Sasan – 3960 MW Coal Based Ultra Mega Power Project

(UMPP) at Sasan, Madhya Pradesh, India

A. Sasan Location Details:

B. About 4000MW Sasan Ultra Mega Power Project:

 Sasan Power Ltd is executing 3960 MW Sasan Ultra Mega Power Project (UMPP) through
at Sasan village, District Singrauli, Madhya Pradesh.
 Sasan UMPP has been allotted 3 captive coal mines which makes it biggest integrated coal
mine cum power project in India.
 Sasan UMPP is a project of national importance and would benefit 35 crore people in 7
states of India. State of Madhya Pradesh is the largest beneficiary with 1,485 MW (37.5% of
total capacity) allocated to the state.
 The EPC Contract for the Project is in place between Sasan Power Limited (Subsidiary of
 Reliance Power Limited) and Reliance Infrastructure Limited.
 Reliance Infrastructure Limited has appointed internationally reputed consultants such as
Black & Veatch, Toshiba Power Systems (TPSC), Development Consultants private Limited
(DCPL), STUP and HOK etc. for design and development of the project.
C. Project details:

Project Classification : Ultra Mega Power Project

Capacity : Total 3960 MW i.e. 6 x 660 MW

Annual Generation : 33BU (Projected FY 15-16)

Type of Plant : Coal Fired

Water Source : Govind Vallabh Pant Sagar Lake Reservoir

Coal Transportation : Over Land Conveyor

Power Evacuation : 765/400 kV Level to PGCIL Pooling Station

Beneficiary State : All India Including 1500 MW to Madhya Pradesh

Major Equipment Suppliers

 M/s Shanghai Electric Corporation, China for Boiler,

Turbine & Generator
 M/s Caterpillar, USA for Dragliners, Dumpers in Coal
Mines
 M/s Sinofinn, China for Ash Handling System
 M/s Northern Heavy Industries, China for Coal Handling
System
 M/s Hyundai Heavy Industries - Generator Transformers.
BTG Erection Agency : M/s Powermech Projects Ltd, M/s IOTEP

Civil Construction Agency : M/s JMC, M/s Gammon and M/s ITDC

Cooling Tower : M/s Hamon

D. Project Highlights:

Super critical technology

 Lower emissions
 Reduced coal consumption
 Reduced power generation cost
 Entitled for carbon credits
Largest integrated coal based power plant in the country

Among top 3 large coal mining operations in India

 Largest in private sector

Among 10 largest coal based plants in the world

Financial Closure as per PPA

E. Project Technological Advancements:

Use of Overland Conveyor for Coal Transportation :

 Sasan UMPP has implemented longest single flight conveyor system in India which is
highly economical over MGR. It has higher reliability, longer service life, compatible for
rough terrain and requires lower human interface.

Multi Terracing Area Grading:

 Different grade levels has been selected for optimization of area

grading
 Natural Gradient has been used for effective drainage
 Critical foundation has been rested on hard soil
 All this ensured minimum cutting and filling of soil leading to faster execution

Use of Fiber Reinforced Plastic ( FRP) material for Cooling Towers:

 The FRP type Cooling Tower at Sasan is one of the very few Cooling Towers employing
“FRP material” & having such a huge capacity in Indian Power Sector.
 Reduction in Critical Path of voluminous Civil works normally in the Conventional
Cooling Towers.
 Pre Engineered Building

 Pre-Engineered building has been utilized for facilities like central bar bending yard as
these structures are easy to handle and erect
 It ensures lesser construction time compared to conventional buildings

Centralized control room

 Remote Centralized control room for operation and control of power plant has ensured
 optimal requirement of operation personnel
 Centralized CCTV monitoring of unmanned areas and equipments
 Centralized control room has ensured no magnetic/ electric noise and vibration
interface
 Use of Simulator for training of O&M personnel

F. Construction Highlights:

 Achieved fastest box up of Turbine in the country in just 92 days

 Achieved fastest Hydro Test (identify leakages if any) of the Boiler in the country with
53,500 high pressure joints, highest ever done in the country
 1sttime in the country, boiler light up for steam blowing is done with coal firing resulting
in savings of precious oil.
 Achieved fastest commissioning of 5 units in succession in the country, may be also in
the world.
 Four Units Synchronized with Grid in record 8 Months time
 All Six Units have been commissioned and power station (6x660MW) Commercial
operation has been declared in April 2015.
G. Sasan Views
 Advanced Construction Methods for New Nuclear Power Plants

A. Introduction

Relative to coal fired and natural gas fired power plants, nuclear power plants are more expensive to
build but less expensive to run. This annex describes advanced construction methods to reduce nuclear
power’s construction costs, mainly by shortening the time needed to build a plant.
Each of the methods described below has been used in one or more of the projects listed in Table IV-1.
None is unique to the nuclear industry, nor to any specific nuclear power plant design. Most are also
used for other large construction projects such as fossil fuel power plants, large civil construction
projects and shipbuilding.

Table IV-1: Reactors built recently using advanced construction methods [References: 1, 2, 3, 4, 5]
Reactor Country Construction Start of Type of reactor
period (months)* commercial (approx. MW(e))
operation **
Kasiwazaki Japan 48 Nov. 1996 ABWR (1350)
Kariwa-6
Kasiwazaki Japan 48 Jul. 1997 ABWR (1350)
Kariwa-7
Lingao-1 China 60 May 2002 PWR (1000)
Lingao-2 China 62 Jan. 2003 PWR (1000)
Qinshan 3-1 China 54 Dec. 2002 PHWR (720)
Qinshan 3-2 China 58 Jul. 2003 PHWR (720)
Tarapur-3 India 75 Aug. 2006 PHWR (540)
Tarapur-4 India 66 Sep. 2005 PHWR (540)
Shin Kori-1 Republic of Korea 54 (planned) Dec. 2010 PWR (1000)
(planned)
Olkiluoto-3 Finland 70 (planned) Jun. 2012 EPR (1600)
(planned)
Kudankulam-1 India 84 (planned) Mar. 2009 PWR (917)
(planned)
* The construction period is generally considered to be the time from the first major pour of
concrete for the main plant building to the commercial operation date.
** ABWR = advanced boiling water reactor; EPR = European pressurized water reactor; PHWR =
pressurized heavy water reactor; PWR = pressurized water reactor

B. Open Top Installation

Constraints on installing major components inside the reactor and containment building can have a
major impact on the construction schedule. In the past, the walls of the reactor and containment
building were constructed with temporary openings to allow the entry of large equipment. In open top
installation (Figures IV-1 and IV-2), the reactor and containment building is built with a temporary
roof with an opening through which major pieces of equipment, such as the reactor vessel and steam
generators, can be lowered into position using very heavy lift (VHL) cranes. Today’s VHL cranes can
lift equipment weighing more than 1000 tonnes, with very long reach. Once the equipment is placed
Page 2

inside, piping and electrical systems can be installed at the same time that construction of the reactor
and containment building is being finished, including the replacement of the temporary roof by a
permanent containment dome.

Open top installation has been used successfully with modularization (see next section) to shorten
construction schedules. VHL cranes add additional costs, but these are more than compensated for by
the shortened construction time. VHL cranes also add to planning requirements as it is vital to ensure
that they are strategically placed to conduct multiple lifting activities including the installation of
heavy equipment in other buildings of the plant or to provide lifting capabilities for two units being
built concurrently next to each other.

During the construction of Qinshan 3-1 and 3-2 in China, a VHL crane was used to position about
70 pieces of equipment (Figure IV-1), including steam generators which weighed 220 tonnes each
(Figure IV-2), the pressurizer (103 tonnes), the reactivity mechanisms deck (43 tonnes), feeder frames
(40 tonnes each), fuelling machine bridges (16 tonnes each) and major heat exchangers. It took just
two days to install each steam generator instead of the two weeks required for traditional horizontal-
access installation.

FIG. IV-1. Very heavy lift crane at Qinshan, China.

 Page 3

FIG. IV-2. Installing a steam generator at Qinshan 3-1 in China

Figure IV-3 shows a VHL crane lifting the 200-tonne containment liner double rings into place at
Olkiluoto-3 in Finland, and Figure IV-4 shows the containment dome at Kudankulam-1 in India being
lifted into position.

FIG. IV-3. Lifting the containment liner double rings at Olkiluoto-3 in Finland.
Page 4

FIG. IV-4. Lifting the WWER-1000 containment dome into position at Kudankulam, India (Photo
credit: NPCIL).

During the construction of Tarapur-3 and -4 in India, open top installation was used to position about
50 pieces of equipment, including the steam generators (Figure IV-5), moderator heat exchangers,
several other heat exchangers, pressurizer, calandria (Figure IV-6), primary circuit headers and
fuelling machine. The lowering and positioning of each steam generator was completed in less than a
day, much less than the installation time of more than one month required by other methods.

FIG. IV-5(a) and IV-5(b): Installing a steam generator at Tarapur-3, India.

 Page 5

FIG. IV-6. Lifting the calandria at Tarapur-3 in India.

C. Modularization with Prefabrication and Pre-assembly

Prefabrication and pre-assembly of modules are construction techniques used in many industries,
including nuclear power plants. A module is an assembly consisting of multiple components such as
structural elements, piping, valves, tubing, conduits, cable trays, reinforcing bar mats, instrument
racks, electrical panels, supports, ducting, access platforms, ladders and stairs. Modules may be
fabricated at a factory or at a workshop at the plant site, and multiple modules can be fabricated while
the civil engineering work is progressing at the site in preparation for receiving the modules. This
reduces site congestion, improves accessibility for personnel and materials, and can shorten the
construction schedule. It can also significantly reduce on-site workforce requirements.

Modularization also facilitates mass production of modules in the event that several reactors are being
built at the same time. Mass production reduces production times and labour requirements.
Modularization makes it easier to assure a controlled production environment, with associated
improvements in quality and efficiency. It makes it possible to manufacture modules before the site
itself is available, and, in the case of concrete, it facilitates the use of accelerated curing techniques.

The decision to apply a modular approach should be made in the conceptual design stage, and then it
must be followed throughout the project, for detailed design, engineering, procurement, fabrication,
and installation, through to the completion of commissioning. This allows equipment to be designed
to conveniently fit into a module, and for modules to be sized to match the capacity of VHL cranes
and transport routes to the site. A site accessible by sea can accept larger modules. For less accessible
sites, sub-modules can be shipped to the site and then assembled into larger modules before
installation. Modularization also affects testing procedures as many components can be initially tested
at the fabrication facility to help eliminate potential faults before formal post-installation tests at the
construction site.

Other impacts of modularization are: the need to complete the total plant design before fabricating
modules; the need for factories or workshops to fabricate modules; earlier expenditures on
Page 6

engineering, materials and components for fabricating modules; the need for expensive heavy lift
cranes; and the costs of transporting modules.

Modularization with prefabrication and pre-assembly has been used in combination with open top
construction in recent construction projects for evolutionary water cooled reactors [1]. At Kashiwazaki
Kariwa-7 in Japan the seven floors of the reactor building were divided into three modules and
fabricated in a pre-assembly yard before the pieces were successively lifted into place by a VHL
crane. The heaviest, most complicated module was the ‘upper drywell super large scale module’ which
consisted of a γ-shield wall, pipes, valves, cable-trays, air-ducts and their support structures and
weighed 650 tonnes (Figure IV-7).

FIG. IV-7. Installing the upper drywell super large scale module at Kashiwazaki Kariwa-7 in Japan.

At Lingao-4 in China the containment dome was assembled on the ground at the site and installed as a
single module weighing 143 tons with a diameter of 37 metres and height of 11 metres (Figure IV-8).
Previously, the dome would have been assembled by moving sections into position – a process that
normally took about two months.

FIG. IV-8. Lifting the dome module into place at Lingao-4 in China.
 Page 7

The Shin-Kori-1 and -2 projects in the Republic of Korea modularized the fabrication and installation
of the containment liner plate. This forms the inner structure of the containment building for the
Korean Optimized Power Reactor. Normally, the installation process would have fifteen stages, each
involving the installation of one containment liner plate ring. At Shin-Kori-1 and -2, except for the
first ring, all the other rings were modularized into two-ring sections and installed with one lift for
each section (Figure IV-9). The number of lifts is reduced, and the overall construction period is
shortened. This method also simplifies connections with auxiliary buildings since connecting
provisions, such as penetration sleeves for piping and electrical wire, are attached to the ring modules
before installation.

FIG. IV-9. Modularization of the containment liner plate assembly at Shin-Kori-1 in the Republic of
Korea.

As a final example of modularization, at Tarapur-3 in India, the prefabrication of piping was increased
to 60–70%, compared with approximately 40% for previous plants in India. This reduced field
welding by 30–40%.

D. Advanced Welding Techniques

Nuclear power plant construction involves numerous welds to connect both components of structures
and components of pressurized systems. It also involves weld cladding, which refers to one metal
being deposited onto the surface of another to improve its performance characteristics. Quality
welding is both crucial and time consuming, and techniques to increase the rate at which weld metal
can be deposited while maintaining high quality can reduce construction times. Recent advanced
welding technologies that meet this objective include gas metal arc welding, gas tungsten arc welding
and submerged arc welding.

In addition, automatic welding equipment that makes it easier to weld in narrow spaces can further
decrease construction times. Automatic welding equipment has been used to weld titanium tubes to
condenser tube sheets at Tarapur-3 in India and to weld piping at Kashiwazaki Kariwa-7 in Japan
(Figure IV-10).
Page 8

FIG. IV-10. Automatic piping welding at Kashiwazaki Kariwa-7 in Japan.

E. Steel Plate Reinforced Concrete and Slip-forming

Reinforced concrete is used in the foundations of nuclear power plants and in structures such as
reactor containments, auxiliary buildings, turbine buildings and spent fuel storage areas.
Conventionally reinforced concrete is fabricated in place using reinforcing bars (‘rebar’) with external
forms to frame the structure prior to pouring the concrete. The time required to place the reinforcing
bars and to construct and remove the forms into which the concrete is poured is considerable. It is a
major part of the construction schedule.

Steel plate reinforced concrete is an alternative to conventionally reinforced concrete [6] and can be
used for most floors and walls. The concrete is placed between permanent steel plate forms with welds
to tie the steel plates, rebar and tie-bars together. The forms can include any necessary penetrations
and piping runs. Because of structural credit for the steel plate–concrete combination, the amount of
rebar may be reduced, and because the steel plate structure can be self-supporting, reinforced concrete
sections can be modularized and prefabricated off-site, followed by placement and welding on site.

Figure IV-11(a) shows standard reinforced concrete, and Figure 11-IV(b) shows steel plate reinforced
concrete.

FIG. IV-11(a): Reinforced Concrete

 Page 9

FIG. IV-11(b). Steel Plate Reinforced Concrete

FIG. IV-11. Comparison of reinforced concrete structures

Steel plate reinforced concrete has been used to significantly shorten construction schedules at plants
recently constructed in Japan.

Construction schedules can also be shortened by slip-forming with modular floor design technology.
Slip-forming is the continuous pouring of concrete at a very specific, calculated and monitored rate
that is achieved by continuous hydraulic lifting and moving of a short section (preferably less than two
metres) of formwork while inserting steelwork and pouring concrete through the top. Using slip-
forming, vertical walls can be constructed at a rate of about two metres per day compared to a typical
value of 1.2–1.5 metres per day without slip-forming. Slip-forming requires a heavy lift crane to lift
the heavy steelwork that is inserted while the concrete is being poured.

Modular floor design and installation are used in conjunction with slip-forming for the walls. After the
outer vertical walls of a building are installed by slip-forming, the modular floors can be installed
through the open top of the building by means of a heavy lift crane. Modular floors consist of steel
modules, which include rebar but no concrete, that are placed on supports embedded in the concrete
walls during the slip-forming process. The modular floors, which are designed to be transported from
the site assembly shop and installed by cranes, are welded to the supports embedded in the walls and
then filled with concrete.

F. Rebar Placement for Reinforced Concrete

Rebar installation by individual placement of bars is quite time consuming. Large amounts of rebar are
needed in the base mat, containment walls, containment dome, and structural walls of the reactor and
turbine buildings. The use of prefabricated modular rebar assemblies for these areas can shorten
construction schedules.

Automation is another way to speed the installation of rebar. There are several techniques.
Figure IV-12 shows an automatic scaffold that moves vertically while horizontally feeding rebar into
Page 10

place. It both speeds the process and reduces labour requirements. Figure IV-13 shows a machine that
automatically assembles rebar according to instructions from a 3-dimensional computer design model.

FIG. IV-12. An automatic scaffold and horizontal rebar feeding machine at Kashiwazaki Kariwa-6 in
Japan.

FIG. IV-13. An automatic rebar assembly machine at Kashiwazaki Kariwa-7 in Japan.

G. Advanced Concrete Composition

In addition to these advanced methods for pouring and installing concrete, there have been recent
advances in the composition of concrete to improve strength, workability, and corrosion resistance.
Examples are self-compacting concrete, high performance concrete and reactive powder concrete.
These are used not only in nuclear power plants but in other large civil projects such as bridges,
highway, large buildings and dams.
 Page 11

H. All Weather Construction and Working around the Clock

To ensure that work can continue in all weather conditions, an all weather cover dome can be put over
the reactor building. This method was used, for example, at Kashiwazaki-Kariwa-6 in Japan.

Working around the clock, both indoors and outdoors (see Figure IV-14), can save considerable time
at critical stages of construction, for example during excavation, concrete pouring, structural steel
erection, calandria vault construction and various welding activities.

FIG. IV-14. Night view of site activities at Tarapur-4 in India.

I. Bending Small Bore Pipes to Reduce Welding Requirements

For small bore pipes, elbow fittings and their associated welds can be eliminated by forming bends
within pipe lengths. Although the bending operation introduces costs of its own, the benefits include
time and labour savings through reduced welding requirements and, because there are fewer welds to
be inspected later, reduced inspection requirements.

J. Advanced Excavation Methods

Advances in excavation that can be applied to nuclear power plants include new equipment, such as
large excavators designed for heavy workloads, massive grading and material handling, and large
equipment for vibratory soil compacting. They also include precision blasting for excavating rock,
which can reduce costs relative to more conventional mechanical excavation methods, for the reactor
building, turbine building and other buildings. Several shafts are drilled in a precise pattern in the
required area to be excavated and filled with explosives, which are then detonated. The possibility of
Page 12

using precision blasting depends on a site’s geology and the plant’s design as well as applicable
regulations governing blasting.

K. Cable Installation

The installation of cables takes a significant amount of time and can be part of the critical path. ‘Cable
pulling’ is the term used for the process of installing cables in cable trays (conduits) to connect plant
equipment to power sources. The conventional method involves applying a lubricant to a cable (or
group of cables) and pulling them into place with a rope. Improvements in this method involve better
lubricants and cable rollers. Another technique reduces the need for cable pulling by splicing together
the ends of cables that pass through different modules. Such splicing techniques are well established in
the ship building industry.

L. Area Completion Schedule Management

The area completion schedule management method has been applied in the Republic of Korea at Shin-
Kori-1 and -2. This approach replaces design and procurement schedules that used to progress system
by system or, for a given building, floor by floor with an approach that divides each level of each
building into zones. This allows more detailed scheduling of material purchase and the issuance of
construction drawings to best integrate requirements in all zones. The approach is also used to
schedule integrated installation work and set priorities among civil, mechanical, electrical and other
needed work in each zone.

M. Computer Systems for Information Management and Control

The use of computer systems for information management and control is well established in the
design, engineering and construction of large projects including power plants. For nuclear power
plants the design and construction information must be maintained throughout the life of the plant
including decommissioning. Computerized databases centralize all design information and allow quick
access by all parties to design and construction drawings, equipment specifications, and inspection and
testing data. The benefits of computerized information management and control systems are that they
improve productivity through concurrent engineering, procurement and construction; allow drawings
to be revised and accessed electronically; facilitate accurate determination of material quantities; and
facilitate efficient procurement and construction management.

Such integrated systems can be used to develop 3-D models of:

• engineered piping and in-line piping components such as valves and strainers,
• raceways,
• structural steel,
• concrete,
• heating, air conditioning and ventilation components,
• equipment (tanks, pumps, heat exchangers, etc.),
• piping supports,
• piping and instrumentation diagrams, and
 Page 13

• embedded parts and plates.

Such 3-D computer models can then be linked to the schedule to provide ‘4-D modelling’. Specific
deliverables at any stage can be extracted from the computer assisted design drawing model, including
piping system isometric drawings, general arrangement drawings, and materials quantities, and the
overall installation plan can be more easily visualized. During operation such models can be used to
train operators and system engineers and to help nuclear safety engineers to visualize systems when
evaluating performance and safety issues. For nuclear power plants, the system can also be expanded
to track the inspections, tests, analyses and acceptance criteria that must be applied during construction
to meet regulatory requirements.

N. Summary

The construction methods available for new nuclear power plants are generally the same as those used
for other large construction projects. There have been numerous improvements in construction
methods in the past few years, and recent experience in nuclear power plant construction has shown
that those advanced methods are fully applicable and can help shorten construction schedules. Recent
nuclear construction projects have been completed in as little as four years. The decision to apply
some of these methods must be made in the conceptual design stage and then followed through
consistently. Some advanced construction methods require earlier investments for factories and
workshops and earlier outlays of funds to purchase materials, although they later save time and labour.
Thus a shorter schedule does not necessarily mean lower total costs, and the relative costs and benefits
for each of the methods summarized here must be weighed for each project independently.

REFERENCES

[1] INTERNATIONAL ATOMIC ENERGY AGENCY, Construction and commissioning experience

of evolutionary water cooled nuclear power plants, TECDOC-1390, IAEA, Vienna (2004).

[2] Application of Advanced Construction Technologies to New Nuclear Power Plants, MPR-2610
(2004), prepared for the US Department of Energy.

[3] INTERNATIONAL ATOMIC ENERGY AGENCY, Improving economics and safety of water
cooled reactors: Proven means and new approaches, TECDOC-1290, IAEA, Vienna (2002).

[4] OECD NUCLEAR ENERGY AGENCY, Reduction of the Capital Costs of Nuclear Power Plants,
OECD, Paris (2000).

[5] CHEN, S., IVANOV, A., KHAN, A., PETRUNIK, K., RICIUTI, R. AND WITTANN, K.,
Qinshan CANDU Project Open Top Construction Method, Proceedings of the 24th Annual Conference
of the Canadian Nuclear Society, Toronto, Ontario, Canada, 8–11June 2003.

[6] A. OMOTO, TOKYO ELECTRIC POWER COMPANY, Improved Construction and Project
Management, International Conference on Advances in Nuclear Power Plants (ICAPP) (2002).
 600MW Coal Based Thermal Power Project
at Butibori, Nagpur, Maharashtra, India

Butibori Location Details:

 (A) About 600 MW Butibori Power Project:

Vidarbha Industries Power Limited (VIPL) subsidiary of Reliance Power Limited has
implemented India's most compact coal based power project at MIDC Area of Butibori, Nagpur.
The EPC Contract for the Project was placed between VIPL and Reliance Infrastructure Limited.
Reliance Infrastructure Limited has appointed DCPL a renowned engineering consultant as
main engineering consultant for the Project.

(B) Project details:

Project Capacity : 600MW

Module Configuration : Two Units of 300MW nominal Capacity.

Major Equipment Suppliers & Contractors:

• Steam Turbines, Generators and Auxiliaries - M/s Shanghai Electric Corporation, China.
• Boiler, ESP and auxiliaries - M/s Shanghai Electric Corporation, China.
• Condenser and Auxiliaries- M/s SEC,China
• Induced Draft Cooling Towers.- M/s Pahargpur Cooling Towers Ltd
• GIS - M/s Xian Electric, China
• Generator Transformers- M/s Alstom T&D India Ltd
• Major Civil Contractors - M/s JMC projects, M/s KT, M/s KM,M/s Mall and M/s D P Jain.
• Major Mechanical Contractors-M/s Sunil Hitech Ltd for TG & TG Auxiliaries, ESP and
Structure Erection, M/s IOTEP for Boiler, M/s Thermax for Water System
• Major Electrical & instrumentation Contractor-M/s TICB and M/s Honeywell Automation.
• Major CHP Contractor -Supply and Erection by M/s NHI, China.

Power Evacuation : Power Evacuation at 220KV Level through 2x220 kV DC

Transmission line from Butibori 220 KV switchyard to
MSETCL 220 KV substation 1 and 3 at Butibori, Nagpur.

Water Conveyance : Raw Water intake from Wadgaon Dam on Venna river
Approximately 18 km from site.

Fuel Supply : Domestic Coal supply is from WCL coal mines near
Chandrapur/wardha and imported coal from Indonesia.
(C) Project Highlights:

• Boiler Light UP- Boiler Light up of Unit #1 & 2 achieved in 18.5 Months & in 21 months
from the start of structure Erection respectively.

• Unit Synchronization- First Unit was synchronized in record time of 21.5 Months from
start of structure Erection i.e. on 25th June, 2012. Second unit was synchronized on 2nd
January, 2013.

• Commercial Operation Declaration- COD of Unit#1 and Unit# 2 were declared on 4th
April ,2013 and 28th March,2014 respectively.

(D) Project Innovation and Uniqueness:

• One of the innovative method implemented for Butibori Project was to design and
construct a Ash Dyke in a area of 39 Acres in a concrete type construction using
available rock within the plant as against the conventional method of earthen
embankment requiring huge land.

• Civil Construction work of 17 KM Railway Siding for Coal transportation with take off
point from Sindhi Railway Station on Nagpur- Wardha main line to Butibori Power
Station was the biggest challenge faced and unique for Butibori TPP. The elevation
difference of 45 mtrs between the take off point at Sindhi railway station and power
plant. The scale / volume of the works involved in construction of entire Railway Siding
includes, 44 Lac Cum of earth for embankment of height 13-15 mtrs.. 50 nos. of Minor
Bridges and 3 nos of Major bridges for crossing River, Nallah and State Highway.

• Dumper Mounted On Rail Wheels-The coal for operation of 2x300 MW Butibori Power
Plant is coming via rail wagons. The rail connectivity is arranged from Sindi station of
Central Railway (situated between Nagpur and Wardha stations). The entire Railway
Siding from Sindi Station to Power Plant is of 17 km route length. The topography of
siding is such that, (i) there is a elevation difference of 45 m between Sindi station &
Power station (ii) it crosses various natural streams, Roads, Highway, Transmission Line
and hence, 3 nos. of Major Bridges & 50 nos. of Minor Bridges are constructed and (iii)
Earthen embankment height varies from 1m to 15 m. The huge height of embankment
resulted in to restriction of transportation of Railway Material (Rails, Sleepers and
Ballast) from Ground Level to top of embankment. This problem was resolved by an
innovative idea of transporting the ballast through a “Dumper mounted on Rail Wheels”.
The rubber Tyres of Dumpers were removed and Rail wheels were fitted. This diesel
driven arrangement can move horizontally from one place to another and can carry
about 6 cum of Ballast at one time. The ballast is loaded in this dumper, at the place,
where embankment is generally matching with ground level. This innovative mechanized
arrangement has not only saved huge Manpower, but also Time & Cost in Hauling of
Ballast.
(E) Plant Optimization:

• Ash Dyke is constructed in Plum Concrete by using free rock of 40000 Cum, which
became available from excavation from other facilities of the project. This has resulted in
to maximizing the storage capacity in given land area and cost savings to the tune of
Rs.14 Crores.
• Maximized Utilization of Fly ash in RMC production. Fly ash is used as partial
replacement of cement to the tune of 30% in all structures including TG foundation
(except Chimney), which saved Rs 4.5 Crs on cement purchase.

• Selection of Chimney with Brick Flue instead of Steel Flue resulting in to cost savings of
Rs.3.42 Crores

• Selection of Generator Circuit Breaker scheme instead of conventional design of

provision of two Station Transformers resulted in saving of around Rs 3.0 Crs.

• Accurate estimation in our projection of TMT, Structural Steel and cement in the initial
stage of project: 100% utilization of TMT & structural steel (Total wastage less than
standard defined wastage norms).

• The Butibori Thermal power plant is most compact-sized thermal plants in the country
with its 600 MW capacity requiring not more than 280 acres of plant land. The per
Megawatt land use at Butibori TPP is one of the lowest when compared to similar plants
in India and abroad.
(F) Butibori Views:
Overall Plant View:
 Project Management
By

Prof Sanjay Kumar

B.E ( Mech Engg)

MBA ( Dual Specialisation Project Management & International
Business) OCES ( BARC) : Nuclear Projects
Certificate in Strategic
Management Professor of Practice
Board of Directors of Corporates
Presentation Flow?
What is project management
Project planning
Project cost management
Project quality management
Project communication management
Best project management tools

Project manager roles and responsibilities

 Fundamental Terms for Project Management:
[Link] Status:
RAG is a project status indicator that indicates the overall health of a project, with red indicating
critical issues, Amber indicating potential concerns, and green indicating progress.

2. Work Breakdown Structure (WBS):

Hierarchical decomposition of project scope involves breaking down deliverables into smaller,
manageable components for better planning and control.

3. Gantt Chart or Schedule:

Gantt charts are visual project schedules that display tasks, durations, dependencies, and
milestones over time, aiding project managers and teams in understanding work sequence and
identifying scheduling conflicts.
4. Triple Constraint:
The project management triangle, also known as the scope, time, and cost constraints,
outlines how any change in one constraint will affect the other two.

[Link]:
Project management is a structured approach, encompassing methodologies like Agile,
Waterfall, Scrum, and PRINCE2, each with its unique principles, practices, and processes.

6. Business Case:
A project justification document outlining project purpose, benefits, costs, risks, and
alternatives helps stakeholders understand the project's rationale and decide whether to
proceed.
7. Requirements:
Requirements are specific criteria that define the success of a project, including
functional capabilities, performance criteria, constraints, and quality standards.

8. Risk:
Risk management involves identifying, assessing, and mitigating uncertain events
or conditions that could impact a project's objectives to minimize their impact.

9. Issue:
An unplanned event or problem that arises during the execution of a project and
requires immediate attention to prevent or minimize its impact on project outcomes.
Issues are typically logged, tracked, and resolved as part of project management
processes.
[Link]:
Milestones are significant events or achievements in a project that indicate key progress
points or major deliverables, helping track progress and ensuring stakeholder
satisfaction.

[Link]:
Stakeholders are individuals, groups, or organizations who have an interest or influence in
a project and its outcomes, including sponsors, customers, team members, regulators,
and others.

[Link] Committee:
A group of senior stakeholders responsible for providing oversight, guidance, and direction
to a project. The steering committee ensures alignment between the project's objectives
and organizational priorities, and helps resolve major issues or conflicts.
 Project Management
Introduction & Definition of Project Management
Project management involves planning, organizing, and managing resources to achieve
specific objectives within a defined scope, budget, and timeframe, coordinating tasks,
activities, and stakeholders for efficient completion.

Importance of project management in achieving organizational goals

Alignment with Strategic Objectives
Resource Optimization
Risk Management
Stakeholder Engagement
Performance Measurement and Evaluation
 Project Planning
Project planning is a crucial phase in the project management process where you define the
scope, objectives, and actions needed to achieve a specific goal within a specified time
frame.
Importance of project planning

Clarity of Objectives
Resource Allocation
Risk Management
Time Management
Cost Management
Steps involved in project planning:
Initiation,
Planning
Execution
Monitoring & Controlling
Closing

Tools used in project planning:

Gantt charts
Work Breakdown Structure
Network diagrams
 Project Cost Management
Project cost management involves planning, estimating, budgeting, financing, managing, and
controlling costs to ensure project completion within the approved budget. .

Components of project cost management:

Cost Estimation Cost Control
Cost Budgeting Cost Forecasting

Techniques for cost estimation:

Analogous Estimation Parametric
Estimation
 Project Quality Management
Project quality management ensures a project meets stakeholder standards by planning,
implementing, and controlling activities throughout its lifecycle. It identifies quality criteria,
establishes objectives, performs quality assurance, and monitors deliverables to improve
customer satisfaction and project success. .

Components of quality management:

Quality planning
Assurance
Control processes
 Project Communication Management

Project Communication Management is a crucial aspect of project management, involving

systematic planning, execution, monitoring, and control of communication processes
throughout the project lifecycle, ensuring stakeholders have access to the right information.

Importance of effective communication in projects:

Clarity of Objectives Problem-Solving

Coordination and Collaboration Stakeholder M anagement
Key components within project
communication management:
Communication planning
distribution
performance reporting
Change Management

Tools for project communication:

Email
M eetings
Project Management Software
 Best Project Management Tools

Project management tools are software applications that aid project managers in efficiently
planning, organizing, tracking, and executing tasks, offering features like task scheduling,
resource allocation, budget management, communication, collaboration, and reporting.

Common project management tools include:

Trello:
A visual project management tool based on boards, lists, and cards, allowing teams to
organize and prioritize tasks in a flexible and intuitive way.
 Asana:
A comprehensive project management tool that enables teams to manage tasks, projects, and
workflows with features like task assignment, due dates, dependencies, and project timelines.

Microsoft Project:
A powerful project management software that offers tools for project planning, scheduling,
resource management, and collaboration, suitable for large-scale projects with complex
dependencies.

Jira:
Primarily used in software development projects, Jira facilitates issue tracking, bug tracking,
and agile project management through customizable workflows and extensive reporting
capabilities.
Considerations for selecting the right tool for
the project:

Project Requirements
Technology Stack
Scalability
Ease of Use and Learning Curve
Security
Vendor Reputation
 Project Manager Roles and Responsibilities

A project manager plays a crucial role in overseeing the planning, execution, and completion
of a project. Their responsibilities encompass various aspects of project management,
including communication, coordination, and leadership.

Project manager's roles and responsibilities:

Project Planning Team Leadership

Stakeholder M anagement Risk Management
Resource Allocation Quality Assurance:
Crucial skills Project Manager
Decision-making:

Identify the problem: Clearly define the issue or decision that needs to be made.
Gather information: Collect all relevant data and information related to the decision.
Generate alternatives: Brainstorm different options or solutions to address the problem.
Evaluate alternatives: Assess the pros and cons of each alternative based on criteria
such as feasibility, cost, and impact.
Make the decision: Choose the best alternative based on the evaluation process.
Implement the decision: Take action to put the decision into effect.
Evaluate the outcome: Monitor the results of the decision and make
adjustments as necessary.
Risk management:

Identify risks: Anticipate potential risks that could impact the project's objectives.
Assess risks: Evaluate the likelihood and potential impact of each risk.
Develop risk response strategies: Determine how to mitigate, transfer, accept, or
avoid each identified risk.
Implement risk response plans: Put strategies in place to address and manage
identified risks.
Monitor and control risks: Continuously monitor the project for new risks and assess
the effectiveness of risk response plans.
Adapt as necessary: Adjust risk management strategies as the project progresses and
new information becomes available.
Conflict resolution:

Acknowledge the conflict: Recognize that there is a disagreement or conflict that needs
to be addressed.
Listen actively: Hear out the concerns and perspectives of all parties involved in the conflict.
Identify underlying issues: Determine the root causes of the conflict and what each
party's interests and needs are.
Explore solutions: Brainstorm possible solutions that address the interests of all parties.
Negotiate a resolution: Work together with the involved parties to find a mutually
acceptable solution.
Implement the resolution: Put the agreed-upon solution into action.
Follow up: Monitor the situation to ensure that the resolution is effective and address
any lingering issues.
Interdisciplinary Nature of Modern Construction Project

Urban built environment in 21st century is focusing on various infrastructural aspects like
commercial buildings, metros, airports etc.

Accordingly, modern infrastructure projects are getting increasingly interdisciplinary

(multidisciplinary) in nature in that they span several disciplines of engineering.

As a manager of these projects, a certain level of awareness and knowledge of diverse

issues is required.
 Interdisciplinary Nature of Project

Illustrative Civil Mechanical Electrical

Examples Engineering Engineering Engineering

Metro construction
project

Automobile Plant

Transmission
line project
Breaking Down a Metro System Into Components
Civil Structures
Buildings
Stations
Tracks
Maintenance Yards
Tunnels
Operations rooms/offices
Bridges
Track
Rolling Stock
Undergroun
Coaches
d On-grade
Locomotives
Above Grade
Control & Monitoring
Systems
Station Maintenance Yard

Operation
Rooms/
Offices
Under- ground Above grade track
track
Other Important Components in a Metro System

Power Supply Lighting

Signaling Ventilation

Ticketing Communication
Air-Conditioning
Emergency Management
Power Supply Fire
Fighting
 Food For Thought

Find out the different cities in the world with well developed metro
system
Study the details of metro system in any three cities. Details may include
the following:
Important stations in the network,
Total length of the metro
Total number of special structures,
Average passenger traffic in a day
 STAGES IN A PROJECT

Concept

At the concept stage there is

Planning Scope of
a “requirement’ and
the
(tentative) location.
a basic survey plan is also Designing present
needed addressing applicable course
bye laws, constraints, soil
condition, etc. Execution

Operation

Decommissioning
 Concept of project

Preparation of PRELIMINARY ESTIMATE

Administrative approval and financial sanction

Planning & detailed design

Preparation of DETAILED ESTIMATE

Final approval and technical sanction

Identification of agency to execute job (Notice Inviting Tender, NIT)

There should be transparency in processes to make sure that the funds are being
used appropriately and effectively.

Procedures should be such that responsibility and accountability can be appropriately

fixed at even a subsequent point in time.

The details being discussed in these lectures are by nature of general discussion, and
different organizations could have their own specific procedures. At times, the
discussion could also be 'theoretical' to the extent that it is not really practiced in
the industry !!
 TENDER

Written offer to execute specified work within a certain time under certain
conditions of contract between the contractor and the client for a certain amount of
money

NOTICE INVITING TENDER

Public document announcing a work, and inviting interested parties to 'bid".

Details of the conditions of the work are also
either indicated, or, the method of obtaining them is given.
Depending upon the scale (estimated cost),the level of circulation could be different.
 General Contents of an NIT

Name of the client inviting tender

Pre-qualifications (if any)
Nature of work
Estimated cost
Time of completion
Conditions while undertaking contract
General conditions of contract (GCC)Special conditions of contract (SCC)
Details of Earnest Money Deposit (EMD)
Details of security deposit (SD) and performance guarantee Last date
(time) for submission
Date, time and place of tender opening
Earnest Money Deposit
NIT
Performance Guarantee
Security Deposit
At the time of bidding, contractor deposits the Earnest Money deposit (say about 2%
of cost put to tender), with the client, as guarantee for 'earnestness' of the bid
. The EMD of bidders other the successful ones is returned after the bids have
been opened.
. The EMD may be forfeited by the client if any bidder wants to withdraw the bid
after opening
The successful bidder is issued an LOI and asked to furnish performance Guarantee
(related to the actual amount of award)before the 'agreement' is signed.
 Letter of Intent and Performance Guarantee

Through the NIT, the client identifies the agency to whom the works to be awarded and
issues a Letter of Intent (LOI) asking the bidder to deposit a 'performance guarantee'
(say 5% of the award value)
mobilize and commence work (the date of commencement is defined in the LOI)
This performance guarantee is released after the issue of the completion certificate
by the client, if the performance (time etc.)during the execution is found satisfactory
 Security Deposit

Security Deposit is a deposit with the client for any repair of the work during the
defect liability period (if the contractor fails to rectify the defect).
The client creates this fund by deducting (say 10%) from each running account
(RA) bills. There may be an upper limit on the amount to be retained in this form
(say 5%of the project cost)
At any point during the project, the client has access to the Performance
Guarantee and a certain amount of the SD
The SD is refunded after this defect liability period has lapsed (and no defect is
pending for rectification)
 Evaluation of bids and identification of 'contractor’

The bids may be evaluated on the basis of lowest cost alone.

In some cases, technical competence, financial soundness, safety record, etc. may
also be a part of the evaluation process. This can be done by an 'empanelment' or
submission of appropriate documents
Bids are invited in two parts technical and financial bids, which are opened
separately.
Financial bids are usually opened for only those bidders which 'qualify'
technically.
Evaluation could be based
[Link] on cost (for technically qualified bidders), or,
[Link] score based on evaluation of technical and financial bids
 NIT

Evaluating bids based on bidding criteria

Award of job and signing of contract

Mobilization Advance

Starting the construction work

After thorough document verification (past record, financial details, etc.)

Mobilization advance: Given to the contractor by client to initiate the
construction activities at site. It is recovered from Running Account bills.
No advance should be given without a supporting guarantee
Construction projects may go on for long periods of
time. Therefore,
The contractor will need to be 'paid' periodically
for parts of the work completed
There is a often a provision for 'escalation' in
agreed prices
Critical items, such as cement and steel, could be
made available by the client at a fixed rate with
some conditions
 Different types of contract

Lump sum
Turnkey
Item rate
Build, own, operate and transfer
(BOOT)
Engineering Procurement and
Construction (EPC)

Food for thought

[Link] out more about these types of contracts. (It will help if you keep a specific (simple)
project in mind.)
2. List some examples of each of the above contracts from information available.
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