FOCUS ON COAL AND ASH HANDLING PLANT

BY N.K.SRIVASTAVA 22nd MAY,2012

CAPACITY ADDITION ANNOUNCED

Announced Capacity

920.7 Gigawatt

914 Projects

CONTINUED
Fuel Coal Under Construction Under Implementation Under Planning Gas Under Construction Under Implementation Under Planning Hydro Under Construction Under Implementation Under Planning Nuclear Under Construction Under Planning Total Under Construction Under Implementation Under Planning Grand Total Projects 571 124 111 336 112 20 18 74 220 48 30 142 11 3 8 11 195 159 560 914 Capacity (MW) 683,402 116,761 113,044 453,597 111,366 10,259 8,465 92,642 86,246 13,417 8,377 64,452 39,700 4,800 34,900 39,700 145,237 129,886 645,591 920,714

Key Clearances

Project Status Cap (MW) Total Land Water Environment Financial Equipment

Under Under Construction Implementation 145,237 195 181 181 183 169 183 129,886 159 126 114 128 60 58

Under Planning 645,591 560 71 74 86 12 13

Grand Total 920,714 914 378 369 397 241 254

Environment Clearance Pipeline

Announced Capacity

417 Gigawatt

370 Projects

Fuel Continues to Be the Biggest Issue

Fuel Pipeline for the Coal Sector

Plant Type Linkage Captive Imported Linkage+Imported Captive+Imported Captive+linkage Captive+Linkage+Imported Not Finalized Grand Total

Projects 255 47 30 26 5 32 1 175 571

Capacity 283,099 62220 47,500 35,532 5,770 36,360 600 212,321 683,402

203 Projects have applied for Linkage but is pending

MAJOR PLAYERS
Coal Companies (CIL) Railways Power Generation Companies CHP Equipment suppliers and contractors

Major Issues
Coal quality Coal Transportation Coal stock Competent contractors

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

Coal transportation
Bunching of rakes

Coal stock
Actual delivery less than requirement Imported coal - handling - blending with domestic coal

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

Trends in manufacturing capacities of key CHP and AHP players

CHP manufacturing companies have augmented their in-house manufacturing capacities to meet the new challenges of capacity addition programme of XII and XIII th Plan. Need for a good AHP player is there . Many companies are trying to enter in the fray.

Key Technology Developments

L&T: Wagon Shifters and Pushers : Developed for reducing the space requirements in outhaul 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.

Key Technology Developments

Hydraulic Drives for Conveyors . Low / zero running maintenance cost. Stacker Reclaimer bucket wheel & slew drives. These will increase the efficiencies over the electro mechanical drives, lower maintenance, reduction in overall machine weight. Permanent Deck sheets for floor slab castings against the conventional shuttering, leads to faster construction.

Key Technology Developments

Flow dividing concept in the junction towers, for efficient blending Increased belt speed up to 4.8 m/sec. HT and LT cables are routed through conveyor galleries, 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

Recently executed projects, their highlights and learning's

Utilities are switching for Wagon Tipplers, to address 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.

 In recent times, most of the utilities are including the Bunker TPs in the scope of CHP Contractor to avoid the delays in overall plant completion, e.g. Malwa CHP, DB Power CHP. Overall CHP execution time has come down. CHPs are now 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 for 12 conveyors.

Recently executed projects, their highlights and learning's

TRENDS IN MANUFACTURING CAPACITIES

-NO CLEAR TRENDS SEEN IN EXPANSION OF MANUFACTURING CAPACITY IN INDUSTRY -PLAYERS ARE GENERALLY STICKING TO CORE AREAS

KEY TECHNOLOGY DEVELOPMENT

HIGH CONCENTRATION SLURRY DISPOSAL SYSTEM

- DRY BOTTOM ASH SYSTEM

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.

THANK YOU

KEY TECHNOLOGICAL DEVELOPMENTS

LATEST HIGH CAPACITY WAGON TIPPLERS (CONFORMING TO RDSO G33 Rev.1)
-

-HIGH CAPACITY CHPs (3000TPH-5000TPH) - HYDRAULIC DRIVE IN PLACE OF ELECTROMECHANICAL DRIVE FOR MAJOR EQUIPMENTS LIKE TIPPLER, STACKER CUM RECLAIMER

TRENDS IN MANUFACTURING CAPACITIES

- HAVE GENERALLY INVESTED IN EXPANDING MANUFACTURING CAPACITIES TO CATER TO HIGHER PRODUCTION VOLUME REQUIRED FOR UPCOMING PROJECTS - HAVE GONE IN FOR COLLABORATION/ ASSOCIATION/ JOINT VENTURES WITH VARIOUS FOREIGN PARTIES TO EXPAND THEIR RANGE

RECENTLY EXECUTED PROJECTPROJECT- HIGHLIGHT & LEARNING

-HIGH CAPACITY PLANT OPERATING SUCCESSFULLY. -CAN PLAN FOR HIGHER CAPACITY CHP. - GENERAL SHORTAGE OF SKILLED MANPOWER