Energy from Wind: A study on a captive windmill installation in TamilNadu

D P Dash,IRSEE

1.0 INTRODUCTION:

India has added renewable sources of

energy aggressively and the total capacity
has been 109.88 GW. By March, 2022, India
has achieved cumulative 40,357 MW wind
energy installations with average annual
installation of 1700MW in last five years
against a target of 60GW. In 2020-21 states
like Gujarat added 1020.3MW out of 1503
MW total installation. Other states such as Karnataka, Maharashtra and AP also have added to their
existing installations apart from Tamil Nadu which leads the league with highest cumulative installation in
the country. The country's largest onshore wind farm( 3 rd largest in the world), the 1,500 MW Muppandal
facilities lies in Tamil Nadu followed by Jaisalmer wind park in Rajasthan with 1064MW installation, is the
second largest wind farm in the country( fourth largest in the world).
1.1 Wind energy Potential : The wind potential in India estimated 300 GW at 100 metres hub height.
However, according to the current study, the total potential is estimated to be 695 GW at 120 metres hub
height. Out of this, the total potential so far utilized is 40.357 GW as on March, 2022, which includes the
installation at various hub heights of 50 metres, 60 meters, 80 meters and 100 meters etc.,. Renewable
energy currently accounts for more than 40% of India’s overall installed power capacity of 382.152 MW as
of 2021-22. During the last decade (i.e.) period from 2011-12 to 2020-21, the installed capacity of wind
energy has significantly increased from 18.42 GW to 40.13 GW. Similarly, the annual generation of wind
energy has doubled i.e., increased from 28,214 GWh in 2014-15 to 59,824 GWh in 2020-21.
Wind resources are not evenly distributed in all states. States like Tamil Nadu, Gujarat,
Maharashtra, Karnataka, Rajasthan and Andhra Pradesh are having better wind potential and thereby
large number of wind installations compared to other states. In terms of installed capacity, Tamil Nadu
stands at rank no.1, followed by Gujarat, Maharashtra, Karnataka, Rajasthan, Andhra Pradesh and
Madhya Pradesh. The pattern of generation of energy from wind in India indicates that 70% of annual
wind energy generation is during the 5
months duration from May to September
(Southwest Monsoon period). It can be
seen that the other source of renewable
energy (i.e.) solar energy is quite
complementary to wind energy as the
maximum generation of solar energy takes
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place in non-monsoon period
in daytime.
The wind
energy profile of various
grids indicate that almost
50% of the wind energy is
generated in Southern
Region, 35% is generated in
Western Region, 10% is
generated in Northern Region and the remaining 5% in Eastern Region. Of the 60 GW target for Wind
energy by 2022, Southern Region accounts for 28.2 GW, Western Regions accounts for 22.6 GW,
Northern Region accounts for 8.6 GW and 0.6 GW in Eastern Region.
Table 1: Targets for Wind power Installation
States Targets States Targets

Andhra Pradesh 8100 Maharashtra 7600

Karnataka 6200 Madhya Pradesh 6200

Rajasthan 8600 Tamil Nadu 11900

Gujarat 8800 Telangana 2000

Other states 600

Fig 3: Achievement of Wind Power installation upto Feb 2022

2.0
Tamil Nadu story:
The state is having wind energy potential of 68.75 GW (at 120 M hub height).Tamil Nadu, has
achieved 9866 MW installed wind energy power, is well ahead of the rest of the country in terms of wind
energy installation. The state also has the country's largest onshore wind farm ( 3rd largest in the world),
the 1,500 MW Muppandal facilities. It is in the Kanyakumari district and features many wind turbines

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ranging in size from 200KW to 1,650KW. The state has made significant advances in wind energy
generation, with large-scale plant construction beginning in the early 1990s. However, this has also been
the reason for the underutilization of wind resources as most of the wind energy plants have either
completed or are nearing the end of their defined lifecycles. These wind turbines have lower capacities
(500 kW) and lower hub heights (25-30 m), and owing to related technical problems and inefficiencies,
these aging turbines typically result in poor Capacity Utilization Factors (CUFs). The energy from wind
face hurdles in form of state policies which tend to burden the developers and from evacuation strategy as
most wind power stations are at remote areas having inadequate local consumption pattern and
evacuation of generated power.

2.1 TARIFF REVISIONS, POLICY CHANGES:

Over the years, tariff of renewable energy has undergone number of revisions and also vary from state to
state. Similarly, there have been number of policy changes introduced by various states regulatory
commissions which includes the revision in transmission charges, wheeling charges, system operating
charges and banking charges, etc. These charges are always on upward revision.

Table 2: Revision of Wind tariff and conditions

Tariff Order Description of Order

Windmill Wheeling Agreement with

TNEB. dt: 05.05.2009

TNERC Order No 6 of 2012. Revision in transmission charges, Wheeling and

dt. 31.07.2012
TANGEDCO dt. 30.08.2013
TANGEDCO dt. 30.08.2014
TNERC Order No 6 of 2014.
dt. 11.12.2014
TNERC Order No.3 of 2016
dt. 03.01.2016
Banking charges.
Revision in transmission charges and Wheeling
charges.
Revision in transmission charges, Wheeling charges,
O & M Charges and Banking Charges.
Extension order of Order No 6 of dt. 31.08.2013.
Revision in Transmission charges, Wheeling charges,
Scheduling charges and System operating charges.

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3.0 Green energy corridor:

In many of the states, the grids are also not receptive during peak generation due to reduction in
local demand during monsoon season and the energy mix has been wind positive i.e., wind energy
becoming higher percentage compared to the other generations. Thus, the potential of generation to its
full capacity have not been achieved by the generators connected to such grids which forces the wind
generators to force buck down. The wind generation in wind intensive states suffers from evacuation
issues, not only within the state grid, but also beyond the state to other areas within the country. In order
to overcome this evacuation issue, the Green Energy Corridor Project was established with objective is to
synchronize electricity generated by renewable sources such as solar and wind with electricity generated
by conventional power plants on the grid. The Ministry sanctioned the Intra State Transmission System
(InSTS) project in 2015–2016 to facilitate the evacuation of large-scale renewable energy. Though the
Green Energy Corridor project was initiated for intra-state transmission system for green energy in 2015-
16 in the states of Gujarat, Karnataka, Tamil Nadu, Rajasthan, Andhra Pradesh, Madhya Pradesh,
Maharashtra, etc. and only 6250 ckm have been built till September 2021. Once this project is fully
completed connecting the remote wind and solar generating hubs the evacuation of the renewable energy
can be achieved. The present design is to evacuate 20 GW which perhaps further needed to be
expanded taking care of the enhanced generation of renewable energy as per the targets of 175 GW set
by the Government of India by 2022 and 500 GW by 2030. It is expected that Green Energy Corridor
would help renewable sector development by providing access to transmission lines.

4.0 Study on a captive Windmill in TamilNadu

For the purpose of the present study, installation of 10.5 MW wind mills located in most populated wind
energy state of Tamil Nadu has been chosen, which is installed by Integral Coach Factory (ICF) under the
Ministry of Railways. This wind farm is located in Tirunelveli District of Tamil Nadu, which is the source of

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renewable energy for Integral Coach Factory (ICF), located in Chennai, to meet its entire industrial
consumption since 2009-10. This particular project was commissioned within 4 months from awarding of
the contract and put into the commercial operation, perhaps it is the shortest possible time to set up any
wind farm anywhere in the country. Therefore, this project is also considered as an ideal project for
studying the present management concept. In the following sections - the salient features of the project
management, Operation & Maintenance, constraints and environment impact are discussed.
Integral Coach Factory is one of the oldest coach manufacturing factories, not only in India, but
also in Asia. This factory has manufactured over 60,000 coaches since its inception and is the largest
manufacturer of railway coaches under one management in the world. ICF is the first among organization
under Indian Railways to have successfully implemented grid connected Wind Mill project in 2009.
Railway Board had sanctioned 10.5 MW wind mill project vide Supplementary Demand for Grants in 2007-
08 at a cost of Rs. 67.81 Crores. This project was successfully commissioned on 31.03.2009 within 15
months from the date of sanction and four months from placement of contract. The 10.5 MW wind mill
project comprises of 7 Nos. of wind mills of 1.5 MW each. These Wind Mills are located in Tirunelveli
District of Tamil Nadu. The energy profile of this factory indicates that this factory consumes 11 million
units of electrical energy on annual basis for industrial purpose. These wind mills have generated 232.5
million units of electricity since the commissioning of wind mills in the year March 2009 against the
consumption of 130 million unit of electricity during this period. Considering the total generation of wind
energy, the net energy requirement of ICF remains negative, the excess generated energy from wind mills
on monthly basis are credited to energy bank with the TANGEDCO, which are adjusted in the subsequent
months against the consumption. With these renewable generation over the last 12 years, ICF had offset
200,000 tonnes of carbon dioxide. After success of this project a number of wind farm projects have been
taken up by Indian Railways and total installed capacity of wind energy stands at 103.4 MW. This
green energy project of Indian Railways assumes great importance in the wake of growing concern o ver
environmental pollution and global warming issues.

5.0 PROJECT MANAGEMENT:

5.1 Centre for Wind Energy Technology (CWET), a Government of India organization under the
Ministry of New and Renewable Energy (MNRE), was hired for rendering assistance for
preparation of tender specification, verification of wind resource assessment of the locations
offered by the bidders and for technical scrutiny of the tender documents.

5.2 ICF also awarded the following contracts for this project to various agencies mentioned below:
Consultancy Contract for Preparing tender specification, verification of wind resource assessment and
technical Scrutiny of tender documents was awarded to CWET. Supply, erection, testing and
Commissioning of windmill was awarded to Suzlon Energy td. Clean Development Mechanism (CDM)
consultancy for preparation of project report And sale of carbon credits was awarded to Emergent
Ventures India Pvt. Ltd and Validation of CDM Project toTUV India Pvt. Ltd.

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5.3 Conditions for performance and O&M
The Plant Load Factor (PLF) of the site offered should not be less than 25%

Clear title of the land required for the project (only one site) as on bid closing date. The land
should be free from all encumbrances and transferable to ICF .

Method of Evaluation of Wind Data offered by the Tenderer clearly specified in the Tender
Document as per the method given by C-WET (consultant) to ensure availability of wind.

Performance Test of the WTG to cross check the actual Power Curve with the certified Power
Curve in the Offer.

Penalty Clause for not meeting the certified Power Curve of the machine.

Machine Availability Factor should not be less that 95%.

Penalty clause for Machine Availability Factor less than 95% at TNEB rate of electricity for the
loss of generation on account of poor machine availability.

Ready Power Evacuation facility.

THOTTAPALLI VILLAGE, SANGANERI,

6.0 SALIENT FEATURES OF PLANT: TIRUNELVELI DISTRICT.
No. of Machines : 7 (Seven)
6.1 PROJECT COST: Capacity of each M/c. : 1500 Kw.
Total Capacity : 10.5 MW
The entire work of supply, erection, testing and Model No. of M/c. : S82 – 1500 kW
commissioning of 10.5 MW Wind Mill project,
rated capacity, Suzlon make.
including comprehensive AMC for a period of 10
Hub Height : 78.5 M
years has been entrusted to M/s. Suzlon Energy Ltd
and further 10 years of Codal life. The details of split Rotor Diameter : 82 M
up between land cost and the machinery cost are Cost : 66.05 cr
given.

7.0 WINDMILL GENERATION:

7.1 Year-wise generation, Machine Availability & Grid Availability of wind mills are tabulated since the
date of commissioning is given below:

Figure4: Windmill Generation:

400.00
Windmill Generation in Lakhs unit
units in lakhs

300.00
200.00
100.00
0.00

Year

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7.2 Grid Availability:

ICF’s 7 wind mills are connected to 4 different 33 kV feeders which are connected to Udayathur
substation (capacity: 4x50kVA). There are totally 16 Nos. of 33 kV feeders in this area to take power from
the wind mills to the substation where it is stepped up to 230 kV and connected to the State Grid. To
each 33 kV feeder, about 10 wind turbine generators are connected. In case of decrease in demand
against supply the feeders are shut down on rotational basis and the average grid availability maintained
for all the feeders is more or less uniform.

7.3 WIND PATTERN Month Wise:

The wind speed vary in various months which influence the generation wind energy.(Fig 5)

Fig 5: Wind speed

10.00 Wind Speed (2020-2021)

in m/sec

5.00
2020-21
0.00
2021-22

Months

Fig 6:PLF, Grid, Machine availability

8.0MAINTANENCE EXPERIENCE:

The performance of the wind

mills largely depend on
availability of the machine
and wind velocity, in addition
to evacuation mechanism.
The availability of machine
further depends on schedule
and unscheduled outages.
8.1 Maintenance Outage
The schedule outages are classified into the preventive maintenance which includes laid down
schedule for WTG, lubrication, hydraulic system and the maintenance of HT yard. A typical
analysis of such preventive checks of typical year 2021-22 of the 7 wind mills indicate that the
machines have been shut down for 228.3 hours, which comprise of 35% of the time for WTG
maintenance, 25% of the time for yard maintenance, followed by 15% for other preventive checks
and 14% for oil change and lubrication.(Fig 8) Each of the shut down ranges between one hour
and six hours. The study on this 7 wind mills which are more than 12 years old, indicate that
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during the year 2021-
Fig 7. Grid Outage
22, there had been
3000
284 unscheduled 2418.3
2500
outages due to 2000
1500
various measures 763.5
1000

time in Hrs
382.3
carried out in 7 wind 500 99.8 150.8
mills resulting 694.8 0
EXTL_Feeder Forced EXTL_Shut Down EXTL_WTG Forced INTL_Feeder INTL_Shut Down
Backdown Taken By EB Backdown BreakDown Taken By OMS
hours of outages in all Grid Outage Reason

the machines.(Fig 9) However, it is noted that an average time taken for attention to each of the
unscheduled break down is 2.5 hours, though it ranges from 0.7 hours to 8.7 hours. The major
breakdowns are listed in Table 3.
8.2 Grid issues
Apart from these issues which arise out of intensive operation and maintenance requirements of
WTGs, almost 4000 hours of machine time is lost in 2021-22 due to grid related issues which
happened in 1794 occasions. Analyzing the grid related issues, it is noted that the forced shut
down of the WTGs is for 60% of the time resulting in non-availability of the machine for
generation to the extent of 2418.3 hours(Fig 7). It is also quite pertinent to note that there had
been feeder breakdown to the extent of 763.5 hours, shut down taken by the Electrical Board
382.3 hours outages and further shut down for OMS resulting in another 171 hours down time.

Even though the grid generation is feasible due to higher machine availability, but the grid related
issues such as shut down for maintenance, forced shut down of WTG, etc had a severe
constraints in utilizing the good potential of wind turbines.

Fig 8. Scheduled Maintenance Down time

70 63.4
60 51.3
50
time in Hrs

40
27.1
30
19.4 16.5
20 13.5
10 6.5 5.4 3
0
HT Yard WTG Annual WTG Half Routine Quarterly Preventive Pitch Drive Oil Gear Oil Hydraulic Oil
Maintenance Maintenance Yearly Checking Lubrication Check change Change Change
Maintenance
Maintenance Remarks

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 Table 3: The Major Breakdowns

Sl. No Location Nature of problem Remarks

No

1 TP 60 Blade Maintenance A minute air crack was observed during routine

maintenance of WTG during the year 2015-16,
2016-17 and same was been rectified.

2 TP 60 Gearbox Failure Gear Box replaced.

3 TP80 Blade Maintenance A minute air crack was observed during routine
maintenance of WTG during the year 2015-16,
2016-17 and same was been rectified.

Fig.9 UnScheduled Break down time

90.0 82.4
80.0
70.0 59.8 59.3
time in Hrs

60.0
50.0 44.1
40.0 36.2 34.0 28.2 26.0
30.0
20.0 13.7
10.0 3.0
1.5
0.0

Breakdown Remarks

9.0 Discussion
This above discussion brings out a success story of one captive wind power installation in Tamil
Nadu and its impact on the industrial set up in driving the organization to sustainability. Against an initial
cost of establishing 10.5 MW wind farm, savings on account of adjustment against this captive power
generation has been Rs. 100 crores over last twelve years. The OM experience of the wind farm under
study indicate that the experience has been quite encouraging except the manufacturing defect in the
blades noticed in early days of operation, followed by development of cracks in blades in two windmills

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and a case of gearbox failure.(Tabe3) Since than the average machine availability has been above the
threshold value. The only concern remain is evacuation issues which had resulted in dip in generation.
The grid availability has been below 80% for 3 years, between 90 to 95% for 4 years and above 95% in
rest of the years. In these 7 years the windmills had lost huge opportunity to generate electricity. The plant
load factor has been low compared to the designed threshold of 25% in all the years except first year. The
wind pattern changes also have been noticed in this region which in turn affects the overall generation and
PLF. Having offset cost of the project, the present cost of wind generation only caters to the OM cost. If
this cost of OM alone is considered at present, the cost of wind generation will work out little over 1 rupee
25 paisa per unit. The benefit from the wind power farm of ICF would have been much better without the
additional financial burden on the wind farms which are levied in subsequent periods such as levy of
additional transmission, wheeling charges and other charges as levied by state govt. from time to time.
Integral Coach Factory’s wind mill project was registered with UNFCCC in the year 2011-12. However,
the benefit of enchasing the certificates to monetize the benefit is yet to take place due to global melt
down of carbon market.
It is also noted that due to change in policy, captive wind energy developers have been paying
higher charges for line loss, enhanced transmission charges, wheeling charges and O&M charges. These
increase in charges also have created a non-friendly atmosphere for proliferation of wind energy
installation in the state in addition to other issues such as evacuation and grid availability. The tariff also
has been reduced to Rs2.80 per unit for non captive developers. With these measures in place the
existing wind farms are feeling the pinch for reduced generation due to non-availability of grid and
additional financial burden due to levy of various charges and reduced tariff and sooner or later the farms
may become NPAs. As a result the annual installations which were at the rate of 1000MW in 2011-12
have reduced to average of less than 205MW since then in TN. Unless an investment friendly
atmosphere is created to encourage the investors and confidence is restored, the aspiration of exploiting
the entire estimated potential of 68GW of the state will remain a distant dream. Similarly a positive
environment would be necessary across all wind rich states to faster exploit the potential wind resources
as wind energy is likely play a major role in 500 GW renewable dream by 2030.
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