Main Stages in Power Station Erection
Transcript of Main Stages in Power Station Erection
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TODAYS TOPIC
MAIN STAGES IN POWER STATIONERECTION
READINESS OF SITE FORERECTION ( RAILWAY SIDING ,STORAGE FACILITY , LABOUR
COLONY,ERECTION TOOLS ANDTACKLES)
METHODS / TECHNICS OF
ERECTION
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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
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PREPERATORY WORKS
DE-VEGITATION OF SITE
AREA LEVELLING
AREA GRADING TO BRING IT TOPLANNED BLOCK LEVEL TO MAKE THESITE READY FOR START OF CIVILWORK
EXCESS EARTH DISPOSAL
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CIVIL WORKS
PILING WORK
PILING DESIGN AS PER LOAD DATA FROMEPC CONTRACTOR
PILING
PILE TESTING
PILE CAP AND FOUNDATION FOR
STRUCTURE( FDN CASTING AFTER JOINT CHECKINGWITH STRUCTURAL ERECTOR)
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CIVIL WORKS- CONTD
CASTING OF FLOORS ANDEQUIPMENT FDN
SPECIAL FDNS LIKE T.G. DECK ANDOTHER FDN WITH V.I.Serecnphotos\Picture tg deck.jpg
HANDING OVER OF FOUNDATION
FINISHING WORKS AFTER ERECTIONCOMPLN
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STRUCTURAL ERECTION
TAKING OVER OF FOUNDATION
CHECK FOR LOCATION
CHECK FOR LEVEL
CHECK FOR BOLT/POCKET LOCATION
PREFABRICATION
SAND BLASTING AND PRIMER COAT
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STRUCTURAL ERECTION-
CONTD
STRUCTURAL ERECTION BLUE MATCHING OF PACKER PLATES WITH
FDNS
FIRST STAGE COLUMN ERECTION & ROUGHALIGNMENT
FURTHER STAGES COLUMNS , FRAME BEAMSAND BRACINGS ERECTIONerecn photos\chp str.jpg
INTERMEDIATE AND FINAL ALIGNMENT
FLOOR BEAMS AND RELEASE OF FRONT FORFLOOR CASTINGerecn photos\typical floor in str.jpg
http://erecn%20photos/chp%20str.jpghttp://erecn%20photos/typical%20floor%20in%20str.jpghttp://erecn%20photos/typical%20floor%20in%20str.jpghttp://erecn%20photos/typical%20floor%20in%20str.jpghttp://erecn%20photos/typical%20floor%20in%20str.jpghttp://erecn%20photos/chp%20str.jpghttp://erecn%20photos/chp%20str.jpghttp://erecn%20photos/chp%20str.jpg -
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EQUIPMENT ERECTION
TAKING OVER OF FOUNDATION
CHECK FOR LOCATION
CHECK FOR LEVEL
CHECK FOR BOLT/POCKET LOCATION
DEVISING HOISTING STRATAGY ANDSELECTION OF HOISTING T&P FORPLACEMENT OF EQUIPMENT
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EQUIPMENT ERECTION
EQUIPMENT PLACEMENT AND ROUGHLEVELLING WITH BOLT GROUTINGerecnphotos\Picture placemnt of id fan.jpg/erecnphotos\tg box up.jpg
FINAL LEVELLING AND GROUTINGerecnphotos\mill erection.jpg
ALIGNMENT OF ROTARY EQUIPMENTS ERECTION OF PIPING AND DUCTINGerecn
photos\flue gas ducting.jpg PRESSURE /LEAKAGE TEST OF PIPING AND
DUCTING
http://erecn%20photos/Picture%20placemnt%20of%20id%20fan.jpghttp://erecn%20photos/Picture%20placemnt%20of%20id%20fan.jpghttp://erecn%20photos/tg%20box%20up.jpghttp://erecn%20photos/tg%20box%20up.jpghttp://erecn%20photos/mill%20%20erection.jpghttp://erecn%20photos/mill%20%20erection.jpghttp://erecn%20photos/flue%20gas%20ducting.jpghttp://erecn%20photos/flue%20gas%20ducting.jpghttp://erecn%20photos/flue%20gas%20ducting.jpghttp://erecn%20photos/flue%20gas%20ducting.jpghttp://erecn%20photos/flue%20gas%20ducting.jpghttp://erecn%20photos/flue%20gas%20ducting.jpghttp://erecn%20photos/mill%20%20erection.jpghttp://erecn%20photos/mill%20%20erection.jpghttp://erecn%20photos/mill%20%20erection.jpghttp://erecn%20photos/mill%20%20erection.jpghttp://erecn%20photos/tg%20box%20up.jpghttp://erecn%20photos/tg%20box%20up.jpghttp://erecn%20photos/tg%20box%20up.jpghttp://erecn%20photos/tg%20box%20up.jpghttp://erecn%20photos/Picture%20placemnt%20of%20id%20fan.jpghttp://erecn%20photos/Picture%20placemnt%20of%20id%20fan.jpghttp://erecn%20photos/Picture%20placemnt%20of%20id%20fan.jpghttp://erecn%20photos/Picture%20placemnt%20of%20id%20fan.jpg -
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ELECTRICAL ERECTION
TAKING OVER OF FRONT FROMSTRUCTURAL ERECTOR / EQUIPMENTERECTOR
ERECTION OF CABLE TRAY SUPPORTSTRUCTUREerecn photos\cross countrycable tray.jpg
CABLE TRAY ERECTION FOR POWERAND CONTROL CABLEpipe rack.jpg
CABLING AS PER CABLE SCHEDULE
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ELECTRICAL ERECTION- CONTD
ERECTION OF LT& HT SW GRS
ERECTION OF TRANSFORMERSerecnphotos\transf erecn.jpg
CABLE TESTING AND TERMINATION
EQUIPMENT EARTHING
SWITCH YARD ERECTION
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C&I ERECTION
ERECTION OF FIELD INSTRUMENTSAND J.BS
PLC / CONTROL PANEL ERECTION
CABLING BETWEEN INSTRUMENTS ,I/O PANELS & PLC / CONTROL PANELS
CABLING BETWEEN MCC AND PLC/CONTROL PANELS
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QUALITY CHECKS DURING
ERECTION
THREE TYPES OF QUALITY CHECKS
A CLASS CHECK : - JOINTLY BYERECTION AND FQA DEPTT. THESE ARE
CRITICAL CHECKS
B CLASS CHECKS: - BY ERECTIONDEPTT
C CLASS CHECKS :- BY THECONTRACTOR
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COMMISSIONING PHASE
RECHECKING OF ERECTION
PRECOMMISSIONING CHECKS
POWERING UP OF PANELS AND
EQUIPMENTS NO LOAD RUN OF MOTORS
COMMISSIONING OF FIELD INSTRUMENTSAND CONTROL SYSTEMS
CHECKING OF LOGICS AND INTERLOCKS INITIAL RUN AND CHECK FOR HEALTHINESS
OF THE SYSTEMS
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POST COMMISSIONING
ACTIVITIES
LIQUIDATION OF MAJOR DEFECTS INTHE SYSTEM
SYSTEM TRIAL OPERATION FORESTABLISHING SYSTEM RELIABILITY
PERFORMANCE AND GUARANTEETEST- TO CHECK WHETHER THEPLANT ACHIEVES THE GUARANTEEDPARAMETERS
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READINESS OF SITE FOR
ERECTION
PRE-REQUISITES
APPROACH AND DRAINAGE SYSTEM
CONTRACTORS LAYDOWN , STORAGEAND PRE FABRICATION AREA
LABOUR COLONY
RAILWAY SIDING:- Track connection from
nearest rail head and unloading bay at site ERECTION TOOLS AND TACKLES
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ERECTION TOOLS AND PLANTS
TYPICAL TOOLS AND PLANTS REQUIRED FORTURNKEY CONTRACTS BATCHING PLANT FOR CONCRETING
TRANSIT MIXERS AND CONCRETE PUMPS
CRAWLER MOUNTED AND TYRE MOUNTED CRANES TRAILERS
ELECTRICAL WINCHES AND CHAIN PULLEY BLOCKSWITH WIRE ROPES AND SLINGS
WELDING AND GAS CUTTING SETS
THEODOLITE, DIAL GUAGES AND OTHER INSTRUMNTS SPECIAL T&P AS REQD
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METHODS AND TECHNICS OF
ERECTION
ADHERENCE TO ERECTION SEQUENCE ASPER ERECTION MANUAL :- VERYIMPORTANT FOR BOILER ERECTION
ADHERENCE TO ACCEPTANCE CRITERIAFOR ERECTION TOLERANCES
SPECIAL TECHNICS :- STRAND JACKMETHOD FOR BOILER DRUM LIFTING
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MAJOR MILESTONES IN
ERECTION
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ERECTION SCHEDULING
TYPES OF PROJECT SCHEDULES
MASTER NETWOR SCHEDULE OR L-1NETWORK
PACKAGE SCHEDULE OR L-2 SCHEDULE
L-3 SCHEDULE
QUANTITATIVE SCHEDULE
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MASTER NETWOR SCHEDULE
OR L-1 NETWORK
PERTAINS TO THE WHOLE PROJECT
COVERS ALL ACTIVITIES FROM ENABLINGWORKS TO COMMERCIAL OPERATION OF
THE UNITS IT ALSO SPECIFIES THE SCHEDULE OF PRE-
AWARD AND POST AWARD ACTIVITIES OFALL MAJOR PACKAGES
SAMPLENCTPP-II(1X490 MW).pdf
http://nctpp-ii%281x490%20mw%29.pdf/http://nctpp-ii%281x490%20mw%29.pdf/http://nctpp-ii%281x490%20mw%29.pdf/http://nctpp-ii%281x490%20mw%29.pdf/ -
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PACKAGE SCHEDULE OR L-2
SCHEDULE
SPECIFIC TO A PACKAGE
IT IS IN PERT NETWORK FORM ANDSHOWS IN DETAIL ALL THEACTIVITIES INCLUDING VARIOUSSTAGES OF MANUF. & ERECTION
IT IS A JOINTLY SIGNED DOCUMENTBETWEEN NTPC & CONTRACTOR
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PACKAGE SCHEDULE OR L-2
SCHEDULE CONTD-
IT IS CONTRACTUALLY BINDINGDOCUMENT BETWEEN NTPC AND THECONTRACTOR
IT ALSO SHOWS THE INTER-RELATION BETWEEN VARIOUSACTIVITIES AND DATE OF RELESE
OF FRONTS TO THE CONTRACTOR
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SAMPLE L-2 SCHEDULE SUPPLY
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SAMPLE L-2 SCHEDULE
ERECTIONtgfinal.pdf
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L-3 SCHEDULE
THIS SCHEDULE IS ACTIVITYSPECIFIC
PREPARED AT PROJECT LEVEL
FOR CLOSE MONITORING OFCRITICAL ACTIVITIES.
SAMPLEL3_mech_1 CT.xls
http://l3_mech_1%20ct.xls/http://l3_mech_1%20ct.xls/ -
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QUANTITATIVE SCHEDULE
MAINLY FOR THE ITEM RATECONTRACTS
THIS SCHEDULE SHOWS QUANTITYFOR DIFFERENT ARES OF THEPACKAGE AND THEIR COMPLETIONSCHEDULE.
QUANTITIES ARE SPREAD OUT IN THECOMPLETION SCHEDULE.
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MEASUREMENT OF PROGRESS
for TURNKEY CONTRACTS
PROGRESS FOR SUPPLY
PROGRESS OF SUPPLY MEASURED INFINANCIAL TERMS i.e. VALUE OF EQUIPMENTSRECEIVED
VALUATION DONE WITH RESPECT TO THEBILLING BREAK-UP FOR REPORTING AS WELLAS FOR BILLING.
FOR S.G. PACKAGE GENERALLYMEASUREMENT IS DONE ON TONNAGE BASIS
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SAMPLE SUPPLY BILLING
BREAK UPbbu supply chp.pdf
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PROGRESS MEASUREMENT
FOR ERECTION
DONE ON SYSTEM COMPLETION WISE FORPHYSICAL MEASUREMENT
FOR BILLING PURPOSE MEASUREMENT
AND VALUATION OF ERECTION WORK ISDONE AS PER THE BILLING BREAK UP
SAMPLE BBU
FOR ITEM RATE CONTRACTSQUANTITATIVE PROGRESS CAN BE GIVEN
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RECORDING OF OUTPUT
RECORDING FOR THE PURPOSE OFBILLING IS DONE AS PER BILLINGBREAK UP FOR THE ERECTION OF
EQUIPMENT COMPLETED
FOR ITEM RATE CONTRACTS ,INSTEAD OF BBU THERE IS BOQ (
BILL OF QUANTITIES)
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REPORTING
PROGRESS REPORTING
MONTHLY PROGRESS REPORT
WEEKLY PROGRESS REPORT
DAILY PROGRESS REPORT
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MONTHLY PROGRESS REPORT
REPORTING OF ACTUAL PROGRESS VIS-A VIS SCHEDULE FOR THE MONTH
REASONS OF SHORTFALL IS TO BERECORDED
THE REPORT ALSO HIGHLIGHTS THEHOLD UPS WHERE SUPPORT FROMCOTPORATE CENTRE/HIGHER
MANAGEMENT IS REQUIRED REPORT IS SENT TO THE CORPORATE
MONITORING GROUP
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WEEKLY PROGRESS REPORT
MONTHLY TARGET BROKEN DOWN TOWEEKLY TARGET
SHOWS PROGRESS VIS A VISTARGET
REVIEWD BY PROJECT HEAD
SITE CO-ORDINATION ISSUESRAISED IN THE REPORT
SAMPLE.
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DAILY PROGRESS REPORT
FOR VERY CRITICAL AREASREQUIRING CLOSE ATTENTION
DAILY MAN POWER AND RESOURCE
DEPLOYMENT IS ALSO BROUGHTOUT
ALSO BRINGS OUT THE
REQUIREMENT OF ADDITIONALMANPOWER/RESOURCES
SAMPLE.DPR pt plant.xls
http://dpr%20pt%20plant.xls/http://dpr%20pt%20plant.xls/ -
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REPORT FOR BUDGET
UTILISATION
REPORTING FOR ACTUAL BUDGETUTILISATION WITH RESPECT TOPROJECTED BUDGET
GOOD INDICATOR OF OVERALLPROGRESS OF THE PACKAGE.
SAMPLEbud uti.xls
http://bud%20uti.xls/http://bud%20uti.xls/ -
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THANK YOU
.