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EDITORIAL

SWITCH ‘ON’… GET GEARED FOR GROWTH

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lectricity makes machines go vroooom, a sound that signifies production in process, a sweet melody for the manufacturer, assuring his profitability and productivity. And while power is the enabling medium here, what enables the smooth and uninterrupted power supply finds itself primely positioned in the value chain and also as a focus sector for this month.

This June, as we focus on switchgear, which is a combination of devices designed to control, regulate, meter and protect electric generation, transmission & distribution equipment, and electric motor control systems, it is sure to shower fresh perspectives into this sector with added analysis. Since switchgear is used at all points of access and control of electricity, every switching point in the electric infrastructure mandates the use of switchgear. No wonder then that the prospects for the switchgear industry are very good, as the Indian economy is riding on power and infrastructural growth. With interconnected growth fortunes, the growth drivers for the switchgear industry are the infrastructure, power generation & transmission, telecom; government initiatives, housing projects and upcoming industries. With each of these sectors on a bullish run, the switchgear industry in India is a developed one, producing and supplying a wide variety of switchgear needed in the industrial and power sector. The current size of the Indian switchgear industry is around `10,000 crore. It is expected to grow 8–10% annually in the next five years. The low voltage (LV) and medium voltage (MV) switchgear markets in India are well established with a matured technology base. The Indian LV switchgear market earned revenues of $950 million in 2010 and estimates this to reach $2,170 million in 2017; while the MV switchgear market earned revenues of $795 million in 2010 and estimates this to reach $1,735 million in 2017. The prosperous predictions are backed by fact that the industry satiated the newer market demand like compact, small, low-weight equipment with high quality, high reliability, low maintenance and easy accessibility. Manufacturers today, understand the importance of a diversified product portfolio. The increasing competitiveness in the industry and constantly changing consumer demands have led to new and upgraded versions of products being launched into the market. Also, there has been a noticeable shift towards upgraded technology among major industry players with Indian manufacturers becoming increasingly competitive with respect to their product designs, manufacturing and testing facilities. Investments in R&D in the electrical machinery industry are among the largest in India’s corporate sector. Against a backdrop of a tough economic climate, success will critically hinge upon the ability to research & develop new innovative products at competitive prices and validate new applications for existing products to distinguish themselves from that of the competitors. Growth in switchgears will also be sustained by government directives to replace older, redundant systems to achieve operational safety, and security in industrial establishments. To sum up, continuous innovation, technology enhancement and product upgradation as per international standards are the key strategies for maintaining our position as a leader in the industrial switchgear market.

Archana Tiwari-Nayudu archana.nayudu@infomedia18.in


CONTENTS SPECIAL FOCUS: Switchgears

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Tracking The Past To Chart Future Trends Switchgears directly define the reliability of electricity supply and therefore, such equipment can never stay behind times. Such a device, which helps users as well as manufacturers, needs to be upgraded with the latest technological innovations. Time & again, the switchgear industry has kept on improvising depending on the market dynamics. These innovations have one main objective—improve the reliability of switchgears as well as their overall performance, as protective devices.

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EDITORIAL

STRATEGY

Switch ‘On’… Get Geared For Growth

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Patenting In India Enforcing Innovation Management

NEWS, VIEWS & ANALYSIS

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Green Design Giving Manufacturers A Competitive Edge

Latest Happenings In The World Of Manufacturing

TIPS & TRICKS

TECHNOLOGY & INNOVATIONS 44

Technology Update Cutting-edge Solutions

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Interview Software With Cloud Computing Is Encouraging Democratisation Of Technology Rajiv Bajaj, Head – Manufacturing, Autodesk India & SAARC; Kaushik Bagchi, Enterprise Sales Director, Autodesk India & SAARC and Jayant Keswani, Head – Marketing, Autodesk India & SAARC

FACILITY VISIT 96

Premier Heavy Engineering Homegrown Techniques, The Success Potion For Premier

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Switchgears Maintenance 6 Ways To Maintain Efficiency And Workability

BOOK REVIEW 119

Management Thoughts On Quality For Every Manager Inspiring Quality

IN CONVERSATION WITH

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AUTOMATION TRENDS 102

Business Intelligence Solution Delivering Outstanding Results

ENERGY MANAGEMENT 104

Software Solutions Going Hi-Tech With Custom-Made Applications

APPLICATION ZONE 106

‘3D For Lifelike Experience Is Going To Help Organisations To Innovate’ Dr Chandan Chowdhury, MD, Dassault Systèmes India

In-Sight ID Reader Delivering Highest Read Rates

HIGHLIGHTS: JULY 2012 

Special Focus: Instrumentation & Control  Insights & Outlook: Nanotechnology  Special Edition: Investment Destination: Gujarat


CONTENTS SPECIALS IN THIS ISSUE

SPECIAL FOCUS Switchgears

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Switchgears Open Page

61 66

INSIGHTS & OUTLOOK Motors

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Testing Switchgears Securing Maintenance-free Switchgears

Switchgear Inspection & Maintenance Ignore At Your Own Risk

Energy-efficient Motors Ensuring Efficiency Along With Productivity

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Indian Switchgear Market Gearing Up For Exponential Growth

L&T Facility Visit Banking On The Innovation Quotient

Tech Advancements Understanding The Recursion To Redevelop

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Shop Floor Innovations@L&T Driving Benefits From Cutting-edge Solutions

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Nano Motors Technology Driving New Possibilities

PRODUCT UPDATE 120

New Launches Latest Products In The Offing

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Switchgears Latest Products In Switchgears

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Motors Latest Products In Motors

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General Products Rolling Out The Best In Class

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International Products Showcasing Products In A Global Arena

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EVENTS LIST

CURTAIN RAISER 180

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ACMEE 12 Harnessing The Potential Of The South

PRODUCT INDEX Alphabetical Listing Of Products Presented In The Issue

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ADVERTISERS’ LIST Advertisers’ List In Chronological Order

REPORT 178

F&S Green Manufacturing Excellence Awards 2012 2 Riding High On Green Manufacturing

PRODUCT UPDATE

Looking For A Specific Product? Searching and sourcing products were never so easy. Se J type SRCH (space) Product Name Just and send it to 51818

eg. SRCH Pump and send it to 51818 eg


GUEST EDITORIAL

ATTEMPTING TO BALANCE THE POWER IMBALANCE SC Bhargava Sr VP & Head – Electrical & Automation, L&T At L&T, Bhargava has spent almost 27 years working on the design aspects of major switchgear products. After a brief stint in design, he took charge of operations at the Madh factory. Later, he moved to the Powai facility as the Head, Electrical Standard Products and subsequently became the head of the erstwhile Electrical Sector comprising of switchgear and electrical systems businesses before taking up his present role. Bhargava is the Chairman of L&T’s recently acquired Tamco Switchgear that has facilities in Malaysia, Indonesia and Australia. He has been actively associated with many industry and trade bodies in the Electrical & Electronics stream. He has been the past President of IEEMA. He takes keen interest in technology development and is an advocate of ethical and sustainable business practices.

Switchgear industry optimises the performance of T&D sector which is neglected in India. When we talk about power shortage, everyone talks about generation because it is easy to address. T&D is difficult as it is more State than Centrecontrolled. If we look at this segment worldwide, the investments in generation are on par with those in T&D. In India, if we take into consideration the last 15–20 years, major shortage of investments in T&D come to the fore. There are two reasons for this. First, it is not a glamour sector, and second, distribution companies have not been in a position to make investments. Thus, a huge imbalance has been created between generation and T&D. To some extent, the power sector suffers owing to this imbalance. We, at IEEMA, have been taking this up at different fora. This imbalance needs to be corrected, otherwise we will not be able to create a healthy power sector. At present, the T&D sector looks forward to the day this imbalance will be corrected. But the problem will not get sorted out on its own. Companies will have to take measures in terms of correction in distribution and reducing the length of the low voltage distribution network. One of the main reasons for high AT&C losses is the very high low voltage distribution network. Reducing the length of the low voltage losses is, therefore, of high importance, but it requires huge investments. Also, in India, distribution networks have grown without proper planning. Owing to this, the last 12 months have not been good as far as the switchgear industry is concerned. At IEEMA, we have seen a gradual slowdown of the growth process in all segments of switchgears. But I am optimistic. I still believe that this cannot continue for a very long time, and we will have to come out of it. I am fairly positive that in the medium term, we will be able to see significant growth taking place as far as the T&D sector is concerned. Today, each of the sectors has built up enough capacity, but this capacity is lying idle and needs to be utilised. At present, acceptance of new age switchgear is very low in India because it is a device that may not be operated for 2–3 years; it requires very high level of reliability. Due to this, the industry is traditionally very conservative; it looks at proven track record. This is one reason that innovations do not get accepted very easily in the industry. But, innovations are being gradually realised. Today, of the four major functions of switchgears, viz., carrying current, breaking current, protection and control, there are some innovations in carrying current and breaking current. But in the area of protection and control, a huge amount of innovations are driven by electronics, which is making the transmission from the electromechanical to numerical relays happen at a very fast rate. Controls are also becoming electronic intensive. We are also looking at reducing the material content. Today, we are driven by the question of reducing the material consumption in switchgear. With all this happening in the industry, I believe that switchgear will witness a growth momentum in the medium term.


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NEWS, VIEWS & ANALYSIS L A T E S T

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INDIA’S INDUSTRIAL PRODUCTION SLUMPS FURTHER India’s industrial production slumped by 3.5% in March for the first time in five months, as manufacturing, mining and capital goods contracted, exerting further pressure on the central bank for monetary easing to prop up the weakening economy. The Index of Industrial Production (IIP) had surged 9.4% in March last year, driving up the base for IIP calculations for March this year. The industrial production has risen at a sluggish 2.8% in the fiscal year through March 2012, compared to 8.2% in the previous fiscal, showed official data released recently. Production in the manufacturing sector, which accounts for around 75% of the industrial output, fell 4.4% in March, compared to a whopping 11% expansion a year before. Mining,

too, declined 1.3% against the growth of 0.4%. Capital goods output, an indicator of investment in the economy, slumped 21.3%, compared to 14.5% expansion during the review period. Consumer goods grew by a meagre 0.7% in March, compared to an impressive 13.2% a year before. Similarly, consumer durables output gained 0.2% against 14.9% growth in the same month last year. Power generation grew 2.7%, compared to 7.2% a year earlier. “I think it is very disappointing. One had not expected such a sharp decline in the industrial production. We all knew that there was a weakening as far as growth is concerned, but not negative growth rate. So, we need to look at the data more carefully. The

GE SUPPLYING WATER RECYCLING TECHNOLOGY TO STEEL MILL IN INDIA GE has announced that its zero liquid discharge (ZLD) wastewater recycling technology will be installed at the POSCO Cold Rolling Mill Steel Plant in Maharashtra in the second quarter of 2013. This marks the first steel mill application of a complete GE ZLD system containing electrodialysis reversal (EDR). Under the contracts signed between GE and Korean-based POSCO Engineering, a wholly owned subsidiary of POSCO, GE will supply a ZLD wastewater treatment system, which includes two EDR trains for water reclamation, for POSCO’s new plant. GE will also provide technical services, including operator training, during installation and commissioning of the facility. “Because of the ongoing water challenges in this region, it is critical to reduce the high levels of water use for industrial applications,” said Kyung Sun Kim, Project Manager, POSCO, adding, “GE’s innovative, customised wastewater system will help POSCO address that challenge while, at the same time, meeting local government regulations for wastewater discharge and supporting initiatives to prevent water pollution.” “POSCO is using the EDR technology to gain a higher recovery of treated wastewater and the ZLD system for reliable wastewater treatment, both of which help to address the challenges of high water consumption in the region, as well as water scarcity on a global level,” said Jeff Connelly, VP – Engineered Systems, Water & Process Technologies, GE Power & Water. The POSCO Cold Rolling Mill Steel Plant is expected to enter commercial service during the second quarter of 2013. The project builds upon an already close relationship between GE and POSCO Engineering. In 2009, GE supplied EDR technology for a thermal power plant to Daewoo Engineering, which later changed its name to POSCO Engineering after a 2011 merger with the POSCO Group.

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capital goods sector has shown a very steep decline. The numbers relating to this sector have been fluctuating from month to month. Therefore, we need to examine very carefully the underlying data before reaching any conclusion. Overall, the picture that has emerged is disappointing,” said C Rangarajan, Chairman, Prime Minister’s Economic Advisory Council (PMEAC). Indranil Pan, Chief Economist, Kotak Mahindra Bank, said, “March IIP numbers came far worse than expected because the policy space for lifting growth is very limited. We are in a bind as far as the fiscal policy is concerned. Therefore, right now, it is more important to clear the pending legislation and push decision making, which can boost the industrial production numbers.”

GIM EXPO 2012 TO BE HELD IN BENGALURU BETWEEN 6-8 JUNE In a move to promote technical advancements in the manufacturing sector, the Government of Karnataka, along with the Karnataka Udyog Mitra (KUM) and MM Activ will be organising Global Investors Meet (GIM) Expo 2012 from June 6-8, 2012 at Bangalore International Exhibition Centre (BIEC), Bengaluru. The Expo will offer exhibitors and visitors a single platform to interact and will offer various business solutions pertaining to technology and services, partnership meets, buyerseller meets, vendor identification and development, business networking, business expansion and investment & funding in Karnataka. It will focus on 14 pavilions including aerospace and defence; agrotech & food processing; automobiles; BFSI; energy and environment; health; ICT, electronics and hardware; infrastructure; education, R&D, innovation; textiles; tourism & hospitality; and states of India. It will boasts of 600 exhibitors on 20,000 sqm of exclusive showcase area.


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WMI KONECRANES BAGS ORDER FROM JSW STEEL WORTH `58 CRORE WMI Konecranes has bagged the order to supply 21 heavy duty cranes worth `58 crore to JSW steel. WMI Konecranes (formerly WMI Cranes Ltd) is a 100% subsidiary of Konecranes Plc, Finland. Konecranes Plc acquired 100% stake in WMI Cranes in August 2011 after which, the company’s name was changed to WMI Konecranes India Ltd. This order is one of the biggest single orders in terms of number of cranes to be supplied and the total value in the Indian crane industry. WMI Konecranes has supplied more than 4,000 cranes till date and is a

dominating market leader in the steel industry crane market segment. WMI Konecranes has been a preferred supplier for cranes to JSW Steel right from the inception of their plant. These cranes will be used for the critical coil handling application in the Cold Rolling Mill in JSW steel plant complex at Torranagallu, Hospet, Karnataka. These cranes will be integrated as a part of the state-of-theart, automated coil yard management system in the Coil Rolling Mill of this steel plant. This single order consist of three 50 tonne cranes, two 50/10 tonne cranes, one 60 tonne crane,

INFRASTRUCTURE IN 12TH PLAN: A ‘REVOLUTIONARY’ OPPORTUNITY A rapidly developing economy coupled with a fast-growing population puts extra pressure on a nation’s infrastructure. India thus cannot afford to overlook those methods, which improve infrastructure, especially project management. This was the topic of discussion at an exclusive session – ‘Role of Project Management in Creating Sustainable Infrastructure’ – organised by the Confederation of Indian Industry (CII). Boman Irani, Chairman & MD, Rustomjee Group, emphasised upon the need for proactive government support for the industry. He said, “The government needs to be an important player in the development of urban centres. Owing to the tremendous pressure on the nation’s infrastructure, there is a need for constant industry and government engagement to foster infrastructure development.” The 12th Five Year Plan that begins from April 2012 has revolutionary allocation on infrastructure. This is a great opportunity for the industry to work with the government to achieve better infrastructure for the nation, thus serving the society while also growing at the same time. V Suresh, Principal Executive Officer, HIRCO Ltd (Former CMD

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HUDCO), also put the onus on the government, when he said, “Half of India’s population, i.e., 450–500 million will be added between 2001 and 2030. How do we update the old infrastructure and build new ones to cope with this pressure? The industry will take care of onsite infrastructure, but it is offsite infrastructure like roads, rails, water supply, etc., where the government needs to step-up and be a critical differentiator.” He talked about the need for technology upgradation in infrastructure, comprehensive planning, designing and implementation, supply chain management, skill development, time management, etc. Supplementing his views, Anshuman Magazine, Conference Chairman & Chairman and MD, CBRE South Asia, said, “The biggest challenge the country is facing today is the implementation of infrastructure projects on time, with the cost and quality being optimal. This can only happen with proper project management.” He added, “We are a maturing economy. Hence, it is much more important to plan, share ideas and see how project management can improve the quality of infrastructure.”

two 60/10 tonne cranes, five 35 tonne cranes, seven 35/10 tonne cranes and one 15 tonne crane for maintenance application. All the cranes are fully automatic backed by the time-tested technology of WMI Konecranes since past four decades. Saeesh Nevrekar, VP, WMI Konecranes India Ltd, said, “The cranes are expected to be delivered to JSW Steel’s Torranagallu plant by the end of 2012. JSW Steel has been one of our prestigious and biggest customers. This order is no less than a positive acknowledgment to our quality products and customer satisfaction.”

LANCO SOLAR COMPLETES 56MW SOLAR PHOTOVOLTAIC POWER PLANT IN GUJARAT Lanco Solar, a fully owned subsidiary of Lanco Infratech Ltd, has recently announced that it has completed a total of 56 MW grid connected Solar Photovoltaic Power Plants in Gujarat. This includes three plants of 35 MW owned by Lanco Infratech Ltd and additional 21 MW built as turnkey EPC for other developers—the Gujarat Power Corporation Ltd (5 MW), GSPC Pipavav Power Company Ltd (5MW), GHI Energy Pvt Ltd (10 MW) and Gujarat State Electricity Corporation Ltd (1 MW). These power plants will generate up to 90 million units of green electricity annually resulting in the reduction of CO2 emissions by 85,757 tonne, annually. “Gujarat Solar Park is Asia’s largest solar park being dedicated by Chief Minister Narendra Modi to the nation. The Park is the “first of its kind in the world, being the largest, multi-developer, multi-facility park to encourage investment in the sector. Lanco is happy to be part of this prestigious solar park community in Gujarat”, said Madhusudhan Rao, Chairman, Lanco Group.


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SYNEFRA AWARDED BEST INDUSTRIAL DEVELOPMENT IN ASIA PACIFIC Integrated Infrastructure Solutions’ provider Synefra Engineering & Construction Ltd, a Tanti Group Company, has once again been honoured with two recognitions at the International Property Awards 2012 recently held in Kuala Lumpur. This year, Synefra E&C bagged the prestigious awards for its three hi-tech industrial parks located at Coimbatore, Vadodara and Padubudri and the other for the Integrated Wind Component Manufacturing Unit at Tianjin, China. Last year, Suzlon One Earth—a project conceived, managed and executed by Synefra— was the official entry at the World

Property Awards under the ‘Office Development’ category. Commenting on the achievement, JR Tanti, MD, Synefra E&C, said, “We are pleased to be honoured at the International Property Awards for the second successive year. This award has indeed catapulted Synefra SEZs into the global arena and brings great responsibility as a corporate to deliver consistent performance and display world-class practices. It is a double bonanza for Synefra to be recognised for our Indian SEZ projects and Tianjin, China, projects of stature. This award emphasises Synefra’s quality delivery for industrial projects as well.”

SUZLON GROUP WINS 39 MW POWER PROJECT ORDER IN POLAND Suzlon Group-subsidiary, REpower Systems SE, has recently announced its largest order to date in Poland with the bagging of the 39 MW Nowy Staw project, near the city of Gdansk. The wind farm will be RWE Innogy’s fourth in Poland. The 19 REpower MM92–2.05 MW wind turbines will be built over an area of 15 sqkm, and are scheduled for commissioning in early 2013. The project has the potential to generate sufficient power to meet the needs of more than 50,000 homes every year. Speaking on the project, Prof Fritz Vahrenholt, CEO, RWE Innogy said, “With Nowy Staw, we are expanding our wind portfolio in Poland by almost 40 MW. This will bring us a step closer to our goal of adding 50 MW of wind capacity in Poland every year until 2015. Our Polish wind pipeline is well filled.” Andreas Nauen, CEO, REpower Systems SE, commented, “With Nowy Staw, we are implementing our largest project in Poland so far. The site in the north of the country, with its average wind velocities, is optimally suited to accommodate the REpower MM92 turbines. To date, we have

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Suzlon crosses 1 GW in Jaisalmer, creates India’s largest wind park The Jaisalmer wind park being developed by the Suzlon Group crossed 1,000 MW of installed capacity at the end of FY12, reaching 1,064 MW. The development of the wind park was initiated by Suzlon in August 2001 and comprises Suzlon’s entire wind portfolio—ranging from the earliest 350 kW model to the latest S9X–2.1 MW series. The wind park comprises of a cluster of wind farm sites within Jaisalmer district including Amarsagar, Badabaug, Baramsar, Tejuva and Soda Mada, among others. The wind park houses projects of some of Suzlon’s key customers including Mytrah Energy, Hindustan Zinc Ltd, Hindustan Petroleum Corporation Ltd, Rajasthan State Mines & Minerals, Rajasthan Renewable Energy Corporation Ltd and Rajasthan Gums. installed more than 2,000 plants of the MM series all over the world. We are delighted that RWE Innogy has put its trust in our proven technology and has once again chosen REpower as its supplier.”

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CUMMINS INDIA INCREASES PRICE OF GENERATOR SET ENGINES The power generation business of Cummins India Ltd has recently announced a price increase of up to 3% for its diesel generator sets and generator set engines in the range of 7.5 kVA and 3000 kVA, owing to the current industry dynamics and projected market conditions. The price increase is effective from June 1, 2012. Cummins powered generator sets, transfer switches and paralleling systems are used for continuous, prime and standby power in a variety of commercial and industrial applications.

SUNIL KUMAR SRIVASTAVA TAKES CHARGE AS CHAIRMAN & MD, OIL INDIA LIMITED Sunil Kumar Srivastava has taken charge as the Chairman & MD of India’s second biggest state-owned exploration firm, Oil India Ltd (OIL). He worked for over 35 years in the upstream sector, out of which he worked for over three decades with OIL. During his more than three-and-a-half decades experience in OIL in on-land and offshore fields in India and abroad, Srivastava had occupied several leadership positions, both in India and overseas in various capacities. He has actively guided OIL in the national and international bidding in several countries in Africa, Middle East, South East Asia and North American Continents. He was also Head of Exploration for OIL in North East India. He did his BSc (Hons) and MSc, (Geology) from Lucknow University with first division in both. He had presented several papers and published in various symposia, conferences and refereed journals. He is the member of the prestigious American Association of Petroleum Geologists.


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EMERSON AUTOMATES STAGE II OF NTPC’S FIRST COASTAL-BASED THERMAL POWER PROJECT Emerson Process Management has recently announced the successful completion of the automation package for the NTPC Simhadri Stage II 2x500 MW super thermal power project. Located near Visakhapatnam, it is NTPC’s first coastal based, coalfired thermal power project. The plant’s output is expected to reduce the power deficit significantly in four southern states, including Andhra Pradesh, Kerala, Tamil Nadu and Karnataka, as well as in the Union Territory of Puducherry. With completion of the project, NTPC Simhadri will be regarded as one of the most modern power plants in India with state-of-the-art control and instrumentation systems. Emerson is the station control and instrumentation (C&I) systems contractor for this plant.

In addition, Emerson has installed the Distributed Digital Control & Management Information System (DDCMIS) for the power plant, along with measuring instruments, UPS, LVS, CCTV, PA system, Instrumentation/control cables, 24 V DC battery system and PlantWeb components. “NTPC, a Maharatna firm and leader in power generation, understands the importance of choosing the right automation technologies for super thermal power plants,” said Amit Paithankar, VP & MD, Emerson Process Management India. He added, “Emerson was best equipped to provide a total solutions package that not only met NTPC’s interface specifications, but also all its process control goals.”

ReNew POWER COMMISSIONS ITS FIRST WIND PROJECT IN GUJARAT ReNew Wind Power Pvt Ltd, an independent power producer, has recently commissioned its first wind farm project at Jasdan, Rajkot district, Gujarat. Chief Minister Narendra Modi inaugurated the 25.2 MW wind farm at Jasdan. This facility comprises of 12 units of Suzlon S88 wind turbines with 2.1 MW capacity each. Construction of the project began in October 2011 and was completed in March 2012. The project is selling its output under a long-term PPA contract with Gujarat Urja Vikas Nigam Ltd (23.1 MW), and the remaining output to Philips India (2.1 MW). The project demonstrates ReNew Power’s vision in recognising the challenge of climate change, and its responsibility to combat it. After commissioning the first wind mill of the farm, Modi said, “It gives me immense pleasure to welcome ReNew Power to Gujarat. Our state has been a dominant player in the wind

energy market and we look forward to have more and more projects and investments in the state to help build sustainable power source for energy starved India.” Speaking at the inauguration, Sumant Sinha, Founder Chairman and CEO, ReNew Power, said, “It gives us great pride to partner with the Government of Gujarat with its far reaching vision for wind potential in the state. We thank Narendra Modi for extending his support to ReNew Power and encouraging us.” He also added, “With this project, we further establish the vision of rapidly expanding our footprint in the growing Indian wind energy market. We, at ReNew Power, are confident of becoming one of the leading renewable energy producers in India. This on-time commissioning of our first wind power project underlines our dedication to power growth through green and sustainable energy solutions and in mitigating climate change.”

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SCHNEIDER ELECTRIC INDIA WINS GOLDEN PEACOCK AWARD FOR CSR Schneider Electric India has received the prestigious Golden Peacock Award for Corporate Social Responsibility (GPACSR) for the year 2012. The award, in recognition of Schneider Electric’s corporate social responsibility initiatives in the areas of village electrification, electrician trainings, employment and entrepreneurship was recently presented to Schneider Electric India by HE Juma Al Majid, Chairman, Dubai Economic Council & Founder Chairman, Juma Al Majid Group at Dubai Global Convention 2012. The winners of the Golden Peacock Awards for 2012 were finalised by a panel of four judges that included Dr Ola Ullsten, former Prime Minister of Sweden; Lt Gen Surinder Nath, PVSM, AVSM (Retd) former Vice Chief of Indian Army & former Chairman, Union Public Service Commission; Justice PN Bhagwati, former Chief Justice, Supreme Court of India; and Dr AN Saksena, former Financial Advisor, Ministry of Petroleum & Natural Gas. On the occasion of receiving the award, Olivier Blum, Country President, Schneider Electric India, said, “The award will inspire and encourage our large group of members of Schneider Electric India and the Corporate Social Responsibility team to intensify and extend their efforts to achieve greater success on the economic, social and environmental fronts.” The award application covered a detailed evaluation process where the evaluators recognised a variety of conditions under which an organisation conducts its activities and considered these factors during the assessment of the organisation’s performance against the assessment criteria.

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ABB TO INVEST `250 CRORE TO EXPAND MANUFACTURING BASE IN INDIA ABB, the leading power and automation technology group, will invest around `250 crore to build new facilities in India to manufacture high-voltage power products and transformers. The expansion is part of ABB’s strategy to develop, manufacture and market products that meet the needs of Indian customers, as well as serve as an export hub. “The new manufacturing units will further strengthen our local footprint and enhance our product portfolio. They will enable us to serve our customers better as we continue to support the development of the country’s power infrastructure,” said Pitamber Shivnani, Local Division Manager, Power Products in India. The facilities will be located in Savli near Vadodara, Gujarat, and will produce high-voltage gas-insulated switchgear (GIS) and plug and switch system

(PASS) hybrid switchgear as well as dry-type and oil immersed distribution transformers. The facilities are expected to be operational by the end of 2012. A pioneer in GIS technology, ABB`s latest series can offer space savings of up to 90% as compared to its conventional air-insulated switchgear. Its low-weight, robust design enables the equipment to be deployed even in harsh conditions and enhances system reliability, efficiency and minimises maintenance needs. The new transformer factory will manufacture vacuum cast coil drytype transformers and oil immersed distribution transformers. It will help bridge the gap in the present product offering in India and extend the distribution transformer range up to 10 megavolt amperes (MVA), 33 kilovolts (kV). It will also enable localisation of vacuum cast coil dry-type transformers.

TATA POWER’S MITHAPUR SOLAR PLANT CROSSES 11,000 MWH GENERATION UNITS Tata Power, India’s largest integrated power utility, announced the crossing of 11,000 MWh of generation units from its solar power plant at Gujarat. With its commissioning and declaration of commercial operation on January 25, 2012, the plant has performed ahead of expectations. The 25-MW Mithapur plant is an important constituent of the Gujarat Government’s dedication ceremony for solar generation of 600 MW in the state. Tata Power’s milestone also coincides with the Gujarat Government dedicating Asia’s first and largest ‘Multi-developer, Multi-facility and Multi-beneficiary’ Solar Park at Charanka village in Patan, which was recently inaugurated by Chief Minister Narendra Modi. Tata Power’s solar power plant was felicitated in the ceremony. Commenting on the milestone, Anil Sardana, MD, Tata Power, said, “We are delighted to have commissioned this

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Tata Power wins ‘Infrastructure Excellence Award’ Tata Power has been awarded the acclaimed ‘Infrastructure Excellence Award’ at an event recently held in New Delhi. Tata Power has been selected as the winner in the Main Awards Category, Energy & Power, for its project, Ultra Mega Power Project at Mundra, Gujarat. The award was presented by Urban Development Minister Kamal Nath. Alok Kanagat Chief – Projects and Executive Director CGPL and KK Sharma, Chief – Mundra Project, received the award on behalf of Tata Power. plant as per schedule and are grateful to the support provided by various authorities. Crossing 11,000 MWh of generation units is an important milestone for our Mithapur Solar Plant and demonstrates the efficiency and the state-of-the-art technology used at the plant.”

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ALSTOM T&D INDIA COMMISSIONS ELECTRICAL BALANCE OF PLANT PACKAGE FOR SALAYA PROJECT Alstom T&D India (globally known as Alstom Grid) has successfully commissioned the electrical balance of plant (eBoP) package for 2x600 MW power plant, located at Salaya Jamnagar district, Gujarat. ESSAR Group awarded this `2,050 million contract to Alstom T&D India for design, manufacturing, supply, erection, testing and commissioning of eBoP package for the power plant.

Alstom T&D India wins 400 kV substation contract from Chhattisgarh State Power Transmission Alstom T&D India has been awarded a contract worth `840 million from Chhattisgarh State Power Transmission Co Ltd (CSPTCL), for the erection, testing and commissioning of a 400 kV substation at Jagdalpur in Chhattisgarh. Under the terms of the contract, Alstom will provide three-phase auto transformers and shunt reactors, as well as the entire substation automation system and associated equipment, including diameters and feeder bays. The eBoP is a critical package that ensures smooth construction of the power plant’s electrical equipment. A well performing eBoP solution is essential to ensure efficient, reliable and stable operations of plant. Alstom T&D India provides complete eBoP solutions for all types of power plants and a full spectrum of products, design, engineering & services to maximise the availability and reliability of the electrical system. Alstom T&D India has won several e-BoP projects in India, particularly in the high end of the market above 300 MW and 600/660 MW power plants. Since 2010, Alstom T&D India has become the market leader in the eBoP domain in India.


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Making India Inc more competitive would be my primary agenda Pradeep Bhargava, MD, Cummins Generator Technologies India, has been recently appointed as Chairman, Confederation of Indian Industry, Western Region for 2012–13. During a tête-à-tête with SEARCH, he discussed his agenda and the most important projects he will be focussing on during his tenure. Excerpts… ENSURING SMEs GROWTH

BHARGAVA’S MANDATE

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OUR PRIMARY AGENDA

CII broadly aims at three concrete measures. We are involved in advocacy, which is mostly policy formulation; efforts to increase membership; and incorporating industrial best practices. The organisation is also concerned about its role towards society and the environment. Thus, we are focussed on advocacy, making India more competitive and contributing towards society & environment. I have been appointed for the western region, which includes Gujarat, Maharashtra, Madhya Pradesh and Goa. Fortunately, we have strong support from state governments. I will soon visit Gujarat & Goa, and interact with the local governments there to finalise on major industrial initiatives and to work towards ensuring that there is no delay on important issues related to critical sectors such as power and infrastructure, among others, in these states.

Maharashtra It is well known that Maharashtra has a very good law & order system, apart from a very well connected network of ports. Despite all the issues that the state is facing, investors are still keen to set up industrial base in the state. I have had talks with the State Government, which is more concerned about ensuring that the state achieves a more balanced growth. For example, some pockets in Pune are doing well, while there are a few areas, which continue to lag behind despite having the potential. Besides, the geographical location of the place is such that it is bound to witness growth. Goa Efforts are on to make Goa more than just a tourist & mining destination. There is a strong potential to develop IT and IT-enabled services (ITeS) in the state. Our main responsibility in Goa will be to understand and help the government bring in stability while simultaneously reconstructing the industrial structure of the state. Gujarat The major focus would be on tapping renewable energy sources in the state. For instance, canals are being covered to prevent water from evaporating. Also, photovoltaic cells have been installed to produce energy from flowing streams. Gujarat is a progressive state and all that we plan to do is a little hand-holding in order to bring in more engagement and synergy. We will act as a bridge and will support the government in the policy making process. Madhya Pradesh As far as Madhya Pradesh is concerned, our focus will be on drawing the road map for industrialisation. Across the region, we will be playing different roles. For instance, we will be focussing on enhancing membership, in terms of values and various programmes. Environment protection will also be on the agenda. But this would not be a success without cooperation from the concerned industries. So, my agenda here would be asking industry players to start adopting practises that would help conserve the natural habitat.

SMEs can never be on a standalone agenda. They can only flourish once the major players are established. As the major players grow in size, their demand from SMEs for raw material and other small components would also grow. So, once the major players set up their base, SMEs would follow suit.

CHALLENGES SMEs FACE TODAY Unfortunately, SMEs have to face both, internal as well as external threats. By internal threats I mean the ownership pattern, the decision making process and various other issues. Since the size is not huge, the top management mostly takes care of the operational as well as management issues. These things become so hectic at times for them that during crucial decision making, they tend to lose their way. So, the need of the hour is for the government to adopt certain measures and help the small players, in whatever way possible. As of now, the SME clusters that are coming up with government support are underoptimised and the regulations and inspections are quite tough in states such as Maharashtra. The situation, however, is a little better in Gujarat. While the government support is essential, we must not forget that 90% of the production needs of any major player are catered to by the SMEs. So, these small players need attention.

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Creating Synergies For A Brighter Future C r e a t i o n o f a n i n v e s t o rfriendly atmosphere, developing infrastructure, easing of regulatory procedures, provision for availing easier finances and political consensus are some of the key areas where the formation of a stronger partnership between the government and the industry can play a critical role in making the manufacturing sector in India highly productive and globally competitive. Here’s identifying the stumbling blocks towards optimising the government-industry partnership and the solutions for it… ARINDAM GHOSH

ith an aim to strongly develop the Indian manufacturing sector, the government came out with the National Manufacturing Policy. The policy targets 25% share of manufacturing in the country’s GDP by 2025. According to Union Finance Minister Pranab Mukherjee, “The government is committed to create an appropriate policy framework to attract both domestic as well as foreign private sector investment into the country. To facilitate private sector investment, the government initiated several policy measures during the last financial year.” However, there are certain key areas where a strong government-industry partnership can be highly fruitful for the growth of the economy and the manufacturing sector, as a whole. These include: Introducing Flexibility Or Removal Of Caps For Foreign Investment Sectors such as multi-brand retail, insurance and defence are of huge

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interest to investors. However, strict norms laid by the government in terms of the level of investment that can be made for these sectors are discouraging foreign investors from pumping in money, which, in turn, is preventing the growth of these industries in the country. Developing An Investor-friendly Climate Regulatory norms have to be made more flexible and better coordination between various authorised agencies has to be established. This will play an important role in encouraging more participation from private and international investors in India. Elaborating on the same, Pankaj Sudan, VP, GE, says, “Transparency and flexibility in regulatory procedures need to be brought in. This will help create favourable conditions for investments in basic infrastructure as well as aid in the development of sustainable models for encouraging financing needs to be designed. Money would not be an issue, if a suitable

framework is created.” Complementing Sudan’s views, P Balendran, Director & VP – Corporate Affairs, General Motors India, comments, “The industry as well as the government need to come up with initiatives, which will lead to smoother facilitation of investment. The manufacturing sector will hugely gain from a strong partnership between the government and the industry because this sector makes a significant contribution to India’s GDP. Unless investment comes in the manufacturing sector, it will be very difficult to make the sector competitive.” Infrastructure The government and industry need to focus on creating strong infrastructure in India as it is crucial for the growth of the country. Developing the DelhiMumbai Industrial Corridor (DMIC) is a major initiative taken in this direction. Such initiatives not only attract investments, but also play a crucial role in providing a fillip to the growth of the manufacturing sector in


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the country. However, more steps are required to be taken in this direction. The economy would need at least $500 billion contribution from the private sector to address the infrastructure bottlenecks and, in the process, realise the $1 trillion investment in infrastructure envisaged during the 12th Plan. Parmeet S Ahuja, President & Country GM, Agilent Technologies, avers, “Infrastructure, which is the basis for the development and growth of any country, is holding India back.” Process Of Allocating Resources Clarity and standard procedures need to be developed in consultation with all the stakeholders while allocating land and other natural resources for carrying out various business activities. To this, Ahuja adds, “With initiatives like the national manufacturing policy, it is clear that the government is keen to allow the industry to play a crucial role in strengthening the growth of our country. I think that both the government and the industry need to have more discussions and develop strategies accordingly.”

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is even more important.” Referring to the global meltdown, he said that policy makers across the globe are following a policy since 2008, i.e., if the problem was created by excess liquidity, the solution also lies in increased liquidity. However, increasing liquidity to ensure money goes into financing businesses has resulted in unexpected outcomes, essentially bubbles in the bond and commodity markets. He added that easy money is sloshing across the globe through risk-on and risk-off trade, which has made bourses across the globe volatile. With respect to India, he commented, “Since 2000 to late 2008 and early 2009, India was seen as a top-down opportunity, which meant that people were allocating money on a top-down micro basis in addition to bottom-up opportunities that psychology has changed. Money for India has moved away from being top-down to being The manufacturing sector will hugely gain specific bottom-up stories.” from a strong partnership between the Sanjay Nayar, CEO, KKR government and the industry because this sector makes a significant India Advisors, said that, given contribution to India’s GDP. the current macro-economic P Balendran, Director & VP – Corporate Affairs, General Motors India scenario along with increasing CHALLENGES INVOLVED risks and volatile capital flows, A constructive partnership between facilitate smoother and easier flow it has become essential for India to the government and the industry can of funds. According to UK Sinha, develop deeper local debt and equity take the growth of the Indian economy Chairman, SEBI, “India needs a lot of markets for the next five years. The to unprecedented heights. However, finances.” It is essential that financing is focus should be on the path of longthere are certain challenges that need provided in a substantial manner so that term flow of money by deepening to be tackled in terms of creating savings can be used by corporates for domestic markets. such a healthy bond. Some these investment, he said. In order to motivate REPEAT OF 1991: A POSSIBLE SOLUTION challenges include: people to invest, there is a need to provide It has been more than 20 years since Political Consensus: A Major Barrier investors with good quality financial the reforms on economic liberalisation According to Union Minister for Heavy assets and also educate investors. Sinha were introduced in India by the then Industries and Public Enterprises emphasised SEBI will ensure that to Finance Minister Dr Manmohan Praful Patel, after achieving a high increase market confidence, a reliable Singh. The policy has played a critical growth rate, India has suddenly hit system has been put in place whereby role in making India what it is today. It a roadblock. Over a period of time, people are assured that there the game can easily be said that the government’s the country seems to have lost its has uniform rules and if these rules policy framework, which promotes “USP” of being globally competitive are not maintained, they will be taken strong participation of the private sector, in many areas and doing business to task. Elaborating further on the can be considered an ideal platform for in India has become difficult on importance of generating finances, Uday India to once again take that giant leap account of high cost of production due Kotak, Executive Vice Chairman & like the one it took after 1991. to high power tariff rates, high land & MD, Kotak Mahindra Bank, remarked, increasing labour costs. Highlighting arindam.ghosh@infomedia18.in “Financing is important, but execution that ‘political consensus’ is a major barrier in India’s growth path, Patel said, “India is at the cusp of becoming something bigger, but is unable to achieve it because of the lack of political consensus.” Citing an example of the country’s power sector, he said that instead of exploiting the country’s vast coal reserves, India is importing costly coal, which has resulted in power becoming expensive. He suggested that the problem can be addressed by contracting private entities to undertake mining activities. India needs to focus more on developing renewable sources of energy. Finance Financial institutions are a key driver of economic growth and industrial development. Given that industry has a vital role to play in terms of creating employment opportunities and taking the growth of the economy upwards, developing strong cooperation will

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CUTTING-EDGE SOLUTIONS

NEW TECHNOLOGY OFFERS SAFER AND EASIER OPTION TO STORE HYDROGEN ydrogen has always been considered an alternative to fossil fuels. Apart from being renewable, it does not emit greenhouse gases after ignition. However, the usage of hydrogen has been restricted owing to problems pertaining to its storage. But now, thanks to nanotechnology, storing hydrogen is comparatively easier. Cella energy, a spin-off from Britain’s Rutherford Appleton Laboratory, has developed a new technology called Coaxial Electrospinning, which will absorb hydrogen and encapsulate it into nano fibre hydrides that are much easier and safer to store than nascent hydrogen. The day is not far when we may soon be able to see thermal plants powered with hydrogen fuels. Besides, there are vehicles based on hydrogen-fired fuel cells that have been commercially launched in Japan and some cities in the US and Columbia. However, these countries are facing hurdles such as storage and lack of hydrogen refuelling network. Moreover, the high cost associated with producing fuel

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cells makes it a commercially unviable option. Recently, Prof LM Das from IIT Delhi has got some path breaking success in this regard. He has developed a special electronic ignition system that directly feeds the engine tiny quantities of gas. It can erase unnecessary development and production of fuel cells. According to Prof Das, this fuel My focus is on the application of hydrogen in existing internal combustion engines without any substantial modification in existing hardware. Professor LM Das, IIT Delhi

injection technology can gain much popularity in India, particularly in the metros where most of the vehicles are already running on LPG or CNG. In such a scenario, it is comparatively easier to shift to hydrogen-powered fuel. He says, “The penetration into the market depends on the economic viability of hydrogen production.

As far as vehicle development is concerned, it is not very expensive. It has been roughly estimated to be a few thousand rupees more than CNGfuelled three wheelers.” Air Products, UNIDO (India), ICHET (Istanbul) and Ministry of New and Renewable Energy (MNRE) have all contributed to this evolutionary process. While the patent is yet to be filed, Prof Das, when talking about the technology, explains, “Hydrogen has got a set of physicochemical characteristics, which are radically different from conventional petroleumbased fuels. Therefore, it is essential that an appropriate fuel injection system is developed on the basis of properties such as high flame speed and minimum ignition energy. The flammability range of hydrogen is very wide (4% to 75% by volume). Moreover, NOx is the only pollutant in hydrogen engines. But this can be dramatically reduced by operating in lean mode. Therefore, the electronic injection system (that we had built) had to take into account all these factors.”

NEW CONTROL CENTER HELPS MAINTAIN AUTOMATION EQUIPMENT ith an aim to eliminate the complexities of installing and maintaining automation equipment, Cognex Corporation, a supplier of machine vision systems and industrial ID readers, has released Cognex Explorer™ control center. This control center helps control, production and maintenance engineers find the intuitive point. This unique utility displays a graphical view of all Cognex vision systems, ID readers and visualisation systems connected to the network. It also incorporates powerful maintenance tools for backing up, restoring or cloning systems, carrying out firmware upgrades and much more. Highlighting the utility of the new control center, Carl Gerst, VP and

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USP The new control center offers the ability to display the identity, type and status of all Ethernet-connected In-Sight® vision systems, DataMan® ID readers and VisionView® display devices on the network; view device settings including IP addresses, firmware/software versions; execute firmware updates; backup and restore multiple systems simultaneously; clone systems when adding more systems to the network and add licences for VisionView. Business Unit Manager – ID Products, Cognex Corporation, says, “The Cognex Explorer control center was designed to help our customers achieve additional efficiency improvements and cost savings when using Cognex vision systems, ID products or visualisation platforms. It eliminates the complexities of installing and

maintaining automation equipment.” “Once a Cognex product has been deployed, we want to make it easier for our customers to monitor and maintain the system with one common utility. Cognex Explorer is a convenient way to monitor, manage and maintain all deployed Cognex products on a network regardless of their location,” he adds.


CUTTING-EDGE SOLUTIONS

ULTRA HIGH-VOLTAGE CIRCUIT BREAKER TO SAVE SPACE ith the advent of USP at higher voltages enables more technology, companies power to flow through lines ABB’s 1,200 kV circuit breaker is safely today are looking at with minimal space impact and housed along with the disconnector in a tank solutions that would reduce significantly lowers transmission filled with insulating gas. This unique design the space presently occupied by line losses. These factors have can result in a space saving of up to 60% as conventional machinery. Taking prompted ABB to develop a compared to conventional designs. The a step in this direction, ABB is 1,200 kV transmission system. configuration also protects critical components in the process of designing and Commenting on the from environmental exposure and brings down developing a new 1,200 kilovolt applicability of this circuit breaker the centre-of-gravity, thereby increasing its (kV) circuit breaker—the highest for PGCIL, Giandomenico ability to withstand seismic events. AC voltage level in the world. Rivetti, Head – High Voltage The innovative circuit breaker Business, ABB, says, “This is being jointly developed by ABB manufactured at ABB’s production 1,200 kV circuit breaker is another engineers in Switzerland and India facility at Vadodara. example of ABB’s commitment to with Power Grid Corporation of India India is presently adding significant remain at the forefront of technology Ltd (PGCIL) supporting the initiative. power generation capacity to meet and innovation. We have pioneered While the innovative circuit breaker the growing demand. This requires many power technologies in India and will be deployed at a national test efficient and reliable transmission & are proud to build on this heritage by station being constructed by PGCIL distribution infrastructure to deliver supporting PGCIL for this benchmark at Bina, Madhya Pradesh, it will be electricity to consumers. Transmitting project.”

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TESTING TECHNOLOGY TO IDENTIFY DESIGN FAULTS DURING AIRCRAFT CUSTOMISATION oday, a major concern for every manufacturer lies in developing solutions and systems according to customer’s requirements. The statement holds true for aircraft as well, wherein airlines are looking for different interior finishes, lighting and ventilation & seating options. These days, companies use design drawings to determine whether individual parts of a system have been attached properly or manufacturers use other rigid and inflexible testing systems to check the concerned parts and compare them with conceptualised photos. However, developing such customised solutions may lead to designing errors, correcting which can prove to be highly expensive. To resolve this issue, researchers at the Fraunhofer Institute for Factory Operation and Automation IFF, Magdeburg, have come up with a testing technology that is reliable and economic even for oneoff production runs. Elaborating on the role of this

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USPs • The system also automatically draws up the testing plan—first, it identifies the best measuring position for every part to be tested. • The system forwards the results to the robot, which, in turn, travels to the position identified, where it shoots the two or three-dimensional images. technology, Steffen Sauer, Project Manager – Measuring and Testing Technology, IFF, avers, “Automated visual testing system generates a digital template and uses it to compare the assembled components. It reliably identifies any errors.” The main challenge while developing this technology was to set up a virtual camera that uses design models to ‘photograph’ the ‘nonexistent’ component. Another crunch point was to quickly and automatically locate the interesting areas from among the many millions of points in the three-dimensional images—to hunt down, in the mass of points, tiny components such as brackets and holders, and to check if they are

properly fitted. In addition to a two-dimensional check using the photos, the system can also check a completed aircraft fuselage in three dimensions as in the case of the photos, it uses design data to generate three-dimensional data that it then compares with measurements on the real assembly. Here, conventional three-dimensional measurement methods are used to digitalise the components. “What’s new about this system is that we convert specifications from the design models into images and 3D data that the system can then compare with the real images,” explains Sauer. The technology can be used wherever flexibility is required and individual parts frequently change.

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OPINIONS & MORE

LATEST TECHNOLOGIES YOU INTEND TO OFFER THIS YEAR? Rajiv Bajaj: Our 2013 portfolio is an ambitious offering of software, which are truly comprehensive solutions in areas ranging from factory layouts and packaging lines to electromechanical components, and the kicker lies in that Autodesk integrates all of it completely within its suites. The new Product Design and Factory Design suites enable a manufacturer or customer to develop complete definitions of product designs, increase productivity through integration of electrical and mechanical systems, visualise designs and build complete factory layouts in 3D. Newly developed one click workflows provide a seamless transition through the design process, which is evident in our updates as well, like Autodesk Inventor, AutoCAD Electrical, Navisworks

Rajiv Bajaj

hardware or IT limitations a manufacturer may have had. We also offer customisation and development services in the form of alias partners who also provide consulting services to firms seeking to transform business and design workflows. This way, clients can work with our partners to modify and improve the existing software to directly suit their specific manufacturing processes and workflows. Thus, manufacturers have the resources to extract the most from these technologies, sometimes in ways they may not have been aware of, and at a fraction of the cost it would take to do themselves.

HOW SIGNIFICANT ARE THESE MANUFACTURING DESIGN DEVELOPMENTS? Rajiv Bajaj: Globally, particularly in the Asia-Pacific region, manufacturing in Autodesk is growing at twice the rate of the whole company’s

Kaushik Bagchi

Jayant Keswani

Software with Cloud Computing is encouraging Democratisation of Technology Simulate and 3ds Max. Further, within the suites, the 2D drawings and the 3D Inventor assembly are synced such that any changes in 2D are directly propagated to the 3D layout and vice versa. Kaushik Bagchi: In addition, all this and more is also available on the cloud alternative—Autodesk 360—which allows a user to remain constantly updated and globally connected with access to all the suites and added services via the cloud. This also gives any user access to unprecedented processing power that, among many things, would allow multiple simulation scenarios to run in parallel—as in Simulation Moldflow—thus evaporating any previous

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growth. In manufacturing, especially for SMEs, it is known that design and initial development are central to the planning process. We believe we have the broadest and deepest portfolio of software in this regard. Kaushik Bagchi: The future lies in Digital Prototyping. This widening of the Autodesk platform gives manufacturers a single portal for all their engineering requirements with compatibility, easy access and speed. More importantly, within the breadth of its suites, Autodesk software indulges the user in realising the world of Digital Prototyping where conceptualising, modelling and testing can be done before even building the physical product. Customers can


OPINIONS & MORE

be given highly detailed interactive, 3D walkthroughs of factory layouts and processing lines, thus giving the manufacturer an opportunity to build confidence like never before. Our comprehensive software solutions are a step forward, as it enables design, visualisation and simulation capabilities that help drive innovation, while, at the same time, integrating discipline specific tools and workflows. Design and visualisation will become highly strategic tools in an incredibly competitive global market and the speed of conceptualisation to final delivery is vital in gaining that edge.

HOW CAN SMEs BENEFIT FROM THIS PORTFOLIO? Rajiv Bajaj: The Autodesk 2013 portfolio is aimed at helping all our large and small clients world over to apply better cost control and enhance their competitiveness in the manufacturing industry, which is an important contributor to GDP growth. The flexibility of our product packages and the variety of specific tools available allow us to cater to customers from the government, large corporations and small to medium enterprises. We intend to expand our distribution network to include more Value Added Resellers (VARs) in more cities, reaching out to newer markets across the country. At present, some of our biggest clients in India include ThyssenKrupp AG and Sandvik Asia Ltd. We also have a web of over 1,900 authorised training centres with over 1.2 million designers trained annually and these centres are crucial in developing the skilled technical manpower that manufacturers sorely need. Kaushik Bagchi: As digitisation extends deep into the nation’s production and manufacturing sectors, a growing concern for SMEs will be effectively accessing & managing

much is accessed and what services are used, thus giving the customer several affordable options.

WHAT ARE THE DEMAND DIFFERENCES BETWEEN MNCs AND SMEs? Rahul Bajaj: There is a difference. SMEs are yet to see how the suites will help them up their effectiveness across all aspects of their manufacturing from the factory floor assembly to rendering a product. So, they tend to purchase in parts. Large corporations actively apply all solutions on offer in the suites and thus help spread the demand for our technology since SMEs would need to compete for increased business and compatibility.

HOW RELEVANT IS CLOUD COMPUTING FOR THE MANUFACTURING SECTOR, TODAY AND IN THE FUTURE? Kaushik Bagchi: The collaborative opportunities provided by cloud computing are revolutionary and uniquely encourage the democratisation of technology for manufacturers worldwide. The primary benefits of the cloud lie in three areas, viz., storage, viewing and sharing. A user can view and edit 2D or 3D files using a browser on a desktop or apps on a mobile device. These files can be updated, shared and worked upon anywhere by anyone the user is looking to collaborate with. This flexibility and functionality is truly where democratisation lies. Currently, the services offered exclusively on the cloud include quick rendering, optimisation of multiple simulations for Inventor and powerful energy and statistical analysis options for Revit. The rendering services alone exemplify the advantage of infinite computing without requiring the investment in expensive hardware and IT infrastructure. Rendering

By 2015, the Indian manufacturing sector is expected to see the meteoric rise of over 50 million SMEs, which will raise the overall contribution from this sector to the national GDP, to over 60%. One of the key trends in this proliferation of products and services will be the reduction in cycle time from design to manufacturing, articulate Rajiv Bajaj, Head –Manufacturing, Autodesk India & SAARC; Kaushik Bagchi, Enterprise Sales Director, Autodesk India & SAARC and Jayant Keswani, Head – Marketing, Autodesk India & SAARC, during an interaction with Tarun Tampi. Excerpts...

this volume of information. They will also have to see the benefits of heavy collaboration—a key feature this software offers. Also, cost reduction and increased R&D funding are a must for sustained development in manufacturing companies. Jayant Keswani: The Autodesk suites come in three costeffective packages—Ultimate, Premium and Standard—that are competitively priced with SRPs ranging from `1.5 lakh– `3 lakh. Customers are free to buy the software in parts, but that will be a more expensive alternative to purchasing the suites. Cloud services, which include the suites, are offered on a subscription pay-as-you-go basis, depending on how

previously had its limitations and often required days to complete, but now, it is possible to create numerous complex renderings in just hours. In the last few decades, we have seen how traditional business models have been evolving at an accelerated rate of change. The speed of implementation, design, analysis and manufacture is vastly reduced as well with projects that usually take hours or days now done in a matter of minutes. The connectivity and services offered hint at an unprecedented era of collaboration, access and processing power. tarun.tampi@infomedia18.in

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DR CHANDAN CHOWDHURY

3D for lifelike experience is going “It is probably the best time for all the leading PLM players to create value for the nation. I think everybody—the customers, players and other stakeholders,” opines Dr Chandan Chowdhury,

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DR CHANDAN CHOWDHURY

TECHNOLOGICAL ADVANCEMENTS SHAPING PLM INDUSTRY Technological advancements have reduced the cycle time for the entire product development process. The requirements not only involve suppliers in the design process, but also need technologies, which can help start the process in the subsystem itself. This is a step wherein various members of the value chain, including suppliers, will collaborate right from the beginning, i.e., from the time the product is being conceived. This will bring about a phenomenal change in the way organisations look at innovation.

SKILLED WORKERS: NEED OF THE HOUR

UP CLOSE & PERSONAL

Presently, the demand for new technologies in the market is high. The young generation and all progressive managers have begun to realise that they need new technology if they want to be innovative and become competitive. This, in turn, will help them differentiate themselves from their competitors in the marketplace. While offering technologies, which can help companies innovate, we also want to add significant value to our customers. This could be achieved if we are able to generate skilled manpower. We believe that generating skilled manpower will help bring about a substantial change in the country. However, for this, students of engineering institutions, schools, colleges and higher education institutions need to be exposed to state-of-the-art technologies. We have got a full-fledged education programme and there are many universities, including the top technology institutes, which are in talks with us. These universities seek to collaborate with us, adopt our technology and make it part of their curriculum. In fact, many of the top institutes have implemented a subset of our technology in their curriculum.

What motivates you? I thank God for giving me another day to contribute. I think if everyone contributes in small ways, we will make this world a better place to live. As human beings, we are extremely greedy and have been merciless when it comes to exploiting our natural resources. The desire to do much more for our planet is what drives me.

VISION FOR THE NEXT DECADE As far as the next decade is concerned, 3D for lifelike experience is going to help organisations to innovate in a big way. We feel that today we have a technological platform, which helps organisations innovate and add value

Your dream project During my career, I have taken up several interesting projects. But if I am asked to name just one project, then it would be the project (which I did for the government) on making Indian manufacturing globally competitive. Here, I was one of the experts along with two professors and another member from the corporate industry. It was an extremely interesting project and a wonderful experience. Leaders you follow I think Steve Jobs has been an inspiration. Apple, under his leadership, has literally shown how an industry can do magic through innovation. What he has done is phenomenal. Message to budding entrepreneurs There are no shortcuts and there is no magic capsule to achieve excellence. One has to be committed and work hard. But before getting into entrepreneurship, one needs to identify what one is good at and what one enjoys doing. It is only then that one can make significant contributions.

to help organisations to innovate that our motto of promoting ‘healthy competition in the market’ will be good for MD, Dassault Systèmes India, during an interaction with Arindam Ghosh. Excerpts… to their customers. As a result, they are able to make better contributions to society & achieve their business objectives at the same cost. As far as our expansion plans are concerned, we see India as a growth market and have been experiencing double-digit growth during the last three years. There is a huge demand for technological solutions in India, given the

rate of growth the country is witnessing.

TECHNOLOGY MUST HAVES Firstly, we take into consideration the usability of the technology, which is used in various projects, products and plants, among others. Hence, while offering our technology,

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DR CHANDAN CHOWDHURY

we try to ensure that our technology is built in such a manner that various stakeholders are able to collaborate effectively. Secondly, while building the technology, we try to make it as user-friendly as possible. If the technology is not easy to use, its implementation will become extremely complex. As a result, people will not be able to implement the technology properly. We try to offer an end-to-end total offering wherein an organisation can visualise how they are going to use a total offering to innovate and bring about substantial improvement. Thirdly, we try to conceive our portfolio of technology such that an organisation can roll out its big plan in phases. Such an offering can help organisations reap quick business benefits. Talking about our total offering, our technology not only allows you to design virtually, but also offers the scope to virtually roll out

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your plans.

INNOVATION AND R&D Traditionally, the PLM offering cuts across organisational boundaries as all the departments including design, engineering & manufacturing and resourcing collaborate to deliver a project. This makes it all the more important for us to do continuous innovation to improve the technology offering in the sector. Besides, the evolving business environment makes it mandatory for us to ensure that the required technologies are available and that companies are equipped to handle those challenges. Since it is important to be able to cope with changes, continuous research and upgradation of technologies becomes very important.

FUTURE OF PLM IN INDIA We believe that if India wants to retain its global positioning in terms of growth in its GDP, organisations

have got to adopt not just PLM, but 3D lifelike experiences as well. We understand that it is important to create awareness about the same, but that needs to be done at the college level. This will ensure that once graduates enter the corporate world, they already know about the benefits of the technology.

MESSAGE TO COMPETITORS The market is very big and there is space for everybody. It is probably the best time for leading PLM players to create value for the nation. If we are going to spend time on creating awareness about what this technology can do for businesses, society, education and research, it will be more beneficial. Besides, I think that our motto of promoting ‘healthy competition in the market’ will be good for everybody—the customers, players and other stakeholders. arindam.ghosh@infomedia18.in


SWITCHGEARS

SWITCHGEARS: Open Page ............................................................................................................56 EVOLUTION OF SWITCHGEARS: Tracking The Past To Chart Future Trends ..............................58 TESTING SWITCHGEARS: Securing Maintenance-free Switchgears ..............................................61 INDIAN SWITCHGEAR MARKET: Gearing Up For Exponential Growth .......................................66 SWITCHGEAR INSPECTION & MAINTENANCE: Ignore At Your Own Risk ...............................70 L&T FACILITY VISIT: Banking On The Innovation Quotient ...........................................................76 SHOP FLOOR INNOVATIONS@L&T: Driving Benefits From Cutting-edge Solutions ..................79

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SWITCHGEARS



Demand Trends Witnessed

The switchgear and control gear segment in the 1st half of 2011–12 has witnessed a growth of 2.4%. Stagnancy in growth has been seen in the medium voltage segment. The high and extra high voltage segment has seen a surge in demand of nearly 20% due to increased demand from power transmission units.



Investments

ABB will invest `250 crore to build new manufacturing facilities to manufacture high-voltage power products and transformers. These facilities will be located at Savli, Gujarat, and will produce high-voltage gas-insulated switchgears (GIS) and plug and switch system (PASS) hybrid switchgears as well as dry-type & oil-immersed distribution transformers. PASS is a hybrid switchgear solution that combines the features of air- and gas-insulated technologies. These facilities are expected to be operational by the end of 2012. Schmersal India, the Indian arm of the German Schmersal Group—world leader in electrical and electronic safety switchgears and systems—has set up its first greenfield manufacturing facility in Pune with an investment of around `54.4 crore. The Ranjangaon facility will manufacture electromechanical safety devices, electronic sensors and life switchgears. The commercial production at the plant will commence in the first quarter of 2013.

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In The News

After registering negative growth from September 2011 till January 2012, the capital goods sector is on the upsurge as it clocked a positive growth of 10.6% in February 2012. Some of the important capital goods such as machine tools, insulated cables & wires, heat exchangers, relays, fuses and switchgears & generator/ alternator, showed positive growth during the month, thereby contributing to the growth of the overall index.



Expectations

Indian switchgear manufacturers should make sufficient investment in R&D Immediate steps needed to tackle increasing raw material cost.


SWITCHGEARS 

Emerging Technology Trends

Move towards embedded intelligence and communication enabled switchgears Shift from electromagnetic to numerical relays Increased acceptance of electronic releases in circuit breakers Shift towards compact switchgears & controlled switching In search for substitute of SF6 Integrating with smart grids Vacuum contractors for higher ratings Improved materials for cost saving and environmental reasons.



Facts

Switchgears are classified on the basis of the breaking and insulation medium used The present size of the switchgear market is around

`10,000–`12,000 crore

Indian switchgear manufacturers are highly organised with 16 players out of the 26 controlling more than 90% of the market share Switchgear manufacturers suffice domestic demand for the voltage range from 240kV–800 kV.



Challenges

The medium voltage and high voltage segments have been suffering from overcapacity due to the lack of orders The lowest quoted price (L1) procurement system in utilities, i.e., procuring products at the lowest price, creates a hurdle, especially when it comes to bringing good quality material into the system Insistence on repeated type testing of products despite inadequate type testing laboratories and no change in design pose additional delays and add to unnecessary costs Low investments in R&D Lack of high voltage switchgear test facilities in the country Entry of unproven contractors/ sub-contractors with minimal technical knowledge.

Compiled by Sumedha Mahorey

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EVOLUTION OF SWITCHGEARS

witchgears have undergone many evolutionary changes over the past few decades,” asserts Soeb Fatehi, President, Control Panel and Switchgears Manufacturers’ Association. Invented by James Harry Castell in 1922, switchgears were first known as ‘trapped key interlocking’. Starting from the 1960s, switchgears made their way into industrial as well as electrical applications. Here’s tracking in detail the evolution of switchgears starting half-a-century back...

“S

Tracking the

Past to chart

Future Trends

Switchgears directly define the reliability of electricity supply and therefore, such equipment can never stay behind times. Such a device, which helps users as well as manufacturers, needs to be upgraded with the latest technological innovations. Time & again, the switchgear industry has kept on improvising depending on the market dynamics. These innovations have one main objective—improve the reliability of switchgears as well as their overall performance, as protective devices. PRATEEK SUR

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IN THE 60s... The sixties saw the evolution of ‘air switchgears’ and ‘oil switchgears’. Air switchgears Be it is low, medium or high voltage switchgears, air has always been used as an insulator. The primitive switches used to be the plain break ones, which would generally stretch over an arc positioned between a stationary and a moving contact. This meant that there was no arc control. The current and voltage ratings were limited and the arching times were very long, which, in turn, hampered the performance. The performance was substantially increased by the use of an arc chute, comprising of a number of bare metal plates arranged at 900 to the length of the arc chute. These had spaces in between to allow the arc to be split into a series of smaller arcs, which helped to increase the resistance and thereby extract heat. At some point, when there was a voltage drop of around 30V, the arc was no longer able to sustain itself and as a result, it snapped. To withstand this, the contact separation in air was, as usual, large and so, large contact pressure springs were used to counter these forces. Oil switchgears Using the cross-jet explosion pot, oil switchgears had evolved in the 60s through arc controlled interruptions. It started dominating the medium voltage switchgear market. Although


EVOLUTION OF SWITCHGEARS

it had a similar operating mechanism, the energy requirements were less despite the fact that it had a longer stroke and had to move through oil containing heavy contacts. Regular maintenance was required for such kind of switchgears because the carbonised oil needed to be changed and the contacts would get worn out after a few faulty interruptions. In a nutshell, the 60s was the time when the switchboard began to gain recognition as a key component. The oil and air interrupting technologies began to dominate the low and medium voltage markets. Switchgears, in the 60s, were not much appreciated as they required frequent oiling and maintenance, but, at that time, they were the path breakers and there was no other alternative. Therefore, they were considered the best for that era.

IN THE 70s... In the 70s, switchgears changed their outlook from oil & air to airless and rotating switchgears, viz., ‘vacuum switchgears’ & ‘rotating arc SF6 switchgears’. Both these had the advantage of longevity and also had considerably low operating energy requirements. Vacuum switchgears These became commercially viable in the beginning of the 1970s. Since the vacuum bottle was sealed, further maintenance of the bottle was redundant. Thus, the bottle had to be well made so that switchgears would not wear out during the later stage of the processes. The advantages of vacuum switchgears had hit the final nail on any R&D in the field of oil and air switchgears. Moreover, the cost of complex designs on vacuum switchgears was also less. Nonetheless, the first designs failed to gain universal approval. This was because manufacturers could not stick hard to the claims of vacuum switchgears being completely maintenance free and this was seconded by the fact that vacuum switchgears started losing their

vacuum integrity over a period of time. Rotating arc SF6 circuit breakers This technology was developed by South Wales Switchgears, which provided the reliability of vacuum switchgears and the inexpensiveness of oil & air switchgears. SF6—a highly insulating, non-toxic, heavy gas—decomposes during the arching process. The advantage of this process was that it quickly recombined at current zero and regained its dielectric properties. The rapid movement for the arc through the SF6 gas caused cooling and enabled extinction at the

switched over to vacuum in India,” avers Fatehi. Thus, in a nutshell, in the 70s, the vacuum and the SF6 switchgears required low energy and were maintenance free.

IN THE 80s... The 80s saw no new innovation in the field of switchgears, but the highlight of this era was the requirement to provide better and more cost-effective switchgears, which were abreast with the latest advancements in the fields of science & technology. For a specific given rating, vacuum switchgears had

CONSIDERATIONS IN SWITCHGEARS’ DESIGNS The changes in switchgear design have been spurred by many considerations including (but not limited to): Advances in material science Demands for faster switching and improved discrimination or coordination Demands for enhanced reliability of protection devices Need for reduction in contact energy losses Need for reduction in let through energy during breaking of faults Better understanding of lifecycle costs of equipment Increasing consciousness about environmental concerns Changes in load behaviour/nature with increasing use of power electronics producing harmonics Changes in duty cycles & means of operation, increased automation and remote operation Increase in capacities of supply sources leading to higher fault levels Constraints in budgets and downtime available for maintenance & replacements Durability demands Mounting pressure from insurance and risk management authorities Enhanced awareness and concern for human safety. first current zero at high fault currents. This was the biggest advantage that SF6 had over the previous switchgears. “While most of the Middle East and Europe favoured SF6, vacuum was preferred in the US and China. However, in India, parts of China, Latin America and Eastern Europe, oil and other technologies persisted. But now, almost every new installation in the medium voltage segment has

become smaller in size and, for that matter, less expensive. The designs developed in this era were mostly withdrawal designs. On all the medium and low voltage switchgears, motorwound spring mechanisms became the standard equipment because of the requirement for reduction in size of substation batteries—the primary source of power for opening and tripping of switchgears. “Superior arc

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EVOLUTION OF SWITCHGEARS

protect the overhead line supply network, especially in unknown remote locations. Auto-reclosers increase the reliability of the distribution network. Continuous research in this field has led to the advancement in switchgears, thereby making the product An ideal set of modern switchgears and protection system more reliable and interruption with excellent thermal maintenance free. An auto-recloser behaviour made both vacuum and performed the most tedious job. “AutoSF6 technologies the preferred choice recloser ensured continuity of supply over conventional switchgears. Both in medium voltage systems. Modern types were suitable for switching switchgears and protection systems magnetising currents of transformers acted fast enough to render it possible with over voltages,” says Fatehi. to reclose sooner. When transient In a nutshell, oil & air switchgears faults (that do almost no damage to went completely out of production in the system) occur, it is preferred if auto this era and a majority of industries reclosing is used,” opines Fatehi. One such innovation was the started using advanced vacuum and invention of the ‘more reliable’ SF6 switchgears. These advances were magnetic actuator operating system, a direct impact of the cost reduced which provided the system the required designs made by production engineers stability. The success of the GVR who used motor-wound spring auto-recloser rang in a new era of mechanisms and withdrawal designs. developments in the medium voltage As a result, these became the most switchgear industry. The importance sought after designs. of the magnetic actuator had increased IN THE 90s... manifold by the late 90s, as there were In the 90s, the GVR pole mounted scarcely any manufacturers who sold an auto-recloser was introduced. This auto-recloser that did not contain it. was the most significant advancement IN THE NEW MILLENNIUM in switchgear technology after a New designs have evolved post long gap. This included a magnetic 2000. These designs have been made actuator mechanism apart from other from scratch with each component radical innovations. These changes are simplified and made more reliable. still shaping new developments in the Every manufacturer wants to keep medium voltage switchgears segment. switchgears as trouble-free as possible Finally, in this era, the operating and wants to capitalise on the potential system became equally reliable as of the magnetic actuator mechanism. switchgears. “Frequent switching at The old technology used in air high currents in applications like arc switchgears would never be able to furnaces was best catered to by vacuum work on the extra high voltage (EVH). breakers. Railways applications at low According to PC Shah, Director, VNS frequencies were another application Switchgears (I) Pvt Ltd, “Selecting where vacuum breakers were preferred,” switchgears completely depends upon adds Fatehi. the end user. We have to work as Auto-recloser, a pole-top mounted per the technological advancements. reclosing switchgear, was made to

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Foreign companies provide much more advanced technologies and India too should come up with such advanced technology at reasonable rates.” Talking about reliability, Fatehi elaborates, “For today’s fiercely competitive business environment, best asset optimisation comprises of increased safety, reduced lifecycle costs, reliability and utilisation of equipment. Investment in new switchgear has to be balanced against reliability through reduced maintenance costs, safety and performance. Reliability of switchgears impacts a plant’s uptime.”

TRACING FUTURE ROUTES So far, we have seen how switchgears have evolved from being just another invention to becoming one of the most important fittings in any electrical or industrial application. According to Fatehi, the major advancements expected in the field of switchgears include: Increasing automation leading to intelligence in metering, control and protection, will direct switchgear builders into new areas of work Reduction in the number of components, especially moving parts, shall lead to higher reliability, lower inventory cost of spares and lower exposure of workmen to risks Ergonomics for the user, operator and maintenance crew will be an area of increasing concern Green initiatives will dominate development trends Safety, above all, will remain the biggest concern. For maintenance-free switchgears, the perfect combination of magnetic actuator and vacuum interrupters is used in the present times. Switchgears, by bolting into the high voltage compartment, are now more compact, simple and much more reliable than they used to be half-a-century ago. The future holds no bars and sky is the limit for any innovation in switchgears. prateek.sur@infomedia18.in


TESTING SWITCHGEARS

Securing Maintenance-free

SWITCHGEARS

Also, outdoor equipment should undergo lighting and other radiated interferences withstand tests.” The tests are conducted as per the user-specified conditions in accordance with Clause 4 of ANSI/ IEEE C37.20.2, except that the temperature of the air surrounding the assembly (ambient) for the continuous current tests shall be within the ambient temperature range of 10°C (50°F) to 40°C (104°F). Commenting on Indian standards, Shenoy says, “Normally, electrical equipment are tested based on the standards set by global technical committees, such as Institute of Electrical and Electronic Engineers (IEEE) or International Electrotechnical Commission (IEC). The Indian standards encompass most of the tests specified by the above universal standards and may include a few other standards as well.”

DESIGN TEST

Switchgears form a key component in electrical power systems. Hence, it is essential to verify its performance after it is designed, manufactured or repaired. Testing of switchgears ought to be done in accordance with ANSI, IEEE and NEMA standards to ensure optimal performance. SUPRITA ANUPAM

witchgears have certainly come a long way since their development— right from vacuum & oil to SF6 circuit breakers that need separate tests for their verification. Switchgears are designed as per customers’ requirements based on temperature rise limits, humidity, and working parameters, including normal current ratings, resistance of the main circuit, short circuit current rating, kinds of insulation required, etc. It is mandatory for all these requirements to meet the

S

corresponding standards (such as IEEE C37.20.2/ ANSI C37.552002 [R2010]). Emphasising on the need for the same, Dr U Jayachandra Shenoy, Principal Research Scientist – Department of Electrical Engineering, IISc, Bangalore, avers, “Electrical instruments should undergo periodic testing in order to check if they meet their specifications under the wide range of environmental conditions such as annual range of variation of temperature, humidity and electromagnetic interference (EMI) in electrical utility substations, etc.

Also known as the type test; the design test is conducted by manufacturers to determine the adequacy, type, style and model of the equipment. It also checks the parts’ rating to meet the required design standard so that the equipment, as a whole, can be operated satisfactorily under the specified service conditions. Design tests are performed either on representative apparatus or on prototypes to get the complete design analysis; and further calculations help to substantiate the ratings assigned. It is the design, which ensures that operators are kept out of HV compartments and as away as possible from the equipment. The test’s result may be applicable to evaluate modifications in future with assured performance. According to Craig McKee, Technical Manager, 3 Phase Design, “You need to consider the design that best suits the market the assembly is going to be used in. For example, you could design your assembly to operate in a 50C ambient with IP55, but if your market only requires 35C & IP31, the board is

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over engineered and therefore, not perfect. I would suggest that you study the market to understand the local specifications and then design & test the board to meet those requirements.”

FAC T FACT

TESTING SWITCHGEARS

Bharat Heavy Electricals Ltd carries out high voltage power-frequency withstand test by disconnecting the moving contact of vacuum interrupter from the mechanism and manually pulling on the moving contact, which requires a force proportional to the area of contact to make it extremely rugged and reliable.

auxiliary switches mounted on the stationary housing performed in the 10 complete cycles of operation. It also takes care of drawout control power transformer, drawout voltage transformer and performance of circuit breaker tests.

PRODUCTION/ROUTINE TEST This ensures quality control by the manufacturer on every device/ representative samples, or on parts/ materials, to meet the design specifications and applicable standards. It includes the critical quality control on statistical sampling basis.

CONFORMATION TEST This demonstrates the compliance with the applicable standards. The test may or may not be as per the design tests. Also, it does not demonstrate the further capabilities of the used instruments beyond the standard provision.

withstand rated withstand voltages. When performing the test, the voltage transformer assembly should be connected, while the primary currentlimiting fuses should be disconnected. The test duration, frequency of the test voltage, supply voltage, voltage application all must be in accordance with the corresponding ANSI/IEEE C37.20.2. Atmospheric conditions stand for the temperature, pressure and humidity presence during the entire test, which should be in accordance with Clause 1.3.5 IEEE Standard 4a-2001. Humidity-correction factors shall be based on Clause 1.4 of IEEE Std 4a-2001.

DIELECTRIC TEST The test verifies the insulation system within the switchgear having a circuit breaker. It includes powerfrequency withstand voltage tests and lightning impulse withstand tests on switchgear assemblies to demonstrate the ability of the insulation system to

MECHANICAL PERFORMANCE TEST This test ensures the proper working of separable primary contacts, separable control contracts, circuit breaker removable element position interlocks, stored energy mechanism interlocks and mechanism-operated cell (MOC)

REFERENCE STANDARDS The following are the referenced standards superseded by a revision in 2010 approved by the American National Standard Institute and supported by IEEE: ANSI C37.54-1990: Conformance test procedures for indoor alternating current medium voltage circuit breakers applied as removable elements in metalenclosed switchgear assemblies ANSI C37.57-1990: Metal-enclosed interrupter switchgear assemblies— conformance testing ANSI C37.58-2002: Indoor medium voltage switches for use in metal-enclosed switchgear—conformance test procedures ANSI/IEEE Std 4-1995: Techniques for high voltage testing, including IEEE standard 4a-2001, amendment to IEEE standard techniques for high voltage testing ANSI/IEEE C37.04-1999: Rating structure for AC high voltage circuit breakers ANSI/IEEE C37.09-1999: Test procedure for AC high voltage circuit breakers rated on a symmetrical current basis ANSI/IEEE C37.20.2-1999: Metal-clad switchgear.

CONTINUOUS CURRENT TEST This test is performed to get the assurance that a switchgear panel can carry the rated current of the circuit breaker at a rated frequency within the temperature limit. Hence, temperature measurements, thermocouples and insulated conductors’ performance are also observed during the test.

NEAR PERFECT, YET NOT PERFECT There are further tests, viz., shorttime withstand current test, main bust test, momentary withstand current test, etc., performed in order to make the switchgear as well the electric power equipment safe and secure. Apart from ANSI standards, there are IEC and Underwriters Lab Inc directives to ensure complete safety within the work environment. McKee stresses, “IEC 61439 lays out the tests and the requirements based on the manufacturer’s specification. I do not believe that there would be a perfect panel that could be used for every scenario. To be perfect, the assembly would need to pass all of its tests, be economical to manufacture, cost effective for the client and easy to assemble.” “In the face of rapidly changing technology, most of the electrical measuring equipment and switchgear control equipment are programmable computer-based instruments. The maintenance of such equipment should be a simpler proposition, as they have built in self-diagnostic capability and need card-level replacement of hardware in case of failure of spares,” concludes Shenoy. suprita.anupam@infomedia18.in

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INDIAN SWITCHGEAR MARKET

he Indian electrical and equipment industry is capable of producing, supplying and exporting a wide variety of electrical equipment, including switchgears and control gear items needed by the expanding industrial and power sector. In fact, the industry sector manufactures the entire voltage range right from 240V to 800 KV. Meanwhile, the 1,200-KV equipment is under development and the technology level is contemporary. It is estimated that the present switchgear market size—excluding ring main units (RMUs), gas insulated switchgears (GIS) and domestic switchgears, which amount to approximately `3,000 crore—is around `10,000 crore. The industry grew in terms of volume in 2010–11. Overall, exports decreased by 15%, whereas imports—mainly of medium voltage (MV) and high voltage (HV) switchgears—increased by over 50%. The switchgear segment accounts for ~15% of the total electrical equipment.

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DEMAND DRIVERS The demand for HV and extra high voltage (EHV) mainly comes from the

utilities. With the government focussing on increasing the penetration of power supply in villages, schemes such as Accelerated Power Development and Reform Programme & Rajiv Gandhi Grameen Vidyutikaran Yojana, provide an excellent opportunity for the low voltage (LV) and MV switchgear market considering that about 10% villages are yet to be electrified. India’s industrial segment accounts for about 30–35% of the GDP with most of the industrial divisions reporting growth in output in the fiscal. Additionally, investment in new infrastructural setup will increase the market for intelligent switchgears, RMUs, moulded case circuit breakers (MCCBs), air circuit breakers (ACBs) and C&Rs. Another indicator of sustainable growth is the increasing gross assets of organisations. Commenting on the demand drivers, Karlheinz Kaul, CEO – Control Components & Systems, Engineering, Siemens AG, informs, “Ours is primarily a derived market. It works on an analogy—if we decrease the price of switchgears, its consumption is not going to rise. Therefore, the primary demand driver is investments in power. So, if we have a new power plant, there is a derived

demand across the chain and that increases the overall electrical market. Therefore, we are upbeat about the plans that the government is making towards increasing the power capacity.” Moreover, a sustained infrastructure development related to power will dramatically increase the market demand for switchgear products. Commenting on India’s situation, Kaul explains, “In order to bridge the gap that we have been witnessing since years in India right from the announcement of plans to its actual implementation, all concerned parties should put their resources together to ensure that everyone is working towards building the infrastructure of India. We should also not forget that with more capability to generate energy, we also need to save energy and achieve sustainability.”

ROLE OF TECHNOLOGY Every modern industry today needs reliable electrical systems to reduce production downtime as well as improve efficiency. No doubt the switchgear industry was always low on technology, but with the changing demand and trends, it has started looking up to automation. In fact, newer

Gearing up for exponential growth Although the switchgear market is facing rough waters as of now, there is still a ray of hope. With the Centre focussing on initiatives such as increasing electricity generation in rural areas, the demand for switchgears—the most crucial equipment in the electrical segment—will observe an upward trend. However, for this growth to take place, the conservative switchgear market needs to adopt the latest technologies and innovations.

Photo By Prateek Sur

SUMEDHA MAHOREY

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INDIAN SWITCHGEAR MARKET

concepts, such as soft starters, margins and still be competitive. Growth Indices for Electrical Equipment Industry intelligent relays, compact The price wars triggered by tier (Cumulative growth compared to the same period the previous year) intelligent switchgears and II & III suppliers can be offset Product Weightage H1 FY 2011–12 energy-efficient switchgears, to some extent by focussing (% Growth) have already made forays into on adopting best practices to Low Tension Motors 5.6 12.0 the industry. The primary improve production efficiencies High Tension Motors 2.0 23.1 technology factors are largely and achieving economies of Alternators 1.9 -21.5 Fractional Horse Power Motors 1.3 -6.8 safety, efficiency optimisation scale to reduce production costs Rotating Machines 10.8 5.7 and reliability. Secondary and maintain profit margins,” Power Contactors 1.9 -6.8 equipment, such as relays or notes Anup Barapatre, Industry Low Tension Circuit Breakers 3.7 -2.3 controlgears used for various Analyst, Frost & Sullivan. Miniature Circuit Breakers 3.0 21.4 types of fault protection, have A new report by IEEMA Switch Fuse/Fuse Switch Units 0.6 3.8 made significant advances due has revealed that the growth of High Tension Circuit Breakers 6.0 0.3 Switchgears 15.2 2.5 to the developments in the field the Indian electrical equipment Power Cables: PVC 16.8 -0.7 of electronics. Digital relays are industry has sharply decelerated Control & Special Purpose Cables 7.6 96.2 fast replacing conventional ones to 0.6% in Q3 of FY12, after Source: IEEMA due to technology advancement, growing at 13.8% & 3.6% in with high quality, high reliability, low compact size & reliability. As per Q1 and Q2, respectively. On the other maintenance and easy accessibility. recent trends, in addition to protection hand, growth in the transformers, Indian manufacturers are becoming and control of power, monitoring & switchgear and rotating machines increasingly competitive with respect to signalling have become an integral part sectors in Q3 has turned negative, their product designs, manufacturing of switchgears. which implies a distinct slowdown in Industries and T&D utilities across and testing facilities. Investments industrial capex activities as well as the country have also raised their demand in R&D in the electrical machinery a slowdown in offtake by users due for space optimisation & efficient industry are among the largest in to credit squeeze, high interest costs switching and prominent end user India’s corporate sector. Manufacturers and the like. But all said and done, industries are investing heavily in indoor today, understand the importance of according to industry experts, there is and GIS. While major manufacturers in a diversified product portfolio. The a lot of scope for the industry in the the MV market are all set to diversify increasing competitiveness in the next few years. their offerings, others are acquiring industry and constantly changing WHAT THE FUTURE HOLDS? technology to address the future demand consumer demands have led to new and The future holds great promise for this for environment-friendly, compact and upgraded versions of products being industry. The 12th Plan (April 2012– efficient MV switchgears. launched into the market. Also, various March 2017) throws huge opportunities players are entering into strategic CAPITALISING ON EXPANSION & for growth with a foreseeable alliances and tie-ups with technology DEVELOPMENT PLANS investment of approximately $300 suppliers to upgrade capabilities. India is emerging as an important global billion, together with exports growth. WHAT MIGHT PLAY SPOILSPORT? supplier of goods and services. Market The global market for switchgears is Despite the market demand, the participants have charted out organic/ expected to post good growth rates huge discount structure erodes the inorganic growth plans to capitalise in the coming years as demand soars topline and bottomline of organised on various anticipated expansion and exponentially worldwide. Also, with participants. Pricing pressures due development plans across end user the Centre focussed on bringing about to high competition and customers’ segments. The Indian LV switchgear improvements in the State Electricity bargaining power impede the overall market earned revenues of $950 million Boards, the market for switchgears growth of the LV and MV switchgear in 2010 and estimates this to reach is likely to post good growth rates markets. Raw materials, including $2,170 million in 2017. The MV by 2020. With reforms on the way, steel, copper and silver, form a major switchgear market earned revenues of the future of the Indian switchgear cost component in the manufacturing $795 million in 2010 and estimates to industry is predicted to be bright and of LV and MV switchgears and any reach $1,735 million in 2017. investment in the market is likely to fluctuation in their prices will have a see a positive trend. INDUSTRY TRENDS direct impact on equipment prices. “It Current trends indicate a demand for sumedha.mahorey@infomedia18.in is challenging for participants to hedge With inputs from IEEMA compact, small, low-weight equipment against price fluctuations, maximise

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SWITCHGEAR INSPECTION & MAINTENANCE

Ignore At Your

Own Risk

Switchgears form an important component of a manufacturing facility. However, not many people think of its maintenance as an integral part of the job. Beware! It is a dangerous approach to adopt, because if the switchgear fails, it might lead to some grievous accidents. This is an economic dance with the devil, with destruction as a final step. VISHESH SHARMA

n general, switchgears have a proven record of reliability with rare occurrences of performance failures. However, when performance failures do occur, the results could be catastrophic. For instance, tanks may burst resulting in the ejection of burning oil or hot gases, causing deaths or serious injury to persons. Besides, it may also cause major damage to plants and buildings in the vicinity of the failed equipment. Thus, the way switchgears are operated, the condition and circumstances existing in the system at the time of operation, to a large extent, determines, whether the equipment will safely perform its duty. Additionally, it is critical that ageing switchgear installations are also evaluated and wherever necessary, precautions are taken to minimise the risk to personnel.

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INSPECTION BEGINS WHILE MANUFACTURING The first inspection of switchgears begins at the manufacturing stage. That is when critical aspects, such as load bearing and tripping, are looked into. Elaborating on the same, Himanshu Sharma, Quality Manager – Haridwar Plant, Anchor Electrical, informs, “Inspection of switchgears begins at the manufacturing plant. While manufacturing switchgears, we conduct mechanical as well as electrical testing, which is done at both, the assembly as well as sub-assembly stages. Besides, the quality inspector inspects the switchgears online at predefined characteristics.” He adds, “To ensure safety of switchgears, we do the final product testing, where 100% products have to pass through. The next stage is the performance test, during which, the switchgears are tested on a certain

current to ensure that it trips at the right time. Once the product is ready, it is packed as per the Bureau of Indian Standards (BIS) requirements.”

VARIOUS APPROACHES Most companies either do not attach much priority to the maintenance of switchgears or ignore it until a failure actually occurs. At many facilities, the maintenance crews only practice some of the easier steps. When you fail to conduct proper maintenance, the risk of loss is high. Implementing a solid maintenance programme would prove to be less costly than the impact of switchgear failure. When you give maintenance the thought and effort it deserves, you not only enhance safety and reliability, but also improve uptime and profitability. The many approaches to switchgear maintenance range from continuous online monitoring to ‘do nothing’


SWITCHGEAR INSPECTION & MAINTENANCE

(also called ‘run-to-failure’). Most STEPS PRIOR TO THE OUTAGE practical maintenance programmes are a combination of these approaches. Perform visual inspections, thermal scanning, partial discharge testing and For instance, replacing indication other testing before the outage so that you can take corrective action when it lights only when they have failed occurs. is an example of run-to-failure Identify and order all materials required for the outage. Take lead times into maintenance. On the other hand, account. Shutdown the switchgear and apply protective grounds. Follow lockout/tagout maintaining disconnect switches on a procedure. Barricade and put up appropriate warning signs. periodic basis—cleaning, lubricating, Check and correct any drawing inconsistencies or connection questions. and exercising them—is an example of Perform inspections and cleanings. preventive maintenance. Annual visual Perform measurements and tests. and thermographic inspections on bus Based on test results, perform additional repairs. connections and breakers are examples Energise switchgear and verify normal operation. of predictive maintenance. Prepare a report of maintenance outage and test results. Include trending and Reliability Centred Maintenance analysis of results and recommendations for future maintenance as appropriate. (RCM) is another approach. RCM is a systematic and comprehensive method, every five years should suffice. One appropriate where equipment reliability would perform at the actual location factor that would require more frequent is critical. It involves analysing system and during various circumstances.” inspection is the actual condition of criticality and component failure VITAL TESTS the plant. If the plant is in very poor modes, evaluating those failure modes While switchgears are being condition, then the switchgears will and the appropriate maintenance manufactured or installed, it is have to be inspected more frequently. activities for each component. RCM essential to perform critical electrical While inspecting, it is essential to programmes improve electrical system tests. Take resistance measurements ensure that the barrier and shutter are reliability and experts credit RCM and insulation-resistance tests on every installed correctly and are operating programmes with improving safety & bus section and every phase-to-ground well. It is advisable to check if management of spare parts, decreasing or phase-to-phase, besides carrying mechanical indicating instruments are repair costs, shortening outages and out electrical tests on instrument functioning properly. Also, ensure that reducing overhaul frequency. transformers. Perform over-potential the filters are placed correctly and that The National Fire Protection tests on every bus section and do the vents are not clogged. Besides, Association (NFPA) has suggested not forget each and every phase-toexamine instrument transformers that switchgears should be inspected at ground. It is important to conduct thoroughly. While inspecting control regular frequencies. Depending on the the insulation resistance tests on both power transformers, look carefully system criticality and the environment control wiring as well as control power for any break or dent, broken leads, in which the equipment is located, transformers. cracked insulation, defective wiring these periodic checks could vary from Elaborating further three months to six years. Implementing a solid maintenance programme would prove on the same, Hemant Because no manufacturer to be less costly than the impact of switchgear failure. When Narvekar, Chief Manager – or standards-making body you give maintenance the thought and effort it deserves, Manufacturing, Switchgear can presume to know how you not only enhance safety and reliability, but also improve Works (Kalwa), Siemens, these conditions differ uptime and profitability. says, “Being the industrial in each installation, it is & connections and check if they are leader, we have to show the way to impossible for them to come up with the other players. Hence, we have to sufficiently tight. a meaningful maintenance frequency. use state-of-the-art technology as far Sharma adds, “We know that the HOW FREQUENT SHOULD THE as inspecting switchgears is concerned. user might fail to properly maintain INSPECTION PERIOD BE? While manufacturing switchgears, we the switchgear. That is why we The inspection period for switchgears use digital techniques to inspect them. conduct the endurance test during depends on the type of switchgears Besides, we have our own calibrated the manufacturing stage itself. In used. For metal-clad switchgears, labs to inspect switchgears. These labs this test, we pass current through the inspections should take place between are NABL certified, which means that switchgear on the higher side. This is six months and a year after first being we are following all the international also called phantom load. This gives installed. From there, an inspection procedures.” a clear picture of how the instrument

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Sharma informs, “We also conduct the Design Failure Mode and Effects Analysis (DFMEA) to explore ways that a product design might fail in realworld use. Once this test is complete, it allows our design team to document what they know and suspect a product’s failure modes prior to completing the design. This information is then used to design the product such that it mitigates the possibility of failure.”

failure, the safety of an operator in the substation is ensured. This feature can be fitted on site to some types of switchgear at a relatively low cost. It must, however, be noted that due to the catastrophic nature of oil circuit breaker failures, this feature cannot be retrofitted to an oil switchgear, unless the circuit breaker is changed to SF6 or vacuum. Retrofitting Modern Protection Protection such as arc detection systems can clear faults in a fraction of the time of traditional protection schemes, thereby limiting danger to personnel and damage to equipment. System Studies All organisations ought to have available a record of their switchgears. Typical information that is required for each item of equipment would include location, manufacturer & type,

frequent faults.

PLANNED MAINTENANCE PROGRAMME

All leading manufacturers of switchgears provide detailed maintenance guidelines for their switchgears. If the switchgears are maintained according to these guidelines, it can last for a long time. Unfortunately, the importance of maintenance is, in several cases, underestimated until a catastrophe occurs. Some of the reasons for none OPTIONS TO IMPROVE SAFETY ON or poor maintenance include lack AGEING SWITCHGEAR of product knowledge & funds and While switchgear manufacturers reluctance to give access to equipment. are meeting their obligations and This problem is compounded by the ensuring maximum safety possible, current employment trends that are users also have to be careful while leading to essential skills in switchgear operating switchgears. There are maintenance departments being lost. certain techniques, which if adopted Basic maintenance should include, religiously, would ensure a safe mechanical and electrical operational working atmosphere for one and all. tests, contact travel tests, resistance Retrofitting Oil Circuit of primary circuit tests, The way switchgears are operated, the condition and Breakers With Vacuum cleaning primary insulation circumstances existing in the system at the time of operation, and checking substation Circuit Breakers to a large extent, determines, whether the equipment will Some manufacturers of batteries. safely perform its duty. Additionally, it is critical that ageing Offering his perspective switchgears have designed switchgear installations are also evaluated and wherever on the same, Nirmal Mitna, modern or vacuum circuit necessary, precautions are taken to minimise the risk to MD, Bhopal Switchgears breakers that are fully personnel. Pvt Ltd, opines, “Inspecting interchangeable with the switchgears should be a regular practice installed oil circuit breaker enclosures. installation date, voltage and current by users. Besides physical testing, it This allows for increased safety and rating, certified fault rating, type of is also important to periodically test lifetime extension to be achieved at operating mechanism, date equipment switchgears digitally. This would give approximately half the cost of a total last maintained, type of protection the required information such as for replacement of the switchboard with fitted and details of the settings. If this how long the switchgear would work, new equipment. In majority of cases, information is not available, it should if it requires replacement or any other additional features such as motorised be prepared as a matter of urgency as it specific detail.” mechanisms and higher fault ratings is essential in risk analysis and planned “Besides, since technology has can also be achieved by retrofitting a maintenance programmes. advanced to such a great extent, circuit breaker. The next stage is to calculate managing switchgears in a healthy Retrofitting Remote Switching the fault level at the terminals of condition does not require much Facility all equipment and compare it with effort,” he says, adding, “Applications, A majority of switchgear failures occurs its certified rating. If the fault level such as laser inspection, should become during or shortly after an operation. exceeds the fault rating, the equipment a regular factor at the user facility.” Therefore, it makes sense to operate must be retrofitted or replaced with It might look like a tedious task old switchgears remotely as this switchgears having the correct rating. to many, but in the long run, these would ensure operator safety. Also, a This will ensure that the equipment procedures would ensure safety for one dependant manual operated switchgear is not overstressed during faults or and all. Remember, even switchgears can be retrofitted with remote actuator becomes a high safety risk. The final labelled “maintenance free” require mechanisms. stage is to perform protection grading periodic testing and maintenance. Retrofitting Internal Arc Rating to ensure that the switchgear trips The ultimate operator protection is when required. This will prevent both, vishesh.sharma@infomedia18.in achieved when, even during equipment nuisance trips and undue stress due to

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L&T FACILITY VISIT

Banking on the innovation quotient As part of India’s numero uno low voltage switchgear manufacturer’s portfolio, L&T’s manufacturing facility at Ahmednagar in Maharashtra boasts of state-of-the-art technologies and unique innovations on its shop floor. Home to many patented design innovations, this facility’s USP lies in its factory inside factory concept and customised solutions for various sectors. With a top down approach to lean management, 5S, value engineering and green initiatives, this facility has been equipped to face challenges that lie in the switchgear business.

SUMEDHA MAHOREY & PRATEEK SUR

state-of-the-art switchgear manufacturing facility is what you come across when a major global manufacturer of low voltage switchgear decides on developing a niche facility for its business. That is precisely what Larsen & Toubro Ltd (L&T) has done with its Ahmednagar unit. While profiling this manufacturing facility, many technological advancements amazed us besides the strategic implementation of lean manufacturing, six sigma and value engineering principles reassuring our belief that you have to be one step ahead of your competitors to remain at the top.

avers, “Our manufacturing process starts from and ends with the customer. The process begins with the enquiry put forward by the client.” He explains, “Usually, once the enquiry is made by the customer, L&T puts forward its quote developed by engineers using a software solution. The solution keeps everything into account—starting from procuring raw materials to the transportation MANUFACTURING PROCESS DECODED of the finished product. The product Since the switchgear business is acceptance discussion takes place at customer driven, the requirement the technical front and commercial of the client is at the heart of the front. Firstly, the technical part is manufacturing design at L&T. accepted and then it comes down to Commenting on the manufacturing the commercial part where the lowest process at L&T, Debasish Chatterjee, bidder emerges as the winner.” FACILITY BRIEF “Once the order is received, the input Sr Deputy GM – MV Business, The Ahmednagar facility manufactures is given to the sales team, which hands Electrical Systems & Equipment, low voltage (LV) and it over to the engineering medium voltage (MV) and execution teams. This process is known as switchboards along with the CXO process. The distribution boards and execution team then control panels. The entire monitors the cost, customer facility has been classified specification changes, into two divisions — market rates and various Electrical Standard Products other factors. Subsequently, (ESP) and Electrical the engineering team Systems & Equipment submits the drawing (ESE). The ESE segment to the customers for consists of two divisions approval. The customer’s including LV and MV. An automatic loader is used to load metal sheets onto the punching machine

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Technically, critical products such as control gears—contactors, relays, control accessories, motor protection circuit breakers, motor starters and rotary switches—are being manufactured here. Each product carries the L&T insignia of reliability & assurance, and the product lines at the facility conform to international standards and are KEMA certified.


L&T FACILITY VISIT

Conveyor belt moves casing plates to paint shop Switchboard being tested before dispatch

suggestions are then incorporated into the design before it is released,” informs Chatterjee.

THE PRODUCTION BEGINS... Inventory management: Once the design is finalised, it is entered into SAP. The items required as per the design are procured and kept in the stores, from where they are distributed to various departments. The major raw material includes sheet steel, aluminium, copper, ICs, relays, insulating material and wires. Assembly & testing: These materials are sent to the respective assembly lines. After assembly, the finished goods (FG) are moved into the testing zones. The company follows power frequency, partial discharge, lightning impulse, corrosion resistance, temperature rise and primary injection testing. Later, the FG go through the quality control (QC) department. Once the product clears the QC process, clients are invited to check the product & conduct tests as per the requirements. This process is known as Factory Acceptance Test (FAT). At times, the company also conducts the Site Acceptance Test (SAT) and intelligent FAT (iFAT). This is only done for very high level of intelligence-specific companies. Once the client checks the product and is satisfied, the product is cleared and finally dispatched. Packaging: The switchboards packaging is done as per the transport and temperature conditions that the product is likely to observe. For export activity, it is packed in aluminium foils, while for inbound transportation, it is wrapped in plastic sheets.

EQUIPPED WITH MODERN MACHINING Since the company believes in using the latest machining technologies for best

quality output, the Ahmednagar facility has been equipped with best machinery from machine tools vendors such as Japan-based AMADA for cutting, bending and milling operations. The machining process starts at the facility for the manufacturing of sheet steel fabrication and bus bars of aluminium and copper. The first step is to punch sheet steel, which is done by the hi-tech AMADA CNC Turret Punch Press for MS CRCA sheet cutting, capable of producing 100 tonne per month. Elaborating on the machining process, C Prabhakar, Joint GM – Manufacturing, Electrical Systems & Equipment (LV), highlights, “Each individual component is loaded in the CNC machine and then punched according to the need. This machine is also available with other manufacturing facilities as well, but the unique feature at L&T is the automatic sheet loading machine that has the capability to identify different thicknesses of sheet metals and load these as and when required. After cutting, bending operations are done on the HDS 8025 HT AMADA bending machine. Then, the material is moved to the automatic tool grinding and welding, if required.” The welded components are moved to the pre-treatment plant where all the extra particles are removed. After this, the components go through the painting process. Prabhakar adds, “During painting, the component is taken through 11 different washing and cleaning chambers where the loose particles are removed by using four magnets at the corners. After this, the spray painting process begins. Post painting, the components are dried and moved into assembly.” Assembly of controlgear: The manufacturing of control gear begins with decoiling, straightening, piercing

and blanking of the CRNGO coil. The cut components are then laminated, stacked and the crimping is performed. After this step, the magnet is ready and riveting is performed. This is followed by grinding, deburring, centre milling and air gaps are removed. The component is then moved into the assembly line. Relays, starters and contactors are manufactured at this juncture. Almost 90% of the switchgears are made in this facility. Initially, many sub-assemblies are prepared and after that, the component moves in for final assembly. Each component is then tested at the same facility. After that, the components are hand packaged and sent for dispatch.

The facility is equipped with HV testing machine

Assembly of Vacuum Circuit Breaker (VCB): To manufacture VCB, the design is released by the design and development department. For this unit, 65 vendors— of which three are from abroad—are supplying components. Once the machined items, copper conducting material, line busbars, flexible conductors, silver contacts, sheet metal parts are received by the store as per the design, the assembly begins with the base assembly and fabricated structures. Explaining the assembly process, K Rajan, DGM & Head, VCB Manufacturing, articulates, “The main line currently follows the trolley system. Each trolley is a workstation. The base assembly is loaded with barriers, mechanism assembly, vacuum bottle, and then the wiring is done. After this, the product

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L&T FACILITY VISIT

is moved into the testing zone where it is manually and automatically tested for 100 operations. After testing, the vacuum circuit breaker is dispatched.” Highlighting the capacity addition initiatives at the VCB line, Rajan informs, “In the next three months, this facility will have a new assembly line and the order for the same has already been placed. This assembly line will have free flow conveyors that will be supplied by a Pune vendor. The assembly line has been designed by us as per the future requirements.” Commenting on the benefits of this new line technology, he adds, “The new line, costing `3 million, is expected to reduce man hours by almost 20%. This reduction will recover

The silver plating line is equipped for selective plating

level, a central council has been formed and every business and sub business unit is represented in this council. This council identifies the areas, where innovations are needed. The teams are formed subsequently with the intent information. These teams come up with proposals and if accepted by the council, these are permitted to implement the concept. The second initiative is ‘ELITE’ where each and every unit focusses on improving the sigma levels, lean management principles and so on. It covers six sigma, value engineering, green mapping, TPM and lean and process management.”

APPROACH TO INDUSTRIAL SAFETY

The trolley based VCB assembly line

the investment in two years. Also, the present manufacturing capacity will go up from 250 to 500 units per month.”

L&T focusses majorly on industrial safety practices and health of the workforce at the shop floor. The company has in place emergency control plans, identification of hazards for all activities and processes & materials with appropriate control measures. Regular training, mock drills, learning, awareness camps are held to generate awareness among the staff regarding safety procedures.

R&D: AT THE CORE OF ALL ACTIVITIES The business has a centralised management system when it comes to R&D. L&T’s Malaysian acquisition TAMCO takes care of the R&D for the MV division. Chatterjee informs, “At L&T, R&D is seamless and patenting is centrally controlled. There are many initiatives in product development like T-ERA, which have been patented.” The innovation management system at L&T has been in place since the last 10 years. However recently, the company has segregated creativity and innovation into two categories. According to Chatterjee, creativity is a concept that can be monetised. He highlights, “At the EBG corporate

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LOWERING CARBON FOOTPRINT The company is known among industrial circles for its green manufacturing principles. Keeping up the tradition of planting trees, the Ahmednagar facility boasts of over 6,000 trees planted in the area since commissioning. With a 90% green cover on the present land occupied by the facility, this manufacturing unit also has an efficient-energy management system in place. This covers building management system, occupancy detection sensors, photo sensors, heat recovery ventilation system, HVDC system through centralised chillers and CO2 monitoring sensors, and solar

Safety gears used while plating

street lighting. This unit is also a zero water discharge facility.

CHALLENGES & ASPIRATIONS The biggest challenge for a switchgear manufacturer, especially in a Tier II city like Ahmednagar, is the retention of manpower. Highlighting the issue, KK Shukla, GM – ESP Manufacturing, points out, “For us, the biggest challenge while operating out of Ahmednagar has been attracting the right talent and retaining them. To solve this issue, we have adopted ITIs and are also in talks with the government to create engineering hubs.” L&T also holds skill development initiatives in the region for youth from the rural belts. With such initiatives and support from the latest technologies and innovations, L&T now plans to strengthen its attention towards miniature circuit breakers. Shukla adds, “The market is huge for compact and light equipment and to suffice this demand, we are now focussing on manufacturing miniature circuit breakers.”

BUSINESS OUTLOOK Even as the switchgear business witnessed a slowdown in recent months, L&T’s Ahmednagar manufacturing facility is looking at increasing productivity to suffice the exponential demands coming in from the agriculture sector. With custommade solutions and direct competition with international players such as ABB, Eaton and Siemens, this facility stands tall to its claim of being the only leading solutions provider for Indian conditions. Many important innovations and thrust on talent development is expected to drive the aspirations of this business in the years to come. Photos by Prateek Sur


SHOP FLOOR INNOVATIONS@L&T

Driving benefits from

Cutting-edge Solutions

The electrical business in India is fraught with various challenges when it comes to driving an innovative culture towards bringing out the latest offerings in the market. Writing a chapter or two for electrical manufacturers to follow, L&T’s Electrical and Automation facility at Ahmednagar is home to many prominent shop floor innovations. SUMEDHA MAHOREY & PRATEEK SUR

nnovation does not have any stature and depends on the benefits that it brings to the company in terms of cost, manpower and energy savings. The importance of innovation has been well realised by L&T’s Electrical and Automation (E&A) Division, which has come up with unique and continuous innovations at its switchgear manufacturing facility

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in Ahmednagar. The company has also recently won the 4th National IP Award 2012 as a token of appreciation for such a successful innovation culture. Profiling below some of the major innovations at the plant...

FIXTURE FOR TESTING OF VACUUM CIRCUIT BREAKER The company has very recently developed a new 800 A-1250 A fixture

VCB testing fixture, designed and created by L&T E&A engineers, has reduced the testing time by 20 minutes.

for testing vacuum circuit breakers. This fixture can bear current upto 40KA. In the old set up, L&T used crocodile clips, which were wired and connected to the test computer. This setup was not only time consuming, but also produced inaccurate data. Moreover, the hygiene factor was also not up to the mark. That is why, a new fixture called VCB testing fixture was designed and created by L&T E&A engineers.The new fixture is chair shaped and the circuit breaker can be rolled on to the fixture. It has all the necessary contacts that are required for testing. This fixture has internally wired and pre-connected conductors and is a permanently wired & fully enclosed wiring system. With this system in place, no individual clamping is required. Besides, the probe connections are much more unique and direct. This fixture eliminates vibrations and noise that exist in the circuit breaker. At present, the company has just commissioned one variant of the fixture. Going forward, it plans to increase the size of this fixture. Also, with this fixture in use, the present testing time has been reduced by 20 minutes. Earlier, one breaker testing took around 30 minutes. The fixture, which also includes steel structure with wiring, and contactors, has been developed at a cost of `40,000. Once the circuit breaker is moved in the fixture, all the contacts are made and the green light switches on. If the circuit breaker is switched on during loading

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on the fixture, then the connection will trip on its own and create a noise to let the tester know that the circuit breaker is on. This makes the fixture much more safer for the person using it.

taken for maintenance. This system also boasts of a scrapping gear, which is similar to the earthing pin used in a 3-pin plug. This works on the ‘make first break last’ principle.

INTERLEAVING OF BUS BARS Due to skin effect, the current flowing

SEGREGATING UNWANTED METAL DUST USING MAGNET FILTERS

The permanent magnets have helped in reducing the water filteration rate and improving the finish of components.

After sheet metal cutting and grinding, fine particles of the metal remain attached to sheet. These, when dipped in water for cleaning, get separated and keep floating in the tank. And when clean components are placed into the pre-treatment tank, these particles get deposited on it and result into bad surface finish. To overcome this, the company has placed permanent magnets at the four corners of the tank. When water is circulated, loose metal dust present in the tank gets deposited on the magnet. This results in lower rate of water filtration and better finish of components.

The tray system for easy maintenance works on the ‘make first break last’ principle.

in the copper bar, which is used as the conductor in switchgears, does not flow in the entire cross section. Therefore, the resistance of the circuit and the temperature is high. Despite this, it actually carries lesser current than it is supposed to. To overcome this problem, the company has, through interleaving of bus bars, made the cross section smaller. This has really helped as the cross section in itself would carry more current than all the bars stacked together. Thus, it can be concluded that by using a small cross section, better results amounting to 5–10% of extra current can be realised. Another technique that has been used on the shop floor includes round edges of the earlier flat bus bars. This measure has curbed low breakdown voltages & break out. This measure has

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NUT & BOLT PLATE FOR BUS BAR JOINTS

These bolts help when assembling the switchboards on uneven surfaces as well as during transportation.

also helped the company in increasing the short-circuit withstand capacity by 10–15%.

TRAY SYSTEM FOR MAINTENANCE OF SWITCHBOARD COMPONENTS The company has developed a unique tray system wherein, the component does not have to be moved from the main body. Instead, it can be rolled out and swivelled to 180º for maintenance. These actions help curb the chances of loose contacts and reduce time

The company has created a recently patented nut & bolt plate, which helps in bolting operation even on uneven ground and in motion conditions. In this type of fish plate, nuts are already fixed in the plate and the need for holding nut & bolt does not arise. Secondly, the advantage of this plate lies in the fact that individual nuts are just crimped and not welded. Individually, these bolts make subtle movements, which cannot be caught by human eye. Because of the crimp joints, the nuts slightly tilt and make proper contact. Thereby, all the nuts come to the same parallel plane and thus, help to tighten easily and ensure better conductivity. Photos by Prateek Sur


ENERGY-EFFICIENT MOTORS

ENERGY-EFFICIENT MOTORS: Ensuring Efficiency Along With Productivity ...............................84 TECH ADVANCEMENTS: Understanding The Recursion To Redevelop ......................................88 NANO MOTORS TECHNOLOGY: Driving New Possibilities ........................................................92

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Ensuring

Efficiency along with

Productivity Times are critical and maintaining an operational edge over competitors has become the need of the hour. An ideal way to reduce operational cost is by using energy-efficient motors. An energy-efficient motor can save on operating costs by providing better reliability than standard motors because less energy is converted into heat, keeping the temperature low inside the enclosure and thus reducing downtime and maintenance. VISHESH SHARMA

lectric motors account for about 65% of industrial electricity consumption in India. In the fiercely competitive marketplace, minimising operational costs could mean the difference between success and failure for many companies. But optimising motor system efficiency can significantly reduce operational costs. In many ways, motors are critical to keep facilities operational and making changes to such a critical function would require a careful evaluation of any potential impact on the overall system performance. Given the complexity of these systems, it is not only important to understand motor efficiency, but also other selection considerations such as motor design, speed and the opportunity to use

E

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adjustable speed drives (ASDs). Electric motors drive both; core industrial processes, like presses or rolls; and auxiliary systems, like compressed air generation, ventilation or water pumping. They are utilised throughout all industrial branches, though the main applications vary. In recent years, many studies identified large energy efficiency potentials in electric motors and motor systems with many saving options showing very short payback times and high cost effectiveness. Still, investments in improving the energy efficiency of electric motor systems are often delayed or rejected in favour of alternative investments due to different barriers and market failures, lack of attention of the plant manager, principal agent dilemmas and

higher initial cost for efficient motors. Besides, in many cases, broken motors are rewound and reused even though it often reduces a motor’s efficiency.

STANDARD VS. ENERGY-EFFICIENT MOTORS Motor efficiency remains one of the highest priorities for maintenance and engineering departments at a manufacturing facility. However, discussions of efficiency inevitably include tough financial decisions. In other words, how much money is a manager willing—and able—to invest in improved motor maintenance and high-efficiency motors to realise potentially greater savings down the road? Because the stakes and the benefits are high, manufacturing facilities can benefit from taking a


ENERGY-EFFICIENT MOTORS

closer look at the components of motor efficiency, incorporating maintenance strategies in order to improve motor performance, and understanding the benefits of new motor technology. Depending on the age and efficiency of the motor in place, the replacement of a less-efficient motor with a highefficiency motor can have considerable saving potentials with payback time of a few years. For applications, which have high annual running hours, in particular—mostly in firms with multishift operations—replacement can be very profitable. The price premium of a high-efficiency motor of about 20% often pays off after several months. According to Sanjay Jadia, Partner, Hindustan Motor Mfg Co, “Normally, the price difference between standard motors and energy-efficient motors varies between 15% and 20%. However, energy-efficient motors help you save energy and are less polluted. So, it is not an expensive option.” He continues, “Considerable variation exists between the performance of standard and energy-efficient motors. Improved design, materials and manufacturing techniques enable energy-efficient motors to accomplish more work per unit of electricity consumed. Energyefficient motors offer additional benefits because they are constructed with improved manufacturing techniques and superior materials. They usually have higher service factors, longer insulation and bearing lives, lower waste-heat output and less vibration—all of which increase reliability.”

MAPPING THE EFFICIENCY Ensuring that you opt only for energyefficient motors is also a critical aspect. Apart from various ratings, which are accredited to motors, there are certain aspects that help decide on the efficiency of a motor. These include: Nominal Efficiency Energy efficiency is the ratio of mechanical output energy to

electrical input energy. Several types of measurable efficiencies depend on the state of the motor during the test and the testing methods used. The efficiency measure most commonly used is ‘nominal efficiency’, which is determined by finding the average fullload efficiency of a sample of motors of the same model. This measure of efficiency can be found on the motor faceplate. Power Factor Another important term for understanding and communicating motor efficiency is the ‘power factor’. Power factor is the ratio of true power used in a system to the apparent power drawn from the source. In general, a high power factor corresponds to higher efficiency. Motor Load The final and, possibly, the most important factor in motor efficiency is the motor load. A ‘load’ is the burden

efficiency is usually near 75% of rated load. Thus, a 10-horsepower (hp) motor has an acceptable load range of 5–10 hp and a peak efficiency of 7.5 hp. A motor’s efficiency tends to decrease dramatically below about 50% load. However, the range of good efficiency varies with individual motors and tends to extend over a broader range for larger motors. A motor is considered under loaded when it falls in the range where efficiency drops significantly with decreasing load. Overloaded motors can overheat and thus, lose its efficiency. Many motors are designed with a service factor that allows occasional overloading. Service factor is a multiplier that indicates how much a motor can be overloaded under ideal ambient conditions. For example, a 10-hp motor with a 1.15 service factor can handle an 11.5-hp load for short periods of time without incurring

SUGGESTIONS TO IMPROVE EFFICIENCY Check if the motor matches the load: Mismatched motors and loads are the leading causes of motor inefficiency. Recover waste heat: Waste heat from running motors may be used to preheat process air or water and provide space heating. Provide shutoff controls: Shutoff controls can improve efficiency by allowing unnecessary motors to be shut off during off-peak times. Use variable speed drives: Variable speed drives can greatly aid in energy efficiency in a setting where loads may vary by allowing the motor to run at different speeds. Institute a good maintenance programme: Ensuring that motors are clean, properly lubricated and maintained according to manufacturer specifications, are the best ways to ensure motor longevity and efficiency. put on the motor by the mechanical task. Motors are most efficient between 75% and 125% of rated full-load capacity. Mismatching motors and loads is the leading contributor to motor inefficiency.

WHY LOAD DETERMINATION IS NECESSARY? Most electric motors are designed to run at 50–100% of rated load. Maximum

significant damage. Although many motors have service factors of 1.15, running the motor continuously above rated load reduces efficiency and motor life. Never operate overloaded when voltage is below nominal or when cooling is impaired by altitude, high ambient temperature, or dirty motor surfaces. “A motor is an integral component of any manufacturing facility. It is true that the motor

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consumes a lot of energy though there electronic motor controls that allow guidance on which motor will bear is no alternative apart from opting for variable speed drives (VSD) are a how much load. Depending on these, an energy-efficient motor. So, we at fairly new technology, which still customers will have to make the final Bosch ensure that the motor is being have considerable market potential decision.” “Of course, the cost also used as per its load capacity. We also in the coming years. As the cost of plays a role here,” Jadia adds. ensure that the motor is not running at power controls production is mainly FUTURE TECHNOLOGY full load capacity, otherwise there are determined by processing and Although electric motors are a mature chances of tripping,” says DV Gokhale, packaging costs, further substantial technology, certain improvements of Deputy Manager – Materials, Bosch declines in VSD costs are expected. energy efficiency are still expected. India. Together with the tendency towards He adds, “While more integrated and Depending on the age and efficiency of the motor in place, ordering a motor, one must smaller motor controls, the replacement of a less-efficient motor with a highlook at various aspects the application of VSD efficiency motor can have considerable saving potentials with carefully. For example, is expected to increase payback time of a few years. suppose I need a motor significantly. Currently, a new generation of with a load capacity of 10 hp during In the long term, superconductivity motors with copper die cast rotors is peak hours, I will order a motor may reduce losses in electric motors being produced, which will increase keeping in mind the load fluctuations even more and thus reach efficiency efficiency by some percentage points as well as the fluctuations severely levels of around 99%. However, this in comparison to standard technology. impacting the health and lifecycle of technology will only be cost-effective The permanent magnet motor shows the motor.” for very large motors (or generators) potential for even higher efficiencies, Jadia elaborates, “A manufacturer in applications with high annual particularly for smaller motors up to offers motors of various load capacities. running hours. several kW. It is up to the customer to select the vishesh.sharma@infomedia18.in Compared to electric motors, right motor. We can only offer expert

Our search for authentic and informative articles… SEARCH solicits, original, well written, application-oriented, unpublished articles that reflect your valuable experience and expertise in the general manufacturing arena. You can send us Technical Articles, Case Studies and product Write-ups. The length of the articles should not exceed 3000 words, while that of product write-up should not exceed 200 words. The article should preferably reach us in soft copy (either E-mail or CD). The text should be in MS Word Format and the images in 300 DPI resolution and JPG format. The final decision regarding the selection and publication of the articles shall rest solely with SEARCH.

So, join our endeavor to provide relevant and useful content to our readers… rush your articles, write-ups to archana.nayudu@infomedia18.in

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TECH ADVANCEMENTS

Understanding the to

Recursion Redevelop Motors are primarily known for producing torque and speed. Torque is generated by electromagnetic induction. However, with tech advancements, variable reluctance, nanoelectromechanics and ultrasonic motor technology are now becoming other popular ways of producing torque and speed.

SUPRITA ANUPAM

achining comprising of rotating machines installed at households, commercial as well as industrial appliances consumes almost 75–80% of electric power, 50–60% of which is actually consumed by motors. Hence, a marginal 1.8% improvement in their efficiency matters the most. This can be better understood with the help of an example. Let’s consider a 10 HP motor running at an efficiency of 80%, wherein per unit of electricity costs `6. Hence, the annual electricity cost can be calculated as: 10 x .746/.8 x 8,766 HR x 6 = 4,90,457 With 1.8% improvement in efficiency: 10 x .746/.818 x 8,766 HR x 6 = 4,79,665 The difference results in the saving of approximately `10,792 for one medium-sized motor. Motors used in industries range from ¼–100 HP and a small improvement in efficiency can help save enormous amounts of energy and money.

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TECHNOLOGY & MOTORS There is a need for further technical upgradation in motors and drives.

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Technology has revolutionised all sections of motors—be it motor design, materials used and drives. Tracking the evolution of motors and drives, Prof G Narayanan, Associate Professor – Department of Electrical Engineering, IISc, Bangalore, elaborates, “Motors have been around for the past 100 years. From the design point of view, all conventional motors have reached a certain level of maturity. Drives, however, came in much later. Motors and load have a particular torque speed characteristic. We cannot control load, but by developing more & more loadspecific drives, we can certainly control motors more efficiently.”

MATERIAL ENGINEERING The period from 1980–2000 was dominated solely by induction motors. However, in the last decade, it was observed that since permanent magnet (PM) motors proved to be more power dense as compared to induction motors, there was minimal use of electrical steel and conductor materials when manufacturing a motor generating the same output. Consequently, a major increment in the manufacturing of PM motors was seen despite the additional cost of permanent magnets used. PM motors offer high performance largely because rare earth metals, such as neodymium-iron-boron formulations, are used. However, since these rare earth metals are not always

available, the use of induction motors was not discontinued. Apart from this, ferrite materials were used for small applications in PM motors. Though less efficient, ferrite materials form almost one-third of rare earth metals in terms of power density, which limits their use for small apps even though they are 10 times cheaper. PM motors are widely used in automobiles, motion control systems, toys and household appliances. A few advancements in design may enormously enhance the motor capacity. Moreover, PM motors made using ferrite magnets can not only significantly exceed the National Electrical Manufacturers Association (NEMA) premium and IE3 efficiency standards, but also exceed the future IE4 motor efficiency standards. This can be made possible by using motor geometries that allow for flux concentration from ferrite magnet components. Flux concentration allows ferrite PM motors to achieve almost the same power density and performance that is achieved by PM motors using rare earth metals without having to pay as much cost penalty. For instance, a ferrite PM motor manufactured by NovaTorque Inc having a 2.2 kW rating can attain 93% efficiency as compared to the IE3 standard of 89.5%. Core losses are reduced by using low loss steel (cold rolled), lower density (larger core area) and thinner steel stampings even though the material used is more expensive.


TECH ADVANCEMENTS

Normally, core loss in a machine is around ~30–50% of the total losses and about 3% of the machine rating. The standard electrical steel used in India is label 8050; while low loss electrical steels are 5350 and 3150 & high permeability electrical steels are 8050H and 5350H. Aluminium rotors are also used in many apps, but when compared to identical aluminium rotors, die cast copper rotors show 1.2–1.7% improvement by reducing the total energy by 15–23%.

DESIGN ENGINEERING It is not only materials, but also the motor design that significantly reduces losses caused due to friction and windage. These losses can be averted by ensuring a better fan design, improved bearings and aerodynamic design of rotor & airflow. While making a high efficiency motor, lowering the losses also lowers the requirement for cooling. For example, stator copper losses can be reduced by increasing the copper cross-section of winding wires. Similarly, rotor copper losses and stray losses can be reduced by increasing the section of rotor bars, end rings & air gap, better electromagnetic design of slots and windings. Motor design is deeply concerned with radial and axial windings, back electromotive force (EMF) wave form, pole count magnet type, axial motor flux concentrations, magnet configuration and radial & axial torque scaling. Coreless Motor Design This solution came into existence to reduce winding losses to 0%. “Yes, there is no more core loss, but all this has happened at the cost of torque,” Prof Narayanan explains, adding, “A core inside a motor is key for torque generation. A coreless motor can achieve thousands of RPM, but it is unable to produce little torque.” Liquid Cooling Technology In another important advancement, Prof Narayanan remarks, “We are working on the liquid cooling technique

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of motors to avoid the current air-fan cooling technology. Air-fans consume a lot of power as well as space—both of which are important parts of motor design today. Additionally, liquid cooling will save lots of power as well as make the motor much more compact and sophisticated.”

DRIVES-MOTOR CONTROL Induction motors are widely used in machining, except in some highprecision apps where servomotors are used. Induction motors can be further subdivided into squirrel cage and wound rotor motors. In the industry, 90% of induction motors are squirrel cage because of the low cost and low maintenance charge associated with it, while synchronous motors and DC motors are only used for heavy duty and precision drives. But now, after the introduction of variable frequency drives for speed and torque control, DC motors are being replaced by three-phase induction motors. Prof Narayanan comments, “Drives not only control the motor, but also provide a suitable signal as well. We are working on pulse width modulation, which offers better and precise control over motors than sinusoidal wave forms.” Switched Reluctance (SR) Drives SR drives technology is primarily provided by Switched Reluctance Drives Ltd (SRDL). It comprises of a simple brushless motor having a dedicated electronic controller. A simple hardware sensor is used to detect the rotor’s position relative to the stator. A trademark of SRDL, the machine can be operated as a motor or a generator, by timing the excitation suitably, with exceptional efficiency over a wide range of speed and torque. Variable Reluctance Being simple in construction, SR motors produce motion as a result of variable reluctance in the air gap between the rotor and the stator. A reluctance torque is produced because of the rotor’s tendency to move to its minimum position while energising

the stator winding. The beauty of this technology is that only the stator has winding, while the rotor contains no winding, permanent magnet or conductors, which makes it the simplest among all the available technologies. However, owing to its limitations, such as not being able to directly run from DC bus or an AC line and difficulty in control; the industry acceptance of this technology so far, is slow. But the picture is not so grim for SR motors believes Amritha Swamy N, R&D – Team Leader, Emsac. “SR motors offer a lot of benefits—low cost, higher reliability and its independency of each phase physically, magnetically and electrically from the other motor phase. We see it as the possible future of motors,” she says. Ultrasonic Motor Technology PILine® ultrasonic piezo motors are another alternate offering high speed at small dimensions. The patented technology of Physik Instrumente, it features maintenance-free ceramic linear motors having a travel range of 50 mm at a maximum possible rate of 200 mm/s and a self locking at rest with zero heat generation, thereby eliminating the need for an additional brake. The core piece of the system is a piezoceramic plate, excited with high frequency eigenmode oscillations.

FUTURE IS POISED TO CHANGE The current industrial motors’ market looks mature with drives’ development still in progress. But with the technologies variable reluctance, nanoelectromechanics, ultrasonic motor technologies still being in a nascent edge, the market’s future is poised to change. They are not only certain to replace some of the current market trends, but also open up new market possibilities. Just like darkness lets you realise the necessity of light, the high scarcity of rare earth metals will help realise the need for newer technologies to replace existing ones. These are essential to ensure sustainability in the long term.


NANO MOTORS TECHNOLOGY

Driving New Possibilities Nano motors have certainly expanded the horizon of motors and drives industry. They are here, not to replace the present motors, but to create a new market segment and a newer user industry, which will be completely different from the prevailing ones. A look at how nano motors are all set to become a driving force… SUPRITA ANUPAM

ack in December 2007, Tata’s much awaited ‘ w o r l d ’ s cheapest car’ was yet to be launched. Ratan Tata had not yet decided on the car’s name. Ravikant, VP, Tata Motors, along with the team, had suggested four names to Tata... and after almost a whole night’s discussion, the name ‘Nano’ was finalised upon. The name ‘Nano’ was indeed the best fit, considering the size of the car; but the wonders of the technology used in the car were definitely not nano.

MOTOR COMPOSITION

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NANO MOTORS TECHNOLOGY Recently, Dutch scientists invented a tiny nano-sized car, which can propel itself forward in response to electrical pulses. This was possible owing to the feasibility of nano motors. HG Wells once said: “There is no intelligence if there is no change” and change is the only constant in this case. This was probably the underlying thought while making nano motors. Berkeley lab scientists have invented a nano motor,

which is 200 nm wide and has a power density that is 100 million times greater than that of a V-6 engine. Chris Regan of Berkeley Lab’s Materials Sciences Division developed the motor with fellow Materials Sciences Researchers Shaul Aloni, Kenneth Jensen and Team Leader, Alex Zettl. According to Aloni, Regan and Zettl (who are also scientists in the University of California at Berkeley’s Department of Physics), “Surface tension becomes more important as objects become smaller and dominate at a nano scale.”

LIFTING BIOMED BARRIERS Nano motors have created new avenues for biomedical instrument manufacturers as they have the potential to revolutionise biomedical instruments such robotic devices made from DNA that can potentially detect specific cell targets within a complex mixture of cell types and deliver important services like commanding cancer cells to self destruct. Thus, it can be used to programme immune responses to treat various diseases. Among the other applications are a variety of microelectromechanical systems (MEMS) actuators, microfluidics, catalysis, chemical & biological sensing, mirror movement for optical applications and oscillator in wireless & microwave communications.

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The motor is made up of carbon nano tubes that are 10,000 times thinner than human hair in terms of radii and were earlier used as a nano scale conveyor belt to move indium like atoms along the tube. The team converted the conveyor belt into a tiny motor possessing Herculean strength. Two molten indium droplets—one big and one small—were positioned side by side on the carbon nano tube. Electric current was then passed through the tube, which caused the indium atoms to shuttle from the large to the small droplets. The small droplets continued to grow until they came into contact with the larger one, after which, surface tension took over. Regan described the meeting of the two beads as an ‘energetic catastrophe’. Regan said, “We pumped a lot of energy into the system and then quickly released it. The cycle repeats after every collapse; every time the small droplet relinquishes its atoms and implodes. This leads to a motor’s slow & fast and back & forth motion, which can be transferred to nano-sized legs that can be further utilised for the desired apps.” Regan believes that “the motor is also ideal for locomotive applications because it is very strong for its size”.

ADVANTAGE OFFERED The advantage of this technology


NANO MOTORS TECHNOLOGY

is that it causes very little or almost negligible friction, which helps it run with higher efficiency. But as per Zettl, natural molecular motors that are present in the brain and a few other parts are way ahead in terms of technology. “They are even smaller,” averred Zettl. In a further development, Chemists at Italy’s University of Bologna and California NanoSystems Institute have succeeded in designing and constructing a molecular motor that would be powered by sunlight. This nano motor would not only

DIAMOND FIBRES: MAKING BONES STRONGER THAN STEEL Apart from being used as oscillators, nano wires, rotating rotors, sliding tuners and indicators…, Author Rav Berg has found a unique application for nano motors. In his book, ‘Nano: Technology of Mind Over Matter’, he elaborated, “There is a lot of empty space in our bones. Some nanotechnologists tell us that if we could inject pure diamond fibres into that empty space, bone strength would surpass steel. Through nanotechnology, the rest of our bodies could also be infused with diamond fabric. Scientists have already calculated that this kind of diamond-based body reinforcement would have ‘G’ force tolerance. In other words, one could fall off a building and walk away unscathed.”

Surface tension becomes more important as objects become smaller and dominate at a nano scale.

EXPANDING APPS’ PURVIEW

Nano motors are not a threat to any market. Shaul Aloni, Chris Regan, Alex Zettl, Apart from creating Materials Sciences Researchers, Berkeley Lab’s new apps, it will create Materials Sciences Division a new market for itself. They may find their apps in DNA manipulators, blood work incessantly without any external vessel cleansers, bio sensors, cell interference, but would also not phones, optics, and digital pens... and produce any chemical waste.

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it is speculated that they can be used in the formation of nano computers and power nano robots. The power nano robots once placed in the bloodstream will seek out and repair damaged tissues in the human body. With such powerful prospects in place, nano motors are all set to become a driving force. suprita.anupam@infomedia18.in


Photo By Joshua Navalkar

PREMIER HEAVY ENGINEERING

Homegrown Techniques,

the SUCCESS POTION for Premier Premier Ltd established its Engineering Division to utilise the in-house facilities & expertise to offer machining services to major automobile industries in Pune. With clients like Tata Motors, Force Motors and Carraro Ltd among others, the division has come a long way. The management gives all credit to determined manpower, in-house advance measures and new technologies that have helped the division to expand. At present, they boast to be one of the leading wind turbine parts suppliers globally. Our recent visit to the Heavy Engineering Division in Pune only supported their leadership claim in the segment. NISHI RATH

remier Ltd, the makers of Premier Padmini cars that once ruled the Indian roads, is smoothly sailing through with their second inning. The company, which faced hard times earlier, has now diversified into machining and heavy engineering business. Besides, it re-entered the auto business after a gap of a decade. In 2011, Maitreya Doshi, Chairman and MD, Premier Ltd, expressed his desire to build the group into a `2,500 crore turnover company in the next six years.

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THE BEGINNING… Premier formed joint ventures (JVs) with Peugeot and Fiat in 1991, but the JVs collapsed. After a difficult period of tax litigations and indebtedness,

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Premier sold its 36 acre Mumbai property to Manohar Joshi-owned real estate company Kohinoor Planet for `120 crore in 2005. This money, along with `250 crore (in debt) and fresh equity infusion was used to expand and modernise the existing plant in Pune. In 2008, Premier entered the heavy engineering business, making generator parts for windmill and infrastructure players. It now also manufactures chassis frames for BEML’s metro train coaches and large cylinder blocks for Cummins. The 52,000 sqft plant is spread over 27 acre and now makes computer numerical control (CNC) tooling machines, mainly gear-making machines and heavy machine blocks for automotive and heavy engineering giants like Tata, Mahindra, Eaton, L&T and BHEL. Premier now boasts

of 70% market share in this business. The company’s collective turnover from its three core businesses is about `300 crore. “Our shed space is dedicated to the manufacturing of wind turbine components for power majors like Tata, Cummins and Enercon India. It has a full complement of manufacturing capabilities including fabrication, machining, blasting and painting of wind turbine; steel parts like disc rotors, stator rings, stator carriers, rotor housings and supporting structures. The division undertakes complete machining of rotor hubs, blade adaptors, axle pins and main carriers made from castings used in wind turbines,” says KG Rathi, VP – Engineering Services Division, Premier Ltd.


PREMIER HEAVY ENGINEERING

AND THE CREDIT GOES TO… Right from fabrication, which involves heavy size thick plates & forgings to the precision machining & shrink fitting of internal gear ring at -40º, the team here has been putting great efforts and has stood tall and proved their mettle. The company officials give all due credit to the dedicated employees because of whom the company has witnessed continuous development. ‘First plan your work, then work your plan!’ The employees at the Engineering Division truly believe and follow this practice. He elaborates that more than 80 continual improvement projects have been implemented in context with improvement in quality, productivity and reduction in cycle time. Some of

machine instead of repeating the whole old procedure of clamping. This has increased the productivity up to 20%. Semi-automatic use of SAW welding machine for hub welding on rotating table Outside welding of hub with flux cored arc (CO2) welding machine on manually rotating table had many drawbacks. It was a time-consuming process, hazardous to environment, involved operative fatigue, less productive (20 hours for single hub), more defects in weld bead and poor aesthetic of welding among others. The process was developed later into a semi-automatic set up of SAW (submerged arc welding) machine with rotating table and prior calculated feed rate & speed of rotation. A study has shown tremendous improvements

nearly by 40%. Packing At the Engineering Division, the ready-to-dispatch components are properly enclosed according to a packing scheme given by customers as well as some developed in-house. Considering the safety of components to avoid any damage during transit, the division has a separate expert team for packing. The safety issue is taken care of by making suitable changes in the packing scheme for safe delivery of finished components at the customer’s end. “These are some of the examples of excellent research, spontaneity and team work of our employees. It is an ongoing process to ensure improvement in quality, productivity, handling of the heavy parts and reducing the fatigue of the operatives at all levels of our operational areas starting from the procurement of raw material,” says Nagaraj MK, Asst GM – Commercial, Engineering Services Division, Premier Ltd.

Photos By Joshua Navalkar

PROCUREMENT AND MATERIAL MANAGEMENT BEST PRACTICES

them, which the division takes pride in, are: Readily available fixture changing with prior clamping arrangements for SG Iron Rotor Hub The set up time for changing the fixture of the rotor hub on horizontal boring machines and its clamping on the table for further machining of next job used to take nearly two hours. Later, this time was reduced to 90% by making separate arrangement of clamping rotor hub on separate fixture. Now, when machining of the previous job is done, only this fixture has to be clamped on the table of the horizontal boring

such as increase in productivity by 70%, making the process environment friendly, reducing the defects in the welding to 95%, ensuring good aesthetic appearance of welding and making operator fatigue negligible. This came across as a major achievement for the employees. Patented procedure of stator carrier arms welding A system, which involves a combination of two different welding processes, was successfully tried and handed over for production. It reduced the cycle time and manpower up to 50% and increased the productivity

Nagaraj also points out that involvement of each and every employee right from the raw material procurement stage to the delivery of the job quality is one of the major reasons for the growth of the division. “We encourage our employees to implement the best practices to make this a better place to work. Here, we make sure we follow certain practices to meet our target on time,” he adds. The employees in the Engineering Division have adapted to some of the best practices in business such as: In depth analysis and forecasting of material requirements All the activities are strictly on the basis of the division’s budget & the same is planned on a quarterly, monthly and daily basis The division is taking care of in-time payment to the supplier and also educates suppliers on their basic requirements. The division also

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provides the necessary assistance to the suppliers at the time of procurement by giving them all the technical & inspection support Employees in the division observe the customer and supplier as a team and conduct 100% quality check and acceptance of material (raw and finished), efficient inbound, WIP and outbound logistics management processes followed for material handling Sometimes due to constraint of supplier & prior intimation to the management, they create a strategic inventory, ‘First In, First Out’. The division has also implemented sorting, cleanliness, standardised processes and maintains discipline along with safety & security. Both Rathi and Nagaraj claim that the quality of the work done here has brought them to where they are now. They hope to continue with the same quality.

CUSTOMERS GET THE BEST QUALITY The Engineering Division has excelled in the field of heavy and critical components supplies of wind turbine parts with strict adherence to the quality & commitment, according to company officials. The division has a proven track record for the design & development of jigs & fixtures, with all latest technologies to produce quality goods within a stipulated time. Rathi states that world-class manufacturing techniques have been implemented to achieve international standards. Special welding, machining and in-house designed precision fixtures and jigs are used to adhere to the close tolerance required in the components. According to him, the approach and inspection facilities are keys to successful completion of the prototype job in the stipulated time. “Today, the competitive world cost plays a very important role in the whole process. We look and take care of non-productive and uncertified activities, which result into best price and satisfaction to our customer,” says

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Rathi. Considering the quantum of work involved, the company decided to have separate ISO certification for the Engineering Division. The division has a built-in Quality Management System. “We obtained separate ISO 9001:2000 certification for our division in 2008. It was upgraded to 9001:2008 in December 2010. QMS is well established & maintained by conducting internal audit once in every four months and external audit once in six months,” adds Rathi. Based on the company’s Quality Policy, the division has a set of quality objectives, which are measured & monitored against targets through Key Performance Indicator (KPI) matrix. KPI with set targets are given to each function. Some of the KPIs are: Function

KPI Customer Marketing Satisfaction Index Reduction Plan Vs. Production Actual No. of Quality QA Deviations Per Job Supplier Performance Purchase Rating Machine Break Maintenance Down Hours Apart from quality, the management also takes pride in the fact that that best practices are implemented for the safety of their employees. The employees are provided with all the basic safety equipment, including helmets and goggles, among others.

EMPLOYEES’ TRAINING The team believes that training is crucial to upgrade the personnel and it gives tangible & intangible benefits. The division, while inducting contractual workmen, imparts training that focusses on subjects like quality, safety and discipline. Orientation programme for new entrant officers are also organised apart from in-house training by internal as well as external faculties on technical training (welding process, non-destructive testing, ISO

9001:2008 awareness, Statistical Process Control, 1S-2S, Vendor Negotiation), and soft skills. Fire fighting drills also form a part in the training process.

EXPANSION PLANS The Engineering Division has become the only approved source in India for supplying metro bogie frames. The division is also setting up an exclusive line for structural & forging parts of 2 MW capacities. “Our division with hands on experience and expertise in developing critical structural parts of wind turbines is moving towards developing higher capacity parts like nacelle hub frame for 2.5 MW wind turbine, which is the heaviest part in the nacelle assembly,” says Nagaraj. The division is now planning a few things on a large scale. “Steel tower for wind turbine manufacturer is one of the sectors that the division is looking forward to. We will set up a state-of-the-art technology plant with exclusive facilities such as bending machine, motorised trolley mounted column and boom, rotators, blasting & painting booth and flange facer, among others, for the same. At present, we have developed components for wind turbines with small capacity. We are preparing to manufacture wind turbine towers for higher capacity,” says Nagaraj. He adds that the division is going to set up an exclusive line for machining of heavy duty cylinder blocks for marine engines with CNC horizontal boring machines & SPMs. This is not all! Looking at the market demand and quality products of castings, the company is planning to set up a world-class foundry for heavy SG iron and alloy steel castings. No wonder the company has come a long way in a short time span. Today, it is among the top players in its segment. However, the company is not contended yet and promises a lot more in future. nisi.rath@infomedia18.in


Outstanding Results

The growing necessity to meet their requirement to easily access, collect, analyse and publish information throughout their enterprise has prodded companies to opt for business intelligence (BI) solutions. BI solutions are an ideal complement to an established software infrastructure and will play a pivotal role in helping companies manage the tremendous growth in business information. n a 2011 survey of 344 Chief Financial Officers, Gartner found that business intelligence (BI) was considered the top technology investment and more than half, i.e., 54%, planned to upgrade their BI solution during the next two years. Since every company depends on information to make the best decisions, the question is not, “Do I need a business intelligence solution?” but “What business intelligence solution do I need?”

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IMPEDIMENTS TO GOOD DECISION MAKING In simple terms, companies need BI to understand their day-to-day and longterm performance, so that they can take proper action to correct problems and tap opportunities. However, there are many challenges towards achieving this. These include: No way to aggregate data into

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meaningful snapshots In some companies, there is a massive amount of raw data, but no way to aggregate it into a meaningful snapshot. There is certainly value in knowing that a single customer ‘X’ bought 400 units of a product. But with thousands of customers and hundreds of thousands of products, aggregating data is the only way to get meaningful information based on which, decisions can be made. Alternatively, it can take too long and require too much staff resource to collect the data because It is stuck in disparate systems that do not communicate with each other It is from different IT vendors It lacks adequate processing power to extract the data quickly. Data analysed from a technical mindset and not business perspective If a BI process requires IT staff to collect, analyse and create reports

for the line of business employees, it will invariably take longer to make decisions. Moreover, involving IT can lead to flaws because the IT staff member does not fully grasp the business issue at hand. This leads to lack of confidence in the accuracy or completeness of the data. In his 2011 report, ‘The Analytical Masses’, Michael Lock, Senior Research Analyst, Aberdeen Group, reported that companies have found that because BI solutions originated in the IT department, data traditionally has been manipulated and analysed from a technical mindset and not a business perspective. He also noted that business users can apply their experience and instincts to ask better questions and generate more meaningful insight. Dependence on spreadsheets Companies that depend on spreadsheets, like Excel, for collecting and processing data are at a disadvantage. Although spreadsheets

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are flexible and give individual users control, they can be inefficient. For example, in response to a request for revenue numbers, an employee may pull the data from many locations and compile a spreadsheet. When the same request is made a few months later, the employee must go through the same time-consuming process because there is no common data storage repository. No cohesive format for presenting data Struggling with the basic tasks of collecting data is only part of the problem. Many companies lack ways to make it clear and concise with no cohesive format or single view for presenting information pertaining to individual business metrics. Data inconsistency This also introduces uncertainty into the decision making process. A company may use disparate systems that store the same type of data, but in a different format. So, it is hard to aggregate and compare. There is often a conflict about which spreadsheet or version contains the most accurate information. Different divisions or parts of the business may have their own criteria for a metric. In this situation, the decision maker is forced into an apples-to-oranges comparison. Some approaches produce lots of data, but lack the ability to transform data into meaningful information. Employees may be required to manually organise the data or use analytical tools that are rudimentary and slow because the BI solution is too inflexible to adapt data gathering and analysis processes fast enough.

impede good decision making, thereby creating numerous opportunities to streamline core processes to reduce costs and improve the timeliness & business value of decisions. No single approach to BI fits every enterprise. But there are common attributes of what constitutes an ideal business intelligence solution. A business intelligence solution: Focusses on business users and their ability to make better & faster decisions Is an easy-to-use interface that minimises training requirements and the involvement of your IT staff in ongoing BI activities. Research for Gartner’s ‘Magic Quadrant for Business Intelligence Platforms’ revealed that ease of use for end users overtook functionality as the most important selection criterion when choosing BI tools Aggregates and consolidates data with high-level & detailed financial/ non-financial data available in real time Connects to any system, transferring data to & from other software systems directly or via interfaces Provides the information level— ranging from sophisticated analysis tools for a power user to broader reports & dashboards—required by users Supports operational and financial planning Streamlines compliance and secures access to critical business information Has the ability to easily evolve to meet new business requirements as they arise.

AN IDEAL BI SOLUTION CONSTITUTES...

ASSESSING BUSINESS INTELLIGENCE OPTIONS

A recent Aberdeen Group report found that best in class users of BI achieve an average 27% year-over-year organic growth. Even those businesses rated as average saw a 20% year-on-year growth. Figures like this are a result of the fact that implementing the right BI solution can help eliminate the information access and analysis obstacles that

The best option for addressing BI requirements will be largely determined by the complexity of a business and the role that information plays in it. For small companies having a limited product line, geographic reach and a modest number of customers, a spreadsheet-based process may suffice.

In these companies, decision making is the responsibility of one person or a small number of people. On the other hand, for more complex companies, the use of spreadsheets to facilitate decision making becomes prohibitive. There are too many variables and data points to efficiently aggregate & analyse data. If the business is relatively simple, with a small number of products, customers, locations and employees, companies may be able to get by with basic information collection, management and analysis capabilities of a broadly focussed enterprise solution. Companies that have a wide range of ERP, financial management, or other core enterprise systems, typically need specialised BI capabilities. These organisations are too complex and fast-changing to depend on a generalised or manual approach to business intelligence. In these situations, BI capabilities that are dependent on transactional systems and IT resources cannot meet the internal demands for reporting, analysis, planning, budgeting, and compliance. The sources of information are simply too widespread. The employees who need the information are too numerous and have responsibilities that are too diverse. In a June 2011 Gartner, Inc. report, ‘Market Trends: Business Intelligence, Worldwide, 2011–14’, Dan Sommer and James Richardson wrote, “The 21st century will be the era of information. Today, information amounts double as rapidly as every 18 months. These huge amounts of data and information will need context. Optimal use of information assets will be critical to business success, and organisations that can derive the best understanding from it will have a major advantage in a globalised and competitive world.” Business intelligence solutions will clearly play a central role in helping companies manage the immense growth in business information. Souma Das, MD and VP – Sales (India), Infor

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Appropriate choice of these software will he power sector plays a 10101010101010101010101010101010101010101010101010101010101010101010101010101010101010 101010101010101010 10101010101010101010101010101010101010101010101010101010101010101010101010101010101010 1010101010101010101010101010101010101010101010 help in right decision making, energy saving and improvement of vital role in the economic 10101010101010101010101010101010101010101010101010101010101010101010101010101010101010 10101010101010101010101010 performance. growth of a country.1010101010101010101010101010101 In 10101010101010101010101010101010101010101010101010101010101010101010101010101010101010 10101010101010101010101010101010101010101010101010101010101010101010101010101010101010 010101010101010101010101010 India, companies today 10101010101010101010101010101010101010101010101010101010101010101010101010101010101010 10101010101010101010101010101010101010 10101010101010101010101010101010101010101010101010101010101010101010101010101010101010 1010101010101010101010101010SUMEDHA MAHOREY face a huge challenge 10101010101010101010101010101010101010101010101010101010101010101010101010101010101010 1010101010101010101010 in the form of demand-supply gap 10101010101010101010101010101010101010101010101010101010101010101010101010101010101010 101010101010101010101010101010101010 10101010101010101010101010101010101010101010101010101010101010101010101010101010101010 1010101010101010101010101010101 in electricity generation and there is 10101010101010101010101010101010101010101010101010101010101010101010101010101010101010 0101010101010101010101010101010101010101010101010101010 10101010101010101010101010101010101010101010101010101010101010101010101010101010101010 10101010101010101010101010101010101010101010101 continuous pressure on power plants 10101010101010101010101010101010101010101010101010101010101010101010101010101010101010 0101010101010101010101010101010101010101010101010101010101010101010101010 10101010101010101010101010101010101010101010101010101010101010101010101010101010101010 1010101010101010101010101010101010101 to improve their efficiencies & output.

SOFTWARE SOLUTIONS

Going HI-TECH with custom-made APPLICATIONS

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In this context, power plants face major challenges in terms of reliable monitoring of auxiliary consumption & reducing energy consumption of auxiliaries. Also, with the grids going smart and multiple renewable sources of energy coming into the picture, a system that taps variable load frequencies has become the need of the hour. As a grid monitoring/control device, the Energy Management Software (EMS) is one of the core technologies that serves as the brain of a smart grid as it monitors and controls the local supply & demand of electricity. EMS is designed to absorb variations in power consumption within a grid and minimise their effects on the electricity network. Milind Joshi, Associate GM – Marketing (Power Metering), Schneider Electric, explains, “EMS performs three functions—formulating comprehensive plans for energy supply and demand; controlling the allocation of economic load and controlling load frequencies in real time. It is particularly important to predict and control electricity.”

APPLICABILITY AND DERIVED PROFITS To understand the role of energy management in the power sector,

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one needs to first understand the different segments in this sector, viz., generation, transmission and distribution. EMS, in general, plays a critical role in each of these segments. Elaborating on these criticalities, Vijay Arora, GM – Control & Automation, Larsen & Toubro, says, “For a stable grid, accurate demand forecasting and balancing that with power generation is of vital importance. Similarly, from a user’s perspective, sourcing of power in a cost-effective way through various options like utilities, solar PV or solar thermal power, wind power, CPP and selling of surplus power at favourable rates directly influences the profitability of the user.” “Energy saving is another vital area for business profitability. One unit of energy saved is equal to three units of primary energy saved. Thus, energy saving not only results in cost saving, but also contributes to creating a green environment. So, one can see the clear role of EMS in grid stability, business profitability and green environment,” he adds. The use of EMS can help companies solve some of the major challenges presently faced. These include:

consumption of power plants & benchmarking with other plants Online monitoring of efficiency of BFP pumps and online Online energy monitoring of large drives, ID fans, etc. Availability based tariff application Scheduling power & close monitoring of import/export power in power trading application Demand controlling application Monitoring area-wise consumption in different time formats Energy consumption comparison between pumps, identify & eliminate inefficiencies Reduction of distribution loss Root cause analysis Correct real-time measurement & verification. All these EMS applications help in decision making, which, in turn, result in saving of energy and improvement in performance.

EMS OPTIONS IN MARKET Presently, there are many EMS available in the market and some of the leaders in this space include Siemens, Infor, L&T and Schneider Electric. These newer solutions are


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full-featured applications with multiple Monitoring these resources through can take decisions to opt for alternate options for data capture, sophisticated EMS can help understand where sources of power (like say, renewable data analytics, configurable alerting and when these resources are being energy), which may be cheaper and systems, best practice databases and used and can give the knowledge to greener. EMS having load forecasting innovative work order capabilities. target the areas of waste or overuse. capability coupled with energy storage Commenting on the customised This would help reduce consumption, mechanism will be the key for its solutions provided by his company, carbon emissions and ultimately, effectiveness in this sector.” Joshi avers, “Today, there are many overall costs.” FUTURE OF EMS players who offer software that give Though most manufacturing EMS is widely used by industries many reports. However, a major facilities have a supervisory control such as metals, mining, automotive, challenge is to understand the and data acquisition system or building cement, power plants, pharmaceutical, requirement of customers and propose automation system monitoring, these oil & gas, chemicals, textiles and glass, the right solutions. Our company, with systems do not have the ability to view among others. All these sectors need EMS installation at 600+ sites in India, trends or allow comparisons of energy a higher level of evolution. To suffice plays an important role in providing data, either within a site or between the demands of these sectors, EMS is the right combination of resources and multiple sites. Hence, the use of EMS evolving based on the cloud computing becomes extremely effective as it allows skills to understand the requirement of concept. Commenting on the next level the comparison of energy use across a customers and meet their expectations of EMS, Arora articulates, “It is very number of similar sites. by offering complete solutions. From difficult to predict the future of EMS. Elaborating on the decision making a customer’s perspective, EMS alone While real-time control will remain support provided by EMS, Arora says, has no USP as such. The USP is in with the facility, computational aspects “Techniques such as load factor analysis offering a complete solution.” like forecasting, asset management, allow users to see where maximum Highlighting the challenges etc., may be handled encountered in the Effective monitoring and targeting of energy can help the through cloud computing. applicability of many EMS industry improve operations, identify savings and track The use of iPad like present in the market, progress against energy and carbon emission targets. These gadgets integrated to EMS Arora points out, “There measures can typically reduce energy consumption by 5–15% will also be a common are many EMS solutions (UK Carbon Trust Survey). thing.” presently available. But Joshi adds, “Going forward, the demand on the grid occurs each day. the problem is that the EMS tag is requirement for EMS will go up If it is spiking at a particular point, a used for applications where only and users will demand a segmentchange to the start time of each shift metre reading and display of energy specific software, which would be could be set to see if a production shift data is implemented to very complex rich in features & intelligence. The could be moved to another time of day, applications with load forecasting, futuristic software will have smart thereby ensuring that your demands state estimation, etc. Consequently, grid compatibility as well as have are kept as low as possible, along with the buyer gets confused and, in turn, capabilities of basic controls & costs. The cost savings can be dramatic opts for a cheaper system where he communication to other ERP systems, when EMS is capable of proliferating cannot actually reap the full benefits thereby helping users analyse energy energy saving data to the staff through of the investment. The EMS must be usage better. However, EMS software energy dashboard displays in public scalable in terms of the number of tags, will have a better meaning only when spaces.” Thus, EMS generates data & number of features & functions, interthese are combined with the right need reports, based on which desired action operable and with open architecture for analysis, hardware and execution.” can be taken. This, in turn, helps integration to other advance software.” In its futuristic avatar, EMS needs improve energy performance. ACHIEVING COST EFFICIENCIES to evolve as a complete solution, With renewable energy getting The process industry is a huge custom-made for the niche industry added to the mainline, load fluctuations consumer of energy, which has player. EMS developers also need to are becoming very frequent. potential for major savings. Expressing consider the demand trends coming Commenting on the use of EMS on his views on the applicability of EMS up in the market towards going green this front, Joshi asserts, “EMS software in this industry, Arora avers, “With and comply with these requirements in can be used as an effective tool to the ever rising energy costs, a large time to come. monitor the existing source of energy proportion of a facility’s overheads & justify the economic/expensive sumedha.mahorey@infomedia18.in can be attributed to energy usage. condition of power. Further, operators

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IN-SIGHT ID READER

Delivering HIGHEST Read Rates ETO Magnetic GmbH, an industrial product manufacturer based in Stockach, Germany, uses Cognex In-Sight® 5100 ID readers to create a continuous monitoring system for traceability at their facilities in Germany, Poland, China and the US. This has helped ETO Magnetic reduce the pseudo-failure rate of its manufactured parts from 4% to almost zero with a vision-based traceability solution.

IDENTIFYING OBSTACLES Laser-etched codes, as a rule, provide good contrast and can be read reliably, while dot peen codes on metal parts

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FACT

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present the last generation of code readers with an impossible reading task. During the production process, metal components are thermally and mechanically distorted to the extent that these 2D codes suffer collateral damage. While stamping the tiny 6x6 mm identification areas in the dot peen process, tool wear can lead to differences in impression depths and angles of the individual marking points. When the last generation of

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TO Magnetic can produce several million defect-free parts for the automotive industry with each step in the production process being a few seconds apart. A factor contributing to its success is the continuous monitoring of parts until they form a finished product, based on intelligent vision systems. Laser-etched and dot peen 2D codes provide the most important methods for creating an individual fingerprint for quality assurance. Since the introduction of innovative traceability solutions from Cognex, the pseudo-failure rate has been reduced from 4% to almost zero.

Cognex In-Sight ID readers are equipped with Cognex IDMax® data matrix code reading software, based on Cognex’s leading PatMax® technology, which guarantees reliable and stable decoding under the most difficult conditions.

code readers attempted to read these dot peen codes, up to 4% of parts were determined to have unreadable codes. “This rate was clearly too high for us. In our manufacturing processes, a product with an unreadable code is treated as a reject. In a plant handling several million parts, our old ID readers were simply not up to scratch. So, we looked for a better system and found it in the In-Sight 5110 from Cognex,” says Klaus Schwanz, Process Planner, ETO Magnetic.

AN INTELLIGENT SOLUTION HELPS It was only when ETO Magnetic began to use In-Sight 5110 fixed-mount ID readers on their manufacturing lines that the 2D dot peen codes could be successfully identified with 100% certainty. “A decisive advantage of the change to the In-Sight 5110


IN-SIGHT ID READER

system is its combination A decisive advantage of the of lighting, camera, change to the In-Sight 5110 system ID software, processor is its combination of lighting, and communications camera, ID software, processor and communications interface. interface,” elaborates Bruno Halter, Senior Application Engineer, Cognex Bruno Halter, Senior Application Engineer, Cognex. An essential spots,” explains Halter. contribution was also the know-how GUARANTEEING RELIABLE DECODING of the vision specialist, who eliminated Decoding cannot be optimised with possible problem points in an additional lighting in every case. illuminating way. For metal surfaces In many industrial environments, that were, in part, highly reflective space limitations often leave room and particularly difficult to identify, only for the ID reader itself. For developers at ETO Magnetic used flat this reason, Cognex In-Sight ID white lighting. “Earlier, we tried to readers are equipped with Cognex read dot peen 2D codes in the same IDMax® data matrix code reading way as printed codes. In particularly software, based on Cognex’s leading difficult cases, the reflective behaviour PatMax® technology. This technology of the dot peen codes rendered this guarantees reliable and stable decoding method ineffective. To address this under the most difficult conditions. Its challenge, we lit the relevant areas digital, high-speed recognition system, uniformly with white light and were DSP architecture and optimised reader able to recognise the impressions of algorithms ensure high reading rates at the dot peen code reliably as black

all times in identification applications with labels and direct marking, even on the fastest production lines.

QUALITY BEYOND CUSTOMERS’ EXPECTATIONS With the comprehensive traceability of parts for the automotive industry, ETO Magnetic goes significantly further than demanded by the company’s customers. Most of the 2D codes are applied solely for internal traceability of the manufacturing processes. In this way, the company can trace every part, however small, in all individual components, down to the delivered load of copper wires for electromagnetic windings. Possible process or material faults are detected early and corrected. Not only satisfied customers, but also the management of ETO Magnetic, are delighted with their cost-optimised production processes. Courtesy: Cognex

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PATENTING IN INDIA

o understand the need for patenting and safeguarding ideas & concepts, one needs to first understand the idea behind innovation. An innovation can happen anywhere, at any hierarchy or at any level in the organisation. In this cutthroat

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Technological Innovations These would include major technological modifications as well as the introduction of a completely new technology in the market. Product Innovations These refer to all the innovations, whi which have been introduced in the market or are implemented in the production process (process innovation).

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PATENTING & ITS TYPES So, what is patenting? Before proceeding to answer that, let us discuss what are the types of innovations that can be patented in India. As per the Controller General of Patents, Designs & Trade Marks (CGPDTM), innovations that can be patented in India include:

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agement

competitive age, innovation is one tool n have successfully successful that businessmen used for a range off products products, services and technologies. However, in such a scenario where tools and techniques are easily available in every corner of the world at the click of a mouse, how do companies ensure that they own the rights to their innovations and also legally protect this right through an established process? The answer to this mindboggling question lies in patenting.

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the impact of innovative efforts has become a true source of competitive advantage. But, how do we develop these innovations in the organisation? The key here is to implement a Collaborative Idea Management (CIM), which is a method to learn from the ‘wisdom of the crowd’ in order to drive innovation. It is an integrated part of the innovation process and is relevant for all types of ideas—from incremental improvements to new and

Many ideas, innovations and success stories go unnoticed and, at times, are replicated due to lack of awareness about patenting. However, companies are now waking up to this procedure, thanks to the many benefits associated with it. Moving towards a patenting culture will not only help companies in realising the benefits of innovation, but also enhance the legal system towards protecting their innovations. SUMEDHA MAHOREY

Design Innovations These are referred to any creative activity, which results in the ornamental or formal appearance of a product, while design right refers to a novel or original design that is accorded to the proprietor of a validly registered design.

INNOVATION: THE NEED OF THE HOUR Every business needs the next level of upgrade amid increasing competition from more and more new market entrants. Also, rapidly changing customer demands have made innovation a must for the survival of businesses. Dr WM Dhumane, Sr Joint Controller of Patents & Designs reveals that intellectual property comes as a knowledge asset, tool for competitiveness & a key component for success in business. In the 21st century, the ability to assess and measure progress and

disruptive business opportunities. It is a structured process for the collection, handling, selection and distribution of ideas. Besides, CIM also involves support for gathering, storing, improving, evaluating and prioritising ideas by providing methods and tools. This method can help organisations to come up with new ideas, improvise on them and make sure that these ideas reach the right audience. It also helps in tapping the innovative energy of employees, customers and partners, who can help the company find differentiating opportunities and drive the culture of collaboration and innovation. Gopakumar Nair, Patent Attorney, avers, “Innovations come from churning knowledge with open minds. It evolves through sources like needbased solutions, serendipity, disruptive inventions, intensive research & incremental innovations.”


PATENTING IN INDIA

INNOVATION TOOLS & IMPULSES Innovation can be brought in through good team work, creativity of Measures such as benchmarking with employees, ability to finance the innovation activities, continued competitors, internal brainstorming, education to employees and proper rate of risk-taking. Once this processes re-engineering, technology innovation has been identified and given the final implementable shape, it is time to patent it. audit, technology forecast, quality Dr RR Hirwani, HoD, CSIR-URDIP function deployment as per customer demands or value analysis as per market conditions could be termed party raises pre-grant opposition, the commercialisation, co-developing as various tools for innovation. While issue is sorted out by the Controller. co-working, co-marketing and the impulses for innovation include After the examination of the patent, IP-sharing.” demand from customers & suppliers, the decision to grant or refuse the HOW AWARE IS INDIA INC? consultants, R&D institutions; new patent is taken. Once the grant process offerings from competitors; new trends India Inc has woken up to the many is completed, publication of the grant in exhibitions, trade fairs, seminars benefits of patenting. A number of of the patent takes place. and conferences. Globalisation and entrepreneurs as well as established influence of foreign manufacturers can THE ADVANTAGES OF PATENTING players in the market are moving Patenting has many benefits. It helps also act as an impulse for innovation. towards imbibing the patenting culture These, along with media, form the the industry improve its existing in their respective organisations. One external impulses for innovation. technology to give cheaper and better such example is that of L&T’s Electrical Innovations can come up internally products. Also, it helps in identifying & Automation (E&A) division, which as well through company’s own emerging technologies, research & won two top intellectual property R&D divisions, design & technology business opportunities. Besides, the awards at the 4th National IP Awards 2012 organised by the Controller divisions, marketing and sales teams, number of patents filed by a company purchase & supplies, guarantee and General of Patents, Designs and also acts as an indicator of a company’s post-guarantee service & owners. Trademarks in collaboration with success. It acts as a tool for increasing the Confederation of Indian Industry Commenting on the impulses for negotiating powers with clients as well (CII). In FY12, the E&A business filed innovations, Dr RR Hirwani, HoD, as suppliers. CSIR-URDIP, says, “Innovation can 162 Patents applications (including 10 With patenting registered in its be brought in through good team international filings), four Trademark name, a company can become a prework, creativity of employees, ability eminent player in the market. Also, applications, 11 Design registrations to finance the innovation activities, a patent can be used as a tool for and nine Copyrights. This was the fifth consecutive year that this continued education to The patentee can use his exclusive rights over the patent and business filed more than employees and proper convert the use of his patent into a monetary activity. He can 100 Patent applications, rate of risk-taking. Once sell, distribute, and licence his patent. He has the right to taking its tally to 856 this innovation has been initiate legal proceedings against infringement of the patent. Patent applications, 318 identified and given the Designs, 147 Trademarks final implementable shape, it is time to patent it.” international trade. The patentee and 32 Copyrights. Excellence in IPR can use his exclusive rights over the processes has resulted in the creation PATENT GRANT PROCEDURE patent and convert the use of his of intellectual wealth, strong IP As per the Controller General of patent into a monetary activity. He protection and has added to L&T’s Patents Designs and Trademarks, can sell, distribute, and licence his intangible assets. the first legislation in India relating patent. He has the right to initiate Looking at the above case, it could to patents was the Act VI of 1856. legal proceedings against infringement be said that Indian companies have The objective of this legislation was realised the importance of patenting of the patent. A major benefit comes to encourage inventions of new and to withstand market competitive in the form of no fear of copying, useful manufacturers and to induce pressures as well gain an upper hand imitation and unauthorised use during inventors to disclose the secret of the terms of the patent. in the international market. What their inventions. The present Act was Highlighting the need to remains to be seen is the spread of last amended in 2006. Under this understand the benefits of patenting use of this tool to safeguard jugaadu Act, companies need to file patent by Indian companies, Nair adds, Indians innovative ideas... applications, which are examined by “There is an intense need to manage sumedha.mahorey@infomedia18.in a team of experts. If, in case, a third IP by licensing, technology transfer,

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GREEN DESIGN

ARINDAM GHOSH

nterest in implementing green design for sustainable manufacturing processes is steadily gaining momentum as part of the smart strategies adopted by companies to gain a competitive edge in the marketplace. So, what

from the market if increasingly opting Many companies are for green designs over opting for solar panels to their companies bag like conventional ones in their bring down the expenses certifications ISO9001. manufacturing process incurred on electricity. Besides, the even though the initial government is playing a major role investments costs are very high. This in terms of promoting green among is because adopting green methods companies. In one of the major in manufacturing activities not only initiatives undertaken, the government enables a company to offer quality has developed a star rating system, products at competitive prices, but also which enables companies to judge their allows it to sustain its business operation products’ energy efficiency levels. This in the marketplace. Sanjay Mantri, initiative has proved to be very effective Sales Manager (North India) as it has helped companies ensure that – OCV Reinforcements wa st their products are energy efficient. Manufacturing, Owens ag Commenting on the government’s Corning, believes stand on going green, Arun Maira, that going forward,

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With issues pertaining to sustainability and energy efficiency evolving as a major challenge in the expansion plans of manufacturing companies, adopting green has emerged as the mantra to tackle this challenge. Companies now increasingly prefer to implement green designs over conventional ones as it leads to lower emissions, conserves energy and brings down wastage levels.

exactly does the term ‘green design’ encapsulate? Green design encompasses a huge ambit and covers varied aspects pertaining to technologies, instruments, systems, solutions, raw materials, etc., which have the ability to conserve energy, generate lower levels of waste, bring down emission levels and ensure higher levels of sustainability. The benefits of adopting green designs are many and companies are

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adopting green technologies will become highly imperative to ensure sustainability.

ASSOCIATED BENEFITS & GOVERNMENT’S TAKE ON GREEN Given the multiple economic advantages that green designs offer companies, its adoption seems to have become more of a necessity rather than a trend. Moreover, manufacturers today have become highly aware of the benefits that they can reap

Member – Planning Commission, says that it is very important for the manufacturing and engineering sector. He adds that in their new plan for the industry for the next 5–10 years, the Commission has devoted an entire new section for laying guidelines to help improve the impact of the industry on the environment. The section highlights the processes industries may need to use, especially to better their technology and standards in manufacturing & production processes,


GREEN DESIGN

which will lead to lower emissions. Also, the government would support and assist smaller industries, who find it difficult to invest in green technologies. “We have laid strong emphasis on implementing green. Our focus is on the adoption and the means required for adopting green technologies faster,” Maira says.

TERI BATS FOR GREEN According to Dr RK Pachauri, Director General, TERI, adopting green technologies would play a key role “in protecting the environment and conserving natural resources”. And now, it is “a business imperative”, he adds. If conventional resources are going to be used inefficiently, then, over a period of time, business activities will suffer as the resources will get scarce. Therefore, it is essential to ensure that resources are used optimally. Commenting on how industries are taking a step in this direction, he went on to cite the example of the cement

GREEN INITIATIVES ADOPTED BY COMPANIES Companies like Panasonic and Godrej have taken a series of initiatives in developing energy-efficient equipment and products. Panasonic Panasonic aspires to become the ‘No.1 Green Innovation Company’ in the electronics industry by 2018–19. A few months ago, the company launched an eco-exhibition to showcase its wide range of environment-friendly products and ideas in four major cities, viz., Delhi, Mumbai, Bengaluru and Chennai. In one of the eco-friendly products, the company unveiled its first-ever standalone power system—the Life Innovation Container—in India, which provides off-grid areas with electricity. The container generates about 6.7 kWh of power a day and assures supply of electricity for 3–4 days even in cloudy weather conditions. Godrej Godrej has embarked on a similar mission to reduce 25% of energy consumption in product manufacturing by 2020. The company is looking at cutting down emission levels arising from its manufacturing processes by 20%. The company further aims to generate about 10% of the total power requirement to come from renewable and green sources by 2020 as well. industry in India, which “has done very well in terms of energy efficiency”.

THE GREENEST WILL SURVIVE Given the huge market potential the country offers, implementing green

designs in manufacturing will play a key role in strengthening the scope of the company to expand. But, more importantly, that expansion will be defined by strong credibility and reputation in the market.

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SWITCHGEARS MAINTENANCE

6

Ways to maintain

Efficiency and Workability Maintenance of switchgears is essential for safety, security and efficient working of industries. To ensure that switchgears perform as per the desired levels, certain maintenance procedures need to be followed and a few tests like visual inspection, humidification test, ground-fault circuit interrupter test and magnetic effect around the high voltage panel enclosure, need to be carried out at regular intervals. This, in turn, will work towards creating a safe and secure workplace. Here are six ways which can help you ensure that your switchgears remain up and running... SUPRITA ANUPAM

witchgears, the control panels used to control, protect and isolate electrical equipment, form one of the most important parts of the power system in industries. They keep the whole power system out of danger even if there is short-circuit within. However, when switchgears malfunction, the consequences are often disastrous. Any damage to the switchgear can prove to be extremely expensive. Thus, implementing an effective switchgear testing, inspection and maintenance programme is essential. Even switchgear labelled ‘maintenance free’ requires periodic testing and maintenance. Here are some tips that will ensure that your switchgears remain up and running.

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BUSHING TEST Bushings are critical components of medium and high voltage circuit breakers. Insulation tests consisting of hipot or doble test are carried out to check the isolation of ‘live’ power circuits. The test indicates the forced or unforced power system failure. Except for the infrared scanning, bushing maintenance must be conducted de-energised.

CIRCUIT BREAKER MAINTENANCE

Switchgears mainly consist of fuses, switches and circuit breakers. Whenever there is short-circuit, they automatically shut down the operation. As a result, switchgears help to isolate and protect costly electrical equipment from damage.

Circuit breakers are used as ‘intentional interruptions’ to prevent power flow during switching operations as well as during fault conditions. There are different kinds of circuit breakers, which need different kinds of inspection and maintenance tests. For instance, moulded case circuit breakers used in low voltage distribution panels need to be loaded for more than 80% of its specified value. Consequently, they need preventive maintenance followed by the overcurrent fault trip testing. High voltage circuit breakers are located in separate enclosures. While oil & air-blast breakers need to undergo contact resistance evaluation and breaker timing motion analyser along with the prevention & overcurrent trip setting test; SF6 breakers have to go under tolerance readings of gas temperature, operation counter, contact wear checking, ground paint & foundation checking and tightening of crew bolt & external terminals. Further, moisture, gas and overhaul breaks must be checked properly.

INSULATION INSPECTION

FIRE DETECTION AND ALARM SYSTEMS

This consists of a doble test, which measures the power frequency dielectric loss, DC insulation resistance and the power factor. It includes visual inspection, cleaning insulation as well as checking of the integrity of the connections further carried out by the doble test. This test ensures that the entire electric circuit is calibrated up to the desired level and the equipment performs efficiently.

Fire detection and alarm systems are external parts of switchgears. Even if the circuit breaker fails, temperature sensors within the switchgears will raise an alarm if the temperature rises above the threshold temperature. As a result, the disaster can be avoided.

ELECTRICAL PREVENTIVE PROGRAMMES (EPMs) These need to be run on a regular basis to detect the potential problems in any electrical equipment and to take corresponding corrective measures. The programme calibrates the standard value of inputs, such as current, voltage and torque, and the corresponding expected values of output finding ground-fault protection.

SHUTDOWN OPERATIONS

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suprita.anupam@infomedia18.in


MANAGEMENT THOUGHTS ON QUALITY FOR EVERY MANAGER

Inspiring Quality Quality is a crucial parameter based upon which, a company can be distinguished from another. Emphasising on the importance of quality is author Aryan Viswakarma’s book ‘Management Thoughts on Quality for Every Manager’. Embellished with creative and simple-to-understand illustrations, the book makes for an interesting read. Targeting working managers, shop floor teams and students who will be future managers & leaders, this book acts as the perfect guide, which illustrates the benefits and criticality of quality for the industry.

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uality is important to ensure competitiveness and customer satisfaction. In today’s volatile times, enterprises should keep themselves ahead of others by offering ‘superior’ products and services. Such ‘superior’ differentiation can be achieved when organisations focus on quality.

MAKING EMPLOYEES QUALITY CONSCIOUS Every nook and corner of a company should reflect quality. But to make this possible, the company needs to deal with a very important challenge—making all the organisation’s employees quality focussed while ensuring that they continue to play their own part. Quality management is an organisationwide approach to understand precisely what customers need while consistently delivering accurate solutions within the budget, thereby ensuring that the solutions are on time and cause minimum loss to society. The implementation of quality management requires commitment from all organisational members across all departments and all management levels.

practices & processes’ by offering a broader understanding of qualities and related attributes. The book also provides management thoughts of various enabling means—including creativity, goal setting, change, problem solving, inspection and customer service—which are indispensable for the success of every organisation. Most of the thoughts are described through an innovative illustration, which will help readers implement it more practically. The book is highly recommended for general reading as well as for people dealing with quality. The use of illustrations makes the thoughts more concrete and generalisations more specific and detailed. Managers can use these illustrations while making presentations and imparting training at various levels. In fact, posters of selected thoughts can be displayed at various strategic locations to further trigger employees’ thoughts on a day-to-day basis. This, in turn, can prove to be a building block for quality management in any organisation.

A UNIQUE TRIBUTE SIMPLE AND IMPRESSIVE The book, ‘Management Thoughts on Quality for Every Manager’, by Aryan Viswakarma supports this endeavour. Comprehensive, yet simple and visually impressive, the quotes mentioned in the book will have a high recall value and will appeal to both, managers as well as workers at the shop floor. The book has been written keeping in mind working managers, shop floor teams and students who will be future managers & leaders, who need to be groomed in the culture of quality. The book has high applicability value and will enrich not just their understanding of quality, but will also motivate them to practice it.

MANAGEMENT THOUGHTS The book covers over 500 excellent management thoughts and views of great intellectuals such as W Edwards Deming, Joseph Juran, Philip Crosby and Masaaki Imai, among others. It aims to help readers ‘discover the self and the organisational

This book is a unique tribute to those ‘quality gurus’ who have given our society new thoughts, ideas and concepts for its betterment. Most of the ‘quality gurus’ have been pictured on its pages. The book also contains a brief profile of 10 ‘quality gurus’. Although these represent only a small sample of the world of quality, they amply illustrate the importance of quality to our industry.

ABOUT THE REVIEWER Rajiv Mandke, a 1979 batch graduate in Mechanical Engineering from IIT Bombay, has 33 years of automotive experience. He has worked with Tata Motors and Schlumberger Kaizen Institute ACMA Centre for Technology. His core competencies include operations management, EHS compliance & audit lean tools, profit ratios improvement, employee engagement, workforce productivity problem identification & resolution, customisation & localisation strategies, TPM, TQM, TPS, machine tool building and proving. He also has 10 years of clustering experience in Indian and overseas component companies, wherein he mentored all the clusters.

This book is available at Kojo Press, 4760/61, “Sai Sarovar”, 2nd Floor, 23, Ansari Road, Daryaganj, New Delhi – 110002. Phone No: 011 23264946

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NEW LAUNCHES This section gives information about products, equipment and services available in the market. If you know what you want. . . refer to Product Index on Page 182 to find it quickly



DOOR ENTRY SYSTEM

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he BTicino D45 is a high-performance door entry system that simplifies installation in residential complexes with a large number of apartments. Th is system can install up to 4000 apartments with the signal reaching up to 2 km. It automatically equalises and amplifies the video signals, providing high quality video performance even with long distance. It is a security monitoring system using serial devices connected using DIGITAL BUS technologies. In addition to the standard functions of door entry systems, the D45 system provides new, innovative security functions.

Legrand (India) Pvt Ltd Mumbai - Maharashtra Tel: 022-30416200 Email: palash.nandy@legrand.co.in, Website: www.legrand.co.in



ELECTRIC ROOF VENTILATOR

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he electrical roof ventilator has replaced the wind ventilator. An aluminium base with a hood is fi xed on the roof with a 15” sweep electrical exhaust fan in it having a suction capacity of 4000 Cu M per hour with an rpm of 1400 per minute. The efficiency of this electrical ventilator is almost 4 times better than the wind ventilator. Theoretically @ 8 kmph wind velocity the suction capacity of a 24” wind ventilator is 2000 Cu M per hour whereas practically speaking it draws only about 1000 Cu M per hour. The electric roof ventilator is used to evacuate hot air in factories and is fitted on the roof and works at the press of a button.

Dax Engineering Chennai - Tamil Nadu Tel: 044-26385464, Mob: 09381475767 Email: daxengg@yahoo.co.in



SMART LOGIC CONTROLLER

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rouzet new Millenium3 smart logic controller has additional function and feature compared to the earlier version of Millenium3 essential. Th is has both ladder and function block diagram (FBD) programming methods. Millenium3 Smart comes with improved blue coloured screen for improved legibility. Models are available with and without display. A model comes with 2 types called compact and expandable range. It can

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expand up to 50 I/Os. A wide range of accessories can be directly connected to this Smart version. These are remote display, touch panels, temperature sensors, light sensors, bluetooth interface and STN & GSM modems.

CST Sensors India Pvt Ltd Bangalore - Karnataka Tel: 080-41132204 Email: india@cstsensors.com, Website: www.cstsensors.com



MULTI-FUNCTIONAL TOOL

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he new Dremel Trio multifunctional tool offers unparalleled style and technology. Poised for nearly any application, ie, cutting, sanding or routing. The Trio brings precise 360-degree cutting technology to users’ fi ngertips. With the help of Trio, users can tackle multiple planes and materials including wood, plastic, drywall, metal and wall tile without switching tools. Dremel Trio is a new addition to the existing Dremel portfolio. It is one-of-a-kind multi-purpose tool that allows users to cut, sand and rout with just one, versatile package. It replaces the need for tools like jigsaw, edge sander and detail router with a compact, all in one, light-weight and approachable solution.

Bosch Ltd Bengaluru - Karnataka Tel: 080-22999118 Email: boschindiafoundation@in.bosch.com, Website: www.boschindia.com



FLANGE FACER

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he electro-mechanical fl ange facer is offered for ID clamping or OD clamps or face clamping, depending upon the job requirement. The fl ange facer consists of a rotary drive unit, horizontal arm, electrical control panel & operator’s console. Powered quill mechanism is optionally offered for depth of cut setting and for boring operations. The spindle (rotary drive shaft) is supported by a pair of heavy duty taper roller bearings in the front and by a pair of ball bearings in the other end. Bearings are lubricated for life with molybdenum sulfide grease. The rotary movement ranges from 2 to 20 rpm in a step-less range through vector VFD. The spindle is made of EN-24, hardened and ground. The box type ram and the ram housing are made of high grade CI.

Shenoy Engineering Pvt Ltd Bangalore - Karnataka Tel: +91-080-28361767 Email: shenoyengg@gmail.com, Website: www.spm-india.com


NEW LAUNCHES



CUTTING TOOL

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his cutting tool Mini-V is costeffective and has high-performance grooving applications. Th is is ideal for small/medium bores featuring a new clamping system for interchangeable carbide shank tool holders and high-precision indexable inserts. Th is is available in bore diameters of 8 to 16 mm; this can accommodate various grooving routines such as square and round grooving, chamfering and as well as threading applications.

Vargus Ltd Pune - Maharashtra Mob: 09899073393 Email: mrktg@vargus.com, Website: www.vargus.com



GEAR HOBBING MACHINE

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he Premier PHA 250 gear hobbing machine is one of the fastest moving models designed specifically for the auto component and engineering industry presented in the EGB version (optional features), technologically suitable for a job shop and completely controlled through software. Technical specifications include:

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NEW LAUNCHES

maximum workpiece diameter 250 mm, maximum module 6 mm, and hob head vertical travel 245 mm.

Premier Ltd Mumbai - Maharashtra Tel: 022-61179024 Mob: 09833866265 Email: valerievaz@premier.co.in, Website: www.premier.co.in



COLD WORK TOOL STEELS

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hese steels are aimed at the manufacturing tools used in cold processing of other steels, cast irons and non-ferrous metals. These include all high-chromium class ‘D’, medium alloy-air hardening class ‘A’ alloys, water hardening ‘W’ alloys and oil hardening ’O’ alloys. These are generally used at a temperature of 200°C. High installed hardness valued and adequate ductility is characteristic of this group of steels. The application consists of stamping dies, sheet metal components, rolls for cold rolling mills, drawing tools, punches & coining tools, cutting tools, pressing tools, and shear blades.

Sandeep Enterprises Delhi Tel: 011-43360000 Email: info@sandeepenterprises.com, Website: www.sandeepenterprises.com

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NEW LAUNCHES



CAMWORKS SOFTWARE

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AMWorks® provides state-of-the-art machining capabilities that help reduce time to market without compromising on the quality. Integrated tools like VoluMill— an ultra high performance tool path engine for high-speed roughing for 2.5 & 3 axis milling operations— can dynamically manage material removal rates, thus reducing machining cycle time up to 80 per cent, and user-controllable load on the cutting tool.

Geometric Ltd Mumbai - Maharashtra Tel: 022-67056500 Email: inquiries@camworks.com, Website: www.camworks.com



LOAD WIRE SPRINGS

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ordignon, Italy offers BLACK—a range of supreme load wire springs for dies. These have been produced through the Cold-Coiling process. The maximum compression of the free length is of about 11%. These range from 16–38 mm.

PI-Tech Services New Delhi Tel: 011-26513704 Email: leonardo@bol.net.in, Website: www.pitechservices.in

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SWITCHGEARS



SAFETY SWITCHGEAR

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he PSR is a comprehensive range of safety switchgear. In addition to the basic approvals for mechanical and plant engineering, the modules are also approved for process engineering, furnaces and shipbuilding. These offer high standard for monitoring safety relevant signals. All connections are pluggable, coded, and designed as both screw or twin spring-cage connection. With their compact and space-saving design, the PSR modules offer increased isolation between input/ output and enabling/signaling current circuits. These are controlled via one/two channels with or without cross-circuiting detection.

Phoenix Contact (I) Pvt Ltd New Delhi Tel: 011-3026 2800 Email: response@phoenixcontact.co.in, Website: www.phoenixcontact.co.in



SWITCHGEARS

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he company manufactures switchgears, viz, Bakelite fuse holders in 20 A, 32 A & 63 A, in a range of 415 V, 50 Hz, 80 kA license No CM/L-8484492. Pushbutton switch

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SWITCHGEARS

units and indicator lights are available in 22.5 mm diameter with license CM/L8546791, pushbutton stations, fuse bases type FBO, LED indicator lights, industrial hooters and solid-state buzzers, CAM operated rotary switches type SC & ST, metal clad plugs & sockets type S and plugs and sockets with box.

Switch Control (India) New Delhi Tel: 011-2246 5589 Email: scidelhi@ndb.vsnl.net.in, Website: www.switchcontrolindia.in



POWER & DISTRIBUTION TRANSFORMERS

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hese are offered up to 5000 kV A. These provide low loss & magnetising current which improve the overall power factor. High conductivity EC grade annealed insulated copper wire/strip of 99.9% purity, best quality insulation material and well fabricated leak proof MS tanks and radiators are used in production.

Indian Transformers & Electricals Gurgaon – Haryana Tel: 0124-2372100 Email: info@indiantransformers.com, Website: www.indiantransformers.com

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SWITCHGEARS



AIR INSULATED SWITCHGEAR

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he FLUOKIT is modular air insulated switchgear for secondary distribution. It offers optimum and flexible switchboard confi guration for every electrical scheme with the highest safety. It has easy installation and operation, clear outline, earthing switch position can be easily checked. It is easy to upgrade as large choice of functions available for any application in distribution.

Schneider Electric India Ltd Gurgaon - Haryana Tel: 0124-3940400 Email: in-care@in.schneider-electric.com Website: www.schneider-electric.co.in



METAL-ENCLOSED SWITCHGEAR

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his metal-enclosed switchgear and control gear modular units up to 24 kV is easily adaptable to one’s specific requirements. Th is has control, monitoring and protection devices which provides protection of one’s installations, continuity of

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SWITCHGEARS

electrical supply and reduces the downtime. Th is is comprehensive and upgradable and offer a highly reliable air insulated modular units for all the MV secondary underground distribution applications.

Schneider Electric India Ltd Gurgaon - Haryana Tel: 0124-3940400 Email: in-care@in.schneider-electric.com Website: www.schneider-electric.co.in



GAS-INSULATED SWITCHGEAR

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his 8DN9 type is gas-insulated highvoltage switchgear. Th is switchgear has space-saving design, low weight, and long operating-life associated with low operating costs makes this switchgear economical. The rated frequency is 50.60Hz; rated normal current busbar are 4000 A and rated short circuit-breaking current is 50 kA.

Siemens Ltd Mumbai - Maharashtra Tel: 022-27645459 Email: kiran.paithankar@siemens.com Website: www.siemens.com

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SWITCHGEARS



SHOCK-PROOF, DURABLE SWITCHGEARS

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abricated using premium quality material, these switchgears have shock proof exterior, dimensional accuracy, durability, corrosion resistance and optimum performance. The range offered is well tested and checked by quality controllers on various quality parameters. These are a type of electrical distribution devices, which are widely used to convert incoming electrical power into several smaller circuits. These are widely demanded for superior power distribution and power monitoring and control.

Shri Dattanath Electric Works Pune - Maharashtra Mob: 09823287672 Email: sales@sdewchakan.com



MCCB AND MPCB SWITCHGEARS

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he company offers a wide range of MCCB and MPCB switchgears. These switchgears are designed by an experienced team of professionals, who are well-versed with the industrial standards that enable them to serve the clients in a better way. These items can be availed in different dimensions and models that suits

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best with the demands and requirements. The features of these switchgears are: feasible rates, durability, and precise designing.

Radiant Electricals Pune - Maharashtra Tel: 020-24497474, Mob: 9822067474 Email: radiant04@rediffmail.com



BUS DUCTS

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hese are designed to provide better connection, superior performance and more security. These come with required rating, and fault level. Designing of bus duct is to achieve required fault level, considering temperature rise, thermal rating, stress, withstand capacity and all applicable derating factors. These are up to 4000A with copper/aluminum busbar. These have busbar supported on DMC/SMC support; and busbar with heat shrinkable sleeve. These are equipped with indoor/out door duty, separate adapter at both end with space heater and earth bus.

Max switchgears Pvt Ltd Coimbatore – Tamil Nadu Mob: 09843082837 / 09444082839 Email: vijay@maxswitchgears.in/muthu@maxswitchgears.com.in Website: www.maxswitchgears.in

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MOTORS



AC MOTORS

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he housing (stator frame) of these motors is of cast iron body with coiling ribs. Rotor is of core insulated lamination with a high pressure die-cast aluminum cage. The whole rotor assembly is dynamically balanced to ensure quiet and vibration-free operation. Surface of the rotor is protected by and anti-corrosion coating.

NBE Motors Pvt Ltd Ahmedabad - Gujarat Tel: 079-22740546 Email: info@newbharat.com Website: www.newbharat.com



SERVO MOTORS

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hese servo motors are offered as energy saving solutions. Complete solutions for a whole range of machine are provided. These not only include servo motors, but also to apply energy-saving on hydraulic systems, cooling systems and heater systems. Th is makes energy saving rate much higher than the machines only with servo motors.

Enaiviv Machinery Industrial Co Ltd Tainan City - Taiwan Tel: +886-6-2544328 Email: enaivivs@ms19.hinet.net Website: www.enaiviv.com.tw



MOTOR PROTECTION RELAY

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icrocontroller based motor protection relay PD-MMPR303 uses the state-of-the-art microcontroller based measurement techniques for providing protection for motors up-to 75HP. The comprehensive protection features of the relay make it ideal for motor protection. The heart of the relay is microcontroller based reliable hardware with special algorithms to calculate the tripping time. The relay continuously monitors the three phase currents to build the thermal replica of the motor. Th is thermal replica is used to protect the motor against thermal over loads.

Prok Devices Pvt Ltd Bengaluru - Karnataka Tel: 080-26760718, Mob: 09845033226 Email: prokdvs@vsnl.com Website: www.prokdvs.com J U N E 2 0 1 2 | SEARCH - THE INDUSTRIAL SOURCEBOOK

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MOTORS



SLIPRING MOTOR STARTER

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he slipring motor starter Magnastart inducer consists of three coils wound on specially shaped steel cores. Eddy currents in these cores are reflected in the windings as impedance which is dependent on rotor frequency. Comprehensive thermal protection prevents any possibility of damage. Smooth acceleration to full speed reduces electric stress in the motors.

JSL Industries Vadodara - Gujarat Tel: 0265-3054631 Email: jyotiltd@jyoti.com, Website: www.jyoti.com



ELECTRIC MOTORS

T

he range consists of 0.12 HP to 425 HP. These have dynamically balanced rotors, corrosionresistant frames and end-bracket hardware. These have high efficient stator laminations with superior low loss CRNGO steel and are designed for 50 oC ambient temperature for entire range. These have stainless steel rating plate and six terminal constructions

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MOTORS

across the range. These have compatible AC drive & software starter range.

BCH Electric Ltd New Delhi Tel: 011-23316029/6539 Email: bilmkt@vsnl.com Website: www.bchindia.com



MOTOR PROTECTION RELAY

T

his displays various parameters, trip count and trip data on 8 digit alphanumeric display, and has separate LEDs for individual fault indication. Th is is four user programmable output relay, it’s built in self supervision & self testing feature helps maintenance. Th is provides easy operation by 5 push buttons. RS485 Port for serial communication with “MSCOM” user friendly software.

Larsen & Toubro Ltd Mumbai - Maharashtra Tel: 022-67054902 Email: karthikm@lntebg.com Website: www.lntebg.com

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INDUCTION MOTORS

L

arge space in the terminal box cable entry can be from either side. Compact square frame sizes range from 42 mm to 104 mm. The silent and reliable AC geared motors are available from 1 W to 200 W. These are also available as single- and three-phase induction motors, single-phase reversible motors, etc.

Pshtech Technology Inc Taoyvan Country - Taiwan Tel: 3-3299968 Email: pshtech@gmail.com



BRUSHLESS DC MOTORS

T

he RapidPower, EXC and E-series are fast, low vibration BLDC motors. By utilising M-8 ceramic and rare-earth neodymium magnets, the BLDC motors provide quick acceleration and consistent speed needed for applications, such as centrifuges, fans and pumps. Sealed ball bearings and reduced torque ripple from skewed magnetisation also ensure a smooth operation at any speed.

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ElectroCraft (Asia) Ltd NT - Hong Kong Tel: +852-31632250 Email: skwok@electrocraft.com, Website: www.electrocraft.com



SERVO MOTORS

A

wide range of highperformance servo motors, which include SVM, SPM, SVMA series, linear motors (LPM series) and torque motors are designed and manufactured to worldclass standards. These servo motors are used in a variety of machines, which include injection moulding machines and blow moulding machines, press punching machine, packaging machine, etc. With high reflection, low torque and low electric energy, a series of servo motors provide efficient performance to keep wide power output. With high compatibility, servo motors are available in various brands of inverters and drivers, such as Siemens, Mitsubishi, Yaskawa, Fanuc, CT, etc. For saving energy cost, servo motors which are used in injection moulding machines save 30-70 per cent electric energy.

Cheng Chang Machinery Electric Co, Ltd Taichung City - Taiwan Tel: +886-4-25624099 Email: sol.power@msa.hinet.net, Web: www.solpower.com.tw

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GENERAL PRODUCTS



UNIVERSAL GRINDING MACHINE

T

he universal grinding machine, HEW 600 mm, is used for high precision grinding of gauges dies & punches dies & punches for tool room application with an accuracy on diameter 0.002 micron. The one piece machine body is made from closed grain casting maximum grinding length 600 mm and height center 150 mm. The grinding wheel spindle is made from EN-24 material case hardened and super finished runs in the white metal bush for smooth running of grinding wheel.

Hitesh Engineering Works Wadhwan - Gujarat Tel: 02752-241926 E-mail: contact@hiteshengineering.com, Website: www.hiteshengineering.com



CYLINDRICAL GRINDING MACHINES

T

he SWIFT-500 CNC cylindrical grinding machine is designed to cater to customers’ requirements of high accuracy, productivity and reliability of performance. These cylindrical grinding machines come with Siemens 802D CNC system, 2-axis and single spindle controlled and have a specially designed heavy-duty machine bed made of single-piece close grained graded casting.

Hi-Life Machine Tools Ltd Ahmedabad - Gujarat Tel: 079-22821615, Mob: 09898083890 Email: info@hilifegroup.com, Website: www.hilifegroup.com



HEAVY DUTY LATHE MACHINE

T

he precision heavy duty lathe machine is with hardened bed. The high quality machine is reliable. The component is within close tolerance limits and is fully inter changeable and therefore, maintenance is reduced. The standard accessories include dead centre, centre adaptor, chuck plate, tool post key, change gear set, motor pulley and V-belt.

Atul Machine Tools Rajkot - Gujarat Tel: 0281-6542034 Email: info@atulmachine.com, Website: www.atulmachine.com



LYOPHILISER

T

he lyophiliser is used for pharmaceuticals, biotechnology and allied industries. Lyophilisation is the preferred drying process, for heat labile substances or where any physical, chemical or enzymic changes are detrimental to the products and its applications. Sublimation of frozen ice

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GENERAL PRODUCTS

directly in the form of vapour under high vacuum forms the basis of lyophilisation process. The system offers optimal flexibility in programming the recipe to suit a wide variety of products. The drying chamber is designed for full vacuum and overpressure of 2.5 bar. Its door has provision of view port and manual/automatic holding clamps.

Machinfabrik Mumbai - Maharashtra Tel: 022-25555596, 25560947 Email: machinfabrik@vsnl.com, Website: machinfabrik.com



PILLAR DRILLING MACHINE

T

he model SEW/P-1 pillar drilling machine is used for drilling, tapping and boring. This drilling machine has a drilling capacity of 25 mm, tapping capacity of 20 mm in mild steel and drilling capacity of 32 mm in cast iron. Quill spacers are made from steel while main spindles are made of EN steel with 6 slots. Spindle nose is MT-3, spindle speed of 8 gears is made from good quality material and helical teethed for smooth and noiseless running. The drilling machine attains standards of IS:2425. It is very useful for every toolroom and maintenance purpose.

Siddhapura Machine Tools Bhavnagar - Gujarat Tel: 0278-2445077 Email: bipin@siddpuradrills.com, Website: www.siddhapuradrills.com

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GENERAL PRODUCTS



QUICK-CHANGE PALLET MODULE

W

ith the electric version of the VERO-S NSE mini quickchange pallet modules, Schunk has made an important contribution to the electrification of machine tools. Instead of being actuated by compressed air, the technology study of the electric modules is actuated, via a torque motor, and separate engine control is no longer required. A patented drive concept provides for pull-in forces of up to 1,000 N. With a 99-mm diameter, and a 20-mm clamping pin diameter, the modules offer excellent conditions for taking full advantage in the machine room, and for direct clamping of small workpieces.

Schunk Intec India Pvt Ltd Bengaluru - Karnataka Tel: 080-40538999, Mob: 09741211766 Email: info@in.schunk.com, Website: www.schunk.com



CRATE WASHING MACHINE

T

ype CrateWash crate washing machine is especially made for cleaning of standard plastic crates. It cleans up to 100 pallets per hour and contains a separate pre-wash-zone and a

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GENERAL PRODUCTS

fi nal rinse-zone. Soiled crates to be washed are manually placed on the machine and conveyed by a chain conveyor into the wash chamber. The crates pass through high-pressure waterjet spray generated by nozzles having accurate spray angles for washing the pallets both externally and internally. Th is ensures optimum cleaning in the shortest possible timing. If needed, the crates can be washed by a detergent solution or hot water.

Flow Control Industries Mumbai - Maharashtra Tel: 022-32227296, Mob: 09833889965 Email: ludwig_vaz@rediffmail.com Website: www.flowcontrol-industries.com



WHEEL LOADER

T

he wheel loader has a payload capacity of 750 kg and transmission of heavyduty sliding mesh with 6 forward and 2 reverse speeds. Th is wheel loader comes with hydraulic brakes provided on the front wheels and mechanical brakes on the rear wheels. Some of the technical specifications include: bucket size 6 cm, maximum height 4.1 mtr, dump height 2.68 mtr, top speed 29 kmph, engine of Simpson’s S433, 4 cylinder, water-cooled, diesel engine with rated power of 49 BHP at 2200 RPM, hydrostatically operated steering wheels with 4.7 mtr turning radius, hydraulic system tandem pump with 2/3 spools control valve, electrical system 12 V, negative earth with a single heavy-duty battery, optional buckets of 0.25 cu mtr to 75 cu mtr capacity 4-in-1 multipurpose bucket, and operating weight of 5500 kg.

Action Construction Equipment Ltd New Delhi Tel: 011-40549900 Email: marketing@ace-cranes.com Website: www.ace-cranes.com



SAFETY SHOES

W

arrior range of safety shoes are crafted from genuine leather uppers and direct injection PU soles and come in 2 different types, ie, low neck and high neck (ankle) designs. These shoes are anti-skid, oil, petrol, alcohol & abrasion resistant. These are also anti-static with a tolerance range between 100 Kilo Ohms and 1000 Mega Ohms. The shoes have been given anti-bacterial & anti-fungal treatment and the soft chrome leather/non-woven inner lining absorbs sweat to keep the feet odour-free and cool. The high ankle design reduces the risk of sprains and the alloy toecaps provide protection from

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heavy falling objects up to 200 joules. Warrior has been subjected to the most stringent tests not just by FDDI (India) but also by PFI (Germany), the most reputed laboratory in Europe.

Liberty Shoes Ltd Karnal - Haryana Tel: 01748-251120 Email: warrior@libertyshoes.com, Website: www.libertyshoes.com



LINEAR VIAL WASHING MACHINE

T

he high-speed linear vial washing machine is made totally of fabricated from SS materials, including the basic frame. Th is machine is suitable for handling wash of 5 ml to 30 ml vials without changing parts. It is provided with high pressure spray nozzles which enter into the vials during washing time. The machine is equipped with safety devices to ensure smooth and silent operation with high rated out put. It has an output capacity ranging from 150 to 250 vials/minute.

Laxmi Industries Ahmedabad - Gujarat Tel: 079-22893810 Email: laxmiindustries_ad@yahoo.com

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GENERAL PRODUCTS



INTERNAL BORE/TRACK GRINDING MACHINE

T

he internal bore/track grinding machine comes with auto cycle and auto feed. The centre height of the machines is 180 mm with minimum/ maximum grinding diameter bore of 15-100 mm. Th is machine has Siemens/Fanuc CNC system. Table (Z-axis) has minimum stroke of 250 mm and speed infinitely variable of 0.1-4 m/mm. The internal grinding head features 60 x 250 mm internal grinding spindle, 18,000 RPM spindle speed, 80 mm spindle housing bore, 0-2 mm automatic grinding infeed, and 0-60 sec automatic spark off time. Workhead features are 120-500 RPM spindle speed (4 steps); 0-30-degrees swivel; and micro taper correction device provided for taper correction facility.

Hi-Life Machine Tools Ltd Ahmedabad - Gujarat Tel: 079-22821615, Mob: 09898083890 Email: info@hilifegroup.com, Website: www.hilifegroup.com



CENTRELESS GRINDING MACHINE

T

he model DG-100 centreless grinding machine’s castings are closely grained and well ribbed, minimise vibration and distortion. The wheel head spindle runs in bush bearings. The wheel spindle runs in taper roller bearing in oil bath. Stepped pulley varies the spindle speed. Wheel

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GENERAL PRODUCTS

head and work head spindle are heat-treated hardened and are ground to achieve dimensional stability and performance roundness of <0.005 mm. Optional accessories are mechanical or hydraulic dressing; work rest carbide tipped; additional wheel fl ange; grinding wheel balancing stand & arbour; and bar feeding attachment (per metre).

Devco Industries Wadhwan - Gujarat Tel: 02752-243997, Mob: 09825343097 Email: devco1980@yahoo.com, Website: www.devcogrinders.com



CONE SPRAY NOZZLE

T

his full cone spray nozzle provides a uniform spray distribution of medium to large size drops results from their vane design which features large flow passage and control characteristics. It removes fly ash and other products of combustion. The application lies in washing and rinsing processes, quenching and cooling of coke, primary metals and other materials, suppression of fugitive dust in the processing of bulk ores, coal, limestone sand and gravel.

Spraytech Systems (India) Pvt Ltd Thane - Maharashtra Tel: 022-25828929, Mob: 09987584555 Email: kharade@spraytechindia.com, Website: www.spraytechindia.com

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TOOL HOLDERS

T

hese tool holders BBT-AHO is a technologically advanced tool holder which generates high precision and influences the machining accuracy of tools to acquire better product quality in less time. These lightweight holders reduce load to the spindle resulting in improved energy efficiency. The chip removal rate increases by 20 to 50 per cent, perfect two-face contact even at high-speed rotation and high repetitive accuracy and inhibition of fretting.

Stitch Overseas Pvt Ltd Gurgaon - Haryana Tel: 0124-4755400, Mob: 09313361202 Email: stitch@vsnl.com, Website: www.stitchtools.com



TORQUE MULTIPLIERS

T

hese torque multipliers are a heavy-duty tool used to increase the torque produced by torque wrenches. They have been developed and designed to meet high torque requirements keeping in view space restrictions in torque wrench applications. Torque multipliers are used either for tightening of high tensile bolts or loosening rusty and frozen nut bolts. The use of torque multipliers reduces the manpower required as


GENERAL PRODUCTS

well as operator fatigues. These have a gear mechanism by which the torque applied on the input side is multiplied in a particular ratio.

Tulex Industrial Tools (P) Ltd Thane - Maharashtra Tel: 0251-2436207 Email: tulex@vsnl.net, Website: www.tulextools.com



LUBRICATION SYSTEMS

T

hese lubrication systems comprises of a controller or timer, a pump and reservoir, metering valves and fittings and supply and feed lines. These typically delivers a controlled amount of lubricant (either grease or oil) to multiple, specific locations on a machine while the machine is operating, at specific times from a central location. Lubrication is the process, or technique employed to reduce wear of one or both surfaces in close proximity, and moving relative to each another, by interposing a substance called lubricant between the surfaces to carry or to help carry the load (pressure generated) between the opposing surfaces.

Spraytech Systems (India) Pvt Ltd Thane - Maharashtra Tel: 022-25828929, Mob: 09987584555 Email: kharade@spraytechindia.com, Website: www.spraytechindia.com

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GENERAL PRODUCTS



SPOT DRILLS

T

hese NC spot drills along with the patented indexable carbide insert give higher efficiency by performing multiple applications. These offer increased cutting speed, long tool life, best position accuracy and reduction in cycle time. The shank diameter ranges from 5 to 20 mm and can be used in CNC lathes, CNC turning centers and machining centers for spotting, chamfering, grooving and engraving. The inserts are interchangeable having four cutting edges each.

Stitch Overseas Pvt Ltd Gurgaon - Haryana Tel: 0124-4755400, Mob: 09313361202 Email: stitch@vsnl.com, Website: www.stitchtools.com



MULTI-SPINDLE HEADS

T

hese multi-spindle heads POLYdrill are used for drilling and tapping applications. The multi-spindle heads are available in both adjustable and fi xed type centre distances. These can be equipped on all types of machines, like conventional drilling and tapping machines, machining centers or any other type of

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automatic drilling and tapping machines. Features include: equipped to deliver precisely what users need, smallest centre distances, high-spindle accuracies, customised multi-spindle heads as per requirements, compact, rigid and sturdy design, special multi-spindle heads for carbide tools, through-coolant operations can be done and optimise production cost.

Suhner India Pvt Ltd Bengaluru - Karnataka Tel: 080-27831108 Email: blroffice.in@suhner.com, Website: www.suhner.com



SOLID CARBIDE DRILL MILLS

T

hese solid carbide drill mill blood has applications in the metal removing industry. These drill mills are available in both 90-degrees and/ or 120-degrees point angle. These can be used for milling, drilling, counter sinking, grooving, chamfering, center-drilling. Moreover, it is useful on NC machines for accurate spotting.

Robin Precision Products Pvt Ltd Rajkot - Gujarat Tel: 0282-287634, Mob: 09909912010 Email: info@bloodtools.com, Website: www.bloodtools.com


GENERAL PRODUCTS



LIGHT DUTY LATHE MACHINE

T

hese precision light duty lathe machines with harden bed is of high quality and is reliable. The light duty lathe machine is suitable for mass production. The components is within close tolerance limits and are fully inter changeable. The standard accessories include dead centre, centre adaptor, chuck plate, tool post key, change gear set, motor pulley and V-belt.

Atul Machine Tools Rajkot - Gujarat Tel: 0281-6542034 Email: info@atulmachine.com, Website: www.atulmachine.com



ARC WELDING TRANSFORMER

T

he arc welding transformer VULCAN is very effective for speedy production, structural work, machine building and fabrications, fi lling jobs, wornout machine parts repair and in arc cutting jobs. Design features include: modern look, novel design concept; epoxy power coated body for long life and coil varnishing by vacuum pressurised impregnating varnishing system.

Canary Electricals Ltd Morbi - Gujarat Tel: 02822-250431 Email: info@vulcanwelding.com, Website: www.vulcanwelding.com



ROLL FORMING MACHINES

T

hese roll forming machines have features inbuilt to provide roll forming solutions for simple to critical jobs. The machines are built from prime material. Body and structure is stress relieved. It has robust design of heavy-duty steel plate body. These are heat treated alloy a roll, easy replacement of parts are also possible and is easy-to-operate. Machine is equipped with gear box, electric brake motor, push button type movable operating switch board and electric control panel for easy & safe operations. It works with 3 rolls pyramid principals. Bottom rolls are fi xed and driven by gears and warm reduction gear box. Top roll rotates in fi xed positions and can be adjusted up & down manually by adjustable screws.

Godson Bending Systems Pvt Ltd Rajkot - Gujarat Tel: 0281-2361467, Mob: 09879079267 Email: godsonindia@hotmail.com Website: www.godson-india.com

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GENERAL PRODUCTS



HYDRAULIC GUILLOTINE SHEARS

T

hese are high-performance hydraulic guillotine shears for requirements of high-precision sheet metal cutting for small and high volume production setups for sheet thicknesses ranging from 0.6 to 25 mm and the length up to 6000 mm.

Kawa Press Systems Pvt Ltd Rajkot - Gujarat Tel: 0281-2461102, Mob: 09825389169 Email: info@shaileshmachines.com, Website: www.shaileshmachines.com



ROLL TURNING LATHE MACHINE

T

he roll turning lathe machine is rigidly designed and suitable for heavy jobs. Th is lathe machine combines all the features which are expected in roll turning lathe machine with great efficiency and is ideal for all sliding, surfacing and screw cutting operation.

Premier Lathe Manufacturing Co Rajkot - Gujarat Tel: 0281-2387556 Email: info@premierlathe.co.in, Website: www.premierlathe.co.in



TESTING SYSTEM

T

his testing system ZWL 9200 adopts the advanced fast spectrum analysis system and has powerful in-built power supply with external power supply. It can accurately test the optical colour and electric parameter for LED luminaries, modules and lamps in short time. Th is is applicable for various kinds of lamps, different fi xtures and is made compatible for LED testing also.

Agate & Agate Marketing Resources (India) Pvt Ltd Pune - Maharashtra Tel: 020-25469864 Email: aaresources@vsnl.com, Website: www.smt-india.com



BOUNDARY SCAN TECHNIQUE

T

he boundary scan technique is the resourceful test access technique. This is similar to in-circuit test, but without physical bed-of-nail adapters, it detects structural fault locations by utilising thousands of test points â&#x20AC;&#x201C; with only four test bus lines.

SLN Technologies Pvt Ltd Bengaluru - Karnataka Tel: 080-26651659 Email: drs@slntechnologies.com, Website: www.slntechnologies.com J U N E 2 0 1 2 | SEARCH - THE INDUSTRIAL SOURCEBOOK

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GENERAL PRODUCTS



SOLAR POWER PACKS

T

hese solar power packs are clean, silent and eco-friendly source of power. These provide power in the range of 1 kWp to 10 kWp. The solar modules convert sunlight into electricity and store it in batteries. It has simple installation which can be mounted on the ground or rooftop. The applications are in lies in farmhouses, fuel pump stations, guest houses, hospitals, hotels, internet centres, laboratories, R&D centres, residential colonies, software development centres, transmission and communication towers.

El Sol Energy Systems Ahmedabad - Gujarat Mob: 9558824681 Email: info@elsolenergysystems.com, Website: www.elsolenergysystems.com



HEAVY-DUTY LATHE MACHINE

T

his extra heavy-duty lathe machine VEH is offered with height of centre up to 1066 mm, length of bed ranging up to 12000 mm, between centres up to 11000 mm, main spindle hollow ranging 150 mm and main spindle nose is A2-12 type. Dynamically balanced spindle enable the

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spindle run at vibration free motion. The spindle carries the 10 T job weight. The norton gear box is able to cut the any of metric, modules and pitch. The bed is made from graded cast iron. Also offered are face plate, carrier plate, steady rest, follow rest, motorised coolant pump with tank and fittings, rear tool post, quick change tool post. The machine is maintenance free and is easy to use.

Vinit Engineering Works Rajkot - Gujarat Tel: 0281-2311734 ,09879022052 Email: vinit@balajilathe.com, Website: www.balajilathe.com



HYDRAULIC PRESSES

T

hese are C-type foot-operated hydraulic presses ranges from 15 to 25 tonne capacity. The rigid and sturdy welded steel frame is without bend. The cylinder is made from honed tube and the hard chrome plated ram is made from mild steel and operated by singleacting cylinder. The good quality seals assure long working life.

Dowel Engineering Works Rajkot - Gujarat Tel: 0281-2362465, Mob: 09824231975 Email: dowel@thedowel.com Website: www.thedowel.com


GENERAL PRODUCTS



PNEUMATIC PRESS BRAKE

T

his pneumatic press brake capacity ranges from capacity 20 to 350 tonne and length is 1525 to 4000 mm. These machines are widely accepted in industries for continuous production runs and also in areas requiring accuracy and repeatability coupled with high production. Th is machine fi nd application in steel furniture industries, door frame & slotted angle, refrigeration, door frame manufacturers etc.

Weldor Engineering Pvt Ltd Rajkot - Gujarat Tel: 0281-2360242 Email: weldor@weldor.com, Website: www.weldor.com



HYDRAULIC PARKING LIFT

T

his hydraulic parking lift can be used for Sedan & SUV. It moves horizontally, so the user has to clear the ground level to get higher level car down. It is hydraulic driven that lifts directly by hydraulics cylinders. The lifting capacity is 2000 kg, lifting height is 2140 and it can be used for car width up to 2000 mm.

Shiromani Hydraulics Pvt Ltd Ahmedabad - Gujarat Tel: 079 - 65121548, Email: info@shiromanihydraulics.com

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INTERNATIONAL PRODUCTS



AUTOMATIC CUTTERS

T

he model MMC-100 automatic cutter offers a wide range of industrial cutting applications. Designed to cleanly cut a wide variety of materials, it processes round or fl at material up to 3.94 inches wide and .63 inches thick (100 mm wide and 16 mm thick). With a maximum cutting force of 600 pounds, the MMC100 cut a virtually limitless range of materials, including copper wire and cable, silver solder, power cords, cellophane, fiberglass sleeving, latex, fabrics, belting, fl at and ribbon cable, strapping, hosing and tubing. Programmable for up to 10 batches and three fi xed feed rates, the MMC100 is rated to cut up to 7,200, four-inch pieces per hour.

The Eraser Company Inc New York - USA Tel: +1-315-4543237 Email: info@eraser.com, Website: www.eraser.com



VIBRATION LEVEL LIMIT SWITCH

V

ibranivo vibration level limit switch (model VN-1000) is used for level monitoring in all types of containers and silos. Th is limit switch is used with all powdery and granulated bulk materials that do not show a strong propensity to form crusts or deposits. It is delivered with ATEX approval for use in hazardous areas. A selection of fields of application includes industry of building materials, food industry, plastics industry, timber industry, chemical industry, and mechanical engineering. The Vibranivo oscillating probe is normally screwed into the lateral container wall so that it is level with the fi lling height to be registered and monitored.

UWT GmbH Germany Tel: +49-831-5712328 Email: eva.konzelmann@uwt.de, Website: www.uwt.de



MAGNETIC SEPARATORS

D

esigned for use on compact sieves, the 316L stainless steel magnetic separators help ensure food and pharmaceuticals remain free from ferrous contaminants. Particles are attracted to and securely held on bars which can be wiped clean between batches. Number and placement of bars promote balanced coverage of open space and magnetic field strength without restricting throughput.

Russell Finex Inc North Carolina - USA Tel: +1-704-5889808 Email: sales@russellfinexinc.com, Website: www.russellfinex.com

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HYDRAULIC FLUID POWER PRODUCTS

A

wide range of high quality DC/AC hydraulic power units and hydraulic power packs are available. These are used in the material handling industry, mobile hydraulic industry and construction engineering equipment industry.

Kiss Machinery Co Ltd Taichung - Taiwan Tel: +886-4-23920237 Email: tom0184@pchome.com.tw, Website: www.kissmachinery.com



CLOSURE SOLUTIONS

T

hese are highly specialised singlepiece closure solutions for CSD, water and soft drinks for PET bottles. The range includes the development of new cap concepts, manufacturing of moulds, production of caps and application of the cap

on the bottle.

Corvaglia Group Eschlikon - Switzerland Tel: +41-71-9737777 Email: m.buff@corvaglia.ch, Website: www.corvaglia.ch



CUTTING & BORING SYSTEMS

T

he cutting & boring system series of cutting tools features excellent dynamic balance up to G2.5. For eg, a BT40, H•BOR50P tungsten carbide arbour with MR or MK cutting insert holder, tool ranges from Ø11 mm to Ø32 mm, spindle speed of 12000 RPM, the boring diameter/depth ratio can be 1:7.

Stanny Machine Tools Co Ltd Taiwan Tel: +886-4-26710805 Email: stanny88@ms45.hinet.net,Website: www.stanny-tool.com



HOT-MELT APPLICATION SYSTEM

T

hermopulse hot-melt application system (series 970) is a highperformance, trouble-free, industrial quality system available with features not previously available except at much higher cost. Compact and ruggedly constructed, an adjustable pressure pulsation free pump, supplies molten adhesive to either a handgun applicator, or one of several types of electromatic automatic applicator heads. Sophisticated electronic solid-state circuitry controls temperature,


INTERNATIONAL PRODUCTS

at three different zones, with an accuracy of Âą1 per cent. All heater circuits are individually fused.

Spraymation Inc Florida - USA Tel: +1-954-4849700 Email: sales@spraymation.com, Website: www.spraymation.com



MULTI-FUNCTION MEASURING INSTRUMENTS

T

he model Testo 435-1 multi-function measuring instrument is used for ambient air conditioning, for assessing indoor air quality and adjusting & inspecting VAC systems. Th is instrument is an affordable introduction to measurement engineering for ambient air conditions. The new IAQ probe measures indoor air quality by measuring CO2 level, air moisture and air temperature. Temperature and humidity measurement is integrated in the new thermal probe. In addition, it is also possible to connect additional temperature probes. Readings from up to 3 temperature probes can be displayed in the clearly laid-out measuring instrument display; data transmission is radio-controlled, therefore wireless. Measurement data is printed onsite on the Testo printer.

Testo AG Germany Tel: +49-7653-681700 Email: vertrieb@testo.de, Website: www.testo.de

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INTERNATIONAL PRODUCTS



VERTICAL MACHINING CENTRE

T

he new robust Ganesh VFM 4020 Express high-performance vertical machining center has table measuring 40” x 23” and weighs over 6 ton. Th is machining centre features cross-roller linear ways to dampen cutting vibration for superior surface fi nish and improved tool life. With pre-tensioned double-anchored ball screws and 40 block look-ahead in the Fanuc OiMD control the machining centre is designed to generate precise programmed feature defi nition. The 20-HP direct-drive spindle supplies spindle speeds up to 15,000 rpm. Axis moves are X=40”, Y=23”, and Z=23”. Up to 40-tools are available with the #40-taper ATC. Both an indexer and a full 4th axis rotary and 5-axis trunnion table are also available.

Ganesh Machinery Inc California - USA Tel: 818-3499166, Mob: 18186310762 Email: sales@ganeshmachinery.com, Website: www.ganeshmachinery.com



MOTION PROCESSOR

M

agellan family of motion processor is available with real-time servo trace capture. Th is advanced trace capability improves servo-tuning performance, optimises

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motion trajectories and can be used to capture time sensitive data. Available in 1, 2, 3 and 4 axis versions, these intelligent motion ICs control DC brush, brushless DC, micro stepping, and pulse and direction motors. The advanced trace feature allows up to four motion variables to be stored at the same time and each variable can be either 16 or 32 bits in size. Twenty-eight separate parameters can be selected for trace, such as position, velocity, acceleration, servo lag and much more.

Performance Motion Devices Inc Massachusetts - USA Tel: +1-781-6749860 Email: motion-control@pmdcorp.com Website: www.pmdcorp.com



ATMOSPHERIC PRE-ALIGNER

A

dept Align 650 from is an atmospheric pre-aligner designed for water handling front-end applications. Perfect for bridge tools, this pre-aligner automatically detects wafer sizes without user intervention. It employs a three-axis mechanism, which accepts wafers from either fork or blade type and effectors. High-speed wafer alignment is accomplished in 4 seconds. Alignment accuracy in the X-Y plane is 0.05 mm and the rotational error is less than 0.05 degrees. The atmospheric pre-aligner has compact footprint, integrated controller and employ full-featured


INTERNATIONAL PRODUCTS

RS-232/485 ASCII command set. Features include automatic identification of wafer size, wafer present detector, compact footprint, integrated controls, etc.

Adept Technology Inc USA Tel: 1-925-2453400 Email: info@adept.com Website: www.adept.com



CAST FILM LINES

T

hese are available with 4.6 m slot die for thin PP fi lms. The lines for production of three-layer PP cast fi lms have three extruders: one extruder of 180 mm screw diameter, 30 L/D and two co-extruders of 90 mm screw diameter, 30 L/D. The slot dies have widths up to 4,600 mm.

Reifenhauser Extrusion GmbH & Co KG Troisdorf Tel: +49-2241-4810 Email: info@reifenhauser.com Website: www.reifenhauser.com



NEEDLE ROLLER BEARINGS

T

hese shell-type open end 1-inch needle roller bearings features extremely highspeed, high load capacity, low profi le, lightweight caged, caged needle bearings up to 3x the speed of uncaged designs, extremely low rolling friction, high lubrication capacity, low sensitivity to misalignment and needles have high length to diameter ratios.

Quality Bearings & Components New York - USA Tel: +1-516-6160436 Email: qbcsupport@qbcbearings.com Website: www.qbcbearings.com



MICRO INJECTION MACHINES

A

new competitive advantage to the micro-injection industry, via its Atom series precision plunger injection moulding machine is available. The production speed of Atom injection machines is several times faster than micro injection machines. Weight of the runner is dramatically reduced by a combination design method. These machines are offered with new design without a sprue intended on 0.0001g micro injection products.

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INTERNATIONAL PRODUCTS

Edex Technology Co Ltd New Taipei City - Taiwan Tel: +886-2-22819918 Email: yescan@edex.com.tw Website: www.edex.com.tw



THERMOPLASTIC ELASTOMERS

T

he Everlon compounds are highperformance thermoplastic elastomers designed specifically for the production of moulded and extruded products on conventional thermoplastic processing equipment. These do not require vulcanisation. These can be seen in numerous processing techniques in which they are used. In the processes, Everlon scrap can be recycled without loss of its physical properties.

Ever Polymer Co Ltd Taoyvan Country - Taiwan Tel: +886-3-3125717 Email: everlon@everlon.com.tw, Website: www.everlon.com.tw The information published in this section is as per the details furnished by the respective manufacturer/distributor. In any case, it does not represent the views of

SEARCH

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EVENT LIST

v

NATIONAL

ABROAD

8-10 JUNE 2012

14-18 June 2012

21-24 June 2012

TECHNO4 Focus: Medium & light engineering Where: CODISSIA Trade Fair Complex, Hall E Coimbatore Tel: 0422 2220014, 4216020 Fax: 0422 2223076 E-mail: techno4@siema.org

ACMEE 2012 Focus: Manufacturing technology Where: Chennai Trade Centre, Chennai Tel: 044 26258619 Fax: 044 26520814 E-mail: info@acmee.in

MANUFACTURING EXPO 2012 Focus: Manufacturing technology Where: BITEC, Bangkok, Thailand Tel: 66 26867222 Fax: 66 2 6867266 E-mail: contactcenter@reedtradex.co.th

v

NATIONAL

ABROAD

5-8 July 2012

27-30 July 2012

10-12 July 2012

AUTOMOBILE WORLD SHOW Focus: Automobile Where: University Ground, Ahmedabad, Gujarat Tel: 079 26469725, 26460624 Fax: 079 26403087

8TH AMTEX 2012 Focus: Machine tools Where: Pragati Maidan, New Delhi Tel: 080 43307474 Mob: 098867 89641 Fax: 080 22352772 E-mail: info@triuneexhibitors.com

ROBOTICS ASIA 2012 Focus: Robotics & automation Where: Putra World Trade Centre, Kuala Lumpur Tel: 603 61406666 Fax: 603 61408833 E-mail: kelly@protempgroup.com

v

NATIONAL

ABROAD

16-18 AUGUST 2012

2-5 August 2012

22-24 August 2012

ENERGEXâ&#x20AC;&#x2122;12 Focus: Energy equipment & heavy fabrication Where: Vestry School, Trichy, Tamil Nadu Tel: 0431 2410641 Fax: 0431 2410656 E-mail: arun.roberts@cii.in

QINGDAO MACHINE TOOLS & MOULDS EXHIBITION Focus: Tools & tooling equipment Where: Qingdao International Convention & Exhibition Centre, Qingdao, China Tel: 86 0532 55552936 Fax: 86 532 55552903

SHANGHAI INTERNATIONAL ASSEMBLY AND HANDLING TECHNOLOGY EXPOSITION Focus: Automotive manufacturing Where: Shanghai New International Expo Centre (SNIEC), Shanghai, China Tel: 86 21 64681300 / 86 21 64681550 Fax: 86 21 34160018 E-mail: info@for-expo.com


EVENT LIST

v

NATIONAL

ABROAD

7-10 September 2012

27-30 September 2012

10-15 September 2012

AUTOMATION 2012 Focus: Industrial & factory automation Where: Bombay Exhibition Centre, Mumbai Mob: 9819872165 E-mail: arokiaswamy@iedcommunications.com

INDIA MANUFACTURING SHOW 2012 Focus: Manufacturing and engineering industry Where: Hall 1 & 2, Bangalore International Exhibition Centre, Bengaluru Mob: 91 98440 68250 E-mail: raghu@ims2012.in

INTERNATIONAL MANUFACTURING TECHNOLOGY SHOW (IMTS) Focus: Manufacturing technology Where: McCormick Place, Chicago Tel: 800 8287469 Fax: 703 8275250 E-mail: peelman@AMTonline.org

v

NATIONAL

4-6 October 2012 INDIA STEEL 2012 Focus: Technology, machinery & equipment in the steel industry Where: Bombay Exhibition Centre, Mumbai Mob: 91 9899392930 Email: kamal@ficci.com

ABROAD

30 October 1 November 2012

3-5 October 2012 POWER-GEN ASIA Focus: Power generation Where: Impact Exhibition & Convention Centre, Bangkok, Thailand Tel: 44 1992656634 E-mail: mathildes@pennwell.com

WIRE & CABLE INDIA 2012 Focus: Developments in wire & cable Where: Bombay Exhibition Centre, Mumbai Tel: 91 011 2697 1745/1056 66 E-mail: sawhneyr@md-india.com

v

NATIONAL

ABROAD

1-5 November 2012

21-24 November 2012

ENGINEERING EVOLUTION Focus: Industrial Machinery Where: Ahmedabad Education Society Grounds, Ahmedabad, Gujarat Tel: 079 40092078 Fax: 079 25895904 E-mail: admin@andestrade.in

INDUSTRIAL AUTOMATION INDIA 2012 Focus: Industrial Automation Application Where: India Expo Center, Greater Noida, India Tel: 022 40050681 Fax: 022 40050683 E-mail: tushar.alekar@hmf-india.com

AHMEDABAD October 5-8, 2012

PUNE November 2-5, 2012

INDORE January 11-14, 2013

21-24 November 2012 EMAF EXPO 2012 Focus: Industrial Tools & Machinery Where: Feira International do Porto, Portugal Tel: 351 229981472 Fax: 351 213826734 E-mail: fernando.reilima@exponor.pt

CHENNAI November 22-25, 2012

AURANGABAD February 1-4, 2013

LUDHIANA December 21-24, 2012

RUDRAPUR February 23-26, 2013

Tel: 022-30034651 • E-mail: engexpo@infomedia18.in • Web: www.engg-expo.com


F&S GREEN MANUFACTURING EXCELLENCE AWARDS 2012

Riding High on Green Manufacturing Green manufacturing is the latest trend doing the rounds of the manufacturing industry. The adverse impact that industrialisation has had on the environment compelled industrial players to explore options beyond the traditional manufacturing methods. Some of these best practices were discussed during the ‘Green Manufacturing Summit and Awards’, recently organised by Frost & Sullivan in Mumbai. The event, with SEARCH as its media partner, saw some insightful presentations by the who’s who of the industry. A report… NISHI RATH & PRATEEK SUR

eld in Mumbai on material conservation and recycling, recycling, reusing and recovering. April 27, 2012, Frost & impact on biodiversity & society, Apart from this, we are also working Sullivan’s Manufacturing occupational health and safety & green towards reducing per capita water Summit focussed on supply chain. consumption and material waste. We The best practices shortlisted for green manufacturing institutionalise sustainability in L&T.” knowledge sharing at the summit and the best practices to be adopted To this, Sharma adds, “It is all were that of HUL; Titan Industries by the industry. The summit proved about the commitment of the top Ltd’s Jewellery & Watch Division; to be an ideal platform for networking, management apart from educating ACC Ltd’s Sindri Cement Works, knowledge exchange and highlighted employees.” The changing trends Thondebhavi Cement Works, Lakheri some of the best green practices suggest that not only manufacturers, Cement Works and Clique Solar; adopted across the manufacturing but even the customers are inclined Larsen & Toubro (L&T) Ltd; India industry. It also witnessed an exchange towards green manufacturing these Glycols Ltd; Rashtriya Ispat Nigam of knowledge on best green practices, days. “The new-age customers Ltd; Kansai Nerolac Paints Ltd; and new trends and future challenges by understand the importance of green Promed Exports Pvt Ltd. industry stalwarts and discussed the manufacturing and so, adopting green constraints & ways to overcome the practices enhances the brand image as THE INDUSTRY GOING GREEN same while deploying these innovative well,” informed Sanjeev Gurwara, VP The green manufacturing practices are practices. “The Indian companies are – Marketing, India Glycols Ltd. still at a nascent stage in terms of technology adoption and have And The Green Manufacturing Excellence Awards 2012 Goes To… a long way to go as compared Hindustan Unilever Ltd Silvassa Overall Leaders to their global counterparts. The Rashtriya Ispat Nigam Ltd Visakhapatnam Steel Plant Overall Leaders – 1st Runner Up key evaluation criteria driving the ACC Ltd, Wadi Cement Wadi Leaders – Large Business adoption of green technologies Works, Plant II are the return on investment and Hindustan Unilever Ltd Haldia Leaders – Medium Business the regulatory requirements. A ACC Ltd, Lakheri Cement Lakheri Leaders – Medium Business positive development noted is Works that few companies are chalking GETTING FUTURE READY been increasingly adopted by the major out long term sustainability plans Improving efficiency is important industrial players in India. and have modified their day-to-day but that cannot be achieved on a Elaborating on the same, Munish activities, keeping in mind the effect on standalone basis. Instead, to emerge Nandwani, Factory Manager, the environment,” said Nitin Kalothia, as winners, companies these days Hindustan Unilever Ltd (HUL), said, Associate Director – Manufacturing & need to understand various other “Sustainability is the key to success Process Consulting Practice, Frost & aspects as well, especially environment as it fuels innovation, drives market Sullivan, South Asia & Middle East. related issues. The need of the hour development, besides saving costs as EVENT IN A NUTSHELL is to broaden the approach towards well. In short, sustainability looks at Some of the green manufacturing sustainability, which is not limited overall growth of a business.” practices, highlighted during the to energy consumption and carbon Alok Sharma, Head – Corporate summit included energy efficiency emissions. And these events really help Sustainability, Larsen & Toubro said, and conservation, water & waste in creating awareness about various “We, at L&T, believe in following management, emission control, such aspects. some of the basics like reducing,

H

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ACMEE 2012

Harnessing the potential of the South Echoing positive demand and growing opportunities for machine tools manufacturers, the 10th edition of ACMEE 2012, with SEARCH as its media partner, will be held during June 14–18, 2012, at the Chennai Trade Centre, Chennai. The international machine tools exhibition, which is coming up with the theme ‘Opportunity for Growth’ this year, promises to be one-stop source for manufacturing solutions. A report... SUPRITA ANUPAM

ith abundance of raw materials, port connectivity, good infrastructure and a favourable industrial climate, South India has been the ‘promised land’ as far as industrial development is concerned. In a bid to capitalise on the potential of the south, Ambattur Industrial Estate Manufacturers Association (AIEMA) and AIEMA Technology Centre will be organising the biggest exhibition on manufacturing technology, the 10 th International Machine Tools Exhibition, ACMEE 2012, at the Chennai Trade Centre, Chennai, during June 14–18, 2012.

W

OFFERINGS IN STORE…

VITAL STATS ACMEE 12 Venue Chennai Trade Centre Date: June 14–18, 2012 Spread over 17,500 sqm

440 participants and counting... A FRUITFUL ASSOCIATION Over the years, ACMEE has registered exponential growth in terms of the number of participants as well as visitors, which is turning ACMEE 2012 into one of the most important machine tools exhibitions in South Asia. “ACMEE 2010 had 428 participants, including 100 from overseas. The event was graced by more than 40,000 business visitors. At the end of the event, over

The display profile indicated by them gives a very interesting picture of the latest in manufacturing. Surely, ACMEE 2012 will be the best venue for anyone interested in the latest developments on the production process,” Robert says. GrindMaster Machine Pvt Ltd has had a fruitful association with ACMEE, as a participant, for years. “We have been showcasing our products at ACMEE for the past several years,” says Mohini Kelkar, MD, Grind Master Machine Pvt Ltd, adding, “The best part about this event is that since it is very well publicised, visitors throng the venue from the entire south region.”

THE CHENNAI FACTOR

Reflecting the right enthusiasm of Chennai, also called the ‘Detroit of India Inc, ACMEE 2012 will harness India’, is the second largest industrial the potential of the south city in the country. The with envious business city is the hub of ancillary ACMEE 2012 will be a one-point venue for deals. The event will engineering units in India understanding the latest in manufacturing offer a single platform and takes immense pride technology. As organisers, we hope that exhibitors will meet the right customers and visitors will be for exhibitors to interact in having one of the able to source the latest in manufacturing with prospective clients largest harbours, besides technology available anywhere in the world. among other visitors an international airport. MV Robert, Chairman, ACMEE 2012 and will showcase the All these factors make latest in manufacturing Chennai a favourable 95% participants indicated that technology. location for organising such an their participation was successful,” Elaborating on the same, MV event. Kelkar avers, “Chennai has Robert reminisces. And this year, Robert, Chairman, ACMEE, shown tremendous industrial growth, the response will be overwhelming. informs, “Technology upgradation is particularly in the automotive sector. “ACMEE 2012 already has 440 a continuous process. Every day, new So, we are expecting a good response participants—including 125 from machine tools, systems, technologies this time as well.” overseas—from 30 countries. and procedures are being introduced With state-of-the-art technologies Exhibitors from South Korea and to achieve perfection, save time and to lure customers and visitors, Taiwan will be showcasing their latest reduce costs. ACMEE 2012 will ACMEE promises to be a one-stop focus on the latest in manufacturing technologies and equipment. The list shop for manufacturing solutions. technology and will showcase the latest of participants would be the who’s suprita.anupam@infomedia18.in in all these aspects.” who of the manufacturing industry.

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PRODUCT INDEX Looking For A Specific Product? Searching and sourcing products were never so easy. Just type SRCH (space) Product Name and send it to 51818

eg. SRCH Pump and send it to 51818 Product

PPg No

Abrasive 150 AC drive 144, 162 AC gear motor 4 AC motor 65, 137, 144, 162 AC servo motor 4, 81 AC variable frequency drive 139 AC/ DC panel 107 Accessories 6 ACCLs 111 Acoustic enclosure 153 Actuators 134, 152 Advance engineering plastic 149 Agitator seals 82 Air insulated switchgear 129 Air-operated diaphragm pumps 126 All geared planning machine 155 Alu-cera polymer 5 Aluma coat 5 Aluminium oxide ceramic composite 5 Aluminium worm geared motors 128 Analog DC drive 20 Annunciator 22 Appliance switches 21 Arc welding transformer 162 Assembly automation 143 Assembly line 143 Automatic back spot facing tool 152 Automatic rolling shutter 19 Automation 12, 150, 189 Automation controllers 122 Automation system 20 Automotive belts 155 Auxilary equipments 144 Ball bearing 117, 124, 160, 191 160 Ball screws Bars 141 Battery charger 20 Battery operated pallet trucks 101 Bearing 37, 117, 124, 157, 160, 166 Belts 155 Billet shearing machines 14 Boilers 170 Bollards 19 Boring machine 155 Boundary scan technique 163 Brake moter 65, 99, 163 Broaching machines 186 Brushless DC motors 142 Building automation 189 Bulk bag fillers 175 Bus ducts 134 Bushes 160 Cable 111 Cable carrier 166 Cable conduits 21 Cable connector 166 Cable gland 53; 109; 159; 163 Cage mill dryer 64 CAM followers 138 CAM works software 124 Cast & extruded products 129 Castor 141 CED coating machines 189 Centreless grinding machine 127, 155

182

Product

Pg No

Centrifugal fans 24 Centrifugal pumps 35 Ceramic 5 Ceramic adhesive cement 5 Ceramic electrical heater parts 5 Ceramic processing furnaces 144 CFT 130 Chain 166 Chain conveyor 143 Chain electric hoist 167 Chain hoist 123 Chain pulley block 116, 167 Cheese head slotted screw 113 Chemlok coating machines 189 Chiller 130 Chrome bars/ shafts 141 CI casting 155 Cleaning equipment 185 Cleated belt 169 Clorine gas cylinder /tonner 142 CNC 17, BIC CNC cutting machines 189 CNC cylindrical external grinding machine 127 CNC external grinding machine 127 CNC hydraulic turret punch press 171 CNC internal grinding machine 127 CNC laser cutting machines 189 25 CNC lathes CNC machines BIC CNC oxyfuel cutting machines 189 CNC plasma cutting machine 171, 189 CNC press brake 171 CNC synchro press brake 171 CNC turning centre BIC CNC vertical machining centre BIC Coating machines 189 Coating plants 189 Coating systems 189 Cold storage dockhouse 19 Cold storage door 19 Cold work tool steels 123 Combination screw 113 Component handing system 143 Conceptline wall mounted enclosure 45 Cone spray nozzle 156 Connector 6, 87, 166 Construction electric hoists 91 Consumer automation system 143 Contactors 111 Container pumps 126 Control cabinet 87 Control damper 152 Control panel 87 Control panel accessories 21 Control system 87 Controller 94 Conventional precision lathes 25 Converter planomiller 152 Conveyor 141, 143 Conveyor accessories 169 Conveyor belt system 169 Conveyor belts 155 Conveyor chains 18 Conveyors and automation systems 19

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Product

Pg No

Cooling tower motors 128 Corrosion preventives 121 Counter 22 Counter balanced pallet trucks 101 Counter current spray dryer 64 Crab assembly 175 Crab hoist 116 Crane 91, 116, 136, 175 Crane duty motor 65, 116, 128 Crane kits 175 Crane technology 123 Crate washing machine 149 Cross connection accessories 6 CSK screw 113 Cushion dock shelters 19 Cutting machines 189 Cutting tool 121 Cylindrical grinding machine 145 Damper 134, 152 DC drive 144, 162 DC motor 65, 144, 162 Diaphragms 167 Didactic equipment for training 87 Digital DC drive 20 Digital panel meters 183 Digital temperature controllers 183 Dip spin coating machines 189 Distrubution board 8 Dock levellers 19 Dock shelters 19 Door - PVC flap 19 Door - PVC strip 19 Door entry system 120 Dosing pump 94 175 Double girder EOT crane DR drives products 135 Drill machine 145 Drives 23, 122, 144, 162 Drum pumps 126 Dry van pump 153 Duplex deburring tools 152 Dynamic braking resistor 156 Electric actuators 154 Electric forklift truck 19 Electric motors 135, 138 Electric roof ventilator 120 Electric wire rope hoist 91, 116, 126, 175 Electrical actuator 134 Electrical CAD/ CAE software 71 Electrical control panel 20 Electrical measuring instruments 107 Electrical product 53, 109, 139, 159, 163 Electronic connectors 183 Electronic dosing pump 94 Electronic process controls instruments 133 Electronic timer 22, 26-32, 183 Electropnematic positioner 121 Element shrink disc 138 ELMCBs 173 Emergency safety kit 142 End carriage 123 End carriage assembly 175 End clap/shop 6 End plate 6


PRODUCT INDEX Product

Pg No

Energy efficient motors 128 Energy meter 22, 183 Energy saving gas burners 144 Engine & transmission assembly 143 Engineering class chains and sprockets 18 Engineering plastic plug & socket 26, 32 Enginnering plastics 129 EOT crane 91, 116, 126, 167 EOT jib crane 136 Evaporator 64 Exhibition - Automach 2013 140 Exhibition - GIM Expo 2012 158 Extended trolley 175 Factory automation system 189 Fail safe assembly system 143 171 Fibre laser marker Financial institute 73 Fire damper 134 Fire shutter 19 Fixed mounting hoist 175 Flame proof motors 65, 128 Flange facer machine 120, 152 Flange mounting b5/b35 motor 65 Flash dryer 64 Flat belt conveyor 143 Flat high tension single-twin igniting electrodes 5 Flexi panel 46 Flexible roller conveyor 143 Flexible screw conveyor 175 164 Floor heating mats Floor plate 155 Flow meters 126

Product

Pg No

Fluidised bed coating machines 189 Fluro polymer 149 FMCG & auto component 143 Force actuation system 125 Forging press 14 Forging system 6 Forklift truck 179 Free flow conveyor 143 Freewheel-oneway-clutches 138 Frequency meters 107 Friction drop hammers 14 Friction screw press 14 Fuel storage 151 Furnances 144 Gantry crane 116, 136, 175 Gap frame press 146 Gas chloronical gravity & vaccume feed 142 Gas springs 67 Gas-insulated switchgear 130 Gaskets 167 Gear box 126, 128 Gear hobbing machine 121, 131 Gear motor 116, 126, 114, 162 Genral engineering plastic 149 Glass & tobacco 143 Glass processing furnaces 144 Glide coating machines 189 Glide wheels 141 Goliath crane 91, 116 Gomet bearings 191 Goods lift 136 Grab buckets 91 Green Manufacturing Excellence Summit 2012 54

Product

Pg No

Grinding machine 127 Grinding media 5 Group marker holder 6 Growth capital & equity assistance for MSMEs 73 Guide rods 141 Hammers 14 Hand roll marking machine 147 Handling system module 87 Hard chrome plating bars 141 Healthcare system 143 Heat exchangers 170 Heat shrink tubing system 53, 109, 159, 163 Heat transfer equipments 24 Heat treatment salts 121 Heaters 146 Heating element 174 Heating equipment 170 Heavy-duty bearing 144 Heavy-duty CNC 163 Heavy-duty cyling duical bearing machine 191 Heavy-duty drill machine 145 Heavy-duty lathe machine 145 Heavy-duty lathe machine 164 Heavy-duty radial drill machine 145 Helical bevel gear reducers 135 Helical gear box 126 Helical gear reducers 135 Helical geared motor 128, 144, 162 Heli-worm geared motors 128 High alumina wear resistant ceramic tiles 5 High pressure blowers 24 High pressure jet clean equipments 172

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PRODUCT INDEX Product

Pg No

HMI 122 HMM technical guidelines 128 Hoist 91, 175 Hold back 138 Home appliances 111 Horizontal CNC machines BIC Horizontal machining centre BIC, 17 Horizontal spindle rotary table surface grinder 127 Hospital equipments 172 HRC fuse body 5 HRC fuse fittings 183 Human machine interface 81, 139 Hydraulic cylinder 174, 186 Hydraulic cylindrical grinding machine 127 Hydraulic dock levellers 19 Hydraulic dock shelters 19 Hydraulic equipments 186 Hydraulic guillotine shears 163 Hydraulic manual pallet trucks 101 Hydraulic parking lift 167 Hydraulic power packs 186 Hydraulic press 146, 164, 186 Hydraulic press brake 171 Hydraulic seals 93 146, 171 Hydraulic shearing machine Hydro pneumatic presses 147 I/P transducers 121 IC counterbalanced forklift 19 Imaging & vision systems 189 IMTMA - AMTTF 148 Indirect water bath heaters 170 Induction heaters 118, 132 Induction machine 132 Induction motors 122, 142 Inductive proximity switches 21 Industrial autmation system 12 Industrial automation products 139 Industrial belts 155 Industrial ceramic 5 Industrial electric power distribution system 8 Industrial heating element 174 Industrial ovens & dryers 144 Industrial overhead doors 19 Industrial service 157 Industrial shoes 181 Inline helical geared motors 128 Instrumentation & control 10, 11 Instrumentation control panels 133 Insulated cables 164 Insulated wires 164 161 Insulating material solutions Integrated solutions 147 Interface modules 6 Interface modules accessories 6 Internal bore/ track grinding machine 155 Inverter duty motors 128 Inverter motor    135 Invertor 81 Invertor control 123 Isolator 75 Isolators and DBS 173 Jib crane 116, 175 Junction box 45 Kanthal 134 Keyless transmisson element 138 Kilns & baths 144 113 Knurled bolt Laboratory furnaces 144 Ladder 172

184

Product

Pg No

Large diameter welded pipes 133 Laser cutting machine 171 Laser engraving machine 171 Laser marker 171 Laser welding machine 171 Lathe machine 155 Lathes 17 LED 21 LED egress route 95 LED emergency 95 LED flash lights 95 LED module pilot lights 183 LED signal tower light 26,32 LED solar street 95 Level controller 196 Light duty lathe machine 162 Lighting 111 Lighting solutions 95 Lighting system 151 Lights 95 Limit switch 26,32,121,183 Linear rods 141 Linear vial washing machine 152 Liquid pumps 126 Load banks 156 Load break switches 21 Load wire springs 124 Loader 179 Loading bay equipment 19 Loom switches 183 Lorry loader 179 19 Low lift pallet truck Lubrication systems 157, 159 Lyophiliser 145 Machining centre 131 Manual chain hoist 144 Manual pallet truck 19 Markers 6 Marking solutions FIC Material handling equipment 101,116 MCB 75 MCCB & MPCB switchgears 133 Measuring instruments 107 Mechanical press brake 171 Mechanical seals 82 Metal cutting tool 3 Metal treatment chemical 121 Metal-enclosed switchgear 129 Meters 107 Micro control switches 183 Micro milling beads 5 Micro PLC 81 Micro switch 26,32, 183 Mill lining blocks 5 Milling centres 17 Miniature micro switches 183 Modular PLC 81 Motion control 81 Motor control centre 20 Motor protection circuit breaker 21 Motor protection relay 137, 141 135 Motor variators Motor/pump protection relay 196 Motorised boom barriers 19 Motorised metering pump 94 Motorised valve 134 Motors 65, 144, 162 Motors & control 186 Motors & drives 12 Moulded cable assemblies 183

SEARCH - THE INDUSTRIAL SOURCEBOOK | J U N E 2 0 1 2

Product

Pg No

Mounting bracket 6 Mounting rails 6 Multi-functional tool 120 Multimedia union 67 Multispeed motor 138 Multi-speed motors 128 Multi-spindle heads 160 Needle roller bearing 160, 191 OHMS meters 107 Oil cooler 130 Oil seals 162, 167 On/off ball valves 154 On/off butterfly valves 154 154 On/off control valves On/off plug valves 154 O-rings 167 Over crank shearing machine 171 Overhead doors 19 Oxy fuel cutting 171 Paint & plating instrument 89 Paint shop equipment 189 Pallet stackers 19 Panel boards 146 Panel cooler 130 Panels 107 Partition plate 6 PCB insertion conveyor 143 Pen heads 113 Phase failure relay 196 Phase monitoring device 22 113 Philips pen head Pick & move crane 179 Pick & place robot 143 PID controllers 133 Pillar drill machine 145, 146 Pilot lamp holders 183 Pilot lights 21 Pin marking systems 147 Pipe bending system 132 Piston bars 141 Planner machine 155, 163 Plano milling machines 163 Plano-miller 155 Plastic chain conveyor 143 Plate bending machine 171 Platform 172 Plotter accessories 6 Plugs and sockets 21 Pneumatic actuators 154 Pneumatic press brake 167 Pointed screw 113 Polyacetal 129 Polycab 134 Polypropylene 129 Polyurethane 129, 155 Power & distribution transformers 126 Power distribution panel 20 Power monitoring relay 196 Power press 14, 146, 171 Power regulator 133 150 Power tool Power transmission chains and sprockets 18 Precision assembly design service 143 Precision component 157 Precision switches 21 Press brake machine 146 Press technology 125 Pre-treatment systems 189 Process automation and control equipment 87 Process gas blowers 24


PRODUCT INDEX Product

Pg No

Production and processing equipment 170 Proline modular (floor mounted) enclosure 45 Protective covers 6 Proximity sensor 26,32 PTFE 130 PTFE tapes 164 PTFE/teflon 129 Pulley lagging 169 Pulleys 155 Pump 35, 82, 126, 153, 186, BC Pump automation product 196 Pump motor 138 Push button switches 183 Push buttons 21 149 Quick-change pallet module Radial drill machine 145 RCCB 75 Reach truck 19 Rear cylinder hydraulic press brake 146 Re-crystallised allumina tubes 5 Relay sockets 183 Relays 195 Re-sharpening solutions 165 Resistor 156 Roll forming machines 162 Roll markers 147 163 Roll turning lathe machine Roller bearing 117, 160 Roller conveyor 143 Roots blower 153 Rope guides 175 Rotary 17 Rotary atomiser 64 Rotary dampers 67 Rotary dry vacuum pumps 24 Rotary joints & unions 67 Rotary shaft seals 93 Rotary switches 21 Rotating unions 67 Rubber parts 167 Rubber products 162 Rust preventives 121 Safety protection devices 21 Safety shoes 150, 181 Safety switchgear 125 Salt spray chamber 89 165 Saw blades Scable ties 53,109, 159, 163 Scissor lift 19 Seal 157, 162 Seamless pipes 133 Sensors 100 Separator plate 6 Servo drives 139 Servo motors 122, 137,139,144 Shaft mounted gear reducers 135 Shafts 141 Shaping machine 146, 155 Shock absorbers 67 Shock proof, durable switchgears 133 Shrouded conductors 167 Shunts 107 Side holding plates 6 133 Single convertor isolator modules Single limit switches 21 Single phase motor 138 Siphon systems 67 Sleeve bearings 191

190

Product

Pg No

Slipring motor starter 138 Small size ball bearings 191 Smart logic controller 120 SMPS 22, 183 Sockets & switches 6 Soft starter 196 Solar power packs 164 Solderless terminal 53, 109,159,163 Solid carbid drill mills 160 Solid carbide drill 3 Solid carbide mill 3 Solid carbide reamer 3 Solid state laser cutter 171 Spaggiari products 135 Special application motors 128 Special pointed screw 113 Special purpose machine 131, 163 Speciality metal 143 Spin flash dryer 64 Spot drills 160 Spray dryer 64 Spray painting equipments 16 Stacker 167 Stainless steel pipes 133 Standard motor 138 Steel 157 91 Steel mill duty & flame proof cranes Super finishing film 123 Super precision bearings 191 Surface plate 155 Switch 75, 111 Switchboard meters 107 Switchgear 12, 125, 134 Tachometer 22 Tail lift 19 Temperature controller 22 Temperature sensors 195 Tensioner nut 138 Terminal blocks 6, 183 Terminal strips 183 Testers 107 Testing system 163 Textile & yarn trolleys 172 63 Thermal imaging cameras Thermostats 146 Threading Machines 125 Time switch 22 Timer 195, 196 Timing belts 155 Tool 124 Tool holders 124, 156 Torque motor 128, 144, 162 Torque multipliers 156 Tower crane 179 Track rollers 138 Transformers 107 Transmission belt 155, 169 Trolley 141, 167 Truck 141 24 Truck blowers Tubes 133 Tubing accessories 87 Tubular drag conveyor 175 Turkkit strips & sheets 130 U & V seals 167 U tubes 133 Universal grinding machine 145 Universal milling attachment 152

SEARCH - THE INDUSTRIAL SOURCEBOOK | J U N E 2 0 1 2

Product

Pg No

Vaccum conveyor Vacuum booster pump Vacuum system Valve Valve positioner Valve terminal Variable speed belts Varistor cabinet V-belts Velocity & feed controllers Vertical boring machine Vertical machining centre Vertical order pickers Vertical turning lathe Vertical turning machine Vertical turnmill centre Vibrate motor Vibrating reed type Vibratory motor Washer head screw Water faucet parts Water heating systems Welded pipes Wheel assembly Wheel barrows Wheel loader Wheels Winch Wire connector Wire grid resistors Wire mesh conveyor Wire rope drum Wire rope hoist Work holding devices Worm drive hose clamps Worm gear reducers

175 153 153 87, 134, 152 121, 154 87 155 45 155 67 155 17 19 163 131, 155 131 138 107 144, 162 113 5 144 133 126 141 150 141 91,136 53, 109, 159, 163 156 143 126 123 113 142 135

INTERNATIONAL PRODUCTS Product

AC/DC power pack Air driven power pack Aluminium Atmospheric pre-aligner Automatic cutters Cartridge valves Cast film lines Closure solutions Coil spring Concrete energy savings Connectors Cranes Cutting & boring systems Energy efficiency solutions Hoist Hot-melt application system Hydraulic fluid power products Magnetic separators Micro injection machines Micro power packs Motion processor Needle roller bearings Pump Thermoplastic elastomers Vertical machining centre Vibration level limit switch Wave spring

Pg No

159 159 149 172 168 159 174 168 137 69 115 52 168 69 52 168 168 168 174 159 172 174 159 175 172 168 137


ADVERTISERS’ LIST

To know more about the advertisers in this magazine, refer to our ‘Advertisers’ List’ or write to us at search@infomedia18.in or call us on +91-22-3003 4640 or fax us at +91-22-3003 4499 and we will send your enquiries to the advertisers directly to help you source better Advertisers’ Name & Contact Details

Pg No

Advertisers’ Name & Contact Details

A Plus Projects And Technology (P) Ltd. T: +91-20-25690620 E: ppm@aplusprojects.biz W: www.aplusprojects.biz

170

Action Construction Equipments Ltd T: +91-11-40549900 E: marketing@ace-cranes.com W: www.ace-cranes.com

179

Actuators India Pvt Ltd T: +91-250-2480916 E: aiplvasai@gmail.com W: www.actvatorsindia.in

134

Cheng Day Machinery Works Co., Ltd T: +886-4-2688-1581 E: christy@chengday.com.tw W: www.chengday.com.tw

136

Classic Polymers & Resins T: +91-22-24465251 E: sales@classicpolymers.co.in W: www.classicpolymers.com

129

Amsak Cranes Private Limited T: +91-44-26273486 E: sales@amsakcranes.com W: www.amsakcranes.com

144

CNP Pumps India Pvt Ltd T: +91-22-25818400 E: sales@nanfangpumps.com W: www.nanfangpumps.com

35

Applied Engineering Services T: +91-20-24448165 E: info@appliedengg.in W: www.appliedengg.in

147

Coatec India T: +91-172-5063436 E: info@coatecindia.com W: www.coatecindia.com

189

Applied Technosystems T: +91-09911244140 E: appliedtechno@gmail.com W: www.appliedtechnosystems.com Arizona Company T: +91-09830030618 E: arizona.company11@gmail.com

125

Cognex Sensor T: +91-20-40147840 E: sales.in@cognex.com W: www.cognex.com

Aqua Services T: +91-265-2331748 E: aquaas@sify.com W: www.aquaservicesindia.com

142

Confederation Of Indian Industry T: +91-124-4014060 E: rachna.jindal@cii.in W: www.jetfindia.in

Aradhana Agency T: +91-09435107289 E: aradhanagroups@gmail.com W: www.aradhanagroup.com

134

Austin Engineering Company Ltd E: sales@aecbearings.com W: www.aec-bearings.com

117

Avasarala Technologies Limited T: +91-80-26083300 E: marketing@avasarala.com W: www.avasarala.com

143

Avcon Controls Pvt Ltd T: +91-22-61504150 E: sales@ashokindustry.com W: www.ashokindustry.com

121

Bhagirath Heavy Transmission T: +91-11-32222661 E: bht_india1998@yahoo.co.in

126

Bharat Bijlee Ltd T: +91-22-24306237 E: vishwajyoti.vengurlekar@bharatbijlee.com W: www.bharatbijlee.com

122

Bonfiglioli Transmissions (Pvt) Ltd T: +91-44-67103800 E: sales.buins@bonfiglioli.com W: www.bonfiglioli.com

23

C&S Electric Ltd. T: +91-11-30887520-29 W: www.cselectric.co.in

Pg No

Champkraft Machine Tools T: +91-2752-241881 E: champ1@sancharnet.in W: www.solcogrinder.com

Connectwell Industries Pvt Ltd T: +91-251-2870636 E: connect@connectwell.com W: www.connectwell.com

75

127

52

Advertisers’ Name & Contact Details

Electronic Automation Pvt Ltd T: +91-80-42802345 E: sales@eaplindiamail.com W: www.eaplindia.com

22

Enapros T: +91-11-25778450 E: ssb@power-resistor.com W: www.resistorsonline.com

156

Essen Deinki T: +91-172-4600600 E: info@essendeinki.com W: www.essendeinki.com

183

Everest Blower Systems T: +91-11-45457777 E: info@everestblowers.com W: www.everestblowers.com

153

Festo Controls Ltd T: +91-80-22894100 E: info_in@festo.com W: www.festo.com

87

Finechrome Shafts Pvt Ltd T: +91-22-29204209 E: finechromespl@yahoo.co.uk

141

100

Flir Systems India Pvt Ltd T: +91-11-4560 3555 E: manpreet.kaur@flir.com.hk W: www.flir.com

63

140

Forech India Limited T: +91-11-26960868 E: info@forech.net W: www.forechindia.com

6

Forging Machinery Manufacturing Co T: +91-161-5011755 E: info@nkhammers.com W: www.nkhhammers.com

Control Engg Co T: +91-33-2248 0192 E: ceco@cecoelectronics.in W: www.cecoelectronics.co.in

139

Freeze Tech Equipments Pvt Ltd T: +91-44-42152387 E: info@freezetechequip.com W: www.freezetechequip.com

Crane-Bel Hydraulics T: +91-120-3263281 E: office@crane-bel.com W: www.crane-bel.com

186

Frost & Sullivan T: +91-33-6160 6666 E: nitin.kalothia@frost.com

DSM India Pvt Ltd T: +91-20-66430800 E: ojas.mehta@dsm.com W: www.dsmep.com

161

Durga Bearing Pvt Ltd T: +91-22-6876073 E: inquiry@durgabearings.com W: www.durgabearings.com

191

Dwij Consultants T: +91-79-26760747 E: info@dwijcon.com

124

Eddycranes Engineers Pvt Ltd T: +91-22-2352 2710 E: eddycranes@vsnl.com W: www.eddycranes.com

Pg No

91

G W Precision Tools India Pvt Ltd T: +91-80-40431252 E: info@gwindia.in W: www.gwindia.in

169

14

130

54

3

Gandhi Automations Pvt Ltd T: +91-22-66720200 E: sales@geapl.co.in W: www.geapl.co.in

19

Gemco Controls Ltd T: +91-129-2274831 E: ys@gemcocontrols.com W: www.gemcocontrols.com

20

General Industrial Controls Pvt Ltd T: +91-20-30680003 E: marketing@gicindia.com W: www.gicindia.com

195

Our consistent advertisers

192

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ADVERTISERS’ LIST Advertisers’ Name & Contact Details

GGB Bearing Technology T: +91-20-3061 6600 E: india@ggbearings.com

Pg No

37

Ghaziabad Flopal Insulation Pvt Ltd T: +91-09650924190 E: sunil.rastogi@hotmail.com W: www.indiamart.com/flopol/

164

Girish Ego Controls T: +91-22-26853681 E: info@saiego.com W: www.saiego.com

146

Goliya Electricals Pvt Ltd T: +91-22-24120456 E: geplmumbai@mtnl.net.in W: www.goliya.com

107

Grundfos Pumps India Pvt Ltd T: +91-44-24966800 E: salesindia@grundfos.com W: www.grundfos.in

.BC

Haas Automation India Pvt Ltd T: +91-22-61392800 E: indiasales@haascnc.com W: www.haascnc.com

17

Advertisers’ Name & Contact Details

Libratherm Instruments Pvt. Ltd. T: +91-22-42555353 E: libratherm@libratherm.com W: www.libratherm.com

Indian Machine Tool Mfgr’s Asso. T: +91-80-66246600 E: imtma@imtma.in W: www.imtma.in

148

Maco Corporation India Pvt Ltd T: +91-33-24758371 E: prbhowmick@macocorporation.com W: www.macocorporation.com

Inventum Engineering Co Pvt Ltd T: +91-22-26730499 E: inventum@vsnl.com W: www.inventumindia.com

118

Macro Tech Equipment Pvt Ltd T: +91-33-24666261 E: info@macrotechcal.com W: www.macrotechcal.com

101

Jagdeep Foundry (Regd.) T: +91-1871-242750 E: jagdeepfoundry@rediffmail.com W: www.jagdeepfoundry.in

155

Marks Pryor Marketing Technology T: +91-20-66743300 E: info@markspryor.com W: www.markspryor.com

FIC

Jai Electrical Industries T: +91-79-22747152 E: info@jaielectrical.com W: www.jaielectrical.com

138

Mehta Cad Cam Systems Pvt Ltd T: +91-79-26840551 E: sales@mehtaindia.com W: www.mehtaindia.com

171

Metalon Marketing T: +91-11-32970291 E: info@metalonmarketingdelhi.com W: www.metalonmarketingdelhi.com

149

Jaibalaji Control Gears Pvt. Ltd., T: +91-44-26251279 E: dchandramohan@jaibalaji.firm.in W: www.jaibalaji.firm.in

Hapman India T: +91-265-2517505 E: info@hapman.in W: www.hapman.in

175

Jyoti Cnc Automation Pvt. Ltd. T: +91-2827-287081 E: info@jyoti.co.in W: www.jyoti.co.in

Havells India Ltd. T: +1800-11-0303;011-41660303 E: marketing@havells.com W: www.havells.com

111

Kanefusa India Pvt Ltd T: +91-124-4208440 E: info@kanefusa.co.in W: www.kanefusa.net

Hensel Electric India Pvt. Ltd. T: +91-44-24541669 E: henselelectric@vsnl.com W: www.hensel-electric.de Hercules Hoists Limited T: +91-219-2274036 E: enquire@indef.com W: www.infef.com

8

167

Pg No

166

175

94

Advertisers’ Name & Contact Details

Igus India Pvt Ltd T: +91-80-39127800 E: info@igus.in W: www.igus.in

Hafa Hoists Pvt Ltd T: +91-22-27694837 E: response@hafahoists.com W: www.hafahoists.com

Heidelberg Prominent Fluid Controls T: +91-80-23578872 E: prominent@hpfcindia.com W: www.prominentindia.com

Pg No

Jyoti Ceramic Industries Pvt Ltd T: +91-253-2350120/338 E: info@jyoticeramic.com W: www.jyoticeramic.com

26-32

5

MGM-Varvel Power Transmission (P) Ltd T: +91-44-64627008 E: ravik@mgmvarvelindia.com W: www.mgmvarvelindia.com

133

67

99

Minilec (India) Pvt Ltd T: +91-20-22922354 E: mkt1@minilecgroup.com W: www.minilecgroup.com

196

165

Mipox T: +91-80-65830898 E: rag-rao@mipox.co.jp W: www.mipoxindia.com

123

Karcher Cleaning Systems Pvt Ltd T: +91-120-4661800 E: info@karcher.in W: www.karcher.in

185

Mitsubishi Electric (I) Pvt. Ltd. T: +91-124-4630300 E: Shinji.Mizoguchi@asia.meap.com W: www.mitsubishielectric.asia/india/

Kiss Machinery Co., Ltd T: +886-2392-0237 E: tom0184@pchome.com.tw W: www.kissmachinery.com

159

MM Activ Sci Tech Communications Pvt Ltd T: +91 80 41131912 E: info@gimexpo.in W: www.gimexpo.in

158

Klipco Pvt Ltd T: +91-22-28684221 E: klipco@mtnl.net.in W: www.klipcoclips.com

142

Motovario Gear Solutions Pvt Ltd T: +91-33-24381357/97 E: india@motovario-group.com W: www.motovario-group.com

135

Knowell International Pvt Ltd T: +91-33-22304627 E: hktrading@vsnl.com W: www.knowell.co.in

124

Moulik Rubber Industries T: +91-22-40037863 E: moulikrubber@gmail.com W: www.moulikrubberindustries.com

167

.BIC

Hi-Fab Engineers Pvt Ltd T: +91-22-40766555 E: info@hi-fab.com W: www.hi-fab.com

82

Hi-Fab Valve Automation T: +91-22-40766539 E: valves@hi-fab.com W: www.hi-fab.com

154

Larsen & Toubro Ltd T: +91-22-67525656 E: ss-ccd@lth.lthindia.com W: www.larsentoubro.com

173

NI Systems India Pvt Ltd T: +91-80-41190000 E: ni.india@ni.com W: www.ni.com

Hindustan Motor Mfg Co T: +91-22-42500500 E: sales@hindmotors.com W: www.hindmotors.com

128

Liberty Shoes Ltd T: +91-1748-251120 E: warriors@libertyshoes.com W: www.libertyshoes.com

181

Nia Controls T: +91-250-2480916 E: ncvasai@gmail.com W: www.tscindia.com

81

10; 11

152

Our consistent advertisers M A Y 2 0 1 2 | SEARCH - THE INDUSTRIAL SOURCEBOOK

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ADVERTISERS’ LIST Advertisers’ Name & Contact Details

Pg No

Advertisers’ Name & Contact Details

NMTG Mechtrans Techniques Pvt Ltd. T: +91-79-22821527 E: nmtg@nmtgindia.com W: www.nmtgindia.com

138

Satra International T: +91-11-25415437 E: satra_nitin@yahoo.co.in W: www.satrainternational.in

Oil Seals Mfg Co Pvt Ltd T: +91-22-22047943 E: omcoseal@rediffmail.com

162

P Parmar Mechanical Works T: +91-278-2447409 E: info@parmardrill.com W: www.parmardrill.com

145

Pentair Technical Products India Pvt Ltd T: +91-80-28454640 E: contact.marketing@pentair.com W: www.pentairtechnicalproducts.com

45

Pg No

Swam Pneumatics Pvt Ltd T: +91-120-4696222 E: swamatic@airtelmail.com W: www.swamatics.com

24

Shachi Engg Pvt Ltd T: +91-20-66546900 E: shachi_engineering@vsnl.com W: www.shachiengg.com

64

Syp Engineering Co Pvt Ltd T: +91-22-28489969 E: syppumps@gmail.com W: www.sypco.co.in

126

Shailesh Sales Corporation T: +91-281-2461102 E: info@shaileshmachines.com W: www.shaileshmachines.com

146

Tee-Vee Tools & Engineering Industr T: +91-250-2023363 E: teeveetools@gmail.com

113

Shende Sales Corporation T: +91-20-24488005 E: shende@shendesales.com W: www.shendesales.com

130

151

Shenoy Engineering Pvt Ltd T: +91-80-28361767 E: info@shenoyengineering.in W: www.shenoyengineering.in

152

Power Belt India T: +91-22-40518888 E: sales@powerbeltindia.com W: www.powerbeltindia.com

155

Shikovi Heat Gen Technologies Pvt Ltd T: +91-22-27607758 E: sales@shikovi.com W: www.shikovi.com

144

Premier Ltd T: +91-22-61179009 E: ericadesouza@premier.co.in W: www.premier.co.in

4

131

Presto Stantest Pvt Ltd T: +91-129-4272727 E: presto@vsnl.com W: www.prestogroup.com

89

Prolite Autoglo Limited T: +91-22-66599223 E: sales@prolite.in W: www.prolite.in

95

Ravi Electronics T: +91-79-65722609 E: sales@fluconautomationinc.com W: www.fluconautomationinc.com Renu Electronics Pvt Ltd T: +91-20-27292840 E: info@renuelectronics.com W: www.renuelectronics.com Rexello Castors Pvt Ltd T: +91-22-40917777 E: rexello@gmail.com W: www.rexellocastors.com Rittal India Pvt Ltd - Eplan Division T: +91-22-39527200 E: eplan@rittal-india.com W: www.eplan.in

121

46

141

71

Royal Electric Engineering Co. T: +91-79-22202008 E: royalelectricmotors@yahoo.com W: www.electricmotor-india.com

144

Sarabsukh Enterprises T: +91-1871-223893 E: sarabsukhbatala@yahoo.co.in W: www.sarabsukhmachines.com

163

Pg No

132

Perennial Technologies Pvt Ltd T: +91-20-22953511 E: sales@perennial.co.in W: www.powerrental.co.in

Precihole Machine Tools Pvt Ltd T: +886-3-329-9968 E: pshtech@gmail.com W: www.peei.com.tw

Advertisers’ Name & Contact Details

Siemens Ltd T: +91-22-27623727 E: motors.in@siemens.com W: www.siemens.com

12

SKF Group W: www.skf.com Small Industries Devt Bank Of India W: www.sidbi.com/growth.asp

69

Smalley Steel Ring Company T: +847-719-5900 E: info@smalley.com W: www.smalley.com

73 137

Spareage Seals Ltd T: +91-22-25800972 E: sales@spareage.com W: www.spareage.com

93

Teknic T: +91-22-26592392 E: teknic@vsnl.com W: www.tecknic.co.in

21

The Indian Electric Co T: +91-20-66865200 E: iecmktg@indianelectric.com W: www.indianelectric.com

65

Theeta Electricals Pvt Ltd T: +91-124-4387400 E: sales@theeta.com W: www.theeta.com TIDC India T: +91-44-42235509 E: industrialchains@tii.murugappa.com W: www.tidcindia.in

174

18

Timken India Limited T: +91-80-40053100 E: ruchir.agarwal@timken.com W: www.timken.com

157

Tox Pressotehnik India Pvt Ltd T: +91-20-66538300 E: RNamboodiri@tox-in.com W: www.tox-de.com

125

Trident Products Pvt Ltd T: +91-124-4300626 E: trident.sales@tridenthydraulics.com

174

160

Tussor Machine Tools Ind P Ltd T: +91-422-3200183 E: info@tussorindia.com W: www.pinachoindia.com

25

Spares & Components Co T: +91-22-28836879 E: sudhir@spco.in W: www.spco.in

162

V R Coating T: +91-20-30781022 E: vrcoatings@eth.net W: www.vrcoatings.com

16

Speed Rider T: +91-79-22202212 E: sr@dcacmotor.com W: www.dcacmotor.com

123

Venus Engineers T: +91-11-32222661 E: enquiry@venusengineers.com W: www.venusengineers.com

116

Stahl Crane Systems Pte Ltd T: +91-44-43523955 E: infoindia@stahlcranes.com W: www.stahlcranes.in

150

Weldor Engineering Pvt Ltd T: +91-281-2360242 E: weldor@weldor.com W: www.weldor.com

171

Suhner India Pvt Ltd T: +91-80-27831108 E: automation.in@suhner.com W: www.suhner.com Sumitron Exports Pvt Ltd. T: +91-11-41410631 E: sumitron@vsnl.com W: www.sumitron.com

53; 109; 159; 163

Western Material Trading (Shanghai) Co., Ltd. 149 T: +86-21-5876-1508 E: tao.cheng@wmt-china.cn W: www.wmt-china.cn

133

Wont Industrial Equipments T: +91-261-2894847 E: info@wantindia.com W: www.wantindia.com

172

Suraj Limited T: +91-79-27540720 E: suraj@surajgroup.com W: www.surajgroup.com

115

Yorks Strength Systems T: +91-11-27028452 E: info@yorkfitness.com

129

Swagelok Company W: www.swagelok.com/connections.

Our consistent advertisers

194

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RNI No: 67827 / 98 Licensed to Post without prepayment License No: WPP - 246 Postal Regd No: KA / BG GPO / 2564 / 2011-13 Posted at MBC, Bangalore GPO on 25th & 26th of Every Previous Month Date of Publication: 18th of Every Month.

RNI No: 67827 /98 Postal Regd No G 2 / NMD / 81 / 2011 -13 Posted at Mumbai PatrikaChannel Sorting Office- GPO, Mumbai 400 001 on 22nd & 23rd of Every Previous Month Date Of Publication: 18th of Every Month

198

Search - June 2012  

‘SEARCH’, India’s leading B2B magazine on general engineering and manufacturing, is aimed to equip its readers with latest business trends,...

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