Manufacturing Complex Ine Tower (Tlt)

JOINT VENTURE OF RINL & POWERGRID

TECHNO ECONOMIC FEASIBILITY REPORT (TEFR)

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

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.

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.

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:

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)

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.

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

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

is manual. The Galvanizing process is automated. Galvanizing unit shall

include all pretreatment and post treatment facilities.

02.07 Plant Services & Utilities

02.07.01 Water Supply Facilities

Water for the proposed integrated complex for manufacturing

transmission line towers will mostly be required for direct and indirect

cooling of plants/ machines/ equipment with a part to be consumed for

drinking and sanitation purpose and other direct process and general

purpose needs. Individual recirculation system has been envisaged for

water systems of various plant units to effect extensive recycling and

reuse of return water from plant processes after necessary treatment and

conditioning.

02.07.02 Air Conditioning & Ventilation System

Ventilation and air-conditioning systems are proposed to provide proper

working conditions necessary for maintaining environment compatible

with human hygienic requirements and to maintain conditions necessary

for proper storage of materials and working of plant and equipment. The

ventilation and air-conditioning systems generally include one or more

items of equipment and accessories such as fans, air filters, air washers,

air-conditioning units, duct work, pumps, cooling tower, air supply grills,

dampers, insulation, instrumentation and controls, electrics, etc.

02.07.03 Fire Fighting Facilities

Many working premises in plant have hazardous and fire prone

environment. To protect the working personnel, equipment and

machineries, adequate safety and fire fighting measures have been

planned for the proposed plant.

02.07.04 Compressed Air System

A centralized compressed air station has been envisaged in order to meet

the requirement of industrial and instrument quality compressed air for

the proposed plant.

02.07.05 Inter Plant & In-Shop Piping Network

Inter-plant piping network will be provided with supporting structures for

supply of compressed air, instrument air and fuel oil to meet the process

requirement from compressed air station and fuel oil installation.

The interplant piping network shall consist of a common trestle / stockade

/ bridge carrying pipes from sources to consumers. In shop piping

network, consist of pipes carrying various fluids, will be supported from

building column / structures.

02.07.06 Fuel Gas / Oil Handling Facilities

The requirement of CO Gas for the Heating Furnaces in the Fabrication

Unit and for the Galvanizing Unit has been estimated based on specific

consumption per ton. Hourly consumption will be around 1100 Nm3/hr.

CO Gas will be tapped from RINL’s existing line and pipeline for

transporting the required quantity along with Nitrogen Line for purging

will be laid from the tapping point to the site.

In addition to above, provision for use of Furnace oil in case of shortage /

disruption of CO Gas supply has also been envisaged.

02.08 Quality Control Facilities

The proposed transmission line towers (TLT) Manufacturing Complex will

produce high quality galvanized transmission line towers according to the

stipulations of various national and international standards. In order to

achieve this objective, efficient and stringent quality assurance measures

are to be enforced at every stage of production. Quality assurance can be

implemented effectively in the form of analyses and test results which

can be provided only by well-equipped laboratories entrusted with day-

to-day quality control at all stages of processing and quality evaluation of

finished products.

02.09 Civil & Structural Works

The Civil works consists of site preparation, providing foundations of Main

building for Fabrication Unit, Galvanizing Unit together with equipment

foundations required and associated works for all plants, auxiliary

buildings, electrical control rooms, transformer rooms, laboratory,

compressed air station, pump house, MSDS, water supply facilities, etc.

suiting to the requirements of TLT Manufacturing Complex and other

service facilities like drainage, sewerage, roads, boundary fencing, site

leveling, etc.

Steel structural work will include supply, fabrication, erection & painting

of all structures of the following units:

a) TLT Fabrication Unit

b) TLT Galvanizing Unit

c) All related Piping support structures

d) Other Miscellaneous structures

The structures will include building structures, pipe trestles etc. for the

TLT Manufacturing Complex.

02.10 Manpower Requirement

Meticulous distribution of manpower is essential for uninterrupted operation and proper maintenance of plant facilities. For the proposed plant, the manpower requirement has been estimated based on the following considerations:

- Production shops and their capacities. - Type of equipment proposed for the main production shops and corresponding auxiliary / services facilities. - Degree of automation and mechanization envisaged in different units. - Extent of manning required for each equipment. - Number of operating shifts. - Supporting personnel for weekly off and leave reserves.

02.11 Project Implementation

The project has been planned to be completed in 16 month from “Zero

date” which is reckoned as “Start of ordering of Main Technological

Units”.

With a target of early realization & stabilization of manufacturing

facilities, it has been foreseen to stagger the implementation of proposed

Fabrication & Galvanizing Units. In this staggering process, one unit each

for Fabrication & Galvanizing may be commissioned first with the Input

Angles from RINL / Market as per the requirement and availability. The

second units for Fabrication & Galvanizing may be subsequently

commissioned.

This staggering of commissioning of different units will facilitate the JV in

two ways:

 Stabilization of Fabrication & Galvanizing process / machines.

 Unit will start producing required TLT parts to meet the huge

market demands. This will establish the standing of this complex in

the market before the Integrated Commissioning of Complex.

However, the execution of the proposed project would call for meticulous

planning, monitoring and control during engineering, procurement and

construction stage. Salient aspects relating to project implementation

strategy are covered in relevant chapter.

02.12 Pollution Control

The pollution control system for the proposed TLT Manufacturing Complex can broadly be divided into the following three categories: - Air pollution control - Noise pollution control - Water pollution control Adequate measures have been envisaged so that all the treated effluents

let out of the complex will conform to permissible limits set by the

statutory authorities/pollution control boards.

02.13 Capital Cost

The capital cost of the proposed 120,000 T/Y capacity TLT manufacturing

complex proposed at VIZAG including galvanizing and other related

auxiliaries and services as envisaged has been estimated and summarized

as given below:

Sl. No. Description Cost (Crore Rs.)

1. Plant Proper 312.8

2 Interest during construction 12.3

3 Capitalized Land use charges 6.2

4 TOTAL 331.3

Including foreign exchange 106.0 component

02.14 Production Cost

The proposed TLT Complex has been envisaged to produce total of 120000 Tons of galvanized finished products annually. It is assumed that the plant would operate at 80 % capacity during first year, 90% during second year and 100 % during third year and onwards.

The average production cost excluding depreciation and interest during third year of operation when the plant achieves rated capacity utilization, works out to Rs 52,263/ton (rounded).

02.15 Financial Appraisal

Financial analysis has been carried out based on capital investment and

operating cost and Average net sales realization. The salient techno-

economic indices of the project have been summarized below:

SALIENT TECHNO-ECONOMIC INDICES

Sl. No. Item description Unit Indices 1 Cumulative retained profit over Crore. Rs. 267.2 10 years of operation 2 Average annual retained profit over Crore. Rs 26.7 10 years of operation 3 Cumulative cash surplus over Crore. Rs 186.3 10 years of operation 4 Average Debt-service coverage ratio over 10 Ratio 1.51 years of operation 5 Pay-back period Years 7.9 6 Break even capacity % 63 7 Internal rate return (IRR) over 20 years Of operation Pre-tax % 22.1 Post-tax % 18.8

03. CHARACTERISTICS & END USES

03.01 OVERVIEW

Transmission line towers are used to transmit electricity at high voltage

(33kV to 800kV AC/DC) from power generation station to utilities, Sub-

stations / Load centers. Transmission line connects two nodes of the

power supply grid.

Generally the towers are of self supporting lattice steel type, designed to

carry the line Conductor with necessary insulators, earth wires and all

fittings under all loading conditions.

The towers are fully galvanized structure, using structural mild steel / high

tensile steel sections for members. Galvanized Bolts and nuts with spring

washers are used for connection.

These towers support one or more overhead line conductors (ACSR /

AAAC/Other types) carrying electrical power at high voltage, mostly 3-

phase AC circuits of voltages ranging from 33kV to 800kV. To prevent

safety against lightening, earth wire / OPGW are placed at tower peak.

OPGW (Optical fiber ground wire) is now being used instead of regular

GSS (Steel stranded wire) as it is being used for data transmission for

broad band as well as earthing the live conductors. The live conductors

are supported by Insulators which in turn is attached to tower cross arm

through Hangers / D’ shackles. To prevent short circuit between live and

earthed parts including the surrounding environment minimum mutual

clearances are prescribed for different voltage capacity of transmission

line as per recommendations of IS: 5613.

The tower are designed such that it can be attached to various body

extensions and leg extensions for maintaining adequate ground clearance

at various ground profiles/road/rail crossings etc.

03.02 TOWER CLASSIFICATIONS/DESIGNATIONS

Transmission Towers can be grouped based on various

design/functional/structural aspects as given below:

CRITERIA TYPES

STRUCTURAL ACTION TO LOADS SELF SUPPORTING TOWERS GUYED

TOWERS

NO. OF CIRCUITS SINGLE/DOUBLE/MULTIPLE CIRCUIT

TOWERS

POWER TRANSMISSION CAPACITY 33KV, 66KV, 132KV, 220KV, 400KV,

[VOLTAGE LEVEL] 765KV, 800KV, etc.

TOWER SHAPES VERTICAL/HORIZONTAL/DELTA/H

STRUCTURES

Mostly self supporting latticed steel towers are used in India and other

countries. These towers support the various loads coming on to the

structure on their own. The design aspects of these towers are covered

under Indian standard (IS: 802 — part 1, 2, 3). These towers are designed,

fabricated and tested prototype in line with various recommendations of

IS: 802.

These towers are made up of structural angle profiles of Mild steel and

high tensile steel grades and members are connected by bolts. Normally

these towers have square or rectangular base.

Guy towers comprise portal structures in ‘Y’ or ‘V’ shape and are

anchored to Ground through steel Guys. They have been used in some

countries for EHV lines up to 735 kV. Such towers occupy much larger

land space compared to self supporting towers and as such area used in

long unoccupied waste land, bush tracts in Canada, Brazil , Russia. In India

such towers are not being used.

TOWER DESIGNATIONS:

Towers are broadly designated as:

a) SUSPENSION TOWERS

b) ANGLE TOWERS

which are further declassified as per angle of deviation as given below:

TOWER DESCRIPTION ANGLE OF REMARKS MARKINGS DEVIATION A/DA/MA Suspension Tower – 00 - 20 Tower nomenclature

Used on straight line may vary

stretch

B/DB/MB Small angle tower 00 -150 D=> Double circuit

M=> Multiple Circuit

C/DC/MC Medium Angle Tower 150 – 300

/ Transposition

Tower

D/DD/MD Big angle Tower / 300 – 600 /Dead

Dead End – Tower End

INDICATIVE STATEMENT OF TOWER WEIGHTS

(APPROXIMATE TOWER WEIGHT (MT)

Tower Type/Tower Weight 765KV 800KV 500KV 400KV 400KV 220KV

(WZ-4) S/C D/C HVDC HVDC D/C D/C D/C HORZ. DELTA QUAD TWIN

MS 8.5 11.1 22 15.3 8.4 9.3 6.9 2.4 A/SA/DA HT 6.4 9.5 27.4 15.2 5.8 7.7 4.4 1.9 B&N 0.6 1.1 2 1.4 0.6 1 0.6 0.3 Total 15.5 21.7 51.4 31.9 14.8 18 11.9 4.6 Total 14.9 20.6 49.4 30.5 14.2 17 11.3 4.3 MS+HT

MS 9.6 17.7 23 14.2 8 8.6 6.6 4.2 HT 8.5 12.8 71.6 30.7 9.5 19.3 9.8 2.1 B/SB/DB B&N 0.7 1.3 4.7 1.8 0.9 1.1 0.7 0.3 Total 18.8 31.8 99.3 46.7 18.4 29 17.1 6.6 Total 18.1 30.5 94.6 44.9 17.5 27.9 16.4 6.3 MS+HT

MS 13.7 19.1 35.5 13.4 11.6 9.1 6.1 4.3 HT 11.1 18.3 68.6 40 9.5 22.8 11.9 2.4 C/SD/DC B&N 0.9 1.4 5.3 2.2 1.1 1.3 0.7 0.3 Total 25.7 38.8 109.4 55.6 22.2 33.2 18.7 7 Total 24.8 37.4 104.1 53.4 21.1 31.9 18 6.7 MS+HT

MS 18.8 21.7 26.7 24.7 14.9 15.2 10.1 4.7 HT 16.7 22.4 78.6 36.7 11.2 24.9 14.9 3.6 D/DD B&N 1.3 1.8 4.7 2.6 1.2 1.8 0.9 0.4 Total 36.8 45.9 110 64 27.3 41.9 25.9 8.7 Total 35.5 44.1 105.3 61.4 26.1 40.1 25 8.3 MS+HT Source: Tower weight data as per POWERGRID designs being used for various lines.

Tower Structure MT per km 57 77 192 111 49 67 42 18 (Plain Terrain) Tower Structure MT per km 81 113 303 161 66 101 61 26 (Hilly/Mount Terrain)

The above weights are for Normal (standard height) towers.

Weight of tower extensions +3/6/9 m are approx. 10 – 20% and extensions + 18/25

m are approx. 80 – 100% extra

INDICATIVE DISTRIBUTION OF TOWERS IN A TYPICAL TRANSMISSION LINE

HILLY/MOUNTAINOUS Type of Terrain PLAIN TERRAIN TERRAIN 400KV, 400KV, 765KV, 765KV, 500KV 220KV 220KV 500KV HVDC HVDC AVERAGE SPAN (m) 370 330 350 300 Suspension Towers 65% Nil (A/DA) Tension Towers 7.5% 30% B/DB C/DC 7.5% 30% D/DD 20% 40% Approx. 20% of towers are with extensions

Average Weight of extension considered to be 20% of Standard tower weight

Factor for extension weight considered 1.04

03.03 GENERAL DETAILS OF TOWERS:

The broad scope of turnkey transmission line project involves following

activities:

a) Preliminary survey, detailed survey, tower spotting, optimization

of tower location, soil resistivity measurements and geo-technical

investigation,

b) Tower design, testing, fabrication and supply of all types of

transmission line towers including bolts, nuts and washer, hanger,

D-shackle and all types of tower accessories like phase plate,

number plate, danger plate, anti-climbing device, etc;

c) Design, selecting type of foundation for different towers and

casting of foundation for towers,

d) Erection of towers, tack welding of bolts and nuts, supply and

application of zinc rich paint,

e) Tower earthing,

f) Fixing of insulator string, stringing of conductors and earth wires

along with all necessary line accessories and

g) Testing and commissioning of the erected transmission lines.

Various steps involved in design of transmission tower are given below:

a) Sag — Tension Calculation

b) Fixing configuration by providing minimum required clearances

c) Loading Calculation

d) Loading Combination

e) Analysis & Design

f) Detailing

g) Prototype testing of towers

Normal Span

Normal span limits for different voltage capacity of transmission line are

as given in IS: 5613. Normal span of 400 m is generally considered for

400KV and 765Kv lines in India.

Wind Span

The wind span is the sum of the two half spans adjacent to the support

under consideration. For normal horizontal spans this equals to normal

span.

Weight Span

The weight span is the horizontal distance between lowest points of the

conductors on the two spans adjacent to the tower.

Minimum Ground Clearance

The minimum ground clearance from the bottom conductor shall not be

less than values stipulated in CEA’s safety regulations/IE rules for various

voltage levels at the maximum sag conditions.

Live Metal Clearance

The minimum live metal clearance to be provided between the live parts

and steel work of super-structure shall conform to IS: 5613

03.04 LOADING CONDITIONS

Loads at conductor and earth wire points

These loads are to be based on IS: 802 / Part-1 1995 and towers are to be

designed to cater for the following loads:

a) Reliability Loads (Normal condition)

b) Security Loads (Broken wire condition)

c) Safety Loads (Construction & Maintenance loads)

03.05 Tower Material

In general the grade wise consumption in overhead transmission tower

comprise about 30-40% of mild steel grade, 60-70 of high strength steel

and 4%-5% of nuts and bolts. The tower member are generally of

structural steel conforming IS 2062. The standard IS: 802 governs the use

of structural steel in overhead transmission line towers which gives the

details of grades of steel to be used in tower members i.e. angles, bolts,

nuts, washers. Profile wise about 90% angle, 4-6% plates and 4%-5% nuts

& bolts are normally being used in Transmission tower. The related size

tolerance in angles products are governed by IS 808 / DIN 1028.

Sometime unequal angles are also being used in design of Transmission

tower.

03.06 TOWER FABRICATION EARTHING/TESTING/ACCESORIES

Galvanizing

Fully galvanized towers and stub are used for the line. Galvanizing of the

member of the towers shall conform to relevant Indian standards.

TOWER EARTHING

All the towers are to be earthed. In no case tower footing resistance shall

exceed 10 ohms in accordance with the stipulation made in IS: 5613

TOWER LOAD TESTS

Galvanized tower of each type complete with Maximum body and leg

extension is subjected to design and destruction tests as per

recommendations of IS: 802.

TOWERS ACCESSORIES.

Various accessories used on a typical transmission line are Step Bolts,

Insulator string and Earth wire Clamps Attachments, Anti climbing Device,

Danger plates, Number plates, Circuit Plate, Phase Plate & Bird Guards.

04.0 MARKET ANALYSIS

04.01 Indian Power Transmission Scenario

The resolve of nation for “Power to all” led to massive capacity augmentation plans in Power Sector envisaging creation of capacities in generation as follows (Table-04.01). Table-04.01 Creation of capacities in generation Item 2006-2007 2016-17 Generation including 140 GW 331 GW captive generation Source: Ministry of Power

The ardent need to evacuate this power and deliver it to consuming centers coupled with the fact that Indian power landscape is characterized by widely spread load centers and generation resources wherein majority of load centers are located in South and West and generation resources in East/ North- eastern part of country and this typicality pressed up the need for massive augmentation of Transmission & distribute network which stands already underinvested in the past.

In view of above, power transmission lines, particularly the bulk power transmission system came in focus and Towers being the most important as well as expansive constituent of the system were studied by CEA and a synopsis w.r.t. steel requirement for the same assessed as per projections for XIIth five yr plan and the same has been brought out by CEA and presented hereunder:

Table - 04.01 CEA’s projection of steel requirement for transmission towers Sl. Voltage By XIIth Plan Type of Steel No. (KV) (Ton) MS HTS 1. 765 416000 60% 40% 2. 500 413640 60% 40% 3. 400 2088680 60% 40% 4. 220 464600 100% - 5. 132 36400 100% - Total 3746920 Say 3.7 MT Source: CEA Document “Requirement of equipment & material for development of power sector”

04.02 Demand Analysis

Attempt has been made to assess the realistic demand of towers and thereby, steel requirement (angles) based on other approaches as outlined hereunder.

Alternative Approach

Based on normative consideration, a projection for tower requirements has also been made by the central transmission utility (POWERGRID) as presented below:

Table-04.05

Expected Average Specific steel Voltage Total estimated additions requirements (Tons/Ckt Sl. level tower wt during 12th Km) assuming Plain to no. (KV) (Million plan(Ckt hilly terrain ratio as 85% Ton) Kms) and 15% respectively 1 765 27000 98 2.65 2 800/50 9440 53 0.50 0 HVDC Bipole 3 400 38000 30 1.14 4 220 35000 10 0.35 Grand 109440 4.64 Total Angle requirement@95% 4.41 Source: Indicative data from POWERGRID based on Draft electricity plan of CEA (Feb’12)

13th Plan: 30% more requirement as per CEA’s Electricity Plan

Final demand assessment

Based on the above two approaches (CEA and POWERGRID Based data), the average demand figures works out as follows:

Estimated Demand (2012-17) 4.1 Million Metric Ton

04.03 International Scenario

The international capex cycle for power sector is observed as follows (Fig- 04.01 and Table-04.06):

2500

2000

1500

1000 IN BILLION US $ 500

0 OECD E.EUROPE ASIA MIDDLE EAST AFRICA LATIN AMERICA

Generation Transmission Distribution

Source: Indbank / merchant banking Ltd. Assessment for Kalptaru Power Transmission and corroborated by CRISIL study. Fig-04.01: International capex cycle for power sector

The scenario exhibits development and growth concentrations in OECD1 and Asian region. Table-04.06 International capex cycle for power sector (In Billion US$) Region Expected Generation Transmission Distribution Capacity Additional (GW) OECD 514 982 279 656

1 OECD = Organization of Economic Co-operation and Development

E. Europe 137 180 55 183 Asia 781 794 433* 894 Middle Cast 78 59 32 67 Africa 59 59 28 58 Latin 121 123 41 84 America World Total 1691 2197 867 1947 *India by 12th plan is assumed included as 42 Billion$ Source : Internet

It is obvious from the above table that T&D network of various countries are undergoing massive change in terms of replacement, up gradation and fresh capacity creations. The total anticipated transmission sector outlay of 867 Billion US$ can be viewed to have been contributed to the tune of 20% by transmission towers as per typical cost structure of power sector. The expected market for towers stands around 173 billion US$, by 2016-17, with largest share taken by Asia and OECD countries and this is an indication of good export potential in these countries for transmission towers. Also, based on information available on websites of various domestic tower manufacture, it is expected that US from CY’ 2012 onwards will be the largest spender on T&D sectors. Given this positive scenario, significant growth opportunities are expected in Middle East, Africa, South Asia and CIS countries from this project.

04.04 Availability

Tower manufacturing capacity

Transmission tower manufacturing Industry is typically very fragmented sector marked by presence of large number of small capacity manufacturers making the estimation of available capacity difficult. However, some of the major player and capacities thereof are listed in Table-04.07.

It is important to note that the available capacities are utilized to manufacture mobile towers, microwave towers, High mast illumination towers and substation structures too. This makes the job of assessing the available capacity for towers production further difficult as disaggregated production data from manufacturers are not available and thus suitable assumptions are to be made to deduce the required figures.

Table-04.07 Tower manufacturing capacity

Source: Indicative PGCIL data

Capacity Utilization of Industry

From the above table, estimated allocable capacity for towers works out around 1.2 Million metric ton with average annual industry capacity utilization around 70%. With this assumption the likely availability figure for towers has been considered as 0.84 Million Metric Ton for the year 2013-14. It has been further assumed that in view of impetus infused in form of incentives for power sector in recently announces budget, the orders may flow and the capacity utilization may improve to 80 % (average) during XIIth plan and thus a figure of 0.96 Million Metric ton/yr has been assumed during XIIth plan period.

Availability of angles for electric towers

CASE-I

Based on above approch, the angle requirement has been estimated as 0.96 Million Tons/yr for period over 2012-17. The results are summarized hereunder:

Average availability during 2012-17 0.96 Million Metric Tons/yr

CASE-II

Angles for electric towers are made from structural products in Light Merchant Products (LMP) as well as sections in Medium Merchant Products (MMP). The availability of angles for electric tower is derived based on the following assumptions:

LMP Share of structural in LMP = 21.9% (estimated from projected values bars & rods and structural in LMP) Share of use for LMP in power sector = 40% of structural in LMP (applied on projected supply of LMP) Share of angles in LMP for power sector = 95%

MMP Share of medium sections in MMP = 36% Share of medium sections for use in power sector = 14% Share of angles in medium sections for use in power sector = 90%

Total availability is assumed to increase by a CAGR of 5% during 2011-12 to 2016- 17.

Based on the above assumptions, the likely availability of angles for use in electric towers are as follows:

Average Availability during 2012-17 0.50 Million tons/y

Total estimated availability over XIIth plan period (2012-17)

Estimated availability from the above figures of Case-I and Case-II are as follows:

2012-17 3.6 Million tons

04.05 Resultant Gaps (-) / Surplus (+)

Based on average demand figures and average ability; the resultant gaps (-) / Surplus (+) are summarized as below (Table-04.08): Table-04.08 Resultant Gaps / Surpluses (Million Tons) 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

05. TECHNOLOGICAL CONSIDERATION

05.01 General

Installation of an Integrated Transmission Line Tower (TLT) manufacturing unit requires analysis of following important factors such as capacity of plant, availability of raw materials, availability of infrastructure facilities and cost considerations

As indicated in related chapters that this plant will be a joint venture between RINL and POWERGRID and the major input material for the unit, i.e., black angles and billet / blooms for conversion into black angles will be made available from RINL Integrated steel plant located at Vizag. 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 various components of transmission towers are angles, plates and bolts & nuts.

05.02 Process Flow

Proposed process flow is shown in the drawing MEC/11/24/123J/TEFR/003.

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.

05.03 Technological Options

05.03.01 General

As indicated in the above process flow the proposed plant will produce approximately 120,000 t/yr of TLT. The various process involved in the production of TLT are as follows.

1. Fabrication of angles as per design drawing of TLT to produce various parts of tower. 2. Galvanizing of various parts fabricated in fabrication unit. 3. Dispatch of galvanized tower parts to construction site.

05.03.02 Input

Transmission line tower normally requires equal angles starting from 45 to 250 mm as per IS 808 / DIN 1028 / Equivalent international standard. Transmission tower also requires gusset plates which are fabricated from plates of thickness from 10 mm to 40 mm.

The various angle sizes required by transmission line tower falls in the following various categories of section products.

Light section - up to 65 mm thickness <8mm Medium section - 70 – 110 mm thickness <12mm Heavy section - 120 – 250 mm thickness >12mm

The angle sizes required by transmission tower fall in light, medium as well as heavy section range. Considering the large size range required by transmission tower, the various input sizes of semis required from RINL are given below:

90x90, 125 x 125, 150 x 150, 200 x 200, 250 x 250, 320 x 250 mm

The angles available in the product-mix of RINL will be procured from RINL. For rest of the angles, semis/billets/blooms will be procured from RINL and converted into black angles through conversion agents or black angles shall be directly sourced from the market as per requirement.

05.03.03 TLT Fabrication Unit

The various processes involved in the fabrication are as follows:

Angles - Angle straightening - Punching - Drilling - Marking / numbering - Shearing / band sawing - Notching - Bending - Punching after bending - Heel milling for LAP joints of angles. Plates - Plate shearing

- Plate thermal cutting - Punching - Drilling - Marking - Bending

Various types of machines are available where various operations required during fabrication can be covered in one machine with state of art CNC machines. Sufficient numbers of automated machines with CNC state of art technology have been envisaged to cater to the requirement of fabrication shop to fabricate angles and plates as per requirement. We have envisaged fabricating about 75-80% of angle sections within 120 x 12 mm and remaining angles sections in the range 120 to 250 mm will be about 20%-25%. About 40-45% angles will be notched in the process. About 4-6% plates have been considered for fabrication.

05.03.04 TLT Galvanizing Unit

The various processes involved in galvanizing process are as follows:

- Dichromating - The galvanizing thickness is normally 460 gms per sq. meter for members below 5 mm thickness and 610 gms per sq. metre for members above 5mm thickness. - With this, the finished tower parts get ready for dispatch to sites.

Considering the annual requirement of the plant a semi automatic operation have been considered. Suitable automation in bay crane have been considered to take care of process requirement. Galvanizing Kettle shall be suitable for oil / gas firing. Galvanizing unit shall have requisite provision for fume extraction and effluent treatment.

06. SITE SELECTION AND GENERAL LAYOUT

06.01 General

Site for TLT manufacturing complex has been finalized based partly on in

house data available with MECON and partly on Site visit at Vizag. Some

major factors have been considered and conclusion has been drawn on

the ten point scale basis. The major factors considered and their ratings

are shown in Table-06.01. In absence of site visit, only quantitative

analysis has been done & no techno economic calculation has been

carried out.

Table – 06.01

Comparison of RINL site with other sites

SITE-2 SITE-3 Sl. Description of SITE-1 (Vizag – Rating Rating (RINL- Rating No. Features (Hyderabad) outside Vizag) RINL) 1. Availability of Available 10 Available 10 Available 10

Land

2. Ease of land May take 8 May take 8 Land is 10

acquisition time and time and already

lots of lots of under

SITE-2 SITE-3 Sl. Description of SITE-1 (Vizag – Rating Rating (RINL- Rating No. Features (Hyderabad) outside Vizag) RINL) problems problems possession

are to be are to be

solved solved

3. Rehabilitation Few houses 7 Few houses 7 Not needed 10

4. Forest land Very small 8 Very small 8 Nil 10

patches patches

5. Soil conditions O.k. for 8 O.k. for 8 O.K even 9

medium medium for heavy

load load foundations

6. Infrastructure Will have to 8 Will have 8 Already 10

be to be developed

developed developed

7. Site Required 8 Required 8 Already 10

development developed

8. Distance of 340Km 6 45Kms 8 3 Km 10

Input source

9. Distance of Various 8 Various 8 Various 8

Despatch of Metro cities Metro Metro cities

SITE-2 SITE-3 Sl. Description of SITE-1 (Vizag – Rating Rating (RINL- Rating No. Features (Hyderabad) outside Vizag) RINL) Finished and other cities and and other

product. consumers other consumers

consumers

Sum Total 71 73 87

Ranking III II I

On the basis of the information indicated in the above table and also that

RINL-Vizag site has added advantage of port facilities, management

control, unidirectional flow of materials such as billet, bloom, oxygen,

mixed gas and other inputs.

As such out of the three sites available, RINL site has emerged as the most

suitable site.

06.02 Location

Proposed site is located very close to the existing steel plant just outside

the plant boundary of M/s RINL in the Northern side of the existing RINL

steel plant and very close to the existing rail gate. Adequate acquired land

is available at this site.

06.03 Road

A well developed road network exists around the site which can be

utilized for both in coming billet/bloom from the RINL plant and dispatch

of finished TLT to various destinations.

Adequate numbers of Hydras & Trucks have been envisaged for

transportation of material from one shop to the other and to & from

Intermediate Storage areas.

06.04 Water

It has been assumed that water for this site will be easily available from

dedicated bore wells.

06.05 Power

Power for the proposed plant can be made available from the existing

power grid source which can be brought to the switch yard of the

proposed plant site.

06.06 Rational of Layout

Layout of the proposed plant has been developed keeping in view of the

following.

f) Availability of adequate land.

g) Direction of Road entry to the plant.

h) Unidirectional flow of material suiting to the sequence of process

flow.

i) Provision for future expansion.

j) Safety considerations.

k) Provision of green belt.

A total area of approximately 50 acres has been envisaged inside the

complex boundary.

Major units are: Black angle storage, Fabrication and galvanizing units,

Prototype assembly & Finished product Storage / dispatch area,

administrative building & Truck parking area.

The relative locations of various plant units have been depicted in the

drawing no MEC/11/14/123J/TEFR/001.

Black Angle storage has been envisaged just at the entrance gate after the

truck parking area on the entry side of the TLT fabrication units for

smooth flow of Input angles. Fabrication and galvanizing units have been

placed adjacent to the storage of black angles. Finished product storage &

dispatch as well as Prototype assembly areas have been planned adjacent

to the Galvanizing units. Auxiliaries and administrative building are

planned adjacent to the main units. Suitable size truck parking unit have

been planned near the raw material entry gate as well as near finished

product dispatch gate. Just between the two gates, Green Park has been

planned. Apart from this all around the periphery of the complex green

belt has been planned.

A well planned road network has been envisaged to cater to the needs of

the various plant units.

06.07 Main features of the plant:

a) Area within the plant boundary: 50 Acres (approx.)

b) Length of boundary wall: 2.0 Km (approx.)

c) Length of road: 1.6 Km (approx.)

d) Number of Road weigh-bridge: 2

e) Number of Gates: 2

f) Number of watch tower: 7

07 TLT FABRICATION UNIT

07.01 General

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 be working for about 300 days per year and

3 shifts per day. 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 will be provided by

RINL. Rest of the angles will be sourced from conversion agents (for which

input billets / blooms will be made available by RINL) or other market

sources. The plates required for the production of TLT parts will be

procured from outside market sources. About 117,990 tons of angles &

6,600 tons of plates will be required annually for the envisaged

production.

07.02 Product Mix

The product mix of TLT Fabrication units is given in Table-07.01.

Table-07.01

Sl. Input Size Range Quantity Product No. (mm) (tons/yr)

a) Angles 45 x 45 – 250 x 250 114,000

b) Plates Up to 40mm thick 6000

Total 120,000

07.03 Major Facilities in TLT Fabrication Unit

Plant and Machinery requirement for the proposed unit has been

estimated considering product mix based on tower weight and section

wise requirement for different type of towers. It is envisaged that

generally 40% of the capacity shall be used for 400KV and 60% for 765KV

lines.

For finalization of the number and types of machine in the TLT Fabrication

unit, we have considered that about 75-80% of angle sections within 120

x 12 mm and remaining angles sections in the range 120 to 250 mm will

be about 20%-25%. About 40-45% angles will be notched in the process.

About 4-6% plates have been considered for fabrication.

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

requirement of fabrication shop to fabricate angles and plates as per

requirement.

Major facilities envisaged for the TLT Fabrication Unit with their brief

technical features are given below:

Quantity Sl. Equipment / facilities Technical feature (for 1 No. Unit) 1. CNC angle punching, For angles 30x30x3 to

marking and shearing 120x120x12mm sizes 4

line

2. CNC angle punching, For angles 30x30x3 to

marking and shearing 120x120x12mm sizes 2 line with Notching CNC

unit

3. CNC angle punching, For angles 40x40x4 to

marking and shearing 160x160x16mm sizes 2

line (with 4 punches)

4. CNC angle punching, For angles 40x40x4 to 1 marking and shearing 160x160x16mm sizes

Quantity Sl. Equipment / facilities Technical feature (for 1 No. Unit) line (with 6 punches)

5. CNC angle drilling, For angles 60x60x6 to 3 marking 250x250x40mm sizes

6. Semi Automatic heel For angles 40x4 to 2 milling machine 250x40mm sizes

7. Angle punching and For angles post bending 2 shearing machine

8. Gas cutting machine with For plates 1 plasma torch

9. CNC plate processor For Punching, marking,

machine drilling, plasma and Oxy 1

cutting of plates

10. CNC plate punching, For plates

marking and drilling 1

machine

11. Semi – Automatic For plates 1 punching machine

12. Manual Universal For angles / plates Punching, Stamping, 2 Shearing, Notching for 500mm plate, 150x16

Quantity Sl. Equipment / facilities Technical feature (for 1 No. Unit) angles 13. Angle notching machines For Manual notching of 6 angles

14. Radial drilling machines For Manual drilling of 4 angles / plates

15. Angle heating furnaces For heating of angle 4 before bending

16. Hydraulic bending For bending 4 presses

17. Plate shearing machine For Plates up to 20mm 1 thickness

18. Manual Press For marking characters 2

19. Angle Grinder 5

20. Straightening Machines 2

21. Band Saw 3

22. Other manual machines

for angles & Plates,

Machine Shop LOT

Equipment, like, shaping

machine, various

Quantity Sl. Equipment / facilities Technical feature (for 1 No. Unit) measuring instruments,

etc.

23. MIG Welding machine

along with its accessories

24. TIG Welding machine

along with its accessories

Adequate number of the above machines has been envisaged in order to

meet the annual capacity of the fabrication units. The production

capacities of individual machines depend primarily on the tower design,

i.e., the size of angles being processed and the number of holes / cuts /

notches required to be done on each piece. We have considered that

about 75-80% of the angles are in the size range up to 120x12mm and 20-

25% of the angles are in the size range above 120x12mm. Tower designs

with greater share of angle in bigger size range will improve the

production capacity of the fabrication units accordingly.

07.04 Process

The angles procured from RINL / from conversion agent / other sources

will be stored in the storage area. The angles will be brought from the

Intermediate storage area to the open Input angle storage bay by trucks /

hydra as per the production planning. The Input angles will be stored in

this storage area as per the sizes / grades in the pre-designated locations.

An in-house Design department for production planning and preparation

of shop fabrication drawings has been envisaged with latest state of art

software & hardware.

Further, the angles / plates will be fed to the respective fabrication lines

as per the production planning with the help of transfer trolleys provided.

The angles will be cut into pieces, holes will be punched / drilled and the

parts will be marked as per the manufacturing design drawings. The

angles will be transported from one line to the other as per the process

requirement with the help of Bay cranes / Forklifts as per the

requirement.

The fabricated TLT parts after QA clearance will be tagged as per the

order / part number and will be sent to the Galvanizing Unit for further

processing.

07.05 Auxiliary Facilities

Auxiliary facilities such as hydraulic systems, lubrication systems, etc. will

be part of the individual machines.

07.06 Layout

The layout of the TLT Fabrication Unit as shown in Drawing No

MEC/11/24/123J/TEFR/002 will ensure smooth and unobstructed

movement of men and materials in the Fabrication bays with minimum

handling.

The TLT Fabrication Unit complex will be mostly of steel structures and

will comprise of bays and administrative building. The shop floor will be at

±0.00 level. Major parameters of each TLT Fabrication Unit are given

below:

Crane Sl. Bay Bay Size Crane Rail Capacity Qty. Remarks No. Designation (m) Height (m) (t)

Angle Storage Pendant 1. 108 x 25 5T 1 7 Bay Operated

Fabrication 108 x 25 x Pendant 2. 5t 3 7 Bays 3 bays Operated

Finished 108 x 25 x Pendant 3. 5t 2 7 product 2 bays Operated

Storage Bay

Administrativ 75 x 12 x 2 4. ------e Building stories

For Inter-bay transfer of angles / cut pieces of angles, sufficient number of Fork-

lifts (4 nos.) has been envisaged in the bay.

08 TLT GALVANIZING UNIT

08.01 General

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.

The TLT Galvanizing Units will be working for about 300 days per year and

3 shifts per day. The TLT Galvanizing Units will use TLT parts fabricated in

the In-house fabrication unit. 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 is manual. The Galvanizing process is

automated.

08.02 Product Mix

The product mix of TLT Galvanizing Unit is given in Table-08.01.

Table-08.01

Sl. Size Range Quantity Product No. (mm) (tonnes/yr)

Fabricated Angle a) 45 x 45 – 250 x 250 114,000 parts

Fabricated Plate b) Up to 40mm thick 6,000 parts

Total 120,000

08.03 Process Sequence

The various processes involved in galvanizing process are as follows:

- Degreasing of tower parts with sodium hydroxide solution. - Pickling to clean up the surface with HCL solution. - Rinsing twice with fresh water to remove the acid content. - Fluxing with synthetic flux to prepare surface for galvanizing - Drying on hot plate - Dipping in zinc bath with 99.95% pure zinc at 450°C to 465°C temperature. - Quenching in water. - Dichromating - The galvanizing thickness is normally 460 gms per sq. meter for members below 5 mm thickness and 610 gms per sq. metre for members above 5mm thickness. - With this, the finished tower parts get ready for dispatch to sites.

08.04 Major Facilities in TLT Galvanizing Unit

Major facilities envisaged for the TLT Galvanizing Unit with their brief

technical features are given below:

Sl. Equipment / facilities Technical feature No.

1. Loading Hangers Adequate number of fabricated

steel hangers for loading the TLT

parts has been envisaged.

2. Degreasing Tank For cleaning the TLT parts with

sodium hydroxide solution.

3. Pickling Tank 4 nos. tanks for pickling the TLT

parts with HCl solution

4. Rinsing Tanks 2 nos. rinsing tanks for rinsing

the acid from TLT parts

5. Fluxing Tank 1 no. fluxing tank for treating

the TLT parts with synthetic flux

to prepare the surface for

galvanizing

6. Drying Hot Plate 1 no. for drying the TLT parts

before dipping into the Zinc

bath

7. Galvanizing Kettle (Size 1 no. for dipping the TLT parts in

10.5x1.5x3) zinc bath with 99.95% pure zinc

at 450°C to 465°C temperature

8. Quenching Tank 1 no. for cooling the Galvanized

TLT parts to below 100°C

9. Dichromating Tank 1 no. for treating the Galvanized

TLT parts with Dichromate

solution for surface protection

10. Fume Exhaust System For clearing the acidic fumes as

well as zinc fumes.

11. Effluent Treatment Plant For treatment of acidic as well

as alkaline effluents.

08.05 Process

The TLT parts fabricated in the TLT Fabrication unit, adjacent to the

Galvanizing Unit will be brought to the loading area of the preparation

bay and will be manually loaded on to the Hangers with the help of Steel

wires. The loaded hangers with counted number of pieces will then be

transferred to the Galvanizing bay with the help of an inter-bay transfer

car.

The loaded Hanger will be taken by the automated crane in the

galvanizing bay and will be dipped in the various tanks for the durations

as entered for that particular lot in the software.

The loaded hanger after coming out of the galvanizing chamber will be

transferred back to the unloading area of the preparation bay where the

galvanized TLT parts will be manually unloaded and counted for

accounting for all the pieces initially loaded on to the hangers. The

galvanized TLT parts are further manually brushed / filed for finishing and

packaged before transferring the same to finished product storage bays.

Galvanizing kettle shall be suitable for oil/gas firing.

08.06 Auxiliary Facilities

Auxiliary facilities such as hydraulic systems, lubrication systems, etc. will

be part of the individual machines.

08.07 Layout

The layout of the TLT Galvanizing Unit as shown in Drawing No.

MEC/11/24/123J/TEFR/002 will ensure smooth and unobstructed

movement of men and materials in the Galvanizing bays with minimum

handling.

The TLT Galvanizing Unit will be mostly of steel structures and will

comprise of bays and administrative building. Fume exhaust system has

been envisaged and is located by the side of the building. The shop floor

will be at ±0.00 level. Major parameters of the TLT Galvanizing Unit

complex are as given below:

Sl. Bay Bay Size Crane Crane Rail Qty. Remarks No. Designation (m) Capacity (t) Height (m)

Preparation Pendant 1. 144 x 25 5t 2 7 Bay Operated

Galvanizing Pendant 2. 144 x 25 2x4t 2 7 Bay Operated

Galvanizing Pendant 3. 144 x 25 2x5t 1 7 Bay Operated

5 nos. Transfer trolleys for transferring fabricated parts from Fabrication units to

galvanizing unit and for transferring Galvanizing parts from galvanizing unit to

finished product storage bays have been envisaged.

2 nos. Transfer car for transferring loaded hangers to and from galvanizing bays

have been envisaged.

09 ELECTRICS & AUTOMATION

09.01 Power requirement

The estimated power requirement of the proposed “Integrated Complex to

manufacture Transmission Line Towers” is 3.5 MW.

MD (MW) Annual Energy Consumption in Million Units (MU)

3.5 4.5

09.02 Source of Power supply:

Power requirement for the proposed plant shall be met preferably through 11 kV

feeders drawn from the nearest APSEB substation.

09.03 Power Distribution scheme

As described earlier, Power requirement for the proposed TLT complex shall be

met from 11 kV feeders drawn from the nearest APSEB substation. Presently, the

power is assumed as available at 11kV at Substation.

Two (2) nos. outgoing feeders of 11 kV Substation shall be used for tapping 11 kV

power supply and same shall be taken to new 11kV switchyard located near

newly proposed “Complex to manufacture Transmission Line Towers” thro new

intermediate transmission line towers using new transmission line conductors.

The downstream power distribution network comprises 11 kV / 415 V

transformers of appropriate ratings to meet the requirements of loads.

The proposed power distribution arrangement in phase wise manner is described

below:

11 / 0.415 kV Distribution Double Main Plant Unit ended Substation

Water supply / ETP / Fire fighting 2x1.0 MVA AN type

Gas/oil/ Compressor /cranes / air 2x1.0 MVA AN type

cond./Ventilation / Lighting

TLT Fabrication Units 2x1.6 MVA AN type

TLT Galvanizing Units 2x1.6 MVA AN type

Capacitor bank with reactors has been envisaged to take care of voltage

fluctuations, reactive power compensation and suppression of harmonics. Power

factor compensation has been foreseen to achieve overall power factor in the

region of 0.9 and above.

09.04 Design considerations

The power distribution network has been designed as a radial system, with two

alternative supply feeders to the load centre.

The design of power distribution system and selection of equipment has been

done based on the considerations of safety, reliability, ease of operation &

maintenance as well as convenience of future expansion.

The equipment shall conform to relevant Indian Standards, IEC specifications and

other applicable code of practice to meet the operational requirements and to

ensure reliable and trouble free service in the plant.

Basic Design Parameters

Incoming Power supply : 11 kV, 3 Ph, 50 Hz.

Drives and other consumers : 415 V, 3 ph, 50 Hz

Illumination and small power : 240 V, 1 ph. 50 Hz

Control power supply AC : 240 V, 1 ph, 50 Hz

DC : 220 V & 110 V

System Earthing

- 415 V : Effectively earthed

Symmetrical Short Circuit level

- 11 kV bus : 31.5 KA, 3 sec.

- 415 V bus : 50 KA, 1sec.

09.05 Major Facilities

09.05.01 11 kV Outdoor Switchyard

Two (2) nos outgoing feeders of existing 11kV Substation has been

envisaged for tapping existing 11kV power supply and same shall be taken

to newly proposed “Complex to manufacture Transmission Line Towers”

thro new intermediate transmission line towers using new transmission

line conductors.

The equipment design is based on capacity to withstand Short circuit

current of 31.5 kA, 3 second. Necessary system protections such as

distance protection, bus differential, transformer differential, over

current, earth fault etc have been foreseen. Aluminium pipe / ACSR

conductor has been considered for bus bars and interconnections.

09.05.02 HT Switchgear

The 11 kV switchgear shall be indoor type sheet metal clad, draw out type

comprising of VCB circuit breakers and shall be provided with necessary

protection, control gear, metering and audio-visual alarm annunciation

system. The circuit breaker mechanism shall be mechanically and

electrically trip free. The circuit breakers shall be electrically operated,

stored energy type.

09.05.03 415 V Switchgear

The 415 V switchboards shall comprise of air circuit breakers, in draw out

design and multi tier formation. The switchboard shall have two bus

sections and a bus coupler breaker with provision for auto changeover in

the event of loss of power of any one-bus section.

The circuit breakers shall be electrically operated and equipped with

microprocessor / static type direct acting releases for over load and short

circuit as well as earth fault protection.

All motor control centers (MCCs), large drives (above 110 kw) and power

distribution boards (PDBs) shall be supplied power from the 415 V

switchboard. The 415 V switchgear shall confirm to relevant IEC

specifications.

09.05.04 Transformers

The transformers shall conform to relevant IS and IEC specifications. The

11 kV transformers shall be copper wound, oil immersed, three phase and

ONAN design.

Off circuit tap-changers shall be provided for 11/0.415 kV distribution

transformers.

All the standard accessories such as conservator, breather, Buchholz

relay, OTI, WTI, oil level gauge, valves, explosion vent etc. shall be

provided for all the transformers.

09.05.05 Cables

Power inside the plant shall be distributed through cables to various

premises. Inter plant cabling has been envisaged through cable tunnel/

cable Trenches. Wherever necessary and where the cables are in small

number, these will be directly buried underground. Wherever cables are

in large number, concrete channels shall be used. GI pipes/ pipe blocks

shall be used at road crossings and paved area for protection of cables

against mechanical damage. Inside the substations and covered premises,

the cables shall be laid in basement or in concrete channels (over cable

supporting structures) or on columns and other available structures.

Power cables shall be laid on ladder type GI cable trays, whereas control

cable shall be laid on perforated cable trays.

All 11 kV cables shall be heavy duty, XLPE insulated, PVC sheathed multi

core, aluminum conductor steel wire armoured and shall be suitable for

resistance earthed/unearthed system.

Cables for 415 V systems shall be heavy duty, 1.1 kV grade, PVC insulated

PVC sheathed aluminum conductor, armoured / unarmoured as required.

The control cables shall be multi strand copper conductor, PVC insulated

and PVC sheathed with minimum cross section of 2.5 sq.mm /1.5 sqmm

for voltage circuit.

The HT cables, LT power and control cable shall confirm to relevant IEC

specifications.

09.06 Environmental conditions:

The following environmental conditions have been considered for

equipment design:-

 Electrical equipment located outside Electrical Control Rooms (ECRs)

shall be designed for maximum ambient temperature of 50C and

maximum relative humidity of 95% (both not occurring

simultaneously).

 Electrical equipment located inside ECR shall be designed for maximum

Ambient temperature of 45C and maximum RH of 95 % (both not

occurring simultaneously.

 Electronic equipment such as digital invertors / VFDs etc. have been

envisaged to be installed inside air conditioned enclosures within ECR

with an ambient temperature of maximum 35 C.

 Electronic equipment such as PLC’s , PCs etc. have been envisaged to

be installed inside air conditioned enclosures within ECR with an

ambient temperature of 21-24C. Pulpits has also been envisaged to be

air conditioned with temp at 21-24C.

09.07 Power Distribution Facilities

.01 HT Voltage 11000V AC +6 –9% %, 3 phase

.02 LT Voltage 415 V AC +/- 10 %, 3 phase

.03 Rated frequency 50 Hz +3 -5%

.04 Control voltage 240V AC through 415 V / 240 V

transformer

.05 PLC Inputs/outputs 24 V DC, 4-20 mA

.06 Solenoids 24V DC

09.08 Shop Electrics & illumination system:-

The following shop electric facilities have been considered covering broadly

the areas as given below: -

i. Illumination system.

ii. LT sub distribution boards

iii. Welding sockets.

iv. Crane power feeding system

v. Motor control centers / Power distribution Board / Main lighting

Distribution board with necessary Local control stations / control desk

for the mill /lines aux. viz. Air conditioning & ventilation system, water

supply system, Compressed air system, Material handling equipment

etc. The ventilation and air-conditioning system for electrical premises

shall be generally located in the respective basement floor.

vi. Complete LT/HT power cables, control cables, screened cables/ special

cables.

vii. Cable structures, racks, trays, GI pipes etc. including various erection

accessories & materials for the complete laying & erection of electrical

equipment.

viii. Equipment earthing system including separate electronic earthing for

PLC/ Electronic equipment.

ix. Lightning protection of building/ structures

x. Fire detection system.

xi. Automatic detection for ECRs , pulpits , oil cellars & transformer

rooms , cable tunnels and sub-station.

xii. Voice communication equipment for all facilities like ECRs, pulpits, oil

cellars, sub-station, pump house, Shop floor area, shift rooms etc.

The lighting system inside and outside plant units has been considered taking

into consideration the architectural arrangement, building dimensions

including mounting height, environmental considerations, ease of

maintenance and reliability of the lighting distribution network. The plant

shall be provided with necessary indoor and outdoor lighting system.

Plant Grid earthing system has been considered for the safety of electrical

equipment and personnel. Parts of all electrical equipment and machinery

not intended to be alive shall have two separate and distinct earth

connections each to conform to the stipulation of the Indian Electricity Rules

and apparatus rated 240V and below may have single earth connections.

Electronic earthing has been considered if separately required for

automation equipment such as PLCs/ HMI etc. Lightning Protection System

for each building /bay has been considered against lightning, for the safety of

building, equipment and personnel.

All LT power and control cables have been considered which shall be of PVC

insulated and sheathed, armoured / unarmoured of 1100V grade. Power

cables shall be of size 6mm & above will be of aluminium. Control cables

shall be of copper conductors. Special cables have also been considered

wherever required.

09.09 DG Set

A DG set of adequate capacity has been envisaged to cater to emergency

power requirements of the Complex.

10 PLANT SERVICES & UTILITIES

10.01 Water Supply Facilities

10.01.01 General

Water for the proposed COMPLEX FOR MANUFACTURING

TRANSMISSION LINE TOWERS will mostly be required for direct and

indirect cooling of plants/ machines/ equipment with a part to be

consumed for drinking and sanitation purpose and other direct process

and general purpose needs. Individual recirculation system has been

envisaged for water systems of various plant units to effect extensive

recycling and reuse of return water from plant processes after necessary

treatment and conditioning.

10.01.02 Requirement of Water

The total make-up water requirements for the proposed integrated

Complex for manufacturing Transmission Line Towers is estimated as 5

m3/h (Approx.).

10.01.03 Breakup of Circulation Water Requirement

The unit wise break-up of make up water and circulating water

requirements of various plant units of the proposed Plant are indicated in

Table-11.01.

Table – 10.01

Estimated Water Requirement (m3/hr)

Sl. Circulating water No. Consumer /units M3/hr

A TLT FABRICATION UNIT (2 Nos.) Industrial Water 20 B HOT DIP GALVANIZING UNIT (2 Nos.) Industrial Water 30 C COMPRESSOR 50 Total Water Circulation (m3/hr) 100

Drinking water requirement for plant = 50 m3 / day

Estimated Make-up water requirement will be of the order of 5 m3/hr.

10.01.04 Source of Fresh Make-Up Water

The requirement of fresh make-up water for the proposed Plant will be

met by a dedicated borewell, subsequently water treatment plant shall be

planned to achieve the desired quality before pumping to the proposed

units.

10.01.05 Proposed Facilities

To cater to the water requirement of the proposed Plant, the following

water system facilities have been envisaged.

i) Make-up water system

Industrial quality treated water, drawn from the make up water

treatment plant will be provided to all the re-circulation systems as well

as other direct consumers of proposed Plant.

ii) Drinking Water System

Treated water will be further processed to have drinking quality water.

10.01.06 Water Re-circulation Systems

The following water re-circulation systems have been envisaged.

a) Clean water re-circulation system for TLT Fabrication unit, Hot Dip

Galvanizing Unit, compressor.

b) Contaminated water system for TLT Fabrication unit, Hot Dip

Galvanizing Unit.

10.01.07 Water pollution control and conservation

Extensive recycling has been adopted in the design of plant water

systems. Quality of circulating water will be maintained through dosing of

conditioning chemicals for controlling corrosion, scale deposit and

microbiological growth.

Waste water from treatment plant will be neutralized before discharge

from the plant. The sludge arising out of different circuits will be disposed

of at suitable location.

10.02 Air Conditioning & Ventilation System

General