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Manufacturing Complex Ine Tower (Tlt) JOINT VENTURE OF RINL & POWERGRID TECHNO ECONOMIC FEASIBILITY REPORT (TEFR) ON TRANSMISSION LINE TOWER (TLT) MANUFACTURING COMPLEX MECON LIMITED RANCHI-834002 JHARKHAND 11. 24.2012.F2068 July’ 2014 CONTENT Sl. Title Page No. No. 1. Introduction 1 – 3 2. Executive Summary 4 – 16 3. Characteristics & End uses 17 – 26 4. Market Analysis 27 – 36 5. Technological Considerations 37 – 41 6. Site Selection & General layout 42 – 47 7. TLT Fabrication Unit 48 – 56 8. TLT Galvanizing Unit 57 – 62 9. Electrics & Automation 63 – 73 10. Plant Services & Utilities 74 – 92 11. Quality Control Facilities 93 – 96 12. Civil & Structural Works 97 – 104 13. Manpower Requirement 105 – 107 14. Project Implementation 108 – 114 15. Pollution Control & Waste Management 115 – 117 16. Capital Cost 118 – 122 17. Production Cost 123 – 127 18. Financial Appraisal 128 – 138 19. Industrial Safety 139 – 141 20. Drawings 142 PREPARED BY CHECKED BY APPROVED BY SAURABH MARKAM NISHEETH KUMAR GOUTAM CHAKRABORTY Design Engineer Asst. General Manager Jt. General Manager Rolling Mills Rolling Mills Rolling Mills JOINT VENTURE OF RINL & POWERGRID TECHNO ECONOMIC FEASIBILITY REPORT FOR TRANSMISSION LINE TOWER (TLT) MANUFACTURING COMPLEX 01. INTRODUCTION 01.01 Background Visakhapatnam Steel Plant (VSP) is an integrated public sector steel plant owned by Rashtriya Ispat Nigam Ltd. (RINL), a Navaratna Company under Ministry of Steel built with an annual production of about 3.6MT of liquid steel per annum. Recently they have completed their expansion of capacity up to 6.3 MT/yr through BF-BOF route with addition of new rolling mills. Power Grid Corporation of India Ltd. (POWERGRID), a Navaratna PSE under ministry of power & the central transmission utility (CTU) of the country, is engaged in power transmission business with responsibility of planning, coordination, supervision and controlling over complete inter- state transmission system and operation of national & regional power grids. Power grid is playing a key role in Indian power sector directly contributing to economic development of the country, through establishing large and complex transmission network and as grid operator. RINL and POWERGRID are entering into a joint venture project to install Transmission Line Tower (TLT) manufacturing complex with a view to ©2014 MECON Limited. All rights reserved Page 1 of 142 JOINT VENTURE OF RINL & POWERGRID TECHNO ECONOMIC FEASIBILITY REPORT FOR TRANSMISSION LINE TOWER (TLT) MANUFACTURING COMPLEX exploit the emerging opportunity in transmission line tower manufacturing business in India and abroad. RINL will supply quality raw material in form of re-rollable steel / black angles to the joint venture company to further produce TLT. 1.02 The Assignment RINL & POWERGRID have assigned MECON vide their letter no. CSM/POWERGRID/I/ dated 9/3/2012 to go ahead for the preparation of Techno-Economic Feasibility Report (TEFR) for setting up Transmission tower Manufacturing Unit. 01.03 Content of the Report The TEFR as set out in the following chapter covers the Introduction, Executive Summary, Market analysis, Technological consideration, Site selection & General layout, TLT Fabrication Unit, TLT Galvanizing Unit, Electrics & Automation, Plant Services and utilities, Quality control facilities, Civil & structural works, Manpower requirement, Project implementation, Pollution control, Capital cost, Production costs and Financial appraisal. ©2014 MECON Limited. All rights reserved Page 2 of 142 JOINT VENTURE OF RINL & POWERGRID TECHNO ECONOMIC FEASIBILITY REPORT FOR TRANSMISSION LINE TOWER (TLT) MANUFACTURING COMPLEX 01.04 Acknowledgment MECON places on record its deep appreciation and gratitude to the Chairman cum Managing Director and other officials of RINL & POWERGRID for the assignment and the guidance and cooperation extended by them during preparation of this report. ©2014 MECON Limited. All rights reserved Page 3 of 142 JOINT VENTURE OF RINL & POWERGRID TECHNO ECONOMIC FEASIBILITY REPORT FOR TRANSMISSION LINE TOWER (TLT) MANUFACTURING COMPLEX 02. EXECUTIVE SUMMARY 02.01 Introduction Visakhapatnam Steel Plant (VSP) is an integrated public sector steel plant owned by Rashtriya Ispat Nigam Ltd. (RINL), a Navaratna company under ministry of Steel & Power Grid Corporation of India Ltd. (POWERGRID), a Navaratna PSE under ministry of Power & the Central Transmission Utility (CTU) of the country, are entering into a joint venture project to install Transmission Line Tower (TLT) manufacturing complex with a view to exploit the emerging opportunity in transmission line tower manufacturing business in India and abroad. RINL will supply quality raw material in form of re-rollable steel / black angles to the joint venture company to further produce TLT parts. 02.02 Market Analysis As analyzed in relevant chapter of this report, based on average demand figures and average availability; the resultant gaps (-) / Surplus (+) are summarized as below: ©2014 MECON Limited. All rights reserved Page 4 of 142 JOINT VENTURE OF RINL & POWERGRID TECHNO ECONOMIC FEASIBILITY REPORT FOR TRANSMISSION LINE TOWER (TLT) MANUFACTURING COMPLEX Year Demand Availability Gaps (-) / Surpluses (+) DOMESTIC 2012-17 4.10 3.60 -0.5 WITH EXPORT (+20%) 2012-17 4.90 3.60 -1.3 02.03 Technical Consideration Installation of a Transmission Line Tower (TLT) manufacturing unit requires analysis of important factors such as capacity of plant, availability of raw materials, availability of infrastructure facilities and cost considerations. The capacity of proposed plant has been decided based on desk study of requirement of TLT in the future considering the proposed massive capacity augmentation plan in power sector. As emerged from the desk study the plant capacity has been fixed as 120,000 t/yr. The Technological unit capacity has been fixed considering the popular plant size capacity as per existing units in India as well as abroad and the limitation in handling no. of pieces annually in a unit etc. The main technological units envisaged are: a) TLT Fabrication Unit (2 units of 60,000 tpy each) ©2014 MECON Limited. All rights reserved Page 5 of 142 JOINT VENTURE OF RINL & POWERGRID TECHNO ECONOMIC FEASIBILITY REPORT FOR TRANSMISSION LINE TOWER (TLT) MANUFACTURING COMPLEX b) TLT Galvanizing Unit (2 units of 60,000 tpy each) The black angles in the product – mix of RINL will be made available by RINL. As per the product – mix & production schedules of RINL, approximately 30% of the angles required would be provided by RINL. Rest of the angles will be sourced from other market sources including authorized conversion agents for which the input billets / blooms will be made available by RINL. Proposed process flow are shown in the drawing MEC/11/24/123J/TEFR/003. 02.04 Site Selection & General Layout Site for TLT manufacturing complex has been finalized based on only quantitative analysis & no techno economic calculation has been carried out. Out of the three sites available, RINL site has emerged as the most suitable site. Proposed site is located very close to the existing steel plant of M/s RINL. Adequate acquired land is available at this site. Layout of the proposed plant has been developed keeping in view of the following: a) Availability of adequate land. b) Direction of Road entry to the plant. ©2014 MECON Limited. All rights reserved Page 6 of 142 JOINT VENTURE OF RINL & POWERGRID TECHNO ECONOMIC FEASIBILITY REPORT FOR TRANSMISSION LINE TOWER (TLT) MANUFACTURING COMPLEX c) Unidirectional flow of material suiting to the sequence of process flow. d) Safety considerations. e) Provision of green belt. A total area of approximately 50 acres has been envisaged inside the complex boundary. 02.05 TLT Fabrication Unit Two (2) TLT Fabrication Units of 60,000 t/yr capacity each has been envisaged. The TLT Fabrication Units will fabricate the TLT parts as per requirement of TLT unit. The TLT Fabrication Units will use angles from RINL / conversion agents /other market sources for fabrication of TLT parts. The plates required for the production of TLT parts will be procured from outside market sources. Multiple operations required during fabrication can be covered in single state of the art CNC machine. Sufficient numbers of automated machines with CNC state of the art technology have been envisaged to cater to the ©2014 MECON Limited. All rights reserved Page 7 of 142 JOINT VENTURE OF RINL & POWERGRID TECHNO ECONOMIC FEASIBILITY REPORT FOR TRANSMISSION LINE TOWER (TLT) MANUFACTURING COMPLEX requirement of fabrication shop to fabricate angles and plates as per requirement. An in-house Design department for production planning and preparation of shop fabrication drawings has been envisaged with latest state of art software & hardware. For Inter-bay transfer of angles / cut pieces of angles, sufficient number of Fork-lifts has been envisaged in the bay together with material transfer trolleys and EOT cranes. 02.06 TLT Galvanizing Unit Two (2) number TLT Galvanizing Units of 60,000 t/yr capacity each has been envisaged. The TLT Galvanizing Units will hot dip galvanize the fabricated TLT parts. About 120,000 tons of fabricated TLT Parts will be galvanized annually for the envisaged production. The maximum length of single part to be galvanized has been envisaged as 8.5 m. A semi-automatic process for galvanizing the TLT parts has been envisaged. The process of hanging the TLT parts on to the Hangers / Jigs before Galvanizing process and removing the TLT parts from the Hangers / Jigs after Galvanizing process ©2014 MECON Limited. All
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