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

Plant Engg
Engg Drgs

Owners
Engr

Owner/EPC
Contractor

Res for Civil & Str

Infrastructure
Raw Mat Supply
Providing Civil fronts

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

Structural

Raw Mats
From
Steel Plants

OR
Civil & Str
BTG & BOP

Civil

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

Detailer

Excavation

Fabrication

concreting

Erection

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

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

50
40
30
20
10
0
NDCT /
Chimney

Buildings

Flooring Foundation
work
Super Str.

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

Description(
Boiler)

Event

Remarks

Ducting work not

complete

LU & CF

Boiler inside duct

BOF to ESP
Duct Foundation inputs issues
Manpower & Welders problems
Shortfall of 30 to 40%

Coal Piping & Mills

completion
Problems

Syn & CF

Foundations
Mat feeding issues
Prob of erecting coal pipes
CHP & AHP Civil work problems

Left side Milling

system

Full Load

Affects 3000 to 5000mt of Boiler work

Late foundation readiness
Integration of TPs, Gallaries, Feeder
Floor,Bunkers,Mills & Coal piping

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 Attitude: Do Initial LU with Coal Firing

Sl
No

Description
Others)

Event

Remarks

Mismatch between
TG Deck and TG
building Readiness

TG
Erection
Start

CEP/CW Piping interface delays

Aux Col Readiness &Deck support
removal

Left side Bunker

Structure

Full
Load

Late start/Foundations availability

Inadequate Cranes & manpower
Mat feeding problems

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 &TP
foundations
working on TPs, Ducting & Fans
simultaneously

Pipe rack
Foundations
Structures

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

DB
Power
(600 MW)

Koradi
(660
MW)

Vallur
(500MW)

Unit

TG Deck
casting
comp. in

TG Bldg
with TG
floor
readiness

EOT Crane
readiness

TG Bldg. Structure
with floors
readiness

(In months)

(In months)

MT

(In months)

MT

#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

#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
Anticipated

28 months
Anticipated

24months
Anticipated

2500 mt

32months
Anticipated

5200mt

#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

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

Area

250mw

500/600mw

660mw

Remarks

Power House Str

5000

6500

7500

Bunker Str

3500

5000

6000

Pipe Racks

600

1500

2500

Common

Service Building

750

1800

2000

Common

ESP Cont Room

250

400

500

Comp House

100

150

200

Common

Air washer Room

150

200

250

Common

Work shop Building

200

350

400

Common

CWP House

500

1000

1200

Common

11050

16900

20350

FOR MULTIPLE
UNITS

Capacity in MW

500

Total Structures

19900

28500

76350

5000

9000

15000

24900

37500

91350

50

31

28

Coal Handling Str

Per MW Steel use in

MT

1000/1200

3300

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

TYPICAL BUNKER SHELL SECTIONAL VIEW FOR ONE UNIT

TRIPPER
FLOOR
56.6m

BUNKER
SHELL
BUNKER
HOPPER
FEEDER
FLOOR
22.4m

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

Tripper floor

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 LENGTH

WEIGHINH 22.00 MT.

Bunker
supporting
str

3rd Part is OF 22.0 m IN LENGTH

WEIGHINH 14.00 MT.

150 MT Capacity crane

22.0 mtr
feeder
floor

METHODOLOGY OF BUNKER STRUCTURE AND BUNKER SHELL ERECTION

Roof floor
BUNKER SHELL ARE SUPPORTED ON
TWO ROWS OF COLUMNS MRK M & N.

Tripper floor

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

Bunker
supporting
str

3rd PART IS 2.50 MITER WEIGH AROUND

7.50 MT .

22.0 mtr
feeder
floor

M
N

150 MT Capacity crane

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.

Tripper floor

Bunker
supporting
str

SS HOPPER ALONG WITH THE RING

BEAM HAD BEEN ERECTED.
FINALLY N- ROW BRACINGS & BEAMS
HAD BEEN ERECTED.

22.0 mtr
feeder
floor
N

150 MT Capacity crane

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

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

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

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

Boiler Foundations

To excavate the Mill side foundations on RHS

To do Bottom ash hopper foundations to GL

A, B Structure column erection

CEP and CWP engg clearance for RCC work

Engg drgs for Cols, bracings, Floors ,trusses
Heavy lift crane

Floors in AB and BC Bay

Readiness of Aux cols

Deck sheeting arrangement

TG Deck work/TG operating floor

readiness

Cup lock/staging arrangement

Inserts incorporation with proper material handling
Bar bending and placement arrangement for
reinforcement
UPV testing arrangement & Deck support
dismantling

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 CHP
work & 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

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