Boiler Erection 1

7/31/2019 Boiler Erection 1

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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???

Documents

Boiler Erection 1