With a standing of 50 years, Electrical Research & Development Association (ERDA) is a premier organization serving the power sector in three technical areas — Testing & Evaluation, Field Services, and R&D and Expert Services. In this exclusive interview with T&D India, we have Dr. Satish Chetwani, Director, ERDA, giving an in-depth understanding of how ERDA is serving diverse equipment manufacturers across the power T&D value chain through a range of customized and cost-effective solutions. Dr. Chetwani asserts that over the years, ERDA has greatly reduced India’s dependence on foreign labs, and is, in fact, now catering to a growing number of international clients.
We understand that ERDA now has over 25 labs with a pan-India presence. Please discuss the growth of ERDA, in terms of number of labs, over the past 3-4 years.
ERDA has experienced remarkable growth over the past 3-4 years, expanding to 39 state-of-the-art laboratories across India. This growth is marked by several key developments. In fiscal year 2023-24, we significantly enhanced our testing capabilities to meet the mandatory requirements for solar PV module testing as per the Bureau of Indian Standards (BIS). We also established a dedicated product testing laboratory at DGVCL in Navsari, reinforcing our commitment to quality and reliability.
Additionally, we inaugurated a 2,400kVp, 120kJ Impulse test facility for high-voltage and extra-high-voltage products, along with a cutting-edge partial discharge test facility for 3-phase transformers. Also, our high voltage partial discharge laboratory upgraded to 900kV, 2,700kVA high voltage resonant test system for evaluation of 400kV class products. Our EMI-EMC Laboratory also upgraded its Radio Susceptibility test facility to 60 v/m, adhering to MIL standards to better serve our defence equipment manufacturing customers.
One of our most significant milestones includes signing a laboratory agreement with UHBVN to establish a modern laboratory in Dhulkot, District Ambala, Haryana. This new facility, set to commence operations shortly, will further reinforce our commitment to quality and reliability, ensuring that we continue to provide unparalleled insights and solutions to our clients.
ERDA’s expansion over the past few years underscores our commitment to innovation and excellence, ensuring that we remain at the forefront of electrical research, evaluation, and development.
ERDA, as we appreciate, has testing facilities for almost every conceivable equipment in the power T&D value chain. Having said that, please discuss ERDA’s competence in the field of transformer testing.
ERDA’s competence in transformer testing is extensive and highly regarded within the industry. ERDA has state-of-the-art test facility for distribution transformer which include 6 parallel test bays, enabling us to test approximately 80 per cent of India’s total distribution transformer testing requirements as per various standards including mandatory IS1180 testing. This facility is backed by India’s largest online short circuit laboratory with fault level of 120kA, 570V. With these facilities, ERDA can undertake type testing of 2.5 MVA, 33kV class transformers within laboratory premises.
In order to meet industry requirement, ERDA is having onsite power transformer testing facility upto 500 MVA, 400kV class which we undertake through our state-of-the-art onsite testing setup. With this facility, we can execute all types of routine testing and temperature rise testing on power transformers at manufacturer premises using ERDA equipment. This testing is part of ERDA’s NABL scope for testing activities. The facility is widely used by various leading state owned transmission and distribution companies of our country.
Additionally, we have dedicated utility laboratories located in Narol, Navsari, and Muradnagar, specifically designed to undertake comprehensive transformer testing projects. This robust infrastructure ensures that we can deliver precise, reliable, and efficient testing services for a wide range of transformer capacities and classes.
It is often felt that India’s has limited testing facilities for high-power transformers, especially for dynamic short-circuit testing. What is your view? How is ERDA growing its competence in this regard?
ERDA recognizes the importance of advanced testing facilities for high-power transformers, particularly for dynamic short-circuit testing. ERDA plans to establish a Centre of Excellence for a Medium Voltage Short Circuit Laboratory, designed to test Medium Voltage Switchgear equipment and Power Transformers up to 50 MVA, 132kV. Recognized as a project of national importance, it requires crucial support from both state and Central governments. The project has an estimated outlay of around Rs.800 crore.
New power ministry guidelines are now recommending the use of HTLS (high temperature low sag) conductors as opposed to conventional ones. Please discuss ERDA’s services in this regard. Please also discuss the “salt spray test” versus the “galvanic protection barrier layer test” for testing HTLS conductors.
India’s transmission segment is going through a rapid phase of expansion. With proposed interstate transmission system for more than 500 GW renewable energy by 2030, and looking at the issues associated with Right of Way (RoW), usage of HTLS conductors will gain momentum through re-conductoring of existing transmission lines.
ERDA, with its commitment to serve the nation, is having state-of-the-art laboratory for evaluation of HTLS conductors. Laboratory can undertake evaluation of various types of HTLS conductors including ZTACTR, TACSR, ACSS, ACFR, ACCC and GTACSR.
Regarding the “salt spray test” versus the “galvanic protection barrier layer test” for HTLS conductors, we are glad to inform that ERDA has facilities to undertake both the tests. As far as utility of tests are concerned, it has to be noted that “galvanic protection barrier layer (thickness) test” is useful for acceptance of conductor in accordance with the standard, while the “salt spray test” is useful to evaluate conductor for its performance in corrosive environment for long service life.
Smart metering, we feel, is a very important area given that India has targeted to rollout around 25 crore smart meters over the next 3-4 years. How has been the response to ERDA’s testing facilities from smart meter manufacturers?
The response has been overwhelmingly positive for the evaluation of smart meters. Smart meters and smart grids hold immense potential to revolutionise the power sector. Under ongoing RDSS initiative, approximate 1 crore smart meters have already been installed against target of around 25 crore smart meters.
Currently, at ERDA, we have the capacity to test around 25 batches per month for full-type testing of smart meters/prepaid meters, and approximately 128 meters (4 no. lots) for routine/acceptance testing each month. ERDA currently handles around 50 per cent of the total smart meter testing requirements across India. To meet the increasing demand, we plan to double our capacity in the next financial year to ensure timely delivery of services. Additionally, we have expanded our Gurugram laboratory for Smart Energy Meter 3-phase tamper simulator along with DLMS facility. In future we shall further expand our facility at Gurugram and Rabale laboratories.
What are the currently the international accreditations of ERDA and how has this helped ERDA offer its services to foreign customers?
ERDA holds several prestigious international accreditations, including those from Intertek (ASTA), UK; UL; DEKRA; Dubai Electricity & Water Authority (DEWA), Dubai; Sharjah Electricity & Water Authority (SEWA), Sharjah; Distribution Code Review Panel (DCRP), Oman; Tenaga Nasional Berhad (TNB), Malaysia; Nepal Electricity Authority (NEA), Nepal; UCA accreditations for IEC 61850 conformance testing and DLMS for smart meter evaluation. These accreditations have significantly bolstered our credibility and trustworthiness on a global scale, allowing us to offer our services to foreign customers with confidence. The credentials ensure that our testing and calibration services meet international standards, facilitating smoother collaborations and partnerships with overseas clients who seek reliable and consistent quality assurance. This has not only expanded our market reach but has also positioned ERDA as a preferred partner for global companies looking for top-tier testing and evaluation services.
How is ERDA planning to support the massive upgrade of India’s power T&D infrastructure?
As per the report from agencies like CEA and others, massive up gradation of transmission and distribution network is planned in the coming 7-10 years. With key drivers such as schemes like RDSS, integration of 500 GW renewable energy into the grid, penetration of E-Vehicles (80 million EVs on road by 2030), 10 GW hydrogen production capacity by 2030 etc., there will be massive requirement of electrical equipment and their evaluation associated with Transmission and Distribution network in India.
ERDA, being leader in the space of Research and Third Party Evaluation Laboratory, has set major plants to meet these requirements. Few of them include state of the art full-fledged laboratories in North and Western part of India, Laboratories for Surge Arrestors, eV Chargers Evaluation Laboratory, Seismic Laboratory, Solar Module (including safety part) and Solar Inverter Laboratory and others.
With above newly planned laboratories and augmentation of the existing labs, ERDA shall be meeting the country’s requirement for independent research and evaluation of the electrical products.
Please discuss how ERDA, over the years, has generally reduced the dependence of Indian electrical equipment manufacturers on foreign labs.
Over the years, ERDA has significantly reduced the dependence of Indian electrical equipment manufacturers on foreign labs through several key initiatives. Firstly, we have continuously expanded our testing capabilities and upgraded our laboratories with state-of-the-art equipment to meet international standards. This has enabled us to provide comprehensive testing services locally, eliminating the need for manufacturers to seek testing and certification from overseas labs.
Secondly, we have built a strong reputation for reliability and accuracy in our testing procedures, gaining the trust of both domestic and international clients. Our accreditations from globally recognized bodies such as Intertek (ASTA), UL, DEWA (Dubai), SEWA (Sharjah), TNB (Malaysia), DCRP (Oman) and approvals at various African Countries have further strengthened our position as a credible alternative to foreign labs.
Additionally, ERDA has focused on developing specialized expertise in areas critical to the Indian market, such as smart metering, renewable energy, and advanced diagnostics for electrical equipment. By doing so, we have addressed specific needs of Indian manufacturers and provided them with tailored solutions that are both cost-effective and efficient.
