boiler erection 1
TRANSCRIPT
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Erectionof
2 X 500MWSteam Generator
((Vindhyachal, Stage-III)
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Introduction
Vindhyachalstage-III, comprises ofcoal based 2X 500 MWunit. It has been planned tosynchronise the unit within36 monthsfromNotification Of Award.
Commissioning of a 500 MW unit within such ashort period requires meticulousplanning andintegrationof various site activities viz.
Supply of materials,
Agency mobilisation,
Special T&Ps etc.
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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
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Major Packages Awarded
Power Transformer
Generator Bus Duct
HT Switchgears
400 KV Switchyard
Electrical EquipmentSupply & Erection
Main Plant Civil works
Chimney
BHEL
Techno
ABB
Areva
L&T
SPML
NBCC
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Contracts
First Contract - SUPPLY Ex.Works basis, including
Mandatory Spares & Type
Test Charges
Payment Terms IA - 15%
PPD - 55%PPR - 20%
Stage Payment - 5%FP - 5%
Second Contract - ERECTION Unloading, receipt, storage,
Complete Installation &
Commissioning, PG tests,Transportation & Insurance
Payment TermsEA - 10%
PPE - 80%
Stage Payment - 5%FP - 5%
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Technical Specifications
Type of Boiler: Controlled circulation with rifledtubing (CC+), Dry bottom, Top supported,Tangentially fired, Balanced Draught Furnace
with Fusion welded Water Walls.
19177 301 - 51
Designation of boiler : --------- ----------CC+
15797 230 51
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Technical Specifications
Design Wt. of unit (Boiler + ESP) :31000 MT Approx.
No. of actual HP joints : 27000 approx.
No. of equivalent HP joints : 30000 approx. No of ceiling girders : 6 No
Type of Main columns : Star section
Type of Auxiliary columns
(Except S4L&R) : Box section Elevation of T.O.S. of main columns : 84.945 m
No of Coal elevations : 10
No of Oil elevations : 5
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Boiler Foundation Plan
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Milestones
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DRUM
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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)
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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 stageReheaters)
Rotary partsPAPH 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
M h i E i S h d l
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Month wise Erection Schedule
Monthly Erection Details of Boiler
0.0
200.0400.0
600.0
800.0
1000.0
1200.0
1400.0
1600.0
Aug'2
006
Jan'2
007
Feb'2
007
Mar'20
07
Apr'2
007
May'20
07
Jun'2
007
Jul'2
007
Aug'2
007
Sep'2
007
Oct'2
007
Nov'2
007
Dec'2
007
Jan'2
008
Feb'2
008
Mar'20
08
Apr'2
008
May'20
08
Jun'2
008
Jul'2
008
Aug'2
008
Sep'2
008
Oct'2
008
Nov'2
008
Dec'2
008
Jan'2
009
Feb'2
009
Mar'20
09
Apr'2
009
May'20
09
Nov'2
009
Dec'2
009
Jan'2
010
Feb'2
010
Month
MonthlyTonnage(MT)
0.0
5000.0
10000.0
15000.0
20000.0
25000.0
Cumul
ativeTonnage(MT)
Monthly Tonnage (MT)
Cumulative Tonnage (MT)
Drum LiftingHydro Test
BLU
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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.
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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.
Infrastructure DevelopmentContinued
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Preservation of Materials
Open yard - Structural materials.
Closed sheds - Items like bearings, valves, actuators, insulation etc
Huge tarpaulins - 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...
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Agency Mobilisation
Main agency for erection of main plant turnkeypackage - BHEL (PSWR)
The erection work of SG package has been given tofollowing 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.
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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.
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Other Erection Facilities
Scrap disposal chute. Construction Elevator.
Pre assembly area temporary weather proofing. Local area illumination. Construction power at different location. Construction water
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Major T&P Requirement
Sl. No. Description Qty.1 325 T FMC CRANE 1
2 150 T Capacity crane 1
3 CRAWLER MOUNTED CRANE 100 T 1
4 CRAWLER MOUNTED CRANE 75 T 3
5HYDRO CRANE/ ESCORTS/ TATA P&H-320 OR
EQUIVALENT
14 TONNES 2
08 TONNES 2
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PLANNING For EXECUTION
Month Wisedistribution 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 Reviewof the planning
Planning for ErectionandWelding
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
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Reports
Objective: Quick and easy analysis of progress/ criticalarea and present work status.
Daily progress monitor sheet with reflection of manpowerdeployment in each area, extra manpower required and critical
activity, will be developed and circulated within the project sothat necessary steps could be taken in advance.
Milestone activity based reports will be generated for accessingthe current status of the milestone to be achieved.
Monthly progress report.
Charts/ diagrams will be prepared for relative analysis ofprogress.
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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
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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
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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 bealways used for better ventilation
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Thank You
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Questions???