BHARAT HEAVY ELECTRICALS LIMITED Power Sector Western Region NAGPUR ERECTION STRATEGY FOR BOILER NTPC RIHAND

ND STPP STAGE-2 BASIC STRATEGY : Basic strategy shall be to go in for cycle time reduction in every area by taking up erection of all possible fronts Parallelly , system completion at first go itself and by applying innovative ideas and modern erection practices. To achieve this we shall have highly experienced and effective execution team posted at site with back up of strong infrastructural support made available to them .They shall be always aiming for achieving the project milestones as planned by changing the intermediate course of direction depending on availability of inputs. The infrastructural support and basic erection sequences / strategy is explained below. SUBCONTRACTING STRATEGY: Subcontractors shall be finalized from the list of vendors duly approved by NTPC (as applicable as per agreement) for following packages, 1) 2) 3) 4) Main boiler and Rotating equipments ESP and Flue gas duct beyond boiler Power Cycle piping Lining and insulation

INSPECTION & QUALITY An exclusive Quality group at site ensures all installation checks and stage protocols with respect to approved quality plans for individual system , involving Consultant/ Customer representatives. List of Area wise applicable quality plan is enclosed. (Annexure-1) In addition to this, to ensure system completion, before execution of a defined Mile Stone activity during installation, an audit team from PS-WR HQ visits the site before Construction Manager is permitted to execute the Mile Stone activity.

SAFETY An exclusive officer shall be deployed at job site to guide, monitor and control all HSE related activities as per companys HSE instructions. He shall directly report to Construction Manager. Also our erection agencies shall nominate exclusive safety supervisor to assist us.

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BHARAT HEAVY ELECTRICALS LIMITED Power Sector Western Region NAGPUR ERECTION STRATEGY FOR BOILER NTPC RIHAND STPP STAGE-2

MATERIAL MANAGEMENT Unique identification system for components is utilized by all BHEL units. A strong team of officers and supervisors shall keep intensive track records of dispatches, receipt, storage and issues of components using modern electronic media. On receipt, components shall be inspected and verified before storage. Exclusive Material Receipt cum Inspection Reports shall be prepared along with Consultant/Customer representative. Components shall be stored in Open , Semi-closed, closed or Special environment conditions as applicable. They shall be preserved during storage and installation stages as per the instruction given in our preservation manual. A comprehensive tracking system, with appropriate records shall be maintained for all issues. DOCUMENTATION AT SITE A totally computerized documentation system shall be adopted at site to keep track of total drawings and manuals required to complete installation to ensure proper monitoring of receipt , issue and revisions . FACILITY ENGINEERING AT SITE An exclusive executive shall be deployed to supervise and monitor the availability of T&Ps being provided by BHEL TOOLS AND PLANTS Sufficient numbers of T&P s shall be deployed either by BHEL or by their erection agencies . Enclosed list of major T&Ps that shall be deployed to execute Boiler , ESP and piping package . ( Annexure-2) MANPOWER DEPLOYMENT : Sufficient number of BHEL staff shall be posted for installation of this package. Area wise deployment plan of BHEL staff is enclosed. (Annexure-3) Following shall be tentative per unit by erection agencies ; manpower ( main category) deployment plan

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BHARAT HEAVY ELECTRICALS LIMITED Power Sector Western Region NAGPUR ERECTION STRATEGY FOR BOILER NTPC RIHAND STPP STAGE-2 Boiler erection agency: Engineer- 7 , supervisors- 15 , Rigger foreman- 2 , Fitters27 , Structural welder 30 , HP welder 12 , Gas cutter - 4 , Grinder 10 , SR technician 4 , Radiographic Technician- 4 ESP erection agency: Engineer- 1 , supervisors- 4 , Rigger foreman- 1 , Fitters- 12 , Structural welder 15 , Gas cutter- 2 , Grinder-2 Piping erection agency: Engineer- 3 , supervisors- 6 ,Rigger foreman- 2 , Fitters12 , Structural welder 10 , HP welder 10 , Gas cutter - 2 , Grinder- 6 , SR technician 4 , Radiographic Technician- 4 ERECTION SEQUENCE: BOILER SUPPORTING STRUCTURE : Main supporting structure columns ( Nos. S1 to S6 L&R, S7 to S12 L&R , S13L&R , shall be erected in following combinations: Bottom tier - single piece 2nd & 3rd tier combined with Tata 75 MT and Link Belt LS 248H 4th & 5th tier combined 6th & 7th tier combined ---------------- with FMC LS 718 HLA 330 ft boom + Jib All connected horizontal beams , MBL members , vertical diagonal bracings as required to maintain verticality of the columns shall be erected before proceeding to next level. All MBL members between box of four columns shall be judiciously pre assembled on ground to ensure better workmanship and speedy erection. Erection of all balance items of such components shall proceed parallelly and shall be completed prior to ceiling girder lifting. It may be noted that all columns for Rihand shall be trial assembled in full length at Trichy hence pre assembly and joint matching at site shall not be required . Once the structure as mentioned above are erected and verticality of columns are ensured Ceiling girder erection shall start . Ceiling Girder Erection shall be done in following sequence: With 1st rigged position of FMC - Girder '0' , Girder-A , Girder-'B' With 2nd rigged position of FMC -Girder-'C' , Girder-'D' With 3rd rigged position of FMC - Girder-'E'

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BHARAT HEAVY ELECTRICALS LIMITED Power Sector Western Region NAGPUR ERECTION STRATEGY FOR BOILER NTPC RIHAND STPP STAGE-2 Ceiling girders will be supplied in three pieces and shall be pre assembled on ground before lifting. Enclosed Annexure-4 may be referred showing proposed assembly locations. It may be noted that casting of foundation pedestal of FD fan-B to be hold till ceiling girder C&D is shifted to boiler cavity after pre assembly. Also it may be noted that the bottom most vertical diagonal bracing between column S10 R&S11R will not be erected for this purpose. Designer clearance towards this is already obtained. For erection of structure as mentioned above the basic sequence of erection will be from front to rear i.e. from Row-D to L keeping the crane inside boiler cavity. Entry of cranes are envisaged from right side of boiler through rear of boiler i.e. from between boiler rear and mill bay col. i.e between Row-L&M. For movement of crane inside boiler cavity it will be necessary to hold erection of middle /air pre heater columns namely Columns Nos. S15L&R , S16L&R, S17, S18, S19L&R, S20L&R, S21, S24R, S25R, S29R,FH-11R,FH-12R, Mill bay M & N row columns . Also it should be ensured that the foundation pedestals of columns S15L&R , S16L&R, S17, S18, S19L&R, S20L&R, S21, Mill bay M row cols 2nos at center. do not project above ground. Enclosed annexure may be referred for better understanding. Annexure-5 Columns nos. S15L&R , S16L&R and its connecting bracings will be erected as soon as FMC moves out to clear the area after Ceiling girder A&B is erected , but necessarily have to be erected before Ceiling girder C erection. Columns nos. S17 , S18 and its connecting bracings will be erected as soon as FMC moves out to clear the area after Ceiling girder C & D is erected , but necessarily have to be erected before Ceiling girder E erection. Columns Nos S14L&R and its connecting bracings shall be erected immediately after boiler drum is erected. Erection of balance columns Nos. S19L&R , S20L&R , S21, S22L&R , S24L&R , S25L&R , S26L&R , S27L&R , S28L&R , S29L&R and its connecting bracings shall be erected independently after ceiling girder erection is completed and FMC crane is moved out. BOILER DRUM UNLOADING AND ERECTION: In case of unit-3 the boiler drum will be received by rail near to boiler LHS i.e. co-ordinate approx 2075N,2250E. Boiler drum will be unloaded with the help of two cranes namely LS248H 180MT and Manitowoc 250MT by the boiler erection agency. The drum then shall be dragged onto temporary rails to boiler cavity.

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BHARAT HEAVY ELECTRICALS LIMITED Power Sector Western Region NAGPUR ERECTION STRATEGY FOR BOILER NTPC RIHAND STPP STAGE-2 In case of unit-4 the boiler drum will be unloaded at the same location and the drum shall be dragged on to temporary rails to unit-4 . the location of temporary rail is shown in enclosed annexure.(Annexure-6) Boiler drum will be lifted in single stage with help of two nos 15MT electric winches and pulleys suspended from temporary structure ( will be either fabricated at site or will be diverted from other site ) at top. Winches will be placed in front of ESP and will be anchored with the help of concrete counterweights of FMC crane placed in pit. After the drum is aligned the lifting arrangement will be removed and pressure part erection will follow. PRESSURE PART ERECTION AND HYDRAULIC TEST : Being top suspended type of boiler , general sequence of erection of pressure part will be from top to bottom and from outside to in side . Actual sequence of erection will be decided at site depending on the sequence of material receipt at site. However our aim shall be to go for maximum possible pre assembly of pressure part components on ground or optimization at works , so that to reduce numbers of lifts and to achieve better quality which will effectively reduce erection cycle time. Following pre assemblies / optimization at works , are envisaged : 1) 2) 3) 4) All headers above roof will be assembled in single piece All possible assemblies to handleable sizes in lines and links above roof All crown plates with end bars for coil suspension above roof Furnace radiant roof Front - in seven assemblies ( each block of suspension arrangement ) , Inlet header shall be lifted separately in single piece and joining with tubes shall be done in position. Rear in two assemblies ( each block with piece of out let header ) 5) Back pass furnace roof with all hanger tubes above it along with inlet header in single assy. 6) Back pass front wall hanger tubes with suspension end bars. 7) Back pass front wall upper with lower panels 8) Back pass side wall upper panels to inter panels 9) Back pass rear wall upper panels to inter panels 10) Back pass rear lower walls with two headers(complete assy) 11) Extended water wall upper panel with lower(individual) 12) Furnace rear wall upper panels with hanger tubes and arch tubes( individual panel) 13) Burner panels with lower inter panels ( individual panels) 14) Furnace side Lower inter walls with lower walls ( individual panels) 15) Furnace front and rear lower panels with floor panels( individual panels) 16) LTSH upper coils to lower coils. ( individual coils) 17) Economiser upper with intermediate coils( individual coils) 18) Sh. Divisional panels front assy to rear assy( individual panels) 19) Furnace bottom Z panels with floor panels and loose tubes
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BHARAT HEAVY ELECTRICALS LIMITED Power Sector Western Region NAGPUR ERECTION STRATEGY FOR BOILER NTPC RIHAND STPP STAGE-2 20) All buckstays with stirrups and keybuckstays 21) Superheater and Reaheater spray control stations However a judicious relook into above assemblies will be essential after detailed engineering of pressure part is completed. Material feeding for first pass will mostly be done from RHS of boiler between columns S8&9 on temporary rail. For back pass material shall be fed from rear side. Also modern erection practices like use of omega lugs , anti deformation frame for handling of Eco , Superheater and Rheater coils , special lifting tackle for coil lifting will be inducted for safe and quicker erection of pressure part. Hydraulic test of boiler will be done in three parts. Drainable part includes the circulation system and drainable portion of the superheater. During this the link connecting the non drainable portion of superheater shall be dummied. This will facilitate early clearance for insulation of water walls and back pass walls required for light up. Nondraianable part , which includes the non drainable portion of the superheater system also , will be done just prior to boiler light up so that preservation and rusting of superheater system can be avoided. Reheater hydraulic test shall be done along with reheat system piping before steam blowing operation. AIR AND FLUE GAS DUCTING ERECTION: Air and flue gas ducting erection shall be taken up parallelly with boiler pressure part so as to reduce the gap between boiler hydrotest and light up. Almost all duct (excepting duct like below back pass U-headers etc. ) shall be pre assembled on ground and shall be kerosene tested to reduce ,number of lifts and work in position which will in turn reduce erection cycle time. The assembled duct will mostly be fed with help of crane from sides of boilers. However the inter connecting hot secondary air duct will be assembled below boiler , for straight lift. AIR PREHEATER ERECTION : Airpreheater erection shall be taken up immediately after the structure is getting ready after ceiling girders lifting. Most of components will be lifted with crane ( Monitowoc-250MT and FMC 350 MT one on either side) depending on accessibility which will help in reducing erection cycle time. FANS ERECTION : This being independent parallel activity it will be taken up as early as possible depending on availability of foundations. There is fixed sequence of erection of fans as specified in erection manual , the same shall be followed strictly.
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BHARAT HEAVY ELECTRICALS LIMITED Power Sector Western Region NAGPUR ERECTION STRATEGY FOR BOILER NTPC RIHAND STPP STAGE-2

MILLS ERECTION : Shall be taken up after availability of foundations . There is fixed sequence of erection of mills as specified in erection manual , the same shall be followed strictly. Major components like mill base , air compartment , separator body , mill top / classifier assy, MDV assy will be placed with crane KH500 . NTPC to coordinate with mill bay structure erection agency regarding hold in structural bracings etc. for crane approach. ESP ERECTION : This is altogether an independent island . ESP erection shall be started as soon as column foundations and material is available . It has an almost fixed sequence of erection. . In ESP also we shall go for all possible pre assembly like casing walls , hopper walls etc. Collecting electrode will be inserted from top. POWER CYCLE PIPING ERECTION : This will be treated as a highly specialized work ,specially in case of P-91 ( High Crome alloy steel ) . The erection can start from any side terminal point , however normal sequence shall be from boiler end to turbine building as the boiler side terminal point will be ready earlier. Utmost care shall be taken by highly experienced engineers / supervisors w.r.t. welding , preheat / post heat treatment of welds , NDT , free floating of lines before connecting to equipments. SPECIAL ERECTION PRACTICES : Following special erection practices will be followed, 1. Permanent flooring of boiler cavity prior to BES : NTPC to provide permanent flooring in boiler cavity (leaving the area for foundations under hold) , around boilers and below ESP before start of erection . This will create a very convenient work atmosphere which will help us in maintaining good house keeping also it will avoid unnecessary rehandling of material / temporary installations to facilitate flooring at later stage. It may be noted that the flooring should have load bearing capacity of 2.5 Kg/Cm2 2. Usage of passenger cum goods erection elevator: BHEL shall provide one no. of passenger cum goods elevator in each boiler ( at location as shown in Annexure-7 enclosed ) which will be installed by our erection agency. This
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BHARAT HEAVY ELECTRICALS LIMITED Power Sector Western Region NAGPUR ERECTION STRATEGY FOR BOILER NTPC RIHAND STPP STAGE-2 will transport people and gas cylinders to higher location which will help in effective supervision and higher productivity. 3. Usage of waste disposal chute: BHEL shall provide and erection agency will install one no. waste disposal chute in each boiler running vertically with branch in each floor ( at location as shown in Annexure-7enclosed ) 4. Construction Power distribution system : BHEL shall ensure that erection agencies follows a standard construction power distribution system as explained below, a) Agency for Main Boiler package: They will lay individual construction power cable from main Sub Station to DBs for individual welding generators booth at 5 locations as follows . These DBs will be provided with ELCBs and the cables will be run underground before reaching boiler island and within the boiler island the cable will be run on cable trays (vertical run will be along column no. S12L&R ) o On ground floor between column box S11L-12L-6L-5L will have provision for 10 welding m/cs - 200 Amps from SS- 9 for U-3 from SS 10 for U-4 o On boiler floor at 18M elevation between column box S11R-12R-6R5R- will have provision for 10 welding m/cs 200 amps from SS 8 for U-3 from SS 13 for U-4 o On boiler floor at 31M elevation between column box S11R-12R-6R5R- will have provision for 10 welding m/cs 200 amps from SS-9 for U-3 from SS 10 for U-4 o On boiler floor at 62 M elevation between column box S9L-10L-4L3L- will have provision for 10 welding m/cs 200amps from SS-8 for U-3 from SS 13 for U-4 o In preassy yard for 10 m/cs 200 amps from SS-6 Tentative quantity of Cable 240sq.mm, three core, Al. cable 2000 M and cable tray 8 500M , DB(200amps) 5 per boiler will be required. All such DBs will cater the need of power supply for Post Weld Heat Treatment also. Above locations of DB and booth installation and routing of Power cable for above are indicative , exact location shall be decided at site in consultation with NTPC .

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BHARAT HEAVY ELECTRICALS LIMITED Power Sector Western Region NAGPUR ERECTION STRATEGY FOR BOILER NTPC RIHAND STPP STAGE-2 Other than welding booth they will provide a power distribution board every after two floors with at least ten points , with standard industrial socket arrangement for miscellaneous use of hand tools and hand lamps. These boards will be connected with nearest DB of welding booth b) Agency for ESP and ducting: They shall lay construction power cable from main Sub station to welding booth as follows DB for

At ground floor on LHS of ESP 10 welding m/cs 200 amps from SS-9 for U-3 from SS 10 for U-4 At ground floor on RHS of ESP 10 welding m/cs 200 amps from SS-8 for U-3 from SS 13 for U-4

DBs will be provided with ELCBs. the cables will be run underground before reaching ESP island and within the ESP island the cable will be run on cable trays. Tentative quantity of Cable 240sq.mm,three core ,Al. cable 600 M and cable tray 8 150M No. of DB (200 apms )-2 per ESP will be required. Above locations of DB and booth installation and routing of Power cable for above are indicative , exact location shall be decided at site in consultation with NTPC . Other than welding booth they shall provide a power distribution board at least ten points one casing manhole door platform and one in pent house of each pass,with standard industrial socket arrangement for miscellaneous use of hand tools and hand lamps. These boards will be connected with nearest DB of welding booth. c) Piping erection agency : They shall lay construction power cable from main Sub station(No. to DB for welding booth as follows At 4.5 M in B- C bay near column 48- 10 welding m/cs - 200 amps + 1 induction heating m/c 200 amps from SS-7 for both units. On boiler floor At 31 M near col. S7L will have provision for 10 welding m/cs 200 amps . Induction Heating m/c will later be shifted from 62M along with power cable to 31M from SS-7 in U-3 and from SS-11 in unit-4 On boiler floor at 62 M elevation between column box S9L-10L-4L3L- will have provision for 10 welding m/cs - 200 amps - from SS-11

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BHARAT HEAVY ELECTRICALS LIMITED Power Sector Western Region NAGPUR ERECTION STRATEGY FOR BOILER NTPC RIHAND STPP STAGE-2 in both units + 1 induction heating m/cs 200amps from SS-7 in both units.

The cables will be run underground before reaching boiler island and within the boiler island and in power house the cable will be run on cable trays . Vertical run in boiler will along cable-S7L It may be noted that Sub Station (SS) -7 shall be provided with back up DG set power supply to avert power failure to Induction Heating M/c. Tentative quantity of Cable 200sq.mm three core al. cable 2000 M and cable tray 8 500M , DB (200apms)- 5 per boiler will be required. Other than welding booth they shall provide a power distribution board at least ten points at least in five suitable locations , with standard industrial socket arrangement for miscellaneous use of hand tools and hand lamps. These boards will be connected with nearest DB of welding booth. Above locations of DB and booth installation and routing of Power cable for above are indicative , exact location shall be decided at site in consultation with NTPC . Location of substation and tentative routing of construction power cables is shown in Annexure-8 d. Winch locations : selected number of winch will be positioned as follows by our erection agencies, Boier Area: a. 2 nos of 5MT winches on ground floor near S5L and near S5R b. 1no of 3 MT winch on boiler floor at 50M near column S4R c. 2 nos of 2MT winches on boiler floor at 75 M near column S4R and S4L ESP area: No winch is envisaged for ESP erection Piping area: a) One 3MT winch on LHS near column no. S7L b) One 3MT winch on LHS near column no. S7R

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BHARAT HEAVY ELECTRICALS LIMITED Power Sector Western Region NAGPUR ERECTION STRATEGY FOR BOILER NTPC RIHAND STPP STAGE-2 Operation of all these winches shall be controlled by Walkie Talkies from remote. Locations of the winches are indicative. Actual location can be decided at site. e. Gas cutting sets : Our erection agencies shall use a set of one DA cylinder and three oxygen cylinders mounted on trolley to be operated on ground floor. Also for transportation of such gas cylinders they shall use hand trolley. f. Small Workshop : Our erection agencies shall install small workshop containing drill m/c and bench grinder g. Erection Techniques : Following erection fixtures will be used for pressure part erection . this will ensure safe and faster erection of pressure part coils / panels, i. Omega lugs : An attachment made of tubes and flat will be welded to pressure part tubes will be used to hang and align pressure part headers to panel , panels to panels , panels to headers , hanger tube to coils , coils to coils etc. A sketch is enclosed showing the arrangement. (Annexure-9) BHEL trichy shall supply the lugs along with a load table . PSWR shall arrange for bolts. Location at wich the lugs to be welded shall be decided by engineers at site and shall be welded accordingly prior to lifting of components. This will help in quick erection of pressure part components and will facilitate easy alignment. ii. Lifting Tool for pressure part Coils : This is a hinged type clamp which develops grip due to self weight of the component being lifted.. This will be fabricated at site by our erection agency. This will be used to lift pressure part vertical coils of superheaters and reheaters. A sketch is enclosed. (Annexure10) iii. Anti deformation frame for coils: The anti deformation frame will be fabricated ( considering actual size of coil ) at site and used for handling longer and heavy pressure part coils like Platen superheater , reheater front , superheater division panel , assembled LTSH / ECO coils , to avoid permanent distortion while lifting.. A sketch is enclosed . (Annexure-11) iv. Floating Pulley system for LTSH and economizer coil erection: An arrangement of a ropeway and a floating pulley will be used for erection of LTSH and Economiser coils . This will reduce erection cycle time to great extent otherwise we would have lost lot of time in changing lifting arrangement after every few coils. A sketch is enclosed.(Annexure-12) v. Erection method of Superheater hanger tubes: a very simple method of lifting sh. Hanger tube will be used which will facilitate faster erection . A sketch is enclosed. (Annexure-13)
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BHARAT HEAVY ELECTRICALS LIMITED Power Sector Western Region NAGPUR ERECTION STRATEGY FOR BOILER NTPC RIHAND STPP STAGE-2 h. Temporary Rail for material feeding: A temporary rail line will be laid between boiler column no. S8-S9 through and through both boilers ( pl. see enclosed Annexure-6 showing location and arrangement). Boiler pressure part materials like water wall panels and sh./rh. Coils will be transported on to this rail with help of dip trolley. The rail will be laid on sleepers at 1m spacing. For transportation / dragging of boiler drum over the same rail continuous sleepers will be laid for two lengths of drum and rolled on. Requirement of material for this purpose will be as follows, Rail - 350 RMS Sleeper 400 nos. ( 200 for normal material feeding + 200 will be used for drum dragging) Rail coupler / fish plate with fastner suitable for 350 RMS rail Rail fixing clips suitable for 350 RMS rail The portion of rail between two boilers will be made removable type ( in panel form ), so that the same can be temporarily removed to give access to other agencys T&P movement. i. Temporary Urinal System : A header of 4PVC pipe shall be run on column S7R with urinal pan connected to 10 floors minimum on boiler and with suitable underground pit arrangement. CRANE PARKING DURING BOILER

MATERIAL FEEDING AND ERECTION (major portion):

i) For main boiler supporting structure erection upto drum lifting : Crane movement / Parking : within boiler cavity . Crane : FMC LS 248H 180MT from 1st to 3rd month , FMC LS 718 with ringer and 330 boom and jib thereafter. Tentative Duration : from 1st to 5th month from BES of each unit. Material feeding : Unit-3From Storage yard / pre assembly area by road though Unit-4 ( either between mill bay-M row and boiler rear or between mill bay N row and ESP) Unit-4 From Storage yard / pre assembly area on road

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BHARAT HEAVY ELECTRICALS LIMITED Power Sector Western Region NAGPUR ERECTION STRATEGY FOR BOILER NTPC RIHAND STPP STAGE-2 ii) Pressure part erection : Crane : All erection will be done with help of winches . For unloading 0f material 75 MT crane will be located on RHS of each boiler. Tentative Duration : from 6th to 18th month from BES of each unit Material feeding : Unit-3From Storage yard / pre assembly area by road though Unit-4 ( either between mill bay-M row and boiler rear ) then on rail to boiler cavity in case of first pass and through boiler rear in case of second pass. After drum lifting of unit- 4 is over the materials can be fed on temporary rail through boiler-4 Unit-4 From Storage yard / pre assembly area on road then on rail to boiler cavity in case of first pass and through boiler rear in case of second pass. iii) For balance component like roof structure , silencer , duct , air preheaters, fans (FD and PA ) erection: Unit-3 LHS Crane: Manitowoc 250MT ( 6th to 10th month ) , LS 248H (10th to 18th month) Tentative Duration : from 6th to 18th month from BES of unit-3 Material feeding : From Storage yard / pre assembly area by road though Unit-4 ( between mill bay-M row and boiler rear or between mill bay N row and ESP) Unit-3 RHS Crane: FMC LS718 350MT ( 6th to 12th month ) , Manitowoc 250MT ( 12 th to 18th month ) Tentative Duration : from 6th to 18th month from BES of unit-3 Material feeding : From Storage yard / pre assembly area by road though Unit-4 ( between mill bay-M row and boiler rear or between mill bay N row and ESP) Unit-4 LHS
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BHARAT HEAVY ELECTRICALS LIMITED Power Sector Western Region NAGPUR ERECTION STRATEGY FOR BOILER NTPC RIHAND STPP STAGE-2 Crane: Manitowoc 250MT ( 6th to 18th month from BES of Unit-4 )

Material feeding : From Storage yard / pre assembly area on road though Unit-4 ( between mill bay-M row and boiler rear or between mill bay N row and ESP) Unit-4 RHS Crane: FMC LS 718 350 MT ( 6th to 18th month BES of Unit-4 )

Material feeding : From Storage yard / pre assembly area by road. iv) Mill erection : unit-3 Crane : KH-500 Tentative Duration: 14th to 20th month from BES of unit-3 Material feeding : From Storage yard / pre assembly area on road though Unit-4 ( between mill bayM row and boiler rear or between mill bay N row and ESP) Unit-4 Crane : KH-500 Tentative Duration: 14th to 20th month from BES of unit-4 Material feeding : From Storage yard / pre assembly area on road v) ESP erection: Crane movement / Parking: all around ESP island Crane: 75MT , KH500 Tentative Duration: 1st to 18th month from ESP erection start of each unit Material feeding : Unit-3 From Storage yard / pre assembly area on road though Unit-4 ( between mill bay N row and ESP & between ESP and ID fan)
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BHARAT HEAVY ELECTRICALS LIMITED Power Sector Western Region NAGPUR ERECTION STRATEGY FOR BOILER NTPC RIHAND STPP STAGE-2

Unit-4 From Storage yard / pre assembly area on road Enclosed Annexure-14 shows the routes through which material shall be fed. HOLDS ON CIVIL FOUNDATIONS / OTHER CONSTRUCTION : a) Civil Foundations : S15L&R , S16L&R, S17, S18, S19L&R, S20L&R, S21, Mill bay M row columns 2nos at center and FD fan B (RHS) in each boiler This is required for erection crane movement / parking inside boiler cavity and for ceiling girder pre assembly as explained in erection sequence. Hold lift Hold shall be lifted as soon as crane is moved out after ceiling girders erection i.e. 5th month from boiler erection start. Agency to act : NTPC b) Other Construction: i) Mill bay M & N row structure in each unit This will be required for FMC entry / exit and parking during boiler structure erection in each unit. Hold Lift : Hold shall be lifted as soon as crane is moved out after ceiling girders erection i.e. around 5th month from boiler erection start. Agency to act : NTPC ii) Inter Connecting Duct / platform between boiler and mill bay each unit : in

This is required for moving out erection crane parked on LHS of boiler for erection of roof structure / fans / APH Hold Lift: the hold is planned to be lifted in 12 th to 14 th month from BES. Agency to act: BHEL

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BHARAT HEAVY ELECTRICALS LIMITED Power Sector Western Region NAGPUR ERECTION STRATEGY FOR BOILER NTPC RIHAND STPP STAGE-2

iii) Duct support structure between mill bay and ESP in each unit: This will be required to facilitate crane movement for Mill heavier components and ESP erection . Hold lift: the hold is planned to be lifted progressively from 18 th month from BES Agency to act: BHEL iv) Duct support structure between ESP and ID fan: this is required to facilitate crane movement for ESP erection and ID fan heavier component erection . Hold Lift: Hold is planned to be lifted progressively from 14 th month from Boiler erection start. Agency to act: BHEL v) Mill bay N row bracings : This will be required to facilitate crane approach for erecting mill heavier components. The particular bracing items need to be hold will be decided at site in consultation with NTPC. Hold Lift : hold is planned to be lifted progressively from 14th month of BES Agency to act : NTPC ADDITIONAL INPUTS (Not Envisaged Originally ) TO BE TIED UP : By NTPC : a) Hold on foundations / structure as mentioned above b) Finished flooring in / around boiler island and below ESP c) Finished flooring / consolidated area for laying temporary rail By BHEL : a) Temporary rail / sleepers etc. b) Bolt for omega lugs c) Temporary structure for drum lifting d) DESH Link temporary Dummy plates for non drainable HT
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BHARAT HEAVY ELECTRICALS LIMITED Power Sector Western Region NAGPUR ERECTION STRATEGY FOR BOILER NTPC RIHAND STPP STAGE-2 e) DG set 500KVA for Induction Heating m/c

By erection agencies: a) b) c) d) e) f) g) h) Construction Power Distribution board Construction power cables Cable trays for above Portable Cutting Gas cylinder skid Cutting gas cylinder transportation trolley Small workshop Walkie talkies for winch control Urinal arrangement on boiler

TENTATIVE ERECTION PLAN : With all above we shall complete erection of boiler package as per the plan enclosed . ( Annexure-15)

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BHARAT HEAVY ELECTRICALS LIMITED Power Sector Western Region NAGPUR ERECTION STRATEGY FOR BOILER NTPC RIHAND STPP STAGE-2

ANNEXURE - I

MASTER LIST OF QUALITY DOCUMENTS SL.NO

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.

DOC. TITLE
FQP FOR BOILER & AUX. (STORAGE & PRESERVATION) FQP FOR STG. & AUX. (STORAGE & PRESERVATION) BOILER STRUCTURE PRESSURE PARTS SOOT BLOWERS & FINE FITTINGS VALVES (BOILER HPBP, TG &AUX) FUEL FIRING SYSTEM C&I OF STATION & BOILER & AUX. ST AND TG COAL PULVERIZER AIR PRE HEATER AND SCAPH BOILER FANS (ID, FD & PA FANS) IGNITOR, SCANNER & SEAL AIR FAN SGWC PUMP ELECTROSTATIC PRECIPITATOR DUCTS, DAMPERS, GATES 7 EXP. JOINTS LINNING AND INSULATION PULVERISER FUEL PIPING GRAVIMETRIC FEEDER POWER CYCLE PIPING STEAM TURBINE AND AUX. INCL. HEATERS, CEP & DEAREATOR GENERATOR & AUX. LP PIPING

UNIT DOC. NO. CUST. DOC. NO.

1230-001-QVG-G-1001 1230-001-QVG-G-1031 1230-001-QVG-G-1002 1230-001-QVG-G-1003 1230-001-QVG-G-1004 1230-001-QVG-G-1005 1230-001-QVG-G-1006 1230-001-QVG-G-1046 1230-001-QVG-G-1007 1230-001-QVG-G-1008 1230-001-QVG-G-1009 1230-001-QVG-G-1010 1230-001-QVG-G-1011 1230-001-QVG-G-1012 1230-001-QVG-G-1013 1230-001-QVG-G-1014 1230-001-QVG-G-1015 1230-001-QVG-G-1016 1230-001-QVG-G-1017 1230-001-QVG-G-1032 1230-001-QVG-G-1033 1230-001-QVG-G-1081

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BHARAT HEAVY ELECTRICALS LIMITED Power Sector Western Region NAGPUR ERECTION STRATEGY FOR BOILER NTPC RIHAND STPP STAGE-2
23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. BOILER FEED PUMP (MOTOR & TUR. DRIVE) DRIVE TURBINE FOR BFP BUSDUCT 21 KV MV BUS DUCT TRANSFORMERS (GENERATOR, STATION, UAT, POWER) SWITCHYARD HT MOTORS EFFULUENT TREATMENT SYSTEM COMPRESSED AIR SYSTEM VACUUM CLEANING SYSTEM CONDENSATE POLISHING UNIT CRANES EOT & MISC FIRE PROTECTION SYSTEM FUEL OIL SYSTEM 1230-001-QVG-G-1034 1230-001-QVG-G-1035 1230-001-QVG-G-1058 1230-001-QVG-G-1059 1230-001-QVG-G-1060 1230-001-QVG-G-1061 1230-001-QVG-G-1062 1230-001-QVG-G-1082 1230-001-QVG-G-1083 1230-001-QVG-G-1084 1230-001-QVG-G-1085 1230-001-QVG-G-1086 1230-001-QVG-G-1087 1230-001-QVG-G-1088

37. 38. 39. 40. 41. 42. 43. 44. 45. 46.

MILL REJECT HANDLING SYSTEM PASSENGER CUM GOODS ELEVATORS TANK & VESSELS HVAC AUX. TRANSFORMER DRY TYPE AUX. TRANSFORMER OIL FILLED CABLING (HT/LT CONTROL CABLE) DC SYSTEM 220/24 V BATTERY BATTERY CHARGER HT SWITCHGEAR

1230-001-QVG-G-1089 1230-001-QVG-G-1090 1230-001-QVG-G-1091 1230-001-QVG-G-1092 1230-001-QVG-G-1063 1230-001-QVG-G-1064 1230-001-QVG-G-1065 1230-001-QVG-G-1093 1230-001-QVG-G-1094 1230-001-QVG-G-1066

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BHARAT HEAVY ELECTRICALS LIMITED Power Sector Western Region NAGPUR ERECTION STRATEGY FOR BOILER NTPC RIHAND STPP STAGE-2
47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. GENERATOR CIRCUIT BREAKER DG SET LT BUSDUCT LT SWITCH GEAR NEUTRAL GROUNDING SYSTEM STATION LIGHTING SYSTEM 132 KV CABLE LAYING & JOINTING GAS CONDITIONING UNIT FABRIC EXPANSION JOINT DIVERTER DAMPER CONDENSER ONLOAD TUBE CLEANING SYSTEM TURBINE INSULATION CONDENSATE STORAGE TANK 1230-001-QVG-G-1067 1230-001-QVG-G-1095 1230-001-QVG-G-1068 1230-001-QVG-G-1069 1230-001-QVG-G-1070 1230-001-QVG-G-1096 1230-001-QVG-G-1071 1230-001-QVG-G-1018 1230-001-QVG-G-1019 1230-001-QVG-G-1020 1230-001-QVG-G-1036 1230-001-QVG-G-1037 1230-001-QVG-G-1097

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BHARAT HEAVY ELECTRICALS LIMITED Power Sector Western Region NAGPUR ERECTION STRATEGY FOR BOILER NTPC RIHAND STPP STAGE-2 LIST OF CE T&P AND SPECIAL EQUIPMENT T&P BEING PROVIDED BY BHEL: Sl. No. A B 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17 18. 19 20. 14. Description of Equipment MM Package Fire Retardant / PVC Tarpaulins Erection Package Telco TFC-280 Crane Telco TFC-280 Crawler Crane Telco 955 ALC Crawler Crane Telco 955 ALC Crawler Crane Telco 955 ALC Crawler Crane Link-Belt LS-718 with Ringer (FMC) Telco KH-500 Crawler Crane Manitowoc M-250 T Truck Crane Passenger Cum Goods Lift 1T Passenger Cum Goods Lift 1T E/O Pipe Bending M/c. Electric Scraper Hydraulic Test Pump Hydraulic Test Pump Induction Heating Equipment Fogging M/c. E/O Winch with rope Multi Sheave Pulley Block 15 sheave. Single Sheave Pulley Block Acid Cleaning Pump with control Panel Huck Bolting M/c. Qty 100 1 1 1 1 1 1 1 1 1 1 2 2 2 1 6 1 2 4 10 7 4 Range / Capacity 10x8M 75 T 75 T 75 T 75 T 75 T 325 T 100T 250 T 1T 1T 4 NA NA NA NA NA NA NA NA NA NA NA NA NA Boiler Erecn. ESP-1 Boiler BOP ESP-II Boiler Mills / Rot. M/c. Str. / Roof top. Boiler-I Boiler-II Boiler / Piping. Blr./ PCP/ TG Boiler Boiler / PCP Boiler / PCP ESP Boiler Drum Boiler Drum Boiler Boiler ESP Accuracy Work Area

600 Kg./CM2 450 Kg NA 125 KW/3 NA MHZ NA 15 T NA 300/200 T NA 10 T 200 TPH NA NA NA

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