50876734 Planning Document Bhavnagar Chimney Revised

GAMMON INDIA LIMITEDPlanning Document For

R

PLANNING DOCUMENT

CONSTRUCTION OF 1 NO. 220m HIGH TWIN FLUE RCC CHIMNEY AT BHAVNAGAR, GUJARAT

REV.NO. 00 20th JAN 2011

PREFACEThe project planning document is prepared with the objective of providing an initial plan incorporating the changes after the tendering stage till date, based on the inputs received from the project site. It attempts to provide a base line plan for monitoring progress, turnover and expenditure at site and corporate office levels. It aims to provide a guide towards optimum resource utilization at site level and planning resource allocation at corporate office level by interlinking the resource requirements from all the sites.

__________________________________________________________________________________________________ GIL H.O._C.P.E.S. GAMMON INDIA LIMITED 3

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Contents:

Sr.No. 1. 2. 3. 4. 4.1 4.2 4.3 4.4 4.5 5. 6. 6.1 6.2 6.3 7 8 9 10 11 12

Description Introduction Salient Features Scope of Work Planning basis, overview & detailed schedule List of Milestones Assumptions in Planning Sequence of work Detailed Schedule Shell Profile Construction methods for major activities Resource requirements Equipment requirements Manpower requirements Productivity Norms Site establishment plan Preventive Safety Measures for Main Activities General Preventive Measures Summary Annexure - I : Construction Programme Annexure - II : Site establishment plan

Page No. 5 6 9 15

18 29

31 31 36 37 38 39


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1)

Introduction:The job consists of design and construction of one(1) no. 220 m high RCC Chimney for 2x250 MW Lignite based Thermal Project at Padva, Bhavnagar district, Gujarat.


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2)2.1) 1. 2.

Salient FeaturesCommercial Features JOB NUMBER CONTRACT PRICE 8933 Rs. 43,00,00,000/- only (Rupees Forty Three Crores only)

3.

TYPE OF CONTRACT

Lump Sum Contract Bhavnagar Energy Company Ltd., Block No. 8, 3rd Floor, Udyog Bhavan, Sector-11, Gandhinagar, Gujarat-382011

4.

NAME OF CLIENT

5. 6. 7. 8. 9. 10. 11.

PROJECT START DATE PERIOD OF COMPLETION PROJECT END DATE SECURITY DEPOSIT LIQUIDATED DAMAGES MOBILISATION ADVANCE PRICE BREAK UP 1. a) On approval of GA drawings and design & detailed foundation drawings b) On approval of design & detailed shell, shell openings drawings c) On approval of structural steel design drawings d) On approval of fabrication drawings

Date of LOA (9th December 2010) 21 Months from the date of LOA 8th September 2012 5 % of Contract Price 0.5 % of Contract Value 10 % of Contract Value

0.5 %

0.5 %

0.5 %

0.5 %

2. Foundation Works a) On completion of excavation work including disposal b) On completion of Raft foundation including pedestals for duct 10 % 1%


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& stair case earth filling (inside), earth filling (outside), compaction etc c) On raising RCC shell to 0.000m level 3. RCC Shell a) On mobilization of slipform equipment at site b) On erection of slipform equipment in position c) On completion of RCC shell upto 45.0m level upto 45.0m level upto 45.0m level upto 45.0m level upto 45.0m level 4. Steel Beam Platforms a) On fabrication of steel beams b) On erection of steel beams including grouting work c) On laying of gratings and handrails d) On painting of steel beams 5. Lining & Insulation (Both Flues) a) On fabrication of steel flues b) On erection of steel flues c) On completion of insulation and cladding works 6. Staircase & Ladder a) On fabrication & galvanising b) On completion of erection work 7. Lift a) On supply of lift at site 1% 1% 1% 12 % 6% 3% 1% 2% 5% 3% 5% 5% 5% 5% 5% 1% 1% 1%


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b) On erection of lift including completion of all related works 8. Painting of Chimney a) External surface of Chimney b) Internal surface of Chimney 9. Electrical works including earthing, lighting works, aviation obstruction lights, lightening protection works etc 10. Miscellaneous works 11. Finishing works, site clearance etc 12. Final commissioning & completion of all other works in all respects Total

1%

1.5 % 1.5 %

5%

8% 2%

5%

100 %


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2.2)

Technical Features

Sr. No 1 2 3 4 5 6 7 8 9 10 11 12 No. of Chimney Height of Chimney

Data

Description 1 220 m 23.000 m 17.300 m Steel Flue 2 Nos. 5.4 m EL(+) 15m 6 Nos. 6 Nos. Slope Straight

Outside diameter of Shell (Bottom) Outside diameter of Shell (Top) Flue Type No. of Flue Flue Diameter C/L Elevation of Flue gas Duct Opening Internal Platforms External Platforms Taper (El. -1.0 to 120 m) Taper (El. 120 to 215 m)


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3)

Scope of Work:The scope includes Analysis, Design, Preparation of Construction drawings and Construction of one number 220m high multiflue RCC Chimney with all accessories. Design of Chimney including all appurtenant civil works. Supply at site of all required materials Construction of RCC raft foundation supporting the wind shield as well as duct supports, staircase etc including excavation, dewatering, backfilling, etc complete. The excavation quantity is about 38650 cum. Construction of RCC wind shield using Slip-form equipment including provision of openings of various sizes in the windshield at various levels. Construction of internal RCC corbels at various levels to support structural steel beams. Construction of RCC roof slab for wind shield including acid resistant tile protection of the roof & drainage arrangement of roof. Fabrication and erection of structural steel platforms at various levels such as roof supporting platform, flue support platform, restraint platform, access platforms etc with openings for flues, flooring of gratings, hand rail etc including their bearing supports on the wind shields. Fabrication and erection of structural steel flues supported from support platform with one expansion joint. Top portion of flue will be of stainless steel construction. Fabrication and erection of bottom portion of structural flues below bottom expansion joint supported below on structural steel work. Fabrication and erection of flue support assembly at support platform, where flues are suspended and flue support assembly at bottom on which the bottom section of flue is supported of specialized construction details. Providing restraints to the flues at various levels with bracket and buffers of specialized construction details. Structural steel flue gas ducting of rectangular configuration from terminal points of supply for steam generator vendor of structural steel upto circular steel flue including structural steel stiffening arrangement for the ducting. Fabrication and erection of restraint & support arrangement for ducts on windshield of specialized construction details.

3.1) Chimney


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Providing ash hoppers of structural steel connected at the lowest level of duct. Providing supporting arrangement for flue duct supports outside windshield of specialized construction details. Providing insulation on the outside of the steel flues & ducts including protective aluminium sheet. Providing structural steel work for supporting bottom supported portion of flue and ducting, both inside and outside of windshield. Fabrication & erection of structural steel staircase inside wind shield from ground floor level to top support platform for flues with interconnection to various platforms and cage ladder from top support platform to roof of chimney. Painting of RCC windshield and structural steel works. Aviation warning lighting, general lighting inside the chimney and obstruction lighting and all connected electrical works and embedding conduits, junction boxes, pull boxes, cabling etc. Earthing and lighting protection system including all connected works from top of chimney to terminal point outside chimney at groun level. Supply and installation of rack & pinion type lift inside the chimney. Provision of inserts/pipe sleeves for mounting instruments for monitoring air quality, including conduiting junction, pull boxes, cabling etc. Construction of plinth protection including surface drains.


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3.2) Schedule of Quantities (As per Tender stage Design)

Sr. No. A. B. Item

Description of Works Grade

Quantity 27400 m3 11250 m3

Excavation in all type of soils Excavation & Backfilling i) Excavate in soil heap on site for suitable material and backfill around and on chimney foundation outside chimney shell -

C. D.

Backfilling with crushed rock Concrete i) P.C.C. under any structural concrete

-

310 m3 230 m3 17200 m3 6800 m3 52 m3 60 m3

M 10 M 30 M 30 M 30

ii) Raft iii) Chimney shell iv) Corbels, beams, roof platform, pedestal and other internal constructions etc v) Floor slab at grade level E. Reinforcement (HYSD) i) Raft ii) Shell iii) Others iv) M.S.Steel plain round bars F. Form work For R.C. Work i) Raft ii) Slip forming for windshield: external + internal iii) Roof Platform iv) Others v) Openings and block-cuts G. Structural Steel i) Corrosion resistant Mild steel COR-TEN-B liners (8mm thick) for height upto EL 210 m including stiffeners, restraints, openings, bottom supports, etc. including fabrication and erection

M 30

IS:1786/IS:432 IS:1786/IS:432 IS:1786/IS:432 Grade 1

1050 MT 476 MT 10 MT 2 MT

-

3100 sqm 26800 sqm 195 sqm 50 sqm 110 sqm

-

515 MT


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ii) Stainless steel liners (AISI Type 304L) at top a) 6 mm thick (EL +210 to EL +220 ) including flashing and cladding on outside. b) 6 mm thick (cap) (Hood) c) 4 mm thick kerb plate iii) HSFG bolts iv) MS flue duct including stiffeners, supports, etc. up to terminal points v) Structural steel in external platforms at all levels including welding and bolted Grade C 1.1 MT 0.7 MT 1 MT 25 MT 16 MT

connections a) ISMC 75x40 @ 1200mm c/c and L75x6 b) GI grating for external platforms (weight 52 Kg/sq.m) c) GI handrailing for platforms d) GI Posts for platforms vi) a) Structural steel in internal platforms at all levels b) GI grating for internal platforms vii) Structural steel hot dip galvanised using a minimum of 610 grams of zinc per sq. m for Staircase from Grade slab to EL 210m (i.e topmost internal platform) Insulation i) Semi-rigid resin bonded fibrous mineral wool or rockwool 64 Kg/cum ii) Rock wool slabs, 150 mm thick (100 kg/cu.m) iii) Rock wool slabs, 75 mm thick (200 kg/cu.m) iv) 20 mm thick AR tile ( IS:4457) on roof and inner surface of shell v) 1.0 mm thick aluminium cladding vi) Structural steel E250 50 MT 1100 sqm 410 RM 410 RM 125 MT 13 MT 470 sqm

H.

-

510 m3 52 m3 7.5 m3 177 sqm 9 sqm 4.3 MT


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vii) 5mm thick lining of Stainless steel I. Painting i) Acid and heat resistant of acrylic polyurethane paint ii) Acid and heat resistant paint

AISI 304L

2.7 MT

IS:5410

13100 m2 12500 m2

IS:158


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4)

Planning basis, overview & detailed schedule4.1) List of Milestones

Sr No 1

Activity Completion of Analysis & design of all elements and submitting the same for approval of Consultant/Owner Mobilisation and completion of all foundation works below ground level including backfilling etc Completion of windshield Erection of steel floor framing Erection of steel flue & completion of all works for unit 1 Erection of steel flue & completion of all works for unit 2 Completion of all works for the chimney

Period of completion from date of LOI 4 months

2

5 months 11 months 14 months 17 months 19 months 21 months

3 4 5 6 7

4.2)

Assumptions in Planning

Commencement of the work is considered from date of LOA i.e. 9th Dec2010. The program is based on tender drawings, tender milestones & estimated quantities. Foundation for chimney is considered as Raft Foundation.

4.3)

Sequence of work

Sequences of work for all major activities are as per detailed construction schedule attached herewith.

Mobilisation and preliminary activities: Preliminary activities like setting up of site office, fabrication yard, batching plant, labour quarters, reinforcement cutting and bending yard etc will be completed during first two months.


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Foundation: The foundation for the chimney consists of a reinforced concrete raft which will rest upon PCC bed. Shell Construction: The Shell will be constructed using the Slipform technique. Steel Flue Erection: The chimney consists of twin flues which will be erected with the help of lifting frames and Jack assembly.

4.4) 4.5)

Detailed Schedule Refer Annexure-I for Construction Schedule. Shell Profile

Sr. No. 1 2

Elevation (m) EL -1.00 to EL 120.00 EL 120.00 to EL 215.00

Outside ProfileSLOPE

Grade of concrete

M 30STRAIGHT


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4.5.1)

External Steel Platforms


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5)5.1)

Construction method of major ActivitiesFoundation: Foundation for chimney mainly involves following activities 1) Excavation, 2) Reinforcement fixing & Concreting, 3) Backfilling

1) Excavation Excavation will be done only after detailed checking of coordinates of the survey pillar handed over by Client. Reference pillars at East-West side and NorthSouth of chimney 10 m away from the outer edge of excavation. Size of pillars should be concrete of size 300x300mm and 600mm deep. Last layer of about 200 mm will be excavated manually/tractor breaker to avoid over excavation. Stock quantity of earth will be use for back filling. Work will be carried out from 8:00 am to 8:00 pm and 8.00pm to 8.00 am every day excluding Sundays.


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Layout of Excavation Note: 1. First excavate the portion in front of ramp in layers and then mucking and cleaning is carried out and continuing in same way. 2. Keep Ramp till completion of PCC and raft footing

2) Reinforcement fixing & concreting The foundation for the chimney consists of a reinforced concrete solid raft of dia.57 m with M30 grade of concrete. Raft is having depth of 6.8 m below the ground level. The general method for construction is as below: Lay 75 mm thick PCC of M10 concrete at raft foundation. Divide entire area for Raft Foundation into 8 equal segments or as per detailed design for raft foundation. (Do partwise reinforcement fixing & concreting.) Cut the reinforcement as per bar bending schedule & fix it manually. Provide timber shuttering/formwork. Provide construction joint with vertical joint. Concrete the raft segment by truck mounted concrete placer boom. Concrete M-30 Grade shall be supplied through batching Plant through Transit Mixers. Concrete


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shall be poured into the foundation Segments using direct chutes or concrete pump as per accessibility Chutes shall be made using M.S. Sheets/G.I. Sheets Chutes shall be placed with appropriate slope for concrete free flow. 40 mm Needle Vibrators will be used for proper compaction of concrete. Cure the foundation by applying curing compound making arrangement of Wet Hassein Cloth. Strip of formwork after minimum of 24 hrs. Cast remaining segments in the same manner

SURVEY PILLAR

POUR No. 8 POUR No. 4

POUR No. 7

POUR No. 5

POUR No. 3

POUR No. 9 POUR No. 1 CHIMNEY CENTER

Foundation for Chimney Raft: POUR No. 6 POUR No. 2 CHIMNEY FOUNDATION AREA

3) Backfilling Trenches shall be backfilled with the suitable material as per specification in layers not exceeding 300 mm loose depth. Each layer of fill shall be adequately consolidated throughout its full depth immediately after placement and prior to placement of additional layer.__________________________________________________________________________________________________ GIL H.O._C.P.E.S. GAMMON INDIA LIMITED 20

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Source: Approved borrow pit and Excavated soil shall be checked up for the suitability for reuse. If it is suitable then use in back filling.

Laboratory test: Before starting of fill work in Laboratory to determine of Maximum Dry Density/Optimum Moisture Content relationship as per IS: 2720.

Field test: Field density test shall be carried out as per IS: 2720 till the minimum 90% compaction achieved. Note: Backfilling should be done after minimum of 7 days after concreting.

5.2)

Shell Construction: Slip-form equipment consists of shuttering attached to walers that stiffens the Shuttering panels and transfers the load to the yokes. Hanging scaffolds and working deck are also connected to the walers. The waler yoke connection is designed to transfer all loads of the decks to the yokes. The yokes transfer the loads to the hydraulic jacks that further transfer the load to the jack rods on which they move up and down. To prevent the jack rods from getting embedded in concrete, sleeve pipes are used which along with the jack rods, transfer the load to the base or the foundations. The following are the major components of slip form equipment:Shuttering/form panels, Walers, Yokes, Working decks, hanging scaffolds, Truss system Hydraulic jacks, Jack rods, Pumping units for jacks, Bracings, Operation screws Extraction jacks, sleeves etc. Main truss type No. of yoke legs Hydraulic jacks = = = = Octagonal 48 Nos 6 t capacity 80 nos. 12 t capacity 16 nos

Note: The slip-form truss design may vary during actual execution


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Typical Schematic Arrangement of Slip form

Elevation

Main Beam/Wing Beam

Spider Beam Ring Beam

Center Frame

Plan__________________________________________________________________________________________________ GIL H.O._C.P.E.S. GAMMON INDIA LIMITED 22

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5.3) A)

Platform Girder (PG) Erection: Shifting of Girders -

Road making The road will be well leveled to avoid any kind of undulations, so that movement of crane or hydra or trailer will be safe.

Bringing the Girder For bringing the top most girders inside the chimney, 75MT capacity crane (suitable capacity crane) will be used. Lifting hooks will be attached to the girder at specified distances by means of sling fixed to D Shackle.

Keeping in to position Bring the girder near to the shell opening; one end of girder will be fixed to the steel wire rope passing through the two sheave pulley (Winch no.1). Then pull the girder inside the chimney & fix another steel wire rope (Winch no.2) to the girder inside the chimney & keep the girder in position.

B)

Lifting of Girders -

STAGE I (At 215.00 M EL.) 2) 3) Bring the top most plate Girder (EL+215.00 m) inside the chimney by hydra. Anchor HT 5/8Wire rope to PG1 Girder at both ends where rope is connected to the double gear hand winch. 4) 5) Lift the PG1 girder by using 2Nos of double gear hand winch. Rest the Girder on Neoprene pad in the opening provided at shell, align it properly as per approved Drawing. 6) 7) 8) 9) Remove Anchoring device from Girder. Repeat the same steps PG2 Girder erection. Lift the rolled section I Beam by material bucket. Fix the entire rolled section I Beam by Bolting as per approved drawing & Specification.


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STAGE II (At 210.00 M EL.) Repeat the step for EL. 210.00 M Plate Girder. Fix & align it properly the entire unit as per approved drawing & specification.

STAGE III Repeat the step for EL. 170.00 M Plate Girder Fix & align it properly the entire unit as per approved drawing & specification.

STAGE IV Repeat the step for EL. 130.00 M Plate Girder Fix & align it properly the entire unit as per approved drawing & specification. STAGE V Repeat the step for EL. 90.00 M Plate Girder Fix & align it properly the entire unit as per approved drawing & specification.

STAGE VI Repeat the step for EL. 50.00 M Plate Girder Fix & align it properly the entire unit as per approved drawing & specification.

STAGE VII Repeat the step for EL. 20.00 M Plate Girder Fix & align it properly the entire unit as per approved drawing & specification.

Note: The Platform Girder levels may change during actual execution depending on the detailed design.

5.4)

Shifting of Flue Cans: For bringing the steel flue can near to chimney, rails of certain LB will be laid first with a trolley over which cans are shifted towards the chimney. 50 T capacity crane will be used for lifting the cans from GL over the side shifting trolleys. Lifting hooks at specified distances are used, inside the steel flue can, to which sling is fixed by D Shackle.


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The flue w i l l b e insulated externally. The insulation w i l l be tightly secured to the exterior surface of the liner by impaling them on studs welded to the surface at 450 mm c/c both horizontally and vertically. The studs will extend a minimum of 25 mm beyond the thickness of insulation and 63 mm circular or square metal plate speed washers of standard thickness will be placed on the extended portion of the studs to hold the impaled insulation material well in place.

Insulation for the exposed portion of flue at the top will consist of 6 layers of insulation material each of a minimum thickness of 25 mm and all joints will be staggered.

5.5)

Erection of Steel Flue Cans:

The steel flues will be fabricated separately in parts of specific height called CANS. The Methodology for erection of Steel Flue for chimney with Twin flues is given below:-

STAGE-I (For Flue-I)

6. The Flue cans are divided in certain units and erection of cans takes place unit wise. 7. Bring the top most Can which is properly insulated, inside the chimney & align it properly. 8. Anchor the HT Strands coming from lifting jack to the lifting bracket of Top most steel flue can. 9. Lift the top most can to a height just sufficient to accommodate next can under it. 10. Bring the next Can inside the chimney which is properly insulated & align it properly. Connect these two cans by Bolting/ welding as per approved drawing & specification. 11. Lift the assembly of cans to accommodate next can under it. 12. Continue the process for remaining cans. 13. Lift the entire Unit # I of Flue # I to its final position & fix with the support platform at an elevation of say EL+ 210.00 M ( as per approved design). 14. Remove the lifting tackles from Unit # I of Flue # I. 15. Assemble the cans for Unit # II in the similar manner as described for Unit# I. 16. Lift the entire Unit # II one by one to its final position and fix with unit # I and access restraint platform at EL+ 170.00 M. 17. Remove the lifting tackles from unit # II of both flues.__________________________________________________________________________________________________ GIL H.O._C.P.E.S. GAMMON INDIA LIMITED 25

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18. Assemble the cans for Unit # III in the similar manner as described for Unit# I. 19. Lift the entire Unit # III one by one to its final position and fix with Unit # II & access restraint platform at EL+ 130.00 M. 20. Remove the lifting tackles from Unit # III of both flues. For the remaining III Units, Apply the similar procedure for lifting the cans as mentioned for the other units and fix them on access restraint platform at ELs (+) 90.00 M, 50.00 M, 20.00 M respectively.

STAGE-II (For Flue-II)

21. Apply the above same procedure for erection of cans for all VI units of Flue # II.

5.5) Ladder: The chimney shall be provided with GI ladder with safety cage. Cage ladder shall be provided from E.L.210.00 m to E.L.215.00 m. 5.6) Staircases: The staircase is supported by structural steel formwork; clear width of stairs treads inside stringers is 750mm. Tread will be 25mm thk. MS Grating with anti-skid nosing, and 250mm wide. Handrails used will be MS Pipes of 32NB with toe protection of 65x8 mm flats. The staircase will be provided from Grade slab to EL 210.00 m

5.7) Roof Slab:The roof of the chimney is at E.L.215.00 m which is protected against acid-corrosion by providing thick layer of acid proof tiles. The arrangement of the roof consists of a reinforced concrete slab with an opening called hatch for access from staircase which stops at last flue support platform. The hatch has a single leaf door of 6mm thk to cover a clear opening of 750mm x 1000mm. For roof Drainage system 200 mm Galvanised MS drain pipe including necessary jointing, fixing to windshield with packing, clamps/brackets, etc will be provided.

5.7) Painting Painting of top 15 m external surface of chimney shall be done with alternate bands of

Red and White. Total DFT not less than 150 microns. Painting of external surface shall be done with acid & heat resistant 2 coats of acrylic polyurethane paint confirming to IS:5410__________________________________________________________________________________________________ GIL H.O._C.P.E.S. GAMMON INDIA LIMITED 26

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over 2 coat of clear epoxy primer. Painting of complete internal surface of chimney shall be with two coats of acid and heat resistant paint confirming to IS:158 (2 coats over a primer). One coat of zinc phosphate primer paint of 35 microns thickness shall be done on inner and outer surface of flues & ducts. The total surface area of painting will be about 33010 sqm. Rope suspender platform will be used for Chimney Painting. The general assembly of Rope suspender platform will be as below: The platform is made to climb on the stationary wire rope by means of hoisters. The platforms are to be hanged from the upper area of the chimney which will be operated within the platform by using the pendant switch. The workmen will use these platforms for painting of chimney


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The General Layout of External Platform for Painting


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6)

Resource requirements6.1) Sr Equipment requirements Description Capacity / Type 1 2 3 4 Transit Mixer 6 Cum/Hr 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Mobile Crane 19 20 21 22 23 Welding Generator / Transformer / Rectifier Water Pump High Lift Plate Bending Machine Bar Cutting Machine Bar Bending Machine 42 mm 42 mm 50 Ton Cap 1 no Concrete Pump Concrete Placer Boom (truck Mounted) Loader Wheeled Compression Testing Machine Theodolite / Total Station Laser Plummet Hand Winch Hand WInch Positive Drive Winch Speed 45 Mtr / Min / 600 mtr wire rope drum Positive Drive Winch Speed 35 Mtr / Min / 600 mtr wire rope drum Curved Hoist Rack & Pinion Type 1 ton Cap for 220 mtr Height Slip Form jacks with power pack complete set Mobile Crane Hydra 6 Cum 35 Cum/ Hr 32 Mtr Long Boom JCB 3DX 200 Ton cap 5 T Cap 10 T Cap 5 T Cap 3 T Cap 2 nos 1 no 1 no 1 no 1 no 1 no 1 no 3 Nos 2 Nos 2 Nos 2 Nos 1 no 14 ton cap 1 set 1 no Concrete Mixer Reversible Drum type Concrete Batching Plant Cement Silo 750 Ltr 30 Cum/Hr 100 MT Cap 1 no 1 no 1 no 2 nos additionally required for Raft Concreting Required only for Raft concreting On Hire for Chimney Girder/Flue Can shifting Nos Remarks

400 Amps UT 220 C

4 Nos 3 Nos 2 Nos 2 Nos 2 Nos

-


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24

Diesel Generator Strand Jack Complete Set with Strands

110 Kva

1 no

25

-

3 Set

For back up power For Flue Can lifting Capacity will be confirmed based on Weight of Flue can modules

Note: 6.2)

1. Slipform Truss may be allocated from Barh site. Manpower requirements

Sr. No. 1 2 3 4 5 6 7 8 9

Designation Project Manager Project Engineer Safety Supervisor Engineers Other Technical Staff (Foremen & Supervisors) Non-Technical Staff (Accts, Stores, Purchase, Admin) Equipment Operators Skilled/Semi-skilled Labours Unskilled Labours

Nos. 01 2 4 8 08 05 16 150 200

6.3)Sr. No.

Productivity NormsActivity Time (Days) Raft Foundation Pouring Rate/Excavation Rate 60 m3/hr 24 m3/hr. 24 m3/hr. 24 m3/hr. 24 m3/hr. 24 m3/hr. 30 m3/hr.

1 2 3 4 5 6 7

Excavation Casting of Central Pour (1st) Casting of 2nd Pour & 3rd pour Casting of 4th Pour & 5th Pour Casting of 6th Pour & 7th Pour Casting of 8th Pour & 9th Pour Inside & Outside Backfilling Slipform Erection

30 20 18 18 18 18 10


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8 9 10

Slipform Fabrication Slipform Erection Slipform Checking

30 30 2

70 M3/Day

Casting of RCC Shell 11 12 Casting of RCC Shell Slipform Maintenance & stoppages (During Concreting) Fabrication & Erection of Flue Cans 13 14 Steel can fabrication (1st Flue) Steel can erection (1st Flue) 185 70 5 days/can 1 day/can 100 50

7)

Site establishment planRefer Annexure-II for site plan

8)

Preventive Safety Measures for Main activity

8.1 Excavation Preventive Measures: Finalize excavation layout considering soil characteristics and nearby structures. Prevent sides from collapsing by battering them to a safe angle.

Provide suitable ramps for movement of Excavators & dumpers. Mark safe parking distance for dumpers, transit mixers etc from the edge of excavated pit. Restrict speed limit of vehicles passing near excavated pit to 20 km/hr. Mark safe distance for dumping excavated material from the edge of excavated pit. Provide proper barricading or guard rails all around the excavated pit.

8.2 Slip form Assembly Preventive measures: Ensure that all components of slip form system are available and checked before starting erection.


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Finalize location of passenger hoist, material hoist, and temporary openings in shell for wire ropes and align the orientation of slip form truss accordingly. Selection of crane for erection of Slip form truss shall be based on weight of individual component to be lifted and operating radius. Avoid necessity of providing secondary or deviation pulleys. Ensure staging for erection of slip form is as per relevant drawing. Ensure that all components of slip form are completely assembled when it is at ground level only. Inspect all welded joints of structural members prior to use. Ensure number of bolts at joints and its grade is as per drawing. Inspect bolts for any visual defects or damage prior to use. D-shackle and slings shall be tested and free from any defects. Use seasoned timber for the decking of main deck and other working platforms for avoiding gaps in future. Ensure that the hydraulic jacks and its hoses are in safe working condition.

8.3 Shell Concreting Preventive measures: Specifications for Concrete winch: Capacity: 3T. Way of mounting: Stationery No. of drum: Single drum with capacity to accommodate 600 m wire rope of 16mm diameter. Speed 65-70 rpm 30 HP, 1440 RPM, 3 Phase Induction motor Wire rope: 16mm Guide rope: 19mm Ensure that the power winches are tested for safe working load. Ensure periodic inspection of wire ropes & alignment pulleys. Ensure that working platform at top is free of gaps and provided with railing and toe boards to avoid fall of material.__________________________________________________________________________________________________ GIL H.O._C.P.E.S. GAMMON INDIA LIMITED 32

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Concrete bucket, unloading chute etc shall be as per relevant drawings. Provide canopy at ground level to protect personnel working below from concrete / material falling from top. Regular inspection of welded / bolts joints shall be carried out at joint locations of ring beam, wing beam, centre tower passenger cage balancing arm, welded portion taking loads of concrete and material buckets, shuttering supports and shutter fixing studs. Winches used for Concrete buckets shall have following safety features: Foot Brake: for gradual stoppage of the winch. Limit switch: In case the material bucket goes above the required upper level, the limit switch cuts the limit and results in the application of both the EHT brakes. Marking on wire rope on every elevation Bell & Signal Bulb arrangement for upward and downward motion.

8.4 Slipping Operations Preventive measures: Check alignment and level of slip form platform at every lifting operation. Check setting time of concrete regularly and adjust mix design to suit slipping speed. Avoid any adjustments in slip form system at higher altitudes. Ensure periodic inspection of jacks / components. Replace the hydraulic hoses as per the manufacturers specifications. To prevent overloading ensure that the concrete accumulated on the truss members is cleaned on daily basis and no unwanted material is stored on main deck and working platforms. Ensure that the jack rod materials, diameters are of given specifications.

8.1 Fabrication of Steel flue cans and Platform Beams Preventive Measures : Ensure that the lifting machine & lifting tackles used for handling MS plate are of rated capacity.__________________________________________________________________________________________________ GIL H.O._C.P.E.S. GAMMON INDIA LIMITED 33

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Provide well planned fabrication yard with sufficient space for plate cutting, rolling, and assembly and welding of flue cans and also for stacking the same.

Provide a goliath gantry running over the entire length of fabrication yard for handling of cans. Capacity and height of gantry shall be decided based on weight and dimensions of flue cans.

Provide well compacted and leveled ground within the fabrication yard. Use of Hydra or crane shall be restricted only for handling of plates or small beams and the selection of the same shall be done considering weight of element to be handled and working radius.

During fabrication the cans shall be placed on raised platform / pedestals which will provide safe and easy access to workers and also will not allow the can to sink in the loose ground below.

Provide guards / barriers close to the moving parts of plate rolling machine.

8.2 Platform Girder Erection Preventive Measures: Follow erection scheme as per relevant drawing. Ensure that the slings and D shackles used for lifting are of rated capacity and tested. The wire rope shall be inspected daily for any defects or damage. Ensure safe functioning of winch prior to start of lifting of girders, shafts, gears and other safety devices. Inspect the pulleys on daily basis prior to start of lifting for condition of sheaves, main shaft, wear and tear and anchorage arrangement. Ensure that beams are fabricated of the required length and actual length required is checked when the beam is at ground level only. Ensure that adjustment in length or repair works of beam are carried out at ground level. No repair or rectification work shall be carried out at higher levels. Ensure temporary platforms with railing are provided for workers at appropriate level for erection of platform beams.


PLANNING DOCUMENT



Parallel working at two levels is to be controlled properly so that people working at lower level are safe against falling objects from top.

The activity shall be carried under supervision of experienced person. Ensure proper inspection, checking and maintenance of Heavy Equipments like cranes, hydra etc. at specified intervals.

8.3 Flue Can Erection Preventive Measures: Daily Inspection of lifting strands Daily Inspection of wire ropes, Jacks used for lifting Daily Inspection of brakes Ensure transportation, loading and unloading arrangement is done by trained and competent person. Follow the erection scheme as per approved construction methodology and relevant drawing.

8.5 Outside Painting Preventive measures Daily inspection of all lifting appliances Equipments manufactured by competent manufacturers shall only be used for shifting of people who are doing the painting works or Use of Boatswain chair. The equipments shall have proper controlling and signaling devices located within the hanging platform so that the workers using the same can control its movement. Selection and fabrication of lifting arrangement as per approved drawing and methodology. Inspection and certification of painting arrangement by the competent person.


PLANNING DOCUMENT



9) General Preventive Safety Measures.9.1 Falls from height Provide safe working platforms at regular elevation intervals. Provide Hand railing for safe working. Provide use fully equipped body safety harness of approved make for every person working at a height of 275m.

9.2 Mechanical Failure Before starting of lifting, third party inspection should be held. Once the third party inspection is done, then periodically after 6 months or 12 months another inspection should be held, as per the acceptance norms of the third party. Power packs, SL-80 Hydraulic jacks, HT Strands, Lifting bracket, D shackles, chain pulley block etc should be checked daily and periodic maintenance to be done. 9.3 Electrical Circuitry ELCB, MCCBs should be provided Armature cables should be used. Periodical inspection of Electrical tools should be carried out.

9.4 Fire Fire Extinguishers should be provided where cutting & welding work is going. 9.5 Additional Precautions Safety precautions for Gas cutter- LPG or Acetylene fuel supply will be safe guarded against blast back. All the cylinders shall be fitted with pressure gauge cap. Good quality rubber hose pipe should be used. Cylinder should be stored at cool & dry place. Cylinders shall be transported by keeping it at upright position on a trolley, standard grinding wheels should be used.


PLANNING DOCUMENT



Gas cutter & grinder men should be well trained, they should always use face shield (Helmet) during work. No men without PPES shall be allowed in the vicinity of chimney. Tool-box talk should be conducted regularly. Highly skilled labour should be hired for Slip form activity.

Summary This document would form a baseline providing sequence of work, construction methodology to be adopted for execution of work, estimation of plant and machinery and its requirement over the project duration, requirement of enabling works, material estimation and its monthly requirement, etc. This document would form the bases for Project Cost estimation required to complete the Project within the stipulated time. This document is prepared taking into account the pre-tender & post-tender stage documents & data available. Also various complexities in the sequence of construction are considered and the most suitable technique of construction is adopted to overcome the same.


Bhavnagar 2 Flue ChimneyID 0 1 2 3 4 Task Name Duration -1 1 2011 2 3 4 5 6 7 8 9 10 11 12 13 2012 14 15 16 17 18 19 20 21 22 23 24 25 2013 26 27 28 29 30

BHAVNAGAR 2 FLUE CHIMNEY

638 days1 day 90 days 90 days 0 days Completion of Analysis & Design of all elements and submitting the same for approval of Consultant/Owner

LOI Mobilisation Engineering Completion of Analysis & Design of all elements and submitting the same for approval of Consultant/Owner Earthwork in excavation Raft Foundation Backfilling Mobilisation & Completion of all foundation works below ground level including backfilling etc Starter Erection of Slipform Truss RCC Shell including Corbels Completion of Windshields Fabrication of Platform Girders Fabrication of Steel flue 1 Fabrication of Steel flue 2 Erection of Platform Girders Erection of Steel Floor Framing Erection of Roof Beams Casting of Roof Slab Dismantling of Slipform truss Erection of Steel Flue 1 Erection of steel flue & completion of all works for unit 1 Erection of Steel Flue 2 Erection of steel flue & completion of all works for unit 2 Painting Erection of Staircase Misc. activities/Finishing Works Completion of all works for the ChimneyTask Progress Milestone

5 6 7 8

30 days 90 days 10 days 0 days Mobilisation & Completion of all foundation works below ground level including backfilling etc

9 10 11 12 13

10 days 30 days 153 days 0 days 72 days Completion of Windshields

14 15 16 17 18 19 20 21 22

180 days 180 days 30 days 0 days 20 days 15 days 27 days 70 days 0 days Erection of steel flue & completion of all works for unit 1 Erection of Steel Floor Framing

23 24

62 days 0 days Erection of steel flue & completion of all works for unit 2

25 26 27 28

100 days 40 days 150 days 0 days Completion of all works for the Chimney

Summary Rolled Up Task Rolled Up Milestone

Rolled Up Progress Split External Tasks Page 1

Project Summary Group By Summary

Project: BHAVNAGAR 2 FLUE CHIMN Date: Jan 14 '11

ANNEXURE-II

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50876734 Planning Document Bhavnagar Chimney Revised

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