MANUFACTURING CAPABILITIES FOR PLANT & EQUIPMENT FOR HYDRO POWER PLANTS

S.K.Kaul
18th August 2009

SCENARIO OF 10TH PLAN CAPACITY ADDITION

Sector Central State Private Target (MW) 8742 4481 1170 Achievement (MW) 4495 2691 700

Total

14393

7886

Delay on account of Equipment supply constraint : 679 MW

Summary of ordering status of TG Sets of Hydro Projects in 10th Plan

The Hydro capacity addition Target Electro-Mechanical equipments awarded Indian Suppliers
BHEL Alstom VA Tech 4945 MW 680 MW 216 MW 6163 MW

14393 MW 12004 MW

Foreign Suppliers

HYDRO CAPACITY ADDITION PROGRAMME FOR 11TH PLAN

Central Sector State Sector Private Sector Total No. of Project No. of Units 8654 MW 3482 MW 3491 MW 15627 MW 45 166

Highest unit size

Smallest unit size

250 MW
11 MW

Summary of ordering status of TG Sets of HE Projects for likely benefits in 11th Plan
The Hydro capacity addition programme: Ordering Status of T.G. Sets: Indian Supplier BHEL VA Tech Alstom Foreign suppliers 6017 MW 366 MW 339 MW 8905 MW 15627 MW

Manufacturing Capabilities of main indigenous manufacturers for plants & equipment for Hydro Power Plants

M/s BHEL M/s Alstom M/s VA Tech M/s Voith Siemens

2500 MW 1260 MW order based order based

Preparedness for 12th Plan & beyond

Candidate Hydro projects prioritised for benefits during 12th Plan: 87 Total no. of Projects under execution in 11th Plan: 45 Projects already under construction for benefits in 12th Plan: 8 (1327 MW)

Categorisation of capacity of Hydro Plants 12th Plan Type of Scheme ROR STO PSS TOTAL Capacity (MW) 16,116 2,448 1,770 20,334 No. of Stations 77 7 3 87

Preparedness for 12th Plan & beyond

Hydro capacity totaling to 24,500 MW has been proposed during the 13th Plan. A shelf of hydro projects totaling to about 43,000 MW has been drawn up out of which the above requirement of 24,500 MW would be selected. In addition, the requirement of capacity addition programmes in neighbouring countries namely, Bhutan (5000 MW), Nepal (1000 MW) are to be considered by the manufacturers / suppliers

It is observed that there is an appreciable increase (almost 2 times) in the no. of proposed Hydro Power schemes in the 12th Plan. Thus, there is a need to revisit the Manufacturing capabilities for Plant & Equipment for Hydro Power Plants.

ESTIMATED REQUIREMENT OF EQUIPMENT FOR HYDRO POWER PLANTS FOR 12th & 13th PLANS
No. Equipment 12th Plan (20,000 MW) 13th Plan (24,500 MW) Total

Hydro-Mechanical 1 Gates & Hoist i. Radial Spillway Gates (set) ii. Vertical lift gates (set) Electro-Mechanical 2 3 Turbine (MW) Turbine (No.) 20,130 238 24,495 286 44,625 524 415 630 505 767 920 1397

4
5

Butterfly Valve (Set)

Main Inlet Valve (Set)

48
198

58
241

106
439

ESTIMATED REQUIREMENT OF EQUIPMENT FOR HYDRO POWER PLANTS FOR 12th & 13th PLANS
No. Equipment 12th Plan (20,000 MW) 238 22,366 238 238 1596 13th Plan (24,500 MW) 286 27,216 286 286 1943 Total

6 7 8 9 10

Digital Governor (Set) Synchronous Generator (MVA) Synchronous Generator (No.) Unit Control Board (set) Motor & MCC (unit)

524 49,582 524 524 3539

11
12 13

Transformer (UAT & SST) MVA

Static Excitation System (set) Dynamic Excitation System (set)

267
238 238

286
286 286

553
524 524

14

NG cubicle incl. Tranfr, (set)

238

286

524

ESTIMATED REQUIREMENT OF EQUIPMENT FOR HYDRO POWER PLANTS FOR 12th & 13th PLANS
No. Equipment 12th Plan (20,000 MW) 28,500 13th Plan (24,500 MW) 29,938 Total

15

11/13.8 kV/24kV Isolated Phase Bus Duct (IPBD) (mtr)

58,498

16

11/13.8/24 kV Current Transformer ( No. of 1-Phase Units)

SAVT Cubicle (Set) 132kV/220kV/400 kV Generator Transformer (MVA) 11kV Switchgear Board (Unit)

10,710

12,876

23,586

17 18 19

321 24,603 242

387 29,938 295

708 54,541 537

ESTIMATED REQUIREMENT OF EQUIPMENT FOR HYDRO POWER PLANTS FOR 12th & 13th PLANS
No.
20

Equipment
EHV Equipment Circuit breaker (No.)

12th Plan
(20,000 MW)

13th Plan
(24,500 MW)

Total

390

515

908

Capacitor voltage transformer

(CVT) (Set)

1125
522 1344 920 1318 650 167 49 22

1367
640 1627 1120 1604 791 203 60 25

2492
1162 2971 2040 2922 1441 370 109 47

EHV Voltage Transformer (No.) Lightning Arrestor (LA) (No.) Isolator (Set) EHV Current Transformer (Set) 21 22 23 24 415 V Switchgear Board (Unit) 220/400 kV GIS Bay (No.) EHV XLPE Cable (km) EHV Bus Duct (km)

REQUIREMENT OF OTHER KEY INPUTS FOR 12th & 13th PLANS

Steel and cement are key inputs needed for construction of hydro power projects & the requirement of the same vary from project to project depending upon type of scheme. For 12th Plan, the requirement corresponds to a hydro capacity of about 20,000 MW & for The 13th Plan requirement is based on the proposed programme of 24500 MW

Sl.No. 1 2 3 Cement

Material

Quantity (in million tonne) 12th Plan 19.244 0.684 1.872 13th Plan 23.422 0.833 2.278

Structure Steel Reinforcement Steel

Areas of Development Specific to Indian Industry

Creation of facility for higher sized runner castings. Presently large size castings are beings imported. Creation of manufacturing facilities for 220kV & 400kV Gas Insulated Switchgear. Creation of manufacturing facilities for 220kV & 400kV XPLE Cables.

R&D Needs in the following fields:

Hard coatings for turbine runners & other under water parts

New materials and alloys for turbines & other under water parts resistant to the silt damages

Action points
To meet additional capacity requirements for 12th plan & beyond, manufacturers/ suppliers need to take appropriate steps. Advance action shall be taken by Project Authorities to Award Contracts for projects identified for the benefits in the 12th Plan so that timely action can be taken by manufacturers/suppliers Qualifying requirements may be modified/ rationalized to enable financially sound new players to compete. The project promoters should streamline, wherever required, the payment system to have better response from the suppliers. Placement of orders, where in few cases, has taken longer time due to various technical & other intricacies creating uncertainty in the planning process of manufacturers, needs to be expedited.

Action points
Tail end bunching can not be avoided. It is observed that in 11th Plan around 40% of the capacity is programmed to be commissioned in the last half of the year 2011-12. The erection, testing & commissioning engineers/contractors have to plan & gear up accordingly. Better quality control at manufacturer works would reduce the erection as well as operational problems. Manufacturers need to review the quality assurance programme of the E&M and HM equipments. Demand for Gas Insulated supplier (GIS) & XLPE Cables is expected to increase Indigenous manufacturing of such equipments/items need to be pursued more vigorously.

Action points
Delivering of equipment needs to be critically verified right from shop to the site store. Non-receipt of even one item which is essential for commissioning may delay the whole process. Enhance the availability of O&M engineers as shortage of operation & maintenance engineers particularly in Power Stations located in remote/difficult areas may also become a bottle neck in near future

THANKS