.

TESTING - TYPE, DEVELOPMENTAL, CERTIFICATION AND SPECIAL ,  INSPECTION, RESEARCH, TECHNOLOGY DEVELOPMENT, CONDITION MONITORING OF EQUIPMENT,  REMAINING LIFE ASSESSMENT,  FAILURE ANALYSIS,  CONSULATNCY,  KNOWLEDGE UPDATING, INFORMATION SERVICES 

PROFILES OF TECHNOLOGIES DEVELOPED AT ERDA

A- Electrical Equipments/ Products     

 

B- Smart Materials

C- Testing and Measuring Instruments

D- Others     

A- Electrical Equipment/ Products

A-1 On Line Fault Sensor for Power Transformers 

Application: 

Detects incipient faults in oil-filled transformers (Power Transformer, Distribution transformer, Rectifier Transformer, Furnace Transformer, LOCO Transformer, Auto Transformer etc) online. 

Salient features: 

  • Detects incipient faults by sensing evolved (free) hydrogen gas

  • Both types of electrical & thermal faults can be detected in any part of transformer tank    

  •  Comparatively more sensitive than conventional Buchholz relay

  •  Easy & quick installation without any major  modification

  •  Provides visual / audio alarms for necessary remedial action

  •  Results observed on field trials of more than a dozen transformers are encouraging

Very economical than equivalent imported one  

Specification:  

  • Range   : 0 – 1999

  • Accuracy          : ± 10 %

  • Repeatability    : ± 2 %

  •  Response Time: < 2 minutes

  • Size : Sensor Head     : 50 mm dia., 50 mm length

  •  Control cum Display Unit: (170 x 100 x 200) mm

  •  Weight : Sensor Head: 0.5 kg : Control cum Display Unit: 1.8kg

  •  Display     : LED ( 4 digit )

  •  Input Power     : 220 V AC, < 100 mA

  • Alarm :  Lower limit : Visual alarm

  • Higher limit : Audio + Visual alarms 

Cost per unit:  Approximately Rs 25,000/- each sensor 

Awards: This product has won the following awards. 

  • Dr. Vikram Sarabhai Young Scientist Award 1998-99, Govt. of Gujarat

  • Best Product at International Exhibition “ELECRAMA -2002” and

  • National NRDC Award -2004 

Patent Granted: No. 204691 dated 1.3.2007

 

A-2 Up - gradation of Short Circuit level of Low tension Air Circuit Breaker

 Application:  

  •  Low Tension Distribution system

  •   Industries 

Salient features:

  • Type tested successfully as per IS : 13947 (Part 2) – 1993

  • Indigenously developed

  • Compact size

  • Modular design

  • Low cost compared with other makes for same capacity.

Specification:

  • Low tension Air Circuit breaker

  • Rated Current – 250 A to 2000 A in three frame sizes

  • Rated operational voltage – 415 V

  • Rated Insulation voltage – 1000 V

  • Rated frequency – 50 Hz

  • Rated making and Breaking capacity Frame – 1 & 2 50 kA

  • Frame – 3 – 60 kA

  • Short time withstand current – 60 kA 1 Sec.

  • Overall size :-Frame 1 & 2 – 513 x 312 x 230 mm

  • Frame 3 – 513 x 505 x 203 mm

  • Weight (Approx.) Frame 1 & 2 – 32 kg., Frame 3 – 50 kg

Award:  National NRDC Award -2005

A-3 Energy Efficient Submersible Pump set 

Application:
Lift irrigation for agricultural purposes and water supply schemes  

Specifications:

 

415 V Model

320V Model

Head , m

90

90

Discharge, lps

5.82

5.82

Overall efficiency, %

53

52.6

Full load current, A

16

20

Speed, RPM

2880

2888

Efficiency %, 100% load

82.3

82.0

Efficiency %, 75% load

82.28

81.7

Starting Torque, %

163

161

P.F.

0.835

0.832

Salient Features: 

  • Meet all requirements of IS 8034: 2002

  • Design based on flat efficiency curve characteristics 

  • Motor efficiency comparable with the imported makes

  • Pump set capable of operation at Low voltage without drop in efficiency

Cost: Estimated cost is Rs 20,000/-  (Payback Period: 6 months)

 

A-4 Frequency Trend Meter 

Application: 

For analyzing power system behavior in case of contingency by continuous, automatic monitoring of dF / dT through PC to avoid unwanted load shedding. 

Specification: 

  • Minimum Sampling interval:  20 milli seconds

  • Operating Voltage: 230 V AC

  • Input Signal Voltage: 230/110 V AC

  • Circular storage buffer, which can hold data for past 21 minutes

Salient Features: 

  • Eight 7 – segment displays for displaying frequency (F) and rate of change of frequency (dF/ dT)

  • Multi level LED indication for dF/ dT. In case dF/ dT exceeds the set value it will provide an LED indication. 

  • RS-232 port to upload data from FTM to PC

  • PC-based software generates file in EXCEL. User can use EXCEL software for analyzing the logged data in textural or graphics form.

  • The format for FREQUENCY display as 50.12 Hz.

  • The format for dF / dT as ±0.12 Hz / sec. 

Cost:  Approx. Rs. 2.5 lakhs per unit.

 

A-5 DC MCB for 5 kA, 130 V DC fault level 

Application:  In low voltage DC circuit as circuit breaker by utilities, railways, etc 

Specification: 

  •  Rated current              : 20 A DC

§       Rated voltage                  : 130 V DC
§         No. of poles                     : Single pole
§        
Rated breaking capacity  : 5 kA at 130 V DC
§        
Din Channel mounted 

 

Salient Features:

§   Meets the requirements of RDSO Specification:  SPEC/E-12/1/03
§    
Indigenously developed
§  
Modification in existing design of AC MCBs.

Patent Filed: No. 1676/ MUM/ 06 dated 11.10.2006

 

A-6 Fault Current Limiter for LT Switchgear & Appliances

Application: To increase short circuit fault level of Low voltage switchgear like MCB etc.  

Specification: 

§         Rated operation voltage        : Ue 240/ 415 V
§        
Rated operation current        : Ie 16 A
§        
Max Short circuit current      : 25 kA rms
§        
Current Limit                       : 3.8 kA peak (at 25  kA, 240 V)
§        
Total operating time              : 3.5 m sec
§        
Total let through energy        : 14 kA2 s
§        
Power loss per phase           : 1.7 watts
§        
Resistance cold                   : 8 milli ohm/ phase

 Salient Features: 

§         No movable parts
§        
Improved safety and reliability
§        
Light in weight
§        
Can be used with MCB to enhance short circuit level
§        
New concept
§        
Increase life of the protective device
§        
Economical 

Cost:  About Rs. 15/- per piece 

Awards: 

  •  Dr. Vikram Sarabhai Young Scientist Award 2004-5, Govt. of Gujarat,

  • Certificate of Appreciation at International Exhibition

  • “ELECRAMA -2004”

  • Best Invention of year 2007 and National NRDC Award –2007

  •  WIPO Gold medal 2008 by WIPO (World Intellectual

  •  Property Organization), Geneva         

Patent Filed: - No. 1200/ MUM/2007 dated 21. 6.2007.

  

A-7 Remote operated 11 kV load break switch and MCCB 

Application:   Demand side management of Electrical Power 

Specification:

  • Rated Voltage – 11 kV

  • Rated Current – 80 A

  • No. of Poles – 3

  • Braking capacity – 1.5 MVA load with 0.7 power factor

  • Rated Short time withstand current – 40 kA Peak

  • Power frequency high voltage – 28 kV

  •  Impulse withstand voltage – 75 kV

  • Mounting Arrangement - Horizontal

Salient Features:

  • Meets requirements of IS : 9920 – 1985

  •  Indigenously developed

  • More economical than 11 kV HT Circuit breaker

  • Centrally controlled from Control room for HT & LT feeder for load shedding

  • Reduces manpower utilization

 

A- 8 ASIC based single/ three phase energy meter (Class 1) 

Application: Energy consumption measurement for domestic consumers  

Specification: 

  •  Type:                      Static: Single phase, 2 wire

                                         Static: Three phase, 4 wire

  • Voltage rating:         240 V (+20% to – 40%)

  • Basic current:          10 A  (Maximum overload current 600% of Ib)

  • Maximum current:    60 A

  • Frequency:              50 Hz

  • Relevant standard:   IS 13779-1993

  •  Class of accuracy:   CL-1%

  •  Energy register:       Impulse counter / Stepper motor counter

  • Calibrated LED:       6400/3200  pulses per kwh

 Salient Features:    Tamper indication by monitoring both phase and neutral  

Cost per Unit: Approx. Rs 400/- (Without box)  

 

A-9 Thermosyphon for Power Transformers

 Application: 

Online conditioning/ treatment of transformer oil in ONAN/ ONAF cooled Transformer 

Specification: 

Online oil filtration system having adsorbents mounted in the flow line of oil and outside main tank of transformer 

Salient Features: 

  • Removes harmful undesirable constituents like acid, sludge, water and polar compounds from oil in services

  • Reduced frequency of oil filtration

  • Easy maintenance

  • Improves electrical properties like BDV, Resistivity and Dielectric dissipation factor

  •  Higher active life span of transformer oil 

Cost: Depends on capacity of transformer 

Patent Filed: No. 1770/ DEL / 1997 dated 27.06.1997 

 

 

A-10 Micro controller based transient free switching of LT Capacitors

 Application: 

  •  Automatic power factor correction, Energy saving and voltage regulation in agricultural and industrial loads.

  •  Can also be installed at sub-stations on the secondary of distribution transformer 

Specification: 

  • Load kVAr based automatic switching.

  • Software complies the relevant REC specifications

  • Capacitors bank ON and OFF operation is based on load kVAr sensing

  • Two minutes delay in switching ON operation

  • Instantaneous switching OFF of capacitor bank

  • Voltage and current unbalance sensing and switching OFF operation of capacitor bank accordingly

Salient Features: 

  • Transient free switching of capacitor bank

  •  Improved life of capacitors

  • Negligible maintenance

  • Any number of noise free operation in a day

  • No dips in supply line of voltage

  • Improved voltage regulation

  • Suitable for outdoor application (IP-55 tested)

  • Intelligent enough to prevent leading power factor

  • All solid state circuitry and no electromechanical device

  • Automatic power factor correction (energy saving)

  • Highly reliable electronic control

 Cost:  Estimated cost of a 9 kVAr unit is Rs 50000/- excluding capacitors.

A - 11 Electronic ballast for HPSV Lamps 

Application: Industrial and Street lighting   

Specification: 

  • Rated Supply Voltage:         :            240V AC

  • Supply Frequency                :           50 Hz (Power Freq.)

  • Supply Current                     :           0.4 Amps

  • Low crest factor for lamp current:       » 1.41

  • Power Factor                       :           > 0.8

  • Low Power Consumption      :           <9 watt

  • Efficacy (Lumens/Watt)        :           >87.5

Salient Features: 

Parameter        

Conventional Ballast

Prototype Electronic Ballast (ERDA)

Power Factor

0.35     

0.8

Input wattage

90 W

78.7 W

Lamp Wattage

70 W

71 W

Power loss

20 W for 70W lamp

7.7 W for 70 W Lamp

 Cost:  Approx.  Rs.  800/- per unit.

A-12 Electronic ballast for TFL 

Application: Industrial and domestic lighting (40 W tubular fluorescent lamp) 

Specification: 

  • Rated Supply Voltage:- 240 V AC

  • Supply Frequency:-50 Hz (Power Frequency)

  •  Supply Current:-  0.183 A

  • Low Crest factor:-  ~ 1.41

  • Power Factor:- > 0.95

  • Low Power Consumption:-  <3 watt

  •  Efficacy (Lumens/Watt):- > 55

  • Ballast Lumen Factor:- > 90 %

  • Cathode Current To any Lead:- As per IS 13021

  • Low harmonics (Less than 26 %)

Salient Features: 

  • Power Factor         : 0.954

  • THD                      : 26 %

  •  Crest Factor          : 1.43

  • Wattage                : 42.9 for 40 watt Lamp

  • Type tests on Prototype were carried out as per IS: 3021 (Pt. I & II)

Cost: Approx.  Rs.  400/- per unit
 

A-13 Active Power Filter

Application: 

For reactive power compensation and harmonic elimination at source side of load of any rating 

Specification: 

  • Load capacity: 4 kVA

  • 4-wire shunt filter configuration

  • Three phase 440 V / 50 Hz supply           

Salient Features: 

§     System is load (Customer) based
§     
Harmonic compensation
§    
Reactive power compensation based on instantaneous active
    reactive power approach

§    
High speed analog control
§   
Current controlled pulse width modulated inverter
§    
Most suitable for rectifier loads 

Cost: Approx. Rs. 5.0 lakhs per unit

A-14 Online Condition monitoring tool for Induction motors –
Motor Current Signature Analysis (MCSA)

 Application:  

For online condition monitoring of rotating machine in process/ power plant by analyzing current signature 

Specification: 

§   To detect online the presence of various internal faults in three phase Induction Motors           

Salient Features: 

  • On line detection of the failure of Rotor bars, Stator faults, Air gap Eccentricity, Bearing degradation, Misalignment/Unbalance within Induction motors

  • Most useful, reliable and cost effective diagnostic technique for Induction Motors

  • Can be used as preventive maintenance tool 

Cost: Approx. Rs. 4.0 Lakhs per unit
 

A - 15 Three phase variable frequency drive for 3-HP motor

 Application:  Speed control of induction motor  

Specification: 

  • I/P :- Voltage 415 Vrms, 50 Hz, 3 Phase

  • O/P :- Variable voltage maximum up to 415 V rms

  • Variable frequency: - Max. up to 50 Hz

  • Constant V/f.

  • 120 deg mode, quasi-square wave    

 Salient Features: 

  • Air cooled

  • IGBT based analog control

  • AT low frequency boost can be adjusted

  • Over current trip

  • Phase sequence protection

Cost per unit: Rs. 20000/-

A - 16 Cooling fan for bus duct 

Application: For Cooling of phase conductors mounted inside the bus duct 

Specification: 

  • 15W, 2880 rpm           

Salient Features: 

  • Can operate without any external power supply

  • Operate with minimum of 5kA current flowing in the
    phase  conductors

  •  Cooling increases with increase in the current in the
     phase conductors
     

Cost: Depends on Rating

 

A - 17 Composite Long Rod Insulator (upto 66 kV)

 Application: Ideally suited for use in High Voltage Transmission 

Specification: (66 kV suspension type insulator) 

§         Mechanical Test     : No breakage observed upto 120 kN 

§         Dry Power Frequency Voltage    : Withstood 140 kV for one
                                                  minute and withstand test 
                                                  flashover occurred at 256 kV rms

  •  Lightning Impulse Voltage withstand test    : Withstood 325 kVp
                                                                       for both polarity 

§         Pollution Performance   : No deterioration of the insulator
                                     has   been observed during the 3500 hrs
                                     long artificial pollution study

Salient features: 

  • Light weight (high strength to weight ratio). A typical 66 kV non-ceramic suspension insulator can weigh between 1.8 to 4.5 kgs, depending on the design

  • Good Hydrophobicity

  • Easy to handle and non-brittle nature

  • Better electrical performance and ultimately good contamination performance

  • The silicone compound is made from indigenously available raw materials

  • Satisfactory field performance of insulator in polluted locations   

Cost: Approx. Rs. 2500/- for a typical 66kV suspension type Insulator

 

A - 18 Plastic Impellers for Submersible Pump sets 

Application: For Impellers of 4”, 6” Submersible Pump sets

 Salient features: 

  • High Yield Strength resulting in dimensional stability

  •  Wear resistance and low water absorption

  • Smooth Surface finish resulting in lower hydraulic losses

  • Increase in Pump efficiency by 2-4% 

Specification:  

  • Suitable for 4”, 6” submersible pumps

  • Head: 90M

  • Discharge: 5lps

  • Rating: 10HP

  • Overall Efficiency: 55%

  • Plastic Impellers for any other rating of pump can be developed

 Cost:  Rs. 35 to 75/- per impeller

 

 

A - 19  Pump Turbine for Standalone Power Generation  

Application: For Standalone Power Generation in PICO Hydel Systems 

Salient features: 

  • Rugged Construction and compact size

  • Maintenance free, Single unit along with Induction Generator

  • Easy installation and does not requires any civil power house

  • IP 68 protected

Specification:  

  • Head: 36M

  • Discharge: 28lps

  • Rating: 7.5kW/10HP

  • Electrical Power Generated: 5kW / 3ph/1ph

  • Voltage: 415V 3ph / 240V 1ph

  • Supplied along with Electronic Load Controller

  • Other Ratings of Pump turbine can also be developed

Cost:  Approx. Rs. 50,000/- per unit

 

B. Smart Materials

B - 1  Fire Retardant Coating Compound 

Application:  

Increases fire retardant characteristics after coating on any solid
surface
 

Specification:         

  • Polymer based Paint  

Salient features: 

  • Good adhesion and compatible with cable sheath

  • Weather resistance

  • Excellent fire resistance

  • Fast curing at ambient

  • Long shelf life

  • Economical

  • Excellent Oxygen Index

Cost:  Approx. Rs.150/- per kg  

Patent Filed: No. 1783/ DEL / 97 (Granted)

 

 

 

B - 2   RTV Silicone Coating 

Application:

Excellent pollution resistant hydrophobic coating for outdoor insulators 

Specification:       

  • Colour                                :   White

  • Consistency                       :   Easily pourable

  • Viscosity                             :   4200 centipoise

  • Tensile strength                  :  10 kg/cm2

  •  Elongation at break            :  245 %

  •  Dielectric strength in air      :  18 kV/mm

  • Volume Resistivity, W - cm  :   6.5 X 1015   

  • Dielectric constant  @1kHz :  6.0

  • Dissipation factor  @1kHz  :  0.001

  • Shore hardness, A              :   48

 Salient features:

  • Room temperature curing

  • Excellent hydrophobicity

  • Good adhesion to solid surface

  • Can be applied by brush or spray

  • Good electrical and mechanical properties

  • Synthesized from indigenously available raw materials

Cost: Approx. Rs.2000/- per kg

B - 3  Thermo chromic material for temperature sensing 

Application: Temperature sensing on any solid surface  

Specification: 

Transition temperatures  

  •  For reversible type    :  50°C and 70°C

  • Recovery time          :  2-3 seconds

  • Colour change          :  Yellow to orange (50°C)

                                         :  Red to black (70°C) 

  • For irreversible type  :  75°C and 110°C

  • Colour change         :  Pink to blue (At both temperatures)

Salient Features: 

  • Reversible and irreversible thermo chromic materials

  • Raw Materials are easily available Indigenously

  • Economical

  • Can be used as sticker or paint

  • Suitable for temperature sensing at remote areas like electrical installations, reaction vessels in chemical industries

Cost:  Approx Rs. 5000/- per kg of material or Rs 2/- per sticker

 

B - 4  Heat Shrinkable material

 Application: Cable jointing and termination, bus bar insulation, sleeving etc. 

Specification: 

  • Tensile strength               : 12 MPa

  •  Elongation at break          : >350 %

  • Dielectric strength in air    : >25 kV/mm

  • Volume resistivity              : > 1015 W cm

  • Dielectric constant             :  2.3

  • Water absorption               :<0.1%

  • Heat resistance                : 200 % (Elongation after 168 h ageing at 158°C)

Salient Features: 

  • Meets the requirements of ASTM D 3149-85

  • Raw Materials are easily available indigenously

  •  Economical

Cost:  Depends on dimensions of heat shrinkable tube and scale of production

B - 5  Rust Dissolving Corrosion Resistant Paint  

Application: On rusted structural parts  

Specifications: 

  •  Suggested coating thickness —30 μm  

Salient Features: 

  • No need of any surface treatment like sand blasting before application

  •  Time saving

  • Comparatively economical compared to similar paints

  • Manpower saving

  • Ease of manufacture

  • Ready availability of raw materials

  • Room temperature curing. 

Cost: Approximately Rs 250/- per liter

 

B - 6 Polymeric Coating System For Under Water Equipment & Components Subjected to Erosion

 Application: 

All under water equipment and components which are subjected to silt / cavitation / erosion, such as hydro turbine runner blades, pump impeller casting 

Specifications: 

  • Three coat polymeric system for silt / cavitation/ erosion resistance

 Salient Features: 

  • Coating system consists of three coats

  • First coat - Putty to fill up cavities formed due to erosion

  • Second coat – Polymeric coating for cavitation resistance

  •  Third coat- Filled polymeric coating for erosion resistance

Cost:  Depends on the type of component to be coated.

B - 7 Electroless Nickel coating for metals  

Application: Any metallic surface which needs better corrosive and wear resistance 

Specifications: 

§         Up to 10 mm coating thickness feasible 

Salient Features: 

  • Excellent uniformity

  • Good wear resistant (due to increase in hardness)

  • Excellent corrosion resistance

  • No need of external power supply

  • No anode is required

  • Simplicity of process

  • Alloy coating of Ni-P and Ni-B

  • Adjustable magnetic and electrical Resistivity

  • Good wetting characteristics

  •  Low Hydrogen absorption

Cost :  Approximately Rs. 3.00 per Sq. inch. (10 micron thickness)

 

B - 8 New polymeric material for wiring Accessories 

Application: 

Potential substitute for expensive Polycarbonate and suitable for electrical wiring accessories like Domestic switches, plug and sockets. 

Specification: 

  • Tracking resistance at 250 V - Withstood 50 drops

  • Water absorption at ambient temperature for 24 hrs   - 0.7%

  • Glow wire test at 850 for 30 sec - Specimens extinguished within 5 sec after removal of flame

  • Ball pressure test at 125 °C - Depth of indentation is less than 2 mm

  • Mechanical strength 10 blows of suitable impact tester- No cracks observed 

Salient Features: 

  • Meets all desired properties as per relevant specification

  • All raw materials and ingredients are easily available in local market

  • Easy processing

  • Can be made of any colour

Cost:  Rs.  110/- per kg. However, it can be reduced further upon bulk production.

 

B - 9 Vinyl Ester Resin (VER) from Epoxy Novalac  

Application: 

VER can be used as thermosetting resin for many industrial applications and as a binder in resin-lean non-ceramic polycrete insulators

Specification: 

  • Dielectric lose factor :0.007

  • Permittivity                          :3.52

  •  Volume Resistivity, W - cm   :1.4x1015

  • Arc resistance, Sec             :76 - 82

  • Electric strength, kV/mm      :16 - 17

  • Shore Hardness, A               :90 – 93

Salient Features: 

  • Apart from above, the resin when used as a binder for making non-ceramic insulators, showed good cantilever strength

  • Economical and suitable for insulator application

Cost:  Approx. Rs. 120/- per kg

 

B-10  Coal Tar Epoxy Coating

 Application: 

Used as corrosion resistant coating on metal, concrete, tank, chemical processing plants, underground water retaining & marine structures, wooden poles, out side sewage pipes and elements exposed to chemical action. 

Specification: 

  • Two components system.

  • Solid content : 85 - 88%

  • Hard, flexible, smooth thick coating

  • Economical

  • Good water and mild chemical resistant

  • Good resistant to salty water

  • Excellent adhesion with any solid surface

  • Good resistant to impact, thermal and abrasion

 Salient Features: 

  • Easily applicable by brush and trowel

  • Seals localized cracks and surface porosity

  • Strongly bond to most of the building material

  • No primer is required

  • Cures to a tough elastic waterproof film

  • Covering capacity: 18-20 sq. mt per liter for an average 20 –25 micron film thickness

Cost: Approx. is Rs. 160-170/- per litre

 

B - 11 Castor oil based capacitor encapsulation material 

Application: As an encapsulant for dry type LT capacitor 

Specification: 

  • Curing time               : 24 h at ambient temperature

  •  Hardness, Shore A   :  10 – 30

  • Volume Resistivity    : > 1012 ohm. cm

  • Tensile strength        : 5 kg / cm2

  • Elongation                : 60 %

  • Thermal conductivity : 0.25 W/m.K

Salient Features: 

  • Easy to use

  • Room temperature curing

  • Easy availability of raw materials

  • Does not affect the properties of capacitor

  • Can be used for encapsulation of other electrical items with a little or no modification

 Cost: Rs. 90/- per kg

B-12  Bird deterrent compound

Application: 

The compound coating can be applied on any solid substrate and deters birds from sitting on that surface 

Specification: 

  • Colour                                 : Pale Yellow

  • Consistency                        : Grease (Gel) like

  • Odour                                 : Similar to vegetable oil

  • Weathering stability           : Slight colour change after 60 days of accelerated ageing test as per ASTM G 53

  • Melting point                        : 70 ºC

  • Cone penetration at 27ºC      : 15 mm

  • Coverage (@ 5mm thickness): 5 kg / m2

Salient Features:

  • Low cost, easily and locally available raw materials

  • Easily applicable by brush and no adverse effect on human skin

  •  Non toxic and eco friendly coating

  • Coating does not cause any harm to birds

 Cost:  Rs. 300/- per kg (approx.)

 

B – 13  Martensitic low alloy steel hammer ring

Application: 

Deployed as impact crushing elements in ring granulators for secondary coal crushing applications. 

Specifications: 

  • Micro alloyed steel based hammer rings for ring granulators

  •  Unnotched Charpy impact strength: 70 Joules / cm2

  • Tensile strength of heat treated material: > 900 MPa

  • The room temperature microstructure comprises of acicular
    ferrite and a distribution of matrix and grain boundary
    primary & secondary carbides
     

Salient Features: 

  • One set of hammer rings can crush about 2.3 lakh metric tonnes 
    of coal

  • The hammer rings are ferromagnetic

  • The rings are fabricated using a proprietary sand casting process

  • Good wear resistance in dry and wet coal grinding condition

Cost: Approx Rs. 1500/- per ring 
Award
:
   Received Dr. Vikram Sarabhai Young Scientist Award 2005-                 06, from Govt. of Gujarat 

B-14 Silver Tin oxide contact material

 Application: Contact tip of low voltage switchgear 

Specifications: 

  • Density  : 98% of theoretical density of monolithic material

  • Hardness   : 87 VPN

  • Conductivity : 78% IACS

  •  Microstructure : Contact tip show uniform distribution
    of tin oxide particles in the matrix of silver

  • Conforms to (32A) AC 3 rating. Endurance and make & break  test as per IS: 13947 – Pt. 4, Sec.1 – 1993 and
     IEC: 947 –4-1(1990)

 Salient Features: 

  • Non toxic

  • Good arc erosion resistance and contact weld ability

  • A novel fabrication route based on electro chemistry followed by powder metallurgy 

Cost:     Material cost is approx. Rs. 25,000/- per kg.

 

B-15 Water Soluble Insulating Coating 

Application: 

Eco-friendly polyester coating for electrical applications e.g. Wire Enamels, impregnating varnish, printed circuit board (PCB), Structural materials. 

Specification: 

  • State     : Liquid

  • Colour    : Pale Yellow to brown

  • Solubility: Soluble in water, alcohol etc.

  • Solid Content: 50 – 70 %

  • Curing Time: 4 – 6 Hrs.

  • Curing Temperature: 150 – 200oC

  •  Thermal Class: Class F

  • Dielectric Strength: 60 kV/mm   

Salient Features: 

  • Eco-friendly insulating coating

  • New technology

  • Economical and reliable material

  • Reduced risk of human health and fire during coating applications

 Cost:  Approx. Rs.200/- per litre 

Patent Filed: No. 442 / MUM / 2005 on 07.04.2005 

 

B-16 Alkyd Resin from Jatropha Oil 

Application:            

The varnish is suitable for the LT electrical applications such as impregnation of motor coils, transformer etc. 

Specification: 

  •  Density, gm/cm3

:

1.075

  • Viscosity, cps

:

50

  •  Non volatile matter, %

:

50

  • Drying time in thin film

:

4 hrs. at 1300 C

  • Flash Point, oC

:

25

  • Ability to cure in   considerable thickness

:

S2,U2, I5 I4.2

  • Check for resoftening

:

W2

  • Flexibility

:

No crack observed

  • Effect of varnish on Enameled wires

:

Passed test

  • Résistance of transformer oil

:

No softening, blistering, wrinkling, disintegration or separation of varnish film 

-          Visual examination-          Acidity of oil -          (before and after aging)

-          Sludge value of oil -          (Before and after aging)

:

:

 
:

Slightly yellow Colour of oil Nil, before and after ageing

 

Nil, before and after ageing

§         Effect of heat aging on flexibility

:

No visible change or detachment of film

§         Volume Resistivity, Ω cm

:

1 X 1012

§         Thermal rating by TGA

:

130oC (Class B)

§         Dielectric constant at 25oC

:

2.22

§         Dissipation factor at 25oC

:

0.0098

§         Electric strength at 25oC, kV/mm

:

66

 Salient features: 

§         Non-Toxic, Cost Effective and User friendly
§        
Raw materials available indigenously
§        
Meets the requirements of IS: 10026
§        
Superior Electric Strength 

Cost: Rs. 70/- per kg

C. Testing and Measuring Instruments

C-1 Low Voltage Impulse Generator
(as per IS: 13779 and IEC- 61000)
 

Application: 

Impulse testing of electrical and electronic equipment such as transformer, energy meter, switchgear etc. 

Specification: 

  •  Input supply             : 230VAC, 50 Hz.

  • Output voltage peak: 0 to 6 kV

  • Open circuit waveform characteristic (equivalent load of 10 k Ohm):

  • Front time   : 1.2 micro seconds ± 30%

  • Tail time     :  50 microseconds ± 20%

  • Short circuit characteristics (impedance 0.1 Ohm):

  • Front time    :  8 microseconds ± 20%

  • Effective output impedance:   2 Ohm  

Salient Features: 

§         Compact design
§        
Fully safe operation due to protected panel
§        
Positive and negative polarity pulse selection
§        
Variable output range from 0 to 6 kV.
§        
Solenoid operated sphere gap trigger arrangement.
§        
Charging voltage display by digital kV meter.
§        
Oscilloscope output is provided to see the wave shape.
§        
Charging capacitor discharge facility provided inside after operation.
§        
Charging supply isolation just before operation of sphere gap.  

Cost per Unit: Approximately Rs. 1,35,000/-

 

C-2 Current surge tester for RCCB 

Application: 

Useful in type testing of RCCB as per IS:12460(Part-1)-2000 specification 

Specification: 

§         As per requirements of IS: 12640 (Part 1) - 2000
§        
0.5 µ sec / 100 kHz ring wave
§        
Peak value: 200 A ± 10%
§        
Virtual front time: 0.5 µ sec ± 30%
§        
Period of the following oscillatory wave = 10  µ s ± 20%
§        
Each successive peak: about 60% of the preceding peak

 Salient Features: 

§         Indigenously developed
§        
Not manufactured in India
§        
Meets the requirements of IS: 12460 (Part-1) – 2000

 Cost: Approx. Rs. 75000/- per unit

 

C-3 Short time over current (half – cycle) test set up for Energy Meter 

Application:  Test equipment is required testing of energy meter 

Specification: 

§         Maximum current  : 3000A AC rms, half cycle
§        
Current control      : Through Variac and Voltage display
§  
Standard applicable: IS :13779, CBIP report  88 for direct connected  meters 

Salient Features: 

§         Reliable electronic control to avoid successive multiple triggering
§        
Guaranteed half cycle
§        
Push button control for trigger and reset special features 

Cost per Unit: Approx. Rs. 1,35,000/- lakh

 

C-4 Voltage dips and interruption test set-up

 Application: In the testing of energy meter as per IS:13779-1999 

Specification: 

  • Eight 7-segment displays for displaying different tests

  •  Feathers touch keypad to program the system in different 3 tests

  • Minimum sampling interval of 20 milliseconds for SYNC operation

  • Multi-level LED indication for different test

  •  A RS-232 port for remote operation

  • PC based software through which whole system can be operated from remote PC

  • The format of test display is T.E.S.T-1

  • Operating voltage for the system is 230 VAC

  • Input signal voltage (output of instrument) 230/ 110 VAC single/ three phase

 Salient Features: 

  • All three tests can be performed on a single set up

  • Serial communication provided

  • PC software stores the test details with date and time

Cost per Unit: Approximately Rs 50,000/-  

 

C-5 Glow wire test Apparatus 

Application: 

To conduct glow wire test on insulating materials used in LT Switchgear, Energy meters, Appliances, Wiring accessories etc. 

Specification: 

  • Apparatus conforms to IS: 11000 (Pt. 2/Sec.1)-1984/ IEC 60695-2-10:2000

  • Glow wire loop: Nickel – Chromium (80 / 20)

  • Thermo Couple: Type K, Sheathed 0.5 mm outer diameter

  • Temperature Range: 550 ºC ± 10 ºC, 650 ºC ± 10 ºC, 750 ºC ± 10 ºC, 850 ºC ± 10 ºC, 960 ºC ± 10 ºC

  • Accuracy:  ± 0.5 % 

Salient Features: 

  •  Indigenously developed

  • Meets all requirements specified in IS: 11000 – 1984

Part 2 / Sec 1)/ IEC 60695-2-10:2000

Cost:  Approx. Rs. 90,000/- per unit
 

C-6  Digital V-Square Hour Meter 

Application:  

In lamps and luminaire industries to determine mean effective life of lamps 

Specification: 

  •  Input signal :- 10 V to 270 V AC

  • Range :- 0 to 99999.9999

  • Supply voltage :- 180 V to 270 V

  • Humidity :- 95 % rh°

  • Operating Temperature :- 0 – 70 °C

  • Accuracy class :- 0.1 % 

Salient Features: 

  • Micro controller based system

  • Liquid Crystal Display : (4 – digit after decimal point)

  •  Memory capacity for more than one month

  • Reset facility

 Cost:  Approx. Rs. 10000/- per unit  

C-7 Point on Wave Switching Apparatus  

Application: 

To conduct short circuit test on MCBs, Transformer & LT Switchgear products at controlled switching 

Specification: 

§         Setting of angle from 0 to 360 degree in one degree resolution
§        
Accuracy 0.5º
§        
Synchronization signal voltage: 230/110 Volt ac, works upto 10% of input voltage
§        
Sampling interval : 20 milli seconds
§        
Operating voltage for the system: 230 Volt ± 10 % ac 

Salient Features:

§       Eight 7-segment displays for displaying DEGREE and operating MODE

§        Feather touch keypad to program the Unit in different modes and setting the points on wave switching angle in degree
§        
LED Indication for Trigger Pulse, Sync Pulse, Firing Angle
§        
The format of MODE as LOC (LOCAL) or RE (REMOTE) 

Cost:  Approx. Rs. 50000/- per unit 

 

C-8 Differential Module for oscilloscope

Application: 

Field study of Harmonics, Waveform Analyzer, Oscilloscope 

Specification: 

§         Input voltage range   :  0 – 1000 V
§        
Step down ratio        : 40 & 200
§         Input impedance       : 1 MW
§        
Operating voltage for the system: 230 volt +/- 10 % AC 

Salient Features: 

§         Ground is isolated
§        
Output of the differential module is floating and can be directly connected to C.R.O. 

Cost:  Approx. Rs. 15000/- per unit

C-9 Surge tester for Energy meters 

Application:  

For testing of Energy meters, electrical transducers as per IEC : 61000 – 4-12  

Specification: 

  •  Input Voltage: 230 V ac, 50 Hz

  • Output voltage peak: 4-15 kV peak

  • Open current wave form characteristic (equivalent, greater or equal to 10 K ohm)

Front Time   : 1.2 µs ± 30%,
                              Tail Time     : 50 µs ± 20%

  • Short circuit waveform characteristics (Load smaller or equal to 0.1 ohm) Front Time   : 8 µs ± 20%,
                  Tail Time     : 20 µs ± 20%

  • Effective out put impedance: 2 Ohms

  • Phase shifting: 0 to 360º

  • Impulse can be superimpose on supply voltage for the load current of 15 Amp.

Salient Features: 

  • Compact design

  • Fully safe operation

  • Positive and negative polarity pulse selection

  • Variable output voltage from 4 – 15 kV

  • Solenoid operated sphere gap trigger arrangement

  • Output voltage peak display by digital kV meter

  • Charging supply isolation just before the operation of sphere gap (trigger)

Cost: Approx. Rs. 6.0 lakhs per unit.
 

C-10  Induced failure test Equipment 

Application: 

To conduct induced failure test on GLS lamps as per IS: 15518 (part 1) 2004 

Specification: 

  •  Input voltage                   : 230 V ac, 50 Hz

  • Output Voltage peak    : 2.8kVp – 3.1kVp(for lamp rated upto    100W)

                                                  2.4 kVp – 3.1 kVp(for lamp
                                                  rated above 100W)

  • Rise time          : < 1 µ sec

  • Tail Time         : <10 µ sec for lamps rated above 100W

                                         8-20 µ sec for lamps rated upto 100W

  • Angle                    : 70º ± 10º

Salient Features: 

  • Lamp rating between 200 V – 250 V

  • No control set up required

  • Single switch for triggering

Cost:  Approx. Rs. 1.5 lakhs per unit

D Others

D-1 Dynamics Training Simulator 

Application: For self training on power system network 

Specification: 

  • Two modules ( i ) Load flow ( ii )  Transient Stability

  • Facility to change the data of different elements through dialog boxes

  • Results of load flow can be seen both graphically as well as in text file

Salient Features: 

§    User friendly and flexible GUL, compatible with any Windows package with minimum required facilities

§        Violation of constraints after execution of load flow is indicated by blinking the corresponding element with sound

§      Transient stability can be executed with different fault options.  Voltage regulator and Governor effects on the stability can be simulated

§        After execution of transient stability results can be seen through different plots

 Cost:  Rs. 1.5 Lakhs

D-2 GENSHED 

Application: Software for Generation Scheduling 

Specification: 

  • Two modules (i) Short Term Load Forecasting & (ii) Generation Scheduling

  • Aid to generate dispatch instructions to generating stations

  • Cumulative display of Plant Load Factor (PLF) and weekly PLF

Salient Features: 

§         Short Term Load Forecasting (STLF) based on day of the week    effect and load inertia

§         Dispatch instructions based on forecasted weekly load

§         Constraints are incorporated for generation capacity of the plant, minimum level based on normative PLF level

§         Minimum costing based on variable cost of IPPs and SEB’s generation sources

 

D-3 Fly-Ash based value added articles 

Brick 

Application: For civil construction purposes as a substitute for clay brick   

Specifications: 

§         Size – 220X110X75 mm  

Salient Features: 

  •  Energy efficient process. Room temperature, water-curing process.

  • Smooth surface and plastering is not essential.

  • Higher compressive strength than clay bricks.

  • Cost is comparable with clay bricks.

  • Cement colour.

Cost: Estimated cost is Rs 1.50 to 1.60 per brick, depending upon raw materials availability

 Molded articles 

Application:    Potential substitute for clay & ceramic products

 Specifications: 

  • Low water absorption

  •  High weather resistance  

Salient Features: 

  • Technology is very simple & easily adaptable

  •  Items having complex contours can be made

Cost:    Depends upon size & shape of article 

 

Soft Composite Board  

Application:  Potential substitute for wooden boards  

Specifications: 

  • Low Water Absorption

  •  Wear Resistance comparable to wooden boards 

  • High flexural strength

Salient Features: 

  • Performance comparable to MDF & similar boards 

  • No effect of UV radiation

  • Drilling & sawing possible

Cost: Approx. Rs. 45 / -  (For size – 300X300X10mm)  
 

Hard Composite Board  

Application: Tile / Flooring  

Specifications: 

  • Low Water Absorption

  • Wear Resistance comparable to Tile - material

  • High flexural strength

Salient Features: 

§         Performance comparable to Kota- Stone, Granite and
      Ceramic Tile.

§        
No effect of UV radiation 

Cost per Unit: Approx. Rs. 35 / - (For size – 250X250X12mm)

D-4 Human Operated Pump 

Application:  Water pumping for Irrigation, gardening and domestic pumping 

Specification: 

  • Delivery:  ¾”

  • Head: 3 M

  • Suction Head: 1M

  • Discharge: 5 lpm

  • Human Operated

Salient Features:

  • No Fuel required for operating the pump. Works on Human  by power pedalling

  • Capable of irrigating 1-2 acre land without any cost of electricity, diesel etc.

  • Being a mobile unit can be used for irrigation, gardening and domestic pumping applications

Cost: Approx. Rs. 1,000/- per unit

D - 5 State of art study on Static Reactive Power Compensator 

Application:  For reactive power compensation in the distribution system 

Specification: 

  • Study on different type of compensator

  • Simulation of Compensator:- Shunt type reactive power compensator

  • Supply system:- Three phase four wire LT distribution system

  • Supply Voltage:-240 Vrms per phase.

  • Load to the system :- 500 kVA

 Salient Features: 

§         Simulations carried for various conditions for both balance loads and unbalance loads.                                            

§         The results provide important base line for developing Static VAR Compensator 

 

D - 6 Mobile Transformer oil filtration set up 

Application: Online reconditioning of oil of transformer upto 66kV 

Specification: 

  • Capacity – One kL/ day

  • Weight – 500 kg

  • Power Consumption – 5.25 kW

Salient Features: 

  • Online transformer oil reconditioning unit useful in remote areas

  • Easy to operate and maintained by a skilled labour

  • Portable and light weight

  • Useful for removal of moisture and polar compounds from oil

 Cost:  Depends on capacity of filtration unit