The Welder Scrolls

The power sector in India is facing a unique crisis. It is not the shortage of raw materials that bugs them nor do the labor go on mass unrest but the acute shortage of high pressure welders. These "torchbearers" are not the local local types who fix the window grills of your house. These fellas are rigorously trained from quality institutes, like Welding Research Institute of Tiruchi run by BHEL. The welding trainees are given first hand experience as a part of training program. These welders have to work in high pressure environment. Basically, there are two categories of welders; Structural (Basic) Welders and the High-Pressure welders. The basic welders get enough work in the cities and do not prefer to go to project sites.The high "profile" welders who are willing to come choose to fly abroad as the moolah is more attractive there. Typically, a welder gets Basic salary of Rs.30,000 a month and is paid Rs. 1,000 per joints welded. In a month, welder would work on 30 to 40 joints, there by earning Rs. 70,000 in a month! The Emirates pay them twice to trice the payment they would receive here. European countries pay almost four times the money.

The production and erection of a thermal power station boiler is a welding intensive affair. There are some 30,000 joints to be welded. As we advance technologically, we would need ultra super critical technology, for which the boilers need to be built at very high pressures of at least 300 bars (and above). To explain it in layman's terms, the pressure cooker in the kitchen when in full steam has a pressure of 1.5 bars. Opening it while in full pressure would be a explosive affair and a visit to ICU is certain.

The work at site is also not a pleasant job. Welders work at the height of more than 100 feet with scorching sun over their head. They have to work very accurately as a little negligence would lead to loss in billions and priceless lives of the power station workers would be at stake!

The shortage of welders is like "pinching where it hurts the most" because Eleventh plan looks forwards to add about 55,000 MW of power compared to 22,000 MW in Tenth Plan! And Twelfth Plan targets to add up extra 86,500 MW!!! The dearth of welders could prove quite detrimental to power sector.

Unless some action is taken fast, the immediate future of Indian power sector might be like the proverbial battle that was lost for the want of a horseshoe nail.

Courtesy: BL060410. Images from google images