divisional plan 2012-17 - rev 01is.bhelepd.com/pdfs/dvp17.pdf · divisional plan -xii plan bharat...
TRANSCRIPT
Strategic Plan
2012-17
DIVISIONAL PLAN -XII PLAN
BHARAT HEAVY ELECTRICALS LIMITED
CERAMIC BUSINESS UNIT
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
0 | P a g e
It gives me immense pleasure to release the BHEL CBU Strategic Plan Document
for 2012-17 in line with our BHEL Culture of Strategic Planning.
“POWER FOR ALL “is continuously giving demand in higher ratings equipments
both in generation and transmission. I.e. This requirement has opened corridors
for higher rating products like Ceralin for super critical boilers of 660 MW, and
full range of generation and transmission system for 800 KV HVDC and 1200 KV
UHVAC Transmission. CBU is in time, to provide insulators and Ceralin to the
market.
Presently CBU is facing a severe competition from Chinese and also both the
plants are running at its full capacity. With the various products that are
developed in time Ceramic Business Unit has made a very ambitious growth plan
with its specialization in complete sets of Ceramic products for Power Generation
like Ceralin and Insulators for Transmission, New Products diversification &
Control Panel Business.
Our Strategic Plan is bringing the future into the present so that we can start acting
upon it now.
With these words, I wish CBU Strategic Plan execution a Great Success.
Foreword
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
1 | P a g e
C O N T E N T S Page No
• • • • EXECUTIVE SUMMARY 2
• • • • OVERVIEW 3
• • • • ORGANISATION STRUCTURE 5
• • • • PRODUCT PROFILE 6
• • • • DIVISIONAL PLAN 2007-12 7
• • • • MACRO LEVEL BUSINESS ENVIRONMENT 9
• • • • STRATEGIC INITIATIVES 14
• • • • CBU SWOT ANALYSIS 17
• • • • PRODUCT- WISE TURN-OVER PROJECTIONS 18
& PRODUCT PLAN FORMATS 21-46
� � � � PORCELAIN DISC INSULATORS 21
� � � � GLASS DISC INSULATORS 23
� � � � COMPOSITE INSULATORS 25
� � � � HOLLOW INSULATORS 27
� � � � CERALIN 29
� � � � CERALIN: NEW APPLICATIONS 37
� � � � INDUSTRIAL CERAMICS 39
� � � � CONTROL PANEL 41
� � � � FILTRATION SYSTEM 43
� � � � GRINDING MEDIA 44
� � � � SCR – Selective Catalytic Reducer 46
•••• CUSTOMER SATISFACTION SURVEY 47
•••• TURNOVER PROJECTIONS: CBU /EPD/IP 48
• • • • BROAD PARAMETERS: 2012-17 49
• • • • TECHNOLOGY PLAN 51
• • • • INVESTMENT PLAN 53
• • • • CONTINGENCY PLAN 54
• • • • BIBLIOGRAPHY 55
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
2 | P a g e
• Perspectives for 2012-17
Considering the overall company objectives, CBU has made a very ambitious growth plan despite of difficulties in capacity expansion due to logistics and environment issues. Major growth is projected through diversification towards non ceramic areas like Glass Insulators, Control Panel, Composite Long Rod & Hollow Insulators, and by widening application areas for Ceralin in Power plant, Mining, Cement & Steel Industries. These new areas contribute almost 50% of growth projection during XII Plan year.
The highlights of the plan are:
► Increase in turnover from current Rs.430 crores in 2011-12 to Rs.1000 crores in 2016-17 and Rs.1600 crores by 2021-22.
► 18.4 % cumulative annual growth rate by 2016-17. ► Growth rate highly dependent on development and commercialisation of new products Like
Filtration System, Composite Insulators & Control Panel at EPD and investment for Glass Insulator manufacturing Plant & capacity augmentation for Higher rating DC & AC Disc Insulators at IP, Jagdishpur.
► Technology for Glass Insulators need to be explored for Collaboration/Joint Venture ► Consolidate engineering strength in new areas, i.e. Control Panel ► Develop engineering strength in new products / applications like filtration system, Composite
Insulators etc. ► Close coordination with Corp R &D and other sister units. ► Thrust on in-house development ► Widening the Ceralin New Application Area.
New Business Areas
► 765 KV & above Composite Long Rod insulators for transmission applications ► 765 KV & above Composite Hollow insulators for power equipment applications ► DC insulators up to 420 KN in IP ► Refractory engineering for CFBC boiler and coal gasification system. ► Manufacturing of Glass Disc Insulators ► Development & Commercialization of Water filtration System ► Expertise in Control Panel in house development ► Application of wear resistance materials in steel, cement & Chemical Corrosion, AHP & CHP
Applications.
Investment ► Investment for capacity expansion at IP, Jagdishpur for Glass Disc Insulators. ► Investment at both EPD and IP towards process automation and quality improvements. ► Investment at EPD for Composite Long Rod & Hollow Insulator Manufacture. ► Total investment envisaged Rs. 75 Crores at IP and 44 Crores at EPD
E X E C U T I V E S U M M A R Y
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
3 | P a g e
HISTORY OF CERAMIC BUSINESS UNIT:
In the year 2000, a new strategic unit called Ceramic Business Unit was formed to meet the growing
needs of Ceramic Business. EPD Bangalore, CTI Bangalore and IP Jagdishpur were the constituent
parts of this CBU.
From a small coal fired Pin and strain Insulators in 1932, to the heaviest, gas fired 420 KN HVDC Insulators, 400 KV Hollow and Station Post Insulators ,Ceralin for Power Plant ,cement and other industries, Industrial ceramics ,Composite Insulators, Membranes for water filtration and control Panels the long journey continues.
BRIEF HISTORY OF EPD-BANGALORE (ELECTRO PORCELAIN DIVISION):
• THE PAST TRACK – MAJOR MILESTONES
► 1932--Government Porcelain Factory was set up, manufacturing low tension Insulators,
crockery & art ware under leadership of Sir Mirza Ismail. Kiln was fired and LT Insulators
were produced.
► 1937-HT testing plant was set up
► 1940-GPF procured Electrical Tunnel Kiln from Brown Boveri, Switzerland
► 1954-Collaboration agreement was signed with NGK Japan
► 1954-His Highness Sri Jayachamaraja Wodeyar Bahadur laid the foundation stone for
factory block.
► 1957-Pandit Jawaher Lal Nehru inaugurated first large scale high voltage insulator factory
in India.
► 1964-Second collaboration with NGK was made.
► 1966-Sri Morarji Desai inaugurated the expansion of plant from 5000 tonnes to 7500
tonnes
► 1967-GPF was converted to Mysore Porcelains Limited (MPL).
► 1976-BHEL took MPL as subsidiary
► 1978-BHEL acquired all the shares of MPL
► 1980-MPL merged with BHEL as EPD
► 1985 – Ceralin (High Alumina Liners) was developed.
► 2000-CBU was formed.
► 2003 - 220 KV SF6 and Station Post Insulators were developed.
► 2004-05 -320 KN Disc Insulators and 320 KN Fog disc Insulators were developed
► 2005- 320 KN and 420 KN ac Disc Insulators were developed.
► 2008-320 KN and 420 KN Insulators for 800 KV HVDC Lines were developed.
► 2007-Composite insulator manufacturing facility was added
► 2009-Control Panel Business Group was established.
OVERVIEW
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
4 | P a g e
Some of the Golden Glimpses of EPD History
BRIEF HISTORY OF IP-JAGDISHPUR (INSULATOR PLANT):
THE PAST TRACK – MAJOR MILESTONES
► In 1982, Foundation stone was laid.
► In 1984, Plant was inaugurated by the then PM late Smt. Indira Gandhi
► 1984-85- TO was Rs.39.73 L
► 1992- Ceralin (High Alumina Liners) was introduced.
► 2000- Became an integral plant of strategic business unit namely CBU
► 2004-Another new product Hollow Insulators introduced
► 2007-08- Crossed Rs.100 Cr. mark Turnover
Some of the Golden Glimpses of IP History
Inauguration of new plant
facilities by Shri Morarji
Desai, then Dy. Prime
Minister on 21st Dec 1968
Visit of Honorable Prime
Minister Pandit Jawahar
Lal Nehru to
EPD, Bangalore
Inauguration of IP Jagdishpur Plant by Smt Indira Gandhi
Government Porcelain
Factory
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
5 | P a g e
EPD-Departments IP-Departments
• INSULATOR ENGINEERING
• INSULATOR PRODUCTION
• CERALIN ENGINEERING & PRODUCTION
• COMMERCIAL
• MATERIAL MANAGEMENT
• NEW PRODUCTS
• CONTROL PANEL BUSINESS GROUP
•HRM,HRD
• FINANCE
• QUALITY
• FACTORY WEX SERVICES
• INFORMATION TECHNOLOGY
• LAB & TECHNOLOGY
• ENGINEERING
• PRODUCTION
• COMMERCIAL
• MATERIAL MANAGEMENT
•HRM,HRD
• FINANCE
• QUALITY
• FACTORY WEX SERVICES
• INFORMATION TECHNOLOGY
• LAB & TECHNOLOGY
ORGANISATIONAL STRUCTURE
CBU HEAD (ED CBU)
CBU Marketing
& Planning
Unit Head-IP Unit Head-EPD CTI (Under Corp R& D)
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
6 | P a g e
PRODUCT PROFILE: CBU
Existing Products
New Products Diversification
Ash Slurry Pipe Composite
Insulators
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
7 | P a g e
ANALYSIS OF STRATEGIC PLAN & TURN-OVER: 2007-12
DIVISIONAL PLAN 2007-12
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
8 | P a g e
ACTUALS 2007-12
22
10 10
27
13
8
30
16
9
38
22
16
46
23
14
0
10
20
30
40
50
2007-08 2008-09 2009-10 2010-11 2011-12(B)
TO/EMPLOYEE VA/EMPLOYEE PBT/TO
20
98
22
11
2
25
13
2
29
15
5
34
17
9
0
5
10
15
20
25
30
35
2007-08 2008-09 2009-10 2010-11 2011-12(B)
TO/EMPLOYEE VA/EMPLOYEE PBT/TO
Values in Lacs
Values in Lacs
EPD
IP
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
9 | P a g e
POWER TRANSMISSION & DISTRIBUTION SECTOR
12TH PLAN DEMAND AND CAPACITY ADDITION REQUIREMENT
Electricity sector in India is growing at rapid pace. The projected Peak Demand in 2012 is about 150 GW
and in 2017 is more than 200 GW. The corresponding Installed capacity requirement in 2012 is about 220
GW and in 2017 is more than 300 GW. The projected Peak Demand and the Installed Capacity
Requirement is shown in Fig.1.1 and 1.2 respectively.
0
50
100
150
200
250
2007 2012 2017
100153
218
0
100
200
300
400
2007 2012 2017
125
220
306
0
50
100
150
10th
Plan
11th
Plan
12th
Plan
21
80104
Fig.1 Fig.2 Fig.3
Thus a capacity addition of about 1, 00,000 MW from conventional power projects is required during the
12th Plan to meet the All-India demand projections.
MACRO LEVEL PRESENT BUSINESS ENVIRONMENT
DEMAND SUMMARY-Fig GW INSTALLED CAPACITY REQ-GW CAPACITY ADDITION-Fig GW
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
10 | P a g e
TRANSMISSION SYSTEM DURING 12TH PLAN
Generation capacity addition of about 1, 00,000 MW is envisaged during 12th Plan consisting of
Thermal-76,500 MW, Hydro-20,000 MW and Nuclear- 3,400 MW. The Thermal Generating Stations /
UMPPs on imported coal would be near coastal areas (Mundra, Krishnapatnam, Tuticorin, Cuddalore,
Ennore) and Thermal stations with indigenous coal would be located near Coal pitheads in Orissa,
Chhattisgarh, Jharkhand, Madhya Pradesh, Maharashtra, West Bengal etc. Whereas Generating Stations
on lignite would be located in Tamil Nadu and Gujarat. The large Hydro Projects would be mainly in Sikkim
& NE Region (Arunachal Pradesh, Uttarakhand, H.P. and J&K apart from cross border imports from
Bhutan). Gas based Power Station would be located along the gas-grid.
In order to meet growing requirement, development of strong transmission system between pit-
head/resource generation complex and bulk consumption centres are required. However, development of
transmission system involves following issues:
Minimization of Right of Way
Protection of flora & fauna, wild life
Creation of long distance high capacity transmission corridors to enable
Minimum cost per MW transfer as well as Optimal Transmission losses
Minimal Impact on Environment
Strengthening of National Grid
In order to address above issues, high capacity transmission corridors comprising 765kV AC and ±800kV
6000MW HVDC system along with 400kV AC and ±500kV/600kV 2500MW/6000MW have been planned to
facilitate transfer of power from remotely located generation complexes to bulk load centers. Apart from
this, the development of next higher AC voltage 1200kV has been undertaken by POWERGRID through a
collaborative research between POWERGRID and Indian manufacturers. In this direction, POWERGRID
along with Indian manufacturers is establishing a 1200kV UHVAC Test Station at Bina (in the State of M.P)
where a 1200kV test line (S/C+D/C) is being constructed and likely to be commissioned by 2012.
The anticipated requirement of Transmission Lines / Equipments / Sub-Station Bays corresponding to
1, 00, 000 MW capacity additions would be as given below:
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
11 | P a g e
Transmission Lines - CKM: (Source- CEA Report)
Voltage Level End of
10th Plan
End of 11th
Plan
Additions in
12th Plan
±800kV HVDC 3600 4000
±600kV HVDC 1000
±500kV HVDC 5872 7478
765kV 2184 7612 25000
400kV
Quad Conductor
Twin Conductor
75722
125000
20000
30000
220kV 114629 293852 40000
1200kV Transmission Lines are also expected during 12th plan after successful trial run at Bina Test
Station and the addition may be around 5000 circuit KM. The addition of lower rating Transmission Line,
132kV, will be same as that in 11th plan, around 20000 circuit KM. Due to the increased pollution level,
usage of Composite Insulators in Transmission Line is expected to increase.
For Transmission Line of voltage class 220kV and below the expected share of Compsoite
Insulators will be 50%.
For 400kV and 765kV the expected share will increase from 15 to 25% during the plan period.
Usage of Composite Insulators in HVDC line will be only where the Transmission Line is entering
the city areas and is expected to be 5%.
For 1200kV line may take some more time as the system itself is under trialDemand supply gap in
lower segment is expected to be filled by Composite Insulators
Substation Equipments: (Source- CEA Report )
Equipments Quantity
765kV 500MVA 1ph Units 210
765kV 333MVA 1ph Units 70
765kV Reactors 80 MVAR 1ph Units 480
765kV Current Transformer (Sets) 1400
765kV CVT's (Sets) 500
400kV 500MVA 3ph Transformer 70
400kV 315MVA 3ph Transformer 150
400kV Reactors 80/63/50 3ph Units 440
400kV Current Transformer (Sets) 4000
400kV CVT's (Sets) 1100
220kV 160MVA 3ph Transformer 600
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
12 | P a g e
220kV Current Transformer (Sets) 2400
220kV CVT's (Sets) 3100
765kV Isolators (Sets) 1300
400kV Isolators (Sets) 3400
220kV Isolators (Sets) 9600
132kV Isolators (Sets) 21840
765kV Circuit Breakers (Sets) 475
400kV Circuit Breakers (Sets) 1300
220kV Circuit Breakers (Sets) 2400
132kV Circuit Breakers (Sets) 5000
Switchyard Equipments: (Source- CEA Report)
Equipments Quantity
Thermal Hydro
765kV Current Transformer 108 124
765kV CVT/PT 72 71
400kV Current Transformer 132 1548
400kV CVT/PT 88 890
220kV Current Transformer 24 3060
220kV CVT/PT 36 3060
132kV Current Transformer 120 7280
132kV CVT/PT 180 7280
765kV Isolators 216 248
400kV Isolators 264 3096
220kV Isolators 72 12240
132kV Isolators 360 21840
765kV Circuit Breaker 81 93
400kV Circuit Breaker 99 1161
220kV Circuit Breaker 24 3060
132kV Circuit Breaker 120 7280
No of Bays: (Source- CEA Report)
kV Class Quantity
765kV Bay 280
400kV Bay 660
220kV Bay 2400
132kV Bay 7280
Usage of Composite Insulators in higher voltage class equipments is in growth phase, especially
765kV and above.
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
13 | P a g e
POWER GENERATION SECTOR
SCENARIO
XIIth Plan(2012-17) Power Demand
Country Thermal Power Generation Requirement during 12th plan: Current Installed Capacity for Country is
1,85,496 MW, out of which Coal based plant, is 102863 (55.5 %) MW. Total Power Generation Capacity
addition is 1,04, 000 MW for Conventional Power projects as per XII (2012 -17) Plan.
MW Capacity Addition during XII Plan
The Country power demand by the twelfth plan is expected to be 218 GW whereas in Eleventh plan it was
153 GW , thus a rise of 65000 MW .Hence to meet the power requirement the total planned capacity
addition is 1,00,000 MW.
Power Plant Type Total MW Capacity AdditionCoal Based 74100
Lignite 2500
Nuclear & Gas 3400
Hydro 20000
Total 100000
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
14 | P a g e
EXPANSION & IMPROVEMENT IN EXISTING PRODUCT OFFERINGS
PRODUCT DIVERSIFICATION-CBU
Products/Services Anticipated Business Potential (Rs Cr) during Plan period
/market share (%)
Key strategies to improve/ retain market share
Ceralin New Application-(EPD & IP)
234
Exploring new Business area for Ceralin Application
Control Panel (EPD)
406 Getting expertise in Control Panel In House Production
Composite Long Rod & Hollow Insulators
80 Long rod for 765 KV & Hollow Insulators
New Products- Related
Diversifications
Anticipated Business Potential (Rs Cr) during Plan period
Key strategies to be followed (TCA/M&A/Joint
Working/In-house development)
Filtration System-EPD
58
In House Development
Glass Insulators-IP
280 TCA
Grinding Media-EPD
32 In House Development & Commercialization
Porcelain Insulators for HVDC -IP
140 In House Development
STRATEGIC INITIATIVES
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
15 | P a g e
CYCLE TIME REDUCTION-CBU
QUALITY IMPROVEMENTS/ACCREDITATION-CBU
Products Cycle Time
Strategies
Action Plan
Including timeframe
Existing Market (Target)
requirement
Hollow insulators
130
Hours
95 Hours
( Bench Marking)
Technical
Assistance &
Research
Trial with different firing cycle
By April 2012.
Product/Services/ Processes
Key Concern of Customers
Strategies
Action Plan Including timeframe
Disc Insulators
Flash over and puncture in line
RCA & To strengthen audit in process
Audit methodology evolved. Sep’12
Hollow insulators
Crack and oil leakage
To improve body characteristic
Trials for diff body composition. Dec’12
Composite insulators
Puncture and breakage of fiber glass rod
RCA - To strengthen routine inspection and acceptance of incoming
materials
To identify fool proof methods and
establish facilities. Oct12
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
16 | P a g e
BUILDING COST COMPETITIVENESS-CBU
Product/Services
facing pricing
pressure
Anticipated Business
Potential (Rs Cr/p.a)
during Plan period
Strategies
Action Plan
Including timeframe
Disc Insulators
990
Rework on
Costing i.e.
Reducing C & A
Overheads
Reduce cost of Rework & Rejection
( progressively 5 % per year) by
IMPRESS Project
-Increase in fired recovery from 92 % to
96 % ( progressively 2 % per annum)
- Rationalization of Product Mix (High
Value Product) 530/420 /320 /210 KN -
2013 Onwards
Hollow insulators
286
Reduce Cycle
time.
Increase
Production,
Reducing C & A
Overheads
-Increase the Specific Loading capacity
using O R study.- From April 2012
-Change over to Alumina body from
existing Quartz - From April 2012
Composite
insulators
80
Develop Product
for 765 KV, Cost
reduction
-Invest Proposal put up.
-Procurement of metal fittings in finished
conditions.- April 2012
Ceralin 200 Development of
Low Cost
Ceralin Tiles
-
Grinding Media 51 Development of
Grinding Media
in line to market
price
Successful field Evaluation awaited
(Dhanu & Vijayawada)
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
17 | P a g e
STRENGTH
� Full Range products in AC & DC Disc Ins
� ± 800 kV HVDC & 1200 kV UHVAC
� Service Experience in AC & DC insulators
� Expertise in Ceralin Manufacture
� In house tech for porous tube for filtration
� Low cost fuel RLNG at IP
WEAKNESS
� High Labour Content
� High Cost of the product
� Longer Cycle Time
� Material Cost
OPPORTUNITIES
o Increased demand for Insulators
o Glass Insulators for transmission Market
o Composite Insulators for transmission
Market & Substation Equipments
o New Application area for Ceralin
THREATS
� Severe Competition from Chinese
manufacturer
� Severe Competition from Indigenous
manufacturer
CBU SWOT ANALYSIS
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
18 | P a g e
PRODUCT WISE TURNOVER PROJECTIONS-CBU
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
19 | P a g e
PRODUCT WISE TURNOVER PROJECTIONS EPD
New Product is 65 % for EPD.
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
20 | P a g e
PRODUCT WISE TURNOVER PROJECTIONS IP
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
21 | P a g e
Product Porcelain Disc Insulator Manufacturing Unit BHEL – CBU / EPD- Bangalore & IP - Jagdishpur
Projected Physical Growth Photograph of the Product Projected Financial Growth
0
5000
10000
15000
20000
2500017639 19133
2082122509
24198 24760
Value in MT
0
100
200
300
157 170 185 200 215 220
Value In Crores
Profile 45kN to 420kN EMS Disc Insulator for Transmission Line from 11kV to
800kV (AC & DC)
Collaboration Existing product covers all ranges
Competition Domestic Competitors: Pvt Companies like ABIL, WSI, MIL, IEC& Saravana
International Competitors: Chinese Insulator Manufacturing Companies
like Zigong Sediver, Nanjing, Dallian, NGK, Zhejiang, Sichuan Yibin, Shuzho
etc.(Glass Insulator manufactures equivalent to porcelain disc in
application)
Market Segments All Electric Utilities like POWERGRID, IPTC, EPC & SEB s
Export Potential Market potential available in Saudi Arabia, USA, Canada etc.
Projections 2012-13 2013-14 2014-15 2015-16 2016-17
Physical
Country
(Circuit
Kms &
Nos of
Ins)
1200kV (cKM) 0 750 1250 1500 1500
1200kV ( Lacs No) 0 10.78 17.96 21.56 21.55
765kV (cKM) 3400 3517 4000 4180 4531
765kV ( Lacs No ) 34.62 35.81 40.73 42.56 46.14
400kV (cKM) 6800 7034 8000 8360 9062
400kV ( Lacs No ) 32.79 33.92 38.58 40.31 43.70
220kV (cKM) 4160 4250 4800 4840 5000
220kV ( Lacs No ) 10.60 10.84 12.24 12.34 12.75
132kV (cKM) 2080 2125 2400 2420 2500
132kV ( Lacs No ) 3.74 3.83 4.32 4.36 4.50
±800kV (cKM) 950 1662.5 712.5 712.5 712.5
±800kV (Lacs No ) 4.24 7.93 3.18 3.18 3.18
Total MT 76459 101871 112477 120968 127426
Financial Country Rs Cr 611 840 912 984 1031
BHEL Rs Cr 170 185 200 215 220
BHEL Share (%) 28 22 22 22 21
PRODUCT PLAN FORMATS
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
22 | P a g e
Note: The demand for transmission insulators are for Porcelain Disc / Glass Disc / Porcelain Longrod /
Composite long rod. Presently major tenders are Porcelain Disc / Glass Disc / Porcelain Longrod.
TECHNOLOGY STATUS
Our Capability All varieties of Porcelain Disc Insulators ranging from 45kN to 420kN for 11kV to
1200kV AC Application and 210kN to 420kN for ±500kV to ±800kV Application
Market Trend Towards higher voltage class ±800kV HVDC and 765kV & 1200kV HVAC
Gaps Unit IP-Jagdishpur to gear-up for higher end Insulators viz. 320kN & 420kN for
both HVAC & HVDC Application
Action Plan to Bridge the Gap Development for higher end Insulators viz. 320kN & 420kN for both HVAC &
HVDC Application under taken at IP-Jagdishpur.
Time Frame 2012-13
Investment Plan No major investment, except some minor investment on balancing facilities and
improving process capabilities at both the plants for 320kN & 420kN Disc
Insulator Manufacturing.
Time Frame 2012-13
STRATEGIC INITIATIVES To concentrate on higher end Insulators like 210kN, 320/420kN HVAC & HVDC
Insulators.
Approaching government for safe-guard duty & anti-dumping duty against
Chinese.
To set-up Glass Insulator Manufacturing Facility at IP-Jagdishpur.
Cost Competitiveness Cost is high when compared to the market.
SKILL GAPS HVDC technology to be transferred to IP
Action Plan All processes of EPD will be transferred and tuned to the local need
Man Power Requirement Existing man power
SWOT ANALYSIS-Porcelain Disc Insulators
Strengths Weakness
� Full range of products in AC & DC Disc Insulator
� Experience in AC & DC Insulators
� ± 800 kV HVDC & 1200 kV UHVAC
� High labour content
� High cost of the product
� High Material cost
� Capacity constraint
Opportunities Threats
ο Increased demand for Insulators � Severe competition from Chinese
Manufacturers
� Severe competition from Indigenous
manufacturer
� Competition from Composite Long Rod
Insulator Manufacturers
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
23 | P a g e
Product Disc Glass Insulator Manufacturing Unit BHEL – CBU / IP - Jagdishpur
Projected Physical Growth Photograph of the Product Projected Financial Growth
0
5000
10000
12-13 13-14 14-15 15-16 16-17
0
8888 8963 8903 8483Value in MT
0
100
12-13 13-14 14-15 15-16 16-17
0
50 60 70100Value In Crores
Profile All ranges of Disc Insulator for Transmission Line from 11kV to 800kV (AC
& DC)
Collaboration Required
Competition Domestic Competitors: Private Companies like ABIL, WSI, MIL, IEC &
Saravana – Porcelain Insulator equivalent to glass in application
International Competitors: Chinese Insulator Manufacturing Companies
like Zigong Sediver, Nanjing, Dallian, NGK, Zhejiang , Sichuan Yibin, Shuzho
etc.
Market Segments All Electric Utilities like POWERGRID, IPTC, EPC & SEB s
Export Potential Market potential available in Saudi Arabia, USA, Canada etc.
Projections 2012-13 2013-14 2014-15 2015-16 2016-17
Physical
Country
(Circuit
Kms &
Nos of
Ins)
1200kV (cKM) 0 750 1250 1500 1500
1200kV (Lacs No) 0 10.78 17.96 21.56 21.56
765kV (cKM) 3400 3517 4000 4180 4531
765kV (Lacs No) 34.62 35.81 40.73 42.56 46.14
400kV (cKM) 6800 7034 8000 8360 9062
400kV (Lacs No) 32.79 33.92 38.58 40.31 43.70
±800kV (cKM) 950 1662.5 712.5 712.5 712.5
±800kV (Lacs No ) 42.37 79.28 31.78 31.78 31.78
Total MT 67797 93022 102482 110890 117014
Financial Country Rs Cr 548 775 839 911 956
BHEL Rs Cr 0 50 60 70 100
BHEL Share (%) 0 6 7 8 10
Note: The demand for transmission insulators are for Porcelain Disc / Glass Disc / Porcelain Longrod /
Composite long rod. Presently major tenders are Porcelain Disc / Glass Disc / Porcelain Longrod.
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
24 | P a g e
TECHNOLOGY STATUS
Our Capability New Product
Market Trend Towards higher voltage class ±800kV HVDC and 765kV & 1200kV HVAC
Gaps Manufacturing Facility and Product Experience.
Action Plan to Bridge the Gap Facility to be set-up through technical collaboration with Qualified
Manufacturer.
Time Frame 2 Years
Investment Plan 107 Cr.
Time Frame 2 Years
STRATEGIC INITIATIVES To concentrate on higher end Insulators like 210kN, 320/420kN HVAC & HVDC
Insulators.
Approaching government for safe-guard duty & anti-dumping duty against
Chinese.
Cost Competitiveness Competitive
SKILL GAPS New technology
Action Plan Technology to be acquired through collaboration
Man Power Requirement 60
SWOT ANALYSIS-Glass Disc Insulators
Strengths Weakness
� Experience in AC & DC Insulators
� New Technology
Opportunities Threats
ο Increased demand for Insulators � Severe competition from Chinese
Manufacturers
� Competition from Composite Long Rod
Insulator Manufacturers
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
25 | P a g e
Product Hollow & Station Post Insulators Manufacturing Unit BHEL – CBU / EPD- Bangalore & IP - Jagdishpur
Projected Physical Growth Photograph of the Product Projected Financial Growth
0
5000 2631 20332930 3528
4246 4604Value in MT
0
50
100
44 3449 59
71 77Value In Crores
Profile Hollow: Up to 800kV for Power Transformers, Instrument Transformers,
Electrostatic Precipitator, and Circuit Breakers.
Station Post Insulators: Upto 400kV
Collaboration Existing product
Competition Domestic Competitors: Private Companies like ABIL, WSI, MIL, IEC &
Saravana.
Market Segments Hollow Insulators: Power Equipment Manufacturers
Station Post Insulators : TBG, SEB & EPC
Export Potential US & Canada being explored
Projections 2012-13 2013-14 2014-15 2015-16 2016-17
Financial Country Rs Cr 376 413 465 500 540
BHEL Rs Cr 34 48.5 59 70.5 77
BHEL Share (%) 9 12 13 14 14
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
26 | P a g e
TECHNOLOGY STATUS
Our Capability Hollow Insulator: Up to 800kV Insulators
Station Post Insulator: Up to 400kV Insulators
Market Trend Hollow Insulators: GIS is in increasing trend and hence equipment manufacturer
preferring Composite Hollow Insulators.
Equipment manufacturers are switching over to live tank type. Sleek design
Insulators in demand.
Station Post Insulator: Higher kV Class Insulators.
Gaps Hollow Insulators: Alumina Body Insulators (Sleek Design) for Live Tank
Equipments
Station Post: 765kV Insulators
Action Plan to Bridge the Gap Initiative taken for development of Alumina Body Insulators
Time Frame Dec 2013
Investment Plan No investment envisaged
Time Frame No investment envisaged
STRATEGIC INITIATIVES Cycle Time reduction to 90Hrs.
Cost Competitiveness High Cost
SKILL GAPS Multi skilling to employees
Action Plan By various training activities
Man Power Requirement Existing man power
SWOT ANALYSIS-Hollow & Station Post Insulators
Strengths Weakness
� Larger Dia Insulators � High labor content
� High cost of the product
� High Cost of Raw Materials (Esp. Alumina)
� Longer Manufacturing Cycle
� Alumina Body Insulators (Sleek Design)
� Limited Capacity
Opportunities Threats
ο Increasing Demand � Severe competition from Indigenous
manufacturer
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
27 | P a g e
Product Composite Long Rod & Hollow Insulators Manufacturing Unit BHEL – CBU / EPD- Bangalore
Projected Physical Growth Photograph of the Product Projected Financial Growth
0
200
400
600
800
30 100200
350
550
750Value in MT
0
5
10
15
20
25
3
10 1015
2025Value In Crores
Profile 45kN to 160kN EMS Composite Insulator for Transmission Line from 11kV
to 400kV AC and 25kV Traction Insulators
Collaboration Existing product upto 400 kV
Competition Domestic Competitors: Private Companies like Goldstone, Deccan, ABIL,
Saravana etc.
International Competitors: Chinese Companies.
Market Segments All Electric Utilities like POWERGRID, IPTC, EPC & SEB s
Export Potential
Projections 2012-13 2013-14 2014-15 2015-16 2016-17
Physical
Country
(Circuit
Kms &
Nos of
Ins)
1200kV (cKM) 0 0 0 0 0
1200kV (Nos) 0 0 0 0 0
765kV (cKM) 600 733 1000 1320 1719
765kV (Nos) 16920 20671 28200 37224 48475
400kV (cKM) 1200 1466 2000 2640 3438
400kV (Nos) 25200 30780 42000 55440 72195
220kV (cKM) 2240 2550 3200 3960 5000
220kV (Nos) 38080 43350 54400 67320 85000
132kV (cKM) 1120 1275 1600 1980 2500
132kV (Nos) 20160 22950 28800 35640 45000
±800kV (cKM) 50 87.5 37.5 37.5 37.5
±800kV (Nos) 350 763 263 263 263
25kV (RKM) 600 640 680 720 760
25kV (Nos) 12050 12720 13390 14060 14730
Financial Country In CR 79 92 117 146 184
BHEL In Cr 10 20 35 55 75
BHEL Share (%) 13 22 30 38 41
Note: The total CKM for transmission is same. The most polluted lines will necessitate Composite Long
Rod Insulators
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
28 | P a g e
TECHNOLOGY STATUS
Our Capability Technology upto 400kV Composite Insulators for AC application
Market Trend Composite Insulators usage opening up a big way in transmission and
distribution segment.
220kV & below major share is for Composite.
Usage of Composite Insulators in 400kV & 765kV expected to increase.
In ±800kV, Composite Insulators will be used only in place the pollution level is
very high.
Gaps 765kV AC Insulators to be developed
±600kV & ±800kV Insulators to be developed
Hollow Insulators to be developed
Action Plan to Bridge the Gap Development & Facility augmentation taken up for 765kV AC Insulators.
Development & Facility augmentation for Hollow Insulators also taken up.
Time Frame Expected to be completed by Mar’13
Investment Plan 10 Cr
Time Frame Dec’12
STRATEGIC INITIATIVES Develop the product under the support of experts
Cost Competitiveness Cost is high.
SKILL GAPS Hollow Insulator manufacturing – New Technology
Action Plan Better procurement method
Man Power Requirement Existing man power
SWOT ANALYSIS-Composite Long Rod & Hollow Insulators
Strengths Weakness
� Experience for more than a decade
� Cost is high
� Limited capacity
� 765kV & Hollow Composite
Opportunities Threats
ο Increased demand
� Severe competition from Chinese
Manufacturers
� Severe competition from Indigenous
manufacturer
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
29 | P a g e
Product Ceralin - TOTAL Manufacturing Unit BHEL – CBU / EPD- Bangalore & IP - Jagdishpur
Projected Physical Growth Photograph of the Product Projected Financial Growth
Profile Ceramic Lined Items for Main Projects, Mandatory Spares, Hyderabad Mill
Items, O&M Spares.
Collaboration Existing technology
Competition Corborundum , Balaji , Hoffman , Demech
Market Segments Main Equipment Power Plant, Hyd Mills, O & M Spares
Export Potential To explore for different application on wear
Projections 2012-13 2013-14 2014-15 2015-16 2016-17 2021-22
Physical
Country MT 11712 12385 13409 13752 13664 12200
BHEL MT 8384 8128 8236 8836 8567 9300
Financial Country Rs Cr 171 182 197 201 200 178
BHEL Rs Cr 130 130 130 130 130 133
BHEL Share % 76 71 66 65 65 73
Assumptions / Remarks:
1) Refer Product Plan : Main Equipment, Mills Components, O & M Spares
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
30 | P a g e
TECHNOLOGY STATUS
Our Capability
Refer Product Plan : Main Equipment, Mills Components, O & M Spares
Market Trend
Gaps
Action Plan to Bridge the Gap
Time Frame
Investment Plan
Time Frame
STRATEGIC INITIATIVES
Cost Competitiveness
SKILL GAPS
Action Plan
Man Power Requirement
SWOT ANALYSIS:
Refer Product Plan: Main Equipment, Mills Components, O & M Spares
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
31 | P a g e
Product Ceralin – MAIN EQUIPMENT Manufacturing Unit BHEL – CBU / EPD- Bangalore & IP - Jagdishpur
Projected Physical Growth Photograph of the Product Projected Financial Growth
Profile Ceramic Lined Items like Bends, pipe, Orifices , Inner Cone etc
Collaboration Existing Product
Competition Corborundum , Balaji , Hoffman , Demech
Market Segments Main Equipment : Coal Fired Thermal Power Plant
Export Potential Applicable for high ash content coal
Projections 2012-13 2013-14 2014-15 2015-16 2016-17 2021-22
Physical
Country MW 22460 24360 25980 26900 26300 22000
MT 8890 9440 10320 10625 10375 8700
BHEL MW 13000 12960 13680 13860 15180 17000
MT 5690 5955 5980 5870 5400 6050
Financial Country Rs Cr 133 142 155 159 156 131
BHEL Rs Cr 93 94 95 93 86 90
BHEL Share % 70 66 61 59 55 69
Assumptions / Remarks:
1) Source of Input Date : CEA Report / Power Sector Marketing
2) Decline in MT for Ceralin is due to domination to Super Critical Boiler during 2012 – 17 plan year.
3) Need to explore market for Ceralin from Non BHEL Boilers segment.
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
32 | P a g e
TECHNOLOGY STATUS
Our Capability Catering complete requirement of Coal P F Pipe in Coal Fired Thermal Plant
Market Trend Stagnant Growth in coal based plants , To extend in other applications
Gaps Existing technology
Action Plan to Bridge the Gap Both the units are having technology
Time Frame Both the units are having technology
Investment Plan Existing capacity can meet the plan requirement
Time Frame Existing capacity can meet the plan requirement
STRATEGIC INITIATIVES Supplies to NON BHEL equipments
Cost Competitiveness Need to Relooked in view of New entrants of Power Equipment Supplier
SKILL GAPS Increase volume by new applications
Action Plan Areas for new applications identified
Man Power Requirement Existing man power
SWOT ANALYSIS
Strengths Weakness
� Providing Total Wear Solution in Coal Fired
Thermal Power Plant.
� Wide acceptability by Customer.
� Limited to catering the requirement of
BHEL Boilers.
� Limited Exposure in Other Industries
like Steel, Mining, Cement etc.
� Limited range of product profile like
coverage of complete fuel piping
Opportunities Threats
ο Can be Explore Non BHEL Orders
ο To Explore New Application Areas in
Power Plant, Other Industries like Steel,
Mining, Cement etc
� Monopolistic status at stake
� Entry of Carborandum in main equipment
segment by crashing the price level.
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
33 | P a g e
Product Ceralin – MILLS ITEMS Manufacturing Unit BHEL – CBU / EPD- Bangalore & IP - Jagdishpur
Projected Physical Growth Photograph of the Product Projected Financial Growth
10
12
12-13 13-14 14-15 15-16 16-17
11 11 11 11
12Value In Crores
Profile Ceramic Lined Items like MDV, MPO, Classifier etc
Collaboration Existing Product
Competition Corborundum , Balaji , Hoffman , Demech
Market Segments Main Equipment through BHEL - Hyd (Mills)
Export Potential Applicable to high ash content coal wear applications
Projections 2012-13 2013-14 2014-15 2015-16 2016-17 2021-22
Physical
Country Plants (Nos) 35 39 42 39 38 40
Mills (Nos) 280 312 336 312 304 320
BHEL Unit (Nos) 19 22 22 22 23 25
Mills (Nos) 160 176 176 176 184 200
Financial Country Rs Cr 13 14.0 15.1 14.3 14.2 15.0
BHEL Rs Cr 11 11.1 11.3 11.4 12 10.5
BHEL Share % 85 79 75 80 85 80
Assumptions:
1) Nos of Mills considered per plant: 8
2) Nos of MDV / MPO set per Mill: 04
3) Need to explore market for Mill Components from Non BHEL Boilers segment
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
34 | P a g e
TECHNOLOGY STATUS
Our Capability Catering complete range of Mill Components for BHEL make Bowl Mills and
Tube Mills
Market Trend Both the units are having technology
Gaps Both the units are having technology
Action Plan to Bridge the Gap Existing capacity can meet the plan requirement
Time Frame Existing capacity can meet the plan requirement
Investment Plan Will be based on the quantum of new applications
Time Frame Will be based on the quantum of new applications
STRATEGIC INITIATIVES Increase volume by new applications
Cost Competitiveness By productivity method reduce cost
SKILL GAPS Technology is available
Action Plan Existing technology
Man Power Requirement Existing man power
SWOT ANALYSIS
Strengths Weakness
� Coverage of almost all the components
having wear in BHEL make Mills
� Wide acceptability by Customer.
� Capability to develop componets having
wear from existing casting to Ceramic
Lined Components.
� Limited to catering the requirement of
BHEL Boilers.
� Limited Exposure in Other make of mills
Opportunities Threats
ο Can be Explore to supply Mill Components
for Non BHEL Mills
� Monopolistic status at stake
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
35 | P a g e
Product Ceralin – O & M SPARES Manufacturing Unit BHEL – CBU / EPD- Bangalore & IP - Jagdishpur
Projected Physical Growth Photograph of the Product Projected Financial Growth
Profile Ceramic Items like Bends, pipe, Elbows, Orifices, Mill Components, Tiles ,
Cones , Hoppers etc
Collaboration Existing product
Competition Highly Competitive. Major Competitors: Carborandum, BMW , Hoffman
Industries, De-Mech , Balaji Industries , Jeeco etc
Market Segments O & M Spares in Thermal Power Plants, Cement Industries, Mining, Steel,
Coal Washeries etc
Export Potential Applicable to high ash content coal wear applications
Projections 2012-13 2013-14 2014-15 2015-16 2016-17 2021-22
Physical Country MT 3583 3763 3951 4148 4356 4573
BHEL MT 2100 2167 2250 2333 2500 2667
Financial Country Rs Cr 43 45 47 50 52 55
BHEL Rs Cr 26 26 27 28 30 32
BHEL Share % 60 58 57 56 57 58
Assumptions:
1) Major share for O & M Spares for Coal Fired Thermal Plants
2) To explore market in other areas like Cement Industries, Mining, Steel, Coal Washeries etc
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
36 | P a g e
TECHNOLOGY STATUS
Our Capability Catering complete range of O & M spares like Coal PF Piping System, Mill
Components for Bowl Mills and Tube Mills for Thermal Power Plants including
Non BHEL Boilers.
Market Trend On growth path
Gaps Technology is existing
Action Plan to Bridge the Gap Technology is existing
Time Frame Technology is existing
Investment Plan Depends on the growth of new applications
Time Frame Based on the growth of new applications
STRATEGIC INITIATIVES Supplies to all makes of equipments / Boilers
Cost Competitiveness Highly cost competitive due to players from Small Scale Industries segment
SKILL GAPS Technology is available
Action Plan Existing technology
Man Power Requirement Existing man power
SWOT ANALYSIS
Strengths Weakness
� Coverage of almost all the components
having wear in BHEL make Boilers as well
as Non BHEL Boilers
� Wide acceptability by Customer.
� Capability to develop componets having
wear from existing casting to Ceramic
Lined Components.
� Having major market share above
� Limited Exposure to plants supplied by
chinese.
� Limited exposure to industries like Steel,
Cement, Coal Washeries, Mining etc
� Delay in supply
� Allow Response to customer’s critical
requirements in time
Opportunities Threats
ο Market for O & M spares is on growth path
specifically chinese supplied plants
ο Big market for Ceramic Application in
industries like Steel, Cement, Coal
Washeries, Mining etc
� From Small Scale Industries due to cost
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
37 | P a g e
Product Ceralin – NEW APPLICATION Manufacturing Unit BHEL – CBU / EPD- Bangalore & IP - Jagdishpur
Projected Physical Growth Photograph of the Product Projected Financial Growth
0
20
40
60
12-13 13-14 14-15 15-16 16-17
30
42
55 54 54
Value In Crores
Profile Ceramic Lined Coal Nozzle Body & Tips , Ash Slurry Pipe , Refractory etc
Collaboration Ceralin is existing product. New Application to be developed
Competition To be assess as it is New Development
Market Segments Main Equipment Power Plant, AHP, IGCC & CFBC based plants
Export Potential Applicable to high ash content coal wear applications
Coal Nozzle Body & Tips
Projections 2012-13 2013-14 2014-15 2015-16 2016-17 2021-22
Physical
Country Plants (Nos) 30 32 35 30 30 35
MT 864 921.6 1008 864 864 1008
BHEL Unit (Nos) 15 17 17 17 18 20
MT 0 489.6 489.6 547.2 518.4 576
Financial Country Rs Cr 14.4 15.4 16.8 14.4 14.4 16.8
BHEL Rs Cr 0 11.5 14.6 13.8 13.8 15.36
BHEL Share 0 47 54 60 60 57
Ash Slurry Pipe
Projections 2012-13 2013-14 2014-15 2015-16 2016-17 2021-22
Physical
Country Plants (Nos) 15 16 17.5 15 15 18
MT 15000 16000 17500 15000 15000 18000
BHEL Plants (Nos) 3 3 4 4 4 4
MT 3000 3000 4000 4000 4000 4000
Financial Country Rs Cr 150 160 175 150 150 180
BHEL Rs Cr 30 30 40 40 40 40
BHEL Share % 20 25 29 37 40 33
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
38 | P a g e
Assumptions:
1) Plant considered for Ash Sluryy Pipe and Coal Nozzle Body & Tips: 500 / 600/660/700/800 MW
2) Ash Sluryy Pipe Length : 10 KM / Plant and 50% plants considered for having lined Slurry Pipe
3) Nos of Coal Nozzle Body & Tips : 24 Nos per Boiler
4) Subject to successful trial of Ceramic Coal Nozzle Body & Tips
5) Coal Nozzle Body & Tips for FY 2012-13 considered Zero as Performance has to assessed.
6) Refractory Application considered as NIL as product to be established.
TECHNOLOGY STATUS
Our Capability Developed various products like Ceramic Lined Coal Nozzle Body & Tips, Ceramic
Lined Ash Slurry Pipe, Deflector Blades etc
Market Trend On High Growth Path
Gaps � Development of Impact Resistance Tiles
� Refractory application in CFBC Boilers
Action Plan to Bridge the Gap Technology is existing. Improvement / Modification is required
Time Frame Technology is existing
Investment Plan Based on the growth
Time Frame Depends on the growth of new applications
STRATEGIC INITIATIVES Based on the growth of new applications
Cost Competitiveness Improve productivity
SKILL GAPS Highly cost competitive due to players from Small Scale Industries segment
Action Plan Technology is available
Man Power Requirement Existing technology
SWOT ANALYSIS
Strengths Weakness
� Availability of market through BHEL –
Trichy and BHEL – ISG for Ceramic Lined
Coal Nozzle Body & Tips and for Ash Slurry
Pipe respectively.
� High potential and Growth Area
� Delay in trial amd performance report for
Developed Ceramic Lined Coal Nozzle
Body & Tips .
� Comparatively higher Cost for Ceramic
Lined Ash Slurry Pipe w r t Cast Basalt
Lined Pipe
Opportunities Threats
o Huge demand for Ceramic Lined Coal
Nozzle Body & Tips as O & M Spares as
well for Main Equipment
� Acceptability of Ceramic Lined Ash Slurry
Pipe over Cast Basalt Pipe by customers.
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
39 | P a g e
Product Industrial Ceramics Manufacturing Unit BHEL – CBU / EPD - Bangalore
Projected Financial Growth-EWLI Photograph of the Product Projected Financial Growth-
Flow Beans
Profile EWLI & Flow Beans
Collaboration Existing Product
Competition Only EPD. Item developed for BHEL VISION by Trichy
Market Segments Main Equipment through BHEL - Trichy
Export Potential In line Trichy boiler
EWLI
Projections 2012-13 2013-14 2014-15 2015-16 2016-17 2021-22
Physical
Country Plants (Nos) 7 9 10 6 3 4
EWLI (Nos) 280 360 400 240 120 160
BHEL Plants(Nos) 7 7 6 6 2 2
Mills (Nos) 280 280 240 240 80 80
Financial Country Rs Lacs 70 90 100 60 30 40
BHEL Rs Lacs 70 70 60 60 20 20
FLOW BEANS
Projections 2012-13 2013-14 2014-15 2015-16 2016-17 2021-22
Financial BHEL Rs Lacs 100 125 150 175 200 200
Assumptions:
1) Catering 100% requirement of BHEL – Trichy
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
40 | P a g e
TECHNOLOGY STATUS
Our Capability Developed to cater BHEL – Trichy requirement.
Market Trend EWLI : Declining as not envisaged for Supercritical Boilers
FLOW BEAN: On Growth Path
Gaps Technology is existing
Action Plan to Bridge the Gap Technology is existing
Time Frame Technology is existing
Investment Plan Existing capacity is adequate
Time Frame Existing capacity is adequate
STRATEGIC INITIATIVES Technology is existing
Cost Competitiveness Cost is competitive
SKILL GAPS Technology is available
Action Plan Existing technology
Man Power Requirement Existing man power
SWOT ANALYSIS
Strengths Weakness
� EWLI BHEL In house Developed Products
� Tungsten Based Flow Bean are outsourced
Opportunities Threats
- � EWLI demand is on declining trend
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
41 | P a g e
Product Control Panel Manufacturing Unit BHEL – CBU / EPD - Bangalore
Photograph of the Product Projected Financial Growth-
Main Equipment(LVSG & Bus duct)
Please refer Financial growth Chart at
RHS
0
100
200
300
12-13 13-14 14-15 15-16 16-17
75135
195230
283Value In Crores
Profile Control Panel
Collaboration In house development
Competition Competitive
Market Segments LVSG & Bus Duct for Main Equipment & Other panels for as Sister Unit
requirement
Export Potential For meeting in house requirement
Control Panel – Main Equipment (LVSG & Bus duct )
Projections 2012-13 2013-14 2014-15 2015-16 2016-17 2021-22
Financial Country Rs Cr 315 351 378 351 342 360
BHEL Rs Cr 81 99 143 199 233 275
BHEL Share 26 28 38 57 68 76
Control Panel - Others
Projections 2012-13 2013-14 2014-15 2015-16 2016-17 2021-22
Financial BHEL – Sister
units
Rs Cr 40 45 50 45 42 47
BHEL CBU Rs Cr 20 25 40 40 40 45
BHEL Share % 50 56 80 89 95 96
Assumptions:
1) For Electrical Items having Control Panel , BHEL Shares considered 50% of total Order share of
BHEL.
2) Rs 9 Cr / plant assumed LVSG & Bus Duct
3) For Sister Units requirement : Total demand of Sister unit and share of CBU considered.
4) The product profile needs to be enlarged from 2014 onwards
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
42 | P a g e
TECHNOLOGY STATUS
Our Capability On learning path. Technical Assistance required
Market Trend Stagnant
Gaps Engineering and Technical Gap
Action Plan to Bridge the Gap Year wise plan drawn
Time Frame To achieve on the full potential by 2017.
Investment Plan 272 Lacs
Time Frame By 2014 progressively
STRATEGIC INITIATIVES
Cost Competitiveness Highly Competitive. To compete with established players.
SKILL GAPS Existing product
Action Plan Existing product
Man Power Requirement Existing man power
SWOT ANALYSIS
Strengths Weakness
� Availabilbity of assitance from PEM and
Sister Units
� On learning path. Technical Assistance in
designing and Engineering capability
required
� Manufacturing facilities augmentation.
Opportunities Threats
o On establishment , Can be marketed as
BHEL product � From established players
� Outsourcing
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
43 | P a g e
Product Filtration Manufacturing Unit BHEL – CBU / EPD - Bangalore
Photograph of the Product Projected Financial Growth
Please refer Financial growth Chart at
RHS
Profile Ceramic Based Porous Tube and UF Filtration System
Collaboration Product already developed under trails
Competition GE , PWN and other major manufacturers
Market Segments Main Equipment Power Plant
Export Potential Upon successful implementation can be explored
5) 1) Under Field Evaluation in Thermal Power Plant.
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
44 | P a g e
Product HIGH ALUMINA GRINDING MEDIA Manufacturing Unit BHEL – CBU / EPD - Bangalore
Projected Physical Growth Photograph of the Product Projected Financial Growth
0
200
400
600
800
1000
1200
12-13 13-14 14-15 15-16 16-17
0140
520
1040 1040
Value in MT
0
5
10
15
12-13 13-14 14-15 15-16 16-17
0
2.4
6
12 12
Value In Crores
Profile High Alumina Balls as Ceramic Grinding Media
Collaboration In house developed product
Competition Jyoti Ceramics for Alumina grinding media & Other Steel ball
manufacturers
Market Segments In Ball tube Mills of Coal Fired TPS
Export Potential In line to Supplies to Hyderabad mills
Projections 2012-13 2013-14 2014-15 2015-16 2016-17 2021-22
Physical
Country Nos of Mills 87 91 99 105 105 105
MT 3654 3822 4158 4410 4410 4410
BHEL Nos of Mills 0 6 13 26 26 26
MT 0 140 520 1040 1040 1040
Financial Country Rs Cr 40 46 48 51 51 51
BHEL Rs Cr 0 2.4 6 12 12 12
BHEL Share % 0 5 13 24 24 24
Assumptions:
1) Market Demand restricted to Coal Fired TPS using Slow Speed Ball Tube Mill.
2) Wt of Charge with Ceramic Ball: 42 MT.
3) Subject to successful trial and satisfactory performance.
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
45 | P a g e
TECHNOLOGY STATUS
Our Capability Complete Technical Know how and support from BHEL – Hyderabad.
Manufacturing Facility augmentation to be initiated.
Market Trend Yet to be assessed vis a vis presently used Steel Grinding Roll
Gaps Establishment of composition, trial and performance
Action Plan to Bridge the Gap PIRs undertaken jointly by BHEL – Hyderabad, Corp R & D , CTI and BHEL – CBU
Time Frame One Year
Investment Plan Based on trials
Time Frame By 2014
STRATEGIC INITIATIVES
Cost Competitiveness Competitive w r t existing Steel Grinding Roll
SKILL GAPS Manufacturing technology to be stabilised
Action Plan To stabilise by 2014
Man Power Requirement Existing man power
SWOT ANALYSIS
Strengths Weakness
� Support of BHEL – Hyderabad and Corp R
& D in esablishing the Product.
� Interest shown by various customers for
trial
� Wt reduction / charge as 42 MT Ceramic
Grinding Ball is required in place 90 MT of
Steel Grinding Roll.
� Product to be established
� Lack of Manufacturing facilities.
� Performance yet to assess.
Opportunities Threats
o Anticipated good response from
market due to various merits of
Ceramic Grinding Ball like Auxiliary
Power Savings and Wt reduction.
o Contineous demand as top up
requirement shall 20% of total
charge / annum
� Market penetration may be difficult intially
over established existing product ie Steel
Grinding Roll.
� Pricing may play important role compare
to existing products.
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
46 | P a g e
Product SCR Manufacturing Unit BHEL – CBU / EPD - Bangalore
Projected Physical Growth Photograph of the Product Projected Financial Growth
Please refer Financial growth Chart at
RHS
0
100
200
300
12-17(Avg) 2022
0
210
Value In Crores
Profile Selective Catalytic Reductor
1) Not assessed as No demand as legislation is not in force.
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
47 | P a g e
As per Customer Satisfaction Study Done By the Nielsen Company
Confidential & ProprietaryCopyright © 2010 The Nielsen Company
Draft Report
Customer Satisfaction Study – BHEL-(EPD), Bangalore •Slide no:52•Slide no:52•Slide no:52
88 87 84
9489
80
2 15
0
10
20
30
40
50
60
70
80
90
100
Ceralin Hollow
Insulator
Disc
Insulator
EqComittment shareVulnerable share
eQTM Score – PRODUCT- EPD
Parameters CeralinHollow
Insulator
Disc
Insulator
Pre-award
Process87 85 87
Engineering
Process89 86 89
Manufacturing
Process89 86 91
Delivery Process 89 98 87
Product
Performance86 83 89
Warranty
Process86 88 94
Service after
Sales Process87 86 90
Image 91 88 79
Base N =10 N =04 N =06
Unit Customer Satisfaction Index- Scores
CBU 85
EPD 86
IP 84
CUSTOMER SATISFACTION SURVEY - OVER ALL
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
48 | P a g e
TURNOVER PROJECTIONS: EPD TURNOVER PROJECTIONS: IP
TURNOVER PROJECTIONS-CBU
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
49 | P a g e
BROAD PARAMETERS -EPD
BROAD PARAMETERS 2012-17
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
50 | P a g e
BROAD PARAMETERS – IP
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
51 | P a g e
TECHNOLOGY STATUS: GLASS INSULATORS
Technology
status
Technology
trend
Gaps
Strategy
Action Plan
Timeframe
Not Available
Glass
Insulator is
cheaper
Manufacturing
technology
Getting into JV or
TC with qualified
Manufacturer
Set up Glass
Insulator
Manufacturing Plant
at IP Jagdishpur
2012-13
TECHNOLOGY STATUS: COMPOSITE HOLLOW INSULATORS
Technology
status
Technology
trend
Gaps
Strategy
Action Plan
Timeframe
Not Available
Composite is
replacing
Porcelain
Technology
Develop In house
Technology /TCA
-Develop technology for
Production
-Set manufacturing facility
-Get Qualifying criteria-Test
Certificates
2013-14
TECHNOLOGY PLAN –CBU (NEW PRODUCTS)
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
52 | P a g e
TECHNOLOGY STATUS: COMPOSITE LONG ROD-765 KV
Technology
status
Technology
trend
Gaps
Strategy
Action Plan
Timeframe
Not Available
Preferred for
highly polluted
zones
Technology is
Available upto
400 kV
Develop In
house
Technology
/TCA
-Develop technology for
Production
-Set manufacturing facility
-Get Qualifying criteria-Test
Certificates
2013-14
TECHNOLOGY STATUS: GRINDING MEDIA
Technology
status
Technology
trend
Gaps
Strategy
Action Plan
Timeframe
Product is
under
development
Presently Ni
Hard balls are
used
Trials under
process
In house
development &
Testing of the
product
-In house testing
-Trials & Customer
Feedback
2012-13
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
53 | P a g e
Products/
Services
Augmentation/
Modernisation
Under
Implementation/
Under Approval/
Under
Formulation
Investment
(Rs Cr)
Period
Year
Target Business
area
Porcelain
Insulators
Modernisation
(Automation of
Plant process)
Under
Implementation
6.67
2011-12
Disc Insulators-
Transmission
Lines, Sub-stn
Glass
Insulator
Augmentation
Under Formulation
75.00
2012-13
Glass Disc
Insulators-Trx
Lines
Ceralin
Augmentation
Under Proposal
14.07
2013-14
Ceralin & New
application
Composite
Long Rod
Insulators
Augmentation
Under Proposal
3.37
2013-14
Composite Long
rod Insulators
Composite
Hollow
Insulator
Augmentation
Under
Implementation
6.82
2011-12
Composite Hollow
Insulator
Canteen
New
Under Proposal
13.23
2013-14
Common facility
EPD & ISG
Control
Panel
New Under Proposal 2.72 2012-13 Control Panel
Assembly
facilities
INVESTMENT PLAN-CBU
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
54 | P a g e
► Concentrated Solar Power
o Solar Power Tower
o Silicon Carbide material for collector
► Thermal insulation for ducting
► Engineering Ceramics
o High Alumina Ceramics for Vacuum Interrupter
o Insulation for Ultra Super Critical Temp applications (700ºC) Ceramic
Blanket in Valves & Actuators.
► Impact resistant wear tile for Hopper etc
CONTINGENCY PLAN FOR STRATEGIC PLAN 2012-17
CERAMICS FOR NEW APPLICATIONS
CERAMIC BUSINESS UNIT
ELECTROPORCELAINS DIVISION INSULATOR PLANT
55 | P a g e
1. CEA REPORT BASE PAPER FOR 2012-17
2. BHEL POWER SECTOR MARKETING PRESENTATION ON STRATEGIC PLAN
3. PLANNING MANAGER CONFERENCE PRESENTATION
4. PRESENTATION ON TRANSMISSION SYSTEM REQUIREMENT FOR THE 12TH
PLAN
5. TRANSMISSION AND DISTRIBUTION IN INDIA –A REPORT FROM POWER GRID
6. CEA PROJECTIONS ON REQUIREMENT AND MATERIAL FOR THE
DEVELOPMENT OF POWER SECTOR GENERATION AND TRANSMISSION
PROJECTS OF 11TH AND 12TH PLAN
7. INTERSTATE TRANSMISSION FOR XII TH PLAN –PLAN & IMPLEMENTATION –
POWER GRID PRESENTATION
8. PRESENTATION ON TRANSMISSION –PLANNING FUTURE SCENARIO BY
POWERGRID
9. CUSTOMER SATISFACTION STUDY-BY THE NIELSEN COMPANY
10. BHEL CBU MARKETING STRATEGIC PLAN 2007-12 DOCUMENT.
BIBLIOGRAPHY