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MSP Report On Construction of

Cooling Tower “Tata Power Unit#5”

Jamshedpur.

MCM 503: COMPUTER WORKSHOP-III

Submitted By

Mr. Ravi Bhushan (221025)

PGP ACM 22nd Batch

(2008-2010)

NATIONAL INSTITUTE OF CONSTRUCTION

MANAGEMENT AND RESEARCH

PUNE

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Contents

1. Introduction ………….…3

2. Project Details ………….…3

3. List of Activities ………….…8

4. Technical Features ….…….…..9

5. Data Collected ……….…..11

6. Conclusion …..…….…13

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Introduction:

Project management is the process of planning, organizing, and managing tasks and resources

to accomplish a defined objective, usually within constraints on time, resources, or cost. A

project plan can be simple, for example, a list of tasks and their start and finish dates written

on a notepad. Or it can be complex, for example, thousands of tasks and resources and a

project budget of crores of rupees. Most projects share common activities, including breaking

the project into easily manageable tasks, scheduling the tasks, communicating with the team,

and tracking the tasks as work progresses.

Cooling tower is one of the complex project in which various activities involves, so more

manpower require than other smaller project of construction. Some activities are critical

which takes more time so we should do proper planning and scheduling to avoid it and make

work faster.

Project Description

To meet the power demands due to TATA STEEL modernisation programme, TPC have

already installed and commissioned one unit of 67.5 MW and three unit of 120MW last unit

was commissioned in October 2005. Power from these units is being fed to TATA STEEL

grid which in turn supplies to steel plant, cement plant, TATA MOTORS, Tinplate co. &

Jamshedpur city. With the anticipated growth, a power deficit of 113.5 MW for Jamshedpur

network by the year 2008-09 is estimated requiring addition of one more unit of 120MW

rating coal based thermal power plant.

Project location-

The 5th unit is in the vacant land available within the existing premises of jojobera power

plant boundary besides availability of coal and water, evacuation of power, features of main

plant equipment including cooling water system, coal and ash handling systems, electrical

systems. Modification to be carried out, environmental aspects, estimates of project cost,

schedule for project implementation and cost generation.

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Site Topography and Grade Level-

The site for the proposed unit is situated in filled up area covered by slag fill. The ground

level of the proposed site varies from RL 180m to RL 170m. The grade level of the existing

120MW units is at EL 180m. Space available for proposed unit no.5 is almost filled with slag

during construction of unit no 1 to 4.

Major Building and Structures

Station building: general arrangement

1. Station building- The span of the turbine generator and auxiliary equipment bay

would be 24m and that of electrical bay would be 10.5m with the existing station

building of unit no.4. The length of the station building would be 67.5m consisting

of 9 bays of 7.5m.

2. TG bay would be serviced by three floors-

Ground floor-0.0m

Mezzanine floor-5.0m

Operating floor-10.5m

(TG bay-22m, electrical bay-32m)

3. The superstructure would be of structural steel framing with brickwork and pre-

coated metal sheet for side cladding and RCC floor slabs.

4. The turbine generator pedestal would be of reinforced concrete frame structure

and would be isolated from the building foundations and superstructure.

Steam Generator Area and Mill Bay

The mill bay would be would be of structural steel-framed construction, supporting

the steel bunkers. The 10.50m wide bay would have floor for the feeders and for the

trippers.

Chimney

Stack of 150m height from SG area grade level to match with the existing 120MW

units. The height takes into consideration the requirement of Indian Emission

Regulations.

Cooling water pump house

Pump house is provided for CW pumps. The CW pumps are located indoor. Each CW

pump would have an independent sump with provision for installation of stoppage

and coarse screens in the pump chamber.

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Miscellaneous buildings

s.no Building/structure Sizes(m)LxBxD remarks

1. ESP control room 28x7x4.5 Single storey building. RCC

construction with brick wall for side

cladding. Roof shall be RCC

2. Air washer room 20x15x8

& 13x7.5x5.5

Single storey building at two

locations.Structuralsteelconstruction

with brick wall for side cladding. Roof

shall be of RCC.

3. Fuel oil pump

house

6x6.5x4.5 Extension of existing pump house by

two bays.

4. D.G house 15x7.5x11 Extension of existing DG house by

one bay.

5. Ash slurry sump

and ash slurry pump

house for bottom

ash and fly

ash(common for

unit#4&5)

50x12x7.5 Single storey building. Structural steel

construction with RCC roofing and

brick wall for side cladding.

6. 132kv switchyard

control room

12x6x10 Extension of existing control room.

7. 220kv switchyard

control room

20x13.5x5 Existing building to be demolished

and new building to be constructed.

8. Clarified water

storage tank

25x25x5 3000cu.m capacity CLWST

9. Silo 7.5m diameter 650 tonnes capacity.

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Cooling Tower for 120MW jojobera thermal power plant

The use of cooling tower is to cool the water in water circulating system. It has two types

induced draft cooling tower and natural draft cooling tower. The above figure shows IDCT

(induced draft cooling tower).

For the above project of cooling tower following are the project details….

Client---Tata Power.

Contractor—Paharpur Cooling Tower.

Number of Cell—5Nos

Contractor Type—EPC (Turnkey)

Project Cost—2cr approx

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Cooling Tower, CT-5

Capacity: 210m3/hr.

Hot water inlet temp. : 47°C

Cold water outlet temp. : 32°C

Wet bulb temp. : 28°C,

No. of cells: 5

About Paharpur-- Paharpur does not rest r ic t i tse l f to only manufactur ing and

supplying cool ing towers , but bel ieves in the concept of turnkey

responsibi l i ty including t ransport ing to s i te , erect ion, commissioning and

test ing of complete cool ing towers . In the case of concrete cool ing towers

the c ivi l work is undertaken by Paharpur on i ts own. They have a ful l

f ledged civi l design and construct ion department with highly t ra ined and

experienced civi l engineers . They also have experienced personnel in

shipping and erect ion departments .

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List of Activities: In order to construct the cooling tower, a series of activities will need

to be undertaken. The following activities are part of the project scope:

Civil Work

EXCAVATION

PCC FOR CW BASIN

RCC FOR CW BASIN

CW BASIN WALL INCL. COLUMN

BEAM AT IST LEVEL

UP TO FILL LEVEL

FILL TO ELIMINATOR

ELIM. TO FAN DECK LEVEL

FAN DECK SLAB

FAN CYLINDER

PRE CAST WORKS

APPRON

Mechanical & Electrical work

INTERNAL BITUMIN PAINTING

H.W.PIPING

HAND RAILING

PVC FILL ERECTION

H.W.DISTRIBUTION

ELIMINATOR ERECTION

EQUIPMENT ERECTION

EQUIPMENT EARTHING

CABLE TRAY ERECTION

SLIDE GATE ERECTION

SLUICE GATE ERECTION

BUTTERFLY VALVE ERECTION

TRIAL RUN

COMMISSIONING

Technical Features

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As per above activities the technical features are as below—

EXCAVATIONS—For excavation purpose excavators are used like Tata Hitachi, JCB are

leading company for this work.

Tata Hitachi--Excavator

PCC FOR CW BASIN—M10 grade of concrete had used for PCC work. Pcc has done only

for surface level purpose of further project work. Transit mixture is useful for concrete

mixing purpose.

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RCC FOR CW BASIN—M30 grade of concrete has used for RCC work and reinforcement

steel was CRS (corrosion resistive steel). Batching plant was used for mixing purpose of

aggregates and cement. Vibrators were used for compaction purpose and for transporting of

concrete transit mixture and concrete pump were used.

CW BASIN WALL INCL. COLUMN—MS steel were used for shuttering or form work.

Jack and U jack were also used for supporting to column and basin wall’s shuttering.

BEAM AT IST LEVEL & UP TO FILL LEVEL—Tower crane is used for lifting the

materials at high elevation. Concrete has transported through concrete pump, it has no any

problem to carry the concrete till hight of 20m.

PRE CAST WORKS— All necessary beams were cast at ground with precise way and after

(28days) cured it properly, it was lifted at elevated position as per drawing. Again crane was

used for lifting the beams to required position of the structure.

H.W.PIPING—

Hot Water Piping (MS-Steel)

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TEST OF CONCRETE—before placing of concrete we should do slump test for checking

the workability. Compressive strength should be checked by cube test and by use of

compressive strength machine. We should check for 7days and 28days cube sample of

15x15cmm size.

Cube sample Compressive strength machine

DATA COLLECTION—Calender-CT-calendar assign as project calendar for the cooling tower schedule.Start date- 28/02/2008Finish date-19/03/2009 before levelling of the resources.

Notes—notes are provided in various activities if required.

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Various activity and Duration

Task name %completion days Start day End day

Resource Allocation:

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Resource name Type initial Group max unit std.rate over time cost/use

Conclusion:

Microsoft Project is used for planning, scheduling and tracking the project. The critical path

of the project is found out by the software and it can be updated whenever necessary. The

resources available can be allocated depending upon the criticality of the activity. It keeps a

record of all the resources involved in the project and any over allocation and under

allocation is determined by the software.

During this project we learned a lot about several aspects of project management. Some

aspects are the overall planning process, the impact of certain planning decisions,

implementation principles, and working with MS-project. Furthermore, we gained insight in

the subsidy process involved with technical projects. Specifically, subsidies for energy

related projects and projects that concern developing countries. This made this project very

interesting and useful.

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