TECHNICAL CONDITIONS OF CONTRACT PART-1 … · PART-1 TECHNICAL SPECIFICATION FOR ... 2.23.7 Gas pressure regulators ... 2.35.22 Aux steam piping to turbine gland seal

TENDER NO:PSER:SCT:ABJ:T1178:11

VOLUME - I F

TECHNICAL CONDITIONS OF CONTRACT PART-1 TECHNICAL SPECIFICATION FOR

IDENTIFICATION & RECEIPT OF MATERIALS, ERECTION, TESTING, COMMISSIONING, HANDING OVER ETC OF STEAM TURBINE & AUXILIARIES, GENERATOR & AUXILIARIES, PUMPS, PIPING, MISC EQUIPMENTS, INSULATION, PAINTING INCLUDING UNLOADING &

PLACEMENT OF GENERATOR STATOR ON FOUNDATION OF TG & AUXILIARIES FOR

2X270 MW

CHANDWA PROJECT, UNIT-1 & 2

LATEHAR, JHARKHAND

BHARAT HEAVY ELECTRICALS LIMITED ( A GOVT. OF INDIA UNDERTAKING )

POWER SECTOR – EASTERN REGION PLOT NO. – 9 / 1, DJ – BLOCK, SECTOR – II, KARUNAMOYEE,

SALT LAKE CITY, KOLKATA – 700091.

TENDER NO – PSER:SCT:ABJ-T1178:11 VOLUME–IF TECHNICAL CONDITIONS OF CONTRACT(TCC) PAGE 2 OF 30

PART-1-TECHNICAL SPECIFICATION

CONTENT

CLAUSE NO

DESCRIPTION

1.0 NAME OF WORK 2.0 SCOPE 3.0 MAJOR EXCLUSIONS 4.0 MAJOR TERMINAL POINTS 5.0 PRELIMINARY WORKS 6.0 MATERIAL HANDLING AND STORAGE 7.0 PRESERVATION OF COMPONENTS 8.0 WELDING HEAT TREATMENT, RADIOGRAPHY AND NON-DESTRUCTIVE

TESTING 9.0 CONDENSER PAINTING 10.0 FINISH PAINTING OF TURBINE, GENERATOR, PIPING, EQUIPMENT,

SYSTEMS AND OTHER PACKAGES 11.0 SPECIAL ERECTION PROCEDURE TO BE FOLLOWED BY CONTRACTOR 12.0 ERECTION INSTRUCTION 13.0 HYDRAULIC TEST AND OTHER TESTS 14.0 PRESSURE TEST FOR PIPING 15.0 DATE OF TEST, IDENTIFICATION OF PIPING TESTED, TEST FLUID, TEST

PRESSURE, APPROVAL OF ENGINEER ETC 16.0 PRE-COMMISSIONING TESTS AND COMMISSIONING OF UNITS 17.0 CLEANING OF PIPES, VALVES, ACTUATORS, BEARINGS, GEAR BOXES,

AND OTHER EQUIPMENT / COMPONENTS OF THE SUPPLIED EQUIPMENTS AND THESE ARE TO BE DULY PROTECTED.

18.0 CHEMICAL CLEANING OF PIPING SYSTEM 19.0 UNLOADING & INSTALLATION OF THE GENERATOR STATOR 20.0 ANNEXURE-I - TENTATIVE LIST AND WEIGHT SCHEDULE OF MAJOR

EQUIPMENT


PART-1-TECHNICAL SPECIFICATION CLAUSE NO

DESCRIPTION

1.0 NAME OF WORK Erection, testing, commissioning etc of steam turbine & auxiliaries, generator & auxiliaries, pumps, piping, miscellaneous equipments etc for 1x270 MW, Package-A (Unit # 1) / Package-B (Unit # 2) of 2x270 MW,Phase-1, Thermal Power station (coal based) being set up at AINL,Chandwa,District-Latehar, Jharkhand.

2.0 SCOPE The scope of services consists of installation of a steam turbine & its auxiliaries, generator & its auxiliaries, condenser, pumps, LP dosing, condenser on line tube cleaning system, Tanks, Integral piping, TG piping, insulation etc of 1x270 MW capacity set. In general the scope also comprises receipt and unloading at TG hall unloading bay/beside A-row of Generator Stator and placement of the same on foundation by strand jack method and unloading of specified items at erection site/stores and its temporary storage and preservation, if required, re-handling, receipt from stores/ storage yard, transportation to TG hall/ site of pre-assembly/ fabrication, site assembly, erection, finish/ preservation/ touch up painting, site testing, insulation, commissioning, trial run, performance guarantee test and readying for handing over for commercial operation.

2.1 STEAM TURBINE It consists of three cylinders (HP, IP and LP) broadly including the following (applicable for respective units).:

2.1.1 Bearing pedestals. 2.1.2 Base plates, foundation holding down bolts. 2.1.3 Combined emergency stop and control valves – 2 nos. 2.1.4 Combined reheat stop and control valves - 2 nos. 2.1.5 Steam strainers & strainer housing for MS lines – 2 nos; HRH lines – 2 nos. 2.1.6 Cross around piping between IP & LP casings. 2.1.7 Hydraulic turning gear with hand barring. 2.1.8 Electro – hydraulic governing system backed up with hydro – mechanical system. 2.1.9 Lubrication & governing oil system. 2.1.9.1 MOT with internals. 2.1.9.2 MOP. 2.1.9.3 AOP with drives - 2X100% AC. 2.1.9.4 EOP with drives, DC – 1 no. 2.1.9.5 JOP with drives – 2 no. 2.1.9.6 Oil Vapour exhauster – 2 nos. 2.1.9.7 Duplex oil filter for LO sys. 2.1.9.8 Duplex oil filter for JO sys. 2.1.9.8 Temp CV for LO sys. 2.1.9.10 LO/ JO sys, piping, valves & all other accessories etc. 2.1.9.11 Unit oil purifier (centrifuge type). 2.1.10 Turbine gland sealing sys including necessary piping, valves, hanger & supports. 2.1.11 Cond spray sys Including necessary piping, valves and hanger & supports. 2.1.12 Turbine drain system Including necessary piping, valves and hanger & supports. 2.1.13 LPBP valves with their supply units & all accessories - 2 nos. 2.1.14 Water inj valves for LPBP valves – 4 nos. 2.1.15 CRH NRVs. 2.1.16 Vacuum breaker valves. 2.1.17 Flow measuring devices for PG test flow nozzles. 2.2 BOILER FEED PUMPS 3x50%. 2.2.1 BFPs. 2.2.2 Hydraulic couplings. 2.2.3 Drive motors. 2.2.4 Booster pumps.


PART-1-TECHNICAL SPECIFICATION 2.2.5 Working oil coolers. 2.2.6 Lub oil coolers. 2.2.7 Seal water coolers. 2.2.8 Suction strainer. 2.2.9 Recirculation valves. 2.2.10 Connecting couplings. 2.2.11 Step–up gear box. 2.2.12 Foundation frame. 2.3 CONDENSATE EXTRACTION PUMPS - 2x100%. 2.3.1 Pump assembly. 2.3.2 Cannister. 2.3.3 Foundation ring. 2.3.4 Suction strainer. 2.3.5 Drive motor. 2.3.6 Motor stool. 2.3.7 Connecting couplings. 2.3.8 Integral piping. 2.4 Auxiliary cooling water pumps with motors – 3 nos. 2.5 DM CW pumps for TG aux with motors - 3 nos. 2.6 DM CW pumps for boiler aux with motors - 3 nos. 2.11 Sump/submersible pump etc. – 2 nos. 2.18 HEAT EXCHANGERS 2.18.1 LPH – 1. 2.18.2 LPH - 2. 2.18.3 LPH – 3. 2.18.4 GSC - 1 no. 2.18.5 Drain cooler – 1 no. 2.18.6 Oil coolers – 2 x 100%. 2.18.7 Tray cum spray type deaerator. 2.18.8 HPH-5. 2.18.9 HPH-6. 2.19 CONDENSER. 2.20 GENERATOR 2.20.1 Stator. 2.20.2 Rotor. 2.20.3 End shields, bearings – 2 sets. 2.20.4 Gas coolers (twin type) – 2 nos. 2.20.5 Six terminal bushings alongwith rectangular terminal connectors -1 set. 2.20.6 Shaft seals. 2.20.7 Foundation plates & studs. 2.21 Brushless exciter. 2.22 SEAL OIL SYSTEM. 2.22.1 Seal oil mounted on frame complete with following. 2.22.1.1 Seal oil coolers – 2 nos. 2.22.1.2 Duplex filter - 1 no. 2.22.1.3 DP regulating valve – 2 nos. 2.22.1.4 Vacuum tank – 1 no. 2.22.1.5 Intermediate oil tank – 1 no. 2.22.1.6 Flow regulators - 2 nos. 2.22.1.7 Flow meters - 4.nos. 2.22.1.8 Interconnecting pipelines, valves & instruments. 2.22.2 Seal oil unit mounted on frame complete with following. 2.22.2.1 AC seal oil pump - 2 nos. 2.22.2.2 DC seal oil pump – 1 no. 2.22.2.3 Vacuum pump - 2 nos.


PART-1-TECHNICAL SPECIFICATION 2.22.2.4 Constant pressure regulator - 3 nos. 2.22.2.5 Interconnecting pipelines, valves & instruments. 2.22.3 Seal oil storage tank - 1 no. 2.22.4 Pipelines & valves & instruments. 2.23 GAS SYSTEM 2.23.1 Gas unit – 1 no. 2.23.2 Duplex gas drier – 1 no. 2.23.3 Hydrogen distributor – 1 no. 2.23.4 Co2 distributor - 1 no. 2.23.5 Co2 vapouriser – 1 no. 2.23.6 Liquid detector rack – 1 no. 2.23.7 Gas pressure regulators - 4 nos. 2.23.8 Piping, valves & instruments. 2.23.9 H2 gas temp control valve and actuator. 2.24 Waste gas system.

Bearing vapour exhauster with AC motor valves & Instruments – 2 nos. 2.25 LP dosing system. 2.26 Deleted. 2.27 Plate heat exchanger for TG aux - 3 nos. 2.28 Plate heat exchanger for boiler aux - 2 nos. 2.29 Central/Portable lub oil storage and purification system with pipe interconnection

with existing system of unit # 1 & 2. 2.29.1 Clean oil tank (60 m3) – 1 no. 2.29.2 Dirty oil tank (60 m3) – 1 no. 2.29.3 Oil unloading tank (1 m3) – 1 no. 2.29.4 Clean oil transfer pump 8250 LPH – 1 no. 2.29.5 Dirty oil transfer pump 8250 LPH – 1 no. 2.29.6 Central lube oil purifier, 7500 LPH – 1 no. 2.30 Portable fire extinguishers. 2.31 Miscellaneous tanks. 2.31.1 DMCW tank – 1 nos. 2.32 Flash tanks. 2.32.1 HP drain flash tanks – 1 no. 2.32.2 LP drain flash tanks – 1 no. 2.32.3 Unit Flash Tank- 1 No. 2.33 INSULATION OF EQUIPMENTS 2.33.1 LPH 1, 2 & 3. 2.33.2 HPH 5 & 6. 2.33.3 Ejectors. 2.33.4 Gland steam cooler, drain cooler. 2.33.5 Deaerator. 2.33.6 Flash tanks, flash boxes their manifolds, vents, drains as reqd. 2.33.7 Other misc equipment. 2.34 INSULATION OF PIPING 2.34.1 LP, HP heaters, GSC, DC drains & vents. 2.34.2 All flash tanks vent to condenser. 2.34.3 Vent from unlisted ppg/ eqpt to condenser. 2.34.4 Other misc piping. 2.34.5 D/A + FST – vent and drain lines. 2.34.6 Turbine washing sys. 2.34.7 Turbine drainage sys. 2.34.8 All safety valve ext From LPH, HPH & D/A. 2.34.9 Any misc piping under scope of erection requiring insulation. 2.35 PIPING (TG ) mainly consisting of following major system [ref Gr-H Annexure-I]. 2.35.1 Drain flash tank vent to condenser.


PART-1-TECHNICAL SPECIFICATION 2.35.2 Unlisted SV exhausts. 2.35.3 HPH SV exhaust to flash tank. 2.35.4 Vent from unlisted ppg/ eqpt to condenser. 2.35.5 Condensate pump vent. 2.35.6 Condenser air evacuation piping. 2.35.7 Turbine washing system. 2.35.8 Condensate for sealing of vacuum. 2.35.9 Unlisted condensate. 2.35.10 D/A safety valve exhaust to atmos. 2.35.11 Unlisted spray water. 2.35.12 Turbine flash tank drain/ vents to condenser. 2.35.13 SJAE drains. 2.35.14 GSC cooler drains. 2.35.15 Drain from unlisted eqpt/ vessels. 2.35.16 TG cycle piping drains & vents. 2.35.17 Lub oil ppg sys. 2.35.18 H&S for non steam lines and TG piping. 2.35.19 Condensate system piping. 2.35.20 LP, HP heaters drains & vents. 2.35.21 Piping related to LP dosing system. 2.35.22 Aux steam piping to turbine gland seal. 2.35.23 Temporary piping for pre boiler system alkali flushing including supply line & return

line upto eutralization pit, TG oil flushing and BFP oil flushing, as required. 2.35.25 Piping system will include but not limited to the following. 2.35.25.1 Pipes. 2.35.25.2 Fittings. 2.35.25.3 Bolts nuts and gaskets. 2.35.25.4 Instrumentation stubs. 2.35.25.5 Valves, air trap, steam trap, flow elements etc wherever required. 2.35.25.6 Expansion bellows wherever required. 2.35.25.7 Welded attachment on pipes for hangers including hanger & supports. 2.35.25.8 Flash boxes. 2.35.25.9 RE joint wherever required. 2.35.25.10 Y-type strainers. 2.35.25.11 ME bellows. 2.35.25.12 Annubar. 2.36 Control & instrumentation. 2.36.1 Erection of thermowells and all first root valves, stubs, etc for various piping sys.

Under the scope of this tender. 2.36.2 Installation of all sensors/ transmitters for measurement of turbine supervisory

parameters including JBs mounted on the equipment. 2.36.3 Impulse pipe up to root valve. 2.36.4 Junction box of bearings. 2.36.5 Assistance during calibration & fitting wherever required for turbovisory instrument

associated with main turbine. 2.36.6 Removal & refitting of Instruments fitted with equipments/ skid mounted aux system 2.36.7 Turbovisory cabling inside turbine bearing. 2.36.8 Assistance for commissioning of valves, replacement etc. 2.37 Maintenace of sump pumps till handing over of the units 2.38 Placement of the Generator Stator on its foundations with strand jack method

including design,fabrication and erection of of the temporarty structures for the strand jack systems.

2.39 Unloading of the following items at designated places in consultation with CM,BHEL :

• GENERATOR STATOR • GENERATOR ROTOR



• HP TURBINE • IP TURBINE • LP ROTOR

These shall be unloaded directly from the trailer /wagon inside project premises] and transport the same to stores/place of work etc. as directed by Engineer. Subsequent re-handling, if required will also be under the scope of work. Detailed weight schedule is as per relevant appendix. Necessary Cranes, as required for this shall be provided by BHEL free of cost.

3.0 MAJOR EXCLUSIONS 3.1 Civil foundation for equipments. 3.2 Transformer, bus duct & other electrical panels. 3.3 MS line. 3.4 CRH line & HRH line. 3.5 HPBP line including valve. 3.6 LPBP line. 3.7 Boiler feed suction, discharge & re-circulation line. 3.8 Cable connection between primary instruments to terminal boxes. 3.9 All AC/ DC motor starters, resistance boxes, switchgear and associated control

centres including permanent cabling & earthing unless otherwise specifically mentioned.

3.10 Extraction steam pipings to D/A, LP heaters, HP heaters. 3.11 Turbine instrument rack. 3.12 Field instruments. 3.13 Impulse pipe from first root valve. 3.14 Condenser instrumentation. 3.15 H2 & seal oil instrumentation. 3.16 Annunciation cabinet. 3.17 Calibration and commissioning of control vales and flow nozzles. 3.18 Turbine insulation. 3.19 Commissioning of actuators and HT motors. 3.20 Power House Bldg Elevators 4.0 MAJOR TERMINAL POINTS 4.1 Instrument/ service air - connection & welding of IA/ SA line with terminal valves of

equipment, which are covered in the scope of this contract. 4.2 ACW piping – at one point near A-row of TG hall. connection & welding of ACW pipe

with respective equipment 4.3 DMCW piping - connection & welding of DMCW pipe with respective equipment

(which are covered in the scope of this contract) header or with inlet and outlet flanges as applicable.

4.4 CW – at inlet nozzle of condenser.BFV & RE Joints,COLTS are excluded 4.5 CW header for hydrogen cooler. 4.6 Generator – upto generator terminal. 5.0 PRELIMINARY WORKS 5.1 The contractor shall, as a first field activity check the turbine, generator and all

auxiliaries foundations for the correctness of the same as per the drawings and satisfy himself in all respects, such as location of foundations, consolidation of foundations, absence of voids, levels, correctness of bolt holes, pockets levels and center lines etc. All measurements should be recorded and submitted to Engineer for approval before erection. The contractor shall make arrangement to unload generator stator, generator rotor, LP rotor, HP turbine & IP turbine directly from the trailer/ wagon [inside project premises] and transport the same to stores/ place of work etc as directed by engineer. Subsequent re-handling, if required will also be under the scope of work. Detailed weight schedule is as per Annexure – I.

5.2 Before starting erection job, contractor shall ensure that the TG area is sufficiently enclosed against ingress of dust and water, and all debris has been cleared off from the floor to a designated area as per instruction of engineer. The contractor shall



arrange to get the working area and surroundings cleaned daily to ensure a dust free atmosphere for working.

5.3 Contractor shall first cover all openings on operating floor and put temporary hand railings on all sides of the floor. Materials for the same will be provided by the contractor at his cost.

5.4 The contractor shall make his T&P stores for special tools and instruments at a convenient location near to the place of working in TG Hall.

5.5 Contractor shall set up longitudinal and transverse access and two or more level bench mark accurately on TG floor which shall be certified by BHEL Engineer. The certified TG center lines and datum level shall be the reference for TG and all auxiliaries erection and alignment work.

5.6 Once the TG and condenser center lines have been established, the contractor shall start setting of sole plates work on TG floor and also transporting condenser, turbine and other aux components to site and arrange them according to sequence of erection.

5.7 All matching surfaces of components shall be well cleaned with cleaning agent and burrs shall be removed by filing and blue matching. Wherever necessary sealing/ lubricating anti-seize compounds shall be applied as per recommendation of engineer. The machining/ grinding required for fittings of keys, pins, packers and dowels coupling bolts, coupling holes enlargements, hanger tie rod items machining etc, ie all kinds of machining related jobs etc shall be carried out by the contractor at his cost.

5.8 The accuracy of all equipment/ instruments and their functioning shall be established before they are permitted for use on the job. If the engineer doubts the accuracy of the precision tools, any time during erection, the contractor shall arrange the checking of tools/ equipment/ instruments at his cost and there will be provision of bench mark readings at regular intervals.

5.9 All the works shall be performed to the lines, grades and elevations indicated on the drawings. The contractor shall be responsible to locate and lay out the works both in horizontal and vertical direction. Control point established by the engineer shall be used as datum for works under this contract. Any work done without being properly located may be removed and dismantled by the engineer at the contractor's expenses, if the contractor refuses to do it.

5.10 The contractor shall provide a temporary small office (150 sq ft approx) for BHEL engineers at TG floor for day to day close monitoring of the work within 30 days from handing over of TG foundation. The temporary office should be portable and a rugged one with insulated walls & good finish. Electrical wiring, 1 nos fans, 1 (one) nos AC of reqd. capacity, 2 nos steel tables, 5 chairs, one computer table, 1 6 ft file rack, 1 filing cabinet & sufficient plug points shall be there inside the office. The contractor shall also provide office stationary, office cleaning services including with supply of a office boy for this purpose and one whole time Computer operator for the above mentioned office. Power will be provided by BHEL free of charges. However this office furnitures including the temporary office will remain property of the contractor and the same shall be taken by them after completion of the work.

6.0 MATERIAL HANDLING AND STORAGE 6.1 While BHEL will endeavor to store/ stack/ identify materials properly in their open

/closed/ semi closed / tarpaulin covered storage yard / shed, it shall be contractor's responsibility to assist BHEL in identifying materials well in time for erection, taking delivery of the same, following the procedure indicated by BHEL and transport the material safely to pre-assembly yard /erection site in time according to program.

6.2 Contractor shall unload the generator stator, generator rotor, HP turbine, IP turbine and LP rotor, HP heaters directly from trailer/ wagon (inside project premises) in respect of the unit and keep the same at designated place shown by BHEL/ customer. Necessary arrangement for transportation/ shifting of the above items from storage place to erection site, if required, shall be under the scope of this tender.

6.3 All the equipment furnished under this contract, other than those specifically mentioned in the tender, shall be received from the project sites/ sheds/ yards etc



located separately and transported to pre assembly area/ erection site safely and stored in the storage spaces in a manner so that they are easily retrievable till they are erected by the contractor. While drawing/ lifting material from BHEL/ customer stores, contractor shall ensure that the balance/ other materials are stacked back immediately.

6.4 Contractor shall ensure that the proper lifting tackle (slings and D-shackles) with test certificates are used during lifting and rigging processes. In case of any damage due to faulty lifting tackles, the cost will be recovered from the contractor.

6.5 Approach road conditions from the stores /yard to the erection site may not be equipped and ideal for smooth transportation of the equipment. Contractor may have to be adequately prepared to transport the materials under the above circumstances without any extra cost. Bad condition of road can not be cited as the reason for delay. Minor repair/ construction of approach roads inside site shall be arranged by the bidder within the quoted/ accepted price.

6.6 Contractor shall be responsible for examining/ verifying all the plant and material issued to him one month prior to requirement and notify the engineer immediately of any damage, shortage, discrepancy etc before they are moved out of the stores/ storage yard. The contractor shall maintain exhaustive record and submit to the engineer every week, a report detailing all the receipts during the week. However, the contractor shall be solely responsible for any shortages or damages in transit handling and or in storage and erection of the equipment once received by him. In case any equipment/ material is lost/ damaged while in the custody of the contractor, the cost of repair/ replacement if any to bring back the equipment in original order shall be deducted from the contractor's bill. BHEL's decision in this regard shall be final and binding on the contractor.

6.7 All the materials in the custody of the contractor and stored in the open and dusty locations must be covered with suitable weather proof/ fire retardant covering material wherever applicable and shall be blocked up on raised level above ground. All covering materials including blocks and sleepers shall be arranged by the contractor at his cost.

6.8 If the material belonging to the contractor are stored in area other than those earmarked for his operation, the engineer will have the right to get it shifted to the area earmarked for the contractor, if the contractor fails to do it within reasonable time. Such shifting will be at the risk and cost of the contractor.

6.9 All electrical items, if required, shall undergo drying up operation. Contractor shall have to carry out the same as per direction of BHEL within the quoted rates. Necessary Halogen lamps etc. will be arranged within quoted price.

6.10 Heavy rotating parts in assembled conditions shall be periodically rotated to prevent corrosion due to prolonged storage.

6.11 The contractor shall ensure that all the packing materials and protective devices used for various equipments during transit & storage are removed before the equipment are installed.

6.12 The contractor shall ensure that all surplus damaged unused material, packing wood/ containers/ special transporting frames etc are returned to BHEL/ owner’s designated place with proper documentation.

6.13 The contractor shall be responsible for making suitable indoor storage facilities to store all equipment which require indoor storage during the period under contractor's custody till erection.

6.14 The contractor shall hand over all parts/ materials remaining extra over the normal requirement with proper identification tags to the BHEL, failing which, suitable recoveries shall be made from bills/ dues of the contractor.

6.15 Contractor shall ensure utmost care in handling Rotors. Contractor should use only lifting tackle wherever supplied by manufacturing unit. Slings of proper size and other tackles are to be used for the above purpose. Contractor shall strictly comply with the instruction of BHEL engineers during the above operation. Contractor shall cover the journals with grease and cloth and also cover the rotor with tarpaulin to avoid any damage to rotor/ rotor blades.


PART-1-TECHNICAL SPECIFICATION 6.16 For unloading, turning and lifting of stators and turbine to the TG floor level and

placing on its foundation the contractor shall strictly comply with the instructions of the BHEL engineers.

6.17 Contractor shall ensure that while lifting turbine, generator, piping, acid, other auxiliaries, transporting slings shall be put over the points indicated on the equipment or as indicated in the manufacturer's drawings. All care should be taken to safeguard the equipment against any damage.

7.0 PRESERVATION OF COMPONENTS 7.1 It shall be the responsibility of the contractor to apply preservatives / touch up paints

primer on equipment handled and erected by him till such time of final painting. It shall be contractor's responsibility to arrange for required manpower, scaffolding materials, cleaning materials like wire brush, emery sheets, grease, etc including paint and thinners. The quoted erection price shall include cleaning of surface, supplying and providing one coat of preservatives / paints (primer) from time to time as decided by BHEL engineer. Painting may have to be done as and when required till such time the final painting is carried out. BHEL engineers decision in this regard is a binding to the contractor.

7.2 A separate gang of minimum two persons with all the necessary materials specified above shall be provided by the contractor within the finally accepted rates/ price for preservative/ touch-up painting.

7.3 The contractor shall protect finished work from action of weather and from damage or deterioration and shall cover the finished parts then and there for it protection.

7.4 Any failure on the part of the contractor to carry out works according to above clauses will entail BHEL to get done the job through any other party and recover the cost from contractor.

8.0 WELDING HEAT TREATMENT, RADIOGRAPHY AND NON-DESTRUCTIVE TESTING

8.1 The equipment and piping shall be erected in conformity with the Indian Boiler Regulations as may be directed as per any other standard/ specification in practice in BHEL. The method of welding (ARC, gas, TIG or other method) may be indicated in the detailed drawings schedules. BHEL Engineer will have the option of changing the method of welding as per site requirements. Contractor can not claim any additional amount from BHEL due to change in welding method. Additional X-ray/ UT/SR/ PWHT if required later on will be in vendor’s scope.

8.2 Welding of equipment, piping shall be done by certified high pressure welders who posses valid certificate of CIB of the state in which the equipment is erected as per provision of IBR. The HP welder who possesses necessary certificate shall appear well in advance before the expiry of the validity of his certificate for re-qualification test as per relevant provision of IBR and keep the certificate valid till the completion of work. The services of such welders, the validity of whose certificates have expired shall have to be terminated forthwith.

8.3 All welders including tack welder, structural and high pressure welder shall be tested as per ASME Section IX/IB and approved by BHEL Engineer before they are actually engaged on work though they may possess the IBR certificate. BHEL reserves the right to reject any welder if the welder's performance is not found to be satisfactory. The records of qualification of welders shall be maintained by the contractor in pro-forma given by BHEL engineer. All the welders qualified for the work will be issued an identity card by BHEL Engineer and welders will keep the same with him at work place. The vendor within his quoted rate to arrange test pieces like plates, pipes etc for welders testing and other statutory formalities.

8.4 BHEL engineer is entitled to stop any welder from the work if his work is unsatisfactory for any technical reason or there is a high percentage of rejection of joints welded by him which, in the opinion of the Engineer will adversely affect the quality of the welding though the welder has earlier passed the tests prescribed by Engineer. The welder, having passed qualification tests, does not relieve the contractor of his contractual obligation to check the welder's performance.

8.5 The contractor shall carry out the root run welding of all HP/ LP piping, valves,



instrumentation tapping points etc. by TIG welding method. Also, the contractor shall have to carry out full TIG welding of tubes up to thickness of 6mm if required, as per drawing. During the root runs, the contractor shall have to purge the pipes with inert gas before and during welding. All arrangements required for the above shall be the responsibility of the contractor at his own cost and no additional cost to BHEL.

8.6 All charges for testing of contractor's welders including destructive and non-destructive tests conducted by BHEL at site or carried out at labs shall have to be borne by the contractor only. All items required for the test like plates, welding electrodes, pipes etc are to be arranged by contractor within quoted rates.

8.7 The regulators used on welding machines shall be calibrated before putting these into use for work. Periodic calibration for the same shall be arranged by the contractor at his cost.

8.8 All welds shall be painted with anticorrosive paint. Necessary consumables and scaffolding etc. including paints shall be provided by contractor at his own cost. The process used/ approved by BHEL engineer shall be qualified/ followed by the vendor at his cost prior to adoption.

8.9 Complete penetration of welding shall be achieved and all welded joints shall be subject to acceptance by the engineer.

8.10 Preheating, radiography and other NDT tests, post heating and stress relieving after welding of tubes, pipes, including attachment welding wherever necessary are part of erection work and shall be carried out by the contractor in accordance with the instructions of the engineer.

8.11 Contractor shall arrange all necessary heating equipment with automatic recording devices. Also, the contractor shall have to arrange for labour, heating elements thermocouples, etc insulating materials like asbestos cloth, ceramic beads asbestos ropes etc required for heat treatment/stress relieving operations. Temperature shall be measured at least at two different points above 200 mm dia. by thermocouple and recorded on a continuous printing type recorder. All the recorded graphs for heat treatment shall be the property of BHEL. The contractor will provide thermo-chalks, temperature recorders, thermocouple attachment units, graphs, sheets etc for checking within the finally accepted rates. All stress relieving equipment will be used after due calibration and submission of test certificate to BHEL. Periodic calibration from Govt approved/ accredited Test Houses, traceable to National/ International standards will also be arranged by the contractor for such equipment at his cost.

8.12 The technical particulars, specification and other general details for radiography work shall be in accordance with ASME, IBR or ISO as specified by BHEL.

8.13 Iridium - 192 shall be used by contractor for radiography work. The geometric un -sharpness shall not exceed 1.5 mm. Taking adequate safety precautions for handling & storing of radiography source (including making of pit for radiography source) shall be the responsibility of the contractor while carrying out radiography. Necessary safeguards required for radiography (including personnel from BARC) shall be arranged by contractor at his cost.

8.14 Low speed high contrast, fine grain films (D-7 or equivalent) in 10 cm. width only shall be used for weld joint radiography. Film density shall be between 1.5 and 2.0.

8.15 All radiography shall be free from mechanical, chemical or process marks, to the extent they should not confuse the radiographic image and defect finding. Penetretometer as per ASME or ISO must be used for each exposure.

8.16 Lead numbers and letters are to be used (generally 6mm size) for identification of radiographs. Contract no; joint identification, source used, welder's identification and SFD are to be noted down on paper cover of radiograph.

8.17 Lead intensifying screens for front and back of the film should be used as per the ASME specification referred above.

8.18 The joint is to be marked with permanent mark A, B, C etc to identify, the segments. For this a low stress stamp shall be used to stamp the pipe on the down stream side of the weld.

8.19 For multiple exposures on pipes, an overlap of about 25 mm of film should be provided.


PART-1-TECHNICAL SPECIFICATION 8.20 The contractor shall have a dark room fully equipped with radiography equipment,

film (unexposed), chemicals and any other dark room accessories. There should be adequate number of radiographic personnel with sufficient experience and certified by M/s BARC as Radiographer for conducting radiographic tests in accordance with safety rules laid down by Division of Radiological protection. These personnel should also be registered with DRP/BARC for film badge service. The proof of having sufficient film/chemicals to complete the entire work should be shown to BHEL.

8.21 All arrangements for carrying out radiography work including dark room and air conditioner and other accessories shall be provided by contractor within the space allotted for office at his cost. As an alternative the contractor may deploy an agency having all above facilities and who are duly approved/ accredited by BARC and/ or other regulatory authorities. Detailed particulars of such agencies will be submitted and got approved by BHEL Engineer before the actual deployment of agency for radiography work.

8.22 Contractor shall note that 100% radiography will be done at the initial stages on all the H.P. welding joints. Subsequently radiographic inspection will be done on the basis of quality of welding. However minimum percentage of joints to be radio-graphed shall not be less than the requirement of IBR or as specified by BHEL. The percentage may be increased depending upon the quality of joints and at the discretion of BHEL.

8.23 If the contractor does not carry out radiography work due to non-availability of source /film /chemical/operator etc. BHEL will get the work done departmentally or through some other agency at the risk and cost of the contractor.

8.24 All the radiographs shall be properly prepared and shall become the property of BHEL.

8.25 Since radio-isotopes are being used, precautions and safety rules as prescribed by BHEL/BARC/BHEL's client shall be strictly followed. BARC/DRP Certificate to be provided before taking up the work.

8.26 The defects as pointed out by the engineer shall be rectified immediately to the satisfaction of BHEL Engineer. The decision of the engineer regarding acceptance or otherwise of the joint will be final and binding on the contractor.

8.27 Radiography of joints shall be so planned after welding that the same is done either on the same day or next day of the welding to assess the performance of HP welders. If the performance of welder is unsatisfactory, he shall be replaced immediately.

8.28 Wherever radiographs are not accepted on account of bad shot, joints shall be re-radiographed; pre/post heating etc. and re-shots shall be submitted for evaluation. Radiographs shall be taken on joints after carrying out repairs. However, if the defect persists after first repair, as per radiographs, carrying out radiography heat treatment etc. shall be repeated till the joint is made acceptable. In case the joint is not repairable, the same shall be cut, re-welded and radiographed, heat treated etc at contractor's cost.

8.29 Heat treatment and radiography may require to be carried out at any time (day and night) to ensure the continuity of the progress. The contractor shall make all necessary arrangements including labour, supervisors, engineer required for the work as per directions of BHEL.

8.30 The contractor shall maintain a record in the form as prescribed by BHEL of all operations carried out on each weld and maintain a record indicating the number of welds, the names of welders who welded the same, date and time of start and completion, preheat temperature, radiographic results, rejection if any, percentage of rejection etc and submit copies of the same to the BHEL Engineer as required. Interpretation of the BHEL Engineer regarding acceptability or other wise of the welds shall be final and binding with contractor.

8.31 All site welding joints shall be subject to acceptance by BHEL engineer & end user. 8.32 All site butt / fillet weld seams subject to vacuum conditions shall be radiographed.

Before the weld seams are subjected to radiography test, the seams shall be properly ground and cleaned.


PART-1-TECHNICAL SPECIFICATION 8.33 All butt welds shall be subject to dye penetration test as per the instructions of

engineer at no additional cost. 8.34 The contractor shall adopt the "stitch welding" while carrying out the assembly of

condenser. Final welding shall be carried out by "step back seam method" to ensure minimum deformation of the welded parts.

8.35 The contractor shall adopt and be equipped for carrying out other NDT like LPI/MPT etc. Steeloscopy /hardness etc. as required as per welding schedule/drawings provided, within the finally accepted price/rates. Ultrasonic testing, wherever required will be arranged by contractor at no extra cost.

8.36 The contractor shall carry out the edge preparation of weld joints at site in accordance with the details acceptable to BHEL Engineer. Machining or automatic flame cutting will be allowed only where edge preparation otherwise is impractical. All slags/burrs shall be removed from cuts and all the hand cuts shall be ground smooth to the satisfaction of engineer.

8.37 The contractor shall assist BHEL Engineer in preparing complete field welding schedule for all the field welding activities to be carried out in respect of piping and equipment erected and involving high pressure welding, at least 30 days prior to the scheduled start of erection work, at site. Such schedules shall be strictly adhered to by the contractor.

8.38 Necessary coordination with IBR authorities for all IBR formalities is to be done by the contractor at his cost except payment of statutory fees.

8.39 Conductance of all kinds of NDTs for the total TG area as per the requirement and applicable drawings/documents /Codes etc. including arranging of all resources with materials , scaffolding materials etc .is in vendor’s scope.

9.0 CONDENSER PAINTING 9.1 The condenser main tube plates will be dispatched to site from the works with

surface protection only on water box side. The same shall be removed as per BHEL Engineer’s instruction and BHEL’s specification. The surface protection of these tube plates shall be maintained by the contractor after the completion of the tube insertion and expansion activities. The surface shall be first painted with at least two coats of chemical resistant epoxy zinc chromate primer after thoroughly cleaning all such parts of all dirt, rust, scales greases, oils and other foreign materials by adopting suitable methods. Afterwards the above parts shall be finished with two coats of high build black coal tar coating. Before the painting is taken up, the contractor shall clean the tube holes and plug all the holes with suitable tapered plastic/wooden plugs to avoid any damage to the tube ends. The plastic/wooden plugs and plants required for the above operations shall have to be arranged by the contractor at his cost. The above paints are also to be applied on water chamber/box.The required paints are to be arranged by the contractor.

9.2 The condenser steam space shall be surface protected with at least two coats of suitable steam washable paint (HE 1712). Before the painting is taken up, the contractor shall clean the surfaces to be coated by adopting suitable methods.

9.3 Inside of water box shall be painted with paint as per BHEL specification after carrying out sand blasting operation.

9.4 Application of painting as well as supply of paints including primer and other material and other resources for condenser inside painting shall be in the scope of contractor. The vendor should take prior approval regarding brand of paint from BHEL and the vendor has to arrange valid test certificates.

10.0 FINISH PAINTING OF TURBINE, GENERATOR, PIPING, EQUIPMENT, SYSTEMS AND OTHER PACKAGES

10.1 All exposed metal parts of the equipment, structure, auxiliaries, piping, and other items/Systems/equipments (covered within the scope of this contract) after installations are to be painted. The surfaces are to be thoroughly cleaned of all dirt, rust, scales, grease, oils and other foreign materials by wire brushing, scrapping, and any other method as per requirement of BHEL. The same will be inspected and approved by the engineer before painting.

10.2 Mostly the equipment/ items/ components will be supplied with one coat of primer



paint and one coat of finish paint. However during storage and handling, the same may get peeled off/ deteriorate. All such surfaces are to be thoroughly cleaned and to be touch up painted with suitable approved primer and finish paint matching with shop paint/ approved final colour. Besides above, two coats of approved primer paint is to be applied on all the bare/ unpainted surfaces. The gas cut stubs would require being ground and rounded.

10.3 The requirements for the dry film thickness (DFT) of paint and the materials to be used shall be as stated below, unless otherwise specified elsewhere in this specification.

10.3.1 Surfaces subject to weathering All surfaces shall have a minimum of four coats of paint made up as follows.

10.3.1.1 Primer coat : 35 micron DFT. 10.3.1.2 Tie coat : 35 micron DFT. 10.3.1.3 Finishing coat (2 nos) : 35 micron DFT per coat. 10.3.1.4 The total minimum DFT shall be 140 micron. 10.3.2 Surfaces Inside Buildings

All surfaces shall have a minimum of three coats of paint made up as follows: 10.3.2.1 Primer coat : 35 micron DFT. 10.3.2.2 Tie coat : 35 micron DFT. 10.3.2.3 Finishing coat (2 nos) : 25 micron DFT per coat. 10.3.2.4 The total minimum DFT shall be 120 micron. 10.4 The type and colour of primer & finish coat shall be selected by the bidder after

approval by the owner. 10.5 COLOUR CO-ORDINATION & FINISH 10.5.1 Exterior surfaces throughout the plant shall be finished in colours and textures which

will blend harmoniously together and with the surrounding landscape. 10.5.2 Interior surfaces throughout the plant shall be finished in colours and textures which

will blend harmoniously together and which will be conducive to the comfort, well-being and high productivity of the operators. Operating plant & services provided shall be colour coded for ease of identification.

10.5.3 All finishes shall be durable and as far as possible maintenance free. Finishes shall be easily cleaned.

10.5.4 Final colours and finishes shall be to the approval of the engineer. 10.5.5 All colour coding shall be in consonance with the existing plant, Colour code shall be

decided during detail engineering. 10.6 Certain equipment like control panels, valves etc shall require spray painting. The

contractor shall make arrangements of the required equipment for spray painting at his own cost. Spray painting at the job site shall be permitted only at times and locations approved by engineer.

10.7 Colour of paint to be applied over pipes/ equipments will be as approved by BHEL site sngineer.

10.8 Contractor at no extra cost to BHEL shall apply all paints, primers; arrange tools and other consumables including scaffolding materials required for finish painting. Required Paint and Primer need to be supplied by Vendor within his quoted rate. The paint need to be sourced from reputed BHEL approved vendor and quality of the paint shall be checked by BHEL/OWNER prior to application. In the event of failure in supply of the paint by the vendor of proper quality and quantity as per requirement, BHEL shall supply the paint and recover the cost with due BHEL overhead from the very next payable bills of the Vendor /Any other dues.

10.9 The contractor may be required to fill up dents/ marks by applying putty before final painting of equipment. All materials and arrangements have to be made within quoted price/ rates.

10.10 The contractor shall provide legends with direction of flow on equipment and piping in size specified by Engineer. Letter writing shall be done in Hindi / English or in both languages.

10.11 The painters have to under go test and only qualified painters will be allowed to work. 10.12 Painting work should be completed within completion period in consultation with site.


PART-1-TECHNICAL SPECIFICATION 10.13 The vendor has to do arrow marking with nomenclature, Legends for the system as

per the requirement of BHEL. 10.14 The total painting job including supply and application with all resources is included in

vendor’s scope. 11.0 SPECIAL ERECTION PROCEDURE TO BE FOLLOWED BY CONTRACTOR

Following erection procedure in the area of Condenser, Turbine, Generator and piping is to be adopted by the vendor to squeeze the cycle time-

11.1 CONDENSER 11.1.1 Proper handling and storage of materials, particularly support plates, tube plates etc.

to avoid any distortion of this item so that time taken in alignment & rectification of various components is reduced.

11.1.2 Proper storage and handling of condenser tubes to avoid any bend and damage to tubes. Lifting beam is required to be used during handling at stores and at site.

11.1.3 Aligning and welding of water box and water chamber pre-assembly outside before placement.

11.1.4 Co2 /semi automatic welding machine, if required to be used during pre-assembly welding of support plate, water box etc., shall be arranged by the contractor.

11.1.5 Pre-matching and marking of support plates for turbine and generator side. 11.1.6 Use of alignment fixture for support plates. The fixture can be fabricated at site and

are to be made available by contractor within quoted rate. 11.1.7 Pre-welding of stiffener rods received in part-lengths from manufacturing units to an

optimum length outside. 11.1.8 Use of good quality tube-expansion and End milling machines, at least four in

number. 11.1.8 All NDTs are in vendor’s scope. 11.1.9 The condenser parts will be sent by BHEL Manufacturing units in pieces as per

transportation ease/norm. The same is to be assembled, including fabrication, welding etc. irrespective of no. of pieces shown in the drawing for despatch. No additional work will be admissible on this account.

11.2 TURBINE, GENERATOR 11.2.1 Permanent packers (between base plate and pedestal) can be installed before

grouting of HP front & HP rear bearing pedestal base plates. 11.2.2 Final packers (between LP base plate and girder) of the LP outer casing after

levelling of the LP outer casing with the help of water level can be installed without waiting for the placement of LP rotor.

11.2.3 Final radial and axial keys of the LP outer casing after its alignment can be installed without waiting for the placement of rotor.

11.2.4 Frequent placement and removal of LP rotor can be avoided by checking all radial and axial clearances of LP inner casing in one attempt.

11.2.5 LP inner casing can be boxed up after placement of LP rotor and checking of radial and axial clearances. There is no need for preliminary coupling of LP- IP rotors.

11.2.6 If proper alignment and centering of the bearing pedestals are maintained before grouting of the pedestals, it requires very little adjustment during alignment and thus less time during alignment process. Also, as the final packers of the bearing pedestals have been installed before grouting, time is saved in fitting of these packers at this stage.

11.3 TG PIPING 11.3.1 Small bore pipings, which are supplied in running length, Electro-hydraulic pipe

bending machines and pipe chamfering machine will be used at least to cater 3” schedule 160 pipes.

11.3.2 Pipe line should be mechanically and chemically cleaned before these are erected, as per BHEL standard procedures and BHEL engineer’s instructions. BHEL will provide chemical free of cost.

11.3.3 The contractor within his quoted rate has to make edge preparation, and if required mismatch in the pipes are also to be removed to make proper pipe joints.

11.3.4 Pipe bending for small bore pipes by filling sand and heating is not allowed.


PART-1-TECHNICAL SPECIFICATION 11.4 ERECTION OF DEAERATOR AND FEED STORAGE TANK 11.4.1 The Feed Storage Tank shall be received at site in three pieces and shall be erected

on the base plate with sliding supports and saddles etc. 11.4.2 The storage tank sections shall be aligned with each other and circumferential joints

(two numbers) shall be welded. 11.4.3 The welding shall require edge-preparation with proper fit-up. For this purpose,

necessary grinding etc. has to be done in case of ovality and mismatch is observed. 11.4.4 Required pre-heating, PWHT and other NDTs as required shall be carried out and

necessary facilities envisaged are included in vendor’s scope. 11.4.5 On completion of Feed Storage Tank welding, the Deaerator has to be placed at

suitable elevation as per drawing and suitable interconnections pipes with welding and other related NDTs.

11.4.6 All the mountings of this package are also included in vendor’s scope. 11.4.7 Suitable high capacity crane (preferably 75 MT or above as required as per the load

chart) for lifting Deaerator and Feed Storage Tank Components in deaerator floor shall be provided by BHEL free of cost as per Annexure-IV. However, the vendor has to make his own arrangement like laying of rails with suitable facility for dragging the components on Deaerator floor.

11.4.8 Erection of the Deaerator platform is included in vendor’s scope at no extra cost to BHEL.

12.0 ERECTION INSTRUCTION 12.1 The bidders may note that guidelines / instructions are tentative and subject to

change depending upon site conditions, the decision of BHEL engineers will be final in this regard.

12.2 The work will comprise of but not limited to the followings. 12.3 Erection of condenser and TG sub-assembly / components auxiliaries as detailed in

the annexure. The schedule of sub-assemblies and weight of individual heavy components given in Technical specifications are approximate and meant for giving a general idea to the tenderer only about magnitude of the work involved. The condenser and turbine generator components are sent in parts for convenience of transportation. They are to be dismantled wherever required, cleaned, assembled stage by stage, erected aligned and adjusted as per drawing / dimensions / tolerances and instructions of BHEL engineers/experts available at site.

12.4 All the work such as cleaning, checking, leveling, assembly, temporary erection, alignment, dismantling of certain equipment for checking and cleaning, overhauling of valves, face preparations, fabrication, welding, heat treatment, NDT and hydraulic test of sheets / plates, tubes, pipes as per general engineering practices at site, cutting, grinding, straightening, filling, chipping, drilling, reaming, lapping, shaping, machining, blue matching, fitting and touch up painting etc as may be applicable in such erection works are treated as incidental to erection and necessary to complete the work satisfactorily. These shall be carried out by the contractor as part of the work.

12.5 Normally weld neck valves will have prepared edges for welding. It may be occasionally necessary to prepare new edges or re-prepare the edges to suit conditions, which shall be done by the contractor at no extra cost. All fittings like 'T' pieces, weld neck flanges, reducers etc. shall be suitably matched, re-edge prepared with pipes for welding. The valves will have to be checked, cleaned, lapped or overhauled in full or in parts before erection, after chemical cleaning and during commissioning. Overhauling of valves is the complete responsibility of the contractor. Experienced technicians for overhauling of valves and labour required to assist the technicians shall be arranged by the contractor at his own cost.

12.6 Suspension for piping etc. will be supplied in running lengths and shall be cut to suitable sizes and adjusted as required. Hangers, components which are being supplied loose shall be assembled at site and erected as part of the work.

12.7 Some pipes may be supplied in running lengths or in fabricated position as per convenience of dispatch. Contractor shall cut and fabricate to suit the layouts. The contractor shall carry out necessary fabrication of these pipes / hangers at site



including hot / cold bending as desired by BHEL Engineer at no extra cost. As per layout, suitable bends shall be fabricated at site either by hot / cold bending as directed by BHEL engineer at no extra cost. Some pipes coming under the HP control oil system are having jacketing pipe over and above the oil carrying pipe. Both pipes are to be fabricated, welded as per requirement of drawings / BHEL engineer's instruction at site at no extra cost.

12.8 All rotating machinery and equipment shall be cleaned, lubricated, checked for smooth rotation. If necessary, dismantling and refitting is also to be done before erection by the contractor at no extra cost to BHEL. If in opinion of the BHEL engineer the equipment is to be further checked at any stage of the work, necessary facilities for dismantling, cleaning, lubricating and refitting shall be provided by the contractor at no extra cost.

12.9 The surface of the pipes to be joined shall be suitably prepared as per instruction of BHEL engineers. Edge preparation shall be done by chamfering machine, wherever required and all welding surfaces must be cleaned thoroughly. All wrongs, due to the mistakes of the contractor shall be repaired / redone at contractor's cost. Instrumentation, drains, stubs, root valves which are sent in loose from manufacturing units are to be welded at site as per BHEL engineer's instruction.

12.10 Erection and welding of control valves and flow nozzles coming in the piping system is included in the scope of the contractor. Necessary calibration and commissioning of control vales and flow nozzles are excluded from the scope of the contractor. However, contractor has to provide assistance for commissioning of control valves and flow nozzles.

12.11 Impulse piping, root valves, flow elements, thermowells etc. wherever required for the equipment is to be welded by the contractor as per the instruction of BHEL engineer. The required equipment will be supplied by supplier free of cost.

12.12 The instruction of the motor manufacturer regarding storage of motors and re-conservation must be strictly followed without any deviation.

12.13 All the motors shall be stripped open, thoroughly serviced with proper care and reassembled properly before erection by the contractor, if necessary. During servicing if any deficiency is observed, the same should be taken up with BHEL engineer. This is included in the scope of work.

12.14 Special slings for stator will be provided by BHEL free of cost. Testing of Stator lifting sling from an authorized agency is under the scope of work. The slings are to be handled carefully and returned to BHEL in proper preserved condition, immediately after the work.

12.15 The contractor shall carry out all necessary checks, such as accuracy of levels, centre lines, bolt hole positions, hanger supports etc., sufficiently in advance to ensure correctness of installation of all equipment covered in the scope of work.

12.16 All equipment /materials to be taken inside the plant building shall be cleaned thoroughly before taking them inside and the erected equipment and piping shall also be kept clean by regular cleaning.

12.17 All the shafts of the rotating equipment shall have to be properly leveled and aligned to those of matching equipment to perfection, accuracy as required, and the equipment shall be free from excessive vibrations so as to avoid overheating of bearings and any other conditions which may tend to shorten the life of the equipment. All bearings shafts and other rotating parts shall be thoroughly cleaned and lubricated as per the recommendation of BHEL engineer before starting. All reaming / face matching of bolt holes / coupling faces after alignment prior to coupling will be in the scope of the contractor.

12.18 The contractor shall also weld all thermo wells, small length of pipes to all tapping for pressure, flow and level points, isolating valves and root valves on all equipment under scope of erection of this contract. All embedded temperature measuring elements provided in the bearings will have to be terminated at the junction box by the contractor. Thermowell’s tapping point connection incorporated in the steam service shall be plugged during the pressure testing and steam blow-out of piping systems. Upon completion of blow-out operation, all thermowells and flow elements



with branch pipes shall be installed and welded as per the Engineer's instruction. 12.19 Installation of coupling bolts of coupling between IPT & LPT and LPT & Generator

requires utmost precision. The contractor has to make arrangement for precise machining operation such as reaming, honing etc. for fit up coupling bolts.

12.20 Sometimes, at site, insulation may require to be removed due to some unforeseen reasons. Its removal and re-application is within the scope of work. No extra payment will be made for such work. However, BHEL will supply the necessary insulation material, as required during such re-application. Decision of BHEL Engineer in this regard, will be final and binding on the contractor.

12.21 Machining of shims ,packers ,Coupling Bolts and other items 12.21.1 The contractor within his quoted rate has to either own or have tie up for a work

shop for machining/cutting/grinding/polishing of key ways, packer plates, hanger/support items , machining of Nuts , bolts, studs, tie-rods ,Coupling Bolts ,bushes of all equipments, dowel pins ,jack bolts etc. and other machining works. The machining scope is elaborated in brief

12.21.2 During the erection, commissioning, handing over of the sets , the contractor within his quoted rate has to carry out necessary machining jobs on Main equipments and Auxiliaries like enlargement of holes by drilling (including flanged faces/ surfaces/ pieces), gas cutting/ grinding/ other machining methods and finishing to achieve proper matching/ parallelism/ proper erection/ leak proof joints etc, machining/ rectification of key ways, machining of coupling bolts, fabrication/ machining of dowel pins, taking out damaged/.seized bolts etc and reconditioning, threading, making additional holes as per requirement, dressing up of holes/ cut out etc and other machining activities as required to carry out the total execution. In case of relocation of holes/ cut outs, the vendor has to carry out blocking of extra holes/ cut outs as per requirement of BHEL. The total machining jobs required during erection, testing, commissioning, handing over of unit to customer is included in the contractor’s quoted rate. The contractor within his quoted rate has to enlarge, relocate, make additional holes in flanges, parts of equipment for mating flanges treating it as part of his scope, in case of any discrepancy found in flanges. The holes are to be finished with precision as decided by BHEL and necessary threading inside holes and dressing up also is to be done. Closing of existing holes by suitable method as suggested by BHEL is also to be carried out by the contractor, in case the holes are not required in earlier locations."

12.22 In addition to the above, the contractor has to arrange machining facilities for carrying out precision machining as required to achieve desired finish for turbine. generator, exciter coupling bolts within the quoted rate as this is part of normal scope of work. They should arrange calibrated balancing machine for weighing of bolts suitable for this work during execution of the above works. The contractor’s quoted rate should be inclusive of all these type of requirements.

12.23 Turbine, Generator, Exciter Coupling holes require precision machining like reaming, honing etc. as per requirement to achieve required finish before bolting of Turbines, Generator, Exciter Couplings and other equipments and these are included in the contractor’s scope of work at no extra cost to BHEL.

12.24 Contingency arrangement The contactor has to arrange for making contingency arrangement to achieve/reschedule major milestones and for this additional material shall be issued at free of cost by BHEL. The contractor has to do erection/commissioning activities accordingly. It may so happen that some regular erectable items are not received in time. The contractor has to make contingency arrangements with the free materials issued by BHEL as per requirement. The contingency arrangements/items are to be removed/replaced with original items received on a later date .For this advance information shall be given to the contractor. The contractor has to return all the contingencies materials to BHEL/Customer’s store. The total activities are treated as regular scope of work. No payment shall be released by BHEL in this account.

12.25 Rescheduling of milestones The activities at site will be reviewed at regular intervals and any additional resource



mobilisation to reschedule the activities/milestones from time to time is included in the contractor’s scope of normal work at no extra cost to BHEL . No extra payment on whatsoever account shall be entertained by BHEL.

12.26 The vendor within his quoted rate has to execute trial run of all motors including checking direction of rotation in uncoupled condition, check alignment and re-couple the motor to driven equipment.

12.27 Drying out arrangements for all kinds of motors/panels/system including laying of cables, arranging of Engineer/electricians for completing of drying out is included in vendor’s scope. Cables for HT Motors or any special cables, if required shall be issued free of cost by BHEL, if required. Motors de-couplings, greasing/servicing of equipments/re-couplings are included in the vendor’s scope. Necessary numbers of Halogen lamps are also to be kept in stock by the contractor to take care of such kinds of activities.

12.28 Area Cleaning The contractor has to do area cleaning on every date on daily basis. The cleaning has to be done during start of the day and at the end of the day .Non compliance of the above cleaning shall call for penal recovery of Rs.2000.00 on each instance and at the same time ,cleaning of the area shall be done by BHEL at the risk and cost of the contractor. No excuses on this above account shall be entertained by BHEL on whatsoever account.

12.28 Approach platforms : - Approach platforms for access to valves/equipments/systems which are not regular in nature are included in the contractor’s scope of work at no extra cost to BHEL. Necessary materials shall be issued at free of cost by BHEL. Some of the Equipments/Electrical panels received will require site painting and this is included in regular scope of work including supplying ,application and arrangement of paints, primers, thinners etc. at no extra cost to BHEL.

12.29 INSTRUCTION FOR PIPELINE ERECTION The work will comprise of but not be limited to the following:

12.29.1 All pipelines shall be erected as per elevation shown in the respective erection drawings.

12.29.2 Erection of piping system shall be coordinated by the contractor as required, with the erection group of the turbine, generator, condenser, boiler, boiler feed pumps and other major equipment. Approval must be obtained from the construction managers and the equipment manufacturer' field engineering representative prior to making piping interface connection to equipment mentioned above. Sequence of work shall be carefully planned to minimise interference with other groups working in the same area. Actual sequence to be followed shall be subjected to the approval of the engineer and the engineer may, at any time, direct the contractor to reschedule his work as per status of the site work.

12.29.3 All workmanship shall be accomplished using accepted method and procedures of the highest recognised pipe fabrication and erection standards and must be done in a neat manner, in accordance with IBR and other standards and as per the direction of BHEL engineers. While laying of piping, precaution / care must be taken for avoiding fouling between site routed piping / fabricated and other pipings.

12.29.4 Modification of shop fabricated pipes prior to installation to accommodate site alterations in pipe routing shall have to be carried out by the contractor at no extra charges to BHEL.

12.29.5 Pipes of size NB 65 mm and below shall be field run as per general routs, which will be indicated to the successful tenderer. They will be supplied with straight pipes in running meters and are to be bent, edge prepared, welded, heat treated, radio-graphed, to suit the routing requirement.

12.29.6 While erecting the field run pipes, the contractor shall check the accessibility of valves, instrument tapping points and maintain minimum headroom requirement and other necessary clearance from the adjoining work areas.

12.29.7 All field welding, stress relieving and heat treatment shall be done as per the drawing and welding procedure that will be furnished to the contractor during the execution of



the contract. 12.29.8 All pipelines shall be given proper slopes towards the drain points, during erection at

site as per drawing. 12.29.9 All pipelines shall be provided with suitable vent and drain points with valves on the

highest and lowest points of the pipe run although may not be specifically mentioned in the drawing.

12.29.10 For instrument connection, pipe stubs including the instrument tubing up to the root valves shall be installed by the contractor. The erection of instruments is not however included in the scope of this specification.

12.29.11 All vents and drains for piping and equipment whether shown in the drawing and not, shall terminate on the ground floor at a suitable point unless otherwise noted.

12.29.12 Wherever piping erected by the contractor is connected to piping or equipment or counter flanges of equipment's erected by some other agencies, the joint at the connecting point including erection of counter flanges supplied along with equipment's, valves etc. shall be done by the contractor.

12.29.13 The contractor shall be responsible for the correct orientation of all valves so that seat, stem and hand wheels will be in desired locations. Information regarding orientation of valves, not fully located on drawings, may be obtained from BHEL engineers.

12.29.14 Setting of limit switch of actuators of valves and its calibration is not in the scope of work. However, assistance for commissioning of valves viz. Mechanical readiness, making approach to valves like temporary scaffolding etc., replacement etc. is in the scope.

12.29.15 Commissioning of the ‘Condenser on line tube cleaning system’ and ‘Self cleaning Strainer’ will be done by the original manufacturer/supplier. The contractor shall provide necessary manpower support etc. during the commissioning. It will require regular cleaning of filters and maintenance of the systems and for this the vendor within his quoted rate has to arrange manpower with all resources treating it as normal scope of work.

12.29.16 The piping system, coming under the purview of IBR should generally meet the requirements of IBR. However, BHEL will have the option of changing of standard or specifications in this regard, depending upon site condition. The decision of BHEL shall be final and binding on the contractor.

12.29.17 All piping shall be routed so as to avoid undertaking routs of other pipes and their hangers and supports, electrical cable trays, ventilation ducting, structural members, equipment etc.

12.29.18 Adequate clearance shall be ensured with respect to the above to accommodate insulation and pipe movements. While routing the field run piping the following requirement should be taken into account by the contractor.

12.29.19 All piping shall be grouped wherever practicable and shall be routed to present a neat appearance.

12.29.20 The piping shall be arranged to provide clearance for the removal of equipment for maintenance and for easy access to valves, instruments and other piping accessories required for operational maintenance.

12.29.21 Overhead piping shall have a minimum overhead clearance of 2/3 meters above walkways and working areas and 6 meters above roadways unless otherwise approved by the BHEL engineer.

12.29.22 Drains shall be provided at all low points and vents at all high points as per actual layout regardless of whether same have been shown in respective drawings or not. The pipelines shall be sloped towards the drain points. All the drains shall be terminated to the drain pit as per the instruction of BHEL engineer.

12.29.23 For field run piping the contractor shall fabricate and erect all hangers and supports as required with due regard to general arrangement layout of other pipes, hangers, cable trays, ducting, structural members etc. and in consultation with and to the approval of BHEL engineer.

12.29.24 Before performing the welding, all corrosion products, grease, dirt and other foreign matter shall be removed from the surface to be joined and all valves shall be opened



full. Tack weld shall be ground or chipped to remove all objectionable projections and all weld splatter shall be removed prior to welding the joint. Piping on both sides of any joint shall be adequately supported throughout the preheating, welding and stress relieving operations to avoid possible cracking of tack welds and initial beads. Temporary supports if used shall be so designed that the joint is relieved of all stress due to weight of the pipe while subject to stress relieving temperature. Whereas joint is subject to cold springs during this operations, the adjacent pipes should be clamped together so as to prevent straining of the metal spacing between joints shall be in accordance with code requirements.

12.29.25 When "C" clamps are tack welded to pipe for the purpose of alignment of a joint, the pipe shall be locally pre-heated in the area where such tack welding is performed, provided such tack welds are adjacent to a joint that will be stress-relieved. However, if preheating is not specified for the adjacent joint, preheating for the above tack weld may be omitted. After the joint is completed all tack welds used for this purpose shall be removed flush with the adjacent surface of the pipe by chipping and/or grinding areas where "C" clamps were attached, shall be included in scope of stress relieving, where required.

12.29.26 Pre-fabrication can be carried out in the fabrication shop to be established at site by the contractor to ensure quality of work and to minimise work on the field. Such pre-fabrication /pre-assembly of piping should be based on isometrics and piping arrangement drawing supplied. However, it shall be borne in mind that there may be variations in dimensions between those stated in isometrics and those actually obtained at site due to slight variations in the location of equipment, location of inserts etc. The contractor shall therefore, provide appropriate field joints and fit in sections permitting the pre-assembled pipe work to be installed without major modifications. In any case no extra claim shall be entertained on this account.

12.29.27 All piping shall be routed and located in accordance with the piping arrangement drawings/ isometrics. No deviations will be allowed.

12.29.28 Before laying the piping on supports, the co-ordinates and elevations of all supports shall be checked by the contractor for correctness. Discrepancies of the execution drawings, if any, shall be promptly brought to the notice of the engineer in writing and correction shall be carried out as per his instruction.

12.29.29 When fitting up mating flanges, the pipe shall be properly aligned and the flanges checked to determine that the forces are parallel and that they can be pulled up without inducing stress into the piping and equipment. The bolt holes of the flanges in the vertical plane shall straddle the vertical centre line of the pipe line in the erected portion and for flange in the horizontal plane; the bolt holes shall straddle the plant north-south axis unless otherwise shown on the drawings.

12.29.30 Flange connection to pumps, fans, turbine etc shall be such as not to induce stress on the equipment/ machinery due to misalignment, excessive gap etc. The final tightening shall be done as per the instruction of BHEL engineers only when the machines are made available for final piping connection.

12.29.31 Supports shall be fabricated and erected as per the erection drawings and as per the instruction of BHEL engineer. The auxiliary steel shall be of size as indicated in the drawing. Supports shall be erected with sufficient margin for turn buckle threads for future adjustments.

12.29.32 Fabrication, erection of permanent & temporary approach platforms for taking reading of valves/ actuators, equipment's, drains, vents, instrumentation points, wherever required to be done as per the drawing/ instruction of engineer. Also, bidder may have to fabricate, erect some platforms/ ladders (not envisaged in any drg/ doc) for operation/ maintenance of valve/ actuators (the total approximate weight will 15MT). The required steel will be given by BHEL free of cost. Bidder’s quoted/ accepted rates shall be inclusive of this scope.

12.29.33 Flash box, Flash tank shall be fixed on foundation provided by BHEL. Necessary chipping, leveling and grouting of foundation is to be done by the contractor at his cost.

12.29.34 All assembly of fittings, gauges, valves etc. on flash tanks shall be carried out by the



contractor at his cost to make it complete in all respect. 12.29.35 All small pipes / tubes shall be carefully routed according to site condition and to

avoid fouling with equipment/ other pipelines. BHEL engineer shall be consulted before starting the activities on small bore lines, whose decision shall be final and binding on the contractor.

12.29.36 For commissioning of the unit, if any contingency schemes are planned in addition to normal PGMA's identified, the same contingency pipelines may be included in the scope of contractor without any extra cost for which materials only will be supplied by BHEL. All T&P, consumables are in the scope of contractor. Subsequently, restoration with piping, valves etc. will be in the contractor’s scope.

12.29.37 Contractor shall provide necessary services for updating the material records, progress reports at no extra cost.

12.29.38 For maintaining the slopes as given in the drawings for larger thickness and larger diameter pipelines, edge preparation for welding may have to be altered suitably to achieve the slope. This shall also form part of the work and the contractor's quoted rate shall include this work also.

12.29.39 In case the supplies of some items are delayed, the contractor has to make temporary spool pieces for the flow control valves, HP bypass valves, flow measurement devices and the pipes are to be prepared for erecting the same temporarily in order to reduce the erection cycle time.

12.29.40 If safety requirements are not being met by the contractor, necessary safety appliances will be provided by BHEL on chargeable basis.

12.29.41 Temporary piping for pre-commissioning activities like, chemical cleaning, alkali flushing, hot water flushing, oil /steam flushing, etc. shall be carried out as part of work.

12.29.42 In addition to above temporary lines, any other contingency lines required due to non-availability of regular pipe materials shall also be erected to meet the commissioning target at no extra cost.

12.29.43 All temporary / contingency pipeline materials shall be arranged by BHEL free of cost. However, consumables like electrodes, gases etc and T&P required are to be arranged by the contractor at his cost. Platform materials for permanent approach platform will be issued free of cost by BHEL.

12.29.44 All the instrumentation tap off points like thermowells, root valves, impulse lines upto root valves etc. shall also be erected and welded by the contractor, irrespective of whether such materials are supplied by BHEL or any other agency.

12.29.45 The root valves, thermowells, instruments will be located in the convenient location/place as required by the customer to facilitate easy operation as per the decision / instruction of BHEL engineers.

12.30 PG TEST :- 12.30.1 Installation and welding of Tapping Points for taking performance test measurements

shall be carried out by the contractor as part of this work for the equipments covered under this tender specification under the guidance of BHEL engineer. The contractor has to install PG Test related instruments and other related hardware in the equipments/piping/systems erected by them. At the same time , the contractor may have to carry out installation of PG Test instruments and related hardware on the equipments/systems which are erected by other vendors to facilitate PG Test activity treating them also as part of their work.

12.30.2 For PG Test purpose, the vendors within quoted rate shall perform the following activities for the Unit :

12.30.2.1 Receiving all the PG test materials including electrical, instruments, mechanical items from BHEL Store/other designated place.

12.30.2.2 Installation of PG Test instruments like impulse piping ,valves, supports, fixing/welding of thermo-wells as per requirement. Tapping points/impulse pipelines , thermowells and other supporting activities required to complete the PG Test are to be installed in the system/piping/equipment erected by the vendor and even in areas which are not erected by TG contractor as per the requirement for PG Test purpose. This is treated as normal scope of work of the vendor.


PART-1-TECHNICAL SPECIFICATION 12.30.2.3 Installation of Root Valves, RTDs, Thermocouples, Temperature instruments,

pressure/Differentials pressure/vacuum gauges, pressure differential pressure/vacuum transmitters, Power transmitters/Watt meters and all other associated activities.

12.30.2.4 Complete necessary PG Test related activities like laying of cables, tuning of instruments, recording datas.

12.30.2.5 Attending to passing valves. 12.30.2.6 Cleaning of passing valves. 12.30.2.7 Cleaning of condenser tubes with high pressure jet cleaning or with suitable method

as suggested by BHEL in addition to Condenser steam space cleaning and inspection, cleaning/inspection of condenser CW system for the portion erected by the vendor.

12.30.2.8 Cleaning of all gauge glass in Hotwell, LP & HP Heaters, FST, Drain Cooler, GSC and other areas with provision of additional lighting.

12.30.2.9 Calibration of all instruments. 12.30.2.10 Replacement of spool pieces/regular flow elements with PG Test Flow

nozzles/orifices and restoration after completion of PG Test. In case the pipelines are having insulations, the same is to be removed (both wool and Al/ GI. Sheeting cladding) and these are to be carefully preserved for restoration after completion of PG Test. This is treated as normal scope of work.

12.30.2.11 Arranging additional lighting arrangements during PG test . 12.30.2.12 Arranging additional watch and wards for protection of PG Test instruments and

items. 12.30.2.13 Exclusive Engineers/supervisors for conductance of PG Test. 12.30.2.14 Manpower for arranging taking PG Test readings manually(around 10 staff during PG

Test exclusively for this purpose) 12.30.2.15 Arranging two number of computer with operators, stationeries, computer papers,

photocopy papers etc. ink-jet /lasor printer with cartridge facilities during PG Test period in addition to the existing computer facilities .

12.30.2.16 Compilation of PG test documents , multiplication and spiral binding for at least six sets of such documents.

12.30.2.17 Conductance of actual PG Test and during this time, the contactor has to arrange Engineers/supervisor, manpower during normal working and OT hours including normal working days, Sundays/Holidays.

12.30.2.18 Dismantling of PG test instruments and all related piping etc. 12.30.2.19 Returning all instruments and impulse piping and other total items. 12.30.2.20 Packing of all PG Tests items in boxes for despatch. 12.30.2.21 Restoration of PG Test flow nozzles/orifices with spool pipes/regular flow elements. 12.30.2.22 All other activities required to accomplish PG test in all respect is to be done treating

it as normal scope of work by the contractor. 12.30.3 Removal/restoration of thermal of thermal insulations/sheeting required after PG Test

completion is included in contractor’s scope of work. 12.31 In pipelines like MS, CRH, HRH lines, extraction lines etc., the NRVs/ESVs/IVs,

Strainers etc will be erected by the Contractor as per drawings and instruction of BHEL.

12.32 The connection of flanged / welded joints with equipment like deaerator, turbine, condenser, pumps, strainers etc. shall also be carried out by the contractor as part of the job.

12.33 Rerouting / modification of pipelines due to revisions in the drawings received before physically taking up the job shall be carried out by the contractor within the scope of work. No extra claim shall be permitted on this account. The contractor shall check up before taking up erection of any pipelines regarding the availability of the latest revision drawings.

12.34 All temporary lines like alkaline flushing, steam blowing etc. shall be supplied in “as is where is” condition. The contractor shall arrange to carry out the required dressing, grinding, cleaning etc. while carrying out erection. No extra claims on this account will be entertained.


PART-1-TECHNICAL SPECIFICATION 12.35 It is likely that dressing set-up of joints in critical piping and LP piping, grinding of the

shop prepared edges will require to be done by the contractor to maintain the desired slopes and all these jobs will be treated as normal erection work.

12.36 All turbo-supervisory pick ups and temperature elements (to be installed inside bearings) for turbine, generator and equipment etc are to be installed by the vendor as per drawing within the quoted rates. The above items may have to be removed for servicing, calibration and then refitted by the vendor.

13.0 HYDRAULIC TEST AND OTHER TESTS 13.1 Hydraulic testing pumps and chemical cleaning pumps along with starter as required

shall be provided by the BHEL. However, supply of cables, DBs, resistance boxes, fuses etc. required for hydraulic test / chemical cleaning operations will be in the contractor's scope of work. The servicing, installation, electrical connection, erection, testing and dismantling shall be carried out by the contractor as part of the work.

13.2 All pressure parts and some of low pressure parts shall be subjected to hydraulic test as per statutory requirements. In addition gas tightness test of generator has to be carried out. The contractor shall supply necessary labour and other services & arrangements to carry out the required tests as per instruction and direction of BHEL engineers, and is included in the scope of work.

13.3 The contractor shall carry out the air tightness test on generator stator to the satisfaction of BHEL engineers. The necessary arrangement of testing with clean dry air shall be made by the contractor. This may have to be repeated on later date as per requirement of BHEL. Arrangement of hot air with drier is to be done by vendor with thermostat. Purging of Air/H2/Co2 in first time & subsequent times till handing over is under the scope.

13.4 Contractor shall lay all necessary temporary piping, install the pumps, blanks, valves, pressure gauges etc. required for the test. Temporary piping, valves, flanges, blanks etc. will be supplied by BHEL on loan basis, free of hire charges. After the test is over all temporary piping, valves, flanges, blanks etc. shall be removed by him and returned to BHEL.

13.5 The hydraulic testing of the equipment and piping covered in this scope of work including vacuum system testing by water filling has to be carried out by the contractor as per instructions of BHEL engineer. The contractor shall provide all facilities required for hydraulic testing.

13.6 All valves coming in the gas system shall have to be hydraulically tested and cocks shall have to be checked for gas tightness before installation in the presence of BHEL engineer.

13.7 All the weld joints of steam inlet pipelines to LPT shall have to be subjected to non-destructive test viz., magnetic particle test, dye-penetration test, and Hardness test in addition to radiography as and when applicable.

13.8 All above tests shall be repeated till all the equipment/ system satisfy the requirement, obligation of BHEL to their customer. As far as the hydraulic pressure test is concerned, the same shall be conducted to the satisfaction of the BOILER INSPECTORATE /CUSTOMER /BHEL. Any rectification required shall have to be done / redone by the contractor at his cost.

13.9 Raw materials for all temporary piping necessary for conducting hydraulic test, chemical cleaning, steam blowing, flushing, effluent disposal etc., will be provided by BHEL free of cost. However, fabrication, servicing, erection including dismantling the same and return of the temporary piping, flanges, valves etc. to BHEL stores is the responsibility of the contractor without any extra charges.

14.0 PRESSURE TEST FOR PIPING 14.1 Soundness of the weld shall be tested hydraulically under the supervision of the

BHEL engineer and customer, to the pressure indicated in the drawing for each piping system as per requirement. Prior to the test, the piping system shall be inspected by the BHEL engineer to the extent necessary to ensure compliance with engineering design with respect to material, and erection clearance for the test shall be obtained by the contractor.


PART-1-TECHNICAL SPECIFICATION 14.2 BHEL will supply the necessary pipes, valves etc for test. The erection of pumps,

temporary piping, valves, pressure gauges and their subsequent removal and return to BHEL after successful completion of the test shall be done by the contractor at his own cost.

14.3 The test shall be repeated till the boiler inspector, BHEL and customer are satisfied. 14.4 Pressure test for piping systems under the purview of IBR shall be carried out

according to the relevant clause of IBR and the requirements of boiler inspector. 14.5 For piping system not under the purview of IBR, testing shall be carried out as per

the instruction of BHEL engineer. 14.6 The following specifications shall be complied with during hydraulic test : 14.6.1 Vent nozzles with valve shall be provided at the highest point of the runs, to eliminate

air pockets. Drain nozzles with valves shall be provided to drain water from pipes. The nozzles and valves shall be of same materials as the pipe.

14.6.2 The lower part of the pipe shall always be filled first with water. 14.6.3 The pressure shall be slowly increased (without shocks) to the stipulated value and

maintained for ten minutes or as long, as required to visually check all joints. 14.6.4 Following the control specified above, the pressure shall be slowly decreased to the

design pressure after which the pipe shall be subjected to a peening test, applying knocks every 150 mm approximately especially in the welded joint areas, with a 0.5 to 1.5 kg Hammer (depending on the pipe wall thickness). The hammer used shall be a round headed one.

14.7 During hydraulic test, the pipes being tested shall be isolated from the equipment which they are connected to.

14.8 Openings for pressure / temperature impulse connections shall be fully closed during and after the test to prevent dust and foreign matter.

14.9 The test records shall be made for pressure testing of each piping system. These records shall contain the following information.

15.0 DATE OF TEST, IDENTIFICATION OF PIPING TESTED, TEST FLUID, TEST PRESSURE, APPROVAL OF ENGINEER ETC Contractor will supply labour and other services for following also, free of cost as part of the contract:

15.1 For transportation, installation, servicing, running of chemical cleaning pumps /test pumps and after completion to dismantle, service and return to BHEL, contractor will provide required manpower at his cost.

15.2 Contractor has to provide required manpower at his cost for erection of piping, valves etc required for alkali flushing / water flushing from mixing tank and pumps of boiler side to TG system, to drain pit, to neutralising pit, and then dismantling & return to BHEL after completion of cleaning.

15.3 For blanking of pipes at suitable point / installation of blanking devices, laying of temporary pipes for steam blowing, installation and their dismantling and return to BHEL store, contractor will have to provide manpower at his cost.

15.4 For transportation, handling, filling, emptying and refilling etc of flushing oil, fresh oil and lubricants for turbine and other main rotating auxiliaries, contractor will provide required manpower at his cost.

15.5 Contractor has to provide required manpower at his own cost for transportation of carbon di-oxide & hydrogen gas cylinders for filling / pumping from plant store and filling of gas as and when required till the unit is commissioned and handing over of the same.

16.0 PRE-COMMISSIONING TESTS AND COMMISSIONING OF UNITS 16.1 Commissioning of the TG set will involve trial runs of all the equipment erected,

blowing through the steam lines, flushing of all the lines by air, alkali, steam, running of centrifuge, pickling with acid etc. as the case may be. On completion of satisfactory pre-commissioning tests including mass flushing, oil flushing, steam rolling, synchronising, the trial operation or the unit shall start. The trial operation shall be successful if it is proved that the unit can be operated at commercial load continuously during the period of trial operation. Trial run of the TG set and any other works are incidental to commissioning. Contractor shall provide services of skilled



labour, supervision and other services in shift for above, without any extra cost under the contract.

16.2 The contractor has to arrange ElLC - Oil filtration machine alongwith vacuum degasser (filtration below 0.01 micron) for moisture and impurities removal during oil flushing, oil filling of various equipments, and the same is under the scope of contractor. In the absence of timely arrangement of the same, BHEL will arrange the same on hire and deduct with overhead the actual amount from contractor’s dues for the period of machine not provided for actual operation.

16.3 The contractor shall carry out the pre-commissioning activities such as alkali flushing of condensate and drip system, oil flushing of lubrication oil and jacking oil, governing system steam blowing of auxiliaries & gland steam pipes, flushing of condenser and generator air tightness test and any other cleaning, blowing and flushing operations required for making the system clean and ready for commissioning. The oil required for initial filling and chemicals required for alkali washing/ acid pickling shall be supplied by BHEL free of cost. All required services for above is in vendor's scope of work.

16.4 All temporary pipelines, tanks, supports and fittings required for carrying out chemical cleaning, steam blowing, oil flushing, alkali flushing, hydraulic testing and for any other pre-commissioning work shall have to be welded and erected by contractor and is in the vendor's scope of work.

16.5 After successful completion of chemical cleaning, steam blowing, oil flushing or other test etc. removal of temporary piping, checking of valves for any accumulation, welding of valves which were kept out during cleaning operation, re-conditioning the valves, restoration of piping and returning of temporary piping, valves, flanges, chemical pumps / test pumps etc. to BHEL store, have to be done by contractor then and there, and is included in the scope of work.

16.6 For above work contractor has to utilise their man power e.g. welders, fitters, riggers, helpers etc, T&P, consumables etc. free of cost.

16.7 All chemicals and required pipes, plates, structures etc. will be supplied by BHEL free of cost but required services is in the vendor's scope.

16.8 HT/LT motor electrical testing and drying out is included from the scope . Manpower help and arrangement of lights for heating is under the scope of work. The contractor shall carry out the trial run of motors including checking the direction of rotation in the uncoupled condition, checking, aligning and coupling the motor to the respective driven equipment.

16.9 Providing continuous manpower for pre-commissioning, testing, commissioning of electrical items by engaging electrician(at least two numbers) and Supervisor as per the requirement on normal days including OT hours on normal working days/Sundays/Holidays.

16.10 Testing of Generator stator and Rotor impedance, IR etc. as per BHEL norms / QP is under the scope of work.

16.11 In case, any erection defect is noticed during various tests / operations/ trial runs as detailed above, such as loose components, undue noise or vibrations, strain in connected equipment etc. the contractor shall immediately attend to these defects and take necessary corrective measures. If any readjustment and re - alignment are necessary the same shall be done as per BHEL engineer instructions. If any part needs repairs / rectification and replacement the same shall be done by the contractor. The parts to be replaced shall be provided by BHEL free of cost, provided the defect is not attributable to the contractor.

16.12 Pre-commissioning of oil lines, includes the flushing of the pipe lines till the entire system and the pipelines are accepted as satisfactorily cleaned after inspection of sediments in the centrifuge bowl and laboratory tests of the oil samples taken from the system. After declaration of completion of oil flushing, oil system including main oil tank and coolers shall be completely drained, thoroughly cleaned and refilled with fresh oil for putting the set on barring gear. Necessary manpower for bringing fresh oil from stores to site and filling the same in main oil tank and the system shall be provided by the contractor at his cost. The contractor shall provide in three shifts,



requisite manpower like skilled, semiskilled workmen during oil flushing as a part of this contact without any extra charge. Before commissioning of oil system, the pipeline should be hydraulically tested using the special hydraulic test pump to the required pressure. During alkaline flushing of condensate /feed water system also, necessary skilled /semiskilled workmen shall be provided by the contractor in three shifts as a part of this contract without any extra charge.

16.13 During this period, though the BHEL's / clients staff will also be associated in the work the contractor's responsibility will be to arrange for the complete manpower and other services required till such time the commissioned unit is taken over by the BHEL's customer.

16.14 It shall be specifically noted that employee of the contractor may have to work round the clock along with BHEL staff, and hence, if any overtime payment is involved, the contractor's quoted rate shall be inclusive of all such contingencies.

16.15 During commissioning, opening of valves, flanges, joints etc changing of gaskets, attending to leakages, minor modification, rectification works may arise. The contractor has to carry out these works at his cost by providing required manpower for servicing, all the three shifts.

16.16 The contractor within his quoted rate has to carry out Cleaning of various strainers, filters, Coolers, Different tanks, vessels, Condenser internals, condenser tubes, Self Cleaning Strainers and their components, Condenser On load tube cleaning system, Deaerator, Feed Storage Tank, level gauges and other equipment, system, Central Oil Purification System with connected equipment and piping coming under the scope of TG Auxiliary and TG piping till the unit is taken over by the customer will be in the scope of respective contractor. The exercise may have to be repeated till satisfactory acceptance by BHEL.

16.17 In case any re-work is required because of contractor's faulty erection, which was noticed during commissioning the same, it has to be rectified by the contractor at his cost.

16.18 In case BHEL requires expert services of OEM for commissioning support of equipment, BHEL will arrange the same.

17.0 CLEANING OF PIPES, VALVES, ACTUATORS, BEARINGS, GEAR BOXES, AND OTHER EQUIPMENT / COMPONENTS OF THE SUPPLIED EQUIPMENTS AND THESE ARE TO BE DULY PROTECTED.

17.1 The contractor shall arrange to dispose off the chemicals used after cleaning operation in a manner acceptable to BHEL / customer.

17.2 The contractor shall ensure that during the cleaning process the procedure adopted shall be such as to consume minimum amount of DM water.

17.3 The contractor shall clean inside of all tubes, pipes and fittings from dirt, sand and loose scales, mechanically and by air blowing before its erection. All pipelines will be thoroughly blown and / or flushed. The contractor shall ensure that no valves and valves actuators are left un-serviced. Whenever necessary, as required by BHEL engineer, the contractor shall arrange to lap / grind valve seats. A system of recording such cleaning, servicing shall be developed and maintained in a manner acceptable to BHEL engineer.

17.4 The contractor shall take necessary measures to see that all the machined surfaces are greased and covered.

17.5 After flushing with water, steam blowing or after chemical cleaning, as directed by the engineer, all parts of equipment (viz. Valves etc) shall be dismantled and checked for accumulation of dust, wear or damage cleaned rectified / replaced if necessary and reassembled by the contractor without claiming any extra cost. However the parts to be replaced in such case will be supplied by BHEL.

17.6 All the bearings, gear boxes etc. of the equipment, valves and electrical motors to be erected are provided with protective grease only. Contractor shall arrange, as and when required by the engineer, for cleaning the bearings, gears etc. with kerosene or some other agent if necessary by dismantling some of the parts of the equipment during erection and shall arrange for re-greasing/lubricating them with recommended lubricants and for assembling back the dismantled parts.


PART-1-TECHNICAL SPECIFICATION 17.7 The contractor shall thoroughly clean all the components before installation. The

components whose surface are coated with protective coating and sent to site are to be thoroughly cleaned by sand blasting or with steam mixed with caustic soda as per the instruction of the BHEL engineer before erecting the same. The sand blasting equipment and the steam washing equipment required for the purpose along with consumables such as sand etc. and compressed air shall be the responsibility of the contractor at his own cost.

17.8 The contractor shall provide all labour for execution of work including installation and dismantling of temporary piping, strainers, valves and instruments required for conducting cleaning works. He shall also supply and erect the chemical cleaning pumps and strainers and arrange to commission the same, giving necessary electric connection from the isolation switch. Upon completion of the work, material given by BHEL for above temporary installation are to be returned to BHEL stores, failing which suitable recovery shall be made from contractors bills/ dues.

17.9 Chemicals required for chemical cleaning shall be supplied by BHEL free of cost. 18.0 CHEMICAL CLEANING OF PIPING SYSTEM

This erection is intended to cover the procedure and scope of work for installation of all temporary equipment and material for chemical cleaning of the piping system as specified hereinafter.

18.1 The chemical cleaning specified herein is intended to remove grease, oil, oxides, silica, mill scale and other contaminate from the piping and equipment. After cleaning, the piping shall be free of visible mill scale and properly passivated without affecting the system material of fabrication.

18.2 The scope of chemical cleaning will cover installation of all temporary & by-pass piping, drain piping, supports, valves, blank plates, tanks, pumps, instruments & controls, chemicals and all other accessories and fittings and services to complete the cleaning process. The above mentioned materials including insulation will be supplied by BHEL free of cost. The chemical cleaning shall be performed by the contractor for the piping systems covered under the scope of this package and shall include off site disposal of wastes duly neutralized, site cleaner, normalisation, reinstallation of the cleaned piping system. All temporary piping, valves, fittings and equipment's used for chemical cleaning shall be dismantled and returned to BHEL.

18.3 Erection of tanks (including fabrication if required & temporary insulation) and its supporting structures (for which steel plates, insulation material sections will be provided by BHEL free of cost) shall be done by the contractor. Contractor shall fabricate bends at site from running meters of temporary piping for the above and lay the piping as per BHEL engineer's instruction.

18.4 Hydraulic test of the temporary piping is to be carried out as per BHEL engineer's instruction.

18.5 It is intended to clean deaerator, power cycle piping (except extraction & steam piping) and heater drains by this chemical cleaning process. Chemical cleaning of all the equipment and piping shall be done as per scheme/drawings/procedures furnished later.

18.6 During initial stages of work, trenches for draining water may not be available after alkali flushing or mass flushing for discharging or emptying the piping. Necessary low point drains and temporary piping for this will have to be provided by contractor from material provided by BHEL and on completion of work these materials are to be returned to BHEL stores.

18.7 Laying effluent discharge/drain line from mixing tank as per instructions of BHEL engineer and dismantling the same and returning after the work is over, are under the scope of this tender.

19.0 Unloading & Installation of the Generator Stator 19.1 Handling, lifting from special trailer/resting place in front of A row, and placement on

TG foundation with the help of Strand-Jack is included in the scope of contractor. The contractor shall tie up with specialized agency sufficiently experienced in handling of 270MW Generator stator by strand jack method and take approval of BHEL Construction Manager regarding the agency and the method.



The vendor shall extend all necessary assistance for releasing the special trailer (which will come in front of A-row or the unloading bay in site with Generator Stator) treating it as his normal scope of work. Stools for keeping the generator stator after unloading shall be fabricated by the contractor as per own/BHEL’s design.

19.2 In case the stator is not lifted directly from the trailer, necessary assistance in Unloading of Generator in front of A row/unloading bay of Power House from trailer, and placement of the same on the designated resting place is included in the scope of work .

19.3 Handling, lifting from special trailer/resting place in front of A row or unloading bay, and placement on TG foundation with the help of Strand-Jack is included in the scope of contractor. The contractor shall tie up with specialized agency sufficiently experienced in handling Generator stator (of unit capacity more than 120MW) by strand jack method and take approval of BHEL Construction Manager regarding the agency and the method. The vendor shall extend all necessary assistance for releasing the special trailer (which will come in front of A-row/unloading bay in site with Generator Stator) treating it as his normal scope of work.

19.4 The Package – A (Unit # 1) & Package –B (Unit # 2) Stators are to be lifted from the A-row side. Positioning of the stator to its designated location before lifting is to be done by the contractor. The contractor shall visit site and take note of the existing TG deck and use the same for any supporting. The foundations required at ground level is to be designed by the contractor and the same shall be furnished to BHEL/Owner for information/construction.

19.5 Stator is to be rested on a Temporary Stool (to be fabricated by the contractor) with a minimum ground clearance of 500 mm at the stator bottom, to facilitate blue matching of the bottom terminal box for final placement. During this time, loading is to be given only on the special insert plates provided on ground alongside of the A-row/Unloading Bay for Stator Movement. Suitable Temporary Stools with adequate strength & Capacity to bear the load (weight) of Generator Stator are to be fabricated and placed on the insert plates by the vendor including supply of necessary steel as required. Necessary compaction and concreting of the area beside A-row/Unloading Bay, where stator will be unloaded and kept on stool temporarily, shall be done by the contractor within his quoted rate, duly considering the load of the stator.

19.6 It may be noted by the contractor that during the entire process of Lifting/Shifting and Placement of the Stator over Generator Foundation Deck, all ground Loads are to be transmitted over ground level ONLY through the existing foundation anchor points provided by some other agency to the contractor. Thus no Load is permitted over the Powerhouse floor Level except the points stated above and the TG Foundation Deck. Any further Civil Works to accommodate resting/positioning of Structural columns are to be done over these foundations only.

19.7 Contractor is also required to furnish a confirmatory certification from any of the Design Consultants as mentioned below, regarding the adequacy of Structural Design and Safety provisions of the Temporary Structures that are proposed for use by Contractor, to Handle the load as detailed above. This confirmation should be submitted and got approved from BHEL before construction of the temporary stool. This Certification regarding Design adequacy may be obtained from any of the following Engg. Consultants, or any National/International Organization of repute duly accredited by Statutory Body/Authorities to this effect- i) BHEL ii) M/S DCPL iii) M/S FISTENER iv) M/S DESEIN v) M/S TCE vi) M/S EIL vii) M/S MECON viii) M/S M N Dastur & Co. ix) M/S Lloyd’s.

19.8 All Equipment/T & P/Temporary Supporting Structures/Slings & Consumables etc. as may be required for the job shall be timely Mobilized and Installed/Erected/ Aligned/ Welded by Contractor at Site, as per tender schedule/site clearance and later



Dismantled/Demobilized from Site within a period of maximum 2 (Two) weeks after completion of the work for each Unit.

19.9 For Heavy Duty Slings including that for handling of Stator, appropriate Test Certificate from Statutory Agencies declaring the sling to be fit for handling the desired load is to be produced by the Bidder prior to use of the same at Site.

19.10 The Contractor shall have the option to retain their Equipment/T & P/Temporary Supporting Structure etc. at Site, which have a repetitive requirement for executing the job in successive Units, in part or full portion for which necessary storage facility shall be provided by BHEL at site, free of cost. However, responsibility of watch & ward/surveillance shall remain with the Contractor.

19.11 The Lifting/Shifting System to be installed at Site is required to be Load tested at 25% overload than the Load it is intended to carry at Site {i.e. 1.25 Times of the weight of Stator (approx.Stator Wt-refer drawing attached.)} added with the load of slings and other lifting tackles used by Contractor. Necessary Insurance Coverage for contractor’s Staff, Workmen, materials and Equipment is to be obtained by the Contractor (successful bidder of this tender), within quoted/accepted rates.

19.12 Contractor is also required to arrange all required safety precautions/protective equipment for his working personnel. Contractor is to furnish the necessary Test Certificates for all relevant Lifting

Equipment e.g. Strand wires, Lifting Tackles etc. In case of poor or non-performance of the Contractor in the job, BHEL reserves the right to take away the job in part or full and get it done by other agency at the risk and cost of the Contractor as may be deemed fit.

Annexure-I (TCC-PART-1-TECHNICAL SPECIFICATION)

( TENTATIVE LIST AND WEIGHT SCHEDULE OF MAJOR EQUIPMENT FOR 1x270MW UNITS )

A. CONDENSER (BHEL-HARDWAR SUPPLY)

NOTE : SL NOS. 82~84, 96, 100 & 107 IS DELETED.

B. TURBINE (BHEL-HARDWAR SUPPLY)

C. GENERATOR (BHEL-HARDWAR SUPPLY)

D. BOIs –BHEL HARDWAR SUPPLY

ITEM ID QTY Unit ITEM DESC Gross wt (KG)

BG001 131 NO EMPTY H2 CYLINDER 7500

BG002 63 NO EMPTY CO2 CYLINDER 3400

BG005 1 ST MOISTURE MEASURING SYSTEM 25

BG007 2 NO VAPOUR EXHAUSTER 250

BG008 1 ST MOTORISED TEMPERATURE CONTROL VALVE WITH ACTUATOR NB250 VAR-02

900

BG009 1 NO H2 GAS ANALYSER CABINET 1000

BG011 2 no REFRIGERATION GAS DRYER 1100

BG018 1 NO STARTING RESISTOR FOR DC S.O MOTOR 250

BG020 1 No SOUND ABSORBING COVER 750

BG080 1 NO STROBOSCOPE 200

BH001 1 ST WELDED AUSTENITIC S.S. TUBES GR.304 (FOR CONDENSOR) 120090

BH010 2 NO CONDENSOR AIR EVACUATION PACKAGE (VACUUM PUMP) 15330

BH012 2 NO AIR EXHAUSTER WITH MOTOR (GSC AIR EXHAUSTER) 300 BT002 1 ST JACKING OIL PUMPS 3480

BT003 1 ST AOP & EOP 5000

BT004 1 NO DUPLEX FILTER (LUB.OIL) 610

BT005 1 NO DUPLEX FILTER (JACKING OIL) 180

BT006 1 ST BUTTERFLY VALVES 80

BT007 1 NO THREE WAY TEMP. CONTROL VALVE 200

BT008 1 NO DOUBLE THREE WAY VALVES 250

BT009 2 NO NRV WITH ALUMINIUM FLAP 30

BT010 1 NO PRESSURE LIMIT VALVE 20

BT011 1 NO OIL PURIFICATION UNIT (OIL CENTRIFUGE) 2500

BT012 2 NO OIL VAPOUR EXHAUSTER 175

BT013 4 NO LEAD DIAPHRAGM 60

BT014 1 ST SPRAY NOZZLES 5

BT015 1 NO DIRT CATCHERS 10

BT016 1 ST DAMPER 180

BT017 1 ST VARIABLE LOAD SPRING CAGES 600

BT023 73 M3 TURBINE OIL 72000

BT025 1 ST OIL PURIFICATION SYSTEM (CENTRAL) 3000

BT027 1 ST TURBINE INTEGRAL PIPING 32730

BT028 1 ST H & S FOR TURBINE INTEGRAL PIPING 8935

BT029 1 ST FLOW NOZZLES FOR PG TEST 1560

BT043 1800 Lt CONTROL FLUID (FRF) 2295

BT046 1 ST LP BYPASS STOP & CONTROL VALVE WITH EHA AND WATER INJECTION VALVE

15000

BT065 1 NO GEAR PUMP (LUB. OIL RECIRCULATION) 50

BT074 1 NO VACUUM BREAKER VALVE WITH PNEUMATIC ACTUATOR 400 BT075 1 ST SEAL STEAM SUPPLY & LEAKAGE STEAM CONTROL VALVE WITH

PNEUMATIC ACTUATOR 5500

BT080 1 ST EHA FOR TURBINE VALVES ALONGWITH HPSU 12050

Total: 321495

E. PUMPS –BFP & CEP (BHEL-HYDERABAD SUPPLY- FOR BOTH UNITS)

DEARAEATOR & FST,HPH 5 DEAREATOR 9.45 (M) x 2.55 (M) x 2.90 (M), 16000 Kgs 1 6 FST (IN THREE SECTIONS) 9.0 (M) x 4.10 (M) x 4.35 (M), 20050 Kgs 1

11.25 (M) x 4.10 (M) x 4.65 (M), 24850 Kgs 9.0 (M) x 4.10 (M) x 4.65 (M), 20500 Kgs

F. MISC TANKS,RE JOINTS & BF VALVES (BOM FOR BOTH UNIT)

S.No. Scope Quantity Dimension MM (LXWXH) Approx. Unit Wt

1. RE Joints

1.1 Outlet Assy. 2 Sets 3100 X 3000 X 3800 15.20 MT 1.2 Inlet Assy. 2 Sets 2800 X 3950 X 6275 17.20 MT

2. Flash Tank 2.1 HP Drain Flash Tank 2 Nos. 4100 X 3000 X 2900 4.60 MT 2.2 LP Drain Flash Tank 2 Nos. 2900 X 2200 X 2100 3.40 MT 2.3 Unit Flash Tank 2 Nos. 2500 X 1500 X 1400 1.00 MT

3. Misc Tanks 3.1 Clean Oil Tank 1 No. 5000 X 4500 X 3000 10.2 MT 3.2 Dirty Oil Tank 1 No. 5000 X 4500 X 3000 10.2 MT 3.3 Oil Unloading Vessel 1 No. 2000 X 1000 X 0.500 0.58 MT 3.4 DMCW O/H Tank 2 Nos. Ø2000 X 7150X 12 Tk 6.00MT

4. HP Heaters 4.1 HP Heater No. 5 2 Nos. 11500 X 2100 X 2500 44.00 MT

4.2 HP Heater No. 6 2 Nos. 12500 X 2100 X 2500 53.50 MT

5. BF Valves 5.1 500 Dia 6 Nos. 1300 X 800 X 350 575 Kg 5.2 450 Dia 24 Nos. 1300 X 800 X 350 400 Kg 6. HT Motors 6.1 BFP Motor 6 Nos. 4000 x 3000 x 3000 15 MT 6.2 CEP Motor 6 Nos. 2000 x 1600 x 2500 6 MT 6.3 DMCW 6 Nos. 2000 x 1800 x 1150 4 MT.

G. MISC PUMPS & EQPTS –PEM SUPPLY

Sl no Description Qty Remarks

1 CHEMICAL DOZING SYSTEM 1-LOT

2 ME Bellows 24 3 VALVES: Gate/Globe/NRV etc. 1-LOT 4 SELF CLEANING STRAINER 6 No. 5 BF VALVES LOT 6 COLTS 1-LOT

H. PIPING – (BOM FOR ONE UNIT)

PGMA WISE DETAILS OF PIPING FURNISHED BELOW

Proj. Def. Short ID Description Estimated Wt In kg

P1/7070 1-80-345 AUX STEAM TO DEAERATING HEATER 2500

P1/7070 1-80-400 CONDENSATE SUCTION 3000

P1/7070 1-80-401 CD FROM PUMP TO LPH1/DC INLET TEE AND RE 7000

P1/7070 1-80-402 CD FROM LPH1/DC INLET TEE TO TG TP 6000

P1/7070 1-80-407 CONDENSATE FOR SEALING OF VACUUM 3500

P1/7070 1-80-408 CONDENSATE DUMP FROM HEADER 2500

P1/7070 1-80-413 UNLISTED CONDENSATE 2000

P1/7070 1-80-446 DEAERATING HEATER OVER FLOW AND DRAIN 2000

P1/7070 1-80-463 TG AUX COOLING WATER 160000

P1/7070 1-80-601 LOW PRESSURE DOSING PIPING 1500

P1/7070 1-80-928 H AND S FOR BOILER LIGHT UP - TG 95000

P1/7070 1-80-369 HP DRAIN FLASH TANK VENT TO SYSTEM 3000

P1/7070 1-80-375 UNLISTED SV EXHAUSTS - TG SCOPE 3000

P1/7070 1-80-381 HP HEATER VENTS - TG SCOPE 1000

P1/7070 1-80-382 LP HEATER VENTS 1500

P1/7070 1-80-385 VENT FROM UNLISTED PPG/EQPT TO COND 6000

P1/7070 1-80-387 CONDENSATE PUMP VENT 1000

P1/7070 1-80-388 CONDENSER AIR EVACUATION PIPING 3500

P1/7070 1-80-440 CONDENSER DRAINS 1000

P1/7070 1-80-442 GLAND STEAM COOLER DRAINS 500

P1/7070 1-80-443 LP HEATER-1 TO CONDENSER 2500

P1/7070 1-80-444 LP HEATER-2/3/4/5 DRAINS AND DRIP PUMP I 3500

P1/7070 1-80-447 HP HEATER DRAINS 7000

P1/7070 1-80-449 TG CYCLE PIPING DRAINS AND VENTS 12500

P1/7070 1-80-457 MANIFOLDS FOR HP FLASH BOX AND CONDENS 2500

P1/7070 1-80-673 LUBE OIL PIPING SYSTEM 3500

P1/7070 1-80-930 H AND S FOR SYNCHRONISATION - TG 6000

TOTAL WEIGHT 343000

TG INTEGRAL PIPING (LUB OIL PIPING, GLAND STEAM PIPING, SEAL OIL PIPING ETC) UNDER BHEL-HARDWAR SCOPE OF SUPPLY IS INCLUDED IN THE SCOPE OF SUPPLY.

NOTE:

1. THE DETAILS FURNISHED ABOVE IS BASED ON PRELIMINARY ENGG. AND THERE IS LIKELYHOOD OF MINOR ALTERATION IN THE ABOVE DETAILS IN THE SCOPE ON FINALISATION OF THE ENGINEERING.

2. THE ABOVE INFORMATIONS IS TO BE USED FOR ASSESSMENT OF THE WORK QUANTUM FOR THE EACH 270MW UNITS CHANDWA PROJECT.

3. THE COMMON SYSTEMS (WHERE EVER APPLICABLE ) IS INCLUDED IN THE SCOPE OF WORK OF UNIT-1.

4. “THE WORD “ADHUNIK” SHALL BE READ AS “ABHIJEET-CHANDWA”.

TENDER NO:PSER:SCT:ABJ:T1178:11

VOLUME -- I F

TECHNICAL CONDITIONS OF CONTRACT PART-2 COMMON TECHNICAL CONDITIONS

FOR

IDENTIFICATION & RECEIPT OF MATERIALS, ERECTION, TESTING, COMMISSIONING, HANDING OVER ETC OF STEAM TURBINE & AUXILIARIES, GENERATOR & AUXILIARIES, PUMPS, PIPING, MISC EQUIPMENTS, INSULATION, PAINTING INCLUDING UNLOADING &

PLACEMENT OF GENERATOR STATOR ON FOUNDATION OF TG & AUXILIARIES FOR

2X270 MW

CHANDWA PROJECT, UNIT-1 & 2

LATEHAR, JHARKHAND

BHARAT HEAVY ELECTRICALS LIMITED ( A GOVT. OF INDIA UNDERTAKING )

POWER SECTOR – EASTERN REGION PLOT NO. – 9 / 1, DJ – BLOCK, SECTOR – II, KARUNAMOYEE,

SALT LAKE CITY, KOLKATA – 700091.


PART-2-COMMON TECHNICAL CONDITIONS

CONTENTS

CLAUSE NO

DESCRIPTION

1.0 NAME OF WORK 2.0 PROJECT INFORMATION 3.0 DEWATERING 4.0 GENERAL 5.0 CIVIL WORKS, FOUNDATIONS AND GROUTING 6.0 CONSUMABLES 7.0 TOOLS & PLANTS (T&P) TO BE PROVIDED BY BHEL (SHARED MACHINERY

EXCEPT EOT CRANES) 8.0 EOT CRANE/ HOIST & MISC CRANES/ CHAIN PULLEY BLOCKS 9.0 T&P/ IMTE's TO BE PROVIDED BY BIDDER (REFER RELEVANT ANNEXURE

OF THE TENDER) 10.0 SUPERVISORY STAFF AND WORKMEN. 11.0 INSURANCE 12.0 PLANNING & PROGRESS REPORTING 13.0 DRAWING AND DOCUMENT 14.0 INSTRUCTIONS TO BIDDER 15.0 FACILITIES TO BE PROVIDED BY BHEL/ BIDDER 16.0 ELECTRICITY 17.0 WATER 18.0 SITE ORGANISATION 19.0 ERECTION SCHEDULE 20.0 CONTRACT MANAGEMENT 21.0 CONSTRUCTION MANAGEMENT 22.0 PROJECT MANAGEMENT 23.0 QUALITY ASSURANCE PROGRAMME 24.0 GENERAL REQUIREMENTS - QUALITY ASSURANCE 25.0 QUALITY CONTROL & QUALITY ASSURANCE 26.0 HEALTH, SAFETY & ENVIRONMENT (HSE) 27.0 TAXES, DUTIES ETC 28.0 SOCIAL OBLIGATION 29.0 COMPLETION PERIOD 30.0 CONSTRUCTION SCHEDULE 31.0 LIQUIDATED DAMAGE/ COMPENSATION FOR DELAY 32.0 PAYMENT FOR WORK COMPLETED 33.0 CONTRACT PRICE 34.0 INTEREST BEARING RECOVERABLE ADVANCE 35.0 PRICE VARIATION CLAUSE 36.0 OVER RUN COMPENSATION 37.0 RATE REVISION 38.0 EXTRA CHARGES FOR RECTIFICATION / MODIFICATION 39.0 GUARNTEE 40.0 OTHER TERMS 41.0 ANNEXURE-I - LIST OF CONSUMABLES TO BE PROVIDED BY BIDDER 42.0 ANNEXURE-II - LIST OF T&P AND MMDs TO BE PROVIDED BY BIDDER 43.0 ANNEXURE-III - T&P TO BE PROVIDED BY BHEL FOR USE OF BIDDER ON

SHARING BASIS (FREE OF CHARGES) 44.0 ANNEXURE-IV - LIST OF CONSUMABLES TO BE PROVIDED BY BHEL (FREE

OF CHARGES)


PART-2-COMMON TECHNICAL CONDITIONS This section of Technical conditions of contract (TCC) is applicable for services part of contract. The conditions mentioned inscribed hereunder shall be read and construed along with general conditions of contract (GCC, Volume-IB) and in case of any conflict or inconsistency, the provision of the TCC shall prevail. CLAUSE NO

DESCRIPTION

1.0 NAME OF WORK PACKAGE-A (Unit # 1)- Identification & Receipt of materials, Erection, Testing, Commissioning, Handing over etc of Steam Turbine & Auxiliaries, Generator & Auxiliaries, Pumps, Piping, Misc Equipments, Insulation, Painting etc. along with common system as per specification including Unloading & Placement of Generator Stator on Foundation of TG & Auxiliaries for 1 x 270 MW (Unit # 1 ) Chandwa Project, , Latehar, Jharkhand. PACKAGE-B (Unit # 2)- Identification & Receipt of materials, Erection, Testing, Commissioning, Handing over etc of Steam Turbine & Auxiliaries, Generator & Auxiliaries, Pumps, Piping, Misc Equipments, Insulation, Painting including Unloading & Placement of Generator Stator on Foundation of TG & Auxiliaries for 1 x 270 MW (UNIT # 2) Chandwa Project, Latehar, Jharkhand.

2.0 PROJECT INFORMATION APPROACH TO SITE.

3.0 Project location (i) Place: Bana near Chandwa (ii) District: AINL,2x270MW Chandwa TPP (iii) State: Jharkhand The site is located between Latitude 230 44' (North) and Longitude 840 46'(East), Nearest railway station Tori (Chandwa Town). Nearest major town Chandwa Town Distance of the town from the project site 12 KM Nearest commercial airport Birsa Airport 92 Km far away from Ranchi. Distance of airport from the project site 92 KM Nearest highway National highway No.99 Other information Further to the information given in this subsection, bidders are advised to visit the project site and collect data on local site conditions Owner Abhijeet Infra Limited.

4.0 GENERAL 4.1 The intent of this specification is to provide services for execution of project according to

most modern and proven techniques and codes. The omission of specific reference to any method, equipment or material necessary for the proper and efficient services towards installation of the plant shall not relieve the bidder of the responsibility of providing such services/ facilities to complete the work or portion of work awarded to him. The quoted



rates / total price shall deem to be inclusive of all such contingencies. The details enumerated below is applicable for respective units unless specified otherwise.

4.2 The bidder shall carry out the work in accordance with standard practices/ codes/ instructions/ drawings/ documents/ specification supplied by BHEL from time to time.

4.3 The work shall conform to dimensions and tolerances given in various drawing and documents that will be provided during erection. If any portion of work is found to be defective in workmanship, not conforming to drawings or other stipulations, the bidder shall dismantle and redo the work duly replacing the defective materials at his cost, failing which, job will be carried out by BHEL by engaging other agencies/ departmentally and recoveries will be affected from bidder's bills towards expenditure incurred including BHEL's usual overhead charges.

4.4 Following shall be the responsibility of bidder and have to be provided within finally accepted rates/ prices.

4.4.1 Provisions of all types of manpower, supervisors, engineers, watch and ward as required, consumables, tools and tackles, calibrated inspection, measuring and test equipment's (MMDs) as specified and otherwise required for the work of material handling, erection, testing and commissioning including handing over of the system.

4.4.2 Proper out-turn as per BHEL plan and commitment. 4.4.3 Completion of work as per BHEL schedule. 4.4.4 Good quality and accurate workmanship for proper performances of equipment. 4.4.5 Repair and rectification as per relevant clause of this tender. 4.4.6 Preservation/ re-conservation of all components during storage under bidder’s custody/

erection till handing over. 4.5 BHEL - Power sector (ER) is ISO 9001-2000 certified company. Quality of work, to

customer's satisfaction and as per system requirements are the essence of ISO 9001-2000 certification. The bidder in all respects will organise his work, systems, environment, process control documentation, T&Ps, measuring and monitoring devices (MMDs) etc as per instructions of BHEL engineer.

4.6 The bidder will comply with HSE (Health, Safety & Environment) requirements of BHEL and follow all applicable Operational Control Procedures (OCPs) within quoted rate/ price.

5.0 CIVIL WORKS, FOUNDATIONS AND GROUTING 5.1 Foundations for all equipment shall be provided by BHEL. The dimensions and locations of

foundations, pockets, and anchor bolt shall be checked by the bidder for their correctness as per drawings. Further, top elevation of foundations shall be checked with respect to bench marks etc. All minor adjustments of foundation level, dressing and chipping of foundation surfaces up to 50mm, enlarging the pockets in foundations etc as may be required for the erection of equipment/ plants shall be carried out by the bidder within the quoted/ accepted rate/ price.

5.2 While on the job, care is essential to avoid too much chipping and resultant lowering of level. In case of excess chipping bidder has to arrange additional packing plates as per requirements provided it is allowed by BHEL engineer. When required by manufacturers, the embedded sub-sole plates shall be scraped and checked with Prussian blue to get the required contact with frames.

5.3 The bidder shall ensure perfect matching of packer plates including scraping and blue matching with foundation by dressing the foundation, as well as perfect matching between the packer plates and the base plate of equipment to the satisfaction of BHEL engineer.

5.4 Grouting of packer plates, seating plates, sole plates and bedding of packers shall be carried out in sequence and stages recommended by the manufacturer. All the matching joints, which are not to be grouted, shall be kept free from the grouting mixture by applying tape or any other alternative approved by engineer. Bidder shall also take care to get the perfect fit in the keys and key-ways to avoid any scratches and damages to keys. Cement both ordinary portland and CONBEXTRA GP-II/ SHRINKOMP-30/ SIKA Pidilite etc, required for such grouting shall be arranged by the bidder at his cost.

5.5 The bidder within his quoted rate shall ensure availability/ guidence of supplier’s engineer (s) during casting and the period of their availability has to be as per the direction of BHEL. However, if BHEL feel, for grouting of equipment of minor in nature, calling of supplier’s



engineer may not be necessary. For this however, the bidder has to take prior approval from BHEL.

5.6 After the grouting, the foundations are to be cured by bidder to the satisfaction of Engineer. The bidder shall check and verify the alignment of equipment, alignment of shafts of rotating machinery, the slopes & height of all bearing pedestals, centering of rotors & coupling alignment etc. as applicable and the like items to ensure that no displacement had taken place during grouting. The values recorded prior to grouting shall be used during post grouting check up and verifications. Such pre and post grout records of alignment details, shall be maintained by the bidder in such a manner that is acceptable to engineer.

5.7 The bidder shall ensure availability of workers and supervisors for ensuring watering arrangements during Sundays and holidays during curing period.

5.8 Besides grouting as above, all civil works, viz grouting/ excavation/ casting of foundation anchor points for derricks, winches, guy ropes, fastening etc and foundations required for any other temporary supports/ works, required for safe and efficient operation of tools and tackles, shall also be the bidder's responsibility. For these civil works all materials including cement and required facilities will have to be arranged by bidder at his own cost.

5.9 Grouting of all equipments erected by the bidder is included in bidder’s scope including supplying of all materials, manpower and other resources.

5.10 The bidder has to arrange adequate number of steel/ CI or standard materials make moulds of required sizes for cubes testing of required sizes as per standard.

5.11 In case, cube testing are chargeable by BHEL’s customer, the same shall be recovered by BHEL from RA bill/ any other bills of the bidder. Otherwise, it will be treated as free, if not claimed by customer.

6.0 CONSUMABLES 6.1 The bidder shall provide within finally accepted price, all consumables like gaskets for

temporary work, gland packing, all welding electrodes (including alloy steel and stainless steel) filler wires, TIG wires, all inert welding gases, soldering materials, dye penetration test kit, radiography kit/ films/consumables etc, other erection consumables such as tapes, joining compound, grease, mobil oil, M-seal, Araldite, petrol, CTC, other cleaning agents, old & new clothes, wooden sleepers, steel required for temporary works such as supports packing, molykote,WD-40,ss shims H&S shims, etc hardware items, sealing compound, gases required for completion of work and as given in relevant annexure of the tender. This excludes only those consumables which are specifically supplied by manufacturing units of BHEL which will be issued by BHEL free of cost.

6.2 All the shims and gaskets which go finally as part of equipment shall be supplied by BHEL free of cost (refer relevant annexure of the tender). However, the bidder has to arrange for temporary and other shims till final alignment of equipments are complete.

6.3 BHEL will provide only shims and packer plates (either machined or plain) which are received from BHEL’s manufacturing plants and go as permanent part of the equipment.

6.4 Machining of un-machined packer plates sent by BHEL/Units are included in bidder’s scope including scrapping, matching, machining etc. Additional packer plates, if required, will have to be arranged and prepared by the bidder out of steel plates (for thickness lesser than 5.0 mm), steel sheets to meet site requirements and this is included within normal scope of work of the bidder. Necessary steel plates for this purpose (for plate thickness of above 5.0 mm) will be provided by BHEL free of cost. SS shims/other shims (for thickness of less than 5.0 mm) which are required in addition to the supplied quantity of BHEL/manufacturing units are included in bidder’s scope at no extra cost to BHEL.

6.5 It shall be the responsibility of the bidder to plan the activities and store sufficient amount of consumables. Non availability of any consumable materials or equivalent suggested by BHEL can not be considered as reason for not attaining the required progress or for additional claim.

6.6 BHEL reserves the right to reject the use of any consumable like electrodes, gases, lubricants/ special consumables etc. if it is not found to be of the required standard/ make/ purity.

6.7 It shall be the responsibility of the bidder to obtain prior approval of BHEL regarding suppliers, type of electrodes etc before procurement of welding electrodes TIG wires. On receipt of electrodes at site, these shall be subjected to inspection and approval by BHEL.



The bidder shall inform BHEL in details regarding type of electrodes, batch no, date of expiry etc and produce test certificate for each lot/batch with correlation of batch/ lot no with respective test certificate. Electrode without valid test certificate will not be allowed for use.

6.8 Shortage of any of the above electrodes/ filler wire or the equivalent suggested by BHEL shall not be quoted as reason for deficiency in progress or for additional rate.

6.9 Storage of electrodes by the bidder shall be done in line with the Welding Manual of BHEL, and as per instruction of the BHEL engineer, at his cost.

6.10 All electrodes shall be dried in the electrode drying oven to the temperature and period specified by the BHEL engineer or as mentioned in WPs before they are used in erection work and each welder should be provided with one portable electrode drying oven at the work spot. Electrode drying oven and portable drying ovens shall be provided by the bidder at his cost.

6.11 The electrode drying oven will have thermometer for temperature indication. The thermostat and thermometer of oven shall be calibrated before use and also periodically as advised by BHEL engineer. Calibration test certificates of thermostat and thermometer (from authorised/ Govt approved/ accredited test house traceable to National/ International standards) will be submitted by the bidder at his cost.

6.12 BHEL reserves the right to reject the use of any electrode filler wire or any other consumables at any stage, if found defective because of bad quality, improper storage, date of expiry, unapproved type of electrodes/ consumables. It shall be the responsibility of the bidder to replace the same at his cost without loss of time.

6.13 In case of improper arrangement for procurement of any consumables, BHEL reserves the right to procure the same from any source and recover the cost from the Bidder's first subsequent bill at market value plus the overhead charges of BHEL from time to time (30% at present). Postponement of such recovery is normally not permitted. The decision of engineer in this regard will be final and binding on the bidder.

6.14 Transport of oil drums from stores, filling of oil and subsequent filling/ making up till the unit is fully commissioned and handed over to customer, is included in this contract. The bidder has to return all the empty drums to BHEL/ BHEL store at no extra cost. Any loss/ damage to above drums shall be to bidder's account.

6.15 All lubricant & chemicals, gases (N2, CO2 & H2) required for testing, Commissioning, preservation and lubricants for trial runs of the equipment shall be supplied by BHEL free of cost. All services including labour and T&P will be provided by the bidder for handling, filling, emptying, refilling etc. The consumption of lubricants/ chemicals shall be properly accounted for. Surplus material if any shall be properly stacked/ returned to stores failing which suitable recovery shall be made from the bidder's bills/ dues etc.

7.0 TOOLS & PLANTS (T&P) TO BE PROVIDED BY BHEL (SHARED MACHINERY EXCEPT EOT CRANES)

7.1 The tools & plants as prescribed in relevant annexure of the tender will be provided to the bidder on free of cost basis as per availability. The list is only indicative.

7.2 The bidder shall ensure that machinery provided to him is kept in good running condition, all along its use by bidder and after use, it is returned to BHEL in good condition. BHEL's decision regarding condition evaluation shall prevail.

7.3 Depending on availability, BHEL owned cranes along with crane operator (refer relevant annexure of the tender) will be provided to successful bidder on sharing basis and free of any hire charges.

7.4 Depending on availability, BHEL’s hired cranes (as per relevant annexure of tender) will be provided to successful bidder on sharing basis. Required fuel, consumables and operator will be provided free of charges as applicable, to the contractor mainly for the purpose of pre-assembly & erection of components. The cranes shall be provided for 14 (fourteen) hours of operation daily, inclusive of one hour lunch break and excluding Sundays and scheduled holidays. For crane working beyond working hours (as specified in the contract of the crane hiring agency), or on Sundays/ holidays with prior permission of the concerned BHEL site engineer, the successful bidder shall bear the excess payment made to the crane supplier, based on the crane log-book jointly signed by BHEL & bidder’s representative.

These cranes have to be shared with other agencies/ contractors of BHEL. The allocation



of cranes shall be the discretion of BHEL engineer, which shall be binding on the contractor.

All arrangements, including providing & laying of sleeper beds, back-filling of approaches wherever necessary for safe movement of the cranes as directed by BHEL shall be the responsibility of the contractor. The contractor shall provide sleepers for this purpose at his cost.

Any boom reduction, extension for their use and restoration to previous state or as directed by BHEL after the use shall be the contractor’s responsibility.

Major breakdowns will be attended to by BHEL. The cranes provided by BHEL will be withdrawn for regular and capital maintenance as per the respective schedule of maintenance. As far as possible such schedules will be intimated to the contractor in advance and may be adjusted depending on the work requirements at site. However no claim whatsoever will be entertained on account of non-availability of cranes.

Where the services of the cranes provided by BHEL are to be shared by other agencies/ contractors of BHEL, the contractor’s responsibilities defined above will also be apportioned accordingly to the beneficiary agency. BHEL engineer will do working arrangements in this regard at site and in any case his decision shall be final and binding.

7.5 Any damage/ breakdown maintenance of the machinery arising out of improper handling by bidder shall be to the account of the bidder. BHEL shall reserve the right of repairing the same to its own satisfaction at bidder's cost. During such outage of the machinery, BHEL shall not be responsible to provide any alternative. The bidder shall arrange for such alternative arrangement at his own cost.

7.6 The bidder shall return BHEL, T&P issued to him in good working condition as and when desired by BHEL (on completion or reduction of work load). If return of equipment is delayed by bidder, hire charges as applicable shall be levied by BHEL from time it was requisitioned till the time of actual return. Hire charges shall also be charged on the equipment returned in damaged / un-serviced condition to BHEL till its satisfactory repair. Equipment returned in damaged un-serviced condition shall be got repaired by BHEL at its own discretion and entire cost of repair with BHEL overheads shall be recovered from the bidder.

7.7 In case of any machinery (given to bidder) remaining idle without any valid reason, BHEL shall withdraw the equipment immediately for allotment to the bidder next in priority and no compensation shall be entertained on this account by BHEL.

7.8 The T&P scheduled to be provided shall be available on sharing basis and distribution of these shall be done at the discretion of project manager, BHEL on the requirement/ priority of the job and the availability of these items. In the event of non-availability of the listed crane, BHEL may explore the possibility of providing alternate crane subject to availability with BHEL site. However, this is not binding for BHEL. Such cranes of higher capacity (if provided by BHEL) will also be issued on same conditions as applicable to cranes listed in Annexure-IV.

7.9 In the event of any damage or theft occurring to the issued T&Ps, while in use with the bidder, due to their negligence, the same shall be repaired/ replaced by the bidder at their own cost within the time stipulated by Construction Manager, BHEL. Bidder's failure to do so shall entitle BHEL to get the above done through other agency and the cost so incurred by BHEL, along with overheads shall be recovered from the bidder's bill.

7.10 The above mentioned items are for general guidance only. Except the above mentioned items, the bidder has to deploy all other tools & plants required for proper & satisfactory completion of the job. The number of such items will be as per requirement.

7.11 Consolidation of ground and arrangement of sleepers/ sand bag filling placement etc. for safe movement of equipments/ cranes/ trailers etc shall be the responsibility of bidder at their cost. Steel plates, if required depending on site condition shall be provided by BHEL, free of cost on returnable basis.

7.12 Increasing/ shortening of the crane boom to suit work requirements shall have to be arranged by bidder at their cost. All necessary inputs for this will have to be arranged by bidder at their cost.


PART-2-COMMON TECHNICAL CONDITIONS 7.13 In case of non-availability of the T&Ps to be provided by BHEL due to any reason, the

bidder shall plan/ amend/ alter his activities to meet erection/commissioning targets in consultation with BHEL. No additional compensation will be given for this.

7.14 Normal/ schedule maintenance of T&P spared to bidder on shared basis shall be carried out by BHEL as per requirement.

7.15 Actual use of T&P including marching as per entry in log-book duly certified by BHEL engineer shall be considered for calculation of overtime charges.

7.16 T&P issued shall be used only for the designated scope of work under specification. 7.17 In the event of bidder not using and/or maintaining BHEL T&P according to BHEL's

instructions, BHEL will have the right to withdraw such equipment without any notice & no claim in this regard shall be entertained and bidder shall be responsible for delay in execution on this account.

7.18 It shall be responsibility of the contractor to take delivery of T&P from stores or place of use of T&P by other contractor at project site, transport the same to site and return the same to BHEL store/ place as intimated by BHEL engineer at project site in good working conditions after use.

8.0 EOT CRANE/ HOIST & MISC CRANES/ CHAIN PULLEY BLOCKS 8.1 TG hall EOT cranes of power house shall be made available to the bidder free of charges

for TG and aux erection on sharing basis. However, Bidder has to provide qualified trained whole time operators for providing EOT crane services during working hours to all at their cost till completion of 3 months after trial operation/ provisional HO of unit to customer. The operators should have experience in operation and maintenance of EOT cranes.

8.2 The crane shall be new and regular maintenance including supply of fast moving consumables like grease, brake shoes , fuses of all ratings etc, during the period of use, to keep the crane in safe running condition to the satisfaction of BHEL, will be in the bidder’s scope. Major components/ items required for maintenance/ repair shall be provided by BHEL on free of cost basis. The crane is to be returned to BHEL/ AINL/CPL in good & acceptable condition after required replacements, painting etc. on completion of use.

8.3 The EOT cranes operations during erection period are free of charges and electricity charges are also free.

8.4 A deduction of Rs 8000.00 per day per operator will be made if the above mentioned operator service is not provided.

8.5 Normally one no. EOT crane in TG hall area shall be provided. 8.6 EOT cranes shall be maintained in new condition. The operation and routine day to day

maintenance of the EOT cranes will be in the scope of the bidder. Major break down, for no fault of manufacturer, is to be rectified by the bidder.

8.7 In case, EOT crane is not available due to maintenance or other problem, the bidder shall plan his activities accordingly so that the erection schedule is not affected.

8.8 The EOT crane shall be used and shared for execution of both the 270MW units. 8.9 Trailing cable and electrical switches as required for extension & operation of EOT cranes

shall be provided by BHEL/OWNER free. 8.10 The bidder within his quoted rate has to arrange continuous manpower for taking care of

trailing cables in the means of providing riggers etc who will carry the cables alongwith crane movement till satisfactory operation of DSL.

8.11 The availability of EOT crane is likely to be hampered from time to time due to routine/ preventive maintenance or break down maintenance. Bidder has to make alternative arrangement or plan/ amend /alter his actions to suit the above condition and the bidder will not be entitled to any compensation due to this non-availability of the crane to maintain the schedule.

8.12 Services of EOT crane have to be provided to other agencies/ OWNER working in the power house building or adjacent area as required. The decision of BHEL engineer for allocation of crane will be final. Bidder has to make adjustments accordingly.

8.13 After completion of TG & aux erection work, the cranes (TG hall) are to be handed over to AINL/CPL in good condition to the satisfaction of their engineers.

8.16 Erection & commissioning of both mechanical & electrical miscellaneous hoist & cranes and chain pulley block is included in the scope of work. Fabrication work may be involved in



erection of Hoist & cranes and same is included in the scope of work of bidder. The quantity and sizes shown may vary later on and for this no extra payment shall be given to the bidder on whatsoever account.

8.17 The bidder within his scope of work has to obtain load testing certificate from statutory authority/ authorized agency. This shall be done after completion of necessary erection, commissioning.

8.19 The successful bidder have to arrange 1 skid-mounted 10-15 KW pump-motor set with electrical starter for imparting thermal shock on TG lub oil/ BFP oil system. The job will cover laying & termination of cables and maintenance of the pump-motor set. BHEL will issue plate, piping, valves and other materials free of cost for making arrangements for imparting thermal shock. For this job, laying of associated steam lines from existing plant with insulation or arranging heating of lub oil by alternate means, ordinary/ DM water connection and all associated jobs are included in the scope. Bidder’s quoted/ accepted rate/ price shall be inclusive of all these.

9.0 T&P/ IMTE's TO BE PROVIDED BY BIDDER (REFER RELEVANT ANNEXURE OF THE TENDER)

9.1 Bidder shall ensure deployment of serviced and healthy T&P including cranes, lifting tackles, wire ropes, manila ropes, winches and slings etc. History card and maintenance records for major T&Ps will be maintained by the bidder along with their service record. Identification for such T&Ps will be done as per BHEL engineer's advice.

9.2 Bidder shall ensure deployment of reliable and calibrated IMTEs (Inspection, Measuring and Test Equipment). The IMTEs shall have the calibration certificates from authorised/ Govt approved/ accredited agencies traceable to National/ International standards. Each IMTE shall have a label indicating calibration status, date of calibration, calibration agency and due date for calibration. A list of such instruments deployed by bidder at site with its calibration status is to be submitted to BHEL engineer from time to time for control.

9.3 Re-testing/ re-calibration shall also be arranged at regular intervals during the period of use as advised by BHEL engineer within the contract price. The bidder will also have alternate arrangements for such IMTE so that work does not suffer when the particular equipment/ instrument is sent for calibration. Also, if any IMTE is not found fit for use, BHEL shall have the right to stop the use of such item and instruct the bidder to deploy proper item and recall i.e. repeat the readings taken by that instrument, failing which BHEL may deploy IMTEs and retake the readings at bidder's cost.

9.4 The month-wise T&P deployment plan to be submitted as per specified format is only to assess the capability as well as understanding of the bidder plan to execute the work. It shall be the bidder's responsibility to deploy the required T&P, for timely and successful completion of the job, to any extent over and above those indicated in the above deployment plan (including those which are not covered in the plan submitted) without any compensation on this account.

10.0 SUPERVISORY STAFF AND WORKMEN. 10.1 The bidder shall deploy all the skilled workmen like Mill Wright fitters, welders, gas cutters,

riggers, sarangs, electricians etc in addition to other skilled, semiskilled and unskilled workmen, required for all the works of handling and transporting from site storage to erection site, erection, testing and commissioning as contemplated under this specification. Only fully trained and competent men with previous experience on the job shall be employed. They shall have valid certificates wherever necessary. BHEL reserves the right to decide on the suitability of the workers and other personnel to be deployed by the bidder. BHEL reserves the right to insist on removal of any employee/ workmen of the bidder at any time, if they find him unsuitable and the bidder shall forthwith remove him.

10.2 The supervisory staffs, including qualified engineers, deployed by the bidder shall ensure proper out-turn of work and discipline on the part of the labour put on the job by the bidder, and in general see that the works are carried out in a safe and proper manner and in coordination with other labour and staff deployed directly by BHEL or other bidder of BHEL or BHEL's client/ other agency.

10.3 The work shall be executed under the usual conditions affecting major power plant construction and in conjunction with numerous other operations at site.

10.4 The bidder's supervisory staff shall execute the work in the most substantial and workmen



like manner in the stipulated time. Accuracy of work and aesthetic finish are essential part of this contract.

10.5 The bidder shall deploy necessary number of qualified and approved full time electricians at his cost to maintain his temporary electrical installation till the completion of work.

10.6 It is the responsibility of the bidder to engage his workmen in shifts or on overtime basis for achieving the targets set by BHEL and also during the period of commissioning and testing of unit. The bidder's finally accepted rates/prices shall include all these contingencies.

10.7 During the course of erection, if the progress is found unsatisfactory, or if the target dates fixed from time to time for every mile stones are to be advanced or in the opinion of BHEL, if it is found that the skilled workmen like fitters, operators, technicians etc deployed are not sufficient, BHEL after giving reasonable opportunity to the bidder, will induct on the work the required workmen in addition to bidder's workmen to improve the progress and recover from the bidder's bills, any charges incurred for engaging the additional workmen with overheads. BHEL's decision in this regard will be final and binding to the bidder.

10.8 If the bidder or his workmen or employees shall break, deface injure or destroy any part of a building, road-curb, fence, enclosure, water pipes, cables drains, electric or telephone posts or wire, trees or any other property or any part of erected components etc. the bidder shall make the same good at his own expense or in default BHEL may cause the same to be made good by other workmen or by other means and deduct the expenses (of which BHEL's decision is final) from any money due to the bidder.

10.9 The month-wise manpower deployment plan to be submitted as per format (refer relevant annexure of the tender) is only to assess the capability as well as understanding of the bidder to execute work. It shall be the bidder's responsibility to deploy the required manpower, for timely and successful completion of the job, to any extent over and above those indicated in the above deployment plan ( including those which are not covered in the plan submitted) without any compensation on this account. Separate persons shall be identified at site for ‘quality control’ and ‘safety’ by the bidder.

10.10 It is mandatory on the part of bidder to seek prior approval before any retrenchment of the workers, supervisors & engineers at any point of time during execution of the complete scope of the work failing which BHEL may deduct any suitable amount considering loss of time, opportunity, Idling of BHEL manpower etc.

10.11 After the start of commercial operation of machine, commissioning activities will continue. It shall be the responsibility of the bidder to provide following manpower along with supervisor as part of commissioning assistance for respective units till handing over of the unit to the customer.

10.11.1 Supervisor - 1 no. 10.11.2 Pipe fitter/ Mill wright fitter - 2 nos. 10.11.3 Welder - 1 no. 10.11.4 Rigger - 1 no. 10.11.5 Electrician - 1 no. 10.11.6 Unskilled worker - 2 nos. 10.11.7 Gas cutter - 1 no. 10.12 Above workmen may have to work for extended period or round the clock/ holidays/

Sunday/ bandh. 10.13 2 nos supervisor with knowledge of plant operation (including all auxiliary systems) per shift

will be required for operation during synchronisation till trial run operation and commercial generation of the unit. This minimum manpower is excluding normal scope of erection, pre-commissioning, commissioning etc. Bidder to arrange these operation supervisors from the date of barring gear so that they are well trained by the time TG is synchronized.

10.14 In addition to the above, the bidder has to ensure minimum no of engineers/ supervisors for carrying out day to day to erection, pre-commissioning, commissioning, PG test , punch points liquidation, site closing etc.

10.15 For attending to problems (other than commissioning) of electrical motors, actuators, erection of which are under the scope of this tender, successful bidder shall provide following exclusive manpower, who will report to BHEL Electrical/ Commissioning In-charge. These electrical manpower are separate from normal manpower of the successful bidder which shall be mobilized for successful completion of the job as per the tender.


PART-2-COMMON TECHNICAL CONDITIONS 10.15.1 Electrical supervisor – 1 no. 10.15.2 Trained electrician – 2 nos. 11.0 INSURANCE 11.1 BHEL shall arrange comprehensive MCE (marine cum erection) Insurance Policy for total

project supply & services including balance of plant package covering transit risks & loss, destruction or damage during handling at site, storage, civil works, erection, testing and commissioning up to trial operation completion of each unit including theft, sabotage, fire, lightning and other natural calamities.

11.2 Bidder shall timely intimate despatches to the underwriter. The name of the underwriter and Policy No shall be intimated in due course of time.

11.3 Bidder shall report to BHEL in writing any damages to equipments/ components on receipt, storing, and during withdrawal of the materials from stores, in transit to site and unloading at place of work and during erection and commissioning till trial operation completion including handing over. The above report shall be as prescribed by BHEL site management. Any consequential loss arising out of non-compliance of this stipulation will be borne by bidder.

11.4 The bidder will take necessary precautions/ due care to protect the material at Project site, while in his custody from any damage/ loss till the same is handed over to BHEL/ customer at Project site. For lodging/ processing of insurance claim the bidder will submit necessary documents. BHEL will reserve the right to recover the loss from the bidder as detailed below in case the damage/loss is due to negligence/ carelessness on the part of the bidder. In case of theft of material under bidder's custody, the same shall be reported to police by the bidder immediately and copy of FIR and subsequently police investigation report shall be submitted to BHEL /customer for taking up with insurance. However this will not relieve the bidder of his contractual obligation for the materials in his custody.

11.5 In case the damage/loss/theft of materials are attributable to negligence/failure in discharging the duties and obligations of the bidder, the expenses incurred for repair/replacement of such components in excess of the amount realized from the underwriters, limited to Normal Excess (Deductible Franchise) shall be recovered from the bidder.

11.6 In case the claim is summarily rejected by the underwriters due to WILFUL NEGLIGENCE of the bidder, the entire cost of repair/ replacement will be recovered from the bidder.

11.7 It will be responsibility of the bidder to replenish the items lost/ damaged in time without hampering the schedule of work and without waiting for settlement of insurance claim. Amount received from the underwriters on settlement of insurance claim shall be passed on to the bidder as and when available.

11.8 Other conditions of Insurance shall be as per relevant clause of GCC. 12.0 PLANNING & PROGRESS REPORTING 12.1 Successful bidder to form a very strong planning group which will be able to work in tandem

with BHEL planning and work as an information exchange nodal agency for erection & commissioning work and generate required output within the given tight schedule in the following area (tentative).

12.1.1 Material planning. 12.1.2 Erection procedure planning. 12.1.3 Progress planning & review of L2 schedule. 12.1.4 Manpower planning. 12.1.5 Billing & cost planning. 12.1.6 Various reports generation as advised by BHEL. 12.1.7 Drawing & documents follow up. 12.1.8 Day to day & weekly work planning. 12.1.9 Managing technical clarifications. 12.1.10 Continuous recovery plan for delay. 12.1.11 Maintaining records in soft form. 12.1.12 Maintain IT infrastructure & emails. 12.1.13 Digital photography of progress & exception reports. 12.2 The bidder shall submit daily, weekly and monthly progress reports for manpower materials

reports, consumables (gases/ electrodes) report and other reports as per pro-forma



considered necessary by the engineer. 12.3 A material mapping report is a must before taking up any erection work in the weekly plan.

All materials required for a particular portion of erection must be recorded with verification details, drawing details in the material mapping report.

12.4 The plan & progress report shall indicate the progress achieved against planned with reasons indicating delays, if any, and shall give the remedial actions which the bidder intends to take to make good the slippage or lost time, so that the slippage's do not accumulate and affect the overall program.

12.5 Before taking up any erection activity, bidder have to submit a erection process plan to BHEL engineer for better understanding and work planning along with weekly plan.

12.6 Weekly progress review meetings will be held at site during which actual progress during the week vis-à-vis scheduled program shall be discussed and actions to be taken for achieving targets will be decided. The program of subsequent week shall also be presented by bidder for discussions. Bidder to note that all the work completed by the bidder becomes billable only when the same is included in the BHEL approved weekly plan. The bidder shall constantly update/ revise his work program and get the approval of BHEL for the same to meet the overall requirement of project. Material for the week must be planned one week in advance so that no work planned for a week is not done due to non availability of material.

12.7 Periodic progress reviews on the entire activities of execution in respect of supply and works in scope of bidder will be held once in a month at Kolkata/ site. These meetings will be attended by reasonably higher officials of the bidder and will be used as a forum for discussing all areas where progress needs to be speeded up. The bidder shall be further responsible for ensuring that, suitable steps are taken to meet various targets decided upon such meetings.

12.8 Digital photography as and when required is a must and bidder to attach photograph with the all reports (monthly report, weekly report, exception report, mails/ letters seeking technical clarification) to the extent possible.

13.0 DRAWING AND DOCUMENT 13.1 The detailed drawings, specifications available with BHEL engineers will form part of this

tender specification. These documents will be made available to the bidder during execution of work at site. The bidder will also ensure availability of all drawings/ documents at work place.

13.2 One set of drawings to carry out the erection work will be furnished to the bidder by BHEL on loan which shall be returned to BHEL Engineer at site after completion of work. Bidder's personnel shall take care of these documents given to them.

13.3 The bidder shall maintain a record of all drawings and documents available with him in a register as per format given by BHEL engineer.

13.4 The data furnished in various annexures enclosed with this tender are only approximate and for guidance. However, the change in the design and in the quantity may occur as is usual in any such large scale of work.

13.5 Should any error or ambiguity be discovered in the specification or information, the bidder shall forthwith bring the same to the notice of BHEL before commencement of work. BHEL's interpretation in such cases shall be final and binding on bidder.

13.6 Deviation from design dimensions should not exceed permissible limit. The bidder shall not correct or alter any dimension details, without specific approval of BHEL.

13.7 The bidder within his scope has to arrange for multiplication of protocols, log sheets and do spiral binding of above for at least six sets. The number of sets will vary as per the requirement and shall be binding on the bidder.

14.0 INSTRUCTIONS TO BIDDER 14.1 Offers received without data/ information required to be submitted under specified tender

clauses are liable to be rejected. All these data/ information should be duly supported by documentary evidences.

14.2 No deviations to the tender conditions will normally be accepted. 14.3 The bidders are advised to actually visit the site and fully acquaint themselves with site

conditions, location of stores, transportation routes, quantum of work etc. before quoting their rates for this work. BHEL shall not be responsible in any way for non-familiarisation of



site conditions. Once the bidder has quoted for the work, it is implied that he has ascertained various site conditions and NO CLAIM whatsoever will be entertained by BHEL on any such account.

14.4 The bidder in the event of this work awarded to him, shall, establish site office at site and keep posted an authorised responsible officer who should hold a valid power of attorney for the purpose of the contract. Any order or instruction of the Engineer or his duly authorised representative shall be communicated to the bidder's representative at site office and the same will be deemed to have been communicated to the bidder at his legal address.

15.0 FACILITIES TO BE PROVIDED BY BHEL/ BIDDER 15.1 Only limited land can be provided free of cost for construction of temporary office, stores,

fabrication area etc. within the project premises. 15.2 Land may be provided for Labour Colony inside / outside the project premises to the

contractor to construct labour colony/hutment. The bidder must visit the plant & surrounding areas to assess the situation so that they can make some arrangement nearby to the project premises in consultation with AINL/CPL/BHEL.However,if land is made available by customer AINL/CPL at later date,same shall be provided to the contractor.

15.3 The contractor will be responsible for handing back all lands, as handed over to him for his temporary use, to BHEL as per the instruction of BHEL Engineer.

15.4 Only limited land can be provided free of cost for construction of temporary office, stores, fabrication area etc. within the project premises.

16.0 ELECTRICITY 16.1 BHEL will provide construction power on Free of charges at 415 V at single point near work

premises within 500 Mtr of 1st row Boiler or Power House Column. Further distribution (including maintenance of the distribution lines) beyond this point to be arranged by the contractor at his own cost. Any other voltage if required shall be arranged by the contractor from power supply as above. Contractor will have to provide necessary calibrated meters (tamper proof, suitably housed in a weather proof box with lock & key arrangement) at each point of power supply along with calibration certificate from authorized / accredited agency for working out the power consumption at his own cost. In case of re-calibration required for any reason the necessary charges including replacement by calibrated meters is to be borne by the contractor. Supply of electricity shall be governed by Indian Electricity Act and Installation Rules and other Rules and Regulation as applicable.

16.2 BHEL shall not be responsible for any inconvenience or delay caused due to any interruption of power supply and no compensation for delay in work can be claimed by the contractor due to such non-supply on the grounds of idle labour, machinery or any other grounds.

16.3 The Contractor should ensure that the work in critical areas is not held up in the event of power break-down and for the same he should have suitable standby arrangement at his cost. As a part of the bid, a specific proposal in this regard has to be submitted by the contractor. In the event of breakdown in the electric supply, if the progress of work is hampered, it will be the responsibility of the Contractor to step up the progress of work after restoration of electric supply so that overall progress of work is not affected.

16.4 The contractor shall have to make arrangements at their own cost for area illumination that will be required in the working areas for execution of the work.

16.5 Deleted. 16.6 Bidder will have to provide necessary calibrated meters (tamper proof, suitably housed in

weather box with lock & key arrangement) at each point of power supply along with calibration certificate from authorised/ accredited agency for working out the power consumption at his own cost. In case of re-calibration required for any reason the necessary charges including replacement by calibrated meters is to be borne by the bidder. Supply of electricity shall be governed by Indian Electricity Act and Installation Rules and other Rules and Regulation as applicable.

16.7 BHEL will not be responsible for any inconvenience/ delay caused due to any interruption of power supply and no compensation for delay in work can be claimed by bidder due to such non-supply on the grounds of idle labour, machinery or any other ground.

16.8 Bidder should ensure that the work in critical areas is not held up in the event of power



break down and for the same he should have suitable stand by arrangement at his cost. In the event of breakdown in the electric supply, if the progress of work is hampered, it will be the responsibility of bidder to step up the progress of work after electric supply gets restored so that overall progress of work is not affected.

16.8.1 In case of power cuts/ load shedding no compensation for idle labour or extension of time for completion of work will be given to the bidder.

16.8.2 Adequate lighting facilities such as flood lamps, hand lamps and area lighting shall be arranged by the bidder at the site of construction, bidder's material storage area etc. within finally accepted rates.

16.8.3 The Bidder shall arrange electricity in their labour colony at their own cost. 16.8.4 Following points should be strictly adhered to by the bidder while drawing construction

power supply from distribution board. 16.8.5 All electrical installations should be as per Indian electricity rules. 16.8.6 All distribution boards installed by the bidder should be constructed with fire proof

materials, viz steel frames, bakelite sheets etc. 16.8.7 Connection for single phase should be taken from phase and neutral. No where the

connection should be taken with earth as neutral. 16.8.8 All electrical connections should be made through connectors, nut and bolts, switches, plug

and sockets. Loose connections or hooking up of wires shall not be permitted. 16.8.9 Bidder will have to make their own earthing arrangement for their equipment/ DB earthing/

temporary installations. The earthing connections have to be done with copper conductor and copper/ brass clamps with BHEL's prior permission.

16.8.10 All electrical equipment/ tools & plants should be properly earthed. DBs to be earthed diagonally opposite at two points.

16.8.11 Bidder should use "MCCB" and "ELCB" either on incoming or out going connections to the DBs.

16.8.12 Bidder should ensure that all the DBs/ TPNs/ Fuses/ MCCB/ ELCB cables etc should be of adequate rating/ capacity.

16.8.13 For permission of supply connections, bidder has to submit a test report of their installations with a single line diagram of connectors proposed loads.

16.8.14 Bidder will submit a report on all electrical connected loads by 7th of every month. 16.8.15 ELCB will be tested once in a week by actually simulating the earth leakage for all

installations and the same shall be recorded by BHEL engineer in the log book to be maintained by the bidder.

16.8.16 The bidder has to arrange adequate number of 24V transformers with sufficient number of lamps for working inside confined space.

17.0 WATER 17.1 BHEL will provide construction water free of cost at one point within 500 Mtrs. from given

work premises. 17.2 BHEL will provide free of cost one Drinking water point within 500 Mtrs. from given work

premises. 17.3 Further distribution beyond above mentioned points to be arranged by the contractor at his

own cost within the working areas. 17.4 Water will be supplied 2 to 3 times in a day. Contractor will have to arrange for storage of

water to meet the day to day requirement. BHEL will however arrange for adequate supply of construction water to meet the requirement of water during major concreting.

17.5 The availability of water at project is limited. Contractor shall ensure that no water is wasted. In this regard the contractor shall take all necessary measure towards preservation of water.

17.6 BHEL shall not be responsible for any inconvenience or delay caused due to any interruption of water supply and no compensation for delay in work for such interruption shall be claimed by the contractor.

18.0 SITE ORGANISATION 18.1 The bidder shall maintain a site organization of adequate strength in respect of manpower,

construction machinery and other implements at all time for smooth execution of the contract headed by a competent construction manager for all site operations with sufficient level of authority to take site decisions. The organization should have organization chart



indicating various levels of experts to be posted for supervision in the fields in erection, commissioning etc. The organization shall be reinforced from time to time, as required to make up slippages from the schedule without any commercial implication to BHEL.

18.2 BHEL reserves the right to reject or approve the list of personnel proposed by the bidder. The persons whose bio-data have been approved by BHEL will have to be posted at site and deviation in this regard will not generally be permitted.

18.3 In addition to above, a well experienced qualified engineer to be designated, as 'Project Co-ordinator' shall be deployed by the bidder. Such engineer shall have adequate exposure to BHEL sets/systems and shall remain fully involved in all planning activities, guidance etc to bidder's own team during the complete execution period of contract.

18.4 The bidder should also submit to BHEL for approval a list of construction equipment's, erection tools, tackles etc prior to commencement of site activities. The tools & tackles shall not be removed from site without written permission of BHEL.

19.0 ERECTION SCHEDULE 19.1 In order to achieve the over all completion schedule the bidder shall provide BHEL all the

information covering erection sequence, testing and commissioning activities. These schedules may be based on the recommended procedures and will be subject to discussions/ agreements with the owner/BHEL subsequent to the award of contract.

19.2 The successful bidder shall have to provide all the above schedules in a tabular form in addition to that in the form of network and these shall necessarily include information not limited to the earliest and latest dates for various activities/ submissions and include any related constraints also.

20.0 CONTRACT MANAGEMENT The bidder should also submit network programs for the erection and commissioning of various items. These networks shall show the owner/ BHEL hold points (CHP) which have to be cleared by owner/ BHEL or their authorised representatives before further erection/ commissioning can take place. These programs for the erection and commissioning would clearly identify responsibilities of the bidder and owner/ BHEL. Networks shall be submitted within stipulated time as per direction of Construction Manager, BHEL site.

21.0 CONSTRUCTION MANAGEMENT 21.1 Based on the PERT network program, within 1 month of the award of the contract, the

bidder shall submit a program of construction/ erection/ commissioning for the implementation. These programs would be amplified showing start of erection and subsequent activities and shall form the basis for site execution and detail monitoring. The three monthly rolling program with the first month's program being tentative based on the site condition would be prepared based on these programs. The bidder shall also be involved along with owner/ BHEL to tie up detailed resources mobilisation plan over the period of time of the contract matching with the performance targets.

21.2 The program would be jointly finalised by the site in-charge of the bidder with BHEL/ owner's project co-ordinator as well as the site planning representative. The erection program will also identify the sequential erectable tonnages.

22.0 PROJECT MANAGEMENT 22.1 The successful bidder will have to establish computerized system to integrate with BHEL’s

existing system and requirement for material management system and SOMS software system. Minimum 2(two) nos computers at least P-4 model and 120 GB hard disc and 1GB RAM with associated accessories, licensed softwares etc are to be provided for the purpose during the period from start of contract till completion of contract period, excluding extension, if any.

22.2 Out of these 2 computers, 1 no computer with operator shall be under the custody of BHEL –TG section till handing over of the set to the customer. In general the bidder has to arrange all kinds of computer stationeries with printer cartridge with regular replacement arrangement.

22.3 Additionally, he has to provide one numbers experienced computer operators for computerised store keeping in line with BHEL’s SOMS (Site Operation Management System) software system requirements. These operators may have to undertake training in one of the BHEL’s premises and the bidder has to bear all expenses towards their TA, boarding, lodging at the designated place where the training shall be arranged. The



computers to be deployed by 1st and 2nd months from date of LOI. 22.4 The successful bidder has to provide cook & one helper for running BHEL Guest House at

Chandwa Town who will work as per direction of BHEL Engineer. 22.5 In case of non supply of computer ,computer operator & other manpower as above, BHEL

shall recover amount as per following rate from the bidder’s dues. 22.5.1 Computer - Rs 5000.00 per month per computer. 22.5.2 Computer operator – Rs 7000.00 per month per operator. 22.5.3 Cook & Helpers- Rs. 6000.00 per month per head. 22.6 Successful bidder has to provide for electronic/ computerised storing and re-production/

printing/ plotting of various data, log sheets, protocols, measurements etc. These may be stored in a virus free Zip Drive/ CD and handed over to BHEL as per requirement.

22.7 The successful bidder shall have to provide BHEL with all erection/ work schedule (in a time scaled L3 network showing details of work system wise and input required thereof) and/ or progress report, protocol, test report in floppies (compatible to BHEL software) and also in requisite no of hard copies. The input and output data of all such schedule shall be furnished to BHEL in a manner compatible with software available at site.

22.8 The successful bidder will have to submit progress report every month in a decent and mutually agreed format showing progress vis-à-vis schedule, delay, constraint (if any) etc to Construction Manager, BHEL site and Project Manager positively by 7th of every month.

23.0 QUALITY ASSURANCE PROGRAMME As per GCC.

24.0 GENERAL REQUIREMENTS - QUALITY ASSURANCE As per GCC. 25.0 QUALITY CONTROL & QUALITY ASSURANCE

As per GCC. 26.0 HEALTH, SAFETY & ENVIRONMENT (HSE) As per GCC 27.0 TAXES, DUTIES ETC 27.1 TDS under Income Tax shall be deducted at prevailing rates on Gross Invoice Value from

the Running Bills.

All taxes (except Service Tax including Educational Cess and other Cess, if any) , charges, royalties, duties, Octroi/ Entry Tax , any State or Central Levy and other Taxes for materials obtained for the work and for the Execution of the Contract shall be borne by the Contractor and shall not be payable extra during the tenure of the Contract. Tax Invoice may be submitted, if required by VAT act.

The Contractor has to make his own arrangement at his cost for completing the formalities, if required, with State V.A.T. Act Authorities, for bringing their materials, plants and machinery at Site . Road Permit / Way Bill, if required, shall be arranged by the Contractor and BHEL-P.S.E.R will not supply any Road Permit/Way Bill for this purpose. The Contractor have to be a Registered Dealer with the State VAT Act and a copy of the said Registration Certificate must be provided to Site R.A.O.

27.2 Service Tax:- Service Tax as legally leviable & payable by the Contractor under “Erection, Commissioning and Installation Services“ of Service Tax law/Act vide Sec 65 (105)(zzd), shall be paid by BHEL-P.S.E.R on Contractor’s Gross Bill. The Contractor shall furnish proof of Service Tax registration with Central Excise Division covering the Services under this Contract. Registration should also bear endorsement for the premises from where the billing shall be done by the Contractor on B.H.E.L-P.S.E.R for this Project. B.H.E.L-P.S.E.R will not be held to be responsible for non-compliance of various Service Tax Rules, being framed from time to time

With introduction of Cenvat Credit Rules,2004 which came into force w.e.f 10.09.2004, excise duty paid on Input Goods including Capital Goods used for providing the output service and service tax paid on Input Service can be taken credit of against the service tax payable on output service . As such, while offering the rates , the Contractor may take in to account the benefit of above provisions as the cost of input to Contractor will be net of Excise Duty and service Tax and adjust their offer price accordingly to make it more



competitive. 27.3 New Taxes & duties,if imposed subsequent to due date of offer submission,by statutory

authority during Contract period (including extension, if the same is not attributable to the contractor), shall be reimbursed by BHEL-P.S.E.R on production of relevant supporting document to the satisfaction of BHEL-P.S.E.R. However, the Vendor shall obtain prior approval from BHEL-P.S.E.R before depositing new taxes and duties.

28.0 SOCIAL OBLIGATION It is imperative on the part of the bidder to join and effectively contribute in joint measures such as tree plantation, environment protection, contributing towards social up-liftment, conversion of packing woods to school furniture, keeping good relation with local populace etc.

29.0 COMPLETION PERIOD 29.1 The entire work of erection, testing and commissioning, up to handing over of the TG &

Auxiliaries of the 270MW unit shall be completed within a period of 18 months (Eighteen months) from the date of start of work for respective unit.

29.2 The bidder shall arrange to mobilse and start the erection work within 15 days from the date of intimation by BHEL.

29.3 The actual date of start of erection will be certified by BHEL site engineers after adequate mobilization of manpower, T&P by the contractor. This certificate date will be deemed as start of work at site for purpose of the contract time schedule.

29.4 The work under the scope of contract will be deemed to be completed in all respects only when all the components are erected and trial runs, testing and commissioning of all individual equipment including trial operations of each units with full load are conducted and handed over to customer. The decision of BHEL shall be final and binding on the bidder.

29.5 There will be a phase gap of three months between the two units.The date of start of work as certified by CM,BHEL shall be considered for all practical purposes.

30.0 CONSTRUCTION SCHEDULE 30.1 The bidder shall plan activities accordingly to match the following milestone schedule.

However, the stated schedule is indicative and actual milestones shall be finalized during execution at site depending on project’s requirement. Bidder, in consultaion with BHEL shall schedule erection activities in such a manner so that synchronization schedule remains unaffected.

30.2 A bar chart showing of various milestones like start of erection of turbine and auxiliaries, box-up, oil flushing, barring gear, synchronization etc is to be submitted by the bidder within one month from date of LOI to Construction Manager, BHEL site for approval.

30.3 The various mile stones schedule to be achieved for the respective units are as under. Mile-stones Broad schedule

30.3.1 Start of condenser erection. 1st Month 30.3..2 Turbine erection start. 2nd Month 30.3.3 Turbine Box Up 9th Month 30.3.4 Barring gear. 10th Month 30.3.5 Synchronisation of unit. 11th Month 30.3.6 Trial operation. 12th Month 30.3.7 Liquidation of pending points 15th Month 30.3.8 Total work completion 18th Month 30.3.9 The above milestone schedules are tentative.These schedule may be required to be

preponed due to availability of front & materials and project commissioning requirements.The contractor shall mobilize additional resources to achieve such compressed schedules to achieve commissioning targets.

31.0 LIQUIDATED DAMAGE/ COMPENSATION FOR DELAY Liquidated damage applicable for this contract shall be as per provision laid down in GCC

separately for each unit depending upon the completion schedule prescribed in the completion schedule for respective unit.

32.0 PAYMENT FOR WORK COMPLETED 32.1 The bidder shall quote rates as required therein for the work in the rate schedule. 32.2 The bidder shall submit his running bill once in a month at the end of each month. The RA

bill complete in all respects accompanied by BHEL engineers certification/ measurement



sheet jointly signed and EPF compliance certificate from EPF authority, will be paid within 30 days of submission of the bill. The measurement will be taken as specified in terms and conditions of contract and certified by the BHEL engineer of actual work. However no extra payment shall be made in the event of delay in release of payment within 30 days.

32.3 Interim payment shall be limited to 95 % of the gross value of interim bill on item rate basis and 5% will be retained from each RA bill which will be released on completion of guarantee period of 12 months. The security deposit will be refunded as per GCC. All admissible recovered/ adjustments etc shall be made from the interim payable amount.

32.4 Subject to any deduction which BHEL may be authorised to make under the contract, the bidder shall on the certification of the BHEL engineer at site, be entitled to receive payment as explained hereunder.

32.5 For erection, testing and commissioning of turbo-set and auxiliaries as described in rate schedule, intermediate payments shall be made as per the billing schedule on the basis of percentage of total contract value of the job as detailed in Annexure-A. (These percentages are only for the purpose of progressive payments and should not be considered as price of individual items and bidder should complete all the work without quoting reference to the break up).

32.6 For erection, testing, commissioning etc of steam turbine, turbo-generator, condenser with auxiliaries, integral piping, payment shall be made as follows on basis of total contract value of work & for percentage as per rate/ payment schedule on monthly basis. The following break up is only for the purpose of regular stage payment and should not be construed as price for individual item and also it does not constitute total scope of work. The total scope of work is as detailed in the tender and shall be completed by bidder without making any reference to the break up given in Annexure-A. BHEL site at its discretion, may further split up/ change or reschedule/ amend the percentages shown in Annexure-A and effect payment to suit the site condition, cash flow requirements according to the progress of the work.

32.7 Billing schedule shall be as per Annexure-A.

33.0 CONTRACT PRICE 33.1 The bidder shall quote their rates strictly in accordance with prescribed price/rate schedule

of Volume-III. 33.2 The quantities mentioned in weight schedule is approximate only and given to facilitate

bidder to make assessment of the magnitude of work under this tender. 33.3 Weight of various equipments, quantities of various items of work covered under these

tender & indicated in relevant annexures are likely to vary. For any upward or downward variation in the quantities, the accepted lumpsum price shall remain unchanged for reasons whatsoever and be applicable without any variation.

33.4 The omission of specific reference to any method and equipment, system or material necessary for proper and efficient services towards installations of the plant shall not relieve the bidder of the responsibility of providing all services/ facilities to complete the work or portion of the work awarded to him. The accepted/ quoted rate shall deem to be inclusive of such contingencies. Only exclusion specifically mentioned in this tender shall be entertained in all matters.

33.5 The quantities of the various items mentioned in Annexure-1 are approximate, based on very preliminary information and may vary to any extent or be deleted altogether. The quoted rates of each item will remain firm throughout the period of execution including extension, for reasons whatsoever, as long as variation in the total value of work executed under any part of this contract including extra items, if any but excluding any price variation remains within plus/ minus twenty percent (± 20%) of the executed contract price of respective LOI/ WO for above job.

34.0 INTEREST BEARING RECOVERABLE ADVANCE NOT APPLICABLE.

35.0 PRICE VARIATION CLAUSE It shall be applicable as per GCC.

36.0 OVER RUN COMPENSATION It shall be applicable as per GCC.


PART-2-COMMON TECHNICAL CONDITIONS 37.0 RATE REVISION

No rate revision is admissible under this tender. 38.0 EXTRA CHARGES FOR RECTIFICATION/ MODIFICATION 38.1 All rectification/ modifications and reworks required for any reasons not due to fault of the

bidder on works already completed, which require less than or up to 50 man hours shall be considered as minor and shall be carried by the bidder free of cost. In case any extra work require more than 50 man hour (say 100 man hour) then total 100 man hours will be considered for admission of extra work. It may be specifically noted that the decision of BHEL as to whether such payment is due shall be final and binding on the bidder. Such payment will be regulated by the terms, conditions and stipulations contained in the clauses contained hereinafter.

38.2 BHEL may consider payment for extra works on man hour basis for such of those works which require major revamping/rework, which is totally unusual to normal erection or commissioning work and are not due to bidder’s faulty erection. The decision of BHEL in this regard shall be final and binding on the bidder. The bidder may submit his extra claim bills (specifically agreed by BHEL engineer) along with the labour sheet duly certified by BHEL engineer at site. But BHEL has also got the option to get these works done through other agencies, if they so desire.

38.3 All the extra work, if any, carried should be done by a separate gang which should be identified prior to start of work for certification of man hours. Daily labour sheets should be maintained and should be signed by bidder’s representative and BHEL engineer. Signing of labour sheet does not necessarily mean the acceptance of extra work. Only those works which are identified as not usual to normal erection and certified so by the construction manager, will be considered for payment.

38.4 The decision of BHEL in this regard shall be final and binding on the bidder. 38.5 Extra work rate for all cases other than high pressure joints shall be as per GCC. 38.7 EXTRA WORK RATE FOR HIGH PRESSURE JOINTS: 38.7.1 The following are all inclusive rates and will be applicable for rectification/ modification/ re-

work involving welding of high pressure joints. 38.7.2 Unit rate per equivalent joint of size OD 63.5 mm x 6.3 mm thick. Type of material Average unit rate per equivalent joint 38.7.2.1 Carbon steel. Rs 200.00 38.7.2.2 Alloy steel. Rs 250.00 38.7.3 The unit rates for welding are all inclusive including joint preparation, scaffolding, edge

preparation, cutting, welding, radiography with films, stress relieving etc with all consumables and tools and plants.

38.7.4 The rates indicated are firm and are not subject to any escalation during the contract period till the completion of work.

38.7.5 For additional radiography, if so desired by BHEL payment @ Rs. 6.00 per cm length of film (100 mm wide) exposed and accepted by site engineer and further certified by site Engineer that the length of the exposed is minimum required for carrying out the radiography shall be paid.

38.8 No PVC, rate revision, over run charge/ compensation is applicable for extra works. 38.9 In the event of any dispute regarding acceptance of any work as “EXTRA”, the work has to

be carried out by keeping man-hour and consumables record jointly signed with remark “for EHQ decision”. Under no circumstances, the bidder can refuse to carry out such work with pre-condition, save and except of keeping daily record of category of man-hours and consumables spent for the particular job for further consideration by EHQ at Kolkata.

39.0 GUARANTEE 39.1 Even though the work will be carried under supervision of BHEL engineers, bidder will be

responsible for the quality of the workmanship and shall guarantee the work done for a period of 12 months from the date of start of guarantee period of respective unit, as certified by the engineer for good workmanship and shall rectify free of cost all defects due to faulty erection. In case bidder fails to repair the defective works within the time specified by engineer, BHEL may proceed to undertake the repairs of such defective works at contractor’s risk and cost without prejudice to any other rights and recover the same from SD/ other dues.


PART-2-COMMON TECHNICAL CONDITIONS 39.2 The guarantee period of each unit will commence from the date of handing over of the

respective unit to customer or six months after completion of full load operation of the respective unit whichever is earlier, provided, all erection, testing and commissioning works are completed in all respect for the unit.

40.0 OTHER TERMS 40.1 Statutory requirements. 40.1.1 Compliance with laws and directives. 40.1.2 The bidder shall in its performance of the contract and the carrying out of the works

ascertain and comply with all relevant Indian Laws and Directives including but not limited to Contract Labour (Regulation & Abolition) Act, 1970, ESI & Provident Fund Act etc. Ignorance on the part of the bidder in this matter cannot be pleaded as reason for non-compliance.

40.1.3 The bidder shall indemnify AINL/CPL the owner’s affiliates and their respective directors, officers, employees and agents against losses, claims and liabilities, including any penalties and sanctions payable to a competent authority, together with all legal expenses incurred in connection therewith, to the extent arising out of any failure of the bidder, any sub-contractor or their respective agents or employees to comply with the performance of the works prior to taking over with any Indian law or directive applicable to the construction, start-up and operational activities conducted at site.

40.1.4 Display of notice of payment of wages mentioning date & time of disbursement of wages every month, a copy of which is to be given to IR department of customer to enable their representative to be present at bidder’s site office to witness the payment and certify the payment register. The certified copy of payment registry month at IR department of customer for their record.

40.1.5 Submitting PF monthly contributions (both employer’s & employees’) to statutory authority by the 15th of the following month is a statutory requirement, a photocopy of which is to be produced at IR department of customer.

40.1.6 All statutory forms viz 2, 3A, 6A, 12 etc are to be submitted in time to the authorities and photocopy of the same to be submitted to IR department of customer.

40.1.7 Deposit ESI subscription in respect of all employees deployed by the said contractor positively by 21st of the next month and producing a photocopy of the same to IR department of customer. Bidder to submit bi-annual returns of contribution to ESI authorities positively by 12th May/ 11th November in each year, a copy of the same is to be produced at IR department of customer.

40.2 Divergences from statutory requirements. If the contractor finds any divergence between any Indian law or Directive and the Technical Specifications it shall immediately give to the other written notice specifying the divergence. The contractor shall promptly upon becoming aware of the same, inform the BHEL in writing of its proposed amendment for removing the divergence, and with the CESC’s consent, which shall not be unreasonably delayed or withheld, the contractor shall entirely at its own cost and expense complete the Works in accordance with the amendment.

40.3 Housing for labour. The bidder shall provide and maintain such temporary accommodation and amenities as may be reasonably necessary for all its and its sub-contractors’ staff and labour employed at the site, including all fencing, water supply (both for drinking and other purposes), electricity supply, sanitation, fire prevention and fire-fighting equipment and other agreed requirements in connection with such accommodation or amenities. The said land on which such facilities are created has to be located outside the project premises.

40.4 Festivals and religious customs The bidder shall in all dealings with its and its sub-contractors’ staff and labour have due regard to all quipment festivals, days of rest and religious or other customs.

40.5 Validity of the offer shall be for six months from the due date of latest priced offer submission (including extension, if any).

40.6 All other term & conditions of this specification shall be governed by the pertinent provisions of GCC, Volume-IB as applicable.



ANNEXURE-I

LIST OF CONSUMABLES TO BE PROVIDED BY BIDDER CLAUSE NO

DESCRIPTION

1.0 Sealing material. 2.0 Preservative & conservative material during storage. 3.0 Abrasives. 4.0 Cleaning materials like petrol, diesel, etc and others as per requirement 5.0 Paints, varnishes & thinners for final/ preservation/ touch up painting. 6.0 Welding and auxiliaries materials. 7.0 Iron and steel section for making scaffolding and other related jobs. 8.0 Other misc items. 9.0 Paints for condenser and other quipment and system, piping 10.0 Flurocsence for condenser laek detection test. 11.0 Spares and consumables for EOT cranes as per relevant clause of SCC. 12.0 Murcury for gen gas tightness test. 13.0 Paints for final/finish painting 14.0 Grouting Cement and other consumables for Grouting

NOTE The items indicated above are only for guidance. The bidder at his own cost has also to arrange all the consumables other than those indicated above, if required.



ANNEXURE-II IIA. LIST OF T&P TO BE PROVIDED BY CONTRACTOR

Contractors may please note that this list is not exhaustive & given for guidance purpose. The contractor may require deploying additional T&Ps not mentioned in this list at their own cost for proper execution of the job. SL NO

DESCRIPTION QUANTITY

1 8T/10T/12 T hydra One 1A 25T/40T crawler crane. One 2 Tube expander (suitable for SS/ Cu-Ni/ Brass tube) cum bell mouthing &

cutting m/c with expanding and cutting tools. 3 nos.

3 Tractor-trailer of suitable capacity (with long bed) and other types. As required 4 Tube cutting tools. As required 5 Truck 10T capacity. 1 no. 6 Wheel barrows. 1 no. 7 Electrical winch 5T/ 2T/ 1T. 1 no each. 8 Hand winch. 2 nos. 9 Hydraulic pipe bending machine(manual & electrical upto 3” SCH 160). 1 no. 10 Master level 0.1mm/metre. 1 no. 11 Hand tacho meter 0-10000 rpm. 1 no. 12 Portable power/ pneumatic hack saw machine. 1 no. 13 Chain pulley block 5T, 3T, 2T. As required. 14 Pull lift 6T, 5T, 3T, 1.5Tt. " 15 Multipurpose pulling and lifting m/c 5T, 3T, 1.6T. " 16 Hydraulic jack (enerpack usa make) with pump – 100T, 50T. 4 nos. 17 Screw jack 25T, 20T, 10T & 5T. As required 18 Single sheave snatch pulley 10T, 5T. 20 Double sheave snatch pulley 10T, 5T. 21 D shakles 10t, 20t, 50T. 22 Turn buckles 3T, 5T, 8T, 10T, 15T, 20T. 23 Welding generator K320. 24 Oil cooled welding transformer 300 amp, 450 amp. 25 Air cooled welding transformer 300 amp. 26 Stress relieving transformer 600 amp. 27 Tig welding torch air cooled. 28 Tig welding torch water cooled. 29 Co2 / semi automatic welding m/c. 30 Oxygen regulator. 31 Acetylene regulator. 32 Cutogen 5. “ 33 Oxygen hose 10 mm. " 34 Acetylene hose 10 mm. " 35 Electrode drying oven. " 36 Portable electrode drying cabinet. " 37 Copper welding cable 600 amp, 400 amp. " 38 Aluminium cable 600 amp, 400 amp. " 39 Temperature recorder. " 40 Thermochalk 100 deg c to 800 deg c. " 41 Air compressor 250 cfm, 80 cfm. " 42 Filling pump 80 m head, 15 ltr/sec. " 43 Flood light with bulb. " 44 Step down transformer. " 45 Drilling m/c of different sizes. "


PART-2-COMMON TECHNICAL CONDITIONS 46 Motorized megger 500V,1000V. " 47 Tong tester. " 48 Grinding m/c of different sizes. " 49 Chamfering m/c of different sizes. " 50 Trip torque wrench (pneumatic & manual). " 51 Aluminium telescopic ladder. " 52 Manila ropes of different sizes. " 53 Steel wire ropes of different sizes. " 54 Drawing board. " 55 Radiography equipment. " 56 Moving platform. " 57 Magnetic particle test equipment. " 58 Ultrasonic flaw detector. " 59 Dye penetrant test kit. " 60 Sheet grooving m/c for outer sheet casing. " 61 Sheet bending m/c for outer sheet casing. " 62 Steel wire rope slings (different size and capacity). " 63 Slings for lifting rotors etc. " 64 Surface plate and straight edge. " 65 Wooden sleepers. " 66 Hand pump for hydro test. " 67 Milling, cutter. " 68 Hand tools. 68.1 Drill bits of different sizes. " 68.2 Taper reamers 25mm, 30mm, 40mm. " 68.3 Taper drill 25mm, 30mm, 40mm. " 68.4 Tap sets M48, M56, M64, M72 - each one set. " 69 ‘sunnen make’ or equivalent good quality reaming m/c. " 70 V- block and parallel plates. " 71 Lifting beam for condenser tube package. " 72 Sling for lifting turbine rotor. " 73 Laser beam alignment kit for alignment of two shafts. " 74 Optical instruments for leveling aligning of bearing base plate, LP base

plate etc. "

75 Mag welding (semi-automatic) m/c for condenser fab. " 76 Bolt stretching device. " 77 Sand blasting equipment. " 78 Steam washing equipment. " 79 Heavy duty vacuum cleaner. 1 no 80 Paint’s thickness measuring instrument. 1 no 81 Electrostatic oil filtration unit/ elc-oil filtration machine (alongwith vacuum

degasser). As required

82 Condenser tube leak detector including u/v lamp and dye. " 83. Gen.gas tightness fixures with sufficient stock of murcury. " 84. Erection & commissioning fixtures & gadgets. " 83 Taper gauge 20mm. " 84 Screw extractor. " 85 24V transformer. " 86 Pneumatic drill machine. " 87 Strand Jack system for Stator Lifting including temporary structures,

jacks,control unit,wire ropes,stator lifting slings and other accessories As Required

NOTE:Apart from the above, any other T&P of required size, accuracy, brand, etc or additional quantities required for completion of work will have to be arranged by the bidder at his cost. All the lifting tackles should have valid test certificates to satisfy the statutory authority.



IIB. LIST OF MMDs TO BE PROVIDED BY BIDDER Contractors may please note that this list is not exhaustive & given for guidance purpose. The bidder may require to deploy additional MMDs not mentioned in this list at their own cost for proper execution of the job. SL NO


1 Dial gauge with magnetic base, 0-25mm range. 4 nos 2 Dial gauge with magnetic base, 0-10mm range. 12 nos 3 Slip gauge box. 1 set 4 Outside micrometer 300-400mm, 400-500mm, 500-600mm. Each 1 set 5 Bore dial gauge, 35-80mm. 1 set 6 Three point micrometer, 50-80 mm. 1 set 7 Dial guage with magnetic base 0-25 mm range, stand 0.01 mm accuracy. 4 nos. 8 Filler gauge, 1000mm long 30mm width of various thickness from 0.1 to

1.00mm in step of 0.05mm. 1 set

9 Special feeler gauge, 6mm width x 600mm long in various thickness from 0.10mm to 1.00mm in step of 0.05mm.

1 set

10 Feeler gauge, 25mm x 300mm long 0.05mm thickness to 2.0mm in step of 0.1mm.

1 set

11 O/S micrometer 0-25, 25–50, 50-75, 0–50 mm stand 0.01mm accuracy. 3 sets each 12 Vernier calliper 0-150, 0–600 & 0–1000mm stand 0.02mm accuracy. 1 each 13 Telescopic gauge (10–300 mm). 1 set 14 Depth micrometers 0–300 mm. 1 no 15 Vernier theodolite - 1 inch accuracy. As required 16 Dumpy level. 17 Micro master level. 18 Spirit level 12 inch, 0.1 mm accuracy. 19 Combination squares. 20 Inside/Outside micrometer. 21 Digital meggar [1KV]. 22 Hand operated meggar [1KV/500V]. 23 Tong tester. 24 Digital multimeter. 25 Micro ohm meter. 26 Coatmeter for measuring paint thickness.



ANNEXURE-III

T&P TO BE PROVIDED BY BHEL FOR USE OF BIDDER ON SHARING BASIS (FREE OF HIRE CHARGES)

SL NO


1 EOT crane (in TG hall) As available/installed for normal parallel erection.

2 Cranes of capacity 75T or higher capacity. As per requirement. 3 Hydro test pump, 400kg/sqcm. One no. 4 Chemical cleaning pump 150T/hr. One no. 5 Suitable high capacity crane (preferably 75 MT or above as

required as per the load chart) for lifting deaerator and feed storage tank components in deaerator floor.

As per requirement.

NOTE Any special tools & plants, stator/ rotor lifting devices supplied by manufacturing Units shall be provided as and when made available free of hire charges to the bidder for executing the specific job. These special tools & tackles are to be used only for the purpose which they are meant for and to be returned in good condition to BHEL store immediately after the particular work is completed. T&P other than special tools supplied along-with the equipment shall not be issued to the bidder for erection purpose. The cranes shall be provided with fuel & operator.



ANEXURE-IV

LIST OF CONSUMABLES TO BE PROVIDED BY BHEL (FREE OF CHARGES) SL NO

DESCRIPTION

1 CHEMICALS FOR CHEMICAL CLEANING AND GASES FOR CARRYING OUT COMMISSIONING ACTIVITIES.

2 LUB-OIL FOR OIL FLUSHING & TRIAL RUN OF EQUIPMENTS. 3 IMPORTED ELECTRODES AS SUPPLIED BY BHEL’S MFG UNITS. 4 SHIMS AND GASKETS GOING INTO THE EQUIPMENT AS SUPPLIED BY BHEL/

MANUFACTURING UNITS. 5 FUEL AND CONSUMABLES FOR CRANES (EXCEPT FOR EOT CRABNE) ON

SHARING BASIS.

Annexure-A (TCC-PART-2-COMMON TECHNICAL CONDITIONS)

32.7 Description of activity Percent

allocated 32.7.1 CONDENSER 32.7.1.1 Foundation preparation 1.00% 32.7.1.2 Assembly of condenser parts. 32.7.1.2.1 Completion of box assly including welding. 1.00% 32.7.1.2.2 Erection & welding of tube support plates. 1.50% 32.7.1.2.3 Erection & welding of dome walls. 0.50% 32.7.1.2.4 Erection of stiffeners/ bracing pipes of dome walls. 0.75% 32.7.1.2.5 Welding of stiffeners/ bracing pipes. 0.75% 32.7.1.2.6 Erection and welding of stiffeners etc of condenser. 0.50% 32.7.1.3 Insertion of tube & tube expansion. 32.7.1.3.1 Insertion of tubes. 2.00% 32.7.1.3.2 Trimming, expansion & bell mouthing,cutting of tubes. 0.50% 32.7.1.3.3 Water fill test. 0.50% 32.7.1.3.4 Assembly of water boxes. 1.00% 32.7.1.4 Hyd test of condenser spring adjustment & final setting. 32.7.1.4.1 Hydraulic test of condenser tubes & water box. 0.50% 32.7.1.4.2 Spring adjustment & final setting and condenser neck erection &

welding. 0.50%

32.7.1.4.3 Erection of water box handling arrangement. 0.50% 32.7.1.4.4 Condenser vacuum leak test. 0.50% 32.7.1.5 Inside painting of condenser. 0.50% 32.7.2 TURBINE 32.7.2.1 Placement, centering, leveling & grouting of brg pedestal & base plates. 1.25% 32.7.2.2 Erection of LP turbine. 32.7.2.2.1 Installation of LPT outer casing B/H. 0.50% 32.7.2.2.2 Installation of LPT inner outer casing B/H. 0.50% 32.7.2.2.3 Placement of LP rotor, radial & axial clearance setting in LPT top &

bottom casing. 0.50%

32.7.2.2.4 Roll check and fitting of final axial & radial keys. 0.50% 32.7.2.2.5 Erection & welding of LP inlet bellows and bracing pipes. 0.50% 32.7.2.2.6 Erection & welding of LP top cover. 0.50% 32.7.2.2.7 Boxing up of turbine & erection of CAP. 1.00% 32.7.2.3 Placement & positioning of HP & IP turbine. 32.7.2.3.1 Placement, positioning of HPT & IPT. 0.75% 32.7.2.3.2 Taking HP & IP rotor load on bearing and preliminary alignment of HP -

IP & IP - LP coupling. 0.50%

32.7.2.3.3 Assly of elbows & breech nut in HPT & in IPT. 0.50% 32.7.2.3.4 Horn drop & roll check of HPT & IPT. 0.50% 32.7.2.3.5 Fitting of axial & radial key in HPT & IPT. 0.50% 32.7.2.4 Alignment. 32.7.2.4.1 Alignment of HP-IP & IP-LP coupling. 0.75% 32.7.2.4.2 Reaming, honing & coupling bolt fitting. 0.75% 32.7.2.4.3 Coupling bolt stretching & swing check. 0.50% 32.7.2.5 Erection of stop & control valves and governing control system. 32.7.2.5.1 Erection of MS & RH stop cum control valves. 0.80% 32.7.2.5.2 Erection of Gov Control rack & LPBP rack. 0.40% 32.7.2.5.3 Erection of LP bypass valves. 0.40% 32.7.2.6 Boxing up of bearing pedestal. 1.50%

Annexure-A (TCC-PART-2-COMMON TECHNICAL CONDITIONS)

32.7.2.7 Erection of turbine integral piping with oil pump etc. 3.50% 32.7.3 GENERATOR. 32.7.3.1 Preparation of foundation and matching of base plates and percentage

should be 2% together. 1.00%

32.7.3.2 Unloading and Placement of Stator on its foundation 3.50% 32.7.3.3 Levelling, positioning and alignment of stator. 2.00% 32.7.3.4 Rotor insertion. 1.00% 32.7.3.5 Alignment of generator rotor with turbine rotor and coupling. 1.00% 32.7.3.6 Generator box up. 1.00% 32.7.3.7 Erection of excitation system. 1.00% 32.7.3.8 Erection of hydrogen filling system. 1.00% 32.7.3.9 Erection of misc integral piping. 1.5.00% 32.7.4 ROTATING AUXILIARIES ALONGWITH INTEGRAL PIPING & ACCESSORIES 32.7.4.1 Erection of BFP (3 nos). 4.50% 32.7.4.2 Erection of CEP (2 nos). 2.00% 32.7.4.3 Erection of Misc Pump (1 LOT). 2.00% 32.7.4.4 Erection of other rotating aux with associated auxiliaries. 3.00% 32.7.5 STATIC AUXILIARIES 32.7.5.1 Erection of LP Heaters 1, 2 & 3. 1.00% 32.7.5.2 Erection of HP heaters 1&2. 1.00% 32.7.5.3 Erection of ejectors/ vacuum pumps, drain coolers & gland steam

condenser. 0.75%

32.7.5.4 Erection of deaerator and feed storage tanks. 2.50% 32.7.5.5 Erection of flash tanks, flash boxes, other tanks and other static aux. 1.75% 32.7.6 MISC EQUIPMENT 32.7.6.1 Erection of HP & LP dosing system. 0.25% 32.7.6.2 Erection of self cleaning strainers/ debris filters. 1.00% 32.7.6.3 Erection of plate heat exchanger, BF valves etc. 0.75% 32.7.7 ERECTION, WELDING, TESTING, NDT ETC OF TG PIPINGS WITH

H&S, VALVES ETC 12.00%

32.7.8 INSULATION OF PIPE & EQUIPMENT 6.00% 32.7.9 COMMON SYSTEM EQUIPMENT & AUXILIARIES 32.7.9.1 Erection of Misc. Hoist etc. 1.00% 32.7.10 FINISH PAINTING (TO BE RELEASED ON PRO-RATA BASIS) 2.00% 32.7.11 PRE-COMMISSIONING & COMMISSIONING 32.7.11.1 Starting of TG oil flushing. 0.80% 32.7.11.2 Completion of TG oil flushing & TG on barring gear. 1.00% 32.7.11.3 Generator air leakage test & dry out. 1.00% 32.7.11.4 Commissioning of 3 nos.BFPs. 1.00% 32.7.11.5 Commissioning of cooling water pumps. 1.50% 32.7.11.6 Commissioning of CEPs. 0.60% 32.7.11.7 Commissioning of misc pumps packages. 1.00% 32.7.11.8 Rolling & synchronisation. 1.00% 32.7.11.9 Full loading. 1.00% 32.7.11.10 Trial run. 1.50% 32.7.11.11 PG test. 0.50% 32.7.11.12 Attending to punch points 5.00% 32.7.12 Handing over of the unit to customer. 0.50% 32.7.13 TOTAL. 100.00%

NOTE : THE ABOVE BILLING SCHEDULE IS APPLICABLE FOR BOTH UNITS

Documents

TECHNICAL CONDITIONS OF CONTRACT PART-1 … · PART-1 TECHNICAL SPECIFICATION FOR ... 2.23.7 Gas pressure regulators ... 2.35.22 Aux steam piping to turbine gland seal