|
Chapter 2 : Department of Atomic Energy
2.1
Nuclear Power Profile
Highlights
-
Against a nuclear
power profile with projection of achieving additional capacity of
7880 megawatt of nuclear power by 2000 AD, the Department of Atomic
Energy has not been able to generate any nuclear power under this
profile in spite of having spent Rs 5291.48 crore as of March 1998.
-
Rather than taking
co-ordinated action for all components of the project, procurement
of material was given precedence. All other related factors like
creation of infrastructure, execution of civil works etc. without
which the material procured could not be utilised, were not given
the matching importance.
-
While the
availability of funds was a constraint, no effort was made to reduce
the number of plants and their capacity to match with the available
funds. As a result, the material had been procured for 10 plants
whereas, civil works had not commenced for any of them.
Consequently, the material worth Rs 1069.61 crore were lying
unutilised for up to 10 years, part of which was not even properly
stored.
-
Finished/semi-finished
material and components worth Rs 523.86 crore procured for the eight
plants, which have not yet been sanctioned, have been rendered
unfruitful as their market value is not likely to be more than the
scrap value.
-
Expenditure of Rs
50.12 crore was incurred on design and consultancy for 12 plants
whereas expenditure on site was confined to only two plants
resulting in burden of consultancy at the rate of Rs 25.06 crore per
plant in stead of mere Rs 4.18 crore per plant.
-
Despite its inability
in successfully implementing the Nuclear Power Profile due to
resource crunch, DAE has embarked on another programme to launch two
Pressurised Water Reactors of 1000 MW each at Kundankulam.
2.1.1 Introduction
In order to increase the
nuclear power capacity to 10000 megawatt (MW) approximately by 2000 AD,
DAE drew up a nuclear power profile for establishment of additional
nuclear power capacity of 7820 MW in 1984 revised to 7880 MW in 1989.
This was in addition to 1840 MW envisaged to be generated from other
existing/on-going plants outside the 'Profile'. Nuclear Power Board (NPB),
a unit of DAE, was responsible for execution of the programme. It was
incorporated as a Public Sector Undertaking in September 1987 by the
name ‘Nuclear Power Corporation of India Limited’ (NPCIL).
2.1.2 Organisational set
up
Secretary DAE is the
Chairman for Atomic Energy Commission. The execution of Nuclear Power
Plants is entrusted to NPCIL, which is headed by a Chairman-cum-Managing
Director. The organisational chart of DAE relating to the ‘Profile’
was as under :
2.1.3
Scope of audit
The records of DAE and
NPCIL pertaining to period 1989-98, relating to the 'Profile', were
examined at DAE secretariat at Mumbai, NPCIL corporate office and its
branch office at Mumbai. To provide an overall picture of the 'Profile'
related information prior to 1989 was also collected, wherever
necessary.
2.1.4 Planning |
| Nuclear Power
Profile of 1984 envisaged installation of twelve 235 MW and ten 500 MW
plants |
The 'Nuclear Power
Profile' of 1984 envisaged installation of twelve 235 MW and ten 500 MW
Pressurised Heavy Water Reactor units (plants) to be implemented during
1985-2000. DAE appointed a Committee in July 1988 for updating the
'Profile' and making recommendations on schedule of setting up of plant
and inputs required for scheduled construction of plants. The Committee
was also to focus attention on capital investment required for reactors,
fuel cycle facilities and other infrastructure etc.
Consequent upon review of
the progress of the implementation of the 'Profile', the Committee came
to the conclusion in November 1989 that the overall target of
establishing an installed capacity of 10000 MW by 2000 AD continued to
be feasible. In view of the advantages of going in for larger sizes of
units, the Committee also decided to replace four 235 MW plants in
respect of which no action had been taken, by two 500 MW plants. As
action for advance procurement of material etc. had already been
initiated in case of other eight 235 MW plants, no recommendation for
change in those cases was made.
The Committee made the
following projections for the capacity addition and flow of funds in a
phased manner:
|
Year |
Capacity addition (progressive)
(MW) |
Funds requirement at * 1989
prices (progressive) (Rs in crore) |
|
Up to 1988-89 |
|
906.50 |
|
1989-90 |
|
1626.50 |
|
1990-91 |
|
2695.50 |
|
1991-92 |
|
4171.50 |
|
1992-93 |
|
5903.50 |
|
1993-94 |
|
7960.50 |
|
1994-95 |
|
10151.50 |
|
1995-96 |
940 |
12183.50 |
|
1996-97 |
1175 |
13796.50 |
|
1997-98 |
2645 |
15006.50 |
|
1998-99 |
4380 |
15915.50 |
|
1999-2000 |
6380 |
16435.50 |
|
2000-01 |
7880 |
16661.50 |
* Includes expenditure on
on-going plants also |
| The committee
did not make any year-wise projections in respect of procurement of
material and creation of infrastructure |
Although the Committee
realised the importance of timely procurement of material and creation
of infrastructure viz. acquisition of land and execution of civil
works, it did not set year-wise mile stones for this.
2.1.5 Finance |
| Financial
sanction for four 235 MW and two 500 MW plants had only been issued as
of March 1998 |
The financial sanctions
were issued in respect of four 235 MW plants in 1986 (two plants) and
1987 (two plants) and an expenditure of Rs 213.07 crore had been
incurred on these four plants up to 1988-89. The total additional
capital outlay required for the programme at 1989 price level required
during 1989-2001 for the 20 plants covered under the 'Profile' and
on-going plants outside the 'Profile' was estimated by the Committee at
Rs 15755 crore. The projections made by the Committee were based on the
presumption that financial sanctions for 10 out of the remaining 16
plants would be available during 1989-90. However, financial sanctions
in respect of only two 500 MW plants for Tarapur Atomic Power Plant - 3
and 4 estimated at Rs 2427.51 crore were issued in January 1991, which
was further revised to Rs 6421.00 crore (at 1996 constant rupee value)
in December 1997. Thus, excluding the interest during construction of Rs
1580 crore, the cost estimates have already gone up by 99 per cent.
The financial sanctions in respect of the remaining 14 plants had not
been issued as of March 1998.
The table below gives the
annual requirement of funds, the funds proposed under plan and funds
actually allocated there-against:
(Rs in crore)
|
Year |
Funds required |
Funds proposed under plan |
Funds allocated |
| |
|
|
Equity |
Loan |
Total |
|
Up to 1987-88 |
466.50 |
N.A. |
185.92 |
- |
185.92 |
|
1988-89 |
440.00 |
461.00 |
211.23 |
- |
211.23 |
|
1989-90 |
720.00 |
799.00 |
230.00 |
- |
230.00 |
|
1990-91 |
1069.00 |
1069.33 |
185.00 |
- |
185.00 |
|
1991-92 |
1476.00 |
1491.46 |
130.57 |
- |
130.57 |
|
1992-93 |
1732.00 |
1433.00 |
143.18 |
- |
143.18 |
|
1993-94 |
2057.00 |
1202.00 |
170.44 |
250.00 |
420.44 |
|
1994-95 |
2191.00 |
1180.00 |
188.92 |
- |
188.92 |
|
1995-96 |
2032.00 |
1229.00 |
214.29 |
- |
214.29 |
|
1996-97 |
1613.00 |
1183.78 |
305.67 |
- |
305.67 |
|
1997-98 |
1210.00 |
1273.00 |
402.19 |
- |
402.19 |
|
1998-99 |
909.00 |
1300.00 |
- |
- |
- |
|
1999-2000 |
520.00 |
1300.00 |
- |
- |
- |
|
2000-2001 |
226.00 |
N.A. |
- |
- |
- |
|
Total |
16661.50 |
13921.57 |
2367.41 |
250.00 |
2617.41 |
NA : Not available
It would be seen from the
above table that the planned target for achievement of capacity was much
more than the target achievable with the funds allocated. This has to be
viewed in the light of 99 per cent increase in cost estimates
over the original projections for Tarapur Atomic Power Plant - 3 and 4
as brought out above. Delay in implementation of the plants due to lack
of funds was, therefore, further bound to multiply the cost. Moreover,
the increased cost of construction would increase the cost of power.
Against the requirement
of Rs 15006.50 crore up to 1997-98 for twenty plants and on-going
plants, only Rs 2617.41 crore had been allocated for the 'Profile'. As
against this, the expenditure incurred was Rs 5291.48 crore, i.e. Rs
2674.07 crore (102.16 per cent) more than the allocation. As the
budgetary support could not be maintained by DAE either as debt or as
equity, the additional funds of Rs 2674.07 crore were mobilised by NPCIL
through Capital Market borrowing. The funds so borrowed included Rs
1443.77 crore for meeting the payment of interest on borrowed funds. The
details of funds borrowed were as follows:
(Rs in crore - cumulative)
|
Year |
Funds allocated |
Market borrowings |
Interest during construction |
Total expenditure |
|
Up to 1988-89 |
397.15 |
- |
- |
298.79 |
|
1989-90 |
627.15 |
53.37 |
3.42 |
585.38 |
|
1990-91 |
812.15 |
319.52 |
18.85 |
1150.52 |
|
1991-92 |
942.72 |
610.66 |
106.06 |
1659.44 |
|
1992-93 |
1085.90 |
898.21 |
248.26 |
2232.37 |
|
1993-94 |
1506.34 |
894.05 |
400.75 |
2801.14 |
|
1994-95 |
1695.26 |
1208.45 |
556.84 |
3460.55 |
|
1995-96 |
1909.55 |
1372.80 |
801.71 |
4084.06 |
|
1996-97 |
2215.22 |
1342.67 |
1120.07 |
4677.96 |
|
1997-98 |
2617.41 |
1230.30 |
1443.77 |
5291.48 |
DAE stated in February
1999 that since the budgetary support was not adequate even to meet the
committed expenditure towards the advance procurement and since NPCIL
had to discharge its obligation for payment, borrowing was resorted to
as a source of funding for part financing of advance procurement
expenditure and therefore interest on such borrowing had also to be
included as expenditure towards advance procurement which was not
envisaged at the time of initiating advance procurement programme.
In respect of four 235 MW
plants under construction, included in the ‘Profile’, against DAE
funds of Rs 1578.40 crore allocated as equity and loan, NPCIL incurred
an expenditure of Rs 3586.30 crore till 1997-98. These projects were
stated to be in the advanced stages of completion. In respect of 10
future plants (four 235 MW and six 500 MW), only Rs 1039.01 crore had
been allocated by DAE till 1997-98 which was less than the requirement
for a single 500 MW plant. No funds had been allocated for the remaining
six 500 MW plants.
DAE stated that
availability of funds was not a problem till VII Five Year Plan (up to
1985). With a view to accelerate the Nuclear Power Programme as per
profile of 1984 and to access the additional fund from market borrowing,
the earlier Nuclear Power Board was incorporated as NPCIL in 1987.
The actual expenditure
against this was Rs 1705.18 crore as detailed below:
(Rs in crore - cumulative)
|
Year |
For four 235 MW plants under construction |
For future ten plants |
| |
Funds allocated |
Market borrowings |
IDC |
Expenditure |
Funds allocated |
Market borrowings |
IDC |
Expen
diture |
|
Up to 1988-89 |
240.52 |
- |
- |
213.07 |
156.63 |
- |
- |
85.72 |
|
1989-90 |
334.52 |
14.92 |
1.65 |
351.09 |
292.63 |
38.45 |
1.77 |
234.29 |
|
1990-91 |
419.52 |
156.07 |
15.73 |
591.32 |
392.63 |
163.45 |
3.12 |
559.20 |
|
1991 -92 |
517.76 |
300.46 |
57.17 |
875.39 |
424.96 |
310.20 |
48.89 |
784.05 |
|
1992-93 |
602.76 |
449.09 |
133.35 |
1185.20 |
483.14 |
449.12 |
114.91 |
1047.17 |
|
1993-94 |
980.26 |
441.44 |
230.08 |
1651.78 |
526.08 |
452.61 |
170.67 |
1149.36 |
|
1994-95 |
984.88 |
803.20 |
306.45 |
2094.53 |
710.38 |
405.25 |
250.39 |
1366.02 |
|
1995-96 |
1058.58 |
1048.20 |
460.13 |
2566.91 |
850.97 |
324.60 |
341.58 |
1517.15 |
|
1996-97 |
1250.33 |
1098.74 |
697.82 |
3046.89 |
964.89 |
243.93 |
422.25 |
1631.07 |
|
1997-98 |
1578.40 |
1042.44 |
965.46 |
3586.30 |
1039.01 |
187.86 |
478.31 |
1705.18 |
Note: IDC Interest during
construction
2.1.6. Additional
Capacity
DAE reduced the total
capacity of 7880 MW envisaged by the Committee to 6050 MW in August
1990. This was further reduced to 3820 MW in March 1994. Even the six
plants sanctioned with capacity of 1940 MW had not been completed and
therefore, there had been no addition to the capacity under the ‘Profile’
as of March 1998.
DAE stated in February
1999 that due to inadequate budgetary support during early 1990s, the
target of the ‘profile’ was slashed down to 8050 MW by 2002 AD.
Even if budget constraint
was the only reason for slashing down the target, it could not be scaled
down below the limit of the capacity for which advance procurement has
already been made.
Even the six plants
sanctioned with capacity of 1940 MW has not been completed and
therefore, there had been no addition to the capacity under the ‘Profile’
as of March 1998.
2.1.7. Procurement of
material
The Committee appointed
to review the 'Profile' had presumed that advance action would be needed
for procurement of material with long lead-time for delivery. In respect
of four 235 MW plants sanctioned prior to 1989, the advance procurement
of material had already been made. In addition, DAE had taken approval
of the Cabinet for advance procurement of material and equipment for Rs
1328.40 crore for 10 plants with total capacity of 3940 MW (including
six 500 MW plants) during February 1986 to July 1988, on the ground that
lead-time of three to four years was required from importing the raw
material for fabrication of finished goods. Lack of matching action in
other areas and constraint of funds, without which the material and
equipment could not be utilised resulted in the material lying unused
for long time. Out of the ten plants, financial sanctions were issued in
respect of only two 500 MW plants in January 1991. Another sanction for
procurement of equipment valued at Rs 182.04 crore was obtained from
Cabinet in January 1991.
DAE stated in February
1999 that setting up of site infrastructure, obtaining environmental
clearance from State and Central Government and obtaining construction
commencement clearance etc. had been completed. The site infrastructure
included fenced land, approach road, job shacks, warehouses etc. Design
and engineering and development works have also progressed. However,
audit scrutiny disclosed that the progress made in works did not match
with the progress in procurement of material.
Some of the finished
goods including equipment had been stored at different locations for the
past one to nine years as may be seen from the following illustrations
noticed during test-check:
|
Sl. No |
Supplier |
Item and date of purchase order |
Payment to supplier (Rs in crore) |
Status of execution of order |
Status as of March 1998 |
|
1 |
BHEL |
Four Turbo-generators in March 1989 |
301.53* |
Order reduced to two Turbo-generators in
October 1997; Order for other two was short closed by taking over
semi-finished goods |
Components for first Turbo generators set
received from 1992 onwards are stored in a shed at site |
|
2 |
KSB, West Germany |
Primary Coolant Pump Motor set consisting of
4 Pumps and 5 Motors in July 1988 |
38.59 |
Order completed in March 1990 |
Stored at site wrapped in aluminium foil
with silica gel since March 1990 |
|
3 |
KSB, Pune |
Primary Coolant Pump Motor set consisting of
4 Pumps and 5 Motors in July 1988 |
26.32 |
4 Pumps completed in March 1996; Work on
motors not yet taken up |
4 Pumps stored at manufacturer’s site |
|
Sl. No |
Supplier |
Item and date of purchase order |
Payment to supplier (Rs in crore) |
Status of execution of order |
Status as of March 1998 |
|
4 |
KSB, Pune |
4 Primary Coolant Pump Motor sets consisting
of 4 Pumps and 5 Motors each in July 1988 |
88.27 |
Order kept under hold |
Raw material is stored at the site of the
supplier |
|
5 |
L&T |
6 orders for Steam generators, End Shields
and sub-assemblies during January 1989 to April 1991 |
122.43Y |
Order kept under hold |
Free issue material and semi-finished
components stored at supplier’s premises |
|
6 |
KBL |
11 canned motor moderator pumps |
10.49 |
Order completed |
Stored with vacuum sealed packing since 1997 |
|
7 |
WIL |
5 Calandria with one pair of End Shield
assemblies and Pressuriser equipment during July 1988 to April
1990 |
7.19 |
Calandrias completed during January 1992 to
October 1994; order for other items closed |
Calandrias stored at manufacturer’s site;
Free issue material and semi-finished goods stored at manufacturer’s
site in sheds. |
|
8 |
ECIL |
Imported Self Powered Neutron detectors |
3.24 |
Order completed for one 500 MW plant |
235 Self Powered neutron detectors lying at
Trombay Village Stores since 1990 |
|
9 |
BHPV |
4 sets of moderator heat exchangers in
November 1989 |
1.11 |
Order agreed to be short closed by taking
over semi-finished goods |
Semi-finished goods yet to be taken
over |
|
10 |
GRE |
One Calandria assembly in February 1989 |
0.50 |
Short closure by taking over semi-finished
goods agreed |
Semi-finished goods yet to be taken
over |
* Including Rs 21.32
crore for short closure of order.
Y Free issue material -
Rs 78.19 crore, advance - Rs 44.24 crore.
¤ Since taken over as
per the reply of the Department of February 1999.
Note: BHEL: Bharat Heavy
Electricals Ltd.; KSB: A German firm having a branch at Pune; L&T:
Larsen and Toubro Limited; KBL: Kirloskar Brothers Ltd.; WIL;
Walchandnagar Industries Ltd; EIL; Electronic Corporation of India Ltd.;
BHPV; Bharat Heavy Plates and Vessels; GRE; G.R. Engineering Works. |
| The equipment
worth Rs 1069.61 crore, which remained unutilised, were stored at
various sites including manufacturer's sites |
The equipment worth Rs
1069.61 crore stood stored at various sites including manufacturer’s
sites. This included raw material valued at Rs 119.28 crore procured
during January 1986 to September 1992 which were lying unused at Trombay
Village stores.
DAE stated that the
advance procurement of material cost was less than 10 per cent of
the total project cost.
The reply had to be
viewed in light of the fact that when there was a financial crunch even
for this expenditure of 10 per cent, the possibility of arranging
90 per cent of the funds to make use of 10 per cent
already invested on procurement was not an easy task. While confirming
that the items procured in advance cannot be sold, DAE stated that the
items procured were mostly custom made to suit the requirement of
Nuclear Power plants and hence may not find use in other industries.
While the cabinet had
been informed that advance procurement was necessary in view of the long
lead-time required for fabrication of equipment from raw material, these
had not been utilised or issued for the purpose of fabrication. A
test-check of stock cards pertaining to stock valued at Rs 50.48 crore
revealed that these material were stored in open yard without any
water/rust proof coating. As a result, the coating initially provided
with the material started deteriorating. The material was covered with
water proof and ultraviolet resistant fully welded tarpaulin only in May
1995.
While the funds stood
blocked in these equipment, expenditure was incurred on their storage.
The expenditure on storage could not be worked out as no separate
accounts were kept for this purpose. It was, however, seen that Rs 12
lakh had been spent on procurement of primer required for preservation
of carbon steel plates and beams at Trombay village stores. The
expenditure incurred for cleaning and application of primer was
estimated at Rs 44.73 lakh. For storage of goods at the site of
Walchandnagar Industries Limited, sheds had specifically been
constructed at a cost of Rs 15 lakh.
DAE stated that in view
of deferment of commencement of the project, a task force was formed in
February 1995. The responsibility of the task force included assessment
of materials at Trombay village stores for their condition and urgent
action for suitable rust prevention wherever required. The task force
carried out their responsibility. Subsequently, due to continued
resource crunch, in October 1996 the Committee was reconstituted and the
scope of the task force was widened to include long term preservation of
the material, equipment and components lying at Trombay stores,
manufacturers premises and sites.
Since the equipment had
been lying unused for a long time, there was very little chance of their
replacement or rectification by the suppliers, if these did not work
satisfactorily at the time of installation.
NPCIL stated in June 1998
that as the pumps and components were being preserved with due
protection based on manufacturer’s guidelines, the question of their
deterioration during storage did not arise. |
| As there was
no possibility of immediate use of the equipment worth Rs 523.86 crore,
there was risk of their deterioration |
The reply of NPCIL should
be viewed in the background of the fact that there was no performance
warranty from the manufacturers for satisfactory performance after
indefinite storage. Moreover, the Primary Coolant Pump Motor sets were
designed for a life of 40 years whereas these had already been stored
for nine years i.e. 23 per cent of their designed life. As the
financial sanctions in respect of four 500 MW and four 235 MW plants,
for which material/equipment were procured had not been issued as of
March 1998, there was no possibility of immediate use of the equipment
worth Rs 523.86 crore procured for these plants. Consequently, there was
a risk of obsolescence and deterioration besides recurring inventory
carrying cost and interest burden. A status report on advance
procurement of material prepared by Chief Engineer (Corporate Planning)
in March 1997 revealed that the possibility of disposal for any sizable
value was difficult due to the specialised and custom made nature of the
items.
DAE stated, in February
1999, that ageing is stress related and depends on parameters which are
encountered in actual working condition, while under storage the
equipment sees parameters far smaller in value resulting in practical no
ageing. It also added that in commissioning these equipment in future,
any reconditioning or repairing if required or replacement of limited
shelf life items can be done by in-house as well as with the help of the
industry. Any expenditure in that regard will not be significant. It
further added that the designs have evolved over a period of time and
have several advanced features. Therefore, risk of obsolescence for the
material procured may not arise.
The reply had to be
viewed in light of the fact that BARC had to constitute two task forces
for rust prevention to reduce the risk of ageing. The reply regarding
subsequent repairs and expenditure thereupon was presumptive and has to
stand the test of time in future. |
| Since the
plants were not likely to be completed in near future the entire
expenditure had to be viewed as infructuous |
Standing Committee of
Tenth Lok Sabha on Energy, in its thirty fourth report titled ‘Nuclear
Power Programme - an Evaluation’, submitted in December 1995, observed
that the handling of the Profile was not satisfactory. The Standing
Committee also observed that though efforts had been made to
divert/dispose off the items, the only possibility in disposal was to
salvage the scrap value. Since the plants were not likely to be
completed in near future and the equipment were left with only scrap
disposal value, the entire expenditure on advance procurement of
material for the plants for which financial sanctions had yet not been
issued, had to be viewed as infructuous. This could have been avoided by
restricting the number of plants within the limit of funds available.
DAE stated that nuclear
power programme of setting up of these units for which advance
procurement action had been taken still stands. It added that only the
timing of commencement will be consistent with fund availability.
Moreover, these items in future would cost more if the factors like cost
escalation, exchange rate variations are considered.
The reply was not
acceptable in view of the fact that the timing for at least a part of
power generation could have been advanced within the resources available
if proper matching action had been planned for all the related
activities rather than merely concentrating on advance procurement.
DAE further stated that
under present restriction and embargo, the decision to go for advance
procurement of equipment and materials was further reinforced.
The reply was not
acceptable in view of the fact that the embargo has been imposed after a
decade of procurement of equipment.
2.1.8 Indigenisation
The Committee appointed
to review the profile, in its report, observed that available indigenous
industrial infrastructure should be used in a balanced manner by
appropriate planning to meet the requirement of the 'Profile'. |
| While payment
of Rs 3.07 crore was made to ECIL for indigenisation of Self Powered
Neutron Detectors, these were not procured from them |
Payment of Rs 17.83 lakh
was made to ECIL for training of personnel at Thermocoax, France to
enable them to indigenise the production of Self Powered Neutron
Detectors. ECIL was also required to get the technological know-how for
this purpose. Payment of Rs 3.07 crore was made to ECIL for transfer of
technology. While the technology was transferred and the personnel were
trained, no indigenously manufactured Self Powered Neutron Detectors
were procured from ECIL as of June 1998.
DAE stated, in February
1999, that since the construction of two of the plants had commenced,
the quantity required for second unit will be procured from ECIL.
A Primary Coolant
Pump-Motor set consisting of four pumps and five motors, was imported
from KSB, West Germany. The coolant Pump-Motor set received from KSB,
West Germany was stored in wrapped condition. For indigenisation, an
amount of Rs 26.32 crore was paid to KSB, Pune for fabrication and
supply of first indigeneous Primary Coolant Pump-Motor set. The payment
of Rs 26.32 crore included Rs 2.35 crore for technology transfer by
imparting training and exchange of documents/technology to KSB, Pune.
After indigenisation, KSB, Pune was to supply four more Primary Coolant
Pump-Motor sets for which Rs 88.27 crore was paid to them. Against the
order of production of the first indigeneous Coolant Pump-Motor set,
while the pumps had been manufactured, the motors had not been
manufactured. As such the objective of indigenisation had not been
achieved. The material issued to KSB, Pune for the Coolant Pump-Motor
sets was lying unused with KSB, Pune.
2.1.9 Consultancy |
| While the cost
of Rs 50.12 crore of consultancy could be apportioned to twelve .plants,
the entire cost was apportioned to only two plants |
For consultancy relating
to various works of 500 MW plants, 58 consultancy contracts, including
two foreign contracts of Rs 6.09 crore, were entered into with various
consultants during 1985 to 1993. A total expenditure of Rs 50.12 crore
was incurred on these consultancies till March 1998. While the cost of
consultancy could be apportioned to the twelve 500 MW plants, the entire
cost of the consultancy got apportioned to only two of the plants as the
financial sanction in respect of other 10 plants had not been issued.
The relevance of the consultancy to other plants, if sanctioned, due to
passage of time and development of technology elsewhere in the world was
doubtful. Thus, the average cost of consultancy amounted to Rs 25.06
crore per plant in stead of Rs 4.18 crore per plant.
Of the 58 consultancies,
49 were completed till March 1998. Work in respect of five consultancies
was in progress whereas three consultancies were short closed and one
was kept pending. Examination of eight of the consultancy contracts
revealed as follows:
-
Rs 8.20 crore was
spent on consultancy work for design, engineering, inspection
services etc. in respect of 500 MW plants at inland site by Tata
Consulting Engineers while no plant at 'inland site' had been
sanctioned as of March 1998.
-
In case of two
contracts with Tata Consulting Engineers for general engineering
consultancy for coastal site and adoption of American Concreate
Institute code, the total estimated cost was Rs 26.43 crore. While
only 50 per cent work had been completed till March 1998, an
expenditure of Rs 25 crore (95 per cent ) had already been
incurred.
DAE stated, in February
1999, that due to regulatory requirements, upgraded design, safety
standard etc., the quantum of work increased. Besides, the design of 500
MW PHWR was being done for the first time.
-
While fee of Rs
3.76 crore was paid for know-how design of a steam generator to a
foreign firm and BHEL, the orders for fabrication of the steam
generator had been put on hold.
-
Fuel handling
system developed at Rs 1.07 crore, had not been installed and
tested as of November 1998.
-
While thermal and
mechanical design consultancy was completed at Rs 27.67 lakh, the
order for supply of heavy water heat exchangers placed on BHEL was
short closed.
-
A consultancy
contract for improvement of computer code “CLAIR” for study of
accidents due to loss of coolant in Pressurised Heavy Water
Reactors was entrusted to a firm at an estimated cost of Rs 35
lakh in January 1991. As the firm closed down their business, the
contract was closed midway in August 1997 without recording any
specific reasons. After making a final settlement of Rs 10.55 lakh
for foreclosure of work, the balance job was completed with
in-house facility.
2.1.10 Land and civil
works
The Committee appointed
to review the profile had expressed that advance action on tendering
main plant civil works would be desirable so as to be in a state of
readiness to award the work when financial sanction for the plant was
received. In order to set up the site infrastructure facilities, sites
for the programme needed to be identified and approved in advance and
then developed. This was considered essential by the Committee in the
context of public acceptability and lead time required for various
clearances. Nevertheless, the site and civil works had to keep pace with
the fabrication of equipment to prevent these from remaining idle after
fabrication. |
| Against total
area of 207 hectare of land required for two 500 MW, the actual land in
possession was 120 hectare only |
Though the financial
sanctions for two plants of 500 MW was issued in January 1991 and
advance procurements had already been made, the land required for the
plants had not been acquired as of September 1998. Thus, the land
acquisition had not been completed even after a delay of more than seven
years against two years envisaged in the 'Profile'. Against total area
of 207 hectare of land required for setting up of these two plants, the
actual land in possession was only 120 hectare. Though land acquisition
awards were declared for 193 hectare, possession of the land would not
be available till Government of Maharashtra took up and completed a
rehabilitation plan for the displaced persons. The probable time for
completion of these programmes was also uncertain.
NPCIL stated in September
1998 that they had adequate land for location of main plant buildings
and commencing construction activities.
The reply was not tenable
in view of the fact that commencement of work without possession of
entire land would leave uncertainty about completion of the work. DAE
already had similar experience in case of Narora Atomic Power Plant and
Kakrapar Atomic Power Plant where resistance from the owners of land had
led to delays.
DAE stated, in February
1999, that the acquisition of remaining land was being pursued with
Government of Maharashtra and it did not envisage any problem in this
regard. The remaining land was required for exclusion zone and for
township which in no way would affect the construction.
2.1.11 Power generation |
| The
actual additional generation of power as on March 1998 was nil in spite
of an expenditure of Rs 5291.48 crore |
Against the targeted
additional power generation of 940 MW by 1995-96, gradually increasing
to 7880 MW by 2001 AD, the actual additional generation of power under
the ‘Profile’ as of March 1998 was nil in spite of having incurred
an expenditure of Rs 5291.48 crore. Had the material been procured
according to availability of funds and other related factors such as
procurement of land, civil works and infrastructure been given
corresponding importance, at least a part of power proportionate to the
funds available could have been generated.
The action of initiating
the work relating to a number of plants disproportionate to funds
available was the main reason for failure of the 'Profile'. DAE,
however, decided to launch two more Pressurised Water Reactors with
installed capacity of 1000 MW each at Kudankulam, Tamilnadu in spite of
continued shortage of funds for the plants for which material had
already been procured. The equity proposed to be released for these two
reactors outside the ‘Profile’ up to 2006 AD was estimated at Rs
5734 crore notwithstanding the fact that the gap in the allocation for
the plants included in the ‘Profile’ was also required to be met
during this period.
DAE stated, in February
1999, that 880 MW of power would be added to the installed capacity by
2000 AD. The reply had to be viewed in the light of the fact that even
this projection of DAE turns out to be only 11 per cent of the
projection under the ‘Profile’.
2.2
Undue benefit to a Joint Sector company
Amount payable to a joint
sector company under the contract was increased by the Department of
Atomic Energy beyond the terms of contract without correspondingly
increasing the amount receivable from them resulting in undue benefit of
Rs 1.22 crore.
A mention was made in
Para 3.2 of Report of the Comptroller and Auditor General of India for
the year ended March 1997 about unilateral deduction of Rs 11.90 crore
by Gujarat State Fertilizers Company (GSFC) for six tonne of Ammonia
against the agreement for compensation for loss of one tonne of Ammonia
per day and failure of Department of Atomic Energy (DAE) to recover the
excess amount claimed by GSFC. |
| DAE invested
Rs 3.82 crore for increase in the capacity of an ammonia plant of SPIC,
who in turn was to route ammonia through plant of DAE |
In a similar agreement between
DAE and Southern Petrochemical Industries Corporation Limited (SPIC), a
joint sector company, the ammonia synthesis gas and liquid ammonia
required at the Heavy Water Plant (HWP) of DAE was to be provided by
Ammonia Plant of SPIC which was to be returned to them in vapour form
after passing through HWP. DAE invested Rs 3.82 crore during 1971-72 to
1975-76 for increasing the capacity of ammonia plant of SPIC from 1000
tonne per day to 1100 tonne per day. SPIC was free to use extra quantity
of ammonia produced for making other products or for sale or for any
other purpose. |
| Payment for
increase in capacity for ammonia production was to be received from SPIC
and compensation for routing ammonia was to be paid by DAE |
For routing ammonia
through HWP, DAE was to pay a compensation of 2.5 per cent of
total cost of production subject to a maximum of Rs 12.50 per kg of
heavy water produced and further subject to the condition that transit
loss of ammonia did not exceed one tonne per day. Similarly, for excess
ammonia produced as a result of increase in the capacity, SPIC was to
pay Rs 63 lakh per annum to DAE for first ten years and Rs 40.50 lakh
per annum thereafter.
DAE revised the
compensation payable to SPIC in May 1993 from Rs 12.50 per kg to slab
rates ranging from Rs 40 per kg to Rs 350 per kg. The revised rates were
given retrospective effect from April 1992. In October 1997, these rates
were further revised retrospectively with effect from April 1995 to
range between Rs 55 per kg and Rs 480 per kg. At this stage DAE also
agreed to revise the rates again in April 2000. While the increase in
the rate of compensation was not justifiable as brought out in the
succeeding paragraph, DAE was negligent in not revising the rate of
recovery for excess ammonia produced out of the facility set up in SPIC
by them. |
| This resulted
in undue payment of Rs 1.22 crore in six years |
Increase in the rates
resulted in a total payment of Rs 1.47 crore against the amount of Rs
24.95 lakh payable under the contract during 1992-98 leading to undue
benefit of Rs 1.22 crore to the joint sector company, which could have
been avoided if the payment had been made as per terms of the contract.
Heavy Water Board stated
in June 1997 that as there was a substantial increase in cost of inputs
and efforts involved on the part of SPIC in maintaining the purity
level, deuterium concentration and pressure of the inlet gas to HWP,
SPIC was insisting for increased compensation.
The reply was not
acceptable in view of the facts that the increase in input cost got
reflected in the cost of production of ammonia which was sold/utilised
by SPIC. Besides, SPIC had derived advantage of increased production of
100 tonne of ammonia per day through investment made by DAE. Moreover,
in a similar agreement of July 1973 between DAE and GSFC, the rate of
compensation of Rs 11.25 per kg for total production of heavy water at
HWP, Baroda had not been revised since 1973.
DAE stated in January
1999 that the basic intent of the agreement with SPIC was to pay
compensation linked to the cost of production of heavy water. It further
added that the agreement with SPIC did not provide for any increase in
the rate of payment by SPIC to DAE.
The reply of DAE ignores
the fact that despite the provision for the amount of compensation
linked to the cost of production of heavy water, the payment was to be
linked to a ceiling of Rs 12.50 per kg of heavy water produced. There
is, therefore, no justification in increase of the amount of
compensation beyond the ceiling. Further while DAE has paid compensation
at rates higher than the maximum amount provided in the agreement, the
contention about their inability to revise the payment by SPIC to DAE
due to absence of any such provision in the agreement is
self-contradictory.
2.3
Retention of an uneconomical motor launch
While the Department of
Atomic Energy has not been able to decide the issue of retention of an
uneconomical launch for more than seven years, an expenditure of Rs
57.07 lakh was incurred for 12 VIP trips of approximately 54 km each
during the period by utilisation of this launch.
The question whether a
launch being maintained by Bhabha Atomic Research Centre (BARC) by
incurring huge expenditure, not commensurate with its utility, should be
retained has been under consideration of the Department of Atomic Energy
(DAE) since February 1989 on which no decision had been taken as of
March 1998. |
| No
decision had been taken by DAE for nine years on retention of an
uneconomical launch |
The existing launch was
acquired in 1960-61. While the audit had been questioning the
desirability of retention of this launch, BARC realised only in February
1989 that the issue of maintaining this launch by incurring huge
expenditure every year had to be critically examined. BARC accordingly
sought the decision of DAE regarding further course of action. No
decision had been taken by DAE on this request of BARC as of 31 March
1998 although an expenditure of Rs 57.07 lakh including Rs 16.59 lakh on
the salary of staff, had been incurred during 1991-98. |
| By
incurring expenditure of Rs 57.07 lakh during seven years, only 12 VIP
trips of 54 km each had been made |
BARC informed DAE in February
1989 that the launch was being utilised for bringing VIPs and other
dignitaries through sea route. An analysis of utilisation of the launch
during October 1991 to January 1998 with this point in view revealed
that in all only 35 to and fro trips were made by the launch in six
years, of which 12 were utilised for taking Chairman, Atomic Energy
Commission/Additional Secretary, DAE/Director, BARC/foreign delegates
from Gateway to BARC/ Elephanta caves. Of the remaining 23 trips, 16
were made for shore patrolling, diesel filling and inspection, and the
purpose of seven trips had not even been placed on record. Each useful
trip of approximately 54 km, thus, on an average, cost Rs 4.76 lakh. |
| Due to
delay in decision, expenditure continues to be incurred |
Due to indecision on the
retention of launch since February 1989, questionable expenditure of Rs
57.07 lakh had been incurred during 1991-98 and further expenditure
continued to be incurred.
While DAE did not clarify
the reasons for indecisiveness for seven years on the proposal of BARC,
it supported the views of Internal Financial Advisor of BARC wherein he
had stated that in the event of VIP visitors including foreigners, which
is not an uncommon event, it takes very long time to take them to BARC
by road owned and operated by Mumbai Port Trust which was very dirty and
generally not in good condition creating an adverse impression.
The reply was not tenable
in view of the fact that the launch had been used for foreigners only on
three occasions during October 1991 to January 1998 and DAE had not
examined the possibility of renting a launch on such occasions.
2.4
Idle equipment
Two furnaces purchased by
BARC for Rs 22.59 lakh without finalising the location of their
installation resulted in their remaining idle for over four and half
years.
Directorate of Purchase
and Stores (DPS), Department of Atomic Energy (DAE) placed orders for
the electric resistance vacuum annealing furnace and electric resistance
high vacuum sintering furnace for refractory metals during November and
December 1989 with the scheduled date of delivery as December 1989 and
March 1991 respectively for installation at BARC. The furnaces were
considered essential for a project “Development of processes for
production and fabrication of reactive and refractory metal alloys”.
The project was scheduled for completion in two phases during Sixth and
Seventh Five Year Plan. |
| BARC
procured two furnaces in December 1993/ March 1994 considered essential
for a project |
Against the scheduled
date of delivery in December 1989/March 1991, the furnaces were received
in December 1993 and March 1994 respectively. Meanwhile the space
earmarked for vacuum annealing furnace had been utilised for some other
purpose and another space was allocated for annealing furnace, which
lacked inbuilt infrastructure facility for its installation. As a result
while the sintering furnace had been installed, the annealing furnace
had not been installed until December 1998.
DAE stated in December
1998 that it must be appreciated that BARC was a multiple-disciplinary
R&D institution and there were conflicting pressures amongst various
specialisations to locate their facilities.
The reply was not tenable
in view of the fact that the importance of expenditure incurred on all
the projects had to be recognised in spite of multiple disciplines and
while allocating an alternative space for annealing furnace, the basic
infrastructure facilities required should have been taken note of. |
| While
the warranty period of two furnaces had expired, none of these had been
utilised |
Head of the Metallurgy
Division of BARC had been unable to determine a suitable location for
installation of annealing furnace until May 1998 i.e. for over four and
half years. While the warranty period of the two furnaces had already
expired in December 1994 and September 1995 respectively, none of the
two furnaces had been utilised. |
| The
project for which two furnaces were procured was completed without the
facility of these furnaces
|
The project for which
these furnaces were essential, was completed by utilising the
small-scale facilities available with Material Group, Atomic Fuel
Division of BARC and Nuclear Fuel Complex, Hyderabad. This indicated
that BARC could have managed the project even without procuring these
furnaces and the entire expenditure on the purchase of the furnaces was
avoidable.
BARC stated in October
1997 that these furnaces when installed, would be used extensively on a
large scale for current and future activities. DAE stated in December
1998 that furnaces would be extensively used in the extended phase II of
the project. DAE further stated that Rs 22.59 lakh constituted a
negligible percentage of the total cost of equipment of Rupees four
crore sanctioned for the project. |
| The
reply of BARC shows low concern for realising value for money |
The reply of BARC
underscores low concern for realising the value for money as not only
have they been unable to use the two furnaces for over four and half
years since their supply and for over eight and a half years since the
need for their purchase was first felt but even the professed extensive
large scale use for current and future activities had not been
initiated. |