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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