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Equipment Supply to Power Projects National Power Conference 2009

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Title: Equipment Supply to Power Projects National Power Conference 2009


1
Equipment Supply to Power Projects National
Power Conference 2009 4th December 2009NEW
DELHI
By P.K. Agarwal General Manager - Marketing
(Power Sector) Bharat Heavy Electricals
Ltd. BHEL House, Siri Fort, New Delhi 110049
2
  • Indian Power Sector - Past, Present and Future
  • BHEL and its contributions to Power Sector
  • Power Sector Issues Related to Equipment
  • Steps taken by BHEL
  • Steps taken by other agencies
  • Major Concerns for Domestic Industry

3
Pre- Electricity Act 2003 period
All India Capacity Addition
All India Capacity addition was always less than
BHELs installed capacity
4
Pre- Electricity Act 2003 period
BHELs Capacity and Loading
  • Orders on BHEL remained far below BHELs
    installed Capacity during VIII, IX Plan and
    initial X Plan period.
  • In 90s, economy opened up with substantial
    incentives by the Government to attract Foreign/
    Private developers and power equipment
    manufacturers - further threatened already
    under-utilized domestic equipment manufacturing
    capacities.
  • Targets for X Plan (41,110 MW) similar to IXth
    Plan (40,245 MW) no indication of improvement
    in success rate till enactment of Electricity Act
    2003.

5
Post - Electricity Act 2003 period
BHELs Capacity Augmentation
Various initiatives by Ministry of Power and
enactment of Electricity Act 2003 and
notification of Electricity Policy provided
clearer road map for Countrys Accelerated
Capacity Addition Programme with higher
confidence to Manufacturers and
suppliers. Capacity augmentation schemes
immediately taken up in BHEL based on MOP/ CEAs
projections.
6
Demand Summary of All India Forecast
(AS PER 17th EPS REPORT)
Source CEA
7
Large Capacity Addition
Source IEP, Table 2.5
8
Indian Power Sector - Future Scenario
  • Based on the projected demand, Integrated Energy
    Policy projections for Capacity addition
    requirement is
  • XI Plan - 102,000 MW (target - 78,577 MW)
  • XII Plan - 104,000 MW
  • XIII Plan - 151,000 MW
  • XIV Plan - 197,000 MW
  • Integrated Energy Policy envisages coal to remain
    the dominant fuel source till 2031-32
  • To bring the per capita consumption to World
    average level, 4 fold growth required.

9
CEA Conclave on Key Inputs 2009
Orders for Main Plant Equipment 11th Plan (as on
end Aug 09)
(Figures in MW)
MAIN PLANT
THERMAL
HYDRO
NUCLEAR
TOTAL
EQUIPMENT
SUPPLIER
BHEL
36,531
6,017
500
43048
(54)
OTHERS
25,192
9,490
2,880
37562
(46)
TOTAL
61,723
15,507
3,380
80,610
Out of above, capacity ordered on Chinese Main
Plant Suppliers - 16,419 MW
All Orders placed for 11th Plan Main Plant
Equipment
10
CEA Conclave on Key Inputs 2009
Status of Implementation Of 11th Plan (as on end
Aug 09)
(as on Aug 2009)
  • 16,395 MW (20) capacity already commissioned
    till date.
  • 64,215 MW (80) under construction i.e. orders
    placed and work is in progress.
  • In addition to above, 12,000 MW Captive Power
    Plants are under execution, against which2700 MW
    has been commissioned and balance under
    construction.
  • Against target of 14,000 MW from Renewables,
    5482 MW commissioned as on 31.03.09
  • Coal linkages have been provided to all thermal
    projects. A capacity of 14,507 MW is scheduled
    for commissioning during 2009-10.
  • Besides, projects aggregating to 32,000 MW
    capacity for commissioning during the 12th
    Five Year Plan are also under execution.


11
CEA Conclave on Key Inputs 2009
Status of Implementation Of 11th Plan..contd.
Reasons for delay in 11th Plan projects
  • Delay in placement of orders - mainly Civil Works
    BOPs.
  • Delay and non-sequential supply of material for
    Main Plant and BoPs.
  • Shortage of skilled manpower for erection and
    commissioning.
  • Contractual disputes.
  • Inadequate deployment of construction machinery.
  • Shortage of fuel (Gas Nuclear).
  • Delay in Land Acquisition.
  • Delay in creation of infrastructure facilities.

12
Mid Term Review
Summary of Likely Capacity Addition during 11th
Plan
13
XII and XIII Plan Total (Tentative) Capacity
Addition
Share of Super Critical Sets expected to be
43,640 MW (59 of Coal based sets) in 12th
PlanShare of Super Critical Sets expected to be
64,000 MW (100 of Coal based sets) in 13th Plan
Source CEA
14
CEA Conclave on Key Inputs 2009

Summary of 12th Plan Capacity Addition
Requirement- 1,00,000 MW
  • Thermal - 76,500 MW
  • About 32,000 MW already under construction

15
CEA Conclave on Key Inputs 2009

Estimated Phasing of Fund Requirement for
Generation during 12th Plan
(Figures in Rs. Crore)
TYPE
2012-13
2013-14
2014-15
2015-16
2016-17
TOTAL
HYDRO
21,857
23,694
25,058
27,136
28,904
1,26,649
THERMAL
76,367
66,905
62,701
61,867
62,828
3,30,668
NUCLEAR
5,753
6,955
7,443
8,255
9,360
37,766
TOTAL
1,03,977
97,554
95,202
97,258
1,01,092
4,95,083
16
CEA Conclave on Key Inputs 2009
Status of BoPs For 11th and 12th Plan Projects

Name of the BoP
BoPs required for projects
Tentative Estimated Requirement
system
Commissioned under const.
of BoPs for 12th Plan
for 11th Plan Projects (Nos.)
Thermal Projects (Nos.)
Coal Handling
67
148
System
Ash Handling
68
148
System
DM Plant
71
211
Cooling Towers
143
218
Chimneys
116
77
Fuel Oil System
74
148
PT Plant
76
160
17
CEA Conclave on Key Inputs 2009
Recommended Capacity Addition during 13th Plan
(2017-22)

TOTAL-1,00,000 MW
18
Increasing Share of Higher Size Supercritical
Units
19
  • Indian Power Sector - Past, Present and Future
  • BHEL and its contributions to Power Sector
  • Power Sector Issues Related to Equipment
  • Steps taken by BHEL
  • Steps taken by other agencies
  • Major Concerns for Domestic Industry

20
BHEL Credentials
  • A Rs.28,033 crore turnover Engineering
    Manufacturing enterprise of its kind in India
  • A Navaratna company and a Major Integrated
    Power Plant Equipment Manufacturer in the World
  • Profit Making Company since 1971-72
  • Consistent Dividend Paying Company for over
    thirty years (FY 1976-77 onwards)
  • References in over 70 countries
  • Installed base of more than 100,000 MW

21
Role of BHEL in Power Sector
  • A major manufacturer of power plant equipment for
    various fuels.
  • Fully indigenized technology up to 600 MW from
    world leaders
  • Supplies Steam turbines, generators, boilers and
    matching auxiliaries upto 800 MW ratings
    including supercritical sets of 660/800 MW.
  • 307 coal based sets installed, including 35 sets
    of 500 MW rating
  • 365 nos. BHEL make Hydro Utility sets installed
    in the country

Installed capacity- Utility 1,38,165 MW (31.03.09)
Generation 2008-09
Practically every 3 houses out of 4 in India are
supplied power generated from BHEL sets
22
BHEL Sets A Profile
As on 31.3.09
Coal based utility sets of BHEL make installed in
the country
Includes Basin Bridge (since abandoned)
Hydro utility sets of BHEL make in the country
365 nos. (16996 MW)
23
BHEL Sets A Profile
Plant Load Factor (Coal based BHEL Sets)
During 2008-09, 191 BHEL supplied coal based sets
achieved PLF of over 70. Of these, 77 sets
registered PLF of over 90 and 56 sets achieved
PLF between 80 - 90.
Operating Availability (OA)
During 2008-09, 141 sets achieved OA higher than
90
24
Performance of 500 MW range Sets
(Last Five Years Averages)
BHEL vs. International Level
Source North American Electric Reliability
Council, (NERC).
25
  • Indian Power Sector - Past, Present and Future
  • BHEL and its contributions to Power Sector
  • Power Sector Issues Related to Equipment
  • Steps taken by BHEL
  • Steps taken by other agencies
  • Major Concerns for Domestic Industry

26
Issues in Power Sector Related to Equipment -
Issues Identified in August09 CEA Conclave
27
Critical Issues Discussed in the Conclave Related
to Equipment
  • Promoting indigenous manufacturing of Boilers and
    Turbines.
  • Manufacturers of Main Plant to develop ancillary
    units/ vendors commensurate with capacity
    addition, deliveries to be sequential.
  • Advance procurement action for long lead items
    like Forgings and castings.
  • Need to attract more vendors in BOP.
  • In view of acute shortage of Erection/
    Commissioning Agencies for executing Civil
    and Mechanical works, to discuss how to attract
    more agencies.

28
Critical Issues Discussed in the Conclave Related
to Equipment
  • IT based monitoring for projects - ways to
    achieve this.
  • Major EPC Contractors should necessarily have
    construction machinery of their own and not
    leased ones. Also to play a proactive role in
    building of large skilled manpower.
  • Transportation Facilities.
  • Improvement of infrastructural facilities to
    speed up project implementation .
  • Standardization This would help in
    reducing design, engineering and approval
    time for drawings thus reducing construction
    period of power plants.

29
Critical Issues Discussed in the Conclave Related
to Equipment
  • There is need to create indigenous capacity for
    long lead items such as Castings and Forgings for
    Turbines Generators, Boiler quality plates,
    P-91 piping and CRGO sheet steel for
    transformers.
  • Latest technologies need to be adopted to
    optimize on the use of Land and Water. Promoting
    new technologies with reduced water requirement.
  • Acquisition of Energy assets abroad by CPSUs/
    Industry.
  • Latest Technology Options
  • Need to develop a Road Map for incentivising
    efficient technologies in Generation,
    Transmission and Distribution.
  • Technologies for minimizing consumptive water
    requirement by adopting Air Cooled Condensers
    and Hybrid Systems for Cooling at Thermal Power
    Stations, Committee by CEA.

30
  • Indian Power Sector - Past, Present and Future
  • BHEL and its contributions to Power Sector
  • Power Sector Issues Related to Equipment
  • Steps taken by BHEL
  • Steps taken by other agencies
  • Major Concerns for Domestic Industry

31
STEPS TAKEN BY BHEL TO MEET ENHANCED CAPACITY
ADDITION REQUIREMENT
32
  • CAPACITY BUILDING
  • CAPABILITY BUILDING

33
BHEL Capacity Augmentation Plan for Power Plant
Equipment
20,000 MW Per annum
15,000 MW Per annum
10,000 MW Per annum
Excluding CFFP Fabrication Plant and Figures
in Brackets are Cumulative
34
Initiatives taken to meet challenges
  • Manufacturing capacity augmentation
  • Manufacturing capacity enhancement for Power
    Plant Equipment from 10,000 MW to 15,000 MW and
    then to 20,000 MW per annum by Mar12.
  • Capacity augmentation of transformers from
    20,500 to 45,000 MVA.
  • Capacity enhancement of Electrical Motors from
    1340 nos. to 2250 nos.
  • Salient Features of BHELs Manufacturing Capacity
    Addition Programme
  • In view of uncertainty of Gas based and Nuclear
    Capacities, provision for inter- changeability
    of facilities have been made
  • Inter-Unit and Intra-Unit Load sharing
  • Respective facilities have inbuilt Capacity for
    Spares based on their consumption.
  • Installed Capacity has 10-15 stretch margin, as
    demonstrated in past

35
Initiatives taken to meet challenges
  • New marketing Initiatives
  • 660 800 MW Super Critical Thermal Sets
  • 600 MW sub-critical sets
  • 525 MW sub-critical sets
  • 270 MW sub-critical sets
  • 250 MW Circulating Fluidized Combustion Chamber
    (CFBC) Boiler for Lignite and Low grade fuel
  • Advance class Gas Turbine
  • Nuclear Steam Generators for 700MWe
  • Partnerships forged with SEBs/ GENCOs for
    leveraging equipment sales
  • BHEL along-with CEA has prepared standard
    specifications in September 2008 for Boilers and
    Turbine - Generators of 500 MW and above.

36
Initiatives taken to meet challenges
  • Strategic Alliances
  • Partnerships forged with NTPC, NPCIL, KEL, HEC
    strengthening the supply chain by developing
    additional sources for critical inputs
  • Entered into collaborations for manufacture of
    Supercritical Units
  • Boiler - Alstom
  • Turbine Generator Siemens
  • Transmission JV route being adopted covering
    Transformers, GIS, ACBs, HVDC etc.

37
Initiatives taken to meet challenges
  • Site capability enhancement
  • Heavy lift and other crawler crane added suitable
    for erection of Ceiling Girders of 600/660/800
    MW sets (Existing Crawler Cranes 83 Nos. Being
    added 41 Nos. in 2009-10, 7 nos. in 2010-11
    41 Nos. in 2011-12).
  • Portal Crane for lifting 500 MW above Stator (
    Existing 2 Nos. being enhanced to 4 Nos. in
    2010-11)
  • Induction Heating equipments (Existing 87 Nos.
    Additional 95 Nos. being added in 2010-11 and 50
    nos. in 2011-12)
  • Strand Jack System being procured by 2010-11
    (was being Hired earlier)

38
Initiatives taken to meet challenges
  • Supply Chain Management (SCM) Initiatives
  • Advanced Manufacturing Actions (AMA) are being
    taken for timely procurement of long lead items
    like large castings forgings, critical pipings,
    CRGO etc.
  • An understanding has been reached with Sheffield
    Forge Masters International Ltd., UK for
    technology transfer in the area of Forgings
  • Leveraging Information Technology
  • Negotiation through Reverse Auction
  • Implementation of e-Procurement
  • Pilot Project at Tiruchy unit successfully
    implemented.
  • Under implementation at Hardwar, Bhopal,
    Hyderabad, EDN, BAP.
  • Long Term Rate Contracts
  • To reduce procurement cycle time, rate contracts
    have been finalized with vendors for inputs
    like steel, copper, CRGO, transformer oil etc.

39
Initiatives taken to meet challenges
  • Supply Chain Management (SCM) Initiatives
  • Vendor Base Expansion
  • 40 new vendors added in 2008-09 for BOPs. 38 new
    vendors added in 2009-10 (till Nov09). 12 more
    likely by Mar10
  • Office opened in Shanghai, China for sourcing
    items with limited vendors
  • Away Centre fabrication adopted
  • Rate Contract for Service Contracts
  • Specifications under finalization

40
Initiatives taken to meet challenges
  • Supply Chain Management (SCM) Initiatives
  • Outsourcing Enhanced thrust is being given for
    outsourcing of low technology/ non-core
    manufacturing.
  • Delivery of Piping
  • Additional suppliers for Fittings identified to
    ensure timely delivery of Piping.
  • Empanelling more fabrication vendors and
    upgrading existing vendors capability.
  • Adopting repeat design of a typical standard unit
    in line with Chinese Model.
  • Standardization measures initiated to reduce
    cycle time.
  • Layout of Boiler Island piping
  • Utility requirement of Boiler Auxiliary
  • Pipe sizes

41
Initiatives taken to meet challenges
  • HR Initiatives
  • In last two years BHEL has added 8500 persons
    (ETs, STs Artisans).
  • Recruitment cycle reduced from 8-10 months
    earlier to 3-3 ½ months now.
  • New windows opened for intake
  • Lateral recruitment of experienced persons
  • Direct Campus recruitment
  • Special recruitment for difficult sites in North
    East and JK.
  • Re-employment of executives who had earlier
    resigned.
  • Skills Development
  • BHEL has taken a stake in ITI in Kabiguru
    Industrial Training Centre at Bolpur,
    Shantiniketan, West Bengal in partnerships with
    DVC, CIL and Sriniketan Shantiniketan Development
    Authority.
  • Welding Research Institute at Trichy being
    leveraged to train high pressure welders of
    contractors. Programmes at Trichy as well as 4
    PS-Regional offices.

42
Initiatives taken to meet challenges
Project Management Initiatives
  • Project Management being accorded top priority to
    match manufacturing and site facilities capacity
    augmentation for meeting the challenges of 11th
    Plan and beyond.
  • Centralized Project Management Group located at
    Delhi provides single window service for the
    Customer, working in close coordination with
    Project Management Groups in respective
    Manufacturing Units and Regions
  • Accelerated Training Programme under-taken to
    develop Power engineers in shorter time to meet
    the growing requirement of erection and
    Commissioning. Two Batches of 30/35 Engrs.
    already trained. 45 Engrs. Under training.
  • ERP
  • Implemented in Trichy, Bangalore, Hyderabad.
    Being spread to other units of BHEL
  • Discussions with SAP consultants planned in I
    Qtr. 2010-11
  • Web Based project monitoring system (Primavera)
    is developed and under implementation for all
    ongoing and future projects
  • Video Conferencing with Manufacturing Units and
    Regional Headquarters. Being implemented in Sites

43
Initiatives taken to meet challenges
  • Additional measures to meet gaps between Shop
    Capacity and Load
  • Joint Venture with M/s. HEC for additional
    capacity for Castings and forgings
  • Development of Vendors for machining jobs
  • Identification of Vendors for sourcing finish
    machined casings. 3 nos. finish machined LP
    shafts of 500 MW already ordered for delivery
    during 2010-11.
  • Part of supplies for Super-critical supplies
    being sourced from collaborators
  • Multi-tasking Machines and multi-Skilling of
    operators.
  • Sourcing from Siemens for TG sets (semi-finished
    and finished) tie-up

With above Measures, BHEL Shop Manufacturing
Capacity shall not be a bottle-neck in meeting
the Capacity addition targets
44
  • Indian Power Sector - Past, Present and Future
  • BHEL and its contributions to Power Sector
  • Power Sector Issues Related to Equipment
  • Steps taken by BHEL
  • Steps taken by other agencies
  • Major Concerns for Domestic Industry

45
Follow-up of International Conclave on Key Inputs
  • Task Force formed comprising MoP, CEA and CII to
    coordinate with industry regarding various inputs
    for power sector. CII has organised number of
    dialogue with specific industry groups and
    interested entrepreneurs.
  • Task Force formed 7 Nos. Specialized Subgroups
    formed to assess 11th Plan requirement and
    constraints being experienced and suggestions for
    removing them.
  • Regional level meetings interactions with
    industry to sensitize them of huge requirement of
    Power Sector and to encourage new vendors.

46
Manufacturing capacity planned by New Ventures
? Due to initiative by MOP and CEA for
augmentation of capacity and technology transfer
within the country, several new JV Companies have
come forward to take up manufacturing of
supercritical power equipment
? Qualifying requirements have been formulated to
facilitate participation of JVs in the bidding
process
47
Manufacturing capacity planned by New Ventures
.contd
  • Some other new manufacturers have built up/ are
    planning to build up manufacturing capacity for
    manufacture of supercritical boilers in technical
    collaboration with overseas manufacturers
  • Thermax in collaboration with Babcock-Wilcox
  • Cethar Vessels in collaboration with Riley Power
  • BGR Energy in collaboration with Foster Wheeler
  • Action has been initiated by LT and Bharat Forge
    for castings forgings

48
JVs and Other Steps Taken
  • Tender floated for Bulk order of 11X660 MW units
    with mandatory indigenous manufacturing.
  • Some new players ( LT and Bharat Forge) have
    plans to enter into the area of setting up
    capacity for Critical long lead inputs .
  • Qualifying requirements of Main Plant Equipment
    and BoP vendors reviewed by CEA and Utilities
    advised to promote entry of new entrants.
  • Committee formed to look into requirement of CRGO
    and discussions with manufacturers. Some
    companies evinced interest in manufacturing CRGO.
  • Existing manufacturers augmented their capacity
    for 765 kV transmission equipment upgradation
    of testing facilities.

49
JVs and Other Steps Taken
  • Larsen Toubro (LT) and Nuclear Power
    Corporation of India (NPCIL) have recently formed
    a Rs 1,725-crore joint venture for specialized
    steel and forging products.
  • Chennai-based BGR Energy Systems is expected to
    formally sign the collaboration agreement with
    Hitachi of Japan for the manufacture of turbines
    for power project.

50
Major Recommendations of Conclave and Action
Taken
  • 38 ITIs already adopted, 13 ITIs being adopted
    by CPSUs, 12 ITIs have been/ are being adopted by
    Private Utilities.
  • NPTI taking action on creation of
    accredited training institutions for
    specialized skills.
  • 7 Power Utilities already making provision of
    atleast 1.5 of salary budget for HRD as per
    recommendations of National Training Policy.
    Further efforts being made to increase it to 5.

51
  • Indian Power Sector - Past, Present and Future
  • BHEL and its contributions to Power Sector
  • Power Sector Issues Related to Equipment
  • Steps taken by BHEL
  • Steps taken by other agencies
  • Major Concerns for Domestic Industry

52
Transportation
  • CEA Conclave in August 2009 has identified
    Development of transportation facilities,
    including port handling facilities for equipment
    and fuel as a key issue
  • 13th Plan and beyond will have only
    Super-critical and ultra super-critical thermal
    sets. Due to the dimensions constraint all 800 MW
    sets and many 660 MW set will have to be
    necessarily transported by road. Due to their
    enormous weight road and bridges of sufficiently
    high strength to with-stand their weight
    required.
  • Advance class Gas turbines, which have to be sent
    in fully assembled condition and hence, weigh
    very high and require road and bridges of high
    strength.
  • Generator Stator of Sipat Project from the
    Russian manufacturer was held up at highway
    between Mumbai and Nasik for more than 3 months
    as the Highway was not fit for transportation of
    the Generator Stator. Such situation to be
    avoided in future.
  • Transportation facilities including dedicated
    freight corridor, port handling capacity,
    facilities for equipment and fuel need to be
    enhanced to commensurate with planned capacity
    addition.

53
Chinese presence in Indian Powers Sector
  • Share of Chinese in Capacity addition during 11th
    Plan (As per the Mid-term review of Power sector)
    - 20,967 MW accounting for around 28 percent of
    the over-all capacity addition of 74,964 MW.
    Similar trend seen in 12th plan.
  • About 95 (19,833 MW out of 20,967 MW) of imports
    from Chinese firms are done by private Customers
  • Many concerns have been raised about the quality,
    performance and the efficiency of the equipment.
    - CEA/ NTPC report after visit to China in April
    09.
  • Even though the initial capital cost of Chinese
    sets is lower, operating cost is higher than
    Indian sets resulting in over-all higher cost
    CLSA report
  • Concern for Energy security due to
    non-development of local vendors for spares and
    services

54
DISADVANTAGES SUFFERED BY DOMESTIC MANUFACTURERS
55
DISADVANTAGES SUFFERED BY DOMESTIC MANUFACTURERS
.. contd
56
DISADVANTAGES SUFFERED BY DOMESTIC MANUFACTURERS
.. contd
57
Concerns for Domestic Players
  • In addition to BHEL, many other manufacturers
    like Bharat Forge, LT, JSW etc. are reportedly
    setting-up of manufacturing facilities and
    acquiring technology for Power Plant Equipment,
    based on the encouragement from Government.
  • The additional domestic capacities thus being
    created involves huge investments.
  • Additional Capacity of BHEL and capacities of new
    manufacturers provides adequate manufacturing
    capacity in the country as well as competition to
    each other to offer the best technology and
    products.
  • Therefore, a level playing field is required to
    be provided to Indian manufacturers so that the
    facilities being set up by them are adequately
    loaded.

58
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