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MSP Report On Construction of Cooling Tower “Tata Power Unit#5” Jamshedpur.
MCM 503: COMPUTER WORKSHOP-III

Submitted By Mr. Ravi Bhushan (221025)

PGP ACM 22nd Batch (2008-2010)

NATIONAL INSTITUTE OF CONSTRUCTION MANAGEMENT AND RESEARCH PUNE

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Contents
1. Introduction 2. Project Details 3. List of Activities 4. Technical Features 5. Data Collected 6. Conclusion ………….…3 ………….…3 ………….…8 ….…….…..9 ……….…..11 …..…….…13

Introduction:
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Project management is the process of planning, organizing, and managing tasks and resources to accomplish a defined objective, usually within constraints on time, resources, or cost. A project plan can be simple, for example, a list of tasks and their start and finish dates written on a notepad. Or it can be complex, for example, thousands of tasks and resources and a project budget of crores of rupees. Most projects share common activities, including breaking the project into easily manageable tasks, scheduling the tasks, communicating with the team, and tracking the tasks as work progresses. Cooling tower is one of the complex project in which various activities involves, so more manpower require than other smaller project of construction. Some activities are critical which takes more time so we should do proper planning and scheduling to avoid it and make work faster.

Project Description
To meet the power demands due to TATA STEEL modernisation programme, TPC have already installed and commissioned one unit of 67.5 MW and three unit of 120MW last unit was commissioned in October 2005. Power from these units is being fed to TATA STEEL grid which in turn supplies to steel plant, cement plant, TATA MOTORS, Tinplate co. & Jamshedpur city. With the anticipated growth, a power deficit of 113.5 MW for Jamshedpur network by the year 2008-09 is estimated requiring addition of one more unit of 120MW rating coal based thermal power plant. Project locationThe 5th unit is in the vacant land available within the existing premises of jojobera power plant boundary besides availability of coal and water, evacuation of power, features of main plant equipment including cooling water system, coal and ash handling systems, electrical systems. Modification to be carried out, environmental aspects, estimates of project cost, schedule for project implementation and cost generation.

Site Topography and Grade LevelThe site for the proposed unit is situated in filled up area covered by slag fill. The ground level of the proposed site varies from RL 180m to RL 170m. The grade level of the existing
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120MW units is at EL 180m. Space available for proposed unit no.5 is almost filled with slag during construction of unit no 1 to 4. Major Building and Structures Station building: general arrangement
1. Station building- The span of the turbine generator and auxiliary equipment bay

would be 24m and that of electrical bay would be 10.5m with the existing station building of unit no.4. The length of the station building would be 67.5m consisting of 9 bays of 7.5m. 2. TG bay would be serviced by three floorsGround floor-0.0m Mezzanine floor-5.0m Operating floor-10.5m (TG bay-22m, electrical bay-32m) 3. The superstructure would be of structural steel framing with brickwork and precoated metal sheet for side cladding and RCC floor slabs. 4. The turbine generator pedestal would be of reinforced concrete frame structure and would be isolated from the building foundations and superstructure. Steam Generator Area and Mill Bay The mill bay would be would be of structural steel-framed construction, supporting the steel bunkers. The 10.50m wide bay would have floor for the feeders and for the trippers. Chimney Stack of 150m height from SG area grade level to match with the existing 120MW units. The height takes into consideration the requirement of Indian Emission Regulations. Cooling water pump house Pump house is provided for CW pumps. The CW pumps are located indoor. Each CW pump would have an independent sump with provision for installation of stoppage and coarse screens in the pump chamber.

Miscellaneous buildings
s.no Building/structure Sizes(m)LxBxD remarks

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1. ESP control room 28x7x4.5 Single storey building. RCC

construction with brick wall for side cladding. Roof shall be RCC 2. Air washer room 20x15x8 & 13x7.5x5.5 Single storey building at two

locations.Structuralsteelconstruction with brick wall for side cladding. Roof shall be of RCC.

3.

Fuel house

oil

pump 6x6.5x4.5

Extension of existing pump house by two bays.

4.

D.G house

15x7.5x11

Extension of existing DG house by one bay.

5.

Ash

slurry

sump 50x12x7.5

Single storey building. Structural steel construction with RCC roofing and brick wall for side cladding.

and ash slurry pump house for bottom ash and fly for ash(common unit#4&5) 6. 132kv switchyard 12x6x10

Extension of existing control room.

control room 7. 220kv switchyard 20x13.5x5 Existing building to be demolished and new building to be constructed. water 25x25x5 3000cu.m capacity CLWST

control room 8. Clarified storage tank 9. Silo 7.5m diameter

650 tonnes capacity.

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Cooling Tower for 120MW jojobera thermal power plant The use of cooling tower is to cool the water in water circulating system. It has two types induced draft cooling tower and natural draft cooling tower. The above figure shows IDCT (induced draft cooling tower). For the above project of cooling tower following are the project details…. Client---Tata Power. Contractor—Paharpur Cooling Tower. Number of Cell—5Nos Contractor Type—EPC (Turnkey) Project Cost—2cr approx

Cooling Tower, CT-5 Capacity: 210m3/hr.
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Hot water inlet temp. : 47°C Cold water outlet temp. : 32°C Wet bulb temp. : 28°C, No. of cells: 5 About Paharpur-- P ahar pur does not r es tr i ct i ts elf to onl y manuf a ctur ing an d s u p p l yi n g cooling tow ers , but believ es in the concept of tur nke y r es p o n s ib il it y including tr ans p or ting to s ite, er ect ion, co mmis s ion ing an d tes t in g o f co mp lete coo ling tow er s . I n the cas e of concr ete cool ing tow ers th e civ i l w or k is under taken b y P ahar pur on its ow n. The y have a f u ll f led g ed civ il des ign and cons tr uct ion depar t ment w ith highl y tr ained an d ex p er ien ced civ il engine er s . The y als o have exper i enced per s onnel in s h ip p in g and er ect ion depar tmen ts .

List of Activities: In order to construct the cooling tower, a series of activities will need to
be undertaken. The following activities are part of the project scope:
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• • • • • • • • • • • • EXCAVATION PCC FOR CW BASIN RCC FOR CW BASIN CW BASIN WALL INCL. COLUMN BEAM AT IST LEVEL UP TO FILL LEVEL FILL TO ELIMINATOR ELIM. TO FAN DECK LEVEL FAN DECK SLAB FAN CYLINDER PRE CAST WORKS APPRON

Mechanical & Electrical work
• • • • • • • • • • • • • • INTERNAL BITUMIN PAINTING H.W.PIPING HAND RAILING PVC FILL ERECTION H.W.DISTRIBUTION ELIMINATOR ERECTION EQUIPMENT ERECTION EQUIPMENT EARTHING CABLE TRAY ERECTION SLIDE GATE ERECTION SLUICE GATE ERECTION BUTTERFLY VALVE ERECTION TRIAL RUN COMMISSIONING

Technical Features
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As per above activities the technical features are as below— EXCAVATIONS—For excavation purpose excavators are used like Tata Hitachi, JCB are leading company for this work.

Tata Hitachi--Excavator PCC FOR CW BASIN—M10 grade of concrete had used for PCC work. Pcc has done only for surface level purpose of further project work. Transit mixture is useful for concrete mixing purpose.

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RCC FOR CW BASIN—M30 grade of concrete has used for RCC work and reinforcement steel was CRS (corrosion resistive steel). Batching plant was used for mixing purpose of aggregates and cement. Vibrators were used for compaction purpose and for transporting of concrete transit mixture and concrete pump were used. CW BASIN WALL INCL. COLUMN—MS steel were used for shuttering or form work. Jack and U jack were also used for supporting to column and basin wall’s shuttering. BEAM AT IST LEVEL & UP TO FILL LEVEL—Tower crane is used for lifting the materials at high elevation. Concrete has transported through concrete pump, it has no any problem to carry the concrete till hight of 20m. PRE CAST WORKS— All necessary beams were cast at ground with precise way and after (28days) cured it properly, it was lifted at elevated position as per drawing. Again crane was used for lifting the beams to required position of the structure. H.W.PIPING—

Hot Water Piping (MS-Steel) TEST OF CONCRETE—before placing of concrete we should do slump test for checking the workability. Compressive strength should be checked by cube test and by use of
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compressive strength machine. We should check for 7days and 28days cube sample of 15x15cmm size.

Cube sample

Compressive strength machine

DATA COLLECTION— CalenderCT-calendar assign as project calendar for the cooling tower schedule. Start date- 28/02/2008 Finish date-19/03/2009 before levelling of the resources. Notes—notes are provided in various activities if required.

Various activity and Duration Task name %completion days Start day End day

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Cooling Tower For Unit# 5 Civil Work Excavation PCC FOR CW BASIN RCC FOR CW BASIN CW BASIN WALL INCL. COLUMN BEAM AT IST LEVEL UP TO FILL LEVEL FILL TO ELIMINATOR ELIM. TO FAN DECK LEVEL FAN DECK SLAB FAN CYLINDER PRE CAST WORKS APPRON Mechanical & Electrical work INTERNAL BITUMIN PAINTING H.W.PIPING HAND RAILING PVC FILL ERECTION H.W.DISTRIBUTION ELIMINATOR ERECTION EQUIPMENT ERECTION EQUIPMENT EARTHING CABLE TRAY ERECTION SLIDE GATE ERECTION SLUICE GATE ERECTION BUTTERFLY VALVE ERECTION TRIAL RUN COMMISSIONING 44% 356days 58% 332days 100% 28 days 100% 26 days 100% 74 days 100% 55 days 100% 112days 67% 113days 56% 128days 48% 125days 0% 50 days 0% 60 days 9% 99 days 0% 13 days 0% 110days 0% 18 days 0% 20 days 0% 15 days 0% 30 days 0% 20 days 0% 18 days 0% 35 days 0% 35 days 0% 35 days 0% 15 days 0% 12 days 0% 15 days 0% 5 days 0% 5 days 28-02-2008 08:00 28-02-2008 08:00 28-02-2008 08:00 01-04-2008 08:00 01-05-2008 08:00 28-06-2008 08:00 01-07-2008 08:00 08-07-2008 08:00 05-07-2008 08:00 14-07-2008 08:00 28-10-2008 08:00 24-11-2008 08:00 01-10-2008 08:00 06-03-2009 08:00 11-12-2008 08:00 11-12-2008 08:00 12-01-2009 08:00 26-02-2009 08:00 26-12-2008 08:00 30-01-2009 08:00 30-01-2009 08:00 09-02-2009 08:00 30-01-2009 08:00 30-01-2009 08:00 30-01-2009 08:00 17-02-2009 08:00 09-03-2009 08:00 01-04-2009 08:00 13-04-2009 08:00 17-04-200900:00 20-03-200900:00 31-03-200817:00 30-04-200817:00 25-07-200817:00 31-08-200817:00 07-11-200817:00 15-11-200817:00 01-12-200817:00 05-12-200817:00 24-12-200817:00 31-01-200917:00 23-01-200917:00 20-03-200917:00 17-04-200917:00 31-12-200817:00 03-02-200917:00 14-03-200917:00 29-01-200917:00 21-02-200917:00 19-02-200917:00 20-03-200917:00 11-03-200917:00 11-03-200917:00 16-02-200917:00 02-03-200917:00 25-03-200917:00 06-04-200917:00 17-04-200917:00

Resource Allocation:
Resource name Type initial Group max unit std.rate over time cost/use

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Project Manager Work P Managem ent Senior Manager Work S Managem ent Engineer Work E Managem ent Masons Work M Construction Carpenter Work C Construction Helper Work H Construction Bar-bender Work B Construction Labour Work L Construction Electrician Work E Construction Mechanic Work M Construction Steel MaterialS Material Cem ent 43OPC MaterialC Material Sand MaterialS Material Aggregates MaterialA Material Lining Bricks MaterialL Material Fly ash MaterialF Material Batching plant Work B Equipment Transit mixer Work T Equipment Dum per Work D Equipment Excavator Work E Equipment Tower Crane Work T Equipment Concrete Pump Work C Equipment Jack hammer/concrete breaker Equipment Work J 1 3 6 4 4 12 3 15 1 1 Rs90,000.00/m Rs0.00/hr on Rs60,000.00/m Rs0.00/hr on Rs24,999.00/m Rs100.00/hr on Rs250.00/day Rs0.00/hr Rs200.00/day Rs0.00/hr Rs160.00/day Rs0.00/hr Rs200.00/day Rs0.00/hr Rs180.00/day Rs0.00/hr Rs200.00/day Rs0.00/hr Rs200.00/day Rs0.00/hr Rs3,500.00 Rs250.00 Rs300.00 Rs1,200.00 Rs12.00 Rs15.00 Rs200.00/hr Rs0.00/hr Rs100.00/hr Rs0.00/hr Rs50.00/hr Rs0.00/hr Rs200.00/hr Rs0.00/hr Rs150.00/hr Rs0.00/hr Rs50.00/hr Rs0.00/hr Rs20.00/hr Rs0.00/hr Rs0.00 Rs0.00 Rs0.00 Rs0.00 Rs0.00 Rs0.00 Rs0.00 Rs0.00 Rs0.00 Rs0.00 Rs0.00 Rs0.00 Rs0.00 Rs0.00 Rs0.00 Rs0.00 Rs0.00 Rs0.00 Rs0.00 Rs0.00 Rs0.00 Rs0.00 Rs0.00 Prorated Prorated Prorated Prorated Prorated Prorated Prorated Prorated Prorated Prorated Prorated Start Prorated Start Prorated Prorated Prorated Prorated Prorated Prorated Prorated Prorated Prorated

1 2 2 1 2 2 2

Conclusion:
Microsoft Project is used for planning, scheduling and tracking the project. The critical path of the project is found out by the software and it can be updated whenever necessary. The resources available can be allocated depending upon the criticality of the activity. It keeps a record of all the resources involved in the project and any over allocation and under allocation is determined by the software. During this project we learned a lot about several aspects of project management. Some aspects are the overall planning process, the impact of certain planning decisions, implementation principles, and working with MS-project. Furthermore, we gained insight in the subsidy process involved with technical projects. Specifically, subsidies for energy related projects and projects that concern developing countries. This made this project very interesting and useful.

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