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1
By
Suresh Chander,
Chief Engineer (TE&TD)
Central Electricity Authority
International Conclave for Key Inputs for 12th Plan
August 18-19, 2009
Manufacturing Capabilities for Main
Plant Equipment for Thermal Power
Plants
2
12th Plan Capacity Addition
(Tentative)
THERMAL 76,500 MW
HYDRO 20,000 MW
NUCLEAR 3,400 MW
TOTAL 1,00,000 MW
Order for about 32,000 MW capacity placed
3
13th Plan Capacity Addition (Tentative)
THERMAL 70,000 MW
HYDRO 24,500 MW
NUCLEAR 8,000 MW
TOTAL 1,02,500 MW
Similar capacity addition is expected in 14th Plan
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Projections for coal based capacity
Capacity addition per plan period
~1,00,000 MW
Share of coal based capacity
60- 70,000 MW
Projected coal based capacity addition per year
12-14000 MW
Projected coal based capacity addition per year (including R&M, spares)
~15000 MW
About 15000 MW manufacturing capacity per annum required for coal based capacity in next two decades
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Total Sub
critical MW
660 MW (nos)
800 MW (nos)
Total Super Critical
MW
Total MW (Thermal)
10th Plan 9620 0 0 0 9620
11th Plan 44490 9 2 7540 52030
12th Plan 30473 54 10 43640 74113
13th Plan 0 54 23 64100 64100
Increasing Share of Higher Size Supercritical Units
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High Efficiency
Fuel Conservation
Lower GHG Emissions
Lower Fuel Costs
Economy of scale
Faster capacity addition
Reduced land/manpower requirement
Platform for Further Technology Development
Why supercritical technology
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Large capacity addition in 12th/13th Plan and beyond
Gap between demand and capacity - Inadequate manufacturing capacity as one of the main reasons for slippage of projects in 10th/11th Plan
More players needed to augment capacity and generate competition
Need for technology within the country to develop know how and know why for long term support for services and spares, customisation and problem solving
Minimise dependence on foreign countries
Cost reduction in long run with high volume and more local content
Platform for further development
Need for augmenting indigenous manufacturing capacity
8
BHEL have entered into collaborations for manufacture of Supercritical Units
Boiler - Alstom
Turbine Generator – Siemens
BHEL have taken up significant capacity augmentation to meet upcoming demand for power projects
BHEL have envisaged to raise capacity for coal based units to 10,000 MW/annum by December, 2009 which can cater to sub-critical and/or supercritical units
BHEL’s manufacturing capacity
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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
Manufacturing Capacity Envisaged
(MW/Yr)
Name of Joint Venture
Boilers Turbine-generators
L&T - MHI 4000 4000
Bharat Forge-Alstom - 5000
JSW - Toshiba - 3000
GB Engg - Ansaldo 2000 -
Manufacturing capacity planned by New Ventures
Qualifying requirements have been formulated to facilitate participation of JVs in the bidding process
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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
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
Action has been initiated by BHEL, L&T and Bharat Forge for castings & forgings
Manufacturing capacity planned by New Ventures ….contd
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Out of 31 nos. 660/800 MW supercritical units under construction, only 4 are being sourced from Indian companies. Most of the orders by IPPs have gone to one foreign country.
Main reasons for this trend are
Higher cost of indigenous equipment
Higher delivery schedule of Indian companies
New facilities are yet to be set up
There is urgent need to arrest this trend and minimise our dependence on foreign countries
CEA regulations have stipulated maximum turbine cycle heat rate of 1850 kcal/kWhr with turbine driven BFPs and 1810 kcal/kWhr with motor driven BFPs for supercritical units thus mandating higher cycle parameters of minimum 246 kg/cm2 (g), 565/593 deg C
Issues
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Thank you for your
kind attention