req equip material devlopment power sector

8/2/2019 Req Equip Material Devlopment Power Sector

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Government of India

Ministry of Power Central Electricity Authority

Planning Wing

New DelhiNovember 2006


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Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector

Contents

CONTENTS CHAPTER TITLE PAGE

Preface i

Foreword iiExecutive Summary ES-1 ES-3

CHAPTER-1 INTRODUCTION 1.1-1.31.1 Background1.2 Growth in Power Sector1.3 Regulatory & Structural Reforms

1.4 National Electricity Policy and Plan

CHAPTER-2 GENERATION CAPACITY ADDITIONPROGRAMME

2.1-2.4

2.1 Eleventh Plan (2007-12)

2.2 Twelfth plan(2012-2017)CHAPTER-3 REQUIREMENT OF ELECTRICAL EQUIPMENTS

( INCLUDING SWITCHYARD EQUIPMENT)3.1-3.16

3.1 Requirement of Electrical Equipments for Generation Plants3.1.1 Thermal Power Plants3.1.2 Hydro Power Plants3.2 Requirement of Electrical Equipments for Power System3.2.1 Estimated Requirement of electrical equipments for voltage

level 765 kV & 400 kV3.2.2 Estimated Requirement of electrical equipments for voltage

level 220 kV & 132 kV

3.2.3 Summary of Requirement of electrical equipment for allvoltage levels( 765 kV, 400 kV, 220 kV, 132Kv)

CHAPTER-4 REQUIREMENT OF STEEL FOR 11 TH AND 12 TH PLAN

4.1-4.10

4.1 Steel Requirement for Generation

4.1.1 Hydro Power Plants4.1.2 Thermal Power Plants4.1.3 Nuclear Power Plants4.2 Requirement of Steel for Power System4.2.1 Requirement of Steel for tower

4.2.2 Steel Requirement & Aluminium for Conductor & Earthwire4.2.3 Requirement in respect of special steel CRGO & Copper

for power transformers4.2.4 Estimated Structural Steel Requirement for Sub-stations


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Contents

LIST OF APPENDICES

S.NO. TITLE PAGENO.

1. Typical Steel quantity for 2x500 MW unit asgiven by BHEL

1.1-1.5

2. Estimated Quantity of Steel for 11 th and 12 th Plan coal based projects

2.1-2.5

3. Estimated Quantity of Steel for 11 th and 12 th Plan Gas based projects

3.1-3.4


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i Preface

PREFACE

The size of the XI and XII Plans of the Power sector are likely to beconsiderably bigger than X Plan. Consequently, the requirement ofelectrical equipment and raw materials like steel would be much higher than in previous Plans. The Sub-Group on Generation Planning ofWorking Group on Power for XI Plan has recommended a capacityaddition of around 66,500 MW in XI Plan whereas for XII Plan, therequirement has been assessed at 86,500 MW.

Such massive addition in power generation capacity would bepossible only if the power/electrical industry also suitably enhances its

manufacturing capabilities to meet this challenge. Other industries likecement, steel and aluminum also have to augment their productionlines to meet the requirements of the power sector.

With a view to give an idea of the requirement of the power sector during XI and XII Plan, this booklet giving details of the major electricalequipment and steel is being brought out by the Central ElectricityAuthority.

I am sure this booklet will be found useful by the industry sector inplanning their production capacities in the years to come.

(RAKESH NATH)CHAIRPERSON

New DelhiDated 23 rd November, 2006


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ii Forward

FOREWORD

This booklet is an effort to provide a broad overview of the electricalequipment and steel requirement during the coming years commensuratewith the power generation and transmission capacity expansion Plans. For the successful implementation of the power expansion Plan evolvedbased on the detailed studies carried out by CEA, it is essential that all thekey inputs required are made available as per the schedule of therequirement of individual power project. The timely supply of key-inputs isimportant not only in the timely completion of the project but also inavoiding implications of cost over-runs in case the project is delayed. Thisassessment would also give appropriate inputs to the manufacturers toplan and formulate their production targets. Advance action to createadditional production capacity is also important to keep the prices ofmanufactured material and equipment in check. This would ensure thatincrease in demand does not lead to increase in prices due to mismatch

of demand and supply, as the power sector is highly price sensitive andconcerted efforts from all quarters need to be jointly made to ensure thatprices remain reasonable. This would be instrumental in realizing theGovernment's mission of providing power to consumers at a reasonableprice.

Requirement of Electrical equipment is one of the most importantinputs for the development of the Power Sector. In this booklet, anattempt has been made to assess the requirement of major electricalequipment for hydro & thermal power stations during the 11 th and 12 th Plans. Requirement of equipment has been assessed for different units ofcoal and gas based plants i.e. coal handling unit, Ash handling unit,

cooling system etc. In case of a hydro power station, tentative steelrequirement for various Electro-Mechanical equipments/systems and for civil works has been estimated. In addition, requirement of variouscategories of steel for these plants has also been worked out.Commensurate with the generation capacity addition, the transmissionsystem requirement has also been worked out and sub-station equipmentand material required has also been covered in this booklet

This book has been prepared by the officers and staff of Planningwing, CEA with inputs from Thermal, Hydro and Power System Wings. Thevarious equipment manufacturers such as BHEL, have been duly consultedfor specific equipment based details and requirement of pipes, tubes,

structural steel etc. and others.It is hoped that the book would serve as a good guide for those

who would plan for future manufacture of equipment for the Power Sector.

New Delhi ( V S Verma)Dated: 23 November 2006 Member ( Planning)


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ES-1 Executive Summary

EXECUTIVE SUMMARY

1. INTRODUCTION

Electricity is a vital input for economic and social development of our society.Adequate and quality power is essential to fuel this growth and all efforts need to bemade to ensure that all bottlenecks are removed in the path of timely implementation of power projects and transmission network. The Governments Mission is to providequality and reliable power to all by 2012.

The Installed Generating Capacity in the country which was only 1,358 MW atthe time of Independence has reached a level of 1,27,673 MW, comprising 83,982 MWthermal, 33,600 MW hydro, 3,900 MW nuclear and 6191 MW from wind and otherrenewable energy sources. There has been corresponding growth in transmission anddistribution network too. The target set for capacity addition during the 10 th Plan was41,110 MW. However it is expected that about 30,641 MW would come up in the 10 th Plan out of which about 17,743 MW has already been commissioned till date. As per thetentative 11th Plan capacity addition programme about 66,463 MW capacity addition isrequired during 11 th Plan and about 86,500 MW during 12 th Plan. Requirement of electrical and mechanical equipment and other materials needs to be tied up and madeavailable for timely implementation of these projects.

The Electricity Act 2003 envisages a strong push to the structural reforms, de-licensing, thrust on rural electrification, incentives to reforming States and importantlymandatory metering with stronger provisions for punishment for theft of electricity. Thepublication of the National Electricity Policy in February 2005 is an important milestoneas it lays the guidelines and provides direction to the evolution of the Power Sectorwithin the ambit of the Electricity Act.

The Policy and the Act stipulate that CEA shall prepare the National ElectricityPlan for a short-term timeframe of five year while giving a 15-year perspective and thevarious aspects to be covered shall include demand forecast for different regions,suggested areas/ locations for capacity addition, integration of such possible locationswith transmission system and development of national grid. The National Electricity Planhas been prepared by CEA and submitted to the Govt. for approval. It is expected thatthe Plan will be notified shortly. The Plan covers 10th Plan (2002-07) in detail whereas

perspective planning has been carried out for the 11th & 12th Plans.For the successful implementation of the power expansion plan, it is essential that

all the key inputs required are made available as per the schedule of their requirement foreach individual power project. Since these are some of the major key inputs, anassessment of the approximate requirement for the 11 th and 12 th Plan power projects willbe useful input for the manufacturers and suppliers. In this booklet a broad overview hasbeen provided about the requirement of electrical equipments and steel during the 11 TH AND 12 TH Plan for generation projects and for power system.


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2. GENERATION CAPACITY ADDITION PROGRAMME

During the 11th Plan, a tentative capacity addition of 66,643 MW is planned

comprising of 17,189 MW of hydro, 46,114 MW of thermal (44,000 MW coal/lignite,2,114 MW gas/LNG) and 3,200 MW of nuclear capacity. During the 12th Plan, atentative capacity addition of 86,500 MW is planned comprising of 30,000 MW of hydro,44,500 MW of thermal and 12,000 MW of nuclear capacity.

For the purpose of assessing the requirement of equipments, thermal plants havebeen categorized into five categories i.e. four categories for coal/lignite plants based onthe unit size of 660/800 MW, 500 MW, 300/250/210 MW and 125 MW, and onecategory for Gas based plants. For each of the above category, norms have been drawn upfor the requirement of equipment. However in case of hydro plants no such categorizationis possible as the equipment requirement is site specific and not dependant on the

capacity of the plant. Therefore equipment has been assessed in totality for hydrocapacity of 17,189 MW during 11th Plan and 30,000 MW during 12th Plan. Requirementof equipment for nuclear plants has not been included in the Report but the steelrequirement for Nuclear power projects coming up in 11 th and 12 th Plans has beenestimated in this report. It is expected that the Nuclear Power Corporation of India wouldseparately ensure development of production capability of equipment commensurate withtheir requirement during 11th and 12th Plans. However, the nuclear capacity expected inthe 11th and 12th Plans is 3,200 MW and 12,000 MW respectively which is a smallfraction of the total tentative capacity addition during these Plan periods.

During the 11th and 12th Plan, electrical equipment for thermal capacity addition

of 88,300MW is expected to be required. This comprises of coal-based units of about 52nos. 660/800 MW units, 65 nos. 500 MW units, 59 nos. 300/250/ 210 MW units, 7 nos.125 MW units and 9 modules of gas turbine stations. Requirement of various electricaland mechanical components of hydro plants for a capacity addition of about 47,200during 11th and 12th plan have been assessed. For timely implementation of projects, it isessential to enhance production capacity to match the requirement.

3. REQUIREMENT OF ELECTRICAL EQUIPMENTS

In this Chapter, requirement of electrical equipments for hydro and thermal powerprojects, along with the corresponding switchyard equipments for different voltage levels,coming up during the 11th & 12th Plan have been assessed based on certain norms.Requirement of various types of transformers like GT, ST, UT, ICT etc in the thermalpower plants of different unit sizes have been estimated along with their ratings. Also therequirement of various types of switchgears, motors, cables etc. required in a thermalplant have been considered estimated


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The substation equipments have also been estimated as per the transmissionexpansion plan for 11th and 12th Plan.

4. REQUIREMENT OF STEEL

An assessment has been made of the requirement of material specifically differenttypes of steel for hydro & thermal power plants and power system network planned for11th and 12th Plan. A detailed exercise has been carried out to assess the requirement of both type of steel i.e. imported & indigenous. An assessment has also been made of therequirement of copper and aluminium required for transmission lines.

In case of the steel requirement for 11th & 12th Plan, it has been assessed that

approximately 6 million MT for hydro power projects, 12 million MT for thermal powerprojects and 2 MT for Nuclear power projects will be required during 11th & 12th Planperiod. Steel requirement for different constituents of power system like towers,conductors, earth wires, sub-stations, power transformers has also been assessed. Someother materials like aluminium for conductors and earth wires, and copper for powertransformers have also been considered. Approximately 5.2 million MT of steel will berequired for completing the transmission expansion planned for 11th & 12th Plan. Thisincludes about 0.2 million MT of Special Steel- CRGO for power transformers and about0.67 million MT of structural steel for substations.

Therefore the total requirement of steel has been estimated to be about 25 million

MT for the 11th & 12th Plan.


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1.1 INTRODUCTION

CHAPTER-1

INTRODUCTION

1. 1 BACKGROUND

Electricity is a vital input for economic and social development of our society.Besides its importance in the growth of the countrys economy, it plays a major role inthe life of a common man and has a direct impact on the quality of life. Our economy isgrowing at a rapid rate with the expected GDP growth rate likely to be over 8% in thecoming years. Adequate and quality power is essential to fuel this growth and all effortsneed to be made to ensure that all bottlenecks are removed in the path of timelyimplementation of power projects and transmission network. The Governments Missionis to provide quality and reliable power to all by 2012.

1.2 GROWTH IN POWER SECTOR

The Installed Generating Capacity in the country which was only 1,358 MW at thetime of Independence has reached a level of 1,2,423 MW, comprising 83,982 MWthermal, 33,350 MW hydro, 3,900 MW nuclear and 6191 MW from wind and otherrenewable energy sources(As on 31.10.06). There has been corresponding growth intransmission and distribution network too. In spite of this impressive addition ingeneration, transmission and distribution capacity, growth in demand for power hasalways exceeded the generation capacity augmentation. As of now the country is facingenergy shortage of 8 % and peak deficit of 12.2%.

The 16 th Electric Power Survey has forecast a demand of 1,15,705 MW for theterminal year of 10 th Plan viz., 2006-07. A need-based capacity addition of about 57,000

MW during 10th

Plan was required to meet this projected demand in full. Howeverdepending on resources available and status of various projects, the target set for capacityaddition during the 10 th Plan was 41,110 MW. Rigorous monitoring of projects wasundertaken by MoP and CEA and the likely capacity addition during 10 th Plan is nowexpected be about 30,641 MW out of which about 17,493 MW has been commissionedtill date. The 11th Plan capacity addition programme is based on this capacitymaterializing during the 10 th Plan. However since equipment corresponding to this furtherslippage is expected to already have been tied up, this reduction in 10 th plan capacityaddition has not been considered while working out the 11 th Plan requirement.

The peak demand in the country by the end of 11 th Plan (2011-12) is expected tobe 1,51,648 MW whereas the demand by the end of 12 th Plan (2016-17) is expected to be2,05,333 MW as estimated by the 16 th Electric Power Survey(with diversity). Studiescarried out by CEA indicate that about 72,000 MW capacity addition is required during11 th Plan taking into account 10 th Plan capacity addition of 30,641 MW. However,depending upon the preparedness of various projects only about 66,000 MW capacityaddition is feasible during 11 th Plan in conventional plants by the various utilities andIPPs. Besides, about 13,500 MW has been programmed from renewable resources as perthe information from Ministry of Non Conventional Energy Resources. In addition to this,Captive capacity of 12,000 MW is also expected to be commissioned during the 11 th Plan.


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1.2 INTRODUCTION

Requirement of equipment and material for Renewable resources and Captive Generationhas not been included in this report. The long term perspective studies for the year 2012-17 carried out by CEA have indicated an installed capacity requirement of about2,72,200 MW to meet the 16 th EPS demand forecasts with 3.6% inter-regional diversity.As a result, the additional capacity requirement during 12 th Plan works out to be about86,500 MW. Requirement of electrical and mechanical equipment and other materials

needs to be tied up and made available for timely implementation of these projects.

1.3 REGULATORY & STRUCTURAL REFORMS IN POWER SECTOR

Government of India has been making constant efforts to move away from theregime of Business As Usual to a more pro-active, market oriented approach.Significant changes have been the entry of private sector in power generation, unbundlingof the vertically integrated business of generation, transmission & distribution andopening up of transmission & distribution sector for private participation, thus setting astage for the quantum jump to realize the capacity addition programme and also makingelectricity available to all including rural households.

The Electricity Act 2003 envisages a strong push to the structural reforms, de-licensing, thrust on rural electrification, incentives to reforming States and importantlymandatory metering with stronger provisions for punishment for theft of electricity. Thesalient features of the Electricity Act, 2003 are

1. The Central Government to prepare a National Electricity Policy and Tariff Policyin consultation with CEA and State Governments.

2. Thrust to complete the rural electrification and provide for management of ruraldistribution by Panchayats, Cooperative Societies, non-Government organizations,franchisees etc.

3. Provision for licence free generation and distribution in the rural areas.

4. Generation is being delicensed and captive generation is being freely permitted.Hydro projects would, however, need clearance from Central ElectricityAuthority.

5. Transmission Utility at the Central as well as State level, to be a Governmentcompany - with responsibility for planned and coordinated development of transmission network.

6. Provision for private licensees in transmission and entry in distribution through anindependent network.

7. Open access in transmission from the outset.8. Open access in distribution to be introduced in phases with surcharge for current

level of cross subsidy to be gradually phased out along with cross subsidies andobligation to supply. SERCs to frame regulations within one year regardingphasing of open access.

9. Distribution licensees would be free to undertake generation and generatingcompanies would be free to take up distribution businesses.


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1.3 INTRODUCTION

10. The formation of State Electricity Regulatory Commissions is a mandatoryrequirement.

11. Provision for payment of subsidy through budget.

12. Trading, a distinct activity is being recognized with the safeguard of theRegulatory Commissions being authorised to fix ceilings on trading margins, if

necessary.13. Provision for reorganization or continuance of SEBs.

14. Metering of all electricity supplied made mandatory.

15. An Appellate Tribunal to hear appeals against the decision of the CERC andSERCs.

16. Provisions relating to theft of electricity made more stringent.

1.4 NATIONAL ELECTRICITY POLICY AND PLAN

The Electricity Act 2003 mandates that the Central Government shall prepare theNational Electricity Policy and Tariff Policy in consultation with the State Governmentsand CEA for development of the Power System based on optimal utilization of resources.The publication of the National Electricity Policy in February 2005 is an importantmilestone as it lays the guidelines and provides direction to the evolution of the PowerSector within the ambit of the Electricity Act.

The main objective of the National Electricity Policy is to make electricityaccessible to all households in next five years(2010) and to facilitate demand to be fullymet by 2012. International standards in reliability and quality of Power are to be achievedby this timeframe. At present the per capita consumption of the country is about 631units. Even though simultaneous efforts are being made to achieve high levels of energyefficiency through energy conservation measures, it is endeavoured to increase the percapita consumption, which is synonymous with progress and development, to 1000 unitsby 2012.

The Policy also stipulates that CEA shall prepare the National Electricity Plan fora short-term timeframe of five year while giving a 15-year perspective and the variousaspects to be covered shall include demand forecast for different regions, suggested areas/ locations for capacity addition, integration of such possible locations with transmissionsystem and development of national grid.

The National Electricity Plan has been prepared by CEA and submitted to theGovt. for approval. It is expected that the Plan will be notified shortly. The Plan covers

10th

Plan (2002-07) in detail whereas perspective planning has been carried out for the11 th & 12 th Plans.


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2.1 GENERATION CAPACITY ADDITION PROGRAMME

CHAPTER-2

GENERATION CAPACITY ADDITION PROGRAMME

The Electricity Act 2003 and the National Electricity Policy announced by theGovernment in February 2005 stipulates that CEA is to prepare the National ElectricityPlan. This Plan shall provide the blueprint for the development of the power sector.Accordingly, CEA has prepared the Plan which, after approval of the Government, shallbe notified for reference of all Stakeholders.

The National Electricity Plan has been prepared based on detailed studies carriedout by CEA. The 10 th Plan has been covered in detail furnishing project wise details of target as well as the likely capacity addition along with status of each project. Perspectiveplanning has been carried out for the 11 th and 12 th Plans. As per the latest review of thestatus of 10 th Plan projects the likely capacity addition is about 30,641 MW, this furtherslippage shall not change the 11 th plan requirement as the equipment and material forthese projects is expected to already have been tied up.

In the National Electricity Plan a number of generation capacity expansion planshave been worked out. These are - Desirable Scenario i.e. Scenario with no limitation onhydro and gas based capacity, Low hydro Scenario, Limited gas Scenario, Most feasibleScenario i.e. low hydro and limited gas scenario, 7%, 8% and 9% Energy Growth RateScenarios. However in this booklet, the requirement of equipment and steel has beenworked out corresponding to the Most feasible Scenario and demand as per the 16 th EPSReport.

In this Chapter, details of tentative capacity addition during 11 th & 12 th Plan havebeen furnished. For the purpose of assessing the requirement of equipments, thermalplants have been categorized into five categories i.e. four categories for coal/lignite plantsbased on the unit size of 660/800 MW, 500 MW, 300/250/210 MW and 125 MW, andone category for Gas based plants. For each of the above category, norms have beendrawn up for the requirement of equipment. However in case of hydro plants no suchcategorization is possible as the equipment requirement is site specific and not dependanton the capacity of the plant. Therefore equipment has been assessed in total for hydrocapacity of 17,189 MW during 11th Plan and 30,000 MW during 12th Plan. Requirementof equipment for nuclear plants has not been included in the Report as their requirement,which includes special type of material, is difficult to estimate. Also it is expected that the

Nuclear Power Corporation of India would separately ensure development of productioncapability for material and equipment commensurate with their requirement during 11 th and 12 th Plans. However the nuclear capacity expected in the 11 th and 12 th Plans is 3160MW and 12000 MW respectively which is approx. 12 % of the total tentative capacityaddition.


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2.1 ELEVENTH PLAN (2007-12)

During the 11 th plan, a tentative capacity addition of 66,463 MW is plannedcomprising of 17,189 MW of hydro, 46,114 MW of thermal and 3,160 MW of nuclearcapacity in the most feasible scenario i.e. low hydro limited gas availability scenario.Fuel-wise break-up of the total capacity addition of 66,463 MW is given in Table 2.1.

Table 2.1Tentative Capacity Addition Plan during 11 th Plan

(Figures in MW)

Details of number of units and projects in each category, corresponding to total thermal*capacity addition during 11 th plan is as given in Table 2.2 below:

Table 2.2

Project wise/ Unit wise break up of total thermal capacity addition during 11 th Plan

Coal/Lignite-44,000 MW

Unit size No. of Units MW No. of projects

a. 800/660 MW 12(2+10) 8,200 6(2+4)

b. 500 MW 47 23,460 30

c. 300/250/210 MW 45 11,465 27

1

d. 125 MW 7 875 4

Gas/LNG - 2114 MWNo. of gas modules No. of projects

2.

9 7

3. Total Thermal Capacity Addition -46,114 MW

* No such categorisation for Hydro Plants

Sector/Fuel TotalHydro 17,189

Thermal 46,114Coal/Lignite 44,000

Gas/LNG 2,114Nuclear 3,160Total 66,463


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2.2 TWELFTH PLAN (2012-2017)

During the 12 th Plan, a tentative capacity addition of 86,500 MW is plannedcomprising of 30,000 MW of hydro, 44,500 MW of thermal and 12,000 of nuclearcapacity. Fuel-wise break-up of the total capacity addition of 86,500 MW is given inTable 2.3.

Table 2.3Tentative Capacity Addition during 12 th Plan

(Figures in MW)

Details of number of units and projects in each category, corresponding to total thermalcapacity addition during 12 th plan, are as given in Table 2.4.

Table 2.4 Project wise/ Unit wise break up of total thermal capacity addition during 12 th Plan

Coal/Lignite- 44000 MW

Unit size No. of Units MW No. of projects

a. 800/660 MW 40(39+1) 31860 10

b. 500 MW 18 9000 10

c. 310/250/210 MW 14 3640 4

* No such categorisation for Hydro Plants

Sector/Fuel TotalHydro 30000Thermal 44,500

Coal/Lignite 44,500Gas/LNG NIL

Nuclear 12000

Total 86500


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SUMMARY

In this Chapter, details of tentative capacity addition planned for the 11 th and 12 th Planshave been furnished. Further, to facilitate assessment of requirement of equipment andmaterial corresponding to this capacity addition, categorization of thermal capacity hasbeen done. In case of thermal capacity, the details of categories and the number of units/ modules in each category tentatively planned for the 11 th and 12 th Plans have beenfurnished in his Chapter. However, hydro plants have not been categorised andassessment has been made for the total number of hydro projects. Requirement of nuclearcapacity has not been included. Corresponding to the tentative capacity addition during11 th and 12 th Plan and the number of units/ modules in each category, the requirement of equipment and material has been worked out in Chapters 3 and 4.


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3. 1 REQUIREMENT OF ELECTRICAL EQUIPMENTS

CHAPTER -3

REQUIREMENT OF ELECTRICAL EQUIPMENTS

In this Chapter, the requirement of electrical and mechanical equipments has beenassessed for power generation stations, both hydro and thermal plants, as well as forpower substations. This requirement has been worked out corresponding to the tentativecapacity addition during the 11 th and 12 th Plans.

Equipment for nuclear stations has not been considered as the same is separatelyexpected to be done by Nuclear Power Corporation. Also the requirement of equipmentsand materials for nuclear plants is difficult to estimate which in any case is expected to be3200 MW and 8800 MW in the 11 th and 12 th Plans respectively and therefore a smallfraction of the total tentative capacity addition.

3.1 REQUIREMENT OF ELECTRICAL EQUIPMENTS FOR GENERATIONPLANTS (INCLUDING SWITCHYARD EQUIPMENT)

The estimated requirement of electrical equipments for generation plants coming upduring the 11 th Plan and 12 th Plans has been worked out considering tentative capacityaddition identified for these Plans, details of which have been furnished in Chapter 2.Thermal projects for commissioning during the 11 th and 12 th Plan have been categorizedin five major groups on the basis of their unit sizes. In case of thermal plants, requirementof major electrical equipment has been worked out for one unit of each of these categoriesand subsequently depending on the number of units in the respective categories, the totalrequirement has been assessed for 11 th and 12 th Plans. In case of hydro units suchcategorisation is not tenable since each project is site specific and therefore the totalrequirement of major equipments has been worked out for the 11 th and 12 th Plan.Switchyard equipment at the generating stations has also been included. Details of theabove assessment are given below.

3.1.1 Thermal Power Plants (Including Switchyard Equipment)

The thermal plants have been categorized into five categories based on the unit sizei.e. 660/800 MW, 500 MW, 300/250/210 MW class and 125 MW for coal/lignite plants,and gas/LNG modules. In case of Gas/LNG based power projects, numbers of modules( comprising of 2GTs and 1 ST) corresponding to each project have been

assessed for 11th

& 12th

plans separately and as per the norms of equipment required for atypical 360 MW gas module, the total requirement of electrical equipment has beenassessed. The requirement of electrical equipments for switchyards at the generatingstation has also been indicated.

i) Item wise requirement of equipment for 660/800 MW category of thermalplants during 11 th and 12 th Plans is given in Table 3.1.


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Table-3.1

Requirement of Equipments for 660/800 Mw Coal/Lignite Based Units of 11 th Plan and 12 th Plan Capacity Addition Programme

11 th Plan 12 th Plan Total

Item

Requirementfor

One unit of 660 MW

12 Units(6 Projects)



GT* 260MVA Gen V/420/ 3kVThree phase bank 3

42 130 172ST 90/45/45 MVA 132/11.5/11.5 kV 1 12 40 52UT 35MVA Gen V/11.5kV 2 24 80 104ICT 200MVA 400/132kV - 6 10 16Misc. Service Transformer - 6 10 1620 MVA 132/34.5kV

Aux. Transformer 11/3.45kV 4 48 160 20833kV Switchgear 8 96 320 41611 kV Switchgear 68 816 2720 35363.3 kV Switchgear 84 1008 3360 4368HT Motors 146 1752 5840 7592LT Motors 1404 16848 56160 73008

LT Transformers 32 384 1280 1664LT MCC Panels 350 4200 14000 18200415 V Switchgear Panel 100 1200 4000 5200DC Battery 5 60 200 260Battery Charger 7 84 280 364

33 kV Single Core Cable (km) 3 36 120 15611kV Single Core Cable (km) 21 252 840 109211kV Multi Core Cable (km) 24 288 960 12483.3 kV Single Core Cable (km) 8 96 320 4163.3 kV Multi Core Cable (km) 12 144 480 6241.1 kV Power Cable (km) 233 2796 9320 121161.1 kV Control Cable(km) 367 4404 14680 19084Emergency DG Set 1500KVA* 1 18 50 68

* 1 no. spare GT and 1 no. spare DG is considered for each project

ii) Item wise requirement of electrical equipments for 500 MW category of thermal plantsduring 11 th and 12 th Plans is given in Table 3.2.


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Table-3.2

Requirement of Equipment for 500 MW Coal/Lignite Based Units of 11 th Plan and 12 th Plan Capacity Addition Programme


Item

Requirementfor

One unit of 500 MW




GT* 200MVA Gen V/420/ 3kV Three Phase Bank 3 171 64 235ST 80/40/40MVA132/11.5/11.5 kV 1 47 18 65UT 50 MVA Gen V/11.5kV 1 47 18 65ICT 125 MVA 400/132kV - 30 10 40Aux. Transformer 5 235 90 325

11 kV Switchgear 63 2961 1134 40953.3 kV Switchgear 66 3102 1188 4290HT Motors 118 5546 2124 7670LT Motors 1135 53345 20430 73775LT Transformers 30 1410 540 1950

LT MCC Panels 287 13489 5166 18655415 V Switchgear Panel 75 3525 1350 4875DC Battery 4 188 72 260Battery Charger 6 282 108 39011 V Single Core Cable(km) 13 611 234 84511 kV Multi Core Cable( km) 18 846 324 1170

3.3 kV Single Core Cable( km) 12 564 216 7803.3 kV Multi Core Cable (km) 8 376 144 5201.1 kV Power Cable( km) 200 9400 3600 130001.1 kV Control Cable (km) 375 17625 6750 24375Emergency DG Set1500KVA* 1 77 28 105

* 1 no. spare GT and 1 no. spare DG have been considered for each project


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iii) Item wise requirement of equipment for 300/250/ 210 MW category of thermal plantsduring 11 th and 12 th Plans is given in Table 3.3.

Table-3.3

Requirement of Equipment for 300/250/210 MW Class Coal/Lignite Based Units of 11 th Plan and 12 th Plan Capacity Addition Programme


Item

Requirement forOne unit of

300/250/210 MW45 Units

(27 Projects)14 Units

(12 Projects)59 Units

(31 Projects)GT* 315MVA Gen V/237kVThree Phase 1 72 18 90ST 55/27.5/27.5 MVA220/6.9/6.9 kV 1 45 14 59UT 20 MVA Gen V/6.9 kV 2 90 28 118Misc Service Trans 10MVA6.6/11.5 1 45 14 5911 kV Switchgear 15 675 210 8856.6 kV Switchgear 96 4320 1344 5664HT Motors 93 4185 1302 5487LT Motors 1041 46845 14574 61419LT Transformers 26 1170 364 1534LT MCC Panels 225 10125 3150 13275415 V Switchgear Panel 75 3375 1050 4425DC Battery 6 270 84 354Battery Charger 6 270 84 35411kV Single Core Cable( km) 2 90 28 11811kV Multi Core Cable( km) 2 90 28 118

6.6kV Single Core Cable(km) 16 720 224 9446.6kV Multi Core Cable( km) 16 720 224 9441.1kV Power Cable (km) 200 9000 2800 118001.1 kV Control Cable(km) 400 18000 5600 23600Emergency DG Set 1 72 18 90

1 no. spare GT and 1 no. spare DG have been considered for each project

iv) Item wise requirement of equipment for 125 MW categories of thermal plants during11 th is given in Table3.4. Requirement of 125 MW sets is nil during the 12 th Plan.


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Table-3.4

Requirement of Equipment for 125 MW Coal/Lignite Based Units Of 11 th PlanCapacity Addition Programme

11 th Plan

ITEM

Requirement forOne unit of 125

MW7 Unit

( 4 Projects)GT* 160MVA Three Phase 1 11ST 55/27.5/27.5 MVA 1 7UT 20MVA 2 14Misc Service Trans 20 MVA 1 711 kV Switchgear 15 1056.6 kV Switchgear 96 672HT Motors 45 315LT Motors 324 2268LT Transformers 25 175LT MCC Panels 17 119415 V Switchgear Panel 75 525DC Battery 6 42Battery Charger 6 4211kV Single Core Cable (km) 2 1411kV Multi Core Cable (km) 2 146.6 kV Single Core Cable (km) 16 1126.6 kV Multi Core Cable (km) 16 1121.1kV Power Cable(km) 200 14001.1 kV Control Cable(km) 400 2800Emergency DG Set 1500KVA* 1 11

* 1 no. spare GT and 1 no. spare DG have been considered for each project

v) Item wise requirement of equipment for gas based thermal plants during11 th and 12 th Plans is given in Table3.5.


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Table-3.5 Requirement of Equipment for Gas/LNG Based Units

of 11 th Plan and 12 th Plan Capacity Addition Programme

11 th Plan

Item

Requirementfor One module

(360 MW)9 modules

(7 projects)Gen. Transformer(2 nos. 114 MVA & 1 nos.146MVA) 3 34

Unit Aux Transformer 20 MVA 2 18HT Motors 13 117LT Motors 36 324LT Transformers 10 90415 V Switchgear Panel 17 153DC Battery 7 63Battery Charger 11 99

Emergency DG Set 1 16Gen. Circuit Breaker 6 546.6 kV Switchgear 31 279HT Power Cable (km) 200 1800LT Power & Control Cable (km) 500 4500

) 1 no. spare GT and 1 no. spare DG have been considered for each project

vi) Total requirement of equipment (Item wise) for thermal plants during 11and12 th Plans is given in Table 3.6.


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Table-3.6

Total Requirement of Equipment for Thermal I.E. Coal, Lignite, Gas/LNG

Based Units of 11 th

Plan and 12 th

Plan Capacity Addition Programme

Item

Total Requirementfor Coal/ Lignite

Based Plants

TotalRequirement

forGas/LNG

Based Plants Total

GT 508 34 542

ST 183 183

UT 301 18 319

ICT 56 56

Misc Service Trans 20MVA 82 82Aux. Transformer 533 533

33kV Switchgear 416 416

11 kVSwitchgear 8621 8621

6.6 kV Switchgear 6336 279 6615

3.3 kV Breaker 8658 8658

HT Motors 21064 117 21181

LT Motors 210470 324 210794

LT Transformers 5323 90 5413

LT MCC Panels 50249 50249

415 V Switchgear Panel 15025 153 15178DC Battery 916 63 979

Battery Charger 1150 99 1249

33kV Single Core Cable (km) 156 156

11kV Single Core Cable (km) 2069 2069

11kV Multi Core Cable (km) 2550 2550

6.6kV Single Core Cable (km) 1056 1056

6.6kv Multi Core CablE (km) 1056 1056

3.3kV Single Core Cable (km) 1196 1196

3.3kV Multi Core Cable (km) 1144 1144

HT Power Cable 1800 1800

LT Power&Control Cable (km) 4500 4500

Gen. Circuit Breaker 54 54

1.1kV Power Cable (km) 38316 38316

1.1kV Control Cable (km) 69859 69859

Emergency DG Set 1500KVA 274 16 290 1 no. spare GT and 1 no. spare DG have been considered for each project


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vii) Requirement of Switchyard equipments for different voltage levels corresponding tothe unit size of each generation project have been assessed. For projects having unit sizeof 800 MW, switchyard equipments at voltage levels 765 kV and 132 kV have beenconsidered. Similarly, for projects having unit size of 660 MW and 500 MW, switchyardequipments at voltage levels 400kV and 132 kV have been considered. For projects

having unit size of 300/250/210 MW & Gas modules having unit size of 360 MW,switchyard equipments at voltage levels 220 kV have been considered. For projectshaving unit size of 125 MW requirement of switchyard equipment has not beenconsidered since it would normally be at a voltage level of lesser than 132 kV.

For assessment of electrical equipments for switchyard of generating stations, 6bays have been considered for each coal/Lignite based project, and 8 bays for eachmodule of gas project.

The layout of the substations has been considered according to the prevailingpractice for respective voltage levels. A Breaker and a half scheme has been assumed at765 kV & 400 kV levels. For 220 kV level, Double main and transfer bus scheme hasbeen assumed. Main and transfer bus scheme has been assumed at 132 kV.

Requirement of electrical equipment (Item wise) for switchyard associated withthermal plants during 11 th and 12 th Plans is given in Table3.7

Table-3.7 Requirement of Electrical Equipments for Switchyards associated with

Thermal Stations

A. 765 kV Switchyard Equipment-Breaker and a half scheme(For projects having unit size of 800 MW)

Item Requirement for one Bay

11th Plan(2 Projects)(12 Bays )


Total(11Projects)(66 Bays )

a. Circuit beaker 3 nos. per 2 bays 18 81 99b. Isolators 4 isolators per bay 48 216 264

c. CurrentTransformer 2 sets per bay 24 108 132

d. CVT/PT 1 set per line bay& 1 set per bus bar 16 72 88e. Lightning arrestor 1 set per bay 12 54 66

f. Wave Trap 2 nos. per bay 24 108 132B. 400 kV Switchyard Equipments- Breaker and a half scheme

(For projects having unit size of 660 MW & 500 MW)



12th Plan(11

Projects)(96 Bays )

Total(53 Projects)(318 Bays )

a. Circuit beaker 3 nos. per 2 bays 306 99 405b. Isolators 4 isolators per bay 816 264 1080


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d. CVT/PT 1 set per line bay& 1 set per bus bar 272 88 360

e. Gapless lightningarrestor 1 set per bay 204 66 270

f. Wave Trap 2 nos. per bay 408 132 540

C. 132 KV Equipments- Main and transfer Scheme(For projects having unit size of 800 MW, 660 MW & 500 MW)



12th Plan(20Projects)(120 Bays )

Total(66 Projects)(336 Bays)

a. Circuit beaker 1 no. per bay 216 120 336b. Isolators 3 isolators per bay 648 360 1008


d. CVT/PT1 set per line bay& 1 set per bus bar 324 180 504

e. Gapless lightningarrestor 1 set per bay 216 120 336f. Wave Trap 2 nos. per bay 432 240 672

D. 220 kV Switchyard equipment-Double main and transfer (For projects having unit size of 300/250 MW & Gas modules having unit size of 360MW) )


11th Plan(34 Projects)(218 Bays)

12th Plan(4 Projects)(24 Bays)

Total(46

Projects)

(290 Bays)a. Circuit beaker 1 nos. per bays 218 24 242b. Isolators 3 isolators per bay 654 72 726


d. CVT/PT 1 set per line bay& 1 set per bus bar 320 36 356

e. Gapless lightningarrestor 1 set per bay 218 24 242f. Wave Trap 2 nos. per bay 436 48 484

Note: 1 set = 3 single phase units

3.1.2 Hydro Power Plants( including switchyard equipment)

For hydro plants, requirement of equipment has been assessed corresponding to acapacity addition of 17,189 MW during 11 th Plan and a capacity addition of about 30,000MW during 12 th Plan. Since each hydro -plant is site specific; there is no set rule ornorms for estimation.


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The broad basis followed in the estimation of the other components of hydroprojects for 11 th & 12 th Plan is as under.

i) Gates & Hoists: The number of radial gates roughly varies between 3 & 14numbers depending on type of hydro scheme. Number of Gates depends onlength of dam and type of scheme i.e. storage scheme or Run-of-River schemes.

The number of spillway radial gates is more for storage scheme compared withROR Scheme.

ii) Vertical Lift Gates: Vertical gift gates are normally installed for overflowspillway, intake structures, desilting chamber outlets, surge shaft outlets, drafttube, tail race outfall etc. Depending on type of scheme it may vary between 5 &20. For ROR scheme with HRT, the number of vertical lift gates is morecompared with storage scheme.

iii) Hydro Turbine and Auxiliaries (Motors plus Control Centres): One set of Turbine and auxiliaries have been considered for each unit. The MW outputrating of turbine shall match unit rating.

iv) Main Inlet Valve (MIV): Generally, One MIVS in each unit is provided inpenstock except for low head HE schemes/Dam Toe HE Schemes.

v) Digital Governor: One set of Digital Governor with accessories is provided foreach Generating Unit.

vi) Synchronous Generator and Associated Auxiliaries: The MVA capacity of synchronous generator has been estimated considering power factor of 0.9.

vii) Static Excitation System: One set of Excitation Equipment with accessories isconsidered for each Generating Unit.

viii) Dynamic Braking Equipment: Dynamic braking equipment is generallyprovided with large hydro generating units with high speed machines. Thenumber has been estimated accordingly.

ix) Unit Control Board (UCB): One set of UCB is considered with each generatingunit.

x) Isolated Phase Bus Duct and terminal / tap-off of equipments: The length of IPBD depends on layout of power house and varies from scheme to scheme. Theestimation is based on experience.

xi) 11kV/13.8kV/24kV CTs: Number of CTs depends on protection and meteringscheme of particular plant, however, for estimation purposes 10 to 19 CT' perphase per unit has been considered depending on unit size.

xii) Neutral Grounding Cubicle : One set of Neutral grounding cubicle is consideredfor each generating unit.

xiii) 132kV/220kV/400kV Generator Transformers: The MVA Generatortransformer rating is normally taken as 110% of generator rating, the same hasbeen considered in estimation.


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xiv) Unit and Line Protection Panels: One set of protection panels are consideredeach for Generating Units, Bus-bar, outgoing feeder, EHV cable / bus-duct,Reactors etc.

xv) Computerized Control System (CCS): One set of CCS equipment has beenconsidered for each hydro station.

xvi) Air Insulated Switchgear and Gas Insulated Switchgear: GIS has beenconsidered for under-ground 220kV / 400kV switchyard, while conventionaloutdoor switchyard for surface / semi underground schemes.

xvii) EOT Cranes: The total installed tonnage capacity of EOT cranes is based onbroad estimation of stator and rotor weights, though these weights may varydrastically even for machines of similar rating.

xviii) EHV, XLPE cables, EHV Bus Duct: The cable requirement depends on layoutof power house and varies from scheme to scheme. The estimation is based onexperience.

xix) Unit Auxiliary and Station Service Transformers: The total capacity of unitand station auxiliary transformers has been considered as 1.2% of installedcapacity.

xx) 11kV Switchgear Board : The 11kV switchgear boards vary from station tostation depending on 11kV scheme. However for estimation purposes two LTboards per unit has been considered.

xxi) Power and Control Cables: There is no set rule for estimating power andcontrol cable lengths as it depends on layout and control philosophy. Theestimation is based on experience.

xxii) 110V/220V DC System (Batteries, Charger and DCDB): The battery capacityvaries between 400AH to 1800AH, and battery chargers from 2 to 4 numbersdepending on number of units and total installed capacity.

xxiii) Grounding System : The total tonnage of grounding material vary from station tostation depending on layout of power plant, fault level, soil resistivity etc.

xxiv) DG Sets : The MVA capacity on DG sets for HE plants vary between 500KVA to2000KVA depending on requirements worked out during detailed engineering.

xxv) Illumination System, Fire Protection System, Service Water System, OilHandling and Purification System, Ventilation System, Air ConditioningSystem, Lifts, Communication System and Miscellaneous items like VideoCamera, Silt Monitoring System, GPS System, Special Cables like OPGWetc. : These systems are provided in power plant as per requirement.

Details of the various equipments are as follows:


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Table-3.8Total Requirement of Equipment for Hydro Projects

of 11th Plan and 12th Plan Capacity Addition Programme

No. Equipment 11 th Plan(17,189 MW)

12 th Plan(30,000 MW)

Total

Hydro-MechanicalGates & Hoist (sets)(i) Radial spillway Gates 276 482 757

1.

(ii) Vertical Lift Gates 403 704 11072 Butterfly Valve (Sets) 31 54 853 Main Inlet Valve (Sets) 115 200 315

Electro-Mechanical4 Turbine (MW) 17189 30000 47,1895 Turbine (No.) 199 350 5496 Digital Governors (Nos.) 199 350 5497 Syn. Generator (MVA) 18908 32999 51,9078 Syn. Generator(No.)

199 350 5499 Unit Control Board (sets) 199 350 54910 Motor & Motor Control Centres

(Units) 1366 2384 3,75011 Transformers (UAT & SST)

(MVA) 228 398 62712 Static Excitation System (Sets) 199 350 54913 Dynamic Braking Isolators (Sets) 60 105 16514 NG cubicle incl.

Transformer (Set) 199 350 54915 11/13.8 kV/24kV Isolated Phase

Bus Ducts (IPBD) (metres) 38367 66962 105,32816 11/13.8/24 kV CTs

( 1-Phase Units) 9208 16072 25,28017 SAVT Cubicle (Sets) 199 350 54918 132kV/220kV/400 kV Generator

Transformer (MVA) 21026 36697 57,72319 11kV Switchgear Boards (Units) 207 361 568

132kV/220kV/400 kV Outdoor switchgear (Units)Circuit breaker 476 831 1307Capacitor voltage 323 565 888EHV Voltage Transformers 161 281 443Lighting Arresters(LA) 967 1687 2654Isolators 497 868 1365

20

EHV Current Transformers 1128 1968 309621 415 V Switchgear Board Units 555 968 152322 220/400 kV GIS (Bays) 134 234 36823 EHV XLPE Cable (Km) 42 73 11524 EHV Bus Duct (Km) 18 32 51


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3.2 REQUIREMENT OF ELECTRICAL EQUIPMENTS FOR POWERSYSTEM

The requirement of electrical requirement for power system has been estimatedbased on the transmission expansion plans corresponding to tentative capacity additionduring the 11 th Plan. In case of 12 th Plan, the transmission expansion has been assumed to

be same as for the 11th

Plan.

The transmission expansion plans include the circuit length of transmission linesat respective voltage levels and details of substation requirement for the entiretransmission system. Based on the number of substations and the voltage levels at eachsubstation, the total number of bays at each voltage level has been estimated as shownbelow in the table 3.9.

Table 3.9Total Number of Bays at each Voltage Level

No. of BaysS.No.

VoltageLevel 11 th Plan 12 th Plan

Total

1. 765 kV 62 62 1242. 400kV 774 774 15483. 220kV 3060 3060 61204. 132kV 7280 7280 14560

The layout of the substations has been considered according to the prevailingpractice for respective voltage levels. Breaker and half scheme has been assumed at 765kV & 400 kV level. For 220 kV level, Double main and transfer bus scheme has beenassumed. Main and transfer bus scheme has been assumed at 132 kV

Based on the substation layout schemes for each voltage level as detailed above, thenormative requirement of substation equipment for each bay corresponding to eachvoltage level have been evolved. The total requirement of substation equipment has beenassessed based on these norms. Details of the same are as furnished in the followingparas.


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3.2.1 Estimated Requirement of Electrical Equipment for Voltage Level 765 kV &400 kV

The estimated requirement of electrical equipments for the transmission expansionplanned for voltage levels 765 kV & 400 kV for 11 th and 12 th Plan is given below in theTable 3.10.

Table-3.10

Estimated Requirement of Electrical Equipment for Voltage Level 765 kV & 400 kV

765 kV 400 kV11thPlan

(2007-2012)

12thPlan

(2012-2017)

11thPlan

(2007-2012)

12thPlan

(2012-2017)

NORMS

Total Nos.

NORMS

Total Nos.Total No. of Bays 62 62 774 774

Circuit Breaker3 nos. per 2

bays 93 933 nos. per 2

bays 1161 1161

Isolator 4 isolatorsper bay 248 2484 isolators

per bay 3096 3096

CT2 sets per/

bay 124 1242 sets per

bay 1548 1548

PT/CVT1 set per linebay & 1 setper bus bar

71 711 set per linebay & 1 setper bus bar

890 8900

LighteningArrestor 1 set per bay 62 62 1 set per bay 774 774

Wave Trap 2 nos. perbay 124 1242 nos. per

bay 1548 1548



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3.2.2 Estimated Requirement of Electrical Equipment for Voltage Level 220 kV &132 kV

The estimated requirement of electrical equipments for the transmission expansionplanned for voltage levels 220 kV & 132 kV for 11 th and 12 th Plan is given below in thefollowing table 3.11 .

Table-3.11

Estimated Requirement of Electrical Equipment for Voltage Level 220 kV & 132 kV for 11 th and 12 th Plan


3.2.3 Summary of Requirement of Electrical Equipment for all Voltage Levels(765 kV, 400 kV, 220 Kv & 132 kV)

The total requirement of various substation equipments like circuit breaker,isolators etc. as per the transmission expansion plan during 11 th & 12 th Plan issummarized in Table 3.12.

220 kV 132 kV11th Plan

(2007-2012)

12th Plan(2012-2017)

11th Plan(2007-2012)

12thPlan

(2012-2017)

Nos.

Total Nos.

Nos.

Total Nos.

Total No. of Bays 3060 3060 7280 7280

CB 1no. per bay 3060 3060 1no. per bay 7280 7280

Isolator 4 isolatorsper bay

12240 12240 3 isolators perbay

21840 21840

CT 1 set per bay 3060 3060 1 set per bay 7280 7280

PT/CVT 1 set per linebay & 1 setper bus bar

3060 3060 1 set per linebay & 1 setper bus bar

7280 7280

LA 1 set per bay 3060 3060 1 set per bay 7280 7280

WaveTrap

2 nos. perbay

6120 6120 2 nos. per bay 14560 14560


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Table 3.12

Total Electrical Equipment for Power System

S.No. Item11 th Plan 12 th Plan Total

1. CircuitBreaker 11594 11594 23188

2. Isolator 37424 37424 748483. CT 12012 12012 240244. PT/CVT 11301 11301 22602

5. LighteningArrestor

11176 11176 22352

6. Wave Trap 22352 22352 44704

While assessing the above requirement, Breaker and Half scheme has beenconsidered for 765 kV & 400 kV level. For 220 kV level, Double Main and Transfer busscheme has been considered and for 132 kV, Main and Transfer Bus scheme has beenconsidered.

SUMMARY

In this Chapter, requirement of electrical equipments for hydro and thermal powerprojects, along with the corresponding switchyard equipments for different voltage levels,coming up during the 11 th & 12 th Plan have been assessed based on certain norms. Thesubstation equipments have also been estimated as per the transmission expansion planfor 11 th and 12 th Plan.


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4. 1 REQUIREMENT OF STEEL FOR 11 TH AND 12 TH PLANS

CHAPTER 4

REQUIREMENT OF STEEL FOR 11 TH AND 12 TH PLAN

In this Chapter, an assessment has been made of the requirement of materialspecifically different types of steel for hydro & thermal power plants and power systemnetwork planned for 11 th and 12 th Plan. A detailed exercise has been carried out to assessthe requirement of both type of steel i.e. imported & indigenous. An assessment has alsobeen made of the requirement of copper and aluminium required for transmission lines.These details shall provide valuable inputs for equipment and material manufacturers andguide them to plan their production capacities accordingly.

In case of thermal power stations, steel requirement for different units of generation plants i.e. boiler, coal handling unit, ash handling unit, condenser, pulveriseretc has been estimated.

For a hydro power plant, estimation has been done for steel requirement in civilworks as well as electro mechanical equipments/systems in the power house.

Transmission system requirement corresponding to the planned generationcapacity addition has also been worked out. Material requirement for this transmissionsystem, including generation switchyard, substation and transmission lines, includingtowers, line conductors & earth wires have also been assessed in this Chapter.

4.1 STEEL REQUIREMENT FOR GENERATING STATIONS

4.1.1 Hydro Power Plants

In case of hydro plants, norms for requirement of steel i.e. Tonnes/MW have beenformulated based on details furnished by NHPC and BHEL of actual project setup. Thesenorms include steel requirement for Electrical & Mechanical package (Turbine &Generator) as well as for civil works. Norms are as given below:

Table 4.1Tonnes/MW

Steel NormsStructural Steel 34Reinforcement Steel 93

Based on the above average requirement per MW, the steel requirement for the 11th

PlanHydro projects works out to be given as under:

Table 4.2Lakhs Tonnes

Steel 11 th Plan (17189 MW) 12 th Plan (30000 MW) TotalStructural Steel 5.8 10.2 16.0Reinforcement Steel 16.0 27.9 43.9Total 21.8 38.1 59.9


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4.1.2 Thermal Power Plants

Requirement of steel (Imported & Indigenous ) for thermal power projects comingup in 11 th Plan is calculated on the basis of detailed steel requirement for typical 2x500

MW coal based unit , provided by BHEL (Given in Appendix 1).

For Coal/Lignite based projects, steel requirement per MW has been worked outand based on this per MW norm, the requirement of steel for the total coal based thermalcapacity has been assessed. For gas based projects, norms for steel requirement per MWhave been assumed to be 50% of coal based project for the applicable items as has beennoted in case of past installations. Also in case of gas based plants items such as furnace,coal handling plant, Electrostatic precipitators etc. are not required and hence have notbeen considered.

During 11 th Plan, total thermal capacity addition planned is 46,114 MWcomprising of about 44,000 MW of coal/lignite based plants and 2114 MW of gas basedplants. Similarly for 12 th Plan, thermal capacity addition planned is 44,500 MW.

Details of steel requirement for different equipments/ systems for the 11 th and 12 th Plan coal based thermal projects are furnished in Table 4.3.


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Table 4.3 Estimated Quantity of Steel for 11 th and 12 th Plan coal/ lignite Based Projects

Sl.No. Equipment/ System

11 th Plan coal based 44,000 MW(MT)

12 th Plan coal based 44500 MW(MT)

Type of steel used Imported Indigenous Total Imported Indigenous Total

1 Boiler

1.1 Drum 20108 1320 21428 20337 1335 216721.2 Structures/Non-Pressure

parts 54912 1312916 1367828 55536 1327836 13833721.3 Pressure Parts 182160 196196 378356 184230 198426 382656Total (Boiler)

257180 1510432 1767612 260103 1527596 17876992 Low Pressure Piping

0 236060 236060 0 238743 2387433 High Pressure/PC piping

93192 0 93192 94251 0 942514 Electrostatic Precipitator 320760 377960 698720 324405 382255 7066605 Main and Aux.Buildings 0 1961520 1961520 0 1983810 19838106 PowerTransformers

(CRGO) 58432 0 58432 59096 0 590967 Motors 13200 18700 31900 13350 18913 322638 Switchyard 0 68200 68200 0 68975 689759 Coal Handling Plant 0 616000 616000 0 623000 62300010 Turbine/Gen./Condenser10.1 Plates 72336 79464 151800 73158 80367 15352510.2 Rounds 1760 14256 16016 1780 14418 1619810.3 Structural Steel, IS 2062 1760 4400 6160 1780 4450 6230

10.4 Bloom,Class2 & Class 3 0 5280 5280 0 5340 5340Total(Turbine/generator/condenser 75856 103400 179256 76718 104575 18129311 Pumps/Heat Exchangers/Drive-Turbines and Pulverisers11.1 LP and HP Heaters 6160 3960 10120 6230 4005 1023511.2 Deaerators 3784 396 4180 3827 401 422811.3 Pulverisers 616 14608 15224 623 14774 1539711.4 Drive Turbines 88 528 616 89 534 62311.5 Structurals 0 616 616 0 623 62311.6 Bar Stock 1100 1056 2156 1113 1068 218111.7 Pipes 968 1672 2640 979 1691 2670Sub Total(Pumps etc.) 12716 22836 35552 12861 23096 35956

GRAND TOTAL (MT) 831,336 4,915,108 5,746,444 840783 4970962 5811745

The detailed steel requirement for 11 th and 12 th plan coal based projects is given inAppendix 2.

Details of steel requirement for different equipments/ systems for the 11 th and 12 th Plan Gas based thermal projects are furnished in Table 4.4


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Table 4.4 Estimated Quantity of Steel for 11 th Plan Gas Based Projects

Sl.No

Equipment/ Systm

11 thPlan Gas- 2114 MW (MT)

Type of steel used Imported Indigenous Total

1. Boiler1.1 Drum: 483 32 5151.2 Structures/Non-

Pressure parts 1319 31540 328591.3 Sub-total for Pressure

Parts 4376 4713 9089Total(Boiler) 6178 36285 42463

2. LP Piping 0 5671 56713. HP/PC Piping 2239 0 22394. Main and

Aux.Buildings 0 47121 471215. Power Transformers

(CRGO) 2807 0 28076. Motors 317 449 7667. Switchyard 0 3277 32778. Turbine/Gen./Condenser8.1 Plates 1738 1909 36478.2 Rounds 42 342 3858.3 Structural Steel, IS

2062 42 106 1488.4 Bloom,Class2 &

Class 3 0 127 127Total(Turbine/gen/condenser) 1822 2484 4306

9 Pumps/Heat Exchangers/Drive-Turbines and Pulverisers9.1 LP and HP Heaters 148 95 2439.2 Deaerators 91 10 1009.3 Drive Turbines 2 13 159.4 Structurals 0 15 159.5 Bar Stock 26 25 519.6 Pipes 23 40 63

Sub Total(Pumps) 291 198 488Grand Total (MT) 13654 95484 109138

The detailed steel requirement for 11 th plan Gas based projects is given inAppendix 3.

A Summary of the total steel requirement for thermal projects coming up in 11 th &12 th Plan is furnished in Table 4.5 below:


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Table- 4.5Summary of Total Steel Requirement for 11 th &12 th Plan Thermal Power Projects

11 th Plan(MT)

12 th Plan(MT)

Total(MT)

Coal Based PowerProjects

57,46,444 58,11,745 1,15,58,189Gas Based PowerProjects

1,09,138 - 1,09,138

Total 58,55,582 58,11,745 1,16,67,327

As evident from above, for 11 th Plan, approximately 58,55,582 Mt of steel is expected tobe required for the planned thermal projects. Similarly, approximately 58,11,745 MT of steel is expected to be required for the thermal projects coming up in 12 th Plan.

4.1.3 Nuclear Power Projects

Assessment of steel for Nuclear Power Plants is based on requirement of steel for coalbased plants. In case of nuclear plants, need for steel for coal handling system, boiler,ESP etc is eliminated whereas amount of steel for turbine etc. is increased. Assuming theeffect of these two factors approximately equal, the norms for the steel requirement fornuclear power plants is taken to be same as that of coal based plants .

Considering the above, the steel requirement for Nuclear Projects is as under:

Table 4.6 (Lakh Tonnes)

4.2 STEEL REQUIREMENT FOR POWER SYSTEM

As per the transmission expansion plan, transmission lines and substation of 765kV, 400 kV, 220kV and 132kVand below are to be added to the existing power grid duringthe 11 th and 12 th Plans. Steel requirement for Towers, conductors, earth wires, powertransformers and sub-stations is calculated as per the design norms for differenttransmission voltage levels.

Imported Steel Indigenous Steel Total Steel

11 th Plan(3160 MW) 0.6 3.5 4.1

12 th Plan(12000 MW) 2.3 13.4 15.7


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4.2.1 Requirement of Steel for Tower for 11 th And 12 th Plan

As per the Transmission plans, the number of circuit kMs of transmission lines atvarious voltage levels has been estimated. Based on Statistics, norms for steelrequirement for transmission towers at 765kV, 500kV, 400kV, and 220kV and 132kV

voltage levels have been evolved in terms of MT per circuit kM at each of these voltagelevels. The requirement of steel is then assessed based on the total circuit kms expected ineach Plan. Details of norms for steel requirement as well as total requirement during 11 th and 12 th Plans for each voltage level along with the type of steels used i.e. MS & HTS.arefurnished in Table 4.6.

Table-4.7 Requirement of Steel for Towers

Total All India(11 th Plan)

Total All India(12 th Plan)

Type of Steel used

S.NoLineVoltage(kV)

Norms forweight of steel forTowersMT/Km

ckt.Km

TotalWeight of steel fortowers(MT)

ckt.Km

TotalWeight of steel fortowers(MT)

MS(MT)

HTS (40%of Totalweight)(MT)

1 765 65 3200 208000 3200 208000 249600 166400

2500

HVDC38.3 5400 206820 5400 206820

248184 165456

3 400 23.5 44440 1044340 44440 1044340 1253208 8354724 220 10.1 23000 232300 23000 232300 4646005 132 9.1 20000 182000 20000 182000 364000

TOTAL 1873460 1873460 2579592 1167328

NOTE: Structural steel angle section manufactured according to the latest IS: 808-1976(Part V & VI) and tested according to the latest edition of IS: 2062-1992 or any otherequivalent or superior International Standards will be used in the fabrication of the towershaving its yield strength not less than 250 N/sq.mm and stress value of high tensile steel(Fe-490 High Tensile and Fe -540 High Tensile) grade according toIS: 8500 -1992.

4.2.2 Requirement of Aluminium and Steel for Conductor and EarthWire for 11 th and 12 th Plan

A. Requirement of Aluminium and Steel for Conductor and Earth Wire for 11 th

Plan

The requirement of Aluminium and Steel for conductor and earth wires has beenassessed based on norms in terms of MT per ckt kM at each voltage level and the totalnumber of ckt kMs planned during the 11 th and 12 th Plans. Tables 4.8 and 4.9 furnish therequirement of aluminium & steel for the conductor and earth wire for the 11 th and 12 th Plans respectively.


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Table-4.8 Requirement of Aluminium and Steel for Conductor and Earth Wire for 11 th Plan

S.

No.Voltage (kV)

Norms for Weight of Material for

Transmission Lines(MT/ckt kM)

Total

Ckt.kM

Total All India Weight

(MT/ckt kM)

Aluminum Steel Aluminum Steel1 765 23.14 4.64 3200 74048 148482 500 (HVDC) 15.43 3.50 5400 83322 189003 400 8.87 4.53 44440 394183 2013134 220 3.60 1.79 23000 82800 411705 132 1.78 1.64 20000 35600 328006 Total 669953 309031

B. Requirement of Aluminium and Steel for Conductor and Earth Wire for 12 th Plan

Table 4.9 shows the requirement of aluminium & steel for the conductor and earth wirefor the 11 th Plan

Table-4.9 Requirement of Aluminium and Steel for Conductor and Earth Wire for 12 th Plan

S. No. Voltage (kV)

Norms for Weight of Material for

Transmission Lines(MT/ckt kM)

TotalCkt.kM

Total All India Weight(MT/ckt kM)

Aluminum Steel Aluminum Steel1 765 23.14 4.64 3200 74048 148482 500 (HVDC) 15.43 3.50 5400 83322 189003 400 8.87 4.53 44440 394183 2013134 220 3.60 1.79 23000 82800 411705 132 1.78 1.64 20000 35600 328006 Total 669953 309031

Note: The Conductor & Earth wire shall comply in all respect with the IS: 398(Part-II)-1996, IS: 398 (Part-V) -1992 & IS: 398(Part-II)-1996, IS:2141-1996 latest amendmentsrespectively or any other International standards which ensure equal or higher quality of material.

4.2.3 Requirement of Special Steel -CRGO and Copper for Power Transformersduring 11 th And 12 th Plan

An assessment of the requirement of special steel and copper for powertransformers is made based on Norms evolved based on Statistics. As per these norms, therequirement in terms of MT per MVA is specified as furnished in Table 4.10 below:


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Table- 4.10 Norms for requirement of Special Steel and Copper for power transformers

765 kV 400 kV 220kV 132kV

CRGO Requirement(MT/MVA) 0.4 0.4 0.5 0.8

Copper Requirement(MT/MVA)

0.2 0.2 0.3 0.5

The total requirement of Special Steel and Copper is worked out based on theNorms and the power transformer capacity at each voltage level planned during the 11 th and12 th Plans and is furnished in Table 4.11 below Plan.

Table-4.11

Requirement of Special Steel and Copper for Power Transformers

11th Plan(2007-2012)

12th Plan(2012-2017)

PowerTransformer

Rating TotalMVA

Capacity

CRGOWT

(inTons)

Copper WT(inTons)

TotalMVA

Capacity

CRGOWT

(in Tons)

Copper WT(in Tons)

765 kV 12500 5000 2500 12500 5000 2500400 kV 44310 17724 8862 44310 17724 8862220 kV 73700 36850 22110 73700 36850 22110132 kV 52000 41600 26000 52000 41600 26000

Total required CRGO weight (in Tons) for 11th Plan 101174

Total required CRGO weight (in Tons) for 12th Plan 101174Total required Copper weight (in Tons) for 11th Plan 59472Total required Copper weight (in Tons) for 12th Plan 59472

4.2.4 Estimated Structural Steel Requirement for Substations for 11 th and 12 th Plan

The requirement of Structural Steel for substations has been assessed based on norms interms of MT per bay at each voltage level and the total number of bays planned duringthe 11 th and 12 th Plans at each voltage level. The total requirement during the 11 th and 12 th Plan at each voltage level is furnished in Table 4.12:


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Table-4.12 Requirement of Special Steel for Substation

A Summary of Steel Requirement for major components of power system i.e. towers,conductors, earth wires, power transformers & sub-stations is furnished in Table 4.13.

Table-4.13Summary of Requirement of Steel for Power System

11 th Plan(MT)

12 th Plan(MT)

Total(MT)

Steel for Tower 1873460 1873460 3746920Steel for conductor & Earth Wire 309031 309031 618062Special Steel -CRGO for PowerTransformer 1,01,174 1,01,174 202348

Structural Steel for Sub-Stations 3,32,450 3,32,450 664900Total 2616115 2616115 5232230

SUMMARY

In this Chapter, an assessment of the requirement of Steel for hydro and thermalPower stations has been made in accordance with the capacities planned during theseplans. For hydro stations, requirement has been assessed separately for structural steel andreinforcement steel. For thermal stations assessment has been made separately for coal/ lignite and gas based stations. For generating stations a total requirement of 8.4 MillionTonnes during 11th and 11.2 Million Tons during 12th plan has been assessed. For majorcomponents of Power system including substations, towers and transmission lines a totalrequirement of 2.6 Million tonnes for 11 th and 12th Plan each, has been assessed.

Steel requirement for 11th

& 12th

Plan projects is summarised below- In Lakh Tonnes11 th Plan 12 th Plan Total

Hydro Projects 21.8 38.1 59.9Thermal Projects 58.5 58.1 116.6Nuclear 4.1 15.7 19.8

Power System 26.2 26.2 52.4Total 110.6 138.1 248.7

11 th Plan 12 th Plan

Voltagelevel

Norms forSpecial steelrequirement

for substation(MT/bay)

Total No.of Bays

Requirement(MT)

TotalNo. of Bays

Requirement(MT)

TotalRequirement

of Special steelfor substation

(MT)765 kV 75 62 4650 62 4650 9300400 kV 50 774 38700 774 38700 77400220kV 35 3060 107100 3060 107100 214200132 kV 25 7280 182000 7280 182000 364000Total 332450 332450 664900


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1. 1 Appendix 1

Appendix-1

Typical Steel quantity for 2x500 MW Thermal unit as given byBHEL

S. No. Equipment /System Typical Qty. for 2 x 500 MW units as givenby BHEL (MT)

Type of steel used : Imported Indigenous Total

1 Boiler 1.1 Drum :

Pipe : (OD 88.9 to 863mm, thickness 11.13 to 130mm)

Carbon Steel Pipe 7 0 7Plate : (Thickness 1.6 to 190mm)

Boiler Quality Plates 421 0 421Stru Plates 0 2 2JPC Plates and Sheets 0 28 28Bar Stock : (Dia 6mm to 250mm)Round 29 0 29Sub-total for Drum 457 30 487

1.2 Structures/Non Pressure partsPipe : (OD 88.9 to 863mm, thickness 11.13 to 130mm)

Alloy Steel Pipes 34 0 34Carbon Steel Pipes 413 100 513ERW Pipes 200 1,701 1,901Plate : (Thickness 1.6 to 190mm)

Alloy Steel Plates 255 0 255Boiler Quality Plates 17 0 17Stru Plates 245 245 490JPC Plates and sheets 0 17,135 17,135Stainless Steel Pipes 0 115 115Bar Stock : (Dia 6mm to 250mm)Round 0 214 214

STRU : (Various Sizes) Angles, Beams and Channels 0 9,844 9,844Tubes : (OD 14.2 to 76.1mm, thickness 2 to 12.5 mm)

Alloy Steel Tubes 18 0 18Carbon Steel Tubes 66 67 133ERW Tubes 0 415 415Stainless Steel Tubes 0 3 3


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1. 2 Appendix 1



Sub- total for Structures / Non-Pressure parts :

1,248 29,839 31,087

1.3 Pressure Parts :Pipe : (OD 88.9 to 863mm, thickness 11.13 to 130mm)

Alloy Steel Pipes 228 0 228Carbon Steel Pipes 500 146 646Plate : (Thickness 1.6 to 190mm)

Alloy Steel Plates 462 0 462Boiler Quality Plates 434 0 434JPC Plates and Sheets 0 982 982Stainless Steel Plates 0 117 117

Bar Stock : (Dia 6mm to 250mm)Round 0 300 300STRU : (Various Sizes)FLAT 134 0 134 Angles, Beams and Channels 0 532 532Tubes : (OD 14.2 to 76.1mm, thickness 2 to 12.5 mm)

Alloy Steel Tubes 951 951 1,902Carbon Steel Tubes 1,330 1,330 2,660Stainless Steel Tubes 101 101 202Sub-total for Pressure Parts 4,140 4,459 8,599

Total Qty. for Boiler (1.1+1.2+1.3) 5,845 34,328 40,173

2 LP piping

IS 3589 0 4,194 4,194IS 1239 0 655 655IS 1239 (GAL) 0 263 263SS 0 253 253Total for LP Piping 0 5,365 5,365

3 HP critical/PC piping

SA335P91 372 0 372SA335P22 1,046 0 1,046SA106GRC 700 0 700Total for HP/PC Piping 2,118 0 2,118


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1. 3 Appendix 1



4 Electrostatic Precipitator

Plates 5/6 mm 0 4,530 4,530CR Coil 1.5/1.25 mm 2,340 1,000 3,340Columns(HEA/HEB), Beams(ISMB300/400)

2,500 500 3,000

Angles(50x50x6,75x75x6,80x80x8,10x75x6)/Channels(C150,C200,C250)

0 2,560 2,560

Hollows (150 to 300) 2,450 0 2,450Total for EP 7,290 8,590 15,880

5 Main and Aux. Buildings

Plates 0 21,460 21,460 Angles 0 3,938 3,938Channels 0 4,296 4,296Joists 0 5,370 5,370Misc. Chequered Plates/Handrails etc. 0 716 716

Reinforce Steel 0 8,800 8,800Total for Main & Aux. Bldgs. 0 44,580 44,580

6 Power Transformers (CRGO)Grade-ZDKH85 0.23 thk 1,120 0 1,120Grade-ZDKH90 0.27 thk 208 0 208Total for Power Transformers 1,328 0 1,328

7 Motors

CRNGO, M530-65A, 800-1250width 300 0 300

Shaft forging (Low Alloy Steel) 0 125 125IS2062 Steel Plates 0 300 300Total for Motors 300 425 725

8 SwitchyardLattice structure 0 725 725Pipes 0 125 125Earthing Rods/Strips 0 700 700Total for Switchyard 0 1,550 1,550

9 Coal Handling Plant Angles, Beams and Channels 0 8,000 8,000


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1. 4 Appendix 1



Reinforce Steel 0 6,000 6,000Total for CHP 0 14,000 14,000

10 Turbine/Gen./Condenser 10.1 Plates :

MS Plates, 5mm to 90mm, IS20062 GR- A &GR-B

530 1480 2,010

B Q Plates, 6mm to 250 mm, IS2002GR-2

1,020 260 1,280

CS Plates, 12mm to 160mm, SA516 GR-70

20 30 50

AS Plates, 10mm to 125mm, 17MO4 &12MX

10 0 10

SS Plates/Sheets, 0.5mm to 80mm, AA10739, AA10740, HW10782 and HW10788

64 36 100

Sub- total for Plates 1,644 1,806 3,45010.2 Rounds :

CS Rounds, AA10109 and AA 10218 4 166 170

AS/SS Rounds, 36 158 194sub- total for Rounds 40 324 364

10.3 Structural Steel, IS 2062 40 100 14010.4 Bloom, Class 2 and Class 3 0 120 120

Total for Turbine/Gen/Condensers(10.1+10.2+10.3+10.4)

1,724 2,350 4,074

11 Pumps/Heat Exchangers/ Drive-Turbines and Pulverisers

11.1 LP and HP Heaters :Plates :Boiler Quality Plates, Various sizes from5mm to 200mm

140 48 188

STRU Plates, Various sizes from 5mm to200mm

0 42 42

Sub- total for plates-HP/LP Heaters 140 90 230

11.2 Deaerators :Plates :Boiler Quality Plates, Various sizes from5mm to 200mm

86 0 86

STRU Plates, Various sizes from 5mm to200mm

0 9 9


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1. 5 Appendix 1



Sub- total for plates for deaerators 86 9 95

11.3 Pulverisers :Plates : Alloy Steel Plates, Various sizes from5mm to 200mm

4 0 4

Boiler Quality Plates :CS / SS Sheets, 1mm to 4mm 10 10 20Structural Steel 0 322 322Sub-total of BQ plates for Pulveriser 10 332 342

11.4 Drive turbines :Plates : Alloy Steel Plates, Various sizes from5mm to 200mm

2 0 2

Stainless Steel Plates 0 12 12Sub- total of plates for drive turbines 2 12 14

11.5 Structurals :STRU :Flat, Various Sizes 0 2 2 Angles, Beams and Channels, VariousSizes

0 12 12

Sub- total for structurals 0 14 1411.6 Bar Stock :

CS Round, 6mm to 400mm 20 18 38 AS Round, 6mm to 400mm 5 2 7SS Round, 6mm to 400mm 0 4 4Sub- total of Bar-stock 25 24 49

11.7 Pipes : Alloy Steel Pipes, OD 16mm to 610mm,1 to 28mm thick

2 0 2

Carbon Steel Pipes, OD 16mm to610mm, 1 to 28mm thick

20 18 38

Stainless Steel Pipes, OD 16mm to610mm, 1 to 28mm thick

0 20 20

Sub- total of pipes 22 38 60Total for Pumps/Heat Exchangers/Drive Turbines and Pulverisers(11.1+11.2+11.3+11.4+11.5+11.6+11.7)

289 519 808

Grand Total (MT) 18,894 111,707 130,601


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2.1 Appendix 2

Appendix 2

Estimated Quantity of Steel for 11 th and 12 th Plan coal based projects

s.no. Equipment /System Typical Qty. for 2 x 500 MWunits as given by BHEL (MT)

Estimated Qty. for XIth Plan coalbased projects 44,000 MW

(In MT)

Estimated Qty. for XIIth Plan coalbased projects 44,500 MW

(In MT)

1 Boiler Type of steel used : Imported Indigenous Total Imported Indigenous Total Imported Indigenous Total

1.1 Drum :Pipe : (OD 88.9 to 863mm, ckness 11.13 to 130mm)Carbon Steel Pipe 7 0 7 308 0 308 312 0 312Plate : (Thickness 1.6 to 190mm)Boiler Quality Plates 421 0 421 18,524 0 18,524 18,735 0 18,735Stru Plates 0 2 2 0 88 88 0 89 89JPC Plates and Sheets 0 28 28 0 1,232 1,232 0 1,246 1,246Bar Stock : (Dia 6mm to 250mm)Round 29 0 29 1,276 0 1,276 1,291 0 1,291Sub-total for Drum 457 30 487 20,108 1,320 21,428 20,337 1,335 21,672

1.2 Structures/Non Pressure partsPipe : (OD 88.9 to 863mm, thickness 11.13 to 130mm) Alloy Steel Pipes 34 0 34 1,496 0 1,496 1,513 0 1,513Carbon Steel Pipes 413 100 513 18,172 4,400 22,572 18,379 4,450 22,829ERW Pipes 200 1,701 1,901 8,800 74,844 83,644 8,900 75,695 84,595Plate : (Thickness 1.6 to 190mm)

Alloy Steel Plates 255 0 255 11,220 0 11,220 11,348 0 11,348Boiler Quality Plates 17 0 17 748 0 748 757 0 757Stru Plates 245 245 490 10,780 10,780 21,560 10,903 10,903 21,805JPC Plates and sheets 0 17,135 17,135 0 753,940 753,940 0 762,508 762,508

Stainless Steel Pipes 0 115 115 0 5,060 5,060 0 5,118 5,118Bar Stock : (Dia 6mm to 250mm)

Round 0 214 214 0 9,416 9,416 0 9,523 9,523STRU : (Various Sizes) Angles, Beams andChannels

0 9,844 9,844 0 433,136 433,136 0 438,058 438,058

Tubes : (OD 14.2 to 76.1mm, thickness 2 to 12.5 mm)

Alloy Steel Tub

req equip material devlopment power sector

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