GET 2012

ON THE JOB TRAINING (OJT) AT

2X660 MW SUPERCRITICAL THERMAL POWER PROJECT KRISHNAPATNAM, ANDHRA PRADESH

SITE LEARNING REPORT

NAME Emp No Designation Branch Location M.AJAY RANGANATHAN 6231 GET MECHANICAL KRISHNAPATNAM

BGR ENERGY SYSTEMS LIMITED 443 Anna Salai, Guna Building, Teynampet, Chennai 600018, India Telephone : 91 44 24334940 web site: www.bgrcorp.com

GET 2012 : ON THE JOB TRAINING (OJT) AT PROJECT SITE

LEARNING REPORT
NAME Emp No Designation Branch Period of On the Job Training (OJT) Project Details / Site Location DEPT MENTOR : HOD ( Name & Designation) CHIEF MENTOR : RCM ( Name & Designation) M.AJAY RANGANATHAN 6231 GET MECHANICAL 10 MONTHS 2X660MW KRISHNAPATNAM THERMAL POWER PROJECT Mr .BALASUBRAMANYAM,GENERAL MANAGER

Mr.PALANICHAMY,Sr.Vice President

AREA OF TRAINING
Sl No AREA OF TRAINING MAIN POWER HOUSE (STRUCTURE 1 & EQUIPMENTS) 3 months PERIOD MENTOR P.V.Krishna Reddy, Deputy manager

GET 2012 : ON THE JOB TRAINING (OJT) AT PROJECT SITE

CONTENTS

AREA OF TRAINING ASSIGNED PERIOD ( As decided by the HOD) MENTOR ( Name & Designation)

MAIN POWER HOUSE (TURBINEGENERATOR)

UMA MAHESWARA /DEPUTY MANAGER

Sl No 1.0 2.0 3.0 4.0 5.0 6.0

DESCRIPTION About the 2 X600 MW SCTPP Project About the "PLOT PLAN" Area assigned Sketch / Schematic diagram of the area/ system assigned About the various drawings used in the area/system assigned EXPOSURE TO CONSTRUCTION / INSTALLATION (Study with more details on the core branch/dept)

Page no 4 9 11 13 15

6.2 Mechanical Installations (as applicable to the trainee's core branch) 8.7 Risk Assesment

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1.0 ABOUT THE PROJECT

INTRODUCTION This 2x600MW Supercritical Thermal Power Project at Krishnapatnam is owned by THERMAL POWERTECH CORPORATION INDIA LTD.

Thermal Powertech Corporation India Ltd., (TPCIL), a company incorporated under Companys Act 1956 on 8th January 2008, is a joint venture between Hyderabadbased Gayatri Energy Venture Pvt Ltd (GEVPL), a wholly-owned subsidiary company of Gayatri Projects ltd. and Singapore-based Sembcorp Utilities, a wholly-owned subsidiary of Sembcorp Industries Ltd,

CLIENT: GPL has established itself as a pioneering organization in construction sector while Sembcorp is a leading energy and water company with worldwide presence and expertise in Singapore, China, Vietnam, the United Kingdom, the UAE and Oman. The clients engineer is Fichtner Consulting Engineers India Ltd

SCOPE OF BGRESL:
According to BGR Energy, the scope of the order includes design, engineering, manufacturing, fabrication, assembly, inspection, testing, transportation, equipment erection, civil and structural works, commissioning and guarantee test for Balance of Plant systems (BOP). This project also turns into EPC since the BTG contractor for this project Dongfang Electric Corporation (DEC) has awarded the contract for erection of boiler, turbine, generator and ESP to BGRESL. BUDGET OF THE PROJECT: The complete budget of the project is 6,869 crore for first phase with production capacity of 1320 MW .In that BGR Energy Systems Limited bagged a Rs.2,168 crore (around $485 million) order for balance of plant (power plant equipments other than boiler, turbine and generator) from Thermal Powertech Corporation Limited. TIME OF PROJECT: The NTP (NOTICE TO PROCEED) for this project has been awarded on 23rd February 2011; the duration for completion of unit 1 is 39 months from date of NTP (i.e.,) 23rd May 2014 and unit 2 is 3 months after completion of unit 1 (i.e.,) 23rd August 2014.

But the planned completion may be extended up to 6 months taking into account site condition. LOCATION OF PROJECT SITE: The Project is proposed to be located near sea coast of Bay of Bengal at Krishnapatnam, Mutukur Mandal, SPS Nellore District of Andhra Pradesh. The site is located 26 km from the Nellore City and 8 km from Krishnapatnam Port. The latitude & longitude of North South extremes of Site are 8008'35.956E & 1419'5.211N and 8009'16.325E &1421'0.874N respectively. The nearest national highway is NH5 which is 18 km away from site (NH5 connects Chennai with Vijayawada). Chennai International Airport is 170 km away from the site. The nearest domestic airport is at Renigunta (Tirupati) which is about 130 km from site. The site is generally barren with minimum undulations and patches of trees & bushes. There is no habitation on the site. This project is carried out in this particular location since it is well connected by roads and nearer to the Krishnapatnam port which is an advantage for coal transportation and water needed for the plant is got from the sea ,it is used after proper treatment in DM plant. PROJECT INFORMATION: SI.No 1 2 3 4 Particulars Project Owner Owners consultant Location Description 2x660 MW Supercritical Thermal Power Project ,Krishnapatnam Thermal Power Tech Corporation (I)Ltd(TPCIL) Fichtner Consulting Engineers Ltd Near Pynanpuram Village ,Mutkur mandal, SPS Nellore District ,AP
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5 6 7 8 9 a b c 10 a b 11 12 a b c d

Nearest railway station Nearest seaport Nearest road Nearest airport Site ambient condition Highest monthly Mean Dry Bulb Temperature Lowest monthly Mean Dry Bulb Temperature Daily Average Temp (dry bulb) Relative humidity Maximum Minimum Wind speed annual mean Annual rainfall Annual average rainfall Maximum intensity of rainfall Monsoon period Design ambient temperature for electrical equipment

Nellore railway station-26KM Krishnapatnam Port-8KM NH5 connecting Chennai&Vijayawada18KM Chennai-170 KM & Renigunta (Tirupathi)130KM 42.2 Deg.C 18.3 Deg.C Max 33 Deg.C 84% 46% 14 kmph 1100mm 100mm/hr July to November 50 Deg.c

WATER AND COAL LINKAGES TO THIS PROJECT: Imported coal will be transported by ship to Krishnapatnam Port. Indigenous coal will be brought by rail from Ib Valley/Talcher to Paradip/ Dhamra Port and then transported by sea to Krishnapatnam Port. From Port, the coal shall be transported to the Power Plant by covered conveyors. Fuel Oil will be transported by road tankers. The sea water from Bay of Bengal, located 0.6 km from the plant boundary, will be used as source of water for the project. Sea water will be directly used for condenser
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cooling through re-circulating type cooling water system. The fresh water requirement for demineralization plant, services and other uses will be met by installation of desalination plant. The estimated water consumption requirement from three units is about 14000 m3 / hr. This water would be made available from sea through submarine pipeline (gravity flow) or a groin type structure. An onshore pump house shall be installed to pump the water to various facilities in the plant. CONNECTION OF PLANT TO NATIONAL GRID: Considering the station size, it is proposed to evacuate power at 400kV level. Power generated from (2x660MW) Phase-1 will be evacuated through a 400kV double circuit overhead line to existing Manubolu substation (Nellore) of Power Grid Corporation India Limited (PGCIL).

2.0 ABOUT THE PLOT PLAN INFORMATION AVAILABLE WITH PLOT PLAN: The plot plan gives the complete details of site buildings, equipment layout, plant systems and position of roads of the proposed project site at a defined scale. USE OF PLOT PLAN: The plot plan is mainly used to get details about retained and proposed buildings, landscape elements, above ground features, areas on hold and obstructions, major infrastructure routes, and critical legal considerations such as property boundaries, setbacks, and rights of way. LEGENDS USED IN PLOT PLAN: RL Reference Level FGL-Finish Ground Level FFL-Finish Floor Level PREPARATION OF PLOT PLAN: The plot plan is prepared initially with location of all plant system for environmental clearance and government approval by the civil team in head office. The plot plan is prepared based on some reference drawings from BGR and customer they are 1. BGR DRAWINGS Layout of plant roads Layout of storm water drains Piping layout for overall pipe rack
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2. Customer drawings GA of main plant buildings General layout plan APPROVAL AND REVISION: After the plot plan is prepared it has to be send to project head and also to HODs of the entire departments especially civil, mechanical and electrical for approval .The plot is taken for follow up after their approval. The plot is revised periodically (once in 4 to 6 months ) after getting information about any changes or modification in the location or area expansion of the plant systems from the customer or project head since the datas given initially in the plot plan subjected to change during detailed engineering of the system. AVAILABILITY OF PLOT PLAN: The plot plan is a controlled document and it is available with site planning department .The other department persons can access it through them KRISHNAPATNAM PLOT PLAN DETAILS: DRAWING NO: GID-145-ME-UMS-XF-1001 RECENT REVISION: E

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3.0 AREA/SYSTEM ASSIGNED (MAIN POWER HOUSE) IMPORTANCE AND FUNCTION MAIN POWER HOUSE: Main power house is termed as heart of a power plant since the electricity is produced from the turbine generator set installed in it. Main power house or turbine-generator island forms an integral part of the power plant since it comprises of massive equipments such as steam turbine, generator, boiler feed pumps ,condensate extraction pumps, deaerator, LP heater, HP heater and condenser. Since it contains all major equipments and performs the vital function of power generation it gains importance. EQUIPMENTS IN MAIN POWER HOUSE: 1. Steam turbine 2. Generator 3. Boiler feed pump (both motor driven and turbine driven) 4. LP feed water heater 5. HP heater 6. Deaerator 7. Condenser 8. Lubricating oil system 9.Gland seal system

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TIME PERIOD OF COMPLETION: According to L2 schedule prepared on January 28th 2012, the time period of completion
S no WORK TIME PERIOD(Days)

1 2 3 4 5 6 7

STG foundation STG building Turbine-Generator and auxiliaries erection Condenser erection LP and HP heaters erection Deaerator erection

425 616 617 536 60 75

Boiler feed pump (motor driven & turbine 312 driven)

Condensate extraction pumps

434

The above given data is subjected to change based on site conditions and priority during detailed engineering work in the site. Input and Output to the system: The input to the system is superheated steam from boiler and output is the 115KV AC current from generator to the generation transformer.

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4.0 SCHEMATIC DIAGRAM OF MAIN POWER HOUSE SCHEMATIC DIAGRAM OF EQUIPMENTS IN MAIN POWER HOUSE: The below is the schematic of equipments in main power house .The systems inside red box in the below diagram gives a depiction of sequence and flow of process within equipments in main power house.

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SCHEMATICS OF STEAM CYCLE: The diagram below shows the steam entering different stages of turbine with valves associated with it.

CV-CONTROL VALVE ESV-ELECTRIC STOP VALVE NRV-NON-RETURN VALVE

SCHEMATIC OF TG DECK: According to the information I got from DEC the turbine configuration is tandem compound 4 cylinder reheat steam turbine.so I have given a diagram showing that configuration.

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5.0 DRAWING READING DRAWING TYPE: The drawings available for erection are two dimensional drawings .It clearly depicts the orientation, elevation and location of the components in all views (front, top and side) and cut sections also illustrated if needed. DRAWING NUMBER OR CODIFICATION: There are separate coding for MPH structure drawings and MPH equipment drawings 1. For the structure drawings TPCIL-BTG-11-117-A3074a-BZ___, the initial code remains same for all drawings only the last numbers differs it denotes the axis and elevation of main power house. 2. The equipment drawings have the coding TPCIL-BTG-T030501E (OR) J0201-___, the initial code followed by number which denotes owners number for those drawings. RELATION BETWEEN DRAWINGS CODE AND MATERIAL PACKING LIST: All the material has DPL (Detail Packing List) contains identity number relating to the drawing number of the item which helps in easy identification and relating of the component while execution. GENERAL ARREANGEMANT DRAWINGS: The general arrangement drawing is a useful tool which clearly illustrates the location of all the equipments and systems in a given area The general arrangement drawings are of great use for planning our erection work and to decide the sequence of work.

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For our MPH, the drawings are prepared by the manufacturer based on Owners requirements and revised by the design person of the manufacturer based on comments from Owners engineering consultant. After all the drawing is approved by owners engineering consultant FICHTNER CONSULTING ENGINEERS INDIA LTD In the site the drawings will be transmitted by DEC (manufacturer) to fichtner, from them to TPCIL (owner) and then through TPCIL the drawings are released to BGRESL for execution. These drawings will be available with respective department heads and planning department.

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6.2 MECHANICAL WORKS IN MAIN POWER HOUSE INTRODUCTION: The mechanical erection/installation works going on at MPH are Steel structure erection and EOT girder erection Technical Sequence of steel structure erection: The steel structures of power house building comprises of columns, frame beams, secondary beams, vertical bracings , crane girder, roof truss, roof purline, horizontal bracing ,gratings ,stair tread and hand rails. The sequence followed in erection is Preparation of column for ground inspection. Erection of columns at ground level. Alignment checking of columns. Grouting of column base. Erection of remaining columns, beams, roof truss at different elevation according to drawing and feasibility Donts during erection: Any erection activity tend to safety violation should not be carried out. Erection activity without using proper tools and shackles should not be done.

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Technical Sequence of erection of EOT GIRDER: The 19 MT EOT girder will be positioned in between the axes 1 &2, and assembly of the platform, Drivers Cab, inclined ladder, overhaul cage for EOT girder will be done at Ground level. Assembly of end carriages (wheels) will be erected on the rail in both the axes and stopper provision will be ensured to arrest the motion. Checking of EOT girders camber & sweep along with the total length of the girder will be done on ground before lifting. Quality aspects i.e. ground inspection and after erection as well (according to FQP), will be documented and maintained.

Schematic of EOT Girder Erection

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CONSTRAINTS IN ERECTION: The main constraint in erection process of power house building is civil works taking place near erection area (CW PIPELINE,CCB FOUNDATION AND MILL BUNKER FOUNDATION) which chunks access to erection. Reasons for delay: Non availability of man power (skilled labor) Lack of supervision of labors from contractor side. Lack of material mobilizing to erection area on time. Lack of proper planning for erection from contractor side. Non-availability of proper tools and shackles for erection` MACHENERIES INVOLVED IN ERECTION:
1.150 MT CRAWLER CRANE-1 Nos 2. 100 MT CRAWLER CRANE-2 Nos Technical Specification of 150 MT CRAWLER crane to be used in EOT girder erection:

Length of the Main boom - 57 mtrs Boom angle (Main) at which the Erection to be carried out is 72-78, to ensure effective lifting. Crane working radius i.e. distance to be maintained between the center points of Crane and EOT Girder to have precise positioning - 16 to 18 mtrs Distance (Height) from ground to the tip of boom - 45 to 52 mtrs the angle of boom) ( varies with

Crane Lifting Capacity at the specified parameters is - 24.4 to 28.7 MT (at specified radius)

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8.7 RISK ASSESMENT Risk assessment is an integral part of risk management. It is the process of: 1) Identifying and analysing safety and health hazards associated with work; 2) Assessing the risks involved and 3) Prioritising measures to control the hazards and reduce the risks. Every workplace should conduct risk assessments for all routine and non-routine work undertaken. DUTIES IN RISK ASSSESMENT:

HAZARD IDENTIFICATION

Study the operation and work area for possible hazards. Using the two concepts of likelihood of occurrence and severity of effects

RISK EVALUATION

RISK CONTROL

Elimination of risk or provide controls to reduce the risk to as low as reasonably practicable.

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RISK ASSESMENT FORM: The risk assessment form has to be prepared before starting of any critical works such as heavy lifting, critical quality inspection and for unavoidable precarious jobs.

The risk assessment for comprises of hazard identification and evaluation of risk for the identified hazard followed by risk control measures. RISK ASSESMENT TOOLS: Accident Severity Chart:

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RISK MITIGATION: Risk mitigation is a systematic reduction in the extent of exposure to a risk and/or the likelihood of its occurrence. Also called risk reduction. Risk mitigation is done by using some proper risk control tools

RISK CONTROL HIERARCHY: The risk control is done following a hierarchy it is depicted in the drawing below

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12.1 LEARNING REPORT EVALUATION - 1st QUARTER

PERIOD : Oct - Dec 2012
HOD's comments

Rating Excellent Very Good Good Just Acceptable

Poor *

* Rewrite the report

Date

Signature of HOD ( Name & Designation)

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