TODAYS TOPIC

• MAIN STAGES IN POWER STATION ERECTION • READINESS OF SITE FOR ERECTION ( RAILWAY SIDING , STORAGE FACILITY , LABOUR COLONY,ERECTION TOOLS AND TACKLES) • METHODS / TECHNICS OF ERECTION

MAIN STAGES IN POWER STATION ERECTION
• • • • • • • • • PREPERATORY WORK CIVIL CONSTRUCTION STRUCTURAL ERECTION EQUIPMENT ERECTION ELECTRICAL ERECTION C&I ERECTION QUALITY CHECKS DURING ERECTION COMMISSIONING POST COMMISSIONING ACTIVITIES

PREPERATORY WORKS
• DE-VEGITATION OF SITE • AREA LEVELLING • AREA GRADING TO BRING IT TO PLANNED BLOCK LEVEL TO MAKE THE SITE READY FOR START OF CIVIL WORK • EXCESS EARTH DISPOSAL

CIVIL WORKS
• PILING WORK
– PILING DESIGN AS PER LOAD DATA FROM EPC CONTRACTOR – PILING – PILE TESTING – PILE CAP AND FOUNDATION FOR STRUCTURE ( FDN CASTING AFTER JOINT CHECKING WITH STRUCTURAL ERECTOR)

CIVIL WORKS- CONTD
• CASTING OF FLOORS AND EQUIPMENT FDN • SPECIAL FDNS LIKE T.G. DECK AND OTHER FDN WITH V.I.Serecn photos\Picture tg deck.jpg • HANDING OVER OF FOUNDATION • FINISHING WORKS AFTER ERECTION COMPLN

STRUCTURAL ERECTION
• TAKING OVER OF FOUNDATION
– CHECK FOR LOCATION – CHECK FOR LEVEL – CHECK FOR BOLT/POCKET LOCATION

• PREFABRICATION • SAND BLASTING AND PRIMER COAT

STRUCTURAL ERECTIONCONTD
• STRUCTURAL ERECTION
– BLUE MATCHING OF PACKER PLATES WITH FDNS – FIRST STAGE COLUMN ERECTION & ROUGH ALIGNMENT – FURTHER STAGES COLUMNS , FRAME BEAMS AND BRACINGS ERECTIONerecn photos\chp str.jpg – INTERMEDIATE AND FINAL ALIGNMENT – FLOOR BEAMS AND RELEASE OF FRONT FOR FLOOR CASTINGerecn photos\typical floor in str.jpg

EQUIPMENT ERECTION
• TAKING OVER OF FOUNDATION
– CHECK FOR LOCATION – CHECK FOR LEVEL – CHECK FOR BOLT/POCKET LOCATION

• DEVISING HOISTING STRATAGY AND SELECTION OF HOISTING T&P FOR PLACEMENT OF EQUIPMENT

EQUIPMENT ERECTION
• EQUIPMENT PLACEMENT AND ROUGH LEVELLING WITH BOLT GROUTINGerecn photos\Picture placemnt of id fan.jpg/erecn photos\tg box up.jpg • FINAL LEVELLING AND GROUTINGerecn photos\mill erection.jpg • ALIGNMENT OF ROTARY EQUIPMENTS • ERECTION OF PIPING AND DUCTINGerecn photos\flue gas ducting.jpg • PRESSURE /LEAKAGE TEST OF PIPING AND DUCTING

ELECTRICAL ERECTION
• TAKING OVER OF FRONT FROM STRUCTURAL ERECTOR / EQUIPMENT ERECTOR • ERECTION OF CABLE TRAY SUPPORT STRUCTUREerecn photos\cross country cable tray.jpg • CABLE TRAY ERECTION FOR POWER AND CONTROL CABLEpipe rack.jpg • CABLING AS PER CABLE SCHEDULE

ELECTRICAL ERECTION- CONTD
• ERECTION OF LT& HT SW GRS • ERECTION OF TRANSFORMERSerecn photos\transf erecn.jpg • CABLE TESTING AND TERMINATION • EQUIPMENT EARTHING • SWITCH YARD ERECTION

C&I ERECTION
• ERECTION OF FIELD INSTRUMENTS AND JBS • PLC / CONTROL PANEL ERECTION • CABLING BETWEEN INSTRUMENTS , I/O PANELS & PLC / CONTROL PANELS • CABLING BETWEEN MCC AND PLC/ CONTROL PANELS

QUALITY CHECKS DURING ERECTION
• THREE TYPES OF QUALITY CHECKS
– A CLASS CHECK : - JOINTLY BY ERECTION AND FQA DEPTT. THESE ARE CRITICAL CHECKS – B CLASS CHECKS: - BY ERECTION DEPTT – C CLASS CHECKS :- BY THE CONTRACTOR

COMMISSIONING PHASE
• RECHECKING OF ERECTION • PRECOMMISSIONING CHECKS • POWERING UP OF PANELS AND EQUIPMENTS • NO LOAD RUN OF MOTORS • COMMISSIONING OF FIELD INSTRUMENTS AND CONTROL SYSTEMS • CHECKING OF LOGICS AND INTERLOCKS • INITIAL RUN AND CHECK FOR HEALTHINESS OF THE SYSTEMS

POST COMMISSIONING ACTIVITIES
• LIQUIDATION OF MAJOR DEFECTS IN THE SYSTEM • SYSTEM TRIAL OPERATION – FOR ESTABLISHING SYSTEM RELIABILITY • PERFORMANCE AND GUARANTEE TEST- TO CHECK WHETHER THE PLANT ACHIEVES THE GUARANTEED PARAMETERS

READINESS OF SITE FOR ERECTION
• PRE-REQUISITES
– APPROACH AND DRAINAGE SYSTEM – CONTRACTORS LAYDOWN , STORAGE AND PRE FABRICATION AREA – LABOUR COLONY – RAILWAY SIDING:- Track connection from nearest rail head and unloading bay at site – ERECTION TOOLS AND TACKLES

ERECTION TOOLS AND PLANTS
• TYPICAL TOOLS AND PLANTS REQUIRED FOR TURNKEY CONTRACTS
– – – – – BATCHING PLANT FOR CONCRETING TRANSIT MIXERS AND CONCRETE PUMPS CRAWLER MOUNTED AND TYRE MOUNTED CRANES TRAILERS ELECTRICAL WINCHES AND CHAIN PULLEY BLOCKS WITH WIRE ROPES AND SLINGS – WELDING AND GAS CUTTING SETS – THEODOLITE, DIAL GUAGES AND OTHER INSTRUMNTS – SPECIAL T&P AS REQD

METHODS AND TECHNICS OF ERECTION
• ADHERENCE TO ERECTION SEQUENCE AS PER ERECTION MANUAL :- VERY IMPORTANT FOR BOILER ERECTION • ADHERENCE TO ACCEPTANCE CRITERIA FOR ERECTION TOLERANCES • SPECIAL TECHNICS :- STRAND JACK METHOD FOR BOILER DRUM LIFTING

MAJOR MILESTONES
• • • • • • • • • • • • • Starting from Zero date( award of main plant pkg) Boiler erection start11 months Drum Lifting 17 months Start of Cond erction – 21 months Start of TG erect 23 months Boiler hydro test 29 months TG box up 32 months BLU and AVO 35 months Compln of TG oil flushing35 months Steam blowing Compln – 37 months Synchronization 39 months Coal firing 39 months Trail operation 42 months

MAJOR MILESTONES IN ERECTION
• • • • • • Daily review/coordination meeting Weekly progress review Monthly progress review (PRT) CRM – Contract review meeting ECM- Engg Coordination meeting Review at various levels

ERECTION SCHEDULING
• TYPES OF PROJECT SCHEDULES
– MASTER NETWOR SCHEDULE OR L-1 NETWORK – PACKAGE SCHEDULE OR L-2 SCHEDULE – L-3 SCHEDULE – QUANTITATIVE SCHEDULE

MASTER NETWOR SCHEDULE OR L-1 NETWORK
• PERTAINS TO THE WHOLE PROJECT • COVERS ALL ACTIVITIES FROM ENABLING WORKS TO COMMERCIAL OPERATION OF THE UNITS • IT ALSO SPECIFIES THE SCHEDULE OF PREAWARD AND POST AWARD ACTIVITIES OF ALL MAJOR PACKAGES • SAMPLENCTPP-II(1X490 MW).pdf

PACKAGE SCHEDULE OR L-2 SCHEDULE
• SPECIFIC TO A PACKAGE • IT IS IN PERT NETWORK FORM AND SHOWS IN DETAIL ALL THE ACTIVITIES INCLUDING VARIOUS STAGES OF MANUF. & ERECTION • IT IS A JOINTLY SIGNED DOCUMENT BETWEEN NTPC & CONTRACTOR

PACKAGE SCHEDULE OR L-2 SCHEDULE CONTD• IT IS CONTRACTUALLY BINDING DOCUMENT BETWEEN NTPC AND THE CONTRACTOR • IT ALSO SHOWS THE INTERRELATION BETWEEN VARIOUS ACTIVITIES AND DATE OF RELESE OF FRONTS TO THE CONTRACTOR

SAMPLE L-2 SCHEDULE SUPPLY

SAMPLE L-2 SCHEDULE ERECTIONtgfinal.pdf

L-3 SCHEDULE
• THIS SCHEDULE IS ACTIVITY SPECIFIC • PREPARED AT PROJECT LEVEL • FOR CLOSE MONITORING OF CRITICAL ACTIVITIES. • SAMPLEL3_mech_1 CT.xls

QUANTITATIVE SCHEDULE
• MAINLY FOR THE ITEM RATE CONTRACTS • THIS SCHEDULE SHOWS QUANTITY FOR DIFFERENT ARES OF THE PACKAGE AND THEIR COMPLETION SCHEDULE. • QUANTITIES ARE SPREAD OUT IN THE COMPLETION SCHEDULE.

MEASUREMENT OF PROGRESS for TURNKEY CONTRACTS
• PROGRESS FOR SUPPLY
– PROGRESS OF SUPPLY MEASURED IN FINANCIAL TERMS i.e. VALUE OF EQUIPMENTS RECEIVED – VALUATION DONE WITH RESPECT TO THE BILLING BREAK-UP FOR REPORTING AS WELL AS FOR BILLING. – FOR S.G. PACKAGE GENERALLY MEASUREMENT IS DONE ON TONNAGE BASIS

SAMPLE SUPPLY BILLING BREAK UPbbu supply chp.pdf

PROGRESS MEASUREMENT FOR ERECTION
• DONE ON SYSTEM COMPLETION WISE FOR PHYSICAL MEASUREMENT • FOR BILLING PURPOSE MEASUREMENT AND VALUATION OF ERECTION WORK IS DONE AS PER THE BILLING BREAK UP • SAMPLE BBU • FOR ITEM RATE CONTRACTS QUANTITATIVE PROGRESS CAN BE GIVEN

RECORDING OF OUTPUT
• RECORDING FOR THE PURPOSE OF BILLING IS DONE AS PER BILLING BREAK UP FOR THE ERECTION OF EQUIPMENT COMPLETED • FOR ITEM RATE CONTRACTS , INSTEAD OF BBU THERE IS BOQ ( BILL OF QUANTITIES)

REPORTING
• PROGRESS REPORTING
– MONTHLY PROGRESS REPORT – WEEKLY PROGRESS REPORT – DAILY PROGRESS REPORT

MONTHLY PROGRESS REPORT
• REPORTING OF ACTUAL PROGRESS VISA VIS SCHEDULE FOR THE MONTH • REASONS OF SHORTFALL IS TO BE RECORDED • THE REPORT ALSO HIGHLIGHTS THE HOLD UPS WHERE SUPPORT FROM COTPORATE CENTRE/HIGHER MANAGEMENT IS REQUIRED • REPORT IS SENT TO THE CORPORATE MONITORING GROUP

WEEKLY PROGRESS REPORT
• MONTHLY TARGET BROKEN DOWN TO WEEKLY TARGET • SHOWS PROGRESS VIS A VIS TARGET • REVIEWD BY PROJECT HEAD • SITE CO-ORDINATION ISSUES RAISED IN THE REPORT • SAMPLE.

DAILY PROGRESS REPORT
• FOR VERY CRITICAL AREAS REQUIRING CLOSE ATTENTION • DAILY MAN POWER AND RESOURCE DEPLOYMENT IS ALSO BROUGHT OUT • ALSO BRINGS OUT THE REQUIREMENT OF ADDITIONAL MANPOWER/RESOURCES • SAMPLE.DPR pt plant.xls

REPORT FOR BUDGET UTILISATION
• REPORTING FOR ACTUAL BUDGET UTILISATION WITH RESPECT TO PROJECTED BUDGET • GOOD INDICATOR OF OVERALL PROGRESS OF THE PACKAGE. • SAMPLEbud uti.xls

THANK YOU
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