KUKKI-1 HEP

SPARES & TOOLS LIST

The Bidder shall quote additional spare parts over and above the above mentioned mandatory parts which he deems essential and necessary for long term operation of the plant. However, they shall not be considered for the purpose of erection.
A) ELECTRICAL: I) GENERATOR & EXCITATION SYSTEM: 1. One (1) lot of stator windings comprising one third (1/ 3) of all bars used for one (1) generator with all necessary material for fixing, clamping, jointing including slot wedges. 2. One set (1) thrust Pads. 3. One (1) lot of guide bearing segments comprising one (1) set each of every different bearing type. 4. One (1) set of thrust bearing pads complete with supports. 5. Four (4) sets of brake lining pads. 6. One (1) lot of seals and gaskets comprising four (4) sets of every type or material or size. 7. One (1) instrument each of any kind and size as applicable. 8. Level switches/pressure switches, pressure gauges Two (2) of each type. 9. DTTs, RTDs of each type 20% of complete requirement. 10. One (1) lot of electronic cards pertaining to the AVR, comprising one (1) piece of every kind, type or size. 11. One (1) set of electronic modules & AVR Module circuits 12. One hundred percent (100%) of Bridge Rectifier Fuses, comprising the total quantity for one (1) installation. 13. 1-set of Filed Pole along with winding. 14. Two(2) sets of field flashing rectifier. II) POWER & AUXILIARY TRANSFORMER: 1. One(1) LV/Neutral bushing of each size 2. One (1) HV bushing with all associated current transformers set including Neutral CT 3. Two (2) thermometers of each type 4. One (1) oil level gauge of each type 5. One (1) gas detecting relay of each type 6. One (1) gas sampling device of each type 7. One (1) pressure relieve device of each type 8. Two (2) valves of each type; 9. Two (2) drain and vent plugs of each type; 10. Two (2) pieces of each type of MCB, auxiliary relay, contactor, heater, 11. lamp, and push button; 12. Two (2) complete sets of all seals and gaskets (except main cover gasket) 13. Two (2) silica gel breathers of each size. 14. One (1) set of lifting jacks. 15. One (1) set of steel slings. 16. 20% Oil after first filling. 17. 1 set of RTCC / OLTC AVR.

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SPARES & TOOLS LIST
III) BATTERY CHARGER SYSTEM: 1. One hundred (100) percent of thyristor and diode stacks for one rectifier/ inverter each, 2. One (1) lot of solid state or electronic control gear required for manual or automatic operation of the concerned equipment, each comprising one (1) piece of every type or size, 3. Two (2) nos. of battery cells. 4. Twenty (20) nos. of connector bolts (if applicable) 5. Two (2) nos. of control switches & supervision relays 6. One (1) no shunt resistor of each type used in the Charger IV) 11KV SWITCHGEAR: 1. One (1) lot of protection relays, comprising of one (1) piece of every type 2. One complete set of Breaker Cubicle in complete shape. V) L.V. SWITCHGEAR: 1. One (1) lot of power contactors, each comprising of two (2) pieces of every type and size used. 2. One (1) lot of power contactor coils, each comprising of two (2) pieces of every type and rating used. 3. One (1) lot of CTs, each comprising of one (1) piece of every size, type and rating used. 4. One (1) lot of protection relays, each comprising of one (1) piece of every 5. type used. 6. One Complete set of Air Circuit Breaker. VI) 1. 2. 3. 4. 5. 6. PROTECTIVE RELAYS:

One (1) Set of Generator Management Relay. One Set of Transformer Management Relay. One Set of Line Management Relay. One Set of Annunciator Cubicle in complete set. One no. each of other Relays if used in the Panel. One (1) lot of DC/ DC converters, power supply filters and other power supply units, each comprising one (1) piece of every kind, type and size. 7. Signal Transducer, Proximity Switches etc., 1 set. VII) CABLES: 1. One (1) lot of every type and size of cables used, with a minimum length of 100 m 2. One (1) lot of cable trays and conduits of every type and size used with a minimum length of 100 m 3. One (1) lot of cable lugs, each comprising five (5) percent of the total installed quantity of every kind, type and size used.

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SPARES & TOOLS LIST
VIII) SUPERVIOSARY CONTROL: 1. Conventional interposing relays (each kind, 5% of total used with minimum of 2. Non-conventional relays (each kind, 5% of total used with minimum of 2) 3. Cooling Fan 1 set of each type. 4. Indicating lamp and fuses of each kind( 500 of total) 5. Circuit switches of each type (minimum of 3) 6. Transducers of each type (20 % of total used with minimum of 1 set 7. Fault indicators (20 % of total) 8. Printed circuit cards of each type ( 20% of total used with minimum of 2 set 9. Control switches, change-over switches of each type(20% of total used with minimum of 2 set. 10. Push-buttons of each type (20% of total used with minimum of 2 sets 11. Instruments and meters of each type (20% of total used with minimum of 1 set 12. Built-in stabilised power sources of each type (30 % of total used with minimum of 1 set). 13. Fibre optic interface modules (two of each type) 14. Telephones (two of each type)

KUKKI-1 HEP
SPARES & TOOLS LIST
B) MECHANICAL I) TURBINE: S# 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 DESCRIPTION Runner complete with moving labyrinth seals, runner cone and fixing bolts. Coupling bolts runner to turbine shaft Coupling bolts turbine shaft to generator shaft Labyrinth seals Upper including fasteners Fixed labyrinth seals Moving labyrinth seals Labyrinth seals Lower including fasteners 1. Fixed labyrinth seals 2. Moving labyrinth seals Shaft seal segments Set of Shaft seal sleeve Turbine guide bearing segments/pads complete set GV & RB servomotor complete set DTT (Dial Type Temp. Thermometer) of each type RTDs (Resistance Temperature Detectors) of each type Water flow indicators of each type Pressure gauges of each type Pressure Switches/ pressure transmitters of each type Oil level gauges of each type QTY. 1 no 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 1 sets sets sets sets set set set nos. set no. nos. nos. nos. nos. nos. no.

II) OIL PUMPING UNIT: 1. Compete Set of Pump & Motor Assembly in Full 1 set 2. Complete set of O Rings & Fasteners used for Solenoid, Check valves, Flow control etc., -- 1 set. 3. Strainers & Filter element of each type used 3 nos. each. 4. 1 complete set of check valves. 5. 1 complete set of connecting hoses used in the system. (each type) 6. Solenoid Coils 3 nos. of each type used in the circuit. 7. 20% Oil after first Filling. III) GEARBOX: 1. 2. 3. 4. 5. 6. One complete set of Bearings, used in the Gearbox. RTD 2 nos. each, used in the set. Oil Level Gauge 2 nos. each (Manual & Electrical). High & Low Speed side Oil Seals 2 sets in full. Compete Set of Pump & Motor Assembly in Full 1 set (Standby) Complete set of O Rings & Fasteners used for Solenoid, Check valves, Flow control etc., -- 1 set. 7. Strainers & Filter element of each type used 3 nos. each. 8. 1 complete set of check valves. 9. 50% Oil after first Filling. 4

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SPARES & TOOLS LIST

VI) COOLINGWATER: 1. Cooling water Booster pump-motor set a) Complete pump with motor 1 no. b) Shaft sleeve 1 no. c) Impeller (stainless steel) 2 nos. d) Coupling pins, collars & nut with Rubber bushes 1 set 2. Automatic Self Cleaning Duplex filters a) Element assembly 2 nos. 3. Simplex filter a) Stainless steel baskets filter with stainless Steel mesh 4 nos. 4. Heat exchangers a) Complete Heat exchanger 1 no. b) Plates for heat exchangers 5 nos. c) Plate sealing 10 nos. 5. Valves of each type 2 sets VII) EOT: 1. Main hoist a) Wire rope One length b) Contactor and springs for master controller One set c) Brake solenoid coils complete One set d) Brake lining complete with rivets etc. for each brake supplied One set e) Electric motor of each type One no. f) Limit switches of each type Two sets 2. a) b) c) d) e) f) 3. a) b) c) d) e) f) Auxiliary hoist (only for Power House EOT cranes) Wire rope One length Contactor and springs for master controller One set Brake solenoid coils complete One set Brake lining complete with rivets etc. One set Electric motor of each type One no. Limit switches of each type Two sets Bridge drive Contacts for main runway collectors One Set Contacts and springs for controller One Set Brake solenoid coils complete One Set Electric motor of each type One No. Brake lining complete with rivets etc. Two Sets Limit Switches of each type One Set

4. Trolley drive a) Contacts and springs for controller One Set b) Brake solenoid coils complete One Set 5

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SPARES & TOOLS LIST
c) Brake lining complete with rivets etc. One Set d) Electric motor of each type One No. e) Limit Switches of each type One Set 5. a) b) c) d) e) f) g) h) i) j) k) l) m) n) o) p) q) r) s) t) u) v) Other miscellaneous spares Circuit breaker of each type One set Springs, O-rings, oil seals, gaskets, packing etc. of each size and type for complete crane Two set Printed Circuit Board of each type (with components) One set Fuses of each type and size including Fast Acting Fuses used in Thyristor circuits Two Sets Indicating lamps each type Ten Sets Indicating light assembly of each type One set Overload relays each type One Set Couplings complete with coupling bolts, rubber sleeves etc. each type and size One Set Bearings for wheels, gear boxes motors etc. for complete crane One Set Push button each type One Set Thyristors and diodes of each type One set Control switch of each type One set Disconnecting switch of each type One set Terminal block of each type One set Resistor of each type One set Condenser of each type One set Fuse block of each type One set Plug connector of each type One set Plug module of each type One set Note: Set is defined as the total number required for one crane.

VIII) DG SET Engine 1. Oil filter 2 nos. of each type 2. Fuel filter 2 nos. of each type 3. Nozzle 2 nos. of each type 4. Complete set of gaskets and O-Ring. 1. 2 sets of each type 2. Complete set of belts 2 sets of each type 3. Air filter element 2 nos. of each type Generating Set 1. Stop relay 2 sets of each type 2. Pressure switch 1 no. of each type 3. Temperature switch 1 no. of each type 4. AVR complete 1 no. of each type 5. Diodes and suppressor 1 no. of each type Control Panel 1. Fuses 2 nos. of each used type 6

KUKKI-1 HEP
SPARES & TOOLS LIST
2. Indicating lamps 2 nos. of each used type 3. Main electronic card 2 nos. of each used type 4. Expansion/auxiliary card 1 no. of each type

KUKKI-1 HEP
SPARES & TOOLS LIST
SPECIAL TOOLS:
The bidder shall purpose the list of special tools including their make and detailed specifications as recommended by manufacturer(s) to be accepted by the owner at the time of award of the contract and incorporated in the Technical Data Sheets. The proposed list of special tools must include the following in addition to the tools recommended by manufacturer(s): 1. One (1) set of hydraulic wrenches for opening each type of bolt size viz. head cover, bottom ring, runner coupling bolts, labyrinths, draft tube cone bolts etc. used in the plant. 2. One (1) set of torque wrenches of adequate torque capacity for Labyrinth, top cover, bottom ring, draft tube cone bolts etc. 3. One (1) set of nylon sling round, for handling turbine components. 4. One (1) set of nylon sling flat, for handling turbine components. 5. Four (4) nos. of eye bolts of each size (M12 or above) used in the turbine components. 6. Four (4) nos. of lifting shackles of each size (M12 or above) used in the turbine components. Customary Tools The bidder shall supply customary tools and devices. For installation, repair and maintenance as specified below. The details including make of these items shall be as proposed and accepted by the owner at the time of award of the contract and incorporated in the Technical data sheets. Customary tools shall be furnished directly to the owner in new condition. They shall in no case be used for erection and /or installation purposes during the construction of the plant. They shall serve for operation, maintenance and overhaul work after taking over. 1. 2. 3. 4. 5. One (1) set of torque wrenches of adequate torque capacity. One (1) set of nylon sling round, for handling turbine components. One (1) set of nylon sling flat, for handling turbine components. Four (4) nos. of eye bolts of each size (M12 or above) used in the turbine components. Four (4) nos. of lifting shackles of each size (M12 or above) used in the turbine components 6. Two (2) sets of pneumatic / hydraulic wrenches for opening sill bolts of the size of M20 and below. 7. One (1) sets of electrically operated nut tightener. 8. One (1) of all lifting shackles, chain pulley blocks of 1,2,3,5,& 10 ton capacity required to facilitate lifting major turbines by the power house crane and servicing the turbine. 9. One (1) set of kit for electrically operated tools. 10. Two (2) sets of kit for mechanically operated tool. 11. One (1) sets flexible shaft electrically operated grinders. 12. One (1) set of drilling machines of size 25 mm. 13. One (1) set of hand drilling machines of size 12, 20, 25 mm with assorted bits in 1 mm step. 14. One (1) set of drilling machines of size 25 mm and 30 mm with magnetic base. 8

KUKKI-1 HEP
SPARES & TOOLS LIST
15. One (1) sets of concrete drilling machines of size 12 mm and 25 mm with assorted bits in 1 mm step. 16. Two (2) sets of hydraulic jacks of 3, & 5 tons capacity required for erection/maintenance. 17. Two (2) sets of optical leveling and measuring instruments. 18. One (1) sets of dial gauges with magnetic base, vernier calipers, micrometer (outside/inside), slip gauge, height gauge etc. required for erection and maintenance. All the tools supplied shall be suitable for 230 V AC supply