Power Transformer - Manufacturing Plant, Detailed Project Report, Profile, Business Plan, Industry Trends, Market Research, Survey, Manufacturing Process, Machinery, Raw Materials, Feasibility Study, Investment Opportunities, Cost And Revenue
|Power Transformers are used in Transmission network so they do not directly connect to the consumers. These are not loaded fully at all time so iron losses takes place 24hr a day and cu losses takes place based on load cycle. Average loads are about only 75% of full load and these are designed in such a way that max efficiency occurs at 75% of full load. These are independent of time so in calculating the efficiency only power basis is enough. Power transformers are used for transmission as a step up devices so that the I to R loss can be minimized for a given power flow. These transformers are designed to utilize the core to maximum and will operate very much near to the knee point of B-H curve (slightly above the knee point value). This brings down the mass of the core enormously. Naturally these transformers have the matched iron losses and copper losses at peak load (i.e. the maximum efficiency point where both the losses match). Bulk AC power transmission necessitates the use of high voltages. Progressively, the transmission voltages have risen to 400 kV AC in India. In India, system voltages up to 400 kV are well established and 800 kV AC transmission systems are being planned. This will require manufacturing of 800 kV transformers. Most of the major transformer manufacturers in India had collaborations with reputed international companies, such as Associated Electrical Industries (AEI,) U.K.; Alsthom, France; Hawker Siddely, U.K.; Hitachi, Japan and Siemens, Germany. Market Survey Electric equipment industry contributes over 2% of GDP which is projected to increase to about 12% in 2015 according to a study by Frost & Sullivan. During the period, consumption of electrical equipment is estimated to increase from over USD 28 bn now to USD 363 bn, growing at a CAGR of about 30%. It is also expected that during 2010-2015, the Indian equipment manufacturing will grow at 5.5 times the growth rate of global electronic equipment production. The electrical industry has been showing signs of recovery after poor performance in the recent years. The domestic electrical industry, which includes equipment for generation, transmission, distribution and use of power in industrial units, constitutes a major part of the electrical products. India's capacity to manufacture power equipment is set to increase four-fold to around 43,000 MW over the next 5 years, through investments of over Rs 300 bn. The additional capacity of 33,000 MW is expected to be added by 2015. With some fast moves at launching fast track projects to augment supplies, the Indian industry needs to improve its competitiveness. The Indian market is growing and multinationals with newer technologies are now more active. The industry, as a consequence, needs strategic alliances and tie-ups with technology suppliers to upgrade their supplies. The technology for the manufacture of transformers, for instance, is largely European. As a result, most players have the same level of technology. Even prices do not differ substantially. Lately, encouraging sign are emerging. The entry of private sector in the power area and the emergence of captive power plants have changed the scenario for the transformer segment. Earlier, the business revolved around power utilities such as the State Electricity Boards. As against this, the customers in the private sector prefer contracting out the entire substation to a single vendor, in the process thus reducing costs as well as avoiding problems of logistics. As more and more MNCs and specialized industries make India their business destination, special economic zones have been allocated and feeding mega projects of robust and efficient transformers, ensuring the optional generation of power. Transformers & Rectifiers India Ltd (TRIL) is a leading player in this industry. Recently TRIL signed a billion rupee MoU with the Government of Gujarat to set up a new plant at Moraiya with an installed capacity of 16,000 MVA. It will make TRIL the third largest transformer manufacturing company of India. Siemens is now setting up a state-of-the-art Greenfield world class facility for manufacturing industrial turbines at Vadodara, Gujarat. Siemens will be manufacturing industrial steam turbines of up to 45 MW capacities, completely with its components at the Vadodara unit. It will also manufacture key components for steam turbines of up to 150 MW capacities. The company is investing Rs 30 mn in its new facility. It has grown to a complex of 14 manufacturing units during its 50 years in India. Of the world's total installed capacity in power generation, 20% is based on the Siemens’ technology. In India, Siemens accounts for about 35% of the generation capacity. Even BHEL manufactures Siemens’ larger turbines under license agreement in India. It also upgraded the traction converter unit at Nasik and a 245 KV circuit breaker unit at Aurangabad. Wartsila India in talks with the Rural Electrification Corporation (REC) for setting up power generation plants. It plans to run the plants on bio-fuels such as Jatropha and palm oil. It will set up small generation plants of 2 to 3 MW at an investment of around Rs 100 mn to Rs 120 mn respectively. The company claims that the engines supplied by it can use raw bio-fuel without the need for esterification process (a chemical reaction in which two chemicals form an ester as the reaction product by which the oil pressed from Jatropha can be used to produce bio-fuel). Four major players in electrical equipment segment recorded high growth of turnover over the previous accounting years: ABB (44%), BHEL (29%), BHEL Power Solutions (144%), Havel’s India (55%), and Kirloskar Electric (43%) Crompton Greaves (32%) and Suzlon Energy (42%). The growth of bottom lines was equally impressive ranging from 12 to 55%. Few Major Players are as under:- Advance Powerinfra Tech Ltd. Ahluwalia Contracts (India) Ltd. Alfa Transformers Ltd. Alstom T & D Distribution Transformers Ltd. Alstom T & D India Ltd. Apex Electricals Ltd. Automatic Electric Ltd. Bharat Bijlee Ltd. Bombardier Transportation India Ltd. Crompton Greaves Ltd. D & H India Ltd. Diamond Power Transformers Ltd. E C E Industries Ltd. East India Udyog Ltd. Electra (India) Ltd. Electra (Jaipur) Ltd. Emco Ltd. General Electric Co. Of India Ltd. Genus Power Infrastructures Ltd. I M P Powers Ltd. Indian Transformers Co. Pvt. Ltd. Indo Tech Transformers Ltd. Kanjikode Apparel Exports Ltd. Kanohar Electricals Ltd. Karnataka Vidyuth Karkhane Ltd. Kirloskar Brothers Ltd. Kirloskar Electric Co. Ltd. Kryfs Power Components Ltd. M & B Switchgears Ltd. Marsons Ltd. Mukati Transformers Ltd. N G E F Ltd. Powergear Ltd. R T S Power Corp. Ltd. Rams Transformers Ltd. Raychem-R P G Pvt. Ltd. Rohini Industrial Electricals Ltd. S E Electricals Ltd. Schneider Electric Infrastructure Ltd. Shilchar Technologies Ltd. Star Delta Transformers Ltd. Star Transformers Pvt. Ltd. Statcon Power Controls Ltd. Sudhir Transformers Ltd. Suzlon Infrastructure Services Ltd. Toyama Electric Ltd. Transformers & Rectifiers (India) Ltd. Tyche Electronics Ltd. Usha (India) Ltd. V H E L Industries Ltd. Victory Electricals Ltd. Vijai Electricals Ltd. Voltamp Transformers Ltd.|
|Plant capacity: 900 Nos. /annum||Plant & machinery: Rs. 305 Lakhs|
|Working capital: -||T.C.I: Cost of Project: Rs. 1024 Lakhs|
|Return: 29.00%||Break even: 52.00%|
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