gov in das amy

8/3/2019 Gov in Das Amy

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Bharat Heavy Electrical Limiteds (BHEL)

Experience in

Coal Fired Power Generation

and

Plant Upgrading


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Indias largest engineering and manufacturing enterpriseOne among the major in the world

Corporate Office New DelhiMajor Units

Construction Management & Services

8 Service Centers18 Regional OfficesAbout 180 Products


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DIRECTOR(E,R&D)

DIRECTOR( HR )

DIRECTOR( FINANCE)

DIRECTOR(POWER)

DIRECTOR(IS&P)

CHAIRMAN AND MANAGING DIRECTOR

Corporate Functional Structure

ED/ IO ED/ P&D

Major Operating Units

BHOPAL / JHANSIBHOPAL / JHANSI HYDERABADHYDERABAD HARDWARHARDWARTIRUCHIRAPPALLI BANGALOREBANGALORE RANIPETRANIPET

The Board includes two Directors nominated by Govt. of Indiaand Six Independent Directors


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Global Presence through Exports

Steam Power PlantsSouth East Asia, Mediterranean, Africa

Gas Turbine Power PlantsSouth Asia, South East Asia, Middle East

Hydro Power PlantsFar East, South East Asia, South Asia, CIS

Sub-StationsSouth & South East Asia,

Africa, Middle East

Power Plant RehabSouth & South East Asia,Middle East, Africa

BHEL Overseas Offices : UAE & Malaysia


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60

80% of Installed Capacity(125414 MW )as of 31.3.07

% of Total Generation during 06-07

BHELs Role in the Indian Power Sector

0

20

40

BHEL others


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60

65

70

75

80

99-00 00-01 01-02 02-03 03-04 04-05. 05-06. 06-07

All IndiaBHEL Sets

Plant

LoadFactor%

65

70

75

80

85

90

99-00 00-01 01-02 02-03 03-04 04-05. 05-06. 06-07

All India

BHEL SetsAvailability%


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BHEL Corporate performance

8662

10335

14525

18702

- - - -

1647818238

18938

35633

2003-04 2004-05 2005-06 2006-07

4.24.14.6 4.7

8.9

2.22.6

3.6

4.7Order inflow $ billion Turn Over $ billion

1015

1582

2564

3675

2003-04 2004-05 2005-06 2006-07

26.89

38.95

68.6

97.4

2003-04 2004-05 2005-06 2006-07

0.25

0.40.64

0.92Profit Before Tax $ billionEarnings Per Share


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BHEL Tiruchirappalli complex


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High Pressure Boiler Plant (HPBP)

Sub-critical Steam Generators for Utilities / Industries FiringFossil Fuels up to 500 MW (PF, CFBC)

HRSGs

Product Profile

uper cr ca s eam genera ors -

Nuclear Steam Generators

Seamless Steel Tubes

Valves, Fittings & Soot blowers

Pressure Vessels & Heat Exchangers


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Boiler Auxiliaries Plant

Radial and Axial Fans

Air Pollution Control Equipment

Air Pre heaters

Desalination Plants

Product Profilecontd

Coal & Ash Handling System

Piping Center

High Pressure Piping System Plant Auxiliary Piping System

Pipe Fittings

Blow Down and Chemical Dosing System


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High Pressure Boiler Plant

Tiruchirappalli


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2201

3536

4607

HPBP performance

502

550

884

1152Turn over in $ million

2003-04 2004-05 2005-06 2006-07


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Shop Area ( M2)

Boiler Plant 166,300SSTP 37,900

BAP 46,600

Resources

Goindwal 3,600

Total 254,400

Work force 11,262

Support facilities for fabrication: 320ancillary units


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Human Resources

Category Tiruchy Ranipet Total

EmployeesExecutives 1651 368 2019

Artisans &Others 5872 1456 7328

Total 9139 2123 11262

Includes IVP Goindwal & Piping Centre Chennai


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Technology Development

1960s 30, 60 MW Czechoslovakian technology

1970s 110, 210 MW(Low Pressure) Technology from CE, USA

1980s 210, 500 MW (170 plus pressure)

Firing system design for Low NOx emission

Desi n Chan e to meet deterioratin coal

Tower type boilers for highly erosive coals

1990s 500 MW Design ImprovementsLower Exit Gas Temperature

2000s Technology for Supercritical BoilersIT based Soot blowing

Design for Washed Coals


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Steam Generators - Contracted

Power Boilers30 to 130 MW 130

200/210/250 MW 177500 MW 66

CFBC 10HRSG 80

Process Plant Boilers

Chemical Recovery 17Stoker/PF/ Oil/Gas Firing 135

CFBC 8

BFBC 66HRSG 51

Total 740


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BoilerComponents

USAChinaEgypt

Valves

USA

Japan

IndonesiaMalta

Cyprus

E t

Steam Generators

Malaysia 11 Nos 1110 MWLibya 2 Nos 240 MWEgypt 2 Nos 60 MWSudan 4 Nos 500 MW

R&M jobsin Libya

R&M andgas conversion

in Malaysia


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Technology Base

Product Technology Source

Utility & Industrial SGs : Combustion Engineering, USAOnce Through Boilers : Alstom, France

CFB Boilers : LLB-Lurgi Lentjes, Germany

HRSG : VOGT-NeM, USAAirpreheaters : CE Airpreheater, U.S.A

Electrostatic Precipitators : Flakt AB, Sweden

Fans : KKK Germany., TLT , Germany


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BMCR

Steam flow at SHO t/h 1675

Steam pressure at SHO kg/Sq.Cm(g) 178

Boiler Parameters 500 MW

Steam temperature at SHO Deg.C 540

Reheat steam flow t/hr. 1387.2

Steam temperature at RHO Deg.C 540

Feed water temperature Deg.C 253.7


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Typical Coal

Design Worst Best

Total Moisture % 12 15 11

Ash % 43 45 36

Volatile Matter % 21 20 24Fixed Carbon % 24 20 29

HHV kcal/kg 3300 3000 3750


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500 MW Thermal Power Stations - India

Station Trombay - 6 Singrauli TalcherCustomer TATA Electric NTPC NTPCSteam (t/h) 1614/1490 1725/1530 1700/1525Fuel Oil/Gas /(Coal) Coal CoalPasses Two Pass Two Pass Single PassCirculation Controlled Controlled Once thro

Draft / Firing Balanced / Tilting Tangential


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Thermal Power Stations India contd..

Station Vijayawada 3&4 Neyveli 4-7 TalcherCustomer APSEB NLC NTPCCapacity 210 MW 210 MW 500 MW

Steam (t/h) 690 690 1700Fuel Coal Lignite CoalPasses Single Pass Single Pass Single PassCirculation Natural Natural Once throDraft Balanced Balanced BalancedFiring Tilting Tangential Fixed Tangential Tilting Tangential


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120 MW Thermal Power Stations - Export

Station Libya Pasirgudang PraiCustomer Electricity Corp. NEB, Malaysia NEB, MalaysiaSteam flow (t/h) 375 390 382Fuel Oil/Gas Oil / Gas Oil

Box Type / Natural Circulation / Balanced Draft / Tilting Tangential


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Improvements

Higher Capacity ( pressure, temperature) units State of the art Technologies

Lower gas exit temperature

Steam Leak Detection System High Efficiency Axial Fans for FD & PA

VFD Drives


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12

15

18

210/250 MW

500 MW

BHEL Unit capacity trend

0

3

6

9

1 2 3 4

2004-05 2007-082006-072005-06


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Unit size increase - India

size MW number of units during

2007-12 2012-17

125 7 nil

210/250/310 45 4

500 47 18

660 10 1

800 2 39


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GAS TEMP. LEAVING175

8687

88

89

AH (CORRECTED) Deg.C

0

125

150

1980s 2000


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99

100

101

Auxiliary Power Consumption

94

95

96

97

1980's 2000


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R &M the need & benefit

Meeting statutory regulations

Ageing shut down, low out put, efficiency, availability

Deterioration in coal quality/change of type of coal

Availability / quality of spares

Obsolete technology/operation philosophy

Capacity uprating

Enhanced life

State of the art systems


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R&M by BHEL in India - completed

unit capacity MW remarks

Kothagudam 2 x 110 up rated to 120 MW

Korba 1 x 120 from 85/90 MW to 120;availability from 79 to 99 %

Ennore 2 x 110 up rated to 120 MW

Bokaro 3 x 50 capacity restoredreliability improved

Neyveli 4 x 50 capacity restoredexit temp reduced (190 to 140 C)


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R&M by BHEL in India being executed

Sl No unit capacity MW remarks

1 Ukai 2 x 120 in progress

2 Gandhinagar 1 x 120 supply andpre s u own wor n progress

3 Panipat 1 x 110 in progress; up rating to 117.8 MW

4 Batinda 2 x 110 up rating to 120 MW

5 Obra 5 x 200 up rating to 216 MW


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R & D Facilities


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Fuel Evaluation Test Facility(Set-up with assistance from USAID)

To study the effects of: Fuel characteristics and burner configurations

Combustion performance

F l B i T F ili i


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Fuel Burning Test Facilities

SOLID FUELS 10 Million kcal / hr capacity

Coal burner/nozzledevelopment

Study of flame stability,combustion efficiency,turndown

LIQUID FUELS

15 Million kcal / hr capacity

For testing of burners and

fuel handling systems

Development of low ExcessAir, low NOx burners.

Fuels - LSHS, vacuum residue

oil, orimulsion, Crude etc.

FBC T t F iliti / P t t B il


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7.5 t/h Prototype Shell Boiler

FBC Test Facilities / Prototype Boilers

10 t/h Prototype Boiler

4 Mkcal/h test rig1979

1 M x 1 M Test Facility-1986

With US AID

(90 t/h Hot water)

CFBC Test Facility - 1991

(90 t/h Hot water)


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Clean Coal Technology - I G C C

Test facility to develop clean coal technology for power generation

Scale up of IGCC to 125 MW under progress demo plant at Uttar Pradeshunderway in collaboration with NTPC


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Welding Research Institute

Established in 1975 with UNDP/UNIDO aid,

Research in advanced welding processes & welding equipment

Consultancy & training in welding

Developing WRI as a Centre for Manufacturing Excellence


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Clean Coal

Large CapacityIGCC

Super CriticalBoilers

Emission ControlTechnologies

Technology

Super CriticalCFBCs

CO2Sequestration

Demo plantAdvanced

Test Facilities


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Thank you


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gov in das amy

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