Beruflich Dokumente
Kultur Dokumente
4
Contents Vol. No. 31 • Issue No. 4
B.Sundaramoorthy,
Project Manager
Vishva Mohan Shrivastava,
Planning Engineer
SFSF pool building houses include low level effluent storage and pumping
• vehicle airlocks facility, de-mineralised water storage tanks (atop
fuel pool building) and security and access control
• cask decontamination/storage area
system. The administrative office area has a good
• EOT cranes, pool bridge and hoists training and conference room with all gadgets.
• underground fuel pool DM plant at
Excellent quality ratings are achieved in this project,
• spent fuel transfer bay along with underground Spent Fuel
which enabled it to bag ECC Quality Trophy.
duct to nearby reprocessing plant for hydraulic Storage Facility
transfer of fuel bundles as per the requirement
of BARC
• leak detection and collection facility for fuel
pool
• pool water polishing unit
• domestic water tank
• approach road for trailer and truck movement
• local control panels
The main objective of the test model is to find out Salient features
the behaviour of the Nuclear reactor’s containment
All the components of the actual reactor is scaled
structure under extreme pressure conditions. The
down to 1:4 including pre-stressing, critical
model is pressurized three times more than the
openings etc.
actual design pressure of the Nuclear Reactor.
The model is also tested to establish and check
Raft
the design parameters of the actual containment
structures and to get better understanding of The inner containment wall is supported on a raft
structural behaviour of the containment structure having dimensions of:
for future. • Diameter -15.60 m and
• Depth of 3 m
Test Model at Tarapur
• Stressing gallery of size 1500mm x 1800mm
The pre-stressed concrete containment test model below the inner containment structure with 4
is scaled down to represent the actual Pressurised access shafts
Heavy Water Reactor of Tarapur Atomic Power
station 3 & 4 at Tarapur, to a factor of 1:4. This Inner Containment wall
model is constructed at Tarapur close to the
• Thickness - 188 mm
existing BARC facilities.
• Height of the wall - 12.475 m above raft
Contented by the performance of L&T in Tarapur
• Constructed using 9 lifts
Atomic Power Project 3&4, NPCIL invited L&T to
construct the model on nomination basis. • The inner diameter of IC wall is 12.40 m
After the construction of the model, the same will Ring Beam
be subjected to a pressure, which is approximately • Height of ring beam is 1.2 m
4.5 to 6 kg/sq.cm or even higher. However, the
• Average thickness is 450 mm
actual failure pressure will be established after
testing. In any case, it is expected that there will • IC wall, ring beam and dome are designed as
be nominal leakage at 5 kg/sq.cm. monolithic structures
The site experiences a tropical climate with Electrical: Erection of electrical equipment and
humidity ranging from 40% to 90% depending on systems - E1 Package
the season and is subjected mainly to the winter
monsoon during the months of October, November Technical Aspects
and December. Kudankulam Reactors are Water-cooled Water
The Kudankulam Nuclear Power Project (KKNPP) moderated Energy Reactor (VVER-1000) of
consists of two units of 1000 MWe with two steam Pressurized Water Reactor (PWR) technology,
driven turbo generators supplied with turbine which is worldwide proven concept. VVER-1000
steam from two pressurized water VVER type reactors are the most advanced reactors
reactors of Russian design. The design of various similar to the PWR’s of western design. Nuclear
equipment, systems and structures are carried out fuel is charged into the reactor where the fission
in accordance with Russian and other International takes place and the heat is liberated. The
Standards. liberated heat in the reactor is carried away by the
light water from the reactor to steam generator
The entire project capacity of 2000 MWe (2 x 1000
by the main coolant pump. De Mineralized
MWe) of power will be supplied to three southern
(DM) water acts as reactor coolant. The coolant
states (Tamil Nadu, Karnataka and Kerala) and the
water is used in the steam generators to produce
Union Territory of Pondicherry. NPCIL has divided
steam. The steam is allowed to pass through
the whole project into number of packages and
turbine blades with high pressure and velocity.
awarded to different contractors. The whole project
The turbine then rotates receiving the kinetic
cost is about Rs. 13,000 cr.
energy of the steam. The generator, which is
mechanically, coupled to the turbine also rotates
Packages
and generates power. The back steam of the
L&T has been awarded M2, M4, M5, C5 and E1 turbine is allowed to pass through the surface
packages directly by NPCIL. M3 and I1 have been type condensers. The condenser will be having
awarded to L&T by BHEL & ECIL. tubes through which sea water is allowed
Mechanical: to flow and over which the steam flows. The
sea water absorbs the heat from the steam and
• Erection of Nuclear Steam Supply System
condenses the back steam. The condensate is
(NSSS)and auxiliary systems (equipment,
recycled back to steam generator. The sea water
piping & tubing works) - M2 Package
after absorbing the heat from the back steam
•
•Seawater
Vol. No. 31system
• Issue (equipment
No. 4 & piping is discharged into sea and fresh water is drawn
erection) - M4 Package through inlet.
Mechanical works for India’s Largest Nuclear Steam Generator (8 x 307 t each) was erected in a
Power Plant confined space with the alignment in the range of
0.4 mm to 0.5 mm.
Larsen & Toubro has won all major mechanical
erection and installation. This includes four Pressurizer (2 x 222 t each) was also erected in
mechanical packages and two electrical and confined walls with the tolerance of 8mm w.r.t
instrumentation packages. containment wall and alignment in the range of
0.4 mm to 0.5 mm.
The scope of work in M2 package include handling,
transportation, pre-fabrication, welding, erection, All the above erections were executed using highly
inspection & testing of piping, instrument tubing precision optical tooling survey instruments viz.,
and erection of associated equipment along with Jig Transit.
accessories for nuclear steam supply systems and Main Coolant Piping (64 Joints of 990 mm OD)
nuclear auxiliary systems for Unit 1 & 2. This main designed for a pressure of 176 kg/cm2 and
mechanical package involves heavy erection of temperature of 320°C has four quadrants. It
critical nuclear equipment like Reactor Pressure is connected to reactor pressure vessel (RPV)
Vessel, Steam Generators, Reactor Cooling assembly, steam generator (SG) and reactor
Pumps, associated piping in reactor and auxiliary coolant pump (RCP). The piping is used to re-
buildings, various safety systems like boron circulate the primary coolant thereby removing
injection system, passive heat removal system heat from reactor and transfer the same to steam
and containment sprinkler system. generator.
Erection and alignment Pipes are made out of low alloy steel having out
of NSSS Equipment side diameter of 990mm and 70mm wall thickness,
cladded inside with austenitic stainless steel. The
In this M2 package, reactor equipment (2 x 316 t
total circuit involves 32 weld joints per unit and
each) was erected in four stages. Being a nuclear
the total weight of piping is about 260 t. The pipes
project, high degree tolerances limit (0.01mm) was
were supplied in pre fabricated piping spool. For
maintained. Another challenge during the erection
the first time in India, a unique and sophisticated
was the clearance between the inner diameter of
welding method was adopted for Main Coolant
support structure and outer diameter of Reactor
piping at a nuclear power plant. Controlled and
Pressure Vessel (RPV), which is only 10 mm and
Induction Heating technique was adopted for the
large volume of blue matching.
first time in India during the welding operation with
M3 Package work involves handling at site store/ • Cold insulation 1,183 sq.m
storage yard, transportation to site of work, erection • Anti-corrosive painting 55,683 sq.m
testing and commissioning of turbine generator,
• Coating and wrapping 4,000 sq.m
feed pumps, piping and its auxiliaries.
• Grit blasting and painting 9,000 sq.m
Alignment of the turbine was done using Optical
Aligning instrument and Fronius was adopted for
Common Service System
orbital welding.
The scope of work M5 Package covers handling,
Sea Water System transportation, pre-fabrication, welding, erection,
inspection, testing of indoor and outdoor piping
M4 Package work covers handling, transportation,
and equipment of common service systems.
pre-fabrication, welding, erection, inspection,
This consists of all indoor and outdoors piping,
testing and painting of sea water systems
which includes HDPE piping for portable water,
equipment and piping in Sea Water Pump house
fire-fighting system (SGA, SGC, SGE), buried
and Chlorination plant. The main work in this
piping (coating and wrapping included), boiler
package include works in pump house like EP
associated works, DM plant associated tanks and
fabrication and erection, anti corrosive painting,
piping, and all nuclear ancillary building piping
and equipment.
• Rotating equipment - 450 t
• Stationary equipment - 2,612 t
• CS piping - 2,452 t
• SS piping - 405 t
• CI piping - 65 t
• HDPE piping - 150 t
• AC piping - 255 t
• RCC piping - 900 t
• Excavation and backfilling - 238000 cu.m
• Coating and wrapping - 7,000 sq.m
• Supply, fabrication and erection of structural
steel - 500 t
• Vol. No. 31 • Issue No. 4
The 1000MWe turbine, first of its kind is a steam heating by HP heater 5,6 and deaerator
condensing, four cylinder configuration (1 HPC + respectively.
3 LPC) with intermediate moisture separation and
• From HPC exhaust steam is extracted by LP
steam reheat, with rotational speed of 50 s-1 (3000
heater 4.
rpm), designed to drive directly an alternating
current generator, mounted on a joint foundation • The steam from exhaust of HPC enters
with the turbine. The total length of turbine with moisture separator reheater.
out generator is about 40.65m. The turbine is • After separator reheater the steam enters LP
provided with throttling steam admission. The cylinder through LP valve blocks which consist
steam from steam generator is supplied to 4 of 1 stop valve and 1 governing valve.
HP valve blocks each HP valve block consist of
one stop valve and one governing valve through • LPC turbine are double flow cylinders having
which the steam enters the HP cylinder. 5 stages in each flow.
HP rotor is an integrally forged rotor. LP rotors • Mass of heaviest part of turbine is LP rotor
are also integrally forged rotors (blade length - 80.5 t
is 1200mm). All rotors are provided with rigid • Mass of turbine - 1800 t
coupling and supported by two journal bearings.
The thrust bearing, mounted between HP cylinder
and LPC 1 serves as a fixed point for the rotor.
Quantum of work
• The steam from 4th stage of each LPC is
Turbine 4,028 t
extracted by 3 LP heaters 1.
Generator 1,297 t
• The steam from 3rd stage of LPC 2 & 3 is
Condenser 2,609 t
extracted by LP heater 2.
Feedpump drive Turbine & Aux 402 t
• The steam from 2nd stage of LPC 1 is
Feedpumps 169 t
extracted by LP heater 3.
Condensate Pumps 257 t
• HPC turbine is of double flow cylinder having
Cross over Pipes 283 t
5 stages in each flow.
Other Auxiliary Equipment 200 t
• The steam is extracted from second, third
Other Piping 12 t
and fourth stages of each flow for feed water
Two views of Stator (345 t) during erection for 1000 MWe Turbine Generator at Unit #2
17 ECC Concord | Jan - Mar 2009
All the pre-commissioning and commissioning
activities were meticulously planned and
implemented successfully. All the erection
sequences and procedures were documented
in 175 volumes. These different packages are
progressing well, meeting the quality standards
set by Russian authorities.
Electrical Scope
E1 Package - Technical Aspects
• Main Power output system
Safety system practiced at the project site is Important features of the plant
extremely stringent as it involves several heavy • First 2 × 1000 MWe power plant in India under
lifts, erection of critical equipment, hot processes construction with single transformer unit of
and working in severe conditions like tunnel and capacity 417 MVA
confined space. L&T’s team religiously follows the
• First time in India having 4200m length of
safety norms as per the requirement of the Atomic
400kV GIBD
Energy Regulatory Board (AERB). L&T has been
awarded the Project Director’s rolling trophy for • Fully inside lined reactor containment, a first
Best House Keeping by the client. time feature in India.
Turbine erection
27MVA 420kV Single phase Shunt reactors 6 Nos • 6.3 MW, 6kV DG
400kV 3150/2000A Single phase SF6 bus duct 4200 m • 6kV switch gear
230kV, 2000A single phase SF6 bus duct 900 m • 1000 kVa & 400kVa, 6/0.4kV and 6/0.433kV
auxiliary transformers
6kV 6.3MW Diesel Generator Sets 10 sets
• 0.38kV and 0.415 kV switchgear/ MCCs
6kV 3150A Isolated phase bus duct 2400 m
• Rectifiers
6kV 3150/1600A Switchgear Panel 522 Nos
• 220 V DC & 110 V DC batteries
6kV/0.4kV 1000KVA/400KVA Dry Type Aux.
Transformer 107 Nos • Inverters
0.38kV MCC Single Front Panel 444 Nos • 220 V DC distribution boards
0.38kV MCC Double Front Panel 668 Nos • 220 V/380 V AC distribution boards
• Cabling
Cables 7800 km
• Cable penetrations
HT & LT Termination 129000 Nos
Group-2: AC supply to the loads, which can
Light Fittings 21285 Nos
tolerate short interruption for a time defined by
Supply, erection, testing and commissioning of the conditions without effecting safety of the
reactor, under all modes of the plant, including the
Line Protection Panels 7 Sets condition of loss of supply from all off-site sources,
Lighting /Power Distribution Board 672 Nos is called the group-2 loads.
GI Conduits 344 km
These are fed from 6kV, 380V and 220 V AC, 50Hz
supply derived from UATS, RATS or CSAT.
Principles of Control, Monitoring and less than 0.5 m below the foundation, with a mesh 220 kV gas insulated
Relay Protection System size of 25m × 25m in the outdoor area and about substation
75m high RCC stack 75 m high x 3.6 m dia Ventilation stack • Plastering - 50000 sq.m
Delay tank 24 x 30 x 6 m below RCC tank of seven • Painting - 75311 sq.m
chambers below GL.
19° C concrete Site team has received appreciation letter for
Substation ‘C’ 30 x 24 x 10 m high 2 storey structure achieving 4 million safe man hours. And has got
excellent customer relation ship, TCE Consulting
Exhaust Fan main plant 50 x 18 x 10 m high 2 storey structure
Engineers are the consultants for this project. Work
Exhaust control Room 19 x 17 x 10 m high 2 storey structure commenced in August 2005 and expected to be
Connecting corridor 25 x 6 x 25 m high 5 storey structure completed by May’09 in all respect.
Fuel Handling Area extn. 21 x 6 x 7 m high These civil structure and electrical works are used
RCC Ventilation Duct 60 m long 2 X 2 m box for Nuclear fuel recycling received from designated
Compressor House 18 x 12 x 7 m Nuclear plants in India.
Apart from being the full fledged dam project • Earth work filling in embankment - View of the dam and
undertaken by ECC, this unique and landmark 48,2407 cu.m hydro-mechanical
structures (gates)
project was fraught with several social and • Rip-rap works - 30,917 cu.m
in position
environmental problems. • Metalled road at the top of dam facilities -
2.60 km
Braving all the odds, L&T successfully completed
the project and the flood gates were formally • Electrical fittings and illumination
opened and inaugurated by Mr. Saraff, President
Remote Location
– Jindal Power Limited on July 13, 2007.
As the site was located at 35 km from Raigarh,
Salient features a 11km approach road to site was strengthened
• Main earthen dam in the Riverbed - 200m before commencement of the work. In addition,
long, 18.5m maximum height L&T had to establish V-sat connection as there
• Right bank dyke of 1150m long and 2 to 15 m were no communication networks available in the
height vicinity.
• Left bank dyke of 201 m long and 2 to 6 m
Diaphragm wall
height
• Spillway dam and energy dissipation Initially, the diaphragm wall for the main dam was
arrangement –145m long with 10 vertical an RCC structure. After the work was awarded,
gates of size 12m x 8.5m and 2 stop logs with the consultant changed the structure from a rigid
operating system D-wall to a flexible D-wall using plastic concrete
• Intake and pump house with stop log and and doing away with the reinforcement. The
trash rack of 4m x 11m Foundation Engineering Competency Cell of ECC
• River diversion works took this challenge and developed a new design
• Complete hydro-mechanical equipment mix for this type of plastic concrete. The formula
• Approach roads to the project with worked perfectly and the work was executed
illumination successfully.
L&T is entrusted with the construction of one of The project had a huge requirement of concrete,
these dream irrigation projects – The Veligonda which was to be poured at a temperature of 15
Dam. The project will provide irrigation benefits degree celsius. The herculean task of achieving
to upland areas of the district besides providing and maintaining the standard of concreting was
safe drinking water to 15 lakh people, who have managed with meticulous planning. As the height
been consuming groundwater with excess fluoride of dam started increasing, earthen ramps up to
content for decades. L&T’s scope of works 30m height was created for the movement of
comprise construction of dam at Gothipadia concrete. Later, conveyor was used for shifting
and excavation of Gottipadia Canal including concrete from the batching plant to the top. As
construction of cross masonry and cross drainage the project required steel formwork, the entire
works, distributory system for 9500 acres. L&T shuttering was designed and schemed in-house
secured this contract in 2005 from Irrigation & at site. Hydra cranes were used for handling the
Command Area Development Department of forms. To reduce the cycle time, the shutters
Andhra Pradesh against stiff competition. were combined (4.8 m combined width) with
Valued at Rs. 395 crore, this is the first major structural steel channels. The whole sequence
concrete dam project executed by L&T on an EPC of operations, from aggregate production to
(Engineering, Procurement and Construction) concreting was mechanized thereby ensuring
basis. The scheme comprises construction of accuracy and maximum output. The client
dam from EL 162 to EL 230 having a base width of awarded commendation certificates for the highest
57.96m and top width of 12m, canal length 11.40 concreting (46000 cu.m) in the month of February
km and distributory system for 9500 acres. 2006.
Veligonda dam project is the first dam project Remoteness of the project posed the biggest
designed by the Engineering Design and Research challenge as management of materials was
Centre (EDRC). EDRC looked at the opportunity a critical task. Except for the aggregates, the
as a challenge and successfully completed the minimum distance for sourcing of other materials
design of concrete dam. The internal arrangements was around 200 km away from project site.
within the dam body like gallery, adit, shaft, and lift Interacting with the vendors and convincing them
were designed with precision. The dam consists of to deliver as per the schedule was one of the most
around 2 km of gallery within it for inspection and critical activity for the smooth progress of the
grouting. Planning and aligning this multi level project.
gallery and the interconnection of the galleries
Sourcing of aggregates was another major issue.
with access adits were really brain racking. Like in
Markapur is famous for slate rock formation
any other dam, ‘A’ holes and ‘B’ holes for grouting
which cannot be used as aggregates because
were designed to improve the impermeability of
of its hard and soft rock combination. The site
dam base. The dam base was grouted with a
has established a rapport with a local quarry for
total drill length of around 22 km. Different types
uninterrupted supply of aggregates.
of instruments were embedded in dam body to
monitor the dam in terms of settlement, plumb Identifying and sourcing the total requirement of
and thermal. The monitoring was reviewed with a boulders (22 lakh mtp), was a major issue during
computerized data acquisition system. the initial phase as the local terrain had affinity
Innovations
CSR
700L Bucket Wheel Excavator, which move on Conveyor Belt Speed 4.7m/s
rough surface with ease is used for excavation Width of Crawler Plates 2800mm
and conveying of overburden / lignite and lignite Cable reel on Undercarriage
bench at the mines. It has a large rotating bucket - cable length 1000m
wheel mounted on the boom. In the outer edge
Min. radius of curve 50m
of the wheel, there are 14 buckets with teeth. As
the wheel rotate, the bucket removes soil / lignite through discharge chute to the discharge boom
from the target area and carry it to the back side conveyor. The discharge boom conveyor carries
of the wheel, where it falls on to a bucket wheel the soil / lignite and pass it to the receiving boom
boom conveyor. The rotary plate carries it to of the Mobile Transfer Conveyor. Bench Conveyor
the receiving chute located at the center of the System then convey the material to the filling /
machine. The conveyor discharges the soil / lignite ultimate location.
700 L bucket
wheel excavator -
manufactured and
supplied by L&T
Green Camps
O n Sundary, April 5, 2009, around 40 L&T-
ites joined together to visit a nursery run by
Isha Foundation in Kodungaiyur at the outskirts of
Chennai. Entering the nursery, the group saw a
big table with varieties of saplings titled in Tamil
and English. Soon they were explained about
the various timber, fruit, flowering and fodder
species. The special characteristics of the trees
like the medicinal properties of neem, the rain
making capacity of the thoongu vaagai, the Ozone
generating properties of the Arasan (peepal)
and the fact that the monetary value generated
by a fifteen year old peepal tree is around 10-12
lakhs per year, were all astounding and thought
provoking.
Followed by the orientation, the experts from Isha Participants of the first green camp organised
Foundation demonstrated the sand-manure mix at Kodungaiyur - the outskirts of Chennai
Human-chain moving the mud-filled packets to the destination Children enjoying their time in the fun game
75 people comprising men, women and kids ECC’s Bakreswar Thermal Power Plant Project – (BMH BU);
participated in the nursery activity in the full Bisalpur Water Supply Project – Jaipur (WET BU); Hooghly Met
morning session. During the break, they took part Coke Power & Co. Ltd Project – Haldia (M&M BU) and DMRC
in games, which took them back to their younger Green Park Project -(Infra OC) have won the Gold Award for
days. After sharing their experience and narrating 2009 while L&T (Oman) LLC’s SBG Palm Garden Township and
the touching aspects of the green initiative and Oxy Mukhaizna Water Treatment Plant Project have won the
concept, they enjoyed the music, mimicry and Silver Award.
dance performances at the end of the day. It was The Royal Society for the Prevention of Accidents (RoSPA) is one
a fruitful and fun-filled camp. of the longest running and most highly respected occupational
As part of the “GreenHands“ campaign, L&T-ites awards programmes. The scheme is open to organizations of
at Coimbatore Project site have taken the initiative all sizes, from the full spectrum of work activities and from all
and planted 100 trees in and around the factory over the world. The prestigious awards recognize and celebrate
campus on April 8, 2009. Mr Sarkar, Head of L&T health and safety achievements, offer ideal way of showing
Growth Centre inaugurated the camp by planting commitment to raising standards, share good practice and
the first sapling. They will be expanding the activity allow benchmarking and provide a prime opportunity for gaining
progressively and are planning to achieve their positive publicity.
target of 1000 trees in the near future.
BusinessWeek said its survey was an effort to “pinpoint the shifts in power
that defined India in the past year, and to predict the players to watch for in
the next year.”
Mr. Naik had first featured in Business Week’s ‘Power List’ in 2007. US-based
BusinessWeek is one of the world’s most reputed business publications. Its
global edition is widely read around the world.
IMS Certification for B&F OC The Certificates were presented by Mr. D.K.S.
Moorthy of M/s DNV (DET NORSKE VERITAS),
B uildings & Factories Operating Company of the Certification Body to Mr. S.N. Subrahmanyan
L&T received accreditation for its integrated (SNS), Executive Vice President & Head – B&F
Management System (IMS) by qualifying for OC at ECC HQ, Chennai, on March 6, 2009, in the
following International Standard Certifications. presence of Section Heads.
• OHSAS 18001:2007 (Occupational Health & SNS acknowledged the efforts of HSE Team in
Safety Assessment Series), establishing the IMS system and getting it certified
• ISO 14001:2004 (Environmental Management in short duration. He also emphasized the need for
System) such recognition.
• ISO 9001:2008 (Quality Management System This Management System Certification will add
of HSE Function). value to the B&F OC businesses by
Mr. D.K.S. Moorthy,
• Integrating HSE in all its processes through a
DNV presenting the
certificate to risk focused approach
Mr. S.N. Subrahmanyan, • Providing external recognition for the systems
Executive Vice President
• Improving HSE Standards and Performance to
& Head – B&F OC
International standards
Dr Kirit Parikh,
Member - Planning
Commission and
Mr S S Kohli, Chairman
& Managing Director,
IIFCL presenting
the award to
Mr. S.N. Subrahmanyan
All L&T-ites have a reason to feel doubly honoured. Padma Bhushan in 2002. Now, seven years later, Mr. Naik
How many other companies have two Padma Bhushan will bring home the high national honour once again. Thank
awardees? Our co-founder Mr. Holck-Larsen received the you, Mr. Naik for making us all stand tall.
Printed by Universal Print Systems Ltd., Chennai, Edited by Mr. V.S. Ramana for Larsen & Toubro Limited - ECC Division, from ECC-HQ,
Manapakkam, Chennai 600 089. The views expressed in this magazine are not necessarily those of the management of Larsen & Toubro
Limited. The contents of this magazine should not be reproduced without the written permission of the Editor. Not for sale. Only for circulation
among the employees, business associates and customers of ECC, L&T’s Construction Division.