jhajjar project management an insight · pdf filereduce capital & maintenance cost and...
TRANSCRIPT
![Page 1: Jhajjar Project Management An Insight · PDF filereduce capital & maintenance cost and installation time 19. ... except Boiler was started before the boiler hydro test to mitigate](https://reader031.vdocuments.site/reader031/viewer/2022022500/5aa09f457f8b9a0d158e7262/html5/thumbnails/1.jpg)
Jhajjar Project Management …An Insight
March 4, 2013
![Page 2: Jhajjar Project Management An Insight · PDF filereduce capital & maintenance cost and installation time 19. ... except Boiler was started before the boiler hydro test to mitigate](https://reader031.vdocuments.site/reader031/viewer/2022022500/5aa09f457f8b9a0d158e7262/html5/thumbnails/2.jpg)
2 x 660 MW
Mahatma Gandhi Thermal Power Plant
Jhajjar, Haryana, INDIA 2
![Page 3: Jhajjar Project Management An Insight · PDF filereduce capital & maintenance cost and installation time 19. ... except Boiler was started before the boiler hydro test to mitigate](https://reader031.vdocuments.site/reader031/viewer/2022022500/5aa09f457f8b9a0d158e7262/html5/thumbnails/3.jpg)
A Brief Introduction
• 2x 660 MW greenfield project, named as “Mahatma
Gandhi Thermal Power Plant” built by Jhajjar Power
Limited (JPL)
• The Plant is located in Jhajjar district of Haryana
• The Project awarded by Government on 23rd July, 2008
with target completion date of 22nd July 2012
• The Plant started commercial operation on 19th July, 2012
i.e. 3 days ahead of the schedule
3
![Page 4: Jhajjar Project Management An Insight · PDF filereduce capital & maintenance cost and installation time 19. ... except Boiler was started before the boiler hydro test to mitigate](https://reader031.vdocuments.site/reader031/viewer/2022022500/5aa09f457f8b9a0d158e7262/html5/thumbnails/4.jpg)
MGTPP Site Layout PlanNORTH
JPL TOWNSHIPTIEJUN LIVING AND OFFICE AREA
GUEST HOUSE
NDCT
SWITH
TIEJUN LABOUR COLONY
ASH DISPOSAL AREA
TIEJUN YARD
CONSTRUCTION MAIN
AREA POWERHOUSE B O PCHIMNEY
COAL HANDLING AREA
RAILWAY SIDING
RAW WATERRESERVOIR ROAD TO PLANT
DRAWING NOT TO SCALE
4
![Page 5: Jhajjar Project Management An Insight · PDF filereduce capital & maintenance cost and installation time 19. ... except Boiler was started before the boiler hydro test to mitigate](https://reader031.vdocuments.site/reader031/viewer/2022022500/5aa09f457f8b9a0d158e7262/html5/thumbnails/5.jpg)
Preparations for the journey….
• Entire Main Plant contract awarded on turnkey basis toSEPCO-III/ TIEJUN after extensive deliberation & evaluation
• CLP Engineering team identified & included the list of reputedChinese vendors for critical equipment in the Owner’sTechnical Requirement (OTR)
• Basic Engineering finalized by CLP Engineering team withinputs from the other CLP Assets
• The specifications of critical equipment like Turbine, Boiler,Generator, Transformer etc. were reviewed by CLPEngineering team
• Site team involved in the review of construction drawings toensure compliance to Indian Standards and ensureconstructability & Plant operability & maintainability 5
![Page 6: Jhajjar Project Management An Insight · PDF filereduce capital & maintenance cost and installation time 19. ... except Boiler was started before the boiler hydro test to mitigate](https://reader031.vdocuments.site/reader031/viewer/2022022500/5aa09f457f8b9a0d158e7262/html5/thumbnails/6.jpg)
Major Contracts Structure
2 X 660 MW COAL FIRED POWER PLANT
MAIN POWER HOUSE
DESIGNERECTIONENGINEERING
INFRASTRUCTURE WORK
(JPL)
& EQUIPMENTSUPPLY
BY
M/S SEPCO-III
& COMMISSIONING
BY
M/S TIEJUN
RAILWAYSIDING BYM/S GDCL
INTAKE WATERSYSTEM
BY
M/SFLOWMORE,
M/S SIMPLEX &M/S GRPAHITE
INDIA
ASH DYKE
BY
M/S SUBHASHINFRA
ENGINEERS
TOWNSHIP,
SITEBOUNDARY
WALL
BY
M/S BHAYANA,AAKAR 6
BUILDERS
![Page 7: Jhajjar Project Management An Insight · PDF filereduce capital & maintenance cost and installation time 19. ... except Boiler was started before the boiler hydro test to mitigate](https://reader031.vdocuments.site/reader031/viewer/2022022500/5aa09f457f8b9a0d158e7262/html5/thumbnails/7.jpg)
Staffing Model for Project Execution
• Integrated Project Execution Team comprised of mainly new
recruits from various organizations with diversified work culture
• Maintenance staff recruited as construction team ensuring
continuity & ownership
• Operational staff recruited well in advance for familiarization,
training and active participation in the commissioning activities
7
![Page 8: Jhajjar Project Management An Insight · PDF filereduce capital & maintenance cost and installation time 19. ... except Boiler was started before the boiler hydro test to mitigate](https://reader031.vdocuments.site/reader031/viewer/2022022500/5aa09f457f8b9a0d158e7262/html5/thumbnails/8.jpg)
JPL SAFETY MISSION
Everyone goes home safely to the family
8
![Page 9: Jhajjar Project Management An Insight · PDF filereduce capital & maintenance cost and installation time 19. ... except Boiler was started before the boiler hydro test to mitigate](https://reader031.vdocuments.site/reader031/viewer/2022022500/5aa09f457f8b9a0d158e7262/html5/thumbnails/9.jpg)
JPL follows “SAFETY FIRST” Philosophy
Measures taken in line with the CLP safety objective of “Zero Incident”
• Direct employee involvement in Safety Issues (Project Sun Flower)
• Animated safety induction program
• Safety Task Forces for high risk activities
• Improving & spreading safety awareness at site
• Providing EHS related amenities (e.g. Drinking water, sanitation etc.) in
the labor camps. Weekly environmental audits to ensure desired
standards
• Regular On-site Tool Box Talks (TBTs)
9
![Page 10: Jhajjar Project Management An Insight · PDF filereduce capital & maintenance cost and installation time 19. ... except Boiler was started before the boiler hydro test to mitigate](https://reader031.vdocuments.site/reader031/viewer/2022022500/5aa09f457f8b9a0d158e7262/html5/thumbnails/10.jpg)
• Co-operation from main & sub-contractors on safety
• Round the clock availability of medical facilities includingdoctor, nurse, paramedics, ambulance etc.
• Class room and on-job safety training for staff andcontractors’ employees
• Management safety walk downs twice a week
• Reward and recognition on safety performance toContractors
10
![Page 11: Jhajjar Project Management An Insight · PDF filereduce capital & maintenance cost and installation time 19. ... except Boiler was started before the boiler hydro test to mitigate](https://reader031.vdocuments.site/reader031/viewer/2022022500/5aa09f457f8b9a0d158e7262/html5/thumbnails/11.jpg)
Salient technical features
• Super -Critical technology
• Mini Oil Ignition technology to reduce oil consumption
• Flue Gas Desulphurization (FGD) for reduction of SOx emission
• Combination of ESP & fabric filter to reduce particulate emission
• Chimney flue duct with Titanium lining to prevent corrosion
• Polymeric insulated SF6 filled current transformer (CT) to reduce theexplosion risk level
• Use of bolted joints instead of welded joints in major structures forreduction in construction time & cost.
11
![Page 12: Jhajjar Project Management An Insight · PDF filereduce capital & maintenance cost and installation time 19. ... except Boiler was started before the boiler hydro test to mitigate](https://reader031.vdocuments.site/reader031/viewer/2022022500/5aa09f457f8b9a0d158e7262/html5/thumbnails/12.jpg)
Project Uniqueness
• Compact Main Plant & CHP layout
12
![Page 13: Jhajjar Project Management An Insight · PDF filereduce capital & maintenance cost and installation time 19. ... except Boiler was started before the boiler hydro test to mitigate](https://reader031.vdocuments.site/reader031/viewer/2022022500/5aa09f457f8b9a0d158e7262/html5/thumbnails/13.jpg)
Project Uniqueness
• Zero discharge philosophy
• 100% dry ash utilization to reduce environmental impacts & ashstorage area requirement
• De-aerator level reduced by locating the BFP Booster Pumps atGround Floor to decrease the turbine building height
13
![Page 14: Jhajjar Project Management An Insight · PDF filereduce capital & maintenance cost and installation time 19. ... except Boiler was started before the boiler hydro test to mitigate](https://reader031.vdocuments.site/reader031/viewer/2022022500/5aa09f457f8b9a0d158e7262/html5/thumbnails/14.jpg)
Project Uniqueness
• Use of bolted connections for Boiler, TG and Switchyard Structures toreduce construction time & cost.
14
![Page 15: Jhajjar Project Management An Insight · PDF filereduce capital & maintenance cost and installation time 19. ... except Boiler was started before the boiler hydro test to mitigate](https://reader031.vdocuments.site/reader031/viewer/2022022500/5aa09f457f8b9a0d158e7262/html5/thumbnails/15.jpg)
Project Uniqueness
• Use of deck sheets for safer & faster concreting for reduction inconstruction time
15
![Page 16: Jhajjar Project Management An Insight · PDF filereduce capital & maintenance cost and installation time 19. ... except Boiler was started before the boiler hydro test to mitigate](https://reader031.vdocuments.site/reader031/viewer/2022022500/5aa09f457f8b9a0d158e7262/html5/thumbnails/16.jpg)
Project Uniqueness
• Chimney flue duct with Titanium lining to prevent corrosion of flue ductduring FGD operation
16
![Page 17: Jhajjar Project Management An Insight · PDF filereduce capital & maintenance cost and installation time 19. ... except Boiler was started before the boiler hydro test to mitigate](https://reader031.vdocuments.site/reader031/viewer/2022022500/5aa09f457f8b9a0d158e7262/html5/thumbnails/17.jpg)
Innovations during Project Execution
• Use of Tower Cranes for faster & safer erection & Gantry cranes forextensive pre-fabrication
17
![Page 18: Jhajjar Project Management An Insight · PDF filereduce capital & maintenance cost and installation time 19. ... except Boiler was started before the boiler hydro test to mitigate](https://reader031.vdocuments.site/reader031/viewer/2022022500/5aa09f457f8b9a0d158e7262/html5/thumbnails/18.jpg)
Innovations during Project Execution
• Deep excavated foundations to substitute time & cost intensive pilefoundations
18
![Page 19: Jhajjar Project Management An Insight · PDF filereduce capital & maintenance cost and installation time 19. ... except Boiler was started before the boiler hydro test to mitigate](https://reader031.vdocuments.site/reader031/viewer/2022022500/5aa09f457f8b9a0d158e7262/html5/thumbnails/19.jpg)
Innovations during Project Execution
• Use of GRP & HDPE pipes in underground water piping system toreduce capital & maintenance cost and installation time
19
![Page 20: Jhajjar Project Management An Insight · PDF filereduce capital & maintenance cost and installation time 19. ... except Boiler was started before the boiler hydro test to mitigate](https://reader031.vdocuments.site/reader031/viewer/2022022500/5aa09f457f8b9a0d158e7262/html5/thumbnails/20.jpg)
Innovations during Project Execution
• Steam blowing was done on coal firing instead of the usual practiceof doing it on oil firing
• No water storage facility (overhead tank) throughout the plant bydesigning round-the-clock running water supply system
• Use of Extranet for review of engineering drawings duringconstruction to win over geographical constraint.
• The thermal insulation of ESP, Main Steam Piping, Ducts etc.except Boiler was started before the boiler hydro test to mitigatethe delay in the boiler erection.
20
![Page 21: Jhajjar Project Management An Insight · PDF filereduce capital & maintenance cost and installation time 19. ... except Boiler was started before the boiler hydro test to mitigate](https://reader031.vdocuments.site/reader031/viewer/2022022500/5aa09f457f8b9a0d158e7262/html5/thumbnails/21.jpg)
Best Practices during Project Execution
In addition to following the CLP standard procedures,manuals & guidelines
• Development of Project Execution Plan & Procedures e.g.• Contract Management Procedure
• Invoice Processing Procedure
• Budget Control & Monitoring Procedure
• Departmental Construction & Commissioning Procedures
• Review & approval of Shop Inspection & Test Plan (ITP) for all criticalequipment including owner’s “hold points”
• Third party inspection & internal inspection by CLP at manufacturer’sfacility
• Review & approval of Field Quality Plans (FQP)
21
![Page 22: Jhajjar Project Management An Insight · PDF filereduce capital & maintenance cost and installation time 19. ... except Boiler was started before the boiler hydro test to mitigate](https://reader031.vdocuments.site/reader031/viewer/2022022500/5aa09f457f8b9a0d158e7262/html5/thumbnails/22.jpg)
Challenges overcome
SAFETY
• Difference in safety approach between CLP, TIEJUN/ SubContractors
• High turnover of workmen who are mostly from villages, unskilledand illiterate
• Prevailing fatalistic attitude amongst workers
• Lack of support from Contractor / Sub Contractors site managementon safety issues
22
![Page 23: Jhajjar Project Management An Insight · PDF filereduce capital & maintenance cost and installation time 19. ... except Boiler was started before the boiler hydro test to mitigate](https://reader031.vdocuments.site/reader031/viewer/2022022500/5aa09f457f8b9a0d158e7262/html5/thumbnails/23.jpg)
Challenges overcome
• Language barrier between SEPCO III/ TIEJUN and JPL
• Timely supply of offshore materials & equipments
• Land related issues for installation of raw water pipeline andrailway line through the villages
• Daily commute of approx. 150 km by the project personnel duringthe construction phase
23
![Page 24: Jhajjar Project Management An Insight · PDF filereduce capital & maintenance cost and installation time 19. ... except Boiler was started before the boiler hydro test to mitigate](https://reader031.vdocuments.site/reader031/viewer/2022022500/5aa09f457f8b9a0d158e7262/html5/thumbnails/24.jpg)
Project Execution Milestones
MILESTONE DATE TIME (Days)
w.r.t. NTP
NOTICE TO PROCEED (NTP) 23-Mar-09 0
FIRST CONCRETE MAIN POWER HOUSE 16-May-09 54
START OF ERECTION OF BOILER STEEL STRUCTURE 1-Nov-09 223
COMPLETION OF ERECTION OF BOILER STEEL STRUCTURE 6-Sep-10 532
TG BED PLATE POSITIONING (START) 15-Nov-10 602
DCS CHARGING 17-Mar-11 724
CHIMNEY OUTER SHELL COMPLETION 18-Apr-11 756
GENERATOR STATOR POSITIONING 24-May-11 792
START UP POWER (BACK ENERGISATION) 2-Jun-11 801
COMPLETION OF BOILER HEATING SURFACE ERECTION 28-Jun-11 827
BOILER HYDRO TEST COMPLETION 18-Aug-11 878 (29 months)
24
![Page 25: Jhajjar Project Management An Insight · PDF filereduce capital & maintenance cost and installation time 19. ... except Boiler was started before the boiler hydro test to mitigate](https://reader031.vdocuments.site/reader031/viewer/2022022500/5aa09f457f8b9a0d158e7262/html5/thumbnails/25.jpg)
MILESTONE DATE TIME (Days)
w.r.t. NTP
TG BOX-UP 20-Aug-11 880
DM WATER GENERATION 27-Aug-11 887
COMPLETION OF CHEMICAL CLEANING OF BOILER 20-Nov-11 972
COMPLETION OF TG OIL FLUSHING 23-Nov-11 975
COMPLETION OF BOILER INSULATION WORKS(only to support steam blowing)
30-Nov-11 982
BOILER LIGHT UP 7-Dec-11 989 (33 months)
START OF STEAM BLOWING (on Coal firing) 8-Dec-11 990
COMPLETION OF STEAM BLOWING 19-Dec-11 1001 (33.4 months)
SYCHRONIZATION & TRIAL OPERATION 11-Jan-12 1024 (34 months)
ACHIEVE FULL LOAD 12-Jan-12 1025 (34 months)
COD AS PER PPA 22-Jan-12 1035 (34.5 months)
COD 29-Mar-12 1102 (36.7 months)25
![Page 26: Jhajjar Project Management An Insight · PDF filereduce capital & maintenance cost and installation time 19. ... except Boiler was started before the boiler hydro test to mitigate](https://reader031.vdocuments.site/reader031/viewer/2022022500/5aa09f457f8b9a0d158e7262/html5/thumbnails/26.jpg)
Achievements
• Project completed within schedule and budget
• Achieved synchronization of Ist Unit within 34 months
of the Notice to Proceed (NTP)
• Achieved Unit full load within 27 hours of first
synchronization
26
![Page 27: Jhajjar Project Management An Insight · PDF filereduce capital & maintenance cost and installation time 19. ... except Boiler was started before the boiler hydro test to mitigate](https://reader031.vdocuments.site/reader031/viewer/2022022500/5aa09f457f8b9a0d158e7262/html5/thumbnails/27.jpg)
Awards & Recognitions
• ECB financing for the Project received the prestigious
“Indian Deal of the Year 2010” award from “Project
Finance International”
• “Indian Power Deal of the Year 2010” award from
“Euromoney”
• CNBC TV18’s Infrastructure Excellence Award for the
Year 2012 (Energy & Power Category)27
![Page 28: Jhajjar Project Management An Insight · PDF filereduce capital & maintenance cost and installation time 19. ... except Boiler was started before the boiler hydro test to mitigate](https://reader031.vdocuments.site/reader031/viewer/2022022500/5aa09f457f8b9a0d158e7262/html5/thumbnails/28.jpg)
The Journey continues……