hydraullic turbine man

7/27/2019 Hydraullic turbine Man

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MANUFACTURINGCAPABILITIES FOR PLANT &

EQUIPMENT FOR HYDROPOWER PLANTS

S.K.Kaul18thAugus t2009


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SCENARIO OF 10TH PLAN

CAPACITY ADDITION

Sector Target (MW) Achievement

(MW)

Central 8742 4495

State 4481 2691

Private 1170 700

Total 14393 7886

Delay on account of Equipment supply constraint : 679 MW


3/18

Summary of ordering status of TG Sets

of Hydro Projects in 10th Plan

The Hydro capacity addition Target 14393 MW

Electro-Mechanical equipments awarded 12004 MW

Indian Suppliers

BHEL 4945 MW

Alstom 680 MW

VA Tech 216 MW

Foreign Suppliers 6163 MW


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HYDRO CAPACITY ADDITION PROGRAMME

FOR 11TH PLAN

Central Sector 8654 MW

State Sector 3482 MW

Private Sector 3491 MW

Total 15627 MW

No. of Project 45

No. of Units 166

Highest unit size 250 MW

Smallest unit size 11 MW


5/18

Summary of ordering status of TG Sets of HE

Projects for likely benefits in 11th Plan

The Hydro capacity addition programme: 15627 MW

Ordering Status of T.G. Sets:

Indian Supplier

BHEL 6017 MW

VA Tech 366 MW

Alstom 339 MW

Foreign suppliers 8905 MW


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Manufacturing Capabilities of main

indigenous manufacturers for plants &

equipment for Hydro Power Plants

M/s BHEL 2500 MW

M/s Alstom 1260 MW

M/s VA Tech order based

M/s Voith Siemens order based


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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 (1327MW)

Categorisation of capacity of Hydro Plants 12th Plan

Type of

Scheme

Capacity (MW) No. of Stations

ROR 16,116 77

STO 2,448 7

PSS 1,770 3

TOTAL 20,334 87


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Preparedness for 12th Plan & beyond

Hydro capacity totaling to 24,500 MW has been proposedduring the 13th Plan. A shelf of hydro projects totaling to about43,000 MW has been drawn up out of which the aboverequirement of 24,500 MW would be selected.

In addition, the requirement of capacity addition programmesin 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 2times) in the no. of proposed Hydro Power schemes in the12th Plan. Thus, there is a need to revisit the Manufacturing

capabilities for Plant & Equipment for Hydro Power Plants.


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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) 415 505 920

ii. Vertical lift gates (set) 630 767 1397

Electro-Mechanical2 Turbine (MW) 20,130 24,495 44,625

3 Turbine (No.) 238 286 524

4 Butterfly Valve (Set) 48 58 106

5 Main Inlet Valve (Set) 198 241 439


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ESTIMATED REQUIREMENT OF EQUIPMENT

FOR HYDRO POWER PLANTS FOR

12th & 13th PLANSNo. Equipment 12th Plan

(20,000

MW)

13th Plan

(24,500

MW)

Total

6 Digital Governor (Set) 238 286 524

7 Synchronous Generator(MVA) 22,366 27,216 49,5828 Synchronous Generator (No.) 238 286 524

9 Unit Control Board (set) 238 286 524

10 Motor & MCC (unit) 1596 1943 3539

11 Transformer(UAT & SST) MVA 267 286 553

12 Static Excitation System (set) 238 286 524

13 Dynamic Excitation System

(set)

238 286 524

14 NG cubicle incl. Tranfr, (set) 238 286 524


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12/18

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

20 EHV Equipment

Circuit breaker (No.) 390 515 908

Capacitor voltage transformer(CVT) (Set)

1125 1367 2492

EHV Voltage Transformer(No.) 522 640 1162

Lightning Arrestor (LA) (No.) 1344 1627 2971

Isolator (Set) 920 1120 2040

EHV Current Transformer(Set) 1318 1604 2922

21 415 V Switchgear Board (Unit) 650 791 1441

22 220/400 kV GIS Bay (No.) 167 203 370

23 EHV XLPE Cable (km) 49 60 10924 EHV Bus Duct km 22 25 47


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REQUIREMENT OF OTHER KEY INPUTS FOR

12th & 13th PLANS

Steel and cement are key inputs needed for construction of hydro powerprojects & the requirement of the same vary from project to projectdepending upon type of scheme.

For 12th Plan, the requirement corresponds to a hydro capacity of about20,000 MW & for The 13th Plan requirement is based on the proposed

programme of 24500 MW

Sl.No. Material Quantity (in million tonne)

12th Plan 13th Plan

1 Cement 19.244 23.422

2 Structure Steel 0.684 0.833

3 Reinforcement Steel 1.872 2.278


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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


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Action points

To meet additional capacity requirements for 12th plan &beyond, manufacturers/ suppliers need to take appropriatesteps.

Advance action shall be taken by Project Authorities toAward Contracts for projects identified for the benefits in the12th Plan so that timely action can be taken bymanufacturers/suppliers

Qualifying requirements may be modified/ rationalized toenable financially sound new players to compete.

The project promoters should streamline, wherever required,the payment system to have better response from thesuppliers.

Placement of orders, where in few cases, has taken longertime due to various technical & other intricacies creatinguncertainty in the planning process of manufacturers, needsto be expedited.


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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 isexpected to increase Indigenous manufacturing of such

equipments/items need to be pursued more vigorously.


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Action points

Delivering of equipment needs to be critically verified rightfrom shop to the site store. Non-receipt of even one itemwhich is essential for commissioning may delay the wholeprocess.

Enhance the availability of O&M engineers as shortage ofoperation & maintenance engineers particularly in PowerStations located in remote/difficult areas may also becomea bottle neck in near future


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THANKS

hydraullic turbine man

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