Project: 6 x 600 MW KSK MAHANADI POWER PROJECT

Owner : KMPCL
Contractor: SEPCO

ERECTION METHODOLOGY

FOR

MPH STRUCTURE

CONTENT

1. SCOPE

2. General

3. Construction Scope

4. Erection Sequence

5. Erection Tools

6. Personal Qualification Required

7. Work Methodology for MPH structural steel

8. Erection Procedures for Main Power House Structure

9. Alignment Procedures for M.P.H. structure

10. Bolt Tightening Methodology for M.P.H structure

11. Shifting Procedures for M.P.H structure.

 Project: 6 x 600 MW KSK MAHANADI POWER PROJECT
Owner : KMPCL
Contractor: SEPCO

1. SCOPE

The scope of this document is to present the controls and methodology adopted by

Punj Lloyd Limited for the erection of steel structures for Main Power House 1, 2, 3,

4, 5 and 6. Approx 40,000 MT

2. GENERAL

Punj Lloyd Limited is responsible for the erection of Unit # 1 to 6 of Main Power

House structure at KMPCL – CG 3600MW Thermal Power Project at Marinara,

Janjgir – Champa, Chattisgarh.

Main Power House Building include A-B Bay (L 30.6 Meters and H 34.7 Meters), B-

C Bay (L 10 Meters and H 34.7 Mtrs) and C-D Bay (L 13 Mtrs and H 48.8 Mtrs) MPH

steel structure include construction equipment inventory, Numbers, inspection, steel,

structure assembly on surface, installation of steel structure and tighten HSFG,

welding of platform as a whole, steel structure adjustment and acceptance, the

safety facilities set up and dismantle, etc

The MPH steel structure includes H-Shape columns/ beams, bracing, roof truss,

stairs, platform, traveling crane rails, coal bunkers, walk way gallery etc

The MPH is constructed of II tiers A-B Bay at El+ 6.66 M and El+13.46 M, & B-C

Bay of III tiers at El+ at 6.66 M, 13.46 M, 23.76 M ,to the height of 33.7 meters. C-D

Bay is constructed for rectangular coal bunkers, to the height of 48.8 M

 Project: 6 x 600 MW KSK MAHANADI POWER PROJECT
Owner : KMPCL
Contractor: SEPCO

3. Construction Scope

• All approved drawings for constructions are to be provided by SEPCO.

• All permanent steel structures to be erected are to be provided by SECPO.

• All foundation for unit 1, 2, and 3 should be completed by SECPO and to be

handed over for erection.

• Erection machinery like Crawler cranes of capacity 250MT and 150MT and

Hydra cranes, trailers of all capacity are to be provided by PLL; Cranes for

loading at SEPCO stores/stack yard to be provided by SECPO.

• Erection engineers, work men and tools for erection are to be provided by PLL.

• All safety measures during erection is to be taken care by PLL.

• Space for office and labor colony to be provided SEPCO.

• Electrical power and water for construction to be provided by SEPCO.

HSE MANAGER (HEALTH, SAFETY & ENVIRONMENT)

• To implement Health, Safety & Environment policy of the Company.

• To ensure the implementation of HSE Manual.
• To maintain good housekeeping and safety practices.
• To review the HSE plan for each project.
• To review HSE procedure as and when required.
• To maintain safety statistics of the Company.
• To ensure safety checks as per HSE plan.
 Project: 6 x 600 MW KSK MAHANADI POWER PROJECT
Owner : KMPCL
Contractor: SEPCO

• To deploy qualified safety personnel in various projects for implementation of

project specific HSE plan.
• To identify training needs in the field of HSE.
• To organize induction training for all employees at the project site.
• To carry out accident investigation and suggest preventive measures.
• To maintain safety records.
• To co-ordinate with various government bodies in respect of HSE.
• To ensure the quality of personnel protective equipment.
• To oversee attending of customer complaints related to HSE.

4. Erection Sequence

1. Erection of D-C Bay grid # 29 to # 27 using 250 MT crane placing between B-C bay

,after completion of D-C Bay up to # 27 Erection of A-B and C will be taken up for the

same grid. Placing the 250T crane in between B-C Bay the crane will be taken back as

by the completion of each grid

 Project: 6 x 600 MW KSK MAHANADI POWER PROJECT
Owner : KMPCL
Contractor: SEPCO

We will place 250 MT Crane on Row-C and Grid-24 to erect the Column No. D-22, D-23,
C-22, C-23. Including all tie beams and vertical bracings. Then we will move the crane
backward and placed Grid 26 in same axis. After erecting the column no D-24,D-25 & C
24,C25 with tie beams and vertical bracing. The crane continuously moved and placed
in grid 28 and complete the erection of column no D-26,C-26 & D-27,C-27. Then we will
move the crane to B-row axis for erecting hopper in between Grid-22 to Grid-23, Grid-23

to Grid-24, Grid-24 to Grid-25, Grid-25 to Grid-26 & Grid 26 to Grid 27.Column no. C-1/19,
C-20 and C-21 will be erected including tie beam & bracing after erection of hopper
between grids mentioned above. Roof Truss will be erected simultaneously.
 Project: 6 x 600 MW KSK MAHANADI POWER PROJECT
Owner : KMPCL
Contractor: SEPCO

At the same time, we will place another more 150/80 MT crane outside Row-A for
erection of column, tie beams & vertical bracings of Row-A,3/A,2/A,1/A if possible. EOT
crane gird will be erected simultaneously.
Project: 6 x 600 MW KSK MAHANADI POWER PROJECT
Owner : KMPCL
Contractor: SEPCO
Project: 6 x 600 MW KSK MAHANADI POWER PROJECT
Owner : KMPCL
Contractor: SEPCO
 Project: 6 x 600 MW KSK MAHANADI POWER PROJECT
Owner : KMPCL
Contractor: SEPCO

D-C Bay erection sequence after handing over of the foundations from SEPCO

i) Erection of base plate, alignment with packing plate and wilding

ii) Erection of 1 tier column

iii) Erection of beams & vertical bracings

iv) Alignment of tier-1

v) Grouting of tier-1

vi) Bolt ting of all the columns

vii) Bolting and torque tightening

viii) Erection of I1 tier column

ix) Erection of beams & vertical bracings

x) Alignment of tier-11

xi) Bolt ting of all the columns

xii) Bolting and torque tightening

xiii) All splice plate welding

xiv) Erection of Coal bunker hopper

xv) Lasing of coal bunker hopper

xvi) Alignment and welding of bunkers bunker

xvii) Erection of left out horizontal bracings.

 Project: 6 x 600 MW KSK MAHANADI POWER PROJECT
Owner : KMPCL
Contractor: SEPCO

xviii) Erection of plate forms, gratings and hand rails. and erection of roof beams and
traveling rails

A-B and C Bay sequence after hand over of foundations by SEPCO

I) Erection of base plate, alignment with packing plate and wilding for A- B bay

II) Erection of column from A to B,C row including Auxiliary Column

III) Erection of beams & vertical bracings

IV) Alignment and grouting of column

V) Bolting and torque tightening

VI) Erection of 11 tier for the main column A B&C

VII) Alignment , bolt tightening and splice plate welding

VIII) Erection of horizontal bracings

IX) subsequently for the three grids #29 to #27 erection will be carried

X) Erection , Alignment and welding of crane girder

XI) Erection , alignment and welding of crane traveling rails

XII) Erection , alignment and welding of bracing of roof truss

XIII) Erection and alignment of Roof Truss

The following is the tentative schedule for erection of MPH 1 TO 6

 Project: 6 x 600 MW KSK MAHANADI POWER PROJECT
Owner : KMPCL
Contractor: SEPCO

Tentative schedule for Unit # 3

MPH ERECTION SEQUENCE

1st Activity
SL DESCRIPTION Start Finish
NO AXIS Date Date
st st
1/19to21 C-Row 1st tier column erection including tie beam 1 April 1 April
st nd
C 1/19-20 connecting beam alignment. 1 April 2 April
rd th
C Row column alignment & Grouting 3 April 4 April
st st
21 - 23 D-Row 1st tier column erection including tie beam 1 April 1 April
st st
D-C C-Row 1st tier column erection including tie beam 1 April 1 April
nd th
D & C Row column alignment & Grouting 2 April 4 April
th th
D-C Floor Beam EL.13.560 7 April 8 April
th th
D-C Floor Beam EL.17.260 11 April 12 April
nd nd
23 - 25 D-Row 1st tier column erection including tie beam 2 April 2 April
nd nd
C-Row 1st tier column erection including tie beam 2 April 2 April
th th
D & C Row column alignment & Grouting 4 April 6 April
th th
D-C Floor Beam EL.13.560 8 April 9 April
th th
D-C Floor Beam EL.17.260 13 April 14 April
nd nd
25- 27 D-Row 1st tier column erection including tie beam 2 April 2 April
nd nd
C-Row 1st tier column erection including tie beam 2 April 2 April
rd th
D & C Row column alignment ,& Grouting 3 April 5 April
th th
D-C Floor Beam EL.13.560 9 April 10 April
th th
D-C Floor Beam EL.17.260 14 April 15 April

rd rd
1/19to21 B-Row 1st tier column erection including tie beam 3 May 3 May
th th
B-C Bracing erection, column alignment &Grouting 4 May 5 May
th th
B-C Bay floor beam eretionEL.6.660M 9 May 9 May
th th
B-C Bay floor beam eretionEL.13.460M 11 May 11 May
rd rd
21 - 23 B-Row 1st tier column erection including tie beam 3 May 3 May
th th
Bracing erection, column alignment &Grouting 4 May 5 May
th th
B-C Bay floor beam eretionEL.6.660M 9 May 9 May
th th
B-C Bay floor beam eretionEL.13.460M 11 May 11 May
th th
23 - 25 B-Row 1st tier column erection including tie beam 6 May 6 May
th th
Bracing erection, column alignment &Grouting 7 May 8 May
th th
B-C Bay floor beam eretionEL.6.660M 10 may 10 may
th th
B-C Bay floor beam eretionEL.13.460M 12 May 12 May
25- 27 B-Row 1st tier column erection including tie beam th
6 May th
7 May
th th
Bracing erection, column alignment &Grouting 7 May 8 May
th th
B-C Bay floor beam eretionEL.6.660M 10 may 10 may
th th
B-C Bay floor beam eretionEL.13.460M 12 May 12 May
 Project: 6 x 600 MW KSK MAHANADI POWER PROJECT
Owner : KMPCL
Contractor: SEPCO

st st
1/19to21 A-Row column 1st tier erection including tie beam 1 June 1 June
th th
A-B 3/A & 2/A,1A Column erection including tie beam 7 June 7 June
nd rd
Bracing erection, column alignment & Grouting 2 June 3 June
th th
A-B Floor beam EL.6.660 M 9 June 10 June
th th
A-B Floor beam EL.13.460 M 13 June 14 June
st st
21 - 23 A-Row column 1st tier erection including tie beam 1 June 1 June
th th
3/A & 2/A,1A Column erection including tie beam 7 June 7 June
nd rd
Bracing erection, column alignment & Grouting 2 June 3 June
th th
A-B Floor beam EL.6.660 M 9 June 10 June
th th
A-B Floor beam EL.13.460 M 13 June 14 June
th th
23 - 25 A-Row column 1st tier erection including tie beam 4 June 4 June
th th
3/A & 2/A,1A Column erection including tie beam 8 June 8 June
th th
Bracing erection, column alignment & Grouting 5 June 6 June
th th
A-B Floor beam EL.6.660 M 11 June 12 June
th th
A-B Floor beam EL.13.460 M 15 June 16 June
th th
25- 27 A-Row column 1st tier erection including tie beam 4 June 4 June
th th
3/A & 2/A,1A Column erection including tie beam 8 June 8 June
th th
Bracing erection, column alignment & Grouting 5 June 6 June
th th
A-B Floor beam EL.6.660 M 11 June 12 June
th th
A-B Floor beam EL.13.460 M 15 June 16 June

2nd Activity
SL Start Finish
NO AXIS DESCRIPTION Date Date
th th
22 - 23 D-Row 2nd tier column erection including tie beam 16 April 16 April
th th
D-C C-Row 2nd tier column erection including tie beam 16 April 16 April
th th
D & C Row column alignment 16 April 17 April
D-C Floor Beam EL.23.760 18 April
th
18 April
th

D-C Floor Beam EL.32.000 18 April

th
18 April
th

D-C Floor Beam EL.40.690 th

18 April
th
18 April
th th
23 - 25 D-Row 2nd tier column erection including tie beam 19 April 19 April
th th
C-Row 2nd tier column erection including tie beam 19 April 19 April
th th
D & C Row column alignment 19 April 20 April
st st
D-C Floor Beam EL.23.760 21 April 21 April
nd nd
D-C Floor Beam EL.32.000 22 April 22 April
rd rd
D-C Floor Beam EL.40.690 23 April 23 April
th th
25- 27 D-Row 2nd tier column erection including tie beam 24 April 24 April
th th
C-Row 2nd tier column erection including tie beam 24 April 24 April
D & C Row column alignment 24
th
April 25
th
April
D-C Floor Beam EL.23.760 26
th
April 26
th
April
D-C Floor Beam EL.32.000 27
th
April 27
th
April
D-C Floor Beam EL.40.690 28
th
April 28
th
April

th th
1/19to21 B-C Row 2nd tier column erection including tie beam 13 May 13 May
 Project: 6 x 600 MW KSK MAHANADI POWER PROJECT
Owner : KMPCL
Contractor: SEPCO

th th
B-C Bracing erection & column alignment. 14 May 15 May
B Row crane girder erection th
19 May
th
20 May
B-C Floor Beam EL 23.760m & Roof structure rd
23 May
th
25 May
th th
21-23 B-Row 2nd tier column erection including tie beam 13 May 13 May
th th
Bracing erection & column alignment. 14 May 15 May
th th
B Row crane girder erection 19 May 20 May
th th
B-C Floor Beam EL 23.760m & Roof structure 25 May 27 May
23-25 B-Row 2nd tier column erection including tie beam 16th
May 16th
May
th th
Bracing erection & column alignment. 17 May 18 May
st nd
B Row crane girder erection 21 May 22 May
th th
B-C Floor Beam EL 23.760m & Roof structure 27 May 29 May
25-27 B-Row 2nd tier column erection including tie beam 16
th
May 16
th
May
th th
Bracing erection & column alignment. 17 May 18 May
st nd
B Row crane girder erection 21 May 22 May
th st
B-C Floor Beam EL 23.760m & Roof structure 29 May 31 May

th th
1/19to21 A-Row column 2nd tier erection including tie beam 17 June 17 June
th th
A-B Alignment 18 June 19 June
rd th
Crane Girder &Roof structure erection 23 June 24 June
th th
21-23 A-Row column 2nd tier erection including tie beam 17 June 17 June
th th
Alignment 18 June 19 June
th th
Crane Girder &Roof structure erection 25 June 26 June
th th
23-25 A-Row column 2nd tier erection including tie beam 20 June 20 June
st nd
Alignment 21 June 22 June
th th
Crane Girder &Roof structure erection 27 June 28 June
th th
25-27 A-Row column 2nd tier erection including tie beam 20 June 20 June
st nd
Alignment 21 June 22 June
th th
Crane Girder &Roof structure erection 29 June 30 June

3rd Activity
SL DESCRIPTION Start Finish Date
NO AXIS Date
D-Row 3rd tier column erection including tie th
29 April
th
29 April
22 -23 beam
th th
D-C C-Row 3rd tier column erection including tie beam 29 April 29 April
th th
D & C Row column alignment 29 April 30 April
Erection of Coal bunkers &Erection of Roof st
1 May
st
1 May
Structure
D-Row 3rd tier column erection including tie th
29 April
th
29 April
23 -25 beam
th th
C-Row 3rd tier column erection including tie beam 29 April 29 April
th th
D & C Row column alignment 29 April 30 April
Erection of Coal bunkers &Erection of Roof st
1 May
nd
2 May
Structure
D-Row 3rd tier column erection including tie th
29 April th
29 April
25- 27 beam
 Project: 6 x 600 MW KSK MAHANADI POWER PROJECT
Owner : KMPCL
Contractor: SEPCO

th th
C-Row 3rd tier column erection including tie beam 29 April 29 April
th th
D & C Row column alignment 29 April 30 April
Erection of Coal bunkers &Erection of Roof st
1 May
nd
2 May
Structure

Unit # 3 MPH Structure beams kept hold for Erection for Turbine Equipments erection

(like Deaerator/HP Heater/LP Heater etc) A row #24 - #26 at El+ 6.66m , A-B #27 to

#28 at El+13.46m , A row #24 to #26 at El+13.46m , A – B #24 to #26 at El+13.46m

CD Bay 28-29 are Kept Hold for EOT Crane and other Eqpt.

MPH ERECTION SEQUENCE UNIT- 4

1st Activity
SL DESCRIPTION Start Finish
NO AXIS Date Date
st st
37to36 D-Row 1st tier column erection including tie beam 1 May 1 May
st nd
D-C C-Row 1st tier column erection including tie beam 1 May 2 May
rd
C&D Row column alignment & Grouting 3 May 4th May
D-C Floor Beam EL.13.560 1st May 1st May
D-C Floor Beam EL.17.260 1st May 1st May
35to34 D-Row 1st tier column erection including tie beam 1st May 1st May
D-C C-Row 1st tier column erection including tie beam 2nd May 4th May
D & C Row column alignment & Grouting 7th May 8th May
D-C Floor Beam EL.13.560 7th May 8th May
D-C Floor Beam EL.17.260 11th May 12th May
33to32 D-Row 1st tier column erection including tie beam 2nd May 2nd May
D-C C-Row 1st tier column erection including tie beam 2nd May 2nd May
D & C Row column alignment & Grouting 4th May 6th May
D-C Floor Beam EL.13.560 4th May 6th May
D-C Floor Beam EL.17.260 8th May 9th May

31 D-Row 1st tier column erection including tie beam 13th May 14th May
D-C C-Row 1st tier column erection including tie beam 2nd May 2nd May
D & C Row column alignment ,& Grouting 2nd May 2nd May
D-C Floor Beam EL.13.560 3rd May 5th May
D-C Floor Beam EL.17.260 9th May 10th May

37to36 B-Row 1st tier column erection including tie beam 3rd June 3rd June
B-C Bracing erection, column alignment &Grouting 4th June 5th June
B-C Bay floor beam eretionEL.6.660M 9th June 9th June
 Project: 6 x 600 MW KSK MAHANADI POWER PROJECT
Owner : KMPCL
Contractor: SEPCO

B-C Bay floor beam eretionEL.13.460M 11th June 11th June

35to34 B-Row 1st tier column erection including tie beam 3rd June 3rd June
Bracing erection, column alignment &Grouting 4th June 5th June
B-C Bay floor beam eretionEL.6.660M 9th June 9th June
B-C Bay floor beam eretionEL.13.460M 11th June 11th June
33to32 B-Row 1st tier column erection including tie beam 6th June 6th June
Bracing erection, column alignment &Grouting 7th June 8th June
B-C Bay floor beam eretionEL.6.660M 10th June 10th June
B-C Bay floor beam eretionEL.13.460M 12th June 12th June
31 B-Row 1st tier column erection including tie beam 6th June 7th June
Bracing erection, column alignment &Grouting 7th June 8th June
B-C Bay floor beam eretionEL.6.660M 10th June 10th June
B-C Bay floor beam eretionEL.13.460M 12th June 12th June

37to36 A-Row column 1st tier erection including tie beam 1st July 1st July
A-B 3/A & 2/A,1A Column erection including tie beam 7th July 7th July
Bracing erection, column alignment & Grouting 2nd July 3rd July
A-B Floor beam EL.6.660 M 9th July 10th July
A-B Floor beam EL.13.460 M 13th July 14th July
35to34 A-Row column 1st tier erection including tie beam 1st July 1st July
3/A & 2/A,1A Column erection including tie beam 7th July 7th July
Bracing erection, column alignment & Grouting 2nd July 3rd July
A-B Floor beam EL.6.660 M 9th July 10th July
A-B Floor beam EL.13.460 M 13th July 14th July
33to32 A-Row column 1st tier erection including tie beam 4th July 4th July
3/A & 1/A Column erection including tie beam 8th July 8th July
Bracing erection, column alignment & Grouting 5th July 6th July
A-B Floor beam EL.6.660 M 11th July 12th July
A-B Floor beam EL.13.460 M 15th July 16th July
31 A-Row column 1st tier erection including tie beam 4th July 4th July
3/A & 1/A Column erection including tie beam 8th July 8th July
Bracing erection, column alignment & Grouting 5th July 6th July
A-B Floor beam EL.6.660 M 11th July 12th July
A-B Floor beam EL.13.460 M 15th July 16th July

2nd Activity
SL Start
AXIS DESCRIPTION
NO Date Finish Date
37to36 D-Row 2nd tier column erection including tie beam 16th May 16th May
D-C C-Row 2nd tier column erection including tie beam 16 h May 16th May
D & C Row column alignment 16th May 17th May
D-C Floor Beam EL.23.760 18th May 18th May
 Project: 6 x 600 MW KSK MAHANADI POWER PROJECT
Owner : KMPCL
Contractor: SEPCO

D-C Floor Beam EL.32.000

D-C Floor Beam EL.40.690 18th May 18th May
35 to34 D-Row 2nd tier column erection including tie beam 18th May 18th May
D-C C-Row 2nd tier column erection including tie beam 19th May 19thMay
D & C Row column alignment
D-C Floor Beam EL.23.760 19th May 19th May
D-C Floor Beam EL.32.000 19th May 20th May
D-C Floor Beam EL.40.690 21st May 21st May
22nd 22nd May
33 to32 D-Row 2nd tier column erection including tie beam May
22nd
22nd May
D-C C-Row 2nd tier column erection including tie beam May
D & C Row column alignment 23rd May 23rd May

D-C Floor Beam EL.23.760 24th May 24th May

D-C Floor Beam EL.32.000 24th May 24thMay
D-C Floor Beam EL.40.690 24th May 25th May
31 D-Row 2nd tier column erection including tie beam 26th May 26th May
D-C C-Row 2nd tier column erection including tie beam 27th May 27th May
D & C Row column alignment 28thMay 28th May
D-C Floor Beam EL.23.760 28thMay 28th May
D-C Floor Beam EL.32.000 28thMay 28th May

37to36 D-C Floor Beam EL.40.690 13thJune 13th June

B-C Bracing erection & column alignment. 14thJune 15th June
B Row crane girder erection 19thJune 20th June
B-C Floor Beam EL 23.760m & Roof structure 23thJune 25th June
35 to34 B-Row 2nd tier column erection including tie beam 13thJune 13th June
Bracing erection & column alignment. 14thJune 15th June
B Row crane girder erection 19thJune 20th June
B-C Floor Beam EL 23.760m & Roof structure 25thJune 27th June
33 to32 B-Row 2nd tier column erection including tie beam 16thJune 16th June
Bracing erection & column alignment. 17thJune 18th June
B Row crane girder erection 21stJune 22nd June
B-C Floor Beam EL 23.760m & Roof structure 27thJune 29th June
31 B-Row 2nd tier column erection including tie beam 16thJune 16th June
Bracing erection & column alignment. 17thJune 18th June
B Row crane girder erection 21stJune 22nd June
B-C Floor Beam EL 23.760m & Roof structure 29thJune 31st June

37to36 A-Row column 2nd tier erection including tie beam 17th July 17th July
A-B Alignment 18th July 19th July
Crane Girder &Roof structure erection 23rd July 24th July
35 to34 A-Row column 2nd tier erection including tie beam 17th July 17th July
Alignment 18th July 19th July
 Project: 6 x 600 MW KSK MAHANADI POWER PROJECT
Owner : KMPCL
Contractor: SEPCO

Crane Girder &Roof structure erection 25th July 26th July

33 to32 A-Row column 2nd tier erection including tie beam 20th July 20th July
Alignment 21st July 22nd July
Crane Girder &Roof structure erection 27th July 28th July
31 A-Row column 2nd tier erection including tie beam 20th July 20th July
Alignment 21st July 22nd July
Crane Girder &Roof structure erection 29th July 30th July

3rd Activity
SL DESCRIPTION Start Date Finish
NO AXIS Date
37 to 36 D-Row 3rd tier column erection including tie beam 29th May 29th May
D-C C-Row 3rd tier column erection including tie beam 29th May 29th May
D & C Row column alignment 29th May 30th May
Hopper Erection 1st June 2nd June
Roof Structure 10th June 11thJune
35 -34 D-Row 3rd tier column erection including tie beam 29th May 29th May
D-C C-Row 3rd tier column erection including tie beam 29th May 29th May
D & C Row column alignment 29th May 30th May
Hopper Erection 3rd June 5th June
Roof Structure 10th June 11th June
33 to 31 D-Row 3rd tier column erection including tie beam 29th May 29th May
D-C C-Row 3rd tier column erection including tie beam 29th May 29th May
D & C Row column alignment 29th May 30th May
Hopper Erection 6th June 9th June
Roof Structure 10th June 11th June

30 to 28 D-Row 1st tier column erection including tie beam 1st August 1st August
2nd
D-C 1st August
C-Row 1st tier column erection including tie beam August
C&D Row column alignment & Grouting 3rd August 4th August
D-C Floor Beam EL.13.560 1st August 1st August
D-C Floor Beam EL.17.260 1st August 1st August
D-Row 2nd tier column erection including tie beam 5th August 5th August
C-Row 2nd tier column erection including tie beam 5th August 5th August
D & C Row column alignment 5th August 6th August
D-C Floor Beam EL.23.760 6th August 6th August
D-C Floor Beam EL.32.000 6th August 6th August
D-C Floor Beam EL.40.690 7th August 7th August
D-Row 3rd tier column erection including tie beam 8th August 8th August
C-Row 3rd tier column erection including tie beam 8th August 8th August
D & C Row column alignment 8th August 8th August
 Project: 6 x 600 MW KSK MAHANADI POWER PROJECT
Owner : KMPCL
Contractor: SEPCO

th
Hopper Coal bunkers 9th August 10 August
th th
Erection of Roof Structure 10 August 10 August
th th
C-B B-Row 1st tier column erection including tie beam 11 August 11 August
th th
Bracing erection, column alignment &Grouting 11 August 12 August
th th
B-C Bay floor beam eretionEL.6.660M 12 August 12 August
th th
B-C Bay floor beam eretionEL.13.460M 12 August 13 August
th th
B-Row 2nd tier column erection including tie beam 14 August 14 August
th th
Bracing erection & column alignment. 14 August 14 August
th th
B Row crane girder erection 15 August 15 August
th th
B-C Floor Beam EL 23.760m & Roof structure 15 August 15 August
B-A A-Row 1st tier column erection including tie beam 16
th
August 16
th
August
th th
Bracing erection, column alignment &Grouting 16 August 17 August
th th
B-A Bay floor beam eretionEL.6.660M 18 August 18 August
th th
B-A Bay floor beam eretionEL.13.460M 18 August 18 August
th th
A-Row 2nd tier column erection including tie beam 19 August 19 August
th th
Bracing erection & column alignment. 19 August 19 August
th th
A Row crane girder erection 20 August 20 August
th th
B-A Floor Beam EL 23.760m & Roof structure 20 August 20 August

For unit 2/unit 1, the same sequence as unit 3 from #19 axis to #1 axis; and for unit

5/unit 6, the same sequence as unit 4from #1/37 axis to #58 axis.
 Project: 6 x 600 MW KSK MAHANADI POWER PROJECT
Owner : KMPCL
Contractor: SEPCO

5. Erection Tools

Sl. No. Tool Description Qty Remarks

1 Theodolite 3
2 Dumpy Level 3
3 Tapes 3 Meter 20
4 Tapes 5 Mtrs 20
5 Tapes 10 Mtrs 20
6 Tapes 30 Mtrs 10
7 Tapes 50 Mtrs 5
8 Plumb 10
9 Spring Balance 10
10 Piano Wire 10
11 Turn Buckles 25
12 Chain Pulley Blocks 10T 20
13 Chain Pulley Blocks 5T 30
14 Chain Pulley Blocks 3T 30
15 Chain Pulley Blocks 7.5T 30
16 Rope Ladder 50
17 Aluminum Ladder 15
18 Grinding Machine AG.5 15
19 Welding Machine 20
20 Drying Ovens 5
21 Wrench Machines 5
22 Wire Ropes 25
23 Slings. set 80
24 D Shackles 60
25 Welding Cables meter 1000
26 Cutting Torch Sets 15
27 Safety Nets 25
28 Fall Arrester 150
Human Safety
29 Equipments 200
30 Hydraulic Jack 8
31 Jim Screw 8
 Project: 6 x 600 MW KSK MAHANADI POWER PROJECT
Owner : KMPCL
Contractor: SEPCO

32 crane 250T 2
33 crane 150T 3
34 crane 70T 4
35 crane 40T 2
36 crane 20T 3
37 Trailer 40 T 3

6. Personal Qualification Required

The various personals involved for the erection are:

i) Site In – Charge 1

ii) Site Manager 2

iii) Erection Engineers, 6

iv) Erection Supervisors, 12

v) Quality Supervisors, 4

vi) Safety Officer, 1

vii) Fitter, 15

viii) Erection Foreman 10

ix) Rigger, 30

x) Welder, 15
 Project: 6 x 600 MW KSK MAHANADI POWER PROJECT
Owner : KMPCL
Contractor: SEPCO

xi) Gas Cutter, 10

xii) Grinder 10

xiii) Khalasi &Helper as required

All special type personnel must have the corresponding qualifications and work
experience. They must be trained and qualified to perform boiler structure erection.

All personnel working at height will be approved by the examination. Medically fit
personals are allowed to work at height. Proper identification cards will be provided for
PLL work men.

7. Work Methodology for MPH Structural Steel

1. Construction Process Flow Chart:

Base plate Erection

Taking over of Transportation of and alignment
Foundation. Material

Dimensional checking Preparation of columns

of material as per • Centerline -marking
• Buffing & cleaning
• Selection of -Bolts
• Fixing of ladder &
 Project: 6 x 600 MW KSK MAHANADI POWER PROJECT
Owner : KMPCL
Contractor: SEPCO

Lifting & positioning of Positioning of material at

columns as per crawler crane reach for
drawings lifting.

Alignment of
Fixing of lifeline & Columns after box
safety nets formation
Lifting & fixing of
connecting
beams & bracings
Bolt tightening of
Removal of columns & beams by
ladder
• 350NM torque
tightening
• 700NM shearing

8. ERECTION Procedures OF MAIN POWER HOUSE STUCTURE

1. Scope of work and project schedule, drawings to be obtained from planning or

M/s. SEPCO 1
2. Check the distance between the foundation centers as per drawing.
3. Check the foundation stud dimensions along the center line and stud top
elevation as per drawing.
4. Column base plate identification and erection.
5. Column base plate center line alignment with respect to the center line of the
foundation.
 Project: 6 x 600 MW KSK MAHANADI POWER PROJECT
Owner : KMPCL
Contractor: SEPCO

6. Base plate elevation to be checked as per drawing and keep +2mm up by

adjusting the jack bolt.
7. The center line distance on both directions between (X-Y) (i.e. Row & grid) base
plates then fix & weld the support channel where the jack bolt not provided
(min. 3 places).
8. Identify the corresponding columns and keep column on 1mtr. Height steel stand
at 450 slope and it should be within reach of the crawler crane.
9. Ø 16mm guy rope to tie at top of column for holding purpose.
10. Identify & shift the bolt and nut as per drawing and keep it ready at erection site.
11. Center line marking & punching on the columns and put the scaling sticker,
cleaning of scaling and mud to be carried out by using electric wire brush /
buffing m/c, manual wire brush and bolts to tie.
12. Provide the scaffolding channel & Tie Rod (Ø 20mm) according to the column
width and fix & tight by M20 double nut and also provide cartoons between the
flange of column and scaffolding channel.
13. Provide the platform by using the double walkway grating (300mm width) on 3
sides and single walkway grating on ladder side.
14. Walkway grating are tied by Ø 12mm U-clamp with nut & lock plate
arrangement.
15. Provide the temporary handrails arrangement by using the scaffold pipe ½\u8221X pipe
& clamp.
16. Fix the hook ladder from top to bottom & provide the wooden runner between
face of column to ladder for climbing purpose.
17. Tie the PP rope Ø 14mm along the ladder with fall arrestor.
18. Fabricate of removal lifting lugs 1set specially designed for column erection and
1set for stair column.
19. Use proper slings and bow shackles according to the weight of the columns.
20. Lift the column from the bed by using 75crolower crane and swing; lower it to
position as per drawing and bolt to manual fix with base plate. Guy ropes to be
released and fix at bottom for holding the same.
21. In the similar process other columns are to be lifted.
22. After lifting consecutive columns main beams to be lifted for box-up and also to
erect bracings (Vertical & Horizontal).
23. Special precaution to be taken by anchoring ladder on Vertical bracings and
then lifting to be done with crawler crane.
24. Area of fixing V. Bracing, arrangement to be made by keeping chain pulley
block so as to transfer the load from crawler crane to chain pulley block and
release the crawler crane.
25. Before erection of Vertical bracings, 1side loose gusset plate is to be erected on
beams.
26. Assembly of Bracings (vertical & horizontal) with angle plate, top end gusset
plate and respective bolts as per drawing at bottom and then to be lifted. Top
end gusset plate final bolting to be done with bracing at bottom.
 Project: 6 x 600 MW KSK MAHANADI POWER PROJECT
Owner : KMPCL
Contractor: SEPCO

27. After the erection of Tier#1 alignment and bolt tightening to be done before
start of Tier#2.
28. Lifeline and safety nets to tie at top of columns before Tier#2 erection.
29. In same above procedure Tier#2 to be erected.
30. The same procedure shall be followed for all structural erection works for
erecting the Tier # 3, Tier up to roof level

9. Alignment Procedures for M.P.H.Structure

1. The civil foundations for the structural shall be checked for any defects. Center to
center distance between the foundations to be checked as per drawing.
2. The PCD of the foundation bolt and diagonal across the bolt holes shall be checked
3. Accepted signed protocol should be taken from civil before starting of erection for
record purpose.
4. Column base plate center line alignment with respect to the center line of the
Foundation (by using level m/c).Approval for acceptance of base plate alignment
to be taken from M/s. SEPCO & M/s.KSK.
5. Tightening of base plate bolt with spanner and carrying out of grouting as per
specification.
6. Base plate alignment protocol should be made for record purpose.
7. Tier#1 column erection to be carried after the above procedure.
8. Center line marking & punching on the columns and put the scaling sticker on 2
sides (X-Y direction) while erection.
9. After boxing of columns & beams verticality checking of columns to be carried out
(by using Theodolite)
10. Verticality checking to be done in both directions (X-Y) (a,b Row & grid).
11. Ø 16mm Coi rope to arrange with length according to height and work area. U-
Clamp, D-shackles and Chain blocks of 3T/5T capacity as per load requirement to
arrange and shift to work site. Ø 14mm PP rope to arrange for lifting purpose.
12. Boxed up columns (i.e. 4 columns) vertical top center position to be checked with
respect to base plate center position by theodolite in both directions (X-Y).
13. Coi rope (Ø 16mm) of required length (approx. 30M for Tier #1) to be lifted with PP
rope to particular column which require centering.
14. Boxed up columns with beams is to be ensured with proper lifeline and safety nets
for work approach.
15. Tie the PP rope Ø 14mm along the ladder with fall arrestor at columns.
16. Column is to tie with coi rope at top by providing packing (gas cut pipes) in
between coi rope at all four ends of column to avoid from damage.
17. The opposite end of ghai rope is to be fixed with chain block and counter weight, to
the direction where by manual pulling of chain blocks load will be applied to move
 Project: 6 x 600 MW KSK MAHANADI POWER PROJECT
Owner : KMPCL
Contractor: SEPCO

the column to the center position so as to match with the center line of the base
plate (confirming by using Theodolite).
18. Chain Blocks to be used 3T for minimum movement (approx.5 to 10mm) of columns
and 5T for (more than 10mm and above) maximum movement. Chain block is to be
fixed with U-clamps (min.3nos.) with coi rope.
19. Boxed column to column center distance and diagonal distance to be checked
with measuring tape.
20. After centering the boxed-up columns the same to be approved by M/s. SEPCOI &
M/s. KSK. and protocol to be maintained for record purpose.
21. After alignment bolt tightening to be done to columns, beams and bracings
keeping chain blocks on load.
22. Accordingly other boxed up columns are to be aligned in the same above
procedure.
23. After the erection of Tier #2, alignment can be done by
following same procedure.
24. The same procedure shall be followed for all the tiers.
Project: 6 x 600 MW KSK MAHANADI POWER PROJECT
Owner : KMPCL
Contractor: SEPCO
 Project: 6 x 600 MW KSK MAHANADI POWER PROJECT
Owner : KMPCL
Contractor: SEPCO

To pull with Coi Rope fix with chain block BEAM

COLUMN

FOUNDATION

Counter wt.

Frame Not Aligned Aligned Frame

Fig .I Fig.II

10 BOLT TIGHTENING METHODOLOGY OF M.P.H STRUCTURE

1. Required quantity of bolts is shifted from SEPCO store to PLL store near MPH area.
These bolts are stored in weather proof area free from dust and water.

2. The quantity required for the day is taken from the package and if left out, the same
is returned to the same package.

3. The bolts are checked for the freeness of nut over bolt, thread damages and rust free
before use. Also when using the bolt, it is not to be polluted.

4. The bolts are used as per the dimensions mentioned on the approved drawings.

5. After completion of alignment of steel structure in a frame work, balance bolting is

done. After inspecting of installing all the bolts, tightening is done manually.

6. After manual tightening, torque tightening is done with torque wrench. The torque
value is provided by the quality department of SEPCO.
 Project: 6 x 600 MW KSK MAHANADI POWER PROJECT
Owner : KMPCL
Contractor: SEPCO

7. The deviation of torque value should be with in ±10 %. After torque tightening is
completed, the bolt is marked with paint for distinguishing.

8. Torque wrench is to be calibrated periodically to prevent error. Over torque

tightening may cause bolts to shear and under torque tightening causes under stability
to the structure.

9. Record of bolt tightening is maintained by PLL for billing and for future records.

10.Boxed up columns after alignment Coi rope are to be kept in load with chain blocks
til bolt tightening have been done.

11. Boxed up columns with beams is to be ensured with proper lifeline and safety nets
for work approach.

12. Tie the PP rope Ø 14mm along the ladder with fall arrestor at columns.

13. Arrange 350NM torque bolt tightening m/c and 700NM torque bolt shear m/c. from
M/s.SEPCO and shift to the work site.

14. Also to arrange for the power cable 2.5mm2 with plug about 50mtr.long for each
type torque m/c. connection and switch board with power connection. Arrange Ø
14mm PP rope for lifting the torque machine.

15. Before taking m/c. at height ensure proper running condition of machine, workmen
should take safety measures by wearing hand gloves while running the machine to
prevent from electric shock.

16.1st lift the 350Nm tightening m/c with pp rope to work area then tight the bolts for
Column and base plate joints, next tight the bolts for main beams with columns and
next tight for beams and bracings.

15. After the completion of 350Nm torque m/c., apply the 700Nm shear cutting m/c. in
the same above process, then release the load from coi rope and remove the ladder &
platform.

16. Always ensure to apply 350Nm tightening m/c. approx.30sec.max. And then 700Nm
shear m/c. til the bolt gets cut.

17. After the bolt tightening for Tier#1; Tier#2 can be erected.

18.After alignment of Tier#2, 1st Tier#1 column to Tier#2 column to be tightened and
cut, next beams and bracings in the same above process.
 Project: 6 x 600 MW KSK MAHANADI POWER PROJECT
Owner : KMPCL
Contractor: SEPCO

19. The same procedure shall be followed for all the tiers.

11. MATERIAL SHIFTING Procedures OF M.P.H STRU CTURE

1. Availability of incoming materials to material yard is being received from SEPCOI

through packing list.
2. Material shifting plan to site is received from concerned site engineer.
3. The plans have been made based on the availability of materials confirmed by
the material shifting department.
4. Based on the plan target for shifting material to localization area, usage of P&E
assets and manpower are being fixed and necessary documentation &
formalities such as equipment requisition voucher to be produced.
5. What should be the lifting assets and nos. of workmen and their category are to
be finalized depending upon the weight of the materials.
6. Skilled workmen are to be used for the lifting and shifting process. If the same are
not available the workmen should be developed by time to time training
programs.
7. Before lifting the materials the lifting machineries like mobile crane (12 to 14T),
320 crawler crane (18T), telescopic tyre mounted crane(75T)and shifting vehicles
like 40T trailer and six wheeler lorry (10T) are to be arranged and the same are to
be checked for its working condition.
8. Proper work approach for work area to confirm and lifting arrangements like
Slings, D-shackles, packing at sharp edges and PP ropes are to made ready and
kept at work area.
9. Proper placement and centering for tying up of slings on the materials to be
done.
10. Safety measures for hook latching of the crane, features of slings and D-shackles,
etc.
11. After loading the materials, scope for transportation to site area to check and
then vehicle mobilization to be done to site work area.
12. At site place for unloading the materials to identify then marching of cranes to
unload the material is to take place.
13. Lastly, taking into consideration of safety measures material can be unloaded to
work area within the reach for erection.