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MSP Report On Construction of

Cooling Tower “Tata Power Unit#5”
Jamshedpur.

MCM 503: COMPUTER WORKSHOP-III

Submitted By

Mr. Ravi Bhushan (221025)

PGP ACM 22nd Batch

(2008-2010)

NATIONAL INSTITUTE OF CONSTRUCTION

MANAGEMENT AND RESEARCH

PUNE
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Contents

1. Introduction ………….…3

2. Project Details ………….…3

3. List of Activities ………….…8

4. Technical Features ….…….…..9

5. Data Collected ……….…..11

6. Conclusion …..…….…13

Introduction:
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Project management is the process of planning, organizing, and managing tasks and resources
to accomplish a defined objective, usually within constraints on time, resources, or cost. A
project plan can be simple, for example, a list of tasks and their start and finish dates written
on a notepad. Or it can be complex, for example, thousands of tasks and resources and a
project budget of crores of rupees. Most projects share common activities, including breaking
the project into easily manageable tasks, scheduling the tasks, communicating with the team,
and tracking the tasks as work progresses.

Cooling tower is one of the complex project in which various activities involves, so more
manpower require than other smaller project of construction. Some activities are critical
which takes more time so we should do proper planning and scheduling to avoid it and make
work faster.

Project Description
To meet the power demands due to TATA STEEL modernisation programme, TPC have
already installed and commissioned one unit of 67.5 MW and three unit of 120MW last unit
was commissioned in October 2005. Power from these units is being fed to TATA STEEL grid
which in turn supplies to steel plant, cement plant, TATA MOTORS, Tinplate co. &
Jamshedpur city. With the anticipated growth, a power deficit of 113.5 MW for Jamshedpur
network by the year 2008-09 is estimated requiring addition of one more unit of 120MW
rating coal based thermal power plant.

Project location-
The 5th unit is in the vacant land available within the existing premises of jojobera power
plant boundary besides availability of coal and water, evacuation of power, features of main
plant equipment including cooling water system, coal and ash handling systems, electrical
systems. Modification to be carried out, environmental aspects, estimates of project cost,
schedule for project implementation and cost generation.

Site Topography and Grade Level-

The site for the proposed unit is situated in filled up area covered by slag fill. The ground
level of the proposed site varies from RL 180m to RL 170m. The grade level of the existing
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120MW units is at EL 180m. Space available for proposed unit no.5 is almost filled with slag
during construction of unit no 1 to 4.
Major Building and Structures
Station building: general arrangement
1. Station building- The span of the turbine generator and auxiliary equipment bay
would be 24m and that of electrical bay would be 10.5m with the existing station
building of unit no.4. The length of the station building would be 67.5m consisting
of 9 bays of 7.5m.
2. TG bay would be serviced by three floors-
Ground floor-0.0m
Mezzanine floor-5.0m
Operating floor-10.5m
(TG bay-22m, electrical bay-32m)
3. The superstructure would be of structural steel framing with brickwork and pre-
coated metal sheet for side cladding and RCC floor slabs.
4. The turbine generator pedestal would be of reinforced concrete frame structure
and would be isolated from the building foundations and superstructure.
Steam Generator Area and Mill Bay
The mill bay would be would be of structural steel-framed construction, supporting
the steel bunkers. The 10.50m wide bay would have floor for the feeders and for the
trippers.
Chimney
Stack of 150m height from SG area grade level to match with the existing 120MW
units. The height takes into consideration the requirement of Indian Emission
Regulations.
Cooling water pump house
Pump house is provided for CW pumps. The CW pumps are located indoor. Each CW
pump would have an independent sump with provision for installation of stoppage and
coarse screens in the pump chamber.
Miscellaneous buildings
s.no Building/structure Sizes(m)LxBxD remarks

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1. ESP control room 28x7x4.5 Single storey building. RCC

construction with brick wall for side
cladding. Roof shall be RCC

2. Air washer room 20x15x8 Single storey building at two

locations.Structuralsteelconstruction
& 13x7.5x5.5
with brick wall for side cladding. Roof
shall be of RCC.

3. Fuel oil pump 6x6.5x4.5 Extension of existing pump house by

house two bays.

4. D.G house 15x7.5x11 Extension of existing DG house by

one bay.

5. Ash slurry sump 50x12x7.5 Single storey building. Structural steel

and ash slurry pump construction with RCC roofing and
house for bottom brick wall for side cladding.
ash and fly
ash(common for
unit#4&5)

6. 132kv switchyard 12x6x10 Extension of existing control room.

control room

7. 220kv switchyard 20x13.5x5 Existing building to be demolished

control room and new building to be constructed.

8. Clarified water 25x25x5 3000cu.m capacity CLWST

storage tank

9. Silo 7.5m diameter 650 tonnes capacity.

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Cooling Tower for 120MW jojobera thermal power plant

The use of cooling tower is to cool the water in water circulating system. It has two types
induced draft cooling tower and natural draft cooling tower. The above figure shows IDCT
(induced draft cooling tower).

For the above project of cooling tower following are the project details….

Client---Tata Power.

Contractor—Paharpur Cooling Tower.

Number of Cell—5Nos

Contractor Type—EPC (Turnkey)

Project Cost—2cr approx

Cooling Tower, CT-5

Capacity: 210m3/hr.
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Hot water inlet temp. : 47°C

Cold water outlet temp. : 32°C
Wet bulb temp. : 28°C,

No. of cells: 5

About Paharpur-- P ahar pur does not r es tr i ct i ts elf to onl y manuf a ctur ing an d
s u p p l yi n g cooling tow ers , but believ es in the concept of tur nke y
r es p o n s ib il it y including tr ans p or ting to s ite, er ect ion, co mmis s ion ing an d
tes t in g o f co mp lete coo ling tow er s . I n the cas e of concr ete cool ing tow ers
th e civ i l w or k is under taken b y P ahar pur on its ow n. The y have a f u ll
f led g ed civ il des ign and cons tr uct ion depar t ment w ith highl y tr ained an d
ex p er ien ced civ il engine er s . The y als o have exper i enced per s onnel in
s h ip p in g and er ect ion depar tmen ts .

List of Activities: In order to construct the cooling tower, a series of activities will need to
be undertaken. The following activities are part of the project scope:

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Civil Work
• EXCAVATION
• PCC FOR CW BASIN
• RCC FOR CW BASIN
• CW BASIN WALL INCL. COLUMN
• BEAM AT IST LEVEL
• UP TO FILL LEVEL
• FILL TO ELIMINATOR
• ELIM. TO FAN DECK LEVEL
• FAN DECK SLAB
• FAN CYLINDER
• PRE CAST WORKS
• APPRON

Mechanical & Electrical work

• INTERNAL BITUMIN PAINTING
• H.W.PIPING
• HAND RAILING
• PVC FILL ERECTION
• H.W.DISTRIBUTION
• ELIMINATOR ERECTION
• EQUIPMENT ERECTION
• EQUIPMENT EARTHING
• CABLE TRAY ERECTION
• SLIDE GATE ERECTION
• SLUICE GATE ERECTION
• BUTTERFLY VALVE ERECTION
• TRIAL RUN
• COMMISSIONING

Technical Features

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As per above activities the technical features are as below—

EXCAVATIONS—For excavation purpose excavators are used like Tata Hitachi, JCB are
leading company for this work.

Tata Hitachi--Excavator
PCC FOR CW BASIN—M10 grade of concrete had used for PCC work. Pcc has done only
for surface level purpose of further project work. Transit mixture is useful for concrete
mixing purpose.

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RCC FOR CW BASIN—M30 grade of concrete has used for RCC work and reinforcement
steel was CRS (corrosion resistive steel). Batching plant was used for mixing purpose of
aggregates and cement. Vibrators were used for compaction purpose and for transporting of
concrete transit mixture and concrete pump were used.

CW BASIN WALL INCL. COLUMN—MS steel were used for shuttering or form work.
Jack and U jack were also used for supporting to column and basin wall’s shuttering.

BEAM AT IST LEVEL & UP TO FILL LEVEL—Tower crane is used for lifting the
materials at high elevation. Concrete has transported through concrete pump, it has no any
problem to carry the concrete till hight of 20m.

PRE CAST WORKS— All necessary beams were cast at ground with precise way and after
(28days) cured it properly, it was lifted at elevated position as per drawing. Again crane was
used for lifting the beams to required position of the structure.

H.W.PIPING—

Hot Water Piping (MS-Steel)

TEST OF CONCRETE—before placing of concrete we should do slump test for checking
the workability. Compressive strength should be checked by cube test and by use of
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compressive strength machine. We should check for 7days and 28days cube sample of
15x15cmm size.

Cube sample Compressive strength machine

DATA COLLECTION—
Calender-
CT-calendar assign as project calendar for the cooling tower schedule.
Start date- 28/02/2008
Finish date-19/03/2009 before levelling of the resources.

Notes—notes are provided in various activities if required.

Various activity and Duration

Task name %completion days Start day End day

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Cooling Tower For Unit#5 44% 356days 28-02-2008 08:00 17-04-200900:00

Civil Work 58% 332days 28-02-2008 08:00 20-03-200900:00
Excavation 100% 28 days 28-02-2008 08:00 31-03-200817:00
PCC FOR CW BASIN 100% 26 days 01-04-2008 08:00 30-04-200817:00
RCC FOR CW BASIN 100% 74 days 01-05-2008 08:00 25-07-200817:00
CW BASIN WALL INCL. COLUMN 100% 55 days 28-06-2008 08:00 31-08-200817:00
BEAM AT IST LEVEL 100% 112days 01-07-2008 08:00 07-11-200817:00
UP TO FILL LEVEL 67% 113days 08-07-2008 08:00 15-11-200817:00
FILL TO ELIMINATOR 56% 128days 05-07-2008 08:00 01-12-200817:00
ELIM. TO FAN DECK LEVEL 48% 125days 14-07-2008 08:00 05-12-200817:00
FAN DECK SLAB 0% 50 days 28-10-2008 08:00 24-12-200817:00
FAN CYLINDER 0% 60 days 24-11-2008 08:00 31-01-200917:00
PRE CAST WORKS 9% 99 days 01-10-2008 08:00 23-01-200917:00
APPRON 0% 13 days 06-03-2009 08:00 20-03-200917:00
Mechanical & Electrical work 0% 110days 11-12-2008 08:00 17-04-200917:00
INTERNAL BITUMIN PAINTING 0% 18 days 11-12-2008 08:00 31-12-200817:00
H.W.PIPING 0% 20 days 12-01-2009 08:00 03-02-200917:00
HAND RAILING 0% 15 days 26-02-2009 08:00 14-03-200917:00
PVC FILL ERECTION 0% 30 days 26-12-2008 08:00 29-01-200917:00
H.W.DISTRIBUTION 0% 20 days 30-01-2009 08:00 21-02-200917:00
ELIMINATOR ERECTION 0% 18 days 30-01-2009 08:00 19-02-200917:00
EQUIPMENT ERECTION 0% 35 days 09-02-2009 08:00 20-03-200917:00
EQUIPMENT EARTHING 0% 35 days 30-01-2009 08:00 11-03-200917:00
CABLE TRAY ERECTION 0% 35 days 30-01-2009 08:00 11-03-200917:00
SLIDE GATE ERECTION 0% 15 days 30-01-2009 08:00 16-02-200917:00
SLUICE GATE ERECTION 0% 12 days 17-02-2009 08:00 02-03-200917:00
BUTTERFLY VALVE ERECTION 0% 15 days 09-03-2009 08:00 25-03-200917:00
TRIAL RUN 0% 5 days 01-04-2009 08:00 06-04-200917:00
COMMISSIONING 0% 5 days 13-04-2009 08:00 17-04-200917:00

Resource Allocation:
Resource name Type initial Group max unit std.rate over time cost/use

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Project Manager Work P Management 1 Rs90,000.00/monRs0.00/hr Rs0.00 Prorated

Senior Manager Work S Management 3 Rs60,000.00/monRs0.00/hr Rs0.00 Prorated
Engineer Work E Management 6 Rs24,999.00/monRs100.00/hr Rs0.00 Prorated
Masons Work M Construction 4 Rs250.00/day Rs0.00/hr Rs0.00 Prorated
Carpenter Work C Construction 4 Rs200.00/day Rs0.00/hr Rs0.00 Prorated
Helper Work H Construction 12 Rs160.00/day Rs0.00/hr Rs0.00 Prorated
Bar-bender Work B Construction 3 Rs200.00/day Rs0.00/hr Rs0.00 Prorated
Labour Work L Construction 15 Rs180.00/day Rs0.00/hr Rs0.00 Prorated
Electrician Work E Construction 1 Rs200.00/day Rs0.00/hr Rs0.00 Prorated
Mechanic Work M Construction 1 Rs200.00/day Rs0.00/hr Rs0.00 Prorated
Steel MaterialS Material Rs3,500.00 Rs0.00 Prorated
Cement 43OPC MaterialC Material Rs250.00 Rs0.00 Start
Sand MaterialS Material Rs300.00 Rs0.00 Prorated
Aggregates MaterialA Material Rs1,200.00 Rs0.00 Start
Lining Bricks MaterialL Material Rs12.00 Rs0.00 Prorated
Fly ash MaterialF Material Rs15.00 Rs0.00 Prorated
Batching plant Work B Equipment 1 Rs200.00/hr Rs0.00/hr Rs0.00 Prorated
Transit mixer Work T Equipment 2 Rs100.00/hr Rs0.00/hr Rs0.00 Prorated
Dumper Work D Equipment 2 Rs50.00/hr Rs0.00/hr Rs0.00 Prorated
Excavator Work E Equipment 1 Rs200.00/hr Rs0.00/hr Rs0.00 Prorated
Tower Crane Work T Equipment 2 Rs150.00/hr Rs0.00/hr Rs0.00 Prorated
Concrete Pump Work C Equipment 2 Rs50.00/hr Rs0.00/hr Rs0.00 Prorated
Jack hammer/concrete
Work breaker
J Equipment 2 Rs20.00/hr Rs0.00/hr Rs0.00 Prorated
Conclusion:
Microsoft Project is used for planning, scheduling and tracking the project. The critical path
of the project is found out by the software and it can be updated whenever necessary. The
resources available can be allocated depending upon the criticality of the activity. It keeps a
record of all the resources involved in the project and any over allocation and under
allocation is determined by the software.
During this project we learned a lot about several aspects of project management. Some
aspects are the overall planning process, the impact of certain planning decisions,
implementation principles, and working with MS-project. Furthermore, we gained insight in
the subsidy process involved with technical projects. Specifically, subsidies for energy related
projects and projects that concern developing countries. This made this project very
interesting and useful.

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