Detailed Project Report on Steel Transmission Line Tower and Rolling Mill to Produce Steel Sections

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STEEL TRANSMISSION LINE TOWER AND ROLLING MILL TO PRODUCE STEEL SECTIONS

[EIRI/EDPR/1382] J.C.158

INTRODUCTION

The transmission line towers are comparatively light structures and the maximum wind pressure is the main criterion for their design. The concurrence of earth quake & intensified wind pressures may also be considered in the earth quake - prone areas for design of the overhead transmission line towers. These towers are fabricated by means of bolted joints only. The structural steels of well specified quality only are used in construction of transmission line towers to ensure the permissible stresses and other design details. Practices followed in material selection, design, fabrication, testing and must suit the field conditions of this country.

Various design considerations are adopted in the design of self-supporting steel lattice towers for overhead transmission lines, including loads, combination of loads, permissible stresses, wind pressures likely to be experienced during service and atmospheric corrosion intensity.

This project does not propose to manufacture guyed towers & special towers for river crossings or other large spans. The intention is to produce overhead electric power transmission line towers to be used in plains.

Electricity is a key input for agricultural, industrial & over all development of the nation. Demand for electrical energy has registered a phenomenal growth @ 10% p.a. during last over 4 decades.

The installed generating capacity of 1700 MW in 1950 has grown to 58,000 MW in 1988-89 and then, to 70,000 MW in 1993-94.

The national average per capita consumption of electricity in 1960 was 47 Kwhs, in 1979-80 it was 200 and in 1989-90, it grew to 360 Kwhs.

The demand for power has always left behind the supply. This is partly due to low generation and due to inadequate power transmission network. There are about 8200 circuit Kms of 132/110 KV, 52,000 circuit Kms of 220 KV and approx. 14,000 circuit Kms of 400 KV lines, in the country.

Moreover, there are counted few potential manufacturers & erectors of Electricity transmission line towers in the country. Most of these manufacturers are concentrated in Gujarat & Maharashtra. Since the transmission line tower industry has started riding at the climax now, new entrants are going to find a bright scope both in the domestic market and abroad.

The project proposes to set-up a self-contained integrated plant which will produce the required steel sections by hot rolling the steel billets/bars, within the factory. Part of the output (25%) of hot rolled products will be meant for its captive use in the overhead power transmission line towers mfg. unit and the balance 75% of its output will be sold in the domestic market. Housing construction industry, general engg. builders will find these steel products highly suitable for their purposes.

The steel hot-rolling mill will work on indigenous plant and machinery. Similarly, all the machineries needed for the transmission line towers plant, are of indigenous make. Thus, no import element is available for setting & operating, this proposed plant. On the other hand, the final products of this plant have a high export potential. Indigenous demand itself is staggeringly highly but if the unit so wishes, these final products can be readily sold in the international market.

COST ESTIMATION

Plant Capacity 500 MT/Day

Land & Building (5 Acres) Rs. 4.34 Cr

Plant & Machinery Rs. 10.98 Cr

Working Capital for 2 Months Rs. 111.82 Cr

Total Capital Investment Rs. 129.38 Cr

Rate of Return 79%

Break Even Point 21%

CONTENTS

INTRODUCTION

TYPES & APPLICATIONS OF TOWERS

B.I.S. SPECIFICATIONS

PROPERTIES

MARKET POSITION

MANUFACTURERS AND SUPPLIERS

MANUFACTURING PROCESS

GALVANIZING TECHNIQUE

PROCESS FLOW DIAGRAM OF FABRICATION

PLANT LAYOUT

PROCESS FLOW CHART FOR HOT ROLLING MILL

PRINCIPLES OF PLANT LAYOUT

PLANT LOCATION FACTORS

EXPLANATION OF TERMS USED IN THE PROJECT REPORT

PROJECT IMPLEMENTATION SCHEDULES

COMPLETE PLANT SUPPLIERS FOR TRANSMISSION LINE TOWER

SUPPLIERS OF PLANT AND MACHINERY

SUPPLIERS OF RAW MATERIALS

PLANT ECONOMICS

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)

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