Boiler Erection 1
Boiler Erection 1
Boiler Erection 1
of
2 X 500 MW
Steam Generator
(
(Vindhyachal, Stage-III)
Introduction
Vindhyachal stage-III, comprises of coal based 2 X 500 MW unit. It has been planned to synchronise the unit within 36 months from Notification Of Award. Commissioning of a 500 MW unit within such a short period requires meticulous planning and integration of various site activities viz.
HT Switchgears 400 KV Switchyard Electrical Equipment Supply & Erection SPML Main Plant Civil works NBCC Chimney
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%
Payment Terms
EA - 10% PPE - 80% Stage Payment - 5% FP - 5%
Technical Specifications
Type of Boiler: Controlled circulation with rifled tubing (CC+), Dry bottom, Top supported, Tangentially fired, Balanced Draught Furnace with Fusion welded Water Walls. 19177 Designation of boiler : --------CC+ 15797 301 - 51 ---------230 51
Technical Specifications
Design Wt. of unit (Boiler + ESP) No. of actual HP joints No. of equivalent HP joints No of ceiling girders Type of Main columns Type of Auxiliary columns (Except S4L&R) Elevation of T.O.S. of main columns No of Coal elevations No of Oil elevations :31000 MT Approx. : 27000 approx. : 30000 approx. : 6 No : Star section
: Box section : 84.945 m : 10 :5
Milestones
DRUM
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)
SG Scope of Work
Structures (9000 MT approx.)
Rotary parts
PAPH 2 nos. SAPH - 2 nos. PA Fans - 2 nos. FD Fans - 2 nos. ID Fans - 2 nos.
1000.0
1200.0
1400.0
1600.0
200.0
400.0
600.0
800.0
0.0
Drum Lifting
Hydro Test
Month 0.0 5000.0 10000.0 15000.0 Monthly Tonnage (MT) Cumulative Tonnage (MT)
BLU
Au g Ja '20 0 Fe n'20 6 M b'20 07 a 0 Apr'20 7 M r'200 7 ay 0 Ju '20 7 n 07 Ju '200 Au l'20 7 Seg'2007 p 0 Oc '20 7 0 No t'20 7 07 De v'20 c 0 Ja '20 7 Fe n'2007 b M '20 08 ar 0 Ap '20 8 M r'200 8 ay 0 Ju '20 8 n 08 Ju '200 Au l'20 8 Seg'2008 p 0 Oc '20 8 0 No t'20 8 08 De v'20 c 0 Ja '20 8 Fe n'2008 b M '20 09 ar 0 Ap '20 9 M r'200 9 ay 0 No '20 9 0 De v'20 9 c 0 Ja '20 9 n'2 09 Fe 0 b'2 10 01 0
20000.0
25000.0
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.
Infrastructure Development
Continued
Preservation of Materials
Open yard Closed sheds Huge tarpaulins - Structural materials.
- Items like bearings, valves, actuators, insulation etc. - Prevent the items from dust and rust.
Grease coating
One closed cabin - Regularly used loose items like HSFG Bolts and emitting electrodes of ESP...
Agency Mobilisation
Main agency for erection of main plant turnkey package - BHEL (PSWR)
The erection work of SG package has been given to following 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.
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.
1
3
2 2
Communication with BHEL manufacturing units Review of the planning Planning for Erection and Welding
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
Reports
Objective: Quick and easy analysis of progress/ critical area and present work status.
Daily progress monitor sheet with reflection of manpower deployment in each area, extra manpower required and critical activity, will be developed and circulated within the project so that necessary steps could be taken in advance. Milestone activity based reports will be generated for accessing the current status of the milestone to be achieved.
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
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 be always used for better ventilation
Thank You
Questions???