High Pressure Piping in Power Plants – Water / …

1 high Pressure Piping in Power Plants Water / Steam Cycles Capital p Markets Day y Power Services at Moorburg g Power Plant December 2, 2010. Ronald Diehl, Member of the Executive Board of BB Power Services GmbH. Agenda g 1. Overview division Piping Technology 2. high - Pressure Piping Systems 3. Service Range 4. Market Structure 5. Clients 6 Contract Types 6. 7. Competitive differentiators and success factors 8. References Bilfinger Berger Capital Markets Day December 2, 2010. Page 2. 1. Overview division Piping Technology Bilfinger Berger activities in the Power plant sector Fields of competence Service range Basic Engineering Steel Quality (Process Manufactu- construction, Commission- Project j Detail Construction,, assurance,, engineering engineering, ring ring, manlifts manlifts, ing Bringing ing, Procurement management engineering Erection welding E/I&C, Fabrication facades, into operation technology Arrangement hoists planning).

2 Planning teams DeNOx Components: C Piping Electrostatic Construction Steam generator, coaling, mill, ash HP system precipitator services firing system removal, IP system Desulfurization (Bilfinger Berger heat recovery LP system Induced draft fan Civil). Forced draft fan Bilfinger Berger Capital Markets Day December 2, 2010. Page 3. 1. Overview division Piping Technology Power Services Companies active in Piping Technology Bilfinger Berger SE. Bilfinger Berger Power Services GmbH. Energy and Steam Generators Mechanical Apparatus Steam Generators Environmental Piping Technology South Africa and Plant Engineering Engineering Babcock Borsig Service Bilfinger Berger Power BHR Hochdruck- MCE Maschinen- Babcock Noell GmbH. GmbH Holdings (Pty) Ltd. Rohrleitungsbau GmbH und Apparatebau GmbH. & Co. KG (Austria). Steinm ller Instand- setzung Kraftwerke Steinm ller Africa PKB Planungsb ro (Pty) Ltd.

3 Rohrleitungs- und MCE Industrietechnik Gesellschaft f r Energie- Anlagentechnik GmbH Aschersleben GmbH. und Umwelttechnik mbH. Steinm ller Engineering Deutsche Babcock Services (Pty) Ltd Ltd. BHR Piping p g Systems y Middle East FZE (Pty) Ltd. (South Africa). (UAE). KOG Group MCE Berlin GmbH. Duro Dakovic Montaza (Croatia). I t Intervalve l (Pty). (Pt ) Ltd Ltd. 50%. Rotring Engineering AG. Bilfinger Berger Capital Markets Day December 2, 2010. Page 4. 1. Overview division Piping Technology Development and volume forecast Orders received Output volume million million 600 600. 500 500. 400 400. 300 300. 200 200. 100 100. 0 0. Orders received and output volume include between 120m and 150m / year standard business ((service). ). Bilfinger Berger Capital Markets Day December 2, 2010. Page 5. 2. high - Pressure Piping Systems Power plant types Water /steam cycles in thermal Power Plants are the connections between the feed Water pumps, the boiler / heat exchanger and the turbine.

4 Coal-fired Power Plants Lignite-fired Power Plants Nuclear Power Plants Combined-cycle Power stations Biomass Power Plants Surrogate fuel Power Plants Bilfinger Berger Capital Markets Day December 2, 2010. Page 6. 2. high - Pressure Piping Systems BoA Power plant reference RWE Neurath lignite-fired g Power plant (optimised plant design, BoA), 1,100 MW. Total material approx. 3,100 t / unit Pipes approx. 2,200 t Form pieces approx 115 t approx. Fittings approx. 190 t Supports/hangers approx. 600 t Total pipe length approx. 11,000 m Main Piping approx. 4,400 m Total circumferential welds approx. 7,000. Total circumferential welds of main Piping approx 1,400. approx. 1 400. Bilfinger Berger Capital Markets Day December 2, 2010. Page 7. 2. high - Pressure Piping Systems BoA Power plant reference RWE Neurath lignite-fired g Power p p plant 172 m level (optimised plant design, BoA), 1,100 MW. Feed Water 430 bar, 250 C, 588 mm, 44.

5 Main steam 295 bar, 610 C, 549 mm, 97. Cold reheat 75 bar, 435 C, 824 mm, 31. Hot reheat 70 bar, 615 C, 806 mm, 43. Bilfinger Berger Capital Markets Day December 2, 2010. Page 8. 3. Service range high intermediate and low Pressure Piping high , Engineering Manufacturing Erection Service Fabrication of Piping Assembly of the Plant maintenance spools prefabricated pipe consulting service spools l anddhhangers Bending Plant maintenance Power plant new engineering Welding builds Piping p g co conceptual ceptua /. Plant Pl t optimization ti i ti basic design Heat treatment Replacement during Piping detail design Power plant outages Power plant retrofits Machining Pressure design Procurement Assessment A t off Destructive and non- residual service life System analysis destructive material Expediting Stress calcluation testing Specifications Pipe hanger Quality Assurance design Scheduling Project management Bilfinger Berger Capital Markets Day December 2, 2010.

6 Page 9. 4. Market Structure Position in Target Markets high Pressure Piping Systems high - Pressure Market leader in Europe Market leader in South Africa One of six leading contractors worldwide Piping Systems in Nuclear Power Plants Market leader in Europe Main Coolant Piping in Nuclear Power Plants (i t (internally ll cladded l dd d pipes). i ). One of three contractors worldwide Bilfinger Berger Capital Markets Day December 2, 2010. Page 10. 4. Market Structure Competitors Germany KAM (Kraftanlagen M nchen). BIP (Babcock Industry and Power ). Anlagenservice WWV (W rmeverwertung). ( e e e u g). Europe YIT (Industrial and Network Services), Finland Fives Nordon, France Fabricom (Suez Gaz de France), Belgium Boccard, France Bassi, Italy I t Integral, l Austria A ti World Shaw / Stone & Webster, USA. Bentec USA. Bentec, ATE (Atomtech Energy & Industrials), Taiwan BHEL (Bharat Heavy Electricals Ltd.)

7 , India Seongwha Industrial, Korea Fabricom / Endel (Suez Gaz de France), Belgium/France Bilfinger Berger Capital Markets Day December 2, 2010. Page 11. 5. Clients Top ten operators and turnkey suppliers / general contractors Bilfinger Berger Capital Markets Day December 2, 2010. Page 12. 6 Contract Types 6. BBPS Client Hourly rates Billing on basis of hours and Service contract material spent according to unit rate list BBPS Client Lump sum fixed price for exactly defined scope of supplies and services Lump sum g Water /steam cycles y Unit rate lists with defined quantities BBPS Client major contract OL3 Finland Unit price contract AREVA reactor building SIEMENS turbine hall BBPS Client Hours ou s spe spentt with t hour ou ccharge a ge rates ates all materials and third-party services (cost plus fee). Cost plus fee no major contracts . Bilfinger Berger Capital Markets Day December 2, 2010.

8 Page 13. 7. Competitive differentiators and success factors Development of efficiency and CO2- CO2 Emission in Coal-Fired Power Plants Higher Hi h process per kWh temperatures and Process temperature ency pressures . efficie am CO2 p increase net Efficiency and reduce CO2 emissions. require better materials gra with higher demands for development, p , manufacturing and fabrication. Bilfinger Berger Capital Markets Day December 2, 2010. Page 14. 7. Competitive differentiators and success factors Competitive differentiators More than 100 years of expertise and know-how from Mannesmann Anlagenbau (MAB), today BHR. Babcock Rohrbau, today BHR. Close cooperation with world market leader Vallourec & Mannesmann (V&M), formerly Mannesmann R hrenwerke Global leader in equipping q pp g p Power p Plants with seamless pipes for high - Pressure Piping systems Joint research p projects j with Vallourec &.

9 Mannesmann (V&M). Ongoing development and improvement of pipe materials (V&M) and their process technologies (BHR). Bilfinger Berger Capital Markets Day December 2, 2010. Page 15. 7. Competitive differentiators and success factors Core competence Process engineering and design calculation Pressure surge g calculation of the main steam Piping system Turbine safety shutdown in max. 150 milliseconds Velocity of steam flow up to approx. 210 km/h Bilfinger Berger Capital Markets Day December 2, 2010. Page 16. 7. Competitive differentiators and success factors Core competence Detail engineering and calculation Control of forces and loads Transfer of forces and loads into the building steel structure by means of Lisega Pipe Hangers Rigids Constant hangers Shock absorbers Spring hangers Bilfinger Berger Capital Markets Day December 2, 2010. Page 17. 7. Competitive differentiators and success factors Core competence The key technologies Inductive bending Submerged arc welding (SAW).

10 SAW socket welding SAW-narrow gap welding Weld cladding g Manual arc welding Inert-gas Inert gas tungsten-arc tungsten arc welding (TIG). TIG pulse orbital narrow gap welding Heat treatment Material testing non-destructive / destructive Bilfinger Berger Capital Markets Day December 2, 2010. Page 18. 7. Competitive differentiators and success factors Example: Key technology inductive bending Pipe p bends Production of bends with flow optimised radii = minimised Pressure loss Reduction of number of welds = increased benefit Bilfinger Berger Capital Markets Day December 2, 2010. Page 19. 7. Competitive differentiators and success factors Example: Key technology inductive bending Movie Inductive Bending Bilfinger Berger Capital Markets Day December 2, 2010. Page 20. 7. Competitive differentiators and success factors Successful in the market Coal- and lignite-fired big sized Power plant new builds in Germany Number of Power plant units (14).