tender no pser:sct:iis-t1077:10 volume id … · bharat heavy electricals limited ......

BHARAT HEAVY ELECTRICALS LIMITED (A Govt Of India Undertaking)

POWER SECTOR – EASTERN REGION PLOT – DJ 9/1, SECTOR II, SALT LAKE

KOLKATA – 700 091

TENDER NO PSER:SCT:IIS-T1077:10

VOLUME ID & II

SPECIAL CONDITIONS OF CONTRACT (SERVICE) & TECHNICAL SPECIFICATION , SCOPE OF WORK, DRAWING ETC

JOB ERECTION,TESTING & COMMISSIONING OF STEAM TURBINE & AUXILLIARIES, GENERATOR & AUXILLIARIES, BPTG, TURBO-BLOWERS, ELECTRICAL AND C&I

CAPACITY UNITS OF 3X 18 MW POWER & BLOWING STATION PROJECT IISCO, BURNPUR

TENDER DOCUMENT NO: PSER:SCT:IIS-T1077:10- VOLUME-ID & II

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TENDER DOCUMENT NO:PSER:SCT:IIS-T1077:10

VOLUME –ID & II

SPECIAL CONDITIONS OF CONTRACT (SERVICE), TECHNICALSPECIFICATION & SCOPE OF WORK, DRAWINGS,

ERECTION,TESTING & COMMISSIONING OF STEAM TURBINE & AUXILLIARIES , GENERATOR & AUXILLIARIES, BPTG, TURBO-BLOWERS, ELECTRICAL AND C&I

OF

3NOS 18 MW STG+1 NO 8.275 MW BPTG + 3 NOS TURBO-BLOWERS

(EACH 2,28,600 NM3/HR)

AT

3X 18 MW, POWER & BLOWING STATION IISCO STEEL PLANT,BURNPUR, BURDWAN,

WEST BENGAL, INDIA

(A GOVT. OF INDIA UNDERTAKING) POWER SECTOR – EASTERN REGION

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

SALT LAKE CITY, KOLKATA – 700091.


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T E N D E R S P E C I F I C A T I O N NO:PSER:SCT:IIS-T1077:10

FOR

MATERIAL RECEIPT FROM STORES/STORAGE YARD, HANDLING/RE-

HANDLING,TRANSPORTING TO PLACE OF ERECTION,STORAGE & PRESERVATION

PRIOR TO ERECTION, ERECTION, TESTING, COMMISSIONING,TRIAL RUN, PG TEST

AND HANDING OVER OF STEAM TURBINE & AUX, TURBO-GENERATOR & AUX,

BPTG, TURBO-BLOWERS, CONDENSER AND MISC HEAT EXCHANGERS, TG

INTEGRAL PIPING & AUXILIARIES, MISC PIPING, ELECTRICALS, CONTROLS &

INSTRUMENTATION, INSULATION, PAINTING ETC OF 3X18 MW STG + 1Nos 8.275

MW BPTG+ 3 NOS TURBO-BLOWERS (EACH 2,28,600Nm3/hr) AT IISCO-BURNPUR

POWER AND BLOWING STATION IN BURNPUR, WEST BENGAL.


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TECHNICAL SPECIFICATION Vol.-II+ID INDEX

Sl.No.

Description

01.

Section-I (Project Information)

02.

Section –II (General requirements & Special conditions of Contract)

03

Appendix-I (weight and list of equipments / components to be received from stores/storage yard, handled/ re-handled, transported to the place of erection, erected and commissioned by the contractor )

04.

Appendix-II (list of T&P to be provided by BHEL free of hire charges on sharing basis )

05.

Appendix-III (major tools and plants & MMDS to be deployed by the contractor )

06. Appendix-IV (list of consumables to be provided by the contractor )

07 .

Appendix-V (list of consumables/ erection material to be supplied/ made available by BHEL on free of cost basis)


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Vol.-II+ID

Section-I

Project Information

1.0 PROJECT SYNOPSIS AND GENERAL INFORMATION

IISCO BURNPUR POWER AND BLOWING STATION is setting up Steam Turbine-based power plant of 3Nos 18 MW STG+1 No 8.275 MW BPTG + 3 Nos Turbo-blowers(each 2,28,600 Nm3/hr) POWER AND BLOWING STATION at BURNPUR, BURDWAN District in the state of West Bengal, India.

The site is approachable and is connected by all weather roads as well as network of Indian Railways.

Road distance from plant site to: - Burnpur Railway Station - 2 Km (approx) - Asansol (Nearest Town) - 6 Km The nearest Airport is at Kolkata which is 200 KM from site . 2.0 SITE VISIT

Before quoting for this job, Bidders are advised to visit worksite and satisfy themselves about the worksite and working conditions thereof. Bidders shall be solely responsible for gathering first-hand information and to inform themselves fully of all local conditions and factors, which may have any effect on the work under this scope. No claim on account of lack of information/ knowledge in respect of the above shall be entertained by BHEL.


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VOL-II+ID

Section –II

General requirements & Special Conditions of Contract

INDEX CLAUSE

DESCRIPTION

1.0 SCOPE OF WORK & GENERAL REQUIREMENTS 2.0 OBLIGATIONS OF THE CONTRACTOR (TOOLS, TACKLES,CONSUMABLES, TAXES &

DUTIES ETC.) 3.0 CONTRACTOR’S OBLIGATION IN REGARD TO EMPLOYMENT OF SUPERVISORY STAFF

AND WORKMEN 4.0 OBLIGATIONS OF BHEL 5.0 INSPECTION / QUALITY ASSURANCE / QUALITY CONTROL / STATUTORY

INSPECTION 6.0 SAFETY, OCCUPATIONAL HEALTH AND ENVIRONMENTAL MANAGEMENT 7.0 DRAWINGS AND DOCUMENTS8.0 MATERIAL UNLOADING ,VERIFICATION,STACKING AND MATERIAL MANAGEMENT

ETC 9.0 TIME SCHEDULE, MOBILIZATION, PROGRESS MONITORING, OVER-RUN,

VARIATION ETC. 10.0 TERMS OF PAYMENT 11.0 EXTRA CHARGES FOR MODIFICATION AND RECTIFICATION 12.0 INSURANCE


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1.1 SCOPE OF WORK & GENERAL REQUIREMENTS The work to be carried out under the scope of these specification covers the complete work of Material receipt from stores/storage yard, handling/re-handling, transporting to place of erection, storage & preservation prior to erection, erection, alignment, hot alignment, welding, radiography, levelling, cold pulling, adjusting, heat treatment, hydraulic test, chemical cleaning, passivation, oil flushing, water flushing, air flushing, pre-commissioning tests, trial running of auxiliaries, governor setting, bearing inspection if required commissioning of steam turbines with auxiliaries, erection, testing & commissioning of generators and auxiliaries, turbo-blowers, piping, electricals, controls & instrumentation, final painting, insulation etc, and trial run/operation, assistance to PG Test, handing over to customer of 3Nos 18 MW STG+1 No 8.275 MW BPTG + 3 Nos Turbo-blowers (each 2,28,600 Nm3/hr) at IISCO-BURNPUR POWER AND BLOWING STATION at Burdwan district , West Bengal.

The work shall conform to dimensions, limits and tolerances specified in various drawings / documents that will be provided during the erection/ commissioning.

The work covered under this specification is of highly sophisticated nature, requiring the best quality of workmanship for fabrication, engineering and construction management. The contractor should ensure timely completion of work. The contractor must have adequate quantity of tools, construction aids, equipments etc, in his possession. He must also have on his rolls adequate, trained, qualified and experienced supervisory staff and skilled personnel. The entire work under this scope shall be directly executed by the contractor with their own resources; BHEL Engineers shall be available only in advisory capacity.

The intent of specification is to provide services according to the most modern and proven techniques and codes. The omission of specific reference to any method, equipment or material necessary for proper and efficient execution of this work shall not relieve the contractor of the responsibility of providing such facilities to complete the work without any extra compensation. The terminal points indicated by BHEL should be final and binding on the contractor for deciding the scope of work and effecting payment for the work done. 1.1.1 The work shall be executed under the usual conditions affecting major power plant

construction and in conjunction with numerous other operations at site. The contractor and his personnel shall cooperate with personnel of BHEL, BHEL’s customer, customer’s consultants and other contractors, coordinating his work with others and proceed in a manner that shall not delay or hinder the progress of work of the project as a whole.

1.1.2 The work covered under this specification is of highly sophisticated nature, requiring

the best quality workmanship, supervision, engineering and construction management. The contractor should ensure proper planning and successful and timely completion of the work to meet the overall project schedule. The contractor must deploy adequate quantity of tools & plants, modern / latest construction aids etc. He must also deploy adequate trained, qualified and experienced supervisory staff and skilled personnel.


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1.1.3 Contractor shall erect and commission all the equipments and auxiliaries as per the sequence & methodology prescribed by BHEL depending upon the technical requirements. Availability of materials and fronts will decide this. BHEL Engineer’s decision regarding correctness of the work and method of working shall be final and binding on the contractor. No claims for extra payment from the contractor will be entertained on the ground of deviation from the methods / sequence adopted in erection of similar sets elsewhere.

1.1.4 All necessary certificates and licenses, permits & clearances required to carry out

this work from the respective statutory / local authorities are to be arranged by the contractor at his cost in time to ensure smooth progress of work.

1.1.5. The work shall conform to dimensions and tolerances specified in the various

drawings/documents that will be provided during various stages of erection. If any portion of work is found to be defective in workmanship, not conforming to drawings or other stipulations due to contractor’s fault, the contractor shall dismantle and re-do the work duly replacing the defective materials at his cost, failing which the work will be got done by BHEL and recoveries will be effected from the contractor’s bills towards expenditure incurred including cost of materials and departmental overheads of BHEL.

1.1.6 The contractor shall perform any services, tests etc. which may not be specified but

nevertheless required for the completion of work within quoted rates. 1.1.7 All necessary certificates and licenses required for carrying out this work are to be

arranged by the contractor expeditiously. 1.1.8 The contractor shall execute the work in the most substantial and workmanlike

manner. The stores shall be handled with care and diligence. 1.1.9 BHEL reserves right to recover from the contractor any loss which arises out of

undue delay / discrepancy / shortage / damage or any other causes due to contractor’s lapse during any stage of work. Any loss to BHEL due to contractor’s lapse shall have to be made good by the contractor.

1.1.10 All cranes, transport equipment, handling equipment, tools, tackles, fixtures,

equipment, manpower, supervisors / Engineers, consumables etc. except otherwise specified as BHEL scope of free issue, required for this scope of work shall be provided by the contractor. All expenditure including incidentals in this connection will have to be borne by him unless otherwise specified in the relevant clauses. The contractor’s quoted rates should be inclusive of all such contingencies.

1.1.11 During the course of erection, testing and commissioning certain rework /

modification / rectification / repair / fabrication etc. may become necessary on account of feedback / revision of drawing. This will also include modifications / re-works suggested by BHEL / customer / other inspection group. Contractor shall carry out such rework / modification / rectification / fabrication / repair etc. promptly and expeditiously. Daily log sheets signed by BHEL Engineer and indicating the details of work carried out, man-hours etc. shall be maintained by the contractor for such reworks. Claim of contractor if any, for such work will be governed by relevant clause.


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1.1.12 The contractor shall make all fixtures, temporary supports, steel structures required

for jigs & fixtures, anchors for load and guide pulleys required for the work. However, necessary steel will be provided on returnable basis by BHEL free of charge from the scrap / surplus materials available at site.

1.1.13 The contractor shall take delivery of the components, equipments, chemicals,

lubricants etc. from the BHEL stores / storage area after getting the approval of BHEL Engineer on standard indent forms of BHEL. Complete and detailed account of the materials and equipments after usage shall be submitted to the BHEL and reconciled periodically. The contractor shall check, tally and inspect all material consignment issued to him and shall maintain proper record or the receipt of material received and such reports shall be produced by the contractor to the Engineer for verification. Any deviation from packing list or damage to any component noticed during receipt of material should be immediately brought to the notice of BHEL engineer. Any claim in this regard after receipt of material by the contractor will not be entertained.

1.1.14 Contractor shall plan and transport equipments, components from storage to

erection site and erect them in such a manner and sequence that material accumulation at site does not lead to congestion at site of work. Materials shall be stacked neatly, preserved and stored in the contractor’s shed and at work areas in an orderly manner. In case it is necessary to shift and re-stack the materials kept at work areas / site to enable other agencies to carry out their work or for any other reason, same shall be done by contractor most expeditiously. No claim for extra payment for such work will be entertained.

1.1.15 Plant materials should not be used for any temporary supports / scaffolding /

preparing pre-assembly bed etc. 1.1.16 Spring suspension / constant load hangers may have to be pre-assembled for

required load and erection carried out as per instructions of BHEL. Adjustments, removal of temporary arrests / locks, cutting of excess thread length of hanger tie-rod etc. have to be carried out as and when required. Load setting of spring hangers, as per BHEL’s documents / instructions, during various stages of erection & testing and after floating of piping / ducting during cold and hot condition will have to be done. This exercise may have to be repeated till satisfactory results are achieved.

1.1.17 Layout of field routed / small bore(up to nb100) piping shall be done as per site

requirement. Necessary sketch for routing these lines should be got approved from BHEL by the contractor. There is a possibility of changes in routing the above pipelines even after completion of erection which shall be done by contractor as part of work.

1.1.18 Welding of necessary instrumentation tapping points, Thermowell, root valves,

condensing vessels, flow metering & measurement devices and control valves to be provided on TG & its auxiliaries and integral piping are covered within the scope of this specification. The installation of all the above items will be contractor’s responsibility even if:


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a) Items are not specifically indicated under the respective product groups as given in the technical specifications.

b) Items are supplied by an agency other than BHEL.

Pre-heating, NDE and post weld heat treatment for above shall be done as per the specifications as part of work.

1.1.19 Fixing and seal welding of thermo wells & plugs before hydro test / steam blowing of

equipment or other piping system is within the scope of work. Contractor shall also remove the seal welded plugs by process of grinding and fix and seal weld thermo wells after hydro test / steam blowing of lines as part of work.

1.1.20 Actuators / drives , valves etc. may have to be serviced, lubricated, before

erection, during pre-commissioning & commissioning, including carrying out minor adjustments required as incidental to the work.

1.1.21 All electrical motors have to be tested for IR & PI values prior to the trial run. Where

required, dry out may have to be carried out by using external heating source. Contractor shall make all arrangements in this regard and complete the work as instructed. Vendor shall all necessary MMDs including the motorized insulation testers for the above test.

1.1.22 All electrical motors have to be tested for IR & PI values prior to the trial run. Where

required, dry out may have to be carried out by using external heating source. Contractor shall make all arrangements in this regard and complete the work as instructed. Vendor shall all necessary MMDs including the motorized insulation testers for the above test.

1.1.22 In installation of various equipments it may become necessary to install these on

temporary supports / hanger due to various reasons including non-availability of suspension materials. Contractor shall install such temporary suspensions / hangers and later on shift the relevant equipments to their respective permanent hangers / suspensions / supports as incidental to work. Requisite materials for such temporary arrangements will be provided by BHEL on free – returnable basis. The same shall be returned to BHEL after the use.

1.1.23 All the works such as cleaning, touch up painting, checking, aligning,

assembling, temporary erection for alignment, dismantling of certain equipment for checking and cleaning, surface preparation, fabrication of tubes and pipes, ducts, supports, as per general engineering practices at site cutting, grinding, straightening, chamfering filing, chipping, drilling, reaming, rapping, shaping, filling up etc and other works, as may be applicable in such erection works which are treated as incidental to the erection works and are necessary to complete the work satisfactorily, shall be carried out by the contractor as part of the work. All consumables including Paints for touch up painting shall have to be supplied by the contractor within the quoted rate.


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1.1.24 Minor adjustments like removal of ovalties in pipes and opening or closing the fabricated bends of high pressure piping to the layout shall be considered part of the work and the Contractor is required to carry out such work free of cost with specified heat treatment procedures.

1.1.25 Extra lengths in various fabricated ducts and piping given as erection allowance,

shall have to be cut to suit site conditions. Fabricated pipes are sent in standard lengths and will be cut to suit the site conditions and the layouts. Tubes or pipes wherever deemed to be convenient will be sent in running lengths with sufficient bends. For any mismatch while matching the joints in tubes cutting, adjusting, re-welding, addition of spool pieces should be done by the contractor to match site condition without any extra payment.

1.1.26 Dewatering arrangements in condenser pit, low point areas, basement

floors/erection and other areas are to be arranged by the contractor within the quoted rate and this facility is to be maintained by the contractor till handing over of the individual Units to the customer. No claims for whatsoever reason on this account shall be entertained by BHEL. In case of non-availability of the same facility at any point of time, the same shall be arranged by BHEL at the risk and cost of the contractor.

1.1.27 The contractor has to make a portable office for BHEL in TG floor for

meeting/discussion with necessary tube lights, fans and other fixtures like wiring etc. The required materials for office construction is to be arranged by the contractor within the quoted rate and at no extra cost to BHEL. The contractor has to arrange for filters for drinking water along with consumables/spares from time to time for arranging filtered drinking water. The contractor shall retain one office boys/peon in this office for up-keepment , documentation and other sundry jobs. This is included in the scope of work till handing over of the set to the customer and this is included in the scope of contractor’s scope of work and no payment whatsoever shall be entertained in this account by BHEL to the contractor.

1.1.28 Transportation of lube oil , special consumables, gas cylinders etc. from

BHEL/Customer’s stores, filling of lubricants, gases etc. and filling of oil for flushing, first filling and topping up till handing over the set to customer is included in contractor’s scope. The contractor shall have to return all the empty and excess drums to the customer/BHEL stores. Similarly, transport of chemicals for various pre-commissioning activities/ processes mentioned in clauses herein from BHEL/customer's stores and charging of chemicals into the system for carrying out various pre-commissioning activities and processes mentioned herein and returning of remaining and/or the empty containers of the chemicals to customer/BHEL stores is the responsibility of contractor.

1.1.29 All packing and forwarding material shall be returned as soon as the material is

unpacked. The location for storage of such materials shall be as indicated by BHEL Engineer.

1.1.30 All Measuring and Monitoring Devices (MMD) used for the work in scope of this

tender specifications, shall be calibrated by the accredited agencies who are approved by BHEL or calibration tractability is established upto National Physical Laboratory.


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1.1.31 Contractor shall furnish the consumption details of chemicals, lubricants, TIG welding filler wire, welding electrodes and other consumables on monthly basis and take prior approval as specified elsewhere.

1.1.32 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.

1.2.0 The work covered under this specification is of highly sophisticated nature,

requiring the best quality of workmanship for fabrication, engineering and construction management. The contractor should ensure timely completion of work. The contractor must have adequate quantity of tools, construction aids, equipments etc, in his possession. He must also have on his rolls adequate, trained, qualified and experienced supervisory staff and skilled personnel. The entire work under this scope shall be directly executed by the contractor with their own resources; BHEL Engineers shall be available only in advisory capacity.

1.2.1 The work shall be executed under the usual conditions affecting major power plant

construction and in conjunction with numerous other operations at site. The contractor and his personnel shall co-operate with the personnel of other agencies, co-ordinate his work with others and proceed in a manner that shall not delay or hinder the progress of work as a whole.

1.2.2 All the work shall be carried out as per the instructions of BHEL engineer. BHEL

engineers decision regarding the correctness of the work and method of working shall be final and binding on the contractor.

1.2.3 The contractor shall at his cost perform any services, tests etc, although not

specified but nevertheless required for the completion of work. 1.2.4 contractor shall erect all the equipments as per sequence prescribed by BHEL at

site. The sequence of erection, methodology will be decided by the BHEL engineers depending upon the availability of material, work fronts etc. No claims for extra payment from the contractor will be entertained on the grounds of deviation from the methods and sequence of erection adopted in erection of similar TG sets at other places or for any reasons whatsoever.

1.2.5 All the necessary certificates and licenses required to carryout this work are to be

arranged by the contractor expeditiously at his cost. 1.2.6 The work to be carried out under the scope of these specifications covers the

complete work of reloading , handling/re-handling, transporting to place of erection, storage & preservation prior to erection, preassembly, erection, alignment, hot alignment, welding, radiography, levelling, cold pulling, adjusting, heat treatment, hydraulic test, chemical cleaning, passivation, oil flushing, water flushing, air flushing, pre-commissioning tests, trial running of auxiliaries, governor setting, bearing inspection if required commissioning of steam turbines with generators and auxiliaries, fabrication, erection & commissioning


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of piping , erection, testing, commissioning of Electricals, Controls & Instrumentation final painting, insulation etc, and trial run/operation, assistance to PG Test, handing over of the unit to customer, etc. The work shall conform to dimensions, limits and tolerances specified in various drawings / documents that will be provided during the erection/ commissioning.

If any portion of the work is found to be defective in workmanship or not

conforming to drawings or other specifications, the contractor shall dismantle and re-do the work duly replacing the defective materials at his cost failing which the work will be got done by BHEL by engaging other agencies or departmentally and recoveries will be effected from contractors bill payment due either of the present contract or any other contract/work etc. towards expenditure incurred including BHEL’s overhead charges which is 30% at present.

.

1.2.7 The terminal points as indicated by BHEL shall be final and binding on the Tender. 1.2.8 The indicative schedule of weight of major equipments given in Appendix is meant

for providing a general idea only to the Tenderer about the magnitude of the work involved.

. 1.2.9 All tools and tackles, fixtures, equipments, materials, manpower, supervisors/

engineers, consumables etc. required for this scope of work shall be provided by the Tenderer within the quoted rate.

1.2.10 The contractor shall make adequate security arrangements including deployment of

security personnel and ensure protection from theft, fire, pilferage, damage and loss of materials/equipments issued to him for the work. Special care will have to be taken to guard against pilferage / theft of copper tubing, brass fittings, brass valves and other costly materials.

1.2.11 All equipments shall be handled very carefully to prevent any damage or loss. No

bare wire ropes, slings etc, shall be used for handling of the equipments without the specific permission of the engineer.

1.2.12 Contractor shall ensure proper housekeeping and remove all scrap materials at

least once in a week from various levels of power house, working area of TG, auxiliaries and piping around power station and deposit the same at the place earmarked for this purpose. In case of contractor's failure to do the same, BHEL reserves the right to do cleaning and remove scrap at contractor's cost and risk.

1.2.13 Access to site for inspection by BHEL and customer engineers shall be made

available by the contractor at all times. 1.2.14 Contractor shall mobilise sufficient quantity of wooden sleepers (on returnable

basis) for stacking of materials in his custody. Scaffolding materials to carry out jobs are to be arranged by the contractor.

1.2.15 The contractor shall weld all Thermowells, small length of pipes to all pressure,

flow and level tapping points, isolating valves and root valves on all equipment under scope of erection of this contract. All embedded temperature measuring


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elements provided in the bearings will have to be terminated at the junction box by the contractor. Thermowells, tapping point connections 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 be installed and welded. Seal welding of thermowells, even if these are erected by other vendors in the erected system of TG vendor’s scope, are to be done by the TG Contractor at no extra cost.

1.2.16 The contractor shall have total responsibility for all equipment and materials in his

custody at contractor’s stores, loose, semi-assembled, assembled or erected by him at site. He shall effectively protect the finished works from action of weather and from damages or defacement and shall also cover the finished parts immediately on completion of work as per BHEL Engineer’s instructions. The machine surfaces / finished surfaces should be greased and covered.

1.2.17 PRESERVATION & PROTECTION OF COMPONENTS At all stages of work, equipments / materials in the custody of contractor, including

those erected, will have to be preserved as per the instructions of BHEL. Necessary preservation agents , if required for the above work shall be arranged by the contractor within the quoted rate.

1.2.18 The contractor shall make suitable security arrangements including employment of

security personnel and ensure protection of all materials / equipment in their custody and installed equipments from theft / fire / pilferage and any other damages and losses.

1.2.19 The entire surplus, damaged, unused materials, packaging materials / containers,

special transporting frames, gunny bags etc. shall be returned to BHEL stores by the contractor.

1.2.20 The contractor shall not waste any materials issued to him. In case it is observed at

any stage that the wastage / excess utilization of materials is not within the permissible limits, recovery for the excess quantity used or wasted will be effected with BHEL’s standard overhead charges from the contractor. Decision of BHEL on this will be final and binding on the contractor.

1.2.21 For any class of work for which no specifications have been laid down in these

specifications, work shall be executed as per the instructions of BHEL.

1.3 COLLECTION AND RETURN OF EQUIPMENTS, MATERIALS & CONSUMABLES

All equipments of TG and their auxiliaries are received and stacked by BHEL in closed / semi-closed sheds and open storage yard. Contractor shall take delivery of equipment and all other materials from the storage yard/stores/sheds of BHEL. He shall also make arrangements for verification of equipment, safe custody, watch and ward of equipment after it has been located and handed over to him till these are fully erected, tested and commissioned and taken over by the customer. The Bidder should note that the transport of equipments to erection site, assembly yards etc should be done by the prescribed route, without disturbing the other


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works and contractors and in the most professional manner. Special equipments such as laboratory equipments, measuring and controls equipments, special electrodes, valves, shims, packing materials for joints and seals, lubricants, actuators etc, shall be stored, when taken over by the Bidder, in appropriate manner as per BHEL’s instructions.

1.3.1 The contractor shall take delivery of the components, equipments, lubricants,

chemicals, special consumables, steel etc from BHEL or Customer’s stores/storage area. The contractor shall hand over all parts, materials, consumables etc. remaining extra over the normal requirement with proper identification tags to BHEL stores. In case of any misuse or use over actual requirement, BHEL reserves the right to recover the cost with departmental charges of parts/materials used in excess or misused.

1.3.2 All material handling equipment required shall be arranged by the contractor for

locating/loading at storage yard/stores, transport to site including pre-assembly area, unloading at site/working area, pre-assembly of equipments at the fabrication yard or at working area, inspection, checking and erection except for the cranes provided by BHEL for purpose specifically identified elsewhere in this tender specification.

1.3.3 The approach road for materials movement may not be smooth. Necessary earth

filling, dressing of approach road, compaction of approach road , filling of sand bags, laying of steel plates, sands including supply of these materials are in the contractor’s scope. Even if it is required to lay steel plate the same has to be done by the contractor for crane/trailer/truck etc. movement for transportation of materials/erection activities by the contractor at no extra cost.

1.4 PREPARATION OF FOUNDATION

1.4.1 Buildings, foundations and other necessary civil works for supporting structures, equipments etc, will be provided by the customer. The checking of dimensional accuracy, axes, elevation, levels etc, with reference to bench marks, of foundations and anchor bolt pits and also adjustments of foundation level, dressing and chipping of foundation surfaces of all equipments contractor/BHEL shall prepare protocols before taking over the foundations as per relevant portion of GCC clause. Dressing and chipping of foundations upto 50mm for achieving proper levels will be within the scope of work/specification.

1.4.2 Enlargement of holes/cut outs /pockets in foundations, relocation of holes/cut

outs/pockets in foundations, making additional holes/cuts out /pockets in foundations/different floors/ walls/roofs etc. in civil related areas to accommodate equipments/ piping/system for erection of TG Equipments/ pipings. etc.

1.4.3 All minor foundations and anchor points required for installing erection equipments

like winches, anchors etc. are to be cast by the contractor. Restoration of the same is also included within contractor’ scope of work.

1.4.4 Grouting of all equipments under the scope of contractor is included in the scope of

work/specification. Supplying of Ordinary Portland Cement, Sand, Stone Chips, pea gravels & Non-shrink, free-flowing special grout cement of required specification


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(like Conbextra-GP-2 or equivalent as per BHEL/Customer’s approval) including arranging the grout mixers for this purpose shall be in the regular scope of the contractor. Arranging of all supporting materials to carry out grouting activities right from starting to curing is included in the contractor’s scope of work .Mixer machines and associated materials and T&Ps to carry out grouting job is included in the contractor’s scope of work .Contractor should also carry out cleaning of the foundation surfaces, pocket holes, anchor bolt pits and de-watering and making them free of oil, grease, sand and other foreign materials by soda washing, water washing, compressed air and other approved methods will be within the scope of this work.

Arranging all kinds of grouting materials including ordinary Portland cement, special

grout materials, sand, stone chips, gravels, plasticiser, iron fillings, rods and other supporting materials including preparation with special skeleton with necessary consumables, wooden planks, trauapalins , diesel/motor operated grout mixer machine, making chute for pouring of all Turbine, Generator, Pumps Package , other equipments including static/rotating auxiliaries , making arrangement for curing and arranging moulds of cast iron of 100 /150 mm size Cubes for testing of strength of grouted portions etc. and all supporting activities for the purpose of grouting are included in contractor’s scope of work at no extra cost.

Special care shall be taken for curing of grouts by providing old watered gunny bags or suitable arrangements round the clock. Manpower deployment for pouring water over grouts has to be retained by the contractor till successful completion of the curing.

Selection/use regarding brand of cements/grouting materials and other materials

shall require prior approval of BHEL/customer and should have valid test certificates.

As a standard practice, the manufacturer’s representatives(grout material supplier)

should be made available during application of special grouting materials during each execution time and this is included in the regular scope of contractor’s work at no extra cost.

1.4.5 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.

Machining of un-machined packer plates sent by BHEL/Units are included in

contractor’s scope including scrapping , matching etc. Additional packer plates if required, will have to be arranged and prepared by the contractor 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 contractor. 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 vendor’s scope at no extra cost.


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1.4.6 The contractor has to either own or have tie up for a work shop for machining of key ways, packer plates, hanger/support items , machining of bushes of all equipments, dowel pins ,jack bolts etc. and other machining works. The total machining jobs required during erection, testing ,commissioning, handing over of Units to customer are included in the contractor’s quoted rate. During the erection, commissioning, handing over of the set , the contractor within his quoted rate has to carry out necessary machining jobs on Main equipments and Auxiliaries like enlargement of holes by gas cutting/grinding/other machining methods and finishing, 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.

1.4.7 In addition to the above , the contractor has to arrange machining facilities for

carrying out precision machining work 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 suitable for this work during execution of the above works. The contractor’s quoted rate should be inclusive of all these type of requirements.

Turbine, Generator, Exciter Coupling holes require precision machining like

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

1.5 EQUIPMENTS INSTALLATION – COMMON REQUIREMENTS

1.5.1 Filling of lubricants for steam turbine, turbo-generator, turbo-blower and other rotating auxiliaries for purpose of oil flushing, initial fill up and subsequent topping up during operation will be issued fee of cost by BHEL. Contractor shall render all above services with manpower, T&P right from taking delivery of these lubricants (which will be in drums from BHEL/customer's stores) and return the empty drums to BHEL stores. After completion of oil flushing operation, the used oil shall be filled in empty drums and which in turn shall be returned to BHEL/customer's stores. Contractor shall be responsible for any shortage of oils/consumables/other items issued by BHEL.

1.5.2 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.


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1.5.3 Rescheduling of milestones

The activities at site will be reviewed at regular intervals and any additional mobilisation to reschedule the activities/milestones from time to time is included in the contractor’s scope at no extra cost.

1.5.4 Steam Turbine shall be supplied in assembled condition. However some items may

be supplied in loose condition which has to be assembled/erected at site by the contractor and is included in the scope of work.

Turbine centring, alignment with generator, coupling, reaming, honing are included

in the scope of work. C.E.P. will be supplied in parts. The contractor shall have to match, assemble and align at site as per instruction of BHEL engineer including placement on foundation.

1.5.5 Services of exclusive electricians & supervisors for carrying out requires support

service works during normal pre-commissioning, commissioning, trial run, handing over, stabilisation, PG Test are to be maintained by the contractor till handing over of the respective Unit to the customer within the quoted rate. This is included in the normal scope of work.

1.5.6 All works such as cleaning, levelling, aligning, hot alignment, trial assembly,

dismantling of certain equipments/ components for checking and cleaning, surface preparation, fabrication of sheets, tubes and pipes as per general engineering practice and as per BHEL engineer's instructions at site, cutting, grinding, straightening, chamfering, filling, machining, chipping, drilling, reaming, scrapping, lapping, shaping, fitting-up, drilling of holes, making dowel pins, machining of keys, minor rectification of foundation bolts/holes, machining of coupling holes, machining of hanger & support components etc. are incidental to the erection/commissioning and any other work/activity which is necessary to complete the work satisfactorily, shall be carried out by the contractor as part of the work.

Enlargement/ relocation of holes/pockets ,making dowel pin holes , arranging threading arrangements in machined holes in the equipments/system/piping are included in the scope. Material build up and dressing up in case of patch up on holes/ cut outs by material build ups are also included in the vendor’s scope at no extra cost.

1.5.7 Cleaning, servicing, greasing of actuators, pumps, headers, governing system ,

Servomotors ,valves , tanks, vessels etc. during erection and commissioning stages shall be arranged by the contractor within the quoted rate. However, gaskets / packing /special lubricants for replacement will be provided by BHEL free of cost.

1.5.8 All equipment shall be preserved and protected periodically before and after

erection as per advice of BHEL engineer. The journals of steam turbine rotors, generator rotor, HT motors and other rotating machines shall be thoroughly cleaned, greased/painted with preservative agents periodically as instructed by BHEL engineer.

1.5.9 All pipes and tube ends of TG components kept at site for erection shall be kept

protected with plastic caps/steel caps or shall be closed with wooden plugs. These caps/plugs shall be provided by the contractor without any extra cost to BHEL.


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1.5.10 The contractor shall carry out scrapping and matching of embedded plates,

permanent spacers and all the matching parts of turbine, generator, pumps and other equipments wherever required. The support and sole plates matching and concrete surface bedding is also covered in the scope of work. The fine dressing of concrete shall be with Prussian blue-match checks.

1.5.11 Packer plates shall not only be blue matched with foundations but also inter-

packer contact surfaces, contact surfaces between packer and pedestals, contact surface between packer and foundation frame etc. shall also be blue matched and required percentage contact shall be achieved by chipping and scrapping as per engineer's instructions. Necessary arrangements like providing consumables and other resources are also to be done by the contractor accordingly.

1.5.12 All necessary checks such as accuracy of levels, centre lines, bolt positions, hanger

supports, anchor/foundation bolt hole/pit positions etc. sufficiently in advance to ensure correctness of installation of all equipments covered in scope of work.

1.5.13 Trial run of all motors including checking direction of rotation in uncoupled

condition, check alignment and re-couple the motor to driven equipment. 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 and 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 number of Halogen lamps are also to be kept in stock by the contractor to take care of such kinds of activities.

1.5.14 Mount instrumentation on turbine, generator and exciter and auxiliaries which are

integral part and main equipments/skids/piping/system etc. and render necessary services for their commissioning.

Providing assistance during dismantling ,erection and commissioning of turbo-visory

and other electrical and C&I items for Turbine, Generator ,Exciter , BFPs, CEPs and other items. For this purpose, the bearing pedestals are to be opened for working by other agencies/Customer. This exercise may have to be repeated till satisfactory functioning of the items and this is treated as normal scope of work at no extra cost to BHEL.

1.5.15 Mount instrumentation on turbine, generator and exciter and auxiliaries which are

integral part and main equipments/skids/piping/system etc. and render necessary services for their commissioning. After initial trial of rotating equipments, control and power cabling for motors and other equipments/instrumentation may have to be disconnected for checking alignment and resetting/realignment/hot alignment. Contractor will have to provide services of disconnection and reconnection of control and power cables.

1.5.16 Condenser internal components/parts/surfaces have to be surface protected with

steam washable paint as per BHEL standards. The total supply of paints including original paints, primers, thinners including accessories for painting as per


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specifications/applicable codes/drawings/documents/BHEL/Customer’s instruction are included in the contractor’s scope.

1.5.17 Erection and commissioning of connecting piping – permanent and temporary for oil

purification equipments and all operations for cleaning, oil flushing, dismantling of temporary piping during pre and post-commissioning of equipment up to full load.

1.5.18 All racks or assembled units like Governing Rack, CO2 systems etc. supplied from

manufacturing units will be tested in BHEL / Customer stores or at site. This may require transportation , filling of oil, water etc. in these racks for carrying out testing of these racks. Defects noticed during erection, testing, commissioning, handing over of the Unit of these racks will have to be rectified by the contractor free of charges. Further , any pipeline / flanges / fittings/equipments not found assembled properly or part of the components received in damaged conditions from BHEL/Manufacturing Units, the same have to be rectified / corrected by the contractor free of charges. Grouting of These racks is included in the contractor’s scope including supply of required grouting and all related materials.

1.5.19 Chipping of foundation, placement, levelling, erection, alignment, setting of correct

orientation, cleaning during erection & pre/post commissioning, grouting, fixing of associated instruments with root valves & fittings and impulse piping for Tanks & vessels shall be the part of scope of work under this contract.

1.6 PIPING INSTALLATION

1.6.1 The scope of work in piping system (air, water, oil, steam ,gas etc.) will include cutting to required length, laying, edge preparation, fixing and welding of the elbows/fittings/valves/ supports/guides etc., fixing supports/hangers/shock absorbers, etc. and carrying out all other activities/works to complete the erection and also carrying out all pre-commissioning/ commissioning operations mentioned in these specifications as per engineer's instructions and/or as per approved drawings.

The contractor shall be fully responsible for completion of all formalities with CIB which are required for executing the job satisfactorily. The contractor shall do necessary co-ordination with IBR authorities at his cost. The material certificates shall be provided by BHEL.

1.6.2 Carrying out of piping as per the specifications between equipments constituting terminal points, whether the terminal equipments fall within the scope of the work/specification or not, is within the scope of the work/specification. The contractor shall complete terminal joints at both ends for all the piping schemes covered in the specification.

1.6.3 Fit up and welding of piping to the terminal points (such as stubs, valves, flanges on terminal points/equipments, stubs on headers, battery limits etc) forming part of the scope of work/specification and stress relieving and radiography of joints so made are also within the scope of work. Also, where the piping connection to the terminal points involves flanged joints as well as terminal equipment matching of flanges are to be done as per relevant clauses of GCC, fixing of gaskets, bolting and tightening as per BHEL engineer's instruction is also in this scope of work/specifications. Permanent fasteners and gaskets will be supplied by BHEL.


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1.6.4 Terminal points works of various piping schemes with customer lines and other contractor’s lines. The terminal points work is inclusive of cutting of existing lines, edge preparation, welding/blanking and hook up work.

1.6.5 The following items of work shall be incidental and forming part of piping fabrication and erection

(1) Matching of flanges for achieving parallelism and alignment by resorting to heat correction or other suitable methods as per instructions of BHEL engineers. To locate the cause of vibrations in pumps or other auxiliaries and to carry out necessary corrections in piping and its supports. This may involve cutting, fresh edge preparation, welding, radiography, stress relieving, etc of suction, discharge, re-circulation and other connected piping and its supports at a number of places

(2) Increase or decrease in length of pipes supplied, including edge preparation, fit up and welding to suit site conditions.

(3) Minor adjustment like removal of ovality, correction of bends by suitable method as directed by BHEL engineer.

(4) Fabrication and erection of racks, steel supports, guides, restraints for all the piping including of those of system piping. Steel for this purpose will be supplied by BHEL.

(5) Erection of flow switches, steam traps, filters, flow meters flow nozzles, other metering elements, flow orifices, flow indicators, valves and other instrumentation fittings supplied either by BHEL or their customer and forming part of the system. This may involve cutting of pipe lines, fresh edge preparation and welding with stress relieving.

(6) Fabrication / making of bends for pipes and tubes of diameter upto Nb 100mm (4”) with Electro-Hydraulic Pipe bending machine. Making of bends by heating/filling sand, cold bending is not allowed.

(7) Matching of all fittings like tees, bends, flanges, reducers valves, socket fittings, etc with pipes for welding. This may involve weld build up, edge preparation, etc.

(8) Servicing of valves, actuators etc.

(9) Cleaning of all pipes by wire brushing and blowing by compressed air.

(10) Removal of welding slag and burrs by hand files, with brushes and/or flexible grinders.

(11) Welding of root valves with small length of piping to the pressure, flow and level tapping points on piping or flow nozzles/orifices/metering elements fixed on piping.

(12) Welding of supports/guides/restraints as per specifications/drawings or as per directives of BHEL Engineer, to pipes using HP welders.

(13) Welding of blanks with stress relieving if required on a temporary basis.


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1.6.6 On all steam, oil, instrument, gas, air piping etc. both TIG welding and subsequent arc welding or total TIG welding process is to be adopted as instructed by BHEL engineer.

1.6.7 Pipes/tubes, which are supplied in random length, may not be in usual standard lengths. Contractor shall cut/join the pipe pieces to suit the site requirement.

1.6.8 Pipelines of oil, air, steam and water of less than Nb 100 mm will be field routed as per schemes or as per the instructions of BHEL engineer, and will be supplied in random lengths / running lengths. The contractor shall have to lay the piping according to instructions at sites, after carrying out the necessary bending, fabrication, edge preparation, routing etc. In best professional manner and as per instructions. The supports for field routed piping will be fabricated and erected by the contractor as per the requirement of the work. The steel required for the supports will be provided by BHEL free of cost.

1.6.9 Contractor shall use only bolted clamps for achieving alignment of piping. Suitable fixtures are to be prepared for the purpose.

1.6.10 All weld joints including cleat welding/spots on piping shall be ground / filed / dressed on completion of welding and before radiography as per instructions BHEL engineer. .

1.6.11 Contractor shall erect piping by doing pre-assembly on ground if possible at the first instant. The pipe laying shall be carried out from the available terminal point/points or any other area between the terminal points. The erection can be carried out on temporary supports to obtain proper alignment and welding. After fixing the permanent supports, all the temporary supports shall be removed. The alignment, distances and loading of the supports shall be checked and the required spring compression achieved in the case of spring hangers.

1.6.12 Contractor shall carryout edge preparations for welds joints / piping / pressure parts in accordance with BHEL drawings/BHEL standards/BHEL engineer's instruction. Flame cutting of piping and high pressure parts shall be strictly done as per BHEL engineer's instructions and in his presence only.

1.6.13 (a) All drains / vents / relief / escapes / safety valve piping to various tanks/ sewage / drain canal / flash box / condenser / sump / atmosphere etc. from the stubs on the piping and equipments erected by contractor is completely covered in the scope of this tender.

All the vent/drain/escape lines are to be terminated to suitable headers with funnel arrangement at different floor and subsequently to be extended to drains outside TG floor at suitable locations as decided by the customer/BHEL. For this necessary pipe and other materials required to carry out such types of jobs, shall be arranged by BHEL at free of cost. This is included in the scope of contractor’s work at no extra work to BHEL.

(b) Normally, all the weld neck valves, fittings etc. will be supplied with edges prepared. However, wherever required, in some cases, contractor will have to prepare edges at no extra cost.


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1.6.14 The C.W piping from C.W. pump house to condensers (supply) and return piping to cooling tower for all condensers for STG &TURBO-BLOWER are included in this scope.

The underground civil work including excavation back filling, sand sealing and compaction, RCC including culverts, encasing, trenches are required to be done by erection contractor.

1.7 CONDENSER INSTALLATION

1.7.1 Condensers for turbo-blowers will be dispatched in semi-assembled condition. Only shell, channel, dome, tube sheet, support plates, CW nozzles, end cover and saddle supports will be sent in assembled condition to site. Tubes will be dispatched loose and tubing is to be done at site. Hotwell connecting pieces, SS expansion bellow, standpipes, surge pipes will also be sent loose for assembly at site by contractor for all six condensers. turbo-generator condenser will be supplied in tubes and tested condition The condenser has to be assembled at site in position by welding the different parts. Condenser tubes insertion , tube expansion , tubes cutting is to be done at site by the contractor, after taking due care to clean all the tube holes. After final alignment and levelling of turbine exhaust and condenser, the same has to be welded to the exhaust position of LP exhaust as per the sequential welding procedure. Condenser Tube material is Stainless Steel. Any hole enlargement/relocation/dressing up of holes in the condenser water box/Main tube plates/tube support plates/other areas are included as regular scope of work.

Necessary scaffolding materials for carrying out condenser erection, commissioning, tubes insertion, tubes expansion, tubes cutting, erection of all works inside condenser steam space ,condenser water handling arrangements , butterfly valves , condenser tube cleaning system and to carry out all the works in TG and associated auxiliaries are to be done by the contractor within his quoted rate.

The contractor has to arrange scaffolding/ temporary platforms for taking readings of hanger/supports during running condition and even for resetting of hangers/ supports, necessary manpower with materials, other resources. This is treated as contractor’s normal scope of work.

The contractor arrange necessary cranes ands arrangements to unload condenser components and place it on foundation

1.7.2 Before insertion of tubes, the contractor shall clean the holes in the main tube plates and tube support plates to remove paint, corrosion spots, oxide scales etc. Usage of suitable cleaning agent may also be required which has to be supplied by the contractor.

Condenser floating and grouting is included in contractor’s scope of work within his quoted rate.

1.7.3 The tubes shall be expanded using an Automatic Electronic Torque Controlled Tube Expanding unit. Tube expansion shall be checked with dial bore gauge. Temporary go-no go gauge may have to be made by the contractor at no extra cost. The total set up including tube expanders and tube cutting tools for tube cutting etc. for carrying out the complete condenser tube expansion works shall be provided by


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the contractor. At least 4 sets cutting tool/expanding tool alongwith diamond cutting bits sets each with all the spares are to be kept in reserve for continuous progress.

1.7.5 The hydrostatic testing of steam space and hydraulic testing of water space along with the cooling water lines after assembly of water boxes are also included in the scope. The contractor has to arrange Fluorescence powder to conduct tube leak detection test in steam space within their quoted rate. In case of tubes leakage, the contractor has to supply required plugs and the exercise may have to be repeated within the normal scope of work till successful completion of the activity. The contractor has to arrange U/V lamp to conduct this activity.

1.7.6 Prior to hydraulic testing of water side of condenser, interior surfaces of water boxes shall be painted. Painting of all internal surfaces including supplying of paints are included in the vendor’s scope. CW piping inside is to be painted by the contractor. The outside portion of the all the pipes and fittings, valves, hangers/supports are to be painted as per applicable standard/drawings/BHEL/Customer’s instructions. .

1.7.7 After completion of tubing and tube side hydro test, all water side surfaces of water chambers including tube plate shall be painted and this painting including supply of paints are include in the vendor’s scope at no extra cost.

1.8 GENERATOR INSTALLATION

1.8.1 GENERATOR

The Generator will be supplied assembled with rotor and bearing and total weight will be 56 Metric Ton(approx.) and will be delivered to site by wagon /trailer.

The shifting of the generator from the place of storage to the unloading bay /lifting area of TG Hall and then lifting the generator on turbine deck would be done by BHEL but arrangements necessary for dragging, placement on foundation/proper elevation, alignment & welding of Generator shall be done independently by the contractor.. Necessary arrangement / T & P / Trailor etc. required for this work is included in the scope of contract.

As the Generator is coming in assembled condition, Rotor threading is not required to be done at site. However, required test and inspection is to be done at site as per instruction of BHEL Engineer.

The bidders rate in the rate/price schedule shall be inclusive of above scope of works and no separate payment will be admissible in this regard

1.9(A ) DEAERATOR AND OTHER MISCELLENOUS TANKS INSTALLATION ABOVE TG FLOOR .

1.9.A1 The contractor has to arrange his own T&P for lifting the Deaerator and Feed Storage Tank components to the nearest possible floor/elevation. Contractor has to make his own arrangement of cranes for loading at stores and unloading at site. Arrangements necessary for dragging, placement on foundation/proper elevation, alignment & welding of Deaerator & Feed Storage Tank and all other associated components shall be done independently by the contractor. Necessary rails for


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dragging has to be arranged by the vendor. Approach road may not be conducive, it may require filling of earth on the approach road, consolidation of approach road, laying of sleepers/steel plates etc. as required for easy crane movement is included in contractor’s scope.

1.9.A2 Local approach platform and approach ladders etc. for Deaerator and FST will be part of contractors work. It may be necessary to cut the structural steel and other members supplied in random length/size to required size and profile for this platform. Dressing of platform and painting are included in the contractor’s scope.

1.9(B) ELECTRICALS AND CONTROLS & INSTRUMENTATION

1.9.B1.1 All the Electrical Controls Panel, Power Distribution Board, MCC, Junction Box are to be erected with the base Channels (ISMC), which may be fabricated at site. All the structural materials will be supplied by BHEL on free of cost. All the necessary test, functional checking are to be carried out and system commissioning is to be done

1.9.B1.2.All the electronic (MAX DNA) panels are to be erected with the base channels (ISMC), which may be fabricated at site. All the structural materials will be supplied by BHEL on free of cost . All the necessary test, functional checking are to be carried out and system commissioning is to be done.

1.9.B1.3 All the loose Instruments (both field mounted & panel mounted) and control valves are to be calibrated/ checked/ set at alarm & tripping value and erected. For calibration the contractor will provide master Instruments with valid certificate of agency approved by BHEL. The Instruments are to be tested on line ,commissioned and put into service.

1.9.B1.4. The cable is to be cut from cable Drum, laid, dressed ,& terminated. All the items of required quantity i.e. PVC adhesive Tape, suitable Copper cable lug up to 2.5 sq mm, wire marker, cable binding strap shall be supplied by the contractor within their quoted price .No separate additional payment will be admissible. All the necessary test including Insulation, continuity etc are to be carried out.

1.9.B1.5. Impulse Pipes are to be cleaned by compressed air, cut ,bent with Pipe Bending Machine ,erected with proper support & Clamps and terminated .All the required GI U Clamps are to be supplied by the contractor within their quoted price. No separate additional payment will be admissible.

1.9.B1.6. The Copper tube is to be cut properly, bent using Tube Bender and laid & terminated.

1.9.B1.7. The Instrumentation job in general is to be done considering aesthetic look.

1.9B1.8. All the control loops are to be commissioned.


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1.9.B2 GENERAL SCOPE & SCOPE OF WORK FOR C&I OF BOP AREA

1.9.B2.1This specification is applicable for Control and Instrumentation of BOP area only. The proposed scope of work is generally complete one for storage,

erection, testing and commissioning under erection contract. The vendor shall make his own arrangement for all material and shall furnish a list of all erection and handling equipment he proposes to employ in the work. He will, provide and maintain at site all equipment, necessary to complete the work in time.

The tenderer is expected to be fully familiar with the local regulations

and statutory requirements and any rework, if insisted by the local authorities, the same will be carried out by the contractor at no extra cost.

It shall be the responsibility of the contractor to obtain necessary license/

work permits from the licensing board of the locality/ state/ country.

The detailed Bill of Material for this project, which the contractor has to supply/ test/ erect/ commission, is given at the end of this document. In clause no-17

1.9.B2.2 Scope of Work

The vendor shall employ skilled technicians and shall be in a position to

carryout the work as per the furnished drgs. The vendor at his own cost shall redo any work, which is not as per the drawings or does not conform to good workmanship, within the stipulated time. The contractor shall also arrange all materials required for redoing the work. The working personnel at site must be familiar with the relevant instrumentation standards

The supply, Erection/Commissioning work shall be carried out in

accordance with the specifications/drawings furnished. The layout drawing furnished is intended to give the tenderer a general idea of the type and extent of work involved. Final drawings shall be issued to the successful bidders before the start of the work at site. All equipment, materials provided by the vendor shall conform to relevant I.S or any international Standard.

The scope of work includes the following:

Complete assembly, erection, calibration, testing, commissioning and putting into successful and satisfactory commercial operation of the control and Instrumentation materials as given in Bill of materials.

a) Installation of field instruments, control valves, safety valves etc.

along with necessary impulse pipes and mounting materials as per the installation drawings.


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b) Installation of Junction boxes along with supply of necessary

angles/channels etc. The Purchaser will supply junction boxes. c) Installation and termination of cables and the supply of necessary

glands, marker wires, cable lugs, solder less terminals, Tag plates etc.

d) Installation of Transmitters along with supply of 2” pipe and necessary

brackets minimum.

e) Field instruments such as transmitters, gauges, and switches shall be grouped and mounted on a rack. This rack along with the supply of angles and channels will have to be fabricated and painted at site by vendor as per the space available. The exact grouping and rack details will be mutually worked out during the execution stage and the vendor will carryout the same at no additional cost implications.

f) The purchaser will lay 2” Instrument air header. Further distribution

starting from 2” air header upto the instrument/valve shall be done by the vendor with proper supporting and fixing of the tube/fittings as per the hookup diagrams.

g) Branch trays of 50 mm or 100 mm size trays wherever required for

laying one or two cables between the field instrument and the nearest Main tray will be supplied and erected by vendor.

h) The vendor will do complete loop-checking starting from primary field

instrument up to the secondary instrument. i) Laying of sample pipes from terminal point to sample handling

system. j) Control valve erection shall also include the erection and wiring/tubing

of related positioner, Solenoid valves, limit switches that may be supplied loose.

k) All site mounted/fabricated structures/impulse lines shall be painted

after applying two coats of primer. The final paint shall be epoxy based and the shade shall be as approved by BHEL site Incharge.

l) Making the necessary excavations and back filling to the original level

after the cables are laid wherever buried cabling is specified. m) Taking delivery of the materials from the owner’s stores and

safe transportation up to the place of erection and excess material back to owner’s stores.

n) Opening of packing cases and inspection of the equipment and

materials at site.


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o) Trial operation for seven days, rectifying defects, if any and making adjustments as necessary.

p) Handing over of installation for commercial operations. q) Re-rolling of cables on drums if so required by site engineer. r) Arranging plate inserts wherever required. s) Making as built drawings. t) Cleaning of all equipment under erection and work area at regular

intervals to the satisfaction of owner’s engineer. u) Carrying out of Touch up painting of equipment, including the supply

of paint.

1.9.B2.3 Foundation and Civil works

Equipment foundations, concrete part of the cable trenches and other civil works will be carried out by the civil contractor.

The VENDOR shall check those foundations before commencement of

erection to ensure their suitability.

All final adjustment of foundation level, chipping and dressing of foundation surfaces, setting and grouting of anchor bolts sills, inserts and fastening devices shall be carried out by the contractor.

Any cutting of masonry work, which is necessary shall be done by the

contractor at his own cost and shall be made good to match the original work. The contractor shall obtain prior approval before cutting any masonry/concrete work.

The contractor shall make his own arrangement for pumping out water

that may accumulate in any excavation or Trenches.

All cable entry openings shall be properly sealed to prevent water seepage from outside trenches/conduits into the building. The required materials for doing so shall be included by contractor in the cable laying prices.

1.9.B2.4 Instrument Calibration Procedure

Note: VENDOR shall ensure the availability of O&M manuals and Manufactures test certificates for a instrument/equipment under calibration.

VENDOR shall calibrate all field instruments in workshop, before field

installation.


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Necessary calibration report shall be generated for each tag/instruments

and shall obtained site in-charge approval before installation.

Transmitters & gauges- It shall be calibrated for 5 point calibration i.e. raising 0%-25%-50%-75%-100% and back as per calibration range. Repeating the calibration thrice shall check output repeatability. All calibration ranges for transmitters shall be as per relevant project specific document (Instrument index). It shall be calibrated by connecting air or nitrogen to transmitter process flange. Electronic calibration by connecting external signal source to transmitter’s electronic is not allowed. Contractors shall arrange nitrogen cylinders/pressure regulators etc. For displacer type level transmitters, electronic calibration is allowed.

All gauges shall be calibrated with reference to Master test gauge. Test Header etc. shall be arrange by contactor.

Smart type transmitters- First transmitter shall be calibrated with

calibrator and it shall be verified by physical calibration using air or nitrogen. Calibrated information shall be stored in calibrator, for each tag.

Field switches- It shall be calibrated for its raising/lowering set point as

per relevant project document. Repeatability shall be checked thrice, for its operation. Calibration report shall be generated for each tag.

Control Valve/On-Off SOV Valves – Its leakage class, stoke length,

actuator & positioner operation shall be checked in workshop. It shall calibrated for 5 point calibration i.e. raising 0%-25%-50%-75%-100% and back as per calibrated range. Repeating the calibration thrice shall check output repeatability. Valve shall be calibrated by connecting 0.2 to 1 kg/cm2 air or nitrogen signals to its positioner and valve strokes for 0%-25%-50%-75%-100% input signals should be verified. At the same time output from its position transmitter shall also be verified and correction shall be carry out, if required. All results shall be recorded. For SOV operated valves, operation of SOV shall be checked by energizing & de- energizing SOV coil by connecting the required voltage. SOV port operation, vent & manual reset functions shall be checked and shall be recorded accordingly.

Mass/ Vertex/turbine flow meters – Electronic calibration shall be carried out by connecting electrical signals to its electronics and 4-20mA output shall be verified with respect to calibration certificate provided by manufactures.

Safety Valves- It shall be calibrated for its raising/lowering set point as

per relevant project document. Repeatability shall be checked thrice, for its operation. Calibration report shall be generated for each tag.


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I/P or P/I Converter- It shall be calibrated by connecting 4-20mA electrical signals and its pneumatic output shall be checked. Reputability shall be carried out thrice. Its air pressure regulator shall be verified and pressure shall be set to required value.

Analyzer system(if applicable):- All analyzers shall be calibrated along

with its sensor/electrode connected to transmitter. Sensor/electrode shall be immersed in Standard solution of various known values and transmitters output & display shall be checked for its correct indication. Reputability to be checked for a thrice. Results shall be recorded.

RTD/Thermocouple- It shall be calibrated by connecting the assembly

in std. Bridge/signal source and output shall be verified at 5 points (0%-25%-50%-75%-100%) of measuring range with respect standard charts for that type of RTD/Thermocouple. These shall also be calibrated using Hot Bath equipment.

1.9.B2.5 Equipment Installation

The contractor shall carryout following: Unpack and check the system hardware/field instruments/equipments

and transport it from site stores and installation at its intended locations. Erection of impulse lines from process connection to upto field

instruments. Carry out the laying of field cables upto control room, system

communication network cables (for PLC/DCS) & fabricate and install all supplies, connections and accessories necessary to provide a complete interconnection between all equipments.

Terminate all interconnecting cables field and control room, communication network, and power & earth cable.

Test the hardware, power supplies, cabling and connections. Termination of all field cables in vendor’s marshalling cabinets, ferruling

of cables, loop checking from field sensor to system.

1.9.B2.6 Equipment Commissioning

The contractor shall carryout the following: Loop checking from control room upto final control element & vice versa

as required. Performing continuity and insulation test for all cables. Cable & cores dressing inside the control room & Junction boxes. Re-calibration of field instruments /loop if required. Contractor shall provide necessary assistance /co-operation to other

vendors for system integration, as required.

1.9.B2.7 Cabling Methods & Scope

All above ground cables from filed instruments to junction box shall be supported by suitable size of MS angle/ tray. Cable shall be fasten to tray at the interval of ½ meter.


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All underground cables from filed instruments to junction box shall be routed through buried cable conduit. Conduit shall be thoroughly cleaned before laying the cable into it.

For cables from Junction Box to Control room /field instruments shall be marked at each end close to the gland with cable no. as per cable schedule. Multi-core cable shall be marked before entry to cabinet/junction box and also inside the cabinet above & below the gland plate.

Cross and Direct ferruling philosophy shall be followed for ferruling inside instrument/ the Junction box/cabinet as follows:

Location FerrulesAt Instrument end JB No+ JBTB+ JBTE + Inst Tag+

Inst TB+ Inst TE At Junction Box, for cable from field Instrument

Inst Tag+ Inst TB+ Inst TE + JB No+ JBTB+ JBTE

At Junction Box, for outgoing multi-pair cable

Control room panel no+ TB No.+ TE no. + JB No+ JB TB+ JBTE

At control room Panel JB No+ JB TB+ JBTE + Control room panel no+ TB No.+ TE no.

VENDOR shall prepare JB terminal drawing for each JB, indicating tag nos. for instruments, JB TB &TE no, core/pair no of all incoming/outgoing cables. Such drawing shall be laminated and pasted inside the respective field junction box.

All cable entry openings shall be properly sealed to prevent water seepage from outside trenches/conduits into the building. The required materials for doing so shall be included by contractor in the cable laying prices.

1.9.B2.8 Routing for Cabling & Impulse Piping

Routing of cables between control room & junction box and with in

control room panel/switchgear room panels shall be as per project specific cable tray layout drawing.

Routes of cables & air supply lines to individual instrument from junction box/air-header to be decided at site to suit conditions.

All cables rising from trenches shall be run in trays. All cables from control room panel to junction boxes or direct run to field

instrument and from junction boxes to field instrument shall be installed in uninterrupted lengths.

All junction boxes/Inst air headers shall be located to nearest pillar/ structure/ column.

Junction boxes/Inst air headers installations shall not obstruct any traffic/passage way nor interface with accessibility or removal of process equipment

All Junction boxes/inst. Air header shall be easily accessible for maintenance purpose.

For cables raising from trench & terminating in JB, trays shall terminate 400mm below/up bottom/ top of junction box.


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Whenever possible, air supply lines shall be run below cable tray, using same support. All cables shall be clamped to tray.

Trays to individual instruments shall terminate as close as possible to instrument. Instrument support may be used to secure tray.

Tray & airline routes shown on layout are for major routes and shall be followed where possible, but if a route is not practical, an alternative route can be decided at site.

All site fabricated items, all supports or brackets needed for Installation shall be fabricated and painted by the contractor with two coats of red chromate Zinc primer and two coats of epoxy based paint of shade 631 of IS-5.

Directly buried cables shall be laid on and covered with sand/riddle with mud protected by brick barriers at sides and pre-cast concrete slabs on top. Location of buried cables shall be indicated clearly by cable marker, made of galvanized from interval of 30 meters and at every change of direction.

The location of cable Joint if any shall be clearly indicated with cable marks with an additional inscription “Cable Joint”.

Cable termination at the equipment end shall be done by the following methods:

a) Power cables : Crimping ( Hydraulic/Manual) b) Control cables & Signal cables : Manual crimping. Each control cable core entering panel / Junction box shall be neatly

dressed and served with Nylon cord to keep it in position at the terminal block.

All cable entry points shall be sealed and made vermin and dust proof. Unused opening, if any shall be effectively closed.

Damaged galvanized surface shall be coated with cold galvanized paint. All equipment after erection shall be touched up where required with

coats of finishing paint.

1.9.B2.9 Mounting of JB’s, Cable Trays & Air headers

Junction box/ Air Header normally shall be mounted to nearest column at operating height. Otherwise it shall be mounted on standpipe.

Generally, JB’s & instrument air headers shall be supported by 50x50x6 mild steel angle frame

1.9.B2.10 VENDORs shall arrange their own test equipments, erection tools, workshop equipments, erection consumables etc.

1.9.B2.11 Documentation along with Bid:

The contractor shall furnish the following along with the Bid without fail. a) Clause wise Deviation list, if any b) Testing equipment available list. c) Material handling equipment availability. d) References where such works are executed earlier. e) List of items to be supplied by VENDOR.


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1.9.B2.12 The suppliers price format shall contain the following:

a) Unit prices for all the supply items. b) Unit prices for meter length of cable/ Tray laid. c) Unit prices for the erection of various equipment and field

instruments. d) Unit prices for the Testing and commissioning of all the above

items. e) Any other unit prices, which the contractor may feel necessary.

1.9.B2.13 The following documents shall be furnished by purchaser to the successful bidder after award of the contract and the contractor shall strictly carry out the work as per these documents:

a) Cable tray layout drawing. b) Cable interconnection drawings. c) Cable schedule/JB grouping. d) Instrument Hook up drawings. e) Instrument sub-header drawings f) Control room Layout (if required). g) Instrument Index.

1.9.B2.14 All the items under the contractor’s scope of supply shall be of reputed Indian make or imported and shall be indicated in the bid in the sub-vendor’s list for each and every item and prior approval of the sub-vendors shall be taken from the owner before taking any Procurement action.

1.9.B2.15 As built drawings

VENDOR shall incorporate all corrections done during erection & commissioning of the plant and as-built drawing shall be furnished in 6 sets. Typical list is given below, however any other document required by site in charge/end user shall be furnished by contractor.

a) Cable tray layout drawing. b) Cable interconnection drawings. c) Cable schedule/JB grouping. d) Instrument Hook-up drawings. e) Instrument sub-header drawings f) Control room Layout.

1.9.B2.16 GUARANTEE:

The contractor shall stand guarantee for all the items supplied by him for 12 months from the date of the completion of the contract and shall procure and install any defective material found during that period.

1.9.B2.17 The owner will provide no electrical power supply. The contractor must make their own arrangements to meet their electrical power


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requirements .

1.10 HYDROSTATIC TESTING, PRESERVATION AND OTHER TESTS

1.10.1 Contractor shall carry out the following tests required to complete the erection and commissioning of the TG Set and auxiliaries :

(1) Hydraulic testing of individual equipments like condenser, coolers, heaters, other auxiliaries and equipments. Required capacity Hydraulic test pump/Fill pump and other necessary arrangement shall have to be arranged by contractor to carry out hydraulic testing of the equipments and piping as part of scope of work under this tender specification.

(2) Ultrasonic test

(3) Dye Penetrant test

(4) Magnetic Particle Test.

(5) Radiographic Testing

(6) Any other NDTs as required to carry out above jobs and deemed necessary

All above facilities (men, materials, equipments, consumables etc) with operating engineer/experienced person and proper approach wherever required shall be provided by the contractor for satisfactory completion of the above tests.

Any re-work for restoration of defective joints/components including arrangement for re-NDT have to be arranged by the vendor at no extra cost.

1.10.2 Contractor shall lay all necessary temporary piping, install pumps, valves,

pressure gauges, electric cables and switches etc, required for the hydro test.

After the test is over, all the temporary piping, pumps, etc will be removed. It may

also specifically be noted that servicing, erection and dismantling of piping and

equipments for conducting hydraulic test will be done by the contractor.

No separate payment shall be made for this purpose.

1.10.3 All the above tests shall be repeated till all the equipments, piping and systems satisfy the technical and statutory requirements. All related works form part of the scope.

1.10.4 Suitable welding and stress relieving of temporary blanks or suitably fixing temporary blank flanges with gaskets and fasteners and welding and providing suitable de-aeration/ venting /drain points with valves as per BHEL engineer’s instruction, for performing hydro test of piping is within the scope of work. Required valves, fasteners, blank flanges, blanks or steel for blank flan1`ges will be provided by BHEL. After completion of hydraulic test, welded blanks shall be cut and removed and weld burrs ground finished and cavities/scars of cutting weld filled and ground as per BHEL engineers’ instruction.


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1.10.5 Hydro test of piping may have to be repeated several times to meet technical and statutory requirements before application of insulation.

1.10.6 While conducting hydraulic test of steam lines, water lines, oil lines either individually or grouping a few lines or in portions. Blanks/spools may have to be put up at terminal points, strainers, walls, flanges etc. After conducting the tests, the blanks shall be removed and the lines restored. Also interconnecting piping between boiler and turbine, the hydraulic test may have to be done section wise and some –times piping of other agencies may have to be combined. Contractor shall carry out all such incidental work to satisfactorily conduct the hydro test. Wherever work is involved in the terminal points, Contractor shall carryout the same as per instruction of BHEL engineer. The decision of BHEL engineer is final and the same is binding on the contractor.

The contractor shall carry out any other tests as desired by BHEL engineers on erected equipment covered in the scope of this contract during testing and commissioning to demonstrate the satisfactory completion of any part or whole of work performed by the contractor.

1.11 PRE-COMMISSIONING TESTS, COMMISSIONING AND POST COMMISSIONING

1.11.1 The following jobs are broadly is the scope :

(a) Commissioning scope of the TG and auxiliaries shall involve the following tests and activities of the equipments erected :

(b) Trial run and commissioning of feed pumps, CEP, and various rotating machineries / pumps and other equipments under the scope.

(c) Trial run of motors for various auxiliaries. De-couplings/ Re-coupling are to be done as per requirement.

(d) Hydraulic Test of pipelines, closed systems, Tanks and Vessels.

(e) Flushing of all pipelines by air/oil/water/steam as the case may be.

(f) Servicing of all valves /actuators and fittings.

(g) 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.

(h) Arrangements for preparation and commissioning of TG, BFPs and other equipment Lub oil, control oil, jacking oil system, gas system, vapour system and other systems. The activities include hydro-test and normalisation also. All materials sent by BHEL Manufacturing Units required to carry out such kind of activities shall be issued at free of cost by BHEL. The contractor has to arrange the pump-motor set with starter etc.

(i) Mechanical seal repair/replacement /attending to oil/other leakages of pumps and other equipment.


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(j) Manual/mechanical cleaning of miscellaneous vessels, Cleaning of different strainers, filters, Cleaning of different Coolers of Turbine and Aux., other filters of Turbine, Generator and auxiliaries, cleaning of Oil tanks, Condenser (both in steam side and CW side ) Deaerator, FST, various other tanks erected by the contractor. This may have to be repeated several times during the erection/commissioning process till handing over of the Unit to customer. Necessary CAF gaskets and other resources are to be arranged by the contractor which may be required are within his quoted rate. BHEL will arrange only special gaskets.

(k) Steam Blowing, alkali flushing/water flushing, washing, air blowing, Chemical cleaning of piping systems, Deaerator and FST as per requirement. Contractor shall carry out disassembly and reassembly of vulnerable components like deaerator spray nozzles, gauges, instruments etc. as instructed by BHEL during this process.

(l) Commissioning of lub oil, control oil, jacking oil ,CO2 system ,vapour system and other system of Turbine, Generator, Pumps and other auxiliaries.

(m) Commissioning of all other packages under scope of supply.

(n) Putting TG on barring gear.

(o) Lub oil system optimisation & Governing system setting of Turbine, BFPs and commissioning.

(p) Preparation of commissioning documentation, log sheets, multiplication, photocopies , spiral binding of total volumes of protocols/log sheets for at least six sets. Total computerisation is to be done by the contractor.

(q) Commissioning of all electrical drives

(r) Commissioning of Alarm, indication,protection & interlock system.

(s) Commissioning of Turbovisory

(t) Commissioning of Control System.

(u) Rolling and synchronisation.

(v) Attending to all defect /punch/stabilisation points

(w) Full load operation.

(x) Trial operation for individual equipments and Unit as a whole for 72 hours.

(y) PG Test and submission of total documentation after multiplication and spiral binding.

The above activities/tests/trial runs may have to be repeated till satisfactory results are obtained and also to meet the technical and statutory requirements.

1.11.2 Contractor shall lay temporary pipelines with fittings and accessories etc. as instructed by BHEL engineer for the purpose of pre-commissioning and


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commissioning activities like Hydraulic testing, chemical cleaning, oil flushing, steam blowing etc. of piping and other equipments as part of the scope of work. Temporary installations shall be dismantled by contractor and returned to BHEL stores as specified elsewhere in this Technical Specifications.

1.11.3 The contractor shall provide all assistance for electrical and instrumentation testing and commissioning of equipments under this scope of work, to BHEL and their Testing & Commissioning agency.

1.11.4 The contractor shall carry out any other test as desired by BHEL engineer on erected equipments covered under the scope of this contract during testing, pre-commissioning and commissioning, to demonstrate the completion of any part or parts of work performed by the contractor

1.11.5 In case any malfunctioning and / or defect is found during tests / trial runs such as loose components, undue noise or vibrations, bearing temperature rise , any kind of leakages or passing etc. strain on connected equipments etc. The contractor shall immediately attend to these defects/ malfunctioning and take necessary corrective measures. If any readjustment and realignments are necessary, the same shall be done as per BHEL engineer’s instructions, free of cost treating it as normal scope of work at no extra cost to BHEL.

1.11.6 Cleaning of vessels /oil tank/Other equipments by sand blasting or other methods as per instructions of BHEL engineer before and before/after oil flushing and other cleaning is responsibility of contractor.

1.11.7 The contractor shall associate for initial and subsequent fillings of gas in generator gas system as and when required till unit is handed over to Customer at no extra cost to BHEL.

1.11.8 Replacing/changing mechanical/other seals, Bearings inspection /replacements, changing and cleaning of all kinds of filters/strainers, lub oil optimisation of equipment, pumps, Turbine, Generator and other auxiliaries under the scope etc. during commissioning stage is within the scope of work. This exercise may have to be repeated as per the requirement at no extra cost. Similarly necessary assistance for facilitating opening of bearing pedestal covers for turbo-visory inspection and other jobs in connection with opening of Turbine. Generator, Exciter bearing pedestals may have to be repeated till handing over of the set to customer. Assistance for calibration of turbo-visory instruments are to be provided by the contractor within the quoted rate.

1.11.9 During the stages of commissioning, and till Unit is handed over to Customer, if any part of TG and auxiliaries need repair/rectification/rework/replacement, the same shall be done expeditiously and promptly by the contractor. Contractor’s claim if any, for such repair/rectification/rework/ replacement etc. for reasons not attributable to the contractor, will be governed by clauses 13.1 to 13.8 of the specification. The parts to be replaced shall however, be provided by BHEL free of cost.

1.11.10 During this period, though BHEL’s and customer’s engineers will also be associated in the work, the contractor’s responsibility will be to make available


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resources in his scope till such time the commissioned units are taken over by the customer.

1.11.11 In case any malfunctioning and/or defects are found during tests, trial run such as loose component, undue noise or vibration, bearing temperature rise problem, strain on connected equipment etc., The contractor shall immediately attend to these defects/ malfunctions and take necessary corrective measures. If any readjustment or realignment is necessary, same shall be done as per BHEL engineer’s instruction. This is included in the normal scope of work at no extra work.

1.11.12 The pre-commissioning activities will start prior to oil flushing of the TG and various trials, commissioning operations shall continue till the TG and Aux. is handed over to customer. Simultaneous commissioning checks, activities will be in progress in various areas like trial run of various equipment, checking of equipment erected, making ready for trial runs, filling up of lubricants, chemicals etc. All these works need specialised gangs including electricians, Instrument Technicians, Fitters, in each area to render assistance to BHEL commissioning staff. Contractor shall earmark separate manpower for various commissioning activities. This manpower shall not be disturbed or diverted. The mobilisation of these commissioning gangs shall be sufficient so that planned commissioning activities are taken up in time and also completed as per schedule and the work is to be undertaken round the clock if required.

1.11.13 Contractor shall cut open works/equipments/piping/system if needed as per BHEL engineer’s instructions during commissioning for inspection, checking and make good the works after inspection is over, without any extra payment.

Servicing and preservation of valves/actuators and other requirements right from receipt from BHEL Store till handing over of the Unit to the customer including arrangements of lapping pastes and other consumables are included in the vendor’s scope.

1.11.14 During pre-commissioning & commissioning time, it shall be the responsibility of contractor to provide following minimum manpower along with Engineer/supervisor as part of commissioning jobs till handing over of the set to the customer .

Manpower module strength(minimum)

1) Engineer 2 Nos.

2) Pipe fitter/Millwright fitter 2 Nos.

3) welder 2 Nos.

4) Rigger 3 Nos.

5) Electrician/instrument technician 2 Nos. each

6) unskilled worker 6 Nos.

1.11.15 The above figures shows only minimum required over and above labour required for completing regular and pending erection and commissioning works


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and clearing of punch lists. Contractor has to provide number of personnel and other resources as per work demand.

1.11.16 It shall be specifically noted that above employees of the contractor may have to work round the clock along with BHEL commissioning engineers during normal working hours and OT hours including working on normal days, Sundays, holidays. The contractor has to make necessary adjustment accordingly at no extra cost to BHEL.

1.11.17 During commissioning, opening of valves/actuators, changing of gaskets, checking, realigning of rotating and other equipment, cleaning of all kinds of filters/strainers, filling /topping up of oils, fluids, filling/purging of gases , attending to leakages in piping, tanks etc. And adjustments of erected equipment may arise. Valves /actuators /equipments/systems shall be repaired/serviced/tuned/readjusted and lubricated to the satisfaction of BHEL engineer during the erection and commissioning as per BHEL engineer’s instructions. This is treated as normal scope of work.

Arranging petrol, CTC, rubber hoses of different sizes as per requirement gaskets and other standard consumables for opening , cleaning of condenser, deaerators, strainers are included in the contractor’s scope at no extra cost till handing over of the Units to the Customer .

1.11.18 It is the responsibility of the contractor to provide for necessary resources till the completion of work under these specification, even in case erection, testing and commissioning of the TG and other equipments are delayed due to reasons not attributable to the contractor.

1.11.19 The contractor shall have to deploy exclusive manpower(1 mechanical fitter+1 helper) for commissioning of electrical & pneumatic actuators under BHEL commissioning engineer.

1.12 WELDING AND HEAT TREATMENT

1.12.1 All electrodes and filler wires shall be procured by the Contractor within the included scope of work. All electrode/filler wire supplied by BHEL/Manufacturing Unit shall be issued free of cost by BHEL. The contractor has to maintain proper accountability of the electrode/filler wires issued by BHEL.

1.12.2 The selection and use of electrodes will be as per the standards and specifications of BHEL.

1.12.3 Contractor should purchase the electrodes as per the recommendations of BHEL engineer, welding manual, welding schedule and other relevant documents. The electrodes shall be purchased only from BHEL approved manufacturers.

1.12.4 The purchase of electrodes shall be accompanied by proper test certificates and these certificates should be submitted regularly for the scrutiny of BHEL engineer.

1.12.5 All electrodes shall be stored in a clean dry area. The storage room shall be of permanent nature and damp proof, and the room shall be exclusively meant for storage of welding electrodes and filler wires. Excepting for a vent in the top, it is not preferred to have any other opening like windows or ventilators. The


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temperature inside the room has to be kept in the range of 8-100 c above atmospheric temperature and humidity should be less than 50%. This is to be accomplished by using electric heaters or infra red lamps. The storage room must be provided with hygrometer and thermometer. Temperature and humidity are to be monitored regularly. 15-20 holders, welding cables, connecting cables to equipments and other welding accessories including temporary electrical connection from construction power point to individual equipment like winches, hoisting equipment, welding generators, transformers, heat treatment equipment and other construction equipment shall be arranged by contractor.

1.12.6 All racks and other items used for storage of electrodes shall be of steel and not of wood.

1.12.7 All electrodes soon after purchase shall be offered for inspection to the BHEL engineer. Contractor shall be strictly prohibited from using electrodes not inspected/approved by BHEL engineer.

All related portable baking ovens for storing/maintaining required temp. range for welding electrodes with proper validity certificates of ovens in adequate quantities are to be maintained by the vendor till completion of the work.

1.12.8 All welding consumables shall be issued to the welders only by authorised person who is controlled by contractor’s welding engineer. The necessary baking requirements are to be ensured by Contractor’s welding engineer.

1.12.9 All welders shall be tested and approved by BHEL engineer/customer before they are actually engaged on work though they may possess the requisite certificate. BHEL reserves the right to reject any welder without assigning any reasons. Statutory requirements like IBR approval for welders are to be complied with before starting of the work. If required, the welders may have to undergo Procedure Qualification test also. The decision of BHEL Engineer will be final in this regard.

1.12.10 All charges for testing of contractor’s welders including destructive and non-destructive tests conducted by BHEL at site shall have to be borne by the contractor including supply of test plates for testing of welders. The materials for testing of welders like plates, pipes both for IBR/Non-IBR welders including making fixtures & payment of statutory charges are included in the scope of work at no extra cost.

1.12.11 BHEL engineer is entitled to stop any welder from his work if his work is unsatisfactory for any technical reason or if there is a high percentage of rejection of joints welded by him, which, in the opinion of BHEL engineers, will adversely affect the quality of welding though the welder has earlier passed the tests prescribed. The fact that the welders have passed the test, does not relieve the contractor from his contractual obligations to check the performance of the welders. Contractor shall submit a monthly performance record of all welders.

1.12.12 All welded joints shall be subject to acceptance by BHEL engineer whose decision will be final and binding.

1.12.13 Pre-heating and stress relieving before and after welding are part of erection work and shall be performed by the contractor in accordance with instructions of BHEL engineer. Contractor has to arrange for the recorders along with


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accessories and suitable technicians for heat treatment purpose. The temperature recorders and thermocouples shall be duly calibrated. During preheat and stress relieving operations the temperature shall be measured as per the instructions of BHEL engineers by thermocouples and recorded graphs for the heat treatment works carried out shall be the property of BHEL.

1.12.14 For the purpose of stress relieving, thermocouples have to be attached to the weld joint. The number of temperature measuring points and locations are as per the standards of BHEL. Thermocouples have to be attached using battery operated portable thermocouple attachment unit and not by manual arc welding. Contractor shall arrange sufficient number of thermocouple attachment units.

1.12.15 Wherever necessary, contractor should provide temperature indicator/temperature recorder as required by BHEL engineer for measuring preheat temperature for welding or for controlling temperature of metal for hot correction etc. Decision of BHEL engineer on method and of checking preheat temperature or controlling temperature for hot correction and welding shall be final and binding on contractor.

1.12.16 Heat treatment may be required to be carried out at any time (day or night) to ensure the continuity of the process. The contractor shall make all necessary arrangements including labour required for the same as per directions of BHEL.

1.12.17 Heat treatment requirements shall be as per the Welding Schedules of BHEL

1.12.18 For weld joints of vessels, equipments, heavy structural items like beams, I-sections, if heat treatment is required, the same shall be carried out as part of the work.

1.12.19 Checking effectiveness of stress relieving by hardness tests (either by Poldi Hardness Tester or other approved test methods as per BHEL engineer’s instruction) including necessary testing equipments is within the scope of the work/specification.

1.12.20 TIG welding process is to be used for all root pass welds in pipes. Subsequent welding after root pass can be carried out by manual metal arc welding with basic coated electrodes. For the pipe of thickness less than 6mm, the entire welding has to be carried out by TIG welding. However, BHEL site engineer will have the option of changing the method adopted. For manual arc welding shall be done as per weaving technique and the width of weaving shall not exceed 1.5 times of the dia of the electrodes.

1.12.21 Two pieces to be joined shall be individually checked for the weld edge preparation and profile dimensions and with respect to the template. Dye penetrant check shall be carried out on edge prepared surfaces at random. The percentage shall depend on piping system as specified by BHEL engineer.

1.12.22 Joint fit up will be a stage for inspection.

1.12.23 All joints shall be offered for visual inspection after root run. Subsequent welding should be made only after the approval of root run.


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1.13 RADIOGRAPHY

1.13.1 Radiographic inspection of welds shall be arranged by the contractor including all consumables like isotope camera, x-ray film, chemicals etc. Scaffolding and approaches for taking radiographs.

The necessary skilled technician and labourers for taking the radiographs shall be provided by the contractor. While taking radiographs, the contractor has to use proper penetrameter/ image quality indicators as instructed by the BHEL engineer. All the processed and accepted films will be the property of BHEL. In this regard, the contractor has to adhere to the safety rules/regulations laid by BARC authorities from time to time. It may please be noted that invariably the radiographic work will be carried after the normal working hours.

1.13.2 Contractor shall note that 100% radiography shall be taken on all high pressure welding till such time the welders’ performance is found to be satisfactory. Subsequently, subject to consistency in welder’s performance, the percentage of radiography will be based on BHEL’s standard practice/IBR/code requirement. The defects shall be rectified immediately and to the satisfaction of BHEL engineer. The decision of BHEL engineer regarding acceptance/rejection of the joints will be final and binding on the contractor.

1.13.3 Wherever radiographs are not accepted, on account of bad shot, joints shall be re-radiographed and re-shots submitted for evaluation. Radiographs shall be taken on joints after carrying out repairs. However, if defect persists after first repair, as per radiograph, carrying out repairs and radiography shall be repeated till joint is made acceptable in case, the joint is not repairable, the same shall have to be cut and repaired at contractor’s cost. Decision of BHEL engineer in all these matters is final and binding on the contractor.

1.13.4 100% radiography of weld joints of certain piping have to be carried out as per BHEL standards/drawings/specification.

1.13.5 It may also become necessary to adopt inter-layer radiography/MPT/UT depending upon the site/technical requirement necessitating interruptions in continuity of the work and making necessary arrangements for carrying out the above work. Necessary trained personnel shall be deployed for this purpose.

Conductance of all kinds of NDTs are in contractor’s scope including arrangement of support of manpower, consumables and all incidental charges are included as contractor’s scope of work.

1.14 CHEMICAL CLEANING/ACID CLEANING / ALKALI FLUSHING / STEAM BLOWING / OIL FLUSHING /OTHER BLOWING AND OTHER CLEANING ETC.

1.14.1 Contractor shall lay temporary pipelines with fittings and accessories and also erect/commission pumps after servicing as per requirements, tanks and other installations, as a system as instructed by BHEL for the purpose of chemical cleaning, steam blowing, steam washing, steam flushing, water flushing, water washing, oil flushing etc. of piping and other equipments which are within the scope


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of work and also systems in which equipments and piping erected by contractor form a part of the scope of work.

It shall be specifically noted by the contractor that all pipes for above works shall be supplied in random length and in loose condition. Contractor has to assemble and erect them as per schemes / drawings provided by BHEL. Further, flanges , bend etc. for completing the scheme shall be machined/ fabricated by the contractor at his own cost . However, plates / steel etc. for the same will be provided by BHEL free of charges.

1.14.2 After the chemical cleaning has been successfully completed, dismantling of all temporary installations as instructed by BHEL is within the scope of work under this specification. The dismantled materials shall be dressed and returned to BHEL as stated elsewhere in this tender specs.

1.14.3 Preservation of the cleaned surfaces will be the responsibility of contractor under the guidance of BHEL engineer.

1.14.4 Hydraulic test of temporary piping is to be carried out as per the instructions of BHEL Engineer. Carrying out repairs, if any, is in the scope of work/specification.

1.14.5 For chemical cleaning of the piping system, contractor will have to lay temporary piping to connect the entire system irrespective of whether the equipment/system connected is in the scope of contractor or not. Decision of BHEL Engineer in this regard will be final and binding on the contractor.

1.14.6 During the initial stages of work, trenches for draining water may not be available after alkali flushing or mass flushing for discharging and emptying. Necessary low point drains and temporary piping for this will have to be provided by contractor from materials provided by BHEL treating it as normal scope of work.

1.14.7 Laying effluent discharge line from mixing tank (for acid cleaning or any other chemical cleaning process) as per the instructions of BHEL engineer and dismantling, servicing for preservation and handing over the same to BHEL stores after completion of the job is within the scope of work/specification.

1.14.8 Radiographic examination of weld joints on temporary pipes as required by the Engineer In-charge should be carried out as a part of normal scope of work.

1.14.9 Contractor shall also carry out the repairs or attend leaks etc., in the temporary piping and equipments for the above operations / activities while carrying out the above activities / operations.

1.14.10 For chemical cleaning of system which consist of equipment/piping erected by the contractor and also equipment/piping erected by other contractors of BHEL/customer’s contractor has to arrange for workers and supervisory staff as required supplementing/complimenting the labour and supervisory staff mobilised by other agencies for chemical cleaning of the portion of equipment erected by them in the system. Decisions on the strength of gangs and supervisory staff for deployment of labour and allocation of work for them at site, by BHEL engineer is final and binding on the contractor.


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1.14.11 Contractors quoted rate shall be inclusive of fabrication, cost of consumables, erection, dismantling of temporary piping and servicing of the equipments and valves and handing over to BHEL.

1.14.12 After acid cleaning/pickling ,hot water flushing as applicable of control/lubricating and other system(including oil piping, oil tank and other fittings) of rotating machines, oil flushing for lubricating systems as per instructions of BHEL Engineer shall be carried out. Cleaning of oil tank of lubricating oil system of rotating machineries, cooler etc. before and after oil flushing is the responsibility of the contractor.

1.14.13 For full welding of structures, tanks and piping etc., only welding generators shall be used. The use of welding transformers will be subject to the approval of BHEL Engineer.

1..15

1.15.1 Contractor shall mount all flow indicators, centrifugal/speed switches of motors, accumulators, pressure regulators, etc which are received loose and which are to be erected/mounted at site on air lines, water lines, oil lines, steam lines, auxiliaries and firemen floor and other operating floors on boiler/power house and other equipments. These are to be mounted during erection for finalising routing/position etc. They are to be dismantled after completion of erection work and handed over to BHEL for calibration. After calibration, these instruments shall be remounted by the contractor in their respective positions just before commissioning.

1.15.2 Certain instrumentation like, pressure gauges, power cylinders, flow meters, valve actuators, flow indicators, etc are received in assembled condition as integral part of equipments. Contractor shall dismantle such equipment at an appropriate stage under the instruction of BHEL and hand them over to BHEL for calibration and storage. Contractor shall re-erect them in position just before commissioning of the equipment.

1.15.3 Seal welding of Thermowells, plugs before Hydro-test of equipments and piping systems is also within the scope of this work/specification. Contractor shall also remove the seal welded plugs by process of grinding and fix and seal weld Thermowells after Hydro-test / steam blowing of lines.

1.15.4 Providing necessary engineer/supervisors/technicians/electricians as required by BHEL engineer for drying out the LT/HT motors /electrical panels etc.under the scope of contractor is within the scope of the work. Job includes testing the motors/equipments for finding out PI & IR values and making necessary cabling connection for heating for dry out from the nearest source of supply and maintaining and controlling the temperature till the IR and PI values are achieved as per standards. The contractor will provide necessary motorised insulation testers for this purpose. The contractor shall lay necessary power/control cables, lugs, glands, crimping facilities for drying out and other tools and consumables for the above works free of charges. BHEL shall issue only power cables free of cost for this purpose, however the contractor has to receive the cable from BHEL/Customer’s store and return in safe working condition after the activities are completed. Before undertaking dry out/trial run of HT motors, the end shields


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and covers shall be opened on both the ends of the motor for inspection, cleaning and greasing of bearings.

1.15.5 Welding of all Thermowells, draft, pressure and temperature instrumentation points, and all other instrumentation points on piping, and auxiliaries is within the scope of this work.

1.15.6 All the HT Motors shall be preserved with space heaters on, and provided with proper cover till the commissioning of the motors.

1.16 GENERAL

1.16.1 During the course of erection, platforms and floor grills are to be cut at certain places to route steam, oil, water and air piping, cable trays, etc or for accommodating erection, rigging etc, the cutting of platforms and grills should be minimum and as approved by BHEL engineer. After completion of work, the platform/grills cut shall be made good neatly as instructed by BHEL engineer.

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. 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.

1.16.2 Erection and welding of stainless steel pipes, fittings, valves and other items has to be done by the contractor including supply of necessary stainless steel welding electrodes and is within contractor’s scope of the work/specification.

1.16.3 No temporary supports should be welded on to the piping. No temporary shed/office with wooden materials are allowed inside the Premises.

1.16.4 Contractor shall carry out preservation painting on all items taken from stores. The preservation painting has to be carried out on material taken from stores and also on material erected wherever the shop painting has given away. Periodical inspection shall be made as per the instructions of BHEL engineer and the portion of items or the complete items needing painting shall be carried out to the satisfaction of BHEL engineer. This facility shall be provided by the contractor till the commissioning and handing over of the equipment to the customer. Preservative and touch up painting on equipments covered under this specification stored at stores/storage yard shall also be carried out by the contractor at no extra cost.

1.16.5 The contractor shall return to BHEL the excess materials left over after completion of work, materials issued for temporary pipelines for HT, chemical cleaning, oil drums, containers, packing materials, flushing, blowing etc. and materials issued on returnable basis in neatly dressed condition. Necessary grinding, edge cutting (square facing), edge preparation (vee), painting etc. to the condition similar to the one at the time of issue shall be in scope of work.


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1.16.6 Mobilisation at Site with all resources are to be done by the contractor within 15 days after getting written instructions for starting of Works in TG & aux. Set .Regular manpower reporting has to be submitted by the contractor to BHEL from the date of starting the work.

1.16.7 All kinds of NDTs as per documents/drawings/standards are included in contractor’s scope of work within his quoted rate at no extra cost to BHEL.

1.17 PG TEST

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.

For PG Test purpose, the vendors shall perform the following activities

Receiving all the PG test materials including electrical, instruments, mechanical items

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.

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.

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

Attending to passing valves.

Cleaning of passing valves.

Cleaning of condenser tubes with high pressure jet cleaning/Condenser steam space inspection and cleaning/inspection & cleaning of condenser CW side.

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

Calibration of all instruments.

Replacement of spool pieces/regular flow elements with PG Test Flow nozzles/orifices. In case the pipelines are having insulations, the same is to be


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removed (both wool and Al/G.I.Sheeting cladding) and these are to be carefully preserved for restoration after completion of PG Test. This is treated as normal scope of work.

Arranging additional lighting arrangements during PG test .

Arranging additional watch and wards for protection of PG Test instruments and items.

Exclusive supervisors for conductance of PG Test.

Manpower for arranging taking PG Test readings manually(around 10 staff during PG Test exclusively for this purpose)

Arranging two number of computers 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 .

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

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

Dismantling of PG test instruments and all related piping etc.

Returning all instruments and impulse piping and other total items.

Packing of all PG Tests items in boxes for despatch.

Restoration of PG Test flow nozzles/orifices with spool pipes/regular flow elements.

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.

Removal/restoration of thermal of thermal insulations/sheeting required after PG Test completion is included in contractor’s scope of work.

1.19 WELD FIT-UP AND WELD JOINT PROTECTIVE PAINT, COMPONENT PRESERVATIVE

PAINTING, & FINAL PAINTING ETC.

All protective paints for the protection of weld joint fit-ups, application of primers on finished weld joints are in the scope of contractor.

1) Adequate number of coats of steam washable paints shall be applied on steam side of turbine and condenser components, as advised by BHEL. The steam washable paints, primer and thinner will be arranged by the vendor and , arrangements for surface preparation and paint application like sand/shot-


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blasting, consumables like surface cleaning agents, paint brush, brush cleanser, labour and necessary tools and plants are in the scope of contractor.

2) All site weld joints falling in steam side shall be painted with two coats of steam washable paint to be arranged by the vendor.

3) All water side surfaces of water chambers , water boxes including tube plate shall be thoroughly surface prepared and painted. Required primer & paints and other consumables for condenser water box and tube plates shall be provided by Contractor within the quoted rate.

4) Preservation of all components/equipments during various stages of erection, commissioning till handing over is in the contractor’s scope. All prescribed methods of surface cleaning prior to application of preservative paint shall be followed by the contractor. Contractor has to arrange all primer and paints, and other consumables like wire brush, painting brush required for this work.

5) Final painting :The scope shall include supply and application of Primer ,final paints as required and specified for the components of Turbine, Generator, Condenser and auxiliaries ,Pumps packages, equipment ,systems, pipings etc within the quoted rate. Arrow marking with nomenclature in English/Hindi or in both languages on the erected system are also included in the scope of work. Even painting with bands and arrows with heat resistant paints in high temperature application zones with arrow and nomenclatures are also included in the scope. The contractor has to arrange required thinner, paints and other supporting materials with resources are included in contractor’s scope. Regarding selection of brands, types of paints and related items, the contractor has to take prior approval of BHEL/Customer. The contractor has to apply painting as per applicable code/instruction of BHEL/Customer to achieve required thickness. The contractor has to arrange one calibrated “coatmeter” for thickness checking. `

6) The total activity of painting including arrangements all materials, manpower and accessories to carry out paintings plus making scaffolding as per requirement is include in the contractor’s scope of work. Before arranging all kinds of materials about paints, the contractor has to take prior approval from BHEL/Customer regarding grade/supplier. Valid certificate also has to be arranged for this purpose.

2.0 OBLIGATIONS OF THE CONTRACTOR (TOOLS, TACKLES,CONSUMABLES

ETC.) 2.1 ACCOMMODATION FOR THE LABOUR / OTHER EMPLOYEES

The contractor has to arrange accommodation and transportation for his staff and workers of his own within his quoted rate.

2.2 TOOLS AND TACKLES, MEASURING AND MONITORING DEVICES: 2.2.1 The contractor shall provide all T&Ps as per Appendix-III (excepting those in BHEL

scope as mentioned specifically ) required tools and plants, monitoring and measuring devices (MMD) and handling & transportation equipments for the scope of work covered under these specifications.


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The contractor has to arrange for regular statutory /fitness certificates arranged for his own T&Ps, MMDs from appropriate/statutory authorities for contractor’s own T&Ps ,MMDs at regular intervals within their quoted rate.

2.2.2 For free issue of cranes by BHEL on sharing basis , the contractor has to

necessary 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. No payment on whatsoever account for this job shall be entertained by BHEL.

2.2.3 Contractor shall provide the complete operating crew like operator, helpers for

handling trailing cable for EOT Cranes for working in TG Hall within their scope of work at no extra cost to BHEL.

It may be specifically noted that the EOT crane shall be shared by many other agencies working within the TG hall. The contractor shall have to extend the services of the EOT crane operation to all such other agencies as instructed by BHEL. This services of cranes operation is expected to be carried in normal and extended hours on working days including OT hours in normal working days/Sundays/Holidays. This is included in the scope of work at no extra cost.

2.2.4 Contractor has to arrange slings of all sizes for completing the works covered

under these specifications . 2.2.5 All tools and tackles to be deployed by the contractor for the work shall have the

prior approval of BHEL engineer with regard to brand, quality and specification ,fitness for use, validity, calibration etc.

2.2. 6 Timely deployment of adequate quantity of T & P is the responsibility of the

contractor. The contractor shall be prepared to augment the T & P at short notice to match the planned programme and to achieve the milestones.

2.2.7 Complete set of hydraulic jacks of 50 tonnes and 100 tonnes capacity shall be

arranged by the contractor for use during erection and commissioning of Turbine , Generator and other auxiliaries. These jacks shall of internationally reputed make, highly reliable and maintained in excellent working condition. They shall be tested for safe working before deploying in actual work. These jacks shall not be permitted for use anywhere other than Steam-Turbine / Generator area. Sufficient spares for these jacks/pumps like “O” rings ,gaskets, washers, hydraulic fluids is included in contractor’s scope of work.

2.2.8 In the event of contractor failing to arrange the required tools, plants, machinery,

equipment, material or non-availability of the same owing to breakdown, BHEL will make the alternative arrangement at the risk and cost of the contractor.

Necessary scaffolding materials of steel pipes and pipe clamps, planks, G.I.Sheets and other related materials for working at height/inside enclosed space are to be arranged by the contractor within the quoted rate. Total scaffolding materials for platform etc. are to be provided by the contractor within the quoted rate.


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2.2.9 The T&P to be arranged by the contractor shall be in proper working condition and their operation shall not lead to unsafe condition. Contractor shall obtain prior approval of BHEL for all the T&P before deploying in actual work. The movement of cranes, and other equipment should be such that no damage / breakage occurs to foundations, other equipments, material, property and men. All arrangements for the movement of the T&P etc shall be the contractor’s responsibility.

2.2.10 Normally, use of welding generators only is permitted for welding. The use of

welding transformers will be subject to prior approval of BHEL. 2.2.11 The contractor at his cost shall carry out periodical testing of his construction

equipments and calibration of Measuring & Monitoring Devices (MMD). Test / Calibration certificates shall be furnished to BHEL. MMD shall be calibrated only at accredited laboratory as per the list available with BHEL or any other laboratory approved by BHEL. All calibration shall be traceable to national or international standards.

2.3 CONSUMABLES 2.3.1 The contractor shall provide all consumables required for carrying out the work

covered under these specifications excepting those which are specifically indicated as BHEL scope.

TG Special Consumables like Hylomar, Golden Hermetite, Stag-B, Molykote , Anabond compounds, Locktite, Rubber fixing compounds/rubber hoses ,petrol,CTC etc. will have to be arranged by the contractor within the quoted rate. Erection, commissioning jobs should not suffer due to non-availability of these types of consumables. Failure to arrange the same in time may call for BHEL’s intervention and BHEL shall arrange the same at contractor’s risk and cost with BHEL’s standard overhead charges.

2.3.2 All consumables/special materials/cements/paints etc. arranged by the contractor

to be used for the work shall have prior approval of BHEL engineer with regard to brand and quality specifications. Test reports / certificates in respect of these consumables, wherever applicable, shall be submitted to BHEL engineer.

2.3.3 PRIMERS & PAINTS

The vendor will provide paint & primer for finish paintings total area of applications like Turbine, Generator, Condenser, BFPs, CEPs and other auxiliaries including arranging all associated arrangements like spray guns, brushes, nozzles etc. within quoted rate. Painting is to be done as per BHEL/customer’s instruction/applicable code/drawings/documents. Required thickness is to be achieved as per customer’s requirement. Painting thickness measuring instruments is to be arranged by the contractor within quoted rate.

2.4 WELDING ELECTRODES, FILLER WIRES FOR TIG WELDING AND GASES 2.4.1 All welding consumables including electrodes/SS Electrodes/filler wires is in the

contractors scope.


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Any TIG/Filler wire supplied by BHEL Manufacturing Unit shall be issued free of cost by BHEL.

2.4.2 All the required welding electrodes as approved by BHEL shall be arranged by

contractor at his cost. It shall be the responsibility of the contractor to obtain prior approval of BHEL , before procurement, regarding manufacturer, type of electrodes etc. On receipt of the electrodes at site, it shall be subject to inspection and approval by BHEL regarding type of electrodes, batch number, date of expiry etc. Batch test certificates shall be made available for verification & record before the actual use of the welding consumables.

BHEL reserves the right to reject the use of any electrodes, if found non-acceptable because of bad quality, deterioration in quality due to improper storage, shelf life expiry, unapproved type / brand etc.

2.4.3 The contractor shall provide all consumables required for carrying out the

work covered under this scope of work including TIG/Filler wires for welding of piping joints.

2.4.4 All the required gases like Argon, Oxygen, Acetylene etc shall be arranged by the

contractor at his cost. 2.5 FIELD OFFICE 2.5.1 The contractor shall make his own arrangements for field office and stores for

accommodating necessary equipments, tools room for execution of the work. Only open space will be provided by BHEL / customer, free of charges within the project premises as per the availability of space. Wooden structure of sheds/office inside the premises is not allowed.

2.5.2 On completion of work, all the temporary buildings, structures, pipelines, cables,

etc shall be dismantled and leveled and debris shall be removed as per instruction of BHEL by the contractor at his cost. In the event of his failure to do so, the same will be arranged to be removed and expenditure thereof will be recovered from the contractor. The decision of BHEL engineer in this regard shall be final. However, the scope of dismantling and leveling the area is limited only to the contractor’s site office, yard and other spaces occupied by the contractor.

2.5.3 Computer facility

The contractor has to make their own separate arrangements for their portion of computerisation /MIRs/other activities.

2.6 AREA LIGHTING 2.6.1 Contractor shall arrange adequate floodlights, hand lamps and area lighting.

Contractor shall use his own materials like cables, fuses, switch boards etc.


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2.7 CONSTRUCTION POWER & WATER 2.7.1 Construction power ( three phase, 415v / 440v, 200 amps, 4-wire) will be provided

at one point near the site free of charge. Accordingly, all cables, fuses, distribution boards, switches, switchboards, bus bars, earthling arrangements, protection devices e.g. ELCB, if any, and any other installation as specified by statutory authority, client in this regard, for drawl of construction power shall be arranged by the contractor. Obtaining approvals, payment of necessary fees, duties etc towards the clearance of such installations, if any, prior to these being put to use or as may be specified, shall be the responsibility of the contractor. The contractor has to lay construction power cables in such a fashion , so that it is not drawn along the main structures of TG building columns. Cables are to be laid from below TG Floor. The cables re-shifting/redressing ,if required on a later date is also included in the contractor’s scope.

2.7.2 Construction and drinking water inside the plant will be provided at ONE point at

free of cost and further branching is to be arranged by the contractor for further distribution and other arrangements within the quoted rate.

2.7.3 In case of non-availability of customer supplied power, it is the responsibility of the

contractor to make alternative arrangements. Contractor shall be adequately equipped to arrange standby in the event of construction power failure. Essential welding jobs should not be stopped on account of main construction power failure. Power failures/low voltage or fluctuation of voltage can not be excuse for delay in execution of projects. No additional payment on this account shall be made to the contractor by BHEL.

2.7.4 BHEL is not responsible for any loss or damage to the contractor’s equipment as a

result of variations in voltage or frequency or interruptions in power supply. Contractor shall take suitable insurance policy for such accidental loss/ damages.

2.8 RESPONSIBILITIES WITH REGARD TO LABOUR EMPLOYMENT ETC. 2.8.1 The contractor has to follow relevant clauses of General Conditions of Contract in

this regard in this regard. 2.8.2 Contractor shall also comply with the requirements of local authorities/ project

authorities calling for police verification of antecedents of the workmen, staff etc.

Exclusive planning engineer/supervisor, QA and Safety Engineer/officer are to be arranged by the contractor within the quoted rate.

2.8.3 BHEL / customer may insist for witnessing the regular payment to the labour. They

may also like to verify the relevant records for compliance with statutory requirements. Contractor shall enable such facilities to BHEL / customer.

2.8.4 It is the responsibility of the contractor to arrange gate pass for all his employees,

T&P etc for entering the project premises. Necessary coordination with customer


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officials is the responsibility of the contractor. Contractor to follow all the procedures laid down by the customer for making gate passes. Where permitted, by customer / BHEL, to work beyond normal working hours, the contractor shall arrange necessary work permits for working beyond normal working hours.

Arranging all erection/commissioning fixtures including required materials and fabrications etc. are included in the contractor’s scope of work.

2.8.5 Contractor shall provide at different elevation suitable arrangement for urinal and

drinking water facility with necessary plumbing & disposal ,regular cleaning ,upkeepment arrangements including construction of septic tank. These installations shall be maintained in hygienic condition at all times. Contractor’s quoted rate should be inclusive of this aspect. If at any time during the execution of work, it is noticed that the work is suffering on account of non-availability/shortfall in provision of resources from the contractor’s side BHEL will make suitable alternate arrangements at the risk and cost of contractor. The expenditure incurred with overheads thereby shall be recovered from the contractor.

2.9 TAXES, DUTIES, LEVIES TAXES, DUTIES ETC 2.9.1. All taxes (except service tax), WCT under VAT act, duties, charges etc. for execution of the contract

shall be borne by the contractor and shall not be payable extra. Any increase of the same at any stage during execution of the contract shall have to be borne by the contractor. The contractorr accepted price shall be inclusive of all such requirements.

2.9.2 Service tax (including educational cess) as legally leviable & payable by the contractor under the provisions of applicable law / act shall be paid by BHEL as per the contractor’s bill. However, the contractor shall have to submit proof of service tax deposited by them immediately after the deposit but not later than the next bill submitted after the due date of deposit. The contractor shall furnish proof of service tax registration with Central Excise Division covering the services covered under this contract. Registration should also bear endorsement for the premises from where the billing shall be done by the contractor on BHEL for this project. The contractor shall obtain prior approval of BHEL before billing the service tax amount. 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 into account the benefit of above provisions as the cost of input to the contractors will be the cost net of excise duty and service tax and adjust the contractor’s offer price accordingly to make it more competitive. As such, the contractor’s quoted rate is Exclusive of the Service Tax (including educational cess). Any changes in Service Tax rules (by Government) shall be complied with.

2.9.3 Value Added Tax (VAT) - the contractor should be registered under State VAT Act of West Bengal. The contractor should produce the contractor’s Registration No. and copy of Registration certificate as proof of registration and the contractor shall produce proof of payment of VAT so that BHEL as main contractor can get the benefit of deduction of input credit from the contractual transfer price under WBVAT Act. The contractor should produce the contractor’s Tax Invoice, copy of tax paid challan, copy


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of returns showing BHEL portion of job value separately and other necessary documents to BHEL as required under VAT Act/ Rules so that BHEL can avail input credit under VAT Act.

2.9.4 New tax & 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 on production of relevant supporting document to the satisfaction of BHEL.

2.9.5 However, the contractor shall obtain prior approval from BHEL before depositing new taxes and duties.

2.10 SUBMISSION OF PERIODICAL REPORTS

Contractor shall submit periodical reports in respect of following aspects of operation: 1) Consumption of consumables like welding electrodes, gases and paints 2) Consumption of construction power 3) Re-conciliation of issued materials and it should be regularly updated. 4) Availability and utilization of BHEL’s Tools & Plants 5) Availability and utilization of contractor’s Tools & Plants 6) Daily manpower and progress reports 7) Daily ,weekly, monthly progress reports/reviews of activities & incidents 8) Calibration reports 9) Records of wages payment 10) Any other report/record as may be specified by BHEL/client. 11) Progress photographs on monthly basis for at least 10

activities/events/visits of dignitaries both in the form of still photography/digital ( 5 sets each).

This is included in the contractor’s scope of work at no extra cost to BHEL.

Non-submission of regular reports and photography will call for penal recovery by BHEL from contractor’s RA Bills etc. and shall be @ Rs.2,000/- for each activity and for each incidence.

3.0 CONTRACTOR’S OBLIGATION IN REGARD TO EMPLOYMENT OF SUPERVISORY STAFF AND WORKMEN

3.1 The contractor shall deploy all the skilled/semiskilled/ unskilled labour including

highly skilled workmen etc. These workmen should have previous experience on similar job. They shall hold valid certificates wherever necessary. BHEL reserves the right to insist on removal of any employee of the contractor at any time if he is found to be unsuitable and the contractor shall forthwith remove him. Contractor should furnish a tentative deployment plan of his manpower as required vide Appendix-VI. Also the actual deployment will be so as to satisfy the erection and commissioning targets set by BHEL.

3.2 It is the responsibility of the contractor to engage his work men in shifts and or on

overtime basis for achieving the targets set by BHEL. This target may be rescheduled/set to suit BHEL’s commitments to its customer or to advance date of completion of events or due to other reasons. Additional resources may have to be arranged by the contractor from time to time to meet target at no extra cost. The


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decision of BHEL in regard to setting the erection and commissioning targets will be final and binding on the contractor.

3.3 Contractor shall deploy only qualified and experienced engineers/ supervisors.

They shall have professional approach in executing the work. 3.4 The contractor’s supervisory staff shall execute the work in the most professional

manner in the stipulated time. Accuracy of work and aesthetic finish are essential part of this contract. They shall be responsible to ensure that the assembly and workmanship conform to dimensions and tolerances given in the drawings/instructions given by BHEL engineer from time to time.

3.5 The supervisory staff employed by the contractor shall ensure proper outturn of

work and discipline on the part of the labour put on the job by the contractor. Also, in general they should see that the works are carried out in a safe and proper manner and in coordination with other labour and staff employed directly by BHEL or other contractors of BHEL or BHEL’s client.

3.6 If at any time, it is found that the contractor is not in a position to deploy the

required engineers/supervisors/workmen due to any reason, BHEL shall have the option to make alternate arrangements at the contractor’s risk and cost.

3.7 SITE ORGANISATION

The contractor shall provide adequate staffing in the following areas in addition to the staffing requirements of execution as instructed/informed by BHEL: Overall Planning, Monitoring & Control Quality Control and Quality Assurance Materials Management Safety, Fire & Security Industrial Relations and fulfilment of Labour Laws and other statutory

obligations. 3.8 ERECTION SCHEDULE

The Contractor has to submit Net-work programs for the erection and commissioning of various items including handing over to customer. These programs for the erection and commissioning would clearly identify responsibilities of the Contractor and Owner/ BHEL. Total Networks for Erection ,commissioning works till handing over activities shall be submitted to BHEL by the contractor within 4 weeks of the date of finalisation of award of work / placement of LOI.

3.9 SUPPORT SERVICES FOR BHEL SITE MANAGEMENT The contractor shall provide BHEL site exclusively with following manpower to assist BHEL in Site Establishment/Guest House till completion of the contract period.


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The contractor shall provide BHEL site exclusively with following manpower to assist BHEL in Site Establishment till completion of the contract period. a) Four semi-skilled manpower for BHEL office/Guest House for exclusive service/usage of BHEL for record keeping. Deduct the amount as per following from Contractor's RA bill or any other dues:

@ Rs 5000 ( five thousands) /month for each manpower for no. of days of non service on pro-rata basis. (for a above) .

b) One experienced supervisor and four computer operator for BHEL Office for

exclusive service/usage of BHEL. If contractor fails to provide manpower as above for a continuous period of 07 days or more, BHEL shall have the right to apply the following alternative:

Deduct the amount as per following from Contractor's RA bill or any other dues:

@8000(eight thousands)/month for each experienced supervisor and @ Rs 6500(six thousands and five hundreds)/month for each computer operator for no of days of non-service on pro-rata basis.(for b above)

Contractor may specifically note that all statutory requirements like payment of regular wages, PF, Gratuity, Medical, Insurance, bonus etc. in respect of above mentioned manpower(a & b above) is to be fulfilled by them within quoted rates and BHEL under no circumstances shall be responsible for non-fulfillment of above.

Manpower identified as above to be mobilized as under.

(1) Category - a - Within one month from the LOI date.

(2) Category –b - Within one month from the LOI date.

3.10 CONSTRUCTION MANAGEMENT 3.10.1 Based on the PERT Network program, within 15 days from the of the Contract, the

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

The contractor should submit the list of Construction Manager, Engineers, Supervisors and related manpower with bio-data and experience at all levels for acceptance by BHEL. The concerned people should have adequate experience to handle 30 MW TG & Aux. Works. BHEL may refuse to accept inexperienced people of contractor. In case of such type of incidence, the contractor has to


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arrange proper manpower. Similarly, in case of misbehaviour by contractor’s manpower , the contractor has to withdraw his respective individual and suitable replacements are to be provided by the contractor.

3.10.2 The program would be jointly finalised by the site in-charge of the contractor with

BHEL/owner's project coordinator as well as the site planning representative. The erection program with also identify the sequential erectable tonnages.

3.10.3 The contractor shall provide following services exclusively for BHEL IISCO

BURNPUR site within his quoted lumpsum rate

In case contractor fails to provide above services, BHEL reserves the right to recover Rs 6000/ month from R/A bill of contractor

3.11 PROJECT PROGRESS REVIEW MEETINGS

Periodic progress reviews on the entire activities of execution in respect of supply & works in scope of bidder will be held once in a month . These meetings are to be attended by reasonably higher officials of the Contractor and will be used as a forum for discussing all areas where progress needs to be speeded up. Actions will be placed on the concerned agencies and decisions will be taken to expedite/speed up the progress. Minutes of such meetings will be issued reflecting the major discussions and decisions taken and circulated to all concerned for reference and action. The contractor shall be further responsible for ensuring that suitable steps are taken to meet various targets decided upon such meetings.

In addition to the above and to streamline the construction and erection at site a suitable frequency and forum of periodic meetings between the contractor and the Owner/BHEL will be decided upon as part of erection coordination procedure.

3.12 CERTIFICATE TOWARDS COMPLETION

The work under the scope of the contractor will be deemed to be completed in all respects only when so certified by BHEL. The decision of BHEL shall be final and binding on the contractor.

4.0 OBLIGATIONS OF BHEL

4.1 FACILITIES TO BE PROVIDED BY BHEL

4.1.1 Construction Power - Already covered in clause 2.7.1

4.1.2 Drinking water - Already covered in clause 2.7.3

a) Providing assistance for various

infrastructural services for proper maintenance of BHEL IISCO BURNPUR site office.

12 MAN MONTHS


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4.1.3 Construction Water - Already covered in clause 2.7.3

TEST MATERIALS (PLATES & PIPES)

BHEL will not provide any plates or pipes for site test of welders including IBR welders before their deployment and all destructive and non-destructive examinations of test blanks / pieces and the same shall be in the scope of contractor. Responsibilities with regard to deployment of IBR welders and meeting the stipulations shall be the responsibility of contractor within their quoted rate.

4.2 FILLER WIRE FOR TIG WELDING

All filler wires (except special filler supplied by BHEL/Manufacturing Units as free issue ) shall be arranged by the contractor.

4.3 EQUIPMENTS – TOOLS & PLANTS

BHEL will make available only those T&P’s that are listed in Appendix-III free of charge. Other required T&P’s shall be arranged by the contractor. Further details are as under:

4.3.1 BHEL will make available on shareable basis, free of hire charges, services of equipments and T&P indicated in Appendix-III. As most of the equipments will be in the custody of BHEL and have to be shared among other contractors, the requirements shall be indicated to BHEL sufficiently in advance and finalise allotment of the same. It may be noted that the contractor has to deploy all necessary tools & plants to suit the activity schedules given by BHEL/ Customer. T&P being supplied by BHEL are only to supplement the resources deployed by the contractor.

4.3.2 EOT crane of customer will be provided free of charge for activities of handling & erection within TG Hall. No electricity charges shall be debited to the contractor for operation of TG Hall EOT Crane.

EOT crane in TG hall will be issued on need basis and is to be shared with other contractors. Qualified & Experienced operators are to be provided by the contractor on full time basis. Carrying out routine maintenance / servicing, providing manpower, tool & tackles for any repair / rectification of the cranes is also in the scope of the contractor. The quoted rates shall be inclusive of the above.

The EOT Crane operator are to work in extended hours on week days/Sundays/holidays in addition to working in normal working hours on normal working days. EOT Cranes are to be shared among all other vendors/Customer and the vendor has arrange operators accordingly. The number of operators may have to be increased as per the job requirement at no extra cost to BHEL. No separate payment on account of arranging EOT cranes shall be entertained by BHEL On whatsoever account.

In case of other hoists/EOT Cranes operation in the areas of vendor’s Erection/Commissioning purview, the vendor has to arrange suitable operator(s) within the quoted rate at no extra cost to BHEL.

4.3.3 All arrangements, including providing & laying of sleeper beds/still plates etc.,

backfilling of approaches wherever necessary for safe movement of the cranes as directed by BHEL shall be the responsibility of the contractor. Sleepers for this


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purpose shall be provided by the contractor. Steel plates, if required shall be issued on free of cost basis. The contractor has to arrange loading, transportation, making approach road for transportation of steel plates, unloading of steel plates and returning to BHEL Store/designated place with reloading, re-transportation, unloading once again within his quoted rate.

4.4 OTHER T&Ps 4.4.1 Special tools which are supplied by BHEL MUs as part of maintenance tools to be

handed over to customer under regular Packages / DU / Dess Numbers in various product groups, may be issued to the contractor free of charges for specific activities only, at the discretion of BHEL. Contractor shall return them in good working condition after the completion of the specific activity for which the tools were spared.

4.4.2 All the tools and plants issued to contractor will be inspected periodically by

BHEL engineer. In case contractor fails to make good, the damages caused, BHEL will do the same at contractor’s cost. The tools and tackles will be issued only to persons nominated by the contractor.

4.4.3 Required temporary structural steel, pipes & fittings, valves for conducting

hydraulic test, chemical cleaning / steam blowing / oil flushing / acid cleaning /other cleaning operation etc shall be provided by BHEL on free and returnable basis.

4.5 CHEMICALS, GASES AND LUBRICANTS FOR PRE-COMMISSIONING AND

COMMISSIONING 4.5.1 All lubricants and chemicals required for testing, chemical cleaning, acid cleaning,

oil/chemical/gas flushing required for testing, pre-commissioning & commissioning up to trial operation of equipments/unit will be provided by BHEL FREE OF COST Contractor shall arrange for taking delivery and loading of all such consumables from BHEL/ Customer Stores/ yard, transportation to site of work and unloading thereon, filling in the system and return the used lube oil, balance quantity of consumables etc, to BHEL stores duly reconciled for quantity.

This is included in the contractor’s scope of work.

5.0 INSPECTION / QUALITY ASSURANCE / QUALITY CONTROL / STATUTORY INSPECTION

5.1 Various inspection/quality control/quality assurance procedures /methods at various stages of erection and commissioning will be as per BHEL/customer quality control procedure/codes/IBR and other statutory provisions and as per BHEL Engineer’s instructions.

5.2 Preparation of quality assurance log sheets and protocols with customer’s engineers, welding logs and other quality control and quality assurance documentation as per BHEL Engineer’s instructions, is within the scope of work/ specification. Total documents for erection, commissioning, trial run, handing over, PG Test reports, Logsheet/ Protocols has to be compiled, multiplied, spiral bound in book forms at least in six sets for distribution to customer, different Units of


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BHEL. Non-submission will call for penal recoveries and BHEL may execute the same at risk and cost of the contractor.

The protocols between contractor and customer/ BHEL shall be made prior to installation for correctness of foundations, materials, procedures, at each stage of installation, generally as per the requirement of customer/BHEL. This is necessary to ensure elimination of errors or keeping them within tolerable limits and to avoid accumulation and multiplication of errors. Exclusive engineer(s) should be made available for this type of jobs.

5.3 A daily log book should be maintained by every supervisor/engineer of contractor on the job in duplicate (one for BHEL and one for contractor) for detailing and incorporating alignment/clearance / centring / levelling readings and inspection details of various equipments etc.

High pressure welding details like serial number of weld joints, welder’s name, date of welding, details of repair, heat treatment etc. will be documented in welding log as per BHEL Engineer’s instructions.

Record of radiography containing details like serial number of weld joints, date of radiography, repairs, if any, re-shots etc. shall also be maintained as per BHEL engineer’s instructions.

Record of heat treatments performed shall be maintained as prescribed by BHEL. Similarly, performance report of all welders shall be furnished for scrutiny of BHEL Engineer.

All kinds of NDTs are included in contractor’s scope of work within the quoted rate.

5.4 In the course of erection, it may become necessary to carry repeated checks of the work with instruments recently calibrated, re-calibrated. Such instruments whenever necessary, will be provided by contractor/ BHEL as per T&P provision scope.

Electrical testing of Generator also shall include the following in addition to the other normal scope of work:

Measurement of DC Resistance of Generator stator, rotor and other electrical equipments like motors etc. impedance test of generator/other rotors, Measurement of IR values of Generator stator, rotor, other electrical motors, equipments, RTDs, Thermocouples etc. Micro-ohm meter with valid test certificates etc. are to arranged by the contractor within their quoted rate.

5.5 Vibration indicators/vibration recorders/vibration analysers will be provided by BHEL for checking and analysing vibration levels of rotating equipments with necessary operators. Contractor shall provide necessary labour with necessary supports for carrying out such tests. This exercise may have to repeated till handing over of the sets to customer and is included within the quoted rate.

5.6 Total quality is the watch word of the work and contractor shall strive to achieve the quality standards, procedures laid down by BHEL. He shall follow all the instructions as per BHEL drawings and quality standards. Contractor shall provide for the services of quality assurance engineer.


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5.7 STAGE INSPECTION BY FES / QA ENGINEERS

5.7.1 Apart from day-to-day inspection by BHEL engineers stationed at site and also by customer’s engineers, stage inspection of equipments under erection and commissioning at various stages of erection and commissioning by teams of engineers from field engineering services of BHEL’s manufacturing units and quality assurance teams from field quality assurance unit/factory quality assurance and commissioning engineers from technical services of BHEL will also be conducted. Contractor shall arrange all labour, tools and tackles, IMTEs etc. for such stage inspections free of cost.

5.7.2 Any modifications suggested by BHEL FES and QA Engineers team shall be carried out. Claims of contractor, if any, shall be dealt as per clause 13.1 to 13.8, provided such modifications have not arisen for reasons attributable to the contractor.

5.8 STATUTORY INSPECTION.

5.8.1 The scope includes getting the approvals from the statutory authorities (like boiler inspector and labour officers). This includes arranging for inspection visits of boiler inspector periodically as per BHEL Engineer’s instructions, submitting documents, radiographs etc. and following up the matter with them.

5.8.2 All fees connected with the contractors for testing his welders / men / workers and testing, inspection, calibrating of his instruments and equipments, shall be paid by the contractor. It shall be contractor’s responsibility to obtain approval of statutory authorities, wherever applicable, for the conducting of any work which comes under the purview of these authorities. Any cost arising from this shall be contractor’s account.

5.8.3 BHEL/CUSTOMER will pay fees for visits, inspection fees etc. of IBR authorities. All other expenses shall be borne by the contractor. In case these inspections have to be repeated due to default / fault of the contractor and fees have to be paid again. The contractor has to bear the charges.

5.9 BHEL, Power Sector – Eastern Region (PSER) has already been accredited with ISO 9002 certification and as such this work is subject to various audits to meet ISO 9002 requirements. One particular aspect which needs special mention is about arrangement of calibration of instruments by the contractor. Contractor shall ensure deployment of reliable and calibrated MMDs (instrument measuring and test equipment). The MMDs shall have test/ calibration certificates from authorised / Government approved / accredited agencies traceable to national / international standards. 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 contractor will also have alternate arrangements for such MMDs so that work does not suffer when the particular equipment / instrument is sent for calibration. Also if any MMDs not found fit for use, BHEL shall have the right to stop the use of such item and instruct the contractor to deploy proper item and recall ie. Repeat the readings taken by that instrument, failing which BHEL may deploy MMDs and retake the readings at contractor’s cost.


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6.0 SAFETY, OCCUPATIONAL HEALTH AND ENVIRONMENTAL MANAGEMENT

6.1.1 RESPONSIBILITY OF THE CONTRACTOR IN RESPECT OF SAFETY OF MEN,

EQUIPMENT, MATERIAL ETC. 6.1.2 The contractor shall take all necessary safety precautions and arrange for

appropriate protective gears as per direction of BHEL or it’s authorized person to prevent loss of human lives, injuries to men engaged and damage to property etc. Code for safety management at construction site shall also be referred to.

The contractor shall provide to his work force & ensure the use of the following

personal protection equipment as found necessary and as directed and advised by BHEL officials.

1. Safety helmets conforming to IS 2925 / 1984 (1990) 2. Safety belts conforming to IS 3521 / 1989 3. Safety shoes conforming to IS 1989 part – II / 1986 (1992) 4. Eye and face protection devices conforming to IS 2573 / 1986 (1991),

IS 6994 / 1973 part – I (1991), IS 8807 / 1978 (1991), IS 8519 / 1977 (1991). 6.1.3 All tools, tackles, lifting appliances, material handling equipment, scaffolds, cradles,

safety nets, ladders, equipment etc. used by the contractor shall be of safe design and construction. Wherever applicable test certificates for the fitness of these shall be furnished. BHEL will have the right to ban the use of any item found unsuitable.

6.1.4 All electrical equipment, connections and wiring for construction power, its

distribution and use shall conform to the requirements of Indian Electricity Act and rules. Only electricians licensed by the appropriate statutory authority shall be employed by the contractor to carry out all types of electrical works. All electrical appliances including portable electric tools used by the contractor shall have safe plugging system to source of power and be appropriately earthed.

6.1.5 For the work in confined spaces, lighting shall be arranged with power source of

not more than 24 volts. At least 04(four) number of 24 Volts transformers with adequate number of lamps are to be arranged for working inside enclosed vessel, areas.

6.1.6 The contractor shall adopt all fire safety measures as laid down in the “code for fire

safety at construction sites” of BHEL and as per directions of BHEL official. A copy of the above referred “code for fire safety at construction sites” shall be made available by BHEL to the contractor for reference.

6.1.7 Where it becomes necessary to provide and / or store petroleum products,

explosives, chemicals and liquid or gaseous fuel or any other substance that may cause fire or explosion, the contractor shall be responsible for carrying out such provisions and / or storage in accordance with the rules and regulations laid down by the relevant government acts, such as petroleum act, explosives act, petroleum and carbides of calcium manual of the chief controller in all such matters.


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6.1.8 The contractor shall arrange at his cost (wherever not specified) appropriate illumination at all work spots for safe working when natural day light may not be adequate for clear visibility.

6.1.9 The contractor shall be held responsible for any violation of statutory regulations

(local, state or central) and BHEL instructions that may endanger safety of men, equipment, material and environment in his scope of work or another contractors or agencies. Cost of damage, if any, to life and property arising out of such violation of statutory regulations and BHEL instructions shall be borne by the contractor.

6.1.10 In case of a fatal or disabling injury / accident too any person at construction sites

due to lapses by the contractor, the victim and / or his / her dependents shall be compensated by the contractor as per statutory requirements. However, if considered necessary, BHEL shall have the right to impose appropriate financial penalty on the contractor and recover the same from payments due to the contractor for suitably compensating the victim and / or his / her dependents. Before imposing any such penalty, appropriate enquiry shall be held by BHEL giving opportunity too the contractor to present his case.

6.1.11 In case of any damage to property due to lapses by the contractor, BHEL shall

have the right to recover cost of such damages from payments due to the contractor after holding an appropriate enquiry.

6.1.12 In case of any delay in the completion of a job due to mishaps attributable to lapses

by the contractor, BHEL shall have the right to recover cost of such delay from payments due to the contractor after notifying the contractor suitably and giving him opportunity to present his case.

6.1.13 If the contractor fails to improve the standards of safety in its operation to the

specification of BHEL after being given a reasonable opportunity to do so, and / or to provide necessary safety devices and equipment or to carry out instructions regarding safety issued by the authorized BHEL official, BHEL shall have the right to take corrective steps at the risk and cost of the contractor after giving a notice of not less than seven days indicating the steps that would be taken by BHEL.

6.1.14 The contractor shall submit report of all accidents, fires and property damage,

unsafe occurrences to the authorized BHEL official immediately after such occurrence but in any case not later than twelve hours of the occurrence. Such report shall be furnished in the manner prescribed by BHEL. In addition, periodic reports on safety shall also be submitted by the contractor to BHEL.

6.1.15 Nonconformity of safety rules and safety appliances will be viewed seriously and

the BHEL has right to impose fines on the contractor as under:

SL.

NO.

SAFETY FINE

(RS.)

01. NOT WEARING SAFETY HELMET 50/-

02. NOT WEARING SAFETY BELT 100/-

03. GRINDING WITHOUT GOGGLES 50/-


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04. NOT USING 24 V SUPPLY FOR INTERNAL WORK 500/-

05. ELECTRICAL PLUGS NOT USED FOR HAND MACHINES 100/-

06. NOT SLINGING PROPERLY 200/-

07. USING DAMAGED SLING 200/-

08. LIFTING CYLINDERS WITHOUT CAGE 500/-

09. NOT USING PROPER WELDING CABLE WITH LOT OF

JOINTS AND NOT INSULATED PROPERLY

200/-

10. NOT REMOVING SMALL SCRAP FROM PLATFORMS 200/-

11. GAS CUTTING WITHOUT TAKING PROPER

PRECAUTION OR NOT USING SHEET BELOW GAS

CUTTING

200/-

12. NOT MAINTAINING ELECTRIC WINCHES WHICH ARE

BEING OPERATED DANGEROUSLY

500/-

13. IMPROPER EARTHING OF ELECTRICAL T&PS 500/-

9.1.16 The Contractor employing all kinds of casual, probationer, regular or permanent or on contract, shall employ at least one full time officer exclusively as Safety Officer to supervise safety aspects of the equipments and workmen, who will co- ordinate with the BHEL/Employer Safety Officer. In case of work being carried out through sub-Contractors, the Sub-Contractor’s workmen/employees will also be considered as the Contractor’s employees/workmen for the above purpose.

The name and address of such Safety Officer of Contractor will be promptly informed in writing to BHEL with a copy to Safety Officer-In-charge before he starts work or immediately after any change of the incumbent is made during currency of the Contract.

In case any accident occurs during the construction/ erection or other associated activities undertaken by the Contractor thereby causing any minor or major or fatal injury to his employees due to any reason, whatsoever, it shall be the responsibility of the Contractor to promptly inform the same to the BHEL / Employer in prescribed form and also to all the authorities envisaged under the applicable laws.

The BHEL/Customer shall have the right at his sole discretion to stop the work, if in his opinion the work is being carried out in such a way that it may cause accidents and endanger the safety of the persons and/or property, and/or equipments. In such cases, the Contractor shall be informed in writing about the nature of hazards and possible injury/accident and he shall comply to remove shortcomings promptly. The Contractor after stopping the specific work can, if felt necessary appeal against the order of stoppage of work to the BHEL/Employer thin 3 days of such stoppage of work and decision of the BHEL/ Customer in this respect shall be conclusive and binding on the Contractor.


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The Contractor shall not be entitled for any damages/ compensation for stoppage of work due to safety reasons as provided above and the period of such stoppage of work will not be taken as an extension of time for completion of the facilities and will not be the ground for waiver of levy of liquidated damages.

The Contractor shall follow and comply with all Safety Rules of the Employer, relevant provisions of applicable laws pertaining to the safety of workmen, employees plant and equipment as may be prescribed from time to time without any demur, protest or contest or reservation. In case of any inconformity between statutory requirement and Safety Rules of the Employer referred above, the later shall be binding on the Contractor unless the statutory provisions are more stringent.

At least 10 nos. of fire extinguishers are to be maintained in each Unit in working condition .Regular refilling of extinguishers are to be done by the contractor as per statutory requirements .Actual requirement of fire extinguishers or other fire fighting equipments is to be changed as per actual site conditions. This is included as regular scope of work.

If the Contractor fails in providing safe working environment as per the Employer's Safety Rules or continues the work even after being instructed to stop work by the Employer’s Manager and the contractor is bound to pay penal rate and should be promptly paid to the Employer, on demand by the Employer compensation at the rate of Rs. 5,000/- per day or part thereof till the instructions are complied with and so certified by the Employer. However, in case of accident taking place causing injury, to any individual, the provisions contained in paragraph below shall also apply in addition to compensation mentioned in this paragraph.

If the Contractor does not take all safety precautions and/or fails to comply with the Safety Rules as prescribed by the Employer or under the applicable law for the safety of the equipment and plant and for the safety of personnel and the Contractor does not prevent hazardous conditions which cause injury to his own employees or employees of other Contractors, or the Employer's employees or any other person who are at Site or adjacent thereto, the Contractor shall be responsible for payment of compensation to BHEL as per the following schedule:-

(a) Fatal injury or accident Causing death Rs. 1,00,000/- per person (b) Major injuries or accident for death/ causing 25% or more injury to any permanent disablement to person workmen or employees Rs. 20,000/- per person

(Above (a) & (b) is applicable causing for death / injury to any person whosoever.)

Permanent disablement shall have same meaning as indicated in Workmen’s Compensation Act. The compensation mentioned above shall be in addition to the compensation payable to the workmen/employees under the relevant provisions of the Workmen’s Compensation Act and rules framed there under or any other applicable laws as applicable from time to time. In case the Employer is made to pay such Compensation then the Contractor is liable to reimburse the Employer such amount in addition to the compensation indicated above.


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7.0 DRAWINGS AND DOCUMENTS 7.1 The detailed drawings, specifications, quality plans available with BHEL engineers

will also form part of this tender specification. Revision of drawings/documents may take place due to various considerations as is normal in such large project. Work will have to be carried out as per revised drawings / documents. These documents will be made available to the contractor during execution of work at site. Multiplication of drawings/documents/logsheets/protocols /spiral binding for at least is included in the contractor’s scope of work.

7.2 One set of necessary drawings/documents to carry out the erection work will be

furnished to the contractor by BHEL on loan which shall be returned to BHEL after completion of the work. Contractor’s personnel shall take care of these documents given to them.

7.3 The data furnished in various sections and appendices and the drawings enclosed

with this tender specification describe the equipment to be installed, tested and commissioned under this specification, briefly. However, the changes in the design and in the quantity may be expected to occur as is usual in any such large scale of works.

7.4 If any error or ambiguity is discovered in the specification/information contained in

the documents/drawings and tender, the contractor shall forthwith bring the same to the notice of BHEL before commencement of the work. BHEL’s interpretation in such cases will be final and binding on the contractor.

8.0 TIME SCHEDULE, MOBILIZATION, PROGRESS MONITORING, OVER-RUN, VARIATION ETC.

8.1 TIME SCHEDULE & MOBILIZATION 8.1.1 The contractor shall mobilize required T&Ps to start the actual work within 15 days

from the date of placement of LOI.

The schedule of major mile stone activities shall be as under

Sl No. Milestone Schedule from date of LOI

1 Erection start of STG unit-1 One month

2 Erection start of STG Unit-2 Two months

3 Erection start of STG Unit-3 Three months

4 Erection start of BPTG Four months

5 Erection start of turbine for blower-1 Five months

6 Erection start of turbine for blower-2 Six months

7 Erection start of turbine for blower-3 Seven months


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8 Erection start of blower-1 Five months

9 Erection start of blower-2 Six months

10 Erection start of blower-3 Seven months

11 Commissioning start of BPTG Six months

12 Commissioning start of blower -1,2,3 Ten months (in a gap of 15 days between two)

13 Commissioning start of STG-1,2,3 Five months (in a gap of 15 days between two)

14 P.G.test Twelve months

15 Start of Electrical job Two months

16 Start of C&I job Three months

8.1.3 Start of Contract Period and Duration.

The total contract period for completion of entire work including PG test and handing over shall be 21 (twenty-one ) months from the start of work i.e start of erection work of STG (unit-1). Start of work date shall be certified by BHEL in writing. The total job from starting of work till completion of all site related activities including handing over shall be completed within 21.months.

The contractor shall complete all the work in the scope of this contract within the contract period.

8.2

8.2.1 Progress Monitoring Progress will be reviewed periodically (daily / weekly / monthly) including month end review vis-a-vis the plans drawn as above. The contractor shall submit periodical progress reports, and other reports / information including manpower, consumables etc as desired by BHEL.

8.2.2 Ascertaining and Establishing the Reasons for Shortfall Delay analysis for contract extension should be mutually agreed upon based on but

not limited to the following : 8.2.2.1

a) Erection / Commissioning programme not achieved owing to non-availability of fronts.

b) Erection / Commissioning programme not achieved owing to non-availability of

materials. 8.2.2.2 Erection/Commissioning programme not achieved owing to non-availability of

tools and plants, manpower and consumables by the contractor or any other reason attributable to the contractor.

8.2.2.3 Erection / Commissioning programme not achieved due to any other reasons not

attributable to the contractor.


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8.3 Liquidated Damage (LD) Unit-I If the contractor fails to complete the job of unit-I within specified completion schedule BHEL shall have the right to re-cover the Liquidated damages(LD) a sum of 0.5% (zero point five percent) of the contract price of unit-I per week or part thereof of the delay. Unit-II If the contractor fails to complete the job of unit-II within specified completion schedule BHEL shall have the right to re-cover the Liquidated damages(LD) a sum of 0.5% (zero point five percent) of the contract price of unit-II per week or part thereof of the delay.

Unit-III If the contractor fails to complete the job of unit-III within specified completion schedule BHEL shall have the right to re-cover the Liquidated damages(LD) a sum of 0.5% (zero point five percent) of the contract price of unit-III per week or part thereof of the delay . However the total amount of LD for all three units i.e. unit-I,unit-II , unit-III shall not exceed the 5% of the total executed contract price of unit-I,unit-II & unit-III. 8.4 CONTRACT VARIATION

Weight of various equipments, quantities of various items of work covered under these specifications, & indicated in relevant appendices are likely to vary. For any upward or downward variation in the quantities, the price accepted shall remain unchanged and be applicable without any variation.

8.5 Advance for Mobilization

Mobilization advance is not payable under this contract.

8.6 Definition of Work Completion

The contractor’s scope of work under these specifications will be deemed to have been completed in all respect, only when all the activities total erection, testing, commissioning, trial run of individual equipments, trial run of total set, PG Testing, completion of all punch points/defect points/pending points etc. are completed satisfactorily and so certified by BHEL site in charge. The decision of BHEL in this regard shall be final and binding on the contractor.

9.0 TERMS OF PAYMENT

For Erection, Testing and Commissioning of the Unit for Steam Turbine,turbo-blowers, Turbo-Generator, Condenser with auxiliaries, integral piping and electrical & C & I job payments shall be made as follows on basis of percentage of total contract value of work as per rate schedule on monthly basis. The following break up is only for the purpose of regular stage payment and should not be construed


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as price for individual item and also it does not constitute total scope of work. The total scope of work is as detailed in this tender document and shall be completed by contractor without making any reference to the following break up.

9.1 Billing break up is as follows :

BILLING SCHEDULE FOR ERECTION & COMMISSIONING OF STG::TG & AUX. PACKAGE (PRICE SCHEDULE-VOL-III/STG)

Note:

1) Payment shall be released on Pro - rata monthly basis on each item of works against submission of bills.

2) It may please be noted that the break up given above is notional break up only, solely to facilitate progress billing thereof. The lump-sum contract price and contract conditions shall remain unchanged and difference, if any, shall be adjusted in accordance with total individual allocation as above and shall be paid alongwith the last pro-rata bill for individual item.

3) Items not appearing in the above break-up but required for the purpose of system completion as per technical specification / drawing shall be executed with out any cross reference to the payment break-up and no additional payment shall be released by BHEL.

4) BHEL site may further split up broad % progressive payment to maintain suitable fund flow in commensurate with the progress of the work

RATE SCHEDULE.

RATE SCHEDULE FOR PACKAGE-1

SL. NO.

ACTIVITY DESCRIPTION PERCENTAGE OF BILLING

1 STG-UNIT1 15 %

2 STG-UNIT2 15 %

3 STG-UNIT3 15 %

4 BPTG 10%

5 TURBO-BLOWER 1 15%

6 TURBO-BLOWER 2 15 %

7 TURBO-BLOWER 3 15 %

TOTAL 100.00%

RATE SCHEDULE FOR PACKAGE -2

ELECTRCAL & C&I ITEMS

TOTAL 100.00%

Further break-up of percentage for each unit shall be done subsequently at site

for Erection & Commissioning for monthly running payment.

9.2 Payment against each monthly running arrear (RA) bill will be restricted to 95% of the value arrived at, based on the accepted measurements. The 5% thus remaining shall be treated as amount payable but not due and shall be on account


69

of Workmanship Guarantee (defect liability) of the work executed as per GCC, the same shall be released after completion of the guarantee period of 12 months from the date of completion of entire work as certified by BHEL engineer. However this amount may be released along with final bill on submission of Bank Guarantee of equal amount and tenure in prescribed format.

However the above 5% Retention Amount can be released during the guarantee period , against the submission of Bank Guarantee for an equivalent amount valid upto completion of guarantee period the Unit , in the prescribed format, subject to certification, acceptance by BHEL stating that all works of that particular Unit is completed.

Submission of Bank Guarantee towards above, is separate and the bank guarantee towards security deposit cannot be utilised for this purpose. The security deposit will be refunded as per certificate of site, on completion of final bill formalities and as per relevant clauses of GCC.

9.3 PAYMENT FOR WORK COMPLETED

9.3.1 The contractor should submit his on account bills with all the details required by BHEL on 5th of every month covering progress of work in all respects and areas up to last day of the previous month.

9.3.2 On receipt of the bill, joint measurement and checking of the work done will be carried out by the concerned BHEL engineer as per General Conditions of the Contract and break-up given vide clause 10.1 of payment break-up. It shall be final and binding on the contractor.

10.0 EXTRA CHARGES FOR MODIFICATION AND RECTIFICATION 10.1 If extra works (requiring up to 50 man hours on each occasion) for modification,

rework, revamping, in brief, any work done to change the state existing to a stage desired and also fabrication, all or any, needed due to any change in or deviation from the drawings and design of equipment, operation / maintenance requirements, mismatching, transit damages and other allied works which are not very specifically indicated in the drawings, but are found essential for satisfactory completion of the work, are done, no extra charges will be paid. The tenderers are requested to take this aspect into account and the quoted rate should include all such contingencies.

10.2 However, BHEL may consider for payment as extra on man hour basis, for such of

those activities detailed in clause 11.1 which require more than 50 man hours and such payment will be regulated by the terms, conditions and stipulations contained in the clauses contained hereinafter. It may be specifically noted that the decision of BHEL as to whether such payment is due shall be final and binding on the contractor. Any extra work require more than 50 man hour ( say for 150 man hours of extra work for a particular job , then extra man hours will be considered for admission of extra work will be (150-50) hrs. ,i,e. 100 hrs. in this extra job subject to acceptance by the BHEL site engineer).


70

10.3 Extra work should be done by a separately identifiable gang, without affecting routine activities. Daily log sheets in the Performa prescribed by BHEL should be maintained and shall be signed by the contractor’s representative and BHEL Engineer. No claim for extra work will be considered / entertained in the absence of the said supporting documents i.e. daily man-hour log sheets. It may, however, be noted that signing of log sheets by BHEL Engineer does not mean the acceptance of such works as payable extra works. Lunch hour/recess hour period will not be counted for the purpose of extra man hours.

10.4 BHEL retains the right to award or not to award any of the major repair / rework /

modification / rectification / fabrication work as defined above to the contractor, at their discretion without assigning any reason for the same.

10.5 It shall be noted that all extra works that arise on account of the contractor’s fault,

will have to be carried out by the contractor free of cost. Under such circumstances, any material and consumable required for this purpose will also have to be arranged by the contractor at his cost.

10.6 After eligibility of extra works is established and finally accepted by BHEL Engineer

/ designer, payment will be released on competent authority’s approval at the following rate

10.7 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 contractor 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 Calcutta.

10.8 EXTRA WORK RATE FOR HIGH PRESSURE JOINTS

The following are all inclusive rates applicable for rectification/modification/rework involving welding of high pressure joints.

Unit rate per equivalent water wall joint of size OD 63.5 mm x 6.3 mm thick.

Type of material Average rate per joint

Carbon steel Rs 200.00

Alloy steel Rs 250.00

The rate indicated above and below are firm and are not subject to any escalation during the contractor period till the completion of work. Unit rates for welding are all inclusive including scaffolding , joint preparation, cutting, edge preparation, welding and stress relieving, radiography with all consumables and tools and plants.

For additional radiography, if so desired by BHEL, payment @ Rs 5.00 per cm length of film (100 mm wide) exposed and accepted by site engineer and further


71

certified by site Engineer that the length of film exposed is minimum required for carrying out the radiography shall be paid.

The following man hour rates will be applicable for modification / rectification work, excluding pressure part joints.

Average single man-hour rates including overtime, if any , supervision ,use of tools & tackles and other site expenses and incidentals including consumables for carrying out rework/revamping as certified by site as may arise during the course of erection testing and commissioning -- Rs 40.00 (Forty) per man-hour.

Average single man-hour rates including overtime, if any, supervision, use of tools and tackles and other site expenses and incidentals excluding consumables for carrying out rework/ revamping as certified by site as may arise during the course of erection testing and commissioning -- Rs 25.00 (Twenty Five) per man-hour.

NOTE: The above man-hour rates towards extra work shall be firm and not

subject to any variation like PVC, rate revision , over run charges /compensation etc during execution of the work.

11.0 INSURANCE 11.1 Transit Storage and Erection Insurance – Repairing Damages 11.1.1 BHEL/client has an insurance cover, inter-alia, for all BHEL supplied equipments/

components covered under scope of this work. Under a transit and storage cum erection policy covering liability against damages/losses etc.

11.2 Reporting Damages / Loss and Carrying Out Repairs / Fabrication 11.2.1 Checking all components/equipments at siding/site and reporting to transport

and/or insurance authorities of any damages/losses will be by BHEL. 11.2.2 Contractor shall render all help to BHEL in inspection including handling, re-stacking

etc, assessing and preparing estimates for repairs of components damaged during transit from BHEL store after issue to the contractor, storage and erection, commissioning and preparing estimates for fabrication of materials lost/damaged during transit from BHEL store after issue to the contractor, storage and erection. Contractor shall help BHEL to furnish all the data required by railways, insurance company or their surveyors.

11.2.3 Contractor shall report to BHEL in writing any damages to equipments/

components on unloading ,receipt, storing, stacking etc and during drawl of the materials from stores, in transit to site and unloading at place of work and during erection and commissioning, testing ,trial run etc. 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 contractor. In case of theft, the contractor has to lodge FIR and for settling insurance claims , arranging FRT from appropriate authority is included in the contractor’s scope of work.


72

11.2.4 Contractor shall carry out fabrication/repair of any material lost/damaged (related to insurance cases) as per instructions from BHEL engineer.

11.2.5 BHEL, however, retains the right to award or not to award to the contractor any of

the rectification/rework/repairs of damages and also fabrication of components. 11.2.6 All the repairs/rectification/rework of damages and fabrication of materials lost, if

any, shall be carried out by a separately identifiable gang for certification of man-hours. Daily log sheets should be maintained for each work separately and should be signed by contractor's representative and BHEL engineer. Signing of log sheets does not necessarily mean the acceptance of these as extra works.

11.2.7 All rectification, repairs, rework and fabrication of components lost, which are

minor and incidental to erection work (consuming not more than 50 man-hours on each occasion) shall be treated as part of normal work without any extra cost to BHEL.

11.2.8 In case of theft / damage / loss of materials due to negligence or failure attributable

to the contractor, the expenses incurred on account of repair/ replacement of such components in excess of the amount realized from the underwriters shall be recovered from the contractor limited to Normal Deductible Franchise (DF) / Excess as per applicable Insurance (TAC) tariff guidelines.

11.2.9 Insurance cover under this contract will be as per General conditions of contract to

the tune modified by the Special Conditions of Contract. 11.2.10 Payments for all extra works for repair/rectification/reworks of damages and

fabrication of materials lost will be as per provisions of clause 13.6. 11.2.11 In case the repairs/rectification/rework and fabrication of materials lost, the

work has been done by more than one agency including the contractor, the payment towards extra charges will be on pro-rata basis and the decision of BHEL in this regard is final and binding on the contractor.

11.3 Insurance by the contractor and indemnification of BHEL

BHEL have taken a third party liability insurance, indicating in the proposal for such insurance that sub-contractors will be taking part in the erection work detailed in this tender. However, the tenderer has to bear any expenses/ consequences over and above the amount that may be reimbursed to BHEL by such coverage of third party liability insurance taken by BHEL.

Such additional liability will be to cover and indemnify BHEL and its customer of all liabilities which may come up and cause harm/damage to other contractors/customer/BHEL properties/personnel or all or anybody rendering service to BHEL/customer or is connected with BHEL/customer’s work in any manner whatsoever. The tenderer’s specific attention is also invited to relevant portion /clause of General conditions of contract.


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12.0 OVER RUN CHARGES (ORC)

1.0 In case, due to reasons not attributable to the contractor, the work gets extended beyond original completion period, stipulated in tender, the contractor shall be entitled for over run compensation (ORC).

2.0 ORC shall be applicable as per following. 2.1 The rate/ price of balance part of job beyond normal completion period shall be revised by 10

% from 1st month of extended period. This revised rate shall remain valid for one year. 2.2 The above revised rate shall be further revised by 10 % per year in the subsequent years

and this re-revised rate shall remain valid for one year and so on till completion of contract. 3.0 During the extended period, contractor shall maintain their resources as per mutually agreed

program. However, the contractor have to deploy additional resources, if required, to complete the job within the re-scheduled completion period.

4.0 Payment of ORC shall be subject to compliance to following condition. 4.1 Contractor shall maintain minimum resources as per agreed program and certified by BHEL. 4.2 Contractor shall achieve the target as per agreed program. 4.3 The example is indicated below:

Rate/Price of Balance job on contractual completion date = A, Say

Revised Rate during the 1st Year after contractual completion date= 1.1 A

Revised Rate during Second Year after contractual completion date PLUS One Year = 1.21 A

And so on for subsequent period if applicable.

NOTE:

(a) Enhanced rate shall not be applicable during the period in extension where reasons for delay are attributable to vendor as explained below :

Contract period extended - 8 Months, say (Out of 8 Months delay, supposing vendor is responsible for 3 months delay and BHEL is responsible for 5 months delay)

Revised Rate 1.1 A shall come into effect on expiry of contract period plus 3 months.

Revised rate 1.1A shall be in force for One Year thereafter.

(b) For further extension if any, for application of ORC, above logic shall be applicable after evaluating the reasons of delay.

That is, the revised rate for 2nd year shall come into effect on expiry of delay period attributable to the vendor during first year. i.e, extended period.

Contract Period + Vendor Delay (3Month in above case) + One year + Vendor delay during one year extended period.

This revised rate 1.21A shall remain in forces for one year thereafter. And so on.

(c) However, the total ORC shall be limited to 10% of the contract price. 13.0 PRICE VARIATION

1.0 After the `Base Date’, and/ or during the progress of work, the monthly price adjustment amount of the contract price will be computed as per the formula given below. The base date shall be reckoned as latest due date of submission of offer.


74

2.0 ER = ER1 – ERo.

3.0 ER1 will be computed as follows. L1 ER1 = ERo (0.15 + 0.85 ---), where Lo ER = Adjustment to contract price payable to the contractor for each billing.

ER1 = Adjusted amount payable/recoverable to the contractor of contract price for each billing.

ER0 = Value of work done in the billing period.

4.0 The payment of price adjustment amount so computed shall be made against a separate invoice linking the corresponding invoice (gross RA bill amount) after retaining the prorate amount due on completion of guarantee/ final bill (as per payment terms of tender). The amount so retained shall be paid on successful completion of guarantee/ final bill (as per payment terms of tender).

L0 = All India Consumer Price Index for Industrial Workers (All India Average) as published by Labour Bureau, Simla, Government of India as on base date.

L1 = All India Consumer Price Index for Industrial Workers (All India Average) as published by Labour Bureau, Simla, Government of India for the month of work done.

5.0 Total PVC payable / recoverable against the contract shall have an overall ceiling of 12% or 15 % or 20% of the contract price for original contract completion period of up to 24 months,36 months or beyond respectively. No PVC is payable for contracts with completion period lower than & up to 12 months.

6.0 The quantum of such price variation amount per month shall be restricted to the ceiling percentage for each RA Bill amount. The final adjusted amount of PVC will be paid along with the final bill.

7.0 The contractor shall produce necessary Government Notifications/ RBI Bulletins of above component for receiving payment from BHEL/ refund to be made to BHEL, as required, in the formula mentioned above.

8.0 The contractor will be required to raise bills for PVC payment on monthly basis along with RA Bill irrespective of the fact whether, any increase/ decrease in price/ index has taken place or not.

9.0 PVC shall be admissible up to the original completion period of tender.

Vol - II

APPENDIX – I(Revision 01)

WEIGHT AND LIST OF EQUIPMENTS / COMPONENTS TO BE RECEIVED FROM STORES/STORAGE YARD,HANDLED/REHANDLED,TRANSPORTED TO PLACE OF ERECTION, ERECTED AND COMMISSIONED BY THE CONTRACTOR


75

1.00: STEAM TURBINE GENERATOR AND AUXILIARIES

MAJOR EQUIPMENT FOR EACH STG SET

1. STEAM TURBINE

2. OIL SUPPLY SYSTEM

3. SURFACE CONDENSER

4. STEAM JET AIR EJECTORS 2X100%

5. GLAND STEAM CONDENSER

6. L.P. HEATER –1 NO

7. H.P.HEATER-1 NO

8. HPH.FLASH TANK

9. DEAERATOR- 1 NO 10. OIL COOLERS – 2 X 100 %

11. AIR COOLERS

12. DRAIN COOLERS

13. GENERATORS 14 BOILER FEED PUMP 15. BALANCE OF PLANT EQUIPMENT- MECHANICAL 16. BALANCE OF PLANT EQUIPMENT- ELECTRICAL 17. BALANCE OF PLANT EQUIPMENT- C&I 18. ELECTRICAL & C&I PARTS FOR BOILER 19. ELECTRICAL & C&I PARTS FOR 3X18 MW TG 20. ELECTRICAL & C&I PARTS FOR 1X8.275 MW BPTG. 21. ELECTRICAL & C&I PARTS FOR 3 NOS TURBOBLOWER


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1.0 STEAM TURBINE:

SL

NO DESCRIPTION WEIGHT IN

TON(EACH) QTY TOTAL

WT(IN

TON) 1 STEAM TURBINE FOR 3X18 MW STG 36 3 108

2 STEAM TURBINE FOR 1 NO 8.275 MW

BPTG 17 1 17

3 STEAM TURBINE FOR 3 NOS TURBO-BLOWERS

30 3 90

TOTAL 215T

2 . OIL SUPPLY SYSTEM

SL NO DESCRIPTION WEIGHT IN

TON(EACH) QTY TOTAL WT(IN

TON) 1 LO SYSTEM FOR 3X18 MW STG

I) LUBE OIL TANK 5.6 3 16.8

II) OVERHEAD LUBE OIL TANK 2.05 3 6.15

III) LUBE OIL PUMP ASSLY 1.45 6 8.7

IV) EMERGENCY OIL PUMP ASSLY 0.6 3 1.8

V) OIL VAPOUR EXTRACTION FAN

ASSLY 0.075 6 0.45

VI) JACKING OIL PUMP ASSLY 0.200 6 1.2

VII) DUPLEX FILTER 1.6 3 4.8

VIII) OIL PURIFICATION UNIT 1.350 3 4.05

SUB-TOTAL 43.95

2 LO SYSTEM FOR 1 NO 8.275MW

BPTG




IV) EMERGENCY OIL PUMP ASSLY 0.65 1 0.65

V) OIL VAPOUR EXTRACTION FAN

ASSLY 0.1 2 0.2

VI) DUPLEX FILTER 1.1 1 1.1

VII) OIL PURIFICATION UNIT 1.4 1 1.4

VIII) OIL ACCUMULATOR ASSEMBLY 0.4 1 0.4

SUB-TOTAL 13.8

3 LO SYSTEM FOR 3 NOS TURBO-BLOWER


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IV) EMERGENCY OIL PUMP ASSLY 1.0 3 3

V) JACKING OIL PUMP ASLY 0.8 3 2.4

VI) DUPLEX FILTER FOR LUBE OIL 0.7 3 2.1

VII) LUBE OIL ACCUMULATORS 1.2 3 3.6

SUB-TOTAL 49.5

4 VALVES & GOVERNING SYSTEM

FOR 3X18 MW STG

I) QCNRV(TAG NO.EX-01) 0.24 3 0.72

II) QCNRV(TAG NO.EX-02) 1.275 3 3.825

III) QCNRV(TAG NO.EX-03) 1.5 3 4.5

IV) GOVERNING CONSOLE 0.7 3 2.1

SUB-TOTAL 11.145

5 GOVERNING SYSTEM FOR 1 NO

8.275MW BPTG

I) GOVERNING CONSOLE 0.380 1 0.380

SUB-TOTAL 0.380

6 VALVES & GOVERNING SYSTEM

FOR 3 NOS TURBOBLOWER

I) GOVERNING OIL

ACCUMULATORS 0.4 3 1.2

II) BARRING GEAR CONSOLE 0.85 3 2.55

III) OIL CENTRIFUGE (TROLLEY

TYPE) 0.45 3 1.35

IV) GOVERNING CONSOLE 0.7 3 2.1

V) SUCTION FILTER & SILENCER 30 3 90

VI) GOVERNING CONSOLE 0.35 3 1.05

VII) VALVES 4.0 - 4

SUB-TOTAL 102.25

TOTAL 221.025

3.SURFACE CONDENSER : SL



TON) 1 SURFACE CONDENCER FOR 3X18 MW

STG 46 3 138

2 SURFACE CONDENCER FOR 3 NOS

TURBO-BLOWER 55 3 165


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TOTAL 303T

4.STEAM JET AIR EJECTOR : SL NO DESCRIPTION WEIGHT IN


TON) 1 STEAM JET AIR

EJECTOR ASSLY FOR 3X18 MW STG

7.1

3 21.3

2 STEAM JET AIR EJECTOR ASSLY FOR 3 NOS TURBO-BLOWERS

7.1

3 21.3

TOTAL 42.6T

5.0 GLAND STEAM CONDENSER :

SL



TON) 1 GLAND STEAM CONDENSER

FOR 3X18 MW STG

1.4 3 4.2

2 GLAND STEAM CONDENSER FOR 1 NO 8.275MW BPTG

5.5 1 5.5

3 GLAND STEAM CONDENSER FOR 3 NOS TURBO-BLOWERS

1.4 3 4.2

TOTAL 13.9T

6.0 L.P.HEATER : SL NO DESCRIPTION WEIGHT IN TON(EACH) QTY TOTAL WT(IN

TON)1 LP HEATER FOR 3X18 MW

STG 4.5 3 13.5

2 LP HEATER FOR 3 NOS

TURBO-BLOWERS 4.5 3 13.5

TOTAL 27T

7.0 H.P.HEATER: SL NO DESCRIPTION WEIGHT IN


TON) 1 HP HEATER FOR 3X18 MW STG 8.5 3 25.5 2 HP HEATER FOR 3 NOS TURBO-

BLOWERS 4.25 3 12.75


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TOTAL 38.25T

8.0 HPH FLASH TANK SL NO DESCRIPTION WEIGHT IN

TON(EACH)QTY TOTAL WT(IN

TON)1 HPH FLASH TANK FOR 3X18

MW STG 1 3 3

2 HPH FLASH TANK FOR 3 NOS

TURBO-BLOWERS 1 3 3

TOTAL 6T

9.0 DEAERATOR : SL NO DESCRIPTION WEIGHT IN


TON) 1 SPRAY-CUM-TRAY

DEAERATOR(OVERALL HEIGHT -7500)

I) HEADER 37(TOTAL) 3 111(TOTAL) II) FEED STORAGE TANK 2 SPRAY-CUM-TRAY DEAERATOR(50

TPH) (OVERALL HEIGHT -5200)

I) HEADER 15.5(TOTAL) 1 15.5(TOTAL)

II) FEED STORAGE TANK

TOTAL 126.5 T

10.0 ST OIL COOLER : SL NO DESCRIPTION WEIGHT IN

TON(EACH) QTY TOTAL WT(IN TON)

1 ST OIL COOLER(2X100%) FOR 3X18 MW STG

5.7 3 17.1

2 ST OIL COOLER(2X100%) FOR 3 NOS TURBO-BLOWER

3.35 3 10.05

3 ST OIL COOLER FOR 1 NOS

8.275MW BPTG 2 1 2

TOTAL 29.15T

11.0 STG AIR COOLER : SL NO DESCRIPTION WEIGHT IN


TON) 1 STG AIR COOLER FOR 3X18

MW STG 0.96 3 2.88

2 STG AIR COOLER FOR 3 NOS

TURBO-BLOWERS 0.96 3 2.88

3 STG AIR COOLER FOR 1 NOS

8.275MW BPTG 0.96 1 0.96

TOTAL 6.72 T


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12.0 DRAIN COOLER : SL NO DESCRIPTION WEIGHT IN


TON) 1 DRAIN COOLER FOR 3X18

MW STG 1.65 3 4.95

2 DRAIN COOLER FOR 3

NOS TURBO-BLOWERS 1.65 3 4.95

TOTAL 9.9T

13.0 GENERATOR

SL. NO.

DESCRIPTION OF EQUIPMENT

WEIGHT IN M.TONS

QTY TOTAL WT IN M.TONS

1. GENERATOR PACKAGE FOR 3X18 MW STG

50.6 3 151.8

2 GENERATOR PACKAGE FOR I NO 8.275 MW

BPTG

25.6 1 25.6

TOTAL 177.4T

14.0 BOILER FEED PUMP SL NO DESCRIPTION WEIGHT IN


TON) 1 BFP SKID(PUMP

ASSLY+BASE

PLATE+TUBING+SEAL

COOLER)

6.9 4 27.6

2 HYDRAULIC COUPLING(DD) 1.06 4 4.24 3 HYD.COUPLING OIL

COOLER(DD) 0.5 4 2

4

HYD.COUPLING LOOSE ITEMS 0.2 4 0.8

5 SUCTION STRAINER AT BFP

SUCTION (DD) 0.8 4 3.2

6 BFP RECIRCULATION

VALVE(DD) 0.35 4 1.4

TOTAL 11.44T

15.0 ERECTION INPUTS PED BOP ( Mechanical), Auxiliary & pipings

Sl.No Equipment Description qty Unit Weighteach

Total weight

Unit -- no tons -- 1. LDO system for boilers

a Condensate drain tank with

2x100% pumps 1 5.0 5.0

b. LDO tank 1 50.0 50 2. Feed water system a. Boiler feed pumps for export 2 1.2 2.4


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b. LP dosing skids 2 4.0 8 c. HP dosing skids 1 6.0 6 3. Condensate system a. CEPs for 18MW STGs 6 2.0 12 b. CEPs for 25MW ST for

blowers 6 3.0 18

4. Cooling water system a. Main cooling water pumps-For

TB 4 15.0 60

b. Main cooling water pumps-For TG

3 12.5 38

c. Auxiliary cooling water pumps 3 10.0 30 d. Cooling water make-up pumps 2 3.5 7

5. Miscellaneous Equipment a) Sump pumps 5 0.025 0.1 b) Boiler fill pumps 4 0.050 0.2 6. Unit condensate float tank 6 25.0 150

7. Condensate transfer pumps for LDO heaters condensate

2 3.5 7.0

8. Miscellaneous pumps 8 0.1 0.8

9. Piping, Valves and fittings,insulation and supports(this is inclusive of tools and tackles(600kg))

907

907

I) CONDENSER COOLING WATER SYSTEM(STG)

-

II) CONDENSER COOLING WATER SYSTEM(TB)

-

III) TURBO-BLOWER’S-1 CONDENSATE SYSTEM UPTO HOTWELL LEVEL CONTROL VALVE

-

IV) TURBO-BLOWER’S-2 CONDENSATE SYSTEM UPTO HOTWELL LEVEL CONTROL VALVE

-

v)

TURBO-BLOWER’S-3 CONDENSATE SYSTEM UPTO HOTWELL LEVEL CONTROL VALVE

vi) SURVICE WATER DISTRIBUTION SYSTEM

vii) PA SYSTEM

viii) POTABLE WATER DISTRIBUTION SYSTEM

ix) STG-1 CONDENSATE SYSTEM UPTO HOTWELL LEVEL CONTROL VALVE

x) STG-2 CONDENSATE SYSTEM UPTO HOTWELL LEVEL CONTROL VALVE

xi) STG-3 CONDENSATE SYSTEM UPTO HOTWELL LEVEL CONTROL VALVE

TOTAL 907 907


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10 Chlorination system for cooling tower

2 0.2 0.4

a CW chlorination booster pumps

2 0.15 0.3

b CW chlorination evaporator 2 0.2 0.4

c N-pit Agitator motor 2 3.0 6.0

d Chlorine tonners

11 Acid dosing system for cooling tower

2 0.2 0.4

a Acid unloading pumps 1 5.0 5.0

b Acid storage tank

c. Acid dosing pumps 2 0.2 0.4

12. Bio-cid dosing system for cooling tower

a. Biocide unloading pumps 2 0.2 0.4

b. Chemical storage tank 2 5.0 10.0

c. Dosing pumps 2 0.2 0.4

d. Chemical mixing tank 1 1.5 1.5

13. a) DM Water transfer pump with electric motor

2 2.0 4.0

b) DM water transfer pump –coke oven plant

2 1.0 2.0

14. CW side stream filter pumps 3 10 30

15 Gear box

a Gear box for 3x18 MW STG 3 13 39

b Gear box for 1X8.275MW STG

1 8 8

16 CBD TANK 1 4 4

17 IBD TANK 1 4 4

18 TURBO-BLOWERS 3 60 180

TOTAL 1597.7T

TOTAL WEIGHT TO BE ERECTED BY PSER 2825.585T

Note:

1 All pipes shall be supplied in available commercial lengths. PSER shall consider the edge preparation, cutting of pipes as per requirement and stub welding to pipes as per isometric drgs in their scope.

2 Notes:

i) Condenser will be dispatched in semi-assembled condition. (for turbo blower only) ii) Only shell, channel, dome, tube sheet, support plates, CW nozzles, End Cover and saddle supports will be sent in assembled condition to site.(turbo blower only) iii) Tubes will be dispatched loose and tubing is to be done at site. (for turbo blower only) iv) Hot well, connecting pieces, SS Expansion Bellow, Standpipes, Surge pipes will also be sent loose for assembly at site by erection agency(For all six condensers) v)Turbo generator condenser will be supplied in tubes and tested condition.


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16.0 BALANCE OF PLANT EQUIPMENT- ELECTRICAL

THIS DOCUMENT CONSISTS OF TWO ANNEXURES

ANNEXURE – I:

CONSISTS OF ITEMS THAT ARE TO BE ERECTED, TESTED AND COMMISSIONED BY VENDOR. THESE ITEMS ARE FOR BOP (ELECTRICAL) USE.

ANNEXURE – II:

CONSISTS OF ITEMS MOSTLY ERECTION HARDWARES THAT ARE TO BE SUPPLIED, ERECTED, TESTED & COMMISSIONED BY VENDOR

INDEX FOR ANNEXURE – I

Sl. No. Description

1. Electrical package

2. HT Power Cable package

3. LT Power Cable package

4. Control & Signal Cable package

5. Cable Lugs & Glands

6. Cable Tray Packages

7. Structural Steels

8. Earthing & Lightning Protection Materials

9. Illumination Package

10. Accessories for Illumination package


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1. BOP (ELECTRICAL) PACKAGE Sl.No.

Description Unit Weight in kg Dimension (LxDxH)

mm Qty

1. 33kV GIS Sw.Board.

(Total of 30 Panels)

2000 k.g.

per Panel

800x2200x2700 Dimension of each Panel.

1

2. i) 1 no 6.6kV Power & Blowing Sw. Bd (Total of 59 Panels )

ii) 1 no. 6.6kV Steel plant Emergency Board(Total of 16 Panels)

2000 k.g.

per Panel

2000 k.g.

per Panel

48380x2355x2700

(Dim. of each Panel : 820x2355x2700)

13120x2355x2700

(Dim. of each Panel : 820x2355x2700)

1

1

3. 11/34.5 kV, 25MVA,ONAN

Generator Trafo. For STG-1,2 &3.

48565 Kg.

Oil Qty: 12880 lts.

6600x4800x

5300mm Dimension

of each Trafo. 3

4. 11/34.5 kV, 12MVA,ONAN

Generator Trafo. For BPTG.

31345 Kg.

Oil Qty: 8250 lts.

6050x4200x

4800mm Dimension

of each Trafo.

1

5. 11/34.5 kV, 20MVA,ONAN

Generator Trafo. For TRT Gen.

42465 Kg.

Oil Qty:

10745 lts.

6500x4900x

5000mm Dimension

of each Trafo

1

6. 33/6.9kV, 31.5MVA,Dyn11

ONAN

PTR-1 & 2

60335 Kg.

Oil Qty: 15430 lts.

7300x4900x

5500mm 2

7. 11/6.9kV, 5MVA,Dyn11

ONAN,PTR-3

12000 Kg.

Oil Qty: 2100 lts.

4700x3300x

3750mm 1

8. 33/6.9kV, 12.5MVA,Dyn11

ONAN,PTR-4

26710 Kg.

Oil Qty: 6750 lts.

5500x4800x

4900mm 1


85

9. 6.6/0.433kV,

2.0MVA,ONAN

SAT-1 to 8

6,000 Kg.

Oil Qty:

1400Ltr

2260x3350x

2900mm 8

10. Lighting Trafo

250 kVA ,415V/433V 1800 Kg. 1500x900x

1900mm 2

11. Emergency Lighting Trafo 100 kVA,415V/433V

1200 Kg. 1500x800x

1600mm 1

12. LT Switchgear

i) 415V PCC-1 ii) 415V PCC-2 iii) 415V PCC-3 iv) 415V PCC-4 v) 415V EPCC vi) 415V STG MCC-1 vii) 415V STG MCC-2 viii) 415V STG MCC-3 ix) 415V BPTG MCC x) 415V TB MCC-1 xi) 415V TB MCC-2 xii) 415V TB MCC-3 xiii) 415V BOP MCC xiv) 415V ACDB xv) 415V MLDB xvi) 415V AC ELDB xvii) 240V UPSDB-1 xviii) 240V UPSDB-2 xix) 220V DCDB-1 xx) 220V DCDB-2 xxi) AC & VENT SYS

MCC

11850kg

13700kg

10925kg

11850kg

7125kg

8550kg

8550kg

8550kg

8375kg

9475kg

9475kg

9475kg

22850kg

5100kg

5600kg

3400kg

6700kg

6700kg

6700kg

7250kg

17400kg

1500x10370x2430

1500x11970x2430

1500x9570x2430

1500x10370x2430

1200x9180x2430

1200x11580x2430

1200x11580x2430

1200x11580x2430

1200x10780x2430

1200x12380x2430

1200x12380x2430

1200x12380x2430

1200x32380x2430

600x7260x2430

600x8060x2430

600x4860x2430

600x9660x2430

600x9660x2430

600x9660x2430

600x10460x2430

1200x26780x2430

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1


86

13. HT Cable Kits.

i) 1Cx630sq.mm,

33kV Al Cables

ii) 1Cx630 sqmm

11kV,Al Cables

iii) 1Cx630Sq.mm,

6.6kV Al Cables

iv) v) 3Cx185Sq.mm,

6.6kV Al Cables

4kg

3kg

2kg

2kg

-----

60

12

110

70

14. PB Stations

i) Start/stop PB with ammeter and L/R Selector

ii) WP start/stop PB

STN with lockable

Stay put lock/Remote switch and stayput stop PB and Ammeter

iii) WP start/stop PB

STN with

lockable

stay put

Lock/Remote

switch and

stay put stop PB

iv) Weather proof

break glass type,

Mushroom type

emergency stop

push bottom station

3kg

5kg

5kg

5kg

180x285x125

180x295x125

180x295x125

145x245x116

40

40

100

20


87

15. 220V Station Battery Chargers.

(Total 2 Panels)

4000kg 3200x830x2350 2

16. 220V Station Battery Chargers.

(Total 1 Panels)

5000kg 4800x830x2350 1

17. 220V Station Battery.

(800AH, 110Cells)

6000kg

4370x830x2500 2

18. 220V Station Battery.

(1600AH, 110Cells)

8000kg 7000X830X2500 1

19. SCAP Panels 10500kg 15600x1250x2200 1

20

6.6 kV load break isolators for SAT-1 to 8

2500kg 2400x1650x2300 8

21 NGR for generator Trafo 400A,47.63 Ohms on 33kV side

2600kg 1900x3200x3000 5

22 NGR for PTR -1,2,3&4 Trafos 600A, 6.35 Ohms

600kg 1800x1500x2000 4

23 Rubber Mat 2mm thick for LT swgr

3kg 1M x 2M 340Nos

24

Rubber Mat 2.5mm thick for 6.6kV swgr

4kg 1M x 2M 70 Nos

25 Rubber Mat 3mm thick for 33kV swgr

5kg 1M x 2M 30 Nos

26 Fire Proof Sealing System

3000 Sq.Mtrs

27 RTCC panel 800kg 800x915x2350 8 Nos

28 Data concentrator 800x800x220 3 Nos

29 LT Bus ducts 415V,4000A,TPN Al Bus bar,50kA/!sec,Al enclosure non segregated from LT side of each Stn Aux Trafo to PMCC

5000kg 400x800x10000

(each bus duct)

8 sets


88

2. HT POWER CABLE PACKAGE

Sl. No. Cable Description Cable Type

Length in Mtrs

1.

2.

3.

4.

33kV (UE) Armoured, Al Conductor XLPE insulated FRLS outer-sheathed cable.

11kV (UE) Armoured, Al Conductor XLPE insulated FRLS outer-sheathed cable.

6.6kV (UE) Armoured; Al Conductor XLPE insulated FRLS outer-sheathed cable.

6.6kV (UE) Armoured; Al Conductor XLPE insulated FRLS outer-sheathed cable.

1C x 630 Sq.mm.

1C x 630 Sq.mm.

1C x 630 Sq.mm.

3C x 185 Sq.mm.

3000

600

6500

6000

3. LT POWER CABLE PACKAGE

Sl. No.

Cable Description Cable Type Length in Mtrs.

1.

1.1KV Armoured A1. Conductor XLPE Insulated, FRLS outer sheathed.

3.5C x 240 Sq. mm 10000

2. 1.1KV Armoured Al. Conductor XLPE Insulated, FRLS outer sheathed.

3.5C x 185 Sq. mm

7000


3.5C x 120 Sq. mm 5000


3.5C x 95 Sq.mm 5000


89

5. 1.1KV Armoured A1. Conductor XLPE Insulated, FRLS outer sheathed.

3.5C x 70 Sq.mm 5000

6 1.1KV Armoured A1. Conductor XLPE Insulated, FRLS outer sheathed.

3.5 C x 50Sq.mm 5000

7 1.1KV Armoured Al. Conductor XLPE Insulated, FRLS outer sheathed.

3.5C x 35Sq.mm 9000


1C x 240 Sq.mm 3000

9 1.1KV armoured Cu. Conductor XLPE Insulated, FRLS outer sheathed.

3C x 4Sq.mm 10000


3C x16 Sq.mm 15000


4C x16 Sq.mm 20000

12 1.1KV PVC/FRLS Un-Armoured Cu. Conductor XLPE Insulated, FRLS outer sheathed.

1C x6 Sq.mm 1000

13 1.1KV Un-Armoured Cu. Conductor XLPE Insulated, FRLS outer sheathed.

1C x 120 Sq.mm 2000

14 1.1KV Un-armoured Cu. Conductor XLPE Insulated, FRLS outer sheathed.

1C x 35 Sq.mm 1000

15 1.1KV armoured Cu. Conductor XLPE Insulated, FRLS outer sheathed.

4C x 4 Sq.mm 20000

Note:

1. The Cables at Sl no 12,13&14 are meant for Electronics Equipment Earthing Purpose. 2. Cables shall be checked for insulation resistance before and after jointing.

3. All cables of 1.1kV grade, 400 Sqmm and above and all HT power cables shall

be subjected to DC high voltage test as per table (4) of IS-1254.


90

4. CONTROL & SIGNAL CABLES PACKAGE

Sl. No.

Cable Description Cable Type Length

in Mtrs.

1.

1.1kV PVC Insulated FRLS Outer Sheathed.

3C x 2.5 Sq. mm

15,000

2. 1.1kV PVC Insulated FRLS Outer Sheathed.

5C x 2.5 Sq.mm 4,000

3 1.1kV PVC Insulated FRLS Outer Sheathed.

7C x 2.5 Sq. mm 3,000

4.

1.1kV PVC Insulated FRLS Outer Sheathed

10C x 2.5 Sq. mm

25,000

5. 1.1kV PVC Insulated FRLS Outer Sheathed

16C x 2.5 Sq.mm 8,000


19C x 2.5 Sq. mm 8,000


24C x 2.5 Sq. mm 2000

5. CABLE GLANDS AND LUGS PACKAGE

Cable Glands & lugs- 1 Lot (For run of 50mts of each variety of cables both side termination shall be considered for estimation)

Note:

1. The Cable glands are double compression type made of Nickel plated brass.

2. Cable lugs are of tinned copper suitable for termination of different cross sections of HT/LT/ Control cables. Lugs for power cables shall be of compression type whereas control/signal cables shall be of crimping type.

3. Individual termination up to wire level shall be considered.

Cable Termination & Connection:

1. The glanding, termination and connection of cables shall be done strictly in accordance with the manufacturer’s instruction, drawings and/or directed by the Purchaser.


91

2. The work shall include all clamping, fitting, fixing, soldering, tapping, compound filling, cable jointing, crimping, shorting and grounding as required for the complete job. All equipment shall be of Contractor’s procurement under this specification.

3. Control cable cores entering control panel/switchgear/MCC etc. shall be neatly bunched and served with PVC perforated tape to keep it in position at the terminal block.

4. The contractor shall put ferrules on all control cable cores in all junction boxes and at all terminations. The ferruling shall be Cross-Ferruling. The ferrules shall carry terminal numbers as per drawings. All ferrules shall be coloured, plastic & interlocked type.

Spare cores shall also be similarly ferruled, crimped with lug and aped on the ends. Spare cores shall be ferruled with individual cable number.

5. Termination & Connection shall be carried out in such a manner as to avoid strain on the terminals. Cables shall be marked with cable numbers as per applicable drawing.

6. All cable entry points shall be properly sealed and made vermin and dustproof. Unusual opening, if any, shall be effectively closed. Sealing work shall be carried out with approved sealing compound having fire withstand capability for at least 3 hours.

6. PRE FABRICATED CABLE TRAYS AND ACCESSORIES

SI no Description Quantity

Unit

1. Ladder type strt run cable tray, W=750mm.

1200 Nos

2. Ladder type strt run cable tray, W=600mm.

3000 Nos

3. Ladder type start run cable tray with 300mm accessories and coupler plates

600 Nos

4. Cover along with accessories for 300mm width ladder type cable

120 Nos

5. Cover along with accessories for 600mm width ladder type cable

600 Nos

6. Vertical down of 600mm bending radius with coupler plates for Ladder

30 Nos


92

Type Cable tray, w=300mm

7. Vertical up of 600mm bending radius with coupler plates for Ladder Type Cable tray, w=300mm

30 Nos

8. Horizontal TEE of 1250mm bending radius with coupler plates for Ladder Type Cable tray, w=750mm

45 Nos

9. Horizontal elbow bend of 1250mm bending radius with access and coupler plates for Ladder Type Cable tray, w=750mm

45

Nos

10. Vertical up of 1250mm bending radius with coupler plates for Ladder Type Cable tray, w=750mm

45 Nos

11. Vertical down of 1250mm bending radius with coupler plates for Ladder Type Cable tray, w=750mm

45 Nos

12. HOR.CROSS of 600mm bending radius for perforated tray with accessories and coupler plates ,w=300mm

12

Nos

13. HOR.ELBOW for 300mm perforated tray

35 Nos

14 HOR.ELBOW for 900mm bending radius for 600 ladder tray with accessories and coupler plates

120 Nos

15. HOR.ELBOW for 600mm bending radius for 300 ladder tray with accessories and coupler plates

30

Nos

16 HOR.CROSS of 1250mm bending rad & coupler plates for 750mm width LDR type

25

Nos

17 HOR.CROSS of 600mm bending rad & coupler plate for 300mm width LDR type

6

Nos

18 VER UP of 900mm bending rad & coupler plates for 600mm width LDR type (channel) cabletray2

120

Nos

19 VER DOWN of 900mm bending rad & coupler plates for 600mm width LDR type(channel) cable tray2

120

Nos

20 HORCROSS OF 900mm bending rad & coupler plates for 600mm width LDR type (channel)

12

Nos


93

cabletray2

21 300mm(W) Perforated type cable tray

600 Nos

22 HOR TEE of 600mm bending rad & coupler plates for 300mm width Perforated type

40 Nos

23 HOR.ELBOW BEND of 900mm bending rad & coupler plate for 600mm width ladder type.

120 Nos

24 Cover along with accessories for Perforated type Cable Tray, W=300mm

600 Nos

25 HOR.T of 600mm bending rad & coupler plate for 300mm width ladder type

30 Nos

26 Vertical up of 600mm bending radius for perforated tray with accessories and coupler plates ,w=300mm

45 Nos

27 Vertical down of 600mm bending radius for perforated tray with accessories and coupler plates ,w=300mm

45

Nos

28 Cover for Perforated type Cable Tray, W=150mm

600 Nos

29 150mm (W) Perforated type cable tray.

600 Nos

Remarks:

i) All the Pre-fabricated Ladder & Perforated type Cable& accessories like Tees, Bends, Elbows, Cross etc are made out GRP Sheets.

ii) Supply of Red Oxide Zinc Chromate Primer for site painting of all Structural Steels (required for cable Tray Supports) in the VENDOR’s scope.

iii) Cable Trays shall be numbered as per layout drawing before laying of cables.

iv) All cables shall be provided with minimum of 2mm thick aluminum sheets as cable identification tags indicating cable designation in accordance with the cable schedule. The cable tags shall be provided at the ends, every 30mtrs and when the cable changes its direction/elevation. The tags shall be of aluminium with the number punched on it and securely attached to the cable by not less than two turns of 16 SWG GI wire.


94

v) The cable trays shall be supported in general at a span of 1.5mtrs horizontally and at a distance of 1mtr vertically.

vi) Cable Tray on the top tier shall have cover whenever running below pipes.

vii) For buried cable, the marker shall project at least 150mm above ground and shall be spaced at an interval of 30mtrs and at every change of direction.

viii) All the cables shall be clamped to the cable trays/support structure with the help of clamps. All power cables shall be clamped individually and control cables shall be clamped in groups of 3 or 4 cables. Clamps for multicore cables shall be fabricated out of 25x3 mm aluminium flats. Single core power cables shall be laid in trefoil formation and suitably clamped with 25mm wide 8 SWG aluminium strips.

ix) All Sharp edges and Burr shall be removed.

x) Cables to be strapped to tray at interval not greater than 300mm.

xi) Vendor shall carry out the plant cabling works in line with customer/consultant’s Technical specifications i.e. “Notes & Details for Plant cable Laying System”

7. STRUCTURAL STEELS

Sl.no Description Quantity (K.gs)

1. ISMC 100x50 mm Channels 75000

2. ISA 50x50x6 mm Runner angles 25000

3. ISA 65x65x6 mm Runner angles 30000

Notes:

i) These materials are supplied for site to make supports for cable trays (in the buried RCC trenches, Overhead tray arrangement on pipe racks and Cable Tray arrangement in Cellars & other arrangements as applicable for the project.

Also these are required for making of frames for PB stations and junction boxes as per the project requirements.

ii) VENDOR shall ensure that all steel structure used for electrical installation shall be painted with one coat of Red Oxide Zinc Chromate Primer of approved shade for indoor installations.


95

iii) VENDOR shall ensure that after welding and drilling (if any) of the steels bracket shall be applied with above mentioned paints of approved shade.

iv) VENDOR shall carry out the structural steel works in line with customer/consultant’s technical specifications “Notes & Details for Plant cable Laying System ”

8. PLANT EARTHING & LIGHTNING PROTECTION MATERIALS

Notes:

VENDOR shall carry out the plant earthing & lightning protection works in line with customer approved “Notes and Details for Plant Earthing & Lightning Protection System”.

Sl. No

Description Quantity

Remarks

1. GI pipe Electrode 100 Nos

2. 75 x 10mm GI Strips 10,000 metresUnderground & Above ground earthing.

3. 50 x 6 mm GI Strip 2000 metres For above ground equipment earthing.

4. 35 x 6mm GI Strips 2000 metres ---do---

5. 8SWG GI wire ,solid 500 metres ---do---

6. 16SWG GI wire , solid 500 metres ---do---

7. Vertical Air Termination Rod 15 metres For Lightning Protection

8. 40 mm diameter, MS rod 5000 metres For Underground


96

9. PLANT ILLUMINATION PACKAGE

1) Details of Various Lighting Fixtures and lamps.

S. no

Equipment Vendor Catalogue

Qty

1. Recessed mounting type downlighter suitable for false ceiling mounting & 60W GLS lamp

Havells LHOL51160399

20

2 Bulk head GLS wall mounting type Havells LHKL01160099

155

3 Industrial type fixture suitable for surface mounting on wall or ceiling & 1x36W fluorescent tube

Havells LHIF71104011

70

4 Industrial type fixture suitable for surface mounting on wall or ceiling & 2x36W fluorescent tube


440

5 Corrosion resistant industrial batten for TLD 2x36W fluorescent lamp


70

6 Recess mounting type decorative lighting fixture with 2x36W flourcent lamps, copper blast ,starter & power factor improvement capacitor

Havells LHCFN1104611

400

7 Integral well-glass luminary suitable for 1x125W HPMV

Havells LHVG26112036

125

8 Industrial wellglass luminary suitable for 1x70 HPSV lamp with non integral control gear

Havells LHVW26170D36

640

9 Street lighting fixture suitable for 125W HPSV lamp with optic reflector & acrylic cover

Havells LHRS11115A36

105

10 Industrial High bay fixture suitable for 125W HPMV LampHigh bay fixture

Havells LHYG13125036

70

11 Industrial High bay fixture suitable for 250W HPMV LampHigh bay fixture

Havells LHYG13125036

155

12 Street lighting fixture suitable for 250W HPSV lamp with optic reflector & acrylic cover

Havells LHRS04125A36

20


97

2) Details of Lighting Panels & JBs:

S No

Description Unit

Weight in kg

Dimension (LxBxH) mm

Make Qty Remarks

1 6 way AC Indoor lighting panels

25 800x600x250

as per customerappro

ved vendor

24 Panel dimensions

are tentative & may vary +/- 10%

2 6 way AC Outdoor lighting panels

30 800x600x250 --do-- 5 --do--

3 6 way DC Indoor lighting panels

35 800x600x250 --do-- 15 --do--

4 6 way DC Outdoor lighting panels

25 800x600x250 --do-- 4 --do--

5 12 way AC Indoor lighting panels

30 900x600x250 --do-- 15 --do--

6 12 way AC Outdoor Lighting panels

35 900x600x250 --do-- 5 --do--

7 18 way AC Indoor Lighting Panels

25 1000x600x250 --do-- 4 --do--

8 18 way AC Outdoor Lighting Panels

1 1000x600x250 --do-- 4 --do--

3) Flexible Wires:

Sl. No

Cable Description Cable Type Length

in Mtrs.

1.

1.1KV, PVC Insulated Single Core Copper

Conductor Flexible Wires.

2.5 Sq .mm, Red 12000

2. 2.5 Sq .mm, Yellow 10000

3. 2.5 Sq .mm, Yellow 10000

4. 2.5 Sq .mm, Yellow 32000

5. 2.5 Sq .mm, Yellow 32000

6.

1.1KV, PVC Insulated Single Core Copper

Conductor Flexible Wires.

4 Sq. mm, Red 2500

7. 4 Sq. mm, Black 7500

8. 4 Sq. mm, Blue 2500

9. 4 Sq. mm, Yellow 2500

10. 4 Sq. mm, Green 7500


98

Notes:

i) VENDOR shall carry out the plant illumination works in line with customer approved “Notes & Details for illumination system” .

10. ACCESSORIES FOR ILLUMINATION PACKAGE

SL

No ITEM DESCRIPTION QTY REMARKS

1 9 mtrs. Lighting pole 16 nos Erection by VENDOR

2 2 mtrs. Lighting pole 150 nos --do--

3 3 mtrs. Lighting pole 10 nos --do--

4 Metsec channel 2500mm length

250 nos --do--

5 1200mm long 120 deg bend 50NB pipe with 2nos suitable clamp with base

125 nos --do--

6 1200mm long 150 deg bend 50NB

pipe with 2 nos suitable clamp with

base

50 nos --do--

7 3000mm long 25mm GI conduit 1000 nos --do--

8 3000mm long 50mm GI conduit 25 nos --do--

9 25mm GI bends 250 nos --do--

10 25mm GI inspection bends suitable for item sl no 7 above

250 nos --do--

11 25 mm GI straight coupler suitable for item sl no 7 above

250 nos --do--

12 3000 mm long 19mm GI down conduit

100 nos --do--

13 3000 mm long 25mm PVC conduit 100 nos --do--

14 25mm PVC bend suitable for item sl no 13 above

50 nos --do--

15 25mm Flexible PVC conduit 200metre --do--

16 PVC gland suitable for 25mm PVC flexible conduit item sl no 15

200 nos --do--

17 4 way conduit branching JB for 25mm GI conduit

250 nos --do--

18 Spring loaded ball and sockets suitable for 19mm dia GI down conduit

500 nos --do--

19 6mm dia x 35mm long anchor bolt with nut &washers

2000 nos --do--


99

20 6mm dia x 35mm long anchor bolt with hook,nuts & bolts & washers

1000 nos --do--

21 12.5mm dia anchor bolt straight with nut & washers

100 nos --do--

22 3mm dia anchor fasteners with nut & washers

500 nos --do--

23 Saddle with saddle bar suitable for 25mm dia conduit with hardware

5000 nos --do--

24 19mm cable clamps with base 5000 nos --do--

25 4 way 150x100x100mm rectangular sheet steel JB with two 1” and two 3/4” cable entries along with glands and TB suitable for 6nos. 35sq.mm cable

100 nos --do--

26 Double compression nickle plated brass cable glands 1” for safe area suitable for item no. 25

250 nos --do--

27 Double compression nickle plated brass cable glands 3/4” for safe area suitable for item no. 25

2000 nos --do--

28 Check nuts suitable for 19mm GI conduit

5000 nos --do--

29 Galvanised steel chain 500 metre --do--

30 S hook 250 nos --do--

31 Rubber grommet(19 mm) 500 nos --do--

32 Rubber grommet (25mm) 500 nos --do--

33 FSB-2 Flush mounted swbd with 2 nos 15A piano type switched & 15A receptable with switch (modular type)

30 nos --do--

34 FSB-3 Flush mounted swbd with 5 nos piano 15A piano type switched &15a receptable with switch (modular type)

30 nos --do--

35 FSB-5 Flush mounted swbd with 5 nos piano 15A piano type switched & 15A receptable with switch (modular type)

20 nos --do--

36 Domestic type 5/15A socket with switch ( flash mounted modular)

20 nos --do--

37 Industrial metal clad weather proof type 5/15A socket with switch

75 nos --do--

38 63ATPN welding receptacles weather proof type

35 nos --do--

39 63A TPN welding receptacles(Flame proof area)

2 nos --do--

40 240V to 24v Supply module with hand lamp and 15 mtr cable

4 nos --do--


100

ANNEXURE – II

MISCELLANEOUS ITEMS REQUIRED FOR ERECTION.

SUPPLY, ERECTION, TESTING COMMISSIONING BY VENDOR

17.0 BALANCE OF PLANT EQUIPMENT- C&I AREA 1.0 a) List of Items to be Procured, Erected & Commissioned by Vendor

Sl. No.

Item Description Applicability (Note1)

Quantity (NOS)

Remarks

1 Cable Glands (Non –ex proof), Double compression, Ni coated brass/SS. (approved make/manufacturer of items to be supplied by bidders as per COMET or equivalent to be approved by BHEL)

Size- ½” Y 2000 Size- ¾” Y 1000 Size-1” Y 1500 Size-1-1/4” Y 500 Size- 1-1/2” N 1200 Size- 2” N 1000 2 Cable Glands (Ex- proof) ), Double compression, Ni coated brass/SS.

(approved make/manufacturer of items to be supplied by bidders as per COMET or equivalent to be approved by BHEL)

Size- ½” Y 500 Size- ¾” Y 400 Size-1” Y 500 Size-1-1/4” Y 200 Size- 1-1/2” Y 300

Sl. No.

Description QTY(nos) Remarks

1. Cable Tags 2mm thick, 75mm long, 15mm width Aluminium Strips.

1000 At entry, exit & at every 30 mtrs of cable run length.

2. Trefoil clamps for single core cables –25mm wide 8SWG Aluminium Strips.

500 @ Every 3 mtrs of cable

length

3. Clamps for multicore cables---25x3mm Aluminium flats.

500 ---do---

4. 3mm dia Nylon Cord 500 Required for tying cables to trays, at every 5mtrs.

5. Hardware for Erection (like Nuts,bolts,washers etc) 500


101

Size- 2” Y 300 3 Tinned Cable Lugs at both ends

(approved make/manufacturer of items to be supplied by bidders as per COMET or equivalent to be approved by BHEL)

Size- for 0.5 mm2 cable Y 2000 Size- for 1 mm2 cable Y 2000 Size- for 1.5 mm2 cable Y 2000 Size- for 2.5 mm2 cable Y 2000 4. PVC Cable Gland shrouds (covers) Y 9000 5 Cable ferruling numbers &

characters Y 10000

6. Name plates/Tag plates with tying/fixing material for cable’s both end & filed instruments

Y 1000 @ 100 meters per run of cable

7 Cable Markers Y 500 @ 100 meters per run of cable

8 Cable Supporting channels/angles (MS) with clamps, from JB to instrument

Y 1MT @25 meters from JB to each inst.

23 Nuts & Bolts, Clamps,Washers Y 500 24 Cable Fastening Material Y 500

Note1: Tick ‘Y’ if applicable, other wise ‘N’.

1.b)Raw material to be Fabricated, Erected & Commissioned by vendor

C&I contractor shall fabricate the instrument supporting structures, stands as per typical drawing enclosed. Contract can use modified drawing as per site convenient, to meet the mounting location, elevation, space availability etc in consultation with site- in charge.


102

Sl. No.

Item Description Quantity Remarks

1 Cable Supporting channels/ angles (MS) with clamps, from JB to instrument

3000 kgs

2 2” GI pipe for transmitter and JB mounting & Support set up

2000 meters

2” Pipe Caps 300 nos 2” GI pipe Elbow 300 nos 3 MS angle iron- 50x50x6 mm for

panel base frame & its site fabrication

3000 kgs

4 MS angle iron- 50x50x6 mm for JB mounting & its site fabrication

2000 kgs

5 Impulse line supporting clamps for pipe ¾” or ½” or ¼”

5000 nos

6 Gusset Plates (6mm TH) 200mm x 80mm, MS 2500 nos

For instrument stand pipe

7 Base Plates (6mm TH) 250mm x 250mm, MS 1500

For instrument stand pipe

8

Angle 40x40x4 mm, MS 1500m

For Inst/ canopy/JB’s supports

9 Angle 35x35x4 mm, MS 1500m 10 Angle 50x50x6 1800 m For JB outlet cable 11 ISMC 100x50 mm Channel, MS 1500m For JB mounting 12

6mm TH plate, MS 1000 kgs For JB / Gauges mounting

13 50 x 6 mm Flat, MS 300 meter 14 Pre-Fabricated canopies for Jb’s,

transmitters, field switches, gauge boards etc. As required

Approx 800 nos

15 False flooring Base frame stand for panels As required

Approx 50nos

Note2: Quantity indicated above is preliminary based on basic engineering documents & it may very during actual erection work. Erection agency shall consider at least +/- 20% on indicated BOM.

Legends: m- Meters


103

2.0 Items to be Erected & Commissioned by VENDOR

2.1 Instrumentation Package

S No. Description Qty 1 Control valves (Approx weight 80 kgs) 100 2 Desuperheaters (Approx weight 100 kgs) 8 3 Turbine Bypass system(Approx weight 130 kgs) 4 4 Pressure Safety valves (Approx weight 75 kgs) 15 5 Thermal Safety valves (Approx weight 75 kgs) 10 6 Flow orifice plates (Approx weight 80 kgs) 30 7 Flow nozzles (Approx weight 80 kgs) 25 8 Mass flow meters 6 9 Pressure gauges 270 10 Pressure transmitters 100 11 Pressure switches 25 12 Diff. pressure gauges 35 13 Diff. pressure transmitters 150 14 Diff. pressure switches 25 15 Temperature gauges 250 16 RTDs 60 17 Thermo couples 70 18 Level gauges 35 19 Level transmitters (Displacer Type) 40 20 Level switches 120 21 Annubars 10 22 Handheld Calibrator 2 23 Instrument canopies 500 24 Erection material for above items ( i ) needle/ globe valve 2000 ( ii )comp & con. fittings LOT ( iii ) condensing chambers 350 (iv) Syphon 350 (v) 5 way manifolds 500 (vi) Air filter regulators 100 (vii) Thermowells 400

25 Impulse pipes &tubes for impulse connection for instrument hookup ( i ) SS tube 12.7 x 2.1 mm 3000m (ii) SS tube 6.35 x 0.9 mm 1600m (iii) ERW / SAW Steel tube 60.8 x 3.65 (NB 50) 4500m (iv) SS pipe 33.4 x 3.4 mm 2000m (v) SS pipe 21.3 x 3.7 mm 4000m (vi) SS pipe 6 x 1 mm 4500m

26 STRL Steel (Std Quality) (i) Strl ST equal angle 50 x 50 x 6 1500 Kgs (ii) Strl St channel 100 x 50 1000 Kgs (iii) Strel St PL 6 600 Kgs


104

2.2 Cables Package

S No. Description Qty 1 Signal Cables 1P x 1.5 sq.mm (Intrinsic Safe), Individual & Overall shielded 5000 m 8P x 0.5 sq.mm (Intrinsic Safe), Individual & Overall shielded 15000 m 12P x 0.5 sq.mm (Intrinsic Safe), Individual & Overall shielded 15000 m 1P x 1.5 sq.mm, Individual & Overall shielded 50000 m 8P x 0.5 sq.mm, Individual & Overall shielded 75000 m 12P x 0.5 sq.mm, Individual & Overall shielded 85000 m 1P x 0.5 sq.mm, Overall shielded 200 m 6P x 0.5 sq.mm, Overall shielded 200 m 12P x 0.5 sq.mm, Overall shielded 200 m 2T x 0.5 sq.mm (Intrinsic Safe), Individual & Overall shielded 200 m 1T x1.5 sq.mm, Individual & Overall shielded 6000 m 8T x1.5 sq.mm, Individual & Overall shielded 15000 m 1P x 16 AWG Cr-Al Extension 5000 m 6P x 20 AWG Cr-Al Extension 1000m 12P x 20 AWG Cr-Al Extension 10000m 2 Junction Boxes 44 terminals, weather proof 150 nos 44 terminals, explosion proof 30 nos

2.3 Analysers Package Erection of analyzers is in VENDOR scope. Vendor will provide commissioning supervision.

S No. Description Qty 1 CONDUCTIVITY ANALYZERS 10 nos 2 PH ANALYZERS 10 nos 3 DISSOLVED OXYGEN ANALYZERS 5 nos

2.4 UPS & VMS Package Erection of UPS & VMS is in VENDOR scope. Vendor will provide. commissioning supervision

S No. Description Qty 1 UPS Package (Approx weight 1000 kgs) 10 no of panels 2 Vibration Monitoring System (Approx weight 600 kgs) 10 no of panels


105

2.5 DCS packages : Erection and commissioning of this package are in the scope of vendor.

18 .0 C&I ITEMS FOR BOILER (EACH UNIT) CUST PG MA NS WBS Description Wt in Kg0492 97 088 8 Elctronic Level Indicator 100492 95 088 8 Fsss Flame Scanner 150492 97 196 8 Electrodes & Gaskets Ewli 0.770492 97 084 1 Analysers 5000492 97 088 1 Elctronic Level Indicator 6000492 97 284 1 Field Gauges 3000492 97 298 1 Mtm Thermo Couples & Junction Boxes 8000492 95 088 1 Fsss Flame Scanner 1000492 95 089 1 Fsss Local Gun Maintenance Switch Box 200492 95 091 1 Fsss Field Interconnecting Equipments 5,000.000492 95 092 1 Fsss Control Cables 10,000.000492 96 088 1 Bearing Vibration Monitering System 1500492 97 195 1 Pressure & Vessel And Accessories Ewli 128.4520492 97 577 1 Erv Control Equipments 100492 09 003 1 Material For Instrument Inserts 175.370492 96 186 1 Soot Blower Motor Control Centre 20,000.000492 96 187 1 Soot Blower Cables & Accesories 28,000.000492 97 285 1 Field Switches 2000492 97 099 1 Acs Field Inter Connecting Equipments 5,000.000492 96 193 1 Miscellaneous Starter Box 2000492 96 188 1 Furnace Temp. Probe starter Box 300492 96 189 1 Local Control Box 300492 25 020 1 Erection Materials for instruments 1400492 97 097 1 Instrumentation Field Transmitters 3000492 97 960 1 Face Cutter Tool Ewli 20492 97 747 1 Earthing System 800

72511.592

19.0 ELECTRICAL AND C&I ITEMS FOR 3X18 STG(UNIT)

SL. NO.


OVERALL DIMENSIONS IN mm

WEIGHT IN M.TONS

QUANTITY IN NOS

2. PHASE SEGREGATED BUS DUCT

40 meters. 1250 400 5

3. PTSP CUBICLE 1950 2100 2500 2 3 4. NGT CUBICLE 1400 1300 2300 1.2 3 5. GENERATOR

CONTROL DESK 1722 1566 1677 1.8 3

6. RELAY PANEL 1600 800 2300 1.2 6


106

CONTROL CABLES: (EACH UNIT) Size Length in meters Weight in tons 3Cx4 sq.mm 1000 1 5Cx2.5 sq.mm 1000 1 10Cx2.5 sq.mm 1500 1.5 2Cx0.75 sq.mm 500 1 3Cx6 sq.mm 500 1

20.0 ELECTRICAL AND C&I ITEMS FOR 1X8.275 MW BPTG

S. NO.


OVERALL DIMENSIONS IN MM WEIGHT IN M. TONS

QUANTITY IN NOS

LENGTH BREADTH HEIGHT 1 PTSP CUBICLE 1950 2100 2500 2 1 2 NGT CUBICLE 1400 1300 2300 1.2 1 3 CONTROL DESK 1722 1566 1677 1.0 1 4 RELAY PANEL 1600 800 2300 1.2 2

5 CONTROL CABLES 4500 5.3 1 LOT for the following cable

CONTROL CABLES

3Cx4 sq.mm 1000 (L) 1(weight in tonns)

5Cx2.5 sq.mm 1000 1

10Cx2.5 sq.mm 1500 1.5

2Cx0.75 sq.mm 500 1

3Cx6 sq.mm 500 1


107

21.0 ELECTRICAL AND C&I ITEMS FOR TURBO BLOWER (EACH UNIT) (ITEMS TO BE CALIBRATED, ERECTED, COMMISSIONED BY VENDOR) A) LOCAL/FIELD MOUNTED INSTRUMENTS AND DEVICES: SL NO ITEM DESCRIPTION QTY(NOS)

REMARKS

1 Pressure gauges 40 750 kgs 2 Differential Pressure gauges. 4 3 Electronic Pressure

transmitters/Temperature transmitters 110

4 Pressure switches 10 5

Electronic diff. Pressure transmitters 6

6 Temperature Gauges (Bimetallic) 6 7 Temperature Gauges (MIS) 6 8 Thermo couples 20 9 Thermo wells 35 10 Level gauges 3 11 Level transmitters 2 12 Speed measuring loop 6 13 Control valves 10 14 Electro-pneumatic converters 3 15 Vibration Probes 12 16 Axial Displacement Probe 5 17 LVDT Casing Expansion Probe 1 18 Probe Housing Assembly 5 19 Differential Expansion Probe 2 20 Safety relief valve 2 21 Solenoid valves 4 22 Velocity probes(Velomitor) 2

Panel mounted instruments SL NO ITEM DESCRIPTION QTY(NOS)

REMARKS

1 Vibration, Axial displacement

monitoring system. (Mounted on EDN panel)

1 Bently nevad 3500 series 120 kgs

2 Tubo log Antisurge control system(Mounted on EDN panel)& surge detector

2 70 kgs

3 Configuration Work station for TSI 1 Bently Nevada 80 kgs


108

BB. PANELS AND CUBICLES:

Sl.No. ITEM DESCRIPTION DIMENSION QTY. REMARKS

1. Local gauge board 1200(W) x 1300(H) 1 200 kgs

2. Governing console board

1400(W) x 1600(H) x 350(D)

1

250 kgs Structural steel supplied, Racks to be fabricated at site

a. CHANNEL 75 X 40mm 50 Meters b. ANGLE 50 X 50 X 6mm 50 Meters

c. SHEET 4mm THICK (400 X 120mm) 60 No.s

d. PLATE 10mm thick (375 X 770mm) 10 No.s PROCESS IMPULSE TUBING AND PNEUMATIC TUBING FITTINGS SL NO ITEM DESCRIPTION QTY(MTS) REMARKS 1 CS PIPE 21.3 X 3.73 600 750KGS 2 SS TUBE 12.7 X 2.1 300 3 SS TUBE 6 X 1 100 80KGS

DD. LOOP CHECKING:

SL NO ITEM DESCRIPTION NO OF LOOPS 1 PNEUMATIC 9 2 ELECTRICAL 180


109

VOl - II

APPENDIX – II

LIST OF T&P TO BE PROVIDED BY BHEL FREE OF HIRE CHARGES ON SHARING BASIS

SL.NO.

DESCRIPTION & CAPACITY OF T&P

QUANTITY PURPOSE

01 EOT CRANE IN TG HALL 35 MT CAPACITY

01 No FOR HANDLING AND ERECTION WITHIN TG HALL.

02 SPECIAL T&Ps SUPPLIED BY BHEL/ MANUFACTURING UNITS **

01 FOR ERECTION, COMMISSIONING OF TG & AUX.

03 CLASS CRAWLER CRANE 150MT CAPACITY

1 no. with free fuel & operator

NOTE: ** The items issued by BHEL shall be used by the contractor for erection and commissioning works and has to be returned to BHEL after job completion in good working condition.

a) OPERATOR FOR EOT CRANE WILL BE PROVIDED BY THE CONTRACTOR.

NORMALLY EOT CRANE IN TG HALL WILL BE PROVIDED BY BHEL/ CUSTOMER. OPERATION OF EOT CRANE WILL BE DONE BY CONTRACTOR'S OPERATOR , WITHIN THE QUOTED RATE. CONTRACTOR HAS TO INDICATE THEIR REQUIREMENT OF EOT CRANE WELL IN ADVANCE AND DEPENDING ON AVAILABILITY, EOT CRANE WILL BE PROVIDED. CONTRACTOR HAS TO ARRANGE OPERATORS TO WORK IN NORMAL WORKING HOURS INCLUDING ON NORMAL WORKING DAYS/HOLIDAYS/SUNDAYS. ALL EOT CRANE OPERATORS SHOULD HAVE LICENSE FOR OPERATING THE EOT CRANES. MINOR DAY TO DAY MAINTENANCE OF EOT CRANE SHALL BE DONE BY THE CONTRACTOR. MAJOR BREAKDOWN WORK SHALL BE TAKEN UP BY BHEL/CUSTOMER. ANY MANPOWER NECESSARY TO CARRY OUT ABOVE MAINTENANCE WORKS SHALL BE PROVIDED BY THE CONTRACTOR WITHIN THE QUOTED RATE. IN CASE OF ANY EXIGENCIES/REQUIREMENT OF WORK OPERATOR FOR EOT CRANE SHALL HAVE TO BE ARRANGED BY CONTRACTOR WITHIN QUOTED RATES.

FOR OPERATION OF EOT CRANE THE CONTRACTOR SHOULD TAKE FULL RESPONSIBILITY TO MAINTAIN IN SAFE WORKING CONDITION. ANY NEGLIGENCE ON CONTRACTOR’S PART SHALL BE VIEWED SERIOUSLY AND THEY SHALL BE ACCOUNTABLE FOR THIS.

IN ADDITION TO BHEL’S TURBINE,GENERATOR &AUX. SCOPE OF WORK,THE CONTRACTOR HAS TO ARRANGE SERVICES OF EOT CRANE OPERATOR(S) FOR CARRYING OUT MATERIAL HANDLING JOBS INSIDE TG HALL EVEN FOR OTHER AGENCIES WHO ARE WORKING FOR BHEL/CUSTOMER.THIS IS INCLUDED IN THE CONTRACTOR’S SCOPE OF WORK AT NO EXTRA COST.SHARING OF CRANE(S) SHALL BE DECIDED BY BHEL/CUSTOMER AND HAS TO BE COMPLIED WITH BY THE CONTRACTOR.CRANE OPERATION SHALL HAVE TO BE CARRIED OUT IN NORMAL AS WELL AS EXTENDED HOURS FOR TG /OTHERS’ SCOPE OF WORK ON REGULAR BASIS ON ALL WORKING DAYS,SUNDAYS AND HOLIDAYS AS PER REQUIREMENT.CONTRACTOR WILL ARRANGE EOT CRANE OPERATION FOR THIS WITHIN THEIR QUOTED RATE. ELECTRICITY CONSUMPTION CHARGES FOR EOT CRANE (S) OPERATION OF TG HALL EOT CRANE IS NOT CHARGEABLE TO THE CONTRACTOR.

b) ALL SPECIAL T&Ps/ Slings SUPPLIED BY BHEL MANUFACTURING UNITS SHALL BE ISSUED TO

CONTRACTOR ON FREE OF COST BASIS. HOWEVER, THE CONTRACTOR HAS TO RETURN THE SAME IN GOOD WORKING CONDITION.

c) EOT CRANE WILL BE USED ON SHARING BAISIS BY OTHER AGENCIES WORKING WITHIN THE TG HALL

UNDER THE INSTRUCTION OF BHEL. THE CONTRACTOR SHALL EXTEND THE SERVICES OF HIS OPERATOR TO SUCH OTHER AGENCIES AS WELL AS ON MUTUALLY AGREED BASIS.


110

APPENDIX-III

MAJOR TOOLS AND PLANTS & MMDs TO BE DEPLOYED BY THE CONTRACTOR

A: TOOL & PLANTS

Sl.No. Description Quantity Deployment period/Remarks

01. Straight edges set As required As required

02. 08 /10/12 MT Hydra Crane/Escort/Tata P&H-1320 or equivalent

Two No Within 15 days from the date of LOI

03 Electro Hydraulic Pipe bending m/c One As required to bend pipes upto Nb 100 mm

04. Trailers with suitable capacity above 20 MT Capacity

As required As required at site

05 Truck ,20 MT Capacity As required As required at site

06 Welding Generators (Electric as well as Diesel)

As required --do--

07 3 Phase complete set up for drawal of Construction Power

As Required --do--

08 Radiography arrangement including source and film viewer

--do-- --do--

09 TIG Welding Sets --do-- --do--

10 Stress Reliving equipment with Temperature Recorders

--do-- --do--

11 Electrical Baking Oven (Big) --do-- --do--

12 Electrical Baking Oven(portable) --do-- --do--

13 Mixer machine for Grouting of Equipment of foundations

--do-- --do--

14 Vacuum Cleaner(Industrial) one --do--

15 Portable Pipe Cutting & Bending M/C for bending pipes upto Nb 100 mm.

One --do--

16 Electro-Hydraulic Pipe Bending M/C for pipes bending pipes upto Nb 100 mm. with pipe wall thickness upto 12 mm,

As required --do--


111

17 Air Compressor 01 As per site requirement

18 Step Down Transformer (230 V/24V) with adequate number of lamps of 24 Volts

As required do--

19 Condenser Tube Expander Set, Flare up tool/bell mouthing tools as per requirement set with adequate spares, mandrels, expanders ,accessories consumables etc.

Minimum 02 sets As per site requirement and to be arranged at site at least one month before tube expansion start

20 Condenser Tube Cutting Set with adequate accessories ,spares, consumables and cutting tools

Minimum 02 sets As per site requirement and to be arranged at site at least one month before tube expansion start

21 Electrically Operated Winches 5/3 MT Capacity

As required As per site requirement

22 Jacking Bolts/Press Out bolts As required As required

23 Jacks of 100 MT Capacity with hand operated pumps and jacks, hoses etc.

04 Nos. As required( M/S Enerpac, Lukas pr approved equivelant).

24 Jacks of 50 MT Capacity with hand operated pumps and jacks, hoses etc.

04 Nos. --do--

25 Torque Wrench (0-200 N-M Capacity) with all fittings

01 no As required

26 Torque Wrench upto 2000 N-M Capacity) or above

01 no As required

27 Bolts Stretching Device ( For Turbine ,Generator and auxiliaries)

As required As required

28 Long filler set As required As required

29 Spanners/eye bolts/de-shakles As required As required

30 Erection/Commissioning Fixtures As required As required

31 Scaffolding materials with steel pipes, clamps, GI Sheets, Planks etc.


32 Coat-meter for thickness checking of Paint thickness

01 No. As required

33 Deleted 02 Nos. As required

34 Micro-ohm meter as per 01 No. As required


112

requirement

35 Digital multimeters (3.5 digits) 02 Nos. As required

36 Digital multimeters (4.5 digits) 01 No. As required

37 Vernier As required As required

38 Dial Gauges of different sizes and types as per requirement


39 Micro-Meter ( both inside and outside)


40 Welding Rectifiers As required As required

41 Chain pulley block of 16 MT As required As required

42 Chain pulley blocks of other capacities


43 Pulling & lifting m/c upto 5MT Capacity


44 Multi Sheave pulley upto 100 MT As required As required

45 Single Sheave pulley blocks upto 20 MT Capacity


46 Gas cutting torches of different sizes and capacity


47 Grinding Machine As required As required

48 Drilling machine As required As required

49 Pistol Drilling M/c As required As required

50 Wire Rope slings(different sizes) As required As required

51 Loose wire ropes (different sizes) As required As required

52 Hydraulic jacks with total sets of 25 ,10,5 MT capacity as per requirement


53 Wooden Sleepers As required As required

54 Hydro-test pumps(hand operated) 02 Nos. As required

55 Deleted

56 NDT test kits as per requirement As required As required

57 Rails as per requirement As required As required

58 Steel Tapes of different sizes as per requirement



113

59 Plumb Block as per requirement --do-- --do--

60 Surface Plates of different sizes As required As required

61 Straight Edges of different sizes --do-- --do--

62 Feeler Gauges of different sizes --do-- --do--

63 Callipers of different sizes as per requirement

--do-- --do--

64 Bolt heating thermocouples --do-- --do--

65 Magnifying glasses as per requirement

--do-- --do--

66 Piano-wire as per requirement --do-- --do--

67 Precision water level micro-meter as per requirement

--do-- --do--

68 Parallel and V-blocks as --do-- --do--

69 Taper wedge as per requirement --do-- --do--

70 Lead wire as per requirement --do-- --do--

71 Dial bore indicator as per requirement

--do-- --do--

72 Digital weighing machine --do-- --do--

73 Thermometer of different ranges --do-- --do--

74 Depth gauges as per requirement --do-- --do--

75 Vernier Callipers of different sizes as per requirement

--do-- --do--

76 GO and No Go Gauge as per requirement

--do-- --do--

77 Drill Sets as per requirement --do-- --do--

78 Taps and die sets as per requirement

--do-- --do--

79 Spirit levels as per requirement --do-- --do--

80 Hg manometer --do-- --do--

81 1.0 KV/2.5 KV/5.0 KV Megger as per requirement

--do-- --do--

82 Variac (3 phase 10 amp) ad per requirement

--do-- --do--

83 Reamers of different sizes as per requirement

--do-- --do--


114

84 Sand blasting m/c as per requirement

--do-- --do--

85 Spray painting m/c as per requirement

--do-- --do--

86 Bearing pullers as per requirement --do-- --do--

87 Bearing scrappers and other scrappers as per requirement

--do-- --do--

88 Slip gauges as per requirement --do-- --do--

89 MIG Welding Sets as per requirement

--do-- --do--

90 Fillers of different sizes as per requirement

--do-- --do--

91 Allen key/screw driver sets as per requirement

--do-- --do--

92 Files of different sizes as per requirement

--do-- --do--

93 Socket wrench sets as per requirement

--do-- --do--

94 Bench grinders as per requirement --do-- --do--

95 Belt ,Number ,Letter punches as per requirement

--do-- --do--

96 Lead, Steel, Test, Wooden, Plastic, Nylon Hammer sets as per requirement

--do-- --do--

97 Fire proof tarpaulins as per requirement

--do-- --do--

98 Pipe Cutters as per requirement --do-- --do--

99 Rubber, PVC hoses with/without re-enforcement of different sizes as per requirement

--do-- --do--

100 Magnetic base for drilling m/c --do-- --do--

101 Vibrator and mixer m/c for grouting as per requirement

--do-- --do--

102 End mill cutter or suitable device for cutting condenser tubes as per requirement

--do-- --do--

103 Mercury plumb block --do-- --do--

104 Needle vibrators --do-- --do--


115

105 Copper Rods --do-- --do--

106 All kinds of NDT Test kits as per requirement

--do-- --do--

107 Other T&Ps as per requirement to complete the job.

--do-- --do--

108 U/V Lamp as required --do-- For condenser leak test and fluorescence test

109 Ropes of different sizes and lengths as per requirement

--do--

110 Gantry crane --do-- As required

B: MEASURING AND MONITORING DEVICES (MMD): AS PER REQUIREMENT TO BE FINALIZED AT SITE.

NOTE :

THIS ABOVE LIST IS ONLY INDICATIVE AND NEITHER EXHAUSTIVE NOR LIMITING. QUANTITIES INDICATED ABOVE ARE ONLY THE MINIMUM REQUIRED. CONTRACTOR SHALL DEPLOY ALL NECESSARY T&P TO MEET THE SCHEDULES & AS PRESCRIBED BY BHEL.


116

APPENDIX-IV

LIST OF CONSUMABLES TO BE PROVIDED BY THE CONTRACTOR

Sl.No. Description Quantity Remarks

01. Gases like O2,CO2,N2,Argon,D/A and others as per requirement

As required

02. Filler wire for both SS and others as required

As required

03. Ordinary Portland Cement As required

04 Grouting materials/ Grouting cements

As required

05. Flourocene powder --do-- For condenser tube leak detection

06 Plugs for condenser tubes --do-- For plugging damaged tubes of condenser

07 Lapping compound --do-- For valves servicing

08 Mercury --do-- For Generator gas tightness test and other applications as required

09 Hydraulic oil --do-- For uses in different equipment and hydraulic jacks, pumps and other applications

10 Paints for preservation, touch up painting, normal and final cum finish painting

--do-- For painting

11 Different types of electrical lamps, tube lights , halogen lamps, sodium vapour lamps with fixtures

--do-- As required

12 Electrodes as per requirement --do-- --do--

13 Test pieces for welders test like plates, pipes etc.

--do-- --do--

14 Brazing Rods --do-- --do--


117

15 Soldering consumables --do-- --do--

16 Consumables for welding and NDTs

--do-- --do--

17 Thermal chalks of different ranges --do-- --do--

18 Consumables for Pre-heating, Stress Relieving, Post heating etc.

--do-- --do--

19 Consumables for arranging welders’ qualifying works

--do-- --do--

20 Welders accessories --do-- --do--

21 Handling accessories for handling chemicals, Control fluid and other items as required

--do-- --do--

22 Services for effluent disposal --do-- --do--

23 Rustolene --do-- --do--

24 Kerosene --do-- --do--

25 CTC, Acetone as per requirement --do-- --do--

26 Petrol --do-- --do--

27 Diesel --do-- --do--

28 Special Consumables for TG & Aux. like Hylomar, Golden Hermetite, Stag-B, Molykote , Anabond compounds, Locktite, Rubber fixing compounds/rubber,plastic,PVC hoses as per requirement

--do-- --do--

29 Shellack Compound

--do--

30 Red Lead --do--

31 Hemp Fibre --do--

32 Asbestos Rope (Pure) 2,4,6,8,10, 12,25 mm and other sizes as required

--do--

33 Insulation Adhesive Tape 20 mm Width and other sizes as per requirement

--do--

34 Emery Tape as per requirement

--do--

35 Hack-shaw of different sizes as per requirement

--do--


118

36 Emery Paper Gr. 60, 80, 100, 120, 150 , 220 and others as per requirement

--do--

37 Asbestos Cloth in Wax Paper 1X1 M –as required

--do--

38 PACKING BLACK PAPER 1X1 M --do--

39 ADHESIVE TAPE 0.3 mm THICKNESS-as required

--do--

40 WHITE COTTON TAPE 12 mm WIDTH-as required

--do--

41 GRAPHITE POWDER FINE QUALITY – as required

--do--

42 GRAPHITE FLAKES as required

--do--

43 RAW LINESEED OIL as required

--do--

44 DOUBLE BOILED LINSEED OIL AS REQUIRED

--do--

45 CYLINDER OIL AS REQUIRED --DO--

46 ENAMEL PAINT ( OF REQUIRED COLOUR) AS REQUIRED

--DO--

47 MOBILE VELOCITE OIL 'S' AS REQUIRED

--DO--

48 TURPENTINE OIL AS REQUIRED --DO--

49 TRICHLORO ETHYLENE AS REQUIRED

--DO--

50 METHYLATED SPIRIT AS REQUIRED

--DO--

51 MOBILOX GREASE 2 (IOC) AS REQUIRED

--DO--

52 SERVOGEM –2,3 GREASE AS PER REQUIREMENT

--DO--

53 OTHER SPECIAL GREASE AS PER REQUIREMENT

--DO--

54 RUST BAN (ESSO) AS PER REQUIREMENT

--DO--

55 MOLYKOTE PASTE AS PER REQUIREMENT

--DO--

56 BIRKOSITE AS PER --DO--


119

REQUIREMENT

57 WASHING SODA AND SOAP AS PER REQUIREMENT

--DO--

58 COTTON WASTE AS PER REQUIREMENT

--DO--

59 CLEAN RAGS AS PER REQUREMENT

--DO--

60 WHITE CLOTH (CEARSE) AND USED CLOTHS AS REQUIRED

--DO--

61 SACK CLOTH AS PER REQUIREMNT

--DO--

62 JELLEY SOAP OR BAR SOAP AS PER REQUIREMENT

--DO--

63 EMERY CLOTH 100 mm WIDTH ROLL GR. 60, 100, 120, 150,220 AND OTHERS AS PER REQUIREMENT

--DO--

64 SAND PAPERS GR. 60, 80 ,120 AND OTHER AS PER REQUIREMENT

--DO--

65 EMERY PASTE (VALVE LAPPING COMPOUND) GR. 60, 80, 100 & 220 AND OTHERS AS PER REQUIREMENT.

--DO--

66 GRINDING WHEELS, STONES OF DIFFERENT SIZES AS PER REQUIREMENT

--DO--

67 WELDING ELECTRODES (CARBON STEEL,M.S., ALLOY STEEL AND FILLER WIRES, STAINLESS STEEL BOTH FERROUS AND NON FERROUS) EXCEPTING THOSE SUPPLIED BYBHEL AS PER ANNEXURE-IV) AS PER REQUIREMENT

--DO--

68 SOLDERING STICK( LEAD -TIN ALLOY) AS PER REQUIREMENT

--DO--

69 SOLDERING WIRE (SILVER ALLOY) AS PER REQUREMENT

--DO--

70 SOLDERING FLUX (SILVER ALLOY) AS PER REQUIREMENT

--DO--

71 BRZING FLUX/BORAX AS REQUIRED

--DO--

72 SOLDERING FLUX (LEAD-TIN --DO--


120

ALLOY) AS REQUIRED

73 MS GAS WELDING WIRE AS REQUIRED

--DO--

74 DP TEST KIT WITH MAGNIFYING GLASS AS REQUIRED

--DO--

75 IRON AND STEEL SECTIONS AS REQUIRED

--DO-- FOR ARRANGING SCAFFOLDING AND FIXTURES ETC.

76 MS BOLTS AND NUTS WITH TWO PLAIN WASHERS AND ONE SPRING WASHER AS REQUIRED.

--DO--

77 MS ANGLES ASSORTED AS REQUIRED

--DO--

78 MS CHANNELS ASSORTED AS REQUIRED

--DO--

79 ROUNDS ,FLATS,MS PLATES ASSORTED AS REQUIRED --DO--

80 ENGINEERS BLUE / PRUSSIAN BLUE AS REQUIRED

--DO--

81 CHALK PIECES- WHITE,COLOUR AND POWDER AS REQUIRED

--DO--

82 TEINE AS REQUIRED --DO--

83 BATTERY CELLS 1.5 VOLTS TORCH LIGHT CELLS,PENCIL BATTERY ETC.AS REQUIRED

--DO--

84 RED AND BLUE PENCILS AS REQUIRED

--DO--

85 GALVANISED STEEL WIRE 1mm DIA AND OTHER SIZES AS REQUIRED

--DO--

86 FLANNEL CLOTH 1M WIDTH AS PER REQUIREMENT

--DO--

87 SPLIT PINS 2mm TO 6 mm AND OTHER SIZES AS PER REQUIREMENT

--DO--

88 WOOD SCREWS 3/4" TO 3" AS PER REQUIREMENT

--DO--

89 LEAD SHEET 3 mm AND 4 mm THICKNESS AS PER REQUIREMENT

--DO--

90 TARPAULINE 3X3 M AND 5X5 M AND 10X5 M AND OTHER SIZES

--DO--


121

AS PER REQUIREMENT

91 VULCANISED RUBBER FIBRE 0.5 MX0.5 MX15 mm THICKNESS AS PER REQUIREMENT

--DO--

92 PLYWOOD 1M X 2M X 3mm AND OTHER SIZES AS PER REQUIREMENT

--DO--

93 NAILS-WIRE 1' TO 3'AS PER REQUIREMENT

--DO--

94 CANDLES MEDIUM SIZE AS PER REQUIREMENT

--DO--

95 PORTABLE SWITCH BOARD CONTAIING 15 AMPS TP METAL CLAD SWITCH WITH FUSE 3X15 AMPS, SWITCHES AND 3 PLUG SOCKETS AS PER REQUIREMENT

--DO--

96 WOODEN PLANK PULLEYS AS REQUIRED

--DO--

97 Any other items as required to complete the jobs

-do--


122

APPENDIX-V

LIST OF CONSUMABLES/ ERECTION MATERIAL TO BE SUPPLIED/ MADE AVAILABLE BY BHEL ON FREE OF COST BASIS SL. No.

DESCRIPTION

1 Shims which form part of equipment supplied 2 Special insulating varnishes which form part of equipment supplies. 3 Lubricants and chemicals for first fill and topping up and preservation /

re-conservation of equipment 4 Acids, chemicals and oils for acid cleaning, alkali flushing and oil

flushing operations 5 Imported electrodes and filler wires (as supplied by BHEL

manufacturing by Units)

FICHTNER Consulting Engineers (India) Private Limited Subject Doc. No. Vol. / Sec.

Rev. A

2012820001-ME-DSN-196-001 Date

Sheet No. 1 OF 3

P&ID No. : 1-381-01-03029 (SHEET 01 OF 03) TITLE :

Stud / Nuts Coupling

Full

Serv. Code

Pipe size

Pipe Class

Sub unit No.

Pipe No.Insu-lation

Line - From Line - To SW SC TOE TBE W T ½" 1" 2"M33 x2

½" 1"

1 CDS 8" 11G 4 101 CONDENSER -1 (TGC-01) 8"-CDS-11G-4-102/103 12 2 1 1

2 CDS 8" 11G 4 102 8"-CDS-11G-4-101 CEP-A (TBPCM01A) 1.5 1 1

3 CDS 8" 11G 4 103 8"-CDS-11G-4-101 CEP-B (TBPCM01B) 1.5 1 1

4 CDD 6" 11C 4 104 CEP-A (TBPCM01A) 6"-CDD-11C-4-106 1.5 1

5 CDD 6" 11C 4 105 CEP-B (TBPCM01B) 6"-CDD-11C-4-106 1.5 1

6 CDD 6" 11C 4 106 6"-CDD-11C-4-104/105 STEAM JET AIR EJECTOR 18 4 2 1 6 1 2 3

7 CDD 6" 11C 4 107 STEAM JET AIR EJECTORHOT WELL LEVEL

CONTROL18 4 4

8 CDD 6" 11C 4 108HOT WELL LEVEL

CONTROLCONDENSATE STORAGE

TANK40 5 3

6" x 4"-2Nos

8" x 6"-1Nos &6" x 4"-2Nos

1

9 CRC 3" 11G 4 109 6"-CDD-11C-4-107CONDENSATE MIN. RECIRCULATION TO

CONSENSER-12 3 2

3" x2"-2Nos

6" x 3"-1Nos & 3" x 2"-2Nos

10 CDD 6" 11C 4 XXX 6"-CDD-11C-4-107 GLAND STEAM INLET-T1 9 3 1 1 1 1/2"-11/2"-1 1 * (Rev-B)

11 CDD 6" 11C 4 XXX GLAND STEAM INLET-T2 6"-CDD-11C-4-107 9 3 1 1 1 1/2"-11/2"-1 1 * (Rev-B)

NOTE:- * MARKED ARE INCORPORATED IN REV-B .

Elb.

900Pipe

M

25/7/2008

STG-1 condensate system upto hotwell level control valve

Gas

ket

Flg.BL. Flg.

Tee uneq.

Red. conc.

Red. ecc.

NON-IBR LINE WISE - BILL OF QUANTITIES

Elb.

450Tee eq.

BHEL Project

Sl. No.

Line Details

Client IISCO STEEL PLANT, BURNPUR, WEST BENGAL

2.5 MTPA NEW STREAM EXPANSION

No

tes

Set

s

Siz

e

Le

ng

th (

mm

)

Hal

f

Nipple Cap

Un

ion

WELD-O-LETVERTICAL

INSERTLine Description

BOQ FOR STG AND TB CONDENSATE TO HOTWELL CONTROL VALVE, 1-381-01-03029 (SH 01 OF 03)

FICHTNER Consulting Engineers (India) Private Limited Subject Doc. No. Vol. / Sec.

Rev. A

2012820001-ME-DSN-196-001 Date

Sheet No. 2 OF 3



Full

Serv. Code

Pipe size

Pipe Class

Sub unit No.

Pipe No.Insu-lation


½" 1"






6 CDD 6" 11C 5 106 6"-CDD-11C-5-104/105STEAM JET AIR EJECTOR

18 4 2 1 6 1 2 3


CONTROL18 4 4



TANK78 5 3

6" x 4"-2Nos

8" x 6"-1Nos &6" x 4"-2Nos

1


CONSENSER-22 3 2

3" x2"-2Nos

6" x 3"-1Nos & 3" x 2"-2Nos




NON-IBR LINE WISE - BILL OF QUANTITIES 25/7/2008


Gas

ket

Tee uneq.

Red. conc.

Red. ecc. Flg.BL. Flg. N

ote

s

Set

s

Siz

e

Le

ng

th (

mm

)

Hal

f

Nipple Cap

Un

ion

WELD-O-LETVERTIC

AL INSERT

BHEL Project

Sl. No.

Line Details

Client


Line Description

IISCO STEEL PLANT, BURNPUR, WEST BENGAL

Tee eq.

Pipe M

Elb.

900

Elb.

450

BOQ FOR STG AND TB CONDENSATE TO HOTWELL CONTROL VALVE, 1-381-01-03029 (SH 02 OF 03 )

FICHTNER Consulting Engineers (India) Private Limited

Subject Doc. No. Vol. / Sec.

Rev. A

2012820001-ME-DSN-196-001 Date

Sheet No. 3 OF 3



Full

Serv. Code

Pipe size

Pipe Class

Sub unit No.

Pipe No.

Insu-lation


½" 1"






6 CDD 6" 11C 6 106 6"-CDD-11C-6-104/105STEAM JET AIR EJECTOR

18 4 2 1 6 1 2 3


CONTROL18 4 4


CONTROLCONDENSATE

STORAGE TANK106 5 3 8" x 6" 1

9 CRC 3" 11C 6 109 6"-CDD-11C-6-107CONDENSATE MIN. RECIRCULATION TO

CONSENSER-32 3 2 6" x 3"




NON-IBR LINE WISE - BILL OF QUANTITIES 25/7/2008BHEL

Client

Project




Sl. No.

Line Details Line Description

Pipe M

Elb.

900

Elb.

450Tee eq.

Tee uneq.

Red. conc.

Red. ecc. Flg.BL. Flg.

Ga

sk

et Nipple Cap

Un

ion

No

tes

Se

ts

Siz

e

Le

ng

th (

mm

)

Ha

lf

WELD-O-LETVERTIC

AL INSERT

BOQ FOR STG AND TB CONDENSATE TO HOTWELL CONTROL VALVE



Rev. A

2012820001-ME-DSN-196-001 Date

Sheet No. 1 OF 3



Full

Serv. Code

Pipe size

Pipe Class

Sub unit No.

Pipe No.Insu-lation

Line - From Line - To SW SC TOE TBE W T ½" 1" 2"M33

x2½" 1"

1 CDS 8" 11G 7 101 CONDENSER -1 (TBC-01) 8"-CDS-11G-7-102/103 12 2 1



4 CDD 6" 11C 7 104 CEP-A (TBPCM01A) 6"-CDD-11C-7-106 1.5 1 1

5 CDD 6" 11C 7 105 CEP-B (TBPCM01B) 6"-CDD-11C-7-106 1.5 1 1

6 CDD 6" 11C 7 106 6"-CDD-11C-7-104/105 STEAM JET AIR EJECTOR 18 4 2 1 6 2 3


CONTROL18 4 4



TANK106

6"-5Nos & 4"-2Nos

36" x 4"-2Nos

8" x 6"-1Nos & 6" x 4"-2Nos


CONSENSER-12

3"-3Nos & 2"-2Nos

23" x 2"-2Nos

6" x 3"-1Nos & 3" x 2"-2Nos




25/7/2008

Cap

Un

ion

No

tes

weld-o-letVERTICA

L INSERT

Flg.BL. Flg.

Ga

sk

et Nipple

Se

ts

Siz

e

Le

ng

th (

mm

)

Ha

lf

Tee eq.

Tee uneq.

Red. conc.Red. ecc.

Pipe M

Elb. 900 Elb.

450Sl. No.

Line Description

Turbolower's-1 condensate system upto hotwell level control valve

BHEL

Client

Project


2.5 MTPA NEW STREAM EXPANSIONNON-IBR LINE WISE - BILL OF QUANTITIES




Rev. A

2012820001-ME-DSN-196-001 Date

Sheet No. 2 OF 3



Full

Serv. Code

Pipe size

Pipe Class

Sub unit No.

Pipe No.Insu-lation

Line - From Line - To SW SC TOE TBE W T ½" 1" 2"M33

x2½" 1"







7 CDD 6" 11C 8 107 STEAM JET AIR EJECTOR HOT WELL LEVEL CONTROL 18 4 4

8 CDD 6" 11C 8 108 HOT WELL LEVEL CONTROLCONDENSATE STORAGE

TANK78

6"-5Nos & 4"-2Nos

36" x 4"-2Nos

8" x 6"-1Nos & 6" x 4"-2Nos

9 CDD 3" 11G 8 109 6"-CDD-11C-8-107CONDENSATE MIN. RECIRCULATION TO

CONSENSER-22

3"-3Nos & 2"-2Nos

23" x 2"-2Nos

6" x 3"-1Nos & 3" x 2"-2Nos




25/7/2008

Cap

Un

ion

No

tes

weld-o-letVERTICA

L INSERT


NON-IBR LINE WISE - BILL OF QUANTITIES

Flg.BL. Flg.

Ga

sk

et Nipple

Se

ts

Siz

e

Le

ng

th (

mm

)

Ha

lf

Tee eq.

Tee uneq.

Red. conc.

Red. ecc.

Pipe M

Elb.

900

Elb.

450Sl. No.


BHEL

Client

Project






Rev. A

2012820001-ME-DSN-196-001 Date

Sheet No. 3 OF 3



Full

Serv. Code

Pipe size

Pipe Class

Sub unit No.

Pipe No.

Insu-lation


½" 1"








CONTROL18 4 4

8 CDD 6" 11C 9 108 HOT WELL LEVEL CONTROLCONDENSATE STORAGE

TANK40

6"-5Nos & 4"-2Nos

36" x 4"-2Nos

8" x 6"-1Nos & 6" x 4"-2Nos

9 CDD 3" 11G 9 109 6"-CDD-11C-9-107CONDENSATE MIN. RECIRCULATION TO

CONSENSER-32

3"-3Nos & 2"-2Nos

23" x 2"-2Nos

6" x 3"-1Nos & 3" x 2"-2Nos




NON-IBR LINE WISE - BILL OF QUANTITIES 25/7/2008BHEL

Client

Project




Sl. No.


Pipe M

Elb. 900 Elb.

450Tee eq.

Tee uneq.

Red. conc.

Red. ecc.

Flg.BL. Flg.

Ga

sk

et

Nipple Cap

Un

ion

No

tes

Se

ts

Siz

e

Le

ng

th (

mm

)

Ha

lf

weld-o-letVERTICAL INSERT


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