manufacturers’ perspective -...

MANUFACTURERS’

PERSPECTIVE

09/01/2015 NEW DELHI 1

MINISTRY OF HEAVY INDUSTRIES & PUBLIC ENTERPRISES NOTIFIES

ELECTRICAL TRANSFORMERS (QUALITY CONTROL ORDER,2014)

DT. 27.01.2014

MANDATES BIS LICENSING FOR DT’S UPTO & INCLUDING 100 KVAAS PER IS 1180:1989AS PER IS 1180:1989

SUPERSEDED BY

ELECTRICAL TRANSFORMERS (QUALITY CONTROL)

AMENDMENT ORDER, 2014 DT.14TH NOV 2014.

MANDATES BIS LICENSING FOR DT’S UPTO & INCLUDING

2500 KVA AS PER IS 1180:2014(PARTI)

09/01/2015 NEW DELHI 2

ELECTRICAL TRANSFORMERS (QUALITY CONTROL)

AMENDMENT ORDER, 2014 DT. 14TH NOV 2014.

THE ENFORCMENT OF THIS ORDER SHOULD BE POSTPONED BY ATLEAST SIX MONTHSFOR THE FOLLOWING REASONS:

GUIDELINES FOR CERTIFICATION OF OUTDOOR TYPE DISTRIBUTION

TRANSFORMERS AS PER IS 1180 WERE ISSUED ONLY ON 27TH NOV. 2014TRANSFORMERS AS PER IS 1180 WERE ISSUED ONLY ON 27TH NOV. 2014

SCHEME OF TESTING AND INSPECTION FOR IS 1180:2014 WAS MADE AVAILABLE VERYLATE AND STILL REQUIRES MANY CLARIFICATIONS ESPECIALLY TATKAL LICENSING.

REGIONAL OFFICES TOO ARE STILL NOT CLEAR ON THE GUIDELINES ISSUED & HAVEDIFFERENT OPINIONS ON THE RANGE & QUANTITIES OF SAMPLES DRAWL ETC. FORTESTING AT THE FIRST INSTANCE.

APPLICATIONS OF MOST MANUFACTURERS WHO HAD APPLIED EARLIER FORCERTIFICATION HAVE BEEN CLOSED & RETURNED OWING TO BIS 1180 QUALITY CONTROLORDER AMENDMENT.

09/01/2015 NEW DELHI 3

THRUST AREAS NEEDING ATTENTION OF REGULATORS & STAKE HOLDERS BEFORE

ENFORCING ELECTRICAL TRANSFORMERS QUALITY CONTROL ORDER, 2014

UTILITIES/DISCOMS HAVE DIFFERENT SPECS. FOR MANUFACTURE OF TRANFORMERS WRT

1. BASIC INSULATION LEVELS

2. ENERGY EFFICIENCY LEVELS 1,2 OR 3

3. FLUX DENSITIES, CURRENT DENSITIES ,

4. NO OF COILS PER LIMB,

5. TYPE OF CONDUCTOR VIZ DPC OR SE

6. TYPE OF INSULATING MATERIAL VIZ. KRAFT PAPER/EPOXY DOTTED KRAFT ETC.

7. WEIGHTS OF CORE/COIL/OIL AND SO ON AND ON

8. TEMEPERATURE RISE OF OIL/WINDINGSCONTD……….

09/01/2015 NEW DELHI 4


ENFORCING ELECTRICAL TRANSFORMERS QUALITY CONTROL ORDER,2014

9 COOLING METHODS, DESIGN & PLACEMENT OF RADIATORS

10 ELLIPTICAL TUBES, ROUND TUBES,PSR,CORRUGATED

11 SHAPE OF TANK-RECTANGULAR, ELLIPTICAL OR ROUND

12 PLACEMENT OF BUSHINGS TOP, SIDE ETC.12 PLACEMENT OF BUSHINGS TOP, SIDE ETC.

13 THICKNESS OF TANK SHEET ETC.

14 DIFFERENT COMPONENT LOSSES EVEN FOR STAR RATINGS

VIDE (CL.BI) GUIDELINES FOR CERTIFICATION AS PER IS 1180 CIRCULATED VIDE

REF. NO. CMDI(BD)/IS 1180 DT. 27.11.2014, ANY CHANGE IN ANY OF ABOVE

PARAMETERS WOULD TANTAMOUNT TO CHANGE OF DESIGN OF TRANSFORMER

AND THIS WOULD REQUIRE TYPE TESTING AGAIN.

CERTIFICATION & LICENSING ONCE GIVEN FOR THE HIGHEST RATING & ENERGY

EFFICIENCY LEVEL SHOULD BE PERMANENT & NOT SUBJECT TO CHANGE DUE TO

CHANGE IN ANY OF ABOVE PARAMETERS09/01/2015 NEW DELHI 5


ENFORCING ELECTRICAL TRANSFORMERS QUALITY CONTROL ORDER,2014

THERE HAS TO BE STANDARDISATION OF SPECIFICATIONS BY THE

REGULATORS & OTHER STAKE HOLDERS:

1. ONE UNIFORM SPECIFICATION DRAFTED JOINTLY BY BIS/REC/BEE WITH1. ONE UNIFORM SPECIFICATION DRAFTED JOINTLY BY BIS/REC/BEE WITH

CEA AS NODAL AGENCY TO BE ADOPTED.

2. MANDATE FOR ALL STAKE HOLDERS TO FOLLOW IN TOTO FOR TENDERING,

MANUFACTURE, INSPECTION & ACCEPTANCE.

3. RECOMMENDATIONS BY CONSULTANT ABPS ON QUALITATIVE

IMPROVEMENT IN MANUFACTURING PRACTICES OF DISTRIBUTION

TRANSFORMERS AND BEST O & M PRACTICES FOR UTILITIES AT THE BEHEST

OF MOP JOINTLY BY ITMA & BEE IS YET TO BE IMPLEMENTED.

09/01/2015 NEW DELHI 6

ELECTRICAL TRANSFORMERS (QUALITY CONTROL) AMENDMENT ORDER

2014 DT.14TH NOV 2014 – PROCEDURES FOR APPLYING:

APPLICATIONS SHOULD BE ACCEPTED ONLINE WITH USER FRIENDLY WEB PORTAL FOR UPLOADING DATA WITH SPECIFIC DROP DOWN MENUS.

• APPLICATION FORMS SHOULD HAVE MINIMUM REQUIRED FIELDS NECESSARY FOR REGISTRATION, CERTIFICATION & LICENSING. EXTRA FIELDS SHOULD BE DONE AWAY WITH AND MINIMUM DETAILS SOUGHT.

• AFTER PERUSAL OF THE APPLICATION IF ANY FURTHER CLARIFICATION IS REQUIRED THEN ONLY SUCH SPECIFIC QUERIES MAY BE RAISED AND DETAILS SOUGHT FROM THE APPLICANT INSTEAD OF CLOSING THE APPLICATION & RETURNING THE WHOLE FILE ALONG WITH FEES & FOR RESUBMISSION OF COMPLETE FRESH APPLICATION.

09/01/2015 NEW DELHI 7

ELECTRICAL TRANSFORMERS (QUALITY CONTROL) AMENDMENT ORDER

2014 DT.14TH NOV 2014 – GRANT OF LICENCE CLARIFICATIONS

BIS HAS BEEN KIND ENOUGH IN CLARIFYING COUPLE OF POINTS VIDE THEIR EMAIL DT 02 JAN 2015. BUT STILL THERE ARE FEW POINTS WHICH NEED CLARIFICATION

IN THE DETAILED STEP BY STEP PROCEDURE FOR GETTING BIS LICENCE

POINT NO. 2 & 3 MENTIONS THAT “THE APPLICANT WILL HAVE TO GET HIS PRODUCT TESTED IN ANY BIS RECOGNIZED LABORATORY AS PER RELEVANT STANDARDS AND THEN APPLY TO BIS FOR LICENCE”. THIS CLEARLY MEANS THAT MANUFACTURER HAS TO GET THE TYPE TESTS DONE BEFORE APPLYING FOR BIS LICENCE.

WHETHER THIS PRE TESTING OF TRANSFORMERS BEFORE APPLYING HAS TO BE DONE ON ALL THE SIZES OR THE LARGEST SIZE

09/01/2015 NEW DELHI 8

ELECTRICAL TRANSFORMERS (QUALITY CONTROL) AMENDMENT ORDER 2014

DT.14TH NOV 2014 – GRANT OF LICENCE CLARIFICATIONS

WHEREAS IN POINT NO. 5 (V) IT STATES THAT REQUISITE SAMPLE WILL BE DRAWN FOR INDEPENDENT TESTING IN BIS LAB WHICH MEANS THAT THE SAMPLE HAS TO BE TYPE TESTED AGAIN AFTER THE FACTORY INSPECTION BY BIS OFFICERS.

IS RE TESTING OF SAMPLE IN BIS LAB COMPULSORY BEFORE GRANT OF LICENCE?

TATKAL SCHEME

IN CASE IF SOMEONE APPLIES FOR TATKAL SCHEME AND HAS THE TYPE TESTS REPORTS AVAILABLE WITH HIM FOR THE SAID SIZE, HE SHOULD BE GRANTED BIS LICENCE ON THE IMMEDIATE BASIS AFTER ASSESSING THE MANUFACTURING FACILITIES WITHOUT GOING INTO ANY FURTHER TESTING ETC.

09/01/2015 NEW DELHI 9

MUCH BEFORE THIS ELECTRICAL TRANSFORMERS QUALITY

CONTROL ORDER WAS NOTIFIED: TRANSFORMERS WERE BEING

PROCURED BY DISCOMS CONFORMING TO IS 1180/2026 &

BUREAU OF ENERGY EFFICIENCY (BEE) INTRODUCED THE STAR

LABELLING PROGRAMME FOR MANUFACTURE OF ENERGYLABELLING PROGRAMME FOR MANUFACTURE OF ENERGY

EFFICIENT TRANSFORMERS WITH IS 1180 AS THE BASE.

• DISTRIBUTION TRANSFORMERS PRESENTLY UPTO 200 KVA ARE

SUBJECT TO BEE STAR LABELLING AND IT IS MANDATED BY CEA

GAZETTE TO MANUFACTURE/ PROCURE DISTRIBUTION

TRANSFORMERS WITH LOSSES EQUAL TO OR BETTER THAN

THREE STAR RATINGS.(LEVEL 1 OF BIS 1180:2014)

09/01/2015 NEW DELHI 10

FOR REDUCING MULTIPLE TESTING TIME & COST

TO THE MANUFACTURERS WHO ARE FROM THE MSME SECTOR

& MAINLY SME ‘S WITH LIMITED RESOURCES

BIS LICENCING SHOULD BE ALIGNED WITH BIS LICENCING SHOULD BE ALIGNED WITH

BEE TESTING & REGISTRATION

PROVISION SHOULD BE MADE FOR AUTOMATIC GRANTING OF

BIS LICENCE ON THE BASIS OF BEE REGISTRATION FOR THE

RATINGS ALREADY REGISTERED WITH BEE FOR STAR LABELLING

UPTO 200 KVA AS OF NOW

09/01/2015 NEW DELHI 11

ITMA MEMBERS ASSURE THIS AUGUST GATHERING THAT:-

WE ARE MANUFACTURING TRANSFORMERS CONFORMING TO INTERNATIONALSTANDARDS IN EFFICIENCY & RELIABILITY & ARE ADOPTING BESTMANUFACTURING PRACTICES & EXERCISING STRICT QUALITY CONTROL.MANUFACTURING PRACTICES & EXERCISING STRICT QUALITY CONTROL.

WE ARE COMMITTED TO USING PRIME MATERIAL BE IT CRGO OR ANY OTHERFOR PRODUCING HIGH EFFICIENCY TRANSFORMERS.

WE APPRECIATE THAT THE ELECTRICAL TRANSFORMERS QUALITY CONTROLORDER , 2014 WILL BE BENEFICIAL FOR ALL STAKE HOLDERS., HOWEVER IT ISOUR HUMBLE REQUEST THAT THE WHOLE PROCESS OF CERTIFICATION ANDLICENSING BE STREAMLINED IN THE WAKE OF OUR SUBMISSIONS EXPLAINEDEARLIER FOR EASIER & FLAWLESS IMPLEMENTATION.

09/01/2015 NEW DELHI 12

THIS TRANSFORMERS QUALITY CONTROL ORDER ORDER IS FOR ENSURING

QUALITY,RELIABILITY & DURABILITY, BUT RELIABILITY & DURABILITY OF

DISTRIBUTION TRANSFORMERS DEPENDS NOT ONLY ON QUALITY

MANUFACTURE BUT ON MANY FACTORS POST MANUFACTURING, VIZ:

• TRANSPORTATION & STORAGE• TRANSPORTATION & STORAGE

• INSTALLATION & COMMISSIONING

• OPERATION & MAINTENANCE.

NEXT FEW SLIDES SHOW THAT INSTALLATION , OPERATION AND

MAINTENANCE PROCEDURES BEING EMPLOYED ARE NOT AS PER BIS

CODES & WHICH IF NOT CHECKED WILL MAKE ALL EFFORTS OF ELECTRICAL

TRANSFORMERS QUALITY CONTROL ORDER FUTILE

09/01/2015 NEW DELHI 13

BIS CODES FOR INSTALLATION & MAINTENANCE NOT FOLLOWED

09/01/2015 NEW DELHI 14

BIS CODES FOR INSTALLATION & MAINTENANCE NOT FOLLOWED.

BRANCHES FOULING WITH HT CONNECTIONS

09/01/2015 NEW DELHI 15

BIS CODES FOR INSTALLATION & MAINTENANCE NOT FOLLOWED.

JUMBLED WIRES

09/01/2015 NEW DELHI 16

BIS CODES FOR INSTALLATION & MAITENANCE NOT FOLLOWED .

HT &LT WIRES CRISS CROSSING

09/01/2015 NEW DELHI 17

BIS CODES FOR INSTALLATION & MAITENANCE NOT FOLLOWED.

LOOSE CONNECTIONS CAUSING HEATING

09/01/2015 NEW DELHI 18


HUGE SIZE OF WIRE FOR HT FUSE

09/01/2015 NEW DELHI 19


OIL LEVEL NOT MAINTAINED

09/01/2015 NEW DELHI 20

• WHOLE SYSTEM SHOULD CONTRIBUTE TO QUALITY

CONTROL AND AS SUCH THE BIS CODES IS 10028 (PART II)

& (PART III) FOR INSTALLATION & MAINTENANCE OF

TRANSFORMERS SHOULD BE IMPLEMENTED & GOING TRANSFORMERS SHOULD BE IMPLEMENTED & GOING

FURTHER MAY BE SUBJECTED TO CERTIFICATION BY BIS.

• WHY SHOULD ONLY MANUFACTURERS OF SMALL

TRANSFORMERS AND WHO ARE MOSTLY FROM THE SME

SECTOR BE SINGLED OUT AND BEAR THE COST OF QUALITY

ASSURANCE FOR FACTORS BEYOND THEIR SCOPE .

09/01/2015 NEW DELHI 21

FOR TOTAL QUALITY MANAGEMENT MINISTRY OF HEAVY

INDUSTRIES & ENTERPRISES SHOULD EXTEND THIS QUALITY

CONTROL ORDER TO ALL SIZES & RATINGS OF TRANSFORMERS

INCLUDING POWER TRANSFORMERS.INCLUDING POWER TRANSFORMERS.

IMPORTS OF ALL RATINGS AND TYPES OF TRANSFORMERS

SHOULD ALSO BE SUBJECTED TO SOME BIS QUALITY CONTROL

ORDER OTHERWISE THE INDIAN SOIL WILL BE FLOODED WITH

SUBSTANDARD TRANSFORMERS AT THE COST OF THE INDIAN

TRANSFORMER MANUFACTURERS.

09/01/2015 NEW DELHI 22

TOGETHER LETS WORK FOR

ENERGY EFFICIENT , RELIABLE & DURABLE

TRANSFORMERS

Thank You

09/01/2015 NEW DELHI 23

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