FOCUS ON COAL AND ASH HANDLING PLANT

BYN.K.SRIVASTAVA

22nd MAY,2012

CAPACITY ADDITION ANNOUNCED

Announced Capacity

920.7 Gigawatt 914 Projects

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 92,642

Hydro 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 39,700 Under Construction 195 145,237 Under Implementation 159 129,886 Under Planning 560 645,591

Grand Total 914 920,714

Key Clearances

Project Status Under 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

Environment Clearance Pipeline

Announced Capacity

417 Gigawatt 370 Projects

Fuel Continues to Be the Biggest Issue

Plant Type Projects CapacityLinkage 255 283,099 Captive 47 62220Imported 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 175 212,321 Grand Total 571 683,402

Fuel Pipeline for the Coal Sector

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 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.

Key Technology Developments

L&T:Wagon Shifters and Pushers :Developed for reducing the space requirements inouthaul side of Wagon Tippler Complex and toreduce the unloading time. Revolutionarydevelopment considering paucity of free hold land.Wagon Tipplers: Development to meet the latest requirements of

RDSO G-33 specification, which has come intoforce from 1st December 2010.

• 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 castingsagainst the conventional shuttering, leads tofaster construction.

Key Technology Developments

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 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, toaddress latest RDSO guidelines and ensureminimum unloading rate of 25 tips / hr.

• Reduced Engineering approval time – for all thecustomers

• Ensure faster availability of customers’ inputs – tobe done by utilities.

Recently executed projects, their highlights and learning's

• In recent times, most of the utilities are including theBunker TP’s 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 ofoff Shore Conveyor with Hydraulic conveyor drives for12 conveyors.

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 ELECTRO-MECHANICAL DRIVE FOR MAJOR EQUIPMENTS LIKE TIPPLER, STACKER CUM RECLAIMER

TRENDS IN MANUFACTURING CAPACITIES

- HAVE GENERALLY INVESTED IN EXPANDINGMANUFACTURING CAPACITIES TO CATER TOHIGHER PRODUCTION VOLUME REQUIRED FOR UPCOMING PROJECTS

- HAVE GONE IN FOR COLLABORATION/ ASSOCIATION/ JOINT VENTURES WITH VARIOUS FOREIGN PARTIES TO EXPAND THEIR RANGE

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