Study on Super Critical Power Plant

A STUDY ON “SETTING UP OF POWER PLANT WITH SUPERCRITICAL TECHNOLOGY”

A PROJECT REPORT

TABLE OF CONTENTS

1. INTRODUCTION.................................................................................................................8

1.1. OVERVIEW OF THE POWER PLANT....................................................................................91.2. GENERAL LAYOUT OF THE PLANT.................................................................................101.3. THE REQUIREMENTS FOR THE SITE................................................................................111.4. THE FUNCTIONING OF THE PLANT.................................................................................121.5. COAL – USE IN ELECTRICITY GENERATION...................................................................141.6. DISADVANTAGES OF COAL............................................................................................141.7. PROXIMATE ANALYSIS OF COAL...................................................................................15

A. Ash.................................................................................................................................15B. Hydrocarbons & Gases.................................................................................................16C. Moisture.........................................................................................................................16

2. PROJECT MANAGEMENT PROCEDURES.................................................................17

2.1. MANAGEMENT APPROACH....................................................................................172.1.1. PRE-AWARD STAGE................................................................................................17a. Planning and Scheduling...............................................................................................17b. Purchase Requisition (PR)............................................................................................17c. Floating of Enquiry and Bid receiving..........................................................................19d. Technical Evaluation Report (TER) and Order Placement...........................................202.1.2. POST AWARD STAGE..............................................................................................21a. Kick off Meeting.............................................................................................................21b. Level Planning...............................................................................................................23c. Document Release Schedule..........................................................................................23d. Post award Engineering................................................................................................23e. Engineering Correspondence between Owner and CLIENT.........................................23f. Obligations with the Owner...........................................................................................24g. Quality/Inspection..........................................................................................................24h. Commercial and other Conditions.................................................................................25i. Material Dispatch and Billing.......................................................................................26II. Establish project Organization.........................................................................................28

3. PROJECT COORDINATION...........................................................................................29

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A. PLANNING & SCHEDULING........................................................................................29B. DOCUMENT CONTROL & DESIGN SUBMISSIONS..................................................32C. CONSTRUCTION MANAGEMENT...............................................................................39

1. The functions of construction project management.......................................................40i. Construction management (CM):..................................................................................40ii. Programme management (ProgM):..............................................................................41iii. Project Control..............................................................................................................41iv. Design, bid, build contracts...........................................................................................43v. Design and build contracts............................................................................................43

D. MANAGEMENT INFORMATION SYSTEM.................................................................441. Monitoring & Progress Reporting.................................................................................442. Project Management Meetings......................................................................................45

E. PROCUREMENT & FIELD CONTRACTING...............................................................501. Sub-Contract Management............................................................................................502. Purchase specifications.................................................................................................52

F. INSPECTION & TESTING..............................................................................................53G. QUALITY ASSURANCE.................................................................................................57

1.1. Quality Assurance Programme..................................................................................581.2. Independent Third Party Inspection..........................................................................601.3. Quality Audit..............................................................................................................611.4. Non-Conformance......................................................................................................621.5. Quality Assurance Documents...................................................................................62

H. COMMISSIONING & TESTING.....................................................................................631.1. General Requirement.................................................................................................631.2. Shop Test....................................................................................................................641.3. Pre-Commissioning...................................................................................................651.4. Commissioning..........................................................................................................661.5. Reliability Test...........................................................................................................661.7. Taking Over...............................................................................................................71

I. SITE MANAGEMENT & INSURANCE.........................................................................711.2. Site Organisation.......................................................................................................731.3. Site Facilities.............................................................................................................741.4. Site Health And Safety Management.........................................................................781.5. Storage And Preservation..........................................................................................801.6. Site Welding & Heat Treatment.................................................................................811.7. Labour Management and Site Industrial Relations...................................................811.8. Site employment policies and practices.....................................................................82

A. FLOW CHARTS OF POWER PLANT............................................................................85

A. SCHEMATIC DIAGRAM OF POWER PLANT...........................................................................85B. BLOCK DIAGRAM OF POWER CYCLE..................................................................................86C. ENERGY CONVERSION CYCLE............................................................................................87D. COAL TO ELECTRICITY...............................................................................................88E. COAL HANDLING & PREPARATION....................................................................................89

A. TIME SCHEDULE..............................................................................................................90

A. COST ESTIMATE FOR SUPER CRITICAL POWER PLANT...................................91

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B. COST BREAK UP OF SUPER CRITICAL POWER PLANT.........................................92C. COMPARISON OF BOILERS.........................................................................................93

D.COST COMPARISON OF BTG PER MW.................................................................................94

SUGGESTIONS & RECOMMENDATIONS..........................................................................95

BIBLIOGRAPHY........................................................................................................................96

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EXECUTIVE SUMMARY

Power Crisis has been a long clamor in India and this seems to persist for

thecoming decade or so. Beyond optimistic illusions, ground realities are toofierce

to be accepted.Seeds of improvement are however being planted at all possible

arenasbroadly Indicating: -

Generation

Transmission

Distribution

The Project Idea springs from one of the reforms Viz. generation of Power.To cater

the accelerated need of the country Ultra Mega Power Plants (UMPPs) have been

proposed. These are giant power plants of 4000 MW at one place. In addition to

these, a number of Mega Power Projects (More than 1000 MW) are also being

promoted. The unit size of power plants has also experienced a supercritical shift

in technology. Thus focus is on more efficient supercritical units of 660 MW and

800 MW. However considering imported coals as the main fuel, unit size can go

up to 1000 MW. As the domestic coalavailable for power sector is having very

high (40 to 45%) ash contentfeasibility of higher size units are yet to be examined.

Meanwhile after500MW / 600 MW (subcritical) the next suitable supercritical size

wasdecided 660 MW or 800 MW for coal based thermal power plants.

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1. INTRODUCTION

a. A project is any related group of work activities which, when completed,

will achieve specific objectives. A project has a stated scope, deliverables,

tasks, work steps, duration and budget, as defined in a Project Charter.

b. This Project is relevant to all related groups of work activities that have a

business objective, whether the solution involves in providing

Information, Technology and communicational inputs.

A project:

a) Has a beginning and an end;

b) Is defined by specific objectives (deliverables);

c) Is undertaken within a well-defined organizational structure;

d) Has a single project manager who is responsible for its success;

e) Has a defined starting point, a defined end point, and defined work

breakdown structure comprising a path from the start to the end.

c. To be successful, a project must move forward in a controlled manner,

from initiation to completion. A project uses resources. These include

work effort of the project team, including significant stakeholders not

assigned directly to the team, infrastructure support, project

administration, money for project related travel and training, etc.

Resources must be used effectively or the project will be late, or over

budget, or both.

d. Project milestones, comprised of specific deliverables, are developed to

show tangible results of work done and to provide substance for quality

assurance reviews. Quality Assurance (QA) reviews are essential, to

identify issues at the earliest possible stage, to enable them to be

addressed so that the overall project objectives, delivery date and budget

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are not adversely impacted.

e. Risks are inherent in all projects. A risk management plan is an essential

element of any project charter.Any and all foreseeable risks must be

documented and relevant mitigation strategy devised.

f. Project Management is the process by which a project is initiated,

controlled, and brought to a successful implementation.The objective of

project management is to plan and control a project from start to end,

with high levels of productivity and quality. A project must be managed

in terms of its structure, work performed by staff assigned to it, specific

deliverables and budget constraints. Levels of control and monitoring will

vary depending on the timeframe and criticality of the project at hand.

g. As the gear of technology is experiencing a critical shift in power sector,

India is keen to welcome the Supercritical technology. The first stage of

capacity shift is seen to be 660 MW which is being adopted by NTPC and

other private sector players for several upcoming projects. The

assignment covers supply of complete main plant with BOP package on

Engineering, Procurement and Construction (EPC) basis. EPC work can

exclude civil works, coal handling system, ash handling system, external

raw water system and water intake system depending upon the projects.

1.1.Overview of the power plant

With the world on a development spree, there is shortage of power in most

places whilst the demand seems to be in a never ending upward spiral. There

are several answers to this challenge such as the nuclear power plants, but

the conventional thermal power plants also play an equally important role in

this power equation. Selecting a proper site for a thermal power plant is vital

for its long term efficiency and a lot many factors come into play when

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deciding where to install the plant. Of course it may not be possible to get

everything which is desirable at a single place but still the location should

contain an optimum mix of the requirements for the settings to be feasible

for long term economic justification of the plant. Old is gold goes the

equally old and wise saying and this is applicable to the black diamond as

well, in the perspective of thermal power plants. Well if you are confused let

me tell you that I am referring to coal which is one of the oldest used fuels in

the world. Though technology has gone skywards in the previous couple of

centuries, yet this source continues to occupy an important position in the

energy production scenario worldwide.

1.2.General Layout of the Plant

There are four main circuits in any thermal power plant and these are

a. Coal & Ash Circuit – this circuit deals mainly with feeding the boiler with coal

for combustion purposes and taking care of the ash that is generated during the

combustion process and includes equipment and paraphernalia that is used to

handle the transfer and storage of coal and ash.

b. Air & Gas Circuit – we know that air is one of the main components of the fire

triangle and hence necessary for combustion. Since lots of coal is burnt inside

the boiler it needs a sufficient quantity of air which is supplied using either

forced draught or induced draught fans. The exhaust gases from the combustion

are in turn used to heat the ingoing air through a heat exchanger before being let

off in the atmosphere. The equipment which handles all these processes fall

under this circuit.

c. Feed Water & Steam Circuit – this section deals with supplying of steam

generated from the boiler to the turbines and to handle the outgoing steam from

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the turbine by cooling it to form water in the condenser so that it can be reused

in the boiler plus making good any losses due to evaporation etc.

d. Cooling Water Circuit – this part of the thermal power plant deals with handling

of the cooling water required in the system. Since the amount of water required

to cool the outgoing steam from the boiler is substantial, it is either taken from a

nearby water source such as a river, or it is done through evaporation if the

quantity of cooling water available is limited.

1.3.The Requirements for the Site

a. As the name implies the power plant is meant for generating power which

obviously means that it will consume huge quantities of fuel. The exact quantity

would depend on the size of the plant and its capacity but it is a general fact that

ample quantities of fuel must be available either in the vicinity or it should be

reasonably economical to transport the fuel till the power plant. Since most

thermal power plants use coal (they can use other fuels as well) it must be

ensured that sufficient coal is available round the clock. Just to give you a rough

idea a power plant with 1000 MW capacity approximately would require more

than ten thousand tons of coal per day hence the necessity for continuous supply

and storage capability of coal in the power station.

b. Ash if the main byproduct of combustion and since the amount of coal used is

huge, you can intuitively imagine the amount of ash generated and it is certainly

in the region of thousand tons per day. Ash is much more difficult to handle as

compared to coal since it comes out hot from the boiler and is very corrosive in

nature. Disposing of such huge quantities of ash requires a large amount of

empty space where it can be safely dumped.

c. There must be ample space for the storage of coal, disposal of ash, building of

the power plant, residential colony of workers, markets and so forth. An

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approximate analysis suggests that for every MW of power generated there

must be at least 3 acres of land available for the purpose. Hence the power plant

site needs to have good amount of land and this land should have good bearing

capacity in order to survive the static and dynamic loads during the operation of

the plant.

d. Large amount of water is required for cooling purposes in the power plant

hence it is better if such a source is available nearby in the form of rivers etc.

e. Apart from these major requirements there are also other requirements which

are equally important such as the availability of skilled people to work for the

plant and good transport facilities in the vicinity.

Hence we see that setting up a thermal power plant requires a lot of factors to be

considered simultaneously.

1.4.The Functioning of the Plant

The four circuits of the thermal power plant make a complete picture when put

together helping to generate electricity out of fuels such as coal which is the most

widely used fuel. The calorific value of coals depends on the quality of the coal

and the place from where it is mined.

Let us perform a simple calculation regarding the amount of coal required in a

power plant.

Let us assume an imaginary thermal power plant which has a capacity of 1000

MW and try to find the amount of coal required for its consumption. Also assume

that the boiler operates at an efficiency of 75% and the heat supplied per kg of

steam is around 500 kcal per kg and that the amount of steam required per kWh is

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nearly 5 kgs. Further let us assume that the type of coal used in the plant has a

calorific value of 5000 kcal/kg

Then the quantity of coal required per hour would be given by

Weight of Coal Required ==>Capacity * Steam Requirement * Heat

Delivered/Calorific Value of Coal * Efficiency of Boiler

==> {1000 * 1000 * 5 * 500}/{5000 * 0.75 * 1000} = 666 tons/hr

Normally it is a practice to store coal for up to one month usage in case the power

plant is situated at a sufficient geographical distance from the coal source so that in

case of any disruption of the transportation system, the region is not immediately

affected. You can calculate that in case the above plant requires such a facility, we

would require space to store and handle nearly 480, 000 tons of coal.

Coming back to the actual operation this coal is then fed to the combustion

chamber of the boiler where steam is generated giving rise to hot exhaust gases and

ash which are handled by their respective circuits. The steam turbine is driven by

the steam which converts this thermal energy into the mechanical energy and is

coupled with an electric generator to convert it to electrical energy.

The electricity generated through the generator coupled to the turbine is then fed to

the main grid via a system of transformers and other electrical equipment and is

usually taken to far off places via high voltage transmission lines before it is

actually supplied in the domestic or industrial sectors at their respective voltage

levels.

Hence we see that how the energy hidden within the ordinary coal is harnessed

through the use of a thermal power plant to light our homes and industries.

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1.5.Coal – Use in Electricity Generation

a. In the earlier days coal might have been used for providing heat for making

food or in the blacksmiths furnace but as technology made strides, so did the

level and importance of coal in the energy production arena went upwards.

Currently thermal power plants produce hundreds of megawatts of electricity

from burning coal.

b. Despite the hue and cry of environmental concerns, which are of course true

to a certain extent, various other parameters have still kept coal as one of the

most important sources of power generation in thermal power plants.

c. The very first parameter is the ample abundance of coal in most parts of the

world including the United States. Estimates suggest that the US has

reserves of coal which could last more than two centuries even at the current

rate of consumption. Apart from the reserves found on land there is also

presence of coal layers beneath the sea although it is difficult to

commercially extract it from there, but there might be a technology for this

in the future.

d. The next factor is directly related to the above factor and is that of cost. As

you know cost is closely associated with availability and more abundant any

commodity is, the lesser will be its price and vice versa which is a law of

economics. Hence producing electricity through the use of coal is much

cheaper than other non-conventional forms of energy such as say wind,

nuclear and so forth.

1.6.Disadvantages of Coal

a. Of course all is not green in the literal sense in the use of coal in power

plants. Environment and health hazards are one of the most prominent

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reasons why many groups are against the use of coal for power production.

Disposal of large quantities of ash could pose problems in the coming years

if the heaps continue to grow.

b. Another major factor to be kept in mind is that despite the abundant supply

of coal it is still a non renewable source of energy which was formed

through a complex process lasting thousands of years and hence cannot be

formulated at a short notice.

Despite the disadvantages, coal is still very popular in its use as power plant fuel

and continues to provide electricity to this power hungry planet.

1.7.Proximate Analysis of Coal

Any substance can be analyzed in different ways such as proximate analysis,

chemical analysis and so forth. We will carry out the proximate analysis of coal

which gives the different categories of compound present in the substance. Apart

from carbon which is an obvious constituent the other constituents are as follows.

A. Ash – this is an undesirable constituent of coal which is contained within

the coal in two forms namely fixed ash and free ash. Fixed ash is inherent in

the coal due to the formation process from vegetable matter and it is not

possible to remove it except that it gets separated on burning. The free ash is

removable via processes such as washing and screening.

It is undesirable to have ash in the coal but normally different types of coal could

have ash content anywhere between say around 2% to 30% which is an

unnecessary burden adding to transportation costs, lowering of heat value of coal

and producing large amounts of corrosive waste which needs to be disposed off in

a proper manner. Another disadvantage is that inside the boiler combustion

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chamber if the ash gets subject to very high temperatures it can form clinkers

which could choke the passages and decrease efficiency of the boiler. It is best to

use such coal in the powdered form if such a possibility exists.

B. Hydrocarbons & Gases – coal contains a variety of combustible gases

such as hydrogen, methane and non-combustible gases such as carbon

dioxide etc. This volatile content could be as low as 3% or even as high as

nearly 50%. These constituents especially the non-combustible gases are just

a waste as far as heat value of the fuel is concerned and an unnecessary

burden which needs to be transported around and stored without any useful

value in return.

C. Moisture – the moisture content of coal could vary from just over 1% to

nearly 30-40% and just like ash it has two forms – inherent moisture and

free moisture. The former is not easily removable as it is a costly process

whilst the latter can be removed by normal drying using slightly heated air.

Obviously since coal is used in the boiler combustion chamber any excess

moisture would interfere with the combustion lowering the actual heat

available to generate steam.

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2. PROJECT MANAGEMENT PROCEDURES

2.1.MANAGEMENT APPROACH

I. Define sequence of work

II. Establish project organization.

Sequence of work mainly consists of

2.1.1. PRE-AWARD STAGE

The processes in the pre-award stage areelaborated below;

a. Planning and Scheduling

1. Planning and scheduling of the complete project including pre-award

schedule, L1 and L2 schedule is prepared by planning department. However,

each package owner shall coordinate with the planning department for

correct planning of their respective packages.

2. The initial project deliverables in the project are monitored/expedited on the

basis of pre-award schedule till L1/L2 schedules are prepared. Once Master

Control Network (Plant L2 Schedule) is prepared, it supersedes the pre-

award schedule for all further monitoring of the Project.

b. Purchase Requisition (PR)

1. Manual Purchase requisitions (PR) of all the Packages are created by

Engineering Department. However, PR of certain materials which are not

directly related to the Main Plant such as Construction Power materials,

miscellaneous site materials, Construction Lights etc may be raised by

Project Management Group/ Site official.

2. Planning department prepared the schedule of the package in consultation

with Project Management group.

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3. Engineering department prepare the list of the Potential Vendors. However,

Package owner (PMG) has to the right to review the same and can modify

the vendor list based on the feedback of the officials in other projects.

4. There shall be no modification in the vendor list once the PR is signed by

Q&A. However modification in the vendor list can be made with the consent

of Q&A.

5. The Engineering departments attach the technical specifications along with

all the required Drawings/Documents as per the requirement of Owner and

modify the same (As the case may be) with the PR and submit the same to

the Package owner (PMG) for further action.

6. The package owner in the PMG check the PR (Hard Copy) submitted by the

Engineering department with respect to the following information;

(a) Technical Specification,

(b) Budgeted Cost,

(c) Schedule,

(d) Q&A,

(e) List of Vendors,

7. In the technical specification, the package owner (PMG) shall check the

followings;

(a) Scope

(b)Battery Limits

(c) Exclusions

(d) Interface with other packages/suppliers

(e) Owners contract/specification

8. Once the package owner is satisfied with PR and the necessary documents

submitted by the Engineering department, the same shall be submitted by the

package owner to the HOD (PMG) for necessary approval in SAP.

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9. Once the PR is approved by the HOD (PMG), the same shall be circulated to

the P&C department for further processing.

c. Floatingof and EnquiryBid receiving

1. The package owner (PMG) should follow up with the P&C department after

circulation of the PR for the bid schedule. The bid schedule shall consist of

the followings;

(a) Date of Floating for enquiry,

(b) Last date of receipt of offers,

(c) Date of TER,

(d) Date of award,

2. P&C should float the tender enquiry to the various vendors once the PR is

received by them. However, there may be a case where the vendors can be

contacted directly for getting the offers in time. Package owner (PMG) shall

obtain a copy of the enquiry letter circulated to the various vendors.

3. Once the techno-commercial offer is submitted by the vendor to the P&C,

the same shall be reviewed by the package owner (PMG) with respect to the

following requirements;

(a) Scope

(b) Battery Limits

(c) Exclusions

(d) Interface with other packages/suppliers

(e) Owners contract /specification

4. Simultaneously one copy of the offer submitted by the vendor is circulated

to the Engineering department for technical review. The commercial review

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is carried out by the P&C department.

5. The P&C shall follow the following time limit (duration of award of

Package from date of receipt of PR ) as mentioned in the table below;

Table 1: Duration of award of package from date of receipt of PR

S.No. Description No. of days

1 For Equipment items 30-35 days

2 For System Package 45 days

d. Technical Evaluation Report (TER) and Order Placement

1. Engineering department carried out a technical review of the offer submitted

by the vendor. In case of any deviation/deficiency in the offer from the

technical point of view, clarifications are demanded from the respective

vendors and the replies of the vendor on the same are analysed.

2. Engineering department hold a meeting for sorting out the issues with the

vendor, the agenda of the meeting includes the following points;

a. Schedule

b. Exclusion

c. Engineering inputs ( required by Owners )

d. General clarification on technical specifications

3. Once the Engineering department is satisfied with the replies of the vendor,

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TER is prepared by them and submitted to the Package owner (PMG). The

package owner (PMG) review the TER submitted by the Engineering and

circulate the same to the P&C.

4. The commercial offer is reviewed by the P&C. Based on technical and

commercial review, the order is placed by P&C and the same is released by

Finance department.

5. Initially the LOI/LOA is issued to the vendor. The PO/WO (subject to

supply or services) is issues within seven (7) days after the issuance of

LOI/LOA. Package owner shall ensure the following to enable P&C to issue

PO/WO in SAP;

a. PR is raised in SAP,

b. Two separate PRs in SAP ( One for supply and other for service),

c. All line items are correctly entered in SAP,

6. The status of all the packages from release of specification to Award is

maintained at a common location in server which is continuously updated by

all the package owners.

2.1.2.POST AWARD STAGE

The processes in the post -award stage are elaborated below;

a. Kick off Meeting

1. The package owner has to organize a kick off meeting within 15 days from

date the contract/LOA. The package owner (PMG) shall prepare an agenda

and it should at least cover the followings;

(a) Clarifications on all technical points, if any,

(b) LOA Acceptance

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(c) Freezing of L2 schedule, Master Procurement schedule / material

sourcing,

(d) Finalization of makes/vendors,

(e) Manpower loaded site mobilization plan,

(f) Billing Break up and Payment schedule,

(g) Progress report and review mechanism,

(h) Format of Documents,

(i) List of T&P& consumables required

(j) Quality Plan , Customer inspection,

(k) Master document list to be finalised for approval/information

category,

(l) Organization for the Package,

(m) Communication Procedure

(n) Insurance

(o) Cash flow statement etc.

2. The package owner (PMG) should take the approval of the HOD (PMG) on

agenda before circulation of the same to the vendor and other department

like

a. Electrical Engineering,

b. Civil Engineering ( on requirement basis ),

c. Planning,

d. Quality,

e. P&C (optional ),

f. Site (on requirement basis ),

3. The package owner (PMG) shall give an intimation of at least seven (7) days

and circulate the agenda in advance to the vendor and concerned division so

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that all can have sufficient time for the preparation of the meeting. Kick off

meeting of small packages may be avoided.

b. Level Planning

1. During kick-off meeting, vendor shall prepare the L3 level schedule in

consultation with the Package owner (PMG) and concerned official from

planning department and it should be based on the L2 level schedule. The

same has to be agreed and signed off during the Kick off meeting by all

concerned officials.

c. Document Release Schedule

1. The vendor shall submit the Master Document List (MDL) and it must

include the drawing/document release schedule and BBU. Based on the

BBU, P.O/W.O will be prepared.

2. In some of the cases, MDL may be submitted by Client to vendor. But in

either case, document number in required format is to be provided by Client.

d. Post award Engineering

1. Once the contract is awarded to the vendor, all the engineering issues are

dealt between vendor and Engineering department. However, the package

owner (PMG) has to ensure that supplier/vendor supplies all the

drawings/documents as per MDL and same shall be approved from the

Engineering Department.

e. Engineering Correspondence between Owner and CLIENT

1. Engineering in consultation with the Owner with information to package

owner (PMG) shall finalise the various categories of drawings/documents

such as for approval/for information etc.

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2. Vendor shall submit a copy of all the drawings / documents (in soft) to

Client document controller. Document controller in turn submits the same to

the Owner in the category already decided for their

comment/approval/information as the case may be.

3. The package owner (PMG) has to follow up with the Owner to obtain their

approval/comments and after receipt of the Approval/comments, the same

has to be communicated to Engineering for resolution

f. Obligations with the Owner

1. The package owner (PMG) has to discuss and finalise the following

activities with the Owner ;

(a) Categorization of Document List

(b) Approval Category,

(c) Information Category etc.

(d) Approval of Package wise BBU,

(e) Document submission procedure,

g. Quality/Inspection

1. The quality department has to play an important role in the post award stage.

Some of main activities to be performed by the quality department are listed

below;

(a) Signing of PR,

(b) Discussion on Quality aspects during technical discussion before

award,

(c) Discussion on Quality aspects and Q&A formats during Kick off

meeting,

(d) Deciding make of equipment/vendor approval based on pre

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definedformat,

(e) Arranging inspection of material,

(f) Release of MDCC for dispatch of material

2. In case of system packages, a copy of offer should also be circulated to the

concerned official in the Q&A for obtaining approval on make of

items/Bought out items.

3. In case, where it is not possible to circulate the complete offer, at least make

of equipment and Quality related portion should be circulated to the Q&A

for their review.

h. Commercial and other Conditions

1. Once the contract is awarded, the package owner(PMG) has to performed

the following activities;

a) Ensure that the Bank Guarantee formats are attached along with the order

b) Obtaining Advance Bank Guarantee (ABG) from the vendor in the desired

format

c) Checking the ABG in terms of correctness and completeness

d) Getting the BG vetted by Finance,

e) Processing of all Bills of the suppliers,

f) Issue of Notice of Payment approval (NOPA),

g) Material dispatch and clearance,

h) Issuance of Road Permit,

i) Issuance of Form “ C” if required,

2. The various guidelines pertaining to the various processes which

are part of the project management has been issued from time to

time by the management.

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3. The various circulars issued by the management are listed in the

table below;

Circular Nos Guidelines with reference to Description

System

Circular-01

Procedure for preparation and

submission of DBR &

Specifications to owner

Activity and Responsibility

System

Circular-02

Procedure for Purchase Indent Activity and Responsibility

System

Circular-03

Procedure for Enquiry floating and

Award of the Packages

Activity and Responsibility

System

Circular-04

Project Management System to be

Followed

Practices and Responsibility

System

Circular-05

Revised Procedure for release of

Initial Advance

Activity

Table 2: Various circulars issued by the management

i. Material Dispatch and Billing

1. Package owner (PMG) has to follow up with the vendor for timely dispatch

and delivery of the equipment at site as per the requirement.

2. Package owner (PMG) has to also ensure the processing of vendor’s bill and

billing to the Owner. The package owner (PMG) has to follow the

procedures as listed below;

(a) The package owner (PMG) should check all the necessary documents

submitted by the vendor as per the format attached in the Annexure-V

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before processing the vendor’s bill.

(b) After verification of the documents, the package owner (PMG) should

forward the NOPA (As per the format attached in Annexure-VI),

vendor’s bill along with the check list as attached in Annexure-V to

the Project Assistant (PA) of HOD.

(c) PA should check the NOPA, vendor’s bill along with the check list

submitted by the package owner. After verifying all the details, PA

should submit the NOPA (mark a billing MIS number on the NOPA

for keeping the record), vendor’s bill to the HOD along with the check

list for further processing.

(d) The NOPA signed by the HOD along with the vendor’s bill and check

list must be submitted to the concerned department such as CEO

Office / Finance etc. by the PA for further processing of the bill.

The Package Owner (PMG) should follow up with the concerned department for

release of payment against the Bill submitted.

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II. Establish project Organization

Typical Organization chart of thermal power plant

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3. PROJECT COORDINATION

Project coordination stages usually include creating an overall goal, planning

essential tasks, plus executing and controlling the project. Develop a SWOT

(strengths, weaknesses, opportunities, threats) or STEP (social, technological,

economic, and political) analysis throughout different stages to evaluate project

progress.

Coordination is essential for a business that deals with two or more related

projects. Projects vary based on business objectives but may include launching a

new product or expanding services into new areas.

A project coordinator often holds different roles and responsibilities, depending on

the industry, business size, and project goal. For example, corporations might

designate separate project coordinators to handle domestic and international

affairs; whereas, small businesses might weave basic project coordination duties

into a management role.

Project coordinators can serve as decision makers or assistantsto lead managers.

It is very important at all levels Viz. Engineering, Procurement, Construction, and

Start Up.

Important aspects of project management are as follows:-

A. PLANNING & SCHEDULING

1. Project planning has the following objectives and deliverables:

a. Confirm all previous assumptions regarding skills required, number of

project staff, effort and duration, etc.

b. Confirm specific skill requirements, confirm that those resources are

available (in-house or by external contract resources), identify the

individuals who will be assigned according to the skill requirements for

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various tasks and sub-projects

c. Document work breakdown structure, including specific tasks, milestones

and deliverables

d. Refine estimates of task efforts

e. Determine task dependencies

f. Determine external dependencies

g. Determine interface and interaction dependencies

h. Determine milestones that will represent quality assurance checkpoints and

their completion dates

i. Schedule the work plan, inclusive of constraints

j. Prepare and review the project plan

k. Submit the initial project plan for approval by the relevant executive

sponsor, project sponsor and steering committee

2. Project planning is an iterative and ongoing process. However, the initial

project plan must be approved and signed-off before the project

commences. At this point, the project plan is to be base lined, to ensure that

any and all variances from that plan are tracked and recorded.Detailed plans

must be revised as necessary throughout the life of the project.

3. When planning a project, the project manager must confirm and build on the

business case developed during the project initiation phase to prepare an

appropriately detailed project charter. The project manager is responsible to

create the project plan. The detailed project plan is used to document

deliverables and to achieve the project objectives detailed in the project

charter.

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4. Project plans should include:

a. task schedules, being project specific detailed work plans,

b. resource schedules,

c. quality management and review plans,

d. a risk management plan,

e. a communications plan,

f. an issue management plan,

g. a scope management plan, and

h. a detailed budget addressing all aspects of the project and its management

5. When preparing the detailed work plans, the project manager must ensure

consideration of:

a. task dependencies

b. task and resource scheduling

c. Addition of any new tasks manifested as the project progresses (assuring

also that the scope of the project is closely managed and changes to that

scope are documented thoroughly).

6. Project plans must be reviewed regularly to identify any slippage from

original delivery dates, to implement corrective measures and to evaluate the

flow on effect on the project schedule overall.

7. The master project plan and all subsidiary plans must include milestones.

Milestones will usually be the completion of project stages. Resource

constraints, quality issues and project risks need to be factored into the

milestone plan.

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8. Each task within a project plan has a narrative description sufficient to

communicate:

a. What is to be achieved/delivered;

b. The steps involved in achieving the deliverable;

c. The completion criteria of each deliverable.

9. During the planning process, it is essential to recognize that some or all of

the project team, and potentially some of the extended stakeholder team, will

need training. Determine the type and duration of training required and

include that training in the detailed project plan.

10.A project plan has many uses, not only as a schedule to manage the

timeliness, sequence and inter-dependency of tasks, but as a tool to assure

clear communications.

B. DOCUMENT CONTROL & DESIGN SUBMISSIONS

1. Calculation with supporting documents to prove the proposed Plant’s

availability as guaranteed/stated (this will include quantitative data of break

down losses, planned maintenance outages and derating losses, as against

the design margins, redundancy and buffer storage offered)

2. Quality Assurance Programme as relevant to the Contract.

3. Total plan (schedule duration & frequency) on the regular maintenance work

of the proposed Plant, also describing the how employer’s personnel will be

trained and utilised in the work.

Note:Client will furnish a proposed maintenance program/schedule as called for

here to enable assessment of preventive maintenance. The program will indicate

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details such as interval between outages, duration of outage, man-hours required

for outage, and the basis of such a program. A proposed shift working pattern to

meet above outage program will also be furnished. It will also furnish a typical

maintenance schedule for plant and other equipment detailing information such as

time required, timing of the activity, nature of activity etc.

4. Clients proposed man-power schedule for the regular and emergency

operation/maintenance of the plant and chart of distribution of manpower at

various location including organizational structure.

5. Drawings as follows

A. Overall plant area layout showing the:

1. Main Plant area

2. Ash dump area

3. Water intake and outfall points with pipe routes

4. Effluent discharge points.

5. Rail-tracks and roads connecting the plant site.

6. Township location

B. Plot plan showing all buildings, outdoor plants & equipment, as well as

the coal stock pile, fuel oil storage area, transformer yard, switch yard,

workshop, green areas, reservoirs, drainage & other pits, effluent

treatment areas, roads, rail tracks, temporary storage areas & buildings

required during erection and also all future provisions if applicable.

C. Equipment layout drawings for

1. All floors of the power house

2. Boiler area

3. Ash handling plant

4. Coal handling plant

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5. Desalination and Demineralization plant

6. Central Control Room and Control equipment room.

7. Fuel oil handling plant

8. CW pump house

9. Sea water intake pump house

10.Fire water pump house

D. General Arrangement drawing and sectional drawing for

i. Turbine assembly

ii. Steam Generator

iii. All major equipment

E. Schematic drawings/one line diagrams along with a brief write-up on

design, operation and control philosophy for

1. SG, TG and Power cycle piping systems (including drains & vents)

2. Cooling water systems (CW as well as auxiliary cooling water

systems)

3. Compressed air systems.

4. Auxiliary steam systems, including the water & steam system for the

auxiliary boilers.

5. Fuel oil handling system.

6. Ash handling system.

7. Coal handling plant

8. Desalination and Demineralising system

9. Fire fighting system

10.Water balance diagram for the entire plant water system including

drainage/effluent flow.

11.Single line diagram (SLD) of electrical power distribution system

12.SLD of 400KV / 220 KV Switchyard with detail bus configuration,

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metering and protections scheme

13.MV and LV system

14.D.C. & A.C emergency system

15.Tripping logic/scheme for generator, generator transformer, and unit

transformer.

16.SCADA system configuration for 400 KV / 220KV switchyard

17.Waste water treatment

18.Overall water treatment scheme.

19.Flue gas desulphurisation plant

20.Air conditioning and ventilation system

21.Fire fighting system

F. Heat balance diagrams for the power cycle system showing TG gross

heat rate, power generation, auxiliary power consumption and all

relevant parameters (pressure, temperature, enthalpy & flow rate) for the

following conditions (with 0% and 3% make-up)

1. Turbine VWO

2. 100% TMCR

3. 75% TMCR

4. 60% TMCR

5. Best efficiency condition

6. Maximum power generation condition when top H.P. heater is out.

7. HP-LP bypass condition with and without turbine on house load.

G.Steam generator unit performance chart with performance coal as well as

worst coal for

1. 100% BMCR

2. 100% TMCR

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3. 75% TMCR

4. 60% TMCR

5. All HP heaters out condition

The above chart will provide the complete heat balance information, fuel

consumption, boiler efficiency, flow rate, pressure and temperature at all the

essential points of the furnace and its draught plant, and also of the feed

water and steam systems.

H. Performance and characteristic curves for TG, boiler ,Generator ,ESP

and all major fans and pumps in Main Plant and in Auxiliary systems.

I. All correction curves for all parameters needed to establish the

guaranteed performance value from the corresponding figures obtained

during the Acceptance test (if parameters vary from specified design

conditions), including the correction curves due to

i. Ambient wet bulb temperature

ii. Dry bulb temperature

iii. Humidity

iv. Fuel properties/composition

v. Na2O Content in ash/Sulphur content in coal

vi. Sea water analysis values

vii. Supply frequency

viii. Supply voltage

J. Correction curves for condenser vacuum for following parameter

variation.

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a) Tubes Plugged conditions

b) Changes in load

c) Changes in CW temperature.

d) Make up water flow

K. A complete list of the internationally accepted codes & standards which

will follow in the design, material selection, manufacturing erection, tests

at works and tests at site for all major plant & equipment as well as

piping, cabling, steel structures etc.

L. A list of statutory regulations which proposed Plant will follow and for

which will prepare all documents needed to obtain the approval of the

statutory bodies.

M. A bar-chart for proposed design, manufacturing, procurement and

delivery activities.

N. A bar-chart for proposed Site activities up to Taking Over of the Unit(s).

This will be supplemented by a detailed write-up on proposed procedure

of project implementation, deployment schedule of key personnel with

their bio- data, schedule of construction machinery etc.

6. Characteristic curves (capacity vs TDH, power, efficiency and NPSH) for

the following pumps:

a) Boiler feed pumps at various operating speeds.

b) Condensate extraction pumps.

c) CW pumps.

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d) Sea water intake pumps.

e) Auxiliary CW pumps.

f) Closed cycle DM cooling water pumps.

g) Fuel oil unloading pumps.

h) Condenser air extraction pump

7. Characteristic curves for the following fans at various speeds and damper

positions.

a) ID fan

b) FD fan

c) PA fan

8. Vibration analysis results for condenser and feed heaters under worst

operating conditions

9. Data on control & instrumentation

a) Plant operational philosophy

b) DDCMIS system architecture drawings and write-up.

c) Description and write-up of control and interlocking system

d) Proposed general arrangement of panels, consoles, system

cabinets, instrument power supply panels

e) Scheme for power supply distribution to equipment / systems

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f) Manufacturer’s catalogues of instruments, control gadgets and

other accessories proposed to be supplied for main plant and

auxiliaries.

g) Scheme for steam & water analysis system.

h) Scheme for machine monitoring system.

i) Schematic drawings of offsite PLC system and hook-up with

DDCIMS

j) Details of plant security and Monitoring system

k) Details of station management system

C. CONSTRUCTION MANAGEMENT

Construction Project Management is the overall planning, co-ordination and

control of a project from inception to completion aimed at meeting a client’s

requirements in order to produce a functionally and financially viable project

that will be completed on time within authorized cost and to the required

quality standards. Project management is the process by which a project is

brought to a successful conclusion. Construction project management

(CPM) is project management that applies to the construction sector.

The most common responsibilities of a Construction Manager fall into the

following 7 categories:

1. Project Management Planning

2. Cost Management

3. Time Management

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4. Quality Management

5. Contract Administration

6. Safety Management

CM Professional Practice which includes specific activities like defining the

responsibilities and management structure of the project management team,

organizing and leading by implementing project controls, defining roles and

responsibilities and developing communication protocols, and identifying

elements of project design and construction likely to give rise to disputes and

claims.

1. The functions of construction project management

1. Specifying project objectives and plans including delineation of scope,

budgeting, scheduling, setting performance requirements, and selecting

project participants.

2. Maximizing resource efficiency through procurement of labor, materials and

equipment.

3. Implementing various operations through proper coordination and control of

planning, design, estimating, contracting and construction in the entire

process.

4. Developing effective communications and mechanisms for resolving

conflicts

i. Construction management (CM):

1. Management of the site.

2. Form of delivery

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ii. Programme management (ProgM):

1. Programme management is concerned with managing time in a

project and is thereby part of the CPM function.

2. Management of a client’s portfolio (client’s programme in this sense

is equivalent to a client’s brief)

iii. Project Control

1. The Project Control function is concerned with gathering data regarding

project progress, producing progress reports, monitoring time, cost, and

quality. Compared to the CPM function, the Project Control function can be

characterized to be passive, whereas a construction project manager needs to

take action.

Project leader (PL): The PL is responsible for achieving the project’s objectives.

He is the manager “in line”.

Project director (PD): The PD is the leader of a big project that can be broken

down in sub-projects (e.g. Channel tunnel). He can also be the head of a PM

organization. OR: The OR is the representative of the owner. This function can be

provided either internally or externally.

DC: Document Control - A key function of a Project Manager.

FBOT: finance build operate transfer

BOT: build operate transfer

DBOT: design build operate transfer

BOO: build own operate

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EPC: engineering procurement construction

PFI: private finance initiative

GC: general contractor

GMP: Guaranteed maximum price

Typically the construction industry includes three parties:

a. an owner,

b. a designer (architect or engineer),

c. the builder (usually called the general contractor).

Traditionally, there are two contracts between these parties as they work together

to plan, design, and construct the project.

1. The first contract is the owner-designer contract, which involves planning,

design, and construction administration.

2. The second contract is the owner-contractor contract, which involves

construction. An indirect, third-party relationship exists between the

designer and the contractor due to these two contracts.

An alternate contract or business model replaces the two traditional contracts

with three contracts:

1. owner-designer,

2. owner-construction project manager,

3. Owner-builder.

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The construction project management company becomes an additional

party engaged in the project to act as an advisor to the owner, to which

they are contractually tied. The construction manager's role is to provide

construction advice to the designer, on the owner's behalf, design advice

to the constructor, again on the owner's behalf, and other advice as

necessary.

iv. Design, bid, build contracts

Design, bid, build describes the prevailing model of construction management in

which the general contractor is engaged through a tender process after the designs

have been completed by the architect or engineer.

v. Design and build contracts

Recently a different business model has become more popular. Many owners –

particularly government agencies have let out contracts which are known as

Design-Build contracts. In this type of contract, the construction team is known as

the design-builder. They are responsible for taking a concept developed by the

owner, completing the detailed design, and then pending the owner's approval on

the design, they can proceed with construction. Virtual Design and Construction

technology has enabled much of the ability of contractors to maintain tight

construction time

There are two main advantages to using a design-build contract.

1. The construction team is motivated to work with the design team to develop

a design with constructability in mind. In that way it is possible for the team

to creatively find ways to reduce construction costs without reducing the

40

function of the final product. The owner can expect a reduced price due to

the increased constructability of the design.

2. The other major advantage involves the schedule. Many projects are given

out with an extremely tight time frame. By letting out the contract as a

design-build contract, the contractor is established, and early mobilization

and construction activities are able to proceed concurrently with the design.

Under a traditional contract, construction cannot begin until after the design

is finished, the project is bid and awarded, and the team can mobilize. This

type of contract can take months off the finish date of a project.

D. MANAGEMENT INFORMATION SYSTEM

1. Monitoring & Progress Reporting

1. The progress reports would be issued every month, one from the head office

of CLIENT and another from the site office. Reports will include such

schedules, charts and drawings as the Owner/Owner’s Engineer considers

necessary for adequately monitoring the Contract. The reports will be made

available to the Owner/Owner’s Engineer at least five working days prior to

scheduled progress review meeting.

2. The progress report issued from the head office should necessarily include

the following sections:

a) Report on key milestones.

b) Management summary indicating critical areas with details of

actions initiated and effect of any on the project.

c) Action needing attention of the Owner/Owner’s Engineer.

41

d) Detailed package wise status of engineering submissions, quality

plan submissions and approval, procurement manufacture and

dispatch.

3. The monthly report generated from the site office should necessarily

include:

a) Report on key milestones.

b) Management summary indicating critical areas with details of

action initiated and effect if any on the project.

c) Action needing attention of the Owner/Owner’s Engineer.

d) Details relating to the receipt of the equipment at the port, port

clearance, transport, receipt at site, erection and commissioning.

4. In addition to the above, as the project execution progresses, CLIENT will

also be responsible for generating more frequent reports on progress in

critical areas so that actions can be expedited. The exact format and contents

of the progress reports will be agreed at the time of signing of the Contract.

2. Project Management Meetings

i. In order to track the physical and financial progress, it is very essential to

have the meeting with the different agencies.

The agenda of the various meetings are;

(a) Issues faced and by the stakeholders and finding solutions of the

same,

(b) Actual progress vs Schedule progress of the project,

42

(c) Resource planning in terms of manpower, money, infrastructure for

the future,

ii. In a project, there are various meetings held between the PMG and various

other agencies like;

(a) Site officials

(b)Other department officials

(c) Vendor

(d)Top Management

iii. There are various meetings arranged by the Project Management Group

(PMG) for smooth and speedy execution of the project.

The purposes of the individual meetings are elaborated below;

(a) Daily meeting: To sort out the issues faced by the package owner (PMG)

and the daily activities to be performed by the package owner (PMG).

Also to track the progress of the project. It is chaired by the HOD

(PMG)

(b) Engineering Review Meeting: The meeting is held with the

Engineering department to sort out the issues (Technical

specifications, drawings etc.) associated with the Engineering

department and discuss the future plan for avoiding the delays in the

parameters which ultimately affect the project.

(c) P&C Review Meeting: The meeting is held with the P&C department

to sort out the issues (Contract, LOA, T&C etc.) associated with the

P&C department and discuss the future plan for avoiding the delays in

the parameters which ultimately affect the project.

(d) Weekly Site Review Meeting by Video Conferencing: In this, a

review meeting with the use of video conferencing facility is held

43

with the site to gauge the progress of the project and discuss the future

strategy for speedy completion of the work. In case of any issues

associated with the work, an appropriate action is taken to sort out the

same.

(e) Project Review Committee (PRC) at Site: In the PRC, a meeting with

the Owner is held at the site to review the progress of the project and

appropriate action is taken to expedite the work.

(f) Project Review Team (PRT) at Site: A Project Review Team headed

by the Head of the Project with various departments of the Project is

constituted for project to review the project on a monthly basis. The

PRT include senior executives of the functions.

The basic purpose of the meeting is to

(i) Review the progress of the project i.e. identification of the

constraints and resolution of the same

(ii) Severe schedule slippages and other critical matters like non-

availability of desired drawings, clarifications, documents

from various departments, non-receipt of required material

from various vendors, impact of delays on the project

including the exception reports are discussed and the decisions

on the same are taken.

(iii) Interface problems amongst Engineering, Contracts and Site

affecting project execution are also reviewed and appropriate

decisions are taken to expedite the work.

(iv) Budgetary review is also done during PRT meeting and

shortfall, if any, identified and responsibility are fixed

(g) Engineering Review By Owner’s Engineer: In this the Owner review

44

the status of the various drawings and takes the appropriate action for

expedition of the same

(h) Engineering Progress Review for Entire Project: In this the

Engineering progress is reviewed from the point of view of the entire

project and depending on the progress, appropriate action is taken for

expedition of the work.

(i) Budget & Commercial Review: It is used for reviewing the budget

allotted and cash flow in the project and the future requirements.

(j) CEO Review Meeting: CEO reviews the Critical Packages and the

progress of Project as per the schedule and discuss the future strategy

for completion of the project.

(k) Vice Chairman Review: Vice Chairman reviews the Critical Packages

and the progress of Project as per the schedule and discusses the

future strategy for completion of the project.

(l) Contract Review Meetings (CRM)

With Vendor

Contract Review Meetings are held with the vendors and is generally

held at manufacturing works.

The basic objectives of CRM meetings are;

(i) To ascertain the status of the manufacturing.

(ii) Review the progress of manufacturing &dispatch.

(iii) Resolves various contractual issues for expediting supplies.

Progress of manufacturing is reviewed with respect to L-2

Network.

With Owner

Contract Co-ordination / Review Meeting will be held once a month

to review the progress of the Contract and discuss various issues

45

affecting the progress of work and suggest / agree remedial measures

to overcome the same. CLIENT and OWNER shall ensure

participation of all concerned in the meeting

(m) Technical Co-ordination Meeting (TCM)

With Vendor

Technical Coordination Meetings take place with the vendor and the

discussion revolves around various engineering requirements,

finalization of engineering details within the time frame and schedules

of engineering activities.

With Owner

TCMs will be held initially TWICE in a month and thereafter at least

once in a month. Should there be a pressing requirement, the Owner &

PM can also call for additional technical meeting by providing

adequate notice to concerned parties.

The Engineering Co-ordinators (ECs) shall depute their concerned

engineers for the meetings. CLIENT shall arrange for the participation

of their vendors also, if required, for the meeting.

(n) Weekly Review Meeting: a weekly review meeting with owner is

conducted at site to review the progress and to discuss any other

immediate requirements with site engineers.

(o) Safety Meeting: Safety meeting with owner is conducted once in

every month and is also attended by the vendor. The basic purpose of

the meeting is to ensure;

(i) All the personal protective equipment’s are available to the

workers (working at site).

(ii) Safe working conditions at the work sites.

(iii) Safe working methods practiced by their workers and their

46

sub-contractor workers all the time.

(iv) All the electrical installations of Client and their Contractors

& sub-contractors shall be in line with statutory regulations.

(v) All accidents are reported to Owner Safety Officer promptly

and record of such accidents shall be maintained by Client.

Client has to co-ordinate with Owner in investigation of

accidents providing all possible assistance.

(vi) Accept and implement all Safety rules / orders that are issued

from time to time by Owner.

(vii) Co-operate in promotion of Safety programs and in prevention

of accidents by displaying safety posters, conducting safety

lectures, screening safety films etc. / arranging safety displays

etc.

E. PROCUREMENT & FIELD CONTRACTING

1. Sub-Contract Management

I. The Contractor and / or his sub-contractor shall procure or sub-contract all

system(s) / equipment / component(s) / service(s) including castings,

forgings and finished components / equipment to (or from) only such

established sub-contractor(s) / manufacturer(s) / supplier(s) who have

adequate for similar or higher size, rating and duty condition and which are

in their regular manufacturing / supply range.

II. All the sub-contractor(s) / manufacturer(s) / supplier(s) for system(s) /

equipment / component(s) / service(s) including castings, forgings and

finished components / equipment shall be subject to Owner’s / Owner’s

Engineer’s approval.

III. A tentative list of sub-contractor(s) / manufacturer(s) / supplier(s) for some

47

of the system(s) / equipment / component(s) / service(s) acceptable to

Owner. The Contractor shall submit a complete list system(s) / equipment /

component(s) / service(s) proposed to be sub-contracted by the Contractor or

his sub-contractor alongwith the proposed sub-contractor(s) /

manufacturer(s) / supplier(s) for such system(s) / equipment / component(s) /

service(s) for Owner’s / Owner’s Engineer’s review & approval.

IV. The Contractor shall submit the details of all proposed sub-contractor(s) /

manufacturer(s) / supplier(s) alongwith the above list in the format to enable

Owner / Owner’s Engineer to consider the proposal. The details of proposed

sub-contractor(s) / manufacturer(s) / supplier(s) shall include following

information / details in respect of each case:

a. The system(s) / equipment / component(s) / service(s) which the

Contractor proposed to sub-contract.

b. The basis on which the Contractor has assessed the quality assurance

arrangement of the sub-contractor(s) / manufacturer(s) / supplier(s)

alongwith details of assessment.

c. The results of any recent evaluations and audits of the sub-

contractor(s) / manufacturer(s) / supplier(s) which have been

performed by the Contractor or other organizations external to the

sub-contractor.

d. Reference list & experience for execution / supply of system(s) /

equipment / component(s) / service(s) along with details of year of

supply / commissioning, feedback (if any), type tests done etc.

The Contractor shall submit all such information / details as may be required to

establish the capability, experience & reliability of the sub-contractor(s) /

manufacturer(s) / supplier(s) to the satisfaction of the owner / owner’ Engineer.

Incase the details / information for any of the sub-contractor(s) / manufacturer(s) /

48

supplier(s) are not submitted to the satisfaction of the Owner / Owner’s Engineer

within the scheduled date, the proposal shall be deemed to have been withdrawn

and the Contractor shall procure / sub-contract to already approved sub-

contractor(s) / manufacturer(s) / supplier(s) .

e. A list of all manufacturer / sub-contractor(s) / manufacturer(s) /

supplier(s) as approved by the Owner / Owner’s Engineer pursuant

shall be complied and shall form part of the Contract. The Contractor

or the sub-contractor through the Contractor may propose additional

sub-contractor(s) / manufacturer(s) / supplier(s) for Owner’s /

Owner’s Engineer’s approval (to be added to list of all manufacturer /

sub-contractor(s) / manufacturer(s) / supplier(s) as approved by the

Owner / Owner’s Engineer) for which the Contractor shall submit the

details. However no additional proposal for approval of sub-

contractor(s) / manufacturer(s) / supplier(s) shall be considered by

Owner / Owner’s Engineer after the scheduled dated of finalization of

such consolidated list of manufacturer / sub-contractor(s) /

manufacturer(s) / supplier(s) as approved by the Owner / Owner’s.

The Contractor shall procure / sub-contract from / to already approved

sources only.

2. Purchase specifications

I. All the purchase specifications for the major bought-out items (equipment,

packages and systems), list of which shall be mutually discussed and

finalized between the Contractor and the Owner, shall be furnished to the

Owner for comments and subsequent approval before orders are placed by

the Contractor. These approved purchase specifications shall be part of the

Contract.

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F. INSPECTION & TESTING

A. The QCP shall cover all checks / tests, standard Quality Control Practices of

the Contractor / manufacturer / sub-contractor which shall include tests for

material properties (as required by specification, Codes & Standards, etc), in

process checks, final inspection at manufacturer works. The QCP for field

activities shall include receipt inspection, storage requirements, erection &

Commissioning. In-addition to this, the tests listed below shall be part of the

QCP.

B. Type, Acceptance, Routine & performance tests on following equipment &

systems but not limited to same as per the Contract requirements, drawing

data sheets, codes & standards etc. The type, routine and acceptance tests as

defined in applicable codes & standards and also in this Technical

Specification shall be applicable. Where-ever it is not clearly defined, the

type tests shall include all such tests required to establish such of those

characteristics which are predominantly effected by design / engineering.

Whereas the routine or production tests shall include all such tests required

to establish those characteristics of the equipment & systems which are

predominately affected by the process or the manufacturing variations.

1.1 Fans (ID, FD, PA etc.)

1.2 BFP including cavitation, NPSH and string tests,

1.3 Centrifugal pumps (CEP, CW pump, DM water pumps etc.)

1.4 Screw pumps (fuel oil, seal oil etc.)

1.5 Coal feeders including checks for accuracy.

1.6 Valves (Stop valve, control valve, Bypass valves etc.)

1.7 Butterfly Fly valves

1.8 Generator

1.9 Excitor including for temperature rise, excitation response etc.

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1.10 AVR

1.11 Coal Handling Plant components like idlers, Belts, gearboxes, fluid

couplings, Belt scales, Coal sampler, pumps etc.

1.12 Ash handling equipment like pipes, pumps, grinders, ejectors,

compressors, valves, material handling equipment etc.

1.13 Vacuum pumps (shall include performance test for visual cavitation,

performance with moist air).

1.14 Miscellaneous pumps

1.15 Expansion bellow

1.16 Fluid couplings

1.17 Valves & actuators

1.18 Compressors

1.19 Various components/equipment of Fire Protection system

1.20 Various components/equipment of Air Conditioning and Ventilation

1.21 Cranes EOT, Hoists etc.

1.22 All electrical equipment like Bus ducts, GCB, Transformers,

switchgears (EHV, MV & LV), CB, Motors, Isolators, CT, CVT, LA,

Insulators, Hardware, cables, cabling and its accessories, station

lighting equipment etc.

1.23 C&I equipment like sensors, Electronics, Transmitters, control valves

etc.

1.24 Cooling Tower Components

1.25 Chimney Accessories

1.26 External Coal Handling

C. Inspection & test program shall be designed to verify / ensure that the

equipment conforms to the specified & intended requirement of this

Technical Specification. Test on various components, raw material, casting

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& forgings, semi-finished / in-process components etc. To be carried shall

be as per relevant codes and standard, drawings, data sheets, manufacturing

standards etc. In addition to same following shall be included but not

limited to same.

D. NDTT / FATT on Turbine & Generator Rotors

E. Resonance frequency analysis of last three stages of LP turbine free standing

/ last stage blade before mounting on the rotor. It shall also be checked /

tested after mounting and after over speed. In addition to above the predicted

vibration characteristic in running condition at designed frequency range

shall be verified on one production rotor.

F. Residual stress checks to establish the process in case of erosion shield of

LP blades.

G. Test for thermal stability of turbine rotors.

H. Creep & rupture test for all high Pr. & high temp casings.

I. Balancing &over speed test of all rotors including of turbine rotor (for

5min), Generator Rotor, Fan rotor, Pumps rotors etc.

J. Running tests on one fully assembled Generator at works which shall

include all tests as per IEC 34, VDE 0530 and IEEE 115 including test for

leakage, OCC, SCC, heat run, harmonic factor / wave form deviation,

sudden short circuit tests, tests to establish Xd, Xd’, Xd’’, time constants,

X2, X0 test for interterm fault before and after sudden short circuit test.

Measurement of vibration of overhang stator winding and stator core during

the running tests in open circuit & short circuit conditions to identify the

resonance frequencies and maximum amplitude of vibration of winding

overhang and core. The routine tests on Generators as per IEC 34, VDE

0530 & IEEE 115 and it shall include measurement of potier’s reactance,

winding resistance, leakage tests, PI test on stator and rotor winding, test for

52

inter-turn fault in rotor, high voltage test on stator and rotor winding, partial

discharge test on stator winding.

K. Testing of insulation of electrical rotating machine as per VDE 0530, IEC

34. The tests shall include following but not limited to same:

L. Type tests on stator bars (voltage rating greater than or equal to 11 KV).

M. Routine tan delta on stator bars greater than or equal to 11 KV.

N. Tan delta on 10 % of the stator bars of all electrical machines with voltage

greater than or equal to 3.3 KV and less than 6.0 KV).

O. Routine delta on stator bars voltage greater than or equal to 6 KV but less

than 11KV. This may be reduced to 10% if the process is statistically

proven to be stable / established.

P. Tan delta on all completed machine up to 1.2 UN for voltage rating greater

than or equal to 3.3 KV.

Q. Type test on bushings as per DIN.

R. Dissolved Gas Analysis on EHV transformer after Type & Routine tests.

S. PD tests on all dry type power and instrumentation transformer of voltage

rating greater than or equal to 3.3 kV.

T. Tests on Boiler circulating pumps which shall include Hydro tests of

Complete unit, Overspeed test of rotor as Routine, Pump performance

including performance test of motor (Starting current at rated voltage, cold

start up tests), Endurance test, noise level, checks for joints & seals, HV test

on windings.

U. Type test on boiler circulating pumps / motor including test for NPSH test,

Temperature rise test for motor, hot stand still & startup test/ QA proof test.,

V. Acceptance test on cables for all Fire resistant low smoke (FRLS) property

as detailed in Technical Specification namely, Oxygen index and

temperature index, Acid gas generation, Smoke density, Ladder test as per

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IEC/IEEE (Type test).

W.All tests on electronic equipment & systems as per IEC. It shall include all

tests on electronic equipment / systems such as PLC, DCS, etc as per IEC

1131

X. Test on Transformer oil after filling / before commissioning including

Dissolved Gas Analysis (DGA). The Contractor shall monitor DGA of oil

for GT, UAT during Defect Liability Period for regular interval

Y. Leak detection of boiler by pressurizing to 250mm of water column and

using sonic guns or similar procedure

Z. Model tests shall be carried out for sea water intake system, Circulating

water system, Stack, ESP and FGD. The model tests on ESP & FGD shall be

carried out together

G. QUALITY ASSURANCE

1. The Contractor shall prepare, submit, finalize and implement an effective

quality management system (Quality Assurance Arrangements) which shall

inter-alia include, reliability and maintainability programme / dependability

programme as per ISO 9000 / ISO 9001 / ISO 9004 / BS 5760 and it shall

cover all equipment & services under the scope of the Contract.

2. The Contractor shall supply field proven equipment / systems (i.e. such

equipment / systems with comparable operating parameters, rating, service

conditions, etc. have been in successful operation for a period and for such

equipment / systems the records of successful type tests / design proving

tests as per the requirement of this Contract, codes and standards shall be

submitted to Owner / Owner’s Engineer for review and acceptance /

approval. The type tests / design proving tests need not be repeated for the

Contract in case the records of type tests / design proving tests already

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carried out and submitted to the satisfaction of the Owner. However, in case

of any changes / difference between proposed equipment / system and field

proven equipment / systems, same shall be clearly brought out by the

Contractor before or during engineering stage and shall establish the basis

of its suitability for its specified / intended use by way of calculation, tests,

etc to Owner / Owner’s Engineer’s satisfaction without any cost implication

to Owner. Owner / Owner’s Engineer reserves the right to insist on supply

of field proven tested equipment / systems.

3. Involvement of Owner / Owner’s Engineer by way of approval of drawings,

quality assurance programs, sub-vendor, purchase specification or

witnessing of tests / review of records or quality audit etc. as required by this

Contract, shall not limit the liabilities and responsibility of the Contractor to

meet the requirements of the Contract.

1.1.Quality Assurance Programme

1. To ensure that the equipment & services under the scope of the Contract are

in accordance with the Technical Specifications, the Contractor shall adopt a

comprehensive quality assurance arrangements for the Contract, detailed in a

document (hereafter referred as Quality Assurance Programme or QA

Programme) to control activities at all stages. Such project specific Quality

Assurance Programs shall be prepared by the Contractor and shall be

submitted to Owner / Owner’s Engineer for their review & approval as per

the agreed schedule. The QA Programme shall be in line with ISO 9000 / IS

14000 series of standards and shall include the requirements listed below.

2. The Quality Assurance Programme of the Contractor shall cover the

following:

a. Organization structure for the management and implementation of the

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proposed Quality Assurance Programme.

b. Contractor’s quality system manual in line with ISO 9001.

c. Qualification data for key personnel & use of suitably qualified and

experienced personnel in required number for each type of work.

d. Design control system. The procedure for quality assurance in design

& engineering shall include the methods, procedures and programme

for presenting, collating and assessing information from the various

sources and its incorporation in design submission.

e. Documentation control system.

f. The procedure for purchase of materials, parts, components, selection

of sub-contractor, vendor analysis, source inspection, incoming raw

material inspection, verification of materials purchased etc.

g. The method of protection, storage, stock control and issue of material

at site.

h. System for shop manufacturing and site erection control including

process controls and fabrication and assembly controls.

i. Inspection, sampling, testing and acceptance procedures for plant and

materials delivered to site.

j. Control of non-conforming items and system for corrective actions.

k. Inspection and test procedure both for manufacture and all site related

works.

l. Control of calibration and testing of measuring and testing equipment.

m. System for quality audit and self assessment.

n. System for indication and appraisal of inspection status.

o. System for authorizing release of manufactured products to the

Owner.

p. System & procedures for packing, handling, storage and delivery to

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site.

q. Final inspection and certification of completed sections of work.

r. Site security procedures.

s. The recording and processing of variations to the Works and their

incorporation on record drawings.

t. System for maintenance of records.

Documents setting out plans for control of quality during manufacturing and field

activities detailing the specific quality control procedure adopted for controlling

the quality characteristics relevant to each item of work / equipment.

1.2.Independent Third Party Inspection

a. The Contractor shall appoint an independent third party inspection agency

acceptable to Owner and with prior written consent of the Owner for

witnessing inspection of components / equipment at manufacturer’s works

abroad. The equipment / components to be inspected by the third party

agency, if imported, are as follows:

b. HP, IP, LP turbine, stop & control valves and governing system – tests /

check during manufacture and final assembly.

c. Generator - tests / check during manufacture and final assembly and type

and routine tests.

d. Boiler feed pumps and BFP turbines - tests / check during manufacture and

final assembly and type and routine tests.

e. Performance test of CW pumps and CEP pumps.

f. Generator Transformer - Manufacture and final tests

g. Performance test of vacuum pumps for condenser.

h. Performance test of ID fan, PA fan and FD fan.

i. Pressure parts of Steam Generator - - tests / check during manufacture and

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final assembly

j. Boiler circulation pumps - acceptance & routine tests.

k. Model tests of ESP, FGD, CW Intake and Sea water intake.

l. The scope of third party inspection agency shall include following but not

limited to following.

i. Witnessing and certification of inspection and tests for stages as

defined in QCP.

ii. Quality surveillance

iii. Analysis of non-conformance and to provide recommendation to

Owner.

m. The costs of such Third Party inspection agency shall be included in the total

Contract Price. The Owner reserves the right to decrease the scope of such

Third party inspection agency with appropriate reduction in the Total

Contract Price.

1.3.Quality Audit

a. Owner / Owner’s Engineer reserves the right to carry out quality audit and

quality surveillance of the systems and procedures of the Contractor’s or

their sub vendor’s quality management and control activities. The Contractor

shall provide all necessary assistance to enable the Owner / Owner’s

Engineer to carry out such audit and surveillance.

b. Quality audit / approval of the results of tests and inspection shall not

prejudice the right of the Owner / Owner’s Engineer to reject an equipment

not giving the desired performance after erection and shall not in any way

limit the liabilities and responsibilities of the Contractor in ensuring

satisfactory performance of equipment / system as per specification,

standards, data sheets, drawings etc.,

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1.4.Non-Conformance

1. The Quality Assurance Programme shall inherently be designed, established

& implemented to identify and prevent non-conformance in early stages of

work. The programme shall inherently provide for replacement of non-

conformance in design, specification, materials, or any other work to ensure

compliance to Contract. All deviation / non-conformance to drawing,

specification, codes & standard including those which effects

interchangeability, performances, safety etc. shall be reported to Owner /

Owner’s Engineer immediately on its occurrence. The details of its review

alongwith details of proposed corrective actions & its justification shall be

submitted to Owner / Owner’s Engineer for his review. The justification

shall include drawings, detailed calculation & explanations on the impact of

deviation on performance, interchangeability, safety, past record of such

deviation, etc..

2. The Owner/ Owner's Engineer reserves the right to accept or reject the work

having deviation. In case of rejection, the Contractor shall immediately take

corrective action to meet the Contract requirement in totality.

1.5.Quality Assurance Documents

a. The Contractor shall be required to submit four (4) hard copies of the

following quality assurance documents within three (3) weeks after dispatch

of the equipment or commissioning of equipment.

b. Material mill test reports of components as specified by the specification /

QCP.

c. The inspection plan with verification, inspection plan check points,

verification sketches, if used and methods used to verify that the inspection

and testing points in the inspection plan were performed satisfactorily.

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d. Non-destructive examination results/reports including radiography

interpretation reports.

e. Factory tests results for testing required as per applicable codes and

standards referred in the specification.

f. Welder identification list listing welder’s and welding operator’s

qualification procedure and welding identification symbols.

g. Sketches and drawings used for indicating the method of traceability of the

radiographs to the location on the equipment.

h. Stress relief time temperature charts.

i. Inspection and test reports duly signed by QA personnel of the Owner /

Owner’s Engineer and Contractor for the agreed customer hold points.

During the course of inspection, the following shall also be recorded.

j. When some important repair work is involved to make the job acceptable.

k. The repair works remain part of the accepted product quality.

l. Letter of conformity certifying that the requirement is in compliance with

finalized specification requirements.

m. Approved QCP, Applicable drawing, datasheets etc.

H. COMMISSIONING & TESTING

1.1.General Requirement

a. The Contractor shall provide sufficient number of competent commissioning

& start-up personnel, specially identified, for the period commencing with

start-up, extending through initial & trial operations, all testing, to placing

the plant to full commercial operation up to the issue of Taking Over

certificates. During this period, the Contractor shall provide all the

consumable materials, tools and tackle, temporary equipment, tapping

points, calibration devices, special test instruments etc. necessary for start-

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up/pre-commissioning, Commissioning, trial and initial operation,

Reliability Test and Performance Tests. The Owner shall associate his

operators in shifts, as required, for commissioning & testing under the

supervision and work instruction of Contractor’s commissioning & start-up

personnel. All other labours, fitters etc. for starting, trial operation, initial

operation, testing, repairs and adjustments shall be supplied by the

Contractor.

b. The Contractor shall start training the Owner’s personnel sufficiently in

advance of Commissioning process and during the Commissioning & start-

up period to make them familiar with the Unit(s)/Plant and intended

operation techniques and to ensure safe and efficient operation &

maintenance of the Unit(s)/Plant after Taking Over.

c. The Contractor shall inform the Owner about his programme of conducting

Commissioning and operator training well in advance and this has to be

agreed by the Owner at least three (3) months in advance of the

commencement of the Commissioning process of the Unit(s)/Plant.

d. The Contractor shall submit to the Owner, not later than 12 months from the

date of ‘Contract’ a proposed procedure for all the tests for approval.

1.2.Shop Test

a. All plant equipment / items shall be tested at manufacturer’s works to ensure

its compliance to Technical Specification, codes, standards, drawings, data

sheets, etc prior to site delivery. The details of the test, test procedures,

acceptance norms for the equipment / item shall be covered in Quality

Control Plans which shall be finalised/approved/agreed and implemented.

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1.3.Pre-Commissioning

a. On completion of erection of the equipment and before start-up, each item of

the equipment shall be thoroughly cleaned by the Contractor and then

inspected jointly by the Contractor and the Owner/Owner’s Engineer for

correctness and completeness of installation and acceptability for start-up,

leading to initial pre-commissioning tests at Site conducted by the

Contractor. The list of pre-commissioning tests to be performed and the

proposed start-up report formats shall be submitted by the Contractor to the

Owner/Owner’s Engineer at least twelve (12) months before the scheduled

date of initial start-up, which shall be mutually discussed and agreed and

included in the Contractor’s quality assurance programme. The Contractor

shall be responsible for carrying out all the pre-commissioning tests/checks,

for which the Contractor shall specifically identify commissioning/start-up

engineers. The checkouts/tests during the pre-commissioning period shall be

programmed to follow the construction completion schedule. On completion

of inspection, testing, checking, cleaning and after the pre-commissioning

tests are satisfactorily over, the complete equipment shall be placed on trial

run during which period the complete equipment shall be operated integral

with sub-systems and supporting equipment as a complete Plant.

b. During this period all adjustments and repairs, as required, shall be made by

the Contractor. The plant/equipment may be shutdown, if necessary, to carry

out such adjustments and repairs. On completion of satisfactory trial run, the

plant /equipment shall be placed under initial operation.

c. When the equipment is operating properly, its characteristics shall be

recorded on the start-up report sheets by the Contractor. Start-up reports for

all equipment shall be completed before the start of the Commissioning.

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1.4.Commissioning

a. Upon completing pre-commissioning of all systems, sub systems, auto loops

and integrity of the Plant as a whole, synchronization, trial operation and

tuning shall be carried out.

b. Once each Unit (generating set) along with its auxiliaries is established, the

Contractor upon 15 days notice to the Owner shall conduct the

Commissioning test. The Commissioning test is aimed to establish the

performance of the Unit(s) / Plant steady-state operation at a required load

level including full load and to provide base-line operating data.

c. During this Commissioning period all necessary adjustments and final

testing of all controls and protections shall be made by the Contractor by

operating over the full load range enabling the Plant to be made ready for

Reliability Tests and subsequently for Performance Tests.

d. During this Commissioning period, the operational requirements, as

mentioned elsewhere in the Technical Specification, are to be demonstrated

to the full satisfaction of the Owner/Owner’s Engineer.

e. All the necessary data, adjustments, repairs etc. made during this operation

are to be recorded properly by the Contractor and submitted to the

Owner/Owner’s Engineer for his verification prior to Reliability Tests and

Performance Tests.

f. The Unit(s)/Plant shall be considered to have been satisfactorily

Commissioned when the performance of the Unit(s)/Plant at its rated

capacity is established for 72 hours continuous operation.

1.5.Reliability Test

a. Within two months of Commissioning of Unit(s)/Plant, the Contractor shall

carryout the Reliability Test to the satisfaction of the Owner/Owner’s

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Engineer. The Unit(s)/Plant shall be on Reliability Test during which period

all necessary adjustments shall be made while operating over the full load

range enabling the Unit(s)/Plant to be made ready for Performance Test.

b. The duration of the Reliability Test of each Unit for the Plant in the

automatic position of control system under varying load shall be fourteen

(14) days, out of which at least seventy-two (72) hours shall be in

continuous operation on full load or any other duration as may be agreed to

between Owner and the Contractor.

c. The Unit(s)/Plant will be put on Reliability Test when the Owner/Owner’s

Engineer is fully satisfied that the offered Unit(s)/Plant has been

commissioned & fully proven with regard to its safety.

d. The Unit(s)/Plant operation shall be continuous without any failure or

interruption of any kind during this fourteen (14) days period. It will be

required to operate the Unit(s)/Plant under various operating modes along

with range of fuels as specified during this period. It is the Contractor’s

responsibility to make the Unit(s)/Plant capable of running continuously for

the 14 days period. For the period of Reliability Test, the time of operation

with any load shall be counted. Minor interruptions not exceeding four (4)

hours at a time caused during the continuous operation shall not affect the

total duration of Reliability Test. However, if in the opinion of the

Owner /Owner’s Engineer, the interruption is long (beyond 4 hrs), the

Reliability Test shall be prolonged for the period of interruption.

e. A Reliability Test report comprising observations and recordings of various

parameters to be measured, in respect of the above Reliability Test shall be

prepared by the Contractor. This report besides recording the details of start

and finish of the Reliability Test and shall be signed by the Owner /Owner’s

Engineer and the Contractor. The report shall have sheets, recording all the

64

details of interruptions occurred, adjustments made and any minor repairs

done during the Reliability Test. Based on the observations, necessary

modifications/repairs to the plant shall be carried out by the Contractor to

the full satisfaction of the Owner to enable the latter to accord permission to

carry out Performance Test on the Unit(s) or the Plant.

However, minor defects which do not endanger the safe operation of the

equipment, shall not be considered as reasons for withholding the aforesaid

permission.

f. Should any major failure or interruption occur in any portion of the

Unit(s)/Plant due to or arising from faulty design, materials, workmanship or

omissions or incorrect erection, sufficient to prevent safe and full use of the

Unit(s)/Plant, the Reliability Test shall be considered void and the

Reliability Test period of 14 days shall recommence after the Contractor has

remedied the cause of defect, without any cost implication to the Owner. In

case of any alteration or redesign is required, it has to be discussed and

approved by the Owner/Owner’s Engineer before implementation.

1.6.Performance Test And Taking Over

a. After completion of satisfactory Reliability Test, the Contractor shall

prepare the Unit(s)/Plant for Performance Test. The final tests for

establishing the performance and guarantees shall be conducted at Site, by

the Contractor. The Performance Tests shall be carried out for equipment &

systems as specified in respective sections of the Technical Specification.

The test shall be carried out on a mutually agreed date and completed not

later than four (4) months after successful completion of Reliability Test or

within such other period as may be mutually agreed between the Owner and

the Contractor, within which period no de-rating of the equipment

65

performance will be permitted. The performance measurements shall be

undertaken with the plant set-up and operation in accordance with the

recommendations of the Contractor for maximum Plant life and integrity.

b. These tests shall be carried out by the Contractor to the requirements of the

Owner/Owner’s Engineer. The Owner will provide the requisite load and

fuel for the test free of cost.

c. In case of delay in carrying out the Performance Test for reasons not

attributable to the Owner, the Contractor shall be required to prove the

specified performance guarantee without any de-rating / ageing factor.

The Performance Tests shall be conducted by the Contractor in accordance with

the codes and standards and the conditions listed in Section V of Technical

Specifications. The Contractor shall submit the test procedure for

Owner’s/Owner’s Engineer’s approval within twelve (12) months from the date of

the Contract. This procedure shall indicate the tentative date & program, the

arrangement & form of the tests, log sheets, duration, control periods, readings to

be taken, number of observers required etc. and any other requirements in

accordance with applied test code. All measuring & monitoring instruments shall

be calibrated by the Contractor in a recognised laboratory not exceeding three (3)

months prior to the date of test and shall furnish the certified calibration reports.

All flow measuring devices (fuel, water or steam) and thermocouples with their

indication shall be certified by an independent authority approved by the

Owner/Owner’s Engineer. The Owner/Owner’s Engineer reserves the right to

witness the calibration tests. Batch calibration shall not be acceptable. The class

and accuracy of the instruments shall be as specified in the applicable code and the

Technical Specifications. The Performance Tests shall be conducted at the

specified load points, and as near the specified cycle conditions as practicable. The

Owner shall apply proper corrections in calculations as elaborated in Performance

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Guarantee requirements enumerated in respective sections of this Technical

Specification to take into account of deviations in conditions from those at which

guarantees are furnished.

d. All special test grade instruments, equipment, tools and tackle, required for

the successful completion of the Performance Tests shall be provided free of

cost by the Contractor.

e. The guaranteed performance figures of the plant and equipment shall be

established by the Contractor during these tests. The Contractor shall submit

a detailed test report in the manner, already agreed to (as a part of test

procedure) within one (1) month of completion of the test, for

Owner’s/Owner’s Engineer’s approval. Should the Owner’s/Owner’s

Engineer’s assessment of these tests show any deterioration from the

guaranteed values or failed to meet the guaranteed requirements, the

Contractor shall modify the equipment as required at no extra cost to enable

it to meet the guarantees. In such case Performance Tests shall be repeated

after the equipment is ready for retest. The entire cost of the repeated tests

including the costs of fuel and consumables necessary to carry out the tests,

less any revenue received by the Owner from electricity sales, to prove that

the equipment meets the guarantees, shall be borne by the Contractor.

However, if the Contractor is not able to demonstrate the guarantee even

after the modifications within a reasonable period allowed by the Owner as

mentioned in Volume-I, the Owner shall have the right to reject the

equipment / system / plant thereof and to proceed with replacement of the

Plant or any part thereof and the cost and expenses incurred by the Owner in

connection therewith shall be paid to the Owner by the Contractor or accept

the equipment / system / plant after levying Liquidated Damages.

f. Six copies and one CD of copies of the test reports shall be furnished by the

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Contractor to the Owner backed up with jointly signed data sheets recorded

during the test period.

1.7.Taking Over

a. Upon successful completion of the Performance Test by the Contractor, the

Owner shall issue to the Contractor a Taking Over certificate as a proof of

the final acceptance of the equipment. Such certificate shall not

unreasonably be withheld nor will the Owner delay the issuance thereof on

account of minor omissions or defects, which do not affect the commercial

operation and/or cause any serious risk to the equipment. Such certificate

shall not relieve the Contractor of any of his obligations which otherwise

survive, by the terms and conditions of the Contract after issuance of such

certificates.

I. SITE MANAGEMENT & INSURANCE

1.1.Site Services

a. These services shall be rendered by the Contractor as part of the overall

project management service. The services shall broadly include but not be

limited to the following.

b. Arranging material dispatch from the shop and transportation by rail, road,

air or sea as applicable; transit insurance.

c. Monitoring movement of materials as necessary with carriers, port clearance

etc. from the time of dispatch F.O.R. works/F.O.B. port of shipment by the

Contractor till receipt of the same at site.

d. Unloading of materials at Railway Station/Railway Siding inside project

area/air port/sea port, transportation to site store, assessment of lost/damaged

items in transit and arranging insurance claims and arranging replacement of

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lost/damaged items.

e. Taking custody of all the materials till the Plant is Taken Over by the Owner

after complete erection and successful Commissioning, Reliability Test and

Performance Tests.

f. Comprehensive insurance for the Plant, equipment and materials.

g. Transportation of materials to their respective places of erection and erection

of the complete plant and equipment as supplied under this Technical

Specification.

h. Trial run and commissioning of individual equipment/sub-systems including

supply of temporary equipment and services for chemical cleaning, steam

blowing and trial run and Commissioning of the Plant as a whole to the

satisfaction of the Owner, as well as Performance Tests.

Provision for preservation of individual equipment after trail run and

commissioning e.g. Nitrogen blanketing etc., as necessary.

i. Supply and application of the final paints on all the equipment to be erected

under this specification.

j. Development of all skilled and unskilled manpower required for erection,

supervision of erection, watch & ward, commissioning and other services to

be rendered under this Technical Specification.

k. Deployment of all erection tools &tackles, construction machinery,

transportation vehicles and all other implements in adequate number,

capacity and size.

l. Supply of all consumables, e.g. welding electrodes, cleaning agents, diesel

oil, lubricant etc. as well as materials required for steam blowing, temporary

supports, scaffolding etc. as necessary.

m. Construction of all civil, structural & architectural works, including

construction of foundation for all equipment supplied as required, grouting

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of equipment on foundation after alignment, and all other related activities

as detailed elsewhere.

n. Obtaining approval of all statutory authorities e.g. Boiler Inspector, Factory

Inspector, Inspector of Explosives etc. for respective portions of work as

applicable

o. Quality assurance of all work executed at site.

p. Providing support services for the Contractor’s erection staff e.g.

construction of site offices, temporary stores, residential accommodation and

transport to work site for erection personnel, insurance cover, watch & ward

for security and safety of the materials under the Contractor’ custody etc. as

required.

q. Maintaining proper documentation of all the site activities undertaken by the

Contractor as per the proforma mutually agreed with the Owner.

r. Providing ‘Industrial Relations’ unit and ‘Medical’ unit to take care of his

erection staff. The Owner shall have no obligation in this regard.

1.2.Site Organisation

a. The Contractor shall maintain a site organisation of adequate strength in

respect of manpower, construction machinery and other implements at all

times for smooth execution of the Contract. This organisation shall be

reinforced from time to time, as required, to make up for slippages from the

schedule without any commercial implication to the Owner. The site

Organisation shall be headed by competent construction manager having

sufficient authority to take decisions at site.

b. A separate Quality Control Department shall be included in the site

organisation with adequate number of competent quality control personnel,

instruments etc. to ensure desired quality standards of all site-works.

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c. On signing of the Contract, the Contractor shall submit to the Owner a site

organisation chart indicating the various levels of experts to be deployed on

the job. The Owner reserves the right to reject or approve the list of

personnel proposed by the Contractor. The persons, whose bio-data have

been approved by the Owner, will have to be posted at site and deviations in

this regard will not generally be permitted.

d. The Contractor shall also submit to the Owner for approval a list of

construction equipment, erection tools, tackle etc. prior to commencement of

site activities. These tools or tackles shall not be removed from site without

written permission of the Owner.

1.3.Site Facilities

a. Contractor’s Central Administration Area

i. The Contractor shall submit, drawing showing proposed locations of both

his and his sub-contractors central office area together with any other

temporary buildings associated with site administration. Car parks, cycle

sheds, and access ways shall also be shown.

b. Contractor’s Site Office Accommodation

ii. Before the erection of any temporary site accommodation commences, the

Contractor must obtain approval from the Owner of the size, type, condition,

location, access and services proposed. The Owner’s approval shall be

obtained before any accommodation is dismantled or removed from the site.

The site office accommodations shall be reasonably maintained and suitably

identified with the Contractor’s name and that of his site Engineer.

c. Owner’s Office Accommodation

iii. The Contractor shall provide, and pay all charges in connection with high

quality site fully furnished and equipped office accommodation of the

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Owner’s Engineer and the Owner’s and Owner’s Engineer’s employees

within the Contractor’s Central Administration Area.

This accommodation should be based on the following:

i. An office for the Owner’s Project Manager.

ii. An office for the Owner’s Site Engineer.

iii. An office for Owner’s Engineer.

iv. A conference room.

v. Office for thirty (30) Engineers and staff with drawing office

facilities.

vi. Store/Drying room.

vii. Kitchen including cooking and food refrigeration equipment.

viii. Day rest room.

ix. Office furnishings.

x. Photocopying and facsimile equipment, personal computers.

xi. Close access to suitable western style WC facilities.

d. This accommodation should be available for occupation by the Owner /

Owner's Engineer within 4 weeks after the site access date.

e. The office for the Owner / Owner's Engineer shall be adequate with all

modern office gadgets and shall be with telecommunications facility.

f. The above accommodation including all services (internal/external telecom,

electricity & water), furniture and facilities shall be made available to the

Owner by the Contractor at the latter’s cost and the facilities shall be to the

approval of Owner.

g. Telecommunication Facilities

i. The Contractor shall provide site telephone facilities for his staff.

ii. The Contractor shall state the proposed extent of supply for telephone

facilities, indicating the number of lines to be connected on site for the

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duration of the Contract.

iii. The Contractor shall obtain permission, from the appropriate

authorities before any radio wave emanating system is used at the

Site. This includes radio telephones and pagers, transreceivers,

cordless and cellular telephones and such any other systems. The

Contractor shall ensure that the radio communication systems do not

cause interference to control and instrumentation and communication

systems installed in the Unit already commissioned, if any..

h. Site Record Office

1. The Contractor shall maintain a suitably staffed records office to maintain

updated records of all relevant documentation and test certificates and to see

that these are available to meet obligations to all statutory bodies and to any

commissioning committees, working parties or test teams which are

established to meet the needs of the Contract. These records shall be

maintained and retained until handover on completion of all works on Site

and shall be subject to audit by the Owner’s Engineer.

The relevant documents envisaged will include:

a) Site Register for lifting appliances, cranes, slings, hooks, lifting beams and

tackle for construction of the works either mobile or fixed.

b) Site Register for lifting appliances, cranes, slings, hooks beams and tackle

supplied as part of the permanent works.

c) Scaffold Register.

d) Commissioning documents.

e) Test Certificates from works and site.

i. Civil

ii. Mechanical

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iii. Electrical

iv. Control and Instrumentation

f) Operation and Maintenance Instructions.

g) Quality Assurance Documents.

h) Site Register for all portable electrically powered apparatus and tools, both

temporary and permanent.

i) Site Registers of all modifications carried out during execution by deviating

from the approved drawing giving modification number against each. Such

modifications shall have to be authorized/approved by the Owner / Owner’s

Engineer.

j) Measurement, inspection & alignment protocols

k) Mechanical completion protocol.

l) Performance test protocols.

m) Handing over/taking over protocols

n) Final Acceptance Protocol.

i. Canteen Facilities

i. An automated food facility shall be provided for 250 persons at a time on the

Site by the Contractor for the reasonable use of both his and his sub-

contractor’s employees, the Owner / Owner's Engineer and his staff.

ii. There shall also be an appropriate canteen for professional managerial staff.

The Contractor shall submit the details of his proposals for the canteen

facilities for Owner’s approval.

j. Site Security

The Contractor shall furnish a schedule for security facilities for the site and

temporary storage areas, including but not limited to:

i. Road access gates manned during construction by uniformed security

personnel.

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ii. Gate control arrangements and search lights.

iii. Peripheral road and lighting.

iv. Security fencing: The location shall be agreed with the Owner. The type

shall be proposed by the Contractor and approved by the Owner’s Engineer.

v. A manned security building/stores/compound for receipt/temporary storage

of equipment prior to erection.

The Contractor shall submit his proposed site security policy and procedures

for the Owner’s approval.

The Contractor shall have responsibility for the security of the site. Security

for all or part of the site, on completion of the works, will be taken over by

the Owner at a time to be agreed with the Owner.

k. Contractor’s Storage Areas

i. The Contractor shall submit details of proposed requirements of space for

storage and construction facilities for the Owner’s approval.

ii. The Contractor shall be responsible for provision of suitable temporary

storage facilities including external hard standings.

l. Sign Boards

i. The erection of sign boards or posters will not be allowed without the

Owner’s Engineer’s approval of the size, type, location, wording etc.

1.4.Site Health And Safety Management

1. The Contractor shall be responsible for:

a. The management organisation for implementation of health and safety on

site.

b. The identification of site hazards and assessment of risks.

c. The system of notifying all employees of the site safety plan, method

statements and site safety rules.

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d. A schedule of safety meetings. The arrangements for site induction course,

training and security. The arrangements for emergency plans, safety

inspections and auditing.

2. The Contractor shall ensure the safety of all workmen, materials and

equipment either belonging to him or to other working at site. He shall

observe safety rules & codes applied by the Owner at site without exception.

3. The Contractor shall notify the Owner /of his intention to bring to site any

equipment or material which may create hazard. The Owner shall have the

right to prescribe the conditions under which such equipment or material

may be handled or prohibit the use of the same for safety reasons. The

Contractor shall abide by Owner’s decision in such cases. No claim for

compensation due to such prohibition will be entertained by the Owner.

4. Storage of petroleum products & explosives for construction work shall be

as per rules and regulation laid down in Petroleum Act, Explosive Act and

Petroleum and Carbide of Calcium Manual. Approvals as necessary from

Chief Inspector of Explosives or other statutory authorities shall be the

responsibility of the Contractor.

5. The Contractor shall be responsible for safe storage of his and his sub-

contractor’s radioactive source.

6. All requisite tests & inspection of handling equipment, lifting tools & tackle

shall be periodically done by the Contractor. Defective equipment shall be

removed from service. Any equipment shall not be loaded in excess of its

recommended safe working load.

7. All combustible waste and rubbish shall be collected and removed from the

work site at least once each day. Use of undercoated canvas paper,

corrugated paper, fabricated carton, plastic or other flammable materials

shall be restricted to the minimum and promptly removed.

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8. The Contractor shall provide adequate number of fire protection equipment

of the required types for his stores, office, temporary structures, labour

colony etc. Personnel trained for fire-fighting shall be made available by the

Contractor at site during the entire period of the Contract.

9. All electrical appliances used in the work shall be in goods working

condition and shall be properly earthed. No maintenance work shall be

carried out on live equipment. The Contractor shall maintain adequate

number of qualified electricians to maintain his temporary electrical

installation.

10.All workmen of the Contractor working in construction site shall wear safety

helmets, safety boots and safety belts. The Contractor shall take appropriate

insurance cover against accidents for his workmen as well as third party.

11.First Aid

A central fully equipped first aid post shall be provided at site by the

Contractor. The facilities shall comprise first aid personnel, including a

registered/qualified nurse, the provision and manning of an ambulance, and

the retention of the services of medical practitioners for advice and

attendance where necessary. These arrangements shall not relieve the

Contractor of any legal/statutory obligations.

1.5.Storage And Preservation

i. The Contractor shall arrange for proper and safe storage of materials till the

same are Taken Over by the Owner as per terms of the Contract.

Manufacturer’s instructions for preservation shall be strictly followed.

ii. All empty containers, packing materials, gunny bags, transport frames as

also surplus and unused materials shall be the property of the Owner and

returned to the Owner by the Contractor.

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1.6.Site Welding & Heat Treatment

i. The Contractor shall submit detailed procedures and specification in respect

of the following for the approval of Owner/ Owner’s Engineer:

a. Welding and Brazing (codes, procedures and electrode specifications).

b. Welder’s Qualification Test.

c. Destructive and Non-Destructive Tests (DT/NDT).

d. Pre/Post heating and stress relieving.

e. Quality Assurance of Welding and Bracing.

1.7.Labour Management and Site Industrial Relations

i. The Contractor shall be wholly and entirely responsible for establishing and

maintaining a strategy for good labour management practices, good

industrial relations and acceptable levels of labour productivity to achieve

completion of the works within programme. A statement of this strategy

must be submitted.

ii. The Contractor shall establish to the satisfaction of the Owner/ Owner’s

Engineer a site contractors’ Group, to determine site labour practices and

ensure their effective implementation and observance by all concerned. The

Owner/ Owner’s Engineer reserves the right to observe proceedings at

Group meetings.

iii. The Contractor, to the satisfaction of the Owner/ Owner’s Engineer shall

employ a site industrial relations manager (together with any necessary staff)

to support line management in operating an effective labour strategy and to

collect and collate employment data covering all site workers.

iv. The Contractor shall be required to promptly inform and advise the Owner/

Owner’s Engineer of all matters relating to the management of site labour

affairs both current and anticipated. The Contractor and all his sub-

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contractors shall also make available to the Owner/ Owner’s Engineer

details of labour deployed, by occupation or trade, on each of the major site

activities arranged so that manning levels involved in modules and elements

set out are clearly identifiable.

v. The appointment of all sub-contractors remains the responsibility of the

Contractor including the assessment of their proposed site labour policies.

1.8.Site employment policies and practices

a. The Contractor shall furnish full details of his own and his intended sub-

contractor’s proposed labour practices and policies for the employment of

labour for site erection work, and the regulation of industrial relations on a

multi-contractor project.

b. Submission of such information shall in no way affect the Contractor’s

obligations under the Contract, nor does it affect his responsibility for the

adequate suitability of such proposals to meet the requirements of the

contract, which responsibility remains entirely with the Contractor.

c. The Contractor shall provide the following information:

i. The Contractor shall detail the experience he has on managing Indian

construction projects site-wise indicating the staffing, organisation,

procedures, co-ordination, labour management matters etc.

ii. Name of Company. (For Sub-contractors, type and extent of work let

in the Sub-contract to be indicated.)

iii. List the Employer Federations(s) or Association(s) of which the

Contractor is a member.

iv. The labour agreement(s) the Contractor will adhere to when

employing labour on site.

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v. The Contractor’s experience in operating Labour Agreements on

major construction projects.

vi. Details of any other types of payment, benefits or allowances which

the Contractor anticipates making on site in addition to those

determined by the relevant Labour Agreement.

vii. The daily and weekly hours of work including all weekday and

weekend overtime and shift work systems.

viii. The Contractor’s policy concerning the numbers of workforce

representatives, their representational areas normally recognized for

the works, together with a senior or works convenor and whether such

appointments are a full time or some other basis. Indicate the facilities

normally granted to workforce representatives on site.

ix. The likely sources of labour supply and the numbers to be employed

from the Contractor’s existing labour force and those to be recruited

for the project. The anticipated percentage of local employees and non

local employees should be provided.

x. Details of the intended method(s) of recruitment of the site workforce.

xi. A list of sub-contracts the Contractor intends to let for the purposes of

labour supply.

xii. A detailed graph of the build up and depletion of each of:

a. Directly employed labour force

b. Sub-contractors’ workforces.

xiii. The Contractor shall indicate his policy assuring quality and

competence of the labour and supervision and provide an outline of

what skill testing will be carried out for the site works, how

employees’ skill standards will be maintained throughout the Contract

and the nature of any employee training he intends to provide for the

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project works.

xiv. The Contractor shall state the intended supervisory ratio i.e. number

of employees reporting to each foreman or supervisor of staff

employees on site for each trade or group of employees on site.

xv. The Contractor shall demonstrate how his supervision and other first

line management are provided with acceptable conditions of

employment in relation to the work people they supervise.

xvi. The Contractor shall indicate any other factors he considers relevant

to the manning of the works or of significance to the project’s

industrial relations.

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A. FLOW CHARTS OF POWER PLANT

A. Schematic diagram of power plant

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B. Block Diagram of Power cycle

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BLR

HPT IPT LPT GEN

COND

CEP

LPHD/AHPHs

BFP

C. Energy Conversion Cycle

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Energy Conversion Cycle

Coal

Chemical Energy

Combustion with oxygen Flue gas

containing primarily N2, CO2, CO, excess O2, NOx, SOx

Thermal Energy

Furnace Zone

Heat transfer

Heat exchangers zone( eco, water wall, S/H etc

Steam

Thermal energy

Shaft work

TurbineMechanical

Energy

Electricity

Electrical Energy

Generator

Thermal expansion

D. COAL TO ELECTRICITY

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Coal to Electricity ….. Basics

Coal

Chemical Energy

Super Heated Steam

Pollutants

Thermal Energy

Turbine Torque

Heat Loss In Condenser

Kinetic Energy

Electrical Energy

Alternating current in Stator

Mech. Energy Loss

ASH

Heat

Loss

Elet. Energy Loss

E. Coal Handling & preparation

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Coal Handling & preparation

Track Hopper

Coal Conveyor Coal

Crusher

Crushed coal Less than 20 mm size

Coal conveyor

Stock yard

Stack reclaimer

Conveyor

Transfer Point

ConveyorCoal tipper

BunkerFeederCoal Mill

Furnace

Coal particle-75 micron

Hot Primary Air

A. TIME SCHEDULE

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Zero Date 01-Jul-10 BTG

Award15-Jul-10

Boiler foundation start

01-Nov-10

Boiler Hydro test 25-Oct-11

Boiler Erection Start1-Feb-11

PHB Structure Erection start 1-Feb-11

TG Erection Start

16-Aug-11

TG deck casting

30-May-11

Condenser erection start

15-Jul-11TG on Barring

Gear25-Feb-12

Boiler Light Up29-Feb-12

Synchronization

30-Apr-12 COD # 1

30-Jun-12

COD # 2

30-Sep-12

PHB foundation start

01-Nov-10

TG Foundatio

n Start15-Dec-10

Site Enabling Facility start01-Aug-10 Chimney Civil

Work start01-Dec-10

CHP Readiness15-May-12

AHP Readiness15-May-12

Fuel Oil System Readiness10-Feb-12

DM / PT Plant Readiness15-Oct-11

IDCT Work start

01-Jan-11

Switchyard Readiness31-Aug-11

Ash Dyke Work start

25-Feb-11

TG on Box-up25-Jan-12

A. COST ESTIMATE FOR SUPER CRITICAL POWER PLANT

Sr.No Preliminary cost estimate for 3 X 660MW Cost ( Crore ) % Cost

100 Preliminary investigation & survey 2.5 0.04%

200 Civil Works 800 11.40%

300 Mechanical Works Main Plant

401 Steam generator with associated auxiliaries 2500 35.61%

401 Turbo generator with associated auxiliaries 1400 19.94%

402 Coal handling Plant 480 6.84%

403 Ash Handling Plant 260 3.70%

404 Water System

404Sea Water Intake including intake piping and

outfall200 2.85%

404 Water treatment plant( Desalination & DM) 180 2.56%

404 Cooling tower including pumps 160 2.28%

405LP & CW piping including valves, specialities

and fittings65 0.93%

406 Air conditioning system and ventilation system 20 0.28%

407 Fire protection system 60 0.85%

408 Cranes/ Hoisting Equipments 10 0.14%

409 Compressed air System 13 0.19%

410Miscellaneous Equipments, tanks, Piping,

Insulation etc19.4 0.28%

411 Sub Total 5367.4 76.46%

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500 GRAND TOTAL MECHANICAL 5367.4 76.46%

501 Electrical Works 350 4.99%

505 Electrical cost AS PER ROW 300 4.27%

600Cost of transmission line & plant instrument &

control Lumpsum200 2.85%

Total works Cost ( Prelims+ civil + mech+

elec+ C& I)7019.9 100.00%

Total Project Cost 7019.9 100.00%

B. COST BREAK UP OF SUPER CRITICAL POWER PLANT

S.No COST BREAK UP COST (Crore)

% Total cost (9023 Crores)

1 Supply Of Main Plant Equipment System 3900 43%

a Supercritical Boiler Including Auxiliaries 2500

b Supercritical STG & Auxiliaries 1400

2 Supply of BOP Equipment System 2317.4 26%

a Other mechanical Equipment System 1467.4

b Electrical Equipment System and C&I 850

3 Engineering & Project management 351 4%

4 Erection & commissioning 352 4%

5 Civil Works 800 9%

Total 7720.4 86%

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C. COMPARISON OF BOILERS

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COMPARISION OF 660 MW Vs 500 MW BOILER

D. COST COMPARISON OF BTG PER MW

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SUGGESTIONS & RECOMMENDATIONS

Growing economies always need a proportional need for power. Country likeIndia

has a required growth in power sector close to 15 %. In order to matchthe

accelerated need of country, there is urgent need is to take the challenge tosqueeze

the time and cost required to complete a coal based power project. Ifsome more

R&Ds could fetch some reductions in total costs and couldincrease operating

efficiencies, it would be a great relief to fund hungry powerprojects.

We should go for large size projects which are more efficient and lesspolluting

than several smaller units. One more field which needs to beprioritized is Risk

management and project management that play a verycrucial role in carrying out

such big projects.

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BIBLIOGRAPHY

www.cea.nic.in

www.ntpc.co.in

http://www.worldenergy.org/

www.google.com

http://en.wikipedia.org/

Project management Handbook – ACU Natianal

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http://en.wikipedia.org/

Study on Super Critical Power Plant

Documents

Transcript of Study on Super Critical Power Plant