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
Thermax Group/ P K Davar/ CII Steel Tube Summit, New Delhi/ 26th Aug. 2011
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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.
Thermax Group/ P K Davar/ CII Steel Tube Summit, New Delhi/ 26th Aug. 2011
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 Group/ P K Davar/ CII Steel Tube Summit, New Delhi/ 26th Aug. 2011 5
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.
Thermax Group/ P K Davar/ CII Steel Tube Summit, New Delhi/ 26th Aug. 2011 6
BOILER TUBES / PIPES - APPLICATION
Thermax Group/ P K Davar/ CII Steel Tube Summit, New Delhi/ 26th Aug. 2011 7
• 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
Thermax Group/ P K Davar/ CII Steel Tube Summit, New Delhi/ 26th Aug. 2011 9
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”.
Thermax Group/ P K Davar/ CII Steel Tube Summit, New Delhi/ 26th Aug. 2011 10
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
Thermax Group/ P K Davar/ CII Steel Tube Summit, New Delhi/ 26th Aug. 2011 11
Source Countries for Tubes & Pipes
Thermax Group/ P K Davar/ CII Steel Tube Summit, New Delhi/ 26th Aug. 2011 12
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
Thermax Group/ P K Davar/ CII Steel Tube Summit, New Delhi/ 26th Aug. 2011 13
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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 ?
Thermax Group/ P K Davar/ CII Steel Tube Summit, New Delhi/ 26th Aug. 2011
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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.
Thermax Group/ P K Davar/ CII Steel Tube Summit, New Delhi/ 26th Aug. 2011
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Thank you
Thermax Group/ P K Davar/ CII Steel Tube Summit, New Delhi/ 26th Aug. 2011
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