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Tekla Structures helps gain significant efficiency in Combined Cycle Power Project

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L&T-S&L is a premier engineering & consultancy firm in the power sector which provides complete power plant engineering services ranging from conceptualization to commissioning and beyond to its clients across the globe. This synergy has enabled the company to consistently deliver technically sound and operationally efficient solutions like Project Management Consultancy, Detailed Engineering, Owner Engineering and Lender engineers to various domestic and international clients

L&T-S&L was entrusted by an EPC company based in the Middle East with detailed engineering of a combined cycle power plant in the region. The company’s scope included detailed designing and preparation of foundation general arrangement drawings as well as Bar Bending Schedule (BBS) of the Steam Turbine Generator foundation which is the most critical part of a power station. Considering the magnitude of load of electricity producing equipment foundation i.e. the Steam Turbine Generator foundation, the scope became wider and the project, in turn, rendered even more challenging.

Further, the project presented other challenges including a mandate for bar bending schedule, which is usually managed by an off-site execution management team. Considering the criticality and complexities of steam turbine engine’s foundation in terms of size, geometry, numerous openings, embedment and large density of reinforcement bars in concrete elements, it was included in the company’s scope of work. Besides, delayed arrival of input for machine foundation left no room for any mistake or rework and completing the project within the given time frame thus became quite demanding. Amongst other construction challenges, placement of reinforcement in large concrete mat and its blocks with multiple embedded parts, requirement of big size cutouts in wall as well as slab, etc. were the significant ones

Zero- error project

Adoption of Tekla software resolved the complexities attached with the foundation geometry, size of concrete elements and amount of reinforcement to be placed in vicinity of many openings and embedment. Graphical interface, intelligent data, accurate BBS and material management offered by Trimble India’s flagship software, Tekla Structures enabled the smooth execution of the entire work, right from making geometry of concrete, modeling of embedded parts (of many complex items), modeling of variety of reinforcement and seamless connection between drawings and modeled items.

Recalling the project experience, Jignesh V Chokshi, Senior Deputy. General Manager, Engineering, L&T-S&L said, “As Tekla provides graphical interface for reinforcement placement, customizable bar numbering, accurate bar lengths, variety of material and reinforcement reports and seamless transfer of modeled information to various drawings in shortest time, the reinforcement with different colors and capability to share the model with site team have helped a lot during preparation, review and execution of this complex task.”

One of the most challenging parts of the entire project was the Bar Bending Schedule (BBS) which was easily surmounted by implementing Tekla software in the process. “We usually avoid including Bar Bending Schedule (BBS) in our scope of work, anticipating a lot of manpower requirement and hassle. The confidence we have gained using Tekla for such a complex foundation has now encouraged us to include Bar Bending Schedule (BBS) for the entire project. Our customer has positively responded to the outcome and is going to consider the full scope in future projects. I am happy to share that this experience has spread positive spirit among our users and the customer, and there is additional enthusiasm to provide end to end solutions at one stop”, said Chokshi

Zero RFI

Tekla Software itself generated BBS layout drawing as well as table with bar type, length and its shape. Therefore, manual interface to integrate bar shape, length and layout was avoided. This resulted in zero error and saved time to check the rebar shape, size or length.

Instant drawings

Tekla generated the rebar detailing section at required locations. Therefore, it was helpful to place “n” numbers of Tekla generated sections.  In fact, based on site demand, additional sections were produced with almost no effort or time.

Easier site coordination in 3D

Tekla Software had better and understandable approach in anticipating rebar detailing at penetrations, which saved time and facilitated easier on- site execution.

Save time and effort

The numerous benefits that Tekla Structures brought to the project can be categorized both quantitatively and qualitatively. Quantitative benefits included man- hours/time saving, greater cost efficiency due to insignificant rework, material savings, on time/ahead of time project completion, etc. According to Chokshi, there is nearly 35% reduction in effort over manual preparation of foundation general arrangement drawing and preparation of bar schedules. Additionally, the software facilitated completion of the project within the specified timeline with savings of around three-four weeks.

On the other hand, the qualitative gains of using Tekla Software included ease of project execution & management, reduced wastage and seamless collaboration among different stakeholders. Visual interface improved placement of multiple bars of complex shapes, curtailing bars at openings and embedment. Preparation and review of entire foundation geometry and reinforcement details with graphical interface turned out to be a seamless task. Ease of modeling rebar and accuracy in BBS for shape, quantities, etc. emerged as the biggest plus factor and most appreciated feature by the project team.

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