11 S K Kodandaramaiah
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Transcript of 11 S K Kodandaramaiah
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CIVIL AND STRUCTURES KEY ISSUES AND ACTIONS
FOR SUCCESSFUL PROJECT EXECUTION
OF LARGE THERMAL POWER PLANTS
POWER LINE MEET 22NDAND 23RD MAY 2012
S K KODANDARAMAIAH
Director(BD) & CEO
Sunil Hi Tech Engrs Ltd
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INDUSTRY PERSPECTIVE AND EXPECTATIONS
Capacity to add 15000mw/ yearManaging costs with Civil and structures being about 20% of EPC cost &45-50% of BOP Costs
Cycle t ime Pressures- 250/300mw 24-26 months
- 500/600mw 32-34 months
- 660mw 44 monthsNeeds about 50% of Labour needs of a Power plantBetter Lay Out management with reduced Land availabili tyProject delays related to Labour non availabili tyCivil and Structures key input for Electro Mech packagesCut down of delays of BTG/Mech packages of 6 to 12 months
due to Civil worksConcreting requirement 4M M3 and Structural reqt of 5 lac MT/yearFocus on improving Engg inputs and Optimization of BOQIncreased mechanization to reduce manpowerBetter interface management & Engg Co ord to reduce delaysSound planning and sequencing of work
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CONTRACT STRUCTURE AND RESPONSIBILITIES
Owner/EPC
Contractor
OwnersEngr
Structural
Civil & StrBTG & BOP
Detailer
Fabrication
Erection
Raw Mats
From
Steel PlantsRes for Civil & StrInfrastructure
Raw Mat SupplyProviding Civil fronts
Plant Engg Engg Drgs
Fab. DrawingsCranesWelding eqptSkilled/UnskilledPainting
Bought out items
OR
Civil
Excavation
Architectural& Buildings
concreting
Batching plantOther equipmentSand & MetalBOIs,Cement & Steel
Bar bendingLabour
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Un certainty in the Soil conditions and below ground work
Infrastructure of Land development, Temporary roads, drains
Availabili ty of Metal and Sand
Key engg inputs from BTG Vendor & BOP Elect/Mech packages
Key layout issues and land availability constraints
Storage yard and Fabrication yard space availability
Inadequate investment in Infrastructure Roads, drains, power & water
Engg co ordination issues between Civil and other areas
Interfacing issues between Civil and Structures
Interfacing issues between Civil and Electro- Mech
Non availabili ty of labour carpenters, barbenders, welders, fitters
Seasonal labour strength depletion and turn around
Delivery of Critical steel sections in Rolled and Plate sections Volatility of steel prices
Major Delays in Civil & Structural works
- Between Boiler & ESP- Bunkers on the LHS General delay of 4 to 6 months
CIVIL & STRUCTURAL WORKS KEY ISSUES
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Concreting in Different Areas
% age of
concreting
0
10
20
30
40
50
60
NDCT /
Chimney
Buildings Flooring
work
Foundation
Super Str.
TG & Bunker Floors CriticalStr completion keyBuildings Delay due to- Engg- BOI items- Const material- Labour
Major augmentation at thetime of LU and Coal firing
Serious manpower shortages
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VARIOUS INTERFACING ISSUES TO BE TACKLED
Completing the Furnace bottom AH works beneath O meter along with
Boiler Foundations
Simultaneous commencement of work in
- Boiler area
- ESP Area
- TG Area( A, B & C rows)- Commencement of Fabrication of TG Structures
Engg drgs of TG Building str from grid 0 to 7 at the time of commencement
CEP pit and CWP drgs release early to Facili tate A and B row foundation
continuity
Mill side foundations on the RHS along with Boiler work up to O level
Aux col interfacing with CW Pit and its eng drg release
Completion of Aux col foundations prior to TG Deck casting
CEP sump along with the liners to be finished prior to TG Deck work
Also priorit ize the foundations for duct ing between ESP to Chimney
planning Foundations work of Transfer Points & Boi ler to ESP
AB Bay f loor at the operating level on A row and B row side
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Areas Needing Attention
From Project Events Points of View
Sl No Description(Boiler)
Event Remarks
1 Ducting work not
complete
LU & CF Boiler inside duct
BOF to ESP
Duct Foundation inputs issues
Manpower & Welders problems
Shortfall of 30 to 40%
2 Coal Piping & Mills
completion
Problems
Syn & CF Foundations
Mat feeding issues
Prob of erecting coal pipes
CHP & AHP Civil work problems
3 Left side Milling
system
Full Load Affects 3000 to 5000mt of Boiler work
Late foundation readiness
Integration of TPs, Gallaries, FeederFloor,Bunkers,Mills & Coal piping
4 LU & CF shortfalls
from the beginning
LU & CF At HT/LU about 20% shortfall
At CF 10 to 15% shortfall
Water & Elect systems civil delays
Major Shift in Atti tude: Do Initial LU with Coal Firing
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Sl
No
Description
Others)
Event Remarks
5 Mismatch between
TG Deck and TG
building Readiness
TG
Erection
Start
CEP/CW Piping in terface delays
Aux Col Readiness &Deck supportremoval
6 Left side Bunker
Structure
Full
Load
Late start/Foundations availability
Inadequate Cranes & manpower
Mat feeding problems
7 BOF to ESP
Foundations & Str
For Ducts
For FD/PA Fans
Fan Handling str
TPs of CHP
PAPH Str
LU/CF/F
ull Load
Prioritizing FD & PA fan foundations
How to accommodate Duct &TPfoundations
working on TPs, Ducting & Fanssimultaneously
8 Pipe rack
Foundations
Structures
LU/CF Early s tart can help events
Interfacing and approach issues to beworked out
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Critical out look on Thermal Power Cycletimes(500-600mw units)
Boiler Island: Civil Engg and Initial Civil works very critical
BLU and Coal firing to be most cri tical
Other events can only be inputs for the above
Typically @ HT, the physical shortfall of LU work is 15-20%
For full load operation the physical shortfall can continue to be 10-15%
Major input delays from Civil Side
Problem Areas:
Not identifying the Commissioning sequence at the time of Civilworks for
Milling system(RHS OR LHS), Ducting system between Boiler andESP
Too many civil works at a time between Boiler & ESP
- Duct foundations & Duct work
- Fan Foundations & Fans erection
- CHP Transfer point foundations & Transfer Point Erection
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TG Island Side
Interfacing of CEP Pit, CW Piping along the A and B row of TGBuilding
Aux column foundation work and structural work around theTG Deck & Operating Floor completion with TG Building work
Key Cycle times with Proper interface management
Foundation start to LU :25-27 months
LU to CF: 3 - 5 months
TG Side Foundation start to EOT Crane+TG Deck-12-14M TG Start to Barring Gear 12 months
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TG Deck and Structure up to 660 MW
Sl.no
Project Unit TG Deckcasting
comp. in
TG Bldgwith TG
floor
readiness
EOT Cranereadiness
TG Bldg. Structurewith floors
readiness
(In months) (In months) MT (In months) MT
1 DB
Power
(600 MW)
# 1 13 months 15 Months 11 Months 2900 MT 18 months 6500 MT
# 2 18 months(Anticipate
d)
21 Months(Anticipated)
17 months(Anticipate
d)
2900 MT 23 months(Anticipate
d)
6000 MT
2 Koradi
(660
MW)
# 8 14 months 18 months 12 Months 3000 MT 21 months
(Anticipate
d)
5200 MT
# 9 21 months
(Anticipate
d)
23 months
(Anticipated)
18 Months 2500 MT 27 months
(Anticipate
d)
5200 MT
# 10 26 months
Ant ic ipated
28 months
Ant ic ipated
24months
Ant ic ipated
2500 mt 32months
Ant ic ipated
5200mt
3 Vallur
(500MW)
# 1 14 Months 750 MT 27 Months 6500 MT
# 2 19 Months 2000 MT 40 Months 6500 MT
NEED TO MATCH THE DECK AND FLOOR SCHDULES
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KEY PROBLEM AREAS OF BTG CIVIL WORKS
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TEMPORARY FRAMING ARRANGMENT FOR INSERTS WORK OF TG DECK
FOR 660MW L&T MHI DESIGN
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SUPPORT FROM DEVLOPERSSUPPORT FROM DEVLOPERS
Liberal investment in Infrastructure
Infrastructure of Roads, Drains, Sewerage system,Lighting
- to with stand IndianMonsoon(2 seasons)- Fit for movement of heavy cranes(200-400mt) & HeavyDumpers
Establishing reliable Construction &Water supply
Drinking water facility
Adequate Lighting arrangements
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CIVIL WORKS-Improving Schedules
o Simultaneous excavation on Boiler, RHS of Mill, ESP & Duct Supportso Explore possibi lity of Civil works between Boiler & ESP before
commencement of Boiler Erection
o Start the TG area foundation along with Boi lero For AB,BC bay along w ith Aux columns for Floor worko Prioritise Floor castings & use Deck sheeting's
o Use cranes for Erection of Cribs erection for TG Deck/or cuplockso Provide Hard crusted surface for Fabrication Areao Provide clear approach roads & Drainso Commence Fabrication of Structures along with Excavationo Complete the TP foundations before Boiler Hydraulic testo Erection of Bunkers wi th Cranes or Jacking Systemo Prioritise the completion of main control and ESP control room
o Kick start of Water system side of Civil workso Focus on the Cable and Pipe racks as a parallel activity
GOOD START IN CIVIL WORKS ENABLES MEETING SCHEDULES
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QUANTUM OF STEEL STRUCTUES FOR LARGEPOWER PLANTS
Sl No Area 250mw 500/600mw 660mw Remarks
1 Power House Str 5000 6500 7500
2 Bunker Str 3500 5000 6000
3 Pipe Racks 600 1500 2500 Common
4 Service Building 750 1800 2000 Common
5 ESP Cont Room 250 400 500
6 Comp House 100 150 200 Common
7 Air washer Room 150 200 250 Common
8 Work shop Building 200 350 400 Common
9 CWP House 500 1000 1200 Common
11050 16900 20350
FOR MULTIPLE
UNITS 2 2 5Capacity in MW 500 1000/1200 3300
Total Structures 19900 28500 76350
Coal Handling Str 5000 9000 15000
24900 37500 91350
Per MW Steel use in
MT 50 31 28
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APPLICATION IN MEGA AND ULTRA MEGA PROJECTS
1000/1200mw and >3200mw
Total Quantum of work 37500mt / 1,00,000mt
Completion schedule 36 / 45 months per unit
Packaging can be part of main Civil works or in BTG civil work for BTG Area
TG Building has two or three bays( Typ for 2 x 600 MW :- 42mx240m)
Bunker on the left and Right side of Boiler or between TG building & Boiler
70% Plates and 30% Rolled Sections
Material Handling is a major input
Fabrication Area Reqt is about 30000m2 to 50000m2
Can be 7 to 10% of Project Costs
Transfer points betn Boiler & ESP can be part of main Str Package
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TYPICAL BUNKER SHELL SECTIONAL VIEW FOR ONE UNIT
Bunker Shell RCC
SS Hopper
ABCDE
FEEDER
FLOOR
TRIPPERFLOOR
BUNKER
SHELL
BUNKERHOPPER
22.4m
56.6m
Deck Sheet
Cladding for Bunker Sealing
N
M
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A
COLUMN HT. OF BUNKER SUPPORTSTRUCTURE IS :- 68.0 m
SAME HAS BEEN FABRICATED &ERECTRED IN 3 PARTS
1st PART is OF 27.0 m IN LENGTH
WEIGHING 60.0 MT
2nd Part is OF 17.0 m IN LENGTHWEIGHINH 22.00 MT.
3rd Part is OF 22.0 m IN LENGTHWEIGHINH 14.00 MT. 22.0 mtr
feeder
floor
Bunker
supporting
str
Tripper floor
Roof floor
METHODOLOGY OF BUNKER STRUCTURE AND BUNKER SHELL ERECTION
150 MT Capacity crane
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A
BUNKER SHELL ARE SUPPORTED ON
TWO ROWS OF COLUMNS MRK M & N.
BUNKER SHELL HT. IS 12.5 m
SAME IS BEEN FABRICATED & ERECTEDIN 3 PARTS
1st PART IS 5.0 MITER HEIGHT AND
WEIGHT IS AROUND 15.00 MT
2nd PART ALSO 5.0 MITER HEIGHTWEIGHT AROUND 15.00 MT
3rd PART IS 2.50 MITER WEIGH AROUND7.50 MT . 22.0 mtr
feeder
floor
Bunker
supporting
str
Tripper floor
Roof floor
METHODOLOGY OF BUNKER STRUCTURE AND BUNKER SHELL ERECTION
150 MT Capacity crane
N
M
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A
THE BUNKER SHELL 1ST PART WITH 4NOS STUB COLUMN RESTED ON DIRECT
BUNKER SUPPORTING STRUCTURE
TOWARDS M-ROW WERE ERECTED.
AFTER PROPER ARRESTING THE SAME2ND PART AND 3RD PART WERE
ERECTED.
AFTER THAT TRIPPER FLOOR BEAMAND ROOF BEAM WERE ERECTED.
SS HOPPER ALONG WITH THE RINGBEAM HAD BEEN ERECTED.
FINALLY N- ROW BRACINGS & BEAMSHAD BEEN ERECTED.
22.0 mtr
feeder
floor
Bunker
supporting
str
Tripper floor
Roof floor
METHODOLOGY OF BUNKER STRUCTURE AND BUNKER SHELL ERECTION
150 MT Capacity crane
N
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BOLTED STRUCTURES ADVANTAGES & DISADVANTAGES
Structures present status
General practice of Fab & Ern @ siteMake shift arrangement for fabricationDesign by Customer & Detailing by ContractorMaterial supply by mostly customerSite erection of welded jointsErection tolerances can be flexibleWelding by MIG/MAW weldingSchedules 30-40 months for 500/600mw units
Bolted Design Requirements
All the structures including cols, main &sec beamsof bolted design
Needs factory manufacture with NC/3 axis m/csVery close tolerances for manufacturing & ErnTransportation logistics to be worked outLocal MM logistics for storage @ siteDesign and Detailed Engg to be with OwnerRaw material supply with the VendorManufacturing to gear up to handle 60 to 80mt wts
Large infra and area to be created for offsite work
Advantages
Factory made work, better qualityErection can be fasterNo need for large infrastructure at siteNo burden of raw material procurementWelding work can be eliminatedSaving in cycle time if properly managedwork can be done with less work forceCENVAT benefits can be taken
Disadvantages
Fab + Ern cost go up by 20 to 25%ED on factory dispatch's on site workTransportation cost extra on large componentsNo flexibility on managing matching itemsNon sequential supplies can delay the site workcan nullify the advantages if shipments are non sequentiAddl cost for site storage and MMHigh levels of accuracy for manufacturing & tolerancesHigh levels of erection accuracy reqdDetailing to be done by CustomerTotal cost per MT can go up by 10-12%
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MAJOR PROBLEMS AND CHALLENGES FOR STRUCTURAL
WORKS IN POWER PLANTS
Structural and Civil works are to be integrated for better execution
Very poor infrastructure at site for Fabrication yard and Movement of material
Major mat. availability problems with Plates of 32mm,36mm,40mm &
Rolled sections ISMB 300,400,500 & 600
General Delay of 3 to 5 months in Critical Steel Sections
Volatili ty in Steel Prices
Manufactur ing capacity of higher sections limited and mismatch between
Site reqt and Steel Plant Roll ing plans Engg input issues between Mechanical inputs for Civil Const Drgs
Transportation bott lenecks for Heavy items at site- Poor Roads
Availability of skil led welders and f itters & Material Handling Equipment
Mismatch with the events of Mechanical fronts w ith Civil and Str fronts
like
- EOT Crane Readiness in TG hall- TG Building readiness for Mechanical Erection
- Bunker Structure for Coal Firing system of Boiler
- Bunker readiness for Coal firing
- CHP Transfer point Erection Problems( Very tall structures)
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CAPABILITIES & LEARNINGS
Critical steel sections in manufacturing to be augmented for timely supply
Better to discuss with the steel supplier at the beginning with tentative sections
Need for Deployment of Higher Capacity cranes of 150mt to 250mt
Present capacity to be increased by about 30-50% for 12th Plan Objectives
There is a general shortage of experienced good Civil and Structural Engrs.
Shop manufacturing as a substitute to site fabrication can be an alternative
Bolted structure can be an alternative to Welded structure for site joints
Investment in site infrastructure for proper Fab Yards, Roads and Approaches
Development of skilled welders and Fitters for site work
Development of more agencies for Fabrication detailing drawings
Safety standards for tall structures erection to improve
Suitable Price Escalation for Steel Price volatility cover up
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FOCUS AREAS KEY ACTIONS
Boiler Foundations To excavate the Mill side foundations on RHSTo do Bottom ash hopper foundations to GL
A, B Structure column erection CEP and CWP engg clearance for RCC workEngg drgs for Cols, bracings, Floors ,trusses
Heavy lift crane
Floors in AB and BC Bay Readiness of Aux colsDeck sheeting arrangement
TG Deck work/TG operating f loorreadiness
Cup lock/staging arrangementInserts incorporation with proper material handling
Bar bending and placement arrangement forreinforcement
UPV testing arrangement & Deck supportdismantling
Foundations between Boiler & ESP
& TPs
Priority for Duct and Fan Foundations for LU
Priority for TP foundations for CF
Sequencing of foundations, duct work and CHPwork & clearances
Erection of TPs the most difficult structure
BOP Buildings( DM plant, CWP
House, FOPH,Aerator,Service
building, APH, Silos
Labour arrangement
Shuttering & staging material
Drgs
Clearances
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SAFETY RECORDSAFETY RECORD
Civil & structure packageCivil & structure package
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LOOKING AHEAD
Engg inputs to be ahead for 3 to 5 months progress of site workAdequate and t imely investment in Roads, Drains, Const Power & Infra
Improve mechanization and reduce dependence on labour
- More Use of Boom placers, concrete pumps
- Use of Deck sheeting for floor work
- Use of RMC wherever it is feasible
- Use of higher capacity cranes and more in nos
- Use of Tower cranes for Building works
Pre pone CHP Civil works between Boi ler and ESP by 6 months
Better integration of Civil and Structural works of TG Building
Invest in Monsoon preparation on temporary works
Switch over to Bolted structure for major structural work
HR init iatives for Strengthening Civil and Structural Supervision
Improving Construction safety records Provide differential rates for concreting of Buildings & Floor works
Proper escalation clauses for Cement and Steel price volatility
Prioritize Bunker work on RHS and LHS
Plan for LU with Coal firing instead of Coal firing for Full load operation