steel tube summit 2011 boiler industry - user perspective

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Steel Tube Summit 2011Boiler Industry - User Perspective

Thermax Group/ P K Davar/ CII Steel Tube Summit, New Delhi/ 26th Aug. 2011

Sustainable Solutions inEnergy and Environment

To be a globally respected high performance organization offering sustainable solutions in energy and environment

Vision

Thermax Group/ P K Davar/ CII Steel Tube Summit, New Delhi/ 26th Aug. 2011 2

Our Belief

“Profit is not only a set of figures, but of values.”

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Rohinton D. Aga1935 - 1996

Founder Chairman, Thermax


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Thermax Evolution• Established in 1966 as Wanson

(India)

• Rs. 5,000 Crore Group with sales & service network in Asia, Middle East, Africa, Europe and the Americas.

• Manufacturing facilities in India and China.

• Supports customers in over 75 countries with solutions to conserve energy and preserve the environment.


Our Core Business

Boiler & Heater

• Package boilers

• Large capacity

power boilers• Thermal oil /

water heaters

• Energy recovery

systems

Boilers & Heaters

Turnkey Power Plants

• Solid fuel based• Gas based

combined cycle • Waste heat

recovery based• RE based incl.

Biomass, Bagasse, solar, etc.

• O&M of power plants

Power Generation

Chemicals• Ion exchange

resins• Cooling water

chemicals• Fireside

chemicals• Polyelectrolyte

Water and wastewater• Wastewater &

Effluent water treatment systems

• Water recycling• Waste

management

Chemicals & Water

Enviro• ESP & Bag

filters• Scrubbers• Air purification• Retrofit &

Revamp

Air Pollution Control

THERMAX

Cooling & Heating

Cooling• Exhaust & Multi-energy

fired chillers• Steam fired chillers• Hot water fired chillers• Direct fired chillers

Heating• Steam/Hot water power

plants• Packaged solid/oil/gas

fired boilers • Fired thermic fluid

heaters• Exhaust waste heat

recovery boilers

Renewable

Solar•

Heating

• Cooling


THERMAX - Boiler Business

Industrial Boilers - Present – Capacity - Max 500 T / Hr,– 165 Kg / cm2 pressure range,– 570 deg C

Utility Boilers – Capacity – Max 1000 T / Hr, – 180 Kg / cm2 pressure range, – 570 deg C

Critical and Super Critical range of Boilers – For and up-to 1000 MW.


BOILER TUBES / PIPES - APPLICATION


• Smoke Tubes• Boiler Panels • In bed tubes• Convection Bank• Super-heater• Re-heater• Economizer• Air Preheater• Mineral Oil Heaters• Fired Heaters• Header’s• RCDC• Internal Piping

Boiler Tubes / Pipes Grades• Types of Grades

– Seamless Carbon & Alloy Steel TubesSA 210 A1 , SA 213 T 11, T12, T22, T23 , T 91 and T92

– Seamless Carbon & Alloy Steel PipesSA 106 Gr B , Gr C, SA 335 P11, P22 & P91

– ERW Tubes BS 3059 , Part I / II , Gr 320/360

– Air Preheater Tubes IS 6323 , Part V , NKLM

– Stainless Steel Tubes SS 304 / 316 / 316 L / 430 TI

• Tube Sizes – OD 31.75 mm OD to 101 mm OD

– Thickness range of 3.25 mm to 10 mm

– Maximum length 13 meter Thermax Group/ P K Davar/ CII Steel Tube Summit, New Delhi/ 26th Aug. 2011 8

Industry Scenario


Growing Industries

Steel

Food

Chemicals

PowerGeneration

Plywood

Beverage Edible Oil

Packaging

Tea

Man Made Fiber

Sponge Iron Automobile

CementTextile

Hospitality

Paper & Pulp

Stagnant, Contracting Industries

Non Ferrous

Refineries &Petrochemical

Pharma

Oil & Gas

Power Scenario– Installed Capacity as on 31st March 2011 – 174,364.4 MW

– Per Capita Energy consumption (2008-09) – 733.54 Kwh / year

– Per Capita Global Energy Consumption – 2,340 Kwh / year

(USA – 15,000 Kwh / year, China – 1,800 Kwh / year)

– Thermal Power generation – 65% ( 113,337 MW)

– “POWER FOR ALL” Mission

• Target to add by 2012 (end of 11th Plan) – 78,000 MW(could be curtailed to 58,000

MW)

• Power required by 2020 – 400,000 MW

by 2030 – 950,000 MW

– A significant reason for missing capacity addition for the 10th & current 11th five

year plan has been equipment shortage “Boiler”.


Power Capacity Addition Plan

Year Generation Capacity (MW)

Tubes Required (Tonnes)

Pipes Required(Tonnes)

11th Plan 78,000 400,000 160,000

Curtailed 11th Plan – By 2012

58,000 300,000 120,000

2020 400,000 2,100,000 820,000

2030 950,000 5,000,000 1,940,000


Source Countries for Tubes & Pipes


China Japan Germany

France Spain Italy

Romania

Market Expectations

• Deliveries

Boiler supply completion

– Process Boilers up-to 10 TPH (Tubes – BS 3059)

Required within Current Performance

• < 1 TPH : 8 Weeks 10-12 Weeks

• 1-6 TPH : 12-14 Weeks 16 Weeks

• 7-10 TPH : 16 Weeks 22 Weeks

– Bi-drum Boilers

• 15-25 TPH : 7 Months 9 Months

– Power Boilers

• 200 TPH 12 months Tubes are expected on 3rd

month from the O date in plant

• 500 T / Hr 18 months Tubes are expected on 4th

month from the O date in plant


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Deliveries– Heaters

• 8 - 10 Mkcal/hr : 5 Months 8 Months

– Europe manufacturers’ take 3/4 months , – China supplies within 2 / 3 months.

– Indian manufacturers’ For Carbon Steel Tubes 4 / 6 months.

However, there are in-ordinate delays.

On Alloy Steel tubes There no firm commitment.

– Allocation of capacities OCTG vs Boiler

– Competition from China – is now a reality to the Indian Boiler manufacturers !!!

Also there is a substantial price difference ?Thermax Group/ P K Davar/ CII Steel Tube Summit, New Delhi/ 26th Aug. 2011

Market Expectations

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Market Expectations

Availability• Along with schedule pipes – Heavy sizes above 14” & extra wall thickness like 28 mm,

35 mm , 40 mm , 60 mm thk seamless pipes for higher pressure ranges for Headers

• T11, T22 & T 91 seamless tubes & P11 , P22 , P91 – heavy thick seamless pipes with straightness requirement of 3 mm / meter

• Availability of alloy steel tubes / pipes from Indian mills on a firm schedule basis.

Quality• For Seamless Tubes/ Pipes – Improvement in surface coating/treatment • For ERW tubes/ Pipes – Improvements in Stenciling / Surface finish desired.

• Value addition - Finning facility , Tube bending by Tube manufacturers ?


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Market Expectations

Others• Fixed Prices

• Latent defects – Warranty / Guaranties (as desired by end users)

• Completion of a Boiler with assembly-wise 100% tubes supply of fixed length – No waiting time on the shop floor – cycle time reduction

• Regular production update with status on Billet / Strip availability to plan in house production

• Documentation – As desired.


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Thank you


steel tube summit 2011 boiler industry - user perspective

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