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2017514 ABCOFTHERMALPOWERPLANT

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ABCOFTHERMALPOWERPLANT
THISBLOGISWRITTENFORCONSTRUCTIONSUPERVISORSANDENGINEERSTOGAINPRACTICALKNOWLEDGEONTHERMALPOWER
STATIONBOTHONSUBCRITICALANDSUPERCRITICALTECHNOLOGY.

Friday,1February2013

TYPICALFIELDQUALITYPLANFORCIVILWORKAT MTV Big F is Back

THERMALPOWERSTATIONS.
NowwewilldiscussthecommonFieldQualityPlanforCivilwork.

Classification of checks like A,B,C and D depends on the importance of the activity . Most important
activity which need vendor signature , consultant signature and customer signature is termed as A. B is
slightlylessimportantthereforemaybeormaynotberequirethepresenceofcustomer.Likethatitgoesup
toDormore.Allthisclassificationofchecksshouldbediscussedandfinalisedbeforethestartofwork.
Dil Ye Ziddi hai
Type of checks can be classified as R = record verification , V = Visual , M = measurement , P =
Physical,T=Test
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Following are few items subjects to field quality checks . These are samples only. There are many more 18
itemswillbeunderFQP'spurview.

i)Bricks BlogArchive

ii)EarthWork 2017(4)
iii)Cement March(1)
iv)FineAggregate(Sand) CONCLUDINGPARTSTEAMBLOWINGPARTIVABCOFTHE...
v)CourseAggregate January(3)
vi)ReinforcingSteel
2016(16)
vii)Water
2015(12)
viii)FormWork(Shuttering)
2014(41)
ix)Concreting
2013(116)
TherearenumberofitemswhichcomesunderFQPincivilwork.
2012(12)

Area of Work : Civil works Sub System of Civil works : Bricks Activities :
Construction Translate

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s.no.DescriptiontocinstrumentclassRef.docfrequency
format

1.0Ensurethatthebricksare
freefromcracks,warpage
andofuniformcolour.VBIScodes1:10000protocol

1.1 Checkforthedimension,
Checkforbond/closers
thicknessofjointsinmasonry,
Line,levelandplumb,MTape,spiritlevelBIScodes1:10000Protocol

1.2Compressivestrength&
waterabsorptionMlaboratoryBIScodes1:10000Protocol

Earthwork(excavation,filling,compactionetc)

2.0StandardProctorTestMLaboratoryAIScodesNote1Protocol Adsense

2.1 RelativeDensityIndexMLaboratoryAIScodesNote1Protocol
WindTurbineIceDetectorPreventdamagetowindturbine
Preventsdamagetoturbinesbydetectingicingconditionsandfreezingrain.campbellsci.ca/windpower/ice
2.2 DryDensitybyCoreCutter
detection
Method/SandDisplacement
MethodMLaboratoryAIScodesNote1Protocol

AboutMe
2.3 MoistureContentofFill DebasishGuha
beforeCompactionMLaboratoryAIScodesNote1Protocol IHAVETHIRTYFIVEYEARSOF
EXPERIENCEONBUILDING
2.4DrydensitybyProctor POWERSTATIONSATDIFFERENT
NeedlePenetration MLaboratoryAIScodesNote1Protocol PARTSOFINDIA.DURING
ERECTIONANDCOMMISSIONING
OFPOWERSTATIONITWASFELT
Cement THATCONSTRUCTION
SUPERVISORSANDENGINEERS
3.0a) ConsistencyofcementMLaboratoryAIScodesNote2Protocol KNOWLEDGEABOUTAPOWER PopularPosts
STATIONISVERYLIMITEDTOHIS
OWNFIELD.CONSTRUCTION ID,FD,PAFANSFORBOILERIN
Initialandfinalsettingtime(vicatneedle)
FIELDISUNORGANISEDININDIA. THERMALPOWERPLANTPLAN
ANDBRIEFDESCRIPTIONOF
ITFELTPRUDENTTOGIVETHEM
KNOWLEDGEOFENTIRE FANS
Compressivestrength(testingm/c) POWERSTATIONINBRIEFSOTHAT TillmylastdispatchIcompleted
thetopicsofBoilerstructure,
THEYCANUNDERSTANDTHE
BoilerPressureParts,Rotaryair
3days&7days LINKOFTHEIRWORKTOSYSTEM.
preheaterasmajorequipment.I
ALSONEWENTRANTSWILLBE ha...
EQUIPPEDWITHGOOD
4.0Sand(TypesofTestcarriedoutonsandbeforeacceptance)
TECHNICALKNOWLEDGE. ERECTIONPLAN

Viewmycompleteprofile ANDSEQUENCE
a) Silt&ClaycontentMLaboratoryAIScodesNote3Protocol FORAIR
b) Sieveanalysis(Particlesizeandshape) PREHEATER
PARTV
c) Bulkingofsand
AirPreheater
d) Specificgravity,density,voids&absorption erectionPartVcontinuesAirpre
e) Moisturecontent heatererectionsequenceand
f) Deleteriousmaterials planisgivenabove.Alsothispr...

g) Petrographicexamination
STEAMBLOWING
h) Soundness PART/IABCOF
i)ReactionwithAlkali: THERMALPOWER

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2017514 ABCOFTHERMALPOWERPLANT
i)ReactionwithAlkali: THERMALPOWER
Mortarmakingproperties PLANT
Steamblowingof

MSlines,
5.0CoarseAggregate(Typesoftestcarriedoutoncoarseaggregatebeforeacceptance. CRH,HRH,SH,RH,HP&LPbypass
pipelinesofturbineiscarriedout
inordertoremoveweldingslag,
loose...
a) SieveAnalysis(ParticleSizeandShape)
b) Moisturecontent BOILERFEED
c) Specificgravity PUMPERECTION
AND
d) CrushingStrength COMMISSIONING
e) Bulkdensity PARTIIIABCOF
f) Absorptionvalue,Abrasionvalue&ImpactValue THERMALPOWER
PLANT
g) Voids
PARTIIIContinuationfromPART
h) Soundness IIPlacementofpumppedestal&
i) ReactionwithAlkali groutingwithreadymixgrout.
Mountingofpumponthepedes...
j) Petrographicexamination
k) Deleteriousmaterials ELECTRICALSYSTEMOFA
l) TemperatureCycletest THERMALPLANTABCOF
THERMALPOWERPLANT.
m) Flakiness
Inmyearlierposterectionof
heaters,deaeratorswere
TheabovetestsarecarriedoutsiteLaboratoryasperIScodesmentionedintheFQP,measuredand discussed.besidethatinTurbine
protocoled. packagethereareotherauxiliaries
bothstat...

ForactualworktestsmentionedintheFQPtobefollowedstrictly.FQPmentionedaboveisonlyfor
BOILERFEEDPUMPERECTION
example. ANDCOMMISSIONINGPARTV
ABCOFTHERMALPOWER
PLANT
Oilpipelinesarereassembled
afteracidcleaningisover.Oiltank
andduplexfiltersareclean.Oil
tankisfilledtotherequir...

BOILERFEEDPUMPERECTION
ANDCOMMISSIONINGPARTVI
ABCOFTHERMALPOWER
PLANT
FINALCOMMISSIONINGOF
BOILERFEEDPUMP(mdbfp)Till
mylastdispatchwehave
discussederectionand
commissioningofBoilerFeed
pum...

ELECTRICALSYSTEMOFA
THERMALPLANTCONCLUDING
PARTABCOFTHERMAL
POWERPLANT.
EarthpitcheckingEachearth
pitischeckedasmentionedinthe
standardchecklistofSwitchyard
earthingsystemCheck...

220VOLTDCSYSTEMBATTERY
CHARGERPRE
COMMISSIONINGPARTIABC
OFTHERMALPOWERPLANT.
220voltdcsystemwithbattery
chargercommissioningTilllast
dispatchIhavediscussedabout
thebasicrequirementofelectrical
sy...

GENERATOR
AUXILIARIES
(SEALOIL
SYSTEM)PARTI
ABCOFTHERMAL
POWERPLANT
TilllastdispatchIhaveoutlined
theinstallationofturbineand
generatorofthermalpowerplant
brieflywiththehelpofphotos.I
ha...

SOMEOFTHELABORATORYEQUIPMENTSHOWNABOVE.

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2017514 ABCOFTHERMALPOWERPLANT

PostedbyDebasishGuhaat11:20 1comment:

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Thursday,31January2013

LABORATORYTESTEQUIPMENTREQUIREDFORCIVIL
WORKATTHERMALPOWERSITES.

TilldatewehavediscussedaboutthespecificpackagesofcivilworklikeMAINPowerHouse,CHP,AHP
, Water System including NDCT ,CW etc. These packages are having high percentage of civil work than
othersinThermalPowerStation.Wehaveleftoutfollowingworkswhicharecomparativelylessinvolume
and easy to execute. Those packages are Roads , drains ,culverts , Security Gate and watch Tower,
enabling works ( The facilities to be created before actual execution of the project) , Quarters for staff and
workersoftheowners,othersocialobligationlikeSchool,Hospital,FirstAidCentreetc.DifferentSmall
pump House , Transformer foundations , Storm water drainage system. All the above packages are
permanentinnatureandrequiredatthePowerStationLocationatdifferenttimes.Onemajorjobwehave
notdiscussedlevellingandfillingoftheland.WehaveexcludedRailwaylines,MerryGoRoundSystem,
sidingsetcasthosepackagesareexecutedbyconstructionwingofRailway.

AcommonrequirementofallprojectsareQualitySystemofthecivilwork.Therearetwodistinctpart.One
is MQP ( Manufacturing Quality Plan) and other is FQP ( Field Quality Plan). Both the plan identifies the
process points where checks to be done and if required the same will be recorded in a predetermined
protocolsheet.Italsoidentifiesthecustomerholdpointsatdifferentstages.Constructionpeoplewhoare
workinginfieldneedsFQPbeforestartoftheirwork.MQPwillnotbeourpartofdiscussion.

Tostartcivilworkatsiteweneedtoestablishacivillaboratorytoconductroutinetestondifferentworks.
Thefollowinginstrumentsareidentifiedtobemobilisedatsite.

RoutineTestLab.

1.1VicatApparatusCementConsistencePenetrationofStd.NeedleIS5513
1.2Lechatelierstest
ApparatusCementshrinkageSizevariationaftercuringofsampleIS5514

1.3Mould(cement)
(70.7x70.7x70.7mm)CementcubesCubesmadeof1:3cement:SandIS10086

1.4CementMortarMould
VibratorCubeCompactionVibrationforfixeddurationIS10078

1.5Concretecubemould
(150x150x150)mmConcretecubesIS10086

1.6Compressivestrength
TestingmachineConcretecubetestCrushingstrengthofcubeIS2505

1.7ConcreteslumpconeWorkabilitycheckDropinconeheightofconcreteIS7320

1.8CoarseaggregatesievesSieveanalysisSievingIS383

1.9FineaggregatesievesSieveanalysisSievingIS383

1.10SieveshakerMechanicalsieving

1.11Aggregateimpacttest
machineImpactvalueofaggregateIS9377

1.12CompactionfactorApparatusWorkabilityofconcreteLabtest

1.13AbrasionandAttritionTestingMachines.

1.14ProctorDensityTestingEquipmentwithMould

1.15Thermometer

1.16MeasuringCylinders

PICTURESOFFEWLABORATORYTEST
INSTRUMENTSAREGIVENBELOW.

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2017514 ABCOFTHERMALPOWERPLANT

PostedbyDebasishGuhaat09:21 21comments:

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Wednesday,30January2013

COMMONWORKFORALLCIVILJOBSINTHERMAL
POWERSTATIONIRRESPECTIVEOFAREA.

PS:Forfurtherinformationon"ABCofthermalpower"clickontheadjacent

advertisement
CONCRETE.

AllconcreteworksshouldconformIS:456orEquivalentstandardslikBS,DINetc.

MixdesignofconcreteshallbeusedeverywhereexceptforleanconcreteandPCC.

ForleanconcreteandPCCnominal/Volumemixispermitted.

DesignMixshouldbecarriedoutasperIS:10262.

MinimumGradeofM25concretingtobedoneforallfoundationsincludingpiling.

ForStructuralandotherareaM20gradeofconcretingcanbedone.

ForUndergroundandoutdoorworkM25concretingistobecarriedout.

Gradeofconcretingforcriticalfoundationswasalreadymentionedearlier.Onenquirysamecanagainbe
furnished.

Unlessotherwisespecified,20mmanddownaggregatesshallbeusedforallstructuralconcreteworks

40mmanddownaggregatesmayalsobeusedunderspecialconditionsformassconcretinginfoundation.

All underground concrete structures like trenches, substructures of pump houses, all water retaining /
carrying structures , etc., shall have superplasticizer cum water proofing cement additive conforming to
IS:9103.Inaddition,limitonpermeabilityasgiveninIS:2645shallalsobemetwith.

Soundandcrushedstoneaggregateshallbeusedforallconcreting.

Allaggregateshouldbetestedforalkalireaction.Highpercentagealkalinesilicashallnotbeused.

Limestoneaggregateshallnobeusedingeneralformachinefoundations.

Thetemperatureoffreshconcreteshallbemaintainedatabout25deg.C.IfnecessaryICEcubesare

generallyusedduringcastingtomaintainthetemperature.

Plasticizer/superplasticizer/retarder/pumpingadditivemaybeusedasrequiredandpermittedbycodes
.Theslumpgenerallybekeptinthisrange.

TGTOPDECK150TO200mm

BFP/ID/FD/PAFANS/MILLSETC100TO150mm

BLOCKFOUNDATIONS100TO150mm

COLUMN100TO150mm

Plywood with film face form work shall be used for the top decks of all machine foundations and also for
columnsofTGfoundation.Formworkisthejobwhichconsumenumberofmandaysincivilwork
forfixinginpositionthenusingproptosupportthemallaround.Wehavenotcomeacrossanymechanical
method to do it in faster way. Adjustment of support firmly behind the form work takes time. Sometime it
disturbs the foundation bolts location to an unacceptable limit . Therefore bolt checking , shear pocket
checkingtobedoneonlyafterformworks.

GenerallyPortlandcement(havingspecificgravity3.15)canbeusedforallpurposes.Howeverthereare
twoothercementsareavailableinthemarket.ThosearePortlandBlastfurnaceSlagcementsand
Portland Pozzolan cement . The specific gravity of these cements varies from 2.85 to 2.94. These
cementsarealsousedwidely.

ThemixesofgradesM5M10,M15,M20,M25M30etccorrespondapproximatelytothemixproportions
(1:4:8),(1:3:6),(1:2:4),(1:1.5:3)and(1:1:2)respectively.Forconcretemixingratioinallgrades
concrete, the mix has to be designed after testing all the materials including water in labs.
For higher grade of concretes the mix has to be designed , it is the water to cement ratio
plays a major part therefore the same has to be monitored. Therefore to achieve the grade
conducting design mix is very important . Ratio arrives during design mix is to be followed
forconcreting.

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2017514 ABCOFTHERMALPOWERPLANT

Base Raft and Top Deck of any any


machine foundations shall be cast in
singlepour.

Ultrasonic pulse velocity test shall be carried out for the top decks of all machine foundations and TG substructure to
ascertainthehomogeneityandintegrityofconcrete.Inadditiontothatadditionalcubesaretobetakenatapredetermined
interval.

PICTURES GIVEN ABOVE ARE THE CEMENT MOULD USED FOR TAKINGS CUBES DURING
CONCRETING.

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PostedbyDebasishGuhaat11:34 1comment:

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Tuesday,29January2013

PUMPHOUSE,AHP,ASHDYKESALIENTPOINTSONCIVIL
WORK
Fueloilpumphouse,pipetrestlesetcmajorportionoftheworkisstructural.Thesamewillbediscussed
whenwewilldiscussstructuralportion.

600mmwidewalkwayisrequiredalongthetrestles.

RCC dyke wall of 1.2m clear height above finished ground level shall be constructed around LDO tank
enclosingaminimumareaof17Mx17M.

OverheadconveyorGalleryofCHP(CoalhandlingPlant)willhavemaximumspanof25M.

DoublestreamGalleryShouldhaveonecentralandtwosidewalkwayshavingwidthof1100mmand800
mmrespectively.ForsinglestreamGallerytwowalkwayshaving1100mmand800mmwidthshouldbe
provided.Galleryshouldhaveantiskidchequeredplate.

Sliding PTFE bearing supports shall be provided at one end of the gallery for relieving forces due to
temperaturevariation.

TransferTower/MaintenanceBuildingroofandsubsequentfloorwillbeRCConstructure.

Ashhandlingplant/system(forbothwetanddry)shallcomprisesofbottomashandflyashsystem.
ItalsocomprisesAshSlurryPumpHouse,AshWaterPumpHouse,AshwaterPipelinesupporttoAsh
dyke,AshwaterrecirculationsystemandAshDyke.Alltheciviljobsandstructuraljobsare
similartootherpackagesinexecutionhoweversalientfeaturesaregivenbelow.

ToplineofPipelinepedestalshallbe300mmofFGL.

TheCapacityoftheashdykeshallbesuitablefor25yrsofusage.

Comprehensiveseepageanalysistobedone.AshdyketobedeignedtakingIS7894intoconsideration.

Theashstorageareaisdividedintotwostoragelagoonandoverflowlagoon.

ThewaterfromstoragelagoongoestooverflowstorageareathroughRCCwelltypestructure.

Embankmentthetopwidthofembankmentistobe6Mandwillhave3.75MwidthWBMroad.

Freeboardwillbeminimum1.5M.

Slideslopeshallbeminimum2.5(H)to1(V).3Mwidebermstobeprovidedforallslopesat6M
heightinterval.

600mmclayblanketistobeprovidedatthebottomofallthethreelagoons.

Internaldrainagearrangementshallbegiven.

Sandchimneyofminimum0.5Mthickness,upto1.5Mbelowdyketop.

Sandblanketofminimum0.5Mdepth

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2017514 ABCOFTHERMALPOWERPLANT
Sandblanketofminimum0.5Mdepth

Heightofrocktoeshouldbeminimum1.0M

Theexitgradientshallnotexceedabout0.14.

When the annual rainfall is more than 200 cm, downstream slopes shall be protected by minimum 30cm
thickstonepitching.

Ontheupstreamslope,stonepitching30cmthickshallbeprovidedforthetopportion.

CWPIPESLAYINGERECTIONINCLUDINGENCASINGUNDERPROGRESS.

LAYOUTPLANISVISIBTLE.CHPGALLERYFROMDIFFERENTTRANSFERPOINTISALSO
VISIBLE.

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SALMBREWERYPLANTS

Established1924inViennaBREWING
EQUIPMENTMANUFACTURER Information

SALMBREWERYPLANTS

Established1924inViennaBREWING
EQUIPMENTMANUFACTURER Information

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2017514 ABCOFTHERMALPOWERPLANT

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