Erection

of

2 X 500 MW
Steam Generator
(

(Vindhyachal, Stage-III)

Introduction
Vindhyachal stage-III, comprises of coal based 2 X 500 MW unit. It has been planned to synchronise the unit within 36 months from Notification Of Award. Commissioning of a 500 MW unit within such a short period requires meticulous planning and integration of various site activities viz.

Supply of materials, Agency mobilisation, Special T&Ps etc.

Major Packages Awarded

Main Plant Package (SG, TG, PCP) Ash Handling System Station Piping Ventilation System AC System CHP CW System Fire Detection and Protection BHEL
M/s DCPS Ltd. BHEL ABB ABB L&T. WPIL (Equipment Supply) Wormald

Major Packages Awarded

Power Transformer Generator Bus Duct
BHEL Techno ABB Areva L&T

HT Switchgears 400 KV Switchyard Electrical Equipment Supply & Erection SPML Main Plant Civil works NBCC Chimney

Contracts
First Contract - SUPPLY
Ex.Works basis, including Mandatory Spares & Type Test Charges

Second Contract - ERECTION

Unloading, receipt, storage, Complete Installation & Commissioning, PG tests, Transportation & Insurance

Payment Terms
IA - 15% PPD - 55% PPR - 20% Stage Payment - 5% FP - 5%

Payment Terms
EA - 10% PPE - 80% Stage Payment - 5% FP - 5%

Technical Specifications
Type of Boiler: Controlled circulation with rifled tubing (CC+), Dry bottom, Top supported, Tangentially fired, Balanced Draught Furnace with Fusion welded Water Walls. 19177 Designation of boiler : --------CC+ 15797 301 - 51 ---------230 51

Technical Specifications
Design Wt. of unit (Boiler + ESP) No. of actual HP joints No. of equivalent HP joints No of ceiling girders Type of Main columns Type of Auxiliary columns (Except S4L&R) Elevation of T.O.S. of main columns No of Coal elevations No of Oil elevations :31000 MT Approx. : 27000 approx. : 30000 approx. : 6 No : Star section
: Box section : 84.945 m : 10 :5

Boiler Foundation Plan

Milestones

DRUM

TG OIL FLUSHING - (33 RD MONTH) BARRING GEAR - (34 TH MONTH) STEAM BLOWING - (34 TH MONTH) SAFETY VALVE FLOATING - (35 TH MONTH) STEAM TO TG SET - (35 TH MONTH) SYNCHRONIZATION WITH OIL - (36 TH MONTH) TRIAL RUN COMPLETION - (40 TH MONTH) COMPLETION OF ALL FACILITIES (TG) - (40 TH MONTH)

SG Scope of Work
Structures (9000 MT approx.)

Pressure parts (Water Circuit with 3 bank economiser,

Steam Circuit including radiant roof,backpass walls,2 no. banks LTSH, divisional SH and platen SH, 2 stage Reheaters)

Rotary parts
PAPH 2 nos. SAPH - 2 nos. PA Fans - 2 nos. FD Fans - 2 nos. ID Fans - 2 nos.

Mills 10 nos. Ducting 4000 MT Insulation 2000 MT

Monthly Tonnage (MT)

1000.0

1200.0

1400.0

1600.0

200.0

400.0

600.0

800.0

0.0

Drum Lifting

Monthly Erection Details of Boiler

Hydro Test

Month wise Erection Schedule

Month 0.0 5000.0 10000.0 15000.0 Monthly Tonnage (MT) Cumulative Tonnage (MT)

BLU

Au g Ja '20 0 Fe n'20 6 M b'20 07 a 0 Apr'20 7 M r'200 7 ay 0 Ju '20 7 n 07 Ju '200 Au l'20 7 Seg'2007 p 0 Oc '20 7 0 No t'20 7 07 De v'20 c 0 Ja '20 7 Fe n'2007 b M '20 08 ar 0 Ap '20 8 M r'200 8 ay 0 Ju '20 8 n 08 Ju '200 Au l'20 8 Seg'2008 p 0 Oc '20 8 0 No t'20 8 08 De v'20 c 0 Ja '20 8 Fe n'2008 b M '20 09 ar 0 Ap '20 9 M r'200 9 ay 0 No '20 9 0 De v'20 9 c 0 Ja '20 9 n'2 09 Fe 0 b'2 10 01 0

Cumulative Tonnage (MT)

20000.0

25000.0

Infrastructure Development
Open store yard Covered Stores 2 nos. (size 60 X 22 M) Preassembly yard of approx. 5,000 sq.m. at erection site One welders testing booth near preassembly yard. Contractors colony is being developed near material gate.

Infrastructure Development
Continued

Construction Power Supply

One ring main fitter @ main plant area

Radial fitter - BHEL store yard, agency offices, fabrication yard.

4 nos. substations for Boiler+TG # 9&10.
Each substation of capacity 667 Amps.

Preservation of Materials
Open yard Closed sheds Huge tarpaulins - Structural materials.

- Items like bearings, valves, actuators, insulation etc. - Prevent the items from dust and rust.

Grease coating

- Items like girder pin assembly etc...

One closed cabin - Regularly used loose items like HSFG Bolts and emitting electrodes of ESP...

Agency Mobilisation
Main agency for erection of main plant turnkey package - BHEL (PSWR)
The erection work of SG package has been given to following contracting agencies by BHEL. Boiler # 10 & ESP#9 erection work to M/s PCPIL.

ESP # 10erection work to M/s BEEL. Boiler # 9 erection work to M/s TPL.

Pre-assembly yards
Objective: To achieve the above target on stipulated time.
Columns, Bracing and Gusset plate etc. Ceiling Structure. Pressure parts , down comer etc. Stairs, Landings, Hand rails etc. Duct , Duct support etc. ESP Columns and walls.

Other Erection Facilities

Scrap disposal chute. Construction Elevator. Pre assembly area temporary weather proofing. Local area illumination. Construction power at different location. Construction water

Tools & Plants

Major T&P Requirement

Sl. No. Description 1 325 T FMC CRANE 2 150 T Capacity crane Qty. 1 1

3 CRAWLER MOUNTED CRANE 100 T

4 CRAWLER MOUNTED CRANE 75 T HYDRO CRANE/ ESCORTS/ TATA P&H-320 OR 5 EQUIVALENT 14 TONNES 08 TONNES

1
3

2 2

PLANNING For EXECUTION

Month Wise distribution of tonnage.
Average rate of erection (for boiler) - 1250 MT/month (25months time) Peak rate of erection - 1500 MT/month

Communication with BHEL manufacturing units Review of the planning Planning for Erection and Welding
Activity based programs PG-MA wise monthly erection program Monthly HP welding joints completion will be programmed.
Average rate of Eq. HP Joints - 3000 Nos/month (10months time) Peak rate of Eq. HP Joints - 3500 Nos/month

Daily erection and welding program

Reports
Objective: Quick and easy analysis of progress/ critical area and present work status.
Daily progress monitor sheet with reflection of manpower deployment in each area, extra manpower required and critical activity, will be developed and circulated within the project so that necessary steps could be taken in advance. Milestone activity based reports will be generated for accessing the current status of the milestone to be achieved.

Monthly progress report.

Charts/ diagrams will be prepared for relative analysis of progress.

Cycle Time Reduction

Welding of 2 auxiliary columns may be planned to erect in single lift . Preassembly of MBLs and erection as a single unit.

Coal pipes will be welded at ground where ever it is

possible. Welding booths at various elevations as per requirement

Field Quality Assurance

Category of Checks
A - class check : Critical B - class check : Major C - class check : Minor

NTPC approved..

Welding manual
Installation manual, NDE manual, Heat treatment manual

Qualified & Experienced welders are/ will be only allowed to work. Qualified & Experienced technicians are only allowed for Radiography/ UT

Safety Assurance
PEP talk to enhance the awareness for safety.
Demonstrations by the Fire fighting persons for emergency handling PPEs is issued by the contractor to every worker. While working inside the boiler drum, one exhaust fan will be always used for better ventilation

Thank You

Questions???