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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

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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

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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

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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