4 n k srivastava

7/28/2019 4 N K Srivastava

1/31

FOCUS ON COAL AND

ASH HANDLING PLANTBYN.K.SRIVASTAVA

22nd MAY,2012


2/31

CAPACITY ADDITION ANNOUNCED

Announced Capacity

920.7 Gigawatt 914 Projects


3/31

CONTINUED

Fuel Projects Capacity (MW)Coal 571 683,402

Under Construction 124 116,761

Under Implementation 111 113,044

Under Planning 336 453,597

Gas 112 111,366



Under Planning 74 92,642Hydro 220 86,246




Nuclear 11 39,700



Total 11 39,700Under Construction 195 145,237



Grand Total 914 920,714


4/31

Key Clearances

Project StatusUnder

Construction

Under

Implementation

Under

Planning

Grand

Total

Cap (MW) 145,237 129,886 645,591 920,714

Total 195 159 560 914

Land 181 126 71 378

Water 181 114 74 369

Environment 183 128 86 397

Financial 169 60 12 241

Equipment 183 58 13 254


5/31

Environment Clearance Pipeline

Announced Capacity

417 Gigawatt 370 Projects


6/31

Fuel Continues to Be the Biggest Issue

Plant Type Projects Capacity

Linkage 255 283,099

Captive 47 62220

Imported 30 47,500

Linkage+Imported 26 35,532

Captive+Imported 5 5,770

Captive+linkage 32 36,360

Captive+Linkage+Imported 1 600

Not Finalized 175 212,321Grand Total 571 683,402

Fuel Pipeline for the Coal Sector

203 Projects have applied for

Linkage but is pending


7/31

MAJOR PLAYERS

Coal Companies (CIL)

Railways Power Generation Companies

CHP Equipment suppliers and contractors


8/31

Major Issues

Coal quality

Coal Transportation Coal stock

Competent contractors


9/31

Coal Quality

very variable

ash content system capacity, component life

moisture & fines flowability in hoppers, chutes,

housekeeping

oversize quantity delays in unloading ,

additional handling

stones and trash delays in unloading, removal

facilities, damage to equipment


10/31

Coal transportation

Bunching of rakes


11/31

Coal stock

Actual delivery less than requirement

Imported coal

- handling

- blending with domestic coal


12/31

CHP /AHP suppliers- Issues

Limited numbers/Bunching of Orders. Shortage of skilled Manpower/Capabilities

Core competency in executing Civil works

Good Civil sub contractors. Fabrication works execution.

Standardisation by Utilities

Steel procurement/Availability of fronts Skewed Cash Flow strategies

Interface issues with main plant& other

Vendors


13/31

Trends in manufacturing capacities of key CHPand AHP players

CHP manufacturing companies have augmentedtheir in-house manufacturing capacities to meetthe new challenges of capacity additionprogramme of XII and XIII th Plan.

Need for a good AHP player is there . Manycompanies are trying to enter in the fray.


14/31

Key Technology Developments

L&T:

Wagon Shifters and Pushers :

Developed for reducing the space requirements inouthaul side of Wagon Tippler Complex and to

reduce the unloading time. Revolutionary

development considering paucity of free hold land.

Wagon Tipplers: Development to meet the latest requirements of

RDSO G-33 specification, which has come into

force from 1st December 2010.


15/31

Hydraulic Drives for Conveyors . Low / zerorunning maintenance cost.

Stacker Reclaimer bucket wheel & slew drives.These will increase the efficiencies over theelectro mechanical drives, lower maintenance,reduction in overall machine weight.

Permanent Deck sheets for floor slab castings

against the conventional shuttering, leads tofaster construction.



16/31


Flow dividing concept in the junction towers, forefficient blending

Increased belt speed up to 4.8 m/sec.

HT and LT cables are routed through conveyorgalleries, instead of cable trestles

Single CHP for both phases of the power plant e.g.

Adani Tiroda,etc.-High capacity CHP 3000-5000TPH Rapid unloading system for small Track Hopper


17/31

Recently executed projects, their highlights

and learning's

Utilities are switching for Wagon Tipplers, toaddress latest RDSO guidelines and ensure

minimum unloading rate of 25 tips / hr. Reduced Engineering approval time for all the

customers Ensure faster availability of customers inputs to

be done by utilities.


18/31

Recently executed projects, their highlights

and learning's In recent times, most of the utilities are including the

Bunker TPs in the scope of CHP Contractor to avoid thedelays in overall plant completion, e.g. Malwa CHP, DBPower CHP.

Overall CHP execution time has come down. CHPs arenow being executed in 20 months e.g. Mahan CHP.

Tuticorin Coal Handling Plant for NTPL (2 x 500 MW) -port based power plant, includes marine piles, 2.2 km of

off Shore Conveyor with Hydraulic conveyor drives for12 conveyors.


19/31

TRENDS IN MANUFACTURING

CAPACITIES

-NO CLEAR TRENDS SEEN IN EXPANSION OF

MANUFACTURING CAPACITY IN INDUSTRY

-PLAYERS ARE GENERALLY STICKING TO CORE

AREAS


20/31

KEY TECHNOLOGY DEVELOPMENT

- HIGH CONCENTRATION SLURRY DISPOSAL

SYSTEM

- DRY BOTTOM ASH SYSTEM


21/31

LEARNINGS FROM PROJECTS UNDER

EXECUTION-

-DELAYS IN ASH HANDLING SYSTEM:

DELAY DUE TO EXECUTION OF CIVIL &

STRUCTURAL WORKS.

COLLABORATORS FULL FLEDGED NON

INVOLVEMENT.DELAY IN PLACEMENT OF ORDERS FOR

BOUGHTOUT ITEMS.

NONAVAILABILITY OF EXPERIENCED & SKILLED

MANPOWER FOR PROJECT EXECUTION.

NON STANDARDISATION OF SYSTEM.

FINANCIAL CAPABILITIES OF CONTRACTORS.


22/31


23/31


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26/31

THANK YOU


27/31

KEY TECHNOLOGICAL

DEVELOPMENTS

- LATEST HIGH CAPACITY WAGON TIPPLERS

(CONFORMING TO RDSO G33 Rev.1)

-HIGH CAPACITY CHPs (3000TPH-5000TPH)

- HYDRAULIC DRIVE IN PLACE OF ELECTRO-

MECHANICAL DRIVE FOR MAJOR EQUIPMENTS

LIKE TIPPLER, STACKER CUM RECLAIMER


28/31

TRENDS IN MANUFACTURING

CAPACITIES

- HAVE GENERALLY INVESTED IN EXPANDING

MANUFACTURING CAPACITIES TO CATER TO

HIGHER PRODUCTION VOLUME REQUIRED FORUPCOMING PROJECTS

- HAVE GONE IN FOR COLLABORATION/

ASSOCIATION/ JOINT VENTURES WITH VARIOUS

FOREIGN PARTIES TO EXPAND THEIR RANGE


29/31

RECENTLY EXECUTED PROJECTRECENTLY EXECUTED PROJECT-- HIGHLIGHT &HIGHLIGHT &

LEARNINGLEARNING

--HIGH CAPACITY PLANT OPERATING SUCCESSFULLY.HIGH CAPACITY PLANT OPERATING SUCCESSFULLY.

--CAN PLAN FOR HIGHER CAPACITY CHP.CAN PLAN FOR HIGHER CAPACITY CHP.

-- GENERAL SHORTAGE OF SKILLED MANPOWERGENERAL SHORTAGE OF SKILLED MANPOWER


30/31


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