PROJECT AT A GLANCE

3 X 660 MW Boilers and Auxiliary Installation

Client Supplier National Thermal Power Corporation Ltd. - Doosan Heavy Industries & Construction Co. Ltd. South Korea

Erection Agency Larsen & Toubro Limited, ECC Division LOI Issued Job Value - 15/04/04. - 296.36 Crores

Salient Features of the Project

* 3 X 660 MW POWER PLANT * UNIQUE IN NATURE First time in India Mega Power Project Declared by Govt.

* INDIVIDUAL BOILER RATING

* WORKING PRESSURE * NO OF BOILERS

2225 MT / Hrs. (660 MW)

255 kg / sqcm 3 NOS

* CUSTOMS DUTY
* HEIGHT OF THE BOILER

Nil ( Decl. by Govt.due to Mega Power Project)

100 MTRS

* NO OF FANS

6 NOS
10 NOS 10 NOS

* NO OF COAL FEEDERS * NO OF MILLS

Uniqueness of the Project

All Structural Members are Bolted Type. No Boiler Drum in this Boiler. Boiler working press. (Sup. Steam) 255 kg/sqcm Furnace wall is Jacket Type. All Ceiling Girders will be erected from outside by using 750 MT crane Ringer mode.

Furnace wall is being erected 28 mtrs in length after preassembly.

Uniqueness of the Project

Extended floor Panel assembled with Header & Buckstays and will be erected. Furnace Bottom hopper with Ring header will be assembled and erected all together.
Most of the Duct Pieces upto 15 mtrs will be assembled at ground and erected.

Approx. 20000 nos welding joints will be done on ground for preassembly before erection out of 42000 nos joints.

Safety Statistics
Description

CUMULATIVE (FROM MARCH 2005)

Safety M/H record Accident records Minor First -aid injuries Fatalities

1488374

10
1

Status of meeting & training Training Multi media safety show

58 15
15.50

PROJECTED MANHOURS =

Millions

SAFETY ACTIVITIES
Screening of the workers are being done before engaging on the job.

Morning Pep-talk is being done before starting the work.

100% PPEs are being implemented at erection site. Training for workers on weekly basis at training hall for better awareness. Usage of 100% full body harness at erection site.

SAFETY ACTIVITIES
Usage of Double Safety net at erection site. Periodic inspection of Tools & Tackles. Method statement is being made and analysed jointly by Contractor and Client before all critical erection.

Sub contractors Performance is being evaluated by Safety committee on Monthly basis.

100% usage of GI Flat for earthing purpose. Total Safe Manhours upto Dec05 = 1488374 Positive customer feed back.

SCOPE OF WORK OF L&T

Port

Clearance,Inland Transportation From Vizag to Sipat & Insurance Material Management Erection Testing & Commissioning

CONTRACT VALUE
MECHANICAL ERECTION : 147.90 CRORES

E&I ERECTION

11.00 CRORES

INLAND TRANSPORTATION INCLUDING TRANSIT INSURANCE : 35.34 CRORES SUPERVISION OF ERECTION AND COMMISSIONING BY DOOSAN : 44.61 CRORES

PORT CLEARANCE CHARGES ( 1.2% OF THE CIF VALUE) : 19.46 CRORES

CONTRACT VALUE
ADDITIONAL COMPENSATION TO BE PAID BY DOOSAN (6.5 M US DOLLAR) : 29.64 CRORES INSURANCE CHARGES : 8.414 CRORES

TOTAL CONTRACT VALUE INCLUDING E&I : 296.36 CRORES

SUMMARY OF TOTAL TONNAGE OF BOILER 3 x 660 MW

BOILER STRUCTURE
BOILER PRESSURE PART & ACCESSORIES POWER CYCLE PIPING

: 20772 MT : 21240 MT : 9096 MT

COAL FIRING SYSTEM

DRAFT SYSTEM (INCLUDING DUCT & DAMPER) REFRACTORY / INSULATION / C&I / MISC.

: 11469 MT
: 15012 MT : 6291 MT

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

MILESTONE EVENTS
Description Unit # 1 Structure Erection As per Contract 15-04-05 Actual 03-03-05 15-09-05 28-06-05 20-01-06

Unit # 1 Pressure part Erection 15-09-05 Unit # 2 Structure Erection Unit # 3 Structure Erection 15-10-05 15-04-06

Quality Aspects
Involves Bolting and torquing of 102615 bolts per Boiler for main structure Welding of hand rails : 700 Mtrs per boiler Welding of 42656 joints in pressure parts per boiler Welding of 22283 joints in power cycle piping per boiler. Involves special P91/T91, T92, P23/T23 and Super 304H materials in boiler pressure parts and piping. Involves Induction heating technique for above special materials

Quality Improvement
100%

implementation of Preparation & approval FQP and Inspection test procedure prior to start of the job to erection.
Stage

wise inspection prior to erection and completion of job and proper documentation of the same.
Reduction

of repair % from 2.9 to 0.60 by stringent control in welding conditions and welder performance.
100%

NDT & PWHT clearance of Preassembled items before erection.

QUALITATIVE IMPROVEMENTS
Pre assembly of most of the Pressure part members before erection. Thereby improving on the following parameters. 1. Safety Improvement - Reduction of exposure of work at height and critical locations. 2. Improvement of quality of welding as maximum welding is done at ground level.
3. Reduction in total completion time by parallel working on pre assembly. 4. Reduction in installation cost by reducing the work in in-situ position.