Req Equip Material Devlopment Powersector

Requirement of EQUIPMENT
AND MATERIAL FOR

DEVELOPMENT OF
POWER SECTOR
Generation and Transmission Projects of
11th And 12th Plan
Government of India
Ministry of Power
Central Electricity Authority

Planning Wing
New Delhi
November 2006
REQUIREMENT OF
EQUIPMENT AND MATERIAL FOR
DEVELOPMENT OF
POWER SECTOR
Generation and Transmission

Projects of
11th And 12th Plan
Requirement of Equipment & Material for Development of Power Sector
CONTENTS
CHAPTER TITLE
CHAPTER-1
1.1
1.2
1.3
1.4
Preface
Foreword
Executive Summary
i
ii
ES-1 ES-3
INTRODUCTION
1.1-1.3
Background
Growth in Power Sector
Regulatory & Structural Reforms
National Electricity Policy and Plan
CHAPTER-2 GENERATION CAPACITY ADDITION

PROGRAMME
2.1
Eleventh Plan (2007-12)
2.2
4.2.3
4.2.4
2.1-2.4
Twelfth plan(2012-2017)
CHAPTER-3 REQUIREMENT OF ELECTRICAL EQUIPMENTS

( INCLUDING SWITCHYARD EQUIPMENT)
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
Steel Requirement for Generation
4.1.1
4.1.2
4.1.3
4.2
4.2.1
4.2.2
PAGE
3.1-3.16
4.1-4.10
Hydro Power Plants

Thermal Power Plants
Nuclear Power Plants
Requirement of Steel for Power System
Requirement of Steel for tower
Steel Requirement & Aluminium for Conductor & Earth
wire
Requirement in respect of special steel CRGO & Copper
for power transformers
Estimated Structural Steel Requirement for Sub-stations
Contents
LIST OF APPENDICES
S.NO.
1.
2.
3.
TITLE
PAGE
NO.
Typical Steel quantity for 2x500 MW unit as 1.1-1.5
given by BHEL
Estimated Quantity of Steel for 11th and 12th 2.1-2.5
Plan coal based projects
Estimated Quantity of Steel for 11th and 12th 3.1-3.4
Plan Gas based projects
Contents
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
Preface
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
Dated: 23 November 2006
( V S Verma)
Member ( Planning)
ii
Forward
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 Governments 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, delicensing, 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.
ES-1
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
ES-2
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.
ES-3
Executive Summary
CHAPTER-1
INTRODUCTION
1. 1 BACKGROUND
Electricity is a vital input for economic and social development of our society.
Besides its importance in the growth of the countrys economy, it plays a major role 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 Governments 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.
1.1
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 201217 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, delicensing, 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.
1.2
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.
1.3
INTRODUCTION
CHAPTER-2
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.
2.1
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)
Sector/Fuel
Hydro
Total
17,189
Thermal
Coal/Lignite
Gas/LNG
46,114
44,000
2,114
Nuclear
Total
3,160
66,463
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
1
Coal/Lignite-44,000 MW
Unit size
2.
3.
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
d.
125 MW
875
Gas/LNG - 2114 MW
No. of gas modules
No. of projects
Total Thermal Capacity Addition -46,114 MW
* No such categorisation for Hydro Plants
2.2
2.2
TWELFTH PLAN (2012-2017)
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 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)
Sector/Fuel
Total
30000
Hydro
44,500
Thermal
Coal/Lignite
44,500
Gas/LNG
NIL
12000
Nuclear
Total
86500
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
40(39+1)
31860
10
a.
800/660 MW
b.
500 MW
18
9000
10
c.
310/250/210 MW
14
3640
* No such categorisation for Hydro Plants
2.3
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.
2.4
CHAPTER -3
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.
3.1
Table-3.1
Requirement of Equipments for 660/800 Mw Coal/Lignite Based Units of 11th
Plan and 12th Plan Capacity Addition Programme
Item
Requirement
for
One unit of
660 MW
GT* 260MVA Gen V/420/3kV

Three phase bank
11th Plan
12th Plan
Total
12 Units
(6 Projects)
40 Units
(10 Projects)
52 Units
(16 Projects)
130
40
80
10
10
172
52
104
16
16
UT 35MVA Gen V/11.5kV

ICT 200MVA 400/132kV
Misc. Service Transformer
20 MVA 132/34.5kV
Aux. Transformer 11/3.45kV
33kV Switchgear
11 kV Switchgear
3.3 kV Switchgear
HT Motors
LT Motors
1
2
-
42
12
24
6
6
4
8
68
84
146
1404
48
96
816
1008
1752
16848
160
320
2720
3360
5840
56160
208
416
3536
4368
7592
73008
LT Transformers
LT MCC Panels
415 V Switchgear Panel
DC Battery
Battery Charger
33 kV Single Core Cable (km)
11kV Single Core Cable (km)
11kV Multi Core Cable (km)
3.3 kV Single Core Cable (km)
3.3 kV Multi Core Cable (km)
1.1 kV Power Cable (km)
1.1 kV Control Cable(km)
Emergency DG Set 1500KVA*
32
350
100
5
7
3
21
24
8
12
233
367
1
384
4200
1200
60
84
36
252
288
96
144
2796
4404
1280
14000
4000
200
280
120
840
960
320
480
9320
14680
50
1664
18200
5200
260
364
156
1092
1248
416
624
12116
19084
68
ST 90/45/45 MVA 132/11.5/11.5 kV
18
* 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.
3.2
Table-3.2
Requirement of Equipment for 500 MW Coal/Lignite Based Units of 11th Plan and 12th
Plan Capacity Addition Programme
Item
GT* 200MVA Gen V/420/3kV
Three Phase Bank
ST 80/40/40MVA
132/11.5/11.5 kV
UT 50 MVA Gen V/11.5kV
ICT 125 MVA 400/132kV
Aux. Transformer
11 kV Switchgear
3.3 kV Switchgear
HT Motors
LT Motors
LT Transformers
LT MCC Panels
DC Battery
Battery Charger
11 V Single Core Cable(km)
11 kV Multi Core Cable( km)
3.3 kV Single Core Cable
( km)
1.1 kV Power Cable( km)
1.1 kV Control Cable (km)
Emergency DG Set
1500KVA*
Requirement
11th Plan
for
One unit of
47 Units
500 MW
(30 Projects)
12th Plan
Total
18 Units
(10 Projects)
65 Units
(40 Projects)
171
64
235
1
1
5
63
66
118
1135
30
287
75
4
6
13
18
47
47
30
235
2961
3102
5546
53345
1410
13489
3525
188
282
611
846
18
18
10
90
1134
1188
2124
20430
540
5166
1350
72
108
234
324
65
65
40
325
4095
4290
7670
73775
1950
18655
4875
260
390
845
1170
12
8
200
375
564
376
9400
17625
216
144
3600
6750
780
520
13000
24375
77
28
105
* 1 no. spare GT and 1 no. spare DG have been considered for each project
3.3
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
Item
GT* 315MVA Gen V/237kV
Three Phase
ST 55/27.5/27.5 MVA
220/6.9/6.9 kV
UT 20 MVA Gen V/6.9 kV
Misc Service Trans 10MVA
6.6/11.5
11 kV Switchgear
6.6 kV Switchgear
HT Motors
LT Motors
LT Transformers
LT MCC Panels
DC Battery
Battery Charger
11kV Single Core Cable( km)
11kV Multi Core Cable( km)
6.6kV Single Core Cable(km)
6.6kV Multi Core Cable( km)
1.1kV Power Cable (km)
Emergency DG Set
1500KVA*
Requirement for
One unit of
300/250/210 MW
11th Plan
12th Plan
Total
45 Units
14 Units
59 Units
(27 Projects) (12 Projects) (31 Projects)
72
18
90
1
2
45
90
14
28
59
118
1
15
96
93
1041
26
225
75
6
6
2
2
16
16
200
400
1
45
675
4320
4185
46845
1170
10125
3375
270
270
90
90
720
720
9000
18000
72
14
210
1344
1302
14574
364
3150
1050
84
84
28
28
224
224
2800
5600
18
59
885
5664
5487
61419
1534
13275
4425
354
354
118
118
944
944
11800
23600
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.
3.4
Table-3.4
Requirement of Equipment for 125 MW Coal/Lignite Based Units Of 11th Plan
Capacity Addition Programme
Requirement for
One unit of 125
MW
1
1
2
1
15
96
45
324
25
17
75
6
6
2
2
16
16
200
400
1
ITEM
GT* 160MVA Three Phase
ST 55/27.5/27.5 MVA
UT 20MVA
Misc Service Trans 20 MVA
11 kV Switchgear
6.6 kV Switchgear
HT Motors
LT Motors
LT Transformers
LT MCC Panels
DC Battery
Battery Charger
6.6 kV Single Core Cable (km)
1.1kV Power Cable(km)
Emergency DG Set 1500KVA*
11th Plan
7 Unit
( 4 Projects)
11
7
14
7
105
672
315
2268
175
119
525
42
42
14
14
112
112
1400
2800
11
* 1 no. spare GT and 1 no. spare DG have been considered for each project
11
th
v) Item wise requirement of equipment for gas based thermal plants during
and 12th Plans is given in Table3.5.
3.5
Table-3.5
Requirement of Equipment for Gas/LNG Based Units
of 11th Plan and 12th Plan Capacity Addition Programme
Item
Gen. Transformer
(2 nos. 114 MVA & 1 nos.146
MVA)
Unit Aux Transformer 20 MVA
HT Motors
LT Motors
LT Transformers
DC Battery
Battery Charger
Emergency DG Set
Gen. Circuit Breaker
6.6 kV Switchgear
HT Power Cable (km)
LT Power & Control Cable (km)
Requirement
11th Plan
for One module 9 modules
(360 MW)
(7 projects)
34
2
13
36
10
17
7
11
1
6
31
200
500
18
117
324
90
153
63
99
16
54
279
1800
4500
) 1 no. spare GT and 1 no. spare DG have been considered for each project
vi) Total requirement of equipment (Item wise) for thermal plants during
12th Plans is given in Table 3.6.
3.6
11and
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
Total
Requirement
for
Gas/LNG
Based Plants
34
GT
Total Requirement
for Coal/ Lignite
Based Plants
508
ST
183
UT
301
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
Item
Total
542
183
18
319
279
6615
3.3 kV Breaker
8658
HT Motors
21064
117
21181
8658
LT Motors
210470
324
210794
LT Transformers
5323
90
5413
LT MCC Panels
50249
15025
153
15178
DC Battery
916
63
979
Battery Charger
1150
99
1249
156
156
2069
2069
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
50249
HT Power Cable
1800
1800
LT Power&Control Cable (km)
4500
4500
54
Gen. Circuit Breaker
54
1.1kV Power Cable (km)
38316
38316
1.1kV Control Cable (km)
69859
69859
274
Emergency DG Set 1500KVA
16
290
1 no. spare GT and 1 no. spare DG have been considered for each project
3.7
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.
a.
b.
c.
d.
e.
f.
B.
a.
b.
765 kV Switchyard Equipment-Breaker and a half scheme

(For projects having unit size of 800 MW)
11th Plan
12th Plan
Requirement for
Item
(2 Projects) (9 Projects)
one Bay
(12 Bays )
(54 Bays )
Circuit beaker
3 nos. per 2 bays
18
81
Isolators
4 isolators per bay
48
216
Current
2 sets per bay
Transformer
24
108
1 set per line bay
CVT/PT
& 1 set per bus bar
16
72
Lightning arrestor 1 set per bay
12
54
Wave Trap
2 nos. per bay
24
108
400 kV Switchyard Equipments- Breaker and a half scheme
(For projects having unit size of 660 MW & 500 MW)
12th Plan
11th Plan
Requirement for
(11
Item
(34 Projects)
one Bay
Projects)
(204 Bays )
(96 Bays )
Circuit beaker
3 nos. per 2 bays
306
99
Isolators
4 isolators per bay
816
264
3.8
Total
(11Projects)
(66 Bays )
99
264
132
88
66
132
Total
(53 Projects)
(318 Bays )
405
1080
Current
Transformer
2 sets per bay
d.
CVT/PT
1 set per line bay

& 1 set per bus bar
e.
Gapless lightning
arrestor
1 set per bay
f.
Wave Trap
2 nos. per bay
c.
C.
a.
b.
c.
d.
e.
f.
D.
a.
b.
c.
d.
e.
f.
408
132
540
272
88
360
204
66
270
408
132
132 KV Equipments- Main and transfer Scheme
(For projects having unit size of 800 MW, 660 MW & 500 MW)
11th Plan
12th Plan
Requirement for
Item
(36 Projects) (20Projects)
one Bay
(216 Bays )
(120 Bays )
Circuit beaker
1 no. per bay
216
120
Isolators
3 isolators per bay
648
360
Current
1 sets per bay
Transformer
216
120
1 set per line bay
CVT/PT
& 1 set per bus bar
324
180
Gapless lightning
1 set per bay
arrestor
216
120
Wave Trap
2 nos. per bay
432
240
540
Total
(66 Projects)
(336 Bays)
336
1008
336
504
336
672
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) )
Total
11th Plan
12th Plan
Requirement for
(46
Item
(34 Projects) (4 Projects)
Projects)
one Bay
(218 Bays)
(24 Bays)
(290 Bays)
Circuit beaker
1 nos. per bays
218
24
242
Isolators
3 isolators per bay
654
72
726
Current
1 sets per bay
Transformer
218
24
242
1 set per line bay
CVT/PT
& 1 set per bus bar
320
36
356
Gapless lightning
1 set per bay
arrestor
218
24
242
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.
3.9
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 CTs: Number of CTs 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.
3.10
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:
3.11
Table-3.8
Total Requirement of Equipment for Hydro Projects
of 11th Plan and 12th Plan Capacity Addition Programme
No.
1.
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Equipment
Hydro-Mechanical
Gates & Hoist (sets)
(i) Radial spillway Gates
(ii) Vertical Lift Gates
Butterfly Valve (Sets)
Main Inlet Valve (Sets)
Electro-Mechanical
Turbine (MW)
Turbine (No.)
Digital Governors (Nos.)
Syn. Generator (MVA)
Syn. Generator(No.)
11th Plan
12th Plan
(17,189 MW)
(30,000 MW)
276
482
757
403
31
115
704
54
200
1107
85
315
17189
30000
199
199
350
350
18908
32999
47,189
549
549
51,907
350
350
549
549
2384
3,750
398
105
627
549
165
350
549
66962
105,328
16072
350
25,280
549
36697
361
57,723
568
831
565
281
1687
868
1968
968
234
73
32
1307
888
443
2654
1365
3096
1523
368
115
51
199
Unit Control Board (sets)
199
Motor & Motor Control Centres
(Units)
1366
Transformers (UAT & SST)
(MVA)
228
Static Excitation System (Sets)
199
Dynamic Braking Isolators (Sets)
60
NG cubicle incl.
Transformer (Set)
199
11/13.8 kV/24kV Isolated Phase
Bus Ducts (IPBD) (metres)
38367
11/13.8/24 kV CTs
( 1-Phase Units)
9208
SAVT Cubicle (Sets)
199
132kV/220kV/400 kV Generator
Transformer (MVA)
21026
11kV Switchgear Boards (Units)
207
132kV/220kV/400 kV Outdoor switchgear (Units)
Circuit breaker
476
Capacitor voltage
323
transformer(CVT)
EHV Voltage Transformers
161
Lighting Arresters(LA)
967
Isolators
497
EHV Current Transformers
1128
415 V Switchgear Board Units
555
220/400 kV GIS (Bays)
134
EHV XLPE Cable (Km)
42
EHV Bus Duct (Km)
18
3.12
350
Total
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
S.N
o.
1.
2.
3.
4.
Voltage
Level
765 kV
400kV
220kV
132kV
No. of Bays
11 Plan 12th Plan
62
62
774
774
3060
3060
7280
7280
th
Total
124
1548
6120
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.
3.13
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
11th
12th
Plan
Plan
(2007- (2012NORMS
2012)
2017)
Total Nos.
Total No. of
Bays
Circuit Breaker
Isolator
CT
PT/CVT
3 nos. per 2
bays
4 isolators
per bay
2 sets per/
bay
1 set per line
bay & 1 set
per bus bar
62
62
93
93
248
248
124
124
71
71
NORMS
3 nos. per 2
bays
4 isolators
per bay
2 sets per
bay
1 set per line
bay & 1 set
per bus bar
400 kV
11th
12th
Plan
Plan
(2007(20122012)
2017)
Total Nos.
774
774
1161
1161
3096
3096
1548
1548
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
3.14
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
220 kV
Nos.
11th Plan
(20072012)
12th Plan
(20122017)
132 kV
Nos.
Total Nos.
Total No. of Bays
3060
3060
11th Plan
(20072012)
12th
Plan
(20122017)
Total Nos.
7280
7280
CB
1no. per bay
3060
3060
1no. per bay
7280
7280
Isolator
4 isolators
per bay
1 set per bay
12240
12240
21840
21840
3060
3060
3 isolators per
bay
1 set per bay
7280
7280
3060
3060
7280
3060
3060
1 set per line

bay & 1 set
per bus bar
1 set per bay
7280
LA
1 set per line

bay & 1 set
per bus bar
1 set per bay
7280
7280
Wave
Trap
2 nos. per
bay
6120
6120
2 nos. per bay
14560
14560
CT
PT/CVT
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.
3.15
Table 3.12
Total Electrical Equipment for Power System
S.No.
1.
2.
3.
4.
5.
6.
Item
Circuit
Breaker
Isolator
CT
PT/CVT
Lightening
Arrestor
Wave Trap
11th Plan
12th Plan
Total
11594
11594
23188
37424
12012
11301
37424
12012
11301
74848
24024
22602
11176
11176
22352
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.
3.16
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
34
93
Structural Steel
Reinforcement Steel
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
Steel
Structural Steel
Reinforcement Steel
Total
11th Plan (17189 MW)

5.8
16.0
21.8
4. 1
Lakhs Tonnes
12th Plan (30000 MW)
Total
10.2
16.0
27.9
43.9
38.1
59.9
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.
4. 2
Table 4.3
Estimated Quantity of Steel for 11th and 12th Plan coal/ lignite Based Projects
Sl.No.
Equipment/
System
Type of steel used

1
1.1
11th Plan coal based 44,000 MW

(MT)
Imported
Indigenous
Total
12th Plan coal based 44500 MW

(MT)
Imported
Indigenous
Total
Boiler
Drum
20108
1320
21428
20337
1335
21672
54912
182160
1312916
196196
1367828
378356
55536
184230
1327836
198426
1383372
382656
257180
1510432
1767612
260103
1527596
1787699
236060
236060
238743
238743
93192
0
Electrostatic Precipitator
320760
377960
Main and Aux.Buildings
0
1961520
PowerTransformers
58432
0
(CRGO)
7
Motors
13200
18700
8
Switchyard
0
68200
9
Coal Handling Plant
0
616000
Turbine/Gen./Condenser
10
10.1
Plates
72336
79464
10.2
Rounds
1760
14256
10.3
Structural Steel, IS 2062
1760
4400
10.4
Bloom,Class2 & Class 3
0
5280
Total(Turbine/generator/condenser
75856
103400
Pumps/Heat Exchangers/Drive-Turbines and Pulverisers
11
11.1
LP and HP Heaters
6160
3960
11.2
Deaerators
3784
396
11.3
Pulverisers
616
14608
11.4
Drive Turbines
88
528
11.5
Structurals
0
616
11.6
Bar Stock
1100
1056
11.7
Pipes
968
1672
Sub Total(Pumps etc.)
12716
22836
GRAND TOTAL (MT)
831,336
4,915,108
93192
698720
1961520
94251
324405
0
0
382255
1983810
94251
706660
1983810
58432
31900
68200
616000
59096
13350
0
0
0
18913
68975
623000
59096
32263
68975
623000
151800
16016
6160
5280
73158
1780
1780
0
80367
14418
4450
5340
153525
16198
6230
5340
179256
76718
104575
181293
10120
4180
15224
616
616
2156
2640
35552
5,746,444
6230
3827
623
89
0
1113
979
12861
840783
4005
401
14774
534
623
1068
1691
23096
4970962
10235
4228
15397
623
623
2181
2670
35956
5811745
1.2
Structures/Non-Pressure
parts
1.3
Pressure Parts
Total (Boiler)
2
3
Low Pressure Piping

High Pressure/PC piping
4
5
6
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
4. 3
Table 4.4
Estimated Quantity of Steel for 11th Plan Gas Based Projects
Sl.
No
1.
1.1
1.2
1.3
2.
3.
4.
5.
6.
7.
8.
8.1
8.2
8.3
8.4
9
9.1
9.2
9.3
9.4
9.5
9.6
Equipment/
Systm
Type of steel used
11thPlan Gas- 2114 MW

Imported
Indigenous
(MT)
Total
Boiler
Drum:
483
32
515
Structures/NonPressure parts
1319
31540
32859
Sub-total for Pressure
Parts
4376
4713
9089
6178
36285
42463
Total(Boiler)
0
5671
5671
LP Piping
2239
0
2239
HP/PC Piping
Main and
Aux.Buildings
0
47121
47121
Power Transformers
2807
0
2807
(CRGO)
Motors
317
449
766
0
3277
3277
Switchyard
Plates
1738
1909
3647
Rounds
42
342
385
Structural Steel, IS
2062
42
106
148
Bloom,Class2 &
Class 3
0
127
127
Total(Turbine/gen/c
1822
2484
4306
ondenser)
Pumps/Heat Exchangers/Drive-Turbines and Pulverisers
LP and HP Heaters
148
95
243
Deaerators
91
10
100
Drive Turbines
2
13
15
Structurals
0
15
15
Bar Stock
26
25
51
Pipes
23
40
63
291
198
488
Sub Total(Pumps)
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 11th &
12 Plan is furnished in Table 4.5 below:
th
4. 4
Table- 4.5
Summary of Total Steel Requirement for 11th &12th Plan Thermal Power Projects
Coal Based Power

Projects
Gas Based Power
Projects
Total
11th Plan
(MT)
12th Plan
(MT)
57,46,444
58,11,745
1,09,138
1,09,138
58,55,582
58,11,745
1,16,67,327
Total
(MT)
1,15,58,189
As evident from above, for 11th 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)
Imported Steel Indigenous Steel Total Steel
4.2
11th Plan
(3160 MW)
0.6
3.5
4.1
12th Plan
(12000 MW)
2.3
13.4
15.7
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.
4. 5
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
Line
S.No Voltage
(kV)
1
2
3
4
5
765
500
HVDC
400
220
132
TOTAL
Norms for
weight of
steel for
Towers
MT/Km
65
Total All India

(11th Plan)
Total
Weight of
ckt.
steel for
Km
towers
(MT)
3200
208000
Total All India

(12th Plan)
Total
Weight of
ckt.
steel for
Km
towers
(MT)
3200
208000
38.3
5400
206820
5400
23.5
10.1
9.1
44440
23000
20000
1044340
232300
182000
1873460
44440
23000
20000
206820
Type of Steel used
MS
(MT)
HTS (40%
of Total
weight)
(MT)
249600
166400
248184
165456
835472
1044340 1253208
232300 464600
182000 364000
1873460 2579592
1167328
NOTE: Structural steel angle section manufactured according to the latest IS: 8081976(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.
4. 6
Table-4.8
Requirement of Aluminium and Steel for Conductor and Earth Wire for 11th Plan
S.
No.
Voltage (kV)
1
2
3
4
5
6
765
500 (HVDC)
400
220
132
Total
Norms for Weight of

Material for
Transmission Lines
(MT/ckt kM)
Aluminum
Steel
23.14
4.64
15.43
3.50
8.87
4.53
3.60
1.79
1.78
1.64
Total
Ckt.kM
Total All India Weight

(MT/ckt kM)
Aluminum
3200
5400
44440
23000
20000
74048
83322
394183
82800
35600
669953
Steel
14848
18900
201313
41170
32800
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
Norms for Weight of
Material for
Total
Total All India Weight
S. No. Voltage (kV)
Transmission Lines
Ckt.kM
(MT/ckt kM)
(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
669953
309031
Total
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:
4. 7
Table- 4.10
Norms for requirement of Special Steel and Copper for power transformers
CRGO Requirement
(MT/MVA)
Copper Requirement
(MT/MVA)
765 kV
400 kV
220kV
132kV
0.4
0.4
0.5
0.8
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
Power
Transformer
Rating
11th Plan
(2007-2012)
Total
CRGO
Copper WT
MVA
WT
(inTons)
Capacity (inTons)
12500
5000
2500
765 kV
44310
17724
8862
400 kV
73700
36850
22110
220 kV
52000
41600
26000
132 kV
Total required CRGO weight (in Tons) for 11th Plan
Total required CRGO weight (in Tons) for 12th Plan
Total required Copper weight (in Tons) for 11th Plan
Total required Copper weight (in Tons) for 12th Plan
Total
MVA
Capacity
12500
44310
73700
52000
101174
101174
59472
59472
12th Plan
(2012-2017)
CRGO
Copper WT
WT
(in Tons)
(in Tons)
5000
2500
17724
8862
36850
22110
41600
26000
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:
4. 8
Table-4.12
Requirement of Special Steel for Substation
Voltage
level
765 kV
400 kV
220kV
132 kV
Total
Norms for
Special steel
requirement
for substation
(MT/bay)
75
50
35
25
11th Plan
12th Plan
Total No.
of Bays
Requirement
(MT)
62
774
3060
7280
4650
38700
107100
182000
332450
Total
No. of
Bays
62
774
3060
7280
Requirement
(MT)
4650
38700
107100
182000
332450
Total
Requirement
of Special steel
for substation
(MT)
9300
77400
214200
364000
664900
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
Steel for Tower

Steel for conductor & Earth Wire
Special Steel -CRGO for Power
Transformer
Structural Steel for Sub-Stations
Total
11th Plan
(MT)
1873460
309031
12th Plan
(MT)
1873460
309031
Total
(MT)
3746920
618062
1,01,174
1,01,174
202348
3,32,450
2616115
3,32,450
2616115
664900
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 belowIn Lakh Tonnes
11th Plan
12th Plan
Total
Hydro Projects
Thermal Projects
Nuclear
Power System
Total
21.8
58.5
4.1
26.2
110.6
4. 9
38.1
58.1
15.7
26.2
138.1
59.9
116.6
19.8
52.4
248.7
4. 10
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 :

1
1.1
Imported
Total
Boiler
Drum :
Pipe : (OD 88.9 to 863mm, thickness 11.13 to 130mm)
Carbon Steel Pipe
Plate : (Thickness 1.6 to 190mm)
1.2
Indigenous
Boiler Quality Plates

421
Stru Plates
0
JPC Plates and Sheets
0
Bar Stock : (Dia 6mm to 250mm)
Round
29
Sub-total for Drum
457
Structures/Non Pressure parts
0
2
28
421
2
28
0
30
29
487
34
413
200
0
100
1,701
34
513
1,901
Alloy Steel Plates

255
17
Stru Plates
245
JPC Plates and sheets
0
Stainless Steel Pipes
0
Round
0
STRU : (Various Sizes)
Angles, Beams and Channels
0
Tubes : (OD 14.2 to 76.1mm, thickness 2 to 12.5 mm)
0
0
245
17,135
115
255
17
490
17,135
115
214
214
9,844
9,844
0
67
415
3
18
133
415
3
Alloy Steel Pipes

Carbon Steel Pipes
ERW Pipes
Alloy Steel Tubes

Carbon Steel Tubes
ERW Tubes
Stainless Steel Tubes
18
66
0
0
1.1
Appendix 1
S. No.
Equipment /System

by BHEL (MT)
1.3
Imported
Sub- total for Structures / Non1,248

Pressure parts :
Pressure Parts :
31,087
228
500
0
146
228
646
Alloy Steel Plates

462
434
0
Stainless Steel Plates
0
Round
0
FLAT
134
0
0
0
982
117
462
434
982
117
300
300
0
532
134
532
Alloy Steel Tubes

Carbon Steel Tubes
Sub-total for Pressure Parts
951
1,330
101
4,140
951
1,330
101
4,459
Total Qty. for Boiler (1.1+1.2+1.3)
5,845
34,328
40,173
1,902
2,660
202
8,599
0
0
0
0
0
4,194
655
263
253
5,365
4,194
655
263
253
5,365
372
1,046
700
2,118
0
0
0
0
372
1,046
700
2,118
LP piping
IS 3589
IS 1239
IS 1239 (GAL)
SS
Total for LP Piping
Total
29,839
Alloy Steel Pipes

Carbon Steel Pipes
Indigenous
HP critical/PC piping
SA335P91
SA335P22
SA106GRC
Total for HP/PC Piping
1.2
Appendix 1
S. No.
Equipment /System

by BHEL (MT)

4
Imported
Total
Plates 5/6 mm
CR Coil 1.5/1.25 mm
Columns(HEA/HEB), Beams(ISMB
300/400)
Angles(50x50x6,75x75x6,80x80x8,10x7
5x6)/Channels(C150,C200,C250)
0
2,340
2,500
4,530
1,000
500
4,530
3,340
3,000
2,560
2,560
Hollows (150 to 300)

Total for EP
2,450
7,290
0
8,590
2,450
15,880
Plates
Angles
Channels
Joists
Misc. Chequered Plates/Handrails etc.
0
0
0
0
0
21,460
3,938
4,296
5,370
716
21,460
3,938
4,296
5,370
716
Reinforce Steel
Total for Main & Aux. Bldgs.
0
0
8,800
44,580
8,800
44,580
1,120
208
1,328
0
0
0
1,120
208
1,328
CRNGO, M530-65A, 800-1250width
300
300
Shaft forging (Low Alloy Steel)

IS2062 Steel Plates
Total for Motors
0
0
300
125
300
425
125
300
725
Lattice structure
Pipes
Earthing Rods/Strips
Total for Switchyard
0
0
0
0
725
125
700
1,550
725
125
700
1,550
Coal Handling Plant

8,000
8,000
Main and Aux. Buildings
Power Transformers (CRGO)

Grade-ZDKH85 0.23 thk
Total for Power Transformers
Indigenous
Motors
Switchyard
1.3
Appendix 1
S. No.
Equipment /System

by BHEL (MT)
Imported
Reinforce Steel
Total for CHP
10
10.1
10.2
10.3
10.4
11
11.1
11.2
Indigenous
Total
0
0
6,000
14,000
6,000
14,000
530
1480
2,010
1,020
260
1,280
20
30
50
10
10
64
36
100
1,644
1,806
3,450
166
170
36
40
40
0
1,724
158
324
100
120
2,350
194
364
140
120
4,074
Pumps/Heat Exchangers/ DriveTurbines and Pulverisers

LP and HP Heaters :
Plates :
Boiler Quality Plates, Various sizes from
5mm to 200mm
STRU Plates, Various sizes from 5mm to
200mm
Sub- total for plates-HP/LP Heaters
140
48
188
42
42
140
90
230
Deaerators :
Plates :
Boiler Quality Plates, Various sizes from
5mm to 200mm
STRU Plates, Various sizes from 5mm to
200mm
86
86
Plates :
MS Plates, 5mm to 90mm, IS20062 GRA &GR-B
B Q Plates, 6mm to 250 mm, IS2002
GR-2
CS Plates, 12mm to 160mm, SA516 GR70
AS Plates, 10mm to 125mm, 17MO4 &
12MX
SS Plates/Sheets, 0.5mm to 80mm,
AA10739, AA10740, HW10782 and HW
10788
Sub- total for Plates
Rounds :
CS Rounds, AA10109 and AA 10218
AS/SS Rounds,
sub- total for Rounds
Bloom, Class 2 and Class 3
Total for Turbine/Gen/Condensers
(10.1+10.2+10.3+10.4)
1.4
Appendix 1
S. No.
Equipment /System

by BHEL (MT)
Imported
Sub- total for plates for deaerators

11.3
11.4
11.5
11.6
11.7
Pulverisers :
Plates :
Alloy Steel Plates, Various sizes from
5mm to 200mm
Boiler Quality Plates :
CS / SS Sheets, 1mm to 4mm
Structural Steel
Sub-total of BQ plates for Pulveriser
Drive turbines :
Plates :
Alloy Steel Plates, Various sizes from
5mm to 200mm
Sub- total of plates for drive turbines
Structurals :
STRU :
Flat, Various Sizes
Angles, Beams and Channels, Various
Sizes
Sub- total for structurals
Bar Stock :
CS Round, 6mm to 400mm
AS Round, 6mm to 400mm
SS Round, 6mm to 400mm
Sub- total of Bar-stock
Pipes :
Alloy Steel Pipes, OD 16mm to 610mm,
1 to 28mm thick
Carbon Steel Pipes, OD 16mm to
610mm, 1 to 28mm thick
Stainless Steel Pipes, OD 16mm to
610mm, 1 to 28mm thick
Sub- total of pipes
Total for Pumps/Heat Exchangers/
Drive Turbines and Pulverisers
(11.1+11.2+11.3+11.4+11.5+11.6+11.7)
Grand Total (MT)
1.5
Indigenous
Total
86
95
10
0
10
10
322
332
20
322
342
0
2
12
12
12
14
0
0
2
12
2
12
14
14
20
5
0
25
18
2
4
24
38
7
4
49
20
18
38
20
20
22
289
38
519
60
808
18,894
111,707
130,601
Appendix 1
Appendix 2
Estimated Quantity of Steel for 11th and 12th Plan coal based projects
s.no. Equipment /System

1
1.2
Estimated Qty. for XIth Plan coal

based projects 44,000 MW
(In MT)
Estimated Qty. for XIIth Plan coal

(In MT)
Imported Indigenous
Imported
Imported
Boiler
1.1
Typical Qty. for 2 x 500 MW

units as given by BHEL (MT)
Total
Indigenous
Total
Indigenous
Total
Drum :
Pipe : (OD 88.9 to 863mm, ckness 11.13 to 130mm)
Carbon Steel Pipe
7
0
7
421
0
421
Stru Plates
0
2
2
0
28
28
Round
29
0
29
Sub-total for Drum
457
30
487
Alloy Steel Pipes
34
0
34
Carbon Steel Pipes
413
100
513
ERW Pipes
200
1,701
1,901
Alloy Steel Plates
255
17
Stru Plates
245
0
0
Round
Angles, Beams and
Channels
308
308
312
312
18,524
0
0
0
88
1,232
18,524
88
1,232
18,735
0
0
0
89
1,246
18,735
89
1,246
1,276
20,108
0
1,320
1,276
21,428
1,291
20,337
0
1,335
1,291
21,672
1,496
18,172
8,800
0
4,400
74,844
1,496
22,572
83,644
1,513
18,379
8,900
0
4,450
75,695
0 11,220
0
748
10,780 21,560
753,940 753,940
5,060 5,060
11,348
757
10,903
0
0
0
0
245
17,135
115
255
17
490
17,135
115
11,220
748
10,780
0
0
214
214
9,844
9,844
9,416
9,416
433,136 433,136
0
0
1,513
22,829
84,595
0 11,348
0
757
10,903 21,805
762,508 762,508
5,118 5,118
9,523
9,523
438,058 438,058

Alloy Steel Tubes
Carbon Steel Tubes
ERW Tubes
Sub- total for Structures /
Non- Pressure parts :
1.3
18
66
0
0
1,248
0
67
415
3
29,839
18
133
415
3
31,087
Pressure Parts :
Alloy Steel Pipes
228
0
228
Carbon Steel Pipes
500
146
646
Alloy Steel Plates
462
434
0
0
0
982
462
434
982
792
0
792
2,904
2,948 5,852
0
18,260 18,260
0
132
132
54,912 1,312,916 1,367,828
801
0
801
2,937
2,982 5,919
0
18,468 18,468
0
134
134
55,536 1,327,836 1,383,372
10,032
22,000
0
6,424
10,032
28,424
10,146
22,250
0
6,497
10,146
28,747
20,328
19,096
0
0
0
43,208
20,328
19,096
43,208
20,559
19,313
0
0
0
43,699
20,559
19,313
43,699
2.1
Appendix 2


(In MT)

(In MT)

117
117
5,148
5,148
5,207
5,207
Round
FLAT
Angles, Beams and
Channels
300
300
13,200
13,200
13,350
13,350
134
0
0
532
134
532
5,896
0
0
23,408
5,896
23,408
5,963
0
0
23,674
5,963
23,674
41,844 83,688
58,520 117,040
4,444 8,888
196,196 378,356
42,320
59,185
4,495
184,230

Alloy Steel Tubes
Carbon Steel Tubes
Parts
951
1,330
101
4,140
951
1,330
101
4,459
1,902
2,660
202
8,599
Total Qty. for Boiler

(1.1+1.2+1.3)
5,845
34,328
40,173
0
0
0
0
0
4,194
655
263
253
5,365
4,194
655
263
253
5,365
0
0
0
0
0
41,844
58,520
4,444
182,160
257,180 1,510,432 1,767,612 260,103 1,527,596 1,787,699
LP piping
IS 3589
IS 1239
IS 1239 (GAL)
SS
Total for LP Piping
372
1,046
700
2,118
0
0
0
0
372
1,046
700
2,118
16,368
46,024
30,800
93,192
SA335P91
SA335P22
SA106GRC
Plates 5/6 mm
CR Coil 1.5/1.25 mm
Columns(HEA/HEB),
Beams(ISMB 300/400)
0
2,340
2,500
4,530
1,000
500
4,530
3,340
3,000
2,560
2,450
7,290
Plates
Angles
Channels
Joists
Misc. Chequered
Plates/Handrails etc.
Reinforce Steel
Total for Main & Aux.
Bldgs.
Angles(50x50x6,75x75x6,80
x80x8,10x75x6)/Channels(C
150,C200,C250)
Hollows (150 to 300)
Total for EP
5
42,320 84,639
59,185 118,370
4,495 8,989
198,426 382,656
184,536 184,536
28,820 28,820
11,572 11,572
11,132 11,132
236,060 236,060
0
0
0
0
0
0
0
0
0
186,633 186,633
29,148 29,148
11,704 11,704
11,259 11,259
238,743 238,743
16,368
46,024
30,800
93,192
16,554
46,547
31,150
94,251
0
0
0
0
16,554
46,547
31,150
94,251
0
102,960
110,000
199,320 199,320
44,000 146,960
22,000 132,000
0
104,130
111,250
201,585 201,585
44,500 148,630
22,250 133,500
2,560
112,640 112,640
113,920 113,920
0
8,590
2,450
15,880
107,800
320,760
0 107,800
377,960 698,720
109,025
324,405
0 109,025
382,255 706,660
0
0
0
0
0
21,460
3,938
4,296
5,370
716
21,460
3,938
4,296
5,370
716
0
0
0
0
0
0
0
8,800
44,580
8,800
44,580
0 387,200 387,200
0 1,961,520 1,961,520
2.2
944,240
173,272
189,024
236,280
31,504
944,240
173,272
189,024
236,280
31,504
0
0
0
0
0
954,970
175,241
191,172
238,965
31,862
954,970
175,241
191,172
238,965
31,862
0 391,600 391,600
0 1,983,810 1,983,810
Appendix 2

6


(In MT)

(In MT)

Total for Power
Transformers
1,120
208
1,328
0
0
0
1,120
208
1,328
49,280
9,152
58,432
0
0
0
300
300
13,200
125
125
0
300
300
425
300
725
49,280
9,152
58,432
49,840
9,256
59,096
0
0
0
49,840
9,256
59,096
13,200
13,350
13,350
5,500
5,500
5,563
5,563
0
13,200
13,200
18,700
13,200
31,900
0
13,350
13,350
18,913
13,350
32,263
Motors
CRNGO, M530-65A, 8001250width
Shaft forging (Low Alloy
Steel)
IS2062 Steel Plates

Total for Motors
Switchyard
0
0
0
0
725
125
700
1,550
725
125
700
1,550
0
0
0
0
31,900
5,500
30,800
68,200
31,900
5,500
30,800
68,200
0
0
0
0
32,263
5,563
31,150
68,975
32,263
5,563
31,150
68,975
Lattice structure
Pipes
Coal Handling Plant
Angles, Beams and
Channels
Reinforce Steel
Total for CHP
8,000
8,000
352,000
352,000
356,000
356,000
0
0
6,000
14,000
6,000
14,000
0
0
264,000
616,000
264,000
616,000
0
0
267,000
623,000
267,000
623,000
530
1480
2,010
23,320
65,120
88,440
23,585
65,860
89,445
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
10
440
440
445
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
1,644
1,806
3,450
72,336
0
79,464
0
151,800
73,158
0
80,367
0
153,525
166
170
176
7,304
7,480
178
7,387
7,565
36
40
40
0
158
324
100
120
194
364
140
120
1,584
1,760
1,760
0
6,952
14,256
4,400
5,280
8,536
16,016
6,160
5,280
1,602
1,780
1,780
0
7,031
14,418
4,450
5,340
8,633
16,198
6,230
5,340
1,724
2,350
4,074
75,856 103,400
179,256
76,718
104,575
181,293
10
10.1
Plates :
MS Plates, 5mm to 90mm,
IS20062 GR-A &GR-B
B Q Plates, 6mm to 250
mm, IS2002 GR-2
10.2

Rounds :
CS Rounds, AA10109 and
AA 10218
10.3
10.4
AS/SS Rounds,
Bloom, Class 2 and Class
3
Total for
Turbine/Gen/Condensers
(10.1+10.2+10.3+10.4)
11
11.1
Pumps/Heat Exchangers/ Drive- Turbines and Pulverisers

LP and HP Heaters :
2.3
Appendix 2


(In MT)

(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
42
42
1,848
1,848
1,869
1,869
140
90
230
6,160
3,960
10,120
6,230
4,005
10,235

200mm
86
86
3,784
3,784
3,827
3,827
STRU Plates, Various sizes

from 5mm to 200mm
396
396
401
401
86
95
3,784
396
4,180
3,827
401
4,228
176
176
178
178
10
10
20
440
440
880
445
445
890
0
14
322
332
322
346
0
616
14,168
14,608
14,168
15,224
0
623
14,329
14,774
14,329
15,397
Alloy Steel Plates, Various

sizes from 5mm to 200mm
88
88
89
89

Sub- total of plates for
drive turbines
0
2
12
12
12
14
0
88
528
528
528
616
0
89
534
534
534
623
Flat, Various Sizes

Angles, Beams and
Channels, Various Sizes
0
0
2
12
2
12
0
0
88
528
88
528
0
0
89
534
89
534

Bar Stock :
Pipes :
Alloy Steel Pipes, OD 16mm
to 610mm, 1 to 28mm thick
14
14
616
616
616
616
20
5
0
25
18
2
4
24
38
7
4
49
880
220
0
1,100
792
88
176
1,056
1,672
308
176
2,156
890
223
0
1,113
801
89
178
1,068
1,691
312
178
2,181
88
88
89
89
20
18
38
880
792
1,672
890
801
1,691

from 5mm to 200mm
Sub- total for plates-HP/LP
Heaters
11.2
Deaerators :
Plates :
Sub- total for plates for

deaerators
11.3
Pulverisers :
Plates :
11.4
Boiler Quality Plates :

CS / SS Sheets, 1mm to
4mm
Structural Steel
Sub-total for plates for
Pulveriser
Drive turbines :
Plates :
11.5
Structurals :
STRU :
11.6
11.7
Carbon Steel Pipes, OD

16mm to 610mm, 1 to 28mm
thick
2.4
Appendix 2

Stainless Steel Pipes, OD
thick
Sub- total of pipes
Total for Pumps/Heat
Exchangers/ Drive
Turbines and Pulverisers
(11.1+11.2+11.3+11.4+11.5
+11.6+11.7)
Grand Total (MT)


(In MT)

(In MT)
20
20
880
880
890
890
22
289
38
519
60
808
968
12,716
1,672
22,836
2,640
35,552
979
12,861
1,691
23,096
2,670
35,552
18,894 111,707
130,601
831,336 4,915,108
5,746,444
840,783
4,970,962
5,811,745
2.5
Appendix 2
Appendix-3
Estimated Quantity of Steel for 11th and 12th Plan Gas based projects
s.
no.
1
1.1
1.2
1.3
Equipment /System
Typical Qty. for 2 x 500 MW Estimated Qty. for XIth Plan

Gas Plant as given by BHEL Gas based projects 2114
(MT)
MW (In MT)
Imported Indigenous Total Imported Indigenous
Total

Boiler
Drum :
Carbon Steel Pipe
3.5
0.0
3.5
210.5
0.0
210.5
Stru Plates
0.0
1.0
1.0
0.0
14.0
14.0
Round
14.5
0.0
14.5
Sub-total for Drum
228.5
15.0
243.5
Alloy Steel Pipes
17.0
0.0
17.0
Carbon Steel Pipes
206.5
50.0
256.5
ERW Pipes
100.0
850.5
950.5
Alloy Steel Plates
127.5
0.0
127.5
8.5
0.0
8.5
Stru Plates
122.5
122.5
245.0
0.0 8,567.5 8,567.5
0.0
57.5
57.5
Round
0.0
107.0
107.0
Angles, Beams and
0.0 4,922.0 4,922.0
Channels
Alloy Steel Tubes
9.0
0.0
9.0
Carbon Steel Tubes
33.0
33.5
66.5
ERW Tubes
0.0
207.5
207.5
0.0
1.5
1.5
Sub- total for Structures /
624.0 14,919.5 15,543.5
Non- Pressure parts :
Pressure Parts :
Alloy Steel Pipes
114.0
0.0
114.0
Carbon Steel Pipes
250.0
73.0
323.0
Alloy Steel Plates
231.0
0.0
231.0
217.0
0.0
217.0
0.0
491.0
491.0
0.0
58.5
58.5
Round
0.0
150.0
150.0
FLAT
67.0
0.0
67.0
3.1
445
0
0
0
2
30
445
2
30
31
483
0
32
31
515
36
437
211
0
106
1,798
36
542
2,009
270
18
259
0
0
0
0
259
18,112
122
270
18
518
18,112
122
226
226
10,405
10,405
19
70
0
0
1,319
0
71
439
3
31,540
19
141
439
3
32,859
241
529
0
154
241
683
488
459
0
0
0
0
1,038
124
488
459
1,038
124
317
317
142
142
Appendix 3
s.
no.
8
8.1
Equipment /System

(MT)
MW (In MT)
Total
0
562
562
0.0
266.0
266.0

Angles, Beams and
Channels
Alloy Steel Tubes
475.5
475.5 951.0
Carbon Steel Tubes
665.0
665.0 1,330.0
50.5
50.5 101.0
2,070.0 2,229.5 4,299.5
Parts
Total Qty. for Boiler
2,922.5 17,164.0 20,086.5
(1.1+1.2+1.3)
LP piping
IS 3589
0.0 2,097.0 2,097.0
IS 1239
0.0
327.5
327.5
IS 1239 (GAL)
0.0
131.5
131.5
SS
0.0
126.5
126.5
Total for LP Piping
0.0 2,682.5 2,682.5
SA335P91
186.0
0.0
186.0
SA335P22
523.0
0.0
523.0
SA106GRC
350.0
0.0
350.0
1,059.0
0.0 1,059.0
Plates
0.0 10,730.0 10,730.0
Angles
0.0 1,969.0 1,969.0
Channels
0.0 2,148.0 2,148.0
Joists
0.0 2,685.0 2,685.0
Misc. Chequered
0.0
358.0
358.0
Plates/Handrails etc.
Reinforce Steel
0.0 4,400.0 4,400.0
Total for Main & Aux.
0.0 22,290.0 22,290.0
Bldgs.
560.0
0.0
560.0
104.0
0.0
104.0
Total for Power
664.0
0.0
664.0
Transformers
Motors
CRNGO, M530-65A, 800150.0
0.0
150.0
1250width
Shaft forging (Low Alloy
0.0
62.5
62.5
Steel)
IS2062 Steel Plates
0.0
150.0
150.0
Total for Motors
150.0
212.5
362.5
Switchyard
Lattice structure
0.0
725.0
725.0
Pipes
0.0
125.0
125.0
0.0
700.0
700.0
0.0 1,550.0 1,550.0
Plates :
MS Plates, 5mm to 90mm,
265.0
740.0 1,005.0
IS20062 GR-A &GR-B
3.2
1,005
1,406
107
4,376
1,005
1,406
107
4,713
2,010
2,812
214
9,089
6,178
36,285
42,463
0
0
0
0
0
4,433
692
278
267
5,671
4,433
692
278
267
5,671
393
1,106
740
2,239
0
0
0
0
393
1,106
740
2,239
0
0
0
0
0
22,683
4,162
4,541
5,676
757
22,683
4,162
4,541
5,676
757
0
0
9,302
47,121
9,302
47,121
2,368
440
2,807
0
0
0
2,368
440
2,807
317
317
132
132
0
317
317
449
317
766
0
0
0
0
1,533
264
1,480
3,277
1,533
264
1,480
3,277
560
1,564
2,125
Appendix 3
s.
no.
8.2
8.3
8.4
9
9.1
9.2
9.3
9.4
9.5
Equipment /System

(MT)
MW (In MT)
Total
275
1,353
510.0
130.0
640.0 1,078

B Q Plates, 6mm to 250
mm, IS2002 GR-2
CS Plates, 12mm to 160mm,
10.0
15.0
25.0
SA516 GR-70
AS Plates, 10mm to 125mm,
5.0
0.0
5.0
17MO4 & 12MX
SS Plates/Sheets, 0.5mm to
32.0
18.0
50.0
80mm, AA10739, AA10740,
HW10782 and HW 10788
822.0
903.0 1,725.0
Rounds :
CS Rounds, AA10109 and
2.0
83.0
85.0
AA 10218
AS/SS Rounds,
18.0
79.0
97.0
20.0
162.0
182.0
20.0
50.0
70.0
Bloom, Class 2 and Class
0.0
60.0
60.0
3
Total for
862.0 1,175.0 2,037.0
Turbine/Gen/Condensers
(8.1+8.2+8.3+8.4)
Pumps/Heat Exchangers/ Drive- Turbines and Pulverisers
LP and HP Heaters :
Plates :
70.0
24.0
94.0
200mm
0.0
21.0
21.0
from 5mm to 200mm
70.0
Sub- total for plates-HP/LP
45.0
115.0
Heaters
Deaerators :
Plates :
43.0
0.0
43.0
200mm
0.0
4.5
4.5
from 5mm to 200mm
Sub- total for plates for
43.0
4.5
47.5
deaerators
Drive turbines :
Plates :
1.0
0.0
1.0
0.0
6.0
6.0
Sub- total of plates for
1.0
6.0
7.0
drive turbines
Structurals :
0.0
0.0
STRU :
0.0
0.0
Flat, Various Sizes
0.0
1.0
1.0
Angles, Beams and
0.0
6.0
6.0
Channels, Various Sizes
0.0
7.0
7.0
Bar Stock :
0.0
0.0
3.3
21
32
53
11
11
68
38
106
1,738
1,909
3,647
175
180
38
42
42
0
167
342
106
127
205
385
148
127
1,822
2,484
4,306
148
51
199
44
44
148
95
243
91
91
10
10
91
10
100
0
2
13
13
13
15
0
0
0
0
0
0
2
13
2
13
0
0
15
0
15
Appendix 3
s.
no.
9.6
Equipment /System

(MT)
MW (In MT)
Total
21
19
40
10.0
9.0
19.0
5
2
7
2.5
1.0
3.5
0
4
4
0.0
2.0
2.0
12.5
12.0
24.5
26
25
52

Pipes :
2
Alloy Steel Pipes, OD 16mm
1.0
0.0
1.0
to 610mm, 1 to 28mm thick
21
Carbon Steel Pipes, OD
10.0
9.0
19.0
thick
0
Stainless Steel Pipes, OD
0.0
10.0
10.0
thick
Sub- total of pipes
11.0
19.0
30.0
23
Total for Pumps/Heat
137.5
93.5
231.0
291
Exchangers/ Drive
Turbines and Pulverisers
(9.1+9.2+9.3+9.4+9.5+9.6+9
.7)
Grand Total (MT)
5,795.0 45,167.5 50,962.5 13,654
3.4
19
40
21
21
40
198
63
488
95,484
109,138
Appendix 3
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
Acronyms

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Requirement of EQUIPMENT

AND MATERIAL FOR

Central Electricity Authority

Generation and Transmission

Central Electricity Authority

Requirement of Equipment & Material for Development of Power Sector

CHAPTER-2 GENERATION CAPACITY ADDITION

CHAPTER-3 REQUIREMENT OF ELECTRICAL EQUIPMENTS

Hydro Power Plants

Central Electricity Authority

Requirement of Equipment & Material for Development of Power Sector

Central Electricity Authority

Requirement of Equipment & Material for Development of Power Sector

Central Electricity Authority

Requirement of Equipment & Material for Development of Power Sector

Central Electricity Authority

Requirement of Equipment & Material for Development of Power Sector

Central Electricity Authority

Requirement of Equipment & Material for Development of Power Sector

GENERATION CAPACITY ADDITION PROGRAMME

REQUIREMENT OF ELECTRICAL EQUIPMENTS

Central Electricity Authority

Requirement of Equipment & Material for Development of Power Sector

Central Electricity Authority

Requirement of Equipment & Material for Development of Power Sector

Central Electricity Authority

Requirement of Equipment & Material for Development of Power Sector

1.3 REGULATORY & STRUCTURAL REFORMS IN POWER SECTOR

Generation is being delicensed and captive generation is being freely permitted.

Transmission Utility at the Central as well as State level, to be a Government

Provision for private licensees in transmission and entry in distribution through an

Open access in transmission from the outset.

Open access in distribution to be introduced in phases with surcharge for current

Distribution licensees would be free to undertake generation and generating

Central Electricity Authority

Requirement of Equipment & Material for Development of Power Sector

The formation of State Electricity Regulatory Commissions is a mandatory

Provision for payment of subsidy through budget.

Trading, a distinct activity is being recognized with the safeguard of the

Provision for reorganization or continuance of SEBs.

Metering of all electricity supplied made mandatory.

Provisions relating to theft of electricity made more stringent.

NATIONAL ELECTRICITY POLICY AND PLAN

Central Electricity Authority

Requirement of Equipment & Material for Development of Power Sector

GENERATION CAPACITY ADDITION PROGRAMME

Central Electricity Authority

Requirement of Equipment & Material for Development of Power Sector

ELEVENTH PLAN (2007-12)

During the 11th plan, a tentative capacity addition of 66,463 MW is planned

Total Thermal Capacity Addition -46,114 MW

* No such categorisation for Hydro Plants

GENERATION CAPACITY ADDITION PROGRAMME

Central Electricity Authority

Requirement of Equipment & Material for Development of Power Sector

TWELFTH PLAN (2012-2017)

During the 12th Plan, a tentative capacity addition of 86,500 MW is planned

* No such categorisation for Hydro Plants

GENERATION CAPACITY ADDITION PROGRAMME

Central Electricity Authority

Requirement of Equipment & Material for Development of Power Sector

GENERATION CAPACITY ADDITION PROGRAMME

Central Electricity Authority

Requirement of Equipment & Material for Development of Power Sector