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FOCUS ON COAL AND
ASH HANDLING PLANTBYN.K.SRIVASTAVA
22nd MAY,2012
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CAPACITY ADDITION ANNOUNCED
Announced Capacity
920.7 Gigawatt 914 Projects
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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 Construction 20 10,259
Under Implementation 18 8,465
Under Planning 74 92,642Hydro 220 86,246
Under Construction 48 13,417
Under Implementation 30 8,377
Under Planning 142 64,452
Nuclear 11 39,700
Under Construction 3 4,800
Under Planning 8 34,900
Total 11 39,700Under Construction 195 145,237
Under Implementation 159 129,886
Under Planning 560 645,591
Grand Total 914 920,714
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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
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Environment Clearance Pipeline
Announced Capacity
417 Gigawatt 370 Projects
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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
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MAJOR PLAYERS
Coal Companies (CIL)
Railways Power Generation Companies
CHP Equipment suppliers and contractors
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Major Issues
Coal quality
Coal Transportation Coal stock
Competent contractors
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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
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Coal transportation
Bunching of rakes
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Coal stock
Actual delivery less than requirement
Imported coal
- handling
- blending with domestic coal
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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
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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.
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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.
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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.
Key Technology Developments
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Key Technology Developments
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
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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.
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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.
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TRENDS IN MANUFACTURING
CAPACITIES
-NO CLEAR TRENDS SEEN IN EXPANSION OF
MANUFACTURING CAPACITY IN INDUSTRY
-PLAYERS ARE GENERALLY STICKING TO CORE
AREAS
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KEY TECHNOLOGY DEVELOPMENT
- HIGH CONCENTRATION SLURRY DISPOSAL
SYSTEM
- DRY BOTTOM ASH SYSTEM
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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.
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THANK YOU
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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
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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
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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
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