Skip to main content

Tekla Structures helps gain significant efficiency in Combined Cycle Power Project

Using Tekla Structures to model an entire power plant

Using Tekla Structures, L&T was able to create a 3D model of the entire power plant, which helped them to identify and resolve clashes in the design phase, and plan the construction process in detail. Tekla Structures enabled them to optimize the construction process and reduce the time required for construction.

Established in 1995, L&T-S&L is a premier engineering & consultancy firm in the power sector that is committed to providing complete power plant engineering services ranging from conceptualization to commissioning and beyond to its clients across the globe.

L&T-S&L brings together the unique strengths of both Larsen & Toubro Limited (L&T), an engineering and construction conglomerate, and Sargent & Lundy L.L.C. - USA, a global consulting firm in the power industry with roots dating to 1891. 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. Further, L&T-S&L has considerable expertise in detailed engineering for various gas-based, coal-based, and solar-based projects, including detailed design of critical facilities like STG building, Steam/Gas Turbine Equipment foundation, etc.

Seizing the opportunity and overcoming challenges

L&T-S&L trusted Tekla for a power plant project in the Middle East

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 and Bar Bending Schedule (BBS) of the Steam Turbine Generator foundation, which is the most critical part of a power station. Considering the magnitude of the 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 a bar bending schedule, which is usually managed by an off-site execution management team. Considering the criticality and complexities of the 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, the delayed arrival of input for the 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, the placement of reinforcement in the large concrete mat and its blocks with multiple embedded parts, the requirement of big size cutouts in the wall and slab, etc., were the significant ones. 

We have usually avoided including the Bar Bending Schedule (BBS) in our scope of work, anticipating a lot of manpower requirements 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 a positive spirit among our users and the customer, and there is additional enthusiasm to provide end-to-end solutions at one stop.
- Mr. Jignesh V Chokshi, Sr. Dy. General Manager, EngineeringL&T-S&L

Zero-error project is now a reality with Tekla

The adoption of Tekla software resolved the complexities attached to the foundation geometry, size of concrete elements, and amount of reinforcement to be placed in the vicinity of many openings and embedments. 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 the geometry of concrete, modeling of embedded parts (of many complex items), modeling of a variety of reinforcement and seamless connection between drawings and modeled items.

Recalling the project experience, Mr. Jignesh V Chokshi, Sr. Dy. General Manager, Engineering, L&T - S&L says, “As Tekla provides a graphical interface for reinforcement placement, customizable bar numbering, accurate bar lengths, variety of material and reinforcement reports, and the seamless transfer of modeled information to various drawings in the 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. Here are the ways how the software benefitted the team 

Zero RFI

Tekla Software itself generated BBS layout drawings and tables with bar type, length, and shape. Therefore, a manual interface to integrate bar shape, length, and layout was avoided. This resulted in zero errors and saved time in checking the rebar shape, size, or length.

Instant Drawings

Tekla generated the rebar detailing section at the required locations. Therefore, it was helpful to place “n” number 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 Structures for easier site coordination and clash detection

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

Tekla Structures for saving time and effort 

Tekla Structures helps reducing working hours, reworks, waste material improving the cost efficiency of the project

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 Mr. Jignesh V Chokshi, Sr. Dy. General Manager, Engineering, L&T - S&L, there is a nearly 35% reduction in effort over manual preparation of foundation general arrangement drawing and preparation of bar schedules. Additionally, the software facilitated the completion of the project within the specified timeline with savings of around 3-4 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 the entire foundation geometry and reinforcement details with a graphical interface turned out to be a seamless task. Ease of modeling rebar and accuracy in BBS for shape, quantities, etc., emerged as the project team's biggest plus factor and most appreciated feature.

Try Tekla Structures for Free!