tender document for o & m of ahs & auxiliaries

8/2/2019 Tender Document for O & M of AHS & Auxiliaries

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MADHYA PRADESH POWER GENERATING COMPANY LIMITED

SANJAY GANDHI THERMAL POWER STATION(2x210MW) PH-I, BIRSINGHPUR

TECHNICAL SPECIFICATION FOR COMPLETE OPERATION AND MAINTENANCE OF ASH

HANDLING SYSTEM AND ASSOCIATED AUXILIARIES

1. Intent of Specification: - This specification is intended to cover complete

operation and maintenance of ash handling system and associated

auxiliaries ofpower house no. I of SGTPS, Birsinghpur.

2. It is not the intent to specify completely herein all the details of equipments, its

design, construction and assembly of the components & accessories. However any

material required in order to meet the intent of this specification and to make the

required system functional in an acceptable manner is under the scope of bidder,

whether the same is specifically indicated or not.

3. It is deemed that technical bid shall be submitted by the bidder complete in all

respects after the bidder fully understood about the scope of work and the

requirement of the specification. Hence no deviation shall be entertained after the

opening of the bid. For this purpose, MPPGCL shall be pleased to have technical

discussion with the bidders, if bidder so desire, prior to submission of bids. Also

MPPGCL will entertain the bidders visits to the concerned power plants if it helps

them to understand the exact scope of work. As the O&M shall have to be carried

out, it is advised that bidders shall visit the site, make them fully conversant with

the job, site conditions.

GENERAL INFORMATION

Sanjay Gandhi Thermal Power Station consists of three power houses i.e.

PH-I, PH-II comprises of (2x210MW) each each & ( 1 x 500 MW) PH-III. The O&M

covered under this specification shall have to be carried out in PH-I. The brief

details of which are as under:-

Steam Generator(Boiler)

Make:- ACC Babcock Limited

Type:- Natural circulation membranetype, water cooled furnace,

Radiant type, two pass, opposed fired.


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01 Qualifying Requirement

The bidder must fulfill the following minimum qualifying requirement for the

participation in this Bid-1. a) Bidder should submit Proof of having at least three years experience of O&M

work of Ash Handling System of 210 MW units or higher capacity.b) Original equipment manufacturer who have success fully commissioned ash

handling system and put the system in operation thereafter at any of thermal

power station shall be exempted from the condition stipulated in 2 (a)above.2. The Bidder should submit audited accounts for at least two years along with latest

income tax clearance certificates.

3. Bidder should submit copy of service tax, EPF code registration, and valid laborlicense from competent authority.

4. Bidder should submit annual turn over certificate of Rs 3 Crore or above from anynationalized / reputed Bank as a Proof of financial soundness to make payments of

at least Six months.

02 SCOPE OF WORK

COMPLETE OPERATION AND MAINTENANCE OF ASH HANDLING SYSTEM AND ITS

AUXILARIES (2 X 210MW), UNIT # 1&2 DESCRIBED AS UNDER

1.0 ASH GENERATION POINTS:-The Ash generated in the boiler is collected underdifferent zones as indicated below:-

1.1 Furnace ash is collected at the bottom of the furnace hence called the bottom ash.1.2 Coarse Ash is collected in the economizer hoppers provided in unit 1 & 2 only. There

are 8 no. hoppers are provided to collect the coarse ash in each unit.1.3 Fly ash is collected in 42 ESP Hoppers and 12 Air Heater Hoppers, per unit.

2.0 MODE OF DISPOSAL:- Different types of Ash stored at various locations are

disposed off, as below-

2.1 The Bottom Ash is stored in water impounded hoppers, at the bottom of the furnace,removed intermittently by operating Clinker Grinder and Jet Propulsion pump to

dispose off the Bottom Ash unto the Ash Slurry Sump located at Ash Pump House

through 04 Nos. 200 NB pipeline.2.2 The coarse ash is collected in through Economizer hoppers by Vacuum conveying

system by using hydraulic exhauster and slurry is formed. Coarse ash evacuation isintermittent and the slurry is removed through separate jet pump. This facility is

provided in unit 1 & 2 only.

2.3 The Fly Ash from ESP & Air Heater Hoppers is collected in a dry from throughVacuum Conveying system and transported unto the surge tank. From the Surge

Tank Pressure System conveys the fly ash unto the far away station silo. In case the

silo is full or any maintenance is being carried out in silo then the silo can bebypassed and fly ash can be evacuated in ash slurry sump. A 350 NB line is used to

dispose of the fly ash unto the ash slurry sump and a 400 NB line is used to transportthe fly ash from ash slurry pump house to silo. The present facilities in the silo are

provided for conditioning unloading through which ash can be disposed in the dryform (duly moistened and suitable for open truck disposal). Dry ash evacuation


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system is also provided with slurry pumping facilities. Moreover blanked dischargepointes are also provided for future.

2.4 Presently, Both the Bottom Ash and Fly ash thus dumped in ash slurry sump is

pumped to the ash pond with the help of Ash Slurry Pump, which is situated around

3.5 km ash pump house through four numbers of lines of 300 NB each. New ashpond is under construction ahead of bout 2 Km of existing pond. After completion/

commissioning of this pond, the wet ash will be dumped their in near future.2.5 Silo by passed system has also been added subsequently only recently even after

construction of the building & sumps, which has been fitted at the end of the

pressure conveying system which allows fly gas removal in slurry pumps directlywithout taking the fly ash into the silos.

3.0 ASH REMOVAL CAPACITIES:-3.1 Ash Generated and system capacities.

Specified Ash data : ASH GENERATION (AT 100% MCR WITH WORST COAL)BOTTOM ASH HOPPER : 39 TPH

ECONOMISER HOPPER : 6 TPHAIR HEATER HOPPER : 6 TPH

ESP HOPPER : 58 TPH

STACK HOPPERS : 3 TPH112 TPH

3.2 EVACUATION CAPACITIES PER UNIT:-

3.2.1 BOTTOM ASH System (From B.A. Hopper to Ash slurry sump):-2x60 TPH through each of 200 NB MS Pipes.

3.2.2 COARSE ASH System:

A. VACUUM( C.A.HOPPER TO C.A. TANK 2X30 TPH) through each of 8 BS pipe.

B. SULLRY( C.A.TANK TO SLURRY PUMP HOUSE ) through each of 12 BS MS pipes.

3.2.3 FLY ASH SYSTEM :

A. VACUUM (ESP & A/H HOPPERS TO SURGE TANK):- 2x60 TPH through 8 & 9 CI& 250 NB MS Pipe.

B. PRESSURE (SURGE HOPPER TO SILO/ASH SLURY SUMP):- 1X120 TPH through

14 & 16 MS Pipe combination.

3.2.4 SLURRY SYSTEM COMMON FOR:- 2x210 MW Unit.A. FOR TRANSPORTING BOTTOM ASH (from slurry sump to ash dam) 1x120 TPH

through 300 NB MS Pipe.

B. FOR TRANSPORTING FLY ASH (from silo slurry sump to ash dam) 1x120 THPthrough 300 NB MS pipe.

Along with the O&M work, the rotation of pipes once in a year shall also be in the

contractor scope.

4.0 ASH CLEANING TIME (PER UNIT):-The Ash Handling System is envisaged to operate for the following duration for each of

the units.4.1 BOTTOM ASH:- Approximately 1 Hrs per 8 hours and operate once per shift per unit.


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4.2 COARSE ASH:- The duration of coarse cleaning is approximately 1 hr per 8 hrs shift .4.3 FLY ASH:- Approximately 4.5 hrs per shift of 8 hours per unit.

5.0 OPERATION PHILOSPHY & STANDBY EQUIPMENT5.1 BOTTOM ASH:-

Bottom Ash are evacuated in sequence by operation two diagonally opposite clinker

grinder, jet pump and eccentric crusher while keeping other two diagonally opposite

sets clinker grinder, jet pump and eccentric crusher as stand by i.e. 100% standby.Bottom Ash is evacuated to ash slurry sump through 200 NB MS Pipe. In all there are

four 200 NB lines, two on each side. During normal operation two evacuates bottomash through 200 NB lines while other two remain as standby.

5.2.1 COARSE ASH:- In unit each unit of PH-I, Coarse ash hoppers has X and y with 4 no.

hoppers in each side. The hoppers are evacuated in sequential manner in the slurryform and dumped in the Coarse Ash Tank. The slurry then transported to ash sump

through 300 NB lines.

5.3 FLY ASH:-i) VACUUM SYSTEM:-

Sequential cleaning from ESP & Air Heater Hoppers up to the surge tank. Two Bag

Filters Operate, keeping other two as standby per unit. Two Sets of water ring typeMechanical Exhauster run for 120 TPH for removal of fly ash from ESP & Air Heater

Hoppers. Two sets of water ring type Mechanical Exhauster remains as standby.ii) PRESSURE CONVEYING SYSTEM:-

Fly Ash from surge hopper to silo is transported by air pressure supplied by one

number of conveying compressors. One number of conveying compressors remains asstand by per unit. For transporting fly ash from surge hopper to silo/ash sump

pressure conveying line is used. For four numbers of Nuva feeder are used for feeding

fly ash from surge hopper to pressure conveying line, while other four remain asstandby.

iii) WATER AND SLURRRY SYSTEM:-

One chain of H.P. Water pump and one chain of Ash Slurry pump are run per unit for

removal of ash slurry from ash slurry sump and transporting it to ash dam. One set of

H.P. Water Pump and one set of Ash slurry pump remain as standby.

6.0 BRIEF EQUIPMENT DESCRIPTION

6.1.0 BOTTOM ASH SYSTEM

6.1.1 BOTTOM ASH HOPPER:-Each unit is provided with one number of water-impounded Bottom ash hoppers with

holding capacity of 160 tones of bottom ash.6.1.2 BOTTOM ASH HOPPER CONFIGURATION AND DISCHARGE ARRANGEMENT:-

Bottom Ash Hopper is W type each V section of the W is provided with two

discharge gates, out of which normally one is to operate during ash removal leavingother one as standby.

6.1.3 BOTTOM ASH EQUIPMENT:-

Each discharge gate is provided with one (1) No. of Eccentric Crusher and one (1) No.

of Jet Pump along with other accessories. In all there are four nos. of discharge gates.

Eccentric crusher can move both the direction i.e. backward and forward.6.1.4 BOTTOM ASH SLURY TRANSPORTATION PIPING:-


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Two (2) pipes of 200 NB (MS) per unit are provided for transporting ash slurry frombottom ash hopper to slurry sump.

6.1.5 BOTTOM ASH OVERFLOWING FACILITIES:-

There are three (3) numbers of Overflow Transfer Pumps situated just near bottom

ash hopper. These Pumps transfer the over flow water from the bottom ash hopper,

which is collected in an overflow sump, is then transferred to either ash slurry sumpor clarifoculator through one no. 200 NB line. At a time only one pump is in operation.

6.1.6 BOTTOM ASH PIT CLEANING FACILITY:-There are two nos. of Jet Pumps for bottom ash pit cleaning through two nos. 65 NB

line from pit to over flow sump.

6.2 COARSE ASH SYSTEM:-

Coarse ash is collected through 2 nos. of hydraulic exhausters operating

intermittently. The slurry is formed in the exhauster.

6.2.1 ASH COLLECTION FROM VARIOUS HOPPERS:-Ash collected in hoppers is evacuated in coarse tank through conveying lines under

vacuum maintained by hydraulic exhausters operating intermittently. The slurry isformed in the exhausters.6.2.2 SLURRY COLLECTION AND DISPOSAL: -

There is one no coarse ash tank with 50 ton capacity is provided for this in each unit.6.2.3 DISPOSAL OF SLURRY FROM COARSE ASH TANK:-

One no. jet pulsion pump with one no. disposal pipeline of 300 NB up to slurry sump

is provided to keep in the operation while second stream is kept as stand by. Thesystem is to operate in intermittently during ash evacuation hydraulic exhauster.

6.3.0 FLY ASH SYSTEM:-

6.3.1 REMOVAL OF ASH FROM HOPPERS:-

Vacuum in the lines connecting ESP & Air Heater Hoppers is created with the help ofmechanical exhauster as a result of which when the gates of the hoppers open

sequentially the ash from the ESP & Air Heater Hoppers get sucked and get

transferred to surge hopper through bag filter and transfer hopper. In all there aretwo streams, in one stream, 21 nos. of ESP hoppers and 06 nos. of Air Heater hoppers

are connected. At a time both the stream is in operation.

6.3.2 DUST COLLECTOR ARRANGEMENT:-

In all there are four nos. of Dust Collector. Each dust collectors consists of 126 nos.filter bags. The mixture of ash and air conveyed through pipelines enter the selected

dust collector on conveying circuit. The combination of filter separator and transfer

hopper arrangement is used for continuous separation of fly ash from the conveyingair and unloading of the free air into the intermediate surge hopper without

interruption of the conveying operation. Out of four dusts collector, at a time only twonos. is in operation.

6.3.3 MECHANICAL EXHAUSTER:-

In all there are 4 sets of Water Ring type Mechanical Exhauster for each unit. In general

two sets are in operation for each unit. When operated they create vacuum, which

helps in removal and conveying of fly ash from ESP & Air Heater hoppers tointermediate surge hopper.

6.3.4 FLY ASH VACUUM TO PRESSURE TRANSFER:-


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Atmospheric surge hopper is provided below dust collector with surge capacity of 60tons/section of surge hopper. There are two such section in one surge hopper

provided per unit.

6.3.5 PRESSURE FEEDER:-

Each section of surge hopper tank is provided with four nos. feeders. The feedersoperate in cycle to discharge fly ash into the pressure conveying lines of 350 NB, in a

regular manner. The pressure conveying system evacuates ash in fly ash from surgehopper to silo/ash slurry sump. The second section of surge hopper provided with

another four feeders, which remain as standby.

6.3.6 PRESSURE CONVEYING PIPELINE:-

There are two pressure conveying pipe lines 350 NB/400 NB, for each unit for

transportation of ash from boiler area to station silo/ash slurry sump. One pipeoperates, keeping the other as standby.

6.3.7 PRESSURE CONVEYING BLOWER:-

Four nos. twin lobe types conveying blower are provided, two for each units. At a time

only one blower is in operation for each unit.

6.4.0 ASH SLURRY DISPOSAL FACILITY

6.4.1 SLURRY PUMPS ARRANGEMENT:-

All the slurry from the plant is received in a distribution chamber. There are four

slurry pump compartment and the distribution chamber has individual isolating gateswith pipe for discharging slurry into the desired pump.

6.4.2 SLURRY PUMP:-

There are four series of slurry pump. Presently there are two stage of slurry pump in

each series for future extension of disposal point.6.4.3 SLURRY DISPOSAL:-

Each series is rated for 120 TPH Ash Slurry Disposal. One such series has to be

operated for removing Bottom Ash from one unit. Fly Ash in slurry from the silo orsilo-bypass system can be removed thereafter in a sequential manner. Two series of

slurry pump operate, one for each unit while the other two remain as standby.

6.4.4 DISPOSAL PIPELINE:-

Four nos. of 300 NB M.S. disposal pipelines are provided through which slurry is

transported. Two such pipes are operating for both the units.7.0 BRIEF DESCRIPTION OF FLY ASH SYSTEM:-

7.1 FLY ASH:-

Fly ash stored in various hoppers is conveyed unto silos (1A+1B) or silo-bypass systemlocated in Ash Slurry Pump House of PH-II, through a vacuum-pressure combination

system followed by pressure system. The transition of vacuum system to pressuresystem takes place adjacent of ESP at a transfer point where the separator isolates the

fly ash from the air and allows it to pass out through the Mechanical Exhauster

(Vacuum Pump), where vacuum is created, and those equipments are located adjacentto ESP and Fly Ash equipment building. Dust separator is located over set of Hopper

known as surge hopper. The fly ash thereafter gets transferred to pressure system

feeders below the surge hopper, where from it is transported, to plant boundary siloor silo bypass system through pressure conveying system.

7.2 DISPOSAL FROM SILO:-


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Each of two silo(1A& 1B) of sized for 1700 tons dry ash storage capacity(11.5 M Dia x31.5 M height)having capacity for storing one ash generation . Silo contains auxiliaries

like vent fan vent filter and silo blowers.To dispose ash from these silo there are two options

i. Truck unloading to un loaders.

ii. Converting dry to slurry and pumping it out through pumps.

8.0 INSTRUMENT AIR SYSTEM:-In PH-I, there are three nos. Instrument Air Compressor Compressors make: Kirloskar

Pneumatic Ltd. Each Compressor is complete with electric motor and other inbuilt

features and accessories are provided to cater to instrument air requirements, for ashhandling system. Out of three Instrument Air Compressors, normally one operates to

deliver the instrument air requirements for entire system, constituting unit # 1&2.

Two nos. of Air Drier units each complete with its own features and accessories, arealso provided and located at discharge of Instrument Air Compressor, out of which,

one Air Drier unit normally operates with the operation of one no. compressor,keeping the other as stand-by. The instrument air is catered to actuate all

pneumatically operated valves, bellows, ash hopper feed gates, Nova feeder gates, dustseparator gates, and other equipment as well as to meet pulsing air requirement forvent filters. Continuous cooling water requirements for the operating I.A. Compressor,

Intercoolers, after coolers, etc. is catered from plant clarified water system and thecooling water return is discharged into the seal water sump.

9.0 WATER SYSTEM:- The water supplied at bottom Ash hopper and seal water trough(LP water pumps/service water pump) overflows from the hopper and is received in

respective over flow transfer sump. The bottom ash overflow transfer pumps are

operated to pump out this water into the common clarified system. Water over flowfrom the clarifier is received into collection well and is pumped beck into the ash

water sump, by means of Re-cycle water transfer pumps, as the normal input to theMakeup Water Pump/HP water pumps. In addition, recovery water from ash pond as

and when available through existing recovery water system will be recycled back into

to the ash water sump clarifier) by means of recycle water transfer pumps to providenormal input to LP&HP water pumps during bottom ash and fly as cleaning. The

return water form mechanical exhauster and air-washer during fly ash cleaning

operation is received in respective drain transfer sump and is discharged into thebottom ash, overflow transfer sump, by means of Drain Transfer pumps, for further

pumping into the clarifier. The sludge pumps belonging to be the clarifier is operatedto pump-out the accumulated sludge from the clarifier, sludge pit into the ash slurry

sump. The seal water pumps are energized to cater to water requirement for

operating pumps/equipment-having requirement of external seal water.

10. CLEANING:

10.1 Ash/Coal dust spread below the coarse ash hopper, air heater, and ESP hoppers has to

be cleaned daily. Fine ash dust collected has to be done either in coarse ash tank or

ash slurry sump of unit 1 &2 directly. The area covered under this will start from backside of P.A. Fan duct around Bottom ash Hopper, Air heater hopper and up to chimney

on the ground flower and below coarse ash hopper at rear side firing floor. Firm also

has to ensure clearness of all three trenches of bottom & coarse ash and pipe linesregularly to facilitate fast maintenance work.


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10.2 Cleaning of wet ash on the floor due to economizer tube leakage: Several timeseconomizers are clogged with wet ash and mud due to tube leakage in economizer

zone. The wet ash in the economizer & fly ash hoppers cannot be handled with ashhandling system and ash has to be dumped on the floor. This wet ash is to be cleaned

subsequently by manual and trucks by the contractor at free of cost.

10.3 The contractor has to ensure emptiness of hoppers. During short shut down of units,

physical inspection of all the hoppers shall be carried out. In case of accumulationfound inside the hoppers, the same shall be cleared/ cleaned through the system or

manual as per instruction of engineer in-charge.

11.ASH MANAGEMENT

Ash management at ash dyke shall cover diversion of water toward floating barge

(Recovery Pump house) by making /maintaining earthen walls with send bags /ashbags by engaging manual labors. Lifting & minor adjustment or shifting of Barge in the

vicinity of existing location shall also be in the scope of contract. No extra paymentshall be made for above work.

ANY MODIFICATION, FRESH CONSTRUCTION i.e. LAYING OF NEW PIPE LINES,CONSTRUCTION OF BRICKS WALL FOR MAKING EMBANKMENT AT ASH DAM FOR

ASH SLURRY AND ALSO FOR THE ADJUSTMENT OF WATER OVERFLOW

THROUGH FILTER SHAFT WILL NOT COVER UNDER THE SCOPE OF THIS

CONTRACT. OTHERTAN ANY CIVIL CONSTRUCTION SHALL BE DONE

SEPERATELY.

12.ELECTRICAL AND INSTRUMENT:-

12.1 CONTROL SYSTEM:- Necessary remote and local control panels and control stations

are provided at strategic locations to offer a duly interfaced and synchronized controlfor the overall ash handling system. The System controls are provided to offer

necessary operating interfaces among the various sub-systems to achieve a duly co-

ordinated system operation from various control panels and control stations. Anelectromagnetic relay/PLC based control network is interlocks associated with the

system operation and control.

12.2. PROGRAMMABLE LOGIC CONTROL (PLC) UNIT:-

There are two numbers of PLC units, one for each unit. This microprocessor-based

unit is configured with Central Processing Unit, power supply unit and set of logic

necessary to operate and control the fly ash system in remote interlocked mode. Oneadditional CPU is provided for each PLC unit to operate as hot stand by to operating

one. The PLC systems of both the units are supplied with a common PC basedprogramming station for access to the Proven logic, uploading and down loading of

process control software and programmed print out. The PLC system of both the units

is located in the control room of the fly ash equipment building. Maintenance offollowing equipment is also in the scope of contractor.

(i). AIR CONDITONERS:-

There are six no air conditioner are provided in the control room to maintain the

adequate temperature of PLC unit and operator console. Any type of repair/ servicingof A.C.s along with gas filling shall be in the contractors scope.


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(ii) LOCAL PANNEL:- All local panels are located near auxiliaries.

13. ELECTRICAL POWER FEEDING NETWORK:-

The power feeding network under system is composed of necessary switchgears, MCCs

etc. provided at strategic location to establish efficient power distribution network. Themaintenance & testing of all such equipments like:-

1. H.T. SUPPLY 6.6 KV SUPPLY.2. L.T. SUPPLY 415 V SUPPLY.

3. CONTROL SYSTEM SUPPLY 240 V SUPPLY

4. D.C. SUPPLY 220 V SUPPLY.5. ALL H.T., L.T., MOTORS.

14. MAINTENANCE & CALIBERATION OF INSTRUMENTS:-1. Pressure Gauge.

2. Limit Switch.3. Level Indicator.

4. Level Probe.5. Pressure Switch.6. Pneumatic Actuators.

7. Motorized Actuators.8. Various types of solenoid valves.

9. Vacuum Gauges.

10. Diaphragm Valves.11. Temperature Gauges.

12. Electrical Instruments such as CT, PT, Ammeter, Voltmeters etc.

15. MAINTENANCE OF VARIOUS TYPES OF RELAYS. Maintenance, Testing & Calibration

of all 0.415KV and 6.6 KV relays of bus MCC and Breaker.

16. Repair and maintenance of the 33 KV supply lines going to barge shall be in the

contractors scope However, assistance like permit etc. shall be provided by theMPPGCL.

THE DETAILS OF AREAS OF WORK ARE AS UNDER

1. Bottom ash hopper, hopper feed gates, air water converter tanks, eccentric

crusher, jet pumps, overflow transfer pumps and bottom ash slurry lines.

2. Fly ash handling system In this system each units has following equipments:-a. ESP hopper including diffuser feeders, ash and air intake valves along

with other associated fittings.

b. Air pre heater hopper including diffuser feeder, ash and air intakevalves along with other associated fittings.

c. Branch feeder isolating valves (TERSG).d. Vacuum and pressure conveying lines.

e. Mechanical exhauster, air washer and bag filters with associated piping

valves etc.f. Surge hopper including vents etc.

g. Transfer hopper with associated valves.

h. Nova feeder along with associated valve and piping.i. Hydraulic exhauster system.


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3. Ash slurry line pumps are in series with slurry piping valves sump etc.

4. H.P. Water Pumps, Seal Water Pumps with associated piping valves sumps etc.

5 Conveying Compressor, ESP Fluidizing Blower, Nova Feeder Fluidizing Blower,Silo Blowers & Blower heaters etc. Instrument Air compressor (KPL make) with

air drying units along with associated piping valves, coolers and fittings.

5. Silo by-pass arrangement with hydraulic exhauster etc.

6. All make up water Pumps, drain and overflow transfer pumps with piping,

valves.

8. All pumps and valves along with the pipelines incorporated in the clarifoculator

system.9. The slurry disposal pipelines unto the disposal point and all associated valves.

10. Electrical maintenance including gas filling of Air-Conditioner.

11. Silo Blowers, Vent Fans in case of U#1&2

THE SCOPE OF CONTRACT ALSO INCLUDES

A. a. PURCHASE OF SPARE AND CONSUMABLE:- The contractor shall assist withplanning and procurement of all needful spares, replacement and other

consumables and furnish a list of spares indicating quantity required for efficient

operation of plant for one year duration well in advance to enable MPPGCL topurchase. However the contractor has to submit the list of record of all purchased

free of supply spare/consumable per month basis to OIC along with bill.The list submitted shall be verified and duly signed by OIC and only necessary

spares will be purchased for smooth O&M of AHP.

The record of spares indented, consumed and balance stock should bemaintained in M.A.S. register and unserviceable spares must be returned to the O&M

stores.

The monthly rate will cover the provision of consumables like gasket, electrodesand DA & Oxygen gases etc., required for execution of the said O&M job, excluding

the supply of lubricant oil, grease and chemicals required for clarifoculator plant,which shall be arranged by MPPGCL, free of cost. However the firm has to maintain

the proper consumption record of the consumables and spares supplied by the

MPPGCL.(I) GASKET The gasket, which is considered as a spare i.e., formed gasket will

be provided by MPPGCL, free of cost. The contractor shall arrangeother gaskets.

(II) ELECTRODE General type electrodes and (if required) to run system smooth,

special purpose electrodes shall also be purchased & used by thecontractor at their own cost.

b. All spares of the Ash Handling system required for unit # 1&2, at SGTPS site shall beprovided to the firm by MPPGCL, free of cost, for the smooth running of the units.


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However the firm will prepare and submit the list of required spares to MPPGCL,will in advance to enable them to take procurement action. Firm will also extend

necessary assistance in this regard.

c. Carrying out routine and preventive maintenance work of running units is within

the contractors scope. In case of any major breakdown/overhauling job required tobe carried out on the following critical bought out items where specialist services

are required from suppliers, the cost involved shall be borne by MPPGCL as perrequirement of the MPPGCL. Contractor shall extend assistance and co-operation for

the items as mentioned below:-

(i) Mechanical Exhauster (Vacuum Pump).(ii) Ash Slurry Pumps.

(iii) Conveying Compressors.

(iv) H.P. Water Pump.(v) PLC (Programmable Logic Control).

(vi) Transformers.(vii) H.T. Motors.

(viii) MCC.(ix) Switch Gears.(x) H.T. Cranes

(xi) UPS(xii) Various types of Relays.

(xiii) Instrument Air Compressor.

d. The repairing of diffuser feeder seats and discs, vent and equalizing valve discs and

seats, TERSG slides, discs and seats of swing gate valves, pulse jetting cards,

pressure and vacuum switches, various gauges etc. due to non availability of spareswill be carried-out by the contractor without additional claim.

e. Rewinding of L.T./H.T. Motors Rewinding of LT/HT Motors, along with

transportation cost is in contractors scope at no extra cost.

f. Repairing of Filter Bags There are 1516 Nos. of bags in Bag Filter of Unit # 1&2.

The necessary repairing of these bags by stitching, replacement of cloth for the

defective portion, changing of collars etc., at any place will be carried-out bycontractor free of cost.

g. Maintenance of 33 KV over head lines (supply to barge) shall be in the scope ofcontractor. They have to keep trained certified staff for maintenance; however work

shall carried out with MPPGCLs consent and approval. (Permit to work on the line

shall provided by MPPGCL)h. Annual Overhauling The cost towards the annual overhauling of any units should

be included by contractor in their monthly rate. In case of annual overhauling of anyunits, overhauling of ash handling system has to be carried out by the contractor on

our advice; no additional payment will be reimbursed by MPPGCL.

i. The contractor shall keep the area of the work i.e. Bottom ash area of boiler,

overflow tank, Air heater, ESP, and all pump house, neat and tidy. Contractor shall

engage labour regularly for cleaning the area.

j. The arrangement for watch and ward personnel as may be required for AHP insideand outside of powerhouse shall remain in contractor scope. The watch and ward of


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the barge pump house and associated auxiliaries and pipelines going to dam arecovered in this scope. Watch & ward of ash slurry pipelines recovery water pipe

lines shall also in the contractor scope.

k. Any major modification, fresh construction i.e. laying of new pipe lines, construction

of brick walls etc., will not cover under the scope of this contract.

l. The contractor must have arrangement of desired vehicle for shifting ofmaterial/crape from store to site or vice versa.

SUPERINTENDING ENGINEER (MM)-I

SGTPS, MPPGCL, BIRSINGHPUR

SCOPE OF WORK

OPERATION AND MAINTENANCE OF ASH HANDLING SYSTEM AND ITS

AUXILARIES, UNIT # 3&4 (2 X 210MW) SGTPS,BIRSINGHPUR

1.0 ASH GENERATION POINTS:-The Ash generated in the boiler iscollected under different zones as indicated below:-

1.1 Furnace ash is collected at the bottom of the furnace hence calledthe bottom ash.

1.2 Fly ash is collected in 24 ESP Hoppers and 12 Air Heater Hoppers,per unit.

2.0 MODE OF DISPOSAL:- Different types of Ash stored at variouslocations are disposed off, as below-


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2.1 The Bottom Ash is stored in water impounded hoppers, at thebottom of the furnace, removed intermittently by operatingClinker Grinder and Jet Propulsion pump to dispose off the BottomAsh upto the Ash Slurry Sump located at Ash Pump House through04 Nos. 200 NB pipeline.

2.2 The Fly Ash from ESP & Air Heater Hoppers is collected in a dryform through Vacuum Conveying system and transported upto the

surge tank. From the Surge Tank,Pressure System conveys the flyash upto the far away station silo. In case the silo is full or any

maintenance is being carried out in silo then the silo can bebypassed and fly ash can be evacuated in ash slurry sump. A 350NB line is used to dispose off the fly ash upto the ash slurry sumpand a 400 NB line is used to transport the fly ash from ash slurry

pump house to silo.2.3 Both the Bottom Ash and Fly ash thus dumped in ash slurry sump

is pumped to the ash pond with the help of Ash Slurry Pump,which is situated around 2.5 km from ash pump house through 04Nos. of 300 NB each lines.

3.0 ASH REMOVAL CAPACITIES:-3.1 ASH GENERATED AND SYSTEM CAPACITIES.

Specified Ash data : Ash Generation (At 100% MCR withworst coal)

Bottom Ash Hopper : 39 TPH

Air Heater Hopper : 12 TPHESP Hopper : 63 TPHTotal : 114 TPH


3.2.1 Bottom Ash System (From B.A. Hopper To Ash Slurry Sump):-

2x60 TPH Through Each of 200 NB MS Pipes.


A. Vacuum (ESP & A/H Hoppers to Surge Tank):- 2x60 TPH through

8 & 9 CI & 350 NB MS Pipe.B. Pressure (Surge Hopper to Silo/Ash Slurry Sump):- 1X120 TPH

through 14 & 16 MS Pipe combination.3.2.3 SLURRY SYSTEM COMMON FOR:-2x210 MW Unit.

For Transporting Bottom Ash (from slurry sump to ash dam)1x120 TPH through 300 NB MS Pipe.

4.0 ASH CLEANING TIMEThe Ash Handling System is envisaged to operate the followingduration for each of the units.4.1 Bottom Ash:- Approximately 1 Hrs per 8 hours and operate once

pershift per unit.

4.2 Fly Ash :- Approximately 4.5 hrs per shift of 8 hours per unit.

5.0 OPERATION PHILOSPHY & STANDBY EQUIPMENT


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5.1 BOTTOM ASH:-Bottom Ash are evacuated in sequence by operationtwo diagonally opposite clinker grinder, jet pump and eccentriccrusher while keeping other two diagonally opposite sets clinkergrinder, jet pump and eccentric crusher as stand by i.e. 10%standby. Bottom Ash is evacuated to ash slurry sump through 200NB MS Pipe. In all there are four 200 NB lines, two on each side.During normal operation two evacuates bottom ash through 200 NB

lines while other two remain as standby.

5.2 FLY ASH:-

5.2.1 VACUUM SYSTEM:- Sequential cleaning from ESP & Air HeaterHoppers up to the surge tank. Two Bag Filters Operate, keepingother two as standby per unit. Two Sets of water ring typeMechanical Exhauster run for 120 TPH for removal of fly ash fromESP & Air Heater Hoppers. Two sets of water ring type MechanicalExhauster remains as standby.

5.2.2 PRESSURE CONVEYING SYSTEM:- Fly Ash from surge hopper to silo

is transported by air pressure supplied by one number of conveyingcompressors. One number of conveying compressors remains asstand by per unit. For transporting fly ash from surge hopper tosilo/ash sump pressure conveying line is used. For four numbers ofNuva feeder are used for feeding fly ash from surge hopper topressure conveying line, while other four remain as standby.

5.2.3 WATER AND SLURRRY SYSTEM:- One chain of H.P. Water pump andone chain of Ash Slurry pump are run per unit for removal of ashslurry from ash slurry sump and transporting it to ash dam. One setof H.P. Water Pump and one set of Ash slurry pump remain asstandby.


6.1.0 BOTTOM ASH SYSTEM6.1.1 BOTTOM ASH HOPPER:-

Each unit is provided with one number of water-impounded Bottomash hoppers with holding capacity of 160 tones of bottom ash.

6.1.2 BOTTOM ASH HOPPER CONFIGURATION AND DISCHARGEARRANGEMENT:-

Bottom Ash Hopper is W type each V section of the W isprovided with two discharge gates, out of which normally one is to

operate during ash removal leaving other one as standby.


Each discharge gate is provided with one (1) No. Eccentric Crusherand one (1) No. Jet Pump along with other accessories. In all thereare four nos. discharge gates. Eccentric crusher can move both thedirection i.e. backward and forward.

6.1.4 BOTTOM ASH SLURY TRANSPORTATION PIPING:-

Two (2) pipes of 200 NB (MS) per unit, are provided fortransporting ash slurry from bottom ash hopper to slurry sump.

6.1.5 BOTTOM ASH OVERFLOWING FACILITIES:-


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There are three (3) numbers Overflowing Transfer Pump situatedjust near bottom ash hopper. These Pumps transfer the over flowwater from the bottom ash hopper, which is collected in a overflowsump, is then transferred to either ash slurry sump or clarifoculatorthrough one no. 200 NB line. At a time only one pump is inoperation.

6.1.6 BOTTOM ASH PIT CLEANING FACILITY:-There are two no. Jet Pumps for bottom ash pit cleaning throughtwo nos. 65 NB line from pit to over flow sump.

6.2.0 FLY ASH SYSTEM:-6.2.1 REMOVAL OF ASH FROM HOPPERS:-

Vacuum in the lines connecting ESP & Air Heater Hoppers is createdwith the help of mechanical exhauster as a result of which when thegates of the hoppers open sequentially the ash from the ESP & AirHeater Hoppers get sucked and get transferred to surge hopperthrough bag filter and transfer hopper. In all there are two streams,in one stream, 12 nos. ESP hoppers and 06 nos. Air Heater hoppersare connected. At a time both the stream is in operation.


In all there are four nos. of Dust Collector. Each dust collectorsconsists of 126 nos. filter bags. The mixture of ash and airconveyed through pipelines enter the selected dust collector onconveying circuit. The combination of filter separator and transferhopper arrangement is used for continuous separation of fly ashfrom the conveying air and unloading of the free air into theintermediate surge hopper without interruption of the conveyingoperation. Out of four dusts collector, at a time only two nos. is in

operation.


In all there are 4 sets of Water Ring type Mechanical Exhauster foreach unit. In general two sets are in operation for each unit. Whenoperated they create vacuum, which helps in removal andconveying of fly ash from ESP & Air Heater hoppers to intermediatesurge hopper.


Atmospheric surge hopper is provided below dust collector with

surge capacity of 60 tons/ section of surge hopper. There are twosuch section in one surge hopper provided per unit.


Each section of surge hopper tank is provided with four nos.feeders. The feeders operate in cycle to discharge fly ash into thepressure conveying lines of 350 NB, in a regular manner. Thepressure conveying system evacuates ash in fly ash from surgehopper to silo/ash slurry sump. The second section of surge hopperprovided with another four feeders, which remain as standby.


There are two pressure conveying pipe lines 350 NB/400 NB, foreach unit for transportation of ash from boiler area to station


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silo/ash slurry sump. One pipe operates, keeping the other asstandby.


Four nos. twin lobe types conveying blower are provided, two foreach units. At a time only one blower is in operation for each unit.


6.3.1 SLURRY PUMP ARRANGEMENT:-

All the slurry from the plant is received in a distribution chamber.There are four slurry pump compartment and the distributionchamber has individual isolating gates with pipe for dischargingslurry into the desired pump.

6.3.2 SLURRY PUMP:-

There are four series of slurry pump. Presently there are two stageof slurry pump in each series for future extension of disposal point.

6.3.3 SLURRY DISPOSAL:-

Each series is rated for 120 TPH Ash Slurry Disposal. One suchseries has to be operated for removing Bottom Ash from one unit.Fly Ash in slurry from the silo or silo-bypass system can beremoved thereafter in a sequential manner. Two series of slurrypump operate, one for each unit while the other two remain asstandby.


Four nos. of 300 NB M.S. disposal pipeline are provided throughwhich slurry is transported. Two such pipes are operating for both

the units.

7.0 BRIEF DESCRIPTION OF FLY ASH SYSTEM:- Fly ash stored invarious hoppers is conveyed unto silos (1A+1B) or silo-bypass systemlocated in Ash Slurry Pump House of PH-II, through a vacuum-pressurecombination system followed by pressure system. The transition of vacuumsystem to pressure system takes place adjacent of ESP at a transfer pointwhere the separator isolates the fly ash from the air and allows it to passout through the Mechanical Exhauster (Vacuum Pump), where vacuum iscreated, and those equipments are located adjacent to ESP and Fly Ashequipment building. Dust separator is located over set of Hopper known as

surge hopper. The fly ash thereafter gets transferred to pressure systemfeeders below the surge hopper, where from it is transported, to plantboundary silo or silo bypass system through pressure conveying system.

8.0 INSTRUMENT AIR SYSTEM:-In PH-II, there are three nos. K.G. KhoslaCompressors Ltd., make Instrument Air Compressor each complete withelectric motor and other inbuilt features and accessories are provided tocater to instrument air requirements, for ash handling system. Out of threeInstrument Air Compressors, normally one operates to deliver theinstrument air requirements for entire system, constituting unit # 3&4. Twonos. Air Drier units each complete with its own features and accessories,

are also provided and located at discharge of Instrument Air Compressor,out of which, one Air Drier unit normally operates with the operation of one


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no. Compressor, keeping the other a stand-by. The instrument air iscatered to actuate all pneumatically operated values, bellows, ash hopperfeed gates, Nova feeder gates, dust separator gates, and other equipmentas well as to meet pulsing air requirement for vent filters. Continuouscooling water requirements for the operating I.A. Compressor, Intercoolers,after coolers, etc. is catered from plant clarified water system and thecooling water return is discharged into the seal water sump.

9.0 WATER SYSTEM:- The water supplied at bottom Ash hopper and sealwater trough (LP water pumps/service water pump) overflows from thehopper and is received in respective over flow transfer sump. The bottomash overflow transfer pumps are operated to pump out this water into thecommon clarified system. Water over flow from the clarifier is received intocollection well and is pumped beck into the ash water sump, by means ofRe-cycle water transfer pumps, as the normal input to the LP&HP waterpumps. In addition, recovery water from ash pond as and when availablethrough existing recovery water system will be recycled back into to the ashwater sump clarifier) by means of recycle water transfer pumps to provide

normal input to LP&HP water pumps during bottom ash and fly as cleaning.The return water form mechanical exhauster and air-washer during fly ashcleaning operation is received in respective drain transfer sump and isdischarged into the bottom ash, overflow transfer sump, by means of DrainTransfer pumps, for further pumping into the clarifier. The sludge pumpsbelonging to be the clarifier are operated to pump-out the accumulatedsludge from the clarifier, sludge pit into the ash slurry sump. The seal waterpumps are energized to cater to water requirement for operatingpumps/equipment-having requirement of external seal water.

10. ELECTRICAL AND INSTRUMENT:-10.1 CONTROL SYSTEM:-Necessary remote and local control panels and

control stations are provided at strategic locations to offer a dulyinterfaced and synchronized control for the overall ash handlingsystem. The System controls are provided to offer necessaryoperating interfaces among the various sub-systems to achieve aduly co-ordinated system operation from various control panels andcontrol stations. An electromagnetic relay/PLC based controlnetwork is interlocks associated with the system operation andcontrol.

Maintenance of the following Equipments

1. PROGRAMMABLE LOGIC CONTROL (PLC) UNIT:-

There are two numbers of PLC unit, one for each unit. This microprocessor -based unit is configured with Central Processing Unit, power supply unit andset of logic necessary to operate and control the fly ash system in remoteinterlocked mode. One additional CPU is provided for each PLC unit tooperate as hot stand by to operating one. The PLC systems of both theunits are supplied with a common PC based programming station for accessto the Proven logic, uploading and down loading of process control softwareand programmed print out. The PLC system of both the units is located inthe control room of the fly ash equipment building. Maintenance of followingequipments.


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2. OPERATORS CONSOLE:-

There are two operator consoles, one for each unit. This PC based operatorconsole is hooked up to the respective PLC unit for control and monitoringof the fly ash system operation. The operators console is also located in thecontrol room of the fly ash equipment building.

3. AIR CONDITONERS :-There are five no air conditioners are provided in the control room tomaintain the adequate temperature of PLC unit and operator console. Anytype of repair/ servicing of A.C.s along with gas filling shall be in thecontractors scope.

4. LOCAL PANNEL:-All local panels are located near auxiliaries.10.2. ELECTRICAL POWER FEEDING NETWORK:-

The power feeding network under system is composed of necessaryswitchgears, MCCs etc. provided at strategic location to establishefficient power distribution network. The maintenance & testing of

all such equipments like:-1. H.T. Supply 6.6 KV Supply.2. L.T. Supply 415 V Supply.3. Control Syatem Supply 240 V Supply4. D.C. Supply 220 V Supply.5. All H.T., L.T., Motors.

10.3 MAINTENANCE & CALIBERATION OF INSTRUMENTS:-1. Pressure Gauge.2. Limit Switch.3. Level Indicator.

4. Level Probe.5. Pressure Switch.6. Pneumatic Actuators.7. Motorized Actuators.8. Various types of solenoid valves.9. Vacuum Gauges.10. Diaphragm Valves.11. Temperature Gauges.12. Electrical Instruments such as CT, PT, Ammeter, Voltmetersetc.

10.4. MAINTENANCE OF VARIOUS TYPES OF RELAYS. Maintenance,Testing & Calibration of all 0.415KV and 6.6 KV relays of bus MCCand Breaker.


1. Bottom ash hopper, hopper feed gates, air water converter tanks,eccentric crusher, jet pumps, overflow transfer pumps and bottom ashslurry lines.

2. Fly ash handling system In this system each units has followingequipments:-

a. ESP hopper including diffuser feeders, ash and air intake valves alongwith other associated fittings.


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c. Branch feeder isolating valves (TERSG).d. Vacuum and pressure conveying lines.e. Mechanical exhauster, air washer and bag filters with associated piping

valves etc.f. Surge hopper including vents etc.

g. Transfer hopper with associated valves.h. Nova feeder along with associated valve and piping.i. Hydraulic exhauster system.

3. Ash slurry line pumps are in series with slurry piping valves sump etc.4. H.P. Water Pumps, Seal Water Pumps with associated piping valves sumps

etc.5. Conveying Compressor, ESP Fluidizing Blower, Nova Feeder Fluidizing

Blower & Blower heaters etc. Instrument Air compressor (Khosla make)with air drying units along with associated piping valves, coolers andfittings.

6. Silo by-pass arrangement with hydraulic exhauster etc.

7. All make up water, drain and overflow transfer pumps with piping, valves.8. All pumps and valves along with the pipelines incorporated in theclarifoculator system.

9. The slurry disposal pipelines unto the disposal point and all associatedvalves.

10. Electrical maintenance including gas filling of Air-Conditioner.

THE SCOPE OF CONTRACT ALSO INCLUDESI. PURCHASE OF SPARE AND CONSUMABLE:-

a. The contractor shall assist with planning and procurement of allneedful spares, replacement and other consumables and furnish alist of spares indicating quantity required for efficient operation of

plant for one year duration well in advance to enable MPPGCL topurchase. However the contractor has to submit the list of record ofall purchased free of supply spare/consumable per month basis toOIC along with bill.

b. The list submitted shall be verified and duly signed by OIC and onlynecessary spares will be purchased for smooth O&M of AHP.

c. The record of spares indented, consumed and balance stock shouldbe maintained in M.A.S. register and unserviceable spares must bereturned to the O&M stores.

d. The monthly rate will cover the provision of consumables likegasket, electrodes and DA & Oxygen gases etc. required for

execution of the said O&M job, excluding the supply of lubricant oil,grease and chemicals required for clarifoculator plant, which shallbe arranged by MPPGCL, free of cost. However the firm has tomaintain the proper consumption record of the consumables andspares supplied by the MPPGCL.Gasket The gasket, which is considered as a spare i.e., formed

gasket will be provided by MPPGCL, free of cost. Thecontractor shall arrange other gaskets.

Electrodes General purpose and special purpose electrodesrequired to carryout the work shall be arranged by thecontractor at their own cost.

II. All spares of the Ash Handling system required for unit # 3&4, at SGTPSsite shall be provided to the firm by MPPGCL, free of cost, for the smooth


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running of the units. However the firm will prepare and submit the list ofrequired spares to MPPGCL, will in advance to enable them to takeprocurement action. Firm will also extend necessary assistance in thisregard.

III. Carrying out routine and preventive maintenance work of running units iswithin the contractors scope. In case of any major breakdown/overhauling job required to be carried out on the following critical bought

out items where specialist services are required from suppliers, the costinvolved shall be borne by MPPGCL as per requirement of the MPPGCL.Contractor shall extend assistance and co-operation for the items asmentioned below:-

(i) Mechanical Exhauster (Vacuum Pump).(ii) Ash Slurry Pumps.(iii) Conveying Compressors.(iv) H.P. Water Pump.(v) PLC (Programmable Logic Control).(vi) Transformers.(vii) H.T. Motors.

(viii) MCC.(ix) Switch Gears.(x) H.T. Cranes(xi) UPS(xii) Various types of Relays.(xiii) Instrument Air Compressor.

IV. The repairing of diffuser feeder seats and discs, vent and equalizing valvediscs and seats, TERSG slides, discs and seats of swing gate valves, pulse

jetting cards, pressure and vacuum switches, various gauges etc. due tonon availability of spares will be carried-out by the contractor without

additional claim.V. Rewinding of L.T./H.T. Motors Rewinding of LT/HT Motors, along with

transportation cost is in contractors scope at no extra cost.VI. Repairing of Filter Bags There are 1008 bags in Bag Filter of Unit # 3&4.

The necessary repairing of these bags by stitching, replacement of clothfor the defective portion, changing of collars etc., at any place will becarried-out by contractor free of cost.

VII. Annual Overhauling The cost towards the annual overhauling of anyunits should be included by contractor in their monthly rate. In case ofannual overhauling of any units, overhauling of ash handling system hasto be carried out by the contractor on our advice; no additional payment

will be reimbursed by MPPGCL.VIII. The contractor has to ensure emptiness of all hoppers. During short

shutdown of units, Physical inspection of the hoppers shall be carried out.In case of any accumulation found inside the hoppers the same shall becleared/ cleaned through the system or manual as per instruction ofengineer in-charge.

IX. The arrangement for watch and ward personnel as may be required forAHP inside and outside of powerhouse shall remain in contractor scope.The watch and ward of the barge pump house and associated auxiliariesand pipelines going to dam are covered in this scope. Watch & ward of ashslurry pipelines recovery water pipe lines shall also in the contractor

scope.


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X. Along with the O&M work, the rotation of pipes once in a year shall alsobe in the contractor scope.

XI. Any major modification, fresh construction i.e. laying of new pipe lines,construction of brick walls etc., will not cover under the scope of thiscontract.

XII. The contractor must have arrangement of desired vehicle to shift thematerial/scrap from stores to site or vise versa for which no extra cost

shall be reimbursed.XIII. CLEANING:-The contractor shall engage labours regularly for cleaning the

area of their scope of work. Ash spread below the bottom ash area ofboiler, overflow tank, air heater, and ESP hoppers all pump house etc. hasto be cleaned daily. Fine ash dust collected has to be dump in ash slurrysump (if required) of unit 3&4 directly. The area covered under this willstart from backside of P.A. fan duct near bottom ash hoppers, air heaterhoppers & up to the last ESP hopper in the ground floor. Firm also has toensure clearness of all trenches of ash pipe lines regularly to facilitate fastmaintenance work. The decision of Engineer-In-Charge shall be final inthis regard

Superintending Engineer (MM)-IISGTPS, MPPGCL, Birsinghpur.

GENERAL TERMS & CONDITIONS

a. The employees/workers shall not any circumstances take their claim for

employment in MPPGCL.

b. During the contractual period the contractor shall be adhere to the deployment

the manpower under various categories proportionately. It is clearly understandthe one number each Mechanical & Electrical Engineer and Supervisor must bedeployed round the clock for smooth running of AHP of PH-I.

c. Contractor shall be responsible for all accident to the labour employed by him.

d. The contractor shall be responsible for any damage to the equipment due toimproper operation, fitting, and misalignment, lack of supervision and

negligence etc. by him or his workmen. Any such damage during the operationand maintenance work, the same shall be made good by the contractor. Any

damage to any other equipment of the thermal station caused due to negligence

of the contractor and his workmen during operation and maintenance of AHPshall be made good by the contractor as assessed by the Engineer-in-charge.


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e. The contract shall be govern by the Factory Act, Minimum wage Act, EPF Act,

workmen compensation Act, contractors Labours Act & other relevant act & ruleas applicable to the labours employed by him.

f. The contractor shall modified the wages period and place, time of disbursementto the workmen engaged on the work as per the payment of wages act and

contract act.

g. To felicitated prompt payment, the contractor shall obtain insurance policy to

cover all labour insurance and submit copy of all documents to the officer-in-charge.

h. Any accident shall be notified instantly to the officer-in-charge and thecontractor shall comply with the instruction issued in this behalf by the MPPGCL.

i. The contractor shall maintain all the register and documents envisaged in the

contract labour act and rules made their under. He shall also send a monthlystatement of workers engaged by him classified according to the skilled andstrength to the officer-in-charge. He shall also allow the verification of register

and documents maintained by him to the inspecting staff of MPPGCL/Govt.

j. The contractor shall note that the labour engaged by him will be working in the

vicinity of running equipments and therefore he shall proper instruction tocautious to the entire worker under their control. The MPPGCL shall not

responsible for any accident that may occur and for any compensation that may

arise out of the accident.

k. No child labour shall be engaged.

l. No advance shall be paid for the subject job/work.

m. Contractor shall obtain license from the appropriate authority under labour act

for undertaking the work and for engaging the workmen. Such license shall be

renewed from time to time.

n. In case of failing to follow statutory rules and regulation the board will be atliberty to recover such amounts from the bills or security deposit of the

contractor and also reserve the right to impose suitable penalty.

o. The contract is liable for termination within 30 days notice if the work carried

out by the contractor is not found satisfactory, security shall also be forfeit.

p. Contractor shall arrange insurance for its own men and material only.

q. Contractor shall deploy required manpower and if required shall schedule their

area of work for smooth and uninterrupted plant operation. Contractor shall be

responsible for any accident that may occur and for any compensation that mayarise of the accident.


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r. In case of delay on contractors part at any stage during the scheduled period, theMPPGCL shall have the option of insuring completion of the job by any other

means and the charges accounted on this shall be recovered from the contractorsbill or security deposit.

s. In case of failure to abide by statutory rules/regulations, the MPPGCL is at libertyto recover such amounts as required from the bills or security deposit of the

contractor.

t. Furnishing adequate technical backup by the contractor including periodical visit

to site by the Engineer for ensuring smooth operation and maintenance of AHP.

u. The contractor shall be responsible for any damage to the equipment due to

improper operation, fitting, and misalignment, lack of supervision andnegligence etc. by him or his workmen. Any such damage during the operation

and maintenance work, the same shall be made good by the contractor. Anydamage to any other equipment of the thermal station caused due to negligence

of the contractor and the contractor as accessed by the Engineer-in-charge shallmake his workmen during operation and maintenance of AHP shall be madegood by the contractor as assessed by the Engineer-In-charge. In case of failure

in doing so, a penalty @5% of the order value (maximum) shall be imposed onthe contractor.

v. In case of generation loss on account of ash handling system occurred penalty @10% shall be imposed on pro-rata basis.

w. The contractor has clean the site daily. In case, the site is not found cleaned in 24hours a penalty @ 10% of contract value maximum shall be imposed on pro-rata

basis.

x. Mobile crane required for loading & unloading shall be provided by MPPGCL free

of cost, if available.

(B) The rules & regulation of M.P. Pollution control board shall be strictly complied and

any violation thereof shall be dealt seriously. If any penalty imposed bydistrict/state/central Govt. pollution control authority due to pure maintenance of

stack emission or water effluent same shall be recovered by from the monthlyrunning bill of contractor.

SUPERINTENDING ENGINEER (P&W)

SGTPS, MPPGCL, BIRSINGHPUR


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Part-B

SCOPE OF WORK

OPERATION AND MAINTENANCE OF ASH HANDLING SYSTEM AND ITS

AUXILARIES, UNIT # 3&4 (2 X 210MW) SGTPS,BIRSINGHPUR

1.0 ASH GENERATION POINTS:-The Ash generated in the boiler iscollected under different zones as indicated below:-1.1 Furnace ash is collected at the bottom of the furnace hence called

the bottom ash.1.2 Fly ash is collected in 24 ESP Hoppers and 12 Air Heater Hoppers,

per unit.

2.0 MODE OF DISPOSAL:- Different types of Ash stored at variouslocations are disposed off, as below-

2.1 The Bottom Ash is stored in water impounded hoppers, at thebottom of the furnace, removed intermittently by operatingClinker Grinder and Jet Propulsion pump to dispose off the BottomAsh upto the Ash Slurry Sump located at Ash Pump House through

04 Nos. 200 NB pipeline.2.2 The Fly Ash from ESP & Air Heater Hoppers is collected in a dry

form through Vacuum Conveying system and transported upto thesurge tank. From the Surge Tank,Pressure System conveys the fly

ash upto the far away station silo. In case the silo is full or anymaintenance is being carried out in silo then the silo can be

bypassed and fly ash can be evacuated in ash slurry sump. A 350NB line is used to dispose off the fly ash upto the ash slurry sump

and a 400 NB line is used to transport the fly ash from ash slurrypump house to silo.

2.4 Both the Bottom Ash and Fly ash thus dumped in ash slurry sumpis pumped to the ash pond with the help of Ash Slurry Pump,which is situated around 2.5 km from ash pump house through 04

Nos. of 300 NB each lines.

3.0 ASH REMOVAL CAPACITIES:-3.1 ASH GENERATED AND SYSTEM CAPACITIES.

Specified Ash data : Ash Generation (At 100% MCR withworst coal)

Bottom Ash Hopper : 39 TPHAir Heater Hopper : 12 TPHESP Hopper : 63 TPHTotal : 114 TPH


3.2.1 Bottom Ash System (From B.A. Hopper To Ash Slurry Sump):-

2x60 TPH Through Each of 200 NB MS Pipes.


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A. Vacuum (ESP & A/H Hoppers to Surge Tank):- 2x60 TPH through8 & 9 CI & 350 NB MS Pipe.

B. Pressure (Surge Hopper to Silo/Ash Slurry Sump):- 1X120 TPHthrough 14 & 16 MS Pipe combination.

3.2.3 SLURRY SYSTEM COMMON FOR:-2x210 MW Unit.For Transporting Bottom Ash (from slurry sump to ash dam)

1x120 TPH through 300 NB MS Pipe.

4.0 ASH CLEANING TIMEThe Ash Handling System is envisaged to operate the following

duration for each of the units.4.1 Bottom Ash:- Approximately 1 Hrs per 8 hours and operate once

pershift per unit.

4.2 Fly Ash :- Approximately 4.5 hrs per shift of 8 hours per unit.

5.0 OPERATION PHILOSPHY & STANDBY EQUIPMENT5.1 BOTTOM ASH:-Bottom Ash are evacuated in sequence by operation

two diagonally opposite clinker grinder, jet pump and eccentriccrusher while keeping other two diagonally opposite sets clinkergrinder, jet pump and eccentric crusher as stand by i.e. 10%standby. Bottom Ash is evacuated to ash slurry sump through 200NB MS Pipe. In all there are four 200 NB lines, two on each side.During normal operation two evacuates bottom ash through 200 NBlines while other two remain as standby.

5.2 FLY ASH:-

5.2.1 VACUUM SYSTEM:- Sequential cleaning from ESP & Air HeaterHoppers up to the surge tank. Two Bag Filters Operate, keepingother two as standby per unit. Two Sets of water ring typeMechanical Exhauster run for 120 TPH for removal of fly ash fromESP & Air Heater Hoppers. Two sets of water ring type MechanicalExhauster remains as standby.

5.2.2 PRESSURE CONVEYING SYSTEM:- Fly Ash from surge hopper to silois transported by air pressure supplied by one number of conveyingcompressors. One number of conveying compressors remains asstand by per unit. For transporting fly ash from surge hopper tosilo/ash sump pressure conveying line is used. For four numbers of

Nuva feeder are used for feeding fly ash from surge hopper topressure conveying line, while other four remain as standby.

5.2.3 WATER AND SLURRRY SYSTEM:- One chain of H.P. Water pump andone chain of Ash Slurry pump are run per unit for removal of ashslurry from ash slurry sump and transporting it to ash dam. One setof H.P. Water Pump and one set of Ash slurry pump remain asstandby.


6.1.0 BOTTOM ASH SYSTEM6.1.1 BOTTOM ASH HOPPER:-


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Each unit is provided with one number of water-impounded Bottomash hoppers with holding capacity of 160 tones of bottom ash.

6.1.2 BOTTOM ASH HOPPER CONFIGURATION AND DISCHARGEARRANGEMENT:-

Bottom Ash Hopper is W type each V section of the W isprovided with two discharge gates, out of which normally one is tooperate during ash removal leaving other one as standby.


Each discharge gate is provided with one (1) No. Eccentric Crusherand one (1) No. Jet Pump along with other accessories. In all thereare four nos. discharge gates. Eccentric crusher can move both thedirection i.e. backward and forward.

6.1.4 BOTTOM ASH SLURY TRANSPORTATION PIPING:-

Two (2) pipes of 200 NB (MS) per unit, are provided fortransporting ash slurry from bottom ash hopper to slurry sump.

6.1.5 BOTTOM ASH OVERFLOWING FACILITIES:-There are three (3) numbers Overflowing Transfer Pump situatedjust near bottom ash hopper. These Pumps transfer the over flowwater from the bottom ash hopper, which is collected in a overflowsump, is then transferred to either ash slurry sump or clarifoculatorthrough one no. 200 NB line. At a time only one pump is inoperation.

6.1.6 BOTTOM ASH PIT CLEANING FACILITY:-

There are two no. Jet Pumps for bottom ash pit cleaning throughtwo nos. 65 NB line from pit to over flow sump.

6.2.0 FLY ASH SYSTEM:-6.2.1 REMOVAL OF ASH FROM HOPPERS:-

Vacuum in the lines connecting ESP & Air Heater Hoppers is createdwith the help of mechanical exhauster as a result of which when thegates of the hoppers open sequentially the ash from the ESP & AirHeater Hoppers get sucked and get transferred to surge hopperthrough bag filter and transfer hopper. In all there are two streams,in one stream, 12 nos. ESP hoppers and 06 nos. Air Heater hoppersare connected. At a time both the stream is in operation.


In all there are four nos. of Dust Collector. Each dust collectorsconsists of 126 nos. filter bags. The mixture of ash and airconveyed through pipelines enter the selected dust collector onconveying circuit. The combination of filter separator and transferhopper arrangement is used for continuous separation of fly ashfrom the conveying air and unloading of the free air into theintermediate surge hopper without interruption of the conveyingoperation. Out of four dusts collector, at a time only two nos. is inoperation.


In all there are 4 sets of Water Ring type Mechanical Exhauster foreach unit. In general two sets are in operation for each unit. When


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operated they create vacuum, which helps in removal andconveying of fly ash from ESP & Air Heater hoppers to intermediatesurge hopper.


Atmospheric surge hopper is provided below dust collector withsurge capacity of 60 tons/ section of surge hopper. There are two

such section in one surge hopper provided per unit.


Each section of surge hopper tank is provided with four nos.feeders. The feeders operate in cycle to discharge fly ash into thepressure conveying lines of 350 NB, in a regular manner. Thepressure conveying system evacuates ash in fly ash from surgehopper to silo/ash slurry sump. The second section of surge hopperprovided with another four feeders, which remain as standby.


There are two pressure conveying pipe lines 350 NB/400 NB, for

each unit for transportation of ash from boiler area to stationsilo/ash slurry sump. One pipe operates, keeping the other asstandby.


Four nos. twin lobe types conveying blower are provided, two foreach units. At a time only one blower is in operation for each unit.


6.3.1 SLURRY PUMP ARRANGEMENT:-

All the slurry from the plant is received in a distribution chamber.There are four slurry pump compartment and the distributionchamber has individual isolating gates with pipe for dischargingslurry into the desired pump.

6.3.2 SLURRY PUMP:-

There are four series of slurry pump. Presently there are two stageof slurry pump in each series for future extension of disposal point.

6.3.3 SLURRY DISPOSAL:-

Each series is rated for 120 TPH Ash Slurry Disposal. One such

series has to be operated for removing Bottom Ash from one unit.Fly Ash in slurry from the silo or silo-bypass system can beremoved thereafter in a sequential manner. Two series of slurrypump operate, one for each unit while the other two remain asstandby.


Four nos. of 300 NB M.S. disposal pipeline are provided throughwhich slurry is transported. Two such pipes are operating for boththe units.

7.0 BRIEF DESCRIPTION OF FLY ASH SYSTEM:- Fly ash stored invarious hoppers is conveyed unto silos (1A+1B) or silo-bypass systemlocated in Ash Slurry Pump House of PH-II, through a vacuum-pressure


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combination system followed by pressure system. The transition of vacuumsystem to pressure system takes place adjacent of ESP at a transfer pointwhere the separator isolates the fly ash from the air and allows it to passout through the Mechanical Exhauster (Vacuum Pump), where vacuum iscreated, and those equipments are located adjacent to ESP and Fly Ashequipment building. Dust separator is located over set of Hopper known assurge hopper. The fly ash thereafter gets transferred to pressure system

feeders below the surge hopper, where from it is transported, to plantboundary silo or silo bypass system through pressure conveying system.

8.0 INSTRUMENT AIR SYSTEM:-In PH-II, there are three nos. K.G. KhoslaCompressors Ltd., make Instrument Air Compressor each complete withelectric motor and other inbuilt features and accessories are provided tocater to instrument air requirements, for ash handling system. Out of threeInstrument Air Compressors, normally one operates to deliver theinstrument air requirements for entire system, constituting unit # 3&4. Twonos. Air Drier units each complete with its own features and accessories,are also provided and located at discharge of Instrument Air Compressor,

out of which, one Air Drier unit normally operates with the operation of oneno. Compressor, keeping the other a stand-by. The instrument air iscatered to actuate all pneumatically operated values, bellows, ash hopperfeed gates, Nova feeder gates, dust separator gates, and other equipmentas well as to meet pulsing air requirement for vent filters. Continuouscooling water requirements for the operating I.A. Compressor, Intercoolers,after coolers, etc. is catered from plant clarified water system and thecooling water return is discharged into the seal water sump.

9.0 WATER SYSTEM:- The water supplied at bottom Ash hopper and sealwater trough (LP water pumps/service water pump) overflows from the

hopper and is received in respective over flow transfer sump. The bottomash overflow transfer pumps are operated to pump out this water into thecommon clarified system. Water over flow from the clarifier is received intocollection well and is pumped beck into the ash water sump, by means ofRe-cycle water transfer pumps, as the normal input to the LP&HP waterpumps. In addition, recovery water from ash pond as and when availablethrough existing recovery water system will be recycled back into to the ashwater sump clarifier) by means of recycle water transfer pumps to providenormal input to LP&HP water pumps during bottom ash and fly as cleaning.The return water form mechanical exhauster and air-washer during fly ashcleaning operation is received in respective drain transfer sump and is

discharged into the bottom ash, overflow transfer sump, by means of DrainTransfer pumps, for further pumping into the clarifier. The sludge pumpsbelonging to be the clarifier are operated to pump-out the accumulatedsludge from the clarifier, sludge pit into the ash slurry sump. The seal waterpumps are energized to cater to water requirement for operatingpumps/equipment-having requirement of external seal water.

10. ELECTRICAL AND INSTRUMENT:-

10.1 CONTROL SYSTEM:-Necessary remote and local control panels andcontrol stations are provided at strategic locations to offer a dulyinterfaced and synchronized control for the overall ash handlingsystem. The System controls are provided to offer necessaryoperating interfaces among the various sub-systems to achieve a


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duly co-ordinated system operation from various control panels andcontrol stations. An electromagnetic relay/PLC based controlnetwork is interlocks associated with the system operation andcontrol.

Maintenance of the following Equipments

1. PROGRAMMABLE LOGIC CONTROL (PLC) UNIT:-There are two numbers of PLC unit, one for each unit. This microprocessor -based unit is configured with Central Processing Unit, power supply unit andset of logic necessary to operate and control the fly ash system in remoteinterlocked mode. One additional CPU is provided for each PLC unit tooperate as hot stand by to operating one. The PLC systems of both theunits are supplied with a common PC based programming station for accessto the Proven logic, uploading and down loading of process control softwareand programmed print out. The PLC system of both the units is located inthe control room of the fly ash equipment building. Maintenance of followingequipments.

2. OPERATORS CONSOLE:-

There are two operator consoles, one for each unit. This PC based operatorconsole is hooked up to the respective PLC unit for control and monitoringof the fly ash system operation. The operators console is also located in thecontrol room of the fly ash equipment building.

3. AIR CONDITONERS :-There are five no air conditioners are provided in the control room tomaintain the adequate temperature of PLC unit and operator console. Anytype of repair/ servicing of A.C.s along with gas filling shall be in the

contractors scope.

4. LOCAL PANNEL:-All local panels are located near auxiliaries.10.2. ELECTRICAL POWER FEEDING NETWORK:-

The power feeding network under system is composed of necessaryswitchgears, MCCs etc. provided at strategic location to establishefficient power distribution network. The maintenance & testing ofall such equipments like:-1. H.T. Supply 6.6 KV Supply.2. L.T. Supply 415 V Supply.3. Control Syatem Supply 240 V Supply

4. D.C. Supply 220 V Supply.5. All H.T., L.T., Motors.

10.3 MAINTENANCE & CALIBERATION OF INSTRUMENTS:-1. Pressure Gauge.2. Limit Switch.3. Level Indicator.4. Level Probe.5. Pressure Switch.6. Pneumatic Actuators.7. Motorized Actuators.

8. Various types of solenoid valves.9. Vacuum Gauges.


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10. Diaphragm Valves.11. Temperature Gauges.12. Electrical Instruments such as CT, PT, Ammeter, Voltmetersetc.

10.4. MAINTENANCE OF VARIOUS TYPES OF RELAYS. Maintenance,Testing & Calibration of all 0.415KV and 6.6 KV relays of bus MCC

and Breaker.


3. Bottom ash hopper, hopper feed gates, air water converter tanks,eccentric crusher, jet pumps, overflow transfer pumps and bottom ashslurry lines.

4. Fly ash handling system In this system each units has followingequipments:-a. ESP hopper including diffuser feeders, ash and air intake valves along

with other associated fittings.


c. Branch feeder isolating valves (TERSG).d. Vacuum and pressure conveying lines.e. Mechanical exhauster, air washer and bag filters with associated piping

valves etc.f. Surge hopper including vents etc.g. Transfer hopper with associated valves.h. Nova feeder along with associated valve and piping.i. Hydraulic exhauster system.

3. Ash slurry line pumps are in series with slurry piping valves sump etc.

4. H.P. Water Pumps, Seal Water Pumps with associated piping valves sumpsetc.

5. Conveying Compressor, ESP Fluidizing Blower, Nova Feeder FluidizingBlower & Blower heaters etc. Instrument Air compressor (Khosla make)with air drying units along with associated piping valves, coolers andfittings.

6. Silo by-pass arrangement with hydraulic exhauster etc.7. All make up water, drain and overflow transfer pumps with piping, valves.8. All pumps and valves along with the pipelines incorporated in the

clarifoculator system.9. The slurry disposal pipelines unto the disposal point and all associated

valves.10. Electrical maintenance including gas filling of Air-Conditioner.


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THE SCOPE OF CONTRACT ALSO INCLUDES

I. PURCHASE OF SPARE AND CONSUMABLE:-a. The contractor shall assist with planning and procurement of all

needful spares, replacement and other consumables and furnish alist of spares indicating quantity required for efficient operation ofplant for one year duration well in advance to enable MPPGCL to

purchase. However the contractor has to submit the list of record ofall purchased free of supply spare/consumable per month basis toOIC along with bill.

b. The list submitted shall be verified and duly signed by OIC and onlynecessary spares will be purchased for smooth O&M of AHP.

c. The record of spares indented, consumed and balance stock shouldbe maintained in M.A.S. register and unserviceable spares must bereturned to the O&M stores.

d. The monthly rate will cover the provision of consumables likegasket, electrodes and DA & Oxygen gases etc. required forexecution of the said O&M job, excluding the supply of lubricant oil,

grease and chemicals required for clarifoculator plant, which shallbe arranged by MPPGCL, free of cost. However the firm has tomaintain the proper consumption record of the consumables andspares supplied by the MPPGCL.Gasket The gasket, which is considered as a spare i.e., formed

gasket will be provided by MPPGCL, free of cost. Thecontractor shall arrange other gaskets.

Electrodes General purpose and special purpose electrodesrequired to carryout the work shall be arranged by thecontractor at their own cost.

II. All spares of the Ash Handling system required for unit # 3&4, at SGTPSsite shall be provided to the firm by MPPGCL, free of cost, for the smoothrunning of the units. However the firm will prepare and submit the list ofrequired spares to MPPGCL, will in advance to enable them to takeprocurement action. Firm will also extend necessary assistance in thisregard.

III. Carrying out routine and preventive maintenance work of running units iswithin the contractors scope. In case of any major breakdown/overhauling job required to be carried out on the following critical boughtout items where specialist services are required from suppliers, the costinvolved shall be borne by MPPGCL as per requirement of the MPPGCL.

Contractor shall extend assistance and co-operation for the items asmentioned below:-

(i) Mechanical Exhauster (Vacuum Pump).(ii) Ash Slurry Pumps.(iii) Conveying Compressors.(iv) H.P. Water Pump.(v) PLC (Programmable Logic Control).(vi) Transformers.(vii) H.T. Motors.(viii) MCC.(ix) Switch Gears.

(x) H.T. Cranes(xi) UPS


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(xii) Various types of Relays.(xiii) Instrument Air Compressor.

IV. The repairing of diffuser feeder seats and discs, vent and equalizing valvediscs and seats, TERSG slides, discs and seats of swing gate valves, pulse

jetting cards, pressure and vacuum switches, various gauges etc. due tonon availability of spares will be carried-out by the contractor without

additional claim.V. Rewinding of L.T./H.T. Motors Rewinding of LT/HT Motors, along with

transportation cost is in contractors scope at no extra cost.VI. Repairing of Filter Bags There are 1008 bags in Bag Filter of Unit # 3&4.

The necessary repairing of these bags by stitching, replacement of clothfor the defective portion, changing of collars etc., at any place will becarried-out by contractor free of cost.

VII. Annual Overhauling The cost towards the annual overhauling of anyunits should be included by contractor in their monthly rate. In case ofannual overhauling of any units, overhauling of ash handling system hasto be carried out by the contractor on our advice; no additional payment

will be reimbursed by MPPGCL.VIII. The contractor has to ensure emptiness of all hoppers. During shortshutdown of units, Physical inspection of the hoppers shall be carried out.In case of any accumulation found inside the hoppers the same shall becleared/ cleaned through the system or manual as per instruction ofengineer in-charge.

IX. The arrangement for watch and ward personnel as may be required forAHP inside and outside of powerhouse shall remain in contractor scope.The watch and ward of the barge pump house and associated auxiliariesand pipelines going to dam are covered in this scope. Watch & ward of ashslurry pipelines recovery water pipe lines shall also in the contractor

scope.X. Along with the O&M work, the rotation of pipes once in a year shall alsobe in the contractor scope.

XI. Any major modification, fresh construction i.e. laying of new pipe lines,construction of brick walls etc., will not cover under the scope of thiscontract.

XII. The contractor must have arrangement of desired vehicle to shift thematerial/scrap from stores to site or vise versa for which no extra costshall be reimbursed.

XIII. CLEANING:-The contractor shall engage labours regularly for cleaning thearea of their scope of work. Ash spread below the bottom ash area of

boiler, overflow tank, air heater, and ESP hoppers all pump house etc. hasto be cleaned daily. Fine ash dust collected has to be dump in ash slurrysump (if required) of unit 3&4 directly. The area covered under this willstart from backside of P.A. fan duct near bottom ash hoppers, air heaterhoppers & up to the last ESP hopper in the ground floor. Firm also has toensure clearness of all trenches of ash pipe lines regularly to facilitate fastmaintenance work. The decision of Engineer-In-Charge shall be final inthis regard.

Superintending Engineer (P&W)

SGTPS, MPPGCL, Birsinghpur.


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tender document for o & m of ahs & auxiliaries

Documents