Professional Documents
Culture Documents
BASIC STRATEGY :
Basic strategy shall be to go in for cycle time reduction in every area by taking
up erection of all possible fronts Parallelly , system completion at first go itself and
by applying innovative ideas and modern erection practices. To achieve this we shall
have highly experienced and effective execution team posted at site with back up of
strong infrastructural support made available to them .They shall be always aiming for
achieving the project milestones as planned by changing the intermediate course of
direction depending on availability of inputs. The infrastructural support and basic
erection sequences / strategy is explained below.
SUBCONTRACTING STRATEGY:
An exclusive Quality group at site ensures all installation checks and stage
protocols with respect to approved quality plans for individual system , involving
Consultant/ Customer representatives. List of Area wise applicable quality plan is
enclosed. (Annexure-1)
SAFETY
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BHARAT HEAVY ELECTRICALS LIMITED
Power Sector Western Region
NAGPUR
MATERIAL MANAGEMENT
DOCUMENTATION AT SITE
MANPOWER DEPLOYMENT :
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BHARAT HEAVY ELECTRICALS LIMITED
Power Sector Western Region
NAGPUR
ERECTION SEQUENCE:
It may be noted that all columns for Rihand shall be trial assembled in full
length at Trichy hence pre assembly and joint matching at site shall not be required .
Once the structure as mentioned above are erected and verticality of columns
are ensured Ceiling girder erection shall start . Ceiling Girder Erection shall be done
in following sequence:
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BHARAT HEAVY ELECTRICALS LIMITED
Power Sector Western Region
NAGPUR
Ceiling girders will be supplied in three pieces and shall be pre assembled on
ground before lifting. Enclosed Annexure-4 may be referred showing proposed
assembly locations. It may be noted that casting of foundation pedestal of FD
fan-B to be hold till ceiling girder C&D is shifted to boiler cavity after pre
assembly. Also it may be noted that the bottom most vertical diagonal bracing
between column S10 R&S11R will not be erected for this purpose. Designer
clearance towards this is already obtained.
Columns nos. S15L&R , S16L&R and its connecting bracings will be erected
as soon as FMC moves out to clear the area after Ceiling girder A&B is erected ,
but necessarily have to be erected before Ceiling girder C erection.
Columns nos. S17 , S18 and its connecting bracings will be erected as soon
as FMC moves out to clear the area after Ceiling girder C & D is erected , but
necessarily have to be erected before Ceiling girder E erection.
In case of unit-3 the boiler drum will be received by rail near to boiler LHS i.e.
co-ordinate approx 2075N,2250E. Boiler drum will be unloaded with the help of two
cranes namely LS248H 180MT and Manitowoc 250MT by the boiler erection agency.
The drum then shall be dragged onto temporary rails to boiler cavity.
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BHARAT HEAVY ELECTRICALS LIMITED
Power Sector Western Region
NAGPUR
Boiler drum will be lifted in single stage with help of two nos 15MT electric
winches and pulleys suspended from temporary structure ( will be either fabricated at
site or will be diverted from other site ) at top. Winches will be placed in front of ESP
and will be anchored with the help of concrete counterweights of FMC crane placed
in pit. After the drum is aligned the lifting arrangement will be removed and pressure
part erection will follow.
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BHARAT HEAVY ELECTRICALS LIMITED
Power Sector Western Region
NAGPUR
Material feeding for first pass will mostly be done from RHS of boiler
between columns S8&9 on temporary rail. For back pass material shall be fed from
rear side. Also modern erection practices like use of omega lugs , anti deformation
frame for handling of Eco , Superheater and Rheater coils , special lifting tackle for
coil lifting will be inducted for safe and quicker erection of pressure part.
Hydraulic test of boiler will be done in three parts. Drainable part includes
the circulation system and drainable portion of the superheater. During this the link
connecting the non drainable portion of superheater shall be dummied. This will
facilitate early clearance for insulation of water walls and back pass walls required for
light up. Nondraianable part , which includes the non drainable portion of the
superheater system also , will be done just prior to boiler light up so that preservation
and rusting of superheater system can be avoided. Reheater hydraulic test shall be
done along with reheat system piping before steam blowing operation.
Air and flue gas ducting erection shall be taken up parallelly with boiler
pressure part so as to reduce the gap between boiler hydrotest and light up. Almost all
duct (excepting duct like below back pass U-headers etc. ) shall be pre assembled on
ground and shall be kerosene tested to reduce ,number of lifts and work in position
which will in turn reduce erection cycle time.
The assembled duct will mostly be fed with help of crane from sides of boilers.
However the inter connecting hot secondary air duct will be assembled below boiler ,
for straight lift.
FANS ERECTION :
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BHARAT HEAVY ELECTRICALS LIMITED
Power Sector Western Region
NAGPUR
MILLS ERECTION :
ESP ERECTION :
2. Usage of passenger cum goods erection elevator: BHEL shall provide one
no. of passenger cum goods elevator in each boiler ( at location as shown in
Annexure-7 enclosed ) which will be installed by our erection agency. This
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BHARAT HEAVY ELECTRICALS LIMITED
Power Sector Western Region
NAGPUR
3. Usage of waste disposal chute: BHEL shall provide and erection agency
will install one no. waste disposal chute in each boiler running vertically with
branch in each floor ( at location as shown in Annexure-7enclosed )
Tentative quantity of Cable 240sq.mm, three core, Al. cable 2000 M and
cable tray 8 500M , DB(200amps) 5 per boiler will be required.
All such DBs will cater the need of power supply for Post Weld Heat
Treatment also.
Above locations of DB and booth installation and routing of Power cable for
above are indicative , exact location shall be decided at site in consultation
with NTPC .
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BHARAT HEAVY ELECTRICALS LIMITED
Power Sector Western Region
NAGPUR
They shall lay construction power cable from main Sub station to DB for
welding booth as follows
DBs will be provided with ELCBs. the cables will be run underground before
reaching ESP island and within the ESP island the cable will be run on cable
trays.
Tentative quantity of Cable 240sq.mm,three core ,Al. cable 600 M and cable
tray 8 150M No. of DB (200 apms )-2 per ESP will be required.
Above locations of DB and booth installation and routing of Power cable for
above are indicative , exact location shall be decided at site in consultation
with NTPC .
Other than welding booth they shall provide a power distribution board at
least ten points one casing manhole door platform and one in pent house of
each pass,with standard industrial socket arrangement for miscellaneous use of
hand tools and hand lamps. These boards will be connected with nearest DB of
welding booth.
c) Piping erection agency : They shall lay construction power cable from main
Sub station(No. to DB for welding booth as follows
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BHARAT HEAVY ELECTRICALS LIMITED
Power Sector Western Region
NAGPUR
The cables will be run underground before reaching boiler island and within
the boiler island and in power house the cable will be run on cable trays .
Vertical run in boiler will along cable-S7L
It may be noted that Sub Station (SS) -7 shall be provided with back up DG
set power supply to avert power failure to Induction Heating M/c.
Tentative quantity of Cable 200sq.mm three core al. cable 2000 M and cable
tray 8 500M , DB (200apms)- 5 per boiler will be required.
Other than welding booth they shall provide a power distribution board at
least ten points at least in five suitable locations , with standard industrial
socket arrangement for miscellaneous use of hand tools and hand lamps. These
boards will be connected with nearest DB of welding booth.
Above locations of DB and booth installation and routing of Power cable for
above are indicative , exact location shall be decided at site in consultation
with NTPC .
Boier Area:
a. 2 nos of 5MT winches on ground floor near S5L and near S5R
b. 1no of 3 MT winch on boiler floor at 50M near column S4R
c. 2 nos of 2MT winches on boiler floor at 75 M near column S4R and
S4L
ESP area:
Piping area:
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BHARAT HEAVY ELECTRICALS LIMITED
Power Sector Western Region
NAGPUR
e. Gas cutting sets : Our erection agencies shall use a set of one DA cylinder
and three oxygen cylinders mounted on trolley to be operated on ground floor.
Also for transportation of such gas cylinders they shall use hand trolley.
ii. Lifting Tool for pressure part Coils : This is a hinged type
clamp which develops grip due to self weight of the component
being lifted.. This will be fabricated at site by our erection
agency. This will be used to lift pressure part vertical coils of
superheaters and reheaters. A sketch is enclosed. (Annexure-
10)
iii. Anti deformation frame for coils: The anti deformation frame
will be fabricated ( considering actual size of coil ) at site and
used for handling longer and heavy pressure part coils like
Platen superheater , reheater front , superheater division panel ,
assembled LTSH / ECO coils , to avoid permanent distortion
while lifting.. A sketch is enclosed . (Annexure-11)
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BHARAT HEAVY ELECTRICALS LIMITED
Power Sector Western Region
NAGPUR
h. Temporary Rail for material feeding: A temporary rail line will be laid
between boiler column no. S8-S9 through and through both boilers ( pl. see
enclosed Annexure-6 showing location and arrangement). Boiler pressure part
materials like water wall panels and sh./rh. Coils will be transported on to this
rail with help of dip trolley. The rail will be laid on sleepers at 1m spacing. For
transportation / dragging of boiler drum over the same rail continuous sleepers
will be laid for two lengths of drum and rolled on. Requirement of material
for this purpose will be as follows,
The portion of rail between two boilers will be made removable type ( in panel
form ), so that the same can be temporarily removed to give access to other
agencys T&P movement.
Tentative Duration : from 1st to 5th month from BES of each unit.
Material feeding :
Unit-3-
From Storage yard / pre assembly area by road though Unit-4 ( either between
mill bay-M row and boiler rear or between mill bay N row and ESP)
Unit-4
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BHARAT HEAVY ELECTRICALS LIMITED
Power Sector Western Region
NAGPUR
Crane : All erection will be done with help of winches . For unloading 0f
material 75 MT crane will be located on RHS of each boiler.
Tentative Duration : from 6th to 18th month from BES of each unit
Material feeding :
Unit-3-
From Storage yard / pre assembly area by road though Unit-4 ( either between
mill bay-M row and boiler rear ) then on rail to boiler cavity in case of first pass
and through boiler rear in case of second pass. After drum lifting of unit- 4 is over
the materials can be fed on temporary rail through boiler-4
Unit-4
From Storage yard / pre assembly area on road then on rail to boiler cavity in
case of first pass and through boiler rear in case of second pass.
iii) For balance component like roof structure , silencer , duct , air
preheaters, fans (FD and PA ) erection:
Unit-3 LHS
Crane: Manitowoc 250MT ( 6th to 10th month ) , LS 248H (10th to 18th month)
Material feeding :
From Storage yard / pre assembly area by road though Unit-4 ( between mill
bay-M row and boiler rear or between mill bay N row and ESP)
Unit-3 RHS
Material feeding :
From Storage yard / pre assembly area by road though Unit-4 ( between mill
bay-M row and boiler rear or between mill bay N row and ESP)
Unit-4 LHS
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BHARAT HEAVY ELECTRICALS LIMITED
Power Sector Western Region
NAGPUR
Material feeding :
From Storage yard / pre assembly area on road though Unit-4 ( between mill
bay-M row and boiler rear or between mill bay N row and ESP)
Unit-4 RHS
Material feeding :
unit-3
Crane : KH-500
Tentative Duration: 14th to 20th month from BES of unit-3
Material feeding :
From Storage yard / pre assembly area on road though Unit-4 ( between mill bay-
M row and boiler rear or between mill bay N row and ESP)
Unit-4
Crane : KH-500
Tentative Duration: 14th to 20th month from BES of unit-4
Material feeding :
From Storage yard / pre assembly area on road
v) ESP erection:
Tentative Duration: 1st to 18th month from ESP erection start of each unit
Material feeding :
Unit-3
From Storage yard / pre assembly area on road though Unit-4 ( between mill bay
N row and ESP & between ESP and ID fan)
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BHARAT HEAVY ELECTRICALS LIMITED
Power Sector Western Region
NAGPUR
Unit-4
From Storage yard / pre assembly area on road
Enclosed Annexure-14 shows the routes through which material shall be fed.
This is required for erection crane movement / parking inside boiler cavity and
for ceiling girder pre assembly as explained in erection sequence.
Hold lift Hold shall be lifted as soon as crane is moved out after ceiling
girders erection i.e. 5th month from boiler erection start.
b) Other Construction:
This will be required for FMC entry / exit and parking during boiler
structure erection in each unit.
Hold Lift : Hold shall be lifted as soon as crane is moved out after ceiling
girders erection i.e. around 5th month from boiler erection start.
ii) Inter Connecting Duct / platform between boiler and mill bay in
each unit :
This is required for moving out erection crane parked on LHS of boiler for
erection of roof structure / fans / APH
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BHARAT HEAVY ELECTRICALS LIMITED
Power Sector Western Region
NAGPUR
iii) Duct support structure between mill bay and ESP in each unit:
Hold lift: the hold is planned to be lifted progressively from 18 th month from
BES
iv) Duct support structure between ESP and ID fan: this is required to
facilitate crane movement for ESP erection and ID fan heavier component
erection .
Hold Lift: Hold is planned to be lifted progressively from 14 th month from Boiler
erection start.
This will be required to facilitate crane approach for erecting mill heavier
components. The particular bracing items need to be hold will be decided at
site in consultation with NTPC.
Hold Lift : hold is planned to be lifted progressively from 14th month of BES
By NTPC :
By BHEL :
a) Temporary rail / sleepers etc.
b) Bolt for omega lugs
c) Temporary structure for drum lifting
d) DESH Link temporary Dummy plates for non drainable HT
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BHARAT HEAVY ELECTRICALS LIMITED
Power Sector Western Region
NAGPUR
By erection agencies:
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BHARAT HEAVY ELECTRICALS LIMITED
Power Sector Western Region
NAGPUR
ANNEXURE - I
MASTER LIST OF QUALITY DOCUMENTS
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BHARAT HEAVY ELECTRICALS LIMITED
Power Sector Western Region
NAGPUR
37.
MILL REJECT HANDLING SYSTEM 1230-001-QVG-G-1089
38.
PASSENGER CUM GOODS ELEVATORS 1230-001-QVG-G-1090
39.
TANK & VESSELS 1230-001-QVG-G-1091
40.
HVAC 1230-001-QVG-G-1092
41.
AUX. TRANSFORMER DRY TYPE 1230-001-QVG-G-1063
42.
AUX. TRANSFORMER OIL FILLED 1230-001-QVG-G-1064
43.
CABLING (HT/LT CONTROL CABLE) 1230-001-QVG-G-1065
44.
DC SYSTEM 220/24 V BATTERY 1230-001-QVG-G-1093
45.
BATTERY CHARGER 1230-001-QVG-G-1094
46. HT SWITCHGEAR 1230-001-QVG-G-1066
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BHARAT HEAVY ELECTRICALS LIMITED
Power Sector Western Region
NAGPUR
47.
GENERATOR CIRCUIT BREAKER 1230-001-QVG-G-1067
48.
DG SET 1230-001-QVG-G-1095
49.
LT BUSDUCT 1230-001-QVG-G-1068
50.
LT SWITCH GEAR 1230-001-QVG-G-1069
51.
NEUTRAL GROUNDING SYSTEM 1230-001-QVG-G-1070
52.
STATION LIGHTING SYSTEM 1230-001-QVG-G-1096
53.
132 KV CABLE LAYING & JOINTING 1230-001-QVG-G-1071
54.
GAS CONDITIONING UNIT 1230-001-QVG-G-1018
55.
FABRIC EXPANSION JOINT 1230-001-QVG-G-1019
56.
DIVERTER DAMPER 1230-001-QVG-G-1020
57. CONDENSER ONLOAD TUBE CLEANING
1230-001-QVG-G-1036
SYSTEM
58.
TURBINE INSULATION 1230-001-QVG-G-1037
59.
CONDENSATE STORAGE TANK 1230-001-QVG-G-1097
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BHARAT HEAVY ELECTRICALS LIMITED
Power Sector Western Region
NAGPUR
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