IWP Magazine Feb March 2017 Issue Webupload

Volume: 2 Issue: 6 February - March 2017 ` 10/-
Bimonthly, Chennai
IWTMA &
INDIAN WIND TURBINE
MANUFACTURERS ASSOCIATION
announce
WINDERGY INDIA 2017

Conference: 26th and 27th April 2017,
Exhibition: 25th, 26th and 27th April 2017
at The Ashok, New Delhi
A Bi-monthly Magazine of Indian Wind Turbine Manufacturers Association
Volume: 2 Issue: 6 February - March 2017
Executive Committee
Chairman
Mr. Sarvesh Kumar
Contents Page No.
President and Chief Operating Officer

RRB Energy Limited, New Delhi Photo Feature 3
Heavy Castings in Wind Turbine 4

Vice Chairman & Honorary Secretary
V. Srinivasa Reddy, Executive Director, Synergy Green Industries Pvt. Ltd., Kolhapur, Maharashtra
Mr. Chintan Shah

President and Head (SBD) Indian Foundry Industry and Wind Turbine Generators 9
Suzlon Energy Limited, Pune Ashok Kumar Anand, Director, The Institute of Indian Foundrymen, New Delhi
Castings and Forgings Oxygen of the Wind Industry 12

Executive Committee Members V. Srinivasa Kannan, Head-SCM, Bonfiglioli Transmissions Private Limited
Mr. Madhusudan Khemka

SG Iron Castings: Powering Energy Efficiency 15
Managing Director
ReGen Powertech Pvt. Ltd., Chennai P.G. Salunkhe, Vice President, Engineering Division, Premier Limited, Mumbai
Mr. Ramesh Kymal Indigenisation of Wind Turbine Components 22

Chairman & Managing Director Sindhuja S, PGPM (Energy), Great Lakes, Institute of Management, Gurugram
Gamesa Renewable Pvt. Ltd., Chennai Raghuram Hariharan, Manager (Purchase), Gamesa Renewable Pvt. Limited, Chennai
Dr. B.S.K. Naidu, Chairman Emeritus, Great Lakes, Institute of Management, Gurugram
Mr. Ajay Mehra

Director, Wind World India Limited, Mumbai Let the Wind Blow in Favour of Indian Foundries 28
Dr. Nithyanandan Devaraaj, Honorary Secretary, Institute of Indian Foundrymen
Mr. Hemkant Limaye
Commercial Director Special Forgings for Critical Gearbox Components 33
LM Wind Power, Bengaluru
Umakanth Papatla, General Manager Quality & Technology, ZF Wind Power, Coimbatore
Secretary General Snippets on Wind Power 39
Mr. D.V. Giri, IWTMA, Chennai Know Your Member- RRB Energy 40
Associate Director and Editor
Dr. Rishi Muni Dwivedi, IWTMA, Chennai Indian Wind Turbine Manufacturers Association
4th Floor, Samson Tower, 403 L, Pantheon Road, Egmore
Views expressed in the magazine Chennai - 600 008. Tel : 044 43015773
are those of the authors and do Email : secretarygeneral@indianwindpower.com
not necessarily reflect those of the associatedirector@indianwindpower.com
Association, Editor, Publisher or Author's Website : www.indianwindpower.com
Organization. (For Internal Circulation only)
From the Desk of the Chairman - IWTMA
Dear Readers,
Greetings from IWTMA!
The Wind Industry is in its fourth quarter with an ambitious plan to install over 4 GW in the financial year 2016-17. There
are two schools of thought on the prospects of 2017-18 with reduction of AD perhaps, withdrawal of GBI and the new
era of competitive bidding, which has just made its beginning.
On the optimistic side, the Industry is confident to install over 6 GW in the financial year 2017-18 and move forward. The
first bid under the competitive bidding for interstate sale has been received with a good response of 2.6 GW - prominent
states are Tamil Nadu, Gujarat and Karnataka. We do hope that the price bid is meaningful for all the stakeholders instead
of an aggressive bid, which can be short lived and may have its own shortcomings.
The country is also eagerly looking forward to the Union Budget 2017; which will have a departure and will include the
Railway Budget for the first time. Aspirations are many - the roll out of GST, which is expected to be in July 2017, would stir
the interest and which may have positive/negative impacts. Wind Industry is thankful to Ministry of New and Renewable
Energy (MNRE) for suggesting concessional rate of duty and it is heartening to read in the newspaper that the Ministry of
Power has in fact suggested 'Zero' rating for renewables to the GST Council.
While on the subject, we are glad to confirm that the Central Pollution Control Board has notified in writing that all
renewable projects and hydro projects under 25 MW will be in the "White Category", which it deserves.
Castings and forgings are basic requirement to any industry and the Wind Industry is no exception. It is, but unfortunate
that a major domestic player in the castings industry has gone to Court for anti-dumping; when there is a cry for finished
castings, which are of good quality and with competitive price when imported. The country does not have enough capacity
for machined castings.
The Ministry of Commerce has reduced the duty of Pig Iron SG grade (7201 1000) and Ferro-silicon-magnesium (7202
2900) from 12% to nil and we are determining the positive impact of this move. Castings and forgings are vital in items
such as gearbox, nacelle casing, main shaft to name a few. Therefore, we are dedicating this issue with six articles to
highlight this aspect.
Finally, the International Conference & Exhibition titled "WINDERGY INDIA 2017" organized by IWTMA and GWEC is in its
feverish pitch and will take place from 25th to 27th April 2017 at Hotel Ashok, New Delhi.
The power of wind and generating power literally from thin air, its policies, challenges and opportunities will be exciting
to every listener. We invite you to be a part of the show as a delegate, exhibitor or visitor. If you are not there, you will
certainly miss something which holds hope for the future.
We have to wait and watch the policy of the new President of United States towards renewables as a super power.
"Let the will of people prevail but with dignity and peace".
With Regards,
Sarvesh Kumar
Chairman
2 Indian Wind Power February - March 2017

Secretary MNRE
Shri Rajeev Kapoor, IAS, 1981 Batch, UP Cadre is the new Secretary in the
Ministry of New and Renewable Energy (MNRE). He was earlier Director,
Lal Bahadur Shastri National Academy of Administration, Mussoorie. Indian
Wind Turbine Manufacturers Association (IWTMA) heartily welcomes Shri
Rajeev Kapoor and extends all support and cooperation.
Photo Feature
Meeting with Mr Rajeev Kapoor, IAS, Incoming Secretary, MNRE
IWTMA arranged an introductory meeting with Mr Rajeev Kapoor, IAS, the incoming Secretary, MNRE and its members on December
28, 2016. Mr. Sarvesh Kumar, Chairman, IWTMA welcomed Mr. Kapoor on behalf of the Association. Mr. Chintan Shah, Vice Chairman
and Honorary Secretary IWTMA presented broad Road Map of wind sector. Mr. Kapoor took keen interest in the discussion and
assured his best efforts to boost the industry. The photos taken during the meeting are given below.
From left to right: Mr. Rajeev Kapoor, Secretary, MNRE; Mr. Santosh Vaidhya, Joint Secretary; Mr. Ramesh Kymal, CMD, Gamesa;
Mr. Madhusudan Khemka, MD, ReGen; Mr. Hemkant Limaye, Director, LM Wind Power and Mr. K.R. Nair, GM, Wind World
Facing Camera from right to left: Mr. Sarvesh Kumar, Chairman, IWTMA; Mr. D.V. Giri, Secretary General, IWTMA; Mr. Chintan
Shah, Vice Chairman and Honorary Secretary, IWTMA; Mr. G. Upadhyay, Scientist F; Mr. O.P. Taneja & Mr. Neeraj Kumar, Scientist C;
Mr. Alok Gupta, Inox; Mr. Awnish Pandey, Inox. Mr. Anant Naik, Suzlon and Mr. Rishabh Dhyani, IWTMA are not in frame.
February - March 2017 Indian Wind Power 3

Heavy Castings in Wind Turbine
V. Srinivasa Reddy, Executive Director

Synergy Green Industries Pvt. Ltd., Kolhapur, Maharashtra; vsr@synergygreenind.com
1. Introduction
Heavy castings are major components for assembly of Producon 2015
rotor, nacelle and gearbox in a wind turbine generator
50
(WTG). Rotor hub, main foundation, bearing housings and
45
reaction torque arm castings are manufactured according
40
35
30
25
20
15
10
5
0
Grey Ducle Steel Aluminium Others
to ferritic ductile iron grade and planetary carrier in gearbox

is of pearlitic grade. Ductile iron castings offer highest
Grade-wise Proporons
reliability even with impact loads at sub zero temperatures. 100%
Casting is one of the most preferred manufacturing
process to designers because of its ability in handling 80%
large size, complexity, repeatability, scalability along with 60%
cost competitiveness. A typical 2 MW WTG design requires
about 40 MT of castings. 40%
2. Indian Foundry Industry 20%
India is the second largest casting manufacturer in the 0%

world with 10.77 million metric tons of production during China India USA World
2015. China leads the casting Industry with 45.6 million
Grey Ducle Steel Aluminium
metric tons and USA is in third position with 10.39 million
metric tons. World's total casting production during 2015
is reported at 104 million metric tons and following graph World's average production for grey iron is 45% and
shows country-wise production details in millions of tons. ductile iron is 25%. India has got potential opportunity to
enhance the ductile iron proportion.
India's casting production is 69% grey iron and 11%
ductile iron. Following graph shows top countries grade- India's casting demand is primarily driven by auto sector
wise proportion along with world average. with 32% share, followed by pipe fittings, agricultural

machines and sanitary parts at 8% each. India's large
casting annual production is estimated to be around one WTG Casngs (MT)
million metric ton. Majority of large castings are produced
for pipe industry in ductile Iron. 80000
Following is the indicative sector-wise casting consumption 70000

in the country.
60000
Industry Consumpon 50000
40000
Others 30000
18% Auto
Power 32% 20000
4%
Valves 10000
4%
Pumps 0
2015-16
2014-15
2013-14
2012-13
2011-12
2010-11
2009-10
2008-09
2007-08
2006-07
2005-06
2004-05
2003-04
2002-03
5%
Railways Agri
6% M/C Pipe
8% ngs
Industrial India's hand moulded large castings annual capacity (>5
8%
M/C 7% Sanitary MT) is estimated to be around 450,000 MT out of which
8% 300,000 MT for iron and 150,000 MT for steel. Presently,
operating wind turbine foundries annual capacity is around
Indian foundry industry is spread across major clusters 100,000 MT. Even though, local production capacity is
catering to some specific markets. Coimbatore in south is higher than consumption, still castings are being imported
into textile & pumps castings, Kolhapur/Belgaum in west from China due to cost competitiveness and to meet peak
is into auto parts, Rajkot cluster into oil engines parts, demands.
Jalandhar/Ludhiana in north is into agricultural parts and
Howrah cluster in east is into sanitary & railway castings.
4. Casting Process
Methoding Simulation: Casting activity begins with
3. Wind Turbine Castings simulation of 3D solid model for mould filling and
solidification analysis.
India's wind turbine casting development started during
mid 90's on a small scale and picked up the momentum
by mid of 2000's. Majority of wind turbine castings weight
range from 5 MT to 15 MT. Prior to wind turbine castings
demand, Indian foundries large casting expertise was
limited to steel & grey iron. Around a dozen foundries had
taken up for developing these parts but succeeded only to
a limited extent. Main reason for this was due to stringent
metallurgical and non-destructive testing requirements in
wind turbine ductile iron parts.
Following are the statistics of Indian wind turbine casting

consumption (assuming 20 MT/MW installations) during
last 15 years.

Apart from geometrical input, material grade and other In order to preserve natural resources like sand and to
manufacturing parameters will be defined for simulation protect the environment from used sand dumping,
process. This process facilitate in analysing mould filling more than 90% of sand is recycled through mechanical
and solidification behaviour of the part with given set of reclamation process.
inputs. Simulation helps in optimising casting production
Moulding is considered as one of the most critical
process and significantly reduce development cycle time.
processes in large casting foundries, demanding highly
Pattern Manufacturing: Once the manufacturing process skilled manpower and involves 30% of workforce.
is validated through simulation, next step is pattern making.
Melting: Key inputs for melting are high quality pig iron
Generally teak wood material is used for patterns. Patterns
and CRC scrap generated from sheet metal industries
are constructed by using small modules machined on
like automobile. Induction melting furnaces are used for
CNC machines and assembled together.
In order to ensure better dimensional stability, higher

productivity and longer life, patterns are mounted on
to match plates. Pattern manufacturing lead time varies
between 4 weeks to 12 weeks depending up on the size
and complexity of part.
preparing the liquid metal. In order to ensure highest

metallurgical quality, metal will be analysed for chemical
analysis and cooling curve assessment through thermal
software.
Melting process consumes 80% of power used in foundry

Alternative pattern materials like aluminium and resin and 70% of raw material cost. Total power consumed
can also be used. However these material selection will for producing one ton of good casting is around 1000 to
be based upon the number of casting to be produced, 1200 units.
flexibility for design changes and initial investments.
Fettling & Finishing: This process removes all unwanted
Moulding: Major inputs for moulding are high quality materials like gating, risering and other extra material
silica sand and chemical binders. These inputs are mixed generated during casting manufacturing. This is one of
in high speed continuous mixers and filled on the patterns the most laborious processes in foundry and requires
for creating casting shape. Moulds are coated with high around 30% of workforce. Still proper mechanisation
refractory materials like zircon/graphite for higher resistance of this process is not evolved and present approach is
to metal temperature and achieve better surface finish. to minimise work content through superior controls in
methoding, pattern, moulding & melting functions.
Quality Inspection: Castings will be validated for

mechanical and metallurgical properties from the test
coupons attached to casting. Casting soundness will be
verified with NDT techniques like ultrasonic & magnetic
particle inspection. Geometrical accuracies are validated
through dimensional inspection and 3D measurements.
Visual inspection will be carried out for surface
imperfections.
Machining & Surface Treatment: Machining is one of the

most critical processes to ensure proper assembly with

mating parts and its geometrical accuracies are vital for Wages: Chinese labour costs have gone up by three folds
WTG functioning. Shot blasting painting is carried out after in last 10 years and stands at 2.5 times the Indian wages.
machining. This advantage is nullified by much lower productivity
levels in Indian foundries. There is a great opportunity to
enhance the productivity levels.
Challenges
Product Development: Present development cycle time

for large castings from drawing to serial production (first 5
castings) is about 8 to 10 months. There is strong need to
reduce the same by 30%.
Manpower Skills: Most difficult task in large castings

foundry is to get skilled manpower. Foundry working
Machining is a high investment process for large castings. environment needs to be improved for attracting the
Machine configurations are highly sensitive to component qualified manpower and train them in structured manner
size and dimensional tolerances. to catch up with global standards of operational excellence.
Raw Material: Biggest challenge for Indian foundries is to

5. Opportunities and Challenges
contain the input material costs. Due to spiralling effect
Opportunities from supply chain, raw material prices are higher by 20%
Demand & Policies: The Government of India's target for as compared to China.
renewable energy by 2022 is 175 GW, out of which 60 Electricity Charges: Electricity contributes 15% of casting
GW is to come from wind power. This is going to give manufacturing cost. Indian electricity charges are growing
sustained growth opportunities for the casting industry and at the rate of 8 to 10% annually. There is hope to reverse
annual wind turbine casting demand will be exceeding
this trend with power sector reforms supported by healthy
100,000 metric tons.
competition and decoupling the populist measures by
Capacities: With more than two decades in to political community.
manufacturing of wind turbine castings, Indian foundries
Financial Resources: Another challenge for Indian
are well positioned to meet the growing demand of the
foundries is limited accessibility to funds and higher
industry.
finance costs. India's interest rates are 50% higher as
Costs: Indian foundries have also developed the cost compared to China. We hope for softening of interest
competitiveness comparable to global casting suppliers rates with governments demonetisation and discouraging
with the help of economy of scale in production, learning parallel economy.
curve effect, and favourable currency conversion factors.
External Factors: Continuity of policy incentives to wind
Following is the currency movement chart between INR & industry, solar technology competition, and impact of GST
Chinese Yuan. implementation needs a close watch on wind industry
demand.
INR to Yuan
12 References
10 1. 50th Census of World Casting Production, published in
8 Modern Casting, December 2016 edition.
6 2. IIF Foundry President's presentation on Sector-wise Casting
4 Consumption in India.
2 3. Wind Power Installed Capacity published by National
0 Institute of Wind Energy, Ministry of New and Renewable
May/15
Nov/07
May/10
Nov/12
Sep/08
Jul/09
Sep/13
Jul/14
Mar/11
Mar/16
Jan/07
Jan/12
Jan/17
Energy, Government of India.
4. Currency chart from www.xe.com

Indian Foundry Industry and
Wind Turbine Generators
Ashok Kumar Anand

Director, The Institute of Indian Foundrymen, New Delhi
The Indian foundry industry manufacturers metal cast and target is to reach installed capacity
components for applications in auto, tractor, railways, machine of 60000 megawatt by 2020. The
tools, sanitary, pipe fittings, defence, aerospace, earth moving, growth of the wind turbine sector
textile, cement, electrical, power machinery, pumps/valves, wind has been excellent to the tune
turbine generators, etc. Indian foundry industry has a turnover of 50% over the last three
of approximately USD 19 billion with export of approximately years. However, this has
USD 2.5 billion. not translated into similar
growth for the foundries
Indian foundry industry is globally ranked number 2 producing
producing castings for wind
approx 10.7 Mn tons of castings per annum. However, China
turbine sector; instead there is
is number 1 casting producer producing approximately 45 Mn
a decline of 50% for the foundry
tons per annum. There is huge gap between India & China.
sector producing castings for wind turbine sector.
However, grey iron castings have the major share i.e. approx
68% of total castings produced in India. India has installed capacity of 200 thousand tons of castings
for WTG sector. However, present utilization of installed capacity
There are approx 5000 units in the country out of which 90% in foundries for WTG is only 30% and is grossly underutilized
can be classified as MSMEs. resulting in injury to the foundry sector as a result of dumping
of castings from China.
Major Foundry Clusters
Each foundry cluster is known for its products. The major Manpower
foundry clusters are located in Batala, Jalandhar, Ludhiana, The total manpower in
Agra, Pune, Kolhapur, Sholapur, Rajkot, Mumbai, Ahemdabad, foundry sector is approx.
Belgaum, Coimbatore, Chennai, Hyderabad, Howrah, Kolkata, 500,000 directly and
Indore, Chennai, Ahmedabad, Faridabad, Gurugram, etc. 150,00,00 indirectly. The
Typically, each foundry cluster is known for catering to some foundry sector is highly
specific end-use markets. For example, Coimbatore cluster is labour intensive & currently
famous for pump-sets castings, Kolhapur and Belgaum clusters generates employment for
for automotive castings and Rajkot cluster for diesel engine 2 Million people directly
castings, Howrah cluster for sanitary castings, etc. & indirectly mainly from
socially & economically weaker sections of society. It has
Approximately 1500 units have International Quality potential to generate additional employment of 2 Million in
Accreditation. Several large foundries are modern & globally
next 10 years.
competitive. Many foundries use cupolas using LAM coke.
However, these are gradually shifting to induction melting. There
Global Scenario
is growing awareness about environment & many foundries are
switching over to induction furnaces & some units in Agra are As per 50th World Casting Census published by Modern
changing over to cokeless cupolas. Castings USA in December 2016, global casting production is
stagnant. Worldwide casting production grew by half a percent
Wind Turbine Generators in 2015-16.
The wind turbine generation in India has installed capacity of In 2015, world casting production reached 104.1 million metric
28700 megawatts. Over 3400 megawatts were added last year tons, a shade over the 103.7 million metric tons produced

in 2014 and 103.02 million metric tons in 2013 there is a is very vital. It is not possible to achieve the above goal without
marginal growth of approx 0.4% from 2014 to 2015. It is the sustainable corresponding growth of the foundry sector.
the 6th year in a row the market has expanded after global
recession from 2008-09. The worlds two top producing Production in Million Tonnes
nations in 2014 both reported small decrease in production.
Chinas total production decreased by 1.3% from 46.2 million
to 45.6 million tons. While the USA's production dropped 0.8%
to 10.39 million metric tons from 10.47 million tons. But there
is a 7.5% increase in production in India to 10.77 million tons.
China accounts for 44% of the total casting production in the
world and India & USA's combine share is 20% of total casting
production.
Brazil, last year 7th largest casting producing nation, has

experienced two straight years of double digit percentage
decreases in production. It now stands at the ninth place of the
worlds top 10 nations. In 2015, the remaining top 10 casting Export-Import Trends
nations by tonnage are Japan at 5.4 million tonnes, Germany The exports have been showing healthy trends approx 25-30%
at 5.3 million, Russia at 4.2 million, Republic of Korea, at 2.6 YOY till 2011-12 after that there was slow down in export.
million, Mexico at 2.56 million, Brazil at 2.32 million and Italy at However, the current exports for FY 2015-16 are approx USD
2.03 million tonnes. 2.5 billion.
Out of the total 37
participating nations
in the census, only 14
countries reported an
uptick in production. Of
the countries reported
growth, Indias & Mexicos
production growth were
the most significant in terms of tonnage, but several small
nations also reported double digit percentage increases like
Portugal, Romania, Sweden & South Africa.
Sector-wise Consumption of Casting
Automobile sector is major consumer of casting as shown in
The total number of casting units in the world is about 47000
the chart below.
down from 48164 in 2010. As global casting production had
increased in the last five years, the decrease in plants indicates
metal castings businesses are consolidating and becoming
more efficient.
(Source: Modern Castings, USA)
Role in Manufacturing Sector

The new manufacturing policy envisages the increase in the
share of manufacturing in the GDP to 25% from current
15% & to create 100
Million additional
jobs in next 10 years.
Since all engineering
& other sectors use
metal castings in their
manufacturing, the role
of foundry industry to
support manufacturing

Castings and Forgings
Oxygen of the Wind Industry
V. Srinivasa Kannan, Head-SCM

Bonfiglioli Transmissions Private Limited
Forgings and castings are primary and basic input material for to steel castings, thanks to invention and specialization of
any mechanical engineering industry. One can say that the Spheroidal Iron castings with improved tensile, yield and
human races have been developing from Stone Age to Bronze elongation properties. There are grades in SG Iron or AD Iron
Age and then to Iron Age through mastering of these 2 ages which even meets to the properties of carbon steel forgings
old manufacturing processes. Wind turbine and its products in certain applications thereby helps in reducing the cost and
are not an exception. Rather one can call these as oxygen of manufacturability including low batch quantity issues. Castings
this industry with its massive usage and application in creating are predominantly chosen in applications like housing or shell
various assemblies in order to manufacture and for the effective by which the system is built or on applications where you need
performance of the wind turbine. to produce with cavities which are asymmetric and also hidden.
Such applications or requirements are best suited for castings
and with its variety of steel/iron and alloying grades we can
create array of products.
While castings are basically used as housings or shells due

to its tensile and corrosive strength, forgings are used for its
malleability/toughness and in order to handle torque at varying Indian casting industry has grown leaps and bounds over last
and taxing weather and atmospheric conditions. The weight 40 years and our foundries are competing at par with any
range of castings/forgings can be anywhere from 2 Kgs to 2 MT international standard of quality across the globe in terms of
of single piece depending upon where it is to be used. In this manufacturing techniques/infrastructures, etc. Most of the
article we will try to look at the usage and impacts of castings foundries are equipped with Metal Flow Simulation Software in
and forgings with respect to medium weight range from 20 Kgs order to design the GATING process without actual iterative trial
to 250 Kgs applications like yaw and pitch drive applications, and error process. This helps Indian foundries manufacturing
which are the heart of wind turbines effective functioning. samples from concept/drawing very fast. An ecosystem
for foundries is well developed in India to produce array of
Castings castings with moulding process like Resin Moulding, Green
Castings are basically made of steel or iron and predominantly Sand Moulding including High Pressure Lines and Auto Pour
uses iron castings over steel castings due to its improved Arrangements apart from state of art Automatic Sand Plant
availability, machinability, technical requirements compatible systems.

With all these strengths, the challenges on the casting industry
are: a) Quality consistency b) Aesthetic c) Post casting operations
like Fettling, De-coring and d) Availability of skilled labour being
a major constraint given the stiff working environment and
physical challenges. While lots of mechanization and deskilling
happened from melting to moulding to pouring and degating
processes, the fettling, de-coring and post operations are the
major areas of bottleneck both in terms of productivity and
quality consistency. While high volume automotive industry
products are being explored now by various foundries for
Fettling Automation with Special Purpose Machines (SPM),
this is a challenge for Low Batch Quantity consuming and While closed die forgings are most prevalent, the manufacturing
High Variety Industries like wind industry. Also, larger portion of process incorporates machines like Belt Drop Hammer,
small batch producing foundry industry are still run by owner Pneumatic Hammers, Hydraulic Presses, Knuckle Joint Presses,
driven industries and their focus on matching to international Counter Blow Hammers, Vertical or Horizontal Up-setters, etc.
quality expectation is on the development stage. Hence, it in various sizes and applications. The forging industry has been
poses a continuous challenge in terms of getting consistency mechanizing and improving their process consistency and
in quality output which the product manufacturing industries reduction is wastages through metal flow simulation techniques
need to balance between these developing foundries and the through computer aided software used for die designing,
demanding wind turbine consumers who have got plenty of process sequencing, etc. to manufacture forgings with least loss
options across the globe. of material and choosing right size of equipment to give right
The foundry industry is highly power intensive and support kind of force to squeeze the material.
from local governments in terms of continuous availability of
Forging industry per say were continuously improving their
good quality power at affordable cost is a determining factor
manufacturing process in terms of Billet Cutting from Shearing
on location and clustering of these industries. It also gives
to precise Bulk Cutting to ensure consistency in input weight,
advantage in the eco system of all support industries gets
Oil Fired Furnace to Induction Heating for very less or no scale
developed around these clusters and helps in developing this
losses, CAD for reduction of flash losses in effective die designing,
molecule bigger and better. Definitely governments and big
trimming with precision dies and punches to eliminate fettling
industries can nurture and develop these clusters in terms
thus by avoiding manual processes, Heat treatment automation
of Common Facility Development for testing and approvals,
through zone-wise CNC controlled continuous furnaces for ISO
sourcing of foundry products like sleeves, ingredients, etc.
Annealing, Normalizing, Quenching and Tempering, etc. and
and training of manpower to shape them better. IIFM (Indian
finally Online or Off-line eddy current or MPI checking process
Institute of Foundrymen) is taking care of some of these aspects
for avoidance of any internal or external defects as well as mix-
as this industry is under developing stage; there is a long way
ups. A heartening aspect in forgings industries is that they are
to go in terms of maturing with consistency.
mostly extending value addition of machining in most of the
cases and is almost a natural extension with most of Indian
Forgings
manufacturers. The main challenge in process improvement in
Forgings are the evolution of Blacksmithy to a full blown industry forging industries is in terms of yield improvement and better
and it is an integral solution providers to any mechanical managed forgers stay competitive and financially healthy while
systems which demands high level of durability, strength and the rest struggle.
reliability. India is developed with variety of forging industries
which uses hammers, presses, up-setters, part formers, etc. However, the most critical input which is steel; is a real
Forgings are manufactured through hot/cold and warm forging challenge for all forging industries in India. While steel
processes and on ferrous and non-ferrous applications. While making in India has been predominantly served by handful
cold and warm forging processes have made greater inroads in of organisations and is supported by Steel Ministry offering
automotive, fasteners, medical kind of applications, hot forgings immunity and support from external factors to protect the
is a process which is predominantly used in India and almost interest of Indian steel manufacturing, which provides livelihood
in many countries to manufacture bigger and medium size to many people. While this is most needed, the same is found
forgings. Again depending on the geometry and applications, to be a having reverse effect on forging industries and as they
the hot forgings are made through Closed Die or Open Die face competition both from Eastern & Western neighbouring
forgings. Wind industry uses both types extensively considering countries. While automotive grade steel manufacturers have
nature of product, application, batch size, etc. been improving continuously over past 30 years in terms of

various technological improvements, the phase of development Road Ahead
with respect to specialised application steel in industrial category
India is becoming world hub of manufacturing and with push
in terms of grades, purity levels, etc. are under refinement to
for Make in India becoming stronger and stronger with many
reach at par with International Steel Quality for selective high
multinationals setting up shops in India including Defense
end applications.
and Aerospace. These 2 ancient and key industries are in
Although the cost of labour is comparatively lower in India, the the cusp of change on its technology, culture, approach and
overall cost of high alloying steel manufacturing is comparatively the competitiveness. While last 20 years was revolutionized
higher with ingot process which is dependent more on the in Indian manufacturing sector through automotive industries
limitations of Bloom size restriction in Indian steel concast rolling boom and growth, the next 20 years is towards engineering
mills. This restriction on Bloom size is limiting the reduction and high technology industries like power sector, defense,
ratio than what is needed on selective applications. This forces aerospace etc. which demands low batch, high end technology
the forging companies to move to ingot route to achieve the and quality, precision and competitiveness.
desired reduction ratio which is dependent characteristic for The foundries and forging companies are to be future ready with
certain applications and in turn this increases the cost and support of steel industries in order to take on the advantages
reduces competitiveness. With this practical issue, the forging of emerging and flowing opportunities to Indian manufacturing
industries are left to resorting to different areas to focus like arena which can consolidate and grow with structural support
value engineering and value addition in order to compete with from these two key industry segments catering creation of a
competition. first form, called casting or forging for next operation.
India will be one of the Largest Installations of Renewable Energy in the World
Asserting that the present generation has the duty to leave behind a better place to live in for the next generation,
Minister of State for Power, Coal, New and Renewable Energy and Mines Shri Piyush Goyal on Saturday said that by
2022, India will be one of the largest installations of renewable energy in the world. He also expressed optimism at
worlds commitment under the Paris Declaration and the Conference of the Parties (CoP) 21 to fight against climate
change. In the Intended Nationally Determined Contributions (INDCs), I am delighted to say that India has been
an integral part of that entire journey where it was at the forefront of negotiations in the Paris agreement, he said.
Snippets on Wind Power
A Green Energy Exchange on Cards to Reduce Power Costs

Power buyers can so-on start buying green electricity - solar and wind - from the exchange at competitive rates. The
Indian Energy Exchange initiative is likely to make green power cheaper, helping reduce the cash outgo on power bills
by consumers. The CEA has agreed to the proposal. Those who buy from the green market can use it to meet their
obligation on purchasing green power. Initially, it will be a day-ahead market where power for the next day would be
traded. The trading window would be opened every day just before the general day-ahead market, which primarily
deals in thermal power, said Rajesh K Mediratta, Director of Business Development at the Indian Energy Exchange.
The move is expected to increase the sale of green power which is witnessing a glut.
Source: The Economic Times, Kolkata, 12th December 2016
Wind Turbines also Fan Growth of Crops

A new study has found that wind turbines in farms not only capture renewable energy but may also help crops grow
more efficiently. Gene Takle, a professor at Iowa State University in the United States has made a study by installing
research towers on a 200-turbine wind farm to discover how the turbulence created affected conditions at ground
level. The data showed wind turbines can change the temperature in the areas around them. It also showed that
turbulence produced by wind turbines leads to temperatures about a half degree cooler during the day and between
a half to a full degree warmer at night; making growing conditions more favourable for corn and soybeans. The
turbulence also suppressed the formation of dew and dried the crops, Takle said, which could combat harmful moulds
and fungi. It also might enrich the carbon dioxide content in the air surrounding crops, which could make the plants
grow more efficiently.
National Award for Innovation in RE JEEVAN SPARDHA by MNRE

MNRE has initiated the National Award for Innovative Ideas in Renewable Energy-JEEVAN SPARDHA vide their Folio
No.10/6(35)/2016-P&C dated 30.11.2016 through various institutions. The detail is available in the folio.

SG Iron Castings:
Powering Energy Efficiency
P.G. Salunkhe, Vice President

Engineering Division, Premier Limited, Mumbai
1980
India becomes the first country in the world to
set up a Ministry of Non-conventional Energy
Resources.
1990 Beginning of the development of wind power

in India.
S G Iron Axle Pin
Electricity is a great boon of modern science. However, the

unequal distribution of fossil fuels across the countries and their
speedy degradation and depletion has led to a growing interest
in using renewable energy resources. In this sector, wind is
commercially and operationally the go-to source of renewable
energy. Forging and casting companies are working relentlessly
to harness this energy form with their extensive product line.
Production, consumption and importance of wind energy in India;

Opportunities that Premier saw:
W or l dw i de posi ti on i n
wind energy production
4 TH
Current installed wind

capacity, which is 10% of the
8.7
world capacity GW
Casting companies realised the tremendous demand for
Percentage of renewable
related assembly components consisting of heavy SG Iron
energy that comes from wind,
amounting to 28700 MW
63% (Spheroidal Graphite Iron) Castings in the windmill industry.
Following overwhelming customer demand and satisfaction,
the companies expanded to include dedicated wind turbine
Per person electricity 25.8
consumption in cities KW component manufacturing lines for its customers.
Large wind turbine manufacturers need trusted

Per person electricity
consumption in villages
8.9
KW 2016 castings for their rotor hubs, main carriers,
blade adaptors and base frames.

An employee checking the quality of the Main Carrier made of
SG Iron Casting parts.
Quality
Fast Fact
Compliance with specifications and contracts is the most
important factor for forgings and castings companies.
7 Stages of stringent quality
checks
Quality check techniques for SG Iron casting products:
3D CNC Coordinate Measuring Machine 20,000 time spent on quality checks
for producing 3.7 GW power
Separate measuring instruments/equipment (calliper, hours by Premier Ltd.
micrometer, surface tester, etc.)
Use of laser tracker Close attention is to be paid to customers needs and work
Customers third party inspection at each stage towards timely delivery of high quality products with efficient
after sales service.
Certified as per the ISO 9001:2008 standards

COMPONENTS AND THEIR USE
Majority of wind turbine parts in the world are made out of the challenging SG Iron material.
the mechanical requirements of many windmill parts without heat treatment, thus reducing cost by
40% and production time by 10%.
How and where some of our SG Iron parts are used...

Wind turbines can mainly function using either one of the two mechanisms, i.e. one with a gearbox and
the other without a gearbox, known as a direct drive mechanism, which has been praised for its less
complex and low maintenance design. Both these mechanisms employ the use of SG Iron parts, resulting
in enhanced eciency.
SG IRON CASTING
PARTS AT WORK IN
WIND TURBINES...
1
Rotor Hub, Cross-section of the inner working
with the help of an Axle Pin, acts like a of the wind turbine, showcasing
pivot for the rotor hub to rotate along parts made from SG Iron
with the blades. The turning blades spin
the axle pin 30 to 40 times per minute.
2
The Axle Pin (Main Axle), manufactured is an
SG Iron casting part on which bearings are
mounted to enable rotary hub functioning.
3The Main Carrier is a single cast frame made of SG
Iron Casting parts that permits stable mechanical
behaviour and performance. It houses the Axle Pin,
the gearbox, the rotor hub and the blade adapter
and is the most precision load carrying member of
the turbine.

4
Some wind turbines also have Blade Adaptors,
which fastened with the Rotary hub, regulate the
wind turbine speed with the aid of a motor. It helps
to quickly adjust the blade as per the direction and
speed of the wind.
5
The Rotor Hub is further connected to the Stator
Carrier and the Disc Rotor. These parts are tted together
with the help of high capacity magnets that are inside the
frame of the Stator Carrier and outside the frame of the
Disc Rotor respectively. On rotation of the rotor hub
through the Axle Pin, the Stator Carrier and Disc Rotor
also rotate cutting the magnetic eld thus creating
electrical energy. The rapidly spinning shaft drives the
generator to produce electric energy. The blades turn a
shaft inside the nacelle which drives the generator.
6
Bearing Housing is required for gearbox type
windmills to hold the Main Shaft in the right
position by supporing them from the front & rear.
The Main Bearing is tted in to the Bearing housing.
Bearing housings are calculated with the most modern
methods to ensure the best possible application of
force and torque.
Electricity from the generator goes to a transformer which converts it to the right voltage for the electricity grid. The

Indigenisation of Wind
Turbine Components
Sindhuja S Raghuram Hariharan, Dr. B.S.K. Naidu

PGPM (Energy), Great Lakes Manager (Purchase), Gamesa Chairman Emeritus, Great Lakes
Institute of Management, Gurugram Renewable Pvt. Limited, Chennai Institute of Management, Gurugram
sindhuja.pgpme17g@greatlakes.edu.in hraghuram@gamesacorp.com dr.bsknaidu@gmail.com
Abstract the tower base may be made of concrete. Nacelles

house the drivetrain/gearbox components, generator,
In-line with the growing Indian economy, the power demand
transformers and other components for yaw control and
also increases steadily and the renewable energy sector will
pitch control mechanism for which range of technologies
play a significant role in meeting the countrys emerging power
are available in the market.
requirements. Indias strategic decision to move away from coal
as a source of electricity in the long run by ratifying the Paris Many types of corporate structures exist among todays
Agreement on Climate Change is expected to boost renewable wind turbine manufacturers. Some firms, like Vestas India
energy sector considerably. With many reforms introduced in and GE India import most of its critical and high value
power sector and Government of Indias emphasis on clean items from European nations, United States & China while
energy with a target of reaching a total installed capacity of remaining components are sourced locally; other firms like
60GW of wind power projects by 2022, there is a clear visibility Gamesa manufacture towers and blades and source other
of substantial growth in wind energy sector. With successful components from various suppliers in international market.
experience in the past, Independent Power Producers are Wind turbine parts are not often interchangeable. Some
now expanding their investments in wind projects in India. components are designed for specific turbine systems
Over the past decade, significant wind turbine manufacturing and a breadth of turbine system designs are available
capacity has been built in India in response to an expanding today to both serve customer needs and sustain firm-level
domestic market and India has secured fourth position in competitive advantages.
global wind energy installation. As of October 31, 2016, the
installed capacity of wind power was 28,279 MW. Looking at VALUE OF MAJOR TURBINE COMPONENTS
the business opportunities and favourable regulations, many Pitch
Mechanism, 4% Control & Safety
foreign companies established their turbine manufacturing System, 2%
plants in India. Nearly 25% of the turbine components are Hub & Nose
cone, 5%
imported from various countries and the balance is sourced
indigenously. The study being reported emphasises on
Blades, 14%
indigenous supplier development and highlights the challenges Nacelle, 52%
involved in developing such suppliers. This paper explores the Tower, 23%
economic and commercial advantages of indigenisation of wind
turbine components as well as the technical competence that
Indian manufacturers gain out of it. This paper also discusses This Chart characterizes the relative capital cost of equipment for
a 1.5 MW onshore based turbine. Installation cost such as tower
the major factors effecting indigenous supplier development founadtion, evacuation & grid connectivity and Project
management cost are excluded
and steps involved in it.
Source: Tegen.S.,et al, (March 2013), "2011 Cost of wind energy review".
1. Introduction
2. Indigenous Supplier Development
Wind turbines are composed of more than 8,000 individual
Wind turbine manufacturing companies in India procure
components and about 90% of the value is captured in
equipment mainly from United States, European Nations,
three main parts: blades, towers, and nacelles. Blades are
China, etc. and its imported components are worth about
typically made of fibreglass and epoxy composites and
INR 1.5 to 1.85 Cr per MW. It takes minimum of 16 to
include some carbon fibre materials. Towers are mainly
24 weeks, which includes transit lead time of 8 weeks, for
composed of rolled steel and in some large-scale designs,
the component to reach manufacturers facility. In addition,

for repair services of imported components like converter, Steps involved in Indigenous
control panels, gearboxes & many such products, the Supplier Development
equipment needs to be sent back to suppliers country
which is again a burden to turbine manufacturer in terms
of time and cost. Besides quality non-conformances & Potential Source Identification
delivery delays has a high resolution time resulting in
instability in production which ultimately affects sales Sharing Specification and drawings with
targets, working capital & loss of capacity. suppliers and RFQ Process
The capability to design, develop and manufacture
equipment within the country, using its own skills and
Supplier Credential Verification and
resources, constitutes indigenisation. The capability to
Pre-Screening of Suppliers
maintain and repair these, as well as equipment sourced
from abroad, makes the nation self-reliant. In addition,
indigenisation is a process which enables the turbine Collecting Techno-Commercial offer
manufacturer to reduce variables/fluctuations in the supply from Suppliers
chain by building the components through Transfer of
Technology (ToT) or by developing supply partners locally.
No
As turbine manufacturers have to meet huge market Tech. cleared
demands to the extent of 60GW by 2022, it is pertinent to
ponder over reducing its extreme dependence on imports Yes
by building indigenous capabilities across the entire Supplier Facility visit for General Audit
value chain from research, design and development to
manufacturing, integration, maintenance and repair.
Commercial Negotiation
Indigenous supplier development or strategic partnership
formulation with the more suitable vendors should be
Micro level System and Technical audits
integrated within the supply chain for improving the
performance in many directions including reducing costs
by eliminating wastages, continuously improving quality Trial Order Placement
to achieve zero defects, improving flexibility to meet the
needs of the end-customers and reducing lead time at
different stages of the supply chain. Product Validation
For developing
domestic vendors for No
Proto Cleared
the product currently
being supplied by Yes
foreign vendors, the
Production Part Approval Process
equipment and its
specification are to
(PPAP) Compliance
be shared with local
Approval of Product and Supplier for
Serial Production
3. Challenges in Indigenisation
3.1 Time Taking Process

suppliers. In some cases, reverse engineering practice is Though indigenisation sounds simple, it is actually a tedious
also used to study the domestic competency. Most of the and time taking process as it requires the identification
wind turbine manufacturers prefer competitive bidding for and selection of right vendor partner. And the identified
developing indigenous suppliers which involves following supplier needs to assimilate the technology and design of
steps: the product that is to be indigenized.

3.2 Costlier Process System (QMS) also play a major role during supplier
selection.
Turbine manufacturing firm needs to set up a team for
indigenisation with good expertise in technology and
4.3 Technical Compliance
commercial arena and this makes the process exorbitant.
Right decision making skill of buyer is crucial for developing Suppliers need competent technical ability to provide
domestic supplier as buying firm establishes long-term high quality product, ensure future improvements in
relationship and it would cost the company heavily if the performance and promote successful development efforts.
supplier fails to perform after order placement. This is considered as a crucial factor while developing local
suppliers as the product which is currently being supplied
3.3 Funding Issues by foreign vendors are to be replaced by domestic suppliers
Access to funds would be the biggest challenge for and the suppliers are required to be competent enough to
suppliers as they are sensitive to a highly capital-intensive meet the technical requirement of global standards. This
business. Components of wind turbine are not standard factor has been measured on the basis of the importance
and it requires customization with respect to each turbine of the following: technical dimensions, compliance
manufacturer. Hence issues related to economies of scale
with drawings/datasheet, compliance with turbine
are also to be addressed.
manufacturers specification, compliance with packaging
standard, R&D team, supply to hi-tech applications like
3.4 Rapid Pace of Obsolescence
defence, space, nuclear, etc., test lab & accreditation of
Once the turbine model becomes obsolete, suppliers are test lab, production machinery, level of automation in
required to upgrade their technology and this is again a
production, customer base, technical JV, RFT of design
time and cost consuming process.
validation of previous development projects, special test
certifications, export market, continuous improvement
4. Factors Effecting Indigenous Supplier Selection
on product, process, etc. In order to rigorously check the
Indigenous supplier selection aims at determining two suppliers capabilities the buyer might request samples of
common decisions viz. which suppliers should be selected
supplier's products and test them to ensure conformance
and how much of any particular order should be allocated
to the buyers requirements.
among them. To do so, a number of criteria and conditions
are involved and major factors are discussed below.
Factors influencing Indigenous Supplier Selection
4.1 Cost Supplier Selection
Cost is more than just price. Buyer should always calculate

landed cost, which includes all the "hidden fees" such as COST QUALITY ORGANIZATION SERVICE RELATIONSHIP
freight, duties, lead time & increased inventory carrying Performance JIT Desire for
Price Quality
History capability business
cost, warranty, etc. This also illustrates the importance of
understanding where the product is made and where each Financial Communication Technical
Reliability Attitude
Position capability
component is manufactured. Other additional expenses System
to watch out are minimum order quantities (MOQs), Operating Repair & Amount of the
Flexibility Reputation past
payment term and service charges. Control Service business
Inventory Procedural Delivery Reciprocal

Consistency
4.2 Quality Cost Compliance arrangements
Quality assessment is one of the key factors in supplier Discount Process

Improvement
Management
and
Warranties & Impression
organization claims
evaluation and it could become the deciding factor. This
factor has been measured on the basis of the importance Packaging Labor Relation Professionalism Long-term
Ability Record relationship
of the following quality dimensions: ISO certificates,
quality policy and planning, quality assurance in supply Quality Geographical
Research Integrity
Standards Location
chain, quality assessment in production, inspection and
experimentation and quality staff/labour/employees of Product Training Experience Culture
development Aids
supplier. It also includes the defective parts detected in
the incoming products. Quality control practices, frequency Expertise Resource
Knowledge
Management
of conducting internal audits and Quality Management

WIND INDUSTRY
AT A CROSSROADS
The wind industry is at a crossroads. Overcoming the challenges of reducing the

Cost of Energy from future offshore wind farms takes world class engineering
capabilities and state-of-the-art testing experience, alongside process and
manufacturing skills built up in a global footprint over decades. Dedication and
creativity alone are not enough.
Developing the LM 88.4 P blade for an 8 MW offshore wind turbine was a huge
lmwindpower.com
undertaking, leveraging all the disciplines of a true global blade supplier. And we
delivered: smoothly and seamlessly interacting with the clients development team;
swiftly converting numerous load iterations into tangible and competitive blade
design details; and ultimately sticking to a proven development plan ensuring
fastest and safest product launch of this pivotal component.
The longest, most advanced, wind turbine blade in the world:

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4.4 Research & Product Development suitability for a particular product. Suppliers are required to
highlight the time duration required for attending to the
When a new product is to be developed or where there
repair issues while submitting their commercial offers.
is a need for product customization, this factor plays a
major role. It focuses on inter-organizational relations by
4.9 Financial Position
focusing on the internal management and organization
of manufacturer-supplier collaborations in new product An assessment of the financial stability and fiscal outlook of
development. This factor has been measured on the basis the supplier is a factor gaining importance in the growing
of the importance of the following dimensions: suppliers trend of supplier-buyer partnerships.
involvement in product development, integration of
The financial status of the supplier can be analysed by
capabilities, and suppliers participation in decision making.
getting financial statements such as Income Statement
Suppliers involvement refers to the resources (capabilities,
and Balance Sheet. From Financial statements, information
investments, information, knowledge, ideas) that suppliers
about annual turnover, Earning per Share, Long-term
provide, the tasks they carry out and the responsibilities
borrowings and Short-term borrowings can be inferred
they assume regarding the development of a part, process
based on which financial stability of supplier can be
or service for the benefit of a buyers current and/or future
understood. When high volume of business is involved,
product development projects.
CRISIL rating can also be referred to. A good supplier
4.5 Capacity and Production Facilities should have a good financial base so that in case of
delayed payments, supply will not be hindered.
When volume of business is huge then capacity becomes
a key aspect to select suppliers. Scalability should also be 4.10 Other Factors
taken into account to judge the best vendors. The potential
Other factors effecting indigenous supplier selection
production capability of each supplier can be analysed by
include, but are not limited to:
verifying the ratio of installed machinery capacity to utilized
capacity. Suppliers will possess necessary documentation Management and Organization
related to their capacity analysis which should be taken as Inventory Cost
a proof to conclude supplier shortlisting process.
Attitude and Level of Interest shown
4.6 Geographical Location Performance history
Procedural compliance
The location of the supplier and its physical and social
Production/Process improvement Initiatives
status should be analysed properly before selection of
Reputation & position in industry
vendor partner. The state of the supplier, the location of
plant, the nature of natural calamities, and other factors Cost Monitoring & Cost Control Tools
should be checked before the selection as for long-term Wind Industry Experience
relation none of these factors should create problems Warranties and Insurance
in the supply of goods. Logistics cost may get reduced
to certain extent by opting closer location of supplier.
5. Advantages of Indigenisation
Suppliers plant located in Special Economic Zone gains Though indigenisation of wind turbine components is a
an advantage due to tax benefit. tedious and time taking process, it is worth doing as it has
so many advantages not only to the turbine manufacturers
4.7 Delivery but also to the complete supply chain and to the nation at
Lead time of delivery gains more weightage and becomes large. The major advantages include, but are not limited to:
a deciding factor when the item is required on an urgent
basis. The ability of the supplier to follow the predefined 5.1 Commercial
delivery schedule is always the prime criteria for selection Typically purchase orders for import equipment will be
in this fast moving world and this acts as post-order placed in foreign currencies depending on the suppliers
monitoring tool for measuring vendors performance and location and their terms. This creates uncertainty to the
this has direct relationship with vendors past performance. deal as currency valuation keeps varying. Indigenisation
would eliminate in a big way the exposure of currency
4.8 Repair Services fluctuation and the order value remains static till the
The response level of the supplier in providing repair service contract period gets over.
to turbine manufacturer is the prime criteria to decide its

Increased local supplier base would reduce tax burden As the cost would be controlled/saved substantially
due to imports. Though tax exemption can be availed through indigenisation, turbine manufacturing companys
for certain import equipment as per MNRE policy, there profit margin would certainly increase and they could
would be substantial savings when those components are provide more value to their customers. Also, it improves
locally sourced as tax exemption/concession is applicable the payback period of their investment.
for domestic sourcing too.
6. Conclusion
Due to continuous research and development, like other
Competitive pressure is increasing to reduce the turbine
industries, wind industry is also getting mature resulting cost in order to survive and shine in the industry and the
in shorter life span of a turbine model. The new platform key to achieve this is indigenous supplier development.
of models makes old models obsolete in a time span of indigenisation helps in achieving substantive self-reliance
4 to 5 years. Hence it is very important that components in the design, development and production of turbine,
are developed locally thereby avoiding huge time spent in enhancing potential of Indian manufacturers especially
development, transportation, coordination, issue resolution, SMEs and in broadening the R&D base of the country.
etc. It would also ensure a sizeable quantum of business to
the local industry over the entire life-cycle of the turbine
5.2 Technical and ensure timely support especially at the time of repair
Proximity of suppliers helps in quick resolution of quality service. Indigenous supplier development is a multi-criteria
& delivery related concerns besides improving service decision-making process depending on a wide range of
factors which involve both quantitative and qualitative
response. Localization will increase consistency of work-
ones.
flow practices due to cultural similarities. Quality inspectors
can go to equipment manufacturers premises anytime for To put in a nutshell, some of the key advantages
quality inspection; hence it leads to better quality control. are considerable savings, significant working capital
improvement, faster turnaround time, shorter supply chain,
Indigenisation enables domestic supplier to develop huge reduction in delivery lead time, faster response to
products through reverse engineering which directly quality concerns, comfort from service standpoint, benefits
helps in gaining competitive advantage. It encourages due to similar culture, last but not the least good value
the suppliers to get CE marking and other required proposition to customer in terms of cost, quality, delivery,
certifications for their product providing them a platform etc.
to compete in global market. It also promotes competition With huge merits in indigenisation, as described in this
in Indian market which in turn provides opportunity for paper, most of the turbine manufacturers have laid
suppliers to bring technical improvements not just from enormous thrust on localization besides contributing in a
price standpoint but also from a technological standpoint. big way to the Make in India mission of Government of
India.
5.3 Economical
Developing local suppliers would enhance job opportunities
References
and skill development of Indian citizens. Also, it supports 1. http://mnre.gov.in/mission-and-vision-2/achievements/
the Make in India initiative of the Government of India 2. https://cleantechnica.com/2014/05/09/ge-will-invest-
Indigenisation reduces monetary value of import to the 200-million-indian-wind-turbine-manufacturing-unit/
nation and the equipment manufactured locally can updated on 09.05.2014
be exported to various countries once the equipment
manufacturer gets global approval for their product. Hence
indigenous supplier development would improve Balance
of trade and Gross Domestic Product (GDP) of our nation.
5.4 Other Advantages

Import lead time is considerably higher compared to Theme of the Next Issue
local buy/purchase. Localization of turbine components
would drastically reduce the delivery period due to close The theme of the next issue of
proximity of supplier which in turn improves the operational Indian Wind Power is
efficiency of the company and it makes the business more "Positioning Wind Energy for the Future"
agile. For wind turbine manufacturers who operate on
We invite relevant articles to the theme. We solicit your cooperation.
push strategy, indigenisation would reinforce their strength
Editor
further by reducing the lead time of manufacturing.

Let the Wind Blow in Favour of Indian Foundries
.As there is 7000+ potential customers in the waiting
Dr. Nithyanandan Devaraaj, Honorary Secretary, Institute of Indian Foundrymen

Secretary@indianfoundry.org/nithin.devaraaj@gmail.com
Thanks to untiring efforts of our beloved Prime Minister, Make It is a common knowledge that there is no manufacturing without
in India and Digital India is redefining Indian businesses. As we foundries. Castings form an important basis - the foundation of
embrace the dawn of a new year, trust the said initiatives of manufacturing value chain, from mining to end customer. Such
our Government will usher in a new era for overall growth & importance is very well recognised by present Government and
prosperity of our country. is beginning to transform Indian Foundry diaspora.
Demand for any products & services are a demand dependant. Avenues for exclusive foundry skill development, upgrading of
This is especially true for businesses operating in Industrial metallurgy syllabus in elite institutions, inclusion of Foundry
Markets B2B segments. It is natural and important for players Sector in Vocation Training Schemes, investment priority for
from respective segments to look for reciprocal relationships absorption of new and modern technologies, cluster approach
and leverage possible opportunities. This is especially true to develop green foundries, re-categorisation of foundries
when a potential exists for a supplier to become a customer to in terms of environmental norms are some well-received
his or her customer. development measures of Government of India specifically for
Foundry Sector and as part of Ease of Doing Business initiatives.
Wind industry is one which offers liberal scope for a mutually
beneficial association and foundry being a power intensive Spread of Foundry Industry
sector, scope is manifold.
Genesis of development of any industry are SMEs. Its more
Back Ground so in Indian Foundry Sector. Majority of Indian foundries came
into existence as part of back ward integration from pumps
Since formation of new Government in the Center, a lot of
& motors to now high-end automotive, earthmoving, agriculture
buoyancy is expected in manufacturing sector. Vital parameters
and engineered castings for critical applications like wind
of economic measures in last few months are to be taken
turbines, defence, medical and aerospace.
as corrections and essential foundations for future economic
growth of the nation. THERE IS NOT ANYTHING IN LIFE, THAT IS UN-TOUCHED
BY FOUNDRY
Make in India initiatives have augured well for Indian Foundry
Industry third largest in the world. From last couple of years,
Indian Foundry Industry has been accorded its rightful status
as an independent sector culminating in formation of Foundry
Development Council under the aegis of DIPP.
Growth achieved by Indian Foundry Industry shows its

versatility and resilience to service any and all emerging needs.
Over the years, Indian Foundries have played a vital role in
adoption, indigenisation and development of castings for critical

applications aiding localisation of casting technologies resulting Indian Foundries Metallurgy-wise Distribution
in substantial foreign exchange savings. There are many firsts,
and continued collaborative efforts with OEMs will ensure this
is just a beginning.
NON-FERROUS
However, ownership pattern, size and spread of Indian foundry 0.65Mi Tons (6.5%)
sector is not in line with that of OEMs, barring a handful of STEEL 1Mi Tons (10%)
corporate owned foundries. This is slightly different from that SG IRON 2Mi Tons (20%)
of consolidation strategies adopted by American, European and
GREY IRON 6Mi Tons (62%)
off late Chinese Foundry Sector.
WE ARE YET TO EXPLORE THE TOP OF THE PYRAMID
Number of Foundry Units and their Production NEEDED METALLURGICALLY STRONG APPLICATION ORIENTATION
Registered Un-Registered
Units Production
Units Units Given the capacity and capability of metallurgists, this is a
Classification Total (Mi dichotomy to be overcome the quickest. Under TQM principles
Average
Nos % Nos. % Nos. %
(TPA)
Ton Per % while QFD is liberally deployed to leverage process excellence
Annum)
in Casting Value Chain, it is possible to drive the same towards
Unorganized 3000 45 1800 60 1200 40 30 0.80 8 product excellence. As mentioned earlier, first step towards
Micro 2500 37 1875 75 750 25 720 1.80 18 this will be nurturing foundries through a model of consistent
Small 1000 15 750 75 250 25 3,600 2.80 28 collaboration and long-term mutually binding relationships with
Medium 200 150 75 50 25 13,000 2.50 25 emphasis on joint value creation.
3
Large 30 30 100 0 0 60,000 2.00 20
Total 6730 4605 2250 9.90
Research says that there are many reasons for such a gambit
commencing from buyerseller behaviour to macro-economic
factors like interest rates, infrastructural costs, entry-exit barriers,
regulatory requirements, socio-economic factors, etc. One
of the most significant and notable aspects is nurturing of
foundry suppliers by OEMs. World over, barring a few, supply
chain development, growth and efficiency is determined by
strong relationships built on trust and mutual confidence.
Foundry being in the middle of supply chain, importance of
such relationships cannot be undermined. It is obvious that this
can happen only with mutual preference between a foundry
and an OEM. This is more so especially when operating in a
niche segment like wind industry.
It is to be noted that foundries are those have expanded rapidly,

irrespective of the sector they cater to, without backing of OEMs
have succumbed to not so benign vagaries of market, meaning
unable to absorb value and volume variations. Such happenings
have ensured that the sector remains a prerogative of SMEs, Current dispersion of value chain ownership and responsibilities
who prefer a measured growth rather than fast growth. indicate that foundries continue to remain just as process owners
and neither specification nor product owners just making
Value Chain Positioning of Indian Foundries in castings as per drawings and specifications. In the long run, and
Wind Industry as already happening in developed economies, the Industry
becomes non-attractive to emerging knowledge workforce and
It is a fact that more than 95% of foundries world over have
demographic spread. Knowledge and skill cannot be mutually
remained component suppliers - either as Tier-1 or Tier-2
exclusive, and foundry industry needs a sound combination of
suppliers and not suppliers of proprietary items. Very few
both across fraternity.
foundries are owned by OEMs as backward integration and
those who make differentiated products are exceptions. Indian It will not be farfetched to say that economic prosperity,
foundries are no different. growth and development can happen only as we move up

the value chain. This will help the industry and its customers to Castings, though form only less than 5% of value in a wind
create value propositions and differentiations while competing turbine are in A Class item, which defines the criticality of value
across countries. Elsewhere in the world, several interventions chain. While there is no dearth of capability in India to meet
and incentives have helped foundry sector to offer attractive specifications and requirements, economics plays a vital role
propositions for all stakeholders, which may not be difficult to in value chain decisiveness. Investment to returns ratio in the
replicate in Indian foundry sector. This will largely depend on present market conditions are heavily skewed towards majority
according right priority to create an end to end value chain for volume sectors where market and demand are stable and less
overall benefit of our country in terms of societal engagement risky.
and employment generation, the very objective of Make in Given the right economics, Indian Foundry Sector will be able to
India initiative. Statistics says every ton of casting produced will fulfil all present and emerging requirements of wind industry. In
create at least one employment in the value chain. fact, as wind turbine industry consolidates globally, if positioned
rightly, Indian foundries have all the potential to become global
Indian Foundries in Wind Market players. Choice and preference of new age population to shy
away from hard core sectors elsewhere in the world will drive
Thanks to initiations in wind industry, the first generation wind
such potential quicker than later.
turbine producers in India was originally from Europe. KW class
wind turbines gradually used castings developed from Indian
foundries. As KW class turbines progressed to MW class, and
as castings in terms of sizes grew bigger, specifications by
and large remained same. Due to gradual growth in terms of
castings size and specifications, wind castings metallurgy was
never a challenge for Indian foundries.
To begin with, there were a few foundries who could manage

the size of castings for MW class turbines. Wind industry is
one of the pioneers to bring in a collaborative approach in
indigenisation of castings. Laudable efforts put in by certain
large players in wind industry, Indian foundries steadily built up
capacity and capability to manufacture MW class wind turbine
castings. Today many Indian foundries are capable of handling
very large size castings and with incremental investments, it is Challenges
possible to meet even future requirements of wind turbines. Indian foundry market in terms of specifications and output
Present combined capacity of Indian foundries will be able to is driven primarily by automotive and agricultural industry.
sustain supplies for an annual installation of up to 10000 MW+ Quite naturally, backend value chain is designed to cater to
of wind turbines. With incremental investments, the same can these major segments more efficiently up to 99.5%. Any
disruptions induced for other segments should be justifiable
go up to 15000 MW per annum.
with performance and a definitive business share. It is possible
however to compensate such disruptions with increase in value.
This may not always help as capacity for such requirements will
remain underutilised.
It is true that performance across sectors is dependent largely on

macro-economic factors and fiscal policies of the Government.
Matured markets have in a way absorbed much of the market
vulnerabilities. However, niche and super segmented markets
such as wind industry is still reliant on such inducements.
Therefore, continuity and consistency in terms of value and
volume remain a challenge. Many purists base their argument
that no market is isolated from value-volume variations. This
has to be understood from a broader perspective - that market
balances for generic products and risks can be avoided with a
portfolio of products and industry within like categories. Niche

segments as that of wind turbines offers limited scope. Under In a Unipolar World, enviro-legal alignment globally will be
the circumstances, strategies adopted across other niche sectors natural. Costs of meeting emerging mandatory requirements
has to be replicated like consolidation and balanced off-takes, are to be understood and benefits shared equally across
rather than planning for peak. value chain. It is not mere compliance. User communities
should prefer and encourage supplier communities to work
SPELT (Socio Political Economic Legal Technological) towards betterment of environment, health and safety of both
of New Order organisation and extended organisations.
Socio Political Economic Legal Technological aspects will see an Wind power is green power. Indian suppliers to wind power
emergence of new order. Hard core industries will be viewed as should be encouraged by sharing the benefits of green energy.
quintessential for strong socio-economic development. However,
An appropriate incentive mechanism can be worked out for
it will remain in the hands of respective industry players to
benefit of entire value chain.
make it more attractive for newer generation workforce. In a
developing economy, every sector needs to be accorded equal At macro level, user industry associations should work towards
importance. Cross industry competition may cannibalise holistic ensuring that benefits from fiscal incentives and special statuses
potential at the cost of core sectors like manufacturing and more accorded to them is passed to the entire value chain. Else, it
importantly foundry sector. This will be detrimental to overall may result in cost to suppliers, as in the case of Central Excise
interest of the nation and business establishments, considering and Customs Duty.
market as a closed loop in which employment generation is key
to sustained growth and development. Closing Remarks
World will sooner be unipolar on all aspects. Learnings from Sustainability is the key mantra for future. Dynamics of business
other economies will help us to re-establish our priorities. A economics is to be understood in appropriate perspective.
cursory study shall reveal that an economy can be vibrant Major market segments are able to evolve and sustain due to
and sustainable if and only if all players in a value chain are creation and dependence on domestic value chain. Domestic
accorded an equal recognition and importance resulting in fair value chain is not a mere option. It is a strategic necessity to
market treatment. It is not possible to create a local market for stimulate employment and sustain demand.
any end user products if we are not able to build and sustain
local value chain. Local value chain will stimulate and drive Let us be determined to work together to create a formidable
sustainable investments. India.
Give Renewable Energy Zero-Rate Status under GST: Ministry

The Ministry of Power (GoI) has recommended that renewable energy be given a zero-rate tax status under the Goods and
Services Tax, predicting several adverse effects to the economy if there is any increase in power tariffs due to the new tax
regime.
CPCB MeoF - Notification Wind Power in White Category

Central Pollution Control Board on 18th January 2017 has published a notification with subject, Clarification in the matter of
Revised Categorization of the Industrial Sector namely Solar power generation through Solar PV cell, Wind power and Mini
Hydel power (less than 25 MW). In the following notification the Wind Power is placed at serial no. 35 in White category
of Industrial Sectors.
China to Invest $100 billion in Wind Power Projects by 2020

According to the National Energy Administration of Chinas latest wind power development plan, China will invest more than
700 billion Yuan (approx. US$100 billion) in wind power facilities from 2016 to 2020.
PGCIL Achieves ` 1 lakh Crore Market Capitalization

Union Minister of State (IC) for Power, Coal, New & Renewable Energy and Mines, Shri Piyush Goyal congratulated PGCIL
on achieving ` 1 lakh crore market capitalization and said that it is no mean feat to achieve, especially looking at the current
state of the global economy. He asked the Maharatna company to develop a robust mechanism to unlock its capital and
expand the portfolio rapidly to achieve the target to integrate 175GW Renewable Energy in the National Grid and reach out
to 5 crore families still without power.
Source: PIB, 21st December 2016

Special Forgings for
Critical Gearbox Components
Umakanth Papatla, General Manager Quality & Technology

ZF Wind Power, Coimbatore
1. Introduction follow international testing standards for testing input

material used for forging.
In pursuit of producing world class gearbox, utmost care is a
must in selecting input material. All the critical components
3. Forging
like planet wheel, ring wheel, slow wheel, fast wheel and
hollow shaft are produced from very high quality forgings. 3.1 Forging Plant Approval
The true advantage with forgings is superior mechanical All the forgings used for critical applications are
properties to weight ratio that enables the designer to manufactured in worlds leading forging plants having
produce a part that is lighter and stronger than could be advanced manufacturing, heat treating and testing facilities.
achieved using other metal forming processes. As designers
During the development of forging process for new
push the limits of load, stresses, and temperature with their
components, simulation and 3D modelling is used to
products, forgings time and time again meet the calling.
ensure impeccable process capability.
2. Input Material
3.2 Forging Process
Very good quality alloy steel is used for forging by ensuring
the following qualities. Internal soundness, grain flow and mechanical properties
depend on reduction ratio (reduction from input raw
1. Very good micro cleanliness
material to forging). Hence, one must ensure that ample
2. Good mechanical properties like tensile and impact reduction ratio is always maintained for each type of
strength forging.
3. Lower gas contents and harmful tramp elements

Hot Forging Process
4. Good internal soundness
Hot forging process is the most suitable process for wind
5. Good surface quality
applications and hence input material is heated in furnace
6. Fine uniform grain size at a controlled predefined temperature for specified time
7. Excellent hardenability (response to heat treatment) before forging. Also the blank used for forging is precisely
by ensuring optimum content of alloying elements weighed to eliminate under filling or other non-conformity.
All the preheated blanks are also descaled using descaler to
The steel used for gearbox forged components, is always
eliminate forged-in scale and other surface imperfections.
processed by secondary refining and vacuum degassing
with very low harmful gases and tramp elements. All the forgings are manufactured by the advanced ring
rolling forging techniques as shown in the following
Both gearbox manufacturer and steel suppliers must
schematic diagram. A few suppliers still use old drop
test every batch of input material at their state of the art
metallurgical laboratories. All forging companies should forging technology.

1. UPSETTING: Starting stock cut to 2. PUNCHING & PIERCING: Workpiece 3. FEEDING FOR ROLLING: Completed
size by weight is first rounded, then is punched, then pierced to achieve preform is ready for placement on
upset to achieve structural integrity starting doughnut shape needed ring mill for rolling.
and directional grain flow. for ring rolling process.
4. RING ROLLING: Ring rolling process begins with the idler 5. SIZING: The process continues until the desired size is
roll applying pressure to the preform against the drive roll. achieved.
4. Heat Treatment after Forging 5.3 Microstructure

Ring rolled forged products are heat treated into the Micro inclusions
batch type furnaces to get the required mechanical and
Phase analysis
metallurgical properties. All the furnaces have automatic
temperature control and timers. A special heat treatment Decarburised layer depth
process after forging is desirable for grain refinement and
Micro-segregation
getting uniform grain size.
5. Inspection of Forging 5.4 Macrostructure

Following testing is done on all the forgings at manufacturers Macro-segregation
end and also at incoming stage.
Forging flaw lines
5.1 Mechanical Properties Macro inclusions by ultrasonic testing
Hardness
Tensile strength and % elongation 5.5 Non-Destructive Testing
Impact strength Magnetic particle test
5.2 Chemical Properties Mobile spectro test or Eddy Current Test (for material
mix up)
Chemical analysis for all the elements
Ultrasonic test
Gas analysis for all harmful elements like Oxygen,
Hydrogen and Nitrogen. Visual inspection

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world, contributing to continuous power for green energy.
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Fax: (65) 6588 3557 Fax: (65) 6588 3557
E-mail: APRegion@NGCTransmission Email: APRegion@NGCtransmission.com
www.NGCtransmission.com/en
5.6 Dimensional Check 7. Traceability
Outer diameter In addition to above, all forging companies insist on
very high levels of traceability. Each and every forging is
Inner diameter identified by a unique serial number. This serial number
Thickness corresponds to raw material heat number, forging batch
number, heat treatment batch number. Also all the forgings
Width
used in gearbox are traceable in the same way.
Ovality
8. ZFs Philosophy
5.7 Other Tests The above process control and product control measures
are being deployed at ZF while making gear elements,
Jominy hardenability test
considering life of the wind turbines.
6. Certification References
All suppliers generally test their products before despatching MIDAS#: Mannesmann Inclusion Detection by Analysing
and certify their material with test certificates as per EN Surfboards
10204 class 3.1. EVA* analysis: Extreme Value Analysis
Wind Industry News
Senvion Wins Firm Framework

Senvion is a leading global manufacturer of onshore and offshore 2 MW to 6.15 MW and rotor diameters of
82 metres to 152 metres wind turbines. Senvion has concluded its first contract in India for the supply of 220
Senvion turbines totalling more than 500 megawatts (MW) under a firm framework agreement with one of the
large Indian IPPs. The 220 turbines will consist of turbines from the recently acquired Kenersys portfolio. The
wind turbines K100 (2.6 MW), K110 (2.4 MW), K110+ (2.6 MW) and K120 (2.3 MW) are part of the planned
acquisition.
Gamesa Tops its Manufacturing Record

Gamesa has beaten its annual turbine manufacturing record, having made more than 1,880 units with productive
capacity of 3,880 MW in 2016. This milestone is markedly international as the turbines were assembled all over
the world: India (36%), Europe (28%), China (26%) and Brazil (10%).
Inox Bags Order from NTPC

lnox Wind Limited has bagged an order for a 50 MW wind power for 25 units of its advanced 2MW DFIG 100
rotor diameter WTGs for Gujarat from NTPC to be executed on a turnkey basis. With 47GW of capacity under
operations, NTPC is India's largest energy conglomerate and this 50 MW maiden order marks its foray into Wind
energy generation.

Landowners' Nod Not Required to Lay Overhead
Snippets on Wind Power Power Lines: Supreme Court
Through this judgment, Supreme Court has settled the
issue which gave rise to conflicting judgments from various
US-India Clean Energy Finance Facility Initiative HCs. The SC's top priority was to enable the Government
17th December 2016 and its agencies to get electricity to the last household in
the remotest areas. The bench said, "As per the provisions
Letter of Intents were signed and exchanged between MNRE of the Indian Telegraph Act, unobstructed access to lay down
and OPIC (Overseas Private Investment Corporation) in telegraph and/or electricity transmission lines is an imperative
presence of Shri Piyush Goyal, Minister for the creation of in the larger public interest."
a $20 million for US-India Clean Energy Finance (USICEF) Source: Economic Times, December 30, 2016
Initiative, equally supported by the United States and India
would support projects upon long-term financing and CEA - Draft National Electricity Plan (NEP), 2016.
deployment, and would qualify for the support of long-term
CEA has published the Draft National Electricity Plan (NEP)
debt financing from OPIC.
on 7th December 2016. The Draft covers a review of the
12th Plan for 2017-2022 in detail and perspective plan for
Incentive for Wind Power Needs to be Revisited: 2022-2027. The comments/suggestions were requested by
Study 22nd January 2017.
The reluctance of distribution companies (Discoms) to
procure wind energy due to their weak financial health is one CERC- Draft Indian Electricity Grid Code (IEGC) Fifth
of the biggest challenges facing the wind energy sector and Amendment Regulation, 2016
there is now a need to shift from Generation-based Incentives CERC has published Draft Fifth Amendment on Indian
(GBI) to Procurement-based Incentives (PBI) in the country, Electricity Grid Code (IEGC) on 9th December 2016.
according to an evaluation of the GBI scheme done by CRISIL. comments/suggestions/objections from the stakeholders and
the interested persons on the Draft regulations were invited
The study found that various wind power developers and
by 30.12.2016.
investors had highlighted that the GBI level of Re. 0.50
per unit is insufficient to promote wind capacity addition in
'Coal Mitra Web Portal Launched
Tamil Nadu, Gujarat and Karnataka due to unviability of FIT
(feed-in-tariff) plus GBI model." The study also found that the Union Minister of State (IC) for Power, Coal, New & Renewable
capacity addition under the GBI second phase was modest. Energy and Mines, Shri Piyush Goyal has launched Coal
Mitra, a web portal for flexibility in Utilization of Domestic
In the second phase, while the capacity addition target was
coal. The Coal Mitra web portal to be used by the State/
15,000 MW, only 5,762 MW has been added. However, the
Central Gencos has been designed to bring about flexibility
study found that GBI remained one of the key incentives that
in utilization of domestic coal by transferring the reserves
has driven investments in the sector especially from number to more cost efficient state/centre owned or private sector
of IPPs who are not availing Accelerated Depreciation (AD) generating stations, leading to lower generation costs and
benefit but doing project finance. ultimately lesser cost of electricity for the consumers.
CRISIL has recommended that suitable mechanisms need
to be developed to use GBI to encourage Discoms to TANGEDCO Not to Go in for Short-term Power Purchase
procure wind power, make timely payments and also prevent
Tamil Nadu Generation and Distribution Corporation
forced backing down of wind power. It also recommended (TANGEDCO) has decided to drop its earlier plan of procuring
a suitable performance-based incentive be developed to 500 MW of short-term power for peak demand as the price
reduce purchase cost of wind power by States. quoted was higher. Instead, the states power utility has
planned to procure higher quantum of round-the-clock power
Source: The Hindu, December 05, 2016
in the range of 632-672 MW at the price of up to ` 4 per
unit.
Stable Outlook for TANGEDCO Bonds from Rating Source: The Hindu, 5.1.2017
Firm
Ratings firm, India Ratings and Research has assigned the final
Compiled By: Mr. Abhijit Kulkarni
rating of IND A(SO) to the `100 crore-bond programme of
Business Unit Head - Energy Segment
Tamil Nadu Generation and Distribution Corporation Limited
(TANGEDCO), with a stable outlook. SKF India Ltd, Pune and
IWTMA Team

Know Your Member RRB ENERGY
Wind power plays a signicant role, especially in the context

of the need for abating global warming and mitigating
advance climate change.
Trendsetters and a pioneering company in the eld of The Company is devoted to fullling its mission to
wind power generation, RRB Energy Limited (RRBEL) set harness wind power for the nations empowerment.
up during the year 1987, offers custom-built turnkey RRB Energy is also an Independent Power Producer
solutions in the area of harnessing wind energy for having established wind farms of aggregate megawatt
power generation, such as site selection, micrositing, capacity.
preparation of detailed project report, project
RRB Energy Limited has successfully established close
engineering, erection, commissioning and after sales
to 2 GW of wind power capacity for various clients
service of the wind power projects RRBEL maintains a
at numerous locations spread across various states
leading position in the wind energy sector.
of India including Tamil Nadu, Kerala, Karnataka,
Being one of the foremost players in the wind energy Maharashtra, Madhya Pradesh, Gujarat and Rajasthan
Sector, RRBEL has an unparalleled track record and and internationally across Europe, US and UK.
expertise in understanding the market environment
and providing requisite solutions in the area of wind
Rakesh Bakshi
power generation.
Chairman & Managing Director
THE STORY SO FAR Popularly known internationally as

the Green Maharaja, the London born
owner of RRB Energy, Rakesh Bakshi is an
Commencing from being successful in nalizing a Indian climate change activist, professor
joint venture with Vestas Wind Systems A/S (Vestas), and businessman credited as one of the
Denmark to obtaining transfer of technology from pioneers in the eld of non-conventional
Vestas, to setting up of indigenous manufacturing energy sources in India.
facilities for wind electric generator blades and wind
electric generator controllers, creating next generation Sarvesh Kumar
of smart wind turbines, the list of accomplishments is President & COO
vast. Mr. Sarvesh Kumar has been associated
in the eld of wind energy for more than
Where RRB Energy stands today in wind power solutions 30 years, the result of which is seen in his
can be traced back to its core ideology during inception strong commitment and vision towards
i.e. to excel and perform under all circumstances. the growth of the eld.
RRB Energys Product Ranges
V27225 kW V39500 kW PS-600 kW PS-1800 kW
pawanshakthi@rrbenergy.com www.rrbenergy.com
Printed by R.R. Bharath and published by Dr. Rishi Muni Dwivedi on behalf of Indian Wind Turbine Manufacturers Association and printed at
Ace Data Prinexcel Private Limited, 3/304 F, (SF No. 676/4B), Kulathur Road, Off NH 47 Bye Pass Road, Neelambur, Coimbatore 641062 and
published at Indian Wind Turbine Manufacturers Association, Fourth Floor, Samson Towers, No. 403 L, Pantheon Road, Egmore, Chennai 600 008.
Editor: Dr. Rishi Muni Dwivedi

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Registered with REGISTRAR OF NEWSPAPERS for India, New Delhi February - March 2017
Vide No. TNENG/2015/60605 Date of Publishing : 10.02.2017
ACE DATA, Coimbatore

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Volume: 2 Issue: 6 February - March 2017 ` 10/-

WINDERGY INDIA 2017

President and Chief Operating Officer

Heavy Castings in Wind Turbine 4

Mr. Chintan Shah

Castings and Forgings Oxygen of the Wind Industry 12

Mr. Madhusudan Khemka

Mr. Ramesh Kymal Indigenisation of Wind Turbine Components 22

Mr. Ajay Mehra

Secretary General Snippets on Wind Power 39

Associate Director and Editor

2 Indian Wind Power February - March 2017

February - March 2017 Indian Wind Power 3

V. Srinivasa Reddy, Executive Director

Grey Ducle Steel Aluminium Others

to ferritic ductile iron grade and planetary carrier in gearbox

2. Indian Foundry Industry 20%

India is the second largest casting manufacturer in the 0%

4 Indian Wind Power February - March 2017

Following is the indicative sector-wise casting consumption 70000

Following are the statistics of Indian wind turbine casting

6 Indian Wind Power February - March 2017

In order to ensure better dimensional stability, higher

preparing the liquid metal. In order to ensure highest

Melting process consumes 80% of power used in foundry

Quality Inspection: Castings will be validated for

Machining & Surface Treatment: Machining is one of the

February - March 2017 Indian Wind Power 7

Product Development: Present development cycle time

Manpower Skills: Most difficult task in large castings

Raw Material: Biggest challenge for Indian foundries is to

Energy, Government of India.

4. Currency chart from www.xe.com

8 Indian Wind Power February - March 2017

Ashok Kumar Anand

February - March 2017 Indian Wind Power 9

Brazil, last year 7th largest casting producing nation, has

(Source: Modern Castings, USA)

Role in Manufacturing Sector

10 Indian Wind Power February - March 2017

V. Srinivasa Kannan, Head-SCM

While castings are basically used as housings or shells due

12 Indian Wind Power February - March 2017

February - March 2017 Indian Wind Power 13

A Green Energy Exchange on Cards to Reduce Power Costs

Wind Turbines also Fan Growth of Crops

National Award for Innovation in RE JEEVAN SPARDHA by MNRE

14 Indian Wind Power February - March 2017

P.G. Salunkhe, Vice President

1990 Beginning of the development of wind power

S G Iron Axle Pin

Electricity is a great boon of modern science. However, the

Production, consumption and importance of wind energy in India;

Current installed wind

Large wind turbine manufacturers need trusted

February - March 2017 Indian Wind Power 15

16 Indian Wind Power February - March 2017

How and where some of our SG Iron parts are used...

18 Indian Wind Power February - March 2017

February - March 2017 Indian Wind Power 19

Sindhuja S Raghuram Hariharan, Dr. B.S.K. Naidu

Abstract the tower base may be made of concrete. Nacelles

22 Indian Wind Power February - March 2017

3.1 Time Taking Process