Manufacturing capabilities for Balance of Plant Equipment for ...

INTERNATIONAL CONCLAVE
ON
KEY INPUTS FOR ACCELERATED DEVELOPMENT OF
INDIAN POWER SECTOR
FOR 12 TH PLAN & BEYOND
Manufacturing Capabilities for Balance of Plant
Equipment for Thermal Plants
BY
D.S. ARORA
CHIEF ENGINEER
CENTRAL ELECTRICITY AUTHORITY
18-19 August 2009

Capacity Addition Targeted for
11 th Plan (2007-12)
(Capacity in MW)
Sector Thermal Hydro Nuclear Total
Central 24840 8654 3380 36874
State 23301 3482 0 26783
Private 11552 3491 0 15043
All India
Total
59693 15627 3380 78700
1

CAPACITY COMMISSIONED AND UNDER
CONSTRUCTION FOR 11 TH PLAN
(Capacity in MW)
Commissioned
Under
construction
Total
Thermal 12504 49219 61723
(77%)
Hydro 3431 12076 15507
(19%)
Nuclear 220 3160 3380
(4%)
Total 16155
(20%)
64455
(80%)
80610
(100%)
Note- Additional 5482 MW Renewable and 2700 MW Captive Commissioned so far
2

CAPACITY ADDITION
IDENTIFIED FOR 12 TH PLAN
Thermal 76,500
Hydro 20,000
Nuclear 3,400
(Capacity in MW)
Total 99,900
Say 1,00,000
3

TENTATIVE THERMAL CAPACITY ADDITION
DURING 12 TH PLAN
COAL AND LIGNITE BASED THERMAL CAPACITY
CATEGORY
SUPER-
CRITICAL
UNIT SIZE
(MW)
NO. OF
UNITS
NO. OF
PROJECTS
CAPACITY (MW)
800-660 64 27 43,640
SUB-
CRITICAL
500-600 34 18 18,300
MEDIUM SIZE 250-350 46 23 14,148
SMALLER SIZE 125 4 2 500
TOTAL 148 70 76,588
(Say 76500)
4

BALANCE OF PLANTS
(BOPs)
5

SUMMARY OF REQUIREMENT OF BOPs DURING 10 TH ,
11 TH and 12 TH PLAN
Sl
No
Name of BOP
No. of BOPs
used during
10 th Plan
For 21180
MW
No. of
BOPs
reqd.
during 11 th
Plan
Tentative
requirement
of BOPs in
12 th Plan
1 Coal Handling Plant (CHP) 23 68 70
2 Ash Handling Plant (AHP) 23 69 70
3 Demineralized (DM) water
Plant
32 69 70
4 Cooling Tower 41 79 (145) 70 (148)
5 Chimney 36 79 (117) 77 (148)
6 Fuel Oil (FO) System 22 71 70
7 Water Treatment Plant 36 76 70
Note: Due to higher unit size, number of BOPs may be less but their capacity may be higher
6

Major BOP vendors available in the country
Sl. No Name of BOP No. of Vendors
1 Coal Handling Plant(CHP) 8
2 Ash Handling Plant (AHP) 9
3 Demineralized (DM) water Plant 5
4 Cooling Tower 5
5 Chimney 4
6 Fuel Oil (FO) System 4
7 Water Treatment Plant 5
8 CW System 3
9 Control & Instrumentation (C&I) 4
10 Switchyard/Switchgear (HT/LT) 5
11 Structural steel erection 3
12 Fire protection System 6
Number of vendors are based on the information available in CEA
7

MAJOR ORDERS PLACED FOR COAL HANDLING
PLANT FOR 11 TH PLAN
Sl. No. Name of Company No. of orders
1 M/s Techpro System Pvt Ltd. 11
2 M/s L&T 7
3 M/s Elecon Engineering Co. Ltd. 6
4 M/s TRF Ltd. 3
5 M/s ThyssenKrupp Industries India 3
6 Others 27@
7 Orders yet to be placed 11
Total 68*
@ Includes single EPC contracts for BOPs which may have further awarded sub-contracts
to the above vendors.
* Number of vendors are based on the information available in CEA
No. of Coal Handling Plants required during 12 th Plan : 70
8

MAJOR ORDERS PLACED FOR ASH HANDLING
PLANT FOR 11 TH PLAN
Sl.
No
Name of Company
No. of orders
1 M/s Indure 12
2 M/s Mecawber Beekay 11
3 M/s D C Industrial Plant Services 5
4 M/s Mahindra Ash Technology 4
5 M/s Techpro Ash Tech. Ltd. 5
6 M/s Macnally Bharat 3
7 Others 19@
8 Orders yet to be placed 10
Total 69*
@ Includes single EPC contracts for BOPs which may have further awarded subcontracts
to the above vendors.
* Number of vendors are based on the information available in CEA
No. of Ash Handling Plants required during 12 th Plan : 70
9

MAJOR ORDERS PLACED FOR DM PLANT
FOR 11 TH PLAN
Sl.
No.
Name of Company
No. of orders
1 M/s Driplex Water Engg Ltd. 10
2 M/s Doshi Ion Exchange 6
3 M/s Ion Exchange, Faridabad 5
4 M/s Thermax Ltd 4
5 M/s Triveni 4
7 Others 28@
8 Orders yet to be placed 12
Total 69 *
@ Includes single EPC contracts for BOPs which may have further awarded sub-contracts
to the above vendors.
* Number of vendors are based on the information available in CEA
No. of DM Plants required during 12 th Plan : 70
10

Sl.
No.
MAJOR ORDERS PLACED FOR COOLING TOWERS
FOR 11 TH PLAN
Name of Vendor
No. of orders
1 M/s Paharpur Cooling Towers 25 [49]
2 M/s Gammon (I) Ltd. 17 [30]
3 M/s BGR 4 [4]
4 M/s NBCC 2 [2]
5 Others 21[41]@
6 Orders yet to be placed 10 [19]
Total 79[145] *
@ Includes single EPC contracts for BOPs which may have further awarded sub-contracts
to the above vendors.
Figures in [ ] indicate number of cooling towers.
* Number of vendors are based on the information available in CEA
No. of Cooling Towers required during 12 th Plan : 70 [148]
11

MAJOR ORDERS PLACED FOR CHIMNEY
FOR 11 TH PLAN
Sl.
No.
Name of Vendor
No. of orders
1 M/s Gammon (I) Ltd. 13 [16]
2 M/s NBCC 10 [12]
3 M/s Simplex 6 [6]
4 M/s Lanco Infrastructures Ltd. 5 [9]
5 Others 35 [61]@
6 Orders yet to be placed 10 [13]
Total 79 [117]*
@ Includes single EPC contracts for BOPs which may have further awarded sub-contracts
to the above vendors.
Figures in [ ] indicate number of flues.
* Number of vendors are based on the information available in CEA
No. of Chimneys required during 12 th Plan : 77
12

COMPONENTS OF MAJOR BOPs
Each Balance of Plant activity consists of various
components which includes:-
• Civil works
• Structural works
• Electro mechanical equipments and various types
of motors, etc
• Control & Instrumentation
13

ISSUES FOR COMPLETION OF BOPs IN TIME
1. Placement of Order
Timely placement of order for BOPs.
2. Review of Pre-qualification Requirements for BOP
vendors
CEA already recommended revised PQ to allow entry of
new players
3. Enhancement of vendor base for Balance of Plants
(BOPs) as the requirement has increased manifold
during 11th plan and will further increase in 12th
Plan.
There are limited number of suppliers in each category and
each having more work than what it can handle.
Favourable conditions to be developed for new / additional
vendors.
14

ACTIONS FOR COMPLETION OF BOPs IN TIME
Vendors must take approval for appointment of
sub-contractors in advance from the project
authorities.
Vendors must place the orders for civil works as
well as procurement of mechanical equipments in
time.
Timely releasing of civil construction drawings
from consultants and construction agencies.
Availability of adequate construction machinery at
project site.
Deployment of adequate skilled / unskilled
manpower at site.
Proper coordination among various executing
agencies engaged at project site.
15

LOSS TO THE UTILITIES ON ACCOUNT OF DELAY IN
COMPLETION OF PROJECTS
Cost of delay (Either due to Main Plant or BOPs)
Loss on account of purchase of costlier power from alternate
sources – Rs. 2.5 to 6 crores / day for a 500 MW pithead unit.
Increase in IDC and consequently the fixed cost Component of
tariff - Rs. 45 lakhs / day for a 500 MW coal based unit.
Loss of return to developer - Rs. 25 lakhs / day for a 500 MW
Unit @ 14% ROE.
Point to be considered :
The Utilities should keep the above costs in view while deciding
contractual matters.
16

Central Electricity Authority