Project : Coal Fired Boiler

Capacity : 14 tph, 10.54

kg/cm2 g.

agenda
Sr

Description
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Introduction of teams
Self-introduction with brief of discipline, experience and expertise
Broad view of project purpose, goals and targets
Big picture of project + FV brief of machine
Project plan time line schedule
Expectations from teams / individual
Dependencies
Deliverables and schedules
Process flow
Bottle necks, Risk and key issues
Communication plans and review meetings
Requirements occl / oem / ec
Tea break
Way forward
Questions and answer
Lunch
Plant round
Detailed discussion on project activities
conclusion

Welcome note
It is our pleasure to welcome you all on a project of setting up a coal
fired boiler in a new plot of @ 6400 sq mt area, adjacent to existing
premise.
The state of the art technology boiler will be supplied by Forbes
Vyncke and detail engineering for the same will be shouldered by
Mott McDonald.
We at OCCL have great faith in both the agencies' domain expertise
and capacities for timely completion of this assignment with great
accuracy.
The project may be little difficult for all of us, as the boiler technology
is bit new to us and this is the first instance, where we all are roping
our efforts to climb a tough cliff, in just 8 months from now.

Team introduction
The members from all 3 agencies are as:
Client - OCCL
Mr Vijay Sabarwal
J V Shah

Designation
Sr V P operation
Dy G M- projects (Focal
point)
G M Engineering
Asst Mgr- Civil
Asst Mgr Mech
Executive Instrument
Cad designer
Manager electrical
Manager- instruments

Roles and responsibilities

Smooth progress of project
Project integration- Focal
point
The real client of project
Integration and execution
Integration and execution
Integration and execution
Integration of scopes on drgs
Integration and execution
Integration and execution

Design Engineer
Project manager (Focal
point)

Back office integration

Project co-ordinator &
execution
Smooth progress of project
Project co-ordinator

Mr Arvind patel

Div. Director
Project manager (Focal
point)
Manager civil

Mr Vinay Patel
Mr Ankur Chavda

Manager mech
Executive- process

Mr Shyam Mathuria
Mr Rahim Multani
Mr Dipak Sharma
Mr Jignesh Solanki
Mr Dhruv Nakoom
Mr Sanjay Agrahari
Mr Sanjay Hiwase
OEM / contractors -FORBES
VYNCKE
Mr Yogesh Barge
Mr Sanjay Sharma
Consultant - MOTT McDonalds
Mr Arpan Shah
Mr Rakesh Mistry

Civil and structure

deliverables
Mech and Piping deliverables
PID and process engineering

Project Outline
Purpose = The purpose of projecting this boiler is to suffice total steam requirement
for all 4 production lines at Mundra. At average 2.3-2.5 Tph saturated steam
requirement at 6 kg/cm2 g per line admeasuring 110 to 120 TPD, running
continuously at varying loads without much deviation in operation efficiency. In case
of its out of operation days, 3 numbers FO fired 3 tph steam boilers will cater the
steam requirements. For full load operation on FO boiler , one more boiler may be
procured in future of required capacity.
The main purpose of this project to avail sustainable and reliable steam supply to
customers at least interruptions and lowest operation coast.
Goal = The goal is to set up all the systems encompassing entire scope conformities.
Targets = The entire project is expected from kick-off to steam out is to be finished in
8 months. Commissioning, training and fine tuning to achieve efficient operating
parameters shall be 1 month, post commissioning.
Special Note: The time base line shall be very important, as our next project of U3U4 will overlap, with these schedules.

Clients expectations
Priorities: OEM and EC are expected to deliver correct drawings and documents on time.
Since they have good experience in their domain, we look forward all good inputs, in advance
stage to incorporate in design and result in documents.
Dependencies: This project is a blend of CCC (client, OEM, consultant and contractor)
interface, it is not a stand alone project. OEM is playing a key role in entire project. The
deliverables from OEM are highly important in terms of time and accuracy. EC will be the first
dependent contributing to schedule. OCCL obviously can not move a step without all of above.
Constraints: scope of work, deliverables, site readiness, stretched delivery, safety norms may
be the major constraints. Seasonal effect are of consideration. Monsoon is scanty and will not
impact field work much, but 80% execution shall be in short days of winter, that may affect
daily outputs. Communication can be a constraint and converted to risk.
In light of above factors, our expectations are more inclined to timely delivery of documents. The
correctness of deliverables will save time, efforts, reduced rework and efficient operation of
generation and distribution systems.
Scope of work: We all have rigorous exercise on scope of work and hope is clear to every one.
However, in case of doubt, please make it clear at the earliest. At the end, OCCL requirement
will be considered decisive for all goods of project success.

Process of work
FV has to deliver documents and specific requirement
for efficient operation of steam generation system. FV
also will extend valuable inputs at the design time to
make project successful.
Based on inputs from OCCL and FV, MM will design
their scope of items, put on drawings and documents.
In both the cases, documents will first be submitted
to OCCL for review and will be corrected for
comments, before issuing for work. All will clearly
mention assumptions considered in design /
documents.
OCCL shall have right to make final decision.

Big picture
Occl has decided to install a 14 tph saturated steam boiler delivering
10.54 kg/cm2 g pressure.
The entire set up right from coal yard and handling system to boiler,
ash handling system, flue gas to chimney emitting gas well within
GPCB norms, boiler feed water with DA and steam to plant customer is
planned in adjacent plot
Max steam pressure required in process is 6 kg/cm2 g. Pressure
requirements of other processes are met by respective PRS in all 4
lines.
The length of plot is 168 mtr and width is apx. 39 mtr having roads on
3 sides of approximate 6400 sq.mtr area.
We have prepared a broad layout of facilities and building s with
overall outer dimensions and expected elevations .Construction
features are indicated in respective drawings.
The new facility will have roads, drains, weigh bridge, security cabin,
area and plant lighting for smooth operation round the clock.

Big picture

Electrical power supply will be tapped from existing PCC

busbar with a PCC module near existing PCC room. The cable
from PCC to MCC of CFB will be routed through racks
constructed by OCCL and shall be in OCCL scope.
Raw water tank will be constructed at place shown in
drawing, of @ 550 Kl capacity in RCC with covered shed for
RO on tank slab. RO water will be stored in 2 FRP tanks near
RCC tank, will be pumped to feed water tank through pipe.
Coal yard as shown in drawing will be constructed per GPCB
guidelines and will have around 10 days inventory level.
Stripper dumpers will deliver coal in 30-40 ton lots. Loader in
labor contractors scope will charge coal to coal handling
system. Entire coal handling system (CHS) will be housed in
coal yard.

Big picture

CHS supply and installation + commissioning with dust

collector will be in FV scope. FV will provide all
dimensional, operation and static load and system specific
requirements to be incorporated in drawings.
Boiler with coal silo and all required support equipment,
electrical and instruments, ancillaries, structure with
approaches, piping, ducting with insulation, control
system, efficiency monitoring system etc will be supplied
by FV.
Ash will be collected and conveyed to ash silo housed in
close shed with access to trucks through belt and screw
conveyors and bucket elevators, where so ever required.
ESP shall be out door equipment with its own structure
and access.
Steam to be piped to plant customers with due
instrumentations, as indicated by OCCL with qty and

Big picture
A control room in RCC having GF+1 floor will have MCC room
at ground floor, where in FV + OCCL scope MCC and LDB etc
will be installed. First floor will be functioning as control room
and will have all instrument panels, operating and control
stations, effimax, small dedicated lab etc. This building will have
provision of change room, toilets and maintenance room. The
second floor will have a DA tank.
FO boilers will be relocated from hot utility building and housed
in a shed as shown in drawing, with their respective operating
panels. MM has to incorporate details accordingly. FO day tank,
boiler feed water tank chimneys shall be o/s FO boiler shed.
Pipe racks connecting to various buildings and facility shall be
laid and designed to carry steam, hot oil and other utility lines.
Electrical and instrument Cable will be routed through these
racks.

The plot

CFB PLOT

The layout

The layout

The layout

The layout

The layout

The layout

The layout

The layout

The layout

Time line

Communication plan
Single contact point:
Occl J V Shah 9687699009
FV Sanjay Sharma
MM Rakesh Mistry
Team members will communicate with specific person, as and when required after prior intimation to
Mr J V shah

Weekly status teleconference between 3 parties at 11.00 am on every tuesday. Can

only be rescheduled with prior confirmation of all.
Project plan updates OCCL will update adherence to schedule and may ask to
compress time in specific case.
Task and activity planning sessions having agreement on scheduled timeline, each
agency will submit their detailed deliverables timelines. OCCL will update to the plan and
will be followed through.
Management updates OCCL will update the progress to management on fortnightly or
monthly basis by status report.
Drawings / documents
all drawings shall be in aotodad -12 + and documents in MS office file formats.
Markups will be on printouts.
Will send scanned copies of markups or courier hard copy.
The final drawings shall be submitted in autocad in 1:1 scale, as well pdf format.
Both the agencies will clearly indicate latest revision number on drawing index. Drawing / document
indexing must contain the word : OCCL/14 TPH/---

Feed back & closure

Question & Answer session.
Exchange of requirements with
defined priorities to avoid chaos.
What next all are requested to
point out their queries, confirm
schedules and act promptly on the
project.