SCOPE OF WORK FOR LP TURBINE ROTOR REPLACEMENT

1. Steam Turbine Generator Technical Data

Make : DEC
Type : N 135-13.2/535/535-2
MW Rating : 135 MW
Generator
Cooling : Air Cooled
Generator Rotor Mass : 33.7 MT
Generator Length : 9.5 Mtr
Rotor Construction : With Slip ring

2. Broad scope of work: Broad scope of work for LP Turbine rotor replacement shall be as under,

a. Dismantling, inspection and assembly of LP turbine.

b. Dismantling, inspection and assembly of Generator.
c. All (Five nos.) bearing and thrust bearing inspection.
d. Optional work: - Damage LP rotor repairing and balancing.

A Dismantling, inspection, replacement and assembly of LP turbine.

Insulation of Cross over pipe to be removed, if required and application of new insulation including
1.
Aluminum sheet. (New insulation supply is in client’s scope)
Dismantling of cross over pipes and all external pipelines, expansion bellows. DP test of expansion
2.
bellow to be carried out, if required repair / replace the same.
3. Loosening and removal of parting plane fasteners, cutting / gouging wherever required.
4. Removal of LP Top Casing (outer and inner) and top internals.
5. Decoupling of LP – Generator, HIP –LP turbine.
6. Checking of radial and facial run out of couplings and correction as per requirement.
7. Removal of rotor, bottom internals and casing studs (cutting / gouging of stuck-up studs if required).
Cleaning of all internals and casing and transfer pipe flanges (shot blasting of internals, if required)
8.
by arranging alumina shots and required accessories.
9. NDT of casing, internals. Minor repairs of diaphragm blades for thinning and crack, if required.
10. Parting plane matching of liners and glands. Replacement of gland housing, if required.
11. Replacement of LP rotor. NDT (DP, MPI and NFT) of spare rotor before replacement.
Alignment of LP/Gen. Rotors, HIP to LP turbine. Correction of bearing slopes if required. Reaming and
12.
honing of coupling hole for alignment correction if required.
13. Flow path and seal axial clearances correction.
14. Centering of all bottom internals.
15. Axial and radial play correction of internals.
16. Matching of Parting Plane of gland boxes.
17. Key clearance and thermal clearance and locking of top internals.
Replacement of damaged seals of diaphragm & gland seals (minor repairs of diaphragm blades, if any)
18.
seal cutting, tape checking, butt clearance and key groove clearance setting.
Replacement of brass segments of oil guards of bearing and matching of vertical and horizontal joints, if
19.
required.
20. Replacement of rupture disc.
21. Replacement of cross over pipe gaskets and repair / replacement of link if required.

1
22. Freeing and fixing of all fasteners.
23. Drilling and taping of damage thread. Riming and re-doweling if dowel is found loose.
24. Thorough cleaning / checking of all internals and polishing of rotor journals. Box up of LP Cylinder
25. Tightening of parting plane fasteners and assembly of cross over pipes.
Checking of coupled run out at thrust bearing HP/IP coupling, LP coupling, LP-generator coupling and
26.
all bearings.
27. Checking of shaft lifts in all bearings and adjustment of jack oil pressure if necessary.
Any additional work post opening of LP turbine if required need to be done by vendor, however time
28.
and price shall be mutually agreed.

B Dismantling, inspection and assembly of Generator

1. Dismantling of both side end cover, connected pipe lines.
2. Checking of cooling fan blades tip clearances.
3. Air gap measurment and correction if required.
4. Exciter fan housing correction, if required.
5. Assembly of Generator.

C All (Five nos.) bearing and thrust bearing inspection

1. Opening of pedestal covers of bearing no. 1 to 5. Removal of Bearings.
2. Checking and correction of SOC, TOC & interferences and clearances of bearing No. 1 to 5
3. All bearing bedding checking and correction if required.
DPT and Ultrasonic test to be carried out for all the bearings including Thrust Pads & MOP Bearings. If
any damage, cracks, babbit looseness etc. observed and any bearing found damage and requires
4.
replacement, agency will have to carry out fitting of new spare bearing with pedestal housing and rotor
journal as per standards practice.
Checking and correction of float. Measuring of thrust pad thickness and replacement of pad (if
5.
required)
6. Matching of bearing pedestal-parting plane, if required.
7. Dismantling of oil guards rings and checking of clearances. Repairing / replacement of damaged parts.
8. Polishing of journal and coupling holes, coupling face etc.
Bearing pedestal box up for oil flushing. Additional filters, marking cloth installation / positioning and
9.
cleaning during oil flushing period till lube oil nas value achieved to NAS 5
10. Dismantling of pedestal after completion of oil flushing. Final cleaning after instrumentation work.
Final box of all bearing, their yokes & setting keys clearances after ensuring the proper oil clearances.
11.
Final fitment/checking of JOP lines for leakage and replacement, if required.
12. Box-up of all pedestals 1 to 5
13. Putting machine on barring gear, steam rolling and synchronization.

D Optional work:- Damage LP rotor repair and Balancing

1. Repairing of damage LP rotor.
2. LP rotor balancing (Vacuum tunnel).

2
3. Materials and Facilities to be Provided by RWPL

a. Service water, service air and electricity for executing different types of works at nearby locations.
Further distribution shall be in the scope of contractor.
b. Spares, special tools and fixtures and tackles (if any), supplied by respective equipment
manufactures, as required, on returnable basis.
c. Consumables like gasket, stag-b etc. which will be consumed permanently during machine box up.
d. Suitable scaffolding material etc. Erection shall be in the scope of Contractor.
e. Suitable material handling equipments such as Crane, trolleys etc.
f. Workshop facility as available at site will be extended free of cost. Contractor has to guide/instruct
workshop personnel accordingly. Structural material required for preparing jigs, fixtures, tackles,
like M.S angles, plates, I-beams, etc as available. However, contractor shall arrange for preparation/
fabrication of the same at his own cost.
g. EOT crane (140/35 MT) (without operator)

4. Materials and Facilities to be Provided by Contractor

a. Experienced and qualified manpower. Contractor to submit the list of manpower to be deployed.
b. Consumables like Rustoline, CRC, OKS, Marking Cloth, cotton waste, hosiery cloth for cleaning
purpose etc.
c. All PPEs e.g. safety helmets, safety shoes, safety gloves, safety belts, etc.
d. Contractor shall have to make his own arrangement for boarding, lodging and local conveyance for
the manpower deployed.
e. All necessary Tools and Tackles, measuring instruments for completing the works as specified
above shall be arranged by contractor. Contractor shall submit the list of such tools, tackles,
measuring instruments along with offer.

5. Contract Duration

The contract validity shall be six months from the date of award of contract.
The work shall be completed as per the scheduled plan within 15 days (Barring stop to TG on barring). For
the mobilization of necessary resources, the contractor shall be given intimation 7 days prior to the
scheduled outage.

Contractor to submit the bar chart indicating major activities to be carried out to complete the work as
specified above along with offer.

6. Site Clean Up

After the completion of works and individual activities, the site shall be cleaned up by the contractor. The
scrap and waste generated shall be disposed off as directed by the EIC.

7. Safety Requirements

a. Safety of contractor manpower at the work premises will be contractor responsibility. All PPE as
per statutory requirements like helmets, safety belts, safety shoes, protective goggles and hand
gloves etc. will have to be provided by the contractor to his manpower. All safety system/practices
must be adhered to in consultation with owner’s safety officer, before commencing the work at
plant. Contractor has to follow all rules of safety.

b. All lifting equipment's of the contractor (chain pulley blocks, lifting & pulling machines, slings, etc)
have to be load tested and certified by the competent authority before being deployed for the job.

3
 Alternately contractor must produce test-certificate of all lifting tools and tackles from any outside
competent person.

c. All electrical equipment like grinders, welding machines, drilling machines, lighting transformers,
etc. have to be properly earthed and terminal provided with suitable sockets and plugs. ELCB is to
be provided for safety of personal.

8. Defect Liability Period

The defect liability period shall be six months from the date of commissioning of steam turbine generating
unit. Any defects observed towards the faulty workmanship shall be rectified by the contractor immediately
upon notice and without financial implications to RWPL.

9. Liquidated Damages

In case of any delay beyond agreed work schedule for reasons attributed to Contractor, the Contractor shall
pay to RWPL Liquidated Damages and not as penalty, a sum equivalent to 1% of basic contract value per
day or part thereof subject to a maximum of 10% of the basic contract value.

10. MANPOWER REQUIREMENT, DEPUTATION AND TECHNICAL QUALIFICATION

a. The contractor shall depute experienced, well qualified and competitive manpower to complete the job
as per the acceptable quality standards and within the given time frame. Depending upon the job
requirements, the contractor may be asked to speed up the job. In this case the contractor may have to
mobilize additional manpower without any cost implication to RWPL within 48 hours from the
intimation of RWPL.

b. The contractor shall depute the manpower at least two days before the start of the actual work along
with the relevant work experience certificates. Preparation of gate passes for the manpower and
permission for T & P shall also be arranged by the contractor.

c. The work is to be carried out round the clock, Seven days a week including Sunday & Holidays. For this
contractor has to deploy man power accordingly to ensure the completion of work within the stipulated
time. The contractor shall make all necessary arrangement including qualified & experienced Engineers
and supervisory staff for the same.

11. GENERAL

a. The list of the jobs mentioned above is indicative only. However any job required for completing the
overhauling activities shall be in the scope of the contractor as directed by the EIC and without any
financial implication to RWPL in schedule time.

b. Any minor jobs, which has not been included in the scope of work and are required to be done for the
completion of work, shall be executed by Agency without any extra cost implication as per the
instruction of EIC.

c. Special tools and tackles for generator rotor removal/insertion available with the owner will be given
to the contractor on returnable basis.

d. It will be the contractor's responsibility to preserve the equipments / materials daily under overhaul
by tarpaulin / cloth/ plastic sheet etc. as per owner's engineer's instruction.

e. The special tools given to the contractor shall be kept and handled properly. In case any damage
observed in these tools, same shall be replaced by the contractor at his own cost. The decision of EIC
regarding acceptance of the same shall be final and binding. The contractor shall keep an account of the
tools issued to him and same shall be returned to RWPL after work completion. The cost of the tools
lost or found defective/damaged shall be recovered from the contractor.
4
f. The contractor shall follow all electricity rules and regulations as applicable for safety of his personnel /
equipment /installation. Contractor shall be liable to provide safety wears and personal protective
equipments to their personnel befitting the area of work e.g. helmets, safety shoes, safety belts, rubber
hand gloves and aprons etc.

g. In case of non-compliance of safety rules and norms, any mishap or accident occurs; EIC shall be free to
deduct any amount as compensation from contractor bills at his absolute discretion.

h. The work is to be carried out round the clock, Seven days a week including Sunday & Holidays. For this
contractor has to deploy man power accordingly to ensure the completion of work within the stipulated
time

i. Any sort of work on lube oil lines for rotor rotation during execution of the work as well as during oil
flushing and system related filters/strainers cleaning to be done by the contractor for normalizing the
same. Oil strainers and filters cleaning to be continued up to 72 hrs after synchronization of the
machine

j. Contractor to prepare/fabricate required flanges/blanking plates, plugs, arrangements etc. required for
generator hydro test, air leak test, rotor purge test etc. Other works not mentioned above but required
to carry out during generator testing/ checking/ overhaul to be carried out by contractor as per
instruction of EIC

k. The contractor shall make required scaffolding platforms at his own cost. The necessary scaffolding
material will be issued to the contractor free of cost on returnable basis.

l. The contractor in consultation with owner's Engineer will prepare job planning in the form of PERT
CHART / BAR CHART. He should prepare detailed working sheets for the various activities separately
including category wise man power required for each activity and nominating one individual
responsible for execution of each activity. Daily progress report in the evening has to be submitted to
EIC.

m. The job completion shall be considered only after the successful trial operation of unit for 72 hours
continuously. During this period, if a damage / break down due to poor workmanship are observed; the
contractor has to attend the same without any cost implication to RWPL. Therefore Contractor has to
keep the required manpower until completion of work.

n. The safety of the dismantled parts at site shall be the responsibility of the contractor

o. Food and snacks for the contract manpower shall be arranged by the contractor

p. The contractor shall be responsible for transportation of material from the central store/departmental
store and return of balance material to designated store as instructed by EIC.

q. Contractor shall dispose the old gaskets, oil/grease waste generated & other hazardous material to
environment in a specially made container/dust bin only.

r. Agency shall have to bear for the loss of any damage to the items belonging to RWPL due to improper
handling / storing or improper fitting etc. and necessary recoveries will be made from the bill of the
agency.

s. It is strongly recommend that contractor should visit the site to make an assessment of local condition
and site requirements. The contractor may seek clarifications regarding technical details of machine
and other requirements before the submission of bids. The maintenance and inspection procedures,
quality norms will be in general in conformance to the contractor’s recommendations. However the
decision of EIC in these areas shall be final and binding.