divisional plan 2012-17 - rev 01is.bhelepd.com/pdfs/dvp17.pdf · divisional plan -xii plan bharat...

Strategic Plan

2012-17

DIVISIONAL PLAN -XII PLAN

BHARAT HEAVY ELECTRICALS LIMITED

CERAMIC BUSINESS UNIT


ELECTROPORCELAINS DIVISION INSULATOR PLANT

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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



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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



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• 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



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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



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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



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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)



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PRODUCT PROFILE: CBU

Existing Products

New Products Diversification

Ash Slurry Pipe Composite

Insulators



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ANALYSIS OF STRATEGIC PLAN & TURN-OVER: 2007-12

DIVISIONAL PLAN 2007-12



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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



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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



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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:



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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 Reactors 80/63/50 3ph Units 440






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765kV Isolators (Sets) 1300




765kV Circuit Breakers (Sets) 475




Switchyard Equipments: (Source- CEA Report)

Equipments Quantity

Thermal Hydro

765kV Current Transformer 108 124

765kV CVT/PT 72 71


400kV CVT/PT 88 890


220kV CVT/PT 36 3060


132kV CVT/PT 180 7280

765kV Isolators 216 248




765kV Circuit Breaker 81 93




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.



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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



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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



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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



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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)



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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



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PRODUCT WISE TURNOVER PROJECTIONS-CBU



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PRODUCT WISE TURNOVER PROJECTIONS EPD

New Product is 65 % for EPD.



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PRODUCT WISE TURNOVER PROJECTIONS IP



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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



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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



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Product Disc Glass Insulator Manufacturing Unit BHEL – CBU / IP - Jagdishpur


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.


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


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.



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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


ο Increased demand for Insulators � Severe competition from Chinese

Manufacturers

� Competition from Composite Long Rod

Insulator Manufacturers



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Product Hollow & Station Post Insulators Manufacturing Unit BHEL – CBU / EPD- Bangalore & IP - Jagdishpur


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


BHEL Rs Cr 34 48.5 59 70.5 77

BHEL Share (%) 9 12 13 14 14



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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


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


ο Increasing Demand � Severe competition from Indigenous

manufacturer



27 | P a g e

Product Composite Long Rod & Hollow Insulators Manufacturing Unit BHEL – CBU / EPD- Bangalore


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.


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



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


SWOT ANALYSIS-Composite Long Rod & Hollow Insulators

Strengths Weakness

� Experience for more than a decade

� Cost is high

� Limited capacity

� 765kV & Hollow Composite


ο Increased demand

� Severe competition from Chinese

Manufacturers

� Severe competition from Indigenous

manufacturer



29 | P a g e

Product Ceralin - TOTAL Manufacturing Unit BHEL – CBU / EPD- Bangalore & IP - Jagdishpur


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



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


Cost Competitiveness

SKILL GAPS

Action Plan

Man Power Requirement

SWOT ANALYSIS:

Refer Product Plan: Main Equipment, Mills Components, O & M Spares



31 | P a g e

Product Ceralin – MAIN EQUIPMENT Manufacturing Unit BHEL – CBU / EPD- Bangalore & IP - Jagdishpur


Profile Ceramic Lined Items like Bends, pipe, Orifices , Inner Cone etc

Collaboration Existing Product


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


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.



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


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


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.



33 | P a g e

Product Ceralin – MILLS ITEMS Manufacturing Unit BHEL – CBU / EPD- Bangalore & IP - Jagdishpur


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



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



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


SWOT ANALYSIS

Strengths Weakness

� Coverage of almost all the components

having wear in BHEL make Mills


� 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


ο Can be Explore to supply Mill Components

for Non BHEL Mills

� Monopolistic status at stake



35 | P a g e

Product Ceralin – O & M SPARES Manufacturing Unit BHEL – CBU / EPD- Bangalore & IP - Jagdishpur


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


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


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



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




SWOT ANALYSIS

Strengths Weakness

� Coverage of almost all the components

having wear in BHEL make Boilers as well

as Non BHEL Boilers


� 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


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



37 | P a g e

Product Ceralin – NEW APPLICATION Manufacturing Unit BHEL – CBU / EPD- Bangalore & IP - Jagdishpur


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


Coal Nozzle Body & Tips

Projections 2012-13 2013-14 2014-15 2015-16 2016-17 2021-22

Physical


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


BHEL Rs Cr 30 30 40 40 40 40

BHEL Share % 20 25 29 37 40 33



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


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


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.



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


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


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



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


Investment Plan Existing capacity is adequate

Time Frame Existing capacity is adequate

STRATEGIC INITIATIVES Technology is existing

Cost Competitiveness Cost is competitive




SWOT ANALYSIS

Strengths Weakness

� EWLI BHEL In house Developed Products

� Tungsten Based Flow Bean are outsourced


- � EWLI demand is on declining trend



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


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



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


Cost Competitiveness Highly Competitive. To compete with established players.

SKILL GAPS Existing product

Action Plan Existing product


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.


o On establishment , Can be marketed as

BHEL product � From established players

� Outsourcing



43 | P a g e

Product Filtration Manufacturing Unit BHEL – CBU / EPD - Bangalore

Photograph of the Product Projected Financial Growth


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.



44 | P a g e

Product HIGH ALUMINA GRINDING MEDIA Manufacturing Unit BHEL – CBU / EPD - Bangalore


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


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.



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


Cost Competitiveness Competitive w r t existing Steel Grinding Roll

SKILL GAPS Manufacturing technology to be stabilised

Action Plan To stabilise by 2014


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.


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.



46 | P a g e

Product SCR Manufacturing Unit BHEL – CBU / EPD - Bangalore



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.



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



48 | P a g e

TURNOVER PROJECTIONS: EPD TURNOVER PROJECTIONS: IP

TURNOVER PROJECTIONS-CBU



49 | P a g e

BROAD PARAMETERS -EPD

BROAD PARAMETERS 2012-17



50 | P a g e

BROAD PARAMETERS – IP



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)



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



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



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



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

divisional plan 2012-17 - rev 01is.bhelepd.com/pdfs/dvp17.pdf · divisional plan -xii plan bharat...

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