CIVIL AND STRUCTURES KEY ISSUES AND ACTIONS FOR SUCCESSFUL PROJECT EXECUTION OF LARGE THERMAL POWER PLANTS

POWER LINE MEET 22ND AND 23RD MAY 2012

S K KODANDARAMAIAH Director(BD) & CEO Sunil Hi Tech Engrs Ltd

INDUSTRY PERSPECTIVE AND EXPECTATIONS

Capacity to add 15000mw/ year Managing costs with Civil and structures being about 20% of EPC cost & 45-50% of BOP Costs Cycle time Pressures 250/300mw 24-26 months 500/600mw 32-34 months 660mw 44 months Needs about 50% of Labour needs of a Power plant Better Lay Out management with reduced Land availability Project delays related to Labour non availability Civil and Structures key input for Electro Mech packages Cut down of delays of BTG/Mech packages of 6 to 12 months due to Civil works Concreting requirement 4M M3 and Structural reqt of 5 lac MT/year Focus on improving Engg inputs and Optimization of BOQ Increased mechanization to reduce manpower Better interface management & Engg Co ord to reduce delays Sound planning and sequencing of work

CONTRACT STRUCTURE AND RESPONSIBILITIES

Owners Engr
Res for Civil & Str Infrastructure Raw Mat Supply Providing Civil fronts

Plant Engg
Engg Drgs

Owner/EPC Contractor OR Civil & Str BTG & BOP

Raw Mats From Steel Plants

Fab. Drawings Cranes Welding eqpt Skilled/Unskilled Painting Bought out items

Structural

Civil

Batching plant Other equipment Sand & Metal BOIs,Cement & Steel Bar bending Labour

Detailer Fabrication Erection

Excavation concreting Architectural

& Buildings

CIVIL & STRUCTURAL WORKS KEY ISSUES

Un certainty in the Soil conditions and below ground work Infrastructure of Land development, Temporary roads, drains Availability 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 availability 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

Concreting in Different Areas

% age of concreting
60 50 40 30 20 10 0
NDCT / Chimney Buildings Flooring Foundation work Super Str.

TG & Bunker Floors Critical

Str completion key Buildings Delay due to - Engg - BOI items - Const material - Labour Major augmentation at the time of LU and Coal firing Serious manpower shortages

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 Facilitate 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 prioritize the foundations for ducting between ESP to Chimney planning Foundations work of Transfer Points & Boiler to ESP AB Bay floor at the operating level on A row and B row side

Areas Needing Attention From Project Events Points of View

Sl No
1

Description( Boiler)
Ducting work not complete

Event
LU & CF

Remarks
Boiler inside duct BOF to ESP Duct Foundation inputs issues Manpower & Welders problems Shortfall of 30 to 40% Foundations Mat feeding issues Prob of erecting coal pipes CHP & AHP Civil work problems Affects 3000 to 5000mt of Boiler work Late foundation readiness Integration of TPs, Gallaries, Feeder Floor,Bunkers,Mills & Coal piping At HT/LU about 20% shortfall At CF 10 to 15% shortfall Water & Elect systems civil delays

Coal Piping & Mills completion Problems

Syn & CF

Left side Milling system

Full Load

LU & CF shortfalls from the beginning

LU & CF

Major Shift in Attitude: Do Initial LU with Coal Firing

Sl No
5

Description Others)
Mismatch between TG Deck and TG building Readiness Left side Bunker Structure BOF to ESP Foundations & Str For Ducts For FD/PA Fans Fan Handling str TPs of CHP PAPH Str Pipe rack Foundations Structures

Event
TG Erection Start Full Load LU/CF/F ull Load

Remarks
CEP/CW Piping interface delays Aux Col Readiness &Deck support removal Late start/Foundations availability Inadequate Cranes & manpower Mat feeding problems Prioritizing FD & PA fan foundations How to accommodate Duct &TP foundations working on TPs, Ducting & Fans simultaneously

LU/CF

Early start can help events Interfacing and approach issues to be worked out

Critical out look on Thermal Power Cycle times(500-600mw units)

Boiler Island:
Civil Engg and Initial Civil works very critical BLU and Coal firing to be most critical 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 1015% Major input delays from Civil Side

Problem Areas:
Not identifying the Commissioning sequence at the time of Civil works for Milling system(RHS OR LHS), Ducting system between Boiler and ESP 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

TG Island Side
Interfacing of CEP Pit, CW Piping along the A and B row of TG Building Aux column foundation work and structural work around the TG 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

TG Deck and Structure up to 660 MW

Sl. no Project Unit TG Deck casting comp. in TG Bldg with TG floor readiness
(In months) 1 DB Power (600 MW) #1 13 months 15 Months

EOT Crane readiness

TG Bldg. Structure with floors readiness

(In months) 18 months MT 6500 MT

(In months) 11 Months

MT 2900 MT

#2

18 months (Anticipate d) 14 months

21 Months (Anticipated) 18 months

17 months (Anticipate d) 12 Months

2900 MT

23 months (Anticipate d) 21 months (Anticipate d) 27 months (Anticipate d) 32months Anticipated 27 Months 40 Months

6000 MT

Koradi (660 MW)

#8

3000 MT

5200 MT

#9

21 months (Anticipate d) 26 months Anticipated

23 months (Anticipated) 28 months Anticipated

18 Months

2500 MT

5200 MT

# 10 3 Vallur (500MW) #1 #2

24months Anticipated 14 Months 19 Months

2500 mt 750 MT 2000 MT

5200mt 6500 MT 6500 MT

NEED TO MATCH THE DECK AND FLOOR SCHDULES

KEY PROBLEM AREAS OF BTG CIVIL WORKS

TEMPORARY FRAMING ARRANGMENT FOR INSERTS WORK OF TG DECK FOR 660MW L&T MHI DESIGN

SUPPORT FROM DEVLOPERS

Liberal investment in Infrastructure Infrastructure of Roads, Drains, Sewerage system, Lighting - to with stand Indian Monsoon(2 seasons) - Fit for movement of heavy cranes(200-400mt) & Heavy Dumpers Establishing reliable Construction & Water supply Drinking water facility Adequate Lighting arrangements

CIVIL WORKS-Improving Schedules

o Simultaneous excavation on Boiler, RHS of Mill, ESP & Duct Supports o Explore possibility of Civil works between Boiler & ESP before commencement of Boiler Erection o Start the TG area foundation along with Boiler o For AB,BC bay along with Aux columns for Floor work o Prioritise Floor castings & use Deck sheeting's o Use cranes for Erection of Cribs erection for TG Deck/or cuplocks o Provide Hard crusted surface for Fabrication Area o Provide clear approach roads & Drains o Commence Fabrication of Structures along with Excavation o Complete the TP foundations before Boiler Hydraulic test o Erection of Bunkers with Cranes or Jacking System o Prioritise the completion of main control and ESP control room o Kick start of Water system side of Civil works o Focus on the Cable and Pipe racks as a parallel activity

GOOD START IN CIVIL WORKS ENABLES MEETING SCHEDULES

QUANTUM OF STEEL STRUCTUES FOR LARGE POWER PLANTS

Sl No 1 2 3 4 5 6 7 8 9 Area Power House Str Bunker Str Pipe Racks Service Building ESP Cont Room Comp House Air washer Room Work shop Building CWP House 250mw 5000 3500 600 750 250 100 150 200 500 11050 FOR MULTIPLE UNITS Capacity in MW Total Structures Coal Handling Str 500/600mw 6500 5000 1500 1800 400 150 200 350 1000 16900 660mw 7500 6000 2500 2000 500 200 250 400 1200 20350 Common Common Common Common Common Common Remarks

2
500 19900 5000

2
1000/1200 28500 9000

5
3300 76350 15000

24900
Per MW Steel use in MT 50

37500
31

91350
28

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 Can be 7 to 10% of Project Costs Transfer points betn Boiler & ESP can be part of main Str Package 30000m2 to 50000m2

TYPICAL BUNKER SHELL SECTIONAL VIEW FOR ONE UNIT

TRIPPER FLOOR
56.6m

BUNKER SHELL BUNKER HOPPER FEEDER FLOOR

22.4m

E M

N
Bunker Shell SS Hopper Deck Sheet Cladding for Bunker Sealing RCC

METHODOLOGY OF BUNKER STRUCTURE AND BUNKER SHELL ERECTION Roof floor COLUMN HT. OF BUNKER SUPPORT STRUCTURE 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 Part is OF 17.0 m IN LENGTH WEIGHINH 22.00 MT. 3rd Part is OF 22.0 m IN LENGTH WEIGHINH 14.00 MT. 2nd Tripper floor

Bunker supporting str 22.0 mtr feeder floor

150 MT Capacity crane

METHODOLOGY OF BUNKER STRUCTURE AND BUNKER SHELL ERECTION Roof floor BUNKER SHELL ARE SUPPORTED ON TWO ROWS OF COLUMNS MRK M & N. BUNKER SHELL HT. IS 12.5 m SAME IS BEEN FABRICATED & ERECTED IN 3 PARTS 1st PART IS 5.0 MITER HEIGHT AND WEIGHT IS AROUND 15.00 MT 2nd PART ALSO 5.0 MITER HEIGHT WEIGHT AROUND 15.00 MT 3rd PART IS 2.50 MITER WEIGH AROUND 7.50 MT . Bunker supporting str 22.0 mtr feeder floor N 150 MT Capacity crane Tripper floor

METHODOLOGY OF BUNKER STRUCTURE AND BUNKER SHELL ERECTION Roof floor THE BUNKER SHELL 1ST PART WITH 4 NOS STUB COLUMN RESTED ON DIRECT BUNKER SUPPORTING STRUCTURE TOWARDS M-ROW WERE ERECTED. AFTER PROPER ARRESTING THE SAME 2ND PART AND 3RD PART WERE ERECTED. AFTER THAT TRIPPER FLOOR BEAM AND ROOF BEAM WERE ERECTED. SS HOPPER ALONG WITH THE RING BEAM HAD BEEN ERECTED. FINALLY N- ROW BRACINGS & BEAMS HAD BEEN ERECTED. 150 MT Capacity crane Tripper floor

Bunker supporting str 22.0 mtr feeder floor N

BOLTED STRUCTURES ADVANTAGES & DISADVANTAGES Structures present status

General practice of Fab & Ern @ site Make shift arrangement for fabrication Design by Customer & Detailing by Contractor Material supply by mostly customer Site erection of welded joints Erection tolerances can be flexible Welding by MIG/MAW welding Schedules 30-40 months for 500/600mw units

Bolted Design Requirements

All the structures including cols, main &sec beams of bolted design Needs factory manufacture with NC/3 axis m/cs Very close tolerances for manufacturing & Ern Transportation logistics to be worked out Local MM logistics for storage @ site Design and Detailed Engg to be with Owner Raw material supply with the Vendor Manufacturing to gear up to handle 60 to 80mt wts Large infra and area to be created for offsite work

Advantages
Factory made work, better quality Erection can be faster No need for large infrastructure at site No burden of raw material procurement Welding work can be eliminated Saving in cycle time if properly managed work can be done with less work force CENVAT benefits can be taken

Disadvantages
Fab + Ern cost go up by 20 to 25% ED on factory dispatch's on site work Transportation cost extra on large components No flexibility on managing matching items Non sequential supplies can delay the site work can nullify the advantages if shipments are non sequential Addl cost for site storage and MM High levels of accuracy for manufacturing & tolerances High levels of erection accuracy reqd Detailing to be done by Customer Total cost per MT can go up by 10-12%

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 Volatility in Steel Prices Manufacturing capacity of higher sections limited and mismatch between Site reqt and Steel Plant Rolling plans Engg input issues between Mechanical inputs for Civil Const Drgs Transportation bottlenecks for Heavy items at site- Poor Roads Availability of skilled welders and fitters & Material Handling Equipment Mismatch with the events of Mechanical fronts with 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)

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

FOCUS AREAS

KEY ACTIONS
To excavate the Mill side foundations on RHS To do Bottom ash hopper foundations to GL CEP and CWP engg clearance for RCC work Engg drgs for Cols, bracings, Floors ,trusses Heavy lift crane Readiness of Aux cols Deck sheeting arrangement Cup lock/staging arrangement Inserts incorporation with proper material handling Bar bending and placement arrangement for reinforcement UPV testing arrangement & Deck support dismantling Priority for Duct and Fan Foundations for LU Priority for TP foundations for CF Sequencing of foundations, duct work and CHP work & clearances Erection of TPs the most difficult structure Labour arrangement Shuttering & staging material Drgs Clearances

Boiler Foundations A, B Structure column erection

Floors in AB and BC Bay TG Deck work/TG operating floor readiness

Foundations between Boiler & ESP & TPs

BOP Buildings( DM plant, CWP House, FOPH,Aerator,Service building, APH, Silos

SAFETY RECORD Civil & structure package

LOOKING AHEAD
Engg inputs to be ahead for 3 to 5 months progress of site work Adequate and timely 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 Boiler 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 initiatives 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