Professional Documents
Culture Documents
ON
MECON LIMITED
RANCHI-834002
JHARKHAND
11. 24.2012.F2068 July’ 2014
CONTENT
Sl.
Title Page No.
No.
1. Introduction 1–3
2. Executive Summary 4 – 16
3. Characteristics & End uses 17 – 26
4. Market Analysis 27 – 36
5. Technological Considerations 37 – 41
6. Site Selection & General layout 42 – 47
7. TLT Fabrication Unit 48 – 56
8. TLT Galvanizing Unit 57 – 62
9. Electrics & Automation 63 – 73
10. Plant Services & Utilities 74 – 92
11. Quality Control Facilities 93 – 96
12. Civil & Structural Works 97 – 104
13. Manpower Requirement 105 – 107
14. Project Implementation 108 – 114
15. Pollution Control & Waste Management 115 – 117
16. Capital Cost 118 – 122
17. Production Cost 123 – 127
18. Financial Appraisal 128 – 138
19. Industrial Safety 139 – 141
20. Drawings 142
01. INTRODUCTION
01.01 Background
rolling mills.
under ministry of power & the central transmission utility (CTU) of the
grids. Power grid is playing a key role in Indian power sector directly
operator.
RINL and POWERGRID are entering into a joint venture project to install
Page 1 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
manufacturing business in India and abroad. RINL will supply quality raw
RINL & POWERGRID have assigned MECON vide their letter no.
The TEFR as set out in the following chapter covers the Introduction,
selection & General layout, TLT Fabrication Unit, TLT Galvanizing Unit,
Financial appraisal.
Page 2 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
01.04 Acknowledgment
Page 3 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
02.01 Introduction
Navaratna PSE under ministry of Power & the Central Transmission Utility
(CTU) of the country, are entering into a joint venture project to install
manufacturing business in India and abroad. RINL will supply quality raw
figures and average availability; the resultant gaps (-) / Surplus (+) are
summarized as below:
Page 4 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
considerations.
The capacity of proposed plant has been decided based on desk study of
study the plant capacity has been fixed as 120,000 t/yr. The Technological
unit capacity has been fixed considering the popular plant size capacity as
per existing units in India as well as abroad and the limitation in handling
Page 5 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
The black angles in the product – mix of RINL will be made available by
Rest of the angles will be sourced from other market sources including
authorized conversion agents for which the input billets / blooms will be
made available by RINL. Proposed process flow are shown in the drawing
MEC/11/24/123J/TEFR/003.
Site for TLT manufacturing complex has been finalized based on only
out. Out of the three sites available, RINL site has emerged as the most
suitable site. Proposed site is located very close to the existing steel plant
Layout of the proposed plant has been developed keeping in view of the
following:
Page 6 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
flow.
d) Safety considerations.
complex boundary.
Two (2) TLT Fabrication Units of 60,000 t/yr capacity each has been
envisaged. The TLT Fabrication Units will fabricate the TLT parts as per
The TLT Fabrication Units will use angles from RINL / conversion agents
/other market sources for fabrication of TLT parts. The plates required for
the production of TLT parts will be procured from outside market sources.
with CNC state of the art technology have been envisaged to cater to the
Page 7 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
requirement.
of shop fabrication drawings has been envisaged with latest state of art
Fork-lifts has been envisaged in the bay together with material transfer
Two (2) number TLT Galvanizing Units of 60,000 t/yr capacity each has
been envisaged. The TLT Galvanizing Units will hot dip galvanize the
About 120,000 tons of fabricated TLT Parts will be galvanized annually for
galvanizing the TLT parts has been envisaged. The process of hanging the
removing the TLT parts from the Hangers / Jigs after Galvanizing process
Page 8 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
transmission line towers will mostly be required for direct and indirect
drinking and sanitation purpose and other direct process and general
reuse of return water from plant processes after necessary treatment and
conditioning.
for proper storage of materials and working of plant and equipment. The
items of equipment and accessories such as fans, air filters, air washers,
Page 9 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
air-conditioning units, duct work, pumps, cooling tower, air supply grills,
supply of compressed air, instrument air and fuel oil to meet the process
Page 10 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
Unit and for the Galvanizing Unit has been estimated based on specific
CO Gas will be tapped from RINL’s existing line and pipeline for
transporting the required quantity along with Nitrogen Line for purging
Page 11 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
finished products.
compressed air station, pump house, MSDS, water supply facilities, etc.
leveling, etc.
Steel structural work will include supply, fabrication, erection & painting
The structures will include building structures, pipe trestles etc. for the
Page 12 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
Units”.
Fabrication & Galvanizing Units. In this staggering process, one unit each
for Fabrication & Galvanizing may be commissioned first with the Input
Angles from RINL / Market as per the requirement and availability. The
Page 13 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
commissioned.
two ways:
Unit will start producing required TLT parts to meet the huge
However, the execution of the proposed project would call for meticulous
let out of the complex will conform to permissible limits set by the
Page 14 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
The capital cost of the proposed 120,000 T/Y capacity TLT manufacturing
as given below:
4 TOTAL 331.3
Page 15 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
Financial analysis has been carried out based on capital investment and
operating cost and Average net sales realization. The salient techno-
Page 16 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
Generally the towers are of self supporting lattice steel type, designed to
carry the line Conductor with necessary insulators, earth wires and all
The towers are fully galvanized structure, using structural mild steel / high
tensile steel sections for members. Galvanized Bolts and nuts with spring
safety against lightening, earth wire / OPGW are placed at tower peak.
OPGW (Optical fiber ground wire) is now being used instead of regular
GSS (Steel stranded wire) as it is being used for data transmission for
Page 17 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
broad band as well as earthing the live conductors. The live conductors
The tower are designed such that it can be attached to various body
CRITERIA TYPES
TOWERS
TOWERS
Page 18 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
STRUCTURES
Mostly self supporting latticed steel towers are used in India and other
structure on their own. The design aspects of these towers are covered
under Indian standard (IS: 802 — part 1, 2, 3). These towers are designed,
IS: 802.
These towers are made up of structural angle profiles of Mild steel and
high tensile steel grades and members are connected by bolts. Normally
Guy towers comprise portal structures in ‘Y’ or ‘V’ shape and are
anchored to Ground through steel Guys. They have been used in some
countries for EHV lines up to 735 kV. Such towers occupy much larger
land space compared to self supporting towers and as such area used in
long unoccupied waste land, bush tracts in Canada, Brazil , Russia. In India
Page 19 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
TOWER DESIGNATIONS:
a) SUSPENSION TOWERS
b) ANGLE TOWERS
stretch
/ Transposition
Tower
Page 20 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
Tower Type/Tower
Weight 765KV 800KV 500KV 400KV 400KV 220KV
Page 21 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
Weight of tower extensions +3/6/9 m are approx. 10 – 20% and extensions + 18/25
HILLY/MOUNTAINOUS
Type of Terrain PLAIN TERRAIN
TERRAIN
400KV,
400KV, 765KV,
765KV, 500KV 220KV 220KV
500KV HVDC
HVDC
AVERAGE SPAN (m) 370 330 350 300
Suspension Towers
65% Nil
(A/DA)
Tension Towers
7.5% 30%
B/DB
C/DC 7.5% 30%
D/DD 20% 40%
Approx. 20% of towers are with extensions
activities:
Page 22 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
investigation,
e) Tower earthing,
c) Loading Calculation
d) Loading Combination
Page 23 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
f) Detailing
Normal Span
Normal span limits for different voltage capacity of transmission line are
Wind Span
The wind span is the sum of the two half spans adjacent to the support
span.
Weight Span
The weight span is the horizontal distance between lowest points of the
The minimum ground clearance from the bottom conductor shall not be
less than values stipulated in CEA’s safety regulations/IE rules for various
Page 24 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
The minimum live metal clearance to be provided between the live parts
These loads are to be based on IS: 802 / Part-1 1995 and towers are to be
comprise about 30-40% of mild steel grade, 60-70 of high strength steel
and 4%-5% of nuts and bolts. The tower member are generally of
structural steel conforming IS 2062. The standard IS: 802 governs the use
nuts, washers. Profile wise about 90% angle, 4-6% plates and 4%-5% nuts
& bolts are normally being used in Transmission tower. The related size
Page 25 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
tower.
Galvanizing
Fully galvanized towers and stub are used for the line. Galvanizing of the
TOWER EARTHING
All the towers are to be earthed. In no case tower footing resistance shall
Galvanized tower of each type complete with Maximum body and leg
TOWERS ACCESSORIES.
Insulator string and Earth wire Clamps Attachments, Anti climbing Device,
Danger plates, Number plates, Circuit Plate, Phase Plate & Bird Guards.
Page 26 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
Page 27 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
Table - 04.01
CEA’s projection of steel requirement for transmission towers
Sl. Voltage By XIIth Plan Type of Steel
No. (KV) (Ton) MS HTS
1. 765 416000 60% 40%
2. 500 413640 60% 40%
3. 400 2088680 60% 40%
4. 220 464600 100% -
5. 132 36400 100% -
Total 3746920
Say 3.7 MT
Source: CEA Document “Requirement of equipment & material for
development of power sector”
Attempt has been made to assess the realistic demand of towers and
thereby, steel requirement (angles) based on other approaches as
outlined hereunder.
Alternative Approach
Page 28 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
Table-04.05
Based on the above two approaches (CEA and POWERGRID Based data),
the average demand figures works out as follows:
Page 29 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
The international capex cycle for power sector is observed as follows (Fig-
04.01 and Table-04.06):
2500
2000
IN BILLION US $
1500
1000
500
0
OECD E.EUROPE ASIA MIDDLE EAST AFRICA LATIN AMERICA
1
OECD = Organization of Economic Co-operation and Development
Page 30 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
It is obvious from the above table that T&D network of various countries
are undergoing massive change in terms of replacement, up gradation
and fresh capacity creations. The total anticipated transmission sector
outlay of 867 Billion US$ can be viewed to have been contributed to the
tune of 20% by transmission towers as per typical cost structure of power
sector. The expected market for towers stands around 173 billion US$, by
2016-17, with largest share taken by Asia and OECD countries and this is
an indication of good export potential in these countries for transmission
towers. Also, based on information available on websites of various
domestic tower manufacture, it is expected that US from CY’ 2012
onwards will be the largest spender on T&D sectors. Given this positive
scenario, significant growth opportunities are expected in Middle East,
Africa, South Asia and CIS countries from this project.
Page 31 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
04.04 Availability
Page 32 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
Table-04.07
Tower manufacturing capacity
Page 33 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
From the above table, estimated allocable capacity for towers works out around
1.2 Million metric ton with average annual industry capacity utilization around
70%. With this assumption the likely availability figure for towers has been
considered as 0.84 Million Metric Ton for the year 2013-14. It has been further
assumed that in view of impetus infused in form of incentives for power sector in
recently announces budget, the orders may flow and the capacity utilization may
improve to 80 % (average) during XIIth plan and thus a figure of 0.96 Million
Metric ton/yr has been assumed during XIIth plan period.
CASE-I
Based on above approch, the angle requirement has been estimated as 0.96
Million Tons/yr for period over 2012-17. The results are summarized hereunder:
CASE-II
Angles for electric towers are made from structural products in Light Merchant
Products (LMP) as well as sections in Medium Merchant Products (MMP). The
availability of angles for electric tower is derived based on the following
assumptions:
Page 34 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
LMP
Share of structural in LMP = 21.9% (estimated from projected values bars & rods
and structural in LMP)
Share of use for LMP in power sector = 40% of structural in LMP (applied on
projected supply of LMP)
Share of angles in LMP for power sector = 95%
MMP
Share of medium sections in MMP = 36%
Share of medium sections for use in power sector = 14%
Share of angles in medium sections for use in power sector = 90%
Based on the above assumptions, the likely availability of angles for use in electric
towers are as follows:
Estimated availability from the above figures of Case-I and Case-II are as follows:
Page 35 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
Based on average demand figures and average ability; the resultant gaps (-) /
Surplus (+) are summarized as below (Table-04.08):
Table-04.08
Resultant Gaps / Surpluses (Million Tons)
Year Demand Availability Gaps (-) / Surpluses (+)
DOMESTIC
2012-17 4.10 3.60 -0.5
WITH EXPORT (+20%)
2012-17 4.90 3.60 -1.3
Page 36 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
05.01 General
The Technological unit capacity has been fixed considering the popular
plant size capacity as per existing units in India as well as abroad and the
limitation in handling no. of pieces annually in a unit etc.
Page 37 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
05.03.01 General
As indicated in the above process flow the proposed plant will produce
approximately 120,000 t/yr of TLT. The various process involved in the
production of TLT are as follows.
05.03.02 Input
The various angle sizes required by transmission line tower falls in the
following various categories of section products.
Page 38 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
90x90, 125 x 125, 150 x 150, 200 x 200, 250 x 250, 320 x 250 mm
Angles
- Angle straightening
- Punching
- Drilling
- Marking / numbering
- Shearing / band sawing
- Notching
- Bending
- Punching after bending
- Heel milling for LAP joints of angles.
Plates
- Plate shearing
Page 39 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
Page 40 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
- Dichromating
- The galvanizing thickness is normally 460 gms per sq. meter for
members below 5 mm thickness and 610 gms per sq. metre for
members above 5mm thickness.
- With this, the finished tower parts get ready for dispatch to sites.
Page 41 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
06.01 General
Site for TLT manufacturing complex has been finalized based partly on in
house data available with MECON and partly on Site visit at Vizag. Some
major factors have been considered and conclusion has been drawn on
the ten point scale basis. The major factors considered and their ratings
analysis has been done & no techno economic calculation has been
carried out.
Table – 06.01
SITE-2
SITE-3
Sl. Description of SITE-1 (Vizag –
Rating Rating (RINL- Rating
No. Features (Hyderabad) outside
Vizag)
RINL)
1. Availability of Available 10 Available 10 Available 10
Land
Page 42 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
SITE-2
SITE-3
Sl. Description of SITE-1 (Vizag –
Rating Rating (RINL- Rating
No. Features (Hyderabad) outside
Vizag)
RINL)
problems problems possession
are to be are to be
solved solved
patches patches
be to be developed
developed developed
development developed
Input source
Page 43 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
SITE-2
SITE-3
Sl. Description of SITE-1 (Vizag –
Rating Rating (RINL- Rating
No. Features (Hyderabad) outside
Vizag)
RINL)
Finished and other cities and and other
consumers
Sum Total 71 73 87
Ranking III II I
On the basis of the information indicated in the above table and also that
As such out of the three sites available, RINL site has emerged as the most
suitable site.
06.02 Location
Proposed site is located very close to the existing steel plant just outside
the plant boundary of M/s RINL in the Northern side of the existing RINL
Page 44 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
steel plant and very close to the existing rail gate. Adequate acquired land
06.03 Road
A well developed road network exists around the site which can be
utilized for both in coming billet/bloom from the RINL plant and dispatch
transportation of material from one shop to the other and to & from
06.04 Water
It has been assumed that water for this site will be easily available from
06.05 Power
Power for the proposed plant can be made available from the existing
power grid source which can be brought to the switch yard of the
Page 45 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
Layout of the proposed plant has been developed keeping in view of the
following.
flow.
j) Safety considerations.
complex boundary.
Major units are: Black angle storage, Fabrication and galvanizing units,
The relative locations of various plant units have been depicted in the
drawing no MEC/11/14/123J/TEFR/001.
Page 46 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
Black Angle storage has been envisaged just at the entrance gate after the
truck parking area on the entry side of the TLT fabrication units for
smooth flow of Input angles. Fabrication and galvanizing units have been
placed adjacent to the storage of black angles. Finished product storage &
planned adjacent to the main units. Suitable size truck parking unit have
been planned near the raw material entry gate as well as near finished
product dispatch gate. Just between the two gates, Green Park has been
planned. Apart from this all around the periphery of the complex green
A well planned road network has been envisaged to cater to the needs of
e) Number of Gates: 2
Page 47 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
07.01 General
Two (2) TLT Fabrication Units of 60,000 t/yr capacity each has been
envisaged. The TLT Fabrication Units will fabricate the TLT parts as per
The TLT Fabrication Units will be working for about 300 days per year and
3 shifts per day. The black angles in the product – mix of RINL will be
made available by RINL. As per the product – mix & production schedules
RINL. Rest of the angles will be sourced from conversion agents (for which
sources. The plates required for the production of TLT parts will be
procured from outside market sources. About 117,990 tons of angles &
production.
Page 48 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
Table-07.01
Total 120,000
Plant and Machinery requirement for the proposed unit has been
generally 40% of the capacity shall be used for 400KV and 60% for 765KV
lines.
For finalization of the number and types of machine in the TLT Fabrication
unit, we have considered that about 75-80% of angle sections within 120
Page 49 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
with CNC state of the art technology have been envisaged to cater to the
requirement.
Major facilities envisaged for the TLT Fabrication Unit with their brief
Quantity
Sl.
Equipment / facilities Technical feature (for 1
No.
Unit)
1. CNC angle punching, For angles 30x30x3 to
line
unit
Page 50 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
Quantity
Sl.
Equipment / facilities Technical feature (for 1
No.
Unit)
line (with 6 punches)
cutting of plates
machine
Page 51 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
Quantity
Sl.
Equipment / facilities Technical feature (for 1
No.
Unit)
angles
13. Angle notching machines For Manual notching of
6
angles
machine, various
Page 52 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
Quantity
Sl.
Equipment / facilities Technical feature (for 1
No.
Unit)
measuring instruments,
etc.
i.e., the size of angles being processed and the number of holes / cuts /
about 75-80% of the angles are in the size range up to 120x12mm and 20-
25% of the angles are in the size range above 120x12mm. Tower designs
with greater share of angle in bigger size range will improve the
07.04 Process
The angles procured from RINL / from conversion agent / other sources
will be stored in the storage area. The angles will be brought from the
Page 53 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
Intermediate storage area to the open Input angle storage bay by trucks /
hydra as per the production planning. The Input angles will be stored in
this storage area as per the sizes / grades in the pre-designated locations.
of shop fabrication drawings has been envisaged with latest state of art
Further, the angles / plates will be fed to the respective fabrication lines
as per the production planning with the help of transfer trolleys provided.
The angles will be cut into pieces, holes will be punched / drilled and the
angles will be transported from one line to the other as per the process
requirement.
The fabricated TLT parts after QA clearance will be tagged as per the
order / part number and will be sent to the Galvanizing Unit for further
processing.
Page 54 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
07.06 Layout
handling.
The TLT Fabrication Unit complex will be mostly of steel structures and
will comprise of bays and administrative building. The shop floor will be at
±0.00 level. Major parameters of each TLT Fabrication Unit are given
below:
Crane
Sl. Bay Bay Size Crane Rail
Capacity Qty. Remarks
No. Designation (m) Height (m)
(t)
Page 55 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
Storage Bay
Administrativ 75 x 12 x 2
4. -- -- -- --
e Building stories
For Inter-bay transfer of angles / cut pieces of angles, sufficient number of Fork-
Page 56 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
Two (2) number TLT Galvanizing Units of 60,000 t/yr capacity each has
been envisaged. The TLT Galvanizing Units will hot dip galvanize the
The TLT Galvanizing Units will be working for about 300 days per year and
3 shifts per day. The TLT Galvanizing Units will use TLT parts fabricated in
the In-house fabrication unit. About 120,000 tons of Fabricated TLT Parts
as 8.5 m. A semi-automatic process for galvanizing the TLT parts has been
envisaged. The process of hanging the TLT parts on to the Hangers / Jigs
before Galvanizing process and removing the TLT parts from the Hangers
automated.
Page 57 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
Table-08.01
Fabricated Angle
a) 45 x 45 – 250 x 250 114,000
parts
Fabricated Plate
b) Up to 40mm thick 6,000
parts
Total 120,000
Page 58 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
Major facilities envisaged for the TLT Galvanizing Unit with their brief
Sl.
Equipment / facilities Technical feature
No.
galvanizing
Page 59 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
bath
as alkaline effluents.
08.05 Process
The TLT parts fabricated in the TLT Fabrication unit, adjacent to the
bay and will be manually loaded on to the Hangers with the help of Steel
wires. The loaded hangers with counted number of pieces will then be
Page 60 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
car.
galvanizing bay and will be dipped in the various tanks for the durations
The loaded hanger after coming out of the galvanizing chamber will be
transferred back to the unloading area of the preparation bay where the
accounting for all the pieces initially loaded on to the hangers. The
galvanized TLT parts are further manually brushed / filed for finishing and
08.07 Layout
Page 61 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
handling.
The TLT Galvanizing Unit will be mostly of steel structures and will
been envisaged and is located by the side of the building. The shop floor
Preparation Pendant
1. 144 x 25 5t 2 7
Bay Operated
Galvanizing Pendant
2. 144 x 25 2x4t 2 7
Bay Operated
Galvanizing Pendant
3. 144 x 25 2x5t 1 7
Bay Operated
5 nos. Transfer trolleys for transferring fabricated parts from Fabrication units to
galvanizing unit and for transferring Galvanizing parts from galvanizing unit to
2 nos. Transfer car for transferring loaded hangers to and from galvanizing bays
Page 62 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
3.5 4.5
Power requirement for the proposed plant shall be met preferably through 11 kV
As described earlier, Power requirement for the proposed TLT complex shall be
met from 11 kV feeders drawn from the nearest APSEB substation. Presently, the
Two (2) nos. outgoing feeders of 11 kV Substation shall be used for tapping 11 kV
power supply and same shall be taken to new 11kV switchyard located near
Page 63 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
below:
cond./Ventilation / Lighting
Capacitor bank with reactors has been envisaged to take care of voltage
factor compensation has been foreseen to achieve overall power factor in the
Page 64 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
The power distribution network has been designed as a radial system, with two
The design of power distribution system and selection of equipment has been
The equipment shall conform to relevant Indian Standards, IEC specifications and
System Earthing
Page 65 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
Two (2) nos outgoing feeders of existing 11kV Substation has been
envisaged for tapping existing 11kV power supply and same shall be taken
line conductors.
current, earth fault etc have been foreseen. Aluminium pipe / ACSR
09.05.02 HT Switchgear
The 11 kV switchgear shall be indoor type sheet metal clad, draw out type
Page 66 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
The 415 V switchboards shall comprise of air circuit breakers, in draw out
design and multi tier formation. The switchboard shall have two bus
sections and a bus coupler breaker with provision for auto changeover in
microprocessor / static type direct acting releases for over load and short
All motor control centers (MCCs), large drives (above 110 kw) and power
specifications.
09.05.04 Transformers
ONAN design.
Page 67 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
transformers.
relay, OTI, WTI, oil level gauge, valves, explosion vent etc. shall be
09.05.05 Cables
premises. Inter plant cabling has been envisaged through cable tunnel/
cable Trenches. Wherever necessary and where the cables are in small
shall be used at road crossings and paved area for protection of cables
Power cables shall be laid on ladder type GI cable trays, whereas control
Page 68 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
All 11 kV cables shall be heavy duty, XLPE insulated, PVC sheathed multi
core, aluminum conductor steel wire armoured and shall be suitable for
Cables for 415 V systems shall be heavy duty, 1.1 kV grade, PVC insulated
The control cables shall be multi strand copper conductor, PVC insulated
and PVC sheathed with minimum cross section of 2.5 sq.mm /1.5 sqmm
The HT cables, LT power and control cable shall confirm to relevant IEC
specifications.
equipment design:-
simultaneously).
occurring simultaneously.
Page 69 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
transformer
The following shop electric facilities have been considered covering broadly
Page 70 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
i. Illumination system.
for the mill /lines aux. viz. Air conditioning & ventilation system, water
vi. Complete LT/HT power cables, control cables, screened cables/ special
cables.
vii. Cable structures, racks, trays, GI pipes etc. including various erection
accessories & materials for the complete laying & erection of electrical
equipment.
xi. Automatic detection for ECRs , pulpits , oil cellars & transformer
Page 71 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
xii. Voice communication equipment for all facilities like ECRs, pulpits, oil
cellars, sub-station, pump house, Shop floor area, shift rooms etc.
The lighting system inside and outside plant units has been considered taking
Plant Grid earthing system has been considered for the safety of electrical
not intended to be alive shall have two separate and distinct earth
and apparatus rated 240V and below may have single earth connections.
for each building /bay has been considered against lightning, for the safety of
Page 72 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
All LT power and control cables have been considered which shall be of PVC
cables shall be of size 6mm & above will be of aluminium. Control cables
wherever required.
09.09 DG Set
Page 73 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
10.01.01 General
consumed for drinking and sanitation purpose and other direct process
recycling and reuse of return water from plant processes after necessary
m3/h (Approx.).
Table-11.01.
Page 74 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
Table – 10.01
Sl.
Circulating water
No. Consumer /units
M3/hr
The requirement of fresh make-up water for the proposed Plant will be
units.
Page 75 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
a) Clean water re-circulation system for TLT Fabrication unit, Hot Dip
Galvanizing Unit.
Page 76 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
microbiological growth.
from the plant. The sludge arising out of different circuits will be disposed
of at suitable location.
Page 77 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
General
for proper storage of materials and working of plant and equipment. The
items of equipment and accessories such as fans, air filters, air washers,
air-conditioning units, duct work, pumps, cooling tower, air supply grills,
climatic conditions prevailing in the region and the plants will generally be
plant rooms will be provided integral with and adjacent to the served
Page 78 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
measures for safety and fire fighting for fire hazardous areas and will be of
washed air ventilation system. The system design will take into account
the requirements of air change as well as excess heat removal. Filters will
The details and types of system proposed will be as shown in the Table
below.
No.
Page 79 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
network, etc.
humidity will be air conditioned. The selection of the type of air conditioning
the size and location of the premises. The air conditioning system shall
0
maintain a temperature of 23 + 2 C and relative humidity 55 + 5 %. The
100% standby
Page 80 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
10.03.01 General
fire protection facilities have been envisaged for the various units of the
plant.
All plant units, office buildings, stores, laboratories, etc will be provided
Page 81 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
A water based hydrant system both yard hydrant and internal hydrant
network system has been envisaged for the plant. Internal hydrants will
plant units. Yard hydrants will be provided normally along the road and in
the close vicinity of the units to meet the additional requirement of water
rooms, cable tunnels, MCC, transformer rooms, switch gear rooms, etc.
Page 82 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
a. Compressors
Page 83 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
Installation Indoor
The Air Dryer units will be of Heatless type. The selection of air dryer
units will be such that performance of the same will not be affected
circumstances the dry air supply will be stopped. Air dryer unit will
The dryer will be installed along with all necessary auxiliaries. The
Quantity 2 (1w+1s)
Page 84 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
b. Air Receiver
Capacity - 3 m³ at 6 Kg/cm²(g)
The instrument air compressors and the service air compressors will be
10.04.03 Electrics
Page 85 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
interlock.
Page 86 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
10.05.01 General
supply of compressed air, instrument air and fuel oil to meet the process
Approach ladders, hand railings etc will be provided for valve operation
plug valves, CI ball valves along with moisture traps and Y-strainers.
Furnace Oil pipes and fittings shall be ERW as per IS: 1239(Part –I) and IS:
1239(part-II) respectively.
Page 87 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
Plant grade & instrument grade compressed air shall be made available at
Temperature - Ambient
Usage - Intermittent
Temperature - Ambient
Usage - Continuous
Page 88 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
10.06.01 General
CO Gas will be tapped from RINL’s existing line and pipeline for
transporting the required quantity along with Nitrogen Line for purging
Unit and for the Galvanizing Unit has been estimated based on specific
Nm3/hr.
Page 89 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
a. CO Gas Pipeline
CO Gas will be tapped from RINL’s existing line and pipeline for
the site. The pipes will be laid on structural trestles as per the
relevant standards.
kL. The tanks will be designed as per IS: 803-1976. Each tank will
- Filling nozzle.
- Roof railing.
Page 90 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
- Lightning arrestor.
- Drain valves.
- Tank earthing.
Two (2) nos. positive displacement delivery pumps (1W + 1S) will
Page 91 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
Duplex filters of 500 micron for unloading pumps & 250 micron for
- Safety devices.
- Lubricating system.
- Base plate.
safe, smooth and trouble free operation of the bulk fuel oil system
will be installed.
Page 92 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
being set up by joint venture plan of Rashtriya Ispat Nigam Ltd. (RINL),
Page 93 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
Page 94 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
The laboratory will be provided with service facilities like power, water,
laboratories.
laboratory
11.05.01 Functions
Functional sections
Page 95 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
projector, etc.
determinator, etc.
Page 96 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
compressed air station, pump house, MSDS, water supply facilities etc
leveling etc.
Page 97 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
The Civil engineering design will be based on norm laid down in relevant
code. All RCC work will be generally of minimum M25 grade concrete and
The building structures will be designed for wind and seismic loads along
Concrete grade
M-10 and For PCC works in drain, screed concrete, grade floor, etc.
Page 98 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
M-15
Building material
portland cement, slag cement sulphate resistant cement, etc. may be used
as per requirement.
Reinforcement steel for RCC - For all RCC work, reinforcement bars has
the requirements of IS: 1077 for common burnt clay building bricks. (Grade
M-5).
Page 99 of 142
©2014 MECON Limited. All rights reserved
JOINT VENTURE OF RINL & POWERGRID
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
TRANSMISSION LINE TOWER (TLT)
MANUFACTURING COMPLEX
of main shop buildings will be of RCC laid over a compacted crushed stone
/ stone boulder. For heavy duty flooring, hard topping will be provided.
12.01.07 Finishing
Walls will be plastered with cement mortar 1:6. Plaster of pairs will be
snowcem over a base coat. Superior wall & ceiling finished like acrylic
12.01.08 Roads
Roads will be of 7m and 4m wide with berms on either side. RCC Side
drains on either side of 7m and 4m wide road will be provided. Roads will
drains will also be provided around structural buildings & on either side of
roads and with provision of pipe culverts at the road crossing. Storm
Septic tank and soak pit concept at unit locations have been envisaged for
structures.
foundations
liquid
Apart from the above, wherever necessary other relevant Indian Standard
12.02.01 General
Steel structural work will include supply, fabrication, erection & painting
The structures will include building structures, pipe trestles etc. for the
Loading will be taken as per IS: 875 – 1987 (Part 1, 2, 3 and 5) in addition
manufacturer/supplier.
a) All steel rolled sections and plates will conform to IS:2062 (Grade
A).
12.02.05 Fabrication
Fabrication of structures will conform to IS: 800 – 1984 and other relevant
standards therein.
12.02.06 Erection
Structures will be applied with two coats of primer and two coats of finish
paint. Primer shall confirm to Red Oxide Zinc Chromate (IS-2074). The
13 MANPOWER REQUIREMENT
13.01 Manpower
Table – 13.01
Estimated Manpower Requirement
Sl. No. Unit Number
1. TLT Fabrication Unit 54
2. TLT Galvanizing Unit 36
3. General administration and
10
miscellaneous
Total 100
13.02 Training
The type of facilities envisaged for the proposed plant is already under
operation for quite a long time in the country’s existing TLT
A good number of plant personnel will also get in-house and on-job
training during trial runs and commissioning of the proposed TLT
Manufacturing Complex.
14 PROJECT IMPLEMENTATION
14.01 General
have been envisaged like raw material handling system, compressed air
water supply system, air conditioning & ventilation system, central stores
Units”.
Fabrication & Galvanizing Units. In this staggering process, one unit each
for Fabrication & Galvanizing may be commissioned first with the Input
Angles from RINL / Market as per the requirement and availability. The
commissioned.
two ways:
Unit will start producing required TLT parts to meet the huge
However, the execution of the proposed project would call for meticulous
furnished below:
Volume of Work
The above estimates, however, are tentative at this stage, and are
the project.
The overall implementation schedule for the project, taking into account
time from the zero-date of the project to attain the ultimate capacity of
the plant.
readiness for cold test of the major units as per proposed schedule has
Completion Milestone
Unit (months from “zero-
date” of the project)
Ready for Cold Test - Auxiliaries for 14-15
Fabrication & Galvanizing Unit
Ready for Cold Test - Tower Fabrication 15
Unit
Ready for Cold Test - Hot Dip Galvanizing 15
Unit
Testing, Trial-Run & Integrated 15-16
Commissioning of Fabrication &
Galvanizing Unit
Civil work for the plant construction shall start from 4th month onwards.
4th month, so that the structural erection can be started from 7 th month
shall start from 9th month and shall be completed by 14th month.
units
Soil investigation
the major production units including auxiliaries and services facilities. The
approach.
15.01 General
The pollution control system for the proposed TLT Manufacturing Complex can
Possible source of air pollution in the proposed complex are the alkaline and
acidic fume from galvanizing unit. These fumes will be extracted by the fume
statutory requirements.
Emission of air pollutants from the other units will be practically negligible. As
Excessive noise produced by the various equipment operating in the plant will be
insulators/dampers for the structures and buildings. The noise level in the
vicinity of the plant and equipment will be generally kept within the permissible
limits.
The equipment and services will be designed such that in working premises the
continuous exposure noise level of 90 db (A) is not exceeded. In case the sound
level in a particular zone near equipment is above the permissible limits, the
exposure duration for the affected workers will be suitably proportional to the
The water supply and effluent disposal system proposed for the plant will be
mostly closed recirculation systems which will help in reducing the fresh water
requirement and also minimize water pollution. Where water is used only for
cooling purposes and there is no change in its characteristics except some rise in
An effluent treatment plant has been envisaged for treating effluents arising
treatment plant will work batch—wise. The treatment system for treating
effluents from galvanizing unit will have a holding tank of adequate capacity. The
waste water and rinse water will be collected in a collection/mixing tank. The
mixed effluent will be neutralized by adding milk of lime and compressed air
supply for oxidation of ferrous chloride. Then the effluent will be transferred to a
rectangular settling tank for clarification. The clarified water will be further
treated for reuse in the system. The settled sludge from settling tank will be
pumped to the sludge drying bed for sun drying and disposal.
Adequate measures have been envisaged so that all the treated effluents let out
16 CAPITAL COST
16.01 General
The capital cost of the proposed TLT manufacturing complex proposed at VIZAG
including galvanizing and other related auxiliaries and services as envisaged has
been estimated and summarized as given below:
4 TOTAL 331.3
Details of capital cost estimate have been furnished in the following table:
Table-16.01 Details of total estimated capital cost
The costs have been worked out on the basis of prices prevailing during 2 ND
Quarter 2014 and do not include any provision for future escalation in costs
during implementation period.
The various assumptions made while estimating the capital cost are elaborated
below: -
Land
The proposed plant is to be set up over an area of 50 Acres. The land shall be
permitted to use against user charges as described hereunder:
The cost towards leveling of this land besides the cost towards laying of internal
roads, boundary wall, gates, security posts etc. have also been covered under
civil costs.
Buildings
The estimated cost of buildings has been worked out on the basis of preliminary
layout and design of facilities detailed in the previous chapters and rates for civil
works as applicable in the region. The facilities included in the estimates are
factory buildings including main and auxiliary services, non-factory buildings and
miscellaneous civil works etc.
ocean freight and insurance has been made @ 5.0% of FOB value of imported
supplies. Import duty has been provided @20.6036 % (5 % (CD, 10.0%CVD,
3%Ed.cess, 4%SAD) of CIF value of imported supplies under project import
provisions. For indigenous plant and equipment, excise duty has been
considered at an average rate of 10.3% and central sales tax at the rate of 2%
on such equipment and spares. Provision has also been made in the estimate
for erection and foundation of plant and machinery.
Financing
The project is considered to be financed in the debt : equity ratio of 3:1. The
debt portion is to come through long term loan bearing an interest rate of 12%
per annum.
Contingencies
Provision for contingencies @ 5% on the capital costs has been made to cover
any unforeseen aspect of the estimate.
Working capital
The working capital requirements have been considered as equivalent to one
months of cost of production. It is also assumed that entire working capital shall
be financed through short term bank borrowings bearing interest rate of 12%
p.a.
Exclusion
The cost estimate does not provide for followings: -
i) Any future escalation in prices
ii) Any currency fluctuations in future
iii) Any changes in rate of duties & taxes
iv) Infrastructure facilities outside the battery limits of the plant proper
Exchange Rates
The imported supplies have been considered at following exchange rates:
Rs/Euro= 82.0
Table-16.01
17 PRODUCTION COSTS
17.01 General
The proposed TLT Complex has been envisaged to produce total of 120000 Tons
of galvanized finished products annually. It is assumed that the plant would
operate at 80 % capacity during first year, 90% during second year and 100 %
during third year and onwards.
The average production cost excluding depreciation and interest during third
year of operation when the plant achieves rated capacity utilization, works out
to Rs 52,263/ton (rounded). The details of annual works cost are given in Table-
17.01.
The plant has been envisaged to source its total black angle requirements from
RINL / Open market / through conversion agents depending upon the supply
constraints, price economics and logistic considerations. In view of such wide
ranged sourcing spectrum it has been decided to consider average delivered
price of black angles to the plant at Rs 41000/t for the purpose of this report.
The costs (Excl. Excise) of major input raw materials (Average as prevailing in the
market) as delivered at site have been adopted as follows: -
3 Zinc 164,000
Rates for raw materials and other inputs are based on information available from
Market feedback/MECON’s in house data.
Cost of consumables includes various consumables like lubricating oil and grease,
etc.
17.03 Utilities
The costs of various utilities such as water, electricity and fuel have been
considered as follows:
Table-17.02
Annual average
Sl. No. of Total annual
Category remuneration/
no. employees cost (Lakh Rs)
employee
1 Executives 25 18 Lakh 450
2 Non - 75 8 Lakh 600
Executives
3 Out sourced LS @730 Rs/ton of 876
services for finished
material Product
handling and
other non-
critical
activities
100 +
Total 1926
Outsourced
Cost towards normal repair & maintenance of plant and buildings and rent, rates,
taxes, insurance, etc have been covered under overheads. The provision includes
for administration and selling expenses also. The repair & maintenance expenses
are Rs 416 Lakh/Annum and remaining Rs 235 Lakhs/annum are towards
overheads provision.
17.06 Depreciation
Depreciation has been worked out based on straight-line method and written-
down value (WDV) method as per existing income tax rules. The details are given
in Table 18.06 in next chapter.
17.07 Interest
The following interest rate has been considered for various types of
financing arrangements: -
Long term loan : 12% p.a.
Bank borrowings for working capital : 12% p.a.
17.08 Escalations
The above production costs are based on the prices/rates prevailing during 2nd
Qr. 2014 and no future escalations have been considered while assessing these
costs.
Table-17.01
18 FINANCIAL APPRISAL
18.01 General
Financial analysis has been carried out based on capital investment and
operating cost elaborated in preceding chapters and Average net sales
realization as discussed in para 18.07. The salient techno-economic indices of the
project have been summarized in Table -18.01.
Table-18.01
SALIENT TECHNO-ECONOMIC INDICES
Sl.No. Item description Unit Indices
1 Cumulative retained profit over Crore. Rs. 267.2
10 years of operation
2 Average annual retained profit over Crore. Rs 26.7
10 years of operation
3 Cumulative cash surplus over Crore. Rs 186.3
10 years of operation
4 Average Debt-service coverage ratio over 10 Ratio 1.51
years of operation
5 Pay-back period Years 7.9
6 Break even capacity % 63
7 Internal rate return (IRR) over 20 years
Of operation
Pre-tax % 22.1
Post-tax % 18.8
18.02 Profit & Loss and Cash Flow Statement and projected Balance sheet
The profit and Loss statement, cashflow statement and projected balance sheet
for 10 years of operation has been given in Table-18.02, 18.03 and 18.07
respectively.
The internal rate of return (IRR) has been calculated considering 20 years project
life by employing discounted cash flow (DCF) technique. The IRR for the project
works out as follows:
The pay back period is defined, as the period required for recouping the original
investment outlay through the cash profit after tax. The pay back period for the
project works out to 7.9 years.
Break even analysis determines the break-even point (BEP)- the level of capacity
utilization at which no profit no loss status can be achieved. The break even
capacity has been calculated as 63 % and presented in Table- 18.04.
The debt-service coverage ratio for 10 years works out as 1.51 and details are
furnished in Table 18.05.
The Average market price of galvanized TLT products have been found varying in
the range of Rs 55000/T to Rs 75000/T depending on various producers and
their loading position in terms of orders .It is a competitive market with
presence of many suppliers with small to large capacities. The actual feel of
bottom of sales realization is difficult to get, however depending upon limited
interactions and market feedback; it has been decided to adopt Rs 59000/T as
average net sales realization for the total finished products for purpose of
working out profitability.
18.08 Assumptions
The total project cost is assumed to be financed in debt equity ratio of 3:1.
The long term loan is considered to be repaid in 32 equal quarterly
installments bearing interest of 12% p.a. with two years moratorium on
repayments from date of commercial operation.
Capacity utilization
It is assumed that the plant would operate at 80 % capacity during first year,
90% during second year and 100 % during third year and onwards.
Depreciation
Corporate tax
CENVAT benefit
Sensitivity analysis has been carried out for the variations in capital costs,
Conversion costs and D:E ratio. The result of this analysis is summarized in Table
18.07.
Table-18.08
Sensitivity Analysis
Post-Tax IRR
Sl. No. Item
(%)
1. Base case 18.8%
2. Variation in capital cost
+10% 17.1%
-10% 20.9%
3. Variation in conversion cost
+10% 17.4%
-10% 20.1%
4. Variation in D:E ratio
2:1 18.5%
2.33:1 (70:30) 18.6%
1:1 18.1%
Table-18.02
Table-18.03
Table-18.04
Table-18.05
Table-18.06
Table-18.07
19 INDUSTRIAL SAFETY
SAFETY
Safety of personnel and the plant are of paramount importance and this
cannot be over looked. The following two major schemes are proposed to
cover the safety aspect viz. the fire protection system & area illumination.
for safety goals and orientation programme for new employee have been
envisaged.
Prevention and fighting of fire is one of the most vital aspects for any
industrial establishment. In a steel plant there are many areas, which are
envisaged to tide over any such eventuality efficaciously. The system has
and other relevant standard/codes. The complete fire protection system will
Communication facilities
sets.
B. AREA ILLUMINATION
scheme.
The following goals shall been suggested to establish for safety in the
plant premises:
and rules.
work within their assigned area. This session will be conducted under
received, understand, and will abide by the Company Safety Program. All
the session.
20 DRAWINGS
Sl.
Description Drawing Number Rev
No.