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High Pressure Piping in Power Plants Water / Steam Cycles

Capital Markets Day Power Services at Moorburg Power Plant

December 2, 2010

Ronald Diehl, Member of the Executive Board of BB Power Services GmbH

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A enda

1. Overview division

Piping Technology

2. High-Pressure Piping Systems

3. Service Range

4. Market Structure

5. Clients

.

7. Competitive differentiators

and success factors

8. References

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Bilfinger Berger Capital Markets Day December 2, 2010

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1. Overview division Piping Technology

Fields of

competence

Service range

DetailPro ectManufactu-

Construction,Commission-

BasicEngineering

(ProcessQuality

assurance,

Steelconstruction,

engineeringmanagementr ng,

Fabrication

Erectionng, rng ng

into operation

eng neer ng,

E/I&C,Arrangementplanning)

welding

technology

rocuremenman s,

facades,hoists

DeNOx

Planning teams

Electrostaticprecipitator

DesulfurizationInduced draft fanForced draft fan

Steam generator,firing system

Components:coaling, mill, ash

removal,heat recovery

Constructionservices

(Bilfinger BergerCivil)

PipingHP systemIP systemLP system

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Bilfinger Berger Power Services GmbH

Bilfinger Berger SE

Steam GeneratorsEnergy and

Environmental Piping TechnologyMechanical ApparatusSteam Generators

Engineering

Babcock Borsig ServiceGmbH

BHR Hochdruck-Rohrleitungsbau GmbH

Bilfinger Berger PowerHoldings (Pty) Ltd.

Babcock Noell GmbHMCE Maschinen-und Apparatebau GmbH& Co. KG (Austria)

Steinmller Instand-setzung KraftwerkeGesellschaft fr Energie-und Umwelttechnik mbH

PKB PlanungsbroRohrleitungs- undAnlagentechnik GmbH

BHR Piping Systems

Steinmller Africa(Pty) Ltd.

Steinmller Engineering

MCE IndustrietechnikAschersleben GmbH

Middle East FZE(UAE)

Duro Dakovic Montazad.d. (Croatia)

(Pty) Ltd. (South Africa).

MCE Berlin GmbHKOG Group

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Rotring Engineering AG

nterva ve ( ty) t . 50%

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600

Orders received Output volume

600 600 million million

400

500

400

500

400

500

100

200

100

200

100

200

300

00 0

Orders received and output volume include between 120m and 150m / yearstandard business service .

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plants are the connections between

the feed water pumps, the boiler / heat

exchanger and the turbine.

Coal-fired power plants Lignite-fired power plants

Combined-cycle power stations

Biomass power plants

Surrogate fuel power plants

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RWE Neurath lignite-fired power plant(optimised plant design, BoA),1,100 MW

Total material approx. 3,100 t / unit

Pipes approx. 2,200 t

.

Fittings approx. 190 t

Supports/hangers approx. 600 t

Total pipe length approx. 11,000 m

Main piping approx. 4,400 m

Total circumferential welds

approx. 7,000

Total circumferential welds

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. ,

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RWE Neurath li nite-fired ower lant 172 m level

(optimised plant design, BoA),1,100 MW

Feed water430 bar, 250 C, 588 mm, w.th. 44

Main steam295 bar, 610 C, 549 mm, w.th. 97

Cold reheat75 bar, 435 C, 824 mm, w.th. 31

Hot reheat70 bar, 615 C, 806 mm, w.th. 43

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3. Service range,

Fabrication of pipingspoolsFabrication of pipingspools

Assembly of theprefabricated pipeAssembly of theprefabricated pipe

Plant maintenanceconsulting service

Plant maintenanceconsulting service

Pi in conce tual / Pi in conce tual /

Bending

Welding

Bending

Welding

spoo s an angers

Power plant newbuilds

spoo s an angers

Power plant newbuilds

Plant maintenanceengineering

Plant maintenanceengineering

basic design Piping detail design

basic design Piping detail design

Heat treatment

Machining

Heat treatment

Machining

Replacement duringpower plant outages

Replacement duringpower plant outages

ant opt m zat on

Power plant retrofits

ant opt m zat on

Power plant retrofits

System analysis

Stress calcluation

System analysis

Stress calcluation

Destructive and non-destructive material

testing

Destructive and non-destructive material

testing

ssessmen oresidual service life

ssessmen oresidual service life

ProcurementProcurement

Expediting

Specifications

Expediting

Specifications

Pipe hangerdesign

Pipe hangerdesign

Quality Assurance

Scheduling

Quality Assurance

Scheduling

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4. Market Structure

-

Market leader in Europe

Market leader in South Africa

One of six leading contractors worldwide

Piping Systems in Nuclear Power Plants

Market leader in Europe

Main Coolant Piping in Nuclear Power Plants

nterna y c a e p pes

One of three contractors worldwide

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4. Market Structure

BIP (Babcock Industry and Power)

E.ON AnlagenserviceWWV Wrmeverwertun

Europe YIT (Industrial and Network Services), FinlandFives Nordon France

Fabricom (Suez Gaz de France), BelgiumBoccard, FranceBassi, Italyn egra , us r a

World Shaw / Stone & Webster, USA,

ATE (Atomtech Energy & Industrials), TaiwanBHEL (Bharat Heavy Electricals Ltd.), IndiaSeongwha Industrial, Korea

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Fabricom / Endel (Suez Gaz de France), Belgium/France

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5. Clients

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.

Billing on basis of hours and

material spent according to unit rate list

Service contract

en

Lump sum fixed price for exactly defined

scope of supplies and services

e. . water/steam c clesLump sum

ClientBBPS

Unit rate lists with defined quantities

e.g. major contract OL3 FinlandClientBBPS

AREVA reactor building SIEMENS turbine hall

Hours s ent with hour char e rates

all materials and third-party services (cost plus fee)

no major contracts Cost plus fee

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7. Competitive differentiators and success factors-

Coal-Fired Power Plants

g er processtemperatures and

pressures er

kWh

Process temperature

nc

y

increase netEfficiency andreduce CO2 emissions. m

CO2

effici

require better materialswith higher demandsfor develo ment

g

r

manufacturing andfabrication.

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7. Competitive differentiators and success factors

know-how from

Mannesmann Anlagenbau (MAB),

Babcock Rohrbau, today BHR

Vallourec & Mannesmann (V&M), formerlyMannesmann Rhrenwerke

Global leader in e ui in ower lants with

seamless pipes for high-pressure piping systems

Joint research ro ects with Vallourec &Mannesmann (V&M)

Ongoing development and improvement of pipe

materials (V&M) and their process technologies

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(BHR)

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Pressure sur e calculation

Process engineering and design calculation

of the main steam piping system

max. 150 milliseconds

approx. 210 km/h

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Control of forces and loads

Detail engineering and calculation

Transfer of forces and loads into the

building steel structure by means of Lisega

Rigids

Constantangers

Shock absorbers

Spring hangers

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The key technologies

Inductive bending

SAW socket welding

Submerged arc welding (SAW)

SAW-narrow gap welding

Weld claddin

Inert- as tun sten-arc weldin TIG

Manual arc welding

TIG pulse orbital narrow gap welding

Material testing non-destructive / destructive

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Pipe bends

Production of bends with

flow optimised radii

= minimised pressure loss

Reduction of number of welds

= increased benefit

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Movie Inductive Bending

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Coal- and lignite-fired big sized

Number of power plant units (14)

power plant new builds in Germany

Number of BHR projects (12)

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8. References-

Olkiluoto 3, Finland, EPR 1,600 MWe

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8. References-


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8. References-


main steamsilencer

steam generator

pressurization system

safety injection system

feed water

nuclear reactor containment

reactor coolant system

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8. References-

Water / Steam Cycles

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Photo: Siemens press release

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8. References-

Water / Steam Cycles

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8. References

Steel pipes for offshore foundations

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Strong arguments for a successful expansionof the share in the worldwide power piping market

Thank you for your attention

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CMD_02122010_Diehl_final

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