Professional Documents
Culture Documents
The origins of our story began in 1994, way before the first gusts of an energy crisis blew
across our land. It was a time when wind energy emerged not as an alternative, but a
mainstream, renewable, eco-friendly source of power generation.
'Since then we've emerged as the country's preferred wind power solution provider, on a
number of counts.
Wind World (India) Limited (WWIL) formerly Enercon (India) Limited has always been a path
breaker, with innovations that have consistently left the others behind. Gearless technology,
an energy-efficient grid feeding system and long-lasting warp resistant blades are just cases
in point.
Our wind farms today straddle seven high wind potential states Karnataka, Maharashtra,
Tamil Nadu, Rajasthan, Gujarat, Madhya Pradesh and Andhra Pradesh, spread across 3,000
kms of India. We have installed over 6204 Wind Energy Converters (WECs) with a capacity of
over 4561 MW.
We are maintaining these WECs round the clock 24 x 7 for optimum performance.
We're an ISO 9001:2008 certified company for Manufacturing, Installations and Services.
Wind energy converters are manufactured at four plants in Daman; while concrete towers
are manufactured at facilities in Gujarat, Karnataka and Tamil Nadu. We employ over 5,600
dedicated people and have set up the Wind World Training Academy at Daman, for training
world class operations, maintenance and asset management support teams.
In terms of business results, we've achieved a turnover of INR 3636 crores in FY 2010-11 and
recorded highest ever turnover of INR 4270 in FY 2011 -12, WWIL is poised to cross INR 4500
crore mark in the year ahead (FY 2013-14).
So what powers our success?
Trained Manpower.
'Over the years, our passion about wind energy continues to power our sails.
52.9 m
74 m
ROTOR
Type: Upwind rotor with active pitch control
Rotational Direction: Clockwise
Number of blades:
Swept Area:
2,198 meter2.
Blade Material:
Rotation Speed:
Pitch Control: Wind World (India) Ltd. blade pitch system, one independent pitching system
per rotor blade with allocated emergency supply.
DRIVE TRAIN WITH GENERATOR
Hub:
Rigid
Main Bearings:
Generator:
- Rotor brake
- Rotor lock
Yaw Control:
Cut-out wind speed: 25 m/s - with Wind World (India) Ltd. storm control
Business Vision
We will foster a culture of care for our stakeholders, and channel our efforts with
integrity to build their trust.
Business Mission
Our mission is to deliver projects from concept, to commissioning, to lifetime care, using
state-of-the-art grid-friendly wind power plants that generate clean and cost-effective
energy for our customers.
We will actively promote and propagate the use of wind energy, as an environment
friendly resource.
We will work towards being the most trusted wind energy company.
Key Statistics
SALES TURNOVER
INSTALLED CAPACITY
Our employees are proudly called WinDirecters. A WinDirecter is one who rededicates
himself, to live up to our motto of "Clean Energy Forever" for our country. They are the ones
who will bring on Quality Gigawatts in times to come.
Employees: 5600
Market share: 26% overall, > 50 % in the most demanding IPP segment
Concrete Towers - Gujarat, Karnataka & Tamil Nadu, Rajasthan (under construction)
WWCC is the control centre of a large network connecting over 5900 wind turbines online. It
comprises of:
Sensors located on each turbine, which give critical input of parameters like Wind
Speed, Wind Direction, RPM, Temperature, Humidity, Power Production, etc.
Linking of all turbines using OFC through the SCADA on a wind farm, enabling better
wind farm control.
Linking of multiple wind farms to the WWCC, through Extended C Band VSAT
Communication links.
The WWCC has given rich benefits to the wind farms, and overall enhanced efficiency of
Wind World operations through:
Increased revenue through improved turbine availability and wind farm production.
The WWCC is an effective asset management solution which stands to realize significant
cost reduction in Operations and Maintenance. The main objective for WWCC is to increase
revenue by minimizing wind turbine generator down time and ensure its optimal
performance as per the Power Curves, which is achieved by quickly responding to turbine
abnormalities round the clock.
'The WWCC uses advanced Business Intelligence (BI) software for in-depth analysis of SCADA
data to maximize turbine availability and performance, and reduce turbine fault with an
objective of better asset management decisions in near or real time. The WWCC BI
application and dashboard gives the operational staff a single view of all multiple wind farms
and their turbines at a glance. Archived data of WWCC SCADA application is interfaced and
utilized in SAP to carry out preventive and breakdown maintenance of turbines, calculate
spares provisioning strategy and also financial budget management.
The WWCC can remotely reset turbines, thus ensuring against major breakdowns. A large
number of faults are diagnosed and reset by the WWCC in an automated mode. The fault
status generated by the WWCC and repair protocols from the Document Management
System at Wind World, enable faster and more coordinated repair of the wind farm assets.
The WWCC team comprises of highly trained engineers, who are experts on wind technology.
These engineers continuously monitor and interpret the data which is being received
through the turbines, on a 24 x 7 mode.
Group Initiatives
Reviewing the functioning of WWIL's wind energy assets, owned by Wind World
(India) Ltd.
Closely monitoring the technical and financial aspects of the asset's performance
Managing day-to-day operations of various SPV's in which these assets are housed.
WWIPDPL is staffed with experienced personnel, who have for many years been
managing the diverse portfolio of Wind World (India) Ltd's wind power generating
assets across seven states, with high levels of prudence and excellence.
One such WWIL project has a long term power purchase agreement signed with private
parties, wherein Wind World (India) Ltd. has established the power project and is supplying
power to private parties, having a high credit rating.
WWFCPL has successfully managed to arrange finance against security of the receivables
due from the sale of power, to the private parties.
TRADITIONAL WIND POWER PROJECT FUNDING
This is done for customers who require funds and are investing in wind based power
projects, with a view to avail tax benefits and sometimes save on power cost.
Applicability for wind power project funding:
All states where wind energy projects are being installed and have wind power
policies in place are eligible for financial assistance.
Projects set up for power sold to the state DISCOM for captive consumption and
power sold through the Open Access routes, are eligible for financial assistance;
subject to detailed due diligence of the project specifics.
Generally the debt: equity ratio of customer should be 70:30 or less. This is however
subject to the due diligence process.
The customer should not have defaulted with any bank/financial institution.
Founder's View
Renewable Energy in India is only just taking off ! The potential for Renewable Energy is
phenomenal, and I would say in India it is definitely equivalent to the 'Conventional Source'
of energy if not more!
The estimated Indian wind energy potential has been assumed by the Ministry of New and
Renewable Energy in a study conducted in the late 90's to be 45,000 MW's. A more recent
study by AWS Truewind, India estimates India's wind energy potential at 65,000 MW's. My
personal estimate is that India has a minimum tap-able potential of 2,50,000 + MW's of wind
energy on-shore.
The major strengths of Wind World (India) Ltd. (WWIL) (formerly Enercon (India) Limited) are
the 3C's - Competent Teams, Cutting Edge Technology and Constant Pursuit of Excellence on
all fronts.
Our major focus points are meticulous planning and seamless coordination, as we go forward
with our growth plans.
As we grow we will need to follow world-class systems to remain competitive and to keep
ahead. Towards the same, we will continue to deploy cutting edge information technology
tools and solutions, coupled with a strong emphasis on Quality, to ensure we achieve our
objectives. The emphasis we place on training and competency-building, equip us well to
spread our wings and sustain our growth.
The year ended March 31, 2013 has seen WWIL scale new peaks; our cumulative Installed
Capacity in the country has crossed 4561 MW's. This milestone has propelled us to be
amongst India's leading organisations in the wind energy sector.
The impetus provided for green energy by our Government, will also enable us to take
bigger strides in the future!
WWIL is my dream, which I am fortunate to live every single day. It's been very challenging
and exciting. We have been able to create the infrastructure required for any organization to
take off and cruise! This includes building a very competent team and systems to help WWIL
not only grow but also sustain its growth levels.
The next 10 years will be the golden period for the Indian Wind Industry, and WWIL will
surely be amongst the leading players in the Wind Industry in India, in the times to come!
Yogesh Mehra
Managing Director
Key Projects
Right from 1994, when the company was known as Enercon (India) Limited, WWIL's wind
energy converters have demonstrated their capabilities in virtually every kind of site locale.
Stretching from India's southern tip - Kanyakumari in Tamil Nadu, to its south-western
frontier - Jaisalmer in Rajasthan, WWIL turbines continue to propel the fortunes of India's
energy destiny forward
Consistency in generation capabilities, low maintenance and grid-friendly properties, have
made them the wind energy convertors of choice, across every state they have been
installed in.
Today WWIL has successfully developed varieties of sites in virtually every Indian terrain,
except the Himalayas.
Some sites combine extremely difficult terrain and high winds, making wind energy
convertor erection a daunting task.
Quality Focus
To stay ahead of a very competitive market scenario, WWIL has endeavored to become a
market leader by meeting customer expectations through quality. It has strived not only to
achieve but also exceed the expectations of the customers through Customer Delight.
We have established and implemented Total Quality Management, a way of not just assuring
product or service quality - it is way of managing people and business processes, to ensure
complete customer satisfaction at every stage, both internally and externally.
Our belief in achieving the FTR (First Time Right) is by focusing on defect prevention, rather
than detection and rectification.
Beyond this our effort is to reach the apex of quality, by continually improving systems and
processes through adoption of advanced quality tools & methodologies:
SIX SIGMA
This journey was initiated in 2007, with the objective of reducing variations in process
efficiency. Over 15 projects in different areas have been completed till date.
Today, we have 5 Certified Black belts, 35 Green Belts and 50 Yellow Belts.
LEAN MANUFACTURING
This was initiated in 2010 and focuses on identifying and eliminating waste in all areas. One
project has already been undertaken on the 'lean concept'
SUPPLIER QUALITY ASSURANCE
Advanced IT Support
At WWIL, Information Technology (IT) is the backbone of virtually every process, from wind
energy research to manufacturing, project implementation and long term after sales service.
IT also facilitates business intelligence and an advanced management dashboard with web
and mobile interfaces for employees, vendors and customers in the form of portal
applications. These applications are tightly integrated with SAP ERP, SCADA and other
legacy systems. In fact, business is unimaginable without support from the IT backbone
currently in place.
All manufacturing plants, regional and business development offices, project and service
sites, are connected with V-SATs/MPLS/VPNs for online access of IT applications, hosted at
the Mumbai data center. IT applications can be accessed even on the go, using smartphones
and other mobile platforms.
Our IT solutions team has created a robust and secured communication infrastructure with
stable high quality HD video conferencing facilities, at all key locations in a board room
environment. These are integrated with a client-based VC facility for users to integrate
business activity planning, and day-to-day reviews and monitoring of business performance.
The Groundwork
Wind Resource Development
Wind is the basic resource on which the continuing success of a project is hinged. Wind
World (India) Ltd's dedicated Wind Resource Department (WRD) has a highly skilled and
experienced team, focused on finding the best wind sites in India for the development of
wind farms. The objective being to maximize investor returns, by optimizing the micro-sitting
of Wind Turbines.
Before preparing the ground, it's important to understand the various stages a wind energy
project goes through at Wind World (India) Ltd:
The most critical aspects for the success of investment in the wind energy sector apart from
a superior product are:
Government agencies publish maps of estimated wind resources for most areas in India,
with active wind power development. Wind prospecting begins with these maps. However
lack of accuracy and detail, render them useful only for preliminary selection of sites for
collecting wind speed data.
To estimate the energy production of a wind site, the WRD performs a wind resource
assessment, which comprises activities like: site identification, wind monitoring, wind
resource mapping and optimization and micrositing.
Site description
Mean, standard deviation and maximum of wind speed at all measurement heights
by date, time, and direction
Wind resource mapping and assessment is critical for a given site to decide the optimized
placement of turbines resulting in maximum wind farm output.
For an accurate wind resource mapping it is important to ensure the accuracy of the data,
which is fed into the software. Wind World (India) Ltd. carries out extensive field surveys,
using latest GIS techniques backed by latest satellite images to get accurate information of
the site.
The accuracy of terrain, roughness, wind data, will decide the accuracy of the wind resource
map prepared by the program.
MICROSITING & PRODUCTION ESTIMATION
Beyond having a good site and a good wind turbine, it is important to ensure that turbines
are put at the right places, to extract the maximum generation out of the wind farm.
Wind World (India) Ltd. uses the latest optimization tools widely used by the wind experts
across the globe, which carries out several thousand iterations to arrive at the most optimal
micrositing for the site. We ensure the maximum returns without compromising the life time
of the turbine for our customers from their wind farm.
These tools can take into account varied parameters like topographical variations, variation
in wind intensities, different turbine configurations, local issues, noise levels, shadow and
flicker issues, etc. The tool works out the best turbine array within the given boundary
conditions / limitations and ensures high generation levels.
TURBINE SUITABILITY STUDY & LOAD ANALYSIS
Wind turbines operate in environmental conditions over which no control can be exercised.
Therefore, the turbines have to be designed such that they will work without damaging
themselves or their environment. Wind turbines are designed and validated by accredited
certification bodies to withstand weather conditions that can be quite harsh. The advanced
calculations take into account possible extreme wind speeds (Ve50 - extreme wind speed - 3
second gust with a return period of 50 years) and turbulence intensities which has an
influence on the fatigue life of the blade and other critical components. Wind turbine design
standards fix overall design parameters such as extreme winds, average wind speeds,
turbulence intensities, inflow angles that the turbine is expected to withstand over its
service life - which is generally taken as 20 years.
As per IEC 61400-1 there are classes of wind conditions to which a turbine could be
designed. Considering the fact that there will be a need to have some flexibility in this, the
standard allows a special class to which the turbine could be designed. Under this, the
designer can define his own wind conditions to which the design will conform. The wind
speeds are so chosen that they are best suited for Indian wind conditions. The extreme wind
(3 second gust) is so chosen that in most of the sites where wind farming is taken up the 50
year return period gusts do not exceed the limit to which the turbine is designed. Keeping in
view possible turbulent conditions, the turbine has been designed to highest class of
turbulence intensity. This makes the model perform the best among the turbines available
without compromising the safety and integrity of the turbine.
Within the wind farm, there will be variations in the flow conditions that each turbine has to
face. Wind World (India) Ltd. uses advanced tools to check the compliance with the specific
class to which the turbine is designed. Some of the factors are extreme wind speed, local
turbulence intensity and its impact on loads, inflow angle, power law index and many other
parameters that will impact the loads on the turbine. A thorough check is made of all critical
parameters for each turbine location before the location is released for construction.
If certain locations in the wind farm do not meet the requirements in spite of higher
generation, the machine location is shifted slightly so that safety of turbine is not
compromised, nor is there a penalty to generation. But beyond a limit, if the location is not
suitable, it would be dropped. With this approach Wind World (India) Ltd. ensures that wind
turbines will perform to their best level.
Infrastructure
While certain sites need minimum road work due to their flat and hard terrain, the extent of
work required for constructing a road on a hilly terrain is huge. The best route to reach the
top of the hill is first worked out.
Next, hill cutting and the road work is undertaken, to enable trailers which carry the
materials and cranes, reach the point of installation. Here, aspects like gradient, width and
turning radius of a road should be considered to support smooth flow of material. Proper
drainage facilities are then constructed and maintained, to ensure natural flow of water
without affecting the ecology.
The roads are maintained thoughout the lifetime of the project. This ensures that each and
every machine is easily accessible, for the benefit of maintenance activities..
Power Evacuation
many times, the state grid development does not get upgraded at the pace at which wind
farms get developed. This may result in curtailment at a later stage, if not properly taken
care of. We at Wind World study the state grid thoroughly, analyse it in-house with software,
and create a fool-proof system for our investors.
We have a proven track record in constructing new substations and upgrading existing ones
at various voltage levels, ranging from 33 KV to 220 KV, across the country. We have
established our own design and specifications complying to relevant standards of the
country. Whereever required, we build lines with multi-circuit towers, instead of poles, for
even 33 KV wind farm internal lines.. The rugged lattice structure is practically maintenance
free and ensures great grid availability.
Our own Electrical Network Asset is comparable with any Power Utility of the country.
Further, we approximately add 700 to 800 kms of 33KV lines year a year.
Manufacturing
Nacelle & Rotor Head
Wind World (India) Limited has two separate plants for assembly of wind turbines at Daman.
Together these occupy a total surface area of 2,500 sq. mts. and have an annual production
capacity over 1000 MW.
NACELLE ASSEMBLY
The Nacelle is the main housing of the turbine, which is assembled with the yaw drive, it is
directly mounted on the tubular tower. The main carrier is a single cast frame that permits
stable mechanical behavior and performance.
ROTOR ASSEMBLY
Rotor head production comprises the manufacture and integration of the pitch drive,
bearing, axle pin, stator-rotor and balancing assembly, under a single roof.
The rotor hub or unit along with pitch drive and annular generator are interconnected to
form a single gearless unit. The rotor unit is then mounted on a fixed axis, called the axle
pin.
As compared to conventional geared systems with a large number of bearing points in a
moving drive train, our drive system requires only two slow-moving taper roller bearings,
due to its low direct drive speed @ 25 RPM. Bearing fitment is executed using the shrink as
well as induction heating techniques.
Wind turbines are equipped with a variable pitch technology. This allows for feathering the
angle of the blades for each wind speed; whereby controlled extraction is done using the
maximum energy in the wind flow.
In below-normal wind conditions, the pitch is tailored to derive maximum energy potential;
while in above-normal conditions, the pitch is altered to derive a controlled amount of
energy, so that the machine produces the rated power in a controlled and stable manner up
to cut out wind speed.
Besides maximizing wind energy derived, this system reduces torque on the device and
allows for the use of the full blade as an aerodynamic brake.
At every stage of assembly standard quality checks are executed as per our quality protocol
requirement. This is executed by trained personnel using high quality calibrated equipment,
to provide evidence of product conformity to requirements.
TRANSPORTATION
After assembly of the Nacelle and Rotor Head, specialized care is taken to mount the
composite equipment onto specially constructed trailer beds that are hauled to their
destination on the wind farm.
Trained drivers deal with some of the country's most challenging and difficult terrain to
ensure their critical load is transported to the end destination safely, meeting all the
stringent quality parameters with which it left the assembly line
Generators
The annular generator is of primary importance in the gearless system design of our wind
turbines. Combined with the rotor hub, it provides an almost frictionless flow of energy. The
Generator Production facility at Daman, covers a surface area of 1970 sq. mts., with an
annual production capacity of over 1000 MW.
ADVANTAGES OF THE WIND WORLD SYNCHRONOUS GENERATOR
Combined with the rotor hub it provides an almost frictionless flow of energy.
Minimal mechanical wear, which makes it ideal for particularly heavy demands and a
long service life.
STATOR WW-53
The Stator is a well designed, ring type construction with small axial length and large
diameter. The production process is very well designed and conforms to very high quality
standards at each stage of manufacturing.
The laminated core is coated with varnish (impregnated and powder coated) to provide
excellent corrosion protection against environment. The stator has a continuous joint-less
single layer winding, especially suitable for low speed generators. The insulation scheme
caters to class 180 requirements. HV Testing ensures the health of the insulation scheme of
the generator.
ROTOR WW-53
The Rotor is a separately excited to have minimum stresses and optimum power, multiple
salient pole type, suitable for a low speed generator. The Pole shoes are manufactured to the
highest quality standards.
IMPREGNATION PROCESS
Wind World (India) Ltd. has a Vacuum Impregnation process under controlled conditions with
resin storage facility, equipped with chillers and well equipped Autocycle impregnation
plants. The process replaces all air pockets from the windings with insulating resin and
ensures good bonding, thus, improving magnetic properties.
BAKING PROCESS
Wind World (India) Ltd. employs well designed air draft ovens equipped with programmed
heating cycle, to provide uniform heating conditions for baking of stator and rotor. The
baking process ensures proper coating of resin and additional mechanical strength to the
windings.
Electricals
Wind World (India) Ltd. wind turbines are equipped with state-of-the-art microelectronic
control technology produced in-house at our Daman plant. Having all the modern equipment
to manufacture all the electrical and electronic components, including testing facility within
the plant. The MPU (Main Processing Unit) is the central element of the control system,
which constantly registers information from the peripheral control elements, such as the yaw
control and active pitch control systems. Its function is to adjust the individual system
parameters, to ensure that the wind turbines achieve maximum output, under all weather
conditions. It also helps in controlling/improving grid parameters as per the requirement of
local grid conditions.
MANUFACTURING
To achieve high quality and reliability, Wind World (India) Ltd. has an in-house facility to
produce control systems at Daman. During manufacturing, stage-wise inspection and testing
of pitch control, yaw system, Nacelle control and converters, ensure its function for smooth
operation. The components and sensors used in the control systems are highly reliable with
proven track records for their enhanced performance in the wind turbines. Each Control and
Power panel is tested individually before installing in the turbine.
Constant evaluation of measurement data from wind sensor to adapt nacelle yaw
control
Vary speed, for maximum wind turbine efficiency at all wind speeds, and elimination
of undesirable output peaks and high operating load.
Active pitch control system, obtains an optimum angle of attack of air flowing
through the rotor blades; this ensures maximum output and stress reduction on the
entire wind turbine.
Brake system is aerodynamic by all three blades' pitch out (it can also stop rotation
of turbine if any blades pitch outs) for maximum turbine reliability, by means of three
independently operated pitch mechanisms, with standby power supply in case of a
mains failure
Temperature and air gap sensors between rotor and stator, ensure dependable
annular generator operation for optimization of power
Allows wind turbines to have very wide operating range of voltage and frequency, to
prevent frequent tripping of turbine.
stepped up to the appropriate medium voltage required by the grid or the wind farm
network.
Rotor Blades
Wind World (India) Ltd. has three dedicated facilities for blade production, which produce 10
blades a day, and cater to the commissioning of 1000 wind energy converters per annum.
The facility is ISO 9001:2008, SGS shop approved, for production of rotor blades, on the
basis of GL rules and guidelines. The foundation of blade manufacturing is based on a
competent team of people, time tested latest equipment and high quality raw material,
received from reputed vendors. Blade production is managed systematically using an
advanced tool like Six Sigma. Going by our track record of producing high quality blades,
right from 1994, we have not had any issue in the field because of blade failure.
SALIENT FEATURES OF ROTOR BLADES
Snout shape aluminium tip design, to reduce noise and air turbulence, and increase
generation output.
Superb surface smoothness - avoids fungus and algae formation, and draws
maximum air velocity.
Hollow axial aerodynamic composite blade design - for high strength to weight ratio.
Periodic checks & maintenance done on mould - for reliable aerodynamic profile of
the blade.
Highly precise VARIM process and auto power hinge mechanism for mold closing
reduces human error and ensures consistent quality.
Auto dust extraction and de-burring system - minimizes dust PPM level inside the
plant.
Highly qualified, well trained and experienced team of engineers & technicians - for
in-house capability to manufacture composite rotor blade plugs, molds and product
manufacturing.
Towers
An 8000 square meter tent surface is situated close to Jamnagar, where our first mobile
prefab concrete tower factory emerged. Arranged in a figure eight, this double tent
measures 50 meters in diameter through the main section and is 36 meters high.
WW-53 towers are produced here in 18 segments with a 5.50 m base diameter and a tower
top diameter of 1.80 m.
Our engineers have been trained at the production site and at various construction sites to
gain experience in producing and mounting prefab towers.
The central point is a Liebherr pivot tower crane. It is used to distribute the concrete in the
production area. A mobile concrete mixer is set up outside the tent. The mixer is also be
used to provide concrete for the foundations. This way, a uniform quality of concrete for the
foundations can be assured.
TOWER CONSTRUCTION
Wind World (India) Ltd. has three Concrete Tower Factories (CTFs) at Gujarat and Karnataka.
The fourth CTF in Rajasthan is under construction.
Towers are important because of their load-bearing capability to support the turbine, which
weighs close to 400 MT, and also because they bear the onslaught of winds, rain, erosion
and other naturally occurring hazards.
The load-dynamic design of the materials and structure used in our towers, provides the
best conditions for transport, installation and use.
Over and above binding national and international norms e.g. DIN and Eurocode, we have
set our own standards which surpass these quality and safety norms.
Virtual 3D models of the tower designs are produced during the development phase, using
the Finite Element Method (FEM). All possible stress factors on the wind turbine are then
simulated on the model. Accurate predictions concerning tower stability and service life are
not left to chance before building a prototype.
We continuously evaluate additional measurements on existing turbines, providing further
verification of the calculated data. Our calculations are confirmed by results produced by
specially commissioned certification bodies, research institutes and engineering firms.
Aesthetic aspects are also a decisive factor during tower development, which is obvious in
the elegant design of the finished product. The streamlined gradually tapered design, offers
a visibly sophisticated ergonomic concept.
In addition, there is also an ice machine at the production plant. At high temperatures, it
produces over 120 tons of ice per day to cool down the concrete. Water for the ice maker is
cleaned in one of our own water treatment plants.
TUBULAR STEEL TOWERS
Tubular steel towers are manufactured in several individual tower sections, connected using
stress-reducing L-flanges. Unlike conventional flange joints, the welding seam of the L-flange
is outside the stress zone.
Other advantages of this connecting technology are:
Due to their relatively small circumference, shorter tubular steel towers are mounted on the
foundation using a foundation basket. This consists of a double-rowed circular array of
threaded steel bolts. A retainer ring, fitted to the tower flange dimensions, is used to hold
the individual bolts in position.
When the foundation is completed, the lower tower section is placed on the bolts protruding
out of the concrete surface and then bolted with nuts and washers.
For taller steel towers, a specially developed foundation connection system is used. A
cylindrical structural element is set on the blinding layer, propped up to the correct height
and precisely aligned with adjusting bolts.
Once the foundation is completed, the tower is flanged together with the foundation section.
Like all other components, tubular steel towers are subject to strict quality standards.
Quality assurance begins in the design development stages, to ensure that the prototype
meets all requirements before going into serial production.
CONCRETE TOWER MANUFACTURING
Wind World (India) Ltd.'s precast concrete towers are made using specially developed prestressed steel reinforcement. The individual tower sections and foundation are fastened
together to form an inseparable unit with stay cables running through jacket tubes in the
core of the concrete tower wall. The tower sections themselves are manufactured entirely in
the pre-casting plant. Specially constructed steel moulds assure manufacturing precision for
each individual concrete section.
This manufacturing process minimizes dimensional tolerances, which assures a high degree
of fitting accuracy. Here again, our quality assurance department carries out strict
inspections. Detailed procedural and work instructions are available for each manufacturing
sector. This ensures that each individual manufacturing stage as well as the materials used
can be completely retraced.
Erection
Foundation
FOUNDATION CONSTRUCTION
The foundation transmits the wind turbines' dead load and wind load into the ground.
Our foundations are always circular. Depending on the site, the ground can only absorb a
certain amount of compressive strain, so the foundation surfaces are adapted accordingly.
Circular foundations are designed based on this elementary realization and as a rule are
installed as shallow foundations.
If necessary, for example in soft soil, a special deep foundation distributes the load down to
deeper load-bearing soil strata. The piles, symmetrically arranged, are slightly inclined so
that the imagined extended pile centre lines meet at a point above the centre of the
foundation. This provides maximum force/load distribution over the entire surface.
Forces are equal in all wind directions, whereas asymmetrical foundation pressure is
possible with square bases or cross-shaped foundations.
Circular design has proven to reduce the amount of reinforcement and concrete
required. The circular design reduces the size of the formwork area.
Backfilling the foundation with soil from the excavation pit is included in the
structural analysis as a load. This means that less reinforced concrete is needed for
foundation stability.
With the installation and commissioning of over 5756 WECs, generating over 4200 MW since
1994, this capability has been developed, honed and enhanced over the years.
Today our Projects Installation team comprises over 1000 highly trained and skilled
professionals, with diverse experience in disciplines like project management, mechanical,
electrical, electronics, civil engineering, etc. An extensive training program is in place to
ensure skill relevance and skill currency.
Our state of the art fleet of six Liebherr LTM 1400 cranes meet 40-50% of our annual wind
turbine erection targets. More cranes are being added to enhance our capability. At any
point in time, we have over a 100 cranes of various capacities deployed across the country.
There is also a continuous endeavor to review our processes in line with Good Engineering
Practices in step with the best in the world.
We pride in our teams and their expertise - operating in extremes of temperatures (from
freezing sub-zero to the searing desert heat of 50 degree Celsius) and high gusty wind
conditions. We salute our heroes involved in such challenging execution - mounting a 32
tonne wind energy generator atop an over 250 foot tower is no mean achievement by any
standard. Coupled with this are the challenges of terrain - from the hills to the dunes, from
sticky black cotton soil to rocky cliffs, there is never a dull moment.
Our teams follow the best practices in safety and quality certified as per ISO 9001:2008
standards, with strict protocols and work instructions. We take pride in having an almost
zero-accident record. Our safety standards have been widely appreciated by our customers.
Logistics
For Wind World (India) Limited's logistics operations, change is the only constant in the
business dynamics; and no day is like another.
Our Logistics initiative is therefore driven with a mission: 'To provide the right material, in
the right quantity, at the right place, at the right time.'
The fragmented and disorganized nature of the Indian logistics industry. Rules and
regulations are just in the process of being standardized and every state follows their
own procedures and practices.
Ensuring the safety of material transport across varied and challenging terrain.
We have trailers of our own design, to provide a logistics solution to shift heavy
turbine & Concrete Tower Segments.
As the bulk of Wind World (India) Limited's moves are ODC (between 75-100 daily moves),
Team Logistics is on call 24 X 7. Receiving demands from our factories and sites; getting
quotes from vendors; ensuring trailer/vehicle placement on time; monitoring all major
moves (between 150 -175 daily moves); ensuring unloading; and final billing & payment to
transporters.
On the safety front, considering the small and narrow village roads and tracks that a trailer
carrying ODC has to negotiate, our major accident record is just 0.05 per cent. Indeed a
commendable logistics achievement.
Strict loading and lashing protocols, daily driver briefings on speed, safety and other
parameters, and vehicle checks, are factors that contribute to our safety record.
Wind World (India) Limited's Logistics team has grown from 4 to a 20 members, handling
approx. 99% of Wind World (India) Limited's logistics requirements.
The team's philosophy aptly defines their responsibility: 'At first, we move the blades and
turbines; the wind then takes over from us'.
Asset Care
Background Note
India's wind energy generation story began in 1984; obviously the country had no history of
wind management. Design and operational frameworks vastly differed from then existing
models in Europe and the USA, which could not be replicated here.
The first five Wind World (India) Ltd. Wind Energy Converters (WECs) were set up in Lamba,
Gujarat. These test cases qualified the tropical, environmental and weak grid, from which
evolved the sophistication and customer experience witnessed today.
We learnt that building reliability into the product reduced failure rate. Thus, we created a
robust technical management interface that incorporated manufacturing, commissioning
and maintenance to deliver a grid-friendly WEC.
Wind World (India) Ltd. Service is configured in a scientific manner with a spectrum of
resources, to gain optimum performance and productivity, and to administer continual
improvement throughout the lifecycle of the Wind Power Plant. Thereby, ensuring lifetime
care, of our customer's investments.
The service net is woven and spread across the country, with its resources of competent
manpower, optimal inventory and specialized machinery. The complete operations and
maintenance activities are monitored and controlled by real time 24 x 7, asset monitoring
and management system at the Corporate Headquarters.
These integrated resources provide the service crew with an opportunity to harness power
against all odds and evens, thus excelling in Wind Power Plant performance management,
and maintaining an availability of 98.5% plus, year on year.
Vision
We shall be the best 'Asset Managing Organisation' in the Wind Industry Worldwide.
Our Empowered, Components & Dedicated Resources shall be a Safe & Secure net for
our Stakeholders.
Mission
We shall continuously strive to optimise yield from the Wind Power Assets through
deployment of most modern means & Asset Management tools.
Strategy
Asset Management
Operation &
Maintenance Service
Facility Service
Facility Service
We have a robust foundation for an Asset Management System. The overall asset efficiency
of a wind power plant is achieved through a holistic approach to asset management, using a
multi-pronged strategy.
The service team at the site is fully equipped with all the resources needed in terms of
competent crew members, high quality of spares and specialized tools; supplemented by
well documented and controlled methods of operation. The complete O & M activities are
monitored and controlled using state of the art information technology and communication
infrastructure.
The team is focused on achieving excellence in wind power plant performance, by
harnessing wind energy against all odds and eventualities. The multi-pronged O & M
strategy comprises of monitoring a host of low and high priority service, maintenance and
solution factors that optimize yield for every customer asset.
Operation &
Maintenance Service
Facility Service
Preventive maintenance
Operation &
Maintenance Service
Facility Service
The Special Task Services are an additional part of the WWO (Wind World Operations)
mandate, undertaken by an experienced team of experts across all sites. The core
responsibility of this team is to optimize the down time of the machine, during the major
restoration of machines. Blade refurbishment is also another core area of responsibility.
The team also does analysis of project performance and proposes the solution like
repowering or relocations, to achieve maximum yield from the wind power project.
Operation &
Maintenance Service
Facility Service
The Technical Support Service (TSS) fleet acts as an interface between Engineering &
Development Division (E & D), Daman and field service, whose main responsibility is
reliability-enhancement of turbines.The team includes technical experts whose average
experience is 8 to 10 years in the wind sector.
The Technical Support Service team specializes in providing due diligence to the customers
acquiring wind assets. The core task of technical support team is to
Operation &
Maintenance Service
Facility Service
A very unique web-enabled generation reporting mechanism wCare, keeps our customers
updated with the performance of their wind power plant on a daily basis.
wCare is a one-of-its-kind internet Customer portal that gives Daily Generation Reports
(DGR) , the status of the wind farm and turbines on a day to day basis. The objective of
wCare is to create a sense of transparency in generation reporting and to keep a central
control on the various activities related to power generation.
We also partner our customers in celebrations and joy, viz. a flag hosting ceremony at the
site, a 'VaayuPooja' for good wind and a Valedictory Function at our Wind World Training
Academy (WTA). Extending greetings on their birthdays, festivals or achievements is our
way to express 'We - CARE'.
OUR VALUE
WE CELEBRATE
Since all work and no play makes Jack a dull boy', we put the same into action, by
celebrating various occasions such as Independence Day, Republic Day, Vaayu Puja,
Birthdays, and festivals, at our Windfarm sites for our technicians.
Facility Service
Operation &
Maintenance Service
Facility Service
For quick restoration of major breakdowns, our exclusive facilities for machine repair, blade
repair and associated component repairs are available in the northern and southern parts of
India.
Holistic Solution
Wind mapping and monitoring, project development, manufacture of WECs, EPC services
and 24 x 7 operation and maintenance. These comprise the key value-drivers of our
business solution.
Additional value-drivers are: arranging for project finance, assistance in power billing and
collections, CDM services and regulatory advisory services; including REC trading and GBI
registration.
The holistic solution our clients enjoy is backed by the technologically superior product,
outstanding service capabilities, obsession with quality and a highly trained and dedicated
manpower base.
Our service capabilities are backed by state of the art tools, superior infrastructure, and on
and off-job training, primarily at our own Wind World Training Academy.
Quality focus can be gauged from the fact that we employ a total of over 200 quality
personnel, who are mandated to ensure the highest standards of quality. Right from a 24 x 7
presence at vendor facilities, through production, to erection, commissioning and operations.
For the above reasons, we're the country's most preferred wind energy solutions provider.
Our clients include some of the largest and most reputed names in different segments, viz.
Utilities, IPPs, different industries, the financial sector, etc.
All this has enabled us today to enjoy an overall market share of 25%, with more than 50%
share in the most demanding IPP segment.
Key Differentiators
Our unique business models encompass the entire spectrum of the solutions journey, from
wind mapping and monitoring to a 20-year commitment of operations and maintenance.
Project Development
Continual retrofits & upgrades - for better product life cycle management
Wind World (India) Limited SCADA for machine performance and diagnosis
Superior Technology