FOCUS ON CIVIL & STRUCTURAL BOP

CONFERENCE ON “BALANCE OF PLANT SYSTEMS”

23RD MAY 2012

Presentation by:

J.P.Rao

Director – Corporate Marketing Strategy

GROUP INTRODUCTION

147 years of rich legacy as an Engineering &

Construction Company with unmatchable delivery

record.

Group Turnover of INR 12500 Crores (US$ 2.5

Billion), with 23,000 Employees.

Strong Presence in India and Internationally

footprint in Middle East, Africa, South East Asia &

Caribbean.

SP GROUP - Introduction

Lanco, Amarkantak – 1 x 300 MW

A Conglomerate with Multiple Business interests

with Progressive Outlook and Professional

Approach

Engineering & Construction – Industrial,

Commercial and Real Estate.

Infrastructure – Coal Mining, Power, Ports and

Roads.

Engineering, Procurement & Construction –

Minerals, Metals, Power.

Business Automation

Engg / Manufacturing of Precision Tools

Others (Bio-fuels, Facades and Interiors, Textiles

and Shipping and Logistics).

SP GROUP - Introduction

BALCO, Korba – 4 x 135 MW

SP Group Companies

General Contracting, Design & Build Solutions for Industries,Utilities, Residential & Commercial projects

Infrastructure construction for Ports, Power plants, Marine, Oil &Gas, Transport.

Electrical, HVAC, Plumbing & Fire Fighting. DG Set manufacturing,Switchyards.

Engineering, Shipping & Logistics and Transaction ManagementSolutions

Building Façade solutions

Engineering, Procurement and Construction solutions for Minerals,Metals & Power sector

Real estate development

Interior fit outs

Infrastructure development and operations / BOT projects

Water and Air purifier, cleaning and security systems

Transactions processing, services and networks

Travel Services

Yarns canvas, Belting ducks and terry towels

Publishing of Magazines like Power Watch, Computer Active,Car & Bike, Smart Photography.

SP Group Companies

Shapoorji Pallonji & Co. Ltd. is the core flagship company.

Synergy within group companies enables us to execute large & complex projects swiftlyand efficiently.

Industries, Utilities,

Buildings

Ports, Transport, Terminals, Infra

Electro-mechanical

works

Power, Minerals &

Metals

Roads, Ports, Power

Projects

Logistics & Water

Systems

Civil & Structural

Works

Intake / Outfall Structures,

Jetties

HVAC, Electrical,

Firefighting

EPC Solutions BOT Projects ETP / WTPDesalination

Synergy for Power Project Execution

Area of work

In Power Plants

SP Group – Synergy for Power projects

Shapoorji Pallonji & Co. Ltd.

One of India’s Oldest and Most Respected Group, operating for 147 years.

Turnover of INR 3174 Crores (2010-11).

An ISO 9001:2008 Company Complying to the ISO

Standards for ‘Design & Build’ & ‘EPC’ Projects.

Certified for ISO 14001:2004 & BS OSHAS 18001:2007

The FIRST Indian Construction Company to enter the

Middle East in 1971.

Strong Presence PAN India and in the Middle East, Africa, & the Caribbean.

Samalpati Power 105 MW Oil Fired plant

Shapoorji Pallonji & Co. Ltd.

Engineering & Construction activities include:

Power plants & Industries (24 Power & 50 Industrial

Projects)

High-rise Buildings & Residential Buildings

Hotels, Hospitals, Airport, Educational institutions, Data

Center, Commercial, Malls & Multiplexes, and Stadiums.

9 Regional offices presently executing 85 sites

Tata Power, Trombay-1 x 500 MW

Afcons Infrastructure Ltd.

A Leading Infrastructure Firm Having Transnational Presence.

Significant Experience and Strong Track Record.

Areas of Operation:-

MARINE – Over 176 + Works

Ports & Harbors', Jetties, Dry Docks, Wet Basins, Breakwater, Outfall & Intake Structuresetc.

OIL & GAS

LNG Plants, EPC Contracts for Offshore Oil & Gas Process Platforms OnshoreOil/Gas/Chemical Plants and Civil works such as Refineries, Gas Plants etc, FabricationYard.

TRANSPORTATION

Roads ( Over 3000 + Lanes km), Bridges, Flyovers, Interchanges ( Over 132 +), Railways andMetros ( 43 km Elevated metro) , Railway Tunnels, Road Tunnels.

9 TUNNELS AND HYDRO PROJECTS

40 GENERAL CIVIL ENGINEERING WORKS

30 + OVERSEAS PROJECTS

Established in 1927 as Wilson Electric works

Turnover of INR 700 Crores (2010-11)

In 1973, Sterling and Wilson was formed in association with SPCL

MEP Services

2005 onwards, ventured into MEP services to support customer’s expansion

plans and expectation of single point contact for Electro-Mechanical services.

Today Sterling and Wilson is India’s leading MEP services company

MEP projects contribute approx. 60% of the business revenue

Sterling & Wilson

Tata Motors, Sanand

DG Sets

Asia’s largest DG set plant at Silvassa ‘Sterling Generators’

ISO 9001:2000, ISO 14001:2008 Certified Facility

In 2008, become largest buyer of MTU engines in Asia

In 2010, become 2nd largest supplier of Gensets in India of above 1000 KVA

In 2011, become largest buyer of Perkins Engineers above 1000KVA, in Asia

Co-Gen capabilities

Established the Co-Gen division in 2011

Offers highly optimized Gas based Combined Heat & Power (CHP)

turnkey solutions for Commercial Buildings & Process Industries

Sterling & Wilson

F-1 Track, Delhi 4 nos. 3000 kVA & 2 nos. 1750 kVA

Solar-Power EPC

Established the Solar EPC division in 2010

16 projects aggregating to 71MW spanning across the country have already been

commissioned and connected to the grid

Working on 4 live solar projects aggregating to 10MW across the country with scope varying

from turkey EPC and balance of system to 33/66 kV power evacuation

Sterling & Wilson

25MWVisual Percept, Surel, Gujarat

POWER PROJECT EXPERIENCE

SPCL - Completed Projects

Name of the project Client LocationYear of

Completion

Civil & Structural works for Coal Handling Plant for 4 x

135 MW Thermal Power plant

BALCO /

SEPCOKorba 2005

Civil works for TG Foundations & Allied Buildings for 1 x

300 MW Coal based Thermal power plantLanco Amarkantak 2008

Civil works for the entire plant for 3 x 350 MW CCPPTorrent /

SiemensSurat 2008

Complete Piling Infrastructure & Enabling works for 370

MW CCPP

GSECL /

Alstom

Utran,

Gujarat2008

1 x 600 MW Thermal Power Project near Barela-

Gorakhpur Village

Jhabua

Power Ltd.

Seoni M.P 2011

Name of the project Client LocationYear of

Completion

Civil works for 2 x 120 MW Thermal Power Project Tata Power

Company Ltd

Jojobera 2001

Independent Power Generation – 105.66 MW Samalpatti power

Company

Tamilnadu 2001

Civil works for TG Building & Allied Buildings for 2 x

500 MW & General Civil works for 1 x 180 MW & 1

x 250 MW

Tata PowerTrombay,

Mumbai2001

SPCL - Completed Projects

Client : Torrent Power Generation LimitedLocation: SuratCompletion: 2008

Description / Major Quantities1130 MW Combined Cycle Power PlantExcavation : 2,01,465 cu.m.RCC Works : 86,990 cu.m. Reinforcement Steel : 7209 MTStructural Steel : 3500 MTRoof Sheeting & Cladding : 18,000 sq.m.

1130 MW TORRENT CCPP, Surat

Scope :

Earthworks

Under reamed Piling

TG Foundations & Decks

Boiler Foundations

Structural Steel Works

Ancillary Buildings

Road Works

CW System

Service Pipelines & Trenches

SPCL - Completed Projects

Client Lanco Location: ChattisgarhCompletion: 2008

Description / Quantities 300 MW Thermal Power StationExcavation : 4,45,000 cu.m.RCC : 1,38,120 cu.m.

Lanco Amarkantak, Chattisgarh

Scope EarthworkTG Foundations & Decks Boiler FoundationsDM Tank Foundation / FD & PA Fan FoundationPick Rack Foundation / Conveyer Foundations Coal Mill & BunkerWater Supply, Drainage & SanitationRain Water ReservoirStructural Steel Works

SPCL - Completed Projects

Client Shandong Electric Power Co.Location: ChattisgarhCompletion: 2005Description / Major Quantities540 MW (4 Units x 135 MW) TPP.Structural Steel : 4250 MTRCC : 78000 Cu.M.Reinforced Steel : 6200 MTTrack Hopper RCC : 200 MStacker RCC : 350 M

Balco, Korba

Scope:Crusher foundation & deck 28 M High RCC Frames Structure for Crusher House22.5 M High RCC Fly Ash Silo – 2 Nos.WTP with DM Tank foundationAir Compressor House / Refrigerating StationPower house Control BuildingCoal handling wash water pump house.

SPCL - Completed Projects

Client Samalpatti Power CompanyLocation: Tamil NaduCompletion: 2001

Description / Scope Independent Power Generation – 105.66 MWBuyer : Tamil Nadu Electricity Board.Seven Wartsila Diesel Engines

Primary Fuel : Low Sulphur Heavy Stock Plant

Samalpatti Power, Tamil Nadu

Client Tata Power Company Ltd.Location: JojoberaCompletion: 2001

Description / Scope Civil works for 2 x 120 MW Thermal Power ProjectWagon Tippler, Reclaim HopperConveyers Tunnel, Pump house

MCC Rooms.

Tata Power

SPCL - Completed Projects

Name of the project Client Location Completion

due

General civil works for Main Plant & Auxiliary

buildings for Unit 2 of 600 MW Power Plant

Bharat Heavy

Electricals Ltd.

Chennai Dec 2012

Site and Infrastructure works and Main Plant Civil &

Structural works for 1 X 600 MW TPP

Korba West Power

Company Ltd.

Raigarh,

Chhattisgarh.

Mar 2013

Piling and Foundations in Main Plant, Power House,

Boiler, ESP, TG, Fans and Transformer foundation

etc. for 2 x 500 MW TPP

Bharat Heavy

Electricals Ltd.

Tuticorin Nov 2012

Construction of BTG - Civil and Structural works for 5

X 270 MW Nasik thermal Power Project

Elena Power &

Infrastructure

Limited

Sinnar, Nasik. Nov 2012

Construction of BTG - Civil and Structural works for 5

X 270 MW Nasik thermal Power Project

Elena Power &

Infrastructure

Limited

Amaravati,

Maharashtra

Dec 2012

SPCL - Ongoing Projects

Name of the project Client Location Completion

due

Civil works for 225 MW Gas based Combined Cycle

Power Plant

Sravanthi Infratech

Pvt.Ltd.

Kashipur,

Uttarkhand.

June 2012

Piling and General Civil works for 2X250 MW Lignite

Based Thermal Power Project

Bhavanagar Energy

Company Limited

Bhavnagar,

Gujarat

Mar 2013

Construction of Main Plant building & Balance of

Plant for 2400 MW Combined Cycle Power plant.

M/s Reliance Utility

Engineers Pvt. Ltd.

(ADAG Group)

Samalkot,

Andhra

Pradesh

Aug 2012

Civil and Structural works of BTG and General Civil

works of construction of 2 X 600 MW Coal based

Thermal Power Plant.

Jindal India

Thermal Power

Angul,

Orissa

June 2013

Civil works for Coal Handling Plant of 2 X 600 MW DVC

Power Plant at Raghunathpur.

The TRF Ltd.

Jamshedpur

Ragunathpur

West Bengal.

June 2012

SPCL - Ongoing Projects

Client: M/s Reliance Utility Engineers Pvt. Ltd

Location: Samalkot,,Andhra Pradesh

Duration: 18 months

Project Gas Based Combined Cycle Power

2 gas turbines and 1 steam turbine

having a capacity of

3 X 800 MW = 2400 MW

Major Quantities Concrete quantity : 1,50,000 cum

Structural Steel : 14000 MT

.

SPCL - Ongoing Project – Project Data Sheet

GT Erected on foundations Block-2

2400 combined Cycle Power Plant, Samalkot

Scope

Total civil works for Main plant area-3 units and General civil works for Balance of plant

Total civil works for switchyard, roads and drains.

Erection of bolted structure for (14000 MT)

2400 combined Cycle Power Plant, Samalkot

Structures include:

GT building, ST building, Transformer yard, HRSG,

Bypass stack, Main Stack, Electrical control

building etc.

Pump houses, Raw water fire water pump house,

Cold water pipe encasement works, PT plant,

Ware house, Admin building, H2, N2, Co2 building,

Chlorination building, PMCC building etc.

Switchyard, GIS ,AIS,ICT, cable trenches (400 KV

& 220 KV).

Major PMV Deployed

- Concrete placing - a boom placer and 3 nos static pumps and 10 transit mixers are arranged.

- 125 KV DG set & 250 KV DG Set

- Concrete plants One 60 Cum/hr & 30 Cu/hr, each

- 150 MT crane

SPCL - Ongoing Project – Project Data Sheet

Structural Work in progress

Client Bhavanagar Energy Co. Ltd.Location: Bhavanagar, GujaratCompletion: Mar - 2013

Description / Scope Piling & General Civil work 2 x 250 MW lignite based Power plants.Scope: Pile caps, Piling works, Structural Steel works

Major Quantities:

No of Piles : 5587 ( 500mm, 750mm, 1000mm)

Pile Concrete :49300cum

Structural Steel :15050MT

Total Concrete : 1,30,000 cum

SPCL - Ongoing Project – Project Data Sheet

2 x 250 MW TPP, Bhavnagar

Client : Elena Power & Infrastructure Ltd.

Location: Nasik

India Bulls Thermal Power Plant, Nasik

Description

Capacity - 5 x 270 MW Thermal Power plant at Sinner, Nasik

ScopeCivil & Structural works for TG, Mill Bunker.

Civil Foundations for ESP.

Major Quantities:-

Structural Steel Fabrication:- 24200 MT.

Structural Steel Erection:- 15100 MT.

1200 Coal Based Power Plant, Derang

Client: Jindal India Thermal Power Limited

Location: Derang, Angul, Orissa

Duration 22 months

Project Description Coal Based Power Plant of 2X600 MW

Major Quantities Reinforcement work is @ 63,500/ MT

Structural @ 1,40,000/MT

Scope of Work

Earthwork, PCC, RCC, Reinf, shuttering, staging, insert

fixing, brickwork, plaster, water stopper.

Structures:

Boiler, ESP,

Power house,

Turbine generator

Mill bunker,

ID fan, PA fan, FD fan,

Air compressor building,

Demineralization tank,

CST tank, CWST tank,

Guard pond,

Coal handling plant,

water intake system,

ash pond etc.

SPCL - Ongoing Project – Project Data Sheet

CHALLENGES

FOR THE

CIVIL & STRUCTURAL (C&S) CONTRACTOR

PRESENT SCENARIO( AS ON MARCH 2012 ) – PAN INDIA

POWER PROJECTS

TOTAL NO OF PLANTS UNDER CONSTRUCTION (THERMAL) : 70 NOS.

TOTAL CAPACITY UNDER CONSTRUCTION IN MW (THERMAL) : 50000 MW

TOTAL NO OF UNITS : 148

TOTAL NOS OF CHP / AHP : 148

DM PLANT : 211, COOLING TOWERS : 218, CHIMNEYS : 77

PROJECTS UNDER CONSTRUCTION BY SPCL

5500 MW / 10 SITES

APPROX. STRUCTURAL STEEL QUANTITY : 1,50,000 MT

APPROX CONCRETING QUANTITY : 4,80,000 MT

CHALLENGES

WORKFORCE ISSUES

Unavailability of Trained Workforce

Mandatory use of Local Labour

LACK OF TRAINING INSTITUTES

Very Limited Institutes for Training the Labors / Executives for the Power Industry

Shortage of Executive Manpower / Power project specialists : @ 4000 nos

Break-up of Shortage: Senior Management – 354

Middle Management – 1302

Junior Management – 2268

CHALLENGES

SITE CONDITION ISSUES

Location of site – not favorable for Logistics, etc

Local Agitations

Space inadequacy for Site Infrastructure, Yard, Colonies, etc

Access roads are generally in bad shape

CHALLENGES

DESIGN & ENGINEERING ISSUES

Inadequate Data for Design & Engineering

Co-ordinated / Interface drawings are usually incorrect resulting in re-working

Approvals / issue of drawings are delayed

Equipment Details / Loading / Sizing are not known well in advance

LACK OF SUPPORT FROM DEVELOPERS

Tough Deadlines...without considering Site Conditions, Local issues, etc

No Project or Site Security

Delay in Bill Certification

Electricity and water availability

CHALLENGES

PLANNING & LOGISTICS ISSUES

Lack of Interface scheduling generally, poses problems!

Coordinated Drawings with vendors, Consultants, Contractors, are delayed

When drawings miss out the openings , redundant works are unavoidable.

When Logistics schedule is not updated for delivery of equipment on site,

Movement of gangway & infrastructure works...suffer.

CHALLENGES

PROCUREMENT & CONTRACTING STRATEGY ISSUES

Many a times Developer is not clear on Project Delivery Model- EPC / Packaging

All Agencies are not finalized at the initial stage...this leads to change in Design data &

Project Scheduling at a later stage!

Cost Escalation for Labour, PMV, Materials is not provided…

Cash Retention is up to Commissioning stage, affects Cash flow…

SOLUTIONS

SOLUTIONS FOR RESOLVING WORKFORCE ISSUES (TAKEN UP BY SPCL)

Preparation of Technical training syllabus for various trades.

Set-up of skill development center at every project site and impart on-site skill training .

Training to Sub-Contractors to handle statutory compliances & HSE norms, Labor

Management through site HR & admin.

Camp Boss posted for labour camps and their welfare

Identified and resolved labour issues in labour camps

Introduced Labor Productivity Incentive Scheme – To sub contractors.

Introduced Labor Retention Incentive Scheme – To Sub-Contractors

SOLUTIONS

SOLUTIONS FOR DESIGN & CONSTRUCTION ISSUES

Vendors to be finalized by Client at the initial stage itself

Data on Equipment Loading / Sizing, to be provided at the beginning.

Erector to confirm the Methodology to be deployed for installation of equipment/s in advance.

Vendor to provide updated information on Delivery schedule & interfacing activities

All concerned players to provide information on Work front availability / access / cutouts to be

left .

Link day to day change and project based change

SOLUTIONS

SUPPORT FROM DEVELOPER

Partnering Approach with WIN-WIN Preposition

Ensuring Co-ordination between Vendors, Consultants & Contractors

LEAN Approach – Optimum Utilization & Resources & Minimizing wastages

Social-Economic Impact Analysis should be carried out by the Developer –

- Very important in order to anticipate local issues which hinder the works.

- Developer should have dedicated CSR Activities for the Locals

SOLUTIONS

SOLUTIONS

SUPPORT FROM DEVELOPER

Understanding of Total supply Chain value Streams

Provide advance time for Mobilization

Inspection & Clearance for raw steel, fabricated items, other bought out items in the shortest

time.

Inspection for Critical items only

Critical areas, Drawing finalization / approval, release within stipulated time

SOLUTIONS FOR PACKAGING & CONTRACTING ISSUES

Civil works for entire unit should be one package (including infrastructure works)

Building related Electro -Mechanical works can be integral part of Civil package.

Bonus clause for early delivery.

Ensure +ve Cash flow throughout the project duration

Cost Escalation for Labour, PMV, Materials is to be provided

Retention should be against Bank Guarantee only till completion of Civil works & not

Commissioning stage

Equitable risk allocation through sharing of risks.

SOLUTIONS

THANK YOU