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Corporate Projects Milestones Issue No: 13 | Oct 2018
Dear Readers,
Team Milestones welcomes all the readers to
the world of 13th issue of Milestones !!
It has been our great endeavour to integrate
various project locations spreaded across the
Inside this issue
country by capturing the views and highlights. Contents Page No
For all the issues of Milestones till date, it has Message from Chief– Engg., Contract & Proj 3
served as a platform for employees of Cor- Message From Skipper 4
porate Projects to share project highlights, Leader’s Talk 5
stories, knowledge, hobbies etc. . Creating Safe Ecosystem 7
Project Highlights 10
Team Milestones extends heartiest thanks to Employees Corner 12
all the readers for their amazing response. Power Sector Highlights 13
We are receiving overwhelming participation Tech Article on BAMTEC Carpet Reinf System 18
from readers outside Corporate Projects as Tech Article on SO2 Emission & Abatement -
well and Team Milestones extends heartiest In Thermal Power Plants 22
thanks to all for making our journey exciting. Article on CYCLONE 27
We have added section for Employee Kids. Know your Colleague 30
Hope you will like it. Feedback link has also Mind Game Quiz 32
been added from this edition and we solicit Power Quiz 33
your honest feedback as a tool for our learn- Identify Company’s Logo 34
ing & improvement. Safety Quiz 35
Our team would also like to thank each and Travelogue 36
every one of you who had directly or indirect- Employee Kids Section 42
ly contributed for our Newsletter. Panorama 43
Health Tips for Preventing Eye Strain 45
Happy Reading…... Foodies Corner 47
Movies Corner 50
Team Milestones Celebrations 52
Message From Chief - Engg, Contracts & Projects Dear Colleagues, As we are aware, it has been mandated to limit SOx emission at all Thermal Power Generating Sta- tions as per notification of MoEF. Accordingly, Tata Power is also gearing up for construction of FGDs in its Maithon, Mundra & Jajobera plants. I am very sure, Tata Power team will complete construction of FGDs within stipulated timeline maintaining highest standards of Safety and Quality. Friends, regarding upcoming Captive Power Plants of 120 MW each at Kalinganagar and Jamshed- pur, we are at very advanced stage of discussions with Tata Steel and hoping, construction work of these projects will progress soon. I wish all the best to our Corporate Projects team for these upcom- ing CPP and FGD projects. Digital India is an initiative and a campaign by the Government of India to transform India into a digi- tally empowered society. Tata Power is also focusing on various digitalization initiatives across the Company. I urge Team Corporate Projects to complete all their digitalization projects like Punch List monitoring digitalization, Project Issue Register Automation etc and roll them out across Tata Power in a timely manner. I wish all the best to Corporate Projects team for upcoming 13th edition of their Newsletter “Milestones”!! Wishing you & your loved ones a joyous and happy season of festivities. Rajit Desai Chief—Engg., Contracts & Projects
Message From Skipper Dear Colleagues On behalf of Corporate Projects Team, I wish you all and your family members a very happy Durga Puja, Dussehra and Diwali. May the almighty shower all the happiness & peace to everyone on this auspicious fes- tive season!! It is indeed a memorable journey of "Milestones" and we have reached to 13th edition. We are very happy to receive responses from employees of various divisions of Tata Power, IEL, MPL, CGPL etc. Feedbacks are always very important for continuous improvement and as such, from this edition of our Newsletter, we have introduced Feedback section. I urge and humbly request all the readers to send their feedbacks positively after reading “Milestones”. So far, Team Corporate Projects has been able to maintain Safety Performance Index at 100% across all locations and project sites. I am very sure, our team will be able to continue the remarkable efforts to maintain desired Safety standards during execution of upcoming CPP of Kalinganagar & Jamshedpur and all the FGDs of Maithon, Mundra & Jajobera. Our Project teams are fully geared up and have been completing all the preliminary works, which are essentially required to be completed before start of con- struction work. In view of our Company’s continuous focus on digitalization, we, at Corporate Projects, have successfully rolled out digitalization of Hand over & Takeover (HOTO) of Renewable Projects across Tata Power. Team Corporate Projects are also working on other digitalization initiatives like Project Issue Register Automation, Punch List Monitoring Digitalization etc. and I am sure, with consistent effort of our team members, we will be able to roll out these initiatives as early as possible. I wish all the best to the editorial team of “Milestones” for publication of 13th edition of Corporate Project’s Newsletter. Thanks and Regards S Saha Head - Corporate Projects
Leader’s Talk
Purushottam Thakur
CEO & ED – MPL and Chief ER Generation
Congratulations on MPL receiving Central Board for
Irrigation and Power (CBIP) Award 2018 for ‘Best Per-
forming Utility in Thermal Power Sector’. What are
your views on opportunities and challenges in set-
ting up such new benchmarks and breaking own
benchmarks?
MPL has been one of the most profitable subsidiaries of
Tata Power family and the recognition of its performance
by CBIP is a culmination of hard work put in by employees
of MPL.
MPL has been performing and has been always amongst
the top 5-6 plants reviewed by CEA. However, over the
last few months, there has been a shortfall in generation
targets due to overall fuel situation over the country for thermal power plants. We have got an oppor-
tunity to get back to a position between 1-5 in the thermal sector as per CEA norms and by the end off
Q3 FY20, to reach to No.1 position by reducing forced outages. We also endeavor to be amongst the
top three supplier of power to our beneficiaries. We would also like to leverage our generating capacity
to earn and improve our PAT by better URS sale and DSM. We would also like to operate our plant
through a language of RCM.
In any coal based Thermal Power Plant, railway connectivity remains critical for smooth supply
of coal. Maithon Plant is operational since more than seven years. In view of non-availability of
railway connectivity of MPL for such long time, what are the challenges MPL is facing in procur-
ing coal?
MPL is facing multifold challenges due to sourcing of coal through road in absence of railway connec-
tivity to plant. Some of the notable impacts both on plant operations and community around us are :
A) Higher cost of coal transportation
B) Inconvenience to the community in view of large no of trucks bringing coal to the plant.
C) Accidents resulting due to large no of vehicle movements.
D) Environmental issues due to movement of trucks on the road.
We believe that sustainable operation over a long period of time may not be possible by bringing coal
through road. This is primarily because over next few years, the traffic on the road through which the
trucks are plying will go up manifold and this might result into coal supply disruptions.
Leader’s Talk (Cont..) Purushottam Thakur, CEO & ED – MPL and Chief ER Generation In recent time, we have seen Tata Steel aggressively bidding for acquisition of new assets and simultaneously, declared expansion of existing Kalinganagar Steel Plant from 3 MTPA to 8 MTPA. What is your outlook on growth of IEL with respect to growth plans of Tata Steel? We have been engaged with Tata Steel over more than last 20 years to meet their power require- ments either on an IPP basis or through joint ventures with Tata Power and Tata Steel (IEL). Over the years, we have been able to meet the expectations of TSL and also at a group strategy level, it has been decided between TSL and Tata Power that, all the new projects under consideration by TSL shall be done by IEL. We are actively pursuing the development of CPP-2 at KPO and Power House # 7 at Jamshedpur. We are also under discussion with TSL to join hands with them for Bhubaneswar Power Ltd in Orissa and captive power houses of recently acquired steel plants by Tata Steel. As we all know, MoEF has mandated to limit SOx emissions in all Thermal Power Generating Stations as per specified limit. Accordingly, MPL would need to build Flue Gas Desulphuriza- tion (FGD) Plant to limit the SOx limit below newly specified MoEF norms (
Creating a Safe ecosystem Pramod Singh, Head - Fire & Safety, CGPL What are the major challenges associated with maintaining required safety standards at con- strution sites of thermal plants? Construction of thermal power plant has many challenges and safety implementation is also a major challenge in such a project. Constructing concrete structure for foun- dation and erection of steel structure above the ground, erection of chimney and erecting machine are the major hazard. The potential hazards in construction include, fall (from height), trench collapse, scaffold collapse, electric shock and arc flash/arc blast, failure to use proper per- sonal protective equipment. The conventional construction hazards in thermal power plant are falls, either falling workmen or things falling on workmen. The reason is that height of Boilers, Chimney and Coal galleries and simultaneous multi- layered activities. Falls consistently account for the greatest numbers of fatalities in the Thermal Pow- er construction industry. A number of factors are often involved in falls, including unstable working spaces, misuse or failure to use fall protection equipment and human error. Major challenge in maintaining Safety Standards is due to the non-availability of trained and skilled workforce, lack of awareness about Safety standards & Processes and frequent turnover of Contract workforce. Risk-based decision making is critical in Successful project management, in which deci- sion makers' attitudes towards risks play an important role. In order to achieve the schedule and cost objectives project quality and Safety objectives are sometimes overlooked and half-hearted attempts are made to achieve those objectives in the sites. Consequently, although contractors consider risks however, recent observations due to the nature of competition, contractors cannot consider to price all kinds of risks, so their bidding decisions are influenced by the amount of risks they can assume . What are the three best practices you have adopted during Project phase at CGPL site to maintain Tata Power safety standards? “Parivartan” - Safety Behavioural Change of Contract Workers: Parivartan, means change in Hindi. As the title suggests, this practice is about bringing change in safety behaviour of the contract workforce. Started at Tata Power’s 5 X 800 MW Ultra Mega Power Project (UMPP) at Mundra, Parivartan aimed to address growing safety issues at the project’s loca- tion, where more than 12,000 contract workforce were engaged at a time. General non-compliance with safety systems, procedures and personal protective equipment, was a major pain point, which
Creating a Safe ecosystem (cont.) Pramod Singh, Head - Fire & Safety, CGPL was reflected in increasing number of near misses and hand and finger injuries. These factors led the management team at Mundra, to think differently, understand the workers’ problems, and redesign systems, towards meeting requirements of the contract workforce, and also achieving safety objec- tives. The program comprised various interventions that enabled the NGO to connect with the workforce, at various times of the day, at all places such as labour colony, tea stall, and playground and construc- tion sites, and disseminate effective communication on safety. The sustained effort and safety initiatives, led to a culture of caring, helping and understanding. Use of Man lifter for high risk jobs Use of Man lifter for high risk height jobs of sheeting at TG Buildings, Trestle erection in cable and coal galleries and Structures erection at 400 KV Switch yard to avoid extensive involvement of man- power and scaffold erection. Horizontal reach, up to 60mtrs height was used to complete the jobs and it has enabled and made sure that workers can safely and effectively get around every height job at site. These man lifters are relatively compact, portable enough to take from site to site, and strong enough to help workers get their work done more effectively. Potential risk factors of fall from height was minimized and it has led to safe and faster jobs at site and changed the way we work. Pre Start Up Safety Review: Pre Start Up Safety Review (PSUSR) is being carried out jointly by a team of operation, commissioning, construction, Safety and Engineering to ensure safety of the peo- ple and equipment before startup of new equipment /systems. This has enabled Mundra Project to Commission and handover the facility in a safe manner. Safety is our Core value. Would you like to mention some of the global best practices adopted by Tata Power or use of new technologies to further improve our safety practices at Project sites? Safety is about people and connecting the mind and the heart which is the challenge especially in cul- tures where human life is not valued much and accidents are seen as part of fate even when there is glaring evidence of omission by individuals who have a duty of care. Safety is CORE VALUE of this Organization and cares for people associated with its business. We have implemented many practices and workplace safety norms to ensure safety of the people inline with the Tata Philosophy. Tata Power has appointed DuPont as Safety Consultant to guide project team. CSM, Incident Investi- gation, Capability Building, STOP (Safety Training Observation Program) processes were deployed during construction phase. Expatriate DuPont Safety Consultants visiting every fortnight and monitor- ing the effectiveness of deployment of practices and system. They are guiding project management team for improvement and providing feedback to top management.
Creating a Safe ecosystem (cont.) Pramod Singh, Head - Fire & Safety, CGPL STOP Data Pro and MySetu are two powerful analytical tool which helped in recording and analyzing statistical data for further improvement and taking management decision. STOP DataPro® software was deployed to monitor improvement in Safety behavior of the workmen. MySetu software was deployed for recording and analyzing incident. Safety Observations, Safety In- spections were also recorded in this online system. Real-time data is readily available. During your exposure to Project site what was the biggest challenge & how did you overcome the same? Despite deploying best safety systems and practices there were high non-compliance, high unsafe acts and low impact of safety training on workers. This dangerous situations triggered hiring of NGO to change safety behavior of workers. NGO - a safety change agent, first time in industry. The activities brought tremendous measurable and non-measurable benefits. Key benefits were: Win- ning workers confidence brought positive changes in their behavior towards safety, Build a culture of caring, helping and understanding each other-infighting among workers reduced, Accident and first aid cases reduced by more than 60%, PPEs compliance increased many folds. Various safety param- eters has shown improving trend and Behaviour towards safety shifted from “imposed on us" to "for us" Your message to Corporate Project team considering upcoming construction of 120 MW of Captive Power Plants at Kalinganagar and Jamshedpur. Planning safety requirements (man, material and machine) at design stage and Risk based approach will help to execute project in a safe manner. Selecting right Business Partners for project execution and explaining Safety requirements at bidding stage will help to reduce last minute surprises.
Projects Highlights
Projects Highlights (Contd…)
KPO CPP-2 PROJECT TAKEOVER FROM TATA STEEL
SITE OF- WORK-
FICE MEN FA-
SETUP CILITIESEmployees’ Corner
GREY COLOUR DAY—
Navaratri
Celebration
Fun @ Work
Fun @ WorkPower Sector Highlights
By - Vishu Vishal
Proposed Amendments in Electricity Act 2003
& Benefits thereof
Introduction
The Ministry of Power has proposed certain amendments in the Electricity Act (EA) 2003. These amend-
ments aim at bringing in efficiency & competitiveness in the Power Sector. They further seek to promote
renewable energy through Distributed Decentralised Generation (DDG) in line with the Government of
India’s (GoI’s) target to set up 175 GW of renewable generation by 2022. This amendment also intends
to support Renewable Energy through Renewable Generation Obligation & Renewable Purchase Obliga-
tion which shall help our country to achieve its commitment under Paris Climate agreement to reduce its
carbon emission intensity - emission per unit of GDP by 33-35% with respect to 2005 by 2030, thus, pav-
ing the way for:
• Clean and safe means of harnessing energy.
• A step further towards achieving energy security (i.e. energy which is sustainable, affordable, availa-
ble & reliable).
• Protect common man from volatile fossil fuel prices due to various geo-political developments.
The draft amendment makes it obligatory for licensees to supply 24x7 power to the Consumers, thereby
in a way uninterrupted and reliable supply of power. The draft amendment will also boost electrification
of automobile segment by exempting Electric Vehicle charging stations from licensing requirement as
per section 12 of EA 2003.
The proposed amendment, provides for separation of carriage and supply business wherein the assets
will be maintained by Distribution licensee/licensees under regulated regime and the supply licensees
shall supply power to customer, thereby, further increasing competition in power supply business which
shall in turn lead to reduction in tariff over a period of time.
The proposed amendment also provides for upgradation of Grids into “Smart Grids”. The large scale dis-
ruptions (large scale renewable addition, Prosumers, EV, IoT etc) is bound to make grid operation com-
plex. Therefore, the proposed provision of Smart Grids shall ensure stable and efficient grid operation.
So, holistically, various provisions of the proposed amendment shall have domino effect which will help
our country achieve energy security, sustainable development, reduce burden on Current Account Deficit
(by reduction in import of fossil fuel & increase in share of exports in world trade driven by elimination of
cross subsidy) and further drive GDP leading to employment growth.Power Sector Highlights By - Vishu Vishal Proposed Amendments in Electricity Act 2003 & Benefits thereof (Contd) Separating carriage and content (supply) business It is noteworthy that section 61 (c) of Electricity Act 2003 provides for creating conducive environment which would encourage competition, efficiency, economical use of the resources, good performance and optimum investments. The amendment has proposed for separation of carriage and supply/content business. The carriage owner shall own and maintain the power distribution infrastructure, while the power supply licensees shall be in the business of supplying electricity to consumers. The carriage/infrastructure will remain a regulated business while the supply business shall be liberalized. This will lead to creation of separate distribution licensees and multiple supply licen- sees, thereby, bringing competition in the retail power segment. The competition driven electricity market will fur- ther increase efficiency in power distribution ecosystem, decrease distribution losses and will subsequently result in cheaper power for the end Consumers. Notably, this would also provide Consumers with an option to choose from various suppliers, thus, will lead to an ecosystem of customer driven market. Rationalisation of Tariff by elimination of Cross Subsidy and promotion of Open Access The proposed amendment provides for rationalisation of tariff which had been a long term objective of the Govern- ment of India. The proposed amendment hence puts a cap on the cross subsidy surcharge at 20%. It also propos- es to progressively reduce and eliminate cross subsidization of tariff within next three years. The need for rationalization of tariff and elimination of cross subsidy surcharge has been appropriately recognised in National Energy Policy 2017 by NITI Aayog. “Currently, industrial customers are charged a price well above the average cost of electricity generation. This excess helps finance below-cost prices charged to other customers (subsidized consumers). The same cross subsidy can be provided under the proposed system by taxing the pur- chases of electricity by industrial customers and using the tax proceeds to subsidize vulnerable customers. An ad- vantage of this arrangement is that it is far more transparent than our current practice. Even more importantly, the proposed arrangement will enforce efficiency through competition among electricity distributors. It will also free up the government from having to periodically bail out discoms. Because private agents will insist on the trans- mission of electricity from Generation Company to the customer without undue losses along the transmission and distribution grid, the proposed system will also force entities owning transmission and distribution grids to operate efficiently as well. It may be noted that states such as Karnataka, which currently offer open access to electricity grid, already practice cross subsidization through taxation.” Since electricity is a major component among factors of production for goods and services, rationalization of tariff will support competitive production of goods and services and will make our exports competitive in the global mar- ket, thereby increasing our GDP and supporting employment generation. The proposed amendments shall also promote open access thereby providing opportunity to industries for competitive sourcing of power.
Power Sector Highlights
By - Vishu Vishal
Proposed Amendments in Electricity Act 2003 & Benefits thereof (Contd)
Grid Security & Operation
The proposed amendment further strengthens adherence to the Grid Standards by licensees, generating
company, transmission companies and any other person whose system is connected to the grid or in-
volved in the operation of the Power System. The proposed amendment directs the appropriate Govern-
ments to issue directions to Regional Load Dispatch Centres & State Load Dispatch Centres to under-
take measures to ensure grid security and safety and for maintaining smooth and stable transmission &
supply of electricity to any region or state.
24*7 Power supply to Consumers
The draft amendment proposes that 24X7 power supply is an obligation and State Electricity Regulatory
Commission’s (SERCs) can penalise the power distribution company (DISCOMs), if it fails to do so. The
Commission can suspend or revoke the license of the Discoms as well, which has been mandated for
the first time and will ensure uninterrupted and reliable power to the Consumers.
Direct Benefit Transfer (DBT) of Subsidy
The draft amendment proposes to introduce DBT mechanism of providing subsidy in electricity to the
targeted class of consumers by way of transferring the subsidy amount directly to the bank account of
the consumers. This is departure from the current practice wherein the Government compensates the
Discoms for providing subsidy in tariff to the class of beneficiaries as notified.
Smart Grids to ensure Grid stability & competitive power tariff
The proposed amendment provides for promotion of smart grids. The proposed upgradation of Grids into
Smart Grids shall improve the efficiency, reliability, economics, and sustainability of generation, transmis-
sion and distribution of electricity.
Due to various disruptions, the grid operation has become very complex and challenging. Some of the
disruptors are as mentioned below:
Large scale addition of Renewable Power which are often unpredictable in nature
Large scale addition of EV charging stations.
Internet of Things based applications.
Increasing numbers of Prosumers.
The proposed upgradation of Grid to Smart Grid will ensure stable and reliable operation of Grids. This
large scale conversion of Grids to efficient Smart Grids shall reduce the operational and maintenance
cost of Grid, facilitate optimum utilization of all the assets in the power sector value chain by increased
responsiveness/agility of electrical .Power Sector Highlights
By - Vishu Vishal
Proposed
Emission Amendments
Control Measuresin Electricity Act 2003 & Benefits thereof (Contd)
(Cont..)
systems. The domino effect of all these shall lead to reduction in cost of power supply to end consumers
over a period of time.
Boost to Clean and Sustainable Mobility
At present, the transportation sector in India accounts for one-third of the total crude oil consumption of
the country, out of which 80 percent of the consumption of the said oil is being consumed by road trans-
portation. In order to reduce dependability on crude oil, the Central Government has launched the Na-
tional Electric Mobility Mission Plan (NEMMP) 2020, which aims to achieve national fuel security by pro-
moting hybrid and electric vehicles in the country.
Accordingly, the Central Government, under the scheme of Faster Adoption and Manufacturing of
(Hybrid &) Electric Vehicles (FAME Scheme) is incentivising the use of Electric Vehicles (EVs) and de-
velopment of the required ecosystem. For the overall development and adoption of EVs in the country, it
is necessary to create an enabling framework and infrastructure (e.g. EV charging stations) for a shift
from the current (oil based) mode of transportation.
Distribution of electricity is only permitted to a distribution licensee under Section 12 of the Electricity Act.
But, under the proposed amendment, “transactions involving charging of batteries for electric vehicles by
charging stations shall not be construed as distribution, trading or supply to the extent undertaken for the
said purpose and subject to such terms and conditions, as may be notified by the Central Government
from time to time”
Thus, any entity is now permitted to set up Electric vehicle charging station without requiring power distri-
bution license under section 12 of the Act. This is a welcome move which will usher in accelerated elec-
trification of automobile industry giving respite to common people from pollution and volatile fuel prices
and leading our country towards Energy Security.
Strengthening Renewable Purchase Obligation
In order to strengthen Renewable Purchase Obligation (RPO), the proposed amendment provides for
imposition of penalty for non-compliance of RPO by licensees to the extent of shortfall of energy to be
complied under renewable purchase obligation. This provision shall boost investors’ confidence and will
drive growth of renewable based generation, thereby leading to reduction in carbon footprints of power
sector.
Renewable Generation Obligation
The proposed amendment provides for Renewable Generation Obligation wherein a coal or lignite based
power generating companies shall be required to establish a renewable generation capacity or to pro-
cure its equivalent amount of renewable power and sell such renewable power along with thermal power.Power Sector Highlights
By - Vishu Vishal
Proposed
Emission Amendments
Control Measuresin Electricity Act 2003 & Benefits thereof (Contd)
(Cont..)
This will promote addition of clean and cheap power to the customers. In recent years the tariff from a
solar plants has declined to a level of Rs 2.44 and the average solar tariff is now hovering below Rs 3
per unit. Large scale addition of cheap and clean renewable power will result in reduced power purchase
cost by Discoms and in turn ultimately reduce the power tariff for consumers.
Ensuring sanctity of PPAs
In recent years, the cases for foreclosure of PPA both by generators and Discoms have cropped up. The
uncertainty in sanctity of PPA leads to difficulty in financial closure of the power projects which in turn
affect the growth of power sector and competitive sourcing of funds for the projects.
The proposed amendments by imposing fine to generators and making Discoms liable for suspension
the licensee is a welcome step. This would ensure sanctity of PPAs, will boost investors’ confidence and
will facilitate competitive sourcing of debts, thereby ultimately paving way for cheaper cost of power.
Boost to Rural Electrification by Renewable Energy based Distributed Decentralised Generation
The draft amendment proposes to promote renewable energy generation (Solar, Biomass etc) by the
way of distributed decentralised generation with an aim to electrify far flung remote areas. The proposed
amendment exempts a person who intends to generate and supply electricity from Renewable Energy
Sources from any licensing requirement for such generation and supply of power.
Further, the amendment proposes for promotion of Cogeneration from Renewable Sources of Energy &
its integration with the grid. This will indeed help us to address Solid Waste management of urban cities
by setting up waste recovery based Power Stations. Promotion of Cogeneration will also channelize bio-
gas/husk/biomass based power stations along with other renewable sources in effective manner, thereby
bringing in value creation for farmers and rural households.Technical Article
BAMTEC Carpet Reinforcement System
By Sujit Jha & Satpal Singh
Preface
BAMTEC Reinforcement Technology was invented in 1994. It followed the worldwide distribution of the
flat in situ concrete floor based on the finite elements of floor calculation.
BAMTEC stands for Bewehrungs-Abbund-Maschinen-Technologie (reinforcement beam machine tech-
nology). BAMTEC carpet reinforcement system is most advanced and complex reinforcement system.
BAMTEC carpet reinforcement system not only reduces the time for construction but it also reduces the
cost of building under consideration. This is due to the substantial speed of reinforcement bar fixings.
The BAMTEC reinforcement system is like lose bar reinforcement arranged or packed into a roll as
shown in Figure-1.
In this article, different aspects like advantages, design and installation of BAMTEC slab reinforcement
system will be discussed.
Concrete when it is in plastic stage follows Bingham’s law which states that the material wont flow till
certain amount of force is applied on it. That applied force is yield shear stress. The graph between
shear stress and rate of shear strain will be drawn as shown in below. Graph of Newtonian fluids is also
shown for better understanding of various fluid characteristics.
Overview
BAMTEC is a revolutionary system for the prefabrica-
tion of rolled carpets which sets new standards of
productivity in the manufacture of reinforcement for
concrete beds and floors Following details regarding
BAMTEC slab reinforcement system is discussed in
brief here:
BAMTEC carpet reinforcement
Advantages of BAMTEC carpet reinforcement sys-
tem
Design of BAMTEC slab reinforcement
Production of BAMTEC carpet reinforcement
Installation of BAMTEC carpet reinforcement Fig.1: BAMTEC Reinforcement System
BAMTEC Carpet Reinforcement
Steel bars utilized in BAMTEC carpet is conventional ribbed reinforcement which can be welded. Vari-
ous bar diameter ranges from 8 mm to 32 mm can be used to construct BAMTEC carpet reinforcement.
The BAMTEC carpet reinforcement can be transported to project site with up to 15 m in length and up to
35m is possible to roll out. The long and spacing of steel bars can be varied as per the requirements of
the design.BAMTEC Carpet Reinforcement System (contd..)
By Sujit Jha & Satpal Singh
That is why BAMTEC carpet reinforcement can be
employed for slabs with openings, non-rectangular
slabs, and slabs on which different loadings are im-
posed, so, as it can be observed that the BAMTEC
carpet reinforcement can be extremely complex that
is why sophisticated design software with partially or
completely automated production machine is needed
to meet the requirements of the BAMTEC system.
Steel bars in BAMTEC carpet reinforcement are kept
Fig.2: Rolling Out BAMTEC Carpet Reinforcement
in place or welded to small size steel strip.
Advantages of BAMTEC Carpet Reinforcement System
They can be used also for reinforcing walls, where in comparison with welded nets, there are lesser re-
inforcement losses due to overlapping. Following are the major advantages of BAMTEC Reinforcement
System:
This system is cost effective, because finite element analysis in which a detailing software is inte-
grated and manufacturing robotics are combined in BAMTEC system. Around 75% of materials em-
ployed in cut and bent reinforcement is needed in this system. This is because finite element cur-
tailed prefabricated reinforcement is provided by the BAMTEC reinforcement system and eventually
waste of material will largely decrease.
Quality control and high efficiency ensured by the computerized and fully automated production pro-
cesses
Reinforcement laying (time and labour force) – savings up to 80-90%
Reduction of the construction period in general
Higher quality of laying operations
Modern delivery solution according to the principle just on time
Simplified structure plan
Excluded drawbacks in the process of reinforcement laying
Ideal solution for covering most ergonomic method for work on the construction site
Different bar diameter and spacing can be provided
On-site checking of fixed reinforcement can be avoidedBAMTEC Carpet Reinforcement System (contd..) By Sujit Jha & Satpal Singh Design of BAMTEC Slab Reinforcement There are number of software which can be used for the design of BAMTEC carpet reinforcement and most of it produces in- put data for the manufacturing machine. There are different methods to calculate forces act on the slabs. These forces will be used to compute reinforcement ratio for various regions of the slab. After that, the calculated reinforcement ratio is used by BAMTEC module and output BAMTEC Fig.3: BAMTEC Carpet Rolling Out Plan carpet. Moreover, if the software which is used to estimate the reinforcement ratio is not integrated with BAM- TEC module, then the designer must allocate specific amount of reinforcement for different parts of the slab based on the requirements of the slab. The plan for unrolling the carpet can be produced by soft- ware. An example of BAMTEC carpet reinforcement roll out plan is shown in Figure-3. Installation of BAMTEC Carpet Reinforcement Installation of BAMTEC carpet reinforcement is considerably quick and need less no of labourer com- pared with conventional reinforcement installation. Large carpet needs three or four workers whereas smaller carpet can be installed with only two workers with the help of cranes, and skilled labourers are not required. It is estimated that 3-8 minutes are required to place a carpet disregard of the size and weight of the car- pet. Therefore, it can be said that, BAMTEC carpet reinforcement is ten times quicker compare with con- ventional method. The carpet installation steps include delivering the carpet to the project site, then the BAMTEC carpet is left to its position on the slab; the first bar in the carpet is placed at its exact location, and finally the car- pet is rolled out. The steps are shown below in pictorial form:
BAMTEC Carpet Reinforcement System (contd..)
By Sujit Jha & Satpal Singh
Fig.4: Delivering BAMTEC Carpet Fig.5: Lifting BAMTEC Carpet
Reinforcement Reinforcement at Construction Site
.
Fig.6: Lifting and Positioning of BAMTEC Fig.7 Rolling Out BAMTEC Carpet
Carpet Reinforcement Reinforcement
Conclusion
BAMTEC Reinforcement Technology is a highly efficient system for planning, manufacture and installa-
tion of rolled reinforcing steel elements. The extraordinary economic efficiency results from the con-
sistent use of electronic data in reinforcement planning and production, from maximum material efficien-
cy and resource optimization in every work step. In near future, with growing demand of high quality and
speedy construction, use of such type of reinforcement technology will prevail Indian market also.Technical Article
SO2 - Emission & Abatement in Thermal Power Plants
By Rohit Gupta & CP Tiwari, Corporate Engineering, Tata Power
1.0 Introduction
Ministry of Environment, Forest & Climate Change (MoEF & CC) issued revised standards for coal-
based thermal power plants in December 2015. The new standards aim to drastically curtail emissions
of particulate matter (PM), Sulphur Dioxide (SO2), Oxides of Nitrogen (NOx) and Mercury. The emission
norms as per MoEF & CC notification dated 07th December 2015 is presented in Table-1 below:
Table 1
Year SPM SO2 NOx Mercury
3 3 3
Pre 2003 100mg/Nm 600mg/Nm for 500MW for >500MW
2003-2016 50mg/Nm3 600mg/Nm3 for 500MW
Post 2017 30mg/Nm3 100mg/Nm3 100mg/Nm3 0.03mg/Nm3
As per above notification, thermal power plants exceeding the limits of SO 2 emissions would need to
mandatorily install De-SOx System for SO2 abatement.
2.0 Technologies for SO2 abatement
Technologies available for SO2 abatement includes Wet Flue Gas De-Sulphurization (Wet FGD) Sys-
tem, Dry Flue Gas De-Sulphurization System (Dry FGD), Sea Water Based Flue Gas De-Sulphurization
System, Efficient Ammonia De-Sulphurization System (EADS), Amine Based De-Sulphurization System,
Activated Coke Based Technologies etc.
2.1 Wet FGD
Wet FGD makes use of chemical reagent for flue gas scrubbing process. Among chemical reagent
based Wet FGDs, most popular reagent is Limestone due to easy & abundant availability, low cost and
gypsum generation as byproduct. Gypsum generated as by-product from Wet FGD process can be used
in cement industry or can be utilized for other industrial applications. Chemical Reaction in Wet Lime-
stone FGD is presented below:
CaCO3 + SO2+ 2H2O+ ½O2 = CaSO4 2H2O (Gypsum) + CO2SO2 - Emission & Abatement in Thermal Power Plants (contd..)
By Rohit Gupta & CP Tiwari, Corporate Engineering, Tata Power
Process Flow Diagram of Wet Limestone Based FGD is presented as Figure-1 below.
Wet FGD Process is used to control SO2 for wide range of Sulphur in fuel (0.5% to 4.5%) & has very
high SO2 removal efficiency. Low cost Reagent such as Limestone is readily available, and byproduct
generated is useful product.
Disadvantages of Wet FGD includes high capital and operating cost, high auxiliary power consumption
and lower flue gas temperature necessitating gas preheating or use of wet stack.
Figure-1: Wet FGD System
2.2 Dry FGD
Dry Scrubbing process is generally used for low-sulfur coal. Dry FGD systems are typically located after
the air preheaters or after ESP. To achieve sulfur dioxide (SO2) reduction above 80% with good reagent
use, the dry scrubber is generally followed by a bag house. Hydrated lime may be used as Reagent in
this process. There are two types of dry FGD system:
Semi-Dry FGD System:
The flue gases after ID fan outlet will enter the absorber centrally from the bottom part of the reactor and
it will move in turbulent flow upward. Hydrated lime will flow downwards. Inside the absorber, water will
be injected to control the temperature and improve abatement performance. The flue gas will exit from
top of the absorber as a dust gas mixture and then enters to Bag filter. After a certain retention time in
recirculation system, by-product will be discharged out through bag filter hoppers.SO2 - Emission & Abatement in Thermal Power Plants (contd..)
By Rohit Gupta & CP Tiwari, Corporate Engineering, Tata Power
Figure-2: Semi dry FGD System
Dry FGD System:
FGD process, injection system shall be installed downstream of the existing ESP like Semi Dry FGD
System. Reagent will be injected directly in the duct. The only difference is that there is no water injec-
tion and dust / by product is not re-circulated. This is not an efficiency process because large amount of
reagent remains unreacted.
Chemical reaction of Dry FGD process is mentioned below:
Ca (OH) 2 + 2HCl → CaCl2 + 2H2O
Ca (OH) 2 + SO2 → Ca SO3 + 2H2O
Ca (OH) 2 + 2HF → CaF2 + 2H2O
The advantage of Dry FGD System includes lower auxiliary power consumption, lower capital cost and
lower foot print required for installation of system.
The disadvantages of Dry FGD System includes use of costly reagent, lower removal efficiency, high
reagent consumption and waste by-product generation.
2.3 Sea Water FGD
This technology makes use of Sea water alkalinity for scrubbing flue gases to remove SO 2. The pH and
dissolved oxygen levels of seawater are maintained prior to discharge back to sea. SO 2 is absorbed and
converted to sulphate which is natural constituent of Sea Water.SO2 - Emission & Abatement in Thermal Power Plants (contd..) By Rohit Gupta & CP Tiwari, Corporate Engineering, Tata Power Chemical reaction of Sea Water FGD is mentioned below: Seawater scrubbing & oxidation combined: SO2 + H2O + ½O2 ⇒ SO42− + 2H+ Mixing/Dilution: HCO3 + H+ ⇒ H2O + CO2 Advantages of Sea Water FGD includes less capital cost, less auxiliary power consumption, no reagent requirement and no by-product generation. However, Sea water Based FGD can be used only in coastal plants. 2.4 Efficient Ammonia De-Sulfurization System (EADS) Technology: EADS makes use of Ammonia for scrubbing of the flue gases containing SO2 and produces ammonium sulphate as by product. The reagent for the EADS makes use of either anhydrous or aqueous ammonia for scrubbing process. The by-product ammonium sulphate finds application as fertilizer as it is rich in Sulfur and nitrogen content. Chemical Reaction: 2NH3+SO2+2H2O ⇒ (NH4)2SO4 (Ammonium Sulphate) Advantage of EADS includes no solid or liquid waste generation & high SO2 removal efficiency. Disadvantages of EADS includes very high reagent cost, only few suppliers for this technology and safety concern related to storage and handling of ammonia. Dry Sorbent Injection (DSI) A potential low capital cost alternative to Wet FGD technology is DSI technology which involves the in- jection of alkaline solids into the flue gas stream. Sodium Bicarbonate in powder form (process called as Dry Sorbent Injection or DSI) can be injected in duct at downstream of Economizer. Though capital cost DSI will be substantially lower than other technology, Reagent cost will be very high leading to very high O&M cost. Also, since sorbent injection will be at upstream of ESP, sodium content in fly ash will increase and it will not be possible to use this ash in cement plant without mixing it with other unit ash. Advantages of DSI includes lower capital cost, smaller process equipment footprint, lower water require- ment, dry waste product captured by ESP, no wastewater generation or treatment requirements and no stack modifications. Disadvantages of DSI includes very high reagent cost, lower SO2 removal efficiency and high sodium content in fly ash.
SO2 - Emission & Abatement in Thermal Power Plants (contd..) By Rohit Gupta & CP Tiwari, Corporate Engineering, Tata Power 2.6 Other Technologies Amine based FGD and activated coke based FGD are two newly developed technologies. Both these processes produce the Sulphur rich gas/liquid which can be converted into Sulfuric acid as a byproduct. The Sulfuric acid can be stored and supplied for use in industrial processes. However not much refer- ences are available for these technologies across globe. 3.0 Selection of Technology General factors to be considered for selection of techno-commercially most suited technology are as under: Technical: Existing SO2 emission levels, SO2 removal efficiency required, location of the plant (inland/ coastal/access to reagent source), space requirements, process water requirement, wastewater quality/ quantity & treatment required, outage requirement, layout feasibility, quality/quantity of waste byproduct generated & its disposal/reuse, provenness of technology for Indian conditions etc. Commercial: Cost of reagent chemical sourcing, availability of reliable suppliers for reagent, feasibility of disposal/reutilization of waste byproduct generated, off-takers for byproduct, selling price expected from waste by product, logistics arrangement for reagent & waste byproduct generated. Economical: Capital cost, operating cost (Cost of reagent chemical, cost of utilities required and cost of increased Aux. power consumption), Impact on tariff, Development of techno-economically feasible model for reuse of waste byproduct. 4.0 Conclusion Considering the SO2 removal requirement, availability of reagent and reagent cost, space availability, ease of reutilization / storage / disposal of byproduct, proven nature of technology and overall feasibility for implementation as retrofit project and finally based on life cycle cost comparison, most optimum tech- nology shall be selected for Maithon, Mundra and Jojobera units.
Article on CYCLONE By Rama Chandra Reddy Butcha, Department - Chemical & Environment, Haldia A cyclone is an area of closed, circular fluid motion characterized by inwardly spiralling winds. The intense tropical storms are known in different parts of the world by differ-ent names. In the Pacific Ocean, they are called ‘typhoons’, in the Indian Ocean they are called ‘cyclones’ and over North Atlantic, and they are called ‘hurricanes’. Among various natural calamities, tropical cyclones are known to claim a higher share of deaths and destruction world over. Records show that about 80 tropical cyclones form over the globe every year. India has a vast coast line which is frequently affected by tropical cyclones causing heavy loss of human lives and property. Cyclones occur usually between April and May (called pre-monsoon cyclonic storms) and between Octo- ber and December (called post-monsoon cy-clonic storms). While cyclonic storms can’t be prevented, the loss of lives and damage to the properties can be mitigat- ed if prompt action is taken after receiving timely warnings. Cyclone Warning: Meteorologists have been using satellite images for monitoring storms for about thirty years. One of the most important applications in this endeavour is to determine the strength and intensity of a storm. In the late 1960’s, meteorolo-gists began observing tropical cyclones at more frequent intervals. The infrared sensors aboard polar orbiting satellites began providing day-and-night obser-vations while geo-stationary satellite provided the contin- uous coverage during day time. There exists a very efficient cyclone warning system in India which is comparable to the best known in the world. The approach essentially involves the prediction of the track and intensity of the cyclone using conventional as well as satellite and radar-based techniques.
Article on CYCLONE (contd…) By Rama Chandra Reddy Butcha, Department - Chemical & Environment, Haldia The most striking advantage of the earth observation satellite data has been demonstrated during the recent Orissa super-cyclone event. A severe cyclonic storm with a wind speed of about 260 kmph hit the Orissa coast at Paradip on 29th October, 1999 causing extensive damage to human life, proper- ty, livestock and public utilities. The National Remote Sensing Agency acted promptly and pro- vided spatial extent of inundated areas. A cyclone warning is issued as soon as gales or stronger winds are expected to affect coastal or island communities within 24 hours. It identifies the communi-ties being threatened and contains the cyclones name, its location, intensity, and its movements. Forecasts of heavy rainfall, flooding and abnormally high tides are included when necessary. Communities under threat are also advised to take precau- tions necessary to safeguard their lives and property. Safety Precautions and Timely Actions to Reduce Damage: Cyclone is 24 hours away: i. Fill water buckets and cover them. ii. Top up your car’s fuel tank. iii. Ensure you have fresh batteries for your radio. iv. Make sure you have adequate supplies of prescribed medicines. v. Stock up on non-perishable food items if required. vi. Ensure your neighbours are aware of the issued warning. Cyclone is 16 hours away: i. Listen to the media for regular updates. ii. Ensure your children are home. iii. Gather tools that will be needed for emergency repairs, e.g. hammer, nails, rope, and tarpaulins. iv. If you live in a caravan, identify a solid structure to which you can move if required. Cyclone is 9 hours away: i. Prepare the safest part of your house (usually the bathroom) and place emer-gency stores there. ii. Account for and lock up your pets. iii. Gather protective gear and place in shelter.
Article on CYCLONE (contd..) By Rama Chandra Reddy Butcha, Department - Chemical & Environment, Haldia Cyclone is 6 hours away: i. Listen to the media for regular updates. ii. If you use gas, turn if off at the bottle. iii. Stay in a safe place, don’t move. iv. Do not make unnecessary demands on the emergency services. v. Beware of the calm “eye” of the cyclone and do not go outside until you are advised to do so. When the Cyclone has passed: i. Listen to the media for regular updates. ii. Do not make unnecessary demands on the emergency services. iii. Do not touch wet switches, and beware of fallen power lines, treat them as if they are live. iv. Stay at home resist the urge to go sightseeing. The water surge caused by your vehicle can send flood water into people’s homes. If a cyclone comes, it is strongly advised that you stay in a safe place, listen to the radio and abide by the instructions on the radio. But move early. Remem-ber that most injuries and fatalities in cyclones result from people being hit by flying debris while outside in high winds. Outside movement becomes both dif-ficult and dangerous once wind gusts exceed 85km/h and should cease once gusts exceed 100km/h. If you feel your house/shelter is not safe, see if you can shelter in a neighbour's house or move to the community emergency centre as advised by the radio. Check to see that your neighbours, in particular those who are elderly, have disabilities, or are living alone, are safe. (Warning, Safety Precautions and Timely Actions to Reduce Damage of Cyclone.)
Know Your Colleague Name: Sujit Jha When do you celebrate your birthday ? 30th December Your current role in the company ? Presently, I am heading Civil Construction team of Kalinganagar CPP 2 project Your native town? I belong to Raiganj which comes under Uttar Dinajpur district of West Bengal Where did you complete your education? I completed my Engineering from Indian Institute of Engineering, Science & Technology, Shibpore (Formerly B E College) and further completed Post Graduate Diploma in Manage- ment from IMT, Ghaziabad Your technical area of expertise? Project Execution, Quality Assurance & Project Engineering Can you please share your previous work experience and any achievement that you would like to highlight? I started my career from C. E. Testing, a company which works in Geo-Technical Investiga- tion field. I also worked in various infrastructure projects as an employee of Consulting En- gineering Services, New Delhi. After that, I joined power industry (Reliance Energy Ltd) and successfully completed construction of 2 x 300 MW Rosa Thermal Power Project. Then under the umbrella of CGPL, I worked for 5 x 800 MW Mundra UMPP and my journey con- tinues in Tata Power in different functions like Engineering, QA&I & Corporate Projects… What's the one difficult thing for you in your current role and how do you address that? Managing project management work for entire civil works of KPO CPP 2 project with very small team is a big challenge for me. I personally believe, Collaborative team effort and very good planning are two major tools to address above challenge. What quality or a characteristic do you really admire in your colleagues or others beyond work? Honesty, sincerity and care for others If you could pick up a new skill in an instant what would it be? I love to learn the skill of Managing emotions in an extreme negative situation
Know Your Colleague (Cont..) Best appreciation or a compliment that you have ever received. Media was running after me for taking my interview when I stood 1 st in North Bengal in my 12th board exam. This was my best recognition I will cherish forever… Describe the Best Work Day in your career. The day I met legendary personality, Mr. Ratan Tata in CGPL is the best memorable day in my career which I remember forever. How do you rejuvenate yourself at work? I love to play games. Whenever, I find leisure time, I used to play Table Tennis, volleyball etc which always rejuvenate me at my work Could you please tell us about your family? My better half, Komal is a homemaker who is sincerely taking care of our kids Saurav and Sanjana. Our Son, Saurav is in std 8th and daughter, Sanjana is in std 5th. Saurav loves ad- venturous sports and Sanjana is fond of dance. What are your hobbies? I love to nurture plants and feel very excited when I see them growing. What’s your favorite travel destination? Though I love to visit deserts & sea beaches, but Hill Stations always attract me and are very close to my heart. Any personality you really admire or a quote that keeps you motivated? There are many personalities I admire. But, if you ask me one name, I will love to take name of Mr. A.P.J. Abdul Kalam. Among his many quotes, one quote always encourages me. “Dream is not that which you see while sleeping it is something that does not let you sleep” If you were to Thank one person for helping you become the person you are today, who would it be and what did he/she do? I am grateful to my father who always stands with me and keeps my moral high. With his motivation, encouragement and blessings I became a person what I am today. Any message to the young colleagues? Whatever job you are doing, do it honestly. I truly believe “honesty is the best policy”. One more thing, do respect others, then only others will respect you.
MIND GAME - Quiz
Send your answers to projectsnewsletter@tatapower.com along with Passport size photograph. The winner (1st cor-
rect entry) will be featured in the next issue and also will be awarded
1. India has made alliance with which country to eliminate TB?
[A] Bhutan [B] United States [C] France [D] Nepal
2. Which of the following is the first country to successfully land robotic rovers on an asteroid Ryugu?
[A] United States [B] China [C] Japan [D] France
3. Which section of Aadhaar Act has been struck down by Supreme Court that permit private entities to
avail Aadhaar data?
[A] Section 58 [B] Section 57 [C] Section 55 [D] Section 59
4. Which of the following has been appointed as the transaction adviser to the Ministry of Defence?
[A] SBI Caps [B] SEBI [C] NITI Aayog [D] Department of expenditure
5. What is the proposed universal broadband connectivity speed under National Digital Communications
Policy -2018 (NDCP-2018) unveiled recently?
[A] 100M [B] 50Mbps [C] 200Mbps [D] 500Mbps
6. Which state has topped the charts among States in terms of “2018 Ease of Living Index” rankings
launched by the Ministry of Housing and Urban Affairs (MoHUA)?
[A] Tamil Nadu [B] Madhya Pradesh [C] Odisha [D] Andhra Pradesh
7. Who has won the women’s singles 2018 China Open badminton title?
[A] Akane Yamaguchi [ B] Carolina Marin [ C] P V Sindhu [D] Nozomi Okuhara
8. Which country hosted the first-ever women-only foreign minister conference?
[A] Canada [B] India [C] South Africa [D] Brazil
9. West Bank, which is in news recently, is the disputed territory between which of the following countries?
[A] Palestine & Syria [ B] Jordan & Egypt [C] Egypt & Syria [ D] Israel & Palestine
10. Which launch vehicle of ISRO has successfully launched NovaSAR and S1-4 earth observation satel-
lites of U.K from Sriharikota spaceport?
[A] PSLV-C40 [B] PSLV-C44 [C] PSLV-C42 [D] PSLV-C41
Answers of Last Issue’s Question Winner of Last Issue’s Questions
Ramdas Sadula
Dept: Project Development, Dherand
1. b- Reunite
2. a- Mia Mottley
3. c- Telangana
4. a- Madhya Pradesh
5. a- Nepal
Congratulations to Mr. Sadula !!!Power Quiz Send your answers to projectsnewsletter@tatapower.com along with Passport size photograph. The winner (1st correct entry) will be featured in the next issue and also will be awarded 1. Which was the first atomic power house of India? A. Jaitapur B. Tarapur C. Kundankulam D. Kaiga 2. Which of the following India’s atomic power house structure shows highest resemblance with Fukushima Daiichi of Japan? A. Jaitapur B. Kundankulam C. Tarapur D. Kaiga 3. Which was the first largest hydro-power project in India? A. Bakeshwar Project B. Giral Project C. Parichha Project D. Shiva-Samundram Dam 4. Which was the India’s first electrified city? A. Chandigarh B. Darjeeling C. Indore D. Ahmadabad 5. Which of the following is not correctly matched? A. Tarapur- Tamil Nadu B. Kalpakkam- Tamil Nadu C. Kaiga- Karnataka D. Jaitapur- Maharashtra 6. Which among the following is not thermal power project? A. Obra Power Station B. Giral Project C. Pochampad Project D. Kudankulam 7. When was Atomic Energy Commission established? A. 1948 B. 1949 C. 1950 D. 1951 8. When was India’s first Nuclear Power Reactor established? A. 1966 B. 1967 C. 1968 D. 1969 9. When was the National Hydro-electric Power Corporation (NHPC) established? A. 1975 B. 1976 C. 1978 D. 1971 10. Gorakhpur Atomic Thermal Power Station located at which state? A) Haryana B) Uttar Pradesh C) Karnataka D) Bihar Answers to last issues Power Puzzle
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