CONFERENCE ON BALANCE OF PLANT SYSTEMS 23RD MAY 2012

FOCUS ON CIVIL & STRUCTURAL BOP

Presentation by: J.P.Rao Director Corporate Marketing Strategy

GROUP INTRODUCTION

SP GROUP - Introduction
147 years of rich legacy as an Engineering & Construction Company with unmatchable delivery record.
Lanco, Amarkantak 1 x 300 MW

Group Turnover of INR 12500 Crores (US$ 2.5 Billion), with 23,000 Employees.

Strong Presence in India and Internationally footprint in Middle East, Africa, South East Asia & Caribbean.

SP GROUP - Introduction
A Conglomerate with Multiple Business interests with Progressive Outlook and Professional

Approach Engineering & Construction Industrial,

Commercial and Real Estate. Infrastructure Coal Mining, Power, Ports and Roads. Engineering, Procurement & Construction Minerals, Metals, Power. Business Automation Engg / Manufacturing of Precision Tools Others (Bio-fuels, Facades and Interiors, Textiles and Shipping and Logistics).
BALCO, Korba 4 x 135 MW

SP Group Companies
General Contracting, Design & Build Solutions for Industries, Utilities, Residential & Commercial projects Infrastructure construction for Ports, Power plants, Marine, Oil & Gas, Transport. Electrical, HVAC, Plumbing & Fire Fighting. DG Set manufacturing, Switchyards. Engineering, Shipping & Logistics and Transaction Management Solutions Building Faade solutions

Engineering, Procurement and Construction solutions for Minerals, Metals & Power sector

Real estate development

SP Group Companies
Interior fit outs

Infrastructure development and operations / BOT projects

Water and Air purifier, cleaning and security systems

Transactions processing, services and networks

Travel Services

Yarns canvas, Belting ducks and terry towels Publishing of Magazines like Power Watch, Computer Active, Car & Bike, Smart Photography.

SP Group Synergy for Power projects

Shapoorji Pallonji & Co. Ltd. is the core flagship company. Synergy within group companies enables us to execute large & complex projects swiftly and efficiently.

Area of work

Industries, Utilities, Buildings

Ports, Transport, Terminals, Infra

Electromechanical works

Power, Minerals & Metals

Roads, Ports, Power Projects

Logistics & Water Systems

In Power Plants

Civil & Structural Works

Intake / Outfall Structures, Jetties

HVAC, Electrical, Firefighting

EPC Solutions

BOT Projects

ETP / WTP Desalination

Synergy for Power Project Execution

Shapoorji Pallonji & Co. Ltd.

One of Indias Oldest and Most Respected Group, operating for 147 years. Turnover of INR 3174 Crores (2010-11). An ISO 9001:2008 Company Complying to the ISO Standards for Design & Build & EPC Projects. Certified for ISO 14001:2004 & BS OSHAS 18001:2007 The FIRST Indian Construction Company to enter the Middle East in 1971. Strong Presence PAN India and in the Middle East, Africa, & the Caribbean.
Samalpati Power 105 MW Oil Fired plant

Shapoorji Pallonji & Co. Ltd.

Engineering & Construction activities include: Power plants & Industries (24 Power & 50 Industrial Projects) High-rise Buildings & Residential Buildings
Tata Power, Trombay-1 x 500 MW

Hotels, Hospitals, Airport, Educational institutions, Data Center, Commercial, Malls & Multiplexes, and Stadiums. 9 Regional offices presently executing 85 sites

Afcons Infrastructure Ltd.

A Leading Infrastructure Firm Having Transnational Presence. Significant Experience and Strong Track Record. Areas of Operation:-

MARINE Over 176 + Works Ports & Harbors', Jetties, Dry Docks, Wet Basins, Breakwater, Outfall & Intake Structures etc. OIL & GAS LNG Plants, EPC Contracts for Offshore Oil & Gas Process Platforms Onshore Oil/Gas/Chemical Plants and Civil works such as Refineries, Gas Plants etc, Fabrication Yard. TRANSPORTATION Roads ( Over 3000 + Lanes km), Bridges, Flyovers, Interchanges ( Over 132 +), Railways and Metros ( 43 km Elevated metro) , Railway Tunnels, Road Tunnels. 9 TUNNELS AND HYDRO PROJECTS 40 GENERAL CIVIL ENGINEERING WORKS 30 + OVERSEAS PROJECTS

Sterling & Wilson

Established in 1927 as Wilson Electric works

Turnover of INR 700 Crores (2010-11)

In 1973, Sterling and Wilson was formed in association with SPCL

Tata Motors, Sanand

MEP Services

2005 onwards, ventured into MEP services to support customers expansion

plans and expectation of single point contact for Electro-Mechanical services.

Today Sterling and Wilson is Indias leading MEP services company

MEP projects contribute approx. 60% of the business revenue

Sterling & Wilson

DG Sets Asias largest DG set plant at Silvassa Sterling Generators ISO 9001:2000, ISO 14001:2008 Certified Facility In 2008, become largest buyer of MTU engines in Asia In 2010, become 2nd largest supplier of Gensets in India of above 1000 KVA In 2011, become largest buyer of Perkins Engineers above 1000KVA, in Asia

Co-Gen capabilities Established the Co-Gen division in 2011 Offers highly optimized Gas based Combined Heat & Power (CHP) turnkey solutions for Commercial Buildings & Process Industries
F-1 Track, Delhi 4 nos. 3000 kVA & 2 nos. 1750 kVA

Sterling & Wilson

Solar-Power EPC

Established the Solar EPC division in 2010 16 projects aggregating to 71MW spanning across the country have already been commissioned and connected to the grid

Working on 4 live solar projects aggregating to 10MW across the country with scope varying from turkey EPC and balance of system to 33/66 kV power evacuation

25MW Visual Percept, Surel, Gujarat

POWER PROJECT EXPERIENCE

SPCL - Completed Projects

Name of the project Civil & Structural works for Coal Handling Plant for 4 x 135 MW Thermal Power plant Civil works for TG Foundations & Allied Buildings for 1 x 300 MW Coal based Thermal power plant Civil works for the entire plant for 3 x 350 MW CCPP Complete Piling Infrastructure & Enabling works for 370 MW CCPP 1 x 600 MW Thermal Power Project near BarelaGorakhpur Village

Client BALCO / SEPCO Lanco Torrent / Siemens GSECL / Alstom Jhabua Power Ltd.

Location

Year of Completion 2005

Korba

Amarkantak

2008

Surat Utran, Gujarat Seoni M.P

2008

2008 2011

SPCL - Completed Projects

Name of the project Civil works for 2 x 120 MW Thermal Power Project

Client Tata Power Company Ltd

Location Jojobera

Year of Completion 2001

Independent Power Generation 105.66 MW

Samalpatti power Company

Tamilnadu

2001

Civil works for TG Building & Allied Buildings for 2 x 500 MW & General Civil works for 1 x 180 MW & 1 x 250 MW Tata Power

Trombay, Mumbai

2001

SPCL - Completed Projects 1130 MW TORRENT CCPP, Surat

Client : Torrent Power Generation Limited Location: Surat Completion: 2008 Description / Major Quantities 1130 MW Combined Cycle Power Plant Excavation : 2,01,465 cu.m. RCC Works : 86,990 cu.m. Reinforcement Steel : 7209 MT Structural Steel : 3500 MT Roof Sheeting & Cladding : 18,000 sq.m.

Scope : Earthworks Under reamed Piling TG Foundations & Decks Boiler Foundations Structural Steel Works Ancillary Buildings Road Works CW System Service Pipelines & Trenches

SPCL - Completed Projects Lanco Amarkantak, Chattisgarh

Client Location: Completion:

Lanco Chattisgarh 2008

Description / Quantities 300 MW Thermal Power Station Excavation : 4,45,000 cu.m. RCC : 1,38,120 cu.m.

Scope Earthwork TG Foundations & Decks Boiler Foundations DM Tank Foundation / FD & PA Fan Foundation Pick Rack Foundation / Conveyer Foundations Coal Mill & Bunker Water Supply, Drainage & Sanitation Rain Water Reservoir Structural Steel Works

SPCL - Completed Projects Balco, Korba

Client Shandong Electric Power Co. Location: Chattisgarh Completion: 2005 Description / Major Quantities 540 MW (4 Units x 135 MW) TPP. Structural Steel : 4250 MT RCC : 78000 Cu.M. Reinforced Steel : 6200 MT Track Hopper RCC : 200 M Stacker RCC : 350 M

Scope: Crusher foundation & deck 28 M High RCC Frames Structure for Crusher House 22.5 M High RCC Fly Ash Silo 2 Nos. WTP with DM Tank foundation Air Compressor House / Refrigerating Station Power house Control Building Coal handling wash water pump house.

SPCL - Completed Projects Samalpatti Power, Tamil Nadu Tata Power

Client Location: Completion:

Samalpatti Power Company Tamil Nadu 2001

Client Location: Completion:

Tata Power Company Ltd. Jojobera 2001

Description / Scope Independent Power Generation 105.66 MW Buyer : Tamil Nadu Electricity Board. Seven Wartsila Diesel Engines Primary Fuel : Low Sulphur Heavy Stock Plant

Description / Scope Civil works for 2 x 120 MW Thermal Power Project Wagon Tippler, Reclaim Hopper Conveyers Tunnel, Pump house MCC Rooms.

SPCL - Ongoing Projects

Name of the project

Client

Location

Completion due

General civil works for Main Plant & Auxiliary buildings for Unit 2 of 600 MW Power Plant Site and Infrastructure works and Main Plant Civil & Structural works for 1 X 600 MW TPP Piling and Foundations in Main Plant, Power House, Boiler, ESP, TG, Fans and Transformer foundation etc. for 2 x 500 MW TPP Construction of BTG - Civil and Structural works for 5 X 270 MW Nasik thermal Power Project

Bharat Heavy Electricals Ltd. Korba West Power Company Ltd. Bharat Heavy Electricals Ltd.

Chennai

Dec 2012

Raigarh, Chhattisgarh. Tuticorin

Mar 2013

Nov 2012

Elena Power & Infrastructure Limited

Sinnar, Nasik.

Nov 2012

Construction of BTG - Civil and Structural works for 5 X 270 MW Nasik thermal Power Project

Elena Power & Infrastructure Limited

Amaravati, Maharashtra

Dec 2012

SPCL - Ongoing Projects

Name of the project

Client

Location

Completion due

Civil works for 225 MW Gas based Combined Cycle Power Plant Piling and General Civil works for 2X250 MW Lignite Based Thermal Power Project Construction of Main Plant building & Balance of Plant for 2400 MW Combined Cycle Power plant.

Sravanthi Infratech Pvt.Ltd. Bhavanagar Energy Company Limited M/s Reliance Utility Engineers Pvt. Ltd. (ADAG Group)

Kashipur, Uttarkhand. Bhavnagar, Gujarat Samalkot, Andhra Pradesh Angul, Orissa

June 2012

Mar 2013

Aug 2012

Civil and Structural works of BTG and General Civil works of construction of 2 X 600 MW Coal based Thermal Power Plant.

Jindal India Thermal Power

June 2013

Civil works for Coal Handling Plant of 2 X 600 MW DVC The TRF Ltd. Power Plant at Raghunathpur. Jamshedpur

Ragunathpur West Bengal.

June 2012

SPCL - Ongoing Project Project Data Sheet 2400 combined Cycle Power Plant, Samalkot
Client: Location: Duration: Project M/s Reliance Utility Engineers Pvt. Ltd Samalkot,,Andhra Pradesh 18 months Gas Based Combined Cycle Power 2 gas turbines and 1 steam turbine having a capacity of 3 X 800 MW = 2400 MW
GT Erected on foundations Block-2

Major Quantities Concrete quantity : 1,50,000 cum Structural Steel : 14000 MT Scope Total civil works for Main plant area-3 units and General civil works for Balance of plant . Total civil works for switchyard, roads and drains. Erection of bolted structure for (14000 MT)

SPCL - Ongoing Project Project Data Sheet 2400 combined Cycle Power Plant, Samalkot
Structures include: GT building, ST building, Transformer yard, HRSG, Bypass stack, Main Stack, Electrical control building etc. Pump houses, Raw water fire water pump house, Cold water pipe encasement works, PT plant, Ware house, Admin building, H2, N2, Co2 building, Chlorination building, PMCC building etc. Switchyard, GIS ,AIS,ICT, cable trenches (400 KV & 220 KV). Major PMV Deployed - Concrete placing - a boom placer and 3 nos static pumps and 10 transit mixers are arranged. - 125 KV DG set & 250 KV DG Set - Concrete plants One 60 Cum/hr & 30 Cu/hr, each - 150 MT crane
Structural Work in progress

SPCL - Ongoing Project Project Data Sheet 2 x 250 MW TPP, Bhavnagar

Client Location: Completion: Bhavanagar Energy Co. Ltd. Bhavanagar, Gujarat Mar - 2013

India Bulls Thermal Power Plant, Nasik

Client : Elena Power & Infrastructure Ltd.

Location: Nasik

Description / Scope Piling & General Civil work 2 x 250 MW lignite based Power plants. Scope: Pile caps, Piling works, Structural Steel works Major Quantities: No of Piles : 5587 ( 500mm, 750mm, 1000mm) Pile Concrete :49300cum

Description Capacity - 5 x 270 MW Thermal Power plant at Sinner, Nasik Scope Civil & Structural works for TG, Mill Bunker. Civil Foundations for ESP. Major Quantities:Structural Steel Fabrication:- 24200 MT.

Structural Steel :15050MT Structural Steel Erection:- 15100 MT. Total Concrete : 1,30,000 cum

SPCL - Ongoing Project Project Data Sheet 1200 Coal Based Power Plant, Derang
Client: Location: Duration Jindal India Thermal Power Limited Derang, Angul, Orissa 22 months Structures: Boiler, ESP, Power house, Turbine generator Mill bunker, ID fan, PA fan, FD fan, Air compressor building, Demineralization tank, CST tank, CWST tank, Guard pond, Coal handling plant, water intake system, ash pond etc.

Project Description Coal Based Power Plant of 2X600 MW Major Quantities Reinforcement work is @ 63,500/ MT Structural @ 1,40,000/MT Scope of Work Earthwork, PCC, RCC, Reinf, shuttering, staging, insert fixing, brickwork, plaster, water stopper.

CHALLENGES FOR THE CIVIL & STRUCTURAL (C&S) CONTRACTOR

PRESENT SCENARIO( AS ON MARCH 2012 ) PAN INDIA

POWER PROJECTS TOTAL NO OF PLANTS UNDER CONSTRUCTION (THERMAL) : 70 NOS.

TOTAL CAPACITY UNDER CONSTRUCTION IN MW (THERMAL) : 50000 MW TOTAL NO OF UNITS : 148

TOTAL NOS OF CHP / AHP : 148 DM PLANT : 211, COOLING TOWERS : 218, CHIMNEYS : 77 PROJECTS UNDER CONSTRUCTION BY SPCL 5500 MW / 10 SITES APPROX. STRUCTURAL STEEL QUANTITY : 1,50,000 MT APPROX CONCRETING QUANTITY : 4,80,000 MT

CHALLENGES

WORKFORCE ISSUES Unavailability of Trained Workforce Mandatory use of Local Labour

LACK OF TRAINING INSTITUTES Very Limited Institutes for Training the Labors / Executives for the Power Industry Shortage of Executive Manpower / Power project specialists : @ 4000 nos Break-up of Shortage: Senior Management 354 Middle Management 1302 Junior Management 2268

CHALLENGES

SITE CONDITION ISSUES Location of site not favorable for Logistics, etc Local Agitations Space inadequacy for Site Infrastructure, Yard, Colonies, etc Access roads are generally in bad shape

CHALLENGES

DESIGN & ENGINEERING ISSUES Inadequate Data for Design & Engineering Co-ordinated / Interface drawings are usually incorrect resulting in re-working Approvals / issue of drawings are delayed Equipment Details / Loading / Sizing are not known well in advance LACK OF SUPPORT FROM DEVELOPERS Tough Deadlines...without considering Site Conditions, Local issues, etc No Project or Site Security Delay in Bill Certification Electricity and water availability

CHALLENGES

PLANNING & LOGISTICS ISSUES Lack of Interface scheduling generally, poses problems! Coordinated Drawings with vendors, Consultants, Contractors, are delayed When drawings miss out the openings , redundant works are unavoidable. When Logistics schedule is not updated for delivery of equipment on site, Movement of gangway & infrastructure works...suffer.

CHALLENGES

PROCUREMENT & CONTRACTING STRATEGY ISSUES Many a times Developer is not clear on Project Delivery Model- EPC / Packaging All Agencies are not finalized at the initial stage...this leads to change in Design data & Project Scheduling at a later stage! Cost Escalation for Labour, PMV, Materials is not provided Cash Retention is up to Commissioning stage, affects Cash flow

SOLUTIONS

SOLUTIONS

SOLUTIONS FOR RESOLVING WORKFORCE ISSUES (TAKEN UP BY SPCL) Preparation of Technical training syllabus for various trades. Set-up of skill development center at every project site and impart on-site skill training . Training to Sub-Contractors to handle statutory compliances & HSE norms, Labor Management through site HR & admin. Camp Boss posted for labour camps and their welfare Identified and resolved labour issues in labour camps Introduced Labor Productivity Incentive Scheme To sub contractors. Introduced Labor Retention Incentive Scheme To Sub-Contractors

SOLUTIONS

SOLUTIONS FOR DESIGN & CONSTRUCTION ISSUES Vendors to be finalized by Client at the initial stage itself Data on Equipment Loading / Sizing, to be provided at the beginning. Erector to confirm the Methodology to be deployed for installation of equipment/s in advance. Vendor to provide updated information on Delivery schedule & interfacing activities All concerned players to provide information on Work front availability / access / cutouts to be left . Link day to day change and project based change

SOLUTIONS

SUPPORT FROM DEVELOPER Partnering Approach with WIN-WIN Preposition Ensuring Co-ordination between Vendors, Consultants & Contractors LEAN Approach Optimum Utilization & Resources & Minimizing wastages Social-Economic Impact Analysis should be carried out by the Developer - Very important in order to anticipate local issues which hinder the works. - Developer should have dedicated CSR Activities for the Locals

SOLUTIONS

SUPPORT FROM DEVELOPER Understanding of Total supply Chain value Streams Provide advance time for Mobilization Inspection & Clearance for raw steel, fabricated items, other bought out items in the shortest time. Inspection for Critical items only Critical areas, Drawing finalization / approval, release within stipulated time

SOLUTIONS

SOLUTIONS FOR PACKAGING & CONTRACTING ISSUES Civil works for entire unit should be one package (including infrastructure works) Building related Electro -Mechanical works can be integral part of Civil package. Bonus clause for early delivery. Ensure +ve Cash flow throughout the project duration Cost Escalation for Labour, PMV, Materials is to be provided Retention should be against Bank Guarantee only till completion of Civil works & not Commissioning stage Equitable risk allocation through sharing of risks.

THANK YOU