main stages in power station erection

7/31/2019 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
http://erecn%20photos/Picture%20tg%20deck.jpghttp://erecn%20photos/Picture%20tg%20deck.jpghttp://erecn%20photos/Picture%20tg%20deck.jpghttp://erecn%20photos/Picture%20tg%20deck.jpghttp://erecn%20photos/Picture%20tg%20deck.jpghttp://erecn%20photos/Picture%20tg%20deck.jpg


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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
http://erecn%20photos/cross%20%20country%20cable%20tray.jpghttp://erecn%20photos/cross%20%20country%20cable%20tray.jpghttp://pipe%20%20rack.jpg/http://pipe%20%20rack.jpg/http://erecn%20photos/cross%20%20country%20cable%20tray.jpghttp://erecn%20photos/cross%20%20country%20cable%20tray.jpghttp://erecn%20photos/cross%20%20country%20cable%20tray.jpghttp://erecn%20photos/cross%20%20country%20cable%20tray.jpg


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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
http://erecn%20photos/transf%20erecn.jpghttp://erecn%20photos/transf%20erecn.jpghttp://erecn%20photos/transf%20erecn.jpghttp://erecn%20photos/transf%20erecn.jpghttp://erecn%20photos/transf%20erecn.jpghttp://erecn%20photos/transf%20erecn.jpg


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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
http://tgfinal.pdf/http://tgfinal.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
http://bbu%20supply%20%20chp.pdf/http://bbu%20supply%20%20chp.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

.

main stages in power station erection

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