directly
In India, the government had planned in the year 2000 to
=
to the transmission system. In network operation, voltage
electrify 100,000 villages with renewable energy and
control is one of the major tasks. DG has influence on the
install solar based powered telephones in every one of the
quality of service supply and on technical problems like short
500,000 villages. This scheme is getting all the priorities.
circuit power and protection system. The voltage bands with
Indian Government has massive energy farms of
= variation admissible as 16%, the allocation of voltage drops
harnessing wind and solar energy farms for rural system. could be 2% deviation at transformer terminals, 6.5% voltage
drop in MV network, 2.5% drop in step-down transformers
Mexico had planned and executed to electrify 60,000
=
and 5% drop in LV network.
villages using photovoltaic.
For successful connection of DG into system with desired
In Zaire,
= several major hospitals depend upon reactive power and voltage control and its integration with the
photovoltaic solar energy. power system, detailed and optimization studies are required.
In Mangolia, the government plans the distribution of 240
= Various forms of DG system are available and have been
small wind/photovoltaic systems for household use as the explored for application into the power network. Besides wind
first phase in a larger implementation farms. and solar plants, the other interesting DG system is Fuel Cells.
In Nepal, 1500 photovoltaic systems were installed way
= Electrical power system has been characterized by large
back in the year 2000. power plants located at long distances, requiring long
transmission and distribution networks for supply of power to
Villages on islands in the Caribbean and Mediterranean
= users. Consequent to restructuring and unbundling of the
are looking at DG as source of power required to power generation industry and impact of environmental and
desalinate drinking water for drinking. financial constraints, Fuel Cells Technology is expected to

www.emcoindia.com GLOW | May-Aug 2010

14 | TECHNICAL ARTICLE

stimulate and accelerate this evolution. transformer.

There are principally five types of Fuel
Cells, viz. Alkaline Fuel Cells, Proton For successful The development of new revolutionary
items such as Powerformers, Dryformers,
Exchange Membrane Fuel Cells, integration of DG into Drycapacitors, FACTS Devices, Numerical
Phosphoric Acid Fuel Cells, Molten
Carbonate Fuel Cells and Solid Oxide
power system with Devices, Fuel Cells, Distributed Generation,
Wide Area Networks, Smart Grid
Fuel Cells. The first two fuel cells are of desired reactive power incorporating Smart Metering and fully
low temperature types (60-120°C) while
the remaining fuel cells are of high
and voltage control integrated Smart Substations etc., has
temperature types (600-1000°C). The calls for detailed and enabled their induction in the power system.
fuel cell of PEM type is of much interest to It is exciting to watch as to how the market
domestic users as it meets the
optimization studies forces will affect their evolution and
requirement of personal power with adaptation in the system and that should
power rating of 7-10 kW. prove to be efficient reliable and cost
effective.
The cost of Fuel Cells had been estimated as US $ 1,000 per
kW in 2001, reducing to US $ 300 in 2003, to US $ 200 per Electrical Engineering Innovation in Power System
kW in 2005 and to US $ 100 per kW in 2007 as a result of
Let there be some appreciation of the reasons to believe that
continuous advancements. The cost of such Personal Power
electrical engineering itself a mystery (!), is still being
Fuel Cells in 2010 is expected to go further down to become
innovated, exploited, researched and developed on
more attractive. The device alone or in conjunction with
continuous basis. The Civil and Mechanical Engineers are very
Micro-turbines would revolutionize the distribution and
lucky that they can physically visualize the end results of their
transmission segment. The dispersed or distributed generation
efforts of development in concrete shapes. The Electrical
is another milestone that is going to improve the distribution
efficiency and would avoid wheeling of power to distant load Engineers are not so lucky.
centers. It will have a big impact on T&D sector and large size The production of electricity is through the Generators,
pithead power plants may not be techno-economically having massive stators built of steel and copper, large rotors
feasible. The establishment of LNG coastal terminals in with huge shafts and forgings with embedded field windings,
Maharashtra, Karnataka, Kerala, Andhra Pradesh and run by steam or hydro turbines. The end product is Electricity
Tamilnadu (hopefully materialized as projected) is going to that is invisible and no one can come near it unless it is fully
initiate the setting up of large size gas power plants, which in insulated. The Electrical Engineers can manage it well but
turn, are going to greatly influence the bulk power cannot feel its beauty and grandeur by touching it. Even when
transmission requirements. The situation is thus quite fluid for one is using it, he cannot see it but knows that it is there. One
India. switches on the light and the room lights up and he is not
The role of Power Electronics in developing new items of surprised. However, if one flicks the switch and nothing
equipment for the power system is going to be much more happens, that is the surprise. This is because everybody takes
complex. The development of Power Electronic transformers the electric light for granted and so do some two billion people
conceived as back as 1965 has progressed to the extent that around the world.
by 2015, this product would be cheaper than the conventional (To be continued in next issue....)

Customer Delight Reader’s Views

Quite impressed with
< Appreciate technical
< I am in receipt of the latest GLOW magazine. My compliments
the factory in terms of knowledge, factory to the TEAM that has put it in shape. I am a regular intense reader of
manufacturing organization and this magazine which has a bright get up and speaks for itself.
capacity, method, product lines. – Paolo As regards this issue specifically, the article on Induction has
testing and cleanliness. Riccobon/Technip come out well, especially the paragraph on the 'Uniqueness of
– Vasu Dandanayak (Italy) EKLAVYA.’ Also the 7 levels of comfort have been briefly explained.
(Bahrain) My suggestion will be that the 8th step may be 'Improvements made
Very helpful and
< based on the analysis of the feedback received in Level 7.’
Dynamic company with
< informative visit and a On the technical side, personally I was happy to hear on the
skilled people, good very impressive factory. successful testing of the EHV transformer at KEMA, Netherlands.
quality, good delivery – Jon Basswat (India) ‘From the Heart’ Mr Satish Gupta adds great influential value
time. We have to to every Emcoite.
Very well organized,
< While the variety of information has covered a wider range
improve on
very cooperative. including CSR, news on the Recognition of People at Middle and
relationship.
Thank you for all the Lower Middle levels would have well balanced the contents.
– Marette/Technip
efforts. Congratulations on the yeoman efforts.
(France) - C S Kumar, Business Excellence Facilitator (Mumbai)
– Deepak Sharma
(USA) Thanks for the feedback. More suggestions are welcome.

GLOW | May-Aug 2010

 FROM THE HEART | 15

From The Heart

Dear Emcoites,
I am now for three months with the organisation but I feel as if I have been very long with
EMCO.
Why this feeling? I reasoned myself and found it is the zeal to bring change which makes
me feel closer to all of you.
I have returned to the power sector after 2 years! I find huge change has taken place in
market, competition has increased more than ever, resilience of T&D industry indicates
how they accelerate when demands increase.
I recollect meeting with Power Secretary about 3 years back when he was challenging
industry stating that growth will be high but Ministry of Power is worried whether T&D can
match production and as IEEMA President I said, “they should not worry as T&D industry
will grow at same or even faster pace than demand grows and now I see this happening.”
EMCO also decided to grow by adding Projects as another vertical to business which
covers Transmission Lines and Substation.
Few important issues which I would like to mention:
Our thoughts ‘Inspired by tomorrow’ - this is very appropriate and all our actions
?
align to this powerful sentence.
Vision and values, ‘world class and great place to work’ - I have been doing dipstick
?
check and find fair amount of awareness and to move forward, I urge each business
to find six parameters; when they are achieved, we move towards values and vision. I
will discuss this with all and put measurement in place.
We have implemented SAP about 2 years before; this is a great tool for business
?
reprocess and also bringing discipline and transparency in organisation. My
observation is there may be feeling that SAP slows down process, I can say from my
experience this is not true. When you work in disciplined manner, it looks painful but to
get transparency and quicker decision this pain is must.
This year is very crucial for EMCO as we have each business growing; however
transformer business remains at base on which other businesses have to be built.
Let us work together; my experience, your aggression & commitment to own as well as
achieve results will definitely take us heights which we have dreamt together. Change is the law of life
and those who look only
to the past or present are
Thank you, certain to miss the future.

- John F Kennedy

Ajay Dhagat
Managing Director

www.emcoindia.com GLOW | May-Aug 2010

 Testing in progress aboard a barge at KEMA, Arnhem, The Netherlands

SETTING GLOBAL BENCHMARKS

EMCO becomes one of the leading transformer manufacturers in the world to have successfully tested
a 315MVA, 230kV Generator Transformer for Dynamic Short Circuit Test

At EMCO, pushing the envelope comes naturally to us. We consider each
challenge a mission to surpass our own expectations and we set about
achieving each task with determination and dedication.
A demonstration of this was evident when India’s largest rating
315 MVA, 16.5/230 kV 3-Phase Generator Transformer indigenously
designed and manufactured by EMCO for M/s. U.P. Rajya Vidyut Utpadan
Nigam Ltd. (UPRVUNL) for their Harduaganj Thermal Power Generating
Station was successfully tested for dynamic short circuit test in
accordance with International Standard IEC: 60076-5 at the KEMA High
Power Test Lab in Arnhem, The Netherlands.
The transformer got through in testing in FIRST GO as against the global
success rate of 50%. This momentous test was witnessed at KEMA
Laboratories by the UPRVUNL’s representatives and their consultant
M/s. National Thermal Power Corporation (NTPC), New Delhi, besides
EMCO’s engineers. For the KEMA lab too, this was the largest rating of
230 kV class generator step-up transformer (with LV short circuit current
rating of 155.7 kA) ever tested by them.
Success of this prestigious test once again reinforces EMCO’s leadership
in the domain of transformer manufacturing and a testimonial to our
relentless quest for excellence and new benchmarks.

Founded in 1964, EMCO limited is one of India's leading electrical solutions and products provider in over 40 countries. With
1700+ EMCOites, 5 certified manufacturing plants in India conforming to global standards, product range upto 765kV, EMCO
anticipates and develops tailor-made solutions for unique customer needs, leveraging customer case studies to build knowledge
references across the company. EMCO is also committed to environmental & social responsibility for a better tomorrow.