balance of plant.doc

7/29/2019 Balance of Plant.doc

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Balance of Plants

Balance of Plants was identified as critical items for timely commissioning of Thermal Power

Projects. It was observed that a number of Thermal units were getting delayed due to delay in

commissioning of Balance of Plants such as Coal Handling Plants (CHPs), Ash Handling Plants

(AHPs), Cooling Tower (CTs) etc.

A coal based thermal power plant consists of large number of integrated plants/systems and

equipment having mechanical, electrical, instrumentation & control and civil components. Theplant systems and equipment can be broadly classified into following two categories:-

i) Main Plant comprising of steam generator, steam turbine and generator along

with their associated auxiliaries.

ii) Balance of Plants (BOP) system which includes all plants and equipment other than those

included in main plant system. The major components of BOP system include coal handling

plant, ash handling plant, fuel oil handling & unloading system, water treatment system,

circulating water system and fire protection, detection & alarm system. As regards BOP systems,

a number of site specific input parameters are involved which have to be kept in view while

designing various systems.

For example while designing coal handling system the site specific points to be considered

include station capacity, quality and source of coal, coal transportation mode, topography and

geometry of the area while for ash handling system, station capacity, ash content in fuel, mode ofash disposal, ash utilization potential, layout and pumping distances have a bearing on the design

of ash handling system. In view of site specific variations, it is very difficult to draft a standard

technical specification incorporating for all possible alternatives of plant systems and equipment.

Accordingly, attempt has been made to evolve standard design criteria/ guidelines which will bea useful reference document and help the utilities in sizing and selection of equipment and

drawing up a detailed specification specific to the plant.

There is a need to develop more vendors for the following Balance of Plants:

i. Ash Handling Plant

ii. Coal Handling Plant

iii. DM Plants

iv. Condensate PolishingUnits

v. CW and Make up System

vi. Cooling Towers

vii. Air Compressors

viii. Chimneys

ix. Civil and MechanicalDesign consultancy

packages

x. De-salination Plants


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There are very limited vendors for each of the above BoPs and at times only

Single Quotation is received. There is also a need to develop adequate

erection and construction agencies for executing civil and mechanical works

and engineering consultants for engineering and design of various packages.

However, adequate capacity is available for the following BoPs as per the

presentation given by the various vendors:

a. Ventilation and Air conditioning

b. Ash water recirculation

c. Bus ducts

d. HV/LV switchgear

e. Insulation

It was also suggested that each BoP should invariably be awarded as a

package instead of breaking up into equipment, civil contracts and

mechanical erection contractors to have single point responsibility.

Supportive and developmental attitude should be adopted by the owners to

encourage new vendors.

Status of Bops For 11th plan Projects

Name of the system BOPs required for projects under

const. (Nos.)

Coal Handling System 68

Ash Handling System 68

DM Plant 69

Cooling Towers 145

Chimneys 117

Fuel Oil System 71

PT Plant 76


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ORDERS FOR MAIN PLANT EQUIPMENT 11thPLAN (Figures in

MW)

MAIN PLANT

EQUIPMENT

SUPPLIER

THERMAL HYDRO NUCLEAR TOTAL

BHEL 36,531 6,017 500 43048

(54%)

OTHERS 25,192 9,490 2880 37562

(46%)

TOTAL 61,723 15,507 3,380 80,610

Thermal and Hydro Main Plant Equipment -Need to augment existing

indigenous manufacturing facilities and create additional capacity

Current Status (BOPs And Main Plant)

BHEL augmentation of manufacturing capacity

To 10,000 MW/annum achieved by Dec 2007.

To 15,000 MW by Dec. 2009 under progress (10,000 MW/annum for large

sized boilers and TGs). Has collaboration with Alstom and Siemens for

manufacture of super critical boilers and turbo-generators. In third phase by

Dec 2011, proposed to augment

JVs

L&T/ MHI Boilers (4000 MW/annum) , TGs (4000 MW). Bharat Forge/

Alstom- TGs (5000 MW).

JSW-Toshiba - TGs (3000 MW).

GB Eng.-Ansaldo-Boilers (2000 MW).

Proposed Bulk tendering of 11X 660 MW units with mandatory

indigenous manufacturing.


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Components of Major BOPs

Each Balance of Plant activity consists of various components which

include:

Civil works

Structural works

Electro mechanical equipments and various types of motors, etc

Control & Instrumentation

Issues For Completion Of Bops In Time

Placement of Order: Timely placement of order for BOPs.

Review of Pre-qualification Requirements for BOP vendor. CEA

already recommended revised PQ to allow entry of new players

Enhancement of vendor base for Balance of Plants

(BOPs) as the requirement has increased manifold during 11th plan

and will further increase in 12th Plan.

There are limited number of suppliers in each category and each

having more work than what it can handle.

Favourable conditions to be developed for new / additional vendors

Actions For Completion Of Bops In Time

Vendors must take approval for appointment of sub-contractors in

advance from the project authorities.

Vendors must place the orders for civil works as well as procurement

of mechanical equipments in time.

Timely releasing of civil construction drawings from consultants and

construction agencies.

Availability of adequate construction machinery at project site.

Deployment of adequate skilled / unskilled man power at site.

Proper coordination among various executing agencies engaged at

project site.


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Loss To The Utilities On Account Of Delay In Completion Of Projects

Cost of delay (Either due to Main Plant or BOPs)

Loss on account of purchase of costlier power from alternate

sourcesRs.2.5 to 6 crores /dayfora500MW pit head unit.

Increase in IDC and consequently the fixed cost Component of tariff-

Rs.45lakhs/dayfora500MWcoalbasedunit.

Loss of return to developer - Rs. 25 lakhs / day for a 500 MW

Unit@14%ROE.

http://www.cea.nic.in/more_upload/standard_design_bop_sep10.pdf

balance of plant.doc

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