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CONSTRUCTION OF R.C.C CHIMNEY FOR 2X250 MW LIGNITE BASED THERMAL POWER PLANT

GAMMON INDIA LTD.By

ASUMMER TRAINING PRESENTATION

ON

UNDER

NIKHIL PRABHUDEVARoll No-GO4126

NATIONAL INSTITUTE OF CONSTRUCTIONMANAGEMENT AND RESEARCH

GOA CAMPUS

CONTENTS

• INTRODUCTION• COMPANY PROFILE• PROJECT PROFILE• EXECUTION• QUALITY• SAFETY• OBSERVATIONS AND CONCLUSION

INTRODUCTION• Bhavnagar Energy Company Limited (BECL) is

promoted by state power supply units such as Gujarat state investment Limited, and Gujarat Industries power companies limited.

• The total cost of the Thermal power plant is Rs 2000 Crores.

• Project completion date-2020.

COMPANY PROFILE

COMPANY PROFILE

• Gammon India Limited is one of the leading construction companies in India.

• The company was established by late Mr John.C.Gammon in 1919 as a firm of civil engineers and contractors which was incorporated as Private limited company in 1922 J.C.Gammon (Bombay) Pvt limited.

• The firm was renamed as Gammon India Limited in 1962 .• The first contract executed by John.C.Gammon was the

construction of Reinforced concrete piles for the Gateway of India.

• Mr Abhijeet Rajan is the Managing director.

MISSION AND VISION

MISSION “To Develop, Build and Service Physical Infrastructure

for better Living, Work Environment and Transportation.”

VISION To be the leaders in innovative engineering, and

timely delivery of our quality construction services, upholding our tradition of being

‘Builders to the nation’

AWARD AND ACHIEVEMENTS

Sr. No Awards Project1 MSRDC Award for J.J. Hospital to Palton Road J.J. Hospital

2 ACCE-L&T Endowment Award for Excellence in construction of Haldia Induced Draught Cooling Towers

Induced Draught Cooling Towers at Haldia

3 IIBE-7th Annual Award Nite for Noida Bridge at Delhi

Noida Bridge at Delhi

4 ACCE-L&T Endowment Award for Excellence in construction of Industrial Structure

Raichur Multiflue Chimney

5 ICI-MC-Bauchemie Award for the Most Outstanding Bridge

Kaladan Bridge

6 ACCE-Sarvamangala Award for Excellence In Construction of Karbude Tunnel

Konkan Railway Tunnel and Viaduct

7 IIBE- Most Outstanding Bridge National Award CMLR Vashi Flyover

8 IIBE- Most Outstanding National Award P.V.Raj Memorial

CERTIFICATESSr. No Certificate Project

1 Indian Concrete Institute Award for Outstanding concrete Structure

Bridge on SutlejRiver, Punjab

2 Export Award for Maximum overseas Construction Contracts Secured

Maximum overseas Project

3 Zero Accident By Gammon Certificate From Nuclear Power Corporation of India Limited

Kaiga Project Unit 3 & 4

4 Parayavaram - Mittra Samman Certificate Sr Abhijeet Rajan

5 ICI-MC- Bauchemie Award for the Most Outstanding Concrete Structure

J.J.Hospital to Paltan Road Section

6 ICI-MC- Bauchemie Award for the Most Outstanding Concrete Structure

Delhi Noida Bridge

7 ACCE-L&T Endowment Award for Excellence in Construction

Induced Draught Cooling Towers at Haldia

8 DNV Management System Certificate ISO-9001-2000

Longest River Bridge at Patna

First Cable Stayed Bridge at Akkar, Sikkim Longest Railway

Tunnel

Sharjah International Airport

LAND MARK PROJECTS

PROJECT PROFILE

NEED OF PROJECT• India is the 6th largest power generator in the world. But, still

electricity shortage is major concern in India.• The state of Gujarat is one of the fastest growing states in the

Country. It has widely diversified resource base and produces wide array of agricultural produce including a rich variety of cash crops.

• It has also a very broad based industrial activity and the State is one of the leaders in refinery and petrochemical, textile etc.

• To support all these activities, the state needs a large supply of electric power whose requirement also keeps increasing at a fast pace.

SALIENT FEATURES

SR.NO KEY FEATURES DETAILS

1. OWNER/CLIENT BHAVNAGAR ENERGY COMPANY LIMITED,GUJARAT

2. CONSULTANT TATA CONSULTANT ENGINEERS

3. CONTRACTOR Gammon India Limited

4. TYPE OF CONTRACT Lump sum Contract

5. SCOPE OF WORK Construction of R.C.C Chimney for 2x250MW Lignite based thermal power plant at Bhavnagar Dist.,Padva,Gujarat

6. EFFECTIVE DATE FOR COMMENCEMENT 9th December2010

7. COMPLETION DATE 9th October 2012

8. CONTRACT PERIOD 21 months

9. CONTRACT PRICE Rs.43 Crores.

CONTINUED..

SR. No.KEY FEATURES DETAILS

10. CONTRACT PERORMANCE GUARANTEE 1)5% of contract price.

11. MOBILIZATION ADVANCE Interest free mobilization advance of 10% of the aggregate contract value will be payable only after the completion of mobilization at site and after the submission of security deposit.

13. SECURITY DEPOSIT 5% of the contract price.

14. LIQUIDATED DAMAGES (LD) 0.5% of the contract value.

15. RETENTION MONEY 5% from each RA. Bill

SCOPE OF WORK

SR. No.

SCOPE OF WORK – STRUCTUREWISE

1.

DESIGN OF CHIMNEY INCLUDING ALL CIVIL WORKS

2. SUPPLY OF ALL MATERIALS REQUIRED AT SITE

3. CONSTRUCTION OF PILE AND RAFT FOUNDATION SUPPORTING THE WIND SHIELD

4. CONSTRUCTION OF RCC WIND SHIELD USING SLIPFORM TECHNOLOGY

5. FABRICATION AND ERECTION OF STEEL FLUE TUBES

6. PROVIDING ASH HOOPERS OF STRUCTURAL STEEL AT LOWEST LEVEL OF DUCT

7. PAINTING THE RCC WIND SHIELD

8. EARTHING AND LIGHTING SYSTEM INSIDE THE CHIMNEY

9. COAL HANDLING & FUEL HANDLING

10. INSTALLATION OF PINION TYPE OF LIFT INSIDE THE CHIMNEY

DESIGN OF RCC CHIMNEY

• The chimney is designed using working stress method.

• Minimum grade of Concrete shell is M30.• Minimum grade of concrete for

platform,foundation,shell,slabs and beams is M30.

• Maximum concrete placing temperature should not exceed 23 degree Celsius.

EXECUTION

EXECUTION

Pile point marking

Pile boring

Reinforcement cage loweringConcrete pouring

Piling

EXECUTION

Pile point marking

Pile boring

Reinforcement cage loweringConcrete pouring

Piling

EXECUTION

Pile point marking

Pile boring

Reinforcement cage loweringConcrete pouring

Piling

EXECUTION

Pile point marking

Pile boring

Reinforcement cage loweringConcrete pouring

Piling

FORM PANELS

Form Panels

Working Platform

Lifting Hydraulic jack

Curing

WORKING PLATFORM

Form Panels

Working Platform

Suspended Scaffolding

Lifting Hydraulic jack

Curing

HYDRAULIC JACK

Form Panels

Working Platform

Suspended Scaffolding

Lifting Hydraulic jack

Curing

CURING

Form Panels

Working Platform

Suspended Scaffolding

Lifting Hydraulic jack

Curing

DOCUMENTATION MAINTAINED AT SITE

DRAWINGSRCC POUR CARDCHECKLIST ISSUE SLIPMEASUREMENT BOOKREQUISITION SLIPDPRLABOUR REPORTBAR BENDING

SCHEDULE( BBS)

QUALITY

QUALITY POLICY

DOCUMENTATION USED AT QA AND QC LAB

• Concrete Requisition Slip• Concrete Pre Pour Inspection Report• Checklist For In-Place Reinforcement Form• Daily moisture correction report• Maximum dry density test• Cube report• Unit weight of steel

DAILY MOISTURE CORRECTION REPORT

SAFETY

SAFETY, HEALTH & ENVIRONMENT POLICY

DAILY ACTIVITIES

• Safety Induction Training for new employee

• Tool Box Meeting• Daily site report • Site supervision for Unsafe Act &

Conditions • Electrical connection check• Housekeeping check• PPE check

WEEKLY ACTIVITIES

• Safety Awareness training session for PRW, Supervisor & Engineers

• First-Aid box check• Vehicle check• Fire extinguisher check• Scaffolding check• Safety requirement check• Welding and Gas Cutting check• Store Room check• Site visit with Site Management

MONTHLY ACTIVITIES

• Labour colony visit • Water tank cleaning • Monthly Safety Performance Report• Accident/Incident Statistic Report• Monthly Safety Report• Safety Committee Meeting • Fire Mock Drill• First-Aid Mock Drill • Plant & machinery Check • Lifting Tool And Tackles check• Power Tool Inspection

OBSERVATIONS

• The project was running behind the schedule by more than 3 months.

• Planning was not done using the planning tools like MSP and PRIMAVERA.

• There was poor co-ordination between the site staff and head office staff.

KNOWLEDGE AND SKILLS GAINED

• Construction work methodology of slipform technology and Piling.

• Preparing Control estimates and Bar bending schedules.

• To manage safety and quality at site.• To tackle various problems in mobilization

stage as well as execution stage of the project.

CONCLUSION

• Summer internship training was a wonderful experience.

• I understood the importance of planning and that the planning is realistic and achievable.

• The company gave good exposure to site work as well as office work which will definitely help me in future.

THANK YOU