Sur IPP 2000MW CCGT Monthly Site Report to MMH from MMS; Progress from 1 st to 31 th MAY2014 (Internal use only) Main Points

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Silas Hamilton
6 years ago
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1 Sur IPP 2000MW CCGT Monthly Site Report to MMH from MMS; Progress from 1 st to 31 th MAY2014 (Internal use only) MM Staff on-site Richard Heggen Werter Di Lallo Phil Scott Tony Maw Bob Data Narasimman Krishnamoorthy - Civil inspector Vinod Mohan Mechanical inspector Roy Tumang - Mechanical inspector Ferdie Santos C&I Inspector Stephen Ambiro Electrical Inspector Augustus Montealegre - Electrical Inspector Reynaldo Lat C&I Inspector Main Points - ST10, 20 & 30 Turbine wall and Generator wall already poured. - Crane girder erection works are completed at ST building. Crane girder level and alignment at ST30 has been checked. Crane rail installation work at ST30 is ongoing. - ST Pipe Rack steel erection works are substantially completed. - ST metal decking installation works are substantially completed. Slab casting works are completed on 3rd April 2013 (ST30) - HRSG Pipe Rack Steel erection works are ongoing. HRSG concrete paving slab casting works are ongoing at 22 & 31 - GT Building, Generator Hall, Oil Skid, GCB structural steel and Pipe Rack steel erection work are completed. GT Building wall and roof cladding installation work is substantially completed (97%). GTG and Oil skid area wall and roof cladding installation work is ongoing (93%). GCB structural steel erection works are completed. - Feed Water Pump Shelter steel erection works are ongoing (62% completed). - Closed Cooling Water steel erection works are completed. However, roof waterproofing works are outstanding. Water leakages are observed. - Cooling water intake: Perimeter wall Fourth lift casting works are completed. Pump room -5.4meter level cast on 17th December Above wall (W6) casting works are completed. Pump Room Roof slab level cast on 19 February Roof slab +0.30m level cast on 22nd March Cooling Water Outfall: Drop structure base slab cast on 01st January Wall first lift cast on 12th & 17th January 2013, second lift cast on 24th and 31st January Channel with open sea opened. Slab at G.L (-) 5.50 meter level cast on 22nd February and 2nd March Wall 3rd lift cast on 3rd & 9th March. Wall fourth lift cast on 19th March 2013.South side wall fourth lift casting works are completed. Gantry rail foundation casting works are completed. Pedestal casting works are ongoing. - Offshore works for outfall and intake pipeline substantially completed with exclusion of rock armor. - GTs top and GTGs walls epoxy injection completed. - GTs top and GTGs walls coating works completed, repairs on small areas are ongoing. Pull out tests completed with satisfactory results.

2 - Fuel oil storage tanks #11 and 12 Erection is complete. Final walk down is done. Punch points noted to be cleared. - FWT # 91 tank erection completed. Final walk down and punch list made. Water filling started for commissioning. - Erection of all the five gas turbines and generators are in progress and are in varying stages of erection. GT # 11 and 12 are in quite advanced stages of installation. The Erection checks such as various alignment and clearance checks on Turbine and Generator shafts, Bolt torquing checks etc are in progress. - Erection of pumps, vessels and other necessary equipment in the Water Treatment Building and Closed Cooling Water Building is complete. Main piping erection is in progress. - The progress is continuing for the Fuel Gas pipe line, Fuel Gas storage area. Buffer and gas heaters installation is in progress. Gas pipe line hydro-test done. Pigging of gas pipe line started. - Fuel oil unloading and forwarding system piping is in progress. - The HRSGs # 21, 22 casing welding is in progress. Installation of casing panels for HRSG #31 is in progress. Module erection for HRSG started and is in progress. - GRE firefighting piping is progressing. - GRP Pipe installation, lamination, backfilling and concrete encasement is ongoing. CIVIL WORKS: Cooling water intake (UPA) Fourth lift perimeter wall casting works are completed. Pump room roof -5.4meter level cast on 18th December Pump room roof slab (@ +0.30m level) part-1 cast on 19th February 2013 and 22 nd March Inner wall: The entire internal wall casting works are completed. External wall: W6 - South wall casting work is completed. W7 - Wall casting work is completed. Gantry rail foundation casting work is completed and pedestal casting works are ongoing. HRSG FOUNDATION (UHA) Concrete Paving slab casting works are ongoing at HRSG 22& 31, dated on 18 & 25 April 2013 respectively. Closed Cooling Water (UQA) Wall cladding installation works are ongoing. 97% completed. Roof waterproofing works are outstanding. Building: GTs (UMB) All turbine and generators are on foundations. All GTs Turbine foundation support grouting works are completed HRSG Pipe rack foundations completed. STs (UMA) ST-10 Foundation: Turbine pedestal cast on 06 th December Generator pedestal cast on 08 th December ST-20 Foundation: Turbine pedestal cast on 03rd January Generator pedestal cast on 05th January Generator erection works being done on 27th March 2013.

3 ST-30 Foundation: Turbine pedestal cast on 18 th February Generator pedestal cast on 26 th February 2013 ST STEP-UP TRANSFORMER (10/20/30) UBF ST10 Raft foundation is completed. Transformer wall (Second lift) casting works are completed on 06th January Wall (Third/Final lift) casting works are completed on 25 th March ST20 and ST30 Transformer walls and foundations are completed. ST Building Footings and tie beam casting works 100% completed. Grade slab casting works are completed at ST10, 20 & 30. ST Pipe Rack decking ST 10 cast on 20 th March 2013 & ST 20 area cast on 10 th March Decking ST30 casting works are completed on 03 rd April Parapet wall casting works are ongoing. ST Hall: Grade slab casting works are completed above GRP location. Hydrogen generation plant (MKG). Steel structure erection completed, roofing completed and inspected. Epoxy painting on floor (except finishing coat) done. Fencing work around the perimeter of the building is in progress and to be inspected. Water leakage test for roof is to be done.2nos of rain water pipes at each side (West & East) of the shelter are to be fixed. Chemical storage shelter (USK) Structural work completed. Wall cladding and floor painting completed. cage ladder fixed. Wall cladding, roof cladding, fixing of doors and louvers etc are to be inspected. Water leak test for roof is to be done. Rain water pipe fixing to be completed. Block wall painting in storage area is to be done. Sea water intake Electrical Bldg (UBA) RC roof work along with parapet wall completed. Plastering and painting completed. Roof water proofing work is ongoing, Inside cable trench work completed. Floor epoxy coating completed. Door closers and floor threshold are to be fixed.installation of doors has to be inspected. Rain water pipes fixed, not inspected. Walk way works to be completed. Sealant works on painted walls to be done. Chlorination Building Structural work completed, cable trenches concrete work finished, gratings are to be fixed. Block work for walls and plastering completed, painting work is in progress. PIB membrane fixed on roof, Membrane protection work done, but inspection is still pending. Doors, louvers, cage ladder and rolling shutters fixed but not offered for inspection till now. Door closers and floor thresholds are to be fixed. Sealant works on painted surfaces to be completed. Administration Building (UYC) Ground floor roof concreting completed, first floor columns completed. Roof shuttering and reinforcement works are ongoing. Guard Hut Wall painting completed. Installation of windows has been done and inspected. Walkway around the building completed. Installation of door has to be inspected. Rain water pipes fixed, not inspected. Inside floor tiling works are pending. Electrical building for fuel oil system (EGA) Roof screed completed, Completion of false ceiling for control bldg completed, Raise floor completed in control room, Floor epoxy paint completed at air cone hvac room, external plaster completed, painting completed. Walkway completed. Cage ladder fixed and inspected Electrical Bdg for Administration and Workshop (UBA) Structural work completed. Block work for walls completed. Inside and outside wall plastering completed. Leak test for roof done and inspected. Heat insulation work is ongoing. Cage ladders fixed, not offered for inspection. Doors and rolling shutters fixed

4 but not offered for inspection. Walkway construction to be completed. Sealant works on plastered surfaces to be completed. Warehouse & workshop (UST) Structural steel work completed. Block work for walls completed, plastering of walls finished,painting work completed. Outside walkway around the building completed. Floor painting, vinyl tile flooring and tiling inside toilet completed.installation of doors and windows completed. False ceiling work completed. Inspections for wall cladding, roof claddings are pending. Sanitary items (water closet, urinals, wash basin, water tap etc) fixed, but inspection is still pending. Inspection for all service lines like water pipe lines, waste water lines etc are still pending. Pressure test for pipes to be done. Toilet cubicle separation work to be done. Door closers and floor thresholds are to be fixed. Rolling shutter fixed but inspection is pending. Rain water pipe fixing to be completed. Guard House and garage. Structural work completed, block work, plastering completed.painting work completed. Walkway completed. Roof water leak test done and inspected.heat insulation work is ongoing.garage structural work and roofing completed. Floor concreting completed. Water leakage test for garage roof to be done. Cage ladder fixed but not offered for inspection till now. Membrane protection works completed on roof but inspection is pending. Fixing of rain water pipes to be completed and inspected. Black starter & EDGB Structural work, cable trenches, block work, plastering and painting work completed. Doors louvers fixing completed.. Fixing of chequer plates on cable trenches is to be done. Outside walk way work to be completed. Main Control Building-1 Structural work completed, block work, External wall plastering completed, Outside and inside painting finished. Floor epoxy painting completed. Installation of doors and windows completed. Water proofing membrane protection completed. Outside staircase structural work including handrails fixing completed. Cage ladders fixed. Walkway work to be done. Main Control Building-2 Structural work completed. Inside and outside painting completed. Outside staircase structural work including hand rail work completed. Staircase tiling to be done. Battery room tile works finished.equipment foundations completed. Raised access floor work in main control room finished. Roof water proofing membrane protection partly completed. Tile fixing in toilets ongoing. Sanitary fittings work is pending. Door and louvers fixing ongoing. Walk way to be done. Main Control Building-3 Structural work completed, block work wall plastering completed, Outside and inside wall painting completed. Epoxy painting on first floor to be done. Door and louver fixing to be done. Equipment foundations completed. Water proofing membrane protection to be completed in north side. Staircase tiling work to be done. Walkway to be completed. Water Treatment Building Steel structure work including wall cladding, roofing completed. Block work completed, wall plastering and painting completed. Tile works in laboratory room completed. Roof water proofing completed. Sanitary works in toilet to be completed. False ceiling work ongoing. Walk way to be done. Lay down Area Road work including asphalting completed. Gravel laying still to be completed. Fuel oil unloading area Asphalting work completed. Work from sub grade level is pending in west side as this area is being used as temporary access road. South side of asphalted area near to pipe rack concreted, not offered for inspection Storm Water Line

5 60% of the line already laid. Work for balance portion is continuing Waste Water Treatment System (UGC) All RC structures completed. Water leakage test (final test) is completed after completion of polyurea coating application. Pipe rack erection work is in progress. Structural steel: GT wall and roof cladding installation work is in progress. GT wall cladding (97%) + GTG and Oil skid area wall cladding (93%) & GT Roof cladding (100%) + GTG and Oil skid area Roof cladding (93%) is completed. GT Pipe Rack steel structure erection works are completed. GCB structural steel erection works are completed. GCB Roof cladding installation works are ongoing (100% completed). GT11, 12, 21, 22, & 31: Transformer trench location steel support installation and grating fixing works are substantially completed. Steel Column erection and welding works for fire- fighting line is ongoing. ST Building main steel column erection works are completed Crane girder erection works and alignment works are completed. ST wall and roof cladding installation works are ongoing. ST wall cladding overall (88%) & ST Roof cladding overall (85%) only completed. ST Pipe Rack structural steel erection works are completed. Metal decking installation works are substantially completed. ST 20 & 30: Transformer trench location steel support installation and grating fixing works are completed. Closed cooling water structural steel erection works are completed. Wall cladding installation work 97% and Roof cladding installation work is 96% is completed Feed water pump shelter structural steel erection works are completed at 21, 22 & 31. Overall 62% completed. Remaining areas erection works yet to be commenced (11 & 12). HRSG pipe rack structural steel erection works are completed at 21, 22 & 31. Overall 73% completed. Remaining areas yet to be completed (11 & 12) Offshore works: Works are ongoing. Progress achieved for Outfall pipeline: Dredging 100%: Bedding 100%: Pipe installation 100%: Backfilling 100%: Armor stone installation 20% Progress achieved for Intake pipeline: Dredging 100%: Bedding 100%: Pipe installation 100% and Intake Head installation-100% completed. Armor stone balance. MECHANICAL WORKS: GENERAL The works progressed normally during the month of May 2014 and considerable progress achieved. BOP Areas (UEJ): FUEL OIL STORAGE TANKS FOT #11 and 12: Fuel oil filling done

6 FOT #13 & 14: Fuel oil filling in progress WATER STORAGE TANKS FWT #91, FWT #92, DWT1 #, DWT #2, TWT1 #, TWT #2, ROT #11, ROT #12: Water treatment Building WWT Building Preparation for performance test is in progress. (Waiting for vendor issues to be closed) Closed cooling water Building Temporary Cooling Tower Fuel oil pumps shelter Fuel Oil system electrical building Synchronize panels is been moved to MCB Gate house and garage Final walk down prior to hand over completed and punch list raised Workshop and Ware house Re walk down for closing the punch list done, some items still balance to be closed. Administration Building Final walk down prior to hand over completed and punch list raised GT Building

7 STG Building Steel structure erection work almost completed. EDG AND BSDG MCB (Early power area) MCB (Area not included in early power) SRCC walk down in progress. FUEL GAS STORAGE AREA Works still outstanding on the gas compress and heater system. SEA WATER INTAKE CIRCULATING WATER OUTFALL Sand back filling completed Chlorination Building Electrical Building for sea water intake Electrical Building for Admin & Workshop H2 GENERATION Old and New storage tanks placed on the foundation. GT #11 GT #12

8 GT#21 GT#22. GT#31 Seal Oil skid building #11 Seal Oil skid building #12 Seal Oil skid building #21 Seal Oil skid building #22 Seal Oil skid building #31 Air Intake #11 Air Intake #12 Air Intake #21 Air Intake #22 Air Intake #31 Commissioning works in progress. Diffuser GT#11

9 Diffuser GT#12 Diffuser GT#21 Diffuser GT#22 Diffuser GT#31 Bypass Stack#11 Preliminary test completed. Bypass Stack#12 Preliminary test completed. Bypass Stack#21 Preliminary test completed. Bypass Stack #22 Preliminary test completed. Bypass Stack #31 Preliminary test completed. Main Stack # 11, 12, 21, 22 and 31 Paint touch up works in progress HRSG #11 Painting and insulation works are in progress. Piping support works in progress. Monorail for BFW pump load completed. SRCC walk down in progress. Painting for stair tower is in progress. Commissioning works are in progress. Steam blow in progress. HRSG #12 Painting and insulation works are in progress. Piping support works in progress. Monorail for BFW pump load completed. SRCC walk down in progress. Painting for stair tower is in progress. Commissioning works are in progress. Steam blow in progress.

10 HRSG #21 Painting and insulation works are in progress. Piping support works in progress. SRCC walk down in progress. Flow meter installation works after the steam blow completed. Painting for stair tower is in progress. Commissioning works are in progress. Works for closing the Punch items is in progress. HRSG #22 Painting and insulation works are in progress. Piping support works in progress. SRCC walk down in progress. Flow meter installation works after the steam blow completed. Painting for stair tower is in progress. Commissioning works are in progress. Works for closing the Punch items is in progress. HRSG #31 Painting and insulation works are in progress. SRCC walk down in progress. Flow meter installation works after the steam blow completed. Painting for stair tower is in progress. Commissioning works are in progress. Works for closing the Punch items is in progress. STG #10 Auxiliary equipment s final alignment and walk down in progress. HP turbine insulation works in progress. Enclosure works are in progress. SRCC walk down are in progress. Steam blow in progress. STG #20 Steam blow completed. Insulation works are in progress. Final walk down for equipment s and skids are in progress. SRCC walk down are in progress. Commissioning works are in progress. Steam pipes and valves inspection after steam blow completed. Enclosure works are in progress. Works for closing the Punch items is in progress. STG #30 Insulation works are in progress. Final walk down for equipment s and skids are in progress. SRCC walk down are in progress. Steam pipes and valves inspection after steam blow completed. Commissioning works are in progress. Enclosure works are in progress. GRE Piping Fire water system Pipe installation, Fire hydrant installation and Pipe pressure testing of various sections is in progress. SRCC walk down are in progress. Commissioning works are in progress.

11 GRP piping Sea water intake Piping installation inside the STG building is in progress. SRCC walk down are in progress. Commissioning works are in progress. Piping Fuel Gas supply system Commissioning works are in progress. Piping Fuel Oil system Piping Firefighting yard area Piping installation and pressure test of above ground lines is in progress. Paint touchup on going. SRCC walk down are in progress. Commissioning works in progress. Piping WTB Piping Cooling water system SRCC walk down are in progress. Commissioning works in progress. Works for closing the Punch items is in progress. Piping - Fuel Gas Buffer storage area Note: 1) Final hand over package review in progress. 2) NDT works and RT film review for golden joint in progress.

12 ELECTRICAL WORKS:

13 INSTRUMENTATION AND CONTROL WORKS: ERECTION WORKS Installed and inspected: Calibration instruments for Early Power and CC. Main Control Building Electronic Room o installation of DCS panels in (partial) Main Control Building Local Control Room o fire alarm o emergency pushbutton and synch panel o FDM DCS communication cables between various systems (installation and testing ongoing) GT11 cables, conduits, instrumentation and control equipment o fuel gas system, o HVAC, o vibration system, o fire alarm and detection, o gas detection, o waste water transfer, o CEMS. GT12 cables, conduits, instrumentation and control equipment o fuel gas system, o HVAC, o vibration system, o fire alarm and detection, o gas detection, o waste water transfer, o CEMS. GT21 cables, conduits, trays o various systems cables, instruments, conduits, cable trays o air intake cables, conduits, trays (partial) o fuel gas cables, conduits, trays, JBs (partial) GT22 o fuel gas cables, conduits, trays JBs (partial) o fuel gas heater instruments (partial) GT31 o JB in fuel gas heater area BSDG & EDG o fire alarm o fire suppression o HVAC Closed Cooling Water o field instruments, conduits and cables (partial) Fuel Oil System

14 o instruments in forwarding area o HVAC o storage tanks 11 & 12 Fuel Gas Receiving o Instruments, cables, purging system instruments Workshop & Admin bldg. o fire alarm instruments and equipment H2 Generation Plant o field instruments, cables, conduits o fire alarm Seawater Intake o level monitoring panel and LCP Temporary Auxiliary Cooling Water System o conduits, cables, instruments Waste Water Treatment System o conduits, field instruments, cables, instrument air supply tubing (partial) o HVAC (partial)

SPACE TYPE: OUTSIDE PARKING (STRUCTURE)

SPACE TYPE: OUTSIDE PARKING (STRUCTURE) Construction Criteria The unit costs for Outside Parking (Structure) space types are based on the construction quality and design features in the following table.