View
215
Download
2
Category
Preview:
Citation preview
RReeqquuiirreemmeenntt ooff EEQQUUIIPPMMEENNTT
AANNDD MMAATTEERRIIAALL FFOORR
DDEEVVEELLOOPPMMEENNTT OOFF
PPOOWWEERR SSEECCTTOORR GGeenneerraattiioonn aanndd TTrraannssmmiissssiioonn PPrroojjeeccttss ooff
1111tthh AAnndd 1122t
thh PPllaann
Government of India Ministry of Power
Central Electricity Authority Planning Wing
New Delhi November 2006
RREEQQUUIIRREEMMEENNTT OOFF
EEQQUUIIPPMMEENNTT AANNDD MMAATTEERRIIAALL FFOORR
DDEEVVEELLOOPPMMEENNTT OOFF
PPOOWWEERR SSEECCTTOORR
GGeenneerraattiioonn aanndd TTrraannssmmiissssiioonn
PPrroojjeeccttss ooff
1111tthh AAnndd 1122t
thh PPllaann
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
Contents
CONTENTS CHAPTER TITLE PAGE
Preface i
Foreword ii
Executive Summary ES-1 – ES-3
CHAPTER-1 INTRODUCTION 1.1-1.3
1.1 Background
1.2 Growth in Power Sector
1.3 Regulatory & Structural Reforms
1.4 National Electricity Policy and Plan
CHAPTER-2 GENERATION CAPACITY ADDITION
PROGRAMME
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 Plants
3.1.1 Thermal Power Plants
3.1.2 Hydro Power Plants
3.2 Requirement of Electrical Equipments for Power System
3.2.1 Estimated Requirement of electrical equipments for voltage
level 765 kV & 400 kV
3.2.2 Estimated Requirement of electrical equipments for voltage
level 220 kV & 132 kV
3.2.3 Summary of Requirement of electrical equipment for all
voltage levels( 765 kV, 400 kV, 220 kV, 132Kv)
CHAPTER-4 REQUIREMENT OF STEEL FOR 11TH AND 12TH PLAN
4.1-4.10
4.1 Steel Requirement for Generation
4.1.1 Hydro Power Plants
4.1.2 Thermal Power Plants
4.1.3 Nuclear Power Plants
4.2 Requirement of Steel for Power System
4.2.1 Requirement of Steel for tower
4.2.2 Steel Requirement & Aluminium for Conductor & Earth
wire
4.2.3 Requirement in respect of special steel – CRGO & Copper
for power transformers
4.2.4 Estimated Structural Steel Requirement for Sub-stations
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
Contents
LIST OF APPENDICES
S.NO.
TITLE PAGE
NO.
1. Typical Steel quantity for 2x500 MW unit as
given by BHEL
1.1-1.5
2. Estimated Quantity of Steel for 11th and 12
th
Plan coal based projects
2.1-2.5
3. Estimated Quantity of Steel for 11th and 12
th
Plan Gas based projects
3.1-3.4
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
i Preface
PREFACE
The size of the XI and XII Plans of the Power sector are likely to be
considerably bigger than X Plan. Consequently, the requirement of
electrical equipment and raw materials like steel would be much higher
than in previous Plans. The Sub-Group on Generation Planning of
Working Group on Power for XI Plan has recommended a capacity
addition of around 66,500 MW in XI Plan whereas for XII Plan, the
requirement has been assessed at 86,500 MW.
Such massive addition in power generation capacity would be
possible only if the power/electrical industry also suitably enhances its
manufacturing capabilities to meet this challenge. Other industries like
cement, steel and aluminum also have to augment their production
lines 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 electrical
equipment and steel is being brought out by the Central Electricity
Authority.
I am sure this booklet will be found useful by the industry sector in
planning their production capacities in the years to come.
(RAKESH NATH)
CHAIRPERSON
New Delhi
Dated 23rd November, 2006
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
ii Forward
FOREWORD
This booklet is an effort to provide a broad overview of the electrical
equipment and steel requirement during the coming years commensurate
with the power generation and transmission capacity expansion Plans. For
the successful implementation of the power expansion Plan evolved
based on the detailed studies carried out by CEA, it is essential that all the
key inputs required are made available as per the schedule of the
requirement of individual power project. The timely supply of key-inputs is
important not only in the timely completion of the project but also in
avoiding implications of cost over-runs in case the project is delayed. This
assessment would also give appropriate inputs to the manufacturers to
plan and formulate their production targets. Advance action to create
additional production capacity is also important to keep the prices of
manufactured material and equipment in check. This would ensure that
increase in demand does not lead to increase in prices due to mismatch
of demand and supply, as the power sector is highly price sensitive and
concerted efforts from all quarters need to be jointly made to ensure that
prices remain reasonable. This would be instrumental in realizing the
Government's mission of providing power to consumers at a reasonable
price.
Requirement of Electrical equipment is one of the most important
inputs for the development of the Power Sector. In this booklet, an
attempt has been made to assess the requirement of major electrical
equipment for hydro & thermal power stations during the 11th and 12th
Plans. Requirement of equipment has been assessed for different units of
coal and gas based plants i.e. coal handling unit, Ash handling unit,
cooling system etc. In case of a hydro power station, tentative steel
requirement for various Electro-Mechanical equipments/systems and for
civil works has been estimated. In addition, requirement of various
categories of steel for these plants has also been worked out.
Commensurate with the generation capacity addition, the transmission
system requirement has also been worked out and sub-station equipment
and material required has also been covered in this booklet
This book has been prepared by the officers and staff of Planning
wing, CEA with inputs from Thermal, Hydro and Power System Wings. The
various equipment manufacturers such as BHEL, have been duly consulted
for 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)
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
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 be
made to ensure that all bottlenecks are removed in the path of timely implementation of
power projects and transmission network. The Government’s Mission is to provide
quality and reliable power to all by 2012.
The Installed Generating Capacity in the country which was only 1,358 MW at
the time of Independence has reached a level of 1,27,673 MW, comprising 83,982 MW
thermal, 33,600 MW hydro, 3,900 MW nuclear and 6191 MW from wind and other
renewable energy sources. There has been corresponding growth in transmission and
distribution network too. The target set for capacity addition during the 10th
Plan was
41,110 MW. However it is expected that about 30,641 MW would come up in the 10th
Plan out of which about 17,743 MW has already been commissioned till date. As per the
tentative 11th Plan capacity addition programme about 66,463 MW capacity addition is
required during 11th
Plan and about 86,500 MW during 12th
Plan. Requirement of
electrical and mechanical equipment and other materials needs to be tied up and made
available 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 importantly
mandatory metering with stronger provisions for punishment for theft of electricity. The
publication of the National Electricity Policy in February 2005 is an important milestone
as it lays the guidelines and provides direction to the evolution of the Power Sector
within the ambit of the Electricity Act.
The Policy and the Act stipulate that CEA shall prepare the National Electricity
Plan for a short-term timeframe of five year while giving a 15-year perspective and the
various aspects to be covered shall include demand forecast for different regions,
suggested areas/ locations for capacity addition, integration of such possible locations
with transmission system and development of national grid. The National Electricity Plan
has been prepared by CEA and submitted to the Govt. 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 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 for
each individual power project. Since these are some of the major key inputs, an
assessment of the approximate requirement for the 11th
and 12th
Plan power projects will
be useful input for the manufacturers and suppliers. In this booklet a broad overview has
been provided about the requirement of electrical equipments and steel during the 11TH
AND 12TH
Plan for generation projects and for power system.
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
ES-2 Executive Summary
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, a
tentative 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 have
been categorized into five categories i.e. four categories for coal/lignite plants based on
the unit size of 660/800 MW, 500 MW, 300/250/210 MW and 125 MW, and one
category for Gas based plants. For each of the above category, norms have been drawn up
for the requirement of equipment. However in case of hydro plants no such categorization
is 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 hydro
capacity of 17,189 MW during 11th Plan and 30,000 MW during 12th Plan. Requirement
of equipment for nuclear plants has not been included in the Report but the steel
requirement for Nuclear power projects coming up in 11th
and 12th
Plans has been
estimated in this report. It is expected that the Nuclear Power Corporation of India would
separately ensure development of production capability of equipment commensurate with
their requirement during 11th and 12th Plans. However, the nuclear capacity expected in
the 11th and 12th Plans is 3,200 MW and 12,000 MW respectively which is a small
fraction 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 52
nos. 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 electrical
and mechanical components of hydro plants for a capacity addition of about 47,200
during 11th and 12th plan have been assessed. For timely implementation of projects, it is
essential to enhance production capacity to match the requirement.
3. REQUIREMENT OF ELECTRICAL EQUIPMENTS
In this Chapter, requirement of electrical equipments for hydro and thermal power
projects, 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 thermal
power plants of different unit sizes have been estimated along with their ratings. Also the
requirement of various types of switchgears, motors, cables etc. required in a thermal
plant have been considered estimated
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
ES-3 Executive Summary
The substation equipments have also been estimated as per the transmission
expansion plan for 11th and 12th Plan.
4. REQUIREMENT OF STEEL
An assessment has been made of the requirement of material specifically different
types of steel for hydro & thermal power plants and power system network planned for
11th 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 the
requirement 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 power
projects and 2 MT for Nuclear power projects will be required during 11th & 12th Plan
period. Steel requirement for different constituents of power system like towers,
conductors, earth wires, sub-stations, power transformers has also been assessed. Some
other materials like aluminium for conductors and earth wires, and copper for power
transformers have also been considered. Approximately 5.2 million MT of steel will be
required for completing the transmission expansion planned for 11th & 12th Plan. This
includes about 0.2 million MT of Special Steel- CRGO for power transformers and about
0.67 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.
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
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 country’s economy, it plays a major role in
the life of a common man and has a direct impact on the quality of life. Our economy is
growing at a rapid rate with the expected GDP growth rate likely to be over 8% in the
coming years. Adequate and quality power is essential to fuel this growth and all efforts
need to be made to ensure that all bottlenecks are removed in the path of timely
implementation of power projects and transmission network. The Government’s Mission
is 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 the
time of Independence has reached a level of 1,2,423 MW, comprising 83,982 MW
thermal, 33,350 MW hydro, 3,900 MW nuclear and 6191 MW from wind and other
renewable energy sources(As on 31.10.06). There has been corresponding growth in
transmission and distribution network too. In spite of this impressive addition in
generation, transmission and distribution capacity, growth in demand for power has
always exceeded the generation capacity augmentation. As of now the country is facing
energy shortage of 8 % and peak deficit of 12.2%.
The 16th
Electric Power Survey has forecast a demand of 1,15,705 MW for the
terminal year of 10th
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. However
depending on resources available and status of various projects, the target set for capacity
addition during the 10th
Plan was 41,110 MW. Rigorous monitoring of projects was
undertaken by MoP and CEA and the likely capacity addition during 10th
Plan is now
expected be about 30,641 MW out of which about 17,493 MW has been commissioned
till date. The 11th Plan capacity addition programme is based on this capacity
materializing during the 10th
Plan. However since equipment corresponding to this further
slippage is expected to already have been tied up, this reduction in 10th
plan capacity
addition has not been considered while working out the 11th
Plan requirement.
The peak demand in the country by the end of 11th
Plan (2011-12) is expected to
be 1,51,648 MW whereas the demand by the end of 12th
Plan (2016-17) is expected to be
2,05,333 MW as estimated by the 16th
Electric Power Survey(with diversity). Studies
carried out by CEA indicate that about 72,000 MW capacity addition is required during
11th
Plan taking into account 10th
Plan capacity addition of 30,641 MW. However,
depending upon the preparedness of various projects only about 66,000 MW capacity
addition is feasible during 11th
Plan in conventional plants by the various utilities and
IPPs. Besides, about 13,500 MW has been programmed from renewable resources as per
the 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 11th
Plan.
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
1.2 INTRODUCTION
Requirement of equipment and material for Renewable resources and Captive Generation
has 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 about
2,72,200 MW to meet the 16th
EPS demand forecasts with 3.6% inter-regional diversity.
As a result, the additional capacity requirement during 12th
Plan works out to be about
86,500 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 the
regime of ‘Business As Usual’ to a more pro-active, market oriented approach.
Significant changes have been the entry of private sector in power generation, unbundling
of the vertically integrated business of generation, transmission & distribution and
opening up of transmission & distribution sector for private participation, thus setting a
stage for the quantum jump to realize the capacity addition programme and also making
electricity 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 importantly
mandatory metering with stronger provisions for punishment for theft of electricity. The
salient features of the Electricity Act, 2003 are
1. The Central Government to prepare a National Electricity Policy and Tariff Policy
in consultation with CEA and State Governments.
2. Thrust to complete the rural electrification and provide for management of rural
distribution 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 Electricity
Authority.
5. Transmission Utility at the Central as well as State level, to be a Government
company - with responsibility for planned and coordinated development of
transmission network.
6. Provision for private licensees in transmission and entry in distribution through an
independent 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 and
obligation to supply. SERCs to frame regulations within one year regarding
phasing of open access.
9. Distribution licensees would be free to undertake generation and generating
companies would be free to take up distribution businesses.
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
1.3 INTRODUCTION
10. The formation of State Electricity Regulatory Commissions is a mandatory
requirement.
11. Provision for payment of subsidy through budget.
12. Trading, a distinct activity is being recognized with the safeguard of the
Regulatory 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 and
SERCs.
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 the
National Electricity Policy and Tariff Policy in consultation with the State Governments
and 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 important
milestone as it lays the guidelines and provides direction to the evolution of the Power
Sector within the ambit of the Electricity Act.
The main objective of the National Electricity Policy is to make electricity
accessible to all households in next five years(2010) and to facilitate demand to be fully
met by 2012. International standards in reliability and quality of Power are to be achieved
by this timeframe. At present the per capita consumption of the country is about 631
units. Even though simultaneous efforts are being made to achieve high levels of energy
efficiency through energy conservation measures, it is endeavoured to increase the per
capita consumption, which is synonymous with progress and development, to 1000 units
by 2012.
The Policy also stipulates that CEA shall prepare the National Electricity Plan for
a short-term timeframe of five year while giving a 15-year perspective and the various
aspects to be covered shall include demand forecast for different regions, suggested areas/
locations for capacity addition, integration of such possible locations with transmission
system and development of national grid.
The National Electricity Plan has been prepared by CEA and submitted to the
Govt. 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 the
11th
& 12th
Plans.
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
2.1 GENERATION CAPACITY ADDITION PROGRAMME
CHAPTER-2
GENERATION CAPACITY ADDITION PROGRAMME
The Electricity Act 2003 and the National Electricity Policy announced by the
Government in February 2005 stipulates that CEA is to prepare the National Electricity
Plan. 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, shall
be notified for reference of all Stakeholders.
The National Electricity Plan has been prepared based on detailed studies carried
out by CEA. The 10th
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. Perspective
planning has been carried out for the 11th
and 12th
Plans. As per the latest review of the
status of 10th
Plan projects the likely capacity addition is about 30,641 MW, this further
slippage shall not change the 11th
plan requirement as the equipment and material for
these projects is expected to already have been tied up.
In the National Electricity Plan a number of generation capacity expansion plans
have been worked out. These are - Desirable Scenario i.e. Scenario with no limitation on
hydro and gas based capacity, Low hydro Scenario, Limited gas Scenario, Most feasible
Scenario i.e. low hydro and limited gas scenario, 7%, 8% and 9% Energy Growth Rate
Scenarios. However in this booklet, the requirement of equipment and steel has been
worked out corresponding to the Most feasible Scenario and demand as per the 16th
EPS
Report.
In this Chapter, details of tentative capacity addition during 11th
& 12th
Plan have
been furnished. For the purpose of assessing the requirement of equipments, thermal
plants have been categorized into five categories i.e. four categories for coal/lignite plants
based on the unit size of 660/800 MW, 500 MW, 300/250/210 MW and 125 MW, and
one category for Gas based plants. For each of the above category, norms have been
drawn up for the requirement of equipment. However in case of hydro plants no such
categorization is possible as the equipment requirement is site specific and not dependant
on the capacity of the plant. Therefore equipment has been assessed in total for hydro
capacity of 17,189 MW during 11th Plan and 30,000 MW during 12th Plan. Requirement
of 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 production
capability for material and equipment commensurate with their requirement during 11th
and 12th
Plans. However the nuclear capacity expected in the 11th
and 12th
Plans is 3160
MW and 12000 MW respectively which is approx. 12 % of the total tentative capacity
addition.
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
2.2 GENERATION CAPACITY ADDITION PROGRAMME
2.1 ELEVENTH PLAN (2007-12)
During the 11th
plan, a tentative capacity addition of 66,463 MW is planned
comprising of 17,189 MW of hydro, 46,114 MW of thermal and 3,160 MW of nuclear
capacity 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 2.1
Tentative Capacity Addition Plan during 11th
Plan
(Figures in MW)
Details of number of units and projects in each category, corresponding to total thermal*
capacity addition during 11th
plan is as given in Table 2.2 below:
Table 2.2
Project wise/ Unit wise break up of total thermal capacity addition during 11th
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 MW
No. 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 Total
Hydro 17,189
Thermal
46,114
Coal/Lignite 44,000
Gas/LNG 2,114
Nuclear
3,160
Total 66,463
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
2.3 GENERATION CAPACITY ADDITION PROGRAMME
2.2 TWELFTH PLAN (2012-2017)
During the 12
th Plan, a tentative capacity addition of 86,500 MW is planned
comprising of 30,000 MW of hydro, 44,500 MW of thermal and 12,000 of nuclear
capacity. Fuel-wise break-up of the total capacity addition of 86,500 MW is given in
Table 2.3.
Table 2.3
Tentative Capacity Addition during 12th
Plan
(Figures in MW)
Details of number of units and projects in each category, corresponding to total thermal
capacity addition during 12th
plan, are as given in Table 2.4.
Table 2.4
Project wise/ Unit wise break up of total thermal capacity addition during 12th
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 Total
Hydro 30000
Thermal 44,500
Coal/Lignite 44,500
Gas/LNG NIL
Nuclear 12000
Total 86500
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
2.4 GENERATION CAPACITY ADDITION PROGRAMME
SUMMARY
In this Chapter, details of tentative capacity addition planned for the 11th
and 12th
Plans
have been furnished. Further, to facilitate assessment of requirement of equipment and
material corresponding to this capacity addition, categorization of thermal capacity has
been done. In case of thermal capacity, the details of categories and the number of units/
modules in each category tentatively planned for the 11th
and 12th
Plans have been
furnished in his Chapter. However, hydro plants have not been categorised and
assessment has been made for the total number of hydro projects. Requirement of nuclear
capacity has not been included. Corresponding to the tentative capacity addition during
11th
and 12th
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.
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
3.1 REQUIREMENT OF ELECTRICAL EQUIPMENTS
CHAPTER -3
REQUIREMENT OF ELECTRICAL EQUIPMENTS
In this Chapter, the requirement of electrical and mechanical equipments has been
assessed for power generation stations, both hydro and thermal plants, as well as for
power substations. This requirement has been worked out corresponding to the tentative
capacity addition during the 11th
and 12th
Plans.
Equipment for nuclear stations has not been considered as the same is separately
expected to be done by Nuclear Power Corporation. Also the requirement of equipments
and materials for nuclear plants is difficult to estimate which in any case is expected to be
3200 MW and 8800 MW in the 11th
and 12th
Plans respectively and therefore a small
fraction of the total tentative capacity addition.
3.1 REQUIREMENT OF ELECTRICAL EQUIPMENTS FOR GENERATION
PLANTS (INCLUDING SWITCHYARD EQUIPMENT)
The estimated requirement of electrical equipments for generation plants coming up
during the 11th
Plan and 12th
Plans has been worked out considering tentative capacity
addition identified for these Plans, details of which have been furnished in Chapter 2.
Thermal projects for commissioning during the 11th
and 12th
Plan have been categorized
in five major groups on the basis of their unit sizes. In case of thermal plants, requirement
of major electrical equipment has been worked out for one unit of each of these categories
and subsequently depending on the number of units in the respective categories, the total
requirement has been assessed for 11th
and 12th
Plans. In case of hydro units such
categorisation is not tenable since each project is site specific and therefore the total
requirement of major equipments has been worked out for the 11th
and 12th
Plan.
Switchyard equipment at the generating stations has also been included. Details of the
above 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 size
i.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 a
typical 360 MW gas module, the total requirement of electrical equipment has been
assessed. The requirement of electrical equipments for switchyards at the generating
station has also been indicated.
i) Item wise requirement of equipment for 660/800 MW category of thermal
plants during 11th
and 12th
Plans is given in Table 3.1.
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
3.2 REQUIREMENT OF ELECTRICAL EQUIPMENTS
Table-3.1
Requirement of Equipments for 660/800 Mw Coal/Lignite Based Units of 11th
Plan and 12th
Plan Capacity Addition Programme
11th
Plan 12th
Plan Total
Item
Requirement
for
One unit of
660 MW
12 Units
(6 Projects)
40 Units
(10 Projects)
52 Units
(16 Projects)
GT* 260MVA Gen V/420/√3kV
Three phase bank
3
42 130 172
ST 90/45/45 MVA 132/11.5/11.5 kV 1 12 40 52
UT 35MVA Gen V/11.5kV 2 24 80 104
ICT 200MVA 400/132kV - 6 10 16
Misc. Service Transformer - 6 10 16
20 MVA 132/34.5kV
Aux. Transformer 11/3.45kV 4 48 160 208
33kV Switchgear 8 96 320 416
11 kV Switchgear 68 816 2720 3536
3.3 kV Switchgear 84 1008 3360 4368
HT Motors 146 1752 5840 7592
LT Motors 1404 16848 56160 73008
LT Transformers 32 384 1280 1664
LT MCC Panels 350 4200 14000 18200
415 V Switchgear Panel 100 1200 4000 5200
DC Battery 5 60 200 260
Battery Charger 7 84 280 364
33 kV Single Core Cable (km) 3 36 120 156
11kV Single Core Cable (km) 21 252 840 1092
11kV Multi Core Cable (km) 24 288 960 1248
3.3 kV Single Core Cable (km) 8 96 320 416
3.3 kV Multi Core Cable (km) 12 144 480 624
1.1 kV Power Cable (km) 233 2796 9320 12116
1.1 kV Control Cable(km) 367 4404 14680 19084
Emergency 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 plants
during 11th
and 12th
Plans is given in Table 3.2.
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
3.3 REQUIREMENT OF ELECTRICAL EQUIPMENTS
Table-3.2
Requirement of Equipment for 500 MW Coal/Lignite Based Units of 11th
Plan and 12th
Plan Capacity Addition Programme
11th
Plan 12th
Plan Total
Item
Requirement
for
One unit of
500 MW
47 Units
(30 Projects)
18 Units
(10 Projects)
65 Units
(40 Projects)
GT* 200MVA Gen V/420/√3kV
Three Phase Bank 3 171 64 235
ST 80/40/40MVA
132/11.5/11.5 kV 1 47 18 65
UT 50 MVA Gen V/11.5kV 1 47 18 65
ICT 125 MVA 400/132kV - 30 10 40
Aux. Transformer 5 235 90 325
11 kV Switchgear 63 2961 1134 4095
3.3 kV Switchgear 66 3102 1188 4290
HT Motors 118 5546 2124 7670
LT Motors 1135 53345 20430 73775
LT Transformers 30 1410 540 1950
LT MCC Panels 287 13489 5166 18655
415 V Switchgear Panel 75 3525 1350 4875
DC Battery 4 188 72 260
Battery Charger 6 282 108 390
11 V Single Core Cable(km) 13 611 234 845
11 kV Multi Core Cable( km) 18 846 324 1170
3.3 kV Single Core Cable
( km) 12 564 216 780
3.3 kV Multi Core Cable (km) 8 376 144 520
1.1 kV Power Cable( km) 200 9400 3600 13000
1.1 kV Control Cable (km) 375 17625 6750 24375
Emergency DG Set
1500KVA* 1 77 28 105
* 1 no. spare GT and 1 no. spare DG have been considered for each project
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
3.4 REQUIREMENT OF ELECTRICAL EQUIPMENTS
iii) Item wise requirement of equipment for 300/250/ 210 MW category of thermal plants
during 11th
and 12th
Plans is given in Table 3.3.
Table-3.3
Requirement of Equipment for 300/250/210 MW Class Coal/Lignite Based
Units of 11th
Plan and 12th
Plan Capacity Addition Programme
11th
Plan 12th
Plan Total
Item
Requirement for
One unit of
300/250/210 MW 45 Units
(27 Projects)
14 Units
(12 Projects)
59 Units
(31 Projects)
GT* 315MVA Gen V/237kV
Three Phase 1 72 18 90
ST 55/27.5/27.5 MVA
220/6.9/6.9 kV 1 45 14 59
UT 20 MVA Gen V/6.9 kV 2 90 28 118
Misc Service Trans 10MVA
6.6/11.5 1 45 14 59
11 kV Switchgear 15 675 210 885
6.6 kV Switchgear 96 4320 1344 5664
HT Motors 93 4185 1302 5487
LT Motors 1041 46845 14574 61419
LT Transformers 26 1170 364 1534
LT MCC Panels 225 10125 3150 13275
415 V Switchgear Panel 75 3375 1050 4425
DC Battery 6 270 84 354
Battery Charger 6 270 84 354
11kV Single Core Cable( km) 2 90 28 118
11kV Multi Core Cable( km) 2 90 28 118
6.6kV Single Core Cable(km) 16 720 224 944
6.6kV Multi Core Cable( km) 16 720 224 944
1.1kV Power Cable (km) 200 9000 2800 11800
1.1 kV Control Cable(km) 400 18000 5600 23600
Emergency DG Set
1500KVA* 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 during
11th
is given in Table3.4. Requirement of 125 MW sets is nil during the 12th
Plan.
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
3.5 REQUIREMENT OF ELECTRICAL EQUIPMENTS
Table-3.4
Requirement of Equipment for 125 MW Coal/Lignite Based Units Of 11th
Plan
Capacity Addition Programme
11th
Plan
ITEM
Requirement for
One unit of 125
MW 7 Unit
( 4 Projects)
GT* 160MVA Three Phase 1 11
ST 55/27.5/27.5 MVA 1 7
UT 20MVA 2 14
Misc Service Trans 20 MVA 1 7
11 kV Switchgear 15 105
6.6 kV Switchgear 96 672
HT Motors 45 315
LT Motors 324 2268
LT Transformers 25 175
LT MCC Panels 17 119
415 V Switchgear Panel 75 525
DC Battery 6 42
Battery Charger 6 42
11kV Single Core Cable (km) 2 14
11kV Multi Core Cable (km) 2 14
6.6 kV Single Core Cable (km) 16 112
6.6 kV Multi Core Cable (km) 16 112
1.1kV Power Cable(km) 200 1400
1.1 kV Control Cable(km) 400 2800
Emergency 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 during
11th
and 12th
Plans is given in Table3.5.
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
3.6 REQUIREMENT OF ELECTRICAL EQUIPMENTS
Table-3.5
Requirement of Equipment for Gas/LNG Based Units
of 11th
Plan and 12th
Plan Capacity Addition Programme
11th
Plan
Item
Requirement
for One module
(360 MW) 9 modules
(7 projects)
Gen. Transformer
(2 nos. 114 MVA & 1 nos.146
MVA) 3 34
Unit Aux Transformer 20 MVA 2 18
HT Motors 13 117
LT Motors 36 324
LT Transformers 10 90
415 V Switchgear Panel 17 153
DC Battery 7 63
Battery Charger 11 99
Emergency DG Set 1 16
Gen. Circuit Breaker 6 54
6.6 kV Switchgear 31 279
HT Power Cable (km) 200 1800
LT Power & Control Cable (km) 500 4500
ϖι) 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 11and
12th
Plans is given in Table 3.6.
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
3.7 REQUIREMENT OF ELECTRICAL EQUIPMENTS
Table-3.6
Total Requirement of Equipment for Thermal I.E. Coal, Lignite, Gas/LNG
Based Units of 11th
Plan and 12th
Plan Capacity Addition Programme
Item
Total Requirement
for Coal/ Lignite
Based Plants
Total
Requirement
for
Gas/LNG
Based Plants Total
GT 508 34 542
ST 183 183
UT 301 18 319
ICT 56 56
Misc Service Trans 20MVA 82 82
Aux. 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 15178
DC 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
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
3.8 REQUIREMENT OF ELECTRICAL EQUIPMENTS
vii) Requirement of Switchyard equipments for different voltage levels corresponding to
the unit size of each generation project have been assessed. For projects having unit size
of 800 MW, switchyard equipments at voltage levels 765 kV and 132 kV have been
considered. Similarly, for projects having unit size of 660 MW and 500 MW, switchyard
equipments 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 projects
having unit size of 125 MW requirement of switchyard equipment has not been
considered since it would normally be at a voltage level of lesser than 132 kV.
For assessment of electrical equipments for switchyard of generating stations, 6
bays have been considered for each coal/Lignite based project, and 8 bays for each
module of gas project.
The layout of the substations has been considered according to the prevailing
practice for respective voltage levels. A Breaker and a half scheme has been assumed at
765 kV & 400 kV levels. For 220 kV level, Double main and transfer bus scheme has
been assumed. Main and transfer bus scheme has been assumed at 132 kV.
Requirement of electrical equipment (Item wise) for switchyard associated with
thermal plants during 11th
and 12th
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 )
12th Plan (9 Projects) (54 Bays )
Total (11Projects) (66 Bays )
a. Circuit beaker 3 nos. per 2 bays 18 81 99
b. Isolators 4 isolators per bay 48 216 264
c. Current Transformer
2 sets per bay 24 108 132
d. CVT/PT 1 set per line bay & 1 set per bus bar 16 72 88
e. Lightning arrestor 1 set per bay 12 54 66
f. Wave Trap 2 nos. per bay 24 108 132
B. 400 kV Switchyard Equipments- Breaker and a half scheme (For projects having unit size of 660 MW & 500 MW)
Item Requirement for one Bay
11th Plan (34 Projects) (204 Bays )
12th Plan (11
Projects) (96 Bays )
Total (53 Projects)
(318 Bays )
a. Circuit beaker 3 nos. per 2 bays 306 99 405
b. Isolators 4 isolators per bay 816 264 1080
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
3.9 REQUIREMENT OF ELECTRICAL EQUIPMENTS
c. Current Transformer
2 sets per bay 408 132 540
d. CVT/PT 1 set per line bay & 1 set per bus bar 272 88 360
e. Gapless lightning arrestor
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)
Item
Requirement for one Bay
11th Plan (36 Projects) (216 Bays )
12th Plan (20Projects) (120 Bays )
Total (66 Projects)
(336 Bays)
a. Circuit beaker 1 no. per bay 216 120 336
b. Isolators 3 isolators per bay 648 360 1008
c. Current Transformer
1 sets per bay 216 120 336
d. CVT/PT 1 set per line bay & 1 set per bus bar 324 180 504
e. Gapless lightning arrestor
1 set per bay 216 120 336
f. 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 360 MW) )
Item Requirement for one Bay
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 24 242
b. Isolators 3 isolators per bay 654 72 726
c. Current Transformer
1 sets per bay 218 24 242
d. CVT/PT 1 set per line bay & 1 set per bus bar 320 36 356
e. Gapless lightning arrestor
1 set per bay 218 24 242
f. 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 a
capacity addition of 17,189 MW during 11th
Plan and a capacity addition of about 30,000
MW during 12th
Plan. Since each hydro -plant is site specific; there is no set rule or
norms for estimation.
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
3.10 REQUIREMENT OF ELECTRICAL EQUIPMENTS
The broad basis followed in the estimation of the other components of hydro
projects for 11th
& 12th
Plan is as under.
i) Gates & Hoists: The number of radial gates roughly varies between 3 & 14
numbers depending on type of hydro scheme. Number of Gates depends on
length 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 with
ROR Scheme.
ii) Vertical Lift Gates: Vertical gift gates are normally installed for overflow
spillway, intake structures, desilting chamber outlets, surge shaft outlets, draft
tube, 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 more
compared 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 output
rating of turbine shall match unit rating.
iv) Main Inlet Valve (MIV): Generally, One MIVS in each unit is provided in
penstock except for low head HE schemes/Dam Toe HE Schemes.
v) Digital Governor: One set of Digital Governor with accessories is provided for
each 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 is
considered for each Generating Unit.
viii) Dynamic Braking Equipment: Dynamic braking equipment is generally
provided with large hydro generating units with high speed machines. The
number has been estimated accordingly.
ix) Unit Control Board (UCB): One set of UCB is considered with each generating
unit.
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. The
estimation is based on experience.
xi) 11kV/13.8kV/24kV CT’s: Number of CT’s depends on protection and metering
scheme of particular plant, however, for estimation purposes 10 to 19 CT'’ per
phase per unit has been considered depending on unit size.
xii) Neutral Grounding Cubicle: One set of Neutral grounding cubicle is considered
for each generating unit.
xiii) 132kV/220kV/400kV Generator Transformers: The MVA Generator
transformer rating is normally taken as 110% of generator rating, the same has
been considered in estimation.
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
3.11 REQUIREMENT OF ELECTRICAL EQUIPMENTS
xiv) Unit and Line Protection Panels: One set of protection panels are considered
each for Generating Units, Bus-bar, outgoing feeder, EHV cable / bus-duct,
Reactors etc.
xv) Computerized Control System (CCS): One set of CCS equipment has been
considered for each hydro station.
xvi) Air Insulated Switchgear and Gas Insulated Switchgear: GIS has been
considered for under-ground 220kV / 400kV switchyard, while conventional
outdoor switchyard for surface / semi underground schemes.
xvii) EOT Cranes: The total installed tonnage capacity of EOT cranes is based on
broad estimation of stator and rotor weights, though these weights may vary
drastically even for machines of similar rating.
xviii) EHV, XLPE cables, EHV Bus Duct: The cable requirement depends on layout
of power house and varies from scheme to scheme. The estimation is based on
experience.
xix) Unit Auxiliary and Station Service Transformers: The total capacity of unit
and station auxiliary transformers has been considered as 1.2% of installed
capacity.
xx) 11kV Switchgear Board: The 11kV switchgear boards vary from station to
station depending on 11kV scheme. However for estimation purposes two LT
boards per unit has been considered.
xxi) Power and Control Cables: There is no set rule for estimating power and
control cable lengths as it depends on layout and control philosophy. The
estimation is based on experience.
xxii) 110V/220V DC System (Batteries, Charger and DCDB): The battery capacity
varies between 400AH to 1800AH, and battery chargers from 2 to 4 numbers
depending on number of units and total installed capacity.
xxiii) Grounding System: The total tonnage of grounding material vary from station to
station 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 to
2000KVA depending on requirements worked out during detailed engineering.
xxv) Illumination System, Fire Protection System, Service Water System, Oil
Handling and Purification System, Ventilation System, Air Conditioning
System, Lifts, Communication System and Miscellaneous items like Video
Camera, Silt Monitoring System, GPS System, Special Cables like OPGW
etc.: These systems are provided in power plant as per requirement.
Details of the various equipments are as follows:
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
3.12 REQUIREMENT OF ELECTRICAL EQUIPMENTS
Table-3.8
Total Requirement of Equipment for Hydro Projects
of 11th Plan and 12th Plan Capacity Addition Programme
No. Equipment 11th
Plan (17,189 MW)
12th
Plan (30,000 MW)
Total
Hydro-Mechanical
Gates & Hoist (sets)
(i) Radial spillway Gates 276 482 757
1.
(ii) Vertical Lift Gates 403 704 1107
2 Butterfly Valve (Sets) 31 54 85
3 Main Inlet Valve (Sets) 115 200 315
Electro-Mechanical
4 Turbine (MW) 17189 30000 47,189
5 Turbine (No.) 199 350 549
6 Digital Governors (Nos.) 199 350 549
7 Syn. Generator (MVA) 18908 32999 51,907
8 Syn. Generator(No.) 199 350 549
9 Unit Control Board (sets) 199 350 549
10 Motor & Motor Control Centres
(Units) 1366 2384 3,750
11 Transformers (UAT & SST) (MVA) 228 398 627
12 Static Excitation System (Sets) 199 350 549
13 Dynamic Braking Isolators (Sets) 60 105 165
14 NG cubicle incl.
Transformer (Set) 199 350 549
15 11/13.8 kV/24kV Isolated Phase
Bus Ducts (IPBD) (metres) 38367 66962 105,328
16 11/13.8/24 kV CTs
( 1-Phase Units) 9208 16072 25,280
17 SAVT Cubicle (Sets) 199 350 549
18 132kV/220kV/400 kV Generator
Transformer (MVA) 21026 36697 57,723
19 11kV Switchgear Boards (Units) 207 361 568
132kV/220kV/400 kV Outdoor switchgear (Units)
Circuit breaker
476 831 1307
Capacitor voltage
transformer(CVT) 323 565 888
EHV Voltage Transformers
161 281 443
Lighting Arresters(LA)
967 1687 2654
Isolators
497 868 1365
20
EHV Current Transformers 1128 1968 3096
21 415 V Switchgear Board Units 555 968 1523 22 220/400 kV GIS (Bays)
134 234 368
23 EHV XLPE Cable (Km)
42 73 115
24 EHV Bus Duct (Km) 18 32 51
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
3.13 REQUIREMENT OF ELECTRICAL EQUIPMENTS
3.2 REQUIREMENT OF ELECTRICAL EQUIPMENTS FOR POWER
SYSTEM
The requirement of electrical requirement for power system has been estimated
based on the transmission expansion plans corresponding to tentative capacity addition
during the 11th
Plan. In case of 12th
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 lines
at respective voltage levels and details of substation requirement for the entire
transmission system. Based on the number of substations and the voltage levels at each
substation, the total number of bays at each voltage level has been estimated as shown
below in the table 3.9.
Table 3.9
Total Number of Bays at each Voltage Level
No. of Bays S.N
o.
Voltage
Level 11th
Plan 12th
Plan Total
1. 765 kV 62 62 124
2. 400kV 774 774 1548
3. 220kV 3060 3060 6120
4. 132kV 7280 7280 14560
The layout of the substations has been considered according to the prevailing
practice for respective voltage levels. Breaker and half scheme has been assumed at 765
kV & 400 kV level. For 220 kV level, Double main and transfer bus scheme has been
assumed. Main and transfer bus scheme has been assumed at 132 kV
Based on the substation layout schemes for each voltage level as detailed above, the
normative requirement of substation equipment for each bay corresponding to each
voltage level have been evolved. The total requirement of substation equipment has been
assessed based on these norms. Details of the same are as furnished in the following
paras.
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
3.14 REQUIREMENT OF ELECTRICAL EQUIPMENTS
3.2.1 Estimated Requirement of Electrical Equipment for Voltage Level 765 kV &
400 kV
The estimated requirement of electrical equipments for the transmission expansion
planned for voltage levels 765 kV & 400 kV for 11th
and 12th
Plan is given below in the
Table 3.10.
Table-3.10
Estimated Requirement of Electrical Equipment for Voltage Level 765 kV & 400
kV
765 kV 400 kV
11th
Plan
(2007-
2012)
12th
Plan
(2012-
2017)
11th
Plan
(2007-
2012)
12th
Plan
(2012-
2017)
NORMS
Total Nos.
NORMS
Total Nos.
Total No. of
Bays 62 62 774 774
Circuit Breaker 3 nos. per 2
bays 93 93
3 nos. per 2
bays 1161 1161
Isolator 4 isolators
per bay 248 248
4 isolators
per bay 3096 3096
CT 2 sets per/
bay 124 124
2 sets per
bay 1548 1548
PT/CVT
1 set per line
bay & 1 set
per bus bar
71 71
1 set per line
bay & 1 set
per bus bar
890 890
0
Lightening
Arrestor 1 set per bay 62 62 1 set per bay 774 774
Wave Trap 2 nos. per
bay 124 124
2 nos. per
bay 1548 1548
Note: 1 set = 3 single phase units
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
3.15 REQUIREMENT OF ELECTRICAL EQUIPMENTS
3.2.2 Estimated Requirement of Electrical Equipment for Voltage Level 220 kV &
132 kV
The estimated requirement of electrical equipments for the transmission expansion
planned for voltage levels 220 kV & 132 kV for 11th
and 12th
Plan is given below in the
following table 3.11 .
Table-3.11
Estimated Requirement of Electrical Equipment for Voltage Level 220 kV & 132 kV
for 11th
and 12th
Plan
Note: 1 set = 3 single phase units
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 11th
& 12th
Plan is
summarized in Table 3.12.
220 kV 132 kV
11th Plan
(2007-
2012)
12th Plan
(2012-
2017)
11th Plan
(2007-
2012)
12th
Plan
(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 isolators
per bay
12240 12240 3 isolators per
bay
21840 21840
CT 1 set per bay 3060 3060
1 set per bay 7280 7280
PT/CVT 1 set per line
bay & 1 set
per bus bar
3060 3060
1 set per line
bay & 1 set
per bus bar
7280 7280
LA 1 set per bay 3060 3060
1 set per bay 7280 7280
Wave
Trap
2 nos. per
bay
6120 6120
2 nos. per bay 14560 14560
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
3.16 REQUIREMENT OF ELECTRICAL EQUIPMENTS
Table 3.12
Total Electrical Equipment for Power System
S.No. Item
11th
Plan 12th
Plan Total
1. Circuit
Breaker 11594 11594 23188
2. Isolator 37424 37424 74848
3. CT 12012 12012 24024
4. PT/CVT 11301 11301 22602
5. Lightening
Arrestor 11176 11176 22352
6. Wave Trap 22352 22352 44704
While assessing the above requirement, Breaker and Half scheme has been
considered for 765 kV & 400 kV level. For 220 kV level, Double Main and Transfer bus
scheme has been considered and for 132 kV, Main and Transfer Bus scheme has been
considered.
SUMMARY
In this Chapter, requirement of electrical equipments for hydro and thermal power
projects, along with the corresponding switchyard equipments for different voltage levels,
coming up during the 11th
& 12th
Plan have been assessed based on certain norms. The
substation equipments have also been estimated as per the transmission expansion plan
for 11th
and 12th
Plan.
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
4. 1 REQUIREMENT OF STEEL FOR 11TH AND 12TH PLANS
CHAPTER –4
REQUIREMENT OF STEEL FOR 11TH
AND 12TH
PLAN
In this Chapter, an assessment has been made of the requirement of material
specifically different types of steel for hydro & thermal power plants and power system
network planned for 11th
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 the requirement of copper and aluminium required for transmission lines.
These details shall provide valuable inputs for equipment and material manufacturers and
guide 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, pulveriser
etc has been estimated.
For a hydro power plant, estimation has been done for steel requirement in civil
works as well as electro mechanical equipments/systems in the power house.
Transmission system requirement corresponding to the planned generation
capacity addition has also been worked out. Material requirement for this transmission
system, including generation switchyard, substation and transmission lines, including
towers, 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 been
formulated based on details furnished by NHPC and BHEL of actual project setup. These
norms include steel requirement for Electrical & Mechanical package (Turbine &
Generator) as well as for civil works. Norms are as given below:
Table 4.1
Tonnes/MW
Steel Norms
Structural Steel 34
Reinforcement Steel 93
Based on the above average requirement per MW, the steel requirement for the 11th
Plan
Hydro projects works out to be given as under:
Table 4.2
Lakhs Tonnes
Steel 11th
Plan (17189 MW) 12th
Plan (30000 MW) Total
Structural Steel 5.8 10.2 16.0
Reinforcement Steel 16.0 27.9 43.9
Total 21.8 38.1 59.9
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
4. 2 REQUIREMENT OF STEEL FOR 11TH AND 12TH PLANS
4.1.2 Thermal Power Plants
Requirement of steel (Imported & Indigenous ) for thermal power projects coming
up in 11th
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 out
and based on this per MW norm, the requirement of steel for the total coal based thermal
capacity has been assessed. For gas based projects, norms for steel requirement per MW
have been assumed to be 50% of coal based project for the applicable items as has been
noted 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 not
been considered.
During 11th
Plan, total thermal capacity addition planned is 46,114 MW
comprising of about 44,000 MW of coal/lignite based plants and 2114 MW of gas based
plants. Similarly for 12th
Plan, thermal capacity addition planned is 44,500 MW.
Details of steel requirement for different equipments/ systems for the 11th
and 12th
Plan coal based thermal projects are furnished in Table 4.3.
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
4. 3 REQUIREMENT OF STEEL FOR 11TH AND 12TH PLANS
Table 4.3
Estimated Quantity of Steel for 11th
and 12th
Plan coal/ lignite Based Projects
Sl.No. Equipment/
System
11th
Plan coal based – 44,000 MW
(MT)
12th
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 21672
1.2 Structures/Non-Pressure
parts 54912 1312916 1367828 55536 1327836 1383372
1.3 Pressure Parts 182160 196196 378356 184230 198426 382656
Total (Boiler) 257180 1510432 1767612 260103 1527596 1787699
2 Low Pressure Piping 0 236060 236060 0 238743 238743
3 High Pressure/PC piping 93192 0 93192 94251 0 94251
4 Electrostatic Precipitator 320760 377960 698720 324405 382255 706660
5 Main and Aux.Buildings 0 1961520 1961520 0 1983810 1983810
6 PowerTransformers
(CRGO) 58432 0 58432 59096 0 59096
7 Motors 13200 18700 31900 13350 18913 32263
8 Switchyard 0 68200 68200 0 68975 68975
9 Coal Handling Plant 0 616000 616000 0 623000 623000
10 Turbine/Gen./Condenser
10.1 Plates 72336 79464 151800 73158 80367 153525
10.2 Rounds 1760 14256 16016 1780 14418 16198
10.3 Structural Steel, IS 2062 1760 4400 6160 1780 4450 6230
10.4 Bloom,Class2 & Class 3 0 5280 5280 0 5340 5340
Total(Turbine/generator/condenser 75856 103400 179256 76718 104575 181293
11 Pumps/Heat Exchangers/Drive-Turbines and Pulverisers
11.1 LP and HP Heaters 6160 3960 10120 6230 4005 10235
11.2 Deaerators 3784 396 4180 3827 401 4228
11.3 Pulverisers 616 14608 15224 623 14774 15397
11.4 Drive Turbines 88 528 616 89 534 623
11.5 Structurals 0 616 616 0 623 623
11.6 Bar Stock 1100 1056 2156 1113 1068 2181
11.7 Pipes 968 1672 2640 979 1691 2670
Sub 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 11th
and 12th
plan coal based projects is given in
Appendix 2.
Details of steel requirement for different equipments/ systems for the 11th
and 12th
Plan Gas based thermal projects are furnished in Table 4.4
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
4. 4 REQUIREMENT OF STEEL FOR 11TH AND 12TH PLANS
Table 4.4
Estimated Quantity of Steel for 11th
Plan Gas Based Projects
Sl.
No
Equipment/
Systm
11th
Plan Gas- 2114 MW (MT)
Type of steel used
Imported Indigenous Total
1. Boiler
1.1 Drum: 483 32 515
1.2 Structures/Non-
Pressure parts 1319 31540 32859
1.3 Sub-total for Pressure
Parts 4376 4713 9089
Total(Boiler) 6178 36285 42463
2. LP Piping 0 5671 5671
3. HP/PC Piping 2239 0 2239
4. Main and
Aux.Buildings 0 47121 47121
5. Power Transformers
(CRGO) 2807 0 2807
6. Motors 317 449 766
7. Switchyard 0 3277 3277
8. Turbine/Gen./Condenser
8.1 Plates 1738 1909 3647
8.2 Rounds 42 342 385
8.3 Structural Steel, IS
2062 42 106 148
8.4 Bloom,Class2 &
Class 3 0 127 127
Total(Turbine/gen/c
ondenser) 1822 2484 4306
9 Pumps/Heat Exchangers/Drive-Turbines and Pulverisers
9.1 LP and HP Heaters 148 95 243
9.2 Deaerators 91 10 100
9.3 Drive Turbines 2 13 15
9.4 Structurals 0 15 15
9.5 Bar Stock 26 25 51
9.6 Pipes 23 40 63
Sub Total(Pumps) 291 198 488
Grand Total (MT) 13654 95484 109138
The detailed steel requirement for 11th
plan Gas based projects is given in
Appendix 3.
A Summary of the total steel requirement for thermal projects coming up in 11
th &
12th
Plan is furnished in Table 4.5 below:
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
4. 5 REQUIREMENT OF STEEL FOR 11TH AND 12TH PLANS
Table- 4.5
Summary of Total Steel Requirement for 11th
&12th
Plan Thermal Power Projects
11th
Plan
(MT)
12th
Plan
(MT)
Total
(MT)
Coal Based Power
Projects 57,46,444 58,11,745
1,15,58,189
Gas Based Power
Projects 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 to
be 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 12th
Plan.
4.1.3 Nuclear Power Projects
Assessment of steel for Nuclear Power Plants is based on requirement of steel for coal
based 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 the
effect of these two factors approximately equal, the norms for the steel requirement for
nuclear 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 765
kV, 400 kV, 220kV and 132kVand below are to be added to the existing power grid during
the 11th
and 12th
Plans. Steel requirement for Towers, conductors, earth wires, power
transformers and sub-stations is calculated as per the design norms for different
transmission voltage levels.
Imported Steel Indigenous Steel Total Steel
11th
Plan
(3160 MW)
0.6 3.5 4.1
12th
Plan
(12000 MW)
2.3 13.4 15.7
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
4. 6 REQUIREMENT OF STEEL FOR 11TH AND 12TH PLANS
4.2.1 Requirement of Steel for Tower for 11th
And 12th
Plan
As per the Transmission plans, the number of circuit kMs of transmission lines at
various voltage levels has been estimated. Based on Statistics, norms for steel
requirement 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 voltage
levels. The requirement of steel is then assessed based on the total circuit kms expected in
each Plan. Details of norms for steel requirement as well as total requirement during 11th
and 12th
Plans for each voltage level along with the type of steels used i.e. MS & HTS.are
furnished in Table 4.6.
Table-4.7
Requirement of Steel for Towers
Total All India
(11th
Plan)
Total All India
(12th
Plan) Type of Steel used
S.No
Line
Voltage
(kV)
Norms for
weight of
steel for
Towers
MT/Km
ckt.
Km
Total
Weight of
steel for
towers
(MT)
ckt.
Km
Total
Weight of
steel for
towers
(MT)
MS
(MT)
HTS (40%
of Total
weight)
(MT)
1 765 65 3200 208000 3200 208000 249600 166400
2 500
HVDC 38.3 5400 206820 5400 206820
248184 165456
3 400 23.5 44440 1044340 44440 1044340 1253208 835472
4 220 10.1 23000 232300 23000 232300 464600
5 132 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 other
equivalent or superior International Standards will be used in the fabrication of the towers
having 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 to
IS: 8500 -1992.
4.2.2 Requirement of Aluminium and Steel for Conductor and Earth
Wire for 11th
and 12th
Plan
A. Requirement of Aluminium and Steel for Conductor and Earth Wire for 11th
Plan
The requirement of Aluminium and Steel for conductor and earth wires has been
assessed based on norms in terms of MT per ckt kM at each voltage level and the total
number of ckt kMs planned during the 11th
and 12th
Plans. Tables 4.8 and 4.9 furnish the
requirement of aluminium & steel for the conductor and earth wire for the 11th
and 12th
Plans respectively.
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
4. 7 REQUIREMENT OF STEEL FOR 11TH AND 12TH PLANS
Table-4.8
Requirement of Aluminium and Steel for Conductor and Earth Wire for 11th
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 Steel
1 765 23.14 4.64 3200 74048 14848
2 500 (HVDC) 15.43 3.50 5400 83322 18900
3 400 8.87 4.53 44440 394183 201313
4 220 3.60 1.79 23000 82800 41170
5 132 1.78 1.64 20000 35600 32800
6 Total 669953 309031
B. Requirement of Aluminium and Steel for Conductor and Earth Wire for 12th
Plan
Table 4.9 shows the requirement of aluminium & steel for the conductor and earth wire
for the 11th
Plan
Table-4.9
Requirement of Aluminium and Steel for Conductor and Earth Wire for 12th
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 Steel
1 765 23.14 4.64 3200 74048 14848
2 500 (HVDC) 15.43 3.50 5400 83322 18900
3 400 8.87 4.53 44440 394183 201313
4 220 3.60 1.79 23000 82800 41170
5 132 1.78 1.64 20000 35600 32800
6 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 amendments
respectively 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 Transformers
during 11th
And 12th
Plan
An assessment of the requirement of special steel and copper for power
transformers is made based on Norms evolved based on Statistics. As per these norms, the
requirement in terms of MT per MVA is specified as furnished in Table 4.10 below:
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
4. 8 REQUIREMENT OF STEEL FOR 11TH AND 12TH PLANS
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 the
Norms and the power transformer capacity at each voltage level planned during the 11th
and
12th
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)
Power
Transformer
Rating Total
MVA
Capacity
CRGO
WT
(inTons)
Copper WT
(inTons)
Total
MVA
Capacity
CRGO
WT
(in Tons)
Copper WT
(in Tons)
765 kV 12500 5000 2500 12500 5000 2500
400 kV 44310 17724 8862 44310 17724 8862
220 kV 73700 36850 22110 73700 36850 22110
132 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 101174
Total required Copper weight (in Tons) for 11th Plan 59472
Total required Copper weight (in Tons) for 12th Plan 59472
4.2.4 Estimated Structural Steel Requirement for Substations for 11th
and 12th
Plan
The requirement of Structural Steel for substations has been assessed based on norms in
terms of MT per bay at each voltage level and the total number of bays planned during
the 11th
and 12th
Plans at each voltage level. The total requirement during the 11th
and 12th
Plan at each voltage level is furnished in Table 4.12:
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
4. 9 REQUIREMENT OF STEEL FOR 11TH AND 12TH PLANS
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-4.13
Summary of Requirement of Steel for Power System
11th
Plan
(MT)
12th
Plan
(MT)
Total
(MT)
Steel for Tower 1873460 1873460 3746920
Steel for conductor & Earth Wire 309031 309031 618062
Special Steel -CRGO for Power
Transformer 1,01,174 1,01,174 202348
Structural Steel for Sub-Stations 3,32,450 3,32,450 664900
Total 2616115 2616115 5232230
SUMMARY
In this Chapter, an assessment of the requirement of Steel for hydro and thermal
Power stations has been made in accordance with the capacities planned during these
plans. For hydro stations, requirement has been assessed separately for structural steel and
reinforcement 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 Million
Tonnes during 11th and 11.2 Million Tons during 12th plan has been assessed. For major
components of Power system including substations, towers and transmission lines a total
requirement of 2.6 Million tonnes for 11th
and 12th Plan each, has been assessed.
Steel requirement for 11th
& 12th
Plan projects is summarised below-
In Lakh Tonnes
11th
Plan
12th
Plan
Total
Hydro Projects 21.8 38.1 59.9
Thermal Projects 58.5 58.1 116.6
Nuclear 4.1 15.7 19.8
Power System 26.2 26.2 52.4
Total 110.6 138.1 248.7
11th
Plan 12th
Plan
Voltage
level
Norms for
Special steel
requirement
for substation
(MT/bay)
Total No.
of Bays
Requirement
(MT)
Total
No. of
Bays
Requirement
(MT)
Total
Requirement
of Special steel
for substation
(MT)
765 kV 75 62 4650 62 4650 9300
400 kV 50 774 38700 774 38700 77400
220kV 35 3060 107100 3060 107100 214200
132 kV 25 7280 182000 7280 182000 364000
Total 332450 332450 664900
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
4. 10 REQUIREMENT OF STEEL FOR 11TH AND 12TH PLANS
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
1.1 Appendix 1
Appendix-1
Typical Steel quantity for 2x500 MW Thermal unit as given by
BHEL
S. No. Equipment /System Typical Qty. for 2 x 500 MW units as given by 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 7
Plate : (Thickness 1.6 to 190mm)
Boiler Quality Plates 421 0 421
Stru Plates 0 2 2
JPC Plates and Sheets 0 28 28
Bar Stock : (Dia 6mm to 250mm)
Round 29 0 29
Sub-total for Drum 457 30 487
1.2 Structures/Non Pressure parts
Pipe : (OD 88.9 to 863mm, thickness 11.13 to 130mm)
Alloy Steel Pipes 34 0 34
Carbon Steel Pipes 413 100 513
ERW Pipes 200 1,701 1,901
Plate : (Thickness 1.6 to 190mm)
Alloy Steel Plates 255 0 255
Boiler Quality Plates 17 0 17
Stru Plates 245 245 490
JPC Plates and sheets 0 17,135 17,135
Stainless Steel Pipes 0 115 115
Bar Stock : (Dia 6mm to 250mm)
Round 0 214 214
STRU : (Various Sizes)
Angles, Beams and Channels 0 9,844 9,844
Tubes : (OD 14.2 to 76.1mm, thickness 2 to 12.5 mm)
Alloy Steel Tubes 18 0 18
Carbon Steel Tubes 66 67 133
ERW Tubes 0 415 415
Stainless Steel Tubes 0 3 3
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
1.2 Appendix 1
S. No. Equipment /System Typical Qty. for 2 x 500 MW units as given by BHEL (MT)
Type of steel used : Imported Indigenous Total
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 0 228
Carbon Steel Pipes 500 146 646
Plate : (Thickness 1.6 to 190mm)
Alloy Steel Plates 462 0 462
Boiler Quality Plates 434 0 434
JPC Plates and Sheets 0 982 982
Stainless Steel Plates 0 117 117
Bar Stock : (Dia 6mm to 250mm)
Round 0 300 300
STRU : (Various Sizes)
FLAT 134 0 134
Angles, Beams and Channels 0 532 532
Tubes : (OD 14.2 to 76.1mm, thickness 2 to 12.5 mm)
Alloy Steel Tubes 951 951 1,902
Carbon Steel Tubes 1,330 1,330 2,660
Stainless Steel Tubes 101 101 202
Sub-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 4,194
IS 1239 0 655 655
IS 1239 (GAL) 0 263 263
SS 0 253 253
Total for LP Piping 0 5,365 5,365
3 HP critical/PC piping
SA335P91 372 0 372
SA335P22 1,046 0 1,046
SA106GRC 700 0 700
Total for HP/PC Piping 2,118 0 2,118
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
1.3 Appendix 1
S. No. Equipment /System Typical Qty. for 2 x 500 MW units as given by BHEL (MT)
Type of steel used : Imported Indigenous Total
4 Electrostatic Precipitator
Plates 5/6 mm 0 4,530 4,530
CR Coil 1.5/1.25 mm 2,340 1,000 3,340
Columns(HEA/HEB), Beams(ISMB 300/400)
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 2,450
Total for EP 7,290 8,590 15,880
5 Main and Aux. Buildings
Plates 0 21,460 21,460
Angles 0 3,938 3,938
Channels 0 4,296 4,296
Joists 0 5,370 5,370
Misc. Chequered Plates/Handrails etc. 0 716 716
Reinforce Steel 0 8,800 8,800
Total for Main & Aux. Bldgs. 0 44,580 44,580
6 Power Transformers (CRGO)
Grade-ZDKH85 0.23 thk 1,120 0 1,120
Grade-ZDKH90 0.27 thk 208 0 208
Total for Power Transformers 1,328 0 1,328
7 Motors
CRNGO, M530-65A, 800-1250width 300 0 300
Shaft forging (Low Alloy Steel) 0 125 125
IS2062 Steel Plates 0 300 300
Total for Motors 300 425 725
8 Switchyard
Lattice structure 0 725 725
Pipes 0 125 125
Earthing Rods/Strips 0 700 700
Total for Switchyard 0 1,550 1,550
9 Coal Handling Plant
Angles, Beams and Channels 0 8,000 8,000
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
1.4 Appendix 1
S. No. Equipment /System Typical Qty. for 2 x 500 MW units as given by BHEL (MT)
Type of steel used : Imported Indigenous Total
Reinforce Steel 0 6,000 6,000
Total 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, IS2002 GR-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 HW 10788
64 36 100
Sub- total for Plates 1,644 1,806 3,450
10.2 Rounds :
CS Rounds, AA10109 and AA 10218 4 166 170
AS/SS Rounds, 36 158 194
sub- total for Rounds 40 324 364
10.3 Structural Steel, IS 2062 40 100 140
10.4 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 from 5mm to 200mm
140 48 188
STRU Plates, Various sizes from 5mm to 200mm
0 42 42
Sub- total for plates-HP/LP Heaters 140 90 230
11.2 Deaerators :
Plates :
Boiler Quality Plates, Various sizes from 5mm to 200mm
86 0 86
STRU Plates, Various sizes from 5mm to 200mm
0 9 9
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
1.5 Appendix 1
S. No. Equipment /System Typical Qty. for 2 x 500 MW units as given by BHEL (MT)
Type of steel used : Imported Indigenous Total
Sub- total for plates for deaerators 86 9 95
11.3 Pulverisers :
Plates :
Alloy Steel Plates, Various sizes from 5mm to 200mm
4 0 4
Boiler Quality Plates :
CS / SS Sheets, 1mm to 4mm 10 10 20
Structural Steel 0 322 322
Sub-total of BQ plates for Pulveriser 10 332 342
11.4 Drive turbines :
Plates :
Alloy Steel Plates, Various sizes from 5mm to 200mm
2 0 2
Stainless Steel Plates 0 12 12
Sub- total of plates for drive turbines 2 12 14
11.5 Structurals :
STRU :
Flat, Various Sizes 0 2 2
Angles, Beams and Channels, Various Sizes
0 12 12
Sub- total for structurals 0 14 14
11.6 Bar Stock :
CS Round, 6mm to 400mm 20 18 38
AS Round, 6mm to 400mm 5 2 7
SS Round, 6mm to 400mm 0 4 4
Sub- 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 to 610mm, 1 to 28mm thick
20 18 38
Stainless Steel Pipes, OD 16mm to 610mm, 1 to 28mm thick
0 20 20
Sub- total of pipes 22 38 60
Total 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
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
2.1 Appendix 2
Appendix 2
Estimated Quantity of Steel for 11th
and 12th
Plan coal based projects
s.no. Equipment /System Typical Qty. for 2 x 500 MW units as given by BHEL (MT)
Estimated Qty. for XIth Plan coal based projects 44,000 MW
(In MT)
Estimated Qty. for XIIth Plan coal based 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 0 312 Plate : (Thickness 1.6 to 190mm) Boiler Quality Plates 421 0 421 18,524 0 18,524 18,735 0 18,735
Stru Plates 0 2 2 0 88 88 0 89 89 JPC Plates and Sheets 0 28 28 0 1,232 1,232 0 1,246 1,246
Bar Stock : (Dia 6mm to 250mm) Round 29 0 29 1,276 0 1,276 1,291 0 1,291
Sub-total for Drum 457 30 487 20,108 1,320 21,428 20,337 1,335 21,672 1.2 Structures/Non Pressure parts Pipe : (OD 88.9 to 863mm, thickness 11.13 to 130mm) Alloy Steel Pipes 34 0 34 1,496 0 1,496 1,513 0 1,513
Carbon Steel Pipes 413 100 513 18,172 4,400 22,572 18,379 4,450 22,829
ERW Pipes 200 1,701 1,901 8,800 74,844 83,644 8,900 75,695 84,595 Plate : (Thickness 1.6 to 190mm)
Alloy Steel Plates 255 0 255 11,220 0 11,220 11,348 0 11,348
Boiler Quality Plates 17 0 17 748 0 748 757 0 757 Stru Plates 245 245 490 10,780 10,780 21,560 10,903 10,903 21,805
JPC 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 5,118 Bar Stock : (Dia 6mm to 250mm)
Round 0 214 214 0 9,416 9,416 0 9,523 9,523
STRU : (Various Sizes)
Angles, Beams and Channels
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 Tubes 18 0 18 792 0 792 801 0 801
Carbon Steel Tubes 66 67 133 2,904 2,948 5,852 2,937 2,982 5,919 ERW Tubes 0 415 415 0 18,260 18,260 0 18,468 18,468
Stainless Steel Tubes 0 3 3 0 132 132 0 134 134 Sub- total for Structures /
Non- Pressure parts : 1,248 29,839 31,087 54,912 1,312,916 1,367,828 55,536 1,327,836 1,383,372
1.3 Pressure Parts : Pipe : (OD 88.9 to 863mm, thickness 11.13 to 130mm) Alloy Steel Pipes 228 0 228 10,032 0 10,032 10,146 0 10,146
Carbon Steel Pipes 500 146 646 22,000 6,424 28,424 22,250 6,497 28,747
Plate : (Thickness 1.6 to 190mm)
Alloy Steel Plates 462 0 462 20,328 0 20,328 20,559 0 20,559
Boiler Quality Plates 434 0 434 19,096 0 19,096 19,313 0 19,313
JPC Plates and Sheets 0 982 982 0 43,208 43,208 0 43,699 43,699
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
2.2 Appendix 2
s.no. Equipment /System Typical Qty. for 2 x 500 MW units as given by BHEL (MT)
Estimated Qty. for XIth Plan coal based projects 44,000 MW
(In MT)
Estimated Qty. for XIIth Plan coal based projects 44,500 MW
(In MT)
Stainless Steel Plates 0 117 117 0 5,148 5,148 0 5,207 5,207 Bar Stock : (Dia 6mm to 250mm)
Round 0 300 300 0 13,200 13,200 0 13,350 13,350
STRU : (Various Sizes) FLAT 134 0 134 5,896 0 5,896 5,963 0 5,963
Angles, Beams and Channels
0 532 532 0 23,408 23,408 0 23,674 23,674
Tubes : (OD 14.2 to 76.1mm, thickness 2 to 12.5 mm)
Alloy Steel Tubes 951 951 1,902 41,844 41,844 83,688 42,320 42,320 84,639
Carbon Steel Tubes 1,330 1,330 2,660 58,520 58,520 117,040 59,185 59,185 118,370 Stainless Steel Tubes 101 101 202 4,444 4,444 8,888 4,495 4,495 8,989
Sub-total for Pressure Parts
4,140 4,459 8,599 182,160 196,196 378,356 184,230 198,426 382,656
Total Qty. for Boiler (1.1+1.2+1.3)
5,845 34,328 40,173 257,180 1,510,432 1,767,612 260,103 1,527,596 1,787,699
2 LP piping
IS 3589 0 4,194 4,194 0 184,536 184,536 0 186,633 186,633
IS 1239 0 655 655 0 28,820 28,820 0 29,148 29,148 IS 1239 (GAL) 0 263 263 0 11,572 11,572 0 11,704 11,704
SS 0 253 253 0 11,132 11,132 0 11,259 11,259
Total for LP Piping 0 5,365 5,365 0 236,060 236,060 0 238,743 238,743 3 HP critical/PC piping
SA335P91 372 0 372 16,368 0 16,368 16,554 0 16,554
SA335P22 1,046 0 1,046 46,024 0 46,024 46,547 0 46,547
SA106GRC 700 0 700 30,800 0 30,800 31,150 0 31,150 Total for HP/PC Piping 2,118 0 2,118 93,192 0 93,192 94,251 0 94,251
4 Electrostatic Precipitator
Plates 5/6 mm 0 4,530 4,530 0 199,320 199,320 0 201,585 201,585 CR Coil 1.5/1.25 mm 2,340 1,000 3,340 102,960 44,000 146,960 104,130 44,500 148,630
Columns(HEA/HEB), Beams(ISMB 300/400)
2,500 500 3,000 110,000 22,000 132,000 111,250 22,250 133,500
Angles(50x50x6,75x75x6,80x80x8,10x75x6)/Channels(C150,C200,C250)
0 2,560 2,560 0 112,640 112,640 0 113,920 113,920
Hollows (150 to 300) 2,450 0 2,450 107,800 0 107,800 109,025 0 109,025 Total for EP 7,290 8,590 15,880 320,760 377,960 698,720 324,405 382,255 706,660
5 Main and Aux. Buildings
Plates 0 21,460 21,460 0 944,240 944,240 0 954,970 954,970
Angles 0 3,938 3,938 0 173,272 173,272 0 175,241 175,241 Channels 0 4,296 4,296 0 189,024 189,024 0 191,172 191,172
Joists 0 5,370 5,370 0 236,280 236,280 0 238,965 238,965
Misc. Chequered Plates/Handrails etc.
0 716 716 0 31,504 31,504 0 31,862 31,862
Reinforce Steel 0 8,800 8,800 0 387,200 387,200 0 391,600 391,600
Total for Main & Aux. Bldgs.
0 44,580 44,580 0 1,961,520 1,961,520 0 1,983,810 1,983,810
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
2.3 Appendix 2
s.no. Equipment /System Typical Qty. for 2 x 500 MW units as given by BHEL (MT)
Estimated Qty. for XIth Plan coal based projects 44,000 MW
(In MT)
Estimated Qty. for XIIth Plan coal based projects 44,500 MW
(In MT)
6 Power Transformers (CRGO)
Grade-ZDKH85 0.23 thk 1,120 0 1,120 49,280 0 49,280 49,840 0 49,840 Grade-ZDKH90 0.27 thk 208 0 208 9,152 0 9,152 9,256 0 9,256
Total for Power Transformers
1,328 0 1,328 58,432 0 58,432 59,096 0 59,096
7 Motors
CRNGO, M530-65A, 800-1250width
300 0 300 13,200 0 13,200 13,350 0 13,350
Shaft forging (Low Alloy Steel)
0 125 125 0 5,500 5,500 0 5,563 5,563
IS2062 Steel Plates 0 300 300 0 13,200 13,200 0 13,350 13,350 Total for Motors 300 425 725 13,200 18,700 31,900 13,350 18,913 32,263
8 Switchyard
Lattice structure 0 725 725 0 31,900 31,900 0 32,263 32,263
Pipes 0 125 125 0 5,500 5,500 0 5,563 5,563
Earthing Rods/Strips 0 700 700 0 30,800 30,800 0 31,150 31,150 Total for Switchyard 0 1,550 1,550 0 68,200 68,200 0 68,975 68,975
9 Coal Handling Plant
Angles, Beams and Channels
0 8,000 8,000 0 352,000 352,000 0 356,000 356,000
Reinforce Steel 0 6,000 6,000 0 264,000 264,000 0 267,000 267,000 Total for CHP 0 14,000 14,000 0 616,000 616,000 0 623,000 623,000
10 Turbine/Gen./Condenser
10.1 Plates :
MS Plates, 5mm to 90mm, IS20062 GR-A &GR-B
530 1480 2,010 23,320 65,120 88,440 23,585 65,860 89,445
B Q Plates, 6mm to 250 mm, IS2002 GR-2
1,020 260 1,280 44,880 11,440 56,320 45,390 11,570 56,960
CS Plates, 12mm to 160mm, SA516 GR-70
20 30 50 880 1,320 2,200 890 1,335 2,225
AS Plates, 10mm to 125mm, 17MO4 & 12MX
10 0 10 440 0 440 445 0 445
SS Plates/Sheets, 0.5mm to 80mm, AA10739, AA10740, HW10782 and HW 10788
64 36 100 2,816 1,584 4,400 2,848 1,602 4,450
Sub- total for Plates 1,644 1,806 3,450 72,336 79,464 151,800 73,158 80,367 153,525
10.2 Rounds : 0 0 0 0
CS Rounds, AA10109 and AA 10218
4 166 170 176 7,304 7,480 178 7,387 7,565
AS/SS Rounds, 36 158 194 1,584 6,952 8,536 1,602 7,031 8,633 sub- total for Rounds 40 324 364 1,760 14,256 16,016 1,780 14,418 16,198
10.3 Structural Steel, IS 2062 40 100 140 1,760 4,400 6,160 1,780 4,450 6,230 10.4 Bloom, Class 2 and Class
3 0 120 120 0 5,280 5,280 0 5,340 5,340
Total for Turbine/Gen/Condensers (10.1+10.2+10.3+10.4)
1,724 2,350 4,074 75,856 103,400 179,256 76,718 104,575 181,293
11 Pumps/Heat Exchangers/ Drive- Turbines and Pulverisers
11.1 LP and HP Heaters :
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
2.4 Appendix 2
s.no. Equipment /System Typical Qty. for 2 x 500 MW units as given by BHEL (MT)
Estimated Qty. for XIth Plan coal based projects 44,000 MW
(In MT)
Estimated Qty. for XIIth Plan coal based projects 44,500 MW
(In MT)
Plates :
Boiler Quality Plates, Various sizes from 5mm to 200mm
140 48 188 6,160 2,112 8,272 6,230 2,136 8,366
STRU Plates, Various sizes from 5mm to 200mm
0 42 42 0 1,848 1,848 0 1,869 1,869
Sub- total for plates-HP/LP Heaters
140 90 230 6,160 3,960 10,120 6,230 4,005 10,235
11.2 Deaerators :
Plates :
Boiler Quality Plates, Various sizes from 5mm to 200mm
86 0 86 3,784 0 3,784 3,827 0 3,827
STRU Plates, Various sizes from 5mm to 200mm
0 9 9 0 396 396 0 401 401
Sub- total for plates for deaerators
86 9 95 3,784 396 4,180 3,827 401 4,228
11.3 Pulverisers :
Plates :
Alloy Steel Plates, Various sizes from 5mm to 200mm
4 0 4 176 0 176 178 0 178
Boiler Quality Plates :
CS / SS Sheets, 1mm to 4mm
10 10 20 440 440 880 445 445 890
Structural Steel 0 322 322 0 14,168 14,168 0 14,329 14,329
Sub-total for plates for Pulveriser
14 332 346 616 14,608 15,224 623 14,774 15,397
11.4 Drive turbines :
Plates :
Alloy Steel Plates, Various sizes from 5mm to 200mm
2 0 2 88 0 88 89 0 89
Stainless Steel Plates 0 12 12 0 528 528 0 534 534
Sub- total of plates for drive turbines
2 12 14 88 528 616 89 534 623
11.5 Structurals :
STRU :
Flat, Various Sizes 0 2 2 0 88 88 0 89 89 Angles, Beams and
Channels, Various Sizes 0 12 12 0 528 528 0 534 534
Sub- total for structurals 0 14 14 0 616 616 0 616 616 11.6 Bar Stock :
CS Round, 6mm to 400mm 20 18 38 880 792 1,672 890 801 1,691
AS Round, 6mm to 400mm 5 2 7 220 88 308 223 89 312 SS Round, 6mm to 400mm 0 4 4 0 176 176 0 178 178
Sub- total of Bar-stock 25 24 49 1,100 1,056 2,156 1,113 1,068 2,181
11.7 Pipes :
Alloy Steel Pipes, OD 16mm to 610mm, 1 to 28mm thick
2 0 2 88 0 88 89 0 89
Carbon Steel Pipes, OD 16mm to 610mm, 1 to 28mm thick
20 18 38 880 792 1,672 890 801 1,691
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
2.5 Appendix 2
s.no. Equipment /System Typical Qty. for 2 x 500 MW units as given by BHEL (MT)
Estimated Qty. for XIth Plan coal based projects 44,000 MW
(In MT)
Estimated Qty. for XIIth Plan coal based projects 44,500 MW
(In MT)
Stainless Steel Pipes, OD 16mm to 610mm, 1 to 28mm thick
0 20 20 0 880 880 0 890 890
Sub- total of pipes 22 38 60 968 1,672 2,640 979 1,691 2,670
Total 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 12,716 22,836 35,552 12,861 23,096 35,552
Grand Total (MT) 18,894 111,707 130,601 831,336 4,915,108 5,746,444 840,783 4,970,962 5,811,745
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
3.1 Appendix 3
Appendix-3
Estimated Quantity of Steel for 11th
and 12th
Plan Gas based projects
s. no.
Equipment /System Typical Qty. for 2 x 500 MW Gas Plant as given by BHEL
(MT)
Estimated Qty. for XIth Plan Gas based projects 2114
MW (In MT)
Type of steel used : Imported Indigenous Total Imported Indigenous Total
1 Boiler
1.1 Drum :
Pipe : (OD 88.9 to 863mm, thickness 11.13 to 130mm)
Carbon Steel Pipe 3.5 0.0 3.5 7 0 7
Plate : (Thickness 1.6 to 190mm)
Boiler Quality Plates 210.5 0.0 210.5 445 0 445
Stru Plates 0.0 1.0 1.0 0 2 2
JPC Plates and Sheets 0.0 14.0 14.0 0 30 30
Bar Stock : (Dia 6mm to 250mm)
Round 14.5 0.0 14.5 31 0 31
Sub-total for Drum 228.5 15.0 243.5 483 32 515
1.2 Structures/Non Pressure parts
Pipe : (OD 88.9 to 863mm, thickness 11.13 to 130mm)
Alloy Steel Pipes 17.0 0.0 17.0 36 0 36
Carbon Steel Pipes 206.5 50.0 256.5 437 106 542
ERW Pipes 100.0 850.5 950.5 211 1,798 2,009
Plate : (Thickness 1.6 to 190mm)
Alloy Steel Plates 127.5 0.0 127.5 270 0 270
Boiler Quality Plates 8.5 0.0 8.5 18 0 18
Stru Plates 122.5 122.5 245.0 259 259 518
JPC Plates and sheets 0.0 8,567.5 8,567.5 0 18,112 18,112
Stainless Steel Pipes 0.0 57.5 57.5 0 122 122
Bar Stock : (Dia 6mm to 250mm)
Round 0.0 107.0 107.0 0 226 226
STRU : (Various Sizes)
Angles, Beams and Channels
0.0 4,922.0 4,922.0 0 10,405 10,405
Tubes : (OD 14.2 to 76.1mm, thickness 2 to 12.5 mm)
Alloy Steel Tubes 9.0 0.0 9.0 19 0 19
Carbon Steel Tubes 33.0 33.5 66.5 70 71 141
ERW Tubes 0.0 207.5 207.5 0 439 439
Stainless Steel Tubes 0.0 1.5 1.5 0 3 3
Sub- total for Structures / Non- Pressure parts :
624.0 14,919.5 15,543.5 1,319 31,540 32,859
1.3 Pressure Parts :
Pipe : (OD 88.9 to 863mm, thickness 11.13 to 130mm)
Alloy Steel Pipes 114.0 0.0 114.0 241 0 241
Carbon Steel Pipes 250.0 73.0 323.0 529 154 683
Plate : (Thickness 1.6 to 190mm)
Alloy Steel Plates 231.0 0.0 231.0 488 0 488
Boiler Quality Plates 217.0 0.0 217.0 459 0 459
JPC Plates and Sheets 0.0 491.0 491.0 0 1,038 1,038
Stainless Steel Plates 0.0 58.5 58.5 0 124 124
Bar Stock : (Dia 6mm to 250mm)
Round 0.0 150.0 150.0 0 317 317
STRU : (Various Sizes)
FLAT 67.0 0.0 67.0 142 0 142
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
3.2 Appendix 3
s. no.
Equipment /System Typical Qty. for 2 x 500 MW Gas Plant as given by BHEL
(MT)
Estimated Qty. for XIth Plan Gas based projects 2114
MW (In MT)
Type of steel used : Imported Indigenous Total Imported Indigenous Total
Angles, Beams and Channels
0.0 266.0 266.0 0 562 562
Tubes : (OD 14.2 to 76.1mm, thickness 2 to 12.5 mm)
Alloy Steel Tubes 475.5 475.5 951.0 1,005 1,005 2,010
Carbon Steel Tubes 665.0 665.0 1,330.0 1,406 1,406 2,812
Stainless Steel Tubes 50.5 50.5 101.0 107 107 214
Sub-total for Pressure Parts
2,070.0 2,229.5 4,299.5 4,376 4,713 9,089
Total Qty. for Boiler (1.1+1.2+1.3)
2,922.5 17,164.0 20,086.5 6,178 36,285 42,463
2 LP piping
IS 3589 0.0 2,097.0 2,097.0 0 4,433 4,433
IS 1239 0.0 327.5 327.5 0 692 692
IS 1239 (GAL) 0.0 131.5 131.5 0 278 278
SS 0.0 126.5 126.5 0 267 267
Total for LP Piping 0.0 2,682.5 2,682.5 0 5,671 5,671
3 HP critical/PC piping
SA335P91 186.0 0.0 186.0 393 0 393
SA335P22 523.0 0.0 523.0 1,106 0 1,106
SA106GRC 350.0 0.0 350.0 740 0 740
Total for HP/PC Piping 1,059.0 0.0 1,059.0 2,239 0 2,239
4 Main and Aux. Buildings
Plates 0.0 10,730.0 10,730.0 0 22,683 22,683
Angles 0.0 1,969.0 1,969.0 0 4,162 4,162
Channels 0.0 2,148.0 2,148.0 0 4,541 4,541
Joists 0.0 2,685.0 2,685.0 0 5,676 5,676
Misc. Chequered Plates/Handrails etc.
0.0 358.0 358.0 0 757 757
Reinforce Steel 0.0 4,400.0 4,400.0 0 9,302 9,302
Total for Main & Aux. Bldgs.
0.0 22,290.0 22,290.0 0 47,121 47,121
5 Power Transformers (CRGO)
Grade-ZDKH85 0.23 thk 560.0 0.0 560.0 2,368 0 2,368
Grade-ZDKH90 0.27 thk 104.0 0.0 104.0 440 0 440
Total for Power Transformers
664.0 0.0 664.0 2,807 0 2,807
6 Motors
CRNGO, M530-65A, 800-1250width
150.0 0.0 150.0 317 0 317
Shaft forging (Low Alloy Steel)
0.0 62.5 62.5 0 132 132
IS2062 Steel Plates 0.0 150.0 150.0 0 317 317
Total for Motors 150.0 212.5 362.5 317 449 766
7 Switchyard
Lattice structure 0.0 725.0 725.0 0 1,533 1,533
Pipes 0.0 125.0 125.0 0 264 264
Earthing Rods/Strips 0.0 700.0 700.0 0 1,480 1,480
Total for Switchyard 0.0 1,550.0 1,550.0 0 3,277 3,277
8 Turbine/Gen./Condenser
8.1 Plates :
MS Plates, 5mm to 90mm, IS20062 GR-A &GR-B
265.0 740.0 1,005.0 560 1,564 2,125
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
3.3 Appendix 3
s. no.
Equipment /System Typical Qty. for 2 x 500 MW Gas Plant as given by BHEL
(MT)
Estimated Qty. for XIth Plan Gas based projects 2114
MW (In MT)
Type of steel used : Imported Indigenous Total Imported Indigenous Total
B Q Plates, 6mm to 250 mm, IS2002 GR-2
510.0 130.0 640.0 1,078 275 1,353
CS Plates, 12mm to 160mm, SA516 GR-70
10.0 15.0 25.0 21 32 53
AS Plates, 10mm to 125mm, 17MO4 & 12MX
5.0 0.0 5.0 11 0 11
SS Plates/Sheets, 0.5mm to 80mm, AA10739, AA10740, HW10782 and HW 10788
32.0 18.0 50.0 68 38 106
Sub- total for Plates 822.0 903.0 1,725.0 1,738 1,909 3,647
8.2 Rounds :
CS Rounds, AA10109 and AA 10218
2.0 83.0 85.0 4 175 180
AS/SS Rounds, 18.0 79.0 97.0 38 167 205
sub- total for Rounds 20.0 162.0 182.0 42 342 385
8.3 Structural Steel, IS 2062 20.0 50.0 70.0 42 106 148
8.4 Bloom, Class 2 and Class 3
0.0 60.0 60.0 0 127 127
Total for Turbine/Gen/Condensers (8.1+8.2+8.3+8.4)
862.0 1,175.0 2,037.0 1,822 2,484 4,306
9 Pumps/Heat Exchangers/ Drive- Turbines and Pulverisers
9.1 LP and HP Heaters :
Plates :
Boiler Quality Plates, Various sizes from 5mm to 200mm
70.0 24.0 94.0 148 51 199
STRU Plates, Various sizes from 5mm to 200mm
0.0 21.0 21.0 0 44 44
Sub- total for plates-HP/LP Heaters
70.0 45.0 115.0 148 95 243
9.2 Deaerators :
Plates :
Boiler Quality Plates, Various sizes from 5mm to 200mm
43.0 0.0 43.0 91 0 91
STRU Plates, Various sizes from 5mm to 200mm
0.0 4.5 4.5 0 10 10
Sub- total for plates for deaerators
43.0 4.5 47.5 91 10 100
9.3 Drive turbines :
Plates :
Alloy Steel Plates, Various sizes from 5mm to 200mm
1.0 0.0 1.0 2 0 2
Stainless Steel Plates 0.0 6.0 6.0 0 13 13
Sub- total of plates for drive turbines
1.0 6.0 7.0 2 13 15
9.4 Structurals : 0.0 0.0 0 0
STRU : 0.0 0.0 0 0
Flat, Various Sizes 0.0 1.0 1.0 0 2 2
Angles, Beams and Channels, Various Sizes
0.0 6.0 6.0 0 13 13
Sub- total for structurals 0.0 7.0 7.0 0 15 15
9.5 Bar Stock : 0.0 0.0 0 0
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
3.4 Appendix 3
s. no.
Equipment /System Typical Qty. for 2 x 500 MW Gas Plant as given by BHEL
(MT)
Estimated Qty. for XIth Plan Gas based projects 2114
MW (In MT)
Type of steel used : Imported Indigenous Total Imported Indigenous Total
CS Round, 6mm to 400mm 10.0 9.0 19.0 21 19 40
AS Round, 6mm to 400mm 2.5 1.0 3.5 5 2 7
SS Round, 6mm to 400mm 0.0 2.0 2.0 0 4 4
Sub- total of Bar-stock 12.5 12.0 24.5 26 25 52
9.6 Pipes :
Alloy Steel Pipes, OD 16mm to 610mm, 1 to 28mm thick
1.0 0.0 1.0 2 0 2
Carbon Steel Pipes, OD 16mm to 610mm, 1 to 28mm thick
10.0 9.0 19.0 21 19 40
Stainless Steel Pipes, OD 16mm to 610mm, 1 to 28mm thick
0.0 10.0 10.0 0 21 21
Sub- total of pipes 11.0 19.0 30.0 23 40 63
Total for Pumps/Heat Exchangers/ Drive Turbines and Pulverisers (9.1+9.2+9.3+9.4+9.5+9.6+9.7)
137.5 93.5 231.0 291 198 488
Grand Total (MT) 5,795.0 45,167.5 50,962.5 13,654
95,484 109,138
Central Electricity Authority Requirement of Equipment & Material for Development of Power Sector
Acronyms
Acronyms
MS Mild Steel
HTS High Tensile Steel
CRGO Cold Rolled Grain Oriented
ISMB Indian Standard Medium Beams
ISMC Indian Standard Medium Channels
ASTM American Standard Testing Materials
UCB Unit Control Board
GT Generator Transformer
ST Station Transformer
UT Unit Transformer
ICT Interconnecting Transformer
XLPE CABLE Cross Linked Poly Ethylene Cable
SAVT Surge Arrester Voltage Transformer
EOT Crane Electric Overhead Travelling Crane
Recommended