presentation21.1.06

8/3/2019 Presentation21.1.06

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PROJECT AT A GLANCE

3 X 660 MW Boilers and Auxiliary Installation

Client - National Thermal Power Corporation Ltd.

Supplier - Doosan Heavy Industries & Construction

Co. Ltd. South Korea

Erection AgencyLarsen & Toubro Limited, ECC Division

LOI Issued - 15/04/04.

Job Value - 296.36 Crores


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Salient Features of the Project*3 X 660 MW POWER PLANT - First time in India

* UNIQUE IN NATURE - Mega Power ProjectDeclared by Govt.

* INDIVIDUAL BOILER RATING - 2225 MT / Hrs. (660 MW)

* WORKING PRESSURE - 255 kg / sqcm

* NO OF BOILERS - 3 NOS

* CUSTOMS DUTY - Nil ( Decl. by Govt.due

to Mega Power Project)

* HEIGHT OF THE BOILER - 100 MTRS

* NO OF FANS - 6 NOS

*NO OF COAL FEEDERS - 10 NOS

*NO OF MILLS - 10 NOS


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All Structural Members are Bolted Type.

No Boiler Drum in this Boiler.

Boiler working press. (Sup. Steam) 255 kg/sqcm

Furnace wall is Jacket Type.

All Ceiling Girders will be erected from outside

by using 750 MT crane Ringer mode.

Furnace wall is being erected 28 mtrs in length

after preassembly.

Uniqueness of the Project


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Extended floor Panel assembled with Header &

Buckstays and will be erected.

Furnace Bottom hopper with Ring header will be

assembled and erected all together.

Most of the Duct Pieces upto 15 mtrs will be

assembled at ground and erected.

Approx. 20000 nos welding joints will be done on

ground for preassembly before erection out of

42000 nos joints.

Uniqueness of the Project


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Safety Statistics

Description

Safety M/H record

Accident records

Minor

First -aid injuries

Fatalities

Status of meeting & training

Training

Multi media safety show

PROJECTED MANHOURS =

CUMULATIVE

(FROM MARCH 2005)

1488374

1

10

1

58

15

15.50 Millions


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Screening of the workers are being done before

engaging on the job.

Morning Pep-talk is being done before starting

the work.100% PPEs are being implemented at erection

site.

Training for workers on weekly basis at training

hall for better awareness.

Usage of 100% full body harness at erection site.

SAFETY AC

TIVITIES


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Usage of Double Safety net at erection site.

Periodic inspection of Tools & Tackles.

Method statement is being made and analysed

jointly by Contractor and Client before all critical

erection.

Sub contractors Performance is being

evaluated by Safety committee on Monthly basis.

100% usage of GI Flat for earthing purpose.

Total Safe Manhours upto Dec05 = 1488374

Positive customer feed back.

SAFETY ACTIVITIES


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SCOPE OF WORK OF L&T

Port Clearance,Inland Transportation From

Vizag to Sipat & Insurance

Material Management

Erection

Testing & Commissioning


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MECHANICAL ERECTION : 147.90 CRORES

E&I ERECTION : 11.00 CRORES

INLAND TRANSPORTATION INCLUDING TRANSIT

INSURANCE : 35.34 CRORES

SUPERVISION OF ERECTION AND COMMISSIONING

BY DOOSAN : 44.61 CRORES

PORT CLEARANCE CHARGES ( 1.2% OF THE CIF

VALUE) : 19.46 CRORES

CONTRACT VALUE


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ADDITIONAL COMPENSATION TO BE PAID BY DOOSAN

(6.5 M US DOLLAR) : 29.64 CRORES

INSURANCE CHARGES : 8.414 CRORES

TOTAL CONTRACT VALUE INCLUDINGE&I : 296.36 CRORES

CONTRACT VALUE


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BOILER STRUCTURE : 20772 MT

BOILER PRESSURE PART & ACCESSORIES : 21240 MT

POWER CYCLE PIPING : 9096 MT

COAL FIRING SYSTEM : 11469 MT

DRAFT SYSTEM (INCLUDING DUCT & DAMPER) : 15012 MT

REFRACTORY / INSULATION / C&I / MISC. : 6291 MT

TOTAL TONNAGE OF 3 BOILERS(3 X 660 MW) : 83880 MT

SUMMARY OF TOTAL TONNAGE OF BOILER 3 x 660 MW


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MILESTONE EVENTS

Description As per

Contract

Actual

Unit # 1 Structure Erection 15-04-05 03-03-05

Unit # 1 Pressure part Erection 15-09-05 15-09-05




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Q lit A t


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Involves Bolting and torquing of 102615 bolts per

Boiler for main structure

Welding of hand rails : 700 Mtrs per boiler

Welding of 42656 joints in pressure parts per boiler

Welding of 22283 joints in power cycle piping per

boiler.

Involves special P91/T91, T92, P23/T23 and Super

304H materials in boiler pressure parts and piping.

Involves Induction heating technique for above

special materials

Quality Aspects


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100% implementation of Preparation & approvalFQP and Inspection test procedure prior to start of the

job to erection.

Stage wise inspection prior to erection andcompletion of job and proper documentation of the

same.

Reduction of repair % from 2.9 to 0.60 by stringentcontrol in welding conditions and welder performance.

100% NDT & PWHT clearance of Preassembled

items before erection.

Quality Improvement

QUALITATIVE IMPROVEMENTS


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Pre assembly of most of the Pressure part

members before erection. Thereby improving on

the following parameters.

1. Safety Improvement - Reduction of exposure of

work at height and critical locations.

2. Improvement of quality of welding as

maximum welding is done at ground level.

3. Reduction in total completion time by parallelworking on pre assembly.

4. Reduction in installation cost by reducing the

work in in-situ osition

QUALITATIVE IMPROVEMENTS

presentation21.1.06

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