You are on page 1of 40

ESSAR PROJECTS (I) LTD SUMMER INTERNSHIP

PLANNING, SCHEDULLING, MONITORING,


CONTROLING OFCOOLING WATER SYSTEMS 2 FOR
DELAY COKER UNIT

By

ABHAY YATIN NAIK


SHILPA KURVA
PGP ACM NICMAR PUNE. PGP
ACM NICMAR HYDERABAD.

(2009- 2011)

UNDER THE GUIDENCE OF

MR. ANIL KUMAR

JOINT GENERAL MANAGER

ESSAR PROJECTS (I) LTD. VADINAR

NATIONAL INSTITUTE OF
CONSTRUCTION
MANAGEMENT AND RESEARCH

NICMAR, HYDERABAD
ESSAR PROJECTS (I) LTD SUMMER INTERNSHIP

D ECLARATION

I declare that the thesis entitled “PLANNING, SCHEDULING AND

MONITORING OF COOLING WATER SYSTEMS FOR DELAY COKER

UNIT” is the bona fide work carried out by me, under the guidance of Mr. MR.

ANIL KUMAR. Further I declare that this has not been previously formed the

basis of award of any degree, diploma, associate-ship or other similar degrees

or diplomas, and has not been submitted anywhere else.

NICMAR, HYDERABAD
ESSAR PROJECTS (I) LTD SUMMER INTERNSHIP

ACK

I extend my heartfelt gratitude andt


for his valuable guidance, constru
work.

I express a deep sense of gratitud


Jethwa, Mr. Girish Nandedkar, M
unfailing support and channelling o
CH 6. CONCLUSION:

NICMAR, HYDERABAD
ESSAR PROJECTS (I) LTD SUMMER INTERNSHIP

1. HISTORY OF ESSAR

Essar began as a construction company in 1969 and diversified into manufacturing, series and retail.
Over the last decade, it has captured new markets and discovered new sources for raw materials
tthrough strategic global acquisitions and partnerships, or through Greenfield and Brownfield
development projects.

The Essar Group is a multinational conglomerate and a leading player in the sectors of Steel, Energy,
Power, Communications, Shipping Ports & Logistics, Construction and Mining & Minerals. With
operations in more than 20 countries across five continents, the group employs 60,000 people, with
revenues of about USD 14 billion in 2008-09.

NICMAR, HYDERABAD
ESSAR PROJECTS (I) LTD SUMMER INTERNSHIP

Industry Conglomerate

Founded 1969

Founders Shashi Ruia

Ravi Ruia

Headquarters Essar House, 11 Keshavrao

Khadye Marg, Mahalaxmi

Mumbai, India

Area Served Worldwide

Key people Shashi Ruia (Chairman)

Ravi Ruia (Vice-Chairman)

Prashant Ruia (Director)

Anshuman Ruia (Director)

Smiti Kanodia (Director)

Rewant Ruia (Director)

Products Steel

Oil

Power

Mobile networks

Engineering Procurement

Construction

NICMAR, HYDERABAD
ESSAR PROJECTS (I) LTD SUMMER INTERNSHIP

2. BRIEF ABOUT ESSAR PROJECTS

PROJECTS

Essar Projects, the Group's foray in the Construction sector, is one of India's largest full-service
Engineering, Procurement and Construction (EPC) providers. It has built most of Essar's and some of
India's finest industrial assets. Today, Essar Projects offers strong capabilities in engineering,
sourcing, construction, fabrication and project management to both the Essar Group and the outside
world. The Projects business continues to play a key role in each of the Group's new projects around
the globe. Concurrently, it is expanding its third-party client base, especially in pipelines, marine
construction, heavy engineering and project management consultancy, as well as beyond into full
EPC for the oil & gas, power and heavy industry sectors. Essar Projects Ltd was formed by the Essar
Group in the year 2000. Before EPL was formed, Essar Constructions India Ltd, another group
company of the Essar Group, was involved in construction of steel plants, power plants, refinery and
other industrial structures. ECIL has been executing construction-related projects since 1990 in the
areas of Plant Construction, Marine Construction, Pipelines, Jetties, Cross Country Canals,
Underwater Dredging and Rock Blasting for the Essar Group as well as for outside companies. EPL
which was mainly floated in order to pursue the Engineering, Procurement and Construction (EPC)
projects outside the Essar Group on cash basis or on a Build-Own-Transfer (BOT) basis.

CONSTRUCTION

The construction arm of the business has four decades of experience executing complex projects in
the areas of industrial plants, civil and irrigation projects, pipe laying (offshore and onshore), highways
and expressways, in addition to constructing almost all of the Essar Group's assets. This business
also owns one of Asia's largest banks of construction equipment.

MARINE CONSTRUCTION

The marine construction business provides Engineering, Procurement, Construction & Installation
(EPCI) services in domestic as well as overseas markets. In the high-growth oil & gas sector, the
business provides EPC services for offshore logistics support and marine construction projects.

HEAVY ENGINEERING

The Heavy Engineering Services vertical has world-class facilities for manufacturing a range of heavy
equipment, like pressure vessels, reactors, vacuum vessels and cranes, with an overall capacity of
12,000 tons per annum. The facility is strategically located at Hazira (Gujarat, India) on the banks of
river Tapi, and has its own jetty for sea transport.

PROJECT MANAGEMENT CONSULTANCY

The Projects business has an independent team of Project Management Consultants bringing
excellence to all the processes of project execution. While serving as consultants to Essar Projects'
new and upcoming assignments for the Group, this team has also extended its reach to assignments

NICMAR, HYDERABAD
ESSAR PROJECTS (I) LTD SUMMER INTERNSHIP

for third-party projects.

ENGINEERING AND PROCUREMENT SUPPORT

Essar Projects is supported by a dedicated Engineering Centres specializing in Engineering and


Design for the Process and Industrial sectors. It also has global procurement support in India, Middle
East, China and the Czech Republic.

Vision

“To be a Global Engineering, Procurement & Construction Contracting Company”

Mission

“To achieve excellence in the field of Engineering, Procurement & Construction through world class
practices and standards in Quality, Safety & Project Management”

ORGANISATION BREAKDOWN STRUCTURE:

NICMAR, HYDERABAD
ESSAR PROJECTS (I) LTD SUMMER INTERNSHIP

3. MAJOR CLIENTS AND PROJECT DETAILS

PRINCIPAL SUBSIDIARIES

• Essar Investments Ltd

• Essar Oil Ltd

• Essar Power Ltd

• Essar Shipping Ltd

• Essar Steel Ltd

• Essar Tele holdings Ltd

• PT Essar Dhananjaya Ltd (Indonesia)

ESSAR PROJECTS (I) ltd has successfully completed many large size projects for ESSAR group.
The current major projects under execution by EPIL at vadinar are as follows:

1. ESSAR OIL LTD-10.5 TO 16 MMTPA REFINERY EXPANSION TRAIN-1 AT VADINAR

2. VADINAR PORT TERMINAL LTD-16MMTPA PORT FACILITIES

3. VADINAR POWER CORPORATION LTD-220MW POWERPLANT

4. VADINAR POWER CORPORATION LTD-325MW POWERPLANT

BREIF ABOUT ESSAR OIL LTD AND PROJECTS AT VADINAR:

The Essar Oil Ltd Grass Roots Refinery in Gujarat, India (started in 1996) was completed and
commissioned in 2006 (commissioned in 3rd quarter). The refinery was delayed several times due to
environmental concerns and financial problems, including initial cost over runs and a shortfall in equity
contributions.

Essar Oil focuses on producing middle distillates such as high-grade kerosene oil and low sulphur
high-speed diesel, which form over 60% of India’s domestic consumer demand.

Substituting imports will help conserve India’s foreign exchange. The refinery will also produce LPG
and lead-free gasoline of various octane levels for the domestic markets and high-octane lead-free
gasoline for export.

COMMISIONING PROCESS:

The units commissioned in the first phase were the CDU, VDU, Sulphur gas unit, Naphtha
Hydrotreater, Catalytic Cracker and Visbreaker. The fluid catalytic cracker and a diesel hydro
deslphuriser were commissioned in November 2006.

NICMAR, HYDERABAD
ESSAR PROJECTS (I) LTD SUMMER INTERNSHIP

The FCC and DHDS plants were modified so as to be compliant with the cleaner Euro III and Euro IV
fuels. The refinery is fully integrated with its own dedicated 77MW power plant, which it plans to
expand to 1,200MW plant.

The docking facilities include an SBM capable of handling vessels up to 350,000DWT with a capacity
of 25MTPA, tankages with interconnecting pipelines of 20Mtpa capacity; marine product dispatch
capacity of 12MTPA and rail-car and truck loading facilities.

EXPNASION:

Essar Oil Refinery will be expanded in two phases. The first phase comprises capacity expansion to
16MMTPA. The phase II, there are plans for establishing a new processing unit with a capacity of
18MMTPA.The expansion work projects have been given to ESSAR PROJECTS (I) ltd.

CLIENT- ESSAR OIL LTD

CONTRACTOR- ESSAR PROJECTS (I) LTD

TYPE OF CONTRACT- EPC CONTRACT/TURNKEY CONTRACT

PROJECT NAME- VADINAR REFINERY EXPANSION TRAIN1-10.5MMTPA TO 16 MMPTPA

PRINCIPAL ENGINNERING CONSULTANT- ESSAR ENGINNERING SERVICES LTD.

PROJECT MANAGEMENT CONSULTANT- EPMC

As earlier presented in the WBS of refinery expansion the whole refinery expansion project has been
broadly classified into two major areas ISBL and OSBl.ISBL is inside battery limit is the zone where all
the major process plant units like DHDS, FCCU, VGO, DCU shall be commissioned.OSBL is outside
battery limit where there will be no units involving process but all the supportive units for the smooth
functioning of the process units shall be in this zone. This area majorly includes all the pipe racks,
utility works, storage and handling areas and other offsite.

Construction activities currently been executed under OSBL area are as follows:

• Desalination plant
• Cooling Water Systems 1 & 2 for ISOM and DCU units of ISBL respectively
• Derrick foundations for Flares and slop system
• Hazardous and Non hazardous pits
• Interconnecting Pipe racks(E-W,PIT,N-S)
• Waste Water treatment facility and U/G pipe facilities.
• Narmada Water facilities
• Plant buildings and Non Plant buildings
• Coke and Coke handling & storage
• Roads, fencing and boundary
• Air Generation System

NICMAR, HYDERABAD
ESSAR PROJECTS (I) LTD SUMMER INTERNSHIP

• Nitrogen System
• Caustic Supply System
• Electrical and Instrumentation Plant comm. System
• SS&H/SPU

Construction activities currently been executed in the ISBL area are as follows:

• ISOM
• CDU/VDU/SGU/REVAMP
• DCU
• VGO-HDT
• DHDT
• HMU-TA
• ARU
• SRU
• SWS
• SRU/REVAMP

My Project Study is for Cooling Water Systems used for cooling of the process water used in the ISBL
plant. In the train 1 expansion Cooling water systems 1 and 2 are under construction for ISOM and
DCU units of the process plants. I have taken Cooling Water Systems 2 as a part of my study.

• The study included mainly the understanding of different units in a cooling tower,
• Brief study of process, detailed quantity estimation of the main cooling tower for all kind of
civil works.
• After the estimation part, the relationships between the civil activities has been studied and a
detailed schedule of level 4 has been prepared for all civil works in the cooling water
systems.
• The scope of the study has not been kept limited to civil works but has extended study for
the planning activities of mechanical equipment erection works, electrical and instrumentation
works followed by actual tracking of the cooling water systems project using Primavera P6.
• The approximate costing of the Cooling water systems for civil works has also been worked
out.I shall begin with the departmental flow chart for civil department for EPIL which is

NICMAR, HYDERABAD
ESSAR PROJECTS (I) LTD SUMMER INTERNSHIP

responsible for execution of all civil works in the refinery expansion.

All the civil works in the refinery are divided under 4 major categories:

ISBL (CDU, VDU, VGO.DHDS, DCU)

OSBL (PIPE RACKS, UTILITY)

NICMAR, HYDERABAD
ESSAR PROJECTS (I) LTD SUMMER INTERNSHIP

SATELITE BUILDINGS AND SUBSTATIONS (SB & SS)

ROAD WORKS

AREA MANAGER
CIVIL WORKS
REFINERY

A.M. A.M. A.M. A.M.


C.W. C.W. C.W. C.W.
OSB ISBL SB& ROA

Civil works in the refinery executed by EPIL are subcontracted to PRW contractors under horizontal
contracting system.The system of e bidding is mandatorily followed for all the works having value
more than 5 lac Rs. The different auction methods used for e-bidding are forward auction, reverse
auction and Dutch auction.

RECONCILATION OF CEMENT AND STEEL: The civil PRW contractors are given works on item
rate basis where all the consumables and non consumables like steel, concrete, all the staging
requirements like props, u heads, angles, HDPE/LDPE sheets, doors and windows in case of
buildings and paints are supplied by EPIL .

The contractors are given works with or without material only for shuttering plates. The equipments
like excavators, millers, placer booms, hydra cranes & other cranes are also supplied by EPIL for all
the works in the refinery.Reconcilation of all the consumables and non consumable materials are
done at the end of every month. All site in charge gives the summary of the consumables and non
consumables to the central stores from where the material is issued. The consumption of concrete on
site is checked by billing done with the batching plant report for the site. Similarly the report for other
consumables like reinforcement steel, tie rods are checked with materials issued from the stores and
consumption is checked in the bills. Non consumable materials should be deposited back to the
stores after use in working conditions.

EQUIPMENT POOL OF EPIL: The refinery has a centralized batching plant area where 4 batching
plants with a capacity of generating 60 cum/hour are commissioned. There are 39 numbers of miller
machines for supplying concrete to the various sites of the refinery, Salaya Power plant and COT area
and 6 number of placer booms for concrete. Excavators are possessed by EPIL as wells as taken on
hired charges whenever required.

CIVIL WORKS CONTRACT DETAILS FOR COOLING WATER SYSTEMS 2:

PROJECT NAME- COOLING WATER SYSTEMS 2

NICMAR, HYDERABAD
ESSAR PROJECTS (I) LTD SUMMER INTERNSHIP

TYPE OF CONTRACT- PRW CONTRACT

SUBCONTRACTOR- SARTHY, DEVEE

SCOPE OF WORK-SARTHY- LACS DEVEE- LACS

SECURITY DEPOSIT-

DURATION OF PROJECT-12 MONTHS

SAFETY: High level of safety standards are followed by EPIL for maintaining the safe working
conditions in the refinery. The detailed report of all near miss accidents, accidents on site, working in
unsafe conditions and performing unsafe acts are maintained by the HSE department for different
sites. This is done by continuous monitoring of all the construction activities at different sites. When a
a labor does not report to the site more than 48 hours after accident then it is termed as LTI..Here
we calculate the safe man hour, then calculate LTIFR. If the LTI FR IS less than .4 gets incentives in
monetary terms. This scheme is called project incentive scheme. The essential PPEs are provided by
EPIL to all the labor working for PRW contractors on returnable basis,

BILLING SYSTEM OF THE SUBCONTRACTORS: The subcontractors are billed on the basis of
quantity of work done on individual site. The site engineer shall prepare the rough bill and gives it to
the billing engineer where proper format bill is made and deductions for previous bills are done and
balance bill is sent to the cost control department where after proper verification the contractor is
liable to get the amount from the finance department.

CH1. INTRODUCTION TO COOLING WATER SYSTEM


1.1 COOLING WATER SYSTEMS:
Cooling Tower is equipment used to reduce the temperature of a water stream by extracting heat from
water and emitting it to the atmosphere. Cooling towers make use of evaporation whereby some of
the water is evaporated into a moving air stream and subsequently discharged into the atmosphere.
As a result, the remainder of the water is cooled down significantly. Cooling towers are able to lower

NICMAR, HYDERABAD
ESSAR PROJECTS (I) LTD SUMMER INTERNSHIP

the water temperatures more than devices that use only air to reject heat, like the radiator in a car,
and are therefore more cost-effective and energy efficient.

1.1.1 TYPES OF COOLING TOWER:

• Based on Structure / Construction

– Wooden / FRP Towers

– RCC Towers

• Based on Water Flow

– Open Cycle

– Closed Cycle

– Indirect Cooling

• Based on Fan Location

– Induced Draft

– Forced Draft

– Balanced Draft

– Natural Draft (No fan)

• Based on Air-Water contact

– Cross Flow Cooling Tower

– Counter Flow Cooling Towers

1.1.2 COMPONENTS OF COOLING TOWER:

The basic components of a cooling tower include:

• Frame and casting


• Hot water deck/basin
• Circulating water pumps
• ID/FD Fans
• Fill Material
• Cold-water basin
• Drift eliminators
• Air inlet
• Louvers
• Water Spray Nozzles

1.2 TOWER MATERIALS:

NICMAR, HYDERABAD
ESSAR PROJECTS (I) LTD SUMMER INTERNSHIP

Originally, cooling towers were constructed primarily with wood, including the frame, casing, louvers,
fill and cold-water basin. Today, manufacturers use a variety of materials to construct cooling towers.
Materials are chosen to enhance corrosion resistance, reduce maintenance, and promote reliability
and long service life. Galvanized steel, various grades of stainless steel, glass fibre, and concrete are
widely used in tower construction, as well as aluminium and plastics for some components.

a) Frame and casting: Wooden towers are still available, but many components are made of
different materials, such as the casing around the wooden framework of glass fibre, the inlet
air louvers of glass fibre, the fill of plastic and the cold-water basin of steel. Many towers are
constructed of galvanized steel or, where a corrosive atmosphere is a problem, the tower
and/or the basis are made of stainless steel. Large towers sometimes are made of concrete.
Glass fibre is also widely used for cooling tower casings and basins, because they extend the
life of the cooling tower and provide protection against harmful chemicals.

b) Fill: Plastics are widely used for fill, including PVC, polypropylene, and other polymers. When
water conditions require the use of splash fill, treated wood splash fill is still used in wooden
towers, but plastic splash fill is also widely used. Because of greater heat transfer efficiency, fill
is chosen for applications where the circulating water is generally free of debris that could
block the fill passageways.

c) Nozzles: Plastics are also widely used for nozzles. Many nozzles are made of PVC, AB,
polypropylene, and glass-filled nylon.

d) Fans: Aluminium, glass fibre and hot-dipped galvanized steel are commonly used fan
materials. Centrifugal fans often fabricated fro galvanized steel. Propeller fans ae made from
galvanized steel, aluminium, or molded glass fibre reinforced plastic.

1.3 ENERGY EFFICIENCY OPPORTUNITIES:

This section includes main areas for improving energy efficiency of cooling towers. The main areas for
energy conservation include:

a) Selecting the right cooling tower: Because the structural aspects of the cooling tower cannot
be changed after it is installed. Once a cooling tower is in place it is very difficult to
significantly improve its energy performance. A number of factors are of influence on the
cooling tower’s performance and should be considered when choosing a cooling tower:
capacity, range, approach, heat load, wet bulb temperature, and the relationship between
these factors.

b) Fill media effects: In a cooling tower, hot water is distributed above fill media and is cooled
down through evaporation as it flows down the tower and gets in contact with air. The fill
media impacts energy consumption in two ways:

• Electricity is used for pumping above the fill and for fans that create the air draft. An
efficiently designed fill media with appropriate water distribution, drift eliminator, fan,
gearbox and motor with therefore lead to lower electricity consumption.

• Heat exchange between air and water is influenced by surface area of heat
exchange, duration of heat exchange (interaction) and turbulence in water effecting
thoroughness of intermixing. The fill media determines all of these and therefore
influences the heat exchange. The greater the heat exchange, the more effective the
cooling tower becomes.

NICMAR, HYDERABAD
ESSAR PROJECTS (I) LTD SUMMER INTERNSHIP

a) Pumps and water distribution:

○ Optimize cooling water treatment : Cooling water treatment (e.g. to control suspended
solids, algae growth) is mandatory for any cooling tower independent of what fill
media is used. With increasing costs of water, efforts to increase Cycles of
Concentration (COC), by cooling water treatment would help to reduce make up
water requirements significantly.

○ Install drift eliminators: It is very difficult to ignore drift problems in cooling towers.
Nowadays most of the end use specifications assume a 0.2% drift loss.

Technological developments and the production of PVC, manufacturers have improved drift
eliminator designs. As a result drift losses can now be as low as 0.003-0.001%.

Cooling tower fans:

The purpose of the cooling tower fan is to move a specified quantity of air through
the system. The fan has to overcome the system resistance, which is defined as the pressure
loss, to move the air. The fan output or work done by the fan is the product of air flow and the
pressure loss. The fan output and kW input determines the fan efficiency.

COOLING TOWERS AT ESSAR:

BASE REFINERY COOLING TOWERS:

○ Design COC :1.35


○ Type : Cross flow, Induced draft, FRP
○ Make up water : Sea water
○ No of Towers : 2 (10 & 14 Cells)
○ Capacity : 24 cells of 2670 m3/hr each
○ Temp range : 8ºC @ 34 S / 42

NICMAR, HYDERABAD
ESSAR PROJECTS (I) LTD SUMMER INTERNSHIP

LIMITATIONS:

• Difficult to operate at high COC

• Special metallurgy like Titanium / Cu-Ni is required for exchangers


Prone to leak in the piping system

A. COOLING TOWERS IN REFINERY EXPANSION PROJECT:

○ Type : Counter flow, Induced draft, RCC towers

○ Manufacturer : SPIG, Italy

○ Make up water : Treated Narmada / Desal water / RO

○ No of Towers : 2 in Train-I & 2 in Train-II

○ Pumps : 8000 m3/hr each, 6.7 kg/cm2

○ Cell capacity : 3500 m3/hr each @ 11 cells in Train-I & 30 cells in Train-II

○ Temp Range : 12 ºC @ 32 S / 44 R

○ Design COC : 5-6 on river water & 8-10 on Desal water

ADVANTAGES:

• Less dissolve solids, flexibility to operated at high COC

• No special metallurgy for piping & exchangers

• Flexibility in makeup water: Narmada / RO / Desal water

• Life span is long, less scale / corrosion tendency of circulating water

NICMAR, HYDERABAD
ESSAR PROJECTS (I) LTD SUMMER INTERNSHIP

SALIENT FEATURES:

• Supplied has a strong presence in market, more than 70 years

• RCC Tower structure gives strength & long life

• FRP fan blades for low power consumption as compared to metallic blades

• Fine spray nozzle & Inverted V splash bar packing imparts good contact area
between water and air

• Anti clog nozzles, self cleaning of nozzles by means of built in impeller

CH 2. UNITS OF COOLING WATER SYSTEMS


2 FOR DELAYED COKER UNIT

2.1 DESCRIPTION OF CONSTRUCTION UNITS


The basic construction units and brief description about their structure that would be included in a
Cooling water system are as follows:

• Cooled water basin: The water cooled in the tower is stored in the cooled water basin. The
basin has break wind walls of height 4.7 meters leaving a certain distance from the ground
across the cell extends up to the level of louvers. It has a purpose to break the wind coming
from the louvers to divert it upwards and facilitate settling of the impurities. The louvers will be
resting on the corbels coming out of the periphery columns.
➢ The entire cooled water basin is an elevated slab above FGL at R.L. of 33.045 which
including the oil skimmed channel behind the water basin. The specific purpose for
creating such an elevated basin from the ground is to avoid going to a larger depth for
construction of sump.
➢ The sump being the storage basin has to be at a level lower than the cooling tower.
There is hard rock at a depth greater than 3.5-4m at refinery project site which would
lead to rock breaking operations consuming more time and cost.
➢ The another reason is that the pipes coming out of the pumps of the storage
basin/sump going towards process units would also have to be kept inside the ground

NICMAR, HYDERABAD
ESSAR PROJECTS (I) LTD SUMMER INTERNSHIP

U/G piping which would again lead to extra cost and effort. Therefore the designers
have elevated the entire cooled water basin to avoid any excessive excavation works
and U/G piping.

• Cooling tower: The Cooling tower is the central and the most important unit where actual
cooling of water takes places. The cooling of water takes place with the help of dispersion
system and the fills which are arranged in the subsequent levels across the width of the
cooling tower. The water from the tower comes down to the basin.
➢ The cooling tower 2 has in total 8 cells where 8 fans shall be erected. The main
structure covers an area of about 2200 sqm.
➢ The height of the cooling tower is 13.3 from the basin slab and total 16.3 m from FGL.
The fan is installed at the same level and each fan has 6 fibre glass blades and 15
segments per cell for fan cylinder.
➢ Motor is to be installed at the deck slab, a transmission shaft and lubrication
assembly for each cell.
➢ The cooling tower structure has cross grids made of cast-in situ primary beams and
precast secondary beams at 2 different levels. These cross grids of beams are made
to facilitate the resting of drift eliminators and PVC fills.PVC Y 20 film filling with
quantity of 1500 pcs per cell, supported on the precast beams are in 3 layers with 1.8
m wide 1#row and 1.2m wide 2# rows and the final protection layer.
➢ The drift eliminators resting on a slightly higher level of the cross grid of primary and
secondary beams are CD-103 type having PVC blades quantity of 2000 nos and
spacers of quantity 400 nos.
➢ The water from the DCU shall come through pipe racks and shall enter the cooling
tower through hot water duct in the wall which shall be resting on the cantilevered
slab which is throughout the length of the cooling tower. The duct is protected by a
roof slab extending only within the dia of the duct. The entry of the hot water is
facilitated by a distribution system made by {PCVC pipes of sizes 10” and 8” ( 16
lines of 14 meter long) 256 springler nozzles’ which are to be fixed per cell of the
cooling tower.

• Oil Skimmed channel: The elevated oil skimmed channel which acts a passage of the cooled
water coming from the tower which runs into the sump. The channel consists of a baffle wall
to trap the heavier impurities entering into the sump. The oil along with water swiftly is carried
towards the sump. The channel also has a a thin cantilevered slab throughout the length of
the tower. A monorail crane shall rest on this slab to facilitate the pulling up and lowering
down operations of the trash screen which are 6 in nos done for maintenance purpose.

• Sump: The Sump is the storage of the Cooling Water System where the water coming from
the cooling tower is stored. It has RCC walls with water bars & expansion joint filled up with
water proofing chemicals as it is a water retaining structure.

• Chlorination building: Chlorination building is part of giving anti microbial treatment to the
water since the same water once cooled down is again used in the process.

• Side Stream Filtration: Cooling towers scrub large volumes of air and effectively remove
solids consisting of dust, microbiological organisms, and various air borne debris. Makeup to
the tower adds suspended solids in the form of corrosion products, microbiological growths
and wood fibers from the tower, and process leaks. If allowed to settle out, these solids can
and do generate many problems within the system. With heavy solids loading, even the best
treatment program can be severely strained. Under these circumstances, significant
improvement might be realized with the use of a side stream filter.

NICMAR, HYDERABAD
ESSAR PROJECTS (I) LTD SUMMER INTERNSHIP

○ A proven method to help manage these and other issues surrounding cooling towers
is to install a properly designed side stream filter. This can benefit your system
through:
 Reduced Corrosion Rates.
 Increased Equipment Life
 Better System Efficiency
 Reduced Maintenance Costs
 Better Chemical Control

• Pumps: The pumps are connected to the sump to carry the water of sump inside the process
units through the pipes passing over various pipe racks. Appropriate Lube oil system is also
arranged for the working of pumps.

2.2 DISCUSSION OF CIVIL WORKS:


The major civil works in the cooling tower shall include

• Construction of basin slab 400 mm thickness for all 9 parts distributed according to expansion
joint from grid 11- grid 32 having 4 expansion joints and 9 parts.
• Construction of RCC basin wall 2.3m after the basin slab along the periphery of the front face.
• Construction of RCC cell bifurcation walls of height 13.3 m.

LAYOUT OF COOLING WATER SYSTEMS

• Construction of cell periphery walls up to 13.3 m but with some passage to be kept for
erection of louvers.

NICMAR, HYDERABAD
ESSAR PROJECTS (I) LTD SUMMER INTERNSHIP

• Construction of precast secondary beams and primary beams.


• Construction of deck slab.
• Construction of the sump, chlorination building, lube oil system and precast sleepers and
pump foundations.

2.3 STAGING DETAILS FOR COOLED WATER BASIN

RCC contractors for this work are sarthy and devee.There is a separate agency for precast elements
and similarly an agency has been deployed for making U heads for the staging.

The staging cycle is so planned because total number of props for all parts shall be supplied by EPIL
to the contractors. The rates are given to the contractors for the erection works for staging in cum.
Parts 1,3 and 5 are to be done by sarthy including the sump whereas devee is given the contract for
part 2, 4 and 6 are to be done by devee.

Planning of the staging usage is so done that the staging for the basin slab used in part 1 shall be
transferred to part 5 and the staging of part 5 is transferred to part 3.Similar will be adopted for the
parts to be executed under devee.

Different kinds of staging used for such structures are H frames which are made of pipes supported
on base available in fixed sizes as well as custom sized can be fabricated, The depth of the slab
being 400mm in this case the entire staging requirement was initially calculated and material indent
was done. There will be RCC walls in the entire structure and hence the consumables shall include
the tie rod requirements for the support.

Major equipments needed for the project shall be excavators which would be periodically needed for
the excavation purpose. The concrete requirements shall be fulfilled as and when required by the
central batching plant with suitable arrangement for placer booms made in advance.

Excavation for isolated footings according to the design given by SPIG is in slope. Due to the slope
excavation back filling of the void is done by PCC.So in actual against the design box excavation was
done rather than doing more difficult sloped excavation. The depth of the footings are 3m.To avoid
such large depth a whole raft foundation could be preferred in the design which would lead to time
saving and cost saving.

NICMAR, HYDERABAD
ESSAR PROJECTS (I) LTD SUMMER INTERNSHIP

CH3.ESTIMATION OF QUANTITITES FOR


CIVIL WORKS
3.1 ESTIMATION FOR COOLING TOWER
Estimation plays a very important role in case of turnkey projects as the client provides only with the
final required output from the project. Detailed BOQ can only be prepared after proper estimation
.Estimation provides with approximate cost of the project to float the tenders for PRW contractors and
also for planning and scheduling of activities in order to complete the project in the given time
duration. The commissioning of such a refinery project shall depend on the functioning of each and
every unit. Moreover completion of civil works shall give a lead to erection works which are then
followed by electrical and instrumentation works.

The client has to bear the cost of storage of equipments to be erected for the project in case of delay;
hence timely completion of civil works needs proper planning and continuous tracking.

NICMAR, HYDERABAD
ESSAR PROJECTS (I) LTD SUMMER INTERNSHIP

All the drawings of the cooled water basin and cooling tower structure were thoroughly studied and
the estimation of the quantities was done. The quantities of already executed work was also been
worked out since the aim of estimation was to make a new plan for the cooling tower 2.

3.1.1 PURPOSE OF ESTIMATION:


Estimation is done to give an approximate idea of the cost and help in planning and scheduling within
the required duration.

1. Estimating Materials

From the estimate of a work it is possible to determine what materials and in what
quantities will be required for the work so that the arrangements to procure them can be made. The
materials shall include concrete quantity for all the works in cum, shuttering formworks in sqm, staging
volume in cum. Thus estimation of materials shall include estimation of all consumable and non
consumables in the project. The estimation of all the materials shall also help in further planning of
individual activities since the scope gets defined after estimation.

2. Estimating Labor

The number and kind of workers of different categories who will have to be employed to
complete the work in the specified time can be found out from the estimate. In civil works there are
skilled and unskilled labors. Skilled labors are the carpenters, fitters, masons and the unskilled labors
are the labors who do the manual operations of lifting and shifting of materials.

3. Estimating Plants and Machinery:

An estimate will help in determining amount and kind of equipment needed to complete the
work. Sometimes certain equipments are used to improve the productivity by using equipments for
works which requires large number of manual labor and also involves some amount of risk. Since the
cooling tower is a major critical structure going till the height of about 18 m from the FGL with just one
intermediate slab at about 3m level, 2 static tower cranes of ____________ make and _______
capacity are used for the lifting of material at heights and also to facilitate covering area about 2200
sqm due to the boom length. The position of these 2 tower cranes have been fixed by the HED
department in coordination with the site in charge and subcontractors.

4. Estimating Time

The estimate of work and the past experience enable one to estimate quite closely the length of
time required to complete an item of work or the work as a whole. Whereas the importance of knowing
the probable cost needs no emphasis, estimating materials, labor, plant and time is immensely useful
in planning and execution of any work

3.2 SCOPE OF VARIOUS CIVIL WORKS AFTER ESTIMATION:


CIVIL WORKS FOR COOLING TOWER2:

➢ EXCAVATION- 16000 CUM


➢ RCC FOR FOOTINGS AND TIE BEAMS-1595 CUM
➢ RCC FOR SUPER STRUCTURE- 4,132.00
➢ REINFORCEMENT STEEL-640 MT

NICMAR, HYDERABAD
ESSAR PROJECTS (I) LTD SUMMER INTERNSHIP

➢ STAGING QUANTITY- 75029.53 CUM


➢ FORMWORK QUANTITY- 19973.14 SqM

CIVIL WORKS FOR SUMP:

➢ EXCAVATION-7000 CUM
➢ RCC FOR FOOTINGS AND TIE BEAMS-645 CUM
➢ RCC FOR SUPER STRUCTURE-735 CUM
➢ REINFORCEMENT STEEL-250 MT
➢ FORMWORK QUANTITY- 2800 SqM

CIVIL WORKS FOR CHLORINATION BUILDING:

➢ EXCAVATION-200 CUM
➢ RCC WORKS- 98 CUM
➢ REINFORCEMENT STEEL-

CIVIL WORKS FOR INSTRUMENTATION PIT:

➢ EXCAVATION- 200 CUM


➢ RCC WORKS- 65 CUM
➢ REINFORECEMENT STEEL-10 MT
➢ FORMWORK QUANTITY- 365 SqM

CIVIL WORKS FOR PRECAST SLEEPERS:

➢ EXCAVATION-500 CUM
➢ RCC WORKS-91 CUM
➢ REINFORCEMENT STEEL-12 MT
➢ FORMWORK QUANTITY- 500 SqM

CIVIL WORKS FOR PUMP FOUNDATIONS:

➢ EXCAVATION-200 CUM
➢ RCC WORKS-110 CUM
➢ REINFORCEMENT STEEL-4 MT
➢ FORMWORK QUANTITY- 500 SqM

CIVIL WORKS FOR SIDE STREAM FILTRATION PLANT:

➢ EXCAVATION-250 CUM
➢ RCC WORKS-25 CUM
➢ REINFORCEMENT-5 MT
➢ FORMWORK QUANTITY- 300 SqM

3.3 CALCULATION OF MAN HOURS:


For the calculation of manhours, we have collected some details from the individual contractors about
the number of labours required to complete particular work of CUM of concrete in particular days.

Contractor A:

NICMAR, HYDERABAD
ESSAR PROJECTS (I) LTD SUMMER INTERNSHIP

Average labour(including skilled and unskilled) strength per month= 40/day

Productivity of sarthy labour = 380 CUM in 40 days

Therefore man hours per CUM =Avg labour×wrking hrs/day×No.of days CUM is compltd/380

=(40×10×40/380)

=43 manhrs/CUM

Contractor B:

Average labour(including skilled and unskilled) strength per month= 40/day

Productivity of sarthy labour = 380 CUM in 29 days

Therefore man hours per CUM =Avg labour×wrking hrs/day×No.of days CUM is compltd/380

=(40×10×29/380)

=37 manhrs/CUM

We also came to know from the observation at site that as the height of the work increases,
productivity decreases. So we also calculated Manhrs/CUM/day with respect to height. The height of
the productivity decreases. Hence, we therefore calculated Manhrs/CUM/day for Sump Walls,
Columns and walls.

Manhrs for Wall:

Avg labour strength in one month= 20/day

Productivity of labour= 18.75 CUM in 7 days

Therefore man hours per CUM =Avg labour×wrking hrs/day×No.of days CUM is compltd/380

=(20×10×7/18.75)

=75 manhrs/CUM

As the height increases, the productivity of wall and hence manhours increases as shown below:

For height <5m = 75/CUM/day

5-10m =100/CUM/day

10-15m = 135/CUM/day

15-20m = 170/CUM/day

3.4 MECHANICAL EQUIPMENTS

NICMAR, HYDERABAD
ESSAR PROJECTS (I) LTD SUMMER INTERNSHIP

Duration for the mechanical works are worked out by using man-hours constant defined for OSBL
units, also with interaction with senior staff of erection of EPIL.

PVC Films and drift eliminators erection works requires 2 gangs where each gang consist of a fitter,
helper, 4 riggers.

Erection of critical structures like Fans and motors requires 2 gangs each of 6 people,3 structural fitter
3 millwright fitter

CH 4 PLANNING AND SCHEDULING

A schedule is a work programme, set data-wise in a logical sequence, it is a time table for action time
scheduling is the process of developing a work programme. It implies programming of the chosen
work plan on a calendar basis and provides the base against which all progress is measured.

4.1 Purpose of Work Scheduling:


• It simplifies the project plan

• It validates the time objectives

NICMAR, HYDERABAD
ESSAR PROJECTS (I) LTD SUMMER INTERNSHIP

• It optimizes the resources employed

• It forecast the input resources, and predicts the outputs

• It evaluates the implications of scheduling constraints

4.1.1BAR CHART METHOD OF WORK SCHEDULING:


In this method, works are first split into activities and then listed in order of construction priorities on
left hand side column, while the time scale is plotted horizontally on top or bottom of the chart, the
start of the bar marks the commencement of the activity and the end of the bar, its completion. The
length represents duration of the activity. It is useful for presentation of schedules as a planning
technique but not suitable for scheduling of complex projects.

4.1.2SCHEDULING THE NETWORK PLAN:


A schedule aims at optimising resources for completion of the project within stipulated time objectives.
Optimization is achieved by suitably adjusting the schedule of non critical activities using available
floats in such a manner that fluctuations from the desires pattern of resource utilization are minimized.
The scheduling of network plan involves the following steps:

• Outlining scheduling constrains

• Identifying the floats of each activity and tabulate

• Preparing the EST schedule

• Determining resource scheduling criteria

• Scheduling critical activities at their EST

• Scheduling non critical activities

• Optimizing other resources

• Validating the project time activities

• Scheduling within the resource constrains

• Scheduling networks of repetitive projects

4.1.3 LOB METHOD OF SCHEDULING REPETITIVE PROJECTS


The ‘line-of-balance’ technique is used for planning, scheduling and controlling of projects involving
construction of a large number of repetitive works such as similar building, multi-storeyed
skyscrapers, roads, airfields, etc. It enables the optimum utilization of resources, improvement in work
efficiency and interference- free scheduling of a wide range of activities. The LOB scheduling entails
preparation of two types of charts:

• Setback chart

• Activities schedule chart

NICMAR, HYDERABAD
ESSAR PROJECTS (I) LTD SUMMER INTERNSHIP

4.2 FACTORS AFFECTING WORK SCHEDULING


The scheduling of a project plan has to take into consideration many variables like time,
resources, and financial constraints. It is difficult to enumerate principles governing all such factors.

However, the guidelines given in the following can be considered for developing the schedule
of project work.

• Time

• Manpower

• Materials

• Machinery

• Capital

4.3 FORECASTING INPUTS AND OUTPUTS

The forecasts predict, date-wise, the future projection, in respect of input resources and production
outputs. The assumptions made at the time of forecasting are based on the available information
which may or may not hold good in the future. The economies of projects depend upon the accuracy
of the forecasts. The work schedule can form the basis for making forecasts. Forecasts can be
prepared for the daily rate of work, input resources and outputs, and cash-in-flow and cash-out-flow.

4.4 SCHEDULE HIERARCHY


The schedule hierarchy depicts the level of various schedule in relation to each other. Each level of
schedules is meant to serve the information needs of the corresponding management level.

This schedule consists of the following:

Level Schedule Title

1 Project summary schedule

2 Project master schedule

3 Contracts master schedule

4 Responsibility centres schedules

5 Supervisors weekly schedules

4.5 SCHEDULING OF COOLING TOWER WORKS ON


PRIMAVERA P6

Here in this project the work shall be done on level 4 schedules for civil works and level 2 schedules
for mechanical erection, electrical and instrumentation works. The entire schedule is made using

NICMAR, HYDERABAD
ESSAR PROJECTS (I) LTD SUMMER INTERNSHIP

Primavera P6. The following are the data required for the software for planning and making a
schedule:

• EPS:Create an enterprise project structure showing ESSAR PROJECTS as a EPS node


having different projects and ESSAR OIL is another sub EPS being the client where Vadinar
refinery Expansion is the main project where there are many sub projects out of which our
project for study is defined as Cooling Water Systems 2.

• WBS:After creating the EPS and project the cooling tower project WBS is created on the
basis of different nature of works like civil, mechanical, and electrical and instrumentation
works. Civil works are again divided on the basis of parts of slab distributed between 2
contractors. Civil works of different units in the cooling water system are also considered like
the sump, chlorination building, pumps, side stream filtration plant, lube oil system etc.

• Project Calendar is assigned and the activities are assigned to the WBS giving appropriate
relationships.
• The duration of the activities is given with help of the manhours constant and estimation of the
quantity of materials during the estimation.

NICMAR, HYDERABAD
ESSAR PROJECTS (I) LTD SUMMER INTERNSHIP

For example:

RCC Basin Slab including the beams 400 mm depth is has a volume of 381 cum.

Manhours calculated for the slabs and beams from actual site data comes to around 30 cum for
height less than 3 m. The height of the slab being almost 3m above FGL manhrs/cum of concrete fot
slabs and beams is taken as 35 manhrs/cum.

35*381=13335 manhrs

Now in an area of 44.4* 16.4 for all the step activities for RCC works of basin slab and beams
assumption of 45 as the labour strength is made considering labour availability, volume of work and
the area clearance for working.

Therefore 13335/45*10 considering each day as 10 hours working, duration of the activity comes to
30 days.

Similarly considering the factors like labour availability, volume of works and the clearance for the
works duration of all the activities is calculated. Duration of mechanical and electrical activities is
given by interaction with field people and also conducting a similar procedure like civil works where
manhrs constant are taken which are already available based on the past works done in the roots
refinery.

• After entering the durations, activity relationships are given depending on the requirement like
FS, SS, FF, SF. Most commonly used are SS and FS. It is advisable to use only one
relationship throughout the project adjusting with the lag and lead. In Cooling tower project
schedule is being made in month of may 2010 whereas work has started since july
2009.Therefore the actual purpose of the schedule is tracking and monitoring of the activities.

• Resources are assigned where labour units are in manhours and material units are RCC,
excavation, PCC. Labour and Non labour i.e. the equipments are the driving units in a project
as cost control cannot be achieved on material except the avoiding the wastage.

Once an overall schedule is prepared a detailed schedule for working out the number of
carpenters and fitters and time taken for each step activity of the main activity RCC of slab is
done. This is micros scheduling for the civil activities.

NICMAR, HYDERABAD
ESSAR PROJECTS (I) LTD SUMMER INTERNSHIP

NICMAR, HYDERABAD
ESSAR PROJECTS (I) LTD SUMMER INTERNSHIP

.Thus the micro schedule is crosschecked with the overall duration planning.

4.6 MONITORING AND CONTROLLING OF THE PROJECT


4.6.1 MONITORING OF A PROJECT:

Basically, project management is managing resources to achieve designed standard of technical


performance and quality, timely completion of project, and completion of project within sanctioned
time and cost through effective monitoring.

Process of monitoring runs concurrently with implementation or execution of the project. It is a


management tool to maintain effective control on time and cost schedule. The specific targets in
respect of physical and financial parameters along with the resource allocation and the priority
structure created at the time of plan formulation generally from the basis for monitoring public sector
projects.

The total work effort involved in a project is divided into activities with their sequencing, time phasing
and resource requirements so as to facilitate their proper monitoring from period to period at different
levels at smaller intervals.

An operational plan, focussing on the physical output or performance alone is not sufficient for
monitoring as it has to be matched with resource inputs. However in reality, it becomes generally
difficult to do resource monitoring in absence of adequate data.

Most of the projects suffer from the dual problems of time and cost overruns. With a view to ensuring
effective implementation of the projects in construction sector, it is imperative that the aspects
pertaining to time, resources and cost management which are sine-qua-non of project management
receive due attention from the project authorities.

NICMAR, HYDERABAD
ESSAR PROJECTS (I) LTD SUMMER INTERNSHIP

4.6.2 TRACKING OF COOLING WATER SYSTEMS 2


Now, after completing the schedule the actual dates and completed units of
labour, material are updated and program is run under retained logic option after
pressing F9.The project is extended in terms of finish date as the activities are
lagging behind in terms of RCC consumed and manhrs consumed which the
major non driving and driving units are for the project.

A.PLANNED SCHEDULE CONSIDERING ACTUAL INPUTS BETWEEN JULY09


AND APRIL 10

NICMAR, HYDERABAD
ESSAR PROJECTS (I) LTD SUMMER INTERNSHIP

B.DIFFERENCE BETWEEN ACTUAL AND PLANNED RCC CONSUMPTION

4.7 ANALYSIS OF THE GRAPHS:


In the first graph it is observed that the excavation works for the project got started very early in july
09 in absence of IFC drawings. Hence deliberately the progress was kept slow as further works could
not be done till IFC drawings are released. Moreover even after the release of the drawings due to the
specific design of 400mm thickness basin slab a new indent for the props requirement had to be
generated and due to the delay is supply of fabricated props the work got further delayed . Since the
engineering, procurement and construction works all are done by EPIL, the delay of one shall affect
the other.Therefore as seen in the graph 2 there are no RCC works done in the month of february
and march except the finishing of the delayed works for the columns.

NICMAR, HYDERABAD
ESSAR PROJECTS (I) LTD SUMMER INTERNSHIP

C.DIFFERENCE BETWEEN ACTUAL AND BUDGETED LABOR UNITS BETWEEN JULY 09 AND
JUNE 10

Here the blue curve shows the actual units while yellow show the budgeted units. The actual units
have remained under consumption even after the month of May where all IFC drawings are issued,.
This shall show the completion of civil works extended by 3 months at the same rate of progress.

NICMAR, HYDERABAD
ESSAR PROJECTS (I) LTD SUMMER INTERNSHIP

D.COMPARISION OF BUDGETED AND ACTUAL LABOUR UNITS

E.LABOUR UNITS FOR REMAINING WORKS AS COMPARED TO BUDGETED UNITS

The difference between the actual consumption of labour unit and planned labour units for the total
project is observed. Due to under utilization or unavailability works in progress is lagging compared to
the planned progress.

COMPARISION BETWEEN PRODUCIVITY OF CONTRACTORS OF PART 1 AND PART2

Left side view is for contractor for part 2 where budgeted units are achieved on time after which the
the progress of work slows down in the month of June. Right side view is for the contractor of part 1
where the progress is slow and a consistent lag is observed.

NICMAR, HYDERABAD
ESSAR PROJECTS (I) LTD SUMMER INTERNSHIP

CH5.PROJECT UPDATING

5.1 PROJECT UPDATING


The process of incorporating change, and replanning or rescheduling is called UPDATING.

The three basic changes that make updating necessary are as under:

1. Changes in project plan

2. Rescheduling activities

3. Changes in the duration of an activity

5.1.1DATA REQURIED FOR UPDATING


The following information is necessary to update the plan at an intermediate stage of execution of a
project

1. Original network

2. Progress report

3. Calculation charts

4. New information and knowledge which will affect the duration in the future

5.1.2 METHODS OF UPDATING


1. By describing the stage

2. By recoding the progress

3. By summarizing the work

4. By calculations.

5.2 WHEN TO UPDATE

The following points must be considered while deciding the time of updating.

1. The updating is done whenever there is a major change in duration of any of the activity

2. For larger duration projects, the process of updating must be increased as the project
progresses towards the completion.

3. For small duration projects, there must be frequent updating to be done while taking into
consideration the latest position of execution of the project.

NICMAR, HYDERABAD
ESSAR PROJECTS (I) LTD SUMMER INTERNSHIP

Thus, it must be noted that critical path method (CPM) is not only useful in the planning phase
of project but also helps the decision maker during execution and also to some extent in controlling
the completion of project on schedule.

5.3 COSTING OF PROJECT


Approximate cost of the Project is also worked out applying the rates given to the subcontractors and
considering RCC 40 grade concrete consumption of cement, sand and aggregates for entire cooling
water systems including wastage.

1 CUM OF CONCRETE OF M40 GRADE:

Cement = 400 kg
Water = 160 kg
Fine aggregate = 660 kg
Coarse aggregate 20 mm = 701 kg
Coarse aggregate 10 mm = 467 kg
Admixture = 0.6 % by weight of cement = 2.4 kg.
Recron 3S = 900 gm

NICMAR, HYDERABAD
ESSAR PROJECTS (I) LTD SUMMER INTERNSHIP

CH 6. CONCLUSION:
To compensate for the delay the software generated labour units shows increase in the labour
strength for the following months.. The project has already extended for civil works from originally
planned JAN 31 to APRIL 18 considering the current rate of progress according to software results.
So to crash the total duration,

➢ Labour strength should be increased to make up for the loss by the contractors between
month of May and June.
➢ The contractor for PART 1 has been observed to be giving slow progress compared to
PART2.The same contractor has been assigned for the sump work as well so to complete the
remaining part of sump and expedite the progress in the PART 1 more labour is required.
➢ The following activities are critical for the remaining project
• Erection of secondary beams
• RCC works for 10 cell bifurcation walls
• RCC works for primary beam2
• Erection of secondary beams
• RCC works for fan deck slab
• Erection of Gear box and motors
• Cable tray erection and earthling
• LT/HT control cable
• Instrumentation cable laying
• Instrumentation SS tubing
• Switch boards
• Commissioning and Handover
➢ Total Project completion is 15.83% till June 23

SUGGESTIONS:

➢ Majority of the works in the refinery are suffered due to inconsistent labour strength
maintained by contractors. To overcome this issue some surplus labour strength should be
maintained by EPIL on Project roll considering the large number of works coming up even in
the train 2 expansion which will help to overcome slow progress due to insufficient and
inconsistent labour supply. Thus it is like creating a buffer or safety inventory of labour units to
produce shutters, reinforcement cutting and bending, etc.Therefore in case where a
contractor suffers due to insufficient shuttering or reinforcement the buffer labour units can
help overcome such shortage and thus can help avoid any delay.

➢ Since the projects taken by the company are EPC in nature, there exists a strong link
between all the 3 departments. Delay in engineering shall be transferred to construction and
procurement and similarly a delay in procurement shall also affect construction. Thus a proper
coordination and track shall be maintained. The role of EPMC would be very vital and thus
would help execution team better by understanding the execution problems and convey
necessary details to the engineering team. For eg: A raft footing of lesser dept would be more
convenient to construct, saves cost and time as compared to isolated footings of depth 3m.

➢ The procurement delays also have affected progress of certain sites where there is constant
difference observed in the actual requirement of bolts an templates and the supply. Such
smaller parts like bolts and templates should be planned in advance to avoid delays because
of such issues.

NICMAR, HYDERABAD
ESSAR PROJECTS (I) LTD SUMMER INTERNSHIP

NICMAR, HYDERABAD

You might also like