The Construction Scheme: Jinnah Hydropower Project Implementation On EPC/Turnkey Basis
The Construction Scheme: Jinnah Hydropower Project Implementation On EPC/Turnkey Basis
The Construction Scheme: Jinnah Hydropower Project Implementation On EPC/Turnkey Basis
Contract No:DEC-PJHP-0008
Feb. 2006
Table of Contents
Section I
1 The Project.......................................................................................................3
1.1 general situation of power station............................................................3
1.2 instalation Work scope............................................................................3
2 Construction Organization structure................................................................4
2.1 Organization chart..................................................................................4
2.2 Manpower Planning................................................................................5
3. Arrangement of Work Yard, water and electricity supply, Temporary Building 6
3.1 Temporary Building .................................................................................6
3.2 Electricity and water supply...................................................................7
4. Construction equipments and facilites planing ...............................................7
4.1 Main construction equipments.................................................................7
4.2 Main test instruments & facilities...........................................................10
5. main equipments Installation technique.........................................................12
5.1Standard and regulations.......................................................................12
5.2Construction progress planing................................................................15
5.3 Loading/unloading &storing...................................................................15
5.4 Power House Overhead Bridge Crane Installation Procedure..............16
5.5 Turbine Generator Unit Installation........................................................17
5.6 Electrical Equipment Installation............................................................20
5.7 oulet and inlet Gates, Trash rack Installation........................................25
5.8 Gantry Crane Installation.......................................................................26
5.9 Transmission line installation.................................................................27
6.Turbine generator Unit test run....................................................................28
7.completion....................................................................................................29
Section Ⅱ
1. The project
The Jannah irrigation sluice lies in the Indian River downstream 5km of the Mianwali
Kalabagh, Mianwali, and Punjab, Pakistan. It is the first key project with the function of rising
The Jannah power station is a diversion type hydropower station located on the right bank of
the irrigation sluice with the river fall formed by irrigation sluice and ancillary works such as
channel and power house, in which 8 silo case turbine generator units will be installed, power
per unit is 12MW and the total capacity is 96MW. Annual output of the power house is
6.88billion Kw h , with max flux 2800m3/s, water head 4.7m, hydro turbine speed 72.6rpm
and generator speed 750rpm connected with the speed up gear box. The electricity will be
delivered at 132v primary voltage to the local electrical fence then transferred to Mari Daud
21 ) The steel structure( including: gantry crane, inlet gauge ,tail water and the trash rack etc.)
1 item
23 ) all Equipment inspection 、 unloading 、 storing and the 2nd handling in site 1 item
24 ) Electrified reconstruction of the 14- water sluice gate headstock gear 1 item
26)all permanent basic Embedded parts and pipes installation and part of built-in part manufacture
1 item
According to the features of Jannah project, with the aim of carrying out further construction,
improving the work efficiency and quality, our company will set the Pakistan Jinnah
hydropower project installation works of the E/M equipment & steel structure project office
with a system of project manager responsible for whole construction; consisting of 1 project
manager; 2 deputy project managers; 1 chief project engineer; under the conduct of project
office there are 4 managerial divisions in charge of the construction in site and arrangement
of daily life; 8 construction groups are responsible for specific construction works.
The organization chart as showing below:
Project manager
Wiring group
Piping group
Lifting group
Steel group
Elect Group
Test group
Wel
M
1.Managerial staffs 18
Project manager
1 4 6 Accountant 1
department
2 Electrical engineer 2 7 Cashier 1
3 Mech. engineer 2 8 Planning control 1
4 Test engineer 2 9 Mater. & equip. 1
5 Q/C engineer 2 10 Logistics department 2
Total 18 persons
Number of staff
3.1 . 1 employer should provide construction site , Lodging house and office refer to the
requirements below:
a. The office: building area is 181m 2, decoration and design standard is the same
as the contractor’s: The project manager office is 26m 2;division offices 6 sets,the
standard is 3.5*5 m 2 and the total area is 105 m 2;total area of conference room and
anteroom is 44m 2;duty room is 6m 2.
b. Lodging house: building area is 577.5m 2, decoration and design standard ( with
one bedroom and one bathroom for two person ) is the same as the contractor’s, total
number is 33sets,17.5m2/set.
c. Canteen: building area is 80m 2, decoration and design standard is the same as
the contractor’s.
d. The local staffs and workers lodging house: 20 sets and 24m 2/set.
The specific arrangement of the camp will be determined together with the general
project camp layout
3.1 . 2 in nine month after starting the works, employer should supply temporary storing
yard and temporary warehouse(including temporary fence). The appliances including:
- Storing yard: Flatted with the pebble or crush, including drainage trench and fence ,the
Total area is 5000 m 2.
a. Equipment & material store house: total area is 319m2;in which heat room takes up
60 m2;
d. Workshop for working group: 5 set, 17 .5 m 2 per set, total area 87.5 m 2;
e. Opening working yard: 500m2, at least require rammed mortar or concreting surface.
The construction area is 1857 m 2; opening working yard area is 500. The temporary
construction yard should be flat, compacted, water and electricity supplied and
automobile accessed.
Employer is responsible for the supply work and sufficient supply of electricity and water
in site. And according to the local water and electricity authority price requirement and
relevant administrative specifications, Contractor should pay employer the fee.
Employer is responsible for providing electricity and water supplying facilities, which
including two LV (0.4kv) adoption points at powerhouse and the gate dam.
Truck 1 15t
Truck 1 5t
Lorry 2 1.5t
Jeep
Fork lifter 1 3t
Winch 2 5t
Chain hoist 4 5t
Chain hoist 5 3t
Chain hoist 3 1t
Screw jack 4 5t
Cable clamp 1
Theologize 1 J2 (T2)ANGLE
Level meter 2 S3
Magnetic detector 1
Remark:
1.If giant Flat truck or large-tonnage loop wheel machine needed, it can be rented in local
place.
2.The others will be purchased from China.
T72-AV 0--600V
24 AC volt-ampere 4sets
0—30A 0.5grade
Japan C1102 0—1000V
25 DC volt-ampere meter 3set
0—30A 0.5grade
26 Millivoltmeter 2set C21-m V 0~100mV
27 Microampere meter 1set ZS-1 0~2000μA
28 Double bridge 1set QJ44 10-4--11Ω
29 Standard resistance box 1set ZX21 0.1--9KΩ
Photoelectric
30 1set DT-2236 0.5--9999RPM
conversion device
Digital clamp current
31 1set MODEL 2002P 2000A
meter
CFMFP03E1 Swiss
32 Standard power meter 1set
3×380V/10A 0.2grade
33 Pressure test device 1set YJY-600A 60Mpa
YB-150 YB-600
0.4grade
35 Clamp phase meter 1set MG64 0~360O
POS-9020
36 Oscillograph 1set
Two trace20MHZ
37 Digital multiemeter 3sets DT840D
1000A/75mV
38 Current divider Set/each
2000A/75mV
39 Three-phase booster 1set TDGC 10KVA
HV electricity pen、
protection、
Remark:
1. The test instrument will be newly purchased in China. In addition to those we rent at site.
2. The model and quantity of test instrument can be changed to meet the practical need.
Considering complete the work on schedule and Due to the Jannah power station’s feature:
the number of generator sets needed to install is large, the time for installment is compacting
and the intercrossing work is heavy, we will carry out the construction with 2 sets of bridge
crane, 2 assembly yards (1 assembly room and 1 steel structure platform) and 2 working
faces operate in the same time. In the aim of completing the works on time we will carefully
1. The unit work quality grade estimation standard & codes of the hydraulic power
station capital works
DL507-93
4. Standard for acceptance test of hydraulic turbine governor and oil pressure system
GBFF9652.2—97
GB50150—91
GBJ233—81
8. Standard for construction and acceptance of equipment in site and pipe welding
engineering GBJ236—82
11. Code for manufacture, installation and acceptance of hydraulic steel structure
DL/T5018-94
12. Code for construction and acceptance of power transformer, oil compression reactor
and transformer electric equipment installation engineering
GBl48—90
13. Code for construction and acceptance of 110—500kV overhead power line GBJ233-
90
15. Code for test run of hydraulic turbine generator unit DL507-93
16. Guideline for construction technique of bulb tubular turbine generator unit
DL/T5038-94
19. Installation and debug workmanship of the turbine thrust bearing and the guide
bearing SD288
20. The static excitation system technical requirement of the large and medium turbine
generator units SD299
JB3372
22. The installation and acceptance of the electrical equipment and facility
GB232
23. The basic automation facility system technical requirement of the hydraulic turbine
generator unit GB/T11805
26. The acceptance technical regulations of the electrical works( pipe line )
DL5031-94
SDJ151-82
28. The acceptance technical regulations of the piping line works ( Steel pipe )
GBJ235-82
GBJ303-88
GB50194-93
31. The acceptance regulations of the installation of the compressor 、 fan and pump
GB50275
32. The grade estimation standard of the installation of the hydraulic mechanical
equipment SDJ249.4
34. The insulation and the HV test technique of the HV transmission facility
GB311
DL/T5080-1997
DL/T546-94
YD5079-99
DL/T534-93
47. The power oil and the sulfur hexafluoride inspection means
SD304~313JGJ46-88
48. The regulation of hydro-power works safety & industrial hygiene DL5061-1996
Works Schedule
1 Switch Yard and transmission line delivery of current 18th Sept. 2008
Construction Plan
The construction schedule plan is based on the time for arrival of equipment specified as the
Implementation on EPC/Turnkey Basis installation works of the E/M equipment & steel
structure.
a. Use of lifting point and hoisting tool will be subject to the marking and weight on the
b. Download the equipment within 30t in weight with the 30t mobile crane, and the equipment
with over 30t could be handled by one or two heavy duty crane rented temporarily at site.
c. Except the equipment suitable for downloading directly in the installation place, the rest
downloading the equipment. Continue further inspection and keep a written record for file if
Storing
a. Temporarily enclosing wall and drainage channel will be built around the storing area.
storing place. Put crossties underneath the equipment and cover them with the waterproof
cloth and cover with asbestos tile before reinforcement. Important equipments such as the
shaft, generator and runner shall be covered with waterproof cloth before erecting the
instruments and equipment with special requirement should be protected in the thermostatic
chamber.
e. The equipment, which stored in the warehouse must be registered and recorded. Every
Installation Procedure
Preliminary Work
Rail erection & Stage II Concrete
Grouting
Electrical wiring
Electrical Drive-Part Wiring
Power Supply Part Winding Drum, Pulley and Wire Rope Connection
Installation
Accessories Installation
No-load Operation
Installation Instructions
a. Use the civil construction company’s crane to lift and install most parts of the bridge crane
load test.
Preparatory Work
Governor Installation
Runner Chamber and Lower Part of
Expansion Joint Positioning Temporarily
Servomotor Installation
Main Shaft Assembly &
Main Shaft Installation
Oil Head Pre-installation
Stage II Concrete Pouring
1. Assemble the tail tube into a whole in the powerhouse and lift down section by section to
verticality and plane, then fix it after checking; no change after rechecking and then pour
concrete.
3. Assemble the access shaft steel case section-by-section in the erection place or on the
steel platform, then lift down to the erection position for adjustment and centering and put
4. Assemble the wicket gate mechanism into a whole in the erection place, then lift it to the
installation place after turning over and connected with the ring seat and adjust it accordingly.
5. Assemble the main shaft and guide bearing in the installation place and lift to position and
the erection place, turn it over and lift to position in connection with the main shaft with
special tools.
7.Install the runner chamber and adjust the gap between the runner and runner chamber.
8. Inspect the speed increaser gearbox in the powerhouse, clean it with the lubrication oil;
and then check its rotation flexibility. Lift it down to the assembly place for installation after
checking.
9. Check the bearing and insulation of electrical parts of generator in the powerhouse and
perform insulation pressure test. Lift it down to the assembly place for installation after
checking.
10 . Before connecting the shaft of speed increaser gearbox and turbine shaft with
generator shaft and speed increaser gearbox, check and adjust the axis deviation to
qualification by jigger. Check rotating part with jigger after their connection.
11.Centering, adjust and fix the oil head according to its actual position.
The main electrical equipment consist of HV system, LV system, control system, lighting
system, communication system.
Preparatory Work
Trial Run
a. Preparation
Be familiar with the design drawing, construction norms and the technical document and
All equipments should be checked carefully in accordance with design requirement, order
inventory, package list, equipment instructions and norms after their arrival on site.
Equipment to be tested shall be exceeded according to standards and requirements for
product.
g. Installation
Carry out installation according to the requirement of design and relevant standard with on
time and quality assurance.
h. Check and Test
After equipment installation, carry out test according to design requirement and relevant
standard. Proceed with other tests and simulation tests according to relevant specifications
prior to passing the test.
i. Trial Operation
After the acceptance of installed equipment, trial operation with power should be preceded
with available start conditions in any other ways.
j., Document Hand-over for Completion
Hand over all relevant documents within one month after the trial operation to facilitate the
client for equipment operation management and maximum efficiency thereof.
Preparatory Work
HV Switchgear Installation
Communication System
Cable Holder & Bridge
Station Transformer
Frame Installation
Cabinet
Installation
Installation
Distribution
Installation
23
Jinnah Hydropower Project Quality Control Procedure of E&M Installation Works
Transformer Installation
HV Circuit Breaker
HV Isolation Switch
Lightning Arrester
Main Transformer
Switchinstallation
Current& Voltage
Installation
Installation
Installation
Installation
Pipeline Wiring
Lamps Installation
1.HV/LV switchgear, control cubicle, distribution box and control box installation
Cabinet Installation
Cabinet Wiring
Acceptance
a. Production of the foundation steel should base on the design drawing. The relative
elevation between the foundation steel and ground after completion shall meet the
requirement of design.
b. The equipment should be transported in good weather. Apply manual-handled forklift for
load & unload and short-distance transport. During handling process, use firmly-tied ropes to
Preparatory work
Insulation Oil
Filtering and Pressure Body Check
Accessories Installation
Oil Filling
Trail Run
a. For main transformer installation, gantry crane, bridge crane or truck-crane can be used
for unloading on site. And the transformer rail or the trailer could be used to transport the
the core, winding, voltage switch, lead line etc. Check all bolts tight and carry out the
electrical test. After the body check, apply qualified transformer oil for washing and then fill
transformer.
Preparatory Work
Dry test
Preparatory Work
Crane Test
1. Lifting and erection the main parts of the gantry with the civil engineering’s crane or mobile
crane.
2. If the load weight of trolley exceeds the lifting capacity of crane, some parts can be
outdoor.
3. After finishing the installation, perform trial run, rated load and 1.25 times load tests, the
load of which can be made by Party A with steel bars for civil engineering.
Preparatory Work
Tower installation
Earthing Work
Test
Acceptance
1.Check the dimension of the parts and clean the base before working.
2. A complete construction scheme shall be available for the tower unit and preventive
etc.
4 . Connection between the earthing line and tower should be contacted well to facilitate
6.Unit Commissioning
Dry test
Manual Start-up
Governor
Generator Test Test
Short-circuit
Jinnah Hydropower Project Quality Control Procedure of E&M Installation Works
7.Acceptance of Works
The reliability of 30days for operation of 8 turbine generator units is over for the completion of
works as specified in the contract. The contractor shall hand over the units 、 spare
parts 、special installation tools and documentations to the client as the requirement of the
contract.
After the finishing the clean of working area and withdrawal of construction equipment and
staff, then the installation of mechanical and electrical and metal construction is fully
complete.