O&M Boiler and Aux NIT

M. P. Power Generating Co.
Ltd
SSTPP Khandwa Phase II
2 x 660 MW Supercritical Units
O&M of Boiler & Auxiliaries

Request for Proposal
Contents
NOTICE INVITING TENDER (NIT) ................................................................................................................................ 6
1. Tender Details ................................................................................................................................................ 11
1.1. Reference Number ................................................................................................................................. 11
1.2. Officer In Charge .................................................................................................................................. 11
3. Disclaimers ..................................................................................................................................................... 12
4. Preliminary Information............................................................................................................................... 13
4.1. A brief introduction of MPPGCL ........................................................................................................ 13
4.2. A Brief Introduction of SSTPP Khandwa ........................................................................................... 13
4.3. A Brief Introduction of Scope of Work ............................................................................................... 13
4.4. What MPPGCL is looking forward with this contract: ..................................................................... 14
5. Pre-Qualifying Requirement for the Bidders.............................................................................................. 16
5.1. Technical Experience ............................................................................................................................ 16
5.2. Financial Capabilities ............................................................................................................................ 16
5.3. Other Requirements .............................................................................................................................. 16
6. Terms & Conditions ...................................................................................................................................... 17
6.1. General Conditions:............................................................................................................................... 17
6.2. Special Terms and Conditions .............................................................................................................. 17
6.2.1. Validity of Offer ............................................................................................................................. 17
6.2.2. Sub-Letting of Contract ................................................................................................................ 18
6.2.3. Security Deposit ............................................................................................................................. 18
6.2.4. Payment to Contractor ................................................................................................................. 19
6.2.5. LD & Penalties ............................................................................................................................... 19
A. Liquidated Damages (LD) for Delayed Mobilisation ......................................................................... 19
B. Penalty for Poor Performance of the Contract ................................................................................... 20
7. Details of Plant and Auxiliaries .................................................................................................................... 23
7.1. List of Auxiliaries & Equipment .......................................................................................................... 23
7.2. Technical Details of the Auxiliaries / Equipment ............................................................................... 24
7.2.1. Brief Description of Boiler ............................................................................................................ 24
a. Economiser:............................................................................................................................................ 25
b. Piping:..................................................................................................................................................... 26
c. Vents and drains: ................................................................................................................................... 26
M.P. Power Generating Company Page 1

d. Water Separator: ................................................................................................................................... 26

e. Water Separator Drain Tank ............................................................................................................... 26
f. Secondary Pass Walls:........................................................................................................................... 27
g. Water wall .............................................................................................................................................. 27
h. Roof Tubes ............................................................................................................................................. 28
i. Secondary Pass and Passage Wall ........................................................................................................ 29
j. Superheaters .......................................................................................................................................... 29
i. Primary Superheater............................................................................................................................. 29
ii. SECONDARY SUPERHEATER ......................................................................................................... 30
iii. Tertiary Superheater ......................................................................................................................... 30
k. Reheater: ................................................................................................................................................ 31
i. Primary Reheater: ................................................................................................................................. 31
ii. Reheater DSH: ....................................................................................................................................... 31
iii. Secondary Reheater: ......................................................................................................................... 31
l. BCP, Recirculation Line & Minimum Flow Line: ............................................................................. 32
i. Warming Water Lines........................................................................................................................... 32
ii. BCP Warming line ................................................................................................................................ 32
iii. BCP and auxiliaries ........................................................................................................................... 33
iv. BCP and auxiliaries ........................................................................................................................... 33
v. BCP Motor Cooler: ............................................................................................................................... 33
vi. BCP Purge Water Cooler & Filling Line: ....................................................................................... 34
7.2.2. Boiler Systems Auxiliaries ........................................................................................................... 34
a. Regenerative Air Pre-Heater ................................................................................................................ 34
b. FD Fans................................................................................................................................................... 36
c. PA Fans................................................................................................................................................... 37
d. ID Fan ..................................................................................................................................................... 39
e. Seal Air Fans .......................................................................................................................................... 41
f. Flame Detector Cooling Air Fan .......................................................................................................... 41
g. Wind Box ................................................................................................................................................ 42
h. Fuel Oil Firing System .......................................................................................................................... 43
7.2.3. FUEL OIL PUMP HOUSE ........................................................................................................... 44
7.2.4. DUCT AND DAMPERS ............................................................................................................... 44
7.2.5. MILLING SYSTEM AND BURNERS ........................................................................................ 45
7.2.6. Coal Firing System ........................................................................................................................ 47

7.2.7. MILL REJECT HANDLING SYSTEM ..................................................................................... 48

7.2.8. Miscellaneous ................................................................................................................................. 48
8. Scope of Work ................................................................................................................................................ 51
a. General Scope of Operations .................................................................................................................... 52
b. Auxiliary Specific Scope of Operations ................................................................................................... 54
c. SOME OF CRITICAL OPERATIONAL LIMITS ................................................................................ 54
d. General Scope of Maintenance ................................................................................................................. 55
The future requirement of general spares including insurance spares is to be assessed jointly by MPPGCL &
the contractor so that effective utilization of the same is ensured ....................................................................... 56
e. Details of Works Attending (Maintenance) ............................................................................................. 56
1 Boiler Tube Failures:................................................................................................................................. 56
2 MODE OF WELDING OF BOILER TUBES: ....................................................................................... 56
3 STRESS RELEIVING: ............................................................................................................................. 57
4 HYDRAULIC TEST ................................................................................................................................. 57
5 Weld Joint Procedure For Welding Of Pipe Line and Valve Replacement ......................................... 58
6 RADIOGRAPHY ...................................................................................................................................... 59
7 SHIELD WELDING, SHIELDING OF TUBES .................................................................................... 60
8 Repair of Scaffolding Door ....................................................................................................................... 60
9 Repair Of Peephole/ Manhole Door, Soot Blower’s & Instrument Seal Boxes .................................. 61
10 Boiler (Tube Bends) Fabrication .......................................................................................................... 61
11 Insulation Works ................................................................................................................................... 61
12 Refractory Removal, Application of Refractory & Making of Refractory Blocks Etc. ................. 62
DEBRIS DISPOSAL / LIGHT SCRAP RETURN ............................................................................................. 62
13 STEEL SCRAP RETURN:- ................................................................................................................. 63
14 MISC SCAFFOLDING WORKS: ....................................................................................................... 63
15 HIGH PRESSURE VALVES ............................................................................................................... 63
16 Safety Valve ............................................................................................................................................ 63
17 Control Valves (Pneumatic / Hydraulic Operated) ............................................................................ 64
18 Electromatic Relief Valve (ERV)/ Hydraulic Relief Valve ................................................................ 64
19 Servicing of HP Valves .......................................................................................................................... 65
20 HP Valves Replacement / Installation.................................................................................................. 65
21 Replacement of HP Valves Requiring Stress Relieving: .................................................................... 65
22 Piping Hangers Inspection/ Servicing/ Adjustment............................................................................ 65
23 Soot Blowers ........................................................................................................................................... 66

24 Lines & Valves ....................................................................................................................................... 67

25 Servicing of Mill, APH and Fan Handling HOIST............................................................................ 68
26 AIR PREHEATERS .............................................................................................................................. 68
27 FD/PA/ID FAN....................................................................................................................................... 74
28 Fuel Oil Firing System .......................................................................................................................... 76
29 Ducts ....................................................................................................................................................... 77
30 DAMPERS ............................................................................................................................................. 78
31 COAL MILL & MILLING SYSTEM ................................................................................................. 80
32 Pulverized Coal Firing System ............................................................................................................. 81
33 Mill Reject Handling System ................................................................................................................ 82
34 Electro Static Precipitator (ESP) ......................................................................................................... 83
35 All Cooling Water Lines in Boiler Area .............................................................................................. 89
36 All Service Air & Instrument Air lines in Boiler Area ....................................................................... 89
37 Associated Air Conditioning & Air Washer System .......................................................................... 89
ii. Miscellaneous ............................................................................................................................................. 94
a. C&I and Electricals and Other..................................................................................................................... 94
b. Electrical/ C&I Maintenance:................................................................................................................... 97
c. Maintenance Planning............................................................................................................................... 97
d. Spare Planning: .......................................................................................................................................... 98
e. Removal of old and used unserviceable spares: ...................................................................................... 98
9. Exclusions to the Scope of Work ................................................................................................................ 100
10. List of Minimum Items, T&P to be provided by the Contractor ........................................................ 100
a. T&P For Mechanical Maintenance........................................................................................................ 100
b. T&P For Electrical and C&I Maint....................................................................................................... 103
c. Consumables ............................................................................................................................................ 105
d. Safety Items .............................................................................................................................................. 106
e. Minimum Manpower & its Type ........................................................................................................... 106
11. Facilities / Items to be MPPGCL............................................................................................................ 109
a. T&P........................................................................................................................................................... 109
b. Manuals and Drawings ........................................................................................................................... 110
c. Spares........................................................................................................................................................ 110
d. Consumables ............................................................................................................................................ 110
e. Others ....................................................................................................................................................... 110
12. Statutory Compliance by the Contractor .............................................................................................. 110

a. Labour Related Compliances ................................................................................................................. 111

b. Health & Safety Related Compliances................................................................................................... 111
c. Quality & Environment Protection Related Compliances................................................................... 112
d. Insurance Related Compliances ............................................................................................................. 112
13. Allocation of Responsibilities .................................................................................................................. 114
14. Check List of Various Activities ............................................................................................................. 119
14.1. Preventive Maintenance Activities ................................................................................................. 119
Pulveriser Recommended Lubrication .......................................................................................................... 119
Routine Maintenance Pressure Parts ............................................................................................................ 121
Routine Maintenance Burner ......................................................................................................................... 123
Routine Maintenance Duct & Dampers ........................................................................................................ 127
Damper Lubrication ........................................................................................................................................ 129
15. Definitions ................................................................................................................................................ 130
16. Abbreviations Used ................................................................................................................................. 135

M.P. POWER GENERATING COMPANY LIMITED
OFFICE OF THE SUPERINTENDING ENGINEER (P&W)

SHREE SINGAJI THERMAL POWER PROJECT, MPPGCL,
Dongalia Distt Khandwa (MP)
E-mail: sepnw.sstpp1@gmail.com: Phone 09425611006
Official Website: www.mppgcl.mp.gov.in
No. 515-1700/SSTPP/MPPGCL/ WT- /T- Date: -
NOTICE INVITING TENDER (NIT)

“Through e-tendering process only”
M.P. Power Generating Co. Ltd. invites Electronic tenders from reputed / established Contractors /
Firms only for the work given below for Shree Singaji Thermal Power Project, MPPGCL, Dongalia,
Distt Khandwa (MP).
1 Tender No. MPPGCL TENDER NO T -
2 Tender Particulars 1. Annual work contract for Operation and

Maintenance of Boiler and Auxiliaries of 2x660 MW
Units No. 3 & 4 of SSTPP Khandwa Phase –II
2. Providing 1 No. each engineer for Desk Operation
support for Boiler and Auxiliaries for unit No. 3 and
4 in every shift of eight hours.
3 Estimated Cost (Rs.) /-
4 EMD (in Rs.) /-
5 Tender Cost (Rs.) /-
6 Purchase of tender end date & time up to 14:00 Hrs
7 Due Date and time for Physical up to 15:00 Hrs

Submission and online submission
8 Due Date & time of 1)PQR Opening at 15:30 Hrs onwards
e- opening of parts
of Tender 2)Technical Bid opening – from 11:00 hrs onwards
This tender is being processed though e-tendering system. For viewing detailed NIT, downloading
tender documents and participating in Electronic Tenders, please visit the website www.mpeproc.gov.in
regularly for any clarifications and/or due date extension or corrigendum. Any Clarification and or due

date of extension or corrigendum/addendum shall be issued on e-tendering website only and shall not be
issued in print media. The documents in physical form are to be submitted up to the date and time
specified as above and same shall be opened in presence of bidders/contractors or their authorized
representative who so ever present on the date and time specified as above.
Note: Following conditions will over-rule the conditions stated in the tender documents, wherever
relevant and applicable.
For E-Tendering:
(i) For participation in e-tendering module of MPPGCL, it is mandatory for prospective

bidders/contractors to get registration on website www.mpeproc.gov.in . Therefore, it is advised
to all prospective bidders/contractors to get registration by making on line registration fees
payment at the earliest.
(ii) Tender documents can be purchased only online and downloaded from website
www.mpeproc.gov.in by making online payment for the tender documents fee
(iii) Service and gateway charges shall be borne by the bidders/contractors.
(iv) Since the bidders/contractors are required to sign their bids online using class-III Digital
Signature Certificates, they are advised to obtain the same at the earliest.
(v) For further information regarding issue of Digital Signature Certificate, the bidders/contractors
are requested to visit website www.mpeproc.gov.in . Please note that it may take up to 7 to 10
working days for issue of Digital Signature Certificate. MPPGCL will not be responsible for
delay in issue of Digital Signature Certificate.
(vi) If bidder is going first time for e-tendering, then it is obligatory on the part of bidder to fulfill all
formalities such as registration, obtaining Digital Signature Certificate etc. well in advance.
(vii) Bidders/contractors are requested to visit our e-tendering website regularly for any clarifications
and/or due date extension or corrigendum.
(viii) Bidder must positively complete online e-tendering procedure at www.mpeproc.gov.in
(ix) MPPGCL shall not be responsible in any way for delay/difficulties/ inaccessibility of the
downloading facility from the website for any reason whatsoever.
(x) For any type of clarifications bidders/contractors can visit www.mpeproc.gov.in and help desk
contract No. 18002748484 and 18002745454.
(xi) Interested bidders/contractors may attend the free training program in Bhopal at their own cost.
For further query please contact help desk.
(xii) The bidder who so ever is submitting the tender by his Digital Signature Certificate shall
invariably upload the scanned copy of the authority letter as well as submit the copy of the
same in physical form with the offer of particular tender.

Apart from uploading e-tender on website, bidder has to submit separate envelopes of (i) credentials/
PQR (ii) envelope of EMD and (iii) envelope of techno-commercial bid. These three envelop are to be
kept in one sealed envelope. This envelope should be properly super scribed that this envelope contains
three envelops of credentials/PQR, EMD and Techno-commercial bid against respective tender with due
date & time of tender opening as per NIT. This envelope should be submitted physically till date of
submission. Tenders received within specified time (e-tender as well as physical submission) shall only
be opened on the date and time specified as above in presence of the tenderer or their authorized
representatives, whosoever may be present.
Credentials and PQR:

(i) The perspective bidders, to fulfill criteria of credentials and the Pre-Qualification Requirement as
detailed hereunder for respective tender, will upload scanned self-certified legible copies of
requisite documents as required in e-tendering process.
Pre-Qualification Requirement
(i) Bidder Status to be intimated- i.e. OEM/ OES.
(ii) Copies of previously executed orders of same/similar type of work in State Owned Power
Generating Companies/ Other Power Utilities/ NTPC/ Govt./ Semi Govt./ Any Leading
Industries/ IPP/ PSUs in India for a minimum periods of one year during any of last seven years
ending with bid opening date are to be submitted.
(iii) EPF Registration is to be furnished.
(iv) GST Registration is to be furnished.
(v) Average annual turnover of the firm for last three financial years (ending March'17 or ending
March’18) shall not be less than Rs--------. Documentary evidence is required to be furnished.
Hard copies of requisite documents (of credentials along with PQR) shall be physically submitted in a
separate sealed envelope super scribing “documents of credentials along with PQR as per tender No. T--
---.
(i) The tender documents in physical form shall be dropped in tender box of this office at “The
SE(P&W), Shree Singaji Thermal Power Project, Dongalia Distt Khandwa (MP) -450112-
(Administrative Block-III Floor)”
(ii) Any mismatch, if found in the documents submitted in physical form and that uploaded online,
the acceptable credential/PQR documents shall be considered.
(iii) First of all the physically submitted envelope of credentials / PQR documents will be opened,
The offers received without pre requisite credential /PQR documents shall not be considered
further for opening of their e-tender. Decision of MPPGCL in this respect shall be final.
(iv) The tenders received without pre-requisite credentials shall be returned unopened to the
respective bidder.

(v) Wherever applicable Labour license and labour insurance should be submit to OIC before
starting the work.
(vi) Any mismatch, if found in the documents submitted in physical form and that uploaded online
the documents ONLINE shall be considered final and no justification regarding this shall be
entertained by MPPGCL.
Techno-commercial bid: Bidders / contractors must positively complete online e-tendering procedure
at www.mpeproc.gov.in they shall have to submit the following documents online in the website.
(i) Their complete techno-commercial offer containing detailed material description, specification
and all commercial terms & conditions. This document should not contain any price part.
(ii) Techno-commercial information in the form of questionnaire and schedules (downloaded from
website and filled as per instructions)
(iii) Hard copies of above techno-commercial offer consisting tender booklet, duly signed and
stamped on each page, questionnaire and schedules (uploaded in the website) must be submitted
in a separate sealed envelope supers scribing “techno-commercial bid for tender no t-xxxx only
those physically submitted documents regarding techno commercial bid will be acceptable and
considered, if, same are uploaded in the website along with techno commercial bid.
(iv) Price bid: Bidder shall have to submit the Price bid document downloaded from website and
uploaded as per instructions therein. Physical submission of price bid will not be consider The
price of techno-commercial qualified bidder shall be opened online at the notified date, online at
www.mpeproc.gov.in Bidders/contractors can view the price bid opening date by logging into
web site.
(v) On the due date of e-tender opening (Techno-commercial Bid opening), the techno-commercial
bid of qualified bidders will be opened online. MPPGCL reserves the right for extension of due
date of opening of techno-commercial bid considering participation of qualified
bidders/contractors in the tender.
(vi) MPPGCL reserves the right to accept or reject any or all tenders without assigning any reason
whatsoever.
(vii) In case, due date for submission & opening of tender declared to be a holiday, the due date shall
be shifted to the next working day for which no prior intimation will be given.
(viii) Any change/modifications/alteration in the tender documents shall not be allowed and such
tender shall be liable for rejection.
(ix) For amendment, if any, please visit www.mpeproc.gov.in web site regularly. In case of any bid
amendment and clarification, the responsibility lies with the bidders/contractors to collect the
same from the web site of MPPGCL or in the office of undersigned before the last date of sale of
tender document. MPPGCL shall have no responsibility for any delay/omission on part of the
bidder.

NOTE: The tender documents in physical form shall be dropped in tender box at office of The SE
(P&W), Shree Singaji Thermal Power Project, Dongalia Distt Khandwa (MP) 450112 (Administrative
Block-III Floor) containing the followings :
a) Envelope 1: Containing PQR / Credentials.
b) Envelope 2: Containing EMD / Documents pertaining to Exemption of EMD.
c) Envelope 3: Containing Techno-Commercial bid along with tender booklet duly signed and
Stamped on each page.
“SAVE ELECTRICITY”
--SD---
SUPERINTENDING ENGINEER (WORKS)
SSTPP, MPPGCL, DONGALIA, DISTT
KHANDWA (MP)

1. Tender Details
The tender is for Operation & Maintenance of Coal Handling plant of 2X660 MW units No. 3 and
4 at SSTPP Khandwa Phase II of MPPGCL.
1.1. Reference Number

i. The following number shall be used in all the correspondences made in regards to this
tender for reference purpose.
SSTPP / PH II / xxx
1.2. Officer In Charge

i. All the correspondences shall be made in regards to this tender with the
following Officer In Charge:
1 Name The Superintending Engineer (P&W)
2 Address
3 Phone
4 E-mail

3. Disclaimers
a. This document is not an agreement or an offer by MPPGCL to Bidders or any third party.
The purpose of this document is to provide interested parties with information to facilitate
the formulation of their Bid Proposal.
b. Neither MPPGCL nor its employees or its consultant make any representation or warranty
as to the accuracy, reliability or completeness of the information in this Document. This
Document does not purport to contain all the information each Bidder may require. The
Document may not be appropriate for all persons, and it is not possible for MPPGCL to
consider the needs of each party who uses or reads this Document. The concerned parties
should conduct their own investigations and analysis and should verify the accuracy,
reliability and completeness of the information in this document and obtain independent
advice from appropriate sources.
c. This Bid Document has been prepared in good faith, neither MPPGCL nor its employees or
its Consultants make any representation or warranty as to the accuracy, reliability or
completeness of the information in this document.
d. Neither MPPGCL nor its employees or Consultants shall have any liability to any Bidder or
any other person under the law of contract, tort, the principles of restitution or unjust
enrichment or otherwise for any loss, expense or damage which may arise from or be
incurred or suffered in connection with this Bid Document, or any matter deemed to form
part of this Bid Document, the award of the work, or the information and any other
information supplied by or on behalf of MPPGCL or its employees, any Consultants or
otherwise arising in any way from the selection process for the project.

4. Preliminary Information
4.1. A brief introduction of MPPGCL
i. M.P. Power Generating Co. Ltd is a wholly owned company of Government of M.P
engaged in generation of electricity in the State of Madhya Pradesh. It is a successor
entity of erstwhile Madhya Pradesh State Electricity Board (MPSEB).
ii. The Company is registered under Companies Act 1956 and was incorporated on
22.11.2001.Its registered office is at Shakti Bhawan, Rampur, Jabalpur.
iii. The Company has installed capacity of 4080 MW (Thermal) and 917.5 MW (Hydro).
4.2. A Brief Introduction of SSTPP Khandwa

i. The plant is located at about 45 Kms (by Road) from Khandwa city and 13 Kms from
Beer Railway Station. Khandwa Railway Station lies on Itarsi-Khandwa Section of
Western Central Railway on Itarsi Mumbai route.
ii. It’s Phase I has an installed capacity of 1200 MW having 2x600MW generating units.
The Boiler, Turbine & Generator (BTG) is M/s BHEL make whereas Balance of Plant
(BoP) has been provided by M/s L&T on Turnkey basis.
iii. Phase II of the station is under construction and will have two super critical units of
660MW each. Both BTG & BoP are being provided by M/s L&T on Turnkey basis.
The units are likely to be commissioned in FY 2018-19.
iv. The primary fuel of the plant is Coal. It is supplied from SECL / WCL & NCL. The
plant is also using washed coal and use of imported coal may also be considered in
future, if required. Secondary fuel of the plant is LDO / HFO.
4.3. A Brief Introduction of Scope of Work

i. The Boiler of Stage-II (2x660 MW) is designed, supplied, erected & commissioned by
M/s L&T MHI.
ii. The scope of work covers Round the Clock Complete Operation & Maintenance of
Boiler and Auxiliaries of SSTPP, Stage-II i.e. 2x660 MW Units.
iii. Salient feature of the work are as under:

a. Providing one Boiler and Auxiliaries expert operation engineer in each
shift in MCR on man month rate basis for each of Unit-3 and Unit No. 4

b. Providing field engineer operator/ technicians and required skilled/ semi-

skilled man power for operation and maintenance of Boiler and Auxiliaries
along with O&M infrastructure for Unit-3 and Unit No. 4.
c. Housekeeping of entire Boiler Area under the scope.
d. Transportation of spares/ consumables from site stores / central store to
work site & return of old worn out spares & their proper stacking.
e. Transportation of scraps/ rejects generated during maintenance work to
identified location by own means.
f. Arranging all the T&P, necessary bulk/ heavy machineries, scaffoldings
etc. for carrying out regular operation and complete maintenance.
g. Complying with all safety, environmental and other statutory norms while
ensuring all rules & regulations defined in GCC of O&M works of
MPPGCL.
h. Arranging required consumables as detailed in subsequent sections of this
tender document.
i. Preparation of periodic (week / fortnight / monthly / half yearly)
maintenance schedule of all major equipment including details of work /
checking to be carried out.
j. Maintain the records of the work being carried out daily, inputs required,
manpower deployment etc.
k. All dewatering facilities required (for O&M of Boiler and Auxiliaries).
l. Operation and Maintenance of Basic communication facilities provided in
the entire scope area.
m. Repair and Maintenance of area lighting of Boiler and Auxiliaries and
illumination systems.
n. Watch & ward of all the equipment/ auxiliaries of 2x660 MW Boiler and
Aux..
iv. Detailed elaboration of the scope of work is provided in Section xxxx
4.4. What MPPGCL is looking forward with this contract:

i. High Level of Service quality.
ii. 100% adherence to all the deliverables.

iii. Zero accidents environment.
iv. 100% reporting of all the near miss incidents and corrective measures for all to
ensure no accident due to the unsafe conditions.

v. Increased availability of all the equipment and the total system to ensure better
efficiency and higher levels of productivity.
vi. Ensuring higher productivity per man hour by introducing better Operating
Procedures.
vii. Introduction of innovative ideas which can save in terms of time or money.

5. Pre-Qualifying Requirement for the Bidders

a. The conditions are for assessing the technical and financial capabilities of the Bidder.
b. This RFP is on OEM/OES basis, therefore, please confirm your capabilities for the
following, duly providing supporting documents.
5.1. Technical Experience

i. Adequate resources are available with you to undertake the work in terms of past
experience, T&P, expert man power etc.
ii. Please provide the order copies of similar works executed for other utilities in past 7
years.
5.2. Financial Capabilities

i. Adequate financial resources are available with the firm to undertake the work.
ii. Please provide audited annual accounts for past three years in support as documentary
evidence.
5.3. Other Requirements

i. Please confirm the status of the firm i.e. OEM or OES.

6. Terms & Conditions

a. The general terms and conditions of the tender are enclosed as Annexure I. The same shall
be binding on the Bidders . It is therefore requested to kindly go through the same. At no
stage any exemption on account of not having full knowledge of these terms shall entitle
the bidder for any kind of exemption / relaxation.
b. In addition to the above following are the Special Terms and Conditions which will form
the part of the contract and will prevail over and above General Terms and Conditions, in
case of any contradiction.
6.1. General Conditions:

a) The general contract terms and conditions of the tender are enclosed as Annexure I. The
same shall be binding on the Bidders. It is therefore requested to kindly go through the
same. At no stage any exemption on account of not having full knowledge of these terms
shall entitle the bidder for any kind of exemption / relaxation. However some of the details
of the tender are given here under-
b) Sealed tenders are invited for the execution of work as per specification attached. Tender
must reach the above mentioned office at specified time and date (As specified in Notice
Inviting Tender) Tenders clearly super scribed Tender NIT No. 515-1700/ SSTPP/
MPPGCL/ WT/ Dtd....……………for………………due on…..……. Earnest money
deposit Rs.………only.
c) Procedure: When hard copies of tenders are delivered by special messenger it should be
deposited in the tender box kept in the office of the Superintending Engineer (P&W),
SSTPP, MPPGCL, Dongalia in office hours on working days. Nobody is authorized to
receive or grant receipt for tender delivered by hand. Tenderers would be bound by the
terms and conditions and specifications as given herein and in the attached schedule. Full
descriptive particular and complete specification should accompany the tender.
d) Cost of Tender Document: No Tender document fee is applicable in the present tender.
6.2. Special Terms and Conditions

In addition to the above following are the Special Terms and Conditions which will form the
part of the contract and will prevail over and above General Terms and Conditions, in case of
any contradiction.
6.2.1. Validity of Offer

Offer should be kept valid for at least SIX (06) months from the date of opening of Price
Bid. Those who do not agree for a validity of six months will do so at their risk and no

request for extension will be intimated from this office. However, if due to circumstances
beyond control, tenderer extends the validity, the firm shall not be permitted to revise their
rates. Any rebate or concessions while extending the validity which may materially result in
any reduction or increase in the computed price of the original offer will not be considered.
6.2.2. Sub-Letting of Contract

No sub-letting of the contract or a part of the contract shall be normally allowed.
However, under specific condition and under specific approval of MPPGCL sub-letting
only to approved vendors may be allowed. Contractor will have to submit documents in
support of competency of the contractor with the application for engaging a sub-
contractor or sub-letting a part of the contract.
6.2.3. Security Deposit

Security Deposit, as Contract Performance Guarantee: On acceptance of tender, the
successful bidder will have to deposit as security, an amount of 10% of the total value of
order in any of the following form for satisfactory execution of the order, and to cover the
guarantee period. The security deposit shall have to be submitted within 10 days of
acceptance of the offer, in one instalment in any of following manner:-
i. Banker's Cheque / Demand Draft / Pay Orders from any of schedule bank of
sufficient standing approved by the company in favour of Sr. A.O. SSTPP,
MPPGCL, Dongalia, payable at SBI Branch-Shivaria (Birpur), Distt.–Khandwa
450112 (MP) Branch code – 13649
ii. Bank guarantee shall also be accepted in lieu of cash deposit. The bank
guarantee shall be sufficiently valid to cover the guarantee period. The bank
guarantee would be furnished on acceptance of tender. Stamp duty for BG shall
be @ 0.25% of SD amount subject to maximum Rs. 25000.00/- only Or Rs.
500/-whichever is higher.
iii. The bidder may be allowed to deposit differential amount of SD after adjusting
the EMD amount, if EMD was deposited in the form of DD/IPO.
iv. Security Deposit slab shall be as under-
Contract Value SD in Percentage of Order value

1 Up to Rs. 2 Lakh Nil
2 Above Rs. 2 Lakh 10%

6.2.4. Payment to Contractor

The contractor shall be required to follow the following procedure for payment of the
subject work-
A. SUBMISSION OF BILL
a) Monthly bill against work executed by the party will have to be
submitted in triplicate to the OIC along with related documents.
b) The payment towards the work executed by the party shall generally
be made against monthly running bills. The bills shall normally be
paid within a period of 45 days. The Company shall not be liable for
any interest in delay of payment.
c) The contractor shall have no claim or reason to stop work if payments
are delayed for more than 45 days
B. PAYMENT: 100% Payment will be made within 45 days, on submission of

bill in triplicate to the Officer-In-Charge, after satisfactory completion of
work. The Company shall not be liable for any interest in delay of payment.
C. GOODS & SERVICE TAX (GST): Goods and Services Tax (GST) shall be
extra as applicable as per GST rule. The firm should invariably submit valid
GST registration no to the OIC. If any increase/decrease in rate of GST is found
than difference shall be payable/Recoverable to/from the contractor. Any other
taxes or duties imposed by the government during currency of the contract shall
be admissible as per rule. MPPGCL GSTIN is 23AADCM4472A1ZZ.
6.2.5. LD & Penalties

i. The contractor is required to perform the work in an efficient and timely
manner. In order to ensure the same, MPPGCL shall impose the following LDs
and Penalties. It may please be noted that these LDs and Penalties shall be
exclusive from each other and shall be applied independently:
A. Liquidity Damages for Delayed Mobilisation: Maximum up to 10% of the
contract value, if leviable from the Contractor.
B. Penalty for Poor Performance of the Contract: Maximum up to 10% of the
contract value, if leviable from the Contractor.
A. Liquidated Damages (LD) for Delayed Mobilisation

i. In case of any failure whatsoever towards timely mobilization of adequate resources
due to any reason attributable to the contractor, the contractor shall be liable to pay to
the liquidated damages, and not by way of penalty, an amount calculated @ 0.5 % of

the monthly contract amount for per week of delay or part thereof, subjected to
maximum of 10 % of the total contract value.
ii. In case of failure to start the work within due date, EMD may also be forfeited.
iii. MPPGCL shall have the right to deduct the liquidated damages from any amount due
or becoming due.
iv. Date of deployment of adequate resources at MPPGCL site, to the satisfaction of the
Engineer in Charge shall be the basis for calculation of LD amount.
B. Penalty for Poor Performance of the Contract

i. Poor housekeeping at work site: After completion of work the contractor should
ensure that the work area / job site is clear of from debris and scraps. The debris and
scraps should be disposed as per the procedure specified by the MPPCGL. If the site is
left un-cleaned after the work, penalty @ ₹ 10,000/- per instance shall be applicable
and shall be recovered from the monthly RA bill. Further, if housekeeping of any part
of entire CHP area is found unsatisfactory, then a penalty @ ₹ 20,000/- per instance
will be imposed & shall be deducted from the contractor’s monthly RA bills.
ii. Breach of discipline/violation of instructions: The contractor shall ensure that its
entire staff are well behaved and maintain discipline inside the plant premises. If it is
observed that any individual or group of workmen engaged by the Contractor do not
obey the instructions of the OIC / MPPGCL’s representative or misbehave, then in
case of such breach of discipline, penalty shall be applicable. The amount will be
decided by the OIC subjected to maximum 1% of the monthly contract price of the
subjected month.
iii. Poor quality of work execution: In the event of failure of the equipment within three
months of repair / service due to reason attributable to the Contractor which lead to
long outage of the equipment / affect the system operation / generation loss, penalty
will be imposed @ 5 % per instance (monthly contract price), limited to maximum of
10% of monthly contract price for the subject month shall be recovered for the loss /
damage occurred to the company from the contractor’s monthly RA bill.
iv. Non-availability of T&P and Consumables: In case of any work delay due to non-
availability of T&P and Consumables which are in the scope of the contractor, Penalty
@ ₹ 500 (Rupees Five hundred only) per instance shall be applicable. In case T&P and
Consumables which are in the scope of the contractor are arranged by the MPPGCL to
expedite the work, the cost of the material along with 24% overhead cost shall be
deducted from the contractor’s monthly RA bill.

v. Non-compliance of EHS (Environment, Health & safety) requirements: The

contractor shall fulfil the EHS requirements of the MPPGCL in totality. In case of
violation of EHS norms, penalty @ ₹ 500/- per instance shall be imposed by the OIC /
safety Officer and the amount shall be deducted from the contractor’s monthly RA
bill. The rules and regulation of M.P pollution control board shall be strictly complied
and any violation of the above shall be dealt seriously. If any penalty imposed by the
district, state, central Govt. Pollution control authority due to poor maintenance of
stack emission or water effluent shall be recovered from the running bill of contractor.
vi. Repetition of Work: The Contractor shall ensure to avoid repetition of work and
maintain work quality at site by strict supervision and monitoring. If the repetition of
work found, penalty @ ₹ 2000/- (Rupees Two thousand only) per instance / job shall
be applicable and shall be recovered from the monthly RA bill.
vii. Penalty for noncompliance of Preventive Maintenance schedule: It is expected that

the contractor should comply the Preventive Maintenance (PM) schedule. Execution
of the PM works shall be monitored on monthly basis and in case average compliance
of PM works in subjected month is not found to be satisfactory, the Engineer in
Charge shall be entitled to impose the penalty. In-case the PM schedule is not properly
adhered to, due to reason attributed to the Contractor, a minimum Penalty @ 0.1% of
the monthly contract price shall be imposed. The penalty amount shall be recovered
from the Contractor’s monthly RA bill subjected to maximum of 1% of the monthly
contract price. In case persistent default to adhere to the PM Schedule, MPPGCL at its
desecration may terminate the contract.
viii. Delay in completion of specified works:- In case of delay in completion of specified

works within stipulated time schedule, a penalty of 1% of proportionate daily contract
price per instance may be levied, subject to a maximum of 5% of monthly contract
price for a particular month.
ix. Inadequate deployment of Workers: In case of workers are found short / less than
the required as per work contract as specified by OIC, an amount of double the
minimum labour wages for per worker per day / shift shall be deducted. In case
persistent default to in the matter, MPPGCL at its desecration may terminate the
contract.
x. Leakages of Water/ Steam/ Air: In case leakage of water, steam or air is found in
steam/ water circuit of plant i.e. steam cycle, water cycle, cooling water cycle,
circulating water system, air conditioning system, service water, fire fighting, drinking
water and instrument/service air from valves/ lines/ tanks/ receivers/ equipment/
auxiliaries drain points etc., a penalty @ ₹ 1000/- per day will be imposed.

xi. Damage to Property by Contractor Workforce: In case of any unwanted strike by

the contractor’s staff / labours or any kind of damage to any person or the equipment
caused by the contractor’s staff or any kind of nuisance created by their staff, penalty
would be imposed as per the decision of OIC. However, the contractor shall also be
responsible to make good the damaged equipment / property.
xii. Timely Payment to Workers: In case of failure to make payment to the workmen
within 7 days after wage period i.e. any month, penalty @ 1% of gross value of bill for
corresponding period for which wage is due per day of default shall be imposed &
deducted from the interim running bill maximum to the extent of 5% of the gross
value of bill for the said period.
xiii. Total Penalties, taken together shall not be more than 10% of the total order
value.
xiv. The overall responsibilities for which the contractor is responsible to bear the
penalty shall be finalised at the end of the contract and if required, corresponding
amount shall be withheld from the monthly bills of the contractor by MPPGCL
till closure of contract on provisional basis.
xv. Withholding of payment or deduction of penalty shall in no way relieve the contractor
from completing the works and discharging all its other obligations under this
contract.
xvi. If any auxiliary / equipment / part damaged due to negligence in O&M in the
contractor’s scope then a penalty equivalent to the current cost of repair / replacement
of auxiliary / equipment / part will be deducted from the contractor’s bill or any If any
auxiliary/ equipment/ part damaged due to negligence in O&M in the contractor’s
scope then a penalty equivalent to the current cost of repair/ replacement of auxiliary/
equipment/ part will be deducted from the contractor’s bill or any payable.

7. Details of Plant and Auxiliaries

7.1. List of Auxiliaries & Equipment
a. The following is the list of major Auxiliaries and Equipment, provided for reference. The
list is indicative and prepared on best effort basis. The same cannot be considered as
comprehensive and final.
b. In case, during execution of the contract O&M of any additional equipment / auxiliary etc is
required to be undertaken, the same shall also be considered as part of the contract.
c. The Bidders are requested to kindly visit the site and acquire additional information, as may
be needed by them in their own interest.
d. Technical Details of these are also provided in Section 6.2
Particulars Qty
1 Boiler pressure Parts 1 Nos. for each unit
2 Boiler Circulation Pump (BCP) 1 Set/Boiler- TORISHIMA
3 Soot Blowers
4 Regenerative Air Pre-heater 2 Sets/ Unit-Vertical, counter flow
regenerative type, tri-sector
5 FD Fans 2 Sets/ Unit- Axial flow, horizontal
6 PA Fans 2 Sets/ Unit- Axial flow, horizontal
7 Seal air Fans 2 Sets/ Unit- Centrifugal, Overhung,
backward curved
8 Flame Detector Cooling Air Fan 2 Nos./ Unit
9 Wind Box On either side of Boiler in each of Units
10 Light Diesel oil Burners 8 Nos. (1 elevation X 8 Corners)/Unit
11 Heavy Fuel oil Burners 24 Nos.(3 elevation X 8 Corners)/Unit
12 LDO Pump 3 Nos. per unit (2 W + 1 S) TUSHACO
Pumps Pvt Ltd , Triple Screw Type
13 HFO Pump 3 Nos. per unit (2 W + 1 S) TUSHACO
Pumps Pvt Ltd , Triple Screw Type
14 Duct and Dampers
15 Coal Pulverizes 6 Nos. per unit -L&T-MHPS(Vertical
Mills)
16 Mill Reject Handling System 1 No. per unit
17 Electro Static Precipitator (ESP) 1 No. per unit
18 Closed Circuit Cooling Water (CCW)
01 No. per Unit
system
19 Associated Air Conditioning & Air
01 Lot
Washer System
20 Fuel Pressurisation Pump House 01 No.

7.2. Technical Details of the Auxiliaries / Equipment

a. The following technical details are provided in good faith on best available basis for the
major Auxiliaries and Equipment. These are provided for reference only. The same cannot
be considered as comprehensive and final.
b. In case, during execution of the contract O&M of any additional equipment, auxiliary etc. is
required to be undertaken or the specifications are found to be different from the details
mentioned below, the same shall also be considered as part of the contract.
c. The Bidders are requested to kindly visit the site and acquire additional information, as may
be needed by them in their own interest.
7.2.1. Brief Description of Boiler

SSTPP, Khandwa Phase-II has 2 units of 660MW boiler supplied by M/S L&T MHPS
Pvt. Ltd. Boiler is Super-critical, once-through, Balance Draught direct pulverized coal
fired with tilting tangential firing, single re-heat Cycle.
Boiler furnace is vertical membrane wall type with height from furnace lower header to
roof as 61.05 M Furnace width is 27.278 M and the depth is 13.267 M. Water wall tubes
are of SA-213 T12 and have Tube OD as 28.6 MM.
Particulars Description
Supercritical, sliding pressure operation,
1 Boiler Type
once through boiler, single reheat cycle
2 Steam Flow at SH outlet (BMCR) 2139.42 t/hr
3 Main steam pressure at BMCR 25 MPa (g) (Tertiary SH outlet)
4 Main steam temperature at BMCR 568 °C (Tertiary SH outlet)

Feed water temperature at Economizer
5 309.5°C
inlet at BMCR
6 Steam pressure at R/H Outlet (BMCR) 4.76 M Pa (g)
7 Reheat steam temperature at BMCR 596 °C (Secondary RH outlet)
8 Excess air at BMCR 20 %
Superheater 26.30 MPa (g)

9 Design pressure
Reheater 5.90 MPa (g)
Superheater 576 °C
10 Design Temp
610 °C
Reheater

Particulars Description
Drafting system Balance draft
11
Ambient Temp. Winter 0.6°C
12
Summer 48.8°C
Changing point between Wet and Dry Approx. 30 % BMCR
13
operation
14 Fuel Coal & HFO/LDO(As start-up fuel)
15 Grade of automatic operation Semi-automated on boiler operation
a. Economiser:
i. Feed water from HP heater outlet is supplied to the Economizer through the economizer
inlet pipe. The recirculation flow from BCP joins at the HP feed water outlet, during wet
mode operation. The total feed water flow to the boiler is measured by the triple redundant
flow transmitters, which are used for feed water flow control. The pressure and
temperature are also measured at the inlet to the economizer. This line has also a drain
connection to the boiler flash tank
ii. The economizer is located in the secondary pass of the boiler. The secondary pass section
of the boiler has two passes viz SH pass and RH pass, and both the passes have economizer
bank, one bank in the RH pass and three banks in the SH pass. One stream of the feed
water from the economizer inlet header flows through the economizer RH pass,
economizer intermediate header RH pass and the economizer hanger RH pass to the
economizer outlet header. The second stream of the feed water from the economizer inlet
header flows through the economizer SH pass, economizer intermediate header RH pass,
the economizer hanger SH pass to the economizer outlet header.
iii.
Design pressure 31.5 MPa (g)
Heating Surface 28110m2
Location Panel No. of Materials Tube Size (mm) Tube Pitch
Pitch(mm) panels Outside Thickness (mm)
Diameter
RH pass 90 300 SA-210C 45.0 7.4 90
SH pass (lower) 90 300 SA-210C 45.0 7.4 90
SA-106C 45.0 7.4 90
SH pass (middle) 90 300 SA-210C 45.0 7.4 90
SH pass (upper) 90 300 SA-210C 45.0 7.4 90
SA-106C 45.0 7.4 90

b. Piping:
Two (2) main steam lines carry the steam from boiler outlet to the HP turbine inlet. The HP
turbine exhaust steam is carried back to the boiler through a single cold reheat pipe, which
bifurcates at the boiler end and connects to RH inlet header. The hot reheat steam is carried to
IP turbine inlet through two (2) HRH steam lines.
c. Vents and drains:

Vents and drains are provided in the boiler pressure parts, main steam and RH steam lines for
air venting and draining condensate formed during start-up, low load operation & shutdown.
d. Water Separator:
All secondary pass outlets join at secondary pass rear wall outlet header from where it flows to
water separator through four (4) WS inlet pipes. The function of Water Separator is to
segregate the steam water mixture. The mixture enters tangentially and is segregated due to the
centrifugal action, where the heavier water particles drain down and steam moves up. The
steam flows to Primary SH and water drains down to WSDT (Water separator Drain Tank)
through WSDT inlet pipe. The secondary pass bypass pipes from roof outlet header join the
WS inlet pipes.
Manufacturer L&T-MHPS BOILERS PVT.
Outside diameter LLLTD.LTD.
980 mm
Thickness 110 mm
Height (Shell end to end) 3.31 m
Design temperature 450 °C
Operating medium Steam/water
Shell material SA-336-F12
e. Water Separator Drain Tank

Manufacturer L&T-MHPS BOILER PVT.
Outside diameter 980mm
LTD.
Thickness 110/120 mm
Height 14.7m
Operating medium Water
Shell material SA-336-F12

f. Secondary Pass Walls:

The secondary pass walls consist of the secondary pass front/rear/side/division walls. The
division walls divides the secondary pass into two (2), the RH pass and SH pass, diverting the
hot flue gas into two streams. Like furnace walls, the secondary pass walls also form a gas tight
enclosure.
The water/steam mixture from roof outlet header flows to secondary pass inlet manifold
located at the two sides of the boiler through secondary pass inlet pipes. The temperature of
water/steam mixture entering the manifold is measured by three (3) temperature elements
provided in each inlet pipe. The manifold can be vented through a common air vent pipe
provided with isolation valves. The secondary pass inlet pipes have drain connection to boiler
flash pipe with isolation valves. Secondary pass front wall inlet header is fed by secondary pass
front wall supply pipes from the two secondary pass inlet manifolds. The water/steam mixture
rises up through secondary pass front wall & secondary pass front wall screen and is collected
at secondary pass front wall outlet header, from where it flows to secondary pass rear wall
outlet header through secondary pass front wall outlet pipe. The secondary pass division wall
inlet header is fed by secondary pass division wall supply pipes from the two secondary pass
inlet manifolds. The water/steam mixture rises up through secondary pass division wall &
secondary pass division wall screen and is collected at secondary pass division wall outlet
header, from where it flows to secondary pass rear wall outlet header through secondary pass
division wall outlet pipe. Secondary pass side wall inlet headers are fed by secondary pass side
wall supply pipes, one each from corresponding side secondary pass inlet manifold. The
water/steam mixture rises up through secondary pass side wall and is collected at secondary
pass side wall outlet headers, from where it flows to secondary pass rear wall outlet header
through secondary pass side wall outlet pipes. The secondary pass rear wall inlet header is fed
by secondary pass rear wall supply pipes from the two secondary pass inlet manifolds. The
water/steam mixture rises up through secondary pass rear wall and is collected at secondary
pass rear wall outlet header. The header is provided with a vent.
g. Water wall
The fluid in the front wall and both side walls are collected at respective outlet headers and
mixed at roof inlet manifold. Thus, fluid temperature is equalized before entering roof inlet
header. The fluid in the rear wall is mixed at rear wall hanger inlet manifold and passage side
wall inlet manifold.
The fluid from roof outlet header is mixed again in the secondary pass inlet manifolds before
distributing to each secondary pass wall tubes. All water wall including passage.
All water walls including passage wall and secondary pass walls are supported from boiler
structure via rigid hanger holding upper headers, except roof wall. The roof wall is supported
from boiler structure via superheater, reheater, and economizer support structures that are

welded to roof tubes.
The water walls have buck stay system which is support that consist of four girders installed in
the four sides of furnace walls; right side wall, left side wall, front side wall and rear side wall.
Buck stay is designed to resist longitudinal load such as internal and external pressure, normal
load such as internal pressure, moment bending because of support bracket of pressure part,
and temporary load such as explosion, wind and seismic forces. It prevents furnace walls from
deformation and also prevents buckling of the tubes during heating and cooling process of the
boiler. At the corner design buck stay is hinged to permit expansion on the furnace walls and
prevents any swing.
The boiler expansion patterns are as follows:
• Vertical direction: 396.2 mm at furnace bottom
• Side direction: 81.0 mm at side wall
• Front direction: 61.5 mm at Furnace Front Wall, 75.5 mm at Inter. 1st Header ( Front Wall)
• Rear direction: 141.259 mm at secondary pass rear wall
As abnormal expansion causes tube failure, boiler expansion should be checked during start-
ups and periodically during normal operation.
All outer surfaces of the water wall are covered by insulation materials and casing. The
insulation materials are held by insulation pins that are fusion welded to the fin part of
membrane wall.
The Water walls have many openings such as manholes, observation ports, soot blower
openings or instrument taps. The water wall tubes are bent to outside of the wall and seal
boxes with refractory cover that area. Removable formed refractory or fire bricks are placed at
big openings such as manholes.
h. Roof Tubes
Subject Specification
TYPE Membrane panel
Heating Surface 1157.49 m2
Tube No. of Tubes Material Tube Size (mm) Tube
Outside Thickness Pitch
Diameter (mm)
Roof front 408 SA-213T12 38.1 5.9 66.75
SA-213T12 45.0 10.4 66.75
Roof Rear 204 SA-213T12 57.1 8.9 133.5

i. Secondary Pass and Passage Wall

TYPE Fin welded panel
Design pressure Passage : 29.6 MPa (g) Secondary Pass : 29.2 MPa
Heating Surface 4318.62 m2 (g)
Tube No. of Material Tube Size (mm) Tube Pitch
Tubes OD Thicknes (mm)
Secondary pass front s
wall
-Lower 204 SA-213T12 38.1 9.9 133.5
-Screen 102 SA-213T12 45.0 8.4 267.0
Secondary pass rear 203 SA-213 38.1 9.9 133.5
wall T12
Secondary pass Left & 2X131 SA-213 38.1 9.9 111.25
Right side wall T12
Secondary pass
division wall
-Screen 136 SA-213T12 45.0 7.4 200.25
-Lower 272 SA-213T12 38.1 9.9 100.125
Passage Left & Right 2x83 SA-213T12 38.1 9.9 89
side wall
j. Superheaters
The steam from the water separator get further heating as it flows through the Primary,
Secondary and tertiary superheater. The superheated steam at boiler outlet flows to HP turbine
through main steam pipe. Steam temperature is basically controlled by ratio of feed water and
firing rate. In addition to fuel ratio, steam temperature is exactly controlled by two (2) stages
of de-superheating. The feed water branched at economizer outlet is sprayed in DSH to lower
the steam temperature.
k. Primary Superheater
Type Drainable
Design pressure 28 MPa (g) (inlet); 27.7 MPa (g) (outlet)
Description Panel No. of Panels Materials Tube Size (mm) Tube Pitch
Pitch Outside Thickness (mm)
(mm) Diameter
Horizontal 133.5 204.0 SA-213T12 45.0 6.9 90.0
Upper
Horizontal 133.5 204.0 SA-213T12 45.0 6.9 90.0
Terminal 267.0 102 SA-213 T12 45.0 6.9 -

l. SECONDARY SUPERHEATER
Type Platen, non-drainable
Panel Pitch No. of Material Tube Size (mm) Tube Pitch
(mm) Panels (mm)
SA-213 T12 45 6.9 54.5
SA-213 T12 45 6.4 54.5
SA-213 T12 31.8 5.4 54.5
SA-213 T12 31.8 6.4 54.5
SA-213 T12 31.8 6.9 54.5
SA-213 T12 31.8 7.4 54.5
1602 16 SA-213 T12 31.8 7.9 54.5
SA-213 T12 31.8 5.9 54.5
SA-213 T22 45.0 9.9 54.5
SA-213 T91 45.0 8.9 54.5
ASME Code Case 2328-2 45.0 5.9 54.5
ASME Code Case 2328-2 45.0 6.9 54.5
ASME Code Case 2328-2 45.0 5.4 54.5
ASME Code Case 2328-2 45.0 8.4 54.5
ASME Code Case 2328-2 45.0 9.9 54.5
Supporting Tube SA-213T12 45.0 6.9 -
ASME Code Case 2328-2 45.0 6.9 -
m. Tertiary Superheater
Type Pendant, non-drainable
Panel Pitch No. of Material Tube Size (mm) Tube Pitch
(mm) Panels O.D. Thickness (mm)
534 50 SA-213 T91 31.8 5.4 54.5
SA-213 T91 31.8 5.9 54.5
SA-213 T91 31.8 6.4 54.5
SA-213 T91 45.0 6.4 54.5
SA-213 T91 45.0 8.9 54.5
ASME Code Case 2328-2 31.8 5.4 54.5
ASME Code Case 2328-2 31.8 5.9 54.5
ASME Code Case 2328-2 31.8 6.4 54.5
ASME Code Case 2328-2 45.0 4.9 54.5
ASME Code Case 2328-2 45.0 5.4 54.5
ASME Code Case 2328-2 45.0 5.9 54.5
ASME Code Case 2328-2 45.0 6.4 54.5
ASME Code Case 2328-2 45.0 6.9 54.5
ASME Code Case 2328-2 45.0 8.9 54.5
Supporting Tube SA213 T91 45.0 8.9

n. Reheater:
Reheat steam is at 596°C, increasing the enthalpy of reheat steam. Reheating of steam
improves the plant cycle efficiency. The reheating is done in two (2) stages, first in the Primary
RH and then in the Secondary RH. A DSH is provided in between the two RH stages, as a
measure for controlling RH steam temperature, in case of emergency. Spray water tapped from
BFP intermediate stage is sprayed into RH DSH. The RH steam is normally controlled by the
gas distribution dampers provided in the secondary pass after the economizer and burner tilt.
o. Primary Reheater:
The Primary RH is located in the secondary pass RH pass. The cold reheat steam pipe (R0) is
connected to Primary RH inlet headers from where it flows to Primary RH outlet header
through Primary RH and Primary RH terminal.
TYPE Drainable
Heating Surface 19203.16m2
Description Panel No. of Material Tube Size (mm) Tube
Pitch Panels Outside Thickness Pitch
(mm) (mm)
Diameter
Upper 133.5 204 SA213-T22 57.1 4.5 115
SA213-T12 57.1 3.5/4.5 115
Middle 133.5 204 SA213-T12 57.1 3.5/4.5 115
p. Reheater DSH:
The steam flows to RH DSH through RH DSH inlet pipe. RH DSH is always kept warmed
during plant operation by a small amount of steam flow through RH DSH warming pipe (R11)
which is tapped from Primary RH inlet header. The RH DSH inlet steam temperature is
monitored by temperature elements Thermowells are also installed at RH DSH inlet. Two (2)
each pressure transmitters and three (3) each temperature elements are installed on both HRH
lines to control RH DSH pressure and temperature by spray control valve. Temperature is also
monitored by temperature elements. Pressure pockets are also installed on each RH DSH spray
line.
q. Secondary Reheater:
The Secondary RH is located in horizontal passage, just after 3ry SH. Steam from RH DSH
flows to Secondary RH inlet header through RH DSH outlet pipes. The steam is further heated
to final RH steam temperature in the Secondary RH Panel and the hot reheat steam flows to
Secondary RH outlet header.
There is only a single stage of de-superheating, done in the reheater, which is located between
the Primary RH outlet and Secondary RH inlet.

Spray water tapped from BFP intermediate stage is used in the RH DSH. The spray is used
during emergency conditions, when the normal means of controlling RH steam temperature
does not provide the desired result and RH steam temperature is still increasing. The spray
flow is measured by a flow transmitter and the spray water pressure and temperature is
monitored by pressure transmitter and temperature element respectively. The spray line
bifurcates and connects to the two RH DSHs, located on LH/RH sides of the boiler
Each spray line to RH DSH has a spray control valve with an air operated ON/OFF inlet valve
and outlet gate valve with balance valve. Check valve & isolation valve is provided. A drain
connection from outlet of check valve is connected to boiler flash pipe through double
isolation valves. There is also a drain line at inlet of spray CV for depressurization during
maintenance, which has double isolation valves.
r. BCP, Recirculation Line & Minimum Flow Line:

The water from WSDT flows to BCP suction through WSDT outlet pipe& WSDT outlet
temperature is monitored by temperature element. The WSDT outlet pipe has two branch off
connections, one to BCP suction and the other to WSDT level control valves. A suction
strainer is provided before BCP. BCP discharge is connected to HP feed water heater outlet
through boiler recirculation valve. A motor operated check valve is provided at outlet of BCP
to prevent any possibility of reverse flow, when BCP is stopped during dry mode operation.
There is motor operated isolation valve at BCP inlet and motor operated check valve at BCP
outlet. The boiler recirculation flow and temperature is monitored by flow transmitter and
temperature element respectively.
s. Warming Water Lines

BCP and WSDT control valves remain closed during dry mode operation of the boiler.
However, it is necessary to keep the equipment and pipelines of start-up system warm, always
during normal operation of the plant. Warming water is tapped from economizer outlet and
supplied to BCP and WSDT control valves. The warming line has an isolation valve.The line
bifurcates and is connected as follows:
t. BCP Warming line

From the warming line, water flows to BCP discharge through a needle valve and check valve
and reverse flow takes place through BCP, suction line, WSDT outlet pipe, injection water line
and gets connected to SH Secondary DSH spray water line. The warming line from injection
water line to SH Secondary DSH spray water line is provided with a motor valve and a control
valve and is in operation only during dry mode operation.

u. BCP and auxiliaries

The function of BCP as described earlier is to recirculate water drawn from WSDT to
economizer inlet, where it joins the BFP outlet flow and flows to economizer. 25% MCR flow is
maintained minimum during start-up of supercritical boiler, and out of this 20%MCR flow is by
BCP. As firing rate is increased, BCP recirculation decreases and when WSDT Level decreases
below some point BCP will be stopped, (load >25% and dry mode operation) the BCP is
stopped.
The main flow path of BCP is the water path from WSDT to HP feed water heater outlet,
minimum flow recirculation and warming flow line. The BCP associated equipment are BCP
heat barrier, BCP purge water cooler, BCP motor and cooler.
v. BCP and auxiliaries

Heat barrier is located between the pump and the motor and minimizes the heat transfer and
possible overheating of the motor. Heat barrier is continuously cooled by circulating cooling
water from CCW system. Water is tapped from the CCW supply through an isolation valve,
check valve and is connected to heat barrier through flexible hoses. The outlet from heat barrier
joins the cooling water return through a flow switch, check valve, and an isolation valve. The
temperature of the water is monitored locally by temperature indicator. Six temperature
elements are provided in the pump casing and motor cavity to monitor the heat barrier
temperature and also are interlocked to trip BCP at high values. There is a provision to supply
emergency cooling water from CCW tank as back up to heat barrier through a check valve and
air operated ON/OFF valve. It joins the cooling water supply line after the check valve. During
such situations, the outlet from heat barrier is drained to floor drain through an isolation valve &
air operated ON/OFF valve.
w. BCP Motor Cooler:

The BCP motor is filled with water which is re-circulated by the bearing thrust plate mounted in
motor shaft for cooling of bearings and motor winding. This water is cooled in an external
cooler by cooling water from CCW system.
Cooling water is tapped from the CCW supply through an isolation valve and is connected
to motor cooler through flexible hoses. A drain line with isolation valve is provided for the
cooler. The outlet from the cooler joins the cooling water return through a flow switch, and an
isolation valve. The temperature of the water is monitored locally by temperature indicator. An
air vent with isolation valve is provided in shell side to clear the entrapped air, after isolation
valve.

x. BCP Purge Water Cooler & Filling Line:

The BCP motor is filled with condensate quality water before start-up; water from Condensate
Pump (CP) outlet is used for this. During operation, it is possible to replenish the fill water by
water tapped from HP heater outlet. Both type of water is cooled in BCP purge water cooler,
before it is used for filling the motor cooling circuit.
Water tapped from HP heater outlet is connected to inlet of BCP purge water cooler
through a check valve and inlet isolation valve. Water tapped from CP outlet joins the above
line through isolation valves and check valve before the inlet isolation valve.
The BCP takes the suction from the WSDT and re-circulates approx. 20 % MCR flow. The
recirculation flow joins the approx. 5 % BFP flow and total approx. 25% is fed to the boiler. The
excess 5 % MCR flow is discharged to the condenser from the WSDT as per the water level in
the WS. This mode of operation of the supercritical boiler is called Wet Mode Operation. The
specification of the Boiler Circulation Pump (BCP) provided in the boiler is as under-
Manufacturer TORISHIMA
Quantity One set/Boiler
Type Spherical casing, centrifugal closed impeller
Model HLAV250-570/1K
Capacity 870 m3/h
Total Head 113 m
Minimum Flow 100 m3/h
Warming Flow 70 m3/h
Suction temperature 306.5 °C
Design pressure 28.30MPag
Operating medium Boiler water
Drive Motor Details 390kW, 6600V, 1465rpm, 50Hz
Heat Barrier normal/ emergency water 30L/min - 18L/min
Motor Cooler Cooling water flow rate
flow rate 183.3 L/min
Cooling water inlet temperature 38°C
7.2.2. Boiler Systems Auxiliaries

a. Regenerative Air Pre-Heater
Two vertical, counter flow regenerative type, tri-sector air preheater of 2x60% is provided with
power operated soot blower device and water washing device.
The rotor is filled with heat transfer elements/ baskets. The total flow area of the air preheater
is divided into three paths. The flue gas leaving the economizer flows through one half of the
AH from top to bottom and air from FDF and PAF flows through the other half, which is

divided suitably as secondary air sector and primary air sector. Air for combustion from FDF
flows through the secondary air sector of the AH, which has a flow area of approximately 66%
area of the air flow half of AH. Primary air from the discharge of PAF flows through the third
sector of AH, having an approximate area of 33% of the air half area.
The rotor with the baskets rotate at slow speed around 0.75 RPM, so that the rotor elements
either pick up heat or transfer heat depending on its position in the stationary duct. The rotor is
driven by an electric motor. Normally the electric motor drives the rotor at a slow speed with
the help of a frequency inverter. This also permits variations in rotor speed if necessary for
washing. The air motor comes into service in case of failure of electric motor.
Electrically driven soot blower is provided in the gas side, at the hot end and cold end of the
AH, which is operated during service conditions. The nozzles on the lance are so arranged that
all parts of the heating surface are covered by the jets during the traverse, the lance travel being
equal to the nozzle pitch. Auxiliary steam at 1.31 MPa(g) and 301°C is used as the blowing
medium in the soot blowers. The valve open /close position and soot blower advance/retract
positions are monitored by limit switches.
A water washing device is located at hot end of AH in the gas side along with hot end soot
blower, which basically comprises of both steam soot blowing and water washing lance tubes.
Low pressure water washing is carried out when the air preheater is out of service and at
reduced rotor speed.
The rotor is supported by two (2) self-aligning spherical roller bearings. are sump lubricated
with an independent oil system.
The air preheater is provided with a fire detection system based on the principle of detecting a
pre-set maximum temperature and also a rate of change of temperature greater than that found
during normal AH operation. It consists of a set of thermocouple probes. Firefighting
equipment comprises of six water nozzles (3 in Gas duct, 2 in SA Duct and 1 in PA Duct)
positioned in all transition ducts. The air preheater is provided with an external flange for each
projector manifold which is suitably connected individually to station main water supply.
Description Details
Number of Air Preheaters Two (2) sets
Type Trisector-Regenerative type contra (gas down & Air up)
Model No.33.0 VAT 1840
Inlet gas flow 2615.8 t/h (BMCR, Design coal)
Primary air entering / leaving 37.4/307.4 oC
Secondary air entering / leaving
Temperature 30.4/317.4°C
temperature
AH gas inlet temperature 339°C
AH gas outlet temperature 131°C (Uncorrected)
Cold end metal temperature 76°C

Description Details
Pressure differential (hot side)
Secondary air to Gas 358 mmAq
Primary air to Gas 1142 mmAq
Pressure drop
Primary air side 51.5 mmAq
Secondary air side 51.7 mmAq
Gas side 67.8 mmAq
Air leakage 6.0 % (max)
Total Effective Heating surface 63996 m2
(single sided)
Heating Element
Hot end layer depth 340 mm/ material IS 513 D
Interim layer depth 1200 mm/ material IS 513 D
Cold end layer depth 300 mm/ material JIS G3125 SPA-C)
Electric Drive details 15 kW, 415 V, 30 AC, 960 RPM
Air motor details 6.2 kW, 975 rpm
a)Type a) Oil Circulation for Top & Bottom Bearing
b) No's & Type of Pump b) 2 per unit assembly, Gear Pump
c) No's & Type of Cooler c) 2 per unit assembly, Plate Heat Exchanger
d) Design Pressure & d) 12.23 kg/cm1g & 100°C
Temperature
Maximum limit of furnace outlet flue gas by probe prior to admission of steam to turbine and
/or establishing flow through RH via turbine bypass system >560ºC, High Alarm (>615°C
FEGT will retract automatically) to avoid RH element over heat.
b. FD Fans
The combustion air is supplied by the two (2) FDF with suction side silencers. Both these fans
are of axial flow type. The output of FD fan is regulated by variable blade pitch control. The
suction pressure is monitored by pressure transmitter and suction temperature by redundant
temperature elements. The fan flow is measured at the suction by triple redundant flow
transmitters.
The FDF discharge is provided with motor operated ON/OFF damper. The discharge pressure
is monitored by pressure transmitter
The combustion (secondary) air flows through the steam air heater and then tri sector AH
secondary air sector and gets heated up. The outlet of secondary air sector has motor operated
ON/OFF dampers. The air temperature at inlet duct of secondary air sector is monitored by

temperature element
The secondary air flows to the eight corners of the Windbox and is further distributed as
combustion air to individual burners and auxiliary air through pneumatic control dampers.
Description Details (With 20% Excess Air)

Number of Fans Two (2) sets
Equipment Number 03HLB01AN101/102
‘ e
yp Axial flow, horizontal
Capacity 12100 m3/min @ 100% BMCR, Design Coal
Inlet Air temperature 27°C
Inlet static pressure -13 mmAq
Discharge static pressure 318 mmAq
Control System Variable Blade Pitch Control
Driving motor 2055 kW, 11kV, 3-phase, 50Hz, 134A, 995rpm
Oil System (Lube & Control Oil)
Lube oil pumps/motors Two (2) nos., 415 V, 1.1 kW, 1400 rpm
Control oil pumps/motors Two (2) nos., 415V, 5.5 kW, 1450 rpm
Oil System Strainer mesh sizes Breather / Filter filling up (Control 10 ^

oil tank)
Double filter unit (Control oil) Filter 10 ^
element
Plug for oil filling (Lube oil tank) 10 ^
Double filter unit (Lube oil) Filter 10 ^

element
Oil Cooler water flow Lube Oil Cooler water flow 0.84 m3/h
Control Oil Cooler water flow 0.84 m3/h
Oil tank capacity Lube Oil tank capacity 120 litres
Control Oil tank capacity 120 litres
c. PA Fans
The PAFs supply the air required to dry and transport pulverized coal directly from pulverizer to
the furnace. There are 2x60% PAF provided, both fans running during normal operation of the
plant. The PAFs are axial flow, horizontal type, with variable blade pitch control.
Each PAF is provided with a self-contained forced oil system to supply the lubrication oil to the
bearings and control oil for the actuation of blade pitch control.
The control oil system consists of an oil tank with nozzles for pump suction, return oil and to
receive all other drains from relief valves and various points. The two (2) nos. of control oil
pumps, A1 & A2 takes suction from oil tank through the suction strainers and passes through a
duplex control oil strainers. The DP across strainers are monitoring by differential pressure

switch from DCS and DP gauge by locally and supplies control oil at high pressure for the
actuation of blade pitch control. One pump is in operation and the other one is on standby. Two
control oil coolers are installed in the control oil return line, one is working and another one is
in stand-by condition. Inlet cooling water pressure of cooler is controlled by a self-actuated
pressure control valve and outlet cooling water temperature and pressure are monitoring locally
by temperature indicator and pressure indicator.
The discharge from the control oil pump passes through control oil strainers before it is
connected to the actuator. Pressure switches measure the oil pressure to hydraulic regulating
unit from DCS and it also senses for high/low alarm, changes over to stand-by control oil pump
with low alarm and fan motor shall be tripper manually by operator in low pressure alarm within
certain time delay. Pressure indicator is provided for monitoring the control oil header pressure
from local. Blade pitch control drive receives electrical signal from plant APC and positions the
blade pitch with control oil, which is supplied at a pressure of max 100 kg/cm2 (g) .The blade
angle positions are monitored and alarmed at DCS by the limit switches as (Min. blade pitch),
(Max. blade pitch), (Fault alarm), (Blade Position less than 42 deg.)
Description Details
Type Axial flow, horizontal
Capacity 6900 m3/min @ 100% BMCR (DC)
Inlet air temperature 27 °C
Inlet static pressure -9.2 mmAq
Driving motor 3775 kW, 11kV, 3-Phase, 50Hz, 223A, 1495rpm
Lube oil pumps/motors Two (2) nos.,415V, 3.7kW, 1430 rpm
Control oil pumps/motors Two (2) nos., 415V, 5.5kW, 1450 rpm
Oil System Strainer mesh Breather / Filter filling up 10 ^
sizes (Control oil tank)
Double filter unit (Control oil) 10 ^
Filter element
Double filter unit (Lube oil) Filter 10 ^

element
Oil Cooler water flow Lube Oil Cooler water flow 1.8 m3/h
Control Oil Cooler water flow 0.84 m3/h
Control Oil tank capacity 120 litres

d. ID Fan
The main function of the ID Fan is to control the furnace pressure to constant value and then
boost up and discharge the flue gas (combustion products from the furnace) to the stack. The ID
Fans are located downstream of the EP.
There are 2x60% ID fans provided, both fans running during normal operation of the plant. The
IDFs are axial flow type, with variable blade pitch control.
Each IDF is provided with a self-forced oil system to supply the lubrication oil to the bearings
and control oil for the actuation of blade pitch control.
The control oil system consists of an oil tank with nozzles for pump suction, return oil and to
receive all other drains from relief valves and various points. The two (2x100%) nos. of control
oil pumps, A1 &A2 takes suction from oil tank through the suction strainers and passes through
duplex control oil strainers. The DP across strainers are monitoring by differential pressure
switch from DCS and DP gauge by locally and supplies control oil at high pressure for the
actuation of blade pitch control. One pump is in operation and the other one is on standby. Two
control oil coolers (2x100%) are installed in the control oil return line, one is working and
another one is in stand-by condition. Inlet cooling water pressure of cooler is controlled by a
self-actuated pressure control valve and outlet cooling water temperature and pressure are
monitoring locally by temperature indicator and pressure indicator.
The discharge from the control oil pump passes through control oil strainers before it is
connected to the actuator. Pressure switches measure the oil pressure to hydraulic regulating
unit from DCS and it also senses for high/low alarm, changes over to stand-by control oil pump
with low alarm and fan motor shall be tripper manually by operator in low pressure alarm within
certain time delay. Pressure indicator is provided for monitoring the control oil header pressure
from local. Blade pitch control drive receives electrical signal from plant APC and positions the
blade pitch with control oil, which is supplied at a pressure of 120 kg/cm2(g). The blade angle
positions are monitored and alarmed at DCS by the limit switches as (Min. blade pitch)
The lube oil system consists of an oil tank with nozzles for pump suction, return oil and to
receive all other drains from various points. The two (2) nos. of lube oil pumps, A1 &A2 takes
suction from oil tank through the suction strainers and supplies lube oil to the fan and motor
bearings. The lubricating oil is cooled by cooling water tapped from plant CCCW System in two
coolers, one is working and another one is in stand-by condition. Inlet cooling water pressure of
cooler is controlled by a self-actuated pressure control valve and outlet cooling water
temperature and pressure are monitoring locally by temperature indicator and pressure
indicator. Lube oil passes through duplex lube oil strainers The DP across strainers are
monitoring by differential pressure switch from DCS and DP gauge from local. Pressure
indicator is provided for lube oil header pressure monitoring from local and temperature element

is provided for monitoring and alarm of lube oil temperature from DCS. Flow switch measures
the lube oil flow to main bearing assembly from DCS and it senses to change over to standby
lube oil pump with low alarm in the IDF control logic.
Oil tank level can be monitored locally by level indicator for control oil tank and for lube oil
tank, the low level is alarmed at DCS by level switch for lube oil and level switch for control
oil. Tank oil temperatures are monitored locally by temperature indicator. Control oil tank and
for lube oil tank, the tank oil temperatures are monitoring and alarm from DCS by the following
temperature element (RTD) for control oil and for lube oil. Pressure gauges indicate the control
oil pump discharge pressure locally, Pressure gauges indicate the lube oil pump discharge
pressure locally, Pressure transmitter indicates in DCS for Monitoring and Alarm.
The seal air prevents any possible entry of dust into the blade pitch control area and the
bearings. The seal air fan sucks atmospheric air through suction filters and discharges to a
common pipe through seal air fan outlet damper and. Seal air is heated by the heating element at
the discharge side. Differential pressure across the suction filter is monitored locally through DP
gauge. Pressure switch senses the Seal air diffuser pressure Low and manually trips the fan main
motor if the low pressure with certain time delay (240 min).
IDF motor is CACW (Closed Air Circuit Water cooled) type, cooling water leakage is
monitored by the water leak detector, detection of water leakage will trip the motor.
Description Details
Type Axial flow, horizontal
Capacity 28100 m3/min
Inlet air temperature 126 °C
Inlet total pressure -312 mmAq
Driving motor 4440 kW, 11kV, 3-Phase, 50Hz, 287A, 597rpm
Lube oil pumps/motors Two (2) nos., 415V, 3.7kW, 1430 rpm
Control oil pumps/motors Two (2) nos., 415 V, 5.5kW, 1450 rpm
Oil System Strainer mesh sizes Breather / Filter filling up (Control oil tank) 10 ^
Double filter unit (Control oil) Filter element 10 ^
Double filter unit (Lube oil) Filter element 10 ^

Description Details
Oil Cooler water flow Lube Oil Cooler water 1.8 m3/h
flow Oil Cooler
Control 1.2 m3/h
water flow
Control Oil tank 170 litres
Seal Air System capacity
Seal air fan/motor 0.24 m3/sec; 2720 Pa @ 20°C /415 V, 3000 rpm, 3.7 kW/ 2pole
e. Seal Air Fans

Description Details
Type Centrifugal, Overhung, backward curved
Capacity 900 m3/min
Inlet Air temperature 37 °C
Head developed by fan 510 mmAq (static)
Driving motor 132 kW / 4 pole / 1480 rpm
specification
f. Flame Detector Cooling Air Fan
Cooling air is tapped from the discharge of FDF to supply for various equipment and
components. The two (2) FDF discharge ducts are interconnected and a tap off is taken for the
suction of the Flame Detector cooling air fans. The common suction duct has two self-actuated
ON/OFF dampers An atmospheric connection duct is also provided and joins with the 3-way
check damper). The flame detector cooling air fans get their suction through this damper from
atmosphere, when both FDF trips. 5. Flame Detector & Burner Cooling Air
Flame detectors are provided for detecting flame of each coal and oil burner of the boiler. Total
72 numbers (48 nos for Oil and 24 nos for coal flame detectors of IDD-ll series) Forney make
Flame detectors are provided for one boiler. The detectors are capable of distinguishing between
the flame produced by oil and coal depending on the detector settings. The flame detectors are
wired directly to the Flame detector modules placed in the BMS panel.
Flame scanner cooling fan supplies cooling air to the flame detector associated with each fuel oil
and coal burner through flexible hoses.

Each fuel oil burner is provided with burner cooling air. This cooling air is supplied by flame
scanner cooling fan and is supplied to all burners through flexible hoses.
In addition, each igniter associated with oil burner is supplied with air tapped from the flame
scanner cooling airline to burners through flexible hoses.
Wind box seal air is also supplied by flame scanner cooling air fan and is tapped from the
common header.
From the common suction duct, one (1) tap offs is taken; which forms the common suction duct
to the AC motor driven flame detector cooling air fan and is provided air filter
Another tap off is taken which forms the suction duct to the DC motor driven flame detector
cooling air fan with air filter
The AC motor driven flame detector cooling fan is on duty normally during plant operation and
the DC motor driven cooling fan comes into operation when AC driven fan trips or during plant
black out. The DC motor driven fan also starts automatically, when the differential pressure
between the furnace and flame detector fan common discharge duct falls below a pre-set value.
There are two no of pressure transmitters at fan Outlet as follows.
The TV camera located at boiler furnace has instrument air for cooling. The instrument air also
goes to the sealing chamber of the TV camera. It prevents the backflow of hot gas from furnace
on account of fluctuation of furnace draft resulting from the combustion of fuel.
g. Wind Box
The steam generators use fuel and combustion air into the furnace through 24 nos. burner
windbox assemblies in 8 corners and 3 different elevations. The fuel (coal and oil) and air (aux.)
nozzles of the windbox assemblies are aligned to form two firing circles at the center of the each
half of the rectangle. This produces a fireball in the furnace with a rotating, swirling action that
mixes the fuel effectively with the auxiliary air.
Each vertically arranged burner assembly consists of two coal burners and one oil
burner. The six coal burners, in each corner, are numbered as A, B, C, D, E & F and the oil
burners are numbered as AB, CD & EF.
There are 48 coal burners and 24 oil burners in steam generator. The oil burner
compartment is located between two coal compartments. The auxiliary air compartments are
located adjacent to each coal burner compartment.
Additional air-port windbox assemblies are located above the burner windbox assembly
in each corner. The use of additional air through the AA burners reduces the production of
nitrogen oxides in the furnace. There are two elevations of AA compartments, in each AA Port
Windbox, naming AA (upper) and AA (lower) in each corner. So, windbox dampers are
composed of oil dampers, coal dampers, dampers at adjacent elevation of oil & coal burner, and
additional air dampers

h. Fuel Oil Firing System

The oil burners are used for boiler start-up & supports the initial firing upto 40% of BMCR load.
The first coal burner is taken into service at 20% TMCR load, when hot PA temperature reaches
the desired value. Each oil burner is equipped with a HEA (High Energy Arc) type direct ignitor,
which discharges an electric spark adequate to ignite the oil spray of start-up oil burner. The oil
burner provides the necessary ignition energy for the pulverized coal burner startup and stabilizes
coal firing. Oil burners are then removed from service and the plant operation continues with coal
firing. Flame monitoring devices are provided for fuel oil and coal burners.
Circular firing is adopted in the furnace and uniform flame distribution is obtained, which brings
minimum flue gas temperature deviation. NOx formation and unburned carbon loss due to
incomplete combustion is reduced by using PM (Pollution Minimum) burners and proper air
distribution. Fuel oil system is combined of 2 systems.
Light Diesel oil (LDO) system.

Heavy Fuel Oil (HFO) System
i. LIGHT DIESEL OIL (LDO) BURNER

Number of burners -Eight (8) (1 elevation x 8 corners), Common for both HFO/LDO type burners
Type Air Atomising M-jet type
Light Diesel Oil combustion rate 14,900 kg/hr
Burner inlet pressure- 9.0 kg/cm²
Air Pressure: - 5 Kg/cm2
Operation oil temperature- 27ºC
Igniter type and total no’s of igniter- HEA (High Energy Arc) igniter 8 nos.
ii. Atomizing Air System For LDO

Service air is used for the atomization of light diesel oil in the burners. Service air is received at
the boiler firing floor through an isolation valve and a drain separator is provided to remove the
condensate. The condensate is drained to atmosphere through trap, which has inlet and outlet
isolation valves and a bypass valve. The atomizing air forms a ring header around the boiler to
supply air to the eight corner burners. At each corner a tapping is taken from the ring header and
air is supplied to the AB elevation burners.
iii. Heavy Fuel Oil (HFO) Burner

Number of burners- Twenty four (24) (3 elevation x 8 corners)
Type- Steam Atomizing M-jet type
Heavy fuel Oil combustion rate- 59,600 kg/hr

Burner inlet pressure- 12.0 kg/cm²

Steam Pressure:- 5 Kg/Cm2
Operation oil temperature- 115ºC
Igniter type and total nos of Ignitor -HEA (High Energy Arc) Igniter 24 Nos.(3 elevations x 8
corners).
Pneumatic shut-off valve is provided at the inlet of CV for quick shut-off on MFT actuation.
The heavy fuel oil forms a ring header around the boiler to supply oil to the eight corner burners.
At each corner a tapping is taken from the ring header and oil is supplied to the three elevation
burners. Each elevation heavy fuel oil supply line to burner at No.1 corner is provided with an
isolation valve a pneumatic ON/OFF valve and NRV and connects to the burner through flexible
hose. Oil pressure at each burner inlet can be monitored locally by pressure indicator.
iv. Atomizing Steam for H.F.O

Atomizing steam is used for the atomization of heavy fuel oil in the burners. The atomizing
steam forms a ring header around the boiler to supply steam to the eight corner burners. At each
corner a tapping is taken from the ring header and steam is supplied to the three elevation
burners. Each elevation steam supply line to burner at No.1 corner is provided with an isolation
valve, a pneumatic ON/OFF valve and NRV and connects to the burner through flexible hose.
7.2.3. FUEL OIL PUMP HOUSE

a. LDO Pump
Quantity:- 03 Nos per unit (02 W + 1 S) TUSHACO Pumps Pvt Ltd make, Rotary Positive
Displacement (Triple Screw Type) Motor Rating 30 KW. Pump Rated Discharge- 22.1 Kg/Cm2
b. H.F.O Pump
Quantity:- 03 Nos per unit (02 W + 1 S) TUSHACO Pumps Pvt Ltd make, Rotary Positive
Displacement (Triple Screw Type) Motor Rating 125 KW. Pump rated discharge- 33.6 Kg/Cm2.
7.2.4. Duct and Dampers

a. Flue Gas Duct
1. From Economiser to APH.
2. From APH to ESP inlet up to distribution box of the ESP.
3. From ESP outlet gate to ID fan inlet
4. ID fan outlet to chimney
5. Eco hopper duct.
b. Air Duct
1 From FD fan discharge to APH inlet

2 From APH outlet to wind box.

3 From PA fan discharge to APH inlet
4 From APH outlet to individual coal mill inlet-hot air gates
5 Cold air duct from PA fan discharge to individual coal mill cold airgateinlet.
6 From PA fan cold air duct to seal air fan suction duct.
7 Seal air fan discharge air pipe line to individual coal mill seal air isolatingvalve
inlet
8 From FD fen discharge to scanner air fan suction duct
9 Repair/ replacement of duct support &to provide extra support of ducts,if
required.
10 Repair/replacement of expansion joint.
c. Butterfly Damper
1 Multi-Louvre Dampers
2 Guillotine damper
7.2.5. MILLING SYSTEM AND BURNERS

The coal is fed to the pulverizer through a coal feeder driven by a variable speed electric motor.
The speed of the coal feeder is varied to control the gravimetric flow rate of coal as per the load
demand. The pulverized coal is transported through independent coal pipes to the four coal
burners for combustion in the furnace of the boiler with the assistance of hot air.
Pulveriser is L&T MHPS make Vertical Mills Model MVM 32 F.
Two pulverizer seal air fans are provided (one working and one standby). Seal air from this fan
is supplied to parts of the pulverizer.
Pulverizerinerting steam from the Auxiliary Steam System is supplied to the lower housing.
Steam is automatically supplied to the hot air inlet duct to establish an inert atmosphere inside
the pulverizer at the time of tripping or cleaning and purging operation of the pulverizer. The
inert atmosphere prevents any possible ignition of residual coal in the stopped pulverizer.
The pulverizer is a vertical, pressurized (air swept) type, essentially consisting of a grinding
chamber with a fixed separator mounted above. Grinding table assembly along with the
three freely rotating rollers on the roller journal assembly constitute the grinding components
of the pulverizer.
a. GEAR BOX
The function of the Gearbox is to transmit power to the Grinding Table from the driving
motor at a reduced speed. The Gearbox is located below the Grinding Table and is driven by a
high voltage induction motor. The Gearbox is lubricated by an external lubricating oil system.
The oil in the Gearbox is pumped by a lubricating oil pump through an oil cooler and a duplex
filter. The cooler performs the cooling function based on the electric control valve. The oil is

directed towards all the bearings and the gears inside the Gearbox by internal openings and
tubing. Cooling water from the Closed Cycle Cooling Water System is provided to cool the
lubricating oil in the oil cooler.
Coal Pulveriser
Quantity (6 nos per Unit)
Pulverizer: Manufacturer L&T-MHPS
Model, Type MVM 32F, Vertical Mill, Pressurized.
Coupling Manufacturer SIEMENS
(Gear Unit - Model RUPAX-ARPEX CPLG COMBIN RAK 560
Motor) Type RUPAX-ARPEX
Torque Capacity Rated Torque:10139 N-m , Maximum Torque:
39000 N-m
Bearing Roller Journal Single Row Cylindrical Roller Bearing Make:
Upper Bearing: NTN, Number: RNU8012CS310PX1
Upper Bearing
Roller Journal Double Row TRB Make: NTN, Number:
Lower Bearing:
5E CRD 8055D0CS995PX1
Lower Bearing
Seals Roller Journal LN67-732-6253-1
Assembly VD seal
Roller Journal LN67-732-6239-1
Assembly Dust
Tensioning
seal System N67-732-6268-1
Assembly Dust
seal
Pulveriser Assembly Weight
Weight Grinding Table Assembly 35T
(192.8 Tons Roller Journal Assembly 23.5T

approximate
Roller Cover Assembly 9.2T
ly)
Upper Housing Assembly 34.6T
Lower Housing Assembly 24T
Middle Housing Assembly 26.5T
Planetary Gearbox 28.5T
Motor 11.5T
Grinding Table speed 28.735 r.p.m.
Planetary Gearbox

Performance Characteristics
Quantity 6 nos per unit
Manufacturer SIEMENS
Type KMP 425
Power Rating 1050 KW
Input Speed 990 r.p.m.
Output Speed 28.735 r.p.m.
Ratio 34.4
Coal Pulverizer Motor

Quantity 6 per Unit
Manufacturer M/s. BHEL
Motor Type Double Cage Rotor
Speed at rated load 990 rpm
Rated Output 1050
b. VARIOUS COMPONENTS OF THE SYSTEM

A. GEAR BOX AND BOWL HUB ASSEMBLY
B. MILL SIDE AND LINER ASSEMBLY
C. SEPARATOR BODY ASSEMBLY
D. ROLLER JOURNAL ASSEMBLY
7.2.6. Coal Firing System

The primary function of the coal firing system is to
• Grind the raw coal received from the coal bunkers to the desired fineness.
• Reject the non-combustible materials from the coal.
• Transport the pulverized coal to the coal burners for the subsequent firing in the furnace.
Coal Burners Description

The coal burner consists of a fixed coal burner body that receives the fine pulverized coal
through the coal pipes. The coal burner body is supported at the partition plate by two supports.
A core assembly located between the above two supports and two splitter plates located at the

rear end of the coal burner body streamline the coal flow into the furnace. The splitter plates in
the coal nozzle are also provided with hard facing to reduce nozzle erosion. The combustion air
for the coal burner is controlled (as per the quantity of coal fired) by adjusting the damper at the
inlet of the windbox. The air control damper in the windbox provides a continuous flow of air to
cool the coal nozzle when the coal burner is not in service.
Manufacturer- L&T MHPS BOILERS P LTD
Quantity - Forty eight (48) (6 elevations x 8 corners)
Type PM Burner
7.2.7. MILL REJECT HANDLING SYSTEM
Description Qty Make / Size
MRHS having a collection of the reject from 6 Mills in one bay to a silo for each
unit of 660 MW
No. of Collection Mills 6 No. @ per unit
No. of Mills working/unit at

MCR worst coal firing 5 No. @ per unit
Outlet points 1 No. @ per mill
Particle size 40 mm max.
Conveying Rate @ per mill 0.948 TPH
Bulk Density of Mill Rejects 1.6-2.4 T/M3
Average Reject Convey

Velocity 5.7 m/s
No. of Transporting Kirloskar-

Compressors 1working+ 1 Reciprocating Type,
2 No. stand by 24 m3 / min.
7.2.8. Miscellaneous
a. All Cooling Water Lines in Boiler Area
All Cooling Water Lines in Boiler Area

S. Quantity Per
No. Item Particulars Unit / Boiler Make / Type
Closed Circuit Cooling Water

1 (CCW) System
Make-Mather & Platt, Type-

Centrifugal Pump, Horizontal
Shaft, Single stage, Axial split
type, Pre Grease Filled for Life
Time, capacity- 280 m3/Hr, Drive
02 Nos Motor Details- 90 kW, 415 V,
CCW Pump (1W+1S) 1480 rpm
CCW Make up tank 01 Set Make L&T EWL, Capacity- 5m3
(A) 2 Nos ( 1 W + Make – Tranter Plate type, Single

PHE 1S) pass, Counter flow , water – water
Make- Positive Metering Pumps

NaOH Dosing Pump 1 (I) Pvt. Ltd , Capacity- 500 Lt
Motor Details- CGL Make, 0.37

kW, 415 V, 3PH, Sq. Cage
Induction Type Motor, 1410
RPM, Flange Mounted, IP 55
Agitator Assembly 1 Protection.
The cooling water in boiler &

auxiliary area is basically
supplied to the following:
• Pulveriser journal oil and lube
oil coolers
• BCP cooler
• Air Pre-heater lube oil coolers.
• ID, FD, PA fan lube oil and
control oil coolers
B • Sampling rack coolers
C ID Fan Coolers Four (4)
D FD Fan Coolers Four (4)
E PA Fan Coolers Four (4)
F AH Oil Coolers Four (4)

Pulveriser Journal and Lube Oil

G Coolers
BCP Motor cooler, Purge cooler

H and Thermal barrier cooling
1. All Service Air & Instrument Air lines in Boiler Area

Regular Maintenance/replacement of All the Service & Instrument Air Lines including
1 valves, fittings etc in the Entire Boiler Area at all Elevations.
2. Associated Air Conditioning & Air Washer System
Package Air Conditioning (PAC)

for ESP/VFD control rooms
areas/building,
1 and Service building
A Package Air Conditioning
i. ESP / VFD Control Room, Unit-1 3 Nos. [17.5 TR Capacity Each]
ii. ESP / VFD Control Room, Unit-2 3 Nos. [17.5 TR Capacity Each]
B Split Air Conditioning
Fuel Oil Handling Area Control

i. Room 4 Nos. [5 TR Capacity Each]
Evaporatory Cooling areas

equipped with Unitary air
Filtration system [UAF Units &
C Roof Extractors]
ESP Control Buildings Non Air-

1 Conditioned area Unit-1
i. Unitary Air Filtration [UAF] 2 Nos. Flow = 65000 Cum./Hr Each
ii. Roof Extractors [RE] 4 Nos. Flow = 1000 Cum./Hr Each
ESP Control Buildings Non Air-

2 Conditioned area Unit-2
i. Unitary Air Filtration [UAF] 2 Nos. Flow = 65000 Cum./Hr Each
ii. Roof Extractors [RE] 4 Nos. Flow = 1000 Cum./Hr Each

Forced Ventilation Areas

Equipped with Supply Fans &
3 Roof Extractors
A Fuel Pressurisation Pump House
i. Supply Air Fan 8 Nos. Flow = 10000 Cum./Hr Each
ii. Supply Air Fan 4 Nos. Flow = 5000 Cum./Hr Each
iii. Roof Extractors [RE] 6 Nos. Flow = 10000 Cum./Hr Each
iv. Roof Extractors [RE] 2 Nos. Flow = 5000 Cum./Hr Each
b. All Cooling Water Lines in Boiler Area

These include the work of all cooling water lines pertaining to various equipment andsub- systems as
per Section 6.1
c. All Service Air & Instrument Air lines in Boiler Area
These include the work of all service/ instrument air lines pertaining to various equipment andsub-
systems as per Section 6.1
d. Associated Air Conditioning & Air Washer System

These include the work of air conditioning and air washer systems in Boiler area.
8. Scope of Work
a. The contractor would be responsible for providing & managing end to end operations &
maintenance of Boiler and accessories round the clock of Stage-II, SSTPP, Khandwa. The
scope of work shall cover Operation and Maintenance of the Boiler and accessories
b. The scope shall also cover complete Operation & Maintenance of Mechanical, Electrical,
and Instrumentation & Hydraulic Systems within the battery limits of 2x660MW Units,
Boiler and accessories of Shree Singaji Thermal power project (SSTPP), Stage-II Dongalia,
Khandwa, which includes the equipment / auxiliaries etc., as per list of Section 6.2.
c. The activities provided are the minimum activities to be discharged by the successful bidder
for O&M of the Boiler and accessories. Any equipment / work / services not mentioned
specifically in the scope but required for satisfactory execution of work shall be provided
by the contractor without any extra cost.

d. The Maintenance of plant and equipment shall cover both preventive as well as breakdown
maintenance.
e. The exclusions to the scope of work are elaborated in Section xxxx
f. For ease of reference it is to mention that the scope of work has been grouped in the
following heads:
a. General Scope of Operations
b. General Scope of Maintenance
i. Running / Routine / Preventive Maintenance
ii. Breakdown Maintenance
c. Attention Issues for Maintenance Work
a. General Scope of Operations

Operation of the plant has to be safe for auxiliaries and manpower while its should have best
Industrial practices also. It includes initial charging, startups, continuous efficient operation
monitoring & logging of the parameters of all auxiliaries and stopping of auxiliaries and plant
system/ sub-systems.
The operational parameters as recommended by the OEM for respective Plant/ Machinery have
to be strictly maintained. Maintaining the parameters and handling any emergency situation is
to be taken care by the contractor’s personnel.
i. Monitoring and controlling of all the on line analyzers
ii. Controlling of De-superheating spray water stations of Boilers and continuous
monitoring for proper functioning to maintain temperature
iii. Handling of emergency situations
iv. Compliance of all applicable MIS clauses in respect of documentations, record keeping,
SOPs and safety norms and standards
v. Provide skilled and adequate experienced manpower required for normal operation of the
Boiler and their accessories in the Power Plant
vi. Provide information and reasonable technical assistance with respect to Operation of the
power plant as necessary and to maintain proper and MPPGCL approved permit to work
system.
vii. Time to time collect data for, among other things analyzing system performance,
performing preventive maintenance and verifying performance criteria. These data shall
be made available at periodicity to be finalized by the MPPGCL for his study and analysis
of the performance of the power plant
viii. Perform and record periodic operational checks and tests of the boiler and its
accessories as required by the operation and maintenance manual of the manufacturer

ix. Immediately inform the MPPGCL of any major deviation in the performance from
predicted performance of the Power Plant during normal operation.
x. Immediately inform the MPPGCL of any abnormal operation failure / breakdown of any
component of Power Plant during operation, giving the sequence of event before and after
component failure / breakdown.
xi. Perform and record periodic operational checks and tests of the Power Plant as required by
the Operational and Maintenance Manual of the Manufacturer.
xii. Maintain appropriate operation log sheets, records, and reports for the power plant.
xiii. To maintain all statutory requirement with respect to labour laws, ESI, PF authority etc.
xiv. To maintain workforce and deploy manpower as per IBR requirement for boiler operation.
xv. Arranging the T&P for round the clock operation of Boiler and Auxiliaries.
xvi. The contractor will provide qualified and experienced personnel as required per shift
according to the qualification and experience mentioned & as per instruction of EIC to
discharge the Contractual Obligations. Suitability of the personnel provided by the
contractor will be examined. Only those personnel will be allowed to work who are found
suitable. If performance of any candidate is not found satisfactory at any point of time
during the work, then the contractor has to withdraw / replace him immediately.
xvii. Class– I Boiler Attendant/ Operator and Class – II Boiler Attendant shall have valid
Competency certificate issued by IBR Authority and shall be having minimum 3.0 years
of experience in handling Field work for pulverized coal fired supercritical boilers. He
shall also be SSC pass or ITI Pass or Intermediate pass.
xviii. The contractor shall have a Station Head as the Senior most assisted by a Deputy Station
Head among the other operating and maintenance personnel’s who shall co-ordinate all
the activities connected with, control the personnel, ensuring the deployment of required
number of personnel at each specified location in each shift as per shift Rota and give
suitable direction to carry out smooth shift operation of units through the other
BOE’s and First Class Boiler Operators.
xix. The Contractor shall ensure round the clock availability of the above nominated
personnel’s to be to be contacted during the shift operation for any slackness in the man
power deployment. However no additional payment will be made on this account.
xx. Round the clock operation from desk shall be taken care by the MPPGCL through separate
arrangement however the same round the clock at field level on various auxiliaries shall be
to contractor’s scope. One Operational engineer for boiler desk operation as mentioned
above shall be provided by the contractor.
xxi. Contractor shall ensure all environmental and statutory compliances for the operation of
the plant, waste disposal, safety of man and machineries.
xxii. Maintaining good ambience at the plant, proper cleanliness and good housekeeping shall
be ensured by the contractor at all plant equipment failing which a suitable penalty shall
be imposed by the Engineer-in-charge.

xxiii. Fire safety alertness and safety drills with the fire protection personnel and other plant
workers employed by the contractor shall be regularly maintained.
xxiv. Flue Gas System and Operational Aspects: If this System is operated under conditions that
deviate from its design, it is suspected that the system may not achieve its performance
objectives and also it is likely to result in serious trouble. The operating personnel should
be well aware of the system of RAPH, IDF, FDF and PAF functions, and associated air
and flue gas paths’ components.
b. Auxiliary Specific Scope of Operations

The auxiliaries shall be operated with utmost care within the definition of proper
operation viz. the following-
a. Safety
b. Efficiency of Operation
c. Low Auxiliary Power Consumption (APC)
d. Avoidance of outages
e. Running the units and auxiliaries within permissible parameters
f. Smooth operation viz. gradual loading etc. as per recommendations of OEMs
c. SOME OF CRITICAL OPERATIONAL LIMITS

Some of the operation limits for boiler for some main equipment are shown as below
A. Economizer water temperature

Application Limitation Remarks
Maximum limit of 10°C below saturation To avoid steaming in

economizer outlet water temperature corresponding economizer
temperature to eco outlet pressure
B. Super Heater Steam Temperature at Outlets

Minimum steam >5° above saturation To avoid over injection
temperature allowed at temperature of spray water
the outlet of SH De-
superheater

C. Reheated Steam Temperature at Outlet

Minimum steam >10° above saturation To avoid over
temperature allowed at temperature injection of spray water
the outlet of RH De-
superheater
Other limitations for Boiler Operation:

i. Being a supercritical boiler, operation for long periods at loads between 20 % and 30 %
of BMCR must be avoided. This region is the wet to dry transfer range.
ii. Steam pressure at superheater and reheater must be lower than design pressures (<26.3
MPag /<5.9 MPag respectively).
iii. Main steam temperature must be lower than 568°C.
iv. Reheat steam temperature must be lower than 596°C.
d. General Scope of Maintenance

i. The maintenance contract would mainly comprise of running / routine maintenance,
preventive maintenance & breakdown maintenance of Turbine & Generator and minor
modification of equipment as well as maintenance of its auxiliary system.
ii. The operator must provide all necessary infrastructures for executing the detailed scope
of work of maintenance of Boiler & Aux so that the system will always available.
iii. It is incumbent upon the field operator to maintain close cooperation with operation
engineers for maintenance activities of the equipment & system etc.
iv. The Contractor is required to follow maintenance program as per schedule.

v. The Contractor has to ensure the availability of stand-by equipment in good condition.
vi. The Contractor will have to ensure that sufficient manpower (highly skilled / skilled /
semi-skilled / unskilled) is engaged round the clock including Sundays & holidays for
repair, preventive & breakdown maintenance so that equipment can run effectively &
smoothly.
vii. The Contractor has to provide adequate technical back-up including periodical visit to
the station by the senior staff of the operator for ensuring smooth maintenance of the
plant for perfect working of these systems. Senior staff must visit the site before start of
the work & frequency of subsequent visits to be decided mutually as per requirement at
site.
viii. The Contractor has to maintain proper register / record / log book of the work / service
covered under the contract.

ix. A list of spares required for execution of contract is to be submitted to the OIC time to
time before exhaust to take necessary procurement action by MPPGCL.
The future requirement of general spares including insurance spares is to be assessed jointly
by MPPGCL & the contractor so that effective utilization of the same is ensured
e. Details of Works Attending (Maintenance)
1 Boiler Tube Failures:
i. Shifting of all T&Ps, cutting and welding accessories etc to the work site.
ii. Opening and closing of manholes and assistance in detection of tube leakage.
iii. Removal of insulation and aluminium cladding sheets, if required.
iv. Tube and header guards/ shields may have to be fabricated and to be fitted as per
requirement
v. Checking of dipper plates in bottom ash hopper and rectification / replacement as per
requirement.
vi. Internal water washing of boiler after cooling to remove ash/slags deposited over the
tubes/ coils/ panels in the leakage area wherever required for inspection and carrying out
the work. The water washing is to be carried in other areas of boiler also for inspection
and repair as per instruction of EIC.
vii. Chipping of refractory and / or cutting of fins, if required.
viii. Hot or cold bending of tubes and MPI, if required.
ix. Shifting of boiler tubes, bends, and electrodes etc. to work site.
x. Thickness survey/ inspection of other failure prone areas of the boiler, and carrying out
DP test etc. as per the requirement of work.
xi. Provision of general lighting inside boiler.
2 MODE OF WELDING OF BOILER TUBES:

i. Cutting of tubes by gas/hack-saw/ gouging/ grinding machine as instructed by engineer-tn-
charge.
ii. Edge preparation of tubes by grinding for welding.
iii. Fitting of new tube inserts after proper edge preparation and maintaining suitable gap to
ensure quality weld joint.
iv. Filing/ grinding of new tube inserts at inner diameter at both ends in case of rifled tubes or
wherever required.
v. Pre-heating of tubes in the case of alloy steel tubes and as per requirement in other cases.
vi. Root run by TIG welding and thereafter electric arc welding to be done strictly as per IBR
norms. The welders may have to undergo procedure -cum-simulation test, if so desired by

boiler directorate or EIC. The 100% joints are subjected to radiography. The tubes of
platen coils and final superheater coils having thickness more than 8 mm are subject to
stress relieving. After completion of welding joint, hydro test of boiler has to be carried
out. All statutory provisions of Indian boiler regulations shall have to be fulfilled by the
contractor.
3 STRESS RELEIVING:
i. Arrangement of stress relieving kit and shifting to location. Mounting of kits over the
place where stress relieving is to be done. All stress relieving materials except asbestos
cloth/ wool to be brought by contractor.
ii. Electrical resistance heating shall be done for SR adequate nos. of thermocouples shall be
mounted for proper measurement of temperature and rate of heating and cooling shall be
as per instruction of Engineer in Charge.
iii. Stress relieving cycles are to be properly recorded and submitted to the Engineer in
Charge.
iv. Stress relieving shall be carried out strictly as per specified code/ cycle given by EIC
4 HYDRAULIC TEST
i. Hydraulic test after attending the tube leakage this includes gagging and de-gagging of
safety valves, and inspection of boiler at different elevations and providing temporary
lighting etc. as per requirement during hydraulic test and attending the defects found
during hydraulic test.
ii. Re-welding of fin, casting of refractory reinstallation of baffles, seal plates, and skin plates
etc as per requirement.
iii. Re-fixing of insulation and aluminium cladding sheet.
iv. Shifting of failed & un-used boiler tubes back to field stores.
v. Cleaning of ash, clinkers etc. for attending tube leakages have to be carried out as per
requirement.
vi. All other allied jobs, felt necessary for satisfactory execution of the repair job shall have to
be done at no extra cost.
vii. Similar mobilizations for attending leakages found in hydraulic test immediately.
viii. Cleaning the site within 24 hours after synchronization.
Note:
a. The intent of this schedule is that the contractor should mobilize sufficient resources both
in terms of manpower and T&P so that work is not held up for want of above.
b. The leaking or other, Economizer/ SH&RH coils may be required for lowering/lifting to

facilitate inspection, thickness survey and repair work. Coils shall be lifted/ lowered in the
position and restored after completion of inspection and repair work. Method of handling
shall be as per discretion of EIC.
c. Arrangement, providing, shifting and erection of scaffolding to attend tube leakage and
sky climber and other facilities for quickly attending the boiler tube leakage/ thickness
survey/ for approach to the required boiler piping where insulation job is to be carried out
etc. shall be to contractor’s scope.
d. Operation of sky climber to the location of leakage point. Sky-climber may be required for
inspection of areas other than leakages zone also.
e. Wherever required, Platform shall be made as per safety norms including handrails all
around the platform.
f. Dismantling of scaffold with due safety care after completion work and getting clearance
from EIC.
g. Lowering of material to zero meter and return of material to the site store or the place
instructed by EIC.
h. Transportation of materials from stores to worksite inclusive of loading and unloading by
crane/ hydra and return of material and scraps, if any, have to be carried out by the
Contractor.
i. Where tubes are cut by gas or cutting electrode a minimum of 5 mm from the edge shall
be removed by grinding, before starting edge preparation.
j. New tubes shall be cleaned from inside by compressed air and/or steam as per instructions
from the MPPGCL representatives, before use.
k. The portion near weld joint shall be cleaned by emery paper or file.
l. The tubes identified by Engineer in Charge shall only be cut for replacement. The decision
of Engineer- in-Charge shall be final and binding for selection of method of cutting of
tubes.
m. All spool pieces shall be cut by saw only.
n. Weld joints may be in coils or may be preassembly joints for making different assemblies
Dissimilar Metal Weld Joints.
5 Weld Joint Procedure For Welding Of Pipe Line and Valve

Replacement
i. Root joint welding by TIG welding process.

ii. Subsequent arc welding by appropriate welding electrode after baking of the same so as to
pass through radiographic test and IBR requirements.
iii. Controlled cooling of joints by wrapping of asbestos cloth, if required.
iv. Dressing of the joints for radiography.

v. Repairing of joints by grind & fill-up / cut & weld, if found during radiography without
any extra cost.
vi. Final decision on welding/ cutting/ edge preparation procedure shall be as per EIC and
binding on contractor.
vii. Joints include edge preparation, tube cutting, fitting of inserts and welding normally for
tube size of 31 to 63.5mm.
viii. Specified filler wire and electrodes shall only be used.
ix. Baking of electrodes as per procedure before use.
x. Maintaining profile of weld bead.
xi. Dressing the joint before radiography.
xii. Violation of procedures/specifications shall attract penalty.
xiii. All the above activities shall confirm to the quality procedure mentioned in IBR & ASME
norms.
xiv. All weld joints which are having identified defects shall be removed/ repaired and re-
radiographed after repair/removal. If again defects are noticed during NOT, then the same
shall be repaired and retested till the same get accepted.
xv. All welding joints shall be done by qualified high pressure welder having valid licences
duly endorsed by chief inspector of Boilers, MP and approved by the MPPGCL after test.
xvi. Cleaning of welded surface area by wire brush/grinder etc. whichever is applicable.
Remove the rust & dirt from area to be DPT and carrying out D.P. Test.
xvii. All joints should be of radiographic quality confirming to ASME/IBR quality.
xviii. All attachments cut for welding of joint shall be restored.
xix. All the reorientation of end connection work shall be done as per drawing or instructions
given by EIC.
xx. Pre-assembly joints shall be marked with identification mark and returned to the
departmental stores after acceptance of radiography.
6 RADIOGRAPHY
i. Mobilization of duly certified and authorized radiography camera with sufficient strength
to the site.(minimumstrength-12 Curie)
ii. Placement of the film on the joint where radiography is to be taken and taking of shot with
proper identification mark
iii. Development of radiography film in the laboratory of their own.
iv. Preparation of report and getting evaluated through MPPGCL.
v. Submission of report to MPPGCL
vi. Re-radiography of repaired joints.
Notes:

a. This work involves taking radiographs of mainly butt weld joints at identified location as
instructed by EIC. Radiography may also be taken during tube leakage inside boiler joints
in socket welded valves, butt welded valves, replacement of HP pipelines and replacement
of bend in high pressure valve area may require radiography work as per requirement.
b. All fresh butt weld joints shall be radiographed, (i.e. 100%).
c. All fresh weld joints including pre-assembly joints and all the old Arc weld joints.
d. All radiographs taken on any day, shall have to be developed on the same day and will be
submitted to MPPGCL within 5 hours after exposure. For this the contractor should keep
adequate arrangements for developing and drying the film.
e. All joints to be marked for repair. After evaluation of radiograph shall be re-radiographed
after repair till it is not been accepted by MPPGCL.
f. If defect is found in the radiograph of old joints then repair of the same shall be done as
per schedule of weld joint (outside boiler). Re-radiography of the joint after repair shall be
done to recheck the repair work.
g. Check radiographs i.e. radiographs taken for correlating the initial radiograph shall be
done in the presence of engr in charge or his representative. These films should be handed
over to MPPGCL immediately. These will have to be developed in the lab. Mismatch in
check radiograph shall attract relevant penalty.
7 SHIELD WELDING, SHIELDING OF TUBES

i. Shifting of ready-made shields from stores/available place to work site.
ii. Cutting of shields in required size and shape as per the instruction of engineer in charge.
iii. Positioning the shield on the eroded tube facing the direction of flue gas flow or as per the
instruction of engineer in charge
iv. Removal of the old /damaged cassette baffle from the coils if required and repair of the
same.
v. In-situ repair of cassette baffles.
vi. Installation of cassette baffles on coil bends and locking with the tubes by welding.
vii. Fixing of cassette baffles, connectors, clamps & wear pads.
8 Repair of Scaffolding Door

i. Remove the cooling water connections of the door.
ii. Repair/ fabricate the door frame, body, flanges and cooling coils as per the requirement.
iii. Removal & re - casting of refractory.
iv. Close the repaired door with proper gasket/ rope fixing.
v. Reconnect the cooling water lines and charge the lines.

9 Repair Of Peephole/ Manhole Door, Soot Blower’s & Instrument

Seal Boxes
i. Open or remove by cutting the peephole/ manhole/seal box door to be repaired.
ii. Remove the damaged refractory and fill refractory
iii. Repair / straighten peephole/ manhole door hinges and other fittings as per requirement
iv. Replace the sealing rope / gasket/glass etc.
v. Replace/ repair the broken lock / hinge etc and weld the seal box if required.
vi. Box up or reweld the peephole/ manhole/ seal box.
10 Boiler (Tube Bends) Fabrication

i. In case of non-availability of bends, the same shall have to be fabricated as per procedure
prescribed by Engr in Charge either by hot or cold bending.
ii. All bends will be visually examined by Engr In Charge.
iii. If necessary, the bends will be taken for further NDT
iv. Stress relieving for bends as per procedures.
v. Hydraulic bending machine required for bend fabrication has to be brought by contractor
at no extra cost.
11 Insulation Works
i. Removal of old or damaged insulation as per instruction of Engineer In Charge.
ii. Welding of hook, fixing of mineral wool blankets and welding of retainers.
iii. Fixing of aluminium cladding sheet, if required.
iv. Fixing of any other component of insulation system.
v. Mineral wool blankets shall have to be fixed in double/ four layer as per the instructions of
MPPGCL Engineer-in-Charge.
vi. Following locations shall be covered under the scope of this work for the purpose of
insulation and sheeting work:-
a. Different headers and pipings inside the penthouse.
b. Boiler first & second pass (up to respective hoppers) and penthouse from outside.
c. Main steam, HRH, CRH and RH/SH spray pipings starting from boiler to the ends where
piping’s enter inside the turbine building.
d. Economizer inlet (from feed regulating station upto the boiler) & outlet and down comer
piping’s.
e. Headers outside the furnace like SCW inlet header, bottom ring headers etc.
f. Different boiler side valve body.
g. Any other pipeline/area as per the direction of Engineer-in-Charge.

12 Refractory Removal, Application of Refractory & Making of

Refractory Blocks Etc.
i. Arrange access, approach and local lighting.
ii. Shift materials (castable, pourable & plastic refractory etc ) to location.
iii. Ensure that while removing, the removed pieces do not fall on lower elevations.
iv. Ensure that the removed pieces are carefully stuffed in to disposal bags and
shifted to identified location as per EIC.
v. Ensure that the area to be covered is thoroughly cleaned and cleared of old refractory
pieces, powder, debris or any other loose material.
vi. Fix retaining meshes, rods, stiffeners etc. as per advice to be obtained from EIC, over the
surface I area to be covered by refractory.
vii. Ensure all crevices, gaps, constricted spaces etc. are thoroughly filled up with the new
refractory. Ram if needed. Agency must provide rubber hand gloves to the person who is
engaged for refractory job. Kami, bucket, tasla & spade to be also arranged by party.
viii. Ensure high quality surface finish.
ix. Plastic refractory is to be applied at soot blower openings, burner bends, LRSB openings,
HRSB openings etc. Application of plastic refractory is to be done by adequately skilled
manpower. Provide proper safety PPE to the manpower during preparation and
application of plastic refractory i.e. rubber hand gloves, gum boot etc.
x. Offer to EIC for visual inspection. Obtain clearance to go ahead with curing process.
xi. Cure/heating the refractory as per specified procedure. Protect the area during curing
time.
xii. Refractory application should be smooth and to be carried out by skilled personnel only.
xiii. Uneven application of refractory will be rejected and rework to be done free of cost till it
is acceptable by EIC.
NOTE:
DEBRIS DISPOSAL / LIGHT SCRAP RETURN
a. The running & breakdown maintenance work generates scrap like aluminium sheets,
mineral / rock wool debris, ropes, gaskets, cable pieces, broken lights etc.
b. Collect the following scrap separately
c. Aluminium scrap alone –separate place.
d. Ropes, gaskets, cable pieces, broken lights and miscellaneous items – separately
e. Debris –wool, refractory and muck- separate
f. Show to EIC and obtain his clearance for loading on to truck / trailer.
g. Aluminium scrap is to be returned to MPPGCL store and weighed.
h. Other debris and scrap load on to truck and dispose at identified place(s).
i. All the scrap return works shall be completed before the time target set by EIC.

13 STEEL SCRAP RETURN:-

i. The coil reclamation work and running maintenance work generates scrap like old boiler
tubes, shields, baffles, bends, plates, rods, etc.
ii. Collect all the steel scrap at one place. Do not mix- up scraps of different types.
iii. Show to EIC and obtain his clearance for loading on to the disposal truck.
iv. Load on to truck / trailer and return to MPPGCL stores, as specified.
v. Weighing of empty and the loaded truck at the weigh bridge available in plant premises
shall be done and the weighing slip obtained from the weigh - bridge in charge.
vi. All steel scrap return shall be completed before the time target set by EIC.
14 MISC SCAFFOLDING WORKS:

i. Issue of scaffold material from stores and its shifting to appropriate location on the
boiler.
ii. Erection of scaffolding for approach to the required boiler piping where insulation job is
to be carried out.
iii. Platform shall be made as per safety norms including handrails all around the platform.
iv. Dismantling of scaffold with due safety care after completion of insulation work and
getting clearance from EIC. Lowering of material to zero meter and return of material to
the site store or the place instructed by EIC.
v. This schedule shall also be operated where ever approach is required to carry out
shielding/ inspection/ repair works inside / outside boiler, APH, Fan, Mill area.
15 HIGH PRESSURE VALVES

i. All the works mentioned shall be carried out in in-situ condition i.e. without removing
the valves from pipeline.
ii. However based on the condition of valve engineer-in-charge at his own discretion may
decide to remove the valve and shift to workshop and then re-weld to the pipelines and
carry other remaining servicing jobs. Reclamation of valves shall be done inside the
plant premises only.
16 Safety Valve
i. Complete dismantling of the valve and cleaning of all parts.
ii. Repair / replacement of damaged components including assisting in case of seat cutting
operation if required. Making new / replaced spares fit to use by repair if required.

iii. Lapping of seat and disc with the help of lapping tool upto required level.
iv. Lapping of stem with disc, and other critical components upto required level.
v. Lapping of test plug with seat surface & installation of test plugs for hydraulic test and
assembly of valve.
vi. Gagging of safety valves at the time of internal and external hydraulic tests as per
requirement.
vii. Installation of disc in place of test plug and final adjustment of setting after the hydraulic
tests.
viii. Floating and adjustment of safety valve set and reset pressure, as per requirement.
Assistance in on-line testing of safety valves also.
ix. Checking for passing and simmering within one month of light-up and attending the
same while running or any next short shutdown as per requirement.
17 Control Valves (Pneumatic / Hydraulic Operated)

i. Removal of actuator from valve and decoupling.
ii. Complete dismantling of valve.
iii. Cleaning of all the components.
iv. Inspection of all the components.
v. Repair/ replacement of damaged components. Making new/ replaced spares fit to use by
repair if required.
vi. Lapping of seat and disc.
vii. Lapping / cleaning of sealing surfaces.
viii. Re-assembly of valve and coupling of valves.
ix. Remounting of actuator or valve and assistance in coupling with actuator.
x. Checking seat passing and bonnet leakage at the time of charging or hydraulic test and to
carry out necessary repair work after hydro test.
xi. Re-assembly of valve.
xii. Commissioning of valve.
xiii. Checking seat passing and bonnet leakage during hydraulic test and attending the defects
after hydro test.
18 Electromatic Relief Valve (ERV)/ Hydraulic Relief Valve

i. Complete dismantling of main ERV/Hydraulic Relief Valve and/or its pilot valve.
ii. Cleaning repair / replacement of damaged components.
iii. Lapping of seat and disc of both main ERV and its pilot valve.
iv. Lapping of bonnet sealing surfaces of both main ERV and its pilot valve.
v. Box up of both main ERV and its pilot valve.

vi. Attending defects notice during hydro test charging.
19 Servicing of HP Valves
i. Removal of gland packing.
ii. Cleaning of stem and making the valve operation free.
iii. Greasing of operating nut, stem and bearings.
iv. Servicing of valve operating mechanism, which may involve opening of yoke bush or
drive bush or replacement of wheel / handles.
v. Cleaning, repair, replacement of yoke bush/ drive bush etc.
vi. Replacement of gland packing.
vii. Commissioning of valve and hot tightening.
viii. Checking of gland leakage during the hydro test and attending leakages after the hydro
test.
20 HP Valves Replacement / Installation

i. Cutting of old valve/pipe line as required, to fit the valve and edge preparation.
ii. Fitting of new valve and appropriate welding to the line. Preheating and post heating
with gas heating set as may be required, to be carried out.
iii. Checking of welding for leakages during hydro test or charging of lines and attending the
same after isolation.
iv. Replacement of sample coolers is also included in this schedule.
21 Replacement of HP Valves Requiring Stress Relieving:

i. Cutting of old valve/pipe line by grinding/ saw cutting or gas cutting as decided by
engineer-in-charge to fit the valve.
ii. Edge preparation and fitting of new valve.
iii. Preheating of the joint with electric coil as per instruction of engineer-in-charge.
iv. Welding of valve- root welding with TIG weld and subsequent weld with manual are
welding.
v. Post weld heat treatment (stress relieving) maintaining correct stress relieving cycle as
per instructions of engineer-in-charge.
vi. Repairing of joints observed in radio graph prior to stress relieving. Payment for
radiography would be done under respective schedule.
22 Piping Hangers Inspection/ Servicing/ Adjustment

i. Cleaning of hanger for taking reading.

ii. Cleaning of all components of hangers and its supports by cotton waste /wire
brush/diesel etc.
iii. Noting down reading of hangers.
iv. Making arrangements for adjustment of hangers, which shall require mobilization of
chain pulley blocks/hook chuck and cutting set and welding machine.
v. Adjustment of hangers to the required position as per the requirement. Weldingof the
component as per requirement.
vi. Painting of hangers and marking writing the hanger no and marking the scale.
23 Soot Blowers
a) Preventive Maintenance
i. Inspection of wall blowers/ long retractable soot blowers.
ii. Remove the dust & clean the blower completely.
iii. Identifying defects and leakages such as in puppet valve flanges, glands, passing of
puppet valves, relief valves, swivel tube gland, traverse gear box, rotary gear box, etc.
rectification of defects and leakages of the same.
iv. Top up /replace oil as per requirement. Attend oil leakage, if any.
v. Carryout manual operation of wall blower for checking freeness of blower.
vi. Tightening of fasteners to control flange and gland leakages.
vii. Check soot blower coupling spider, replace the same if found damaged.
b) Servicing Of Soot Blowers

i. Dismantling of puppet valve completely.
ii. Lapping of seat and stem disc assembly.
iii. Blue matching of seat.
iv. Box up of valve and providing new packings.
v. Hydraulic testing of the serviced valve,
vi. Fixing back the puppet valve with new gaskets.
vii. Servicing of gear box assemblies which include inspection of worm gear, worm shaft,
bearing etc.and replacement if required. Refitting of gear boxes after work completion
with proper alignment with motor.
viii. Inspection and cleaning of RAPH soot blowing pipe, nozzles & Barco joint, and
replacement/ patching/ shielding of pipe/ nozzles if required as instructed by EIC.
ix. DPT of swivel tube assembly for finding out any crack.
x. Oil top up and connecting motor cable connection.

xi. Servicing of power pack assemblies of LRSB

xii. Servicing of travelling carriage assembly of LRSB
xiii. Attending for steam leakages, if any, and pressure setting on the puppet valve after unit
synchronisation during first blowing operation.
xiv. Replacement of the soot blower sleeve.
xv. Clean the soot blower opening.
xvi. Check the co-axiality of the sleeve w.r.t soot blower swivel tube.
xvii. Servicing of soot blowers–electrical
xviii. Removal of junction box cover and motor TB covers and cleaning
xix. Continuity checking and meggering of motors and replacement of the motor, if found
faulty.
xx. Checking of limit switches and cam, replacement of cam/mounting pin, if required and
adjusting/setting of the same to the desired positions.
xxi. All electrical connections tightness checking at local and MCC and replacement of any
parts like overload relay, contactor, switch, if found any defective.
xxii. Checking of Blower operation electrically from local and from MCC and noting the time
taken for operation of each blower.
xxiii. Putting back all the covers removed in position after satisfactory electrical operation of
the equipment.
24 Lines & Valves

a) Flange Gasket Replacement of Pipes / Valves:
i. Unbolting the flange bolts and nuts.
ii. Lifting or separation of flanges as required.
iii. Cleaning of gasket seating surface of the flanges.
iv. Cutting of gasket from Gasket sheet if required.
v. Installation of gasket, Nut and bolts.
vi. Even tightening of Nut and Bolts as per EIC instructions.
vii. Retightening of flange in case of any leak during hydro test
viii. Removal and normalization of pipe clamps to be done if required.
b) Patching/ Repairing of Pipe Lines

i. Removal of insulation if any.
ii. Cutting and removal of old pipelines / bends.
iii. Laying and fitting of new pipelines after edge preparation at both ends.
iv. Giving proper supports to the piping.
v. Redoing of insulation.

vi. Laying of HP/ LP pipeline shall be done against this schedule.

vii. Weld joint for HP pipeline shall be done by approved HP welder. Radiography of weld
joint shall be done and repair if any observed shall be attended.
25 Servicing of Mill, APH and Fan Handling HOIST

The following works shall be done on electrically operated travelling hoists each installed
i. Disconnection of electrical cables and lowering of hoist from monorail
ii. Servicing of complete hoist assembly which includes: checking of gear box internals, brake
assembly components, wire rope fixing, rope guides, hook, drums, all limit switches and
other assemblies.
iii. Servicing of complete hoist assembly which includes: brake assembly components, wire
rope fixing, rope guides, hook, drums, all limit switches and other assemblies
iv. Repair /replacement of damaged components as per requirement
v. Lifting of hoist from working platform to travelling guide (monorail) where hoist is to
travel.
vi. Electrical connection of hoist and its commissioning.
vii. Checking smooth movement of hoist (trial operation). Rectification of defects if any.
viii. Load testing of hoist before competent authority.
ix. Dismantling of hoist from one unit, shifting to another unit, servicing and erection of the
hoist at another unit is also included in this scope of work.
x. Lowering of existing CC pump hoists from their location in boiler to zero meter and shifting
them to allocation identified by EIC is also included in the scope of work.
xi. Any other minor associated works as per job requirement.
26 AIR PREHEATERS
i. Ash accumulated in Center-section (hot end) – entire guide bearing area, over the sector
plates and bellows, around support bearing, Pin rack assembly and in the Pinion housing
cover areas to be removed.
ii. Ash is to be collected in gunny bags dropped to zero meters.
iii. In-situ (without removal of basket) water jet cleaning of air heater baskets and internals
from hot end. (Including making arrangements of hot washing of baskets using existing
permanent system).
iv. Repair/ replacement of water washing/ (including cleaning/ replacement of nozzle,
strengthening of support and shielding of pipelines).
v. Minor repair of diaphragm/partition plates (hot end and cold end) by welding/ grinding/
patching.
Various works under APH shall be as under-

a. Lub Oil System Servicing (Both Guide & Support Bearings):

i. Oil draining from cooler, filters and piping.
ii. Cleaning of coolers & filters. Hydraulic testing of coolers and attending defects or
replacement as per requirement.
iii. Checking freeness of oil and water line valves and servicing / providing new valves as per
requirement.
iv. Checking pump condition, coupling condition, replacement / adjustment shall be done, if
required. Lub oil lines and water lines upto root valves connecting with cooling water
header are also to be cleaned by air jet. Cutting / welding may be required for above
cleaning.
v. Cleaning of lube oil pump, checking it and do necessary servicing as per requirement If
required existing system of pump may be replaced with new pumps for which necessary
modification of lines shall be carried out.
vi. Filling oil in guide and support bearings, trial of lub oil system when the sytem is ready,
adjustment of pressure, attending defects, if any.
vii. Mark dip stick in the oil filling line
viii. Monitoring oil level during trial run of LOP's.
b. Guide Bearing Servicing:

i. The bearing housing cover, pipeline connections and fittings are to be dismantled.
ii. Drain / Remove the Oil / Grease from the Housing.
iii. All components including damper tank and its fittings are to be thoroughly cleaned with
diesel and compressed air.
iv. Inspection of all components is to be carried out.
v. Clearance between housing and bearing, roller and outer race to be recorded.
vi. All gaskets and ropes are to be replaced.
vii. Re assembly of components as per the instruction of EIC.
viii. Oil / Grease to be filled in the housing.
ix. Guide fixtures of the bearing housing are to be checked and rectified.
x. Bearing housing level to be checked and recorded.
xi. Reassemble all connections to the bearing housing.
c. Support Bearing Servicing:

i. The bearing housing cover, pipeline connections and fittings are to be dismantled.
ii. Drain/Remove the Oil /Grease from the Housing.
iii. All components including damper tank and its fittings are to be thoroughly cleaned with
diesel and compressed air.

iv. Inspection of all components is to be carried out.

v. Clearance between housing and bearing, roller and outer race to be recorded.
vi. All gaskets and ropes are to be replaced.
vii. Re assembly of components.
viii. Oil/Grease to be filled in the housing.
ix. Guide fixtures of the bearing housing are to be checked and rectified.
x. Bearing housing level to be checked and recorded.
xi. Reassemble all connections to the bearing housing.
d. Checking of Rotor Run Out & Levelling

i. Run out of both top and bottom flanges of air heater rotor as
ii. Well as COG rim to be checked and recorded.
iii. High point of rotor flanges to be marked.
e. Rotor Levelling:
i. Rotor to be levelled as per quality norms by adjusting the jack bolts of guide-bearing
housing.
ii. Foundation bolts to be tightened.
iii. Defective fasteners / lock plates found damaged are to be repaired or replaced.
f. Maintenance of Sealing System and Sector Plates Of Air Preheaters:

LEVELLING OF HOT END RADIAL SECTOR PLATE:
i. Fix the finger tabs at inboard and outboard.

ii. Record the previous setting readings of sector plate.
iii. Level the sector plate as per requirement.
iv. Repair/replace the sector plate actuating mechanism if required.
v. Lock the sector plate after completion of levelling.
g. LEVELLING OF COLD END RADIAL SECTOR PLATE:

i. Fix the finger tabs at inboard and outboard.
ii. Record the previous setting readings of sector plate.
iii. Level the sector plate as per requirement.
iv. Repair/replace the sector plate actuating mechanism if required.
v. Lock the sector plate after completion of levelling.

h. LEVELLING OF AXIAL SECTOR PLATE:

i. Fix the finger tabs at hot and cold end.
ii. Record the previous setting readings of axial sector plate.
iii. Level the axial sector plate as per the requirement as directed by the EIC.
iv. Repair/replace the axial seal adjusting bolts if required.
v. Lock the axial seal plates after completion of levelling.
i. Radial Seals Repair/Replacement & Setting:

i. Fix the straight edge to set seals at pre-determined seal leaf to sector plate gap, as directed
by the EIC.
ii. Loosen all fasteners of the seals to be set.
iii. Replace all the worn out / damaged fasteners and seals.
iv. Set all the seals one by one against straight edge and tighten all the seal fixing bolts & nuts.
Lock the adjusting mechanism.
v. Set all the seals of every sector in the same way.
vi. Remove the straight edge and check free rotation of the rotor by rotating with air motor.
j. Axial Seal/ Bypass Seal Repair/Replacement & Setting:

i. Fix the straight edge to set seals at pre-determined seal leaf to axial sector plate gap as
directed by EIC.
ii. Loosen all fasteners of the seal to be set.
iii. Replace all the damaged seals and fasteners.
iv. Set all the seals one by one against the straight edge and tighten the fixing bolts & nuts and
locking thereof.
v. Remove the straight edge and check free rotation of the rotor by rotating with air motor.
k. In-Situ Condition Repair of Sector Plates:

i. Identify the eroded portion of sector plate.
ii. Grind / gouge out the eroded portion.
iii. Repair the eroded portion by welding/patching.
l. SERVICING OF AXIAL SECTOR PLATES & ITS MECHANISM:
i. Ensure smooth movement of the sector plate. Repair / replace the components of
links, adjusting bolt / nuts etc.
ii. Adjust / set the clearance between the sector plate and rotor flanges as per
instruction of the engineer in charge. Hot adjustment may also have to be done if
required.

m. Maintenance of Heating Elements System of Air Preheaters:

a. Cleaning of cold end baskets after removal from the air preheater
i. Access doors on the air heater casing to be opened.

ii. Basket removal doors (both welded cover and bolted door) on the rotor are to be
opened.
iii. Cold end Baskets are to be taken out. For proper identification sector No. &
basket nomenclature to be marked.
iv. Clean identified old baskets by using high-pressure water jet. Cleaning may be
done either at air heater floor or at zero meter floors.
v. Reposition water cleaned baskets on the support lattice.
vi. Close basket removal doors (both welded cover and bolted door) and access door
on the casing after replacing sealing rope.
vii. Restore the original condition of rotor.
b. Cleaning of hot end basket in-situ/ after removal from the APH
i. The scope of work starts after removal of the hot end Radial Seals.
ii. If required, install a new beam of adequate size inside APHs for lifting /
removing the baskets from their position.
iii. Install travelling trolley & chain pulley block(s) of adequate capacity on the
beam.
iv. With the help of this and / or any additional arrangement as deemed necessary,
remove the hot end baskets out of Air Pre-Heater diaphragms.
v. The removed hot end basket to be cleaned by using high-pressure water jet.
vi. The intermediate basket below the removed H.E. basket to be cleaned in-situ by
using water jet.
vii. Reposition the cleaned HE basket either in same or reversed position as per
instruction of EIC.
c. Repair/replacement of support lattice:
i. The support clits holding the lattices are to be cut and weldment to finish by
grinding to fit new lattice. Repair of partition plates / diaphragm plates by cutting
the damaged portion and grafting new plate or by metal build up (by welding) &
grinding of damaged area as per instruction of Engineer in charge. Damaged
portion of diaphragm plate / partition to be repaired by welding & grinding or
patch welding.
ii. Remove damaged lattice.

iii. Position the new lattice and provide the support clits. (To insert the lattice inside
the APH opening may have to be made in the duct. The same has to be restored
after completion of job.)
iv. Welding of the clits should be done to ensure adequate load bearing capacity of
the lattice.
v. Provide support to the lattice by welding structural (angles, flats etc.)
n. SERVICING OF DRIVE SYSTEM OF AIR PREHEATERS:

Regular inspection of gear box, drive pinion & pin rack: Remove all the driving equipment
e.g. motor, fluid coupling, air motor etc. Remove the main drive gearbox from its position
and place on the platform. Remove the drive pinion from the gearbox. Drain the oil from the
gearbox. Dismantle the gearbox internals and clean. Inspect all the internals and replace the
damaged parts as directed by Area engineer. Assemble the gearbox. Flush the gearbox with
oil. Fill the fresh oil. Reposition the gearbox with drive pinion. Fix and align all the driving
equipment. Fix the pinion cover. Clean externally the gearbox and the area in the vicinity.
Take trial run and attend the defects if any. Point-wise Procedure shall be as below-
i. Opening of pinion cover and visual inspection of pins and pinion teeth.
ii. Gear box oil draining, flushing and filling with new oil.
iii. Greasing of bearings.
iv. Tightness checking of the pinion fixing bolts.
v. Checking and adjustment of pinion root gap & turn down (after rotor leveling
activity is done) as per norms.
vi. Putting back pinion cover by providing proper packing rope so that there is no
leakage in running condition
vii. Proper alignment of gearbox with the electrical motor and other critical
dimensions like coupling gap etc. is also required to be done as per instruction of
EIC.
o. Checking and servicing of air motor and associated valves / lines.

i. Removal of air motor from its base, dismantling of air motor, cleaning and
inspection of blades, bearings and other internal parts. Replacement of damaged
ones.
ii. Assembling of all the parts providing lubrication.
iii. Removal of water clogging in the air line. Servicing of manual valve as per
requirement.
iv. Fixing back the air motor, restoring air line connections, (if removed) coupling
back and trial run of the air motor, checking for any defects and attending the
same

p. Servicing of Fluid Coupling :

i. Remove the Fluid coupling from motor/gear box.
ii. Drain the oil from fluid coupling.
iii. Dismantle the fluid coupling.
iv. Check the internals and replace the damaged parts.
v. Replace oil seals and bearings, if required.
vi. Assemble the fluid coupling.
vii. Align the fluid coupling with motor and gearbox.
viii. Refill fresh oil.
q. COG Rim Alignment:

i. Pinion covers are to be removed and manhole doors are opened to provide access to
the cog rim. If required body block shields also is to be removed.
ii. Cog rim run out and axial alignment are to be measured.
iii. Bracket supports of cog rim are to be cut and removed. After giving temporary
support to the cog rim. Damaged and defective segments or pins are to be placed.
iv. The cog rim is to be aligned radially and axially. It should be tack welded in the
aligned position. Checking of alignment. Fixing of bracket supports and full welding
are to be carried out.
v. Normalization: All manhole covers, shield etc. opened should be boxed up. Pinion
covers are to be boxed up after checking of proper mating of pinion with cog rim.
r. Alignment of Drive Motors, Fluid Couplings and Gear Boxes.

i. Decoupling of Electric motor and fluid coupling.
ii. Fixing of alignment fixture and dial gauge.
iii. Checking of mis-alignment.
iv. Necessary loosening of electric motor foundation bolt.
v. Aligning of the same as per desired values.
vi. Reassembly and coupling of the same.
27 FD/PA/ID FAN
The following are part of general maintenance works required to be done in the Fans
i. Alignment checking, rotor levelling& re-alignment.
ii. Coupling replacement as per requirement (in between motor and fan)
iii. Shaft seal & impeller seal replacement/repair if required
iv. Checking & repair /replacement of casing and duct supports.
v. Inlet & outlet guillotine gates& IGV manual opening and closing if required, gear

box greasing and servicing if required.

vi. Removal of IGV power cylinder from its position & refitting and servicing of power
cylinder
vii. Cleaning of lube oil suction and discharge filters, breather and lube oil tank etc
viii. Cleaning of lube oil cooler, hydro test of the cooler, refitting & replacement of
cooler.
ix. Checking of lube oil tank level and top up/replacement of lube oil as and when
required. Centrifuging of lube oil if required
x. Fan bearings/ motor bearings replacement, if required.
xi. Lube oil pump repair & replacement
xii. To attend any leakage in oil line & cooling water line
xiii. Cooling water and oil line valves servicing and replacement if required
xiv. Repair/ replacement of links and pipes for IGV operation & servicing of IGV
xv. Removal and refitting of coupling for maintenance of motor and fen (servicing of
motor is also included) and alignment of the fan with the motor.
xvi. Replacement of damper seals.
xvii. Balancing of fan.
xviii. Replacement of foundation bolt, checking and cleaning of casing guide, repair of fan
casing etc
xix. Mono-rail hoist servicing. Repair / redressing of hoist rail.
a. Replacement of Rotor Bearing of FD/ PA/ID Fan

i. Removal of fan top casing.
ii. Dismantling of impeller blades of the fan. Remove the hub disc by oil injection
process.
iii. Check bearing condition & remove the bearings, if not in good condition
iv. Measure the clearance of new bearing before mounting.
v. Measure shaft OD, bearing seating area housing ID, new bearings OD & ID
vi. Assemble the bearing
vii. Replace the simmer rings/ O-rings.
viii. Assemble the rotor.
ix. Measure axial float.
x. All measurements to be recorded.
xi. Assemble the hub disc by oil injection process.
xii. Assemble the blades.
xiii. Fitting of top casing
xiv. Re-alignment and shifting of tools and tackles, scraps etc.

b. Replacement of Impeller Blade of FD/ PA/ID Fan

i. Removal of fan top casing.
ii. Dismantling of impeller blades of the fan.
iii. Fitting of new impeller blades.
iv. Proper setting of the tip clearance of the blades by grinding.
v. Fitting of top casing
vi. Re-alignment and shifting of tools and tackles, scraps etc.
28 Fuel Oil Firing System

i. Check the LDO and HFO supply headers for damage and signs of oil leakage.
ii. Check the piston operated LDO and HFO shut-off valve for correct operation and
signs of damage.
iii. Check the LDO and HFO flow control valve for correct operation and signs of
damage.
iv. Check the LDO and HFO check valve for correct operation and signs of damage.
v. Check the pneumatically operated burner oil supply valve and the manual isolation
valve for correct operation and signs of damage.
vi. Check the pneumatically operated burner air atomization supply valve and the
manual isolation valve for correct operation and for signs of damage.
vii. Check the pneumatically operated burner steam atomization supply valve and the
manual isolation valve for correct operation and for signs of damage.
viii. Check the atomizing air control valve and atomizing steam control valve for correct
operation and for signs of damage.
ix. Check that the oil and air check valves function correctly.
x. All connections and mountings are to be monitored for damage or leakage.
a. Oil (LDO/HFO) Burner

i. Check the fuel oil (LDO/HFO), atomizing air/atomizing steam supply pipes for
security and signs of leakage or damage.
ii. Check the oil and air connections and oil and steam connection between the
stationary union and the removable union block for signs of leakage.
iii. Check that the burner is fired without any problem. Ensure that the burner tips
(spray plate and back plate) are clear and installed correctly during regular burner
cleaning operation.
iv. Check the spray plate and back plate for crack, damage or blockage.
v. Check the peep hole glass for cracks or smoke deposits. Clean the glass or replace it

with a new glass if necessary.
29 Ducts
i. The boiler ducts are to be externally inspected carefully for any corrosion or welding
leakage when the boiler is in service. Leakage can be detected by hissing noise, fly
ash leakage or by obvious de-colorization of the ducts or insulation cladding.
Perform repair depending upon the severity of the leakage and the plant operational
requirements. Patch-up welding can be performed if the boiler is to be restarted
urgently.
ii. The manhole doors on the ducts are to be inspected for leakage of air or flue gas.
Tighten the door fasteners immediately to arrest the leakage. Replace sealing ropes
or gaskets with new ones during the next available shutdown, if leakage cannot be
arrested by tightening,
iii. Inspect metallic and non-metallic expansion joints for any leakage. Make a note of
any leakage and rectify or replace the damaged expansion joint during the next
available shut down.
iv. The duct supports, guides and stoppers are to be inspected for their integrity and for
proper movement in their designated directions. Any obstruction for free movement
could cause problems for the supports and/or the connected equipment. The cause of
movement restriction should be identified and rectified immediately or during next
shut-down depending on the severity. This can usually be done without any effect on
the unit operation.
v. The hanger supports are to be inspected for their integrity, loose/missing parts and
proper expansion movement. Repair or replace any missing or damaged component
immediately.
vi. Check that the movement of spring hangers confirms to the recommended “HOT”
position marked on the spring housings. Remove any restriction for free movement
of hanger support at the first instant. Problem with one hanger support can lead to
increased loading on the nearby supports and lead to failure.
vii. The hoppers on the flue gas ducts are to be inspected for ash accumulation at regular
intervals. Ash accumulation leads to increased loading on the duct supports and ash
loading on the EPs. Increased ash loading can lead to deterioration in the
performance of EPs. Evacuate accumulated ash immediately manually or by ash
removal equipment, following the recommended procedures.
viii. The insulation cladding sheets on the hot air and flue gas ducts are to be inspected
for their integrity or damage. Replace with new sheets if any cladding sheet is found
damaged. Secure loose cladding sheets to their original positions with proper screws.
ix. After inspection and replacement of defective parts, individual blades are to be

checked for full opening and closing positions. Replace the link rod and link pins
and then check operation of the full damper manually. Ensure proper closing and
opening operation for each blade. If necessary adjust the link rod and turnbuckle
and ensure full opening and closing positions.
x. Ensure that the actuator is inspected and serviced by I&C team. Operate and check
for full travel and free movement of the power cylinder before connecting the
damper. The anti-friction bearings are to be inspected for any damage, pitting,
rusting or seizure. The bush bearings are to be inspected for any damage on the
bearing surface. Defective bearings should be replaced with new. Grease the
bearings as required.
xi. Inspect the shaft gland packing for any damage or deterioration and for the
presence of ash deposit. Inspect the shaft sleeve for any damage or scratch on the
packing surface. Replace with new gland packing as per the procedure described
below if damage or deterioration is observed.
30 DAMPERS
a. Butterfly Damper
i. Visually inspect the damper frame and seats for deformation, corrosion or erosion.
Repair or replace the defective parts as necessary.
ii. Visually inspect the damper blade for any damage, deformity, corrosion or erosion.
Perform thickness survey of blades where erosion is apparent. Repair or replace the
defective blades as follows:
iii. Completely worn blades are to be replaced with new blades. Where the wear is
local and the blade thickness is < 4 mm for air side, perform patch-welding to
restore the blade to its original thickness
Multi-Louvre Dampers
i. Check with operating personnel for details of any operational problems of a damper
and investigate as necessary.
ii. The multi-Louvre dampers are to be checked for smooth operation. A sticky damper
is to be checked for friction between stationary and moving parts, tight gland
packing and damaged bearings. Replace any damaged bearing or gland packing and
provide necessary clearance between moving and stationary parts during shut-down.
iii. The multi-Louvre dampers are to be visually inspected for the presence of any
sticking or loose linkage/hinge pins and connecting links. Restore loosened pins and
connecting links and secure them with proper washers and split pins.

iv. An external inspection is to include a check for missing link pins and bent or
damaged links. Record any damage and repair damaged links and pins during a shut
down. Replace and secure with new ones if any pin or link is damaged beyond
repair.
v. The damper shafts are to be checked for any air or gas leakage from the shaft glands.
Gland leakage is to be corrected by tightening the gland packing follower. If leakage
persists, replace the gland packing during a shut down.
vi. The damper actuators are to be checked for any instrument air leakage. Rectify air
leakage immediately on notice.
vii. The drain cock on each actuator air-filter regulator is to be opened at regular
intervals and checked for the presence of moisture. If water is observed, investigate
and rectify the air driers in the Instrument Air System.
b. Guillotine Damper
i. The guillotine dampers are to be checked for smooth operation. A sticky damper is
to be checked for friction between stationary and moving parts, tight gland packing
and damaged bearings. Replace any damaged bearing and provide necessary
clearance between moving and stationary parts during shut-down.
ii. The guillotine dampers are to be visually inspected, if any looseness appears in
mating flange, mating flange hardware and gasket. Tighten the loosened mating
flange, its hardware and gasket. Replace with new ones if any parts found in
damaged condition beyond repair.
iii. Frame seals are to be visually inspected and replace the same, if found any damage.
iv. Blade connection and side frame connection are to be checked and if found any
loosened bolts tighten the loosened bolts immediately with the help of spring
washers.
v. The damper line shafts are to be inspected for any damage due to pitting, rusting or
seizure. Defective line shafts should be rectified or replaced.
vi. Flexible coupling and universal coupling are to be checked for any loosened
coupling bolts. Tighten the loosened coupling bolts immediately on notice.
vii. The electrical actuator needs to be checked for any loosened mounting bolts. Tighten
the loosened mounting bolts immediately on notice.
viii. Gearbox connection and actuator connection are to be checked for any loosened
bolts and if any loosened bolts are found, tighten the loosened bolts immediately
with the help of spring washers
ix. Servicing of dampers/gates along with its gear box as and when required. Servicing
of its actuator is also included some of which are the following-
i. ID fan inlet/ outlet gates

ii. ESP inlet outlet gates

iii. Air pre heater flue gas inlet outlet dampers
iv. FD fan discharge outlet dampers
v. SCAPH inlet outlet dampers
vi. APH air inlet outlet dampers
vii. PA fan discharge outlet gate
viii. APH primary air inlet outlet dampers
31 COAL MILL & MILLING SYSTEM

i. All routine, preventive, breakdown maintenance of milling plant of unit # 3&4 have
to be carried out as per details given here under. The contractor shall keep milling
system available at optimum level in each unit to cater full load level of the
operating time during operation of the boiler.
ii. The contractor shall submit advanced monthly & fortnightly maintenance program
to MPPGCL.
iii. Requirement of monthly/ maintenance spare shall be submitted along with monthly
advanced program.
a. GEAR BOX AND BOWL HUB ASSEMBLY

i. Alignment motor-gear box arrangement. Mill coupling greasing, mill coupling
replacement.
ii. Removal of foreign materials and internal inspection of mill including scrapper
chamber and bowl chamber. Minor repairing as required if found any abnormality.
Attending mill labyrinth seal as and when required. Repairing / adjustment of skirt.
iii. Repair of scrapper and guard assembly, replacement & setting of scrapper after hard
facing.
iv. Bowl extension ring work - removal, replacement/ welding /cutting/ tapping/ fitting/
hard facing as required.
v. Replacement of broken / damaged bull ring segments (upto 03 nos.) Each occasion.
vi. Air restriction guide vane fabrication / welding / fitting / placement as required.
vii. Servicing of planetary gearbox is also included.
b. Mill Side and Liner Assembly

i. Inspection / repair/ replacement of liners.
c. Separator Body Assembly

i. Adjustment of classifier as per coal fineness report.

ii. Replacement of eroded classifier blades.

iii. Repairing of separator body & separator body liners & covers.
d. Roller Journal Assembly

i. Journal spring assembly bearing replacement it detected during spring compression
setting.
ii. Rotor journal shaft (oil seal location) repairing - welding, grinding as required.
iii. Checking and adjustments in grinding roll assembly and other subsystems:
iv. Checking and adjustment of spring compression for journal / stroke spring assembly
by spring compression device as required.
v. Checking and adjustment of roll ring clearance as required.
vi. Checking and adjustment the gap between journal head and stroke spring assembly.
vii. Oil level checking in roller journal and pouring.
viii. Greasing of all grease point of spring assembly.
ix. Grinding roll wear depth measurement using wear measuring gauge. Bull ring
segment wear , measurement with the help of contour template made when the
equipment is new.
x. Grinding roll lock plate checking.
xi. Measuring inverted cone clearance and adjustment.
xii. Measuring pyrite scraper clearance and its adjustment.
xiii. Minor repairing of journal assembly.
32 Pulverized Coal Firing System

i. Check the pulverized coal firing system for signs of coal leakage.
ii. Check the functioning of the hot and cold primary air dampers and gates.
iii. Check that the raw coal is flowing smoothly from the coal bunkers.
iv. Check the coal feeder belt and scraper blade for damage.
v. Check for coal powder leakage from the burner wind box joints.
vi. Check the quality of the coal flame inside the furnace. A pulsating or unstable flame
should be investigated and corrected by adjustment of burners.
vii. The ignition point is not too near or far from the burner nozzle. The flame should be
bright and of a proper length without smoke. It should be adjusted so that it does not
spread excessively upward or downward or impinge against the furnace wall.
viii. Damper setting suitable for one specific occasion may need to be adjusted for
another. Burning conditions must therefore be checked periodically.
ix. Check for proper movement of the coal burner drive shaft levers in all the eight
corners.

a. Coal Pipe Maintenance

i. To attend any leakage from MDV
ii. During coal pipe maintenance, the respective burner inlet valves, Mill outlet valves
& coal pipe purge air valves shall be closed and respective breather valves shall be
opened to enhance proper cooling of burner nozzles.
iii. Cleaning of coal pipe choking by cutting pockets wherever necessary, normalization
and box-up
iv. Victaulic/dresser/sleeve coupling/its gasket replacement
v. Reassembly
vi. After completion of coal pipe maintenance, the burner inlet valves, Mill outlet
valves, coal pipe purge air valves and breather valves shall be lined-up as per the
operational requirements.
vii. After completion of coal pipe maintenance, the burner inlet valves, Mill outlet
valves
viii. Coal pipe purge air valves and breather valves shall be lined-up as per the
operational requirements
33 Mill Reject Handling System
i. Complete operation and maintenance of the Mill reject handling system is to be

ensured by the contractor.

34 Electro Static Precipitator (ESP)

Routine maintenance work shall include all the jobs related to ESP Electrical System,
mechanical equipment and field internals require for trouble free efficient operation of ESP.
i. Regular Monitoring of Field Voltage, Field current, spark rate etc

ii. Regular Monitoring of ash level in the hopper
iii. Check of heater availability at hopper
iv. Monitoring of Leakage area and its rectification
v. periodic lubrication of external equipment of ESP
vi. Inspection of components like drives elements of collecting and emitting rapping
systems. Motors, gear reducers, vibrators, air valves and cylinders, chain drives or
similar mechanical equipment.
vii. Checking of All motor driven rapping shafts to see whether they are actually rotating
or not.
viii. Routine check-up of T-R sets to see all selector switches are in the correct position
and temperature indicators are normal.
ix. Regular preventative maintenance checks of T-R set oil
x. Regular inspection of the precipitator control room to check whether ambient
temperature is in range or not, and to ensure cabinets are clean, both inside and
outside.
xi. Recording of Electrical meter readings in every shift and its evaluation at the end of
the shift for maintenance needs.
xii. Weekly checking of all control panels, viewing windows of gas relay, dial
thermometer, oil level indicator, breathers and silica gels of transformers
xiii. Quarterly check up to clean SCR/ thyristor heat sinks of electronic controller,
control cards and contacts, switches breakers, oil level top up of rapping motors
xiv. Half Yearly Check-up of fuse contacts, cable terminations, HT connections
xv. Half Yearly cleaning of complete transformer rectifier Units
xvi. Check-up of all earthing and positive terminals for proper connection and earth
resistance of transformer rectifier
xvii. Checking of oil level and centrifuge of oil, if required in transformer rectifier unit
xviii. Inspection of Rapping Mechanism (Bearings, Gearbox & Shaft)
xix. All minor repairing work related to inlet, outlet cone, deflector plates, ESP roof
platforms etc
xx. Repair of any damaged cable leads in various panels/JBs etc.
xxi. Regular checking of Heaters’ auto cut in cut off system and necessary electrical/
Instrumentation side repair and calibrations.
xxii. Regular/ Periodical calibration of Ash Level Indicators.

xxiii. Attending illumination system circuits and rectification of faults of ESP area.
xxiv. Breakdown Maintenance work shall include removal of damages items, repairing/
replacement of electrical, mechanical and field internal equipment of ESP as and
when required.
a. Internal Cleaning of ESP Fields:

i. ESP internals to be thoroughly cleaned by wire brush/broom or water jet as per
instruction of EIC. All accumulated ash in the field (on collecting/emitting
electrodes, and other ESP internals, hoppers (from ESP top to flushing apparatus) to
be removed by (Poking / Brushing / vacuum cleaner. Any ash accumulation /
bridging in the field to be cleared. Personnel engaged in internal washing will have
to go inside the ESP to thoroughly clean the internals.
ii. Ash falling on the ground floor and adjoining area of ESP due to ESP work, is to
shifted to the nearest ash dyke in gunny bags.
iii. Scrap / non usable materials like distorted / damaged / dislocated collecting
electrodes (plates), flow guide vanes, G.D. screens or any other material lying inside
ESP / Inlet or outlet funnel / Hopper to be removed. If required these materials to be
cut to manageable size to ensure removal through manholes.
b. Preparation of scaffolding & internal inspection & restoration of field

i. Identification of the cause of field non-availability like snapped emitting electrode,
loose / misaligned collecting electrodes etc.
ii. Prepare the scaffolding inside ESP ( in each field/ hoppers) for proper inspection.
iii. Refix the loose emitting electrodes / align the collecting electrodes.
iv. Inspect for condition of components like plain bearings, collecting plates, emitting
electrodes, rapping hammers (inner and outer arms), shock bars, shock bar guides,
rapping shafts etc.
v. Reposition dislocated shock bars. Its alignment with respect to collecting plates to be
ensured. Tack-weld the fasteners.
vi. Repair/Repositioning/Replacement of Shock bar guides:
vii. Damaged / distorted shock bar guide and its support to be either rectified by heating
with cutting / heating gas or to be cut and removed. New shock bar guide to be
placed and aligned with shock bar guide and sleeve to be fully welded.
viii. Damaged shock bar guide support to be replaced.
ix. All the fasteners of guide support to be tack welded.
x. Refixing of collecting plates on hook:
xi. Dislocated collecting plates (where the plate has dislocated from Inside clit / U
guide) to be lifted up and repositioned on hook. Inside clit / U guide is to be

repaired. Any distortion in collecting plates to be removed by heating. The plate is to

be aligned with the remaining plates.
xii. Attend defects observed during trial charging so as to ensure the availability of the
field.
c. Cleaning & inspection of support insulator

i. Including Cleaning of the area around the support insulator.
ii. Inspection the support insulator.
iii. Cleaning of the support insulator from inside and outside.
iv. Closing of the covers after replacing the sealing ropes if the insulator is in healthy
condition.
d. Cleaning inspection of shaft insulator:
i. Including Cleaning of the area around shaft insulation and inspect the shaft insulator.
ii. Cleaning of the shaft insulator from inside and outside.
iii. Closing the inspection door after replacing the sealing rope.
e. Alignment of emitting frame:
i. Alignment of Misaligned emitting frames with respect to the collecting plates.
ii. Damaged/dislocated diagonal bracings to be positioned/replaced and fasteners are to
be tack welded.
iii. Bend collecting plates are to be corrected by heating with oxy acetylene flame.
Proper spacing to be maintained all along the length of collecting plates with respect
to emitting frame.
f. Replacement of damaged components of ESP:
A. Inspection & rectification of plane bearing or, bush bearings& bush bearing housings:
i. Damaged Plane bearing to be removed by gas cutting the fasteners.

ii. New plain bearing to be fixed and realigned with shaft by providing shims below t
the plain bearing housing.
iii. All the fasteners of bearing are to be tightened and tack welded.
iv. If Bush bearing and housing of EERM is required to be replaced, replace the same
g. Replacement of rapping hammers of rapping mechanism
i. Damaged/Eroded Hammers (Inner & Outer arms) are to be removed by removing
the fasteners of inner arm by gas cutting.
ii. Re-fix new inner and outer arm on the shaft.
iii. All the fasteners of inner and outer arm are to be tightened properly and to be tack
welded.
h. Repair of Shock Bar:

i. Rectification of the bend/distorted shock bar by heating with oxy-acetylene flame or

replace the damaged bar.
ii. Aligning the new/rectified shock bar with respect to collecting plates, shock bar
guide and hammers.
iii. All fasteners to be tack welded.
iv. Repair/replacement of shock bar pads:
i. Replacement of Shaft Insulators:

i. Open the inspection door.
ii. Inspection of the shaft insulator for any physical damage.
iii. Replacement the damage shaft insulator.
iv. Closing of the inspection door after replacing the sealing rope.
v. Replacement of support insulators:
vi. Inspection of the support insulator for any physical damage.
vii. Replacement the damaged support insulator:
viii. Positioning the lifting tool on the emitting frame.
ix. Raising the emitting frame until the suspension tube is relieved of load Close the
covers after replacing the sealing ropes if the insulator is in healthy condition.
x. Dismantling of the nut, suspension tube, support frame and damaged support
insulator. Before unlocking the nut, arrest the suspension tube. It is essential to use
alignment jig to ensure that the emitting frame is not disturbed from its original
alignment after replacement of support insulator.
xi. Removal of the damaged insulator and place a new insulator by providing proper
supporting pads.
xii. Tightening of all four adjusting nuts of support insulator just to bear the load of
emitting frame.
xiii. Removal lifting tool and check up for any deviation in alignment. If any deviation is
observed repeat the above procedure.
xiv. Repair of gas distribution screen:
xv. Removal of Damaged/eroded sections G.D. screens to be cut
xvi. New G.D. screen to be cut to suitable size and placed in position and welded to the
adjoining healthy G.D. screen.
xvii. Missing deflectors to be mounted on G.D. screen.
xviii. Alignment the new GD screen with base support / frame. Repair base frame if
required.
j. Repairing of Collecting Electrode :

i. Opening for inserting collecting plates to the section where replacement is required.
This may be done by cutting the ESP hopper or ESP body or through the manhole
depending upon the location and convenience of replacement.
ii. Insertion the collecting plate, position it at required location and suspend it from the
hook.
iii. Fixing of the collecting plate to the shock bar by providing sleeves and fasteners.
iv. Fixing of the collecting plate to the clit and align it with remaining plates.
v. Normalization & Restoration of normal condition including closing of openings
made for access.
k. Replacement of Emitting Electrodes:

i. Inspection of the field for the snapped/ loose/ missing electrodes.
ii. Removal of the electrode and replace it by new one supplied by MPPGCL.
l. Repairing of rapping hammers of rapping system:

i. Identification of the defective portion of the shaft and Cutting of the defective
portion, fixing the suitable spool piece with joining sleeves, align the same and
weld.
ii. Replacement of the complete shaft also if necessary. New shaft is to be placed on
bearing supports and aligned together.
iii. All the fasteners of inner arm, outer arm and plain bearings are to be tack welded.
iv. Coupling and carbon bushes are to be mounted on the shaft and realigned with the
rapping gearbox.
m. Replacement/repair of vertical shaft of emitting electrode rapping

mechanism (EERM):
i. Removal of the couplings of shaft and the sleeve joints after proper support
to the shafts.
ii. Removal of shaft. If required, repair the shaft by built up, and grinding.
iii. If machining of the shaft is required, shifting the same to workshop and back
will be in contractor’s scope.
iv. Fit the shaft. Connect the shaft sleeves. Compel the shaft to the drive shaft.
v. If the small gear wheel is required to be replaced, replace the same.
vi. Shift the scraps to a place identified by the Engineer in charge.
n. Reclamation & replacement of jaw couplings of CERM/EERM/

GDRM:

i. Remove the damaged Jaw Couplings

ii. Cut & remove the worn out portion.
iii. Fabricate the worn out portion from flat of 10/12 mm thickness.
iv. Weld it with the jaw coupling of grind.
v. Paint with two coat of red oxide paint.
vi. Replacement of gland packing of CERM, EERM and GDRM:
vii. Replacement of gear wheels of EERM:
o. Replacement of oil in rapping mechanism

i. Dirty oil/grease of gear boxes to be drained and stored properly in oil/grease drums.
ii. Flush gearboxes of both stages with fresh oil.
iii. Fill up fresh oil/grease fill up to required level.
iv. Gauge glasses of gearboxes are to be cleaned properly and new gasket is to be
provided if necessary.
v. Drain plug/filling cap are to be properly tightened.
p. Repair & reclamation of Miscellaneous ESP components:
Reclamation of outer arms:
i. Collect the damaged outer arm from scrap yard / area identified.
ii. Gauge out by cutting the worn out pins/flat & remove the hammer roller.
iii. Fabricate the new outer arm by replacing the pin / flat using, the above hammer
roller.
iv. Paint the reclaimed outer arm with two coat of red oxide.
v. Repair of ESP manhole door
vi. Repair of ESP hoppers: Including Fabrication of repaired patch plate and attending
defects / leakage’s as detected during air tightness test.
q. Servicing & replacement of rapping gear boxes:
i. Including replacement of damaged components and Inspection the condition of the
bearing on the intermediate shaft in case of emitting rapping gearbox and condition
of the coupling halves
ii. Including inspection of the condition of pinion on motor shaft and the gear on the
input shaft of the 1st stage gearbox. Replace the defective damaged ones. Remove
all ash from the casing of motor pinion and gearbox input gear. Clean it with diesel.
iii. Remove the gearbox assembly from the foundation & shift it to an area identified by
the area-in-charge for maintenance/storage. Replace damage components.
iv. Rectification of defects observed during the trial run of the rapping system including
oil top up.

35 All Cooling Water Lines in Boiler Area
Intent of Specification: - The intent of this specification is Routine / Preventive / Breakdown

maintenance of all the associated cooling water lines i.e. CCW, DMCW etc involved in the
entire boiler area, associated valves, piping’s & related equipment / instruments etc in
accordance with the work schedule given up to entire satisfaction of Engineer-In–Charge
during the contract.
Following jobs / maintenance of the system is included:
i. Attending leakages in the cooling water lines, various valves, fittings, its associated
instruments etc in the entire boiler area at all elevations.
ii. Replacement of valves, pipings, fittings, instruments etc, if required.
iii. Shifting of material from store to site.
iv. Removal of scraps, debris & cleaning of site after completion of job shall be in the
contractor’s scope.
v. Take successful trial run of the equipment / auxiliary after doing preventive /
breakdown maintenance and attend the defects if any.
36 All Service Air & Instrument Air lines in Boiler Area
INTENT OF SPECIFICATION:- The intent of this specification is Routine / Preventive /

Breakdown maintenance of all the service air & instrument air lines, receiver tanks, its
associated valves, & related equipment / instruments etc involved in the entire boiler area for
2x660 MW Units SSTPP, Stage-II, Dongalia in accordance with the work schedule given by
the Engineer-In–Charge during the contract.
Following jobs / maintenance of the system is included:
i. Attending leakages in all the instrument and service air lines, associated valves,
fittings, instruments, receiver tanks, headers etc in the entire boiler area at all
elevations.
ii. Replacement of valves, fittings, instruments etc in the service / instruments air lines,
if required
iii. Shifting of material from store to site
iv. Removal of scraps, debris & cleaning of site after completion of job shall be in the
v. Take successful trial run of the equipment / auxiliary after doing preventive /
breakdown maintenance and attend the defects if any.
37 Associated Air Conditioning & Air Washer System

INTENT OF SPECIFICATION: The intent of this specification is Routine / Preventive /

Breakdown maintenance / servicing of all the package air conditioners, split air conditioners,
air washers system, roof extractors, Unitary Air Filtration [UAF], associated auxiliaries,
compressors, cooling towers, chillers, pumps, pipelines & related equipment, instruments,
fittings including electrical fittings, relays, PLC system, refrigerant gas filling etc involved in
the HVAC system of entire boiler area for 2x660 MW Units SSTPP, Stage-II, DONGALIA in
accordance with the work schedule given by Engineer-In–Charge during the contract.
Complete operation & maintenance of the entire HVAC system of the

Area under scope
Involved in the entire boiler area i.e. Split AC’s, Package AC’s, Air washers, Roof extractors,
cooling towers, chillers, AHU’s etc.
a. Package Air Conditioning: Complete O&M of system with maintain the required
temperature which includes day to day regular maintenance / servicing as per OEM
recommendations, filters cleaning, attending leakages, refrigerant filling,
maintenance of cooling towers, chillers pumps, duct & dampers, pipelines, Air
handling units & associated PLC system, equipments, instruments, fittings including
electrical fittings involved.
b. Split Air Conditioners: Complete O&M of system with maintain the required
temperature which includes day to day regular maintenance / servicing as per OEM
recommendations, filters cleaning, attending leakages, refrigerant filling & its
associated fittings including electrical fittings involved.
c. Air Washer System: Regular operation & maintenance of air washer units including
air blowers including its electrical system, nozzles, pipelines, headers, pumps, filters,
ducting with insulation, dampers, associated civil structures, air handling units
including associated instruments & electrical fittings. Repair & replacement of faulty
parts, if required in the entire system.
d. Unitary Air Filtration system [UAF]: Regular operation & maintenance of all UAF
installed in the entire boiler area including day to day maintenance / servicing,
greasing / oiling, maintaining associated electrical fittings with repairing /
replacement of faulty parts etc.
e. Roof Extractors: Regular operation & maintenance of all roof extractors installed in
the various locations of entire boiler area including day to day maintenance /
servicing, greasing / oiling, maintaining associated electrical fittings with repairing /
replacement of faulty parts etc.
f. Supply Air Fans, Exhaust / Ventilation Fans: Regular operation & maintenance of
all the supply air fans, exhaust / ventilation air fans installed in the various locations
of entire boiler area including day to day maintenance / servicing, greasing / oiling,
maintaining associated electrical fittings with repairing / replacement of faulty parts
etc.
Any other work which is not specifically mentioned in this scope, but required for
smooth operation & maintenance of the system shall be in the contractor’s scope.

Daily Checks & Services for Operation Contract (HVAC)

i. Wherever applicable the contractor shall register operating status of the system,
condenser and chilled water temperature and pressures at the inlet and outlet of Heat
Exchangers, Voltage and current on hourly basis in log sheets.
ii. The Contractor personnel will keep all units externally cleaned.
iii. The contractor personnel will check all the rotating machines for smoothness of
drive, vibration and noise level.
iv. The contractor personnel will check and adjust if required belt tension of all V- Belt
drives.
v. The Contractor personal will check starter for smooth operation.
vi. The contractor personnel shall maintain Daily logging of operating parameters.
Boiler Miscellaneous
SCOPE OF WORK:
Routine operation & maintenance work
i. Servicing of sky climber including repair/replacement of defective components,

motors
ii. Cleaning and servicing of other electrical components of sky climber like centrifugal
switch, micro switch, limit switch, starter, replacement of defective wire etc.
iii. Servicing Winch/Chain Pulley Block/Travelling Trolley/wire ropes/slings/D-
Shackles including repair and replacements of damaged components.
iv. Testing of sky climber, Winch/Chain Pulley Block/Travelling Trolley and attending
defects found during testing.
v. Attending minor defects of Hoist.(Electrical and Mechanical Works)
vi. Fabrication of racks, for boiler spares and consumables and steel fabrication of
walkway ladders, approaches, toe guards/handrails, canopies etc
vii. Laying of New/ Patching of Pipe Lines including cutting and removal of old
pipelines/ bends and fitting of new pipelines including edge preparation and
fabrication of bends from supplies pipes, if required.
viii. Checking of leakage of pipelines and welding of pipelines with proper electrodes
and ensuring proper support to the pipeline
ix. Ensuring insulation of pipeline wherever required in boiler area
x. Repair of Peephole/ Manhole Door door hinges and other fittings as and when
required including repair/replacement of broken lock.
xi. Replacement of sealing rope/ gasket/ glass, seal box.
xii. Operation and maintenance of Elevators in Boiler side area
xiii. Operation and maintenance of sump pumps
xiv. Repair of Insulation at Boiler area as and when required.

xv. Daily routine checking of various vents, drains, blow down valves and its
maintenance.
xvi. Removal and application of refractory & making of refractory Blocks and ensuring
high quality surface finish.
xvii. Removal of Honey comb of bees.
xviii. Removal, replacement/ rectification of gratings, handrails, staircases and minor
repair/modification if any.
xix. Cleaning of hangers and noting reading of hangers
xx. Servicing of piping hangers and its adjustment of hangers to the required position as
per the requirement and welding of the component as and when needed.
xxi. Miscellaneous Scaffolding works including erection of scaffolding for approach to
the required boiler area to carry out shielding/ inspection/ repair works inside/
outside boiler, APH, fan, mill area
xxii. Servicing of all the Control and instrumentation equipment in the scope area,
replacing the damaged items with the spares.
xxiii. Small additions/deletions/modification works involved in the cable route, cable tray,
impulse lines, instruments, panel cut-outs etc. should be carried out by Contractor as
and when required.
xxiv. Calibration, dismantling, mounting, repair, servicing, routine maintenance,
preventive maintenance, cleaning, replacement and checking the operating condition
while on site and in the laboratory for all the field instruments viz. – pressure
indicators, pressure indicating switches, pressure switches, differential pressure
indicators, differential pressure indicating switches, differential pressure switches,
level switches, pressure transmitters, differential pressure transmitters, level
transmitters, flow transmitters, level switches, temperature indicators, temperature
indicating switches, temperature elements. RTDs’, Thermocouples, limit switches,
solenoid valves, on-line analyzers, analytical instruments etc.
xxv. Routine checking of control power supply, main power supply, connection tightness
etc. for all the electrical actuators, impulse line tightness checking/leakage detection
and arresting for all the pneumatic actuators and tightness associated with hydraulic
lines.
xxvi. Contractor has to arrange for temporary power supply from the point provided in
plant by Owner for site calibration, maintenance, and repair works execution.
Contractor shall provide all the hardware required for making these arrangements.
xxvii. Contractor has to arrange for temporary instrument air supply line, from the point
provided at site for calibration, maintenance, and repair works execution. Contractor
shall provide all the hardware required for making these arrangements.
xxviii. All maintenance/repair jobs in DCS and PLCs’ will be in Contractor scope.

xxix. Contractor using the laboratory/laboratory equipment provided by Owner will carry
out all calibration works in the laboratory or if possible in the field itself whichever
is applicable. The routine/preventive maintenance in the laboratory such as
charging/replacing batteries for electronic equipment, minor rectification/repair jobs,
cleaning of laboratory will be in Contractor scope.
xxx. Contractor has to daily/periodically check/inspect the field instruments, panels,
actuators, transmitters, impulse lines etc. In case of any damage/misalignment/mal-
operation/abnormal conditions, will have to immediately rectify and inform the same
to Owner Engineers.
xxxi. All maintenance/ repair/ servicing etc. for the pneumatic/ motorized/ hydraulic
actuators.
xxxii. Interlock; loop (starting from field end till the field termination assembly/panel).
Continuity-checking, cable, impulse line-tracing, sequence of operation checking,
trip setting are to be carried out by Contractor at the discretion/guidance/instructions
of Engineer-in-Charge..
xxxiii. Routine/ daily cleaning/removal of oil stains, dust, rust from panels, actuators,
junction boxes, field transmission assemblies, flame scanners, field instruments/
mounting/ supports, other equipment etc. will be in Contractor scope. Whenever
possible mechanical means will be used.
xxxiv. Maintenance, minor repair works, cleaning of computers, printers, mouse etc.
involved in plant automation.
xxxv. Painting of damaged, dismantled, and rusted portions etc. in field instrumentation
and panels.
xxxvi. Applying lubricant, cleaning filters, removing chokes in the impulse line, filters,
plugging leaks etc.
xxxvii. Attending Trouble shooting and other emergency time/jobs.
xxxviii. Removing the indicators, recorders, transmitters, valves and other instruments,
equipment, monitors of the entire power plant and transporting them to stores,
laboratory and vice versa or outside the plant for servicing, repair and re-fixing them
in their appropriate places.
xxxix. Checking of cables and terminations, Laying and connecting of cables as and when
required
xl. Fabrication of items like canopies, junction boxes, Panel cut-outs for installing any
instruments, mounting brackets for any field mounted instruments, siphons for
instruments, thermo wells for temperature gauges and impulse lines fabrications.
xli. The checking instruments like multi-meters, meggers, clamp meter, loop calibrator,
pneumatic receiver gauges, soldering station, pneumatic/instrument line tools like
cutter bender etc. shall be contractor’s scope.

xlii. The removing, replacement, shifting of field and panel instruments and motorized
valves, control valves as per advice of EIC shall be in contractor’s scope.
xliii. Maintenance of lab instruments, provided by MPPGCL & of its own.
xliv. Calibration of Master calibrating instrument by recognized and authorized external
agency.
xlv. Passivation and preservation of removed instrument.
xlvi. Access / scaffold, removal of insulation, cutting of fins / plates, grinding, on-line
welding and fitting of clamps, redoing of insulation/ protection, removal scaffold.
The supervisor and manpower of required nature of skill shall report to site along
with general T&P required for this work within 4 hours of intimation.
xlvii. Preservation of boiler tube/ coils etc. At site.
xlviii. Sorting and stacking of boiler tube and other items at various locations.
xlix. Colour coding of various tubes etc.
l. Assistance in material mix up checks of boiler tubes and bends.
li. Coal nozzle tip repair by cutting & welding/ hard facing with help of sky climber.
lii. Attending of defective vane diffuser of oil gun,
liii. HVT probe operation,
liv. Intermediate pressure settings of soot blowers. This pressure setting shall be done in
an interval of three / six months after first setting of soot blowers after OH. First
setting shall not be covered in the scope of this schedule.
lv. Fixing of buckstay pins / repair work for arresting vibrations.
lvi. Minor repair of railing / toe guards / small opening in floors. Steel required for this
work shall be issued through deptt. stores to the contractor.
lvii. General housekeeping /beautification and proper stacking of spares in areas
pertaining to deptt. stores as specified by EIC.
lviii. Assistance in issue and shifting of general materials related to pressure parts and
soot blowers from different stores.
lix. Shifting of sump pump/submersible pump as per instruction of EIC.
lx. Repair of submersible pumps.
lxi. Cleaning of steam traps etc.
lxii. Any other job directed by EIC required for smooth running of unit in the areas
covered in the scope of this work.
ii. Miscellaneous
a. C&I and Electricals and Other
i. Lubricate Servicing of all the Control and instrumentation equipment in the
entire power plant, replacing the damaged items with the spares.

ii. Small additions/deletions/modification works involved in the cable route,

cable tray, impulse lines, instruments, panel cutouts etc. should be carried out
by Contractor as and when required.
iii. Spares like washers, small screws, bolts and nuts etc. will be in Contractor
scope and should be replaced as and when required.
iv. Calibration, dismantling, mounting, repair, servicing, routine maintenance,
preventive maintenance, cleaning, replacement and checking the operating
condition while on site and in the laboratory for all the field instruments viz. -
pressure indicators, pressure indicating switches, pressure switches,
differential pressure indicators, differential pressure indicating switches,
differential pressure switches, level switches, pressure transmitters,
differential pressure transmitters, level transmitters, flow transmitters, level
switches, temperature indicators, temperature indicating switches,
temperature elements. RTDs, Thermocouples, limit switches, solenoid valves,
on-line analyzers, analytical instruments etc.
v. Routine checking of control power supply, main power supply, connection
tightness etc. for all the electrical actuators, impulse line tightness
checking/leakage detection and arresting for all the pneumatic actuators and
tightness associated with hydraulic lines.
vi. Contractor has to arrange for temporary power supply from the point
provided in plant by MPPGCL for site calibration, maintenance, and repair
works execution. Contractor shall provide all the hardware required for
making these arrangements.
vii. Contractor has to arrange for temporary instrument air supply line, from the
point provided at site for calibration, maintenance, and repair works
execution. Contractor shall provide all the hardware required for making
these arrangements.
viii. All maintenance/repair jobs in DCS and PLCs will be in Contractor scope.
ix. Contractor using the laboratory/laboratory equipment provided by MPPGCL
will carry out all calibration works in the laboratory or if possible in the field
itself whichever is applicable. The routine/preventive maintenance in the
laboratory such as charging/replacing batteries for electronic equipment,
minor rectification/repair jobs, cleaning of laboratory will be in Contractor
scope.
x. Contractor has to daily/periodically check/inspect the field instruments,
panels, actuators, transmitters, impulse lines etc. In case of any
damage/misalignment/mal- operation/abnormal conditions, will have to
immediately rectify and inform the same to MPPGCL Engineers.

xi. All maintenance/repair/servicing etc. for the pneumatic/motorized/hydraulic

actuators.
xii. Interlock; loop (starting from field end till the field termination
assembly/panel). Continuity-checking, cable, impulse line-tracing, sequence
of operation checking, trip setting are to be carried out by Contractor at the
discretion/guidance/assistance of MPPGCL Engineers.
xiii. Routine/daily cleaning/removal of oil stains, dust, rust from panels,
actuators, junction boxes, field transmission assemblies, flame scanners, field
instruments/mounting/supports, other equipment etc. will be in Contractor
scope. Whenever possible mechanical means will be used.
xiv. Maintenance, minor repair works, cleaning of computers, printers, mouse etc.
involved in plant automation.
xv. Painting of damaged, dismantled, and rusted portions etc. in field
instrumentation and panels.
xvi. Applying lubricant, cleaning filters, removing chokes in the impulse line,
filters, plugging leaks etc.
xvii. Attending Trouble shooting and other emergency jobs.
xviii. Removing the indicators, recorders, transmitters, valves and other
instruments, equipment, monitors of the scope area in power plant and
transporting them to stores, laboratory and vice versa or outside the plant for
servicing, repair and re-fixing them in their appropriate places.
xix. Checking of cables and terminations, Laying and connecting of cables as and
when required
xx. Fabrication of items like canopies, junction boxes, Panel cut out for installing
any instruments, mounting brackets for any field mounted instruments,
siphons for instruments, thermo wells for temperature gauges and impulse
lines fabrications.
xxi. The checking instruments like multi meters, meggers, clamp meter, loop
calibrator, pneumatic receiver gauges, soldering station,
pneumatic/instrument line tools like cutter bender etc. shall be contractor’s
scope.
xxii. All consumables including brass fittings, non-metallic & metallic tubes shall
be under contractor’s scope.
xxiii. Removing, replacement, shifting of field and panel instruments and motorized
valves, control valves as per advice of MPPGCL engineers shall be in
xxiv. Maintenance of lab instruments, provided by MPPGCL& of its own.
xxv. Calibration of Master calibrating instrument by recognized and authorized
external agency.

xxvi. Passivation and preservation of removed instrument.

xxvii. OEM support for specialized activities on MPPGCL’s instruction.
xxviii. Tagging of instruments and cables.
xxix. Instrument network maintenance
xxx. Communication tools such as laptop, cables will be contractors scope
however relevant software will be MPPGCLs scope
xxxi. Requirements related to boiler inspector and environmental auditors to be
fulfilled by contractors
xxxii. Material movement from store to site and site to store.
xxxiii. Managing of local store for critical spares.
xxxiv. Site cleaning after maintenance activity.
b. Electrical/ C&I Maintenance:
Electrical/ C&I Maintenance works including Power and control cables, HT/ LT
switch gears, HT/ LT Motors/ DC Motors, Batteries/ UPS, Protections,
interlocks, field instruments, monitoring system, controls logics, PLC, auto
loops etc. for each of system/ sub-systems/ equipment/ auxiliaries shall be to
contractor’s scope. Availability of these systems with smooth functioning shall
be ensured by the contractor.
c. Maintenance Planning
i. Preparation of report for preventive Maintenance, Predictive Maintenance
Trend and Analysis report, Inventory Consumption, Plant Availability/Down
Time, Failure Analysis, Preventive Maintenance Effectiveness and specific
consumption etc.
ii. Records of equipment inspection’s operational checks relating to facility as
per good engineering practices, records of maintenance and repairs carried
out.
iii. Devising maintenance strategy based on Equipment Criticality Analysis to
establish best practices of preventive maintenance, and condition based
maintenance.
iv. Planning and scheduling of maintenance jobs.
v. Executing maintenance task of Preventive Maintenance / Lubrication
Schedule.
vi. To carry out the predictive maintenance / opportunity maintenances.
vii. To carry out reliability based condition monitoring maintenance.
viii. To carry out turnaround maintenance.
ix. Carry-out repairs and replacement of the equipment under the instruction /
supervision.
x. Ensuring optimum Plant / Equipment availability for the operations.

xi. Quality workman ship for the Operation & Maintenance work carried out for
the MPPGCL.
xii. Periodic maintenance reports as per the following
1. Daily report
2. Weekly Report
3. Monthly Report
4. Annual Report
xiii. A log book shall be maintained by contractor in which, dates, observations,
defects noticed and corrective action taken shall be recorded at the end of
every activity. All defect noticed will also be entered and the personnel shall
fill up their findings/corrective action taken, in the remarks column, after the
job has been completed.
d. Spare Planning:
i. It is to specifically clarify that O&M and capital spares for items and
systems under warrantee/ guarantee of OEM shall be provided by the
contractor as the tender is on OEM basis. However, the items which wear
and tear in short span of time and are not part of warrantee/ guarantee
shall be provided for replacement by MPPGCL free of charge.
ii. Contractor has to inform MPPGCL about their spare requirements well in
advance.
e. Removal of old and used unserviceable spares:

i. Replaced old & used unserviceable spares & scraps at Boiler area and
Aux. to be shifted from Boiler area and Aux to the store of MPPGCL
with their own arrangement at no extra cost to MPPGCL. Used old
unserviceable spares / scraps shall be collected immediately from site
and shall be kept at specified places for further ROM. Old serviceable
spares shall be collected from site immediately & shall be kept at
specified places for repair / maintenance of the same. All will be in the
scope of contractor. After replacement of belts, old belts shall be brought
to the specified place on the same day.
ii. New spares should be kept orderly at specified areas. No new spares
should be noticed here & there. Unused spare will be collected after
completion of work & they will be kept at proper place.
1. The above work activities is only tentative and broad view of works, any other
maintenance required for smooth running of system and for availability of
equipment has to be ensured by contractor.
2. Electrical/ C&I Maintenance works including Power and control cables, HT/ LT

switch gears, HT/ LT Motors/ DC Motors, Batteries/ UPS, Protections, interlocks,

field instruments, monitoring system, controls logics, PLC, auto loops etc. for each
of system/ sub-systems/ equipment/ auxiliaries shall be to contractor’s scope.
Availability of these systems with smooth functioning shall be ensured by the
contractor.
3. The contractor shall have to carry out some or all of the following jobs under his
supervision by deploying required number and category of skilled and unskilled
manpower as per instruction of EIC. Following jobs may have to be carried out any
time/ round the clock basis/ or in general shift as per requirement.
4. Maintenance of all the Field Instrumentation , Control systems , Control Panel, PLC,
DCS Main Boiler and associated BOP plant which includes Preventive, Routine
maintenance , Repair , Servicing, Modifications, New Installations (For replacement
& Improvement jobs), Routine/Non Routine Calibrations, Trouble Shooting ,
Dismantling, Fabrication, Mounting , Lubrication, Covering, Cleaning, Checking &
Replacement, Addition/ Deletion of Instrumentation process connections, Cable
testing , removing / Laying (whenever required) with conduit/ Tray and painting of
Instruments (whenever required) and maintaining track/ Record of all the activities
as per ISO Standards. Further, the Scope of contractor covers the following also-
NOTES TO SCOPE OF WORK :

1. Check list of various works is annexed as ANNEXURE-II. The description given in
the scope of work is only a broad outline of the job. Engineer in charge will give
detailed and more specific instructions at the time of execution of work. The
contactor shall have to perform all additional associated jobs (whose description
may not necessarily be there in the scope of work given above), which are
considered necessary for successful completion of the work without any additional
charge.
2. Any component, cut for the purpose of executing any work covered under scope of
work or any associated work, shall be restored as per instruction of engineer in
charge without any additional financial implication.
3. Contractor shall have to set-up temporary shed at a location near work place for his
stores as well as site office for MPPGCL before the start of work .no additional
payment shall be admissible for the temporary shed work.
4. The testing of sky-climber hoists & electrical hoists erected at boilers, all Lifting
Tools and tackles. Pressure Vessels etc shall be witnessed by competent person
designated under factory act. The competent person to witness the test shall be
arranged by MPPGCL.
5. There shall be no defect liability period for the work of sky-climber / electrical

hoists. Certification by the competent authority or the EIC after testing shall be
deemed final.
6. For the work of sky climber, minimum of two skilled fitters, two skilled riggers, one
skilled electrician, besides one supervisor and required no of helpers shall be
required separately.
9. Exclusions to the Scope of Work

The following supplies, works and activities are excluded from the scope of works. The items not
specifically mentioned here shall be considered as part of the Scope of Work in the contract.
a. Rewinding of HT Motors
b. Major Consumables
c. Civil Works (if not damaged by the contractor during O&M works)
d. Supply of Capital & O&M Spares- It is to specifically clarify that O&M and capital
spares for items and systems under warrantee/ guarantee of OEM shall be provided
by the contractor as the tender is on OEM basis. However, the items which wear and
tear in short span of time and are not part of warrantee/ guarantee shall be provided
for replacement by MPPGCL free of charge.
e. Painting
f. Major Modification / Fabrications
g. Security by MPPGCL at complex boundary
10. List of Minimum Items, T&P to be provided by the

Contractor
The list below provides the minimum T&P, Trucks & Dumpers and other facilities to be provided
by the Contractor. Please note that the list below is minimum and not comprehensive. In-case,
during the execution of the contract, anything required and not mentioned in the scope of supplies
by MPPGCL (as elaborated in Section xxxx below), the same shall be provided by the Contractor
at no extra cost.
i. The table below elaborates the minimum T&P required for O&M work, to be provided
by the contractor: -
a. T&P For Mechanical Maintenance

Name of Tools Quantity
1 Allen key set (inches/mm) 6
2 Bearing Pullers as required size 3


3 Bore gauge 2
4 Box Spanner Set 3
5 Buffing Machine GQ-4 2
6 Center Punch 4
7 Chisels 6
8 Circlip Pliers (Inside/Outside) 6
9 Cutting Knife 6
10 Cutting set with ISI flash back arrestor & gauges 6
11 Heating sets along with hose and flashback arrester 4
12 Dial gauges 16
13 Dial gauge stand (magnetic) 16
14 Die sets (Inch and MM) 2
15 Diesel/Oil Fill Pump (hand operated) 2
16 Divider 6
17 Double ended open spanner set 6 to 32 mm 11
18 Double ended open spanner – 32 to 55 mm 6
19 Double ended Ring spanner set 6 to 32 mm 11
20 Double ended Ring spanner – 32 to 55 mm 6
21 Feeler gauges 6
22 File set 6
23 Tap Set 2
24 Flexible grinding machine 2
25 Hacksaw Frame with blades 6
26 Hammer-4lb, 6lb, 8lb, 10lb, (each) 7
27 Hammer Heavy duty 3
28 Hammering Open Spanner – 27 mm to 75 mm 3
29 Hammering Ring Spanner – 27 mm to 75 mm 3
30 Hand drilling machines 3
31 Magnetic based drilling machine ) 2
32 Hand grinding machine -AG4 6
35 Hand Lamp 24V DC – Set 25
36 Hot Blower 3
37 Ladder - 10 mtr long - Alumina 3
38 Lubricating oil Can 6
39 Mallet 3
40 Master level 2
41 Material shifting trolley 4


42 Measuring tapes different sizes 8
43 Mechanical bearing pullers of type 3& 4 jaw for bearing size up to 350 3
mm
44 Nose Plier, Monkey Plier 6
45 Pincer 3
46 Pipe Wrench different sizes 6
47 Pitch gauge both in inchs & mili meters 2
48 Plump Bob 3
49 Right angle 6
50 Rope heavy duty (Mtrs) 300
51 Rope ladder 2
52 Rotary cutting machine with cutter 2
53 Screw drivers different sizes 8
54 Screw Spanner 6
55 Screw driver set 4
56 Set Needle file , Flat file, Round file , half round file 6
57 Set of Aluminium rod for hammering 3
58 Set of Bearing scraper 3
59 Set of Copper rod for hammering 2
60 Set of Rubber mallet 2
61 Set of Teflon mallet 2
62 Set of telescopic gauge 2
63 Set of thread cleaner (Inch and MM) 2
64 Set of thread remover (Inch and MM) 2
65 Shim Cutter different sizes 4
66 Slip gauge 2
67 Spirit Level 6
68 Sufficient wooden planks As per
requirement
69 Switch boards & cables 15
70 V Blocks for up to 200 mm shaft 2
71 Valve insitu lapping tool 2
72 Cannvas slings of different sizes ( sizes & lengths as per job
requirement) –sets 3
73 Wire rope slings of capcity upto 135T ( sizes & lengths as per job
requirement) 4
74 D-shackle sets of different sizes as per requirement 4
75 Eye Bolts sets of different sizes as per requirement 4
76 Chain Block – 2T, 3T, 5T, 10T,20T 8
77 Hook chuck upto 10T (varying sizes & lengths) 2
78 Ratchet hoist – 1.5 Tonn 2


79 Diversion pulleys 4
80 Rope pull lift – 3T, 5T 3
81 Heavy and Portable Welding machines with power cable of atleast 13
15M, Welding & earthing cable at least 50 meter-400 AMP
82 Portable welding machines with power cable of atleast 30M. - 4
200AMP
83 Hand Grease gun with hose and adapter up to 2 kg 6
84 Machine Grease gun with hose and adapter up to 5kg 3
85 Hydraulic bearing pullers of type 3&4 jaw for bearing size up to 350 2
mm
86 Hydraulic Bottle Jack (5 T) 2
89 Hydraulic Jack – 50 T 4
90 Hydraulic Jack – 100 T 2
91 Screw Jack (heavy duty) 4
92 Hydro testing pump –15 ksc Pressure water pressure pump (manual) 2
93 Inside micro meter 0-1000mm 2
94 Micro meters- Outside up to 750 mm 2
95 Pipe bending machine with die up to 3” size 2
96 Power Hack saw for pipe cutting 2
97 Straight edge300mm,600mm, 2000 mm Length 2
98 Straightedge for VT pumps (For CW & SWIP pump) 2
99 Sufficient scaff holding pipes As per
requirement
100 Vernier caliper upto750 mm 2
101 Vernier Calipers 4
ii. Apart from the T&P mentioned above, all other minor and major necessary T&P
which would be required for O&M work shall also be arranged by contractor.
b. T&P For Electrical and C&I Maint.

1 Tool bag / box with general minimum tools required on daily basis for
4
Electrician / Lineman / technician
2 Line tester 4
3 Screw driver set of various types (Size 6” , 12”) 4
4 Insulated combination pliers 150mm, 250mm 4
5 Insulated cutting pliers 4
6 Nose pliers 4
7 Wire stripper 4


8 Dry cell torch 4
9 Test lamp with 2 nos. 60W B/C lamps 4
10 Ring Spanner for 4 mm – 36 mm 4
11 DE spanner 4 mm – 36 mm 4
12 Hacksaw frame and blades 6
13 Ring spanner (slugging) 36 mm- 75 mm in between sizes 2
14 DE spanner (slugging) 36 mm- 75 mm in between sizes 2
15 Box Spanner set 8
16 Slide Wrench 8” – 12” 8
17 Nut Driver 4mm – 10 mm 4
18 Allen Key set (mm & inches both) 6
19 Crimping tools for control wiring (1.5-6.0 mm2) 9
20 Crimping machine / Tools for cables and conductors up to 1000 2
21 Smooth / Coarse Files 12” size 4
22 Digital multi meter (reputed make i.e. Fluke, Rishabh,
8
Motwane, MECO etc.)
23 Clamp on Meter (0-1000A AC/DC) for current measurement (Reputed
4
make i.e. Fluke, Rishabh, Motwane.)
24 Megger 500 V (Hand driven / Digital) –(Reputed make i.e. Rishabh,
5
Motwane etc.)
25 Megger 250 V (Digital) (Reputed make i.e. Rishabh, Motwane etc.) 2
26 Megger 5 KV (Motorized / Battery operated) (Reputed make i.e.
1
Motwane, Meggar etc.) suitable for use in 400KV Switchyard.
27 Earth Meggar 3
28 Hand Drill (0-13mm) machine with bits 2
29 Tap sets 1
30 Power operated hand blowers 4
31 5 cell / 3 cell Torches 4
32 Hole punch for gasket of different size 4
33 Alpha-numeric punch 4
34 Gas cutting set including torch & regulator 4
35 Portable Welding Machines with Cable 4
36 Hammer of various sizes 4
37 Chain pulley block, Slings and D – Shackles: 1, 3, 5, 10, 20 Tonnes. 4
38 Wire Brushes for cleaning. 4
39 Hand lamps and lamp sets for temporary lighting. 8
40 Tarpaulins / polythene sheets etc. 3
41 Oil bath with heating arrangement for checking of functioning of
5
temp. Gauges.
42 Oil sampling bottles (250, 500, 1000 ml) 4
43 Earthing rods suitable for use on 400KV systems 3


44 Earthing rods suitable for use on 33 / 11KV systems 8
45 Winches with rope. 1
46 Power extension Boards 6
47 Rope of different sizes 2
48 Spray Equipment 4
49 Ladder (upto 12 M height) 2
50 Sets of Hose Pipes of various sizes 2
Note: The minimum T&P mentioned above are not exhaustive and the Contractor has to
deploy additional T&P as per site requirement to complete the scope of works in all
respect without any additional cost to MPPGCL.
c. Consumables
The contractor shall be required to provide the following consumables. In case the work
requires additional consumables, the same shall also be provided by the contractor, at his own
cost:
S.No Description
1 Emery Paper & TAPE(Grit no.) 36,50,80,120,200 & 500 Carborundum
2 Teflon tape Pocket box/Roll
3 Prussian blue
4 Graphite Powder
5 M-Seal Set
6 Cotton Waste, Cotton cloth & Net Cloth
7 Rustolene,WD40 rust removal spray
8 DPT Kit
9 MS cutting & grinding wheels for AG-4, AG-5, AG-7 grinding machines
10 SS cutting & grinding wheels for AG-4, AG-5, AG-7 grinding machines
11 Grinding Wheels of FF2 grinder
12 Buffing wheel 2”,3”,4”,6” Grindwell Norton/ Carborandum
13 Grinding Stones Set Conical oval, Cylindrical etc.
14 Milling Cutter Conical oval, Cylindrical etc
15 Wire Brush of different sizes
16 Rust cleaner Compound Omega 636 or equivalent
17 Diesel for Equipment cleaning
18 Hacksaw blades
19 Oxygen, DA/LPG and Argon cylinder
20 Coir & Manila rope
21 Welding Electrodes General:6013,7018→2.5,3.15,4 mm of make D&H/ESAB or any
approved electrode

S.No Description
22 Brazing material (Flux &filler wire) L&T
23 Belcha, Taklon, Spade tools
24 Valve lapping paste fine, medium & coarse.
25 Grinding & cutting goggles
26 All Consumables including Gas and Filler Wire etc for HP welding works.
27 Lead wires
d. Safety Items
The contractor shall be required to provide the following safety items to its work force during
execution of contract. In case the work requires additional safety items, the same shall also be
provided by the contractor, at his own cost:
1. Safety Helmets.
2. Gas cutting and welding goggles.
3. Argon gas welding equipment.
4. Hand gloves Cotton & Leather.
5. Grinding goggles
6. Dust Mask
7. Flash back arrestor
8. Double Hook Safety belts
9. Safety nets
10. Safety Shoes
11. Safe Ladders
e. Minimum Manpower & its Type

i. The contractor should clearly understand that technically competent supervision of
work is an extremely important part of the work specified in the contract. The
contractor should have a sound site organization to take care of this aspect of work.
ii. The contractor shall open a site office at SSTPP, Dongalia with a Site In Charge
(Resident Engineer) for this contract.
iii. The site in charge shall be the sole representative of the contractor for this work. He
should be empowered to take all decisions on behalf of the contractor for his work.
Instructions / information issued to this site In-Charge shall be deemed as issued to the
contractor. The site in charge should be equipped with mobile.

iv. The site in charge shall co-ordinate all activities to ensure safe, satisfactory & smooth
execution of work covered in the contract.
v. The site in charge should be technically competent person capable of understanding &
ensuring satisfactory execution of technical aspect of work in addition to his
administrative function.
vi. In addition to the site in charge the contractor has to ensure supervision of work in
progress by deploying technically competent & authorized site supervisors equipped
with mobile.
vii. For attending routine & breakdown maintenance work, the site in charge or shift site
supervisor of the contractor has to be available inside the plant round the clock for the
entire period of contract (including holidays).
viii. Shift site supervisor of the contractor has to be in close contact with the OIC or his
authorized representative to take instruction regarding commencement of work & to
report progress of work.
ix. The names of site in charge & shift site supervisors shall be communicated in writing
to the OIC prior to the commencement of work.
x. Collection & return of materials required & execution of work. The site in charge of
the contractor shall authorize two of his representatives to collect material form
MPPGCL as per requirement of work.
xi. In case of emergency, if required, it is the responsibility of supervisor to call extra
manpower as directed by OIC.
xii. The table below elaborates the minimum manpower required. In case, if work requires,
the contractor shall be required to provide additional manpower at his own cost for
successful discharge of the work.
Gen.Shift
A-Shift
C-Shift
B-Shift
Required Experience /
Total
Categories Qualification
A Site-In-Charge 2 2 BE/Diploma(O&M Exp.-7/10

years)
Sub-Total 2
B Manpower for Field Operation
Operation Shift-In-
1 1 1 1 3 BE/Diploma(Opn.Exp.-5/7 years)
Charge of Boiler Area

Raw Coal Feeder

2 4 4 4 12
Floor
3 Mill Area 4 4 4 12
4 ID, FD, PA Fans 4 4 4 12
All the associated

Valves Operation in
5 4 4 4 12 ITI / Graduate(Exp.:-2-3 Yrs of
boiler side including
blow down, vents etc Relevant)
HFO, LDO Day Tank

6 & Main Oil Tank 4 4 4 12
Operation
Lift Operator for

7 Boiler Goods / 2 2 2 6
Passenger Lift
Sub-Total 69
C Field Operation of Coal Mill Reject Handling System
Control Room
1 Operator for Mill 1 1 1 3 Diploma/ ITI (Exp.-4-5 Years)
Reject Control Room
Field Operator for

2 2 2 2 6 ITI / Graduate(Exp.:-2-3 Years)
Mill Reject System
Helper for Mill Reject Semi/Un-skilled with Relevant

3 2 2 2 6
System experience
Sub-Total (C) 15
Manpower for
Unskilled Labour to be deployed
D Housekeeping of 30 30
for Housekeeping
Entire Boiler Area
Sub-Total 30
Manpower for Maintenance of Entire Boiler Area including

E
MRHS
Maintenance Engineers
B.E. / Diploma(Exp.-5/7 years)
1 Mechanical Engineer 1 1 1 3

2 Electrical Engineer 1 1 1 3
3 C&I Engineer 1 1 1 3
4 Supervisor 1 1 1 3 Diploma/ ITI (Exp.-5-7 Years)
5 High Pressure Welder 2 2 IBR Certified Welder
Technician (General
6 4 4 4 4 16
Fitter)
7 Mill Wright Fitter 2 2
Welder Cum Gas

8 2 1 1 1 5 ITI ( Exp.-4 to 6 years)
Cuter
9 Rigger 2 1 1 1 5
Electrician cum C&I

10 3 3 3 3 12
Technician
Semi/Un-skilled(Exp. 2 to 4
11 Helpers 4 2 2 2 10
years )
Sub-Total 64
Grand Total
180
(A+B+C+D+E)
11. Facilities / Items to be MPPGCL

a. The list below elaborates the items to be provided by MPPGCLfree of cost basis.
b. In case any item / facility is not specifically mentioned in the list, the same shall be
provided by the Contractor at no extra cost.
a. T&P
i. Special T&P provided with the original equipment, machineries shall be handed over
to the Contractor.
ii. While using, the Contractor shall also be responsible to maintain and upkeep these
T&P at its own cost.
iii. At the end of contract, these T&P shall be returned to MPPGCL in the condition at
which it was handed over to the contractor.

b. Manuals and Drawings

i. MPPGCL shall provide access to manuals and drawings provided by the OEM
c. Spares
i. The O&M spares for replacement shall be provided by MPPGCL. However, the spares
under warrantee or guarantee of the OEM shall be provided by the OEM, if failed in
guarantee period.
ii. All Capital spares for replacement shall be provided by MPPGCL. However, the
spares under warrantee of the OEM shall be provided by the OEM, if failed in
guarantee period.
iii. The contractor shall maintain the record of spares used, inventory record etc.
iv. The contractor shall assist MPPGCL in spares/ inventory planning and intimate well in
advance about the requirement of spares based on MPPGCL’s trend of procurement
time.
v. Transportation and shifting of spares to site/ site store and returning to store/ scrap
yard shall be to contractor’s scope.
d. Consumables
i. Special purpose welding electrodes (except 6013 and 7018) shall be provided by
MPPGCL
ii. Special consumable of Boiler such as special sealing compound, lubricants.
e. Others
i. Water for operation and maintenance and potable water at available points
ii. Compressed Air for O&M work

iii. Power at available points on board or on MCCs.
12. Statutory Compliance by the Contractor

a. The list below elaborates the indicative list of statutory compliances and is not limiting in
any manner. The Contractor shall be liable to comply all statutory compliances at his own
cost.

b. The contractor shall also indemnify MPPGCL / it’s officer/ employees from all damages
and consequences arising out of his failure to comply any of the Statutory compliances.
a. Labour Related Compliances

i. The contractor has to comply with all labour related statutory rules and laws of the
land prevailing at the time of contract or modified w.e.f. retrospective dates of the
contract. Various rules/ compliances mentioned here under to be followed include but
not limited to the following-
a. EPF
b. Labour Minimum wages Act

c. Factory Act
d. Workman compensation Act

e. Leave and Bonus Rules
ii. Employment to local workers: The contractor shall comply with the policy of the state
to employ local labour/ worker.
b. Health & Safety Related Compliances

i. The contractor is required to take adequate steps to ensure the safety for his workers or
staff employed by him or his sub-contractors . He shall abide by the safety precautions
and instructions enforced concerning safety to the plant and personnel at MPPGCL
(SSTPP Khandwa) site.
ii. All employees will be given adequate Safety Training before they are asked to work at
MPPGCL (SSTPP Khandwa) site. A certificate duly signed and stamped by Safety
Department will be handed over to the OIC,
iii. Contractor will provide all Safety Equipment and PPEs to all the workmen working at
the site, as per the type of work and Safety Guidelines Rules and ensure their usage by
the contractor’s personnel. In case the contractor fails to provide necessary personal
protective equipment to the workers and tools tackles etc. confirming the rules in force
and for safe execution of work, the same shall be provided by the MPPGCL on the
expenses of the contractor.
iv. Contractor will ensure all Safety and Health related Compliance are followed at
SSTPP site.
v. OIC/ Safety In charge or their representatives are authorized to check for any Safety
Violation and will recommend suitable deductions/ action against the respective

contractor for not complying with Safety Instructions and the respective contractor
Security Inspector will take immediate action as directed.
vi. The contractor shall take all necessary safety precaution for his worker working inside
the plant premises and shall be responsible for any first aid / emergency treatment and
any subsequent treatment for his employee/workmen engaged by him. He shall have
workmen compensation policy for all his workmen. He shall abide by all fire, safety
and environment policies and statutory.
vii. The contractor is required to take adequate steps to ensure the safety for his workers or
staff employed by him or his subcontractors and he shall abide by the safety
precautions and instructions enforced concerning safety to the plant and personnel at
SSTPP site.
viii. MPPGCL’s safety document is attached as Annexure-B, The same is to be strictly
followed in true spirit by the contractor during the contract period at his own cost.
c. Quality & Environment Protection Related Compliances

The contractor will comply with the following:-
i. The standards of the quality to be followed as per standard/mutually agreed Field
Quality and material quality assurance plan.
ii. Contractor will make all good efforts to ensure that there shall be no adve₹ e impact
on environment within and surrounding SSTPP by the way of activities being carried
out under the works of the purchase order.
iii. Contractor will ensure that disposal of all type of waste to be done as per the
procedures and in case there is no reference then the same shall be disposed as per the
standards practices being followed in the Industry of similar type and size.
d. Insurance Related Compliances

MPPGCL’S INSURANCE SCOPE
i. MPPGCL, if so considers, will take comprehensive plant and equipment insurance and
O&M contractor will comply with all obligations under the insurance policy.
CONTRACTOR’S INSURANCE SCOPE
i. The Contractor shall obtain and maintain in effect during the term or cause to be
maintained in effect during the contract period, the insurance coverage set forth below

underwritten by insurers of sound financial standing acceptable to MPPGCL and

authorized to underwrite such risks in India. To the extent these insurance coverage
are available through Indian insurance companies, preference shall be given to use
these companies subject to cost considerations:
ii. workers compensation and occupational illness insurance for all the Contractor staff or
such statutory requirements under the applicable law of the home countries for foreign
workers;
iii. employer’s liability insurance with adequate limits per occurrence and in the
aggregate;
iv. comprehensive or commercial general liability insurance with bodily injury and
property damage subject to deductibles; such insurance shall include, but not
necessarily be limited to, contractual liability, property damage liability personal
injury liability, liability for pollution (sudden and accidental) and, where applicable,
watercraft protection;
v. Comprehensive automobile liability insurance with bodily injury and property damage
combined covering vehicles owned, hired or non-owned; excess umbrella liability
insurance.

O&M of Coa
13. Allocation of Responsibilities Request
a. The allocation of responsibility of the contract has been elaborated in various sections of
Contents
this tender document; however, those not clearly defined elsewhere shall be covered
1. Tender Details.............................................
through the following responsibility matrix.
1.1. Reference Number .............................
Description of work / Activity Responsibility REMARK
MPPG Scope
Matrix/ Contra
O&M of Coa
CL ctor
1 Total Operation & Maintenance of 
the Boiler and List of Auxiliaries as
Request
2 Battery Limit
per scope for the following:
of works. MPPGCL shall furnish details of procedure/
systems presently adopted and is in operation
A. Waste from Boiler area & Boiler at Plant site. responsibility
Contractor’s Procedure shall includedesigned
- System battery
Blow Down  limit for Contractor against each disposal.
for handling this and Contractor has to
B. Disposal of Solid Waste  Contractor
operate andshall dispose
maintain the Plant solid waste
the system.
in a Contents
mutually agreed location.
C. Scrap Disposal  Contractor shall dispose the Scrap as per the
1. Tender Details.............................................
contract finalized by the MPPGCL.
1.1. Reference Number .............................
The project scrap is also lying in plant,
Contractor to assess the same and transfer to
scrap yard for further disposal as per EIC
3 Laboratories
A. Electrical Laboratory along with  Lab equipment’s (Electrical, instrumentation
Calibrated Test Instruments & & chemical laboratory) usage, maintenance,
B. Instrumentation Laboratory 
equipment repair, calibration and upkeep of the same
along with Calibrated Test shall be with
4 O&M and Capital
Instruments Spare Parts
& equipment Spares for Contractor.
items and systems under
which go in to the System /   warrantee/ guarantee of OEM shall be
equipment as per OEM/Manual provided by the contractor aas the tender is on
OEM basis. The items which wear and tear in
short span of time and are not part of
warrantee/ guarantee shall be provided for
replacement by MPPGCL free of charge.
Assisting and supporting Inventory
management and storage and making timely
indents will be with Contractor.
Informing of purchase requisition by
Contractor. Contractor shall also maintain the
Store at Plant premises and manage
inventories as per guidelines stipulated.
5 Space / Covered storage sheds for   Space and/ or shedsbewill
Procurement be by
will beMPPGCL
provided
Material Management by MPPGCL.shall done
Contractor shalltheprepare the
based
shed foronthetimely
spares/indents
T&P andbeing raised by
its manpower
Contractor
etc. of its own cost and arrangement as
required.

6 Stores Management / Material  Contractor shall assist in inventory

Management services verification and monthly Physical verification
as per MPPGCL/ third party appointed by
MPPGCL. Arranging and transporting spares/
T&P etc from store to site store/ site also.
7 Regular, Preventive, Breakdown  Contractor’s responsibility. MPPGCL to
maintenance provide the spares after assessment of its need
and on availability.
8 Annual Maintenance Contract with  Contractor to identify and arrange AMCs with
OEM's OEMs/ Experts as per EIC of MPPGCL, so as
to have quality work/ supervision. The cost to
9 Special Tools and Tackles   be borne tools
Special by Contractor
and tackles as provided by
EPC/OEM shall be handed over to
Contractor.
10 Use of EOT's Cranes   EOTupkeep
as givenand
by EPC shall be given to
to return
The the responsibility
Contractor by MPPGCL for use and upkeep.
those at the end of Contract in good working
condition shall
Contractor be withall
to provide Contractor.
required operator &
also to maintain the crane. The services shall
also be given to other users such as Boiler
vendor or others as required by MPPGCL.
11 Manpower for contract 
The contractor shall deploy adequate
manpower required for smooth effective
maintenance of the Plant. The contractor shall
furnish the proposed deployment plan for
manpower.
Accepting the deployment plan shall not
devolve the contractor from any responsibility
towards proper Maintenance of the Plant. Any
additional manpower required to meet the
normal and emergency needs during
breakdown or otherwise shall be arranged by
the contractor without any additional cost to
MPPGCL.
 Contractor’s
the O&Mresponsibility,
of Boiler and including
12 Condition monitoring, Special jobs
like online leak arrest As Aux., provided in
submission of regular reports and assisting in
the plant is specialized in nature & dusty
execution as recommended.
atmosphere which is directly linked with the
13 Evaluation of Plant Operation and  Contractor’sthe
generation, responsibility.
work shall be carried out only
furnishing recommendations on cost by
But implementation shall beand
engaging experienced highly
with skilled
MPPGCL.
effective ways to improve the Plant engineers/ technicians.
14 Performance.
Power evacuation  400KV Switch yard within the Plant, grid co-
ordination, all coordination with shall be
arranged by MPPGCL. Contractor shall assist
in the activity.

15 Fire Fighting Equipment / Fire  Fire Tender as available shall be handed over
Tender to the Contractor.
However supply of refilling agents / other
consumables, hoses, fire extinguishers shall
be in the scope of Contractor.
16 Third Party Audit   All third party Audits including but not
limited to Energy Audit, Inventory
management, physical verification, safety etc
shall be arranged by MPPGCL, the contractor
shall extend all necessary support and
17 Medical/OHC Facilities  assistance
Medical/OHC in each of activities.
facility, Costinofthe
as available all
such third
factory party audit
premises shall
will be be to MPPGCL’s
provided by
scope.
MPPGCL.
18 Safety, Security & road traffic   However the
Contractor required
shall extendFirst Aid hascooperation
necessary to be kept
management
19 Painting at premises of all
& Maintenance   ready inupPlant
Touch area and
painting by Contractor.
painting due to any
equipment / building /Road/ operation and maintenance activity including
structures etc
supply of paints by Contractor.
Maintenance, up-keeping and painting of
buildings/offices/Road/Structures shall be to
MPPGCL’s scope
20 Plant horticulture, landscaping &   Contractor shall repair Plant horticulture,
green belt landscaping & green belt if the same is
damaged during the course of its O&M
activity.
21 Plant Housekeeping Services  For all remaining
Contractor area theHousekeeping/
shall arrange activity shall be to
MPPGCL scope
cleaning services of the area under scope.
22 Maintenance of internal roads,   Repair & day to day maintenance of offices,

buildings, boundary wall & civil storage sheds, laboratories, internal roads,
maintenance works
buildings, boundary wall and workshop will
be by MPPGCL.
23 Insurance for the Plant & Machinery  However,
MPPGCLany willdamage during theplant
obtain required O&M and
as applicable activities shall be required to be repaired
machinery insurance and will also pay for by the
the
contractor.
renewals.
24 Arrangement of Insurance covers &   assistance
All support & for required paper
coordination works
for the for
insurance
claim management the insurance
claim will be
will be done byprovided
Contractor.by Contractor.
25 Insurance- Pertaining to Contractor  Workman Compensation, Group Insurance
policies and any other requirement as per the
local laws for the personnel engaged by
Contractor shall be responsibility of
Contractor
26 Suitable Office accommodation &   Available facility/ office space will be
furniture including storage facilities, provided by MPPGCL, however furnishing
rest room & office equipment
facilities minor modifications after MPPGCL’s
consent. Other requirements shall be
Contractor scope.
27 Telephone, Fax & LAN/IP facilities   All the available facility will be provided by
at Office MPPGCL. However, other requirements/
maintenance shall be to Contractor scope.

28 Residential Accommodation  Contractor’s responsibility

29 Statutory Compliances  Maintaining all the compliances &
Environmental aspects Boiler coordination with relevant regulatory &
Inspectorate Electrical Inspectorate
Factory inspectorate / Licensing and statutory Authorities shall be in the scope of
Permits from local & central Contractor, however Owner will support as
authorities per requirement for authorization & issuing
the required documents.
30 PPE 
Personnel Safety Equipment such as
uniforms (as per MPPGCL’s/ MP State
norms), safety belt, full safety harness, fall
arrestor, helmet, shoes, masks, welding
screens, gloves, protective glasses, ear plugs,
special aprons and first aid kit etc. shall be in
the scope of the contractor and would need to
confirm to standards prescribed by
MPPGCL.
31 SAFETY 
Proper adoption of safety rules and
preventive measures to ensure accident free
working as per EHS guidelines.
32 Proper precautions
Maintenance of Records, Daily/  Contractor will regarding the fire safety
be responsible for
Weekly /Monthly report(s). rules
maintaining all necessary documentation and/
as per guidelines of TAC / OPCB
NFPA
records/ such
EHS as
shall
logbesheets,
followed.
weekly, monthly,
performance/ consumption reports etc. These
documents shall be developed in consultation
with MPPGCL. Relevant important data
shall be computerized for easy scrutiny of
various parameters as well as graphical form
as desired by MPPGCL. Contractor will
facilitate monitoring of the performance on a
monthly basis by the first week of every
month in agreed format periodically.
33  The daily/weekly/monthly report(s) of O&M
Statutory Requirements Contractor shall fulfil / meet all requirements
andper
as other data norms/regulations
statuary / records, statements, special
and comply
reports
with all applicable laws, including as
will be submitted to MPPGCL per
Labor
requirement and instructions of MPPGCL
Laws, regulations, ordinance etc issued by in
agreed
state orformat.
centralShift logand
Govt. books/
otherregisters will
authorities
also be maintained
from time to time. in the requisite form.
Workman Compensation, Group Insurance
policies and any other requirement as per the
national and local laws for the personnel
engaged by contractor shall be responsibility
of contractor.

34 
License/ Approval from Boiler The contractor shall obtain and submit Boiler
Directorate and other Government
Agencies. Maintenance License from competent
authority.
Liasoning with IBR is part of the scope. The

contractor shall liasoin with Boiler
Directorate for renewal of the License to
operate the Boiler. He shall also arrange
approval of Boiler Inspector for any works
done on the system and all approvals /
sanctions from other government agencies to
fulfill all statuary norms shall be the
Contractor’s responsibility. Mandatory
Inspection fee payable to the authorities shall
be reimbursed by MPPGCL on production of
documentary evidence.
35 
Accommodation and transportation The Contractor shall arrange for its staff /
for the staff workers at site at his own cost.
36 
Employment of Local Persons. The contractor shall employ local persons as
per guidelines.

14. Check List of Various Activities

14.1. Preventive Maintenance Activities
Listing of various preventive maintenance activities to be undertaken by the contractor
under the contract has been done during the detailing of scope of work on best effort basis.
However, those not clearly defined elsewhere shall be covered through the following check
list of maintenance activities.
Pulveriser Recommended Lubrication
S
Consumable Component Quality Equivalent Requirement Remarks
No
Make-up as and when

Refer required based on level
ISO Siemens’s 21900 Litres gauge inspection.
Lubricating Planetary
1 VG- Manual (1520X12X1.
Oils Gear Box (20% extra included
320 Recommende 2= 21888)
d Oil Quality for makeup purpose.)
Make-up as and when

Shell: Omala required based on level
S2 G 680 guage inspection.
Mobil:
ISO 1900 Litres (20% extra included
Lubricating Roller Mobilgear
2 VG- (42X3X12X1. for makeup purpose.)
Oils Assembly 636 Series-
680 2= 1814)
600, IOC:
Servomesh
SP 680
2560 Litres
(1065X2X1.2
Refer =2556)
Flushing Oil
ISO Siemens’s Flushing oil
(For Planetary Required once only
3 VG- Manual can be used
planetary Gear Box before start up
320 Recommende for 6 flushing
Gear Unit)
d Oil Quality operations.
Hydraulic 9900Litres(75 Make-up as and when

ISO Servosyste m
Pressurizing 0X12X1.1= required based on level
VG- 68 HLP 68 /
Hydraulic Unit 9900) (750 guage inspection.
4 Mobil DTE
Oil Litres includes
Heavy
oil for Tank, (10% extra included
Medium
Cylinder & for makeup purpose.)

pipelines)
Servosystem
HLP 46 500 Litres as & when
(Indian oil) / required for
Roller
Mobil - DTE 500 Litres
opening & ISO
5 Medium / (220X2X1.1=
Closing VG- 46
Shell - Tellus 484) maintenance based on
Device
46 / HP - oil analysis report
Enklo 46
Shell: Avania
45 Kgs Make up of 124 Kgs
EP2
(1.1X3X12X1
Bush for
Grease Alvania .1) = 43.56 per annum.
6 piston in
EP2 Kgs (a)
Roller cover
(0.06X3X52x12X1.1
EP2 Mobil
=123.5 Kgs (b)
7 Gap Bolt in Grease Mobilux EP2 5 Kgs Make up of 21 Kgs

Roller Cover EP2 IOC: 0.11X3X12X1 Per annum.
Servogem .1 =4.35 Kgs
EP2 (0.01X3X52X12
X1.1
=20.5 Kgs
8
Endcaps 9 Kgs Make up of 42 Kgs per

Bushings & (0.11X6X12X annum.(0.01X6X52X1
Seals 1.1= 8.7 Kgs 2X1.1=41.1 Kgs
9 Vane 30 kgs
Assembly (0.05X40X12
X1 .2 = 28.8)
10 Outlet Ring 8 Kgs
drive (0.15X3X12X
assembly 1. 1= 7.92)
11 Link Lever 11 Kgs
(0.02X40X12
X1 .1= 10.56
Kgs)
12 Pillow Block 3 Kgs
(0.2X12X1.1
= 2.64)
13 Actuator/Gea 20 Kgs
r Box (1.5X12X1.1

= 19.8)
65894 litres at
26 bar
(832X6X12X
Hydraulic
1.1 =65894
Nitrogen Cylinder
14 N.A N.A Litres N.A
Gas Accumulator
(Approx 8 nos
Cylinder
N2 cylinder
bottles of 10
m3)
Routine Maintenance Pressure Parts
Action to
be Taken Recommended
Major Check Check
No. Description (if beyond Remarks Maintenance
Check Item Method Reference
acceptable Frequency
limit)
High furnace
Temperature,
temperature
fuel Carryout
with high
Plant consumption wall
fuel As required
instruments and steaming deslaggers
consumption
conditions operation.
and sluggish
normal
steaming
Check for
and
Visual and As per remove
Boiler
expansion predicted any Weekly
expansion
measurements movement obstruction
to free
movement
Water wall
1 No missing Change the
tubes Furnace
Visual corner link comer link Weekly
buckstay
pins pins
Remove
any
Boiler Free
Visual restriction Weekly
stoppers movement
to free
movement
Repair
Water or
leakage
steam Visual No leakage Every shift
during unit
leakage
outage
Shut down
Abnormal Refer ASLD
Acoustic and repair Every shift
noise manual
leakage

Repair
Flue gas or
leakage
fly ash Visual No leakage Every shift
during unit
leakage
outage
Check for
and
Visual and As per remove
Boiler
expansion predicted any Weekly
expansion
measurements movement obstruction
to free
movements
No missing Change the
Furnace
Visual corner link comer link Weekly
buckstay
pins pins
Remove
any
Boiler Free
Visual restriction Weekly
Furnace stoppers movement
to the free
2 hopper movement
panel Repair
Water or
leakage
steam Visual No leakage Every shift
during unit
leakage
outage
No abnormal
Shut down
Abnormal noise (Refer
Acoustic and repair Every shift
noise to ASLD
leakage
manual)
Restoration
High
of bottom
accumulation No abnormal
Visual ash Every shift
of bottom accumulation
evacuation
ash
system
Fligh flue
Carryout
Fouling on gas and low
Plant soot
the tube superheat Every shift
instruments blowing
surface steam
operation
3 Superheaters temperature
Shutdown
Abnormal
Refer ASLD and repair
noise and Acoustic Every shift
manual tube
vibration
leakage
Fligh flue Carryout
Tube surface Plant gas and low soot
Every shift
fouling instruments reheat steam blowing
temperature operation
4 Reheaters
Shutdown
Abnormal
manual tube
vibration
leakage

Fligh flue
gas and low Carryout
Fouling on
Plant economizer soot
the finned Every shift
instruments outlet feed blowing
tube surface
water operation
5 Economizer temperature
Shutdown
Abnormal
manual tube
vibration
leakage
Please
refer to
Safety
No steam
Value
Boiler safety leakage
Manual.
valves and Steam visible and
Please
6 other boiler leakage, Visual no Every shift
refer to
attached simmering simmering
vendor
valves sound
manuals of
audible
other
attached
valves.
Repair skin
Boiler skin No gas
7 Gas leakage Visual casing As required
casing leakage
leakage
Routine Maintenance Burner
Action to
Recommend
be Taken
Major Check Check ed
No. Description (if beyond Remarks
Check Item Method Reference Maintenance
acceptable
Frequency
limit)
Coal
Visual No leakage Repair Daily
leakage
Correct
operation of
Pulverised hot and cold Visual and Correct
Rectify Daily
1 Coal Firing primary air Instrument
system dampers
and gates operation
Damage of
Rectify or
coal feeder Visual No damage Weekly
replace belt
belt

Damage of Rectify or
coal feeder replace
Visual No damage Weekly
scraper Scraper
blade blade
Coal
Visual No leakage Rectify Daily
leakage
Check
2 Coal Burner Check coal
Good coal windbox
flame Visual Daily
flame damper
quality
operation
Fuel oil
(LDO/HFO) No leak or
Visual Repair Daily
leak or damage
damage
Correct
Rectify or
operation of
Visual and replace
LDO/HFO Valve shut Monthly
instrument Shut-off
shut-off
valve
valves
Correct
Rectify or
operation of Visual and System
replace Monthly
LDO/HFO instrument charged
FCVs
FCVs
Correct
Operating Rectify or
operation of Visual and
Fuel Oil replace Monthly
LDO/HFO instrument
firing FCVs
3 FCVs correctly
system
(LDO/HFO) LDO/HFO
Strainer Clean the
strainer Instrument Daily
clear filter
clear
Correct
operation of Rectify or
air/steam Visual and Operating replace
Monthly
atomization instrument correctly supply
supply valves
valve
Correct Rectify or
operation of replace
Visual and Operating
air/steam air/steam Monthly
instrument correctly
atomization atomization
PCV PCVs
Correct
Rectify or
Fuel Oil operation of
Visual and Operating replace
4 (LDO/HFO) air/steam Monthly
instrument correctly supply
burner atomization
valve
ON/OFF

valve
Correct Rectify or
operation of Visual and Operating replace
Monthly
fuel oil instrument correctly burner
burner valve valve
Rectify
burner
Burner ON/OFF
Visual and control or
ON/OFF operation Daily
instrument Adjust
operation correct
limit
switch
Flexible Repair or
Visual and No leak or
hose leak or replace Daily
touch damage
damage hose
Oil or air Replace
Visual and
connection No leak copper As required
touch
leakage rings
Oil or steam Replace
connection Visual No leak copper As required
leakage rings
Correct
operation of Operating
Visual Rectify Monthly
retract correctly
mechanism
Cleanliness
of burner tip
Clean Clean the
(spray plate Visual As required
burner tip burner tip
and black
plate)
Not
Diameter of
Measure enlarged Replace
spray plate Monthly
ment and within spray plate
orifice
limits
Condition
of spray
Visual Satisfactory Replace Monthly
plate and
back plate
Correct
Operating
operation of Visual Rectify Monthly
correctly
air latch
Easy and
Safety air
5 Correct correct
latch
removal and removal
insertion of and
oil burner insertion of
burner

Easy and
Correct correct
operation of removal
hinged and
cover insertion of
cover
A-A
± 30 degree
Windbox
from
tilting Visual Rectify Daily
horizontal
mechanism
position
operation
Windbox ± 15 degree
tilting from
Visual Rectify Daily
mechanism horizontal
6 Windbox operation position
Condition Satisfactory Clean or
of Burner Visual replace Daily
sight glass condition glass
Cracks in
casing and No crack or
Repair as
loose pieces Visual loose Monthly
necessary
of buckstay pieces
joint
Correct
Operating
operation of Visual Rectify Daily
correctly
dampers
Correct
Air control operation of Operating
7 Visual Rectify Daily
dampers pneumatic correctly
cylinder
Visual and Rectify or
Air leakage No leakage Daily
touch change
Carbon Remove
No carbon
buildup on Visual carbon Weekly
deposit
spark plug build up
Damage to Proper Repair or

Visual and
8 Ignitors ignition ignition replace the Weekly
Testing
transformer spark transformer
Damage to
Repair or
ignition Visual No damage Weekly
replace
cable
Damage to
Visual No damage Replace Weekly
spark plug

Routine Maintenance Duct & Dampers

Action to be
Taken (if Recommended
No Descriptio Major Check Check Check Remark
beyond Maintenance
. n Item Method Reference s
acceptable Frequency
limit)
Debris
accumulation
on FD fan Visual No debris Clear debris Monthly
suction duct
silencer
Debris
accumulation
on PA fan Visual No debris Clear debris Monthly
suction duct
silencer
Air or flue Visual, No Repair weld
Monthly
gas leakage Audible leakage joints
Tighten
1 Ducts door
Manhole Visual, No fasteners. If
Monthly
door leakage Audible leakage leak persists
replace
gasket.
Ash Visual,
No ash
accumulation Installed Empty ash
accumula Daily
in duct instrume hoppers
tion
hoppers nts
Repair and
No loose
replace
cladding
Insulation insulation
Visual or No Monthly
cladding cladding
rain
after
ingress
shutdown.
Repair or
No
replace
Expansion Damage or Visual leakage
2 expansion Monthly
Joints leakage Audible or
joint after
damage
shutdown
Duct Design Remove
supports, Proper
obstruction
3 guides, expansion Visual Weekly
expansion for free
stoppers, movement
movemen movement
Hangers
t

No
Replace and
Loose or missing
secure loose
missing Visual or loose 6 months
or missing
components compone
components
nts
Check and
adjust spring
Variable Movemen hanger for
Spring t to match the correct
hanger Visual design COLD 6 months
(Continued expansion HOT setting.
3 movement position Remove
)
expansion
constraint.
Check and
adjust spring
Movemen hanger for
Spring
t to match the correct
hanger
Visual design COLD 6 months
expansion
HOT setting.
movement
position Remove
expansion
constraint.
Remove
friction
between
Multi-
stationary
Louvre
and moving
damper 3-
parts.
way
Smooth Smooth Replace
damper Visual Daily
operation operation over-
Butterfly
tightened
damper
gland
Windbox
packing.
damper
Replace
damaged
4 bearings.
No
Missing link
missing
pins and Repair or
Guillotine Visual pins or Daily
damaged replace
damaged
links
links
Air leakage
Repair at the
from shaft No
Damper Visual earliest Daily
glands and leakage
opportunity
damper joints
Instrument No air Rectify
Audible Daily
air leakage leakage leakage

Check
operating
Presence of
instrument
moisture in
Visual Dry air air drier and Daily
instrument
changeover
air
to standby
drier
Check and
Reverse
No rectify
rotation of
Visual reverse louver Daily
standby
rotation damper seat
cooling fan
4 Continued and disc
Check
instrument
air leakage
Uniform
Check and
operation of
rectify
wind box Uniform
Visual sticking Daily
dampers in opening
damper
the same
elevation Check and
replace
defective
actuator
Damper Lubrication
Item Multi Louvre Dampers and Duplex Multi Louvre Dampers

Application point Bearings
Recommended Silicon grease or High temperature grease Alvania Grease

No.2 (Shell make) Mobilux Grease No.2 (Mobil)
Lubricants
Application Method Hand operated Grease pump / gun
Quantity of initial fill As required
Replacement
Annually
Frequency
Quantity
Caution
Make-up
As required
Frequency
Quantity
Caution

15. Definitions
DEFINITIONS AND INTERPRETATIONS
a. The following terms shall have the meanings specified in this Section.
b. “Abandonment” means the substantial cessation of the operation and maintenance of any or
all of the Plant or any other Services, which cessation is not excused under this O&M
Agreement and continues for a period of one (1) day i.e. 24 continuous hours.
c. “Additional Services” means those additional services and responsibilities of the Operator
during the Term, other than the Services specifically described in scope of work under
Section XX and elsewhere in this Document, Services which are reasonably incidental to
such Services on the assumption that such Services are performed in accordance with
Prudent Utility Practices, which are within the general scope of services provided for, and
which are reasonably requested by the MPPGCL in writing; provided, that in the Operator’s
reasonable judgment it is able and qualified to perform such additional services and doing
so will not impair its ability to perform all of its other responsibilities hereunder; and,
provided, further, that the Contractor shall only be reimbursed for costs and expenses
actually incurred or paid by the Operator in connection with the Operator providing such
Additional Services and only if it is determined, by mutual agreement or by Dispute
resolution, that such Additional Services cannot reasonably be performed by employees,
agents or Sub-Contractors of the Contractor without interference with their existing duties.
d. “Annual Operating Plan” means the approved annual operating and maintenance plans and
assumptions described in or required under Section 6.11.
e. “Annual Plant Load Factor” means in relation to a period of 365 days the ratio, expressed
as a percentage of the Gross Generation over the Rated Capacity (expressed in kW)
multiplied by number of hours in the relevant period;
f. “Annual Report” means the annual report upon performance prepared by the Contractor.
g. “Authorization to Proceed” means written authorization from the MPPGCL to the
Contractor authorizing the Contractor to proceed with performance of the Services as
specified by such authorization.
h. “Auxiliary Consumption” means the Energy consumed in the auxiliaries of the Generating
Station.
i. “Availability Factor” means the ratio of the Cumulative Average Availability and the
Normative Plant Load Factor
j. “Commercial Operation Date” - With respect to each Unit, the date upon which it has
successfully completed its Acceptance Tests and is available to commence operation on a
continuous, full-time, commercial basis as declared by the MPPGCL.
k. “Competent Authority” means any local or national or supra-national agency, authority,
department, inspectorate, ministry, official, court, tribunal, or public or statutory person

(whether autonomous or not) of the Republic of India (including but not limited to any
Government Agency) which has jurisdiction over the parties to, or the subject matter of,
this Agreement or any of the other Plant Agreements, and this definition includes, for the
avoidance of doubt, any authority that may affect the MPPGCL's or the Contractor’s ability
to cost or perform any of its or their obligations under the Plant Agreements or any
authority that gives consents or permits (including Permits).
l. “Contract Year” means each twelve Month period commencing on the date as described in
the document
m. “Contractor” means all contractors of the MPPGCL in relation to the Plant (including
without limitation the EPC Contractor), and their respective approved subcontractors, all in
their respective capacities as such and the successors and permitted assigns of any of the
foregoing.
n. “Declared Capacity” In relation to a Unit or the Power Station at any time means the net
capacity of the Unit or the Power Station at the relevant time (expressed in MW at the
Interconnection Point) as declared by the O&M Contractor in accordance with the Grid
Code and dispatching procedures as per the Availability Based Tariff;
o. “Demobilization Period” means the period of time beginning on the first day following:
i. The end of the Plant Operating Period or
ii. The earlier delivery of a Termination Notice and continuing for a period of fifteen
(15) days thereafter or
iii. mutually agreed period.
p. “Directive” means any present or future law, regulation, decree, directive, requirement,
instruction, or rule of any Competent Authority, or the conditions of or attaching to any
duly issued Permit, binding on the MPPGCL or the Contractor and includes any
modification, extension or replacement thereof then in force, and further includes any
Guidelines.
q. “Effective Date” means the date of signing of this Agreement.
r. “Emergency Event” means a sudden and unexpected event or circumstance which has
caused or reasonably threatens to cause (a) serious bodily injury to any personnel employed
at the Site or any other persons at or in the vicinity of the Site; (b) serious physical damage
to the Plant, including the Site or other material or property located at or in the vicinity of
the Site; (c) a work stoppage or other serious labour disturbance at the Site; (d) a shutdown
or other serious interruption in or interference with the operation or functioning of the
electrical distribution facilities relevant to or otherwise affecting the Plant; (e) imposition of
fines or other penalties or sanctions under any Directive, (except those penalties levied by
MPPGCL as per the agreements of this Contract with Contractor) which fines, penalties or
sanctions would be likely to affect seriously the ability of MPPGCL or the Contractor to
perform any of its or their obligations; or (f) an occurrence of any accident materially
impacting on the environment.

s. “Environmental Law” means any Directive relating to the environment, health or safety or
affecting the environment or Hazardous Materials, which governs, affects, or relates to the
MPPGCL, the Operator, the Plant (including the Site), as now or hereinafter in effect.
t. “Forced Outage” means an interruption or reduction in the generating capacity of the Plant
that is-
i. not a Scheduled Outage of a Unit, a Switchyard or a Grid System;
ii. not a request of MPPGCL to curtail generation;
iii. not a Force Majeure Event;
iv. created either directly or indirectly due to negligence/ignorance /mal operation of
the Contractor.
u. “Gross Generation” means the total energy delivered at the generator terminals for the
Facility or for a Unit.
v. “General/Standard Terms and conditions” means terms and conditions as per Annexure I
w. “Guidelines” means the environmental guidelines or procedures required to be followed by
the MPPGCL at any time during the Term.
x. “Hazardous Materials” means any chemical, material, contaminant, substance or waste
declared to be hazardous, dangerous, and toxic or a polluting material by any Competent
Authority and/or pursuant to any Directive, or exposure to which is prohibited or regulated
by any Competent Authority.
y. “Initial Staffing Plan” means the initial estimate of the Operator Staff and Plant Staff
required to perform the Services,
z. “INR” means Indian Rupees, the legal currency of the Republic of India.
aa. “Lien” means any lien, claim, security interest, mortgage, trust arrangement, judgment,
charge, easement, encumbrance, title retention, preferential right or any other security
agreement, arrangement or similar right in favour of any Person.
bb. “Liquidated Damages” means any liquidated and ascertained damages calculated under and
payable by the Contractor to the MPPGCL.
cc. “Losses” means any and all liabilities, losses, damages, claims, costs, obligations, charges
and expenses (including without limitation reasonable attorneys" fees) of whatsoever kind
or nature.
dd. “Major Sub-Contract” means any Sub-Contract [under which the total consideration
payable is or may reasonably be expected to be in excess of Rupees ten lakhs] (or the
equivalent) or which concerns the provision of any of the Services which is entered into
with an Affiliate of the Operator.
ee. “Manufacturers’ Manuals” means manufacturers" instruction manuals and operating and
maintenance procedures to be delivered or delivered by the EPC Contractor under the EPC
Contracts.
ff. “Material” shall mean all materials, documents and computer software, whether in
electronic format or otherwise used, created, prepared or developed by the Contractor or its

employees, representatives or Sub-Contractors pursuant to or otherwise in connection with

this Agreement, including but not limited to all manuals, data, designs, drawings, plans,
specifications, reports and accounts.
gg. “Mobilization Period” means period till the takeover of the plant from effective date.
“Month” means a period that starts at 00:00 local standard time the first day of any calendar
month and ends at 24:00 local standard time of such calendar month.
hh. “Monthly Report” means the report upon operation and maintenance prepared by the
Operator each Month.
ii. “O&M Manuals” means operating and maintenance manuals for the Plant, which shall
include any management and administrative policies and operating and maintenance
procedures required in the Agreement to be developed, together with the documents and
schedules described in such manuals, which shall be developed and mutually agreed upon
by the MPPGCL and the Contractor. (As such manuals may be amended, modified or
replaced from time to time by the Operator with the prior written approval of the MPPGCL,
which approval shall not be unreasonably withheld save where the amendment,
modification or replacement is a valid requirement.).
jj. “Office Staff” means the office manager and all subordinates of the office manager.
“Operating Costs” means those costs and expenses of operating, maintaining and repairing
the Plant incurred or paid by the Contractor on behalf of the MPPGCL in connection with
Contractor’s performance of the Services, but excluding any Liquidated Damages,
indemnities, penalties or other amounts payable by the Contractor hereunder or for which
the Contractor is responsible.
kk. “Contractor Staff” means those employees of the Contractor, which are dedicated solely for
the purposes of providing the Services, reside in India and work at the Site. Only those
employees who are included within the then current Staffing Plan are considered to be
Operator Staff.
ll. “MPPGCL’s Engineer” means engineer appointed or hired by the MPPGCL from time to
time to advise and assist the MPPGCL, among other things, in connection with the subject
matter of this Agreement;.
mm. “Performance Guarantee” means the irrevocable, unconditional Bank Guarantee of the
Guarantor in the form prescribed.
nn. “Plant Agreements” means the O&M Agreement, the Coal Supply Agreements, the EPC
Contracts, the Land Lease Agreement, Secondary Fuel Supply and Transportation
Agreements, and the other contracts or subcontracts of the MPPGCL relating to the
construction, operation, overhaul, maintenance and repair of the Plant or the Services,
contracts for the removal, transportation and disposal of waste or ash from the Site, as such
agreements exist on the date hereof and, except for this Agreement, have been delivered by
the MPPGCL to the Contractor and as such agreements may be amended or modified after

the date hereof, where such amendments or modifications have been made available to the
Operator in writing.
oo. “Plant Operating Period” means the period of time commencing on the takeover of the
Plant by the Contractor and continuing until the end of the Contract
pp. “Best Practices” means the exercise of that degree of skill, diligence, prudence, foresight,
and operating/maintenance practice generally followed internationally by highly qualified,
prudent professionals in any of the following businesses as the context may require:
a. the loading, unloading, handling and storage of Coal or Secondary Fuel and
b. the private electric power generation industry with respect to the design, engineering,
construction, testing, metering, repair, operation and maintenance of electric generating,
transmission and distribution facilities, including in the procurement of spare parts, spare
equipment and spare components in relation thereto; which in any such case should have
been expected to accomplish the desired result at the lowest reasonable cost, consistent with
licensing and regulatory considerations, environmental considerations, reliability, safety
and expedition. Prudent Utility Practices is not intended to be limited to the optimum
practice, method or act, to the exclusion of all others, but rather to be a spectrum of possible
practices, methods or acts employed by MPPGCLs and operators of facilities similar in size
and operational characteristics to the Plant.
qq. “Rated Capacity” means the generating capacity of the SSTPP-II Plant which shall be 1320
MW
rr. “Representative” means, for each Party, a Person designated by notice in writing to the
other Party.
ss. “Scheduled Maintenance” means such scheduled and pre-agreed maintenance as may be
authorised in the relevant Annual Operating Plan.
tt. “Services” means any or all of the obligations to be performed, responsibilities to be carried
out and goods to be provided by the Operator pursuant to this Agreement, including any
Additional Services.
uu. “Spare” means those spare parts, spare equipment and spare components maintained or to
be maintained by the Operator in accordance with the terms of this Agreement in
connection with the operation, maintenance and repair of the Plant.
vv. “Staffing Plan” means the approved Staffing Plan of the Contractor.
ww. “Store” means a storage of all kind of (included but not limited to) engineering spares,
consumables, tools & tackles, administrative infrastructural goods etc.
xx. “Inventory Management” means complete management of receipts, issue and accounting of
stores & ensuring safe custody and preservation as per standard norms.
yy. “Sub-Contract” means any contract duly approved by MPPGCL (except this Agreement)
entered into by the Contractor, or a Sub-Contractor, and a third party for the carrying out of
any of the responsibilities or obligations of the Contractor under this Agreement.

zz. “Sub-Contractor” means any person/ agency duly approved by MPPGCL for carrying out
any of the responsibilities or obligations of the Contractor under this Agreement under or
pursuant to a Sub-Contract, the sub-contractor being duly approved by the MPPGCL.
aaa. “Termination Notice” means the notice delivered by MPPGCL, following Event of
Default by Contractor, which notice shall specify the range of rights and obligations to be
terminated and the Termination Date.
bbb. “Unit” means Unit 3 or Unit 4, as the case may be.
16. Abbreviations Used

a. MPPGCL: M.P. Power Gen. Co. Ltd.
b. SSTPP: Shree Singa Ji Thermal Power Project, Dongalia, Khandwa

c. OEM: Original Equipment Manufacturer
d. SD: Security Deposit

e. EMD: Earnest Money Deposit
f. ID Fan: Induced Draft Fan

g. APH: Air Pre-Heater
h. FD Fan: Forced Draft Fan

i. PA Fan: Primary Air Fan
j. IAC: Instrument Air Compressor

k. SAC: Service Air Compressor
l. PHE: Plate Heat Exchanger

m. ACW: Auxiliary Cooling Water
n. DMCW: De-Mineralized Cooling Water

o. LDO: Light Diesel Oil
p. HFO: Heavy Furnace Oil

q. HVAC: Heating Ventilation and Air Conditioning

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M. P. Power Generating Co.

O&M of Boiler & Auxiliaries

M.P. Power Generating Company Page 1

d. Water Separator: ................................................................................................................................... 26

M.P. Power Generating Company Page 2

7.2.7. MILL REJECT HANDLING SYSTEM ..................................................................................... 48

M.P. Power Generating Company Page 3

24 Lines & Valves ....................................................................................................................................... 67

M.P. Power Generating Company Page 4

a. Labour Related Compliances ................................................................................................................. 111

M.P. Power Generating Company Page 5

M.P. POWER GENERATING COMPANY LIMITED

OFFICE OF THE SUPERINTENDING ENGINEER (P&W)

No. 515-1700/SSTPP/MPPGCL/ WT- /T- Date: -

NOTICE INVITING TENDER (NIT)

1 Tender No. MPPGCL TENDER NO T -

2 Tender Particulars 1. Annual work contract for Operation and

3 Estimated Cost (Rs.) /-

4 EMD (in Rs.) /-

5 Tender Cost (Rs.) /-

6 Purchase of tender end date & time up to 14:00 Hrs

7 Due Date and time for Physical up to 15:00 Hrs

M.P. Power Generating Company Page 6

(i) For participation in e-tendering module of MPPGCL, it is mandatory for prospective

M.P. Power Generating Company Page 7

Credentials and PQR:

M.P. Power Generating Company Page 8

M.P. Power Generating Company Page 9

M.P. Power Generating Company Page 10

1.1. Reference Number

1.2. Officer In Charge

1 Name The Superintending Engineer (P&W)

M.P. Power Generating Company Page 11

M.P. Power Generating Company Page 12

4.2. A Brief Introduction of SSTPP Khandwa

4.3. A Brief Introduction of Scope of Work

iii. Salient feature of the work are as under:

M.P. Power Generating Company Page 13

b. Providing field engineer operator/ technicians and required skilled/ semi-

4.4. What MPPGCL is looking forward with this contract:

ii. 100% adherence to all the deliverables.

M.P. Power Generating Company Page 14

M.P. Power Generating Company Page 15

5. Pre-Qualifying Requirement for the Bidders

5.1. Technical Experience

5.2. Financial Capabilities

5.3. Other Requirements

M.P. Power Generating Company Page 16

6. Terms & Conditions

6.1. General Conditions:

6.2. Special Terms and Conditions

6.2.1. Validity of Offer

M.P. Power Generating Company Page 17

6.2.2. Sub-Letting of Contract

6.2.3. Security Deposit

Contract Value SD in Percentage of Order value

M.P. Power Generating Company Page 18