CONFERENCE ON BALANCE OF PLANT SYSTEMS 23 RD MAY 2012 FOCUS ON CIVIL - - PowerPoint PPT Presentation

FOCUS ON CIVIL & ST RUCT URAL BOP

CONFERENCE ON “BALANCE OF PLANT SYSTEMS” 23RD MAY 2012

Pres entation by: J .P.Rao Director – Corporate M arketing Strateg y

GROUP INTRODUCTION

 147 years of rich legacy as an Engineering & Construction Company with unmatchable delivery record.  Group Turnover of INR 12500 Crores (US$ 2.5 Billion), with 23,000 Employees.  Strong Presence in India and Internationally footprint in Middle East, Africa, South East Asia & Caribbean.

SP GROUP - Introduction

Lanco, Amarkantak – 1 x 300 MW

 A Conglomerate with Multiple Business interests with Progressive Outlook and Professional Approach

• Engineering

& Construction – Industrial, Commercial and Real Estate.

• Infrastructure – Coal Mining, Power, Ports and

Roads.

• Engineering, Procurement & Construction –

Minerals, Metals, Power.

• Business Automation
• Engg / Manufacturing of Precision Tools
• Others (Bio-fuels, Facades and Interiors, Textiles

and Shipping and Logistics).

SP GROUP - Introduction

BALCO, Korba – 4 x 135 MW

SP Group Companies

General Contracting, Design & Build Solutions for Industries, Utilities, Residential & Commercial projects Infrastructure construction for Ports, Power plants, Marine, Oil & Gas, Transport. Electrical, HVAC, Plumbing & Fire Fighting. DG Set manufacturing, Switchyards. Engineering, Shipping & Logistics and Transaction Management Solutions Building Façade solutions Engineering, Procurement and Construction solutions for Minerals, Metals & Power sector Real estate development

Interior fit outs Infrastructure development and operations / BOT projects Water and Air purifier, cleaning and security systems Transactions processing, services and networks Travel Services Yarns canvas, Belting ducks and terry towels Publishing of Magazines like Power Watch, Computer Active, Car & Bike, Smart Photography.

SP Group Companies

 Shapoorji Pallonji & Co. Ltd. is the core flagship company.  Synergy within group companies enables us to execute large & complex projects swiftly and efficiently.

Industries, Utilities, Buildings Ports, Transport, Terminals, Infra Electro- mechanical works Power, Minerals & Metals Roads, Ports, Power Projects Logistics & Water Systems Civil & Structural Works Intake / Outfall Structures, Jetties HVAC, Electrical, Firefighting EPC Solutions BOT Projects ETP / WTP Desalination Synergy for Power Project Execution Area of work In Power Plants

SP Group – Synergy for Power projects

Shapoorji Pallonji & Co. Ltd.

 One of India’s Oldest and Most Respected Group, operating for 147 years.  Turnover of INR 3174 Crores (2010-11).  An ISO 9001:2008 Company Complying to the ISO Standards for ‘Design & Build’ & ‘EPC’ Projects.  Certified for ISO 14001:2004 & BS OSHAS 18001:2007  The FIRST Indian Construction Company to enter the Middle East in 1971.  Strong Presence PAN India and in the Middle East, Africa, & the Caribbean.

Samalpati Power 105 MW Oil Fired plant

Shapoorji Pallonji & Co. Ltd.

 Engineering & Construction activities include:

• Power plants & Industries (24 Power & 50 Industrial

Projects)

• High-rise Buildings & Residential Buildings
• Hotels, Hospitals, Airport, Educational institutions, Data

Center, Commercial, Malls & Multiplexes, and Stadiums.  9 Regional offices presently executing 85 sites

Tata Power, Trombay-1 x 500 MW

Afcons Infrastructure Ltd.

 A Leading Infrastructure Firm Having Transnational Presence.  Significant Experience and Strong Track Record.  Areas of Operation:-  MARINE – Over 176 + Works Ports & Harbors', Jetties, Dry Docks, Wet Basins, Breakwater, Outfall & Intake Structures etc.  OIL & GAS LNG Plants, EPC Contracts for Offshore Oil & Gas Process Platforms Onshore Oil/Gas/Chemical Plants and Civil works such as Refineries, Gas Plants etc, Fabrication Yard.  TRANSPORTATION Roads ( Over 3000 + Lanes km), Bridges, Flyovers, Interchanges ( Over 132 +), Railways and Metros ( 43 km Elevated metro) , Railway Tunnels, Road Tunnels.  9 TUNNELS AND HYDRO PROJECTS  40 GENERAL CIVIL ENGINEERING WORKS  30 + OVERSEAS PROJECTS

• Established in 1927 as Wilson Electric works
• Turnover of INR 700 Crores (2010-11)
• In 1973, Sterling and Wilson was formed in association with SPCL

MEP Services

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

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

• Today Sterling and Wilson is India’s leading MEP services company
• MEP projects contribute approx. 60% of the business revenue

Sterling & Wilson

Tata Motors, Sanand

DG Sets

• Asia’s largest DG set plant at Silvassa ‘Sterling Generators’
• ISO 9001:2000, ISO 14001:2008 Certified Facility
• In 2008, become largest buyer of MTU engines in Asia
• In 2010, become 2nd largest supplier of Gensets in India of above 1000 KVA
• In 2011, become largest buyer of Perkins Engineers above 1000KVA, in Asia

Co-Gen capabilities

• Established the Co-Gen division in 2011
• Offers highly optimized Gas based Combined Heat & Power (CHP)

turnkey solutions for Commercial Buildings & Process Industries

Sterling & Wilson

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

Solar-Power EPC

• Established the Solar EPC division in 2010
• 16

projects aggregating to 71MW spanning across the country have already been commissioned and connected to the grid

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

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

Sterling & Wilson

25MW Visual Percept, Surel, Gujarat

POWER PROJECT EXPERIENCE

SPCL - Completed Projects

Name of the project Client Location Year of Completion Civil & Structural works for Coal Handling Plant for 4 x 135 MW Thermal Power plant BALCO / SEPCO Korba 2005 Civil works for TG Foundations & Allied Buildings for 1 x 300 MW Coal based Thermal power plant Lanco Amarkantak 2008 Civil works for the entire plant for 3 x 350 MW CCPP Torrent / Siemens Surat 2008 Complete Piling Infrastructure & Enabling works for 370 MW CCPP GSECL / Alstom Utran, Gujarat 2008 1 x 600 MW Thermal Power Project near Barela- Gorakhpur Village Jhabua Power Ltd. Seoni M.P 2011

Name of the project Client Location Year of Completion Civil works for 2 x 120 MW Thermal Power Project Tata Power Company Ltd Jojobera 2001 Independent Power Generation – 105.66 MW Samalpatti power Company Tamilnadu 2001 Civil works for TG Building & Allied Buildings for 2 x 500 MW & General Civil works for 1 x 180 MW & 1 x 250 MW Tata Power Trombay, Mumbai 2001

SPCL - Completed Projects

Client : Torrent Power Generation Limited Location: Surat Completion: 2008 Description / Major Quantities 1130 MW Combined Cycle Power Plant Excavation : 2,01,465 cu.m. RCC Works : 86,990 cu.m. Reinforcement Steel : 7209 MT Structural Steel : 3500 MT Roof Sheeting & Cladding : 18,000 sq.m.

1130 MW TORRENT CCPP, Surat

Scope : Earthworks Under reamed Piling TG Foundations & Decks Boiler Foundations Structural Steel Works Ancillary Buildings Road Works CW System Service Pipelines & Trenches

SPCL - Completed Projects

Client Lanco Location: Chattisgarh Completion: 2008 Description / Quantities 300 MW Thermal Power Station Excavation : 4,45,000 cu.m. RCC : 1,38,120 cu.m.

Lanco Amarkantak, Chattisgarh

Scope Earthwork TG Foundations & Decks Boiler Foundations DM Tank Foundation / FD & PA Fan Foundation Pick Rack Foundation / Conveyer Foundations Coal Mill & Bunker Water Supply, Drainage & Sanitation Rain Water Reservoir Structural Steel Works

SPCL - Completed Projects

Client Shandong Electric Power Co. Location: Chattisgarh Completion: 2005 Description / Major Quantities 540 MW (4 Units x 135 MW) TPP. Structural Steel : 4250 MT RCC : 78000 Cu.M. Reinforced Steel : 6200 MT Track Hopper RCC : 200 M Stacker RCC : 350 M

Balco, Korba

Scope: Crusher foundation & deck 28 M High RCC Frames Structure for Crusher House 22.5 M High RCC Fly Ash Silo – 2 Nos. WTP with DM Tank foundation Air Compressor House / Refrigerating Station Power house Control Building Coal handling wash water pump house.

SPCL - Completed Projects

Client Samalpatti Power Company Location: Tamil Nadu Completion: 2001 Description / Scope Independent Power Generation – 105.66 MW Buyer : Tamil Nadu Electricity Board. Seven Wartsila Diesel Engines Primary Fuel : Low Sulphur Heavy Stock Plant

Samalpatti Power, Tamil Nadu

Client Tata Power Company Ltd. Location: Jojobera Completion: 2001 Description / Scope Civil works for 2 x 120 MW Thermal Power Project Wagon Tippler, Reclaim Hopper Conveyers Tunnel, Pump house MCC Rooms.

Tata Power SPCL - Completed Projects

Name of the project Client Location Completion due General civil works for Main Plant & Auxiliary buildings for Unit 2 of 600 MW Power Plant Bharat Heavy Electricals Ltd. Chennai Dec 2012 Site and Infrastructure works and Main Plant Civil & Structural works for 1 X 600 MW TPP Korba West Power Company Ltd. Raigarh, Chhattisgarh. Mar 2013 Piling and Foundations in Main Plant, Power House, Boiler, ESP, TG, Fans and Transformer foundation

• etc. for 2 x 500 MW TPP

Bharat Heavy Electricals Ltd. Tuticorin Nov 2012 Construction of BTG - Civil and Structural works for 5 X 270 MW Nasik thermal Power Project Elena Power & Infrastructure Limited Sinnar, Nasik. Nov 2012 Construction of BTG - Civil and Structural works for 5 X 270 MW Nasik thermal Power Project Elena Power & Infrastructure Limited Amaravati, Maharashtra Dec 2012

SPCL - Ongoing Projects

Name of the project Client Location Completion due Civil works for 225 MW Gas based Combined Cycle Power Plant Sravanthi Infratech Pvt.Ltd. Kashipur, Uttarkhand. June 2012 Piling and General Civil works for 2X250 MW Lignite Based Thermal Power Project Bhavanagar Energy Company Limited Bhavnagar, Gujarat Mar 2013 Construction of Main Plant building & Balance of Plant for 2400 MW Combined Cycle Power plant. M/s Reliance Utility Engineers Pvt. Ltd. (ADAG Group) Samalkot, Andhra Pradesh Aug 2012 Civil and Structural works of BTG and General Civil works of construction of 2 X 600 MW Coal based Thermal Power Plant. Jindal India Thermal Power Angul, Orissa June 2013 Civil works for Coal Handling Plant of 2 X 600 MW DVC Power Plant at Raghunathpur. The TRF Ltd. Jamshedpur Ragunathpur West Bengal. June 2012

SPCL - Ongoing Projects

Client: M/s Reliance Utility Engineers Pvt. Ltd Location: Samalkot,,Andhra Pradesh Duration: 18 months Project Gas Based Combined Cycle Power 2 gas turbines and 1 steam turbine having a capacity of 3 X 800 MW = 2400 MW Major Quantities Concrete quantity : 1,50,000 cum Structural Steel : 14000 MT .

SPCL - Ongoing Project – Project Data Sheet

GT Erected on foundations Block-2

2400 combined Cycle Power Plant, Samalkot

Scope Total civil works for Main plant area-3 units and General civil works for Balance of plant Total civil works for switchyard, roads and drains. Erection of bolted structure for (14000 MT)

2400 combined Cycle Power Plant, Samalkot

Structures include: GT building, ST building, Transformer yard, HRSG, Bypass stack, Main Stack, Electrical control building etc. Pump houses, Raw water fire water pump house, Cold water pipe encasement works, PT plant, Ware house, Admin building, H2, N2, Co2 building, Chlorination building, PMCC building etc. Switchyard, GIS ,AIS,ICT, cable trenches (400 KV & 220 KV). Major PMV Deployed

• Concrete placing - a boom placer and 3 nos static pumps and 10 transit mixers are arranged.
• 125 KV DG set & 250 KV DG Set
• Concrete plants One 60 Cum/hr & 30 Cu/hr, each
• 150 MT crane

SPCL - Ongoing Project – Project Data Sheet

Structural Work in progress

Client Bhavanagar Energy Co. Ltd. Location: Bhavanagar, Gujarat Completion: Mar - 2013 Description / Scope Piling & General Civil work 2 x 250 MW lignite based Power plants. Scope: Pile caps, Piling works, Structural Steel works Major Quantities: No of Piles : 5587 ( 500mm, 750mm, 1000mm) Pile Concrete :49300cum Structural Steel :15050MT Total Concrete : 1,30,000 cum

SPCL - Ongoing Project – Project Data Sheet 2 x 250 MW TPP, Bhavnagar

Client : Elena Power & Infrastructure Ltd. Location: Nasik

India Bulls Thermal Power Plant, Nasik

Description Capacity - 5 x 270 MW Thermal Power plant at Sinner, Nasik Scope Civil & Structural works for TG, Mill Bunker. Civil Foundations for ESP. Major Quantities:- Structural Steel Fabrication:- 24200 MT. Structural Steel Erection:- 15100 MT.

1200 Coal Based Power Plant, Derang

Client: Jindal India Thermal Power Limited Location: Derang, Angul, Orissa Duration 22 months Project Description Coal Based Power Plant of 2X600 MW Major Quantities Reinforcement work is @ 63,500/ MT Structural @ 1,40,000/MT Scope of Work Earthwork, PCC, RCC, Reinf, shuttering, staging, insert fixing, brickwork, plaster, water stopper. Structures: Boiler, ESP, Power house, Turbine generator Mill bunker, ID fan, PA fan, FD fan, Air compressor building, Demineralization tank, CST tank, CWST tank, Guard pond, Coal handling plant, water intake system, ash pond etc.

SPCL - Ongoing Project – Project Data Sheet

CHALLENGES FOR THE CIVIL & STRUCTURAL (C&S) CONTRACTOR

PRESENT SCENARIO( AS ON MARCH 2012 ) – PAN INDIA POWER PROJECTS  TOTAL NO OF PLANTS UNDER CONSTRUCTION (THERMAL) : 70 NOS.  TOTAL CAPACITY UNDER CONSTRUCTION IN MW (THERMAL) : 50000 MW  TOTAL NO OF UNITS : 148  TOTAL NOS OF CHP / AHP : 148  DM PLANT : 211, COOLING TOWERS : 218, CHIMNEYS : 77 PROJECTS UNDER CONSTRUCTION BY SPCL  5500 MW / 10 SITES  APPROX. STRUCTURAL STEEL QUANTITY : 1,50,000 MT  APPROX CONCRETING QUANTITY : 4,80,000 MT

CHALLENGES WORKFORCE ISSUES  Unavailability of Trained Workforce  Mandatory use of Local Labour LACK OF TRAINING INSTITUTES  Very Limited Institutes for Training the Labors / Executives for the Power Industry  Shortage of Executive Manpower / Power project specialists : @ 4000 nos Break-up of Shortage: Senior Management – 354 Middle Management – 1302 Junior Management – 2268

CHALLENGES SITE CONDITION ISSUES  Location of site – not favorable for Logistics, etc  Local Agitations  Space inadequacy for Site Infrastructure, Yard, Colonies, etc  Access roads are generally in bad shape

CHALLENGES DESIGN & ENGINEERING ISSUES  Inadequate Data for Design & Engineering  Co-ordinated / Interface drawings are usually incorrect resulting in re-working  Approvals / issue of drawings are delayed  Equipment Details / Loading / Sizing are not known well in advance LACK OF SUPPORT FROM DEVELOPERS  Tough Deadlines...without considering Site Conditions, Local issues, etc  No Project or Site Security  Delay in Bill Certification  Electricity and water availability

CHALLENGES PLANNING & LOGISTICS ISSUES  Lack of Interface scheduling generally, poses problems!  Coordinated Drawings with vendors, Consultants, Contractors, are delayed  When drawings miss out the openings , redundant works are unavoidable.  When Logistics schedule is not updated for delivery of equipment on site, Movement of gangway & infrastructure works...suffer.

CHALLENGES PROCUREMENT & CONTRACTING STRATEGY ISSUES  Many a times Developer is not clear on Project Delivery Model- EPC / Packaging  All Agencies are not finalized at the initial stage...this leads to change in Design data & Project Scheduling at a later stage!  Cost Escalation for Labour, PMV, Materials is not provided…  Cash Retention is up to Commissioning stage, affects Cash flow…

SOLUTIONS

SOLUTIONS FOR RESOLVING WORKFORCE ISSUES (TAKEN UP BY SPCL)  Preparation of Technical training syllabus for various trades.  Set-up of skill development center at every project site and impart on-site skill training .  Training to Sub-Contractors to handle statutory compliances & HSE norms, Labor Management through site HR & admin.  Camp Boss posted for labour camps and their welfare  Identified and resolved labour issues in labour camps  Introduced Labor Productivity Incentive Scheme – To sub contractors.  Introduced Labor Retention Incentive Scheme – To Sub-Contractors SOLUTIONS

SOLUTIONS FOR DESIGN & CONSTRUCTION ISSUES  Vendors to be finalized by Client at the initial stage itself  Data on Equipment Loading / Sizing, to be provided at the beginning.  Erector to confirm the Methodology to be deployed for installation of equipment/s in advance.  Vendor to provide updated information on Delivery schedule & interfacing activities  All concerned players to provide information on Work front availability / access / cutouts to be left .  Link day to day change and project based change SOLUTIONS

SUPPORT FROM DEVELOPER  Partnering Approach with WIN-WIN Preposition  Ensuring Co-ordination between Vendors, Consultants & Contractors  LEAN Approach – Optimum Utilization & Resources & Minimizing wastages  Social-Economic Impact Analysis should be carried out by the Developer –

• Very important in order to anticipate local issues which hinder the works.
• Developer should have dedicated CSR Activities for the Locals

SOLUTIONS

SOLUTIONS SUPPORT FROM DEVELOPER  Understanding of Total supply Chain value Streams  Provide advance time for Mobilization  Inspection & Clearance for raw steel, fabricated items, other bought out items in the shortest time.  Inspection for Critical items only  Critical areas, Drawing finalization / approval, release within stipulated time

SOLUTIONS FOR PACKAGING & CONTRACTING ISSUES  Civil works for entire unit should be one package (including infrastructure works)  Building related Electro -Mechanical works can be integral part of Civil package.  Bonus clause for early delivery.  Ensure +ve Cash flow throughout the project duration  Cost Escalation for Labour, PMV, Materials is to be provided  Retention should be against Bank Guarantee only till completion of Civil works & not Commissioning stage  Equitable risk allocation through sharing of risks. SOLUTIONS

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