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7/30/2019 94631852 Diff Erection Stages in Construction of Power Station
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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 THE
SITE READY FOR START OF CIVIL
WORK
EXCESS EARTH DISPOSAL
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CIVIL WORKS
PILING WORK
PILING DESIGN AS PER LOAD DATA FROM
EPC CONTRACTOR
PILING
PILE TESTING
PILE CAP AND FOUNDATION FOR
STRUCTURE( FDN CASTING AFTER JOINT CHECKING
WITH 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://localhost/var/www/apps/conversion/tmp/scratch_6/erecn%20photos/Picture%20tg%20deck.jpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/erecn%20photos/Picture%20tg%20deck.jpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/erecn%20photos/Picture%20tg%20deck.jpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/erecn%20photos/Picture%20tg%20deck.jpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/erecn%20photos/Picture%20tg%20deck.jpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/erecn%20photos/Picture%20tg%20deck.jpg7/30/2019 94631852 Diff Erection Stages in Construction of Power Station
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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://localhost/var/www/apps/conversion/tmp/scratch_6/erecn%20photos/chp%20str.jpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/erecn%20photos/typical%20floor%20in%20str.jpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/erecn%20photos/typical%20floor%20in%20str.jpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/erecn%20photos/typical%20floor%20in%20str.jpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/erecn%20photos/typical%20floor%20in%20str.jpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/erecn%20photos/chp%20str.jpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/erecn%20photos/chp%20str.jpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/erecn%20photos/chp%20str.jpg7/30/2019 94631852 Diff Erection Stages in Construction of Power Station
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EQUIPMENT ERECTION
TAKING OVER OF FOUNDATION
CHECK FOR LOCATION
CHECK FOR LEVEL
CHECK FOR BOLT/POCKET LOCATION
DEVISING HOISTING STRATAGY AND
SELECTION OF HOISTING T&P FOR
PLACEMENT 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://localhost/var/www/apps/conversion/tmp/scratch_6/erecn%20photos/Picture%20placemnt%20of%20id%20fan.jpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/erecn%20photos/Picture%20placemnt%20of%20id%20fan.jpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/erecn%20photos/tg%20box%20up.jpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/erecn%20photos/tg%20box%20up.jpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/erecn%20photos/mill%20%20erection.jpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/erecn%20photos/mill%20%20erection.jpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/erecn%20photos/flue%20gas%20ducting.jpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/erecn%20photos/flue%20gas%20ducting.jpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/erecn%20photos/flue%20gas%20ducting.jpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/erecn%20photos/flue%20gas%20ducting.jpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/erecn%20photos/flue%20gas%20ducting.jpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/erecn%20photos/flue%20gas%20ducting.jpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/erecn%20photos/mill%20%20erection.jpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/erecn%20photos/mill%20%20erection.jpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/erecn%20photos/mill%20%20erection.jpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/erecn%20photos/mill%20%20erection.jpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/erecn%20photos/tg%20box%20up.jpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/erecn%20photos/tg%20box%20up.jpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/erecn%20photos/tg%20box%20up.jpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/erecn%20photos/tg%20box%20up.jpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/erecn%20photos/Picture%20placemnt%20of%20id%20fan.jpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/erecn%20photos/Picture%20placemnt%20of%20id%20fan.jpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/erecn%20photos/Picture%20placemnt%20of%20id%20fan.jpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/erecn%20photos/Picture%20placemnt%20of%20id%20fan.jpg7/30/2019 94631852 Diff Erection Stages in Construction of Power Station
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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://localhost/var/www/apps/conversion/tmp/scratch_6/erecn%20photos/cross%20%20country%20cable%20tray.jpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/erecn%20photos/cross%20%20country%20cable%20tray.jpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/pipe%20%20rack.jpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/pipe%20%20rack.jpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/erecn%20photos/cross%20%20country%20cable%20tray.jpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/erecn%20photos/cross%20%20country%20cable%20tray.jpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/erecn%20photos/cross%20%20country%20cable%20tray.jpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/erecn%20photos/cross%20%20country%20cable%20tray.jpg7/30/2019 94631852 Diff Erection Stages in Construction of Power Station
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ELECTRICAL ERECTION- CONTD
ERECTION OF LT& HT SW GRS
ERECTION OF TRANSFORMERSerecn
photos\transf erecn.jpg
CABLE TESTING AND TERMINATION
EQUIPMENT EARTHING
SWITCH YARD ERECTION
http://localhost/var/www/apps/conversion/tmp/scratch_6/erecn%20photos/transf%20erecn.jpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/erecn%20photos/transf%20erecn.jpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/erecn%20photos/transf%20erecn.jpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/erecn%20photos/transf%20erecn.jpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/erecn%20photos/transf%20erecn.jpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/erecn%20photos/transf%20erecn.jpg7/30/2019 94631852 Diff Erection Stages in Construction of Power Station
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C&I ERECTION
ERECTION OF FIELD INSTRUMENTS
AND JBS
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 BY
ERECTION AND FQA DEPTT. THESE ARE
CRITICAL CHECKS
B CLASS CHECKS: - BY ERECTION
DEPTT
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 HEALTHINESSOF THE SYSTEMS
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POST COMMISSIONING
ACTIVITIES
LIQUIDATION OF MAJOR DEFECTS IN
THE SYSTEM
SYSTEM TRIAL OPERATION FOR
ESTABLISHING SYSTEM RELIABILITY
PERFORMANCE AND GUARANTEE
TEST- TO CHECK WHETHER THE
PLANT ACHIEVES THE GUARANTEED
PARAMETERS
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READINESS OF SITE FOR
ERECTION
PRE-REQUISITES
APPROACH AND DRAINAGE SYSTEM
CONTRACTORS LAYDOWN , STORAGE
AND 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 AS
PER ERECTION MANUAL :- VERY
IMPORTANT FOR BOILER ERECTION
ADHERENCE TO ACCEPTANCE CRITERIAFOR ERECTION TOLERANCES
SPECIAL TECHNICS :- STRAND JACK
METHOD FOR BOILER DRUM LIFTING
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MAJOR MILESTONES
Starting from Zero date( award of main plant pkg)
Boiler erection start- 11 months
Drum Lifting - 17 months
Start of Cond erction 21 months
Start of TG erect - 23 months
Boiler hydro test - 29 months TG box up - 32 months
BLU and AVO - 35 months
Compln of TG oil flushing- 35 months
Steam blowing Compln 37 months
Synchronization - 39 months
Coal firing - 39 months
Trail operation - 42 months
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MAJOR MILESTONES IN
ERECTION
Daily review/coordination meeting
Weekly progress review
Monthly progress review (PRT) CRM Contract review meeting
ECM- Engg Coordination meeting
Review at various levels
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ERECTION SCHEDULING
TYPES OF PROJECT SCHEDULES
MASTER NETWOR SCHEDULE OR L-1
NETWORK
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 ENABLING
WORKS TO COMMERCIAL OPERATION OF
THE UNITS IT ALSO SPECIFIES THE SCHEDULE OF PRE-
AWARD AND POST AWARD ACTIVITIES OF
ALL MAJOR PACKAGES
SAMPLENCTPP-II(1X490 MW).pdf
http://localhost/var/www/apps/conversion/tmp/scratch_6/NCTPP-II(1X490%20MW).pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_6/NCTPP-II(1X490%20MW).pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_6/NCTPP-II(1X490%20MW).pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_6/NCTPP-II(1X490%20MW).pdf7/30/2019 94631852 Diff Erection Stages in Construction of Power Station
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PACKAGE SCHEDULE OR L-2
SCHEDULE
SPECIFIC TO A PACKAGE
IT IS IN PERT NETWORK FORM AND
SHOWS IN DETAIL ALL THE
ACTIVITIES INCLUDING VARIOUS
STAGES OF MANUF. & ERECTION
IT IS A JOINTLY SIGNED DOCUMENT
BETWEEN NTPC & CONTRACTOR
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PACKAGE SCHEDULE OR L-2
SCHEDULE CONTD-
IT IS CONTRACTUALLY BINDING
DOCUMENT BETWEEN NTPC AND THE
CONTRACTOR
IT ALSO SHOWS THE INTER-
RELATION BETWEEN VARIOUS
ACTIVITIES 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://localhost/var/www/apps/conversion/tmp/scratch_6/tgfinal.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_6/tgfinal.pdf7/30/2019 94631852 Diff Erection Stages in Construction of Power Station
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L-3 SCHEDULE
THIS SCHEDULE IS ACTIVITY
SPECIFIC
PREPARED AT PROJECT LEVEL
FOR CLOSE MONITORING OF
CRITICAL ACTIVITIES.
SAMPLEL3_mech_1 CT.xls
http://localhost/var/www/apps/conversion/tmp/scratch_6/L3_mech_1%20CT.xlshttp://localhost/var/www/apps/conversion/tmp/scratch_6/L3_mech_1%20CT.xls7/30/2019 94631852 Diff Erection Stages in Construction of Power Station
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QUANTITATIVE SCHEDULE
MAINLY FOR THE ITEM RATE
CONTRACTS
THIS SCHEDULE SHOWS QUANTITY
FOR DIFFERENT ARES OF THE
PACKAGE AND THEIR COMPLETION
SCHEDULE.
QUANTITIES ARE SPREAD OUT IN THE
COMPLETION SCHEDULE.
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MEASUREMENT OF PROGRESS
for TURNKEY CONTRACTS
PROGRESS FOR SUPPLY
PROGRESS OF SUPPLY MEASURED IN
FINANCIAL TERMS i.e. VALUE OF EQUIPMENTS
RECEIVED
VALUATION DONE WITH RESPECT TO THE
BILLING BREAK-UP FOR REPORTING AS WELL
AS FOR BILLING.
FOR S.G. PACKAGE GENERALLY
MEASUREMENT IS DONE ON TONNAGE BASIS
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SAMPLE SUPPLY BILLING
BREAK UPbbu supply chp.pdf
http://localhost/var/www/apps/conversion/tmp/scratch_6/bbu%20supply%20%20chp.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_6/bbu%20supply%20%20chp.pdf7/30/2019 94631852 Diff Erection Stages in Construction of Power Station
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PROGRESS MEASUREMENT
FOR ERECTION
DONE ON SYSTEM COMPLETION WISE FOR
PHYSICAL 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 OF
BILLING IS DONE AS PER BILLING
BREAK 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 TO
WEEKLY TARGET
SHOWS PROGRESS VIS A VIS
TARGET
REVIEWD BY PROJECT HEAD
SITE CO-ORDINATION ISSUES
RAISED 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://localhost/var/www/apps/conversion/tmp/scratch_6/DPR%20pt%20plant.xlshttp://localhost/var/www/apps/conversion/tmp/scratch_6/DPR%20pt%20plant.xls7/30/2019 94631852 Diff Erection Stages in Construction of Power Station
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REPORT FOR BUDGET
UTILISATION
REPORTING FOR ACTUAL BUDGET
UTILISATION WITH RESPECT TO
PROJECTED BUDGET
GOOD INDICATOR OF OVERALL
PROGRESS OF THE PACKAGE.
SAMPLEbud uti.xls
http://localhost/var/www/apps/conversion/tmp/scratch_6/bud%20uti.xlshttp://localhost/var/www/apps/conversion/tmp/scratch_6/bud%20uti.xls7/30/2019 94631852 Diff Erection Stages in Construction of Power Station
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THANK YOU
.