Thermax Babcock & Wilcox (TBW), the 60:40 joint venture
between Pune-based Thermax Ltd and Babcock Wilcox, is
doing the unthinkable.
For the first
time in India, a boiler from Ballarpur Industries Ltd
(BILT) has been dismantled, transported and re-erected
with a total change of fuel-and-firing system and relocated
seven hundred kilometres - from Andhra Pradesh to Orissa.
The deal worth Rs 5 crore has opened up new vistas not
only for TBW but the entire manufacturing industry,
which is hoping to save millions of rupees on refurbished
probably for the first time in the Indian corporate
history, a rival company is refurbishing BILT''s giant
boiler weighing 800 tonnes of steel (38-metre high,
equivalent to a 12-storey building) and enhancing its
dimensions further. For TBW, apart from the handsome
earnings, it has been a big learning exercise as this
is the largest project of its kind.
Says TBW senior
manager (renovation and modernisation division) Sanjay
Jumde: "The trickiest thing was converting the
fuel input from black liquor spray to coal in fluidised
bed firing. It seemed like altering a trouser just in
its waistline, but in reality it was more complicated
that sewing a new one."
The boiler in
question was located at BILT''s AP Rayon unit in Kamlapuram,
Andhra Pradesh, delivering 31.3 TPH with 415 oC specification
and was supplied by a leading public sector competitor.
When the LM Thapar group company BILT thought of converting
this recovery boiler, they relied on rival TBW''s tried-and-tested
expertise to convert liquid and gas fired boilers to
solid fuel fired atmospheric fluidised bed boiler (AFBC).
of the recovery boiler basically involved the salvage
the boiler, which had become spare. At the same time,
BILT''s Sewa Paper Mill at Jeypore needed an FBC boiler
to fire coal and generate additional steam required.
The TBW team burnt midnight oil to not only execute
the effective changes in the boiler''s configuration
within 12 months, but also shipped it hundreds of miles
away across the adjacent state, from Andhra Pradesh
to BILT''s location at the Sewa unit in Jeypore, Orissa.
manufactures and installs a vast range of steam generation
systems for captive and co-generation power plants and
the process industry. The company''s quality system is
certified under ISO 9001. TBW also has its manufacturing
approved under the ASME (American Society of Mechanical
Engineers) for power boilers, unfired pressure vessels
and pressure piping. TBW acquired ISO 9001 certification
in 1994 with the latest revision in 1997 for the design,
manufacture, supply, erection and commissioning of boilers.