TG ,RLA & AUXILARIES SCOPE OF WORK FINAL 01.02.2024 (1)

JSW ENERGY LIMITED
THERMAL POWER PLANT

Capital Overhauling Contract
For
Turbo Generator and TG Aux – 130MW
(Turbine: K30-16 + N30-2 x 3.2; M/C No: T-0441,
Generator: THRI – 93/98)
ADDRESS:
JSW ENERGY LIMITED,
Vijaynagar, Village. & P.O.: Toranagallu,
Dist.: Bellary, Pin.: – 583123,
Karnataka
BID: DOCUMENTS
Bid document consists of the following:
I. Intent of work
II. Equipment details
III. Validity of the contract
IV. Scope of work
V. General terms & conditions of the contract
VI. Scope of services
VII. Quality assurance
VIII. Measurement sheets & Reporting Procedure.
IX. Defect liability

I. A ) Shutdown Work Main Turbine Generator
The main intent of capital overhauling(COH) is to improve the efficiency of Turbo Generator and
restore the health by attending all defects and deficiencies of Unit-1, 130 MW. The works involves
overhauling & NDT related works, Insitu-balancing activity, HIP & LP Turbine, Generator, Exciter,
governing valves i.e. HPCV, IPCV, HPSV & IPSV and its actuators, Steam Strainers, HP Bypass control &
spray valves, LP Stop & Control valves with actuator works as described in the scope. The service scope
involves quality consumables, tools and skilled manpower and technical expertise.
a) Capital overhaul of Steam Turbine, Generator & Connected valves / Strainers.

b) NDT of Turbine & Generator including required tests.
II. Equipment details:

a) Main Turbine:
Tandem compounded, Two Cylinder reheat condensing turbine.

Make: BHEL, KRAFT WORK UNION
Cylinder -1 (HP/IP), Type: K30-16, Combined HP-IP turbine with 44 (25+19) reaction stages.
Cylinder -2 (LP), Type: N30-2 x 3.2, Double flow LP turbine with 9 reaction stages.
Bearing No. 1 250 mm Bearing No. 2 400 mm Bearing No. 3 400 mm
b) Generator:
Type: THRI – 93/98, Make: BHEL, Cooling System: Hydrogen, Air gap: 62.5 mm
Front Gen Bearing 330 mm Rear Gen Bearing 330 mm Slip ring Bearing 140 mm
c) Other Details:
WEIGHT (Ton)
Combined HP-IP cylinder, assembled complete with HP & IP valve casings 139.4
Combined HP-IP cylinder, assembled complete without HP & IP valve casings 108.0
Combined HP-IP turbine outer casing upper part 19.0
Combined HP-IP turbine outer casing complete with blade 37.9
HP stop & control valve casing assembly (each) 5.8
IP stop & control valve casing assembly (each) 9.9
LP cylinder upper outer casing complete 12.1
LP cylinder, upper outer shell of inner casing with blading, guide wheel &diffuser 15.4
Rotor of HP-IP cylinder complete with blading 18.0
Rooter of LP cylinder, complete with blading 29.7
Cross beam 1.7
Generator Rotor 27.37
d) Main Stop and Control Valve;
Arranged in Common body, Type: SSV 160-150-E1-K-AL , Type: STV 125-150-E1-K-AL(lift-50mm),
Qty - 2 No.
e) Reheat Stop &Control valve

Arranged in Common body, Type: SSV 320-45-E1-K-BL, Type: STV 280-45-E1-K-BL (lift- 95mm),
Qty: 2 No
f) Bypass stop and control valve

Arranged in common body, Type: UV 150, 2 Nos
III. Work schedule

1. The effective period of COH work shall be 30 days from bar to bar (Desynchronization to
synchronization). For the mobilization of necessary resources, the contractor shall be given
intimation 15 days prior to the scheduled outage.
2. Contractor required to submit the L2 schedule as per specified completion schedule of 30
days.
3. Contractor required to carry out pre outage survey to capture operating
conditions/abnormalities of the unit at different load conditions to rectify during COH.
Scope of work
1. CAPITAL OVERHAULING WORKS OF TURBINE GENERATOR:
A. HP/IP TURBINE:
1. Assistance such as scaffolding, welding and removal of insulation wherever required to
commence the COH.
2. Check, record and ensure JSW witness of all control/reference dimensions for every TG
component before dismantling.
3. Contractor required to assess the condition of every dismantled equipment by visual inspection
and dimensional inspection for necessary recommendations and subsequent corrective action for
timely execution.
4. Ensure the temporary support arrangement for necessary dismantling of TG components e.g
bottom casing etc.
5. Check and record of coupled run out at thrust bearing HP/IP coupling, IP coupling,LP-Generator
coupling and all bearings.
6. Check and record the bump and roll check (Steam side) at coupled condition.
7. De coupling of LP - HP rotor
8. HP-IP, IP-Generator Coupling alignment checks with loose bolt.
9. Removal of HP-IP top casing bolting’s.
10. Lifting of HP-IP outer casing
11. Removal of outer casing dowel pins.
12. Removal of HP/IP inner casing top half bolting’s.
13. Lifting of HP-IP inner casing (top).
14. Check and record the flow path clearances before lifting of the rotors.
15. Removal of HP/IP rotor. Check and record rotor inter stage run out at different locations before
removal.
16. Loosening of valve body flange cap nuts after recording necessary reference readings.
17. Jacking of HP. IP valve body flanges for checking of angle rings.
18. Inspection and removal of HP-IP inner casing(bottom) from position and carrying out the
corrective action
19. Aluminum grit blasting [Alumina grit in the scope of vendor] on the HP/IP rotary and static
components and jointly inspection to be carried along with JSW. Manual cleaning to be done for
non-feasible zones of grit blasting.
20. HP, IP inlet, Exhaust, extraction angle rings (L rings) visual, dimensional. If required replacement
of Angle rings.
21. Angle rings clearance check and maintaining the design values, if found deviated from the design
readings.
22. Balancing leak off expansion joints (Inner top and bottom half’s) clearances check and if
clearances observed beyond design values replacement of expansion joints (Necessary welding
technique, radiography, stress relieving of the weld joint, IBR welder is in the scope of the
contractor)
23. Conducting DP test on Balancing leak off lines weld joints.
24. Thickness survey of balancing leak off lines-4 no’s
25. Tightness check of inner casing (Top and Bottom) dummies.
26. Turbine valve drains thoroughness check.
27. Checking and rectification of casing thermocouples including brazing works
28. Positioning of HP inner bottom half.
29. Assembling the valve bodies (HP&IP) to position and tightening of flange cap nuts.
30. Bearings journal slope check and necessary correction.
31. Placing of HP/IP rotor.
32. Checking all the required axial and radial clearances and rectification with respect to last COH
/errection value.
33. Placing of HP-IP inner casing top half
34. Tightening of HP-IP inner casing top half bolting
35. Placing of HP-IP outer top half Casing.
36. Tightening of HP /IP outer casing top half bolting.
37. Taking outer gland reference readings in outer casing prior to removal of bottom casing support.
38. Centering, of HP IP outer casing.
39. Roll check and bump check (With half casing and full casing) of HP IP outer casing,
40. Horn & drop check of outer casing
41. Removal of bottom casing support prior to coupling alignments.
42. Checking & correction of the alignment between HP / IP rotor and LP rotor.
43. Reaming, honing to be done in case of any coupling bolt seizure/physical damage, which is
identified during vi/ndt
44. Checking of coupled run out at thrust bearing HP/IP coupling, LP coupling, I-P-generator coupling
and all bearings.
45. Checking of shaft lifts in all bearings and adjustment of jack oil pressure.
46. Setting of rotor axial float
47. Coordinating for Application of casing insulation.
48. EOT operators to be provided by the vendor to operate minimum two EOT crane round the
clock.
B. LP TURBINE:
1. Removal of LP outer casing and locking of inner outer casing bottom.
2. Checking of coupled run out at thrust bearing HP/IP coupling, IP coupling, LP-generator
coupling and all bearings
3. Removal of inner outer casing top half bolting’s.
4. Lifting of inner outer casing.
5. Removal of inner - inner casing top half bolting’s.
6. Lifting of inner-inner top half casing
7. Clearance checking of LP rotor internals prior to rotor lifting
8. De coupling of LP - to Generator rotor
9. HP-IP, LP-Generator Coupling alignment checks with loose bolt
10. Removal of LP rotor. Check and record rotor inter stage run out at different locations before
removal.
11. Sand / Aluminum blasting on the LP rotor, top and bottom halves of inner-outer and inner –
inner casings.
12. Manual cleaning of LP bottoms half inner-outer and inner-inner casings.
13. Replacement of LP outer casing rupture diaphragms - 4 no
14. Inspection and carrying out corrective actions on LP rotor.
15. Placing of the LP rotor.
16. Checking of all axial and radial clearances of LP rotor.
17. Inspection and intactness checking of the balancing weights holes cleaning and weights,
recording the hole locations/hole numbers.
18. Placing of inner-inner top half casing.
19. Tightening of inner -inner casing top half bolting’s
20. Placing of inner-outer top half.
21. Tightening of inner -outer casing top half bolting’s.
22. Placing of LP outer top half
23. Tightening LP of top half of outer casing.
24. Checking & correction of the alignment between LP-Generator rotors.
25. Checking of coupled run out at thrust bearing HP/IP coupling, LP coupling, LP-generator
coupling and all bearings.
26. Checking of shaft lifts in all bearings and adjustment of jack oil pressure if necessary.
27. Visual Inspection, DPT of extraction bellows in LP turbine, IP-LP cross over bellows
inspection and replacement if any damage
28. LP last stage blades dismantling and inspection(VI and NDT)
29. Provision of proper covering of GI sheet over condenser tube bundle before doing L.P
turbine work.
30. Grit blasting, NDT of the removed LP rotor .
31. Replacement of LP rotor if requited with necessary dimensional and NDT tests.
** Insitu dynamic speed Balancing of the complete train after overhauling to achieve ISO
standards/to achieve below the values which were captured during pre-outage survey.
C. TURNING GEAR
1. Loosening the bolts and removal of the hydro motor.
2. Healthiness of the hydro motor to be checked and replace if necessary.
3. Inspection of the overrunning clutch to be checked and replace in necessary.
4. Inspection of splined shaft, connecting shaft, ball bearings and journal bearing,
5. Setting of the axial clearance between hydraulic turning gear and turbine shaft.
6. Healthiness of the inlet solenoid valve to be ensured.
7. Checking and Setting of the clutch lift pressure to be done.
8. Check for any oil leakages or passing of the valves for maintain the sufficient jack oil
pressure.
9. Alignment of the turning gear with respect to the turbine as designed.
10. Ensuring the free rotation of the rotor with turning gear.
D. TURBINE VALVES SERVICING (HPSV, HPCV, IPSV, IPSV, LPBP STOP & CONTROL VALVES)
1. Complete dismantling, thorough cleaning, NDT & dimensional check.
2. Replacement of damaged parts/components.
3. Seat to cone blue contact check and improving the contact.
4. Assembly of the valves after NDT check.
5. Hydro test of actuator to be carried out.
E. TURBINE VALVES ACTUATORS SERVICING (HPSV, HPCV, IPCV, IPSV, LPBP STOP & CONTROL VALVES)
1. Complete dismantling of the actuator.
2. Visual inspection of the components.
3. Dimensional inspection of the mating parts.
4. Assembly of the actuator with new O rings and seals.
F. STEAM STRAINERS INSPECTION

1. Coordinating for Strainers insulation removal.
2. Cutting of MS & HRH strainer drains for removal of the strainers.
3. MS strainers – 2 no and HRH strainers – 2 no dismantling, thorough cleaning of the
components.
4. Conducting SR, RT on the internals and the weld joints.
5. Dimensional check
6. Replacement of the damaged parts / components if any.
7. Box up of the strainers with new gaskets.
8. Argon welding of the strainer drains with necessary preheating and post heating works.
9. Coordinating for Laying of the insulation.
G. GENERATOR WORK
1. Removal of all connected oil pipelines
2. Removal of Stiffeners at exciter and turbine ends.
3. Removal of shaft seals exciter end and placing of bearing no 5
4. Removal of fan hood at exciter end
5. Removal of End shield top halve exciter end.
6. Removal of shaft seal Turbine end and placing of bearing no 4.
7. Removal of fan hood at Turbine end
8. Removal end shield top halve turbine end
9. Removal of cover plate turbine and exciter end.
10. Air gap measurement and rotor axial reference.
11. Placing of shoes at Turbine and exciter end.
12. Removal of Bottom bearings no. 5 and 6
13. Lowering of Bottom half end shield on exciter side.
14. Lowering of bottom half end shield on turbine end
15. Lifting of exciter by crane and placing the sliding plate.
16. Lifting of turbine end and positioning of the Shoe over the sliding plate.
17. Threading out the Rotor from stator
18. Inspection of the stator and rotor.
19. Rotor CC bolts leak check with nitrogen and rectification if and leakages observed. Special
tools and seal kit is in the Contractor scope.
20. Varnishing of rotor and stator after though cleaning. Required varnish is in the scope of the
contractor. The grade and quality has to be approved by M/s JSWEL. Necessary varnish drying
equipment’s like hot air blowers and hand lamps shall be in contractor scope.
21. Placing of the sliding plate.
22. Positioning of the rotor with crane on the shoe
23. Insertion of the rotor
24. Placing the support shoe at exciter end and lowering the crane.
25. Positioning of the bottom end shield at exciter end.
26. Positioning of bottom end shield at turbine end
27. Placing of the bottom bearing no 4& 5.
28. Air gap Inspection and rotor axial reference.
29. Positioning of the cover plates top and bottom exciter end.
30. Positioning of the cover plates top and bottom Turbine end
31. Positioning of Top End shield at exciter end
32. Positioning of Top End shield at Turbine end
33. Positioning of Fan hood at exciter end
34. Positioning of fan hood at turbine end.
35. Clearance adjustment of fan blades and DPT at exciter and turbine end
36. Positioning of top End shield at Exciter end.
37. Positioning of top End shield at Turbine end
38. Removal of bottom half of bearing no 5.
39. Assembly of shaft seal at exciter end.
40. Placing of bearing no 5 bottom half
41. Removal of bottom half of bearing no 4.
42. Assembly of shaft seal at Turbine end.
43. Placing of bearing no 4 bottom half.
44. Assembly of bearing no 5 top halve.
45. Assembly of bearing no 4 top halve.
46. Positioning of the stiffener at both ends.
47. Replacement of all gaskets and connection of all Hydrogen pipelines and control station.
48. Generator terminal bushes seals replacement and ensure leak free. O rings and seals shall be
in contractor scope.
49. Pressurizing the generator to 3 Ksc with air and soap leak test. Servicing of H2 drier.
50. Observation of the pressure drop for 24 hours after attending all the leakages and bring down
the pressure drop with in design limit.
51. Generator bushing removal and replacing to be done if any leaks/damage found.
52. DP test of welding joints of oil piping connected to Generator end shield TE & EE
H. EXCITER WORK
1. Removal of bearing no 6 pedestal top half.
2. Removal of bearing no 6 top half.
3. Removal of exciter shaft.
4. Removal of bearing no 6 bottom half.
5. Removal of pedestal no 6 bottom half.
6. Blue matching of pedestal no 6.
7. Alignment between generator rotor to exciter rotor.
8. Swing check of exciter rotor and rectification.
9. Bearing no —6 box up.
10. Pedestal no —6 box up.
11. Slip ring CC bolts leak check with nitrogen and rectification if and leakages observed. Special
tools, seal kit and leak attending is in the contractor scope.
12. Slip ring surfaces to be checked for unevenness. In case abnormal necessary
Polishing/Grinding shall be in Contractor scope.
13. Replacement of exciter rotor if any abnormality.
I. BEARINGS (Bearing no 1 to 6)
1. Seal bore measurement and correction.
2. Inspection of bearing and blue matching of touress to cylindrical support.
3. Removal of bearing bottom half’s.
4. Visual and dimensional check of bearing top and bottom half’s.
5. Polishing of bearing top and bottom half’s.
6. Assembly of bottom half and setting the inlet oil key clearances.
7. Replacement of all 6 bearing oil guard fins/oil guard. Removal of oil guard’s fins, caulking
fixing & machining is in the contractor scope. Sealing fins will be supplied by M/s JSW
Energy.
8. Assembly of bearings after taking the journal OD and bearing ID with setting clearances.
9. Checking of shaft lifts in all bearings and adjustment of jack oil pressure if necessary.
10. Thickness measurement of thrust pads, blue contact checking with thrust collar. Setting of
rotor axial float.
11. Replacement of bearings and touress .
12. Bearing housing no 1,2 and 3 foundation bolts tightness checking.
J. HYDROGEN COOLER INSPECTION.

1. Opening of water box, inspection and cleaning of tubes in position.
2. Removal of cooler bundle based on the requirement
3. Cleaning of coolers, hydro test and assembly back with proper gaskets.
K. Minor, medium repair & machining works on Turbine & generator.
1.Turbine, Generator, Governing Valves and Control Valves
a) Machining of valve cones if stucked in the valve casing.
b) U seal rings machining after replacement
c) Lock pin and screw drilling and locking for Turbine Governing Valves and Control Valves, for angle
rings if replaced.
d) All packers and keys to be machined for attending the OEM clearances.
e) Casing, valve mating faces/bodies welding and repair works.
f) Oil catcher strip old fins removal, new fins fixing & machining work as per required OEM
recommended clearances. The fins will be supplied by JSWEL.
g) Supply of Alloy Steel Turbine Bolts, pins, screws, nuts, etc. as per Drawing or Sample, Machining along
with required material in the scope of vendor.
L.ELECTRICAL WORKS:.
Following tests are to be done on the Generator Rotor
1. Slip Rings surface is to be checked

2. Rotor Checks as per BHEL Manual
a) Rotor Run out Checks
b) Withdrawn Check Rotor.
c) Perform UT of Rotor Retaining Rings
d) Check Rotor Wedges and Retaining Rings.
e) Check end windings and Gas Outlet Ducts.
f) Check Bearing Surfaces
g) Check Shaft seal contact face.
h) Check Rotor Fan
i) Check Coupling Flanges.
j) Check Rotor Alignment
2. PROBLEM TO BE ADDRESSED:
1. Turbine heat rate to be improved by optimizing flow path clearances setting.
2. Vibrations of the turbine are high in 3 A ( LP Turbine rear bearing housing Axial) and 1X ,2X
,2Y should be <100 microns.
3. Bearing temperatures of all the bearings should maintain below 90 deg c.
4. Zero Steam leak near front and rear gland area of HP-IP turbine.
5. Zero oil leaks, steam leaks and water leaks.
A. TURBINE & GENERATOR AUXILARIES (U1, 130 MW)
The scope of work envisages works on control oil system, lube oil system, jacking oil system, hydrogen
system, seal oil system, HP Bypass system, Generator chamber exhaust fans, OVEF fans as per the detailed
scope. These works are to be carried out for SBU#1 Unit-1, 130 MW, Make: M/S.BHEL Thermal power
plant, Turbine Type: K 30-16 N30-2 x 3.2 as per the schedule of quantities & as per Instruction of Engineer-
In-Charge. The works shall be carried out in the presence of competitive, highly experienced Engineer like
Ex-BHEL experts and bearing NDT by certified agencies with necessary equipment’s & same to be arranged
by the Contractor. The detailed scope of work is described hereunder.
DESCRIPTION: SHUTDOWN WORKS ON CONTROL OIL SYSTEM
SCOPE OF WORK:
1. Shifting of all the required materials from stores to the work location.
2. Ensure necessary PTW & Safety clearance.
3. Control oil tank draining, thorough tank cleaning & refilling of oil.
4. Checking the 4 Nos accumulator pressure and recharging to the required pressure; replacing of
damaged bladder.
5. Pre shutdown survey of oil leaks and rectification accordingly
6. Replacement of all filters in the system with new one; Replace filters of HPSV, HPCV, IPSV, IPCV,
LPSV, LPCV hydraulic actuators.
7. Servicing / Adjustment /Replacement of all relief valves.
8. Arresting of all oil leakages, including replacement of ferrule fitting and cutting and welding of
lines.
9. Cleaning of control oil coolers (2Nos) & Hydro test of same.
10. Inspection and replacement of coupling and spider of control oil & circulating oil pumps (2 + 1
Nos).
11. Servicing or replacement of valves to carry out the related jobs.
12. Any temporary platform required is to be arranged using proper materials.
13. Job involves fabrication & replacement works.
14. Scraps generated have to be removed & shifted to location as per SEI and Good Hose keeping to
be maintained at work place.
15. Arrangement of proper illumination (Hand Lams (24 V & 230V), Halogen Lamps at every location
of works as per the instruction of SEI. All materials like hand lamps, 24 V Transformers, Switch
boards, Cables, scaffolding, & other T&P are in the scope of contractor etc.,
16. Successful Trail Run & full load operation.
DESCRIPTION: SHUTDOWN WORKS ON HP- BYPASS SYSTEM
SCOPE OF WORK:
3. Replacement of all system & line filters.
4. Check the tightness of all joints and arresting all the leakage's.
5. Oil tank (2 Nos) draining, thorough tank cleaning & refilling of fresh oil.
6. Check the quick opening accumulator pressure recharge to the required pressure; replace bladder
7. Checking the accumulator (2 Nos) pressure and recharging to the required pressure; replace
bladder.
8. Inspection & replacement of motor to pump coupling bushes.
9. Replacement of high pressure hoses.
DESCRIPTION: SHUTDOWN WORKS ON SEAL OIL SYSTEM

SCOPE OF WORK:
3. Alignment check & correction of seal oil pumps (3 Nos).Oil leak arresting/pump servicing
4. Replace all flange gaskets of seal oil lines. And flushing of oil lines with compressed air.
5. Replacement of all H2 line flange gaskets & successful soap leak test.
6. Charging of air, observe any pr. drop for 24 hrs
7. Replacement or Servicing of valves in hydrogen system .
8. Arresting of all hydrogen leaks.
9. Inspection of Tanks and required rectification work.
11. Replacement of valves in the system .
12. Replacement of valves in hydrogen filling panel rack.
13. Seal oil cooler cleaning (Shell & Tube Side) and its hydro test (2Nos).
14. Seal Oil filters cleaning or replacement up to full load operation of unit.
15. Servicing / replacement of seal oil system DPR.
16. Generator exhauster fans internal inspection & bearing replacement (2 Nos).
17. Generator manhole door gasket replacement.
18. Replacement of generator terminal bushes O rings.
19. Attending of oil & H2 leaks if any.
DESCRIPTION: SHUTDOWN WORKS ON TURBINE LUBE OIL & JACKING OIL SYSTEM.
3. Replacement / Cleaning of Jacking oil filters up to full load operation of unit.
4. Cleaning of lube oil filters up to full load operation of unit.
5. Cleaning of basket filter for achieving oil cleanliness.
6. Servicing of thermostatic valve (1No).
7. Servicing or replacement of three-way valve of TG oil cooler.
8. Replacement of lube oil line gaskets.
9. Replacement of jacking oil hoses.
10. Jacking oil PRV replacement.
11. Relief valve & individual pedestal pressure setting.
12. Oil draining and Oil filling up to full load.
13. Turbine lube oil Cooler (02 No) cleaning both oil (shell) side & water (tube) side. Box up with new
gaskets and Successful hydro test of same.
15. OVEF fans suction strainer cleaning and inspection of the fan impeller and fasteners.
16. Cleaning of all oil lines, MOT and its dykes, oil canal and as per requirement.
17. Supporting manpower for electrical motor removal and placement of all oil pump and motor.
21. Checking and attending of lube oil leaks if any.
22. Servicing of oil vapor exhauster fans (2 Nos) and cleaning of suction strainer mesh.
boards, Cables , scaffolding, & other T&P are in the scope of contractor etc.,
IV. General terms & conditions of the contract
1. QUALIFYING REQUIREMENTS:
1. The bidder should have the overhauling experience of capital overhauling M/s BHEL supplied
130 MW of TG set.
2. The agency shall have proven track record in maintaining similar type of equipment’s of coal
based thermal power plants of capacity more than 130 MW TG set of BHEL units & similarly he
has to submit job completion certificate from user of last 03 numbers of unit major overhauling of
Turbine of said specification.
3. Bidder has to depute right experienced workmen and engineer for COH
4. Vendor to provide List of manpower with names of Main Persons for Turbine, Valves,
Generator and Aux systems and experience.
NOTE: Bidder to complete the attached checklist.
The break up period is as under for Unit-1 (130MW) Turbine and Generator Tentative time
Schedule for Individual activity
DAY OF COMPLETION
Sr.
COMPLETION ACTIVITY OF ACTIVITY FROM THE
No.
DATE OF UNIT OUTAGE.
PRE OVERHAUL PLANNING: Pre-overhauling survey to be carried out by Contractor for all TG related
parameters capturing for analysis to rectify during capital overhauling.
*JSWEL will intimate to Vendor 15 days in prior to outage of TG for COH
07 days before actual
1 Mobilization of manpower, tools and tackles at site for necessary
start of OH works with
arrangements like gate passes, Accommodation etc.
necessary documents
Note: Documents for Gate Pass formalities 1, Aadhar Card, 2, Passport for gate pass
photos 4Nos, 3, ESI 4, PF 5) Experience certificate processing, T&P
shifting,
*Workmen interviews will be held for experience / skill verification.
Accommodation etc..
Minimum 2 Yrs industrial experience required for Power plant entry.
Identification and shifting of special tools, fixtures, jigs, etc. before 04 04 Days before actual
2
days withdrawal of unit. start of OH works
UNIT WITHDRAWL
Description
Completion of TG overhauling: 30 days from De-
1
Ø HIP Turbine Overhauling synchronization to
Ø LP Turbine Overhauling synchronization of unit.
Ø Generator rotor thread in and out with bearing inspection
Ø Exciter removal and Overhauling
Ø Turbine Valves, Hydraulic actuators overhauling, lube oil system
overhauling
Ø Mechanical assistance for removal / fixing of bearing RTD / TC
Recording of measurements, logged in Protocol & documentation
Ø Dismantling observation report, Protocol signed with JSWEL EIC
2 Ø Test report NDT (UT and DPT) report/ NFT/MPI of blades 100%
Ø Assembly observation report, assembly Protocol signed with JSWEL EIC
Ø Recommendation if any, for future action.
Within 15 days from
3 Complete site mobilization in terms of manpower, T&P etc.
Notice to
proceed.
4 Mobilization for any unforeseen incidental / accidental repair. Within 12 hrs
5 EOT operators by contractor to operate minimum two EOT crane round the Round O’ Clock.
clock.
6 Expertise M/s BHEL Engineer supervision required in case Non-OEM Round O’clock.
awarded for capital overhauling job.
Availability of sufficient T&P’s, temporary platform materials,
7 100%.
scaffoldings etc. to execute parallel activities simultaneously.
No delay due
Safe storage of dismantled parts at site in proper manner, tagging with
8 to
name and numbering.
missing/unm
atched
component.
Safety compliances.
Ø All the measuring instruments should have calibration certificate. Ø All
9 lifting devices should have load test certificate. 100% as per standard.
Ø All Electrical appliances should be provided with ELCB(30mA) and
other safeguard provisions.
Ø All hydraulic jack operation must be approved by JSWEL.
Ø Induction heating machine must be checked in prior to overhaul
and enough spares to be kept ready to avoid work delays.
Ø PPE’s to be used as per the standard.
Housekeeping of working area:
10 Ø Proper handling of lube oil & storage. On Daily / Shift Basis
Ø Proper disposal of Hazardous/non Hazardous waste to designated
place within overhauling schedule
HR compliance-
12 A. ESIC/Pf registration of company with MS 100% Required for gate
B.ESIC/Pf challan to be submitted for the workers working at JSWEL site. pass processing.
2. GENERAL TERMS
The scope of work envisages, Inspection of complete HIP- LP and Generator Jobs for 130 MW Thermal
power plant as per the schedule of quantities. The Turbine & generator is supplied by M/s BHEL &
operating efficiently. Detailed scope of work is described hereunder. Stipulated overhauling outage
duration is 30 days bar to bar’.
1. Barring gear will be stopped on 5th day of unit shutdown.
2. Machine barring gear will be stopped on 5th day (HP-IP shaft mean temperature < 100 Deg
C) & effective working days will be 25 days (The detailed scope is shown below).
3. During course of outage, all dismantling, assembly activities, and dimensional inspection
need call JSW for inspection.
4. Job involves high care and precision; no parts shall be damaged during dismantling or
assembly due to poor workman ship, negligence and improper tools application etc.
5. All safety related works to be carried as per the JSW EHS policy
6. Housekeeping of area daily separation of Food waste, oil waste to designated places.
7. Maintaining safety and integration at residing company premises of JSWEL/JSWSL
8. Painting of Generator, LP Turbine, Exciter, bearing housing, Control and stop valves and oil
system and Valves including all consumables, thinner, paint etc.
9. All lube oil lines and bearing lube oil openings must be covered immediately after
dismantling by proper means. No foreign particles should fall inside, if any must be
immediately brought to notice of JSW area Engineer In-charge.
10. All dummies/sheets must be recorded and removed from oil lines /openings before final
assembly.
11. Shifting of all spares, handling tools, machining assistance at work shop, installation,
removal and returning/storing safely as per JSW engineer in charge.
12. Submission of Shut down report in 3 sets and check list/protocol within 7 days after shut
down.
13. Empty oil drums shifting from stores and returning waste oil /empty drums.
14. Hydraulic testing hand pumps for all the coolers must be maintained with necessary hoses
and connectors.
15. Oil spillage/wastage/mixing with water/mixing with soil is not permitted, proper trays,
bucket/cans to be arranged by contractor.
16. All the alignment fixtures related to rotating equipment has to be fabricated prior to
Overhauling by contractor itself.
17. Air/Water/oil hoses for cleaning/flushing is under the scope contractor.
18. Oil soaked cotton waste and filters to be disposed separately.
19. EOT crane operators to be engaged round the clock operation for 2 cranes by Contractor.
20. Manpower assistance to operation for isolation and normalization of the system and during
valves stroking and calibration.
3. TECHNICAL TERMS AND CONDITIONS:

1. CONTRACTOR shall mobilize sufficient skilled manpower including Site in-charge, supervisor,
Foreman, LP/IBR Welder, riggers, safety officer, etc.
2. CONTRACTOR to provide list of manpower with names of main persons for Turbine, Valves,
Generator and Aux systems and experience.
3. CONTRACTOR shall submit detail list of tools & tackles, measuring & testing instruments,
manpower details etc. minimum 15 days in advance for JSW approval.
4. JSW has all the rights to accept and reject, deduct on account of performance and quality of the
CONTRACTOR if found not fit for the job.
5. Any damages to equipment and its parts due to inexperience, negligence or due to skill are not
acceptable and may lead to penalties as decided by client.
a. JSWEL’s safety and Area Engineer / In charge / HOD has all rights to stop / evaluate and question
the Safety of all personnel who are working inside client premises.
6. CONTRACTOR has to submit medical check-up of employee
7. CONTRACTOR has to submit Load test certificates for lifting tools & tackles, calibration record of
testing & measuring equipment.
8. Shifting of spares, special tools from JSW store to workplace is in scope of contractor. Balance
spares and special tools after work completion to be handed over to JSW stores.
9. All final assembly clearance on due approval of JSW and ensuring joint protocols. If violated,
equipment to be dismantled as per JSW engineer in charge instructions.
Detailed schedule (L2) in MS-Project for above mentioned work to be submitted by contractor before
starting work.
1. Contractor has to submit all test report with all pre & post inspection reading, protocols duly
signed by JSW.
2. Contractor has to submit detailed overhauling report (soft copy and three hard copy) within 15
days from completion of overhaul.
3. Residual magnetism at journal areas has to be demagnetized after MPI and same to be ensured
by proper meter/instrument.
4. Aluminum grit blasting until required finish and cleanliness of deposits.
5. Contractor shall mobilize manpower and tools and tackles in advance. All manpower shall
undergo statutory safety training to get entry pass before starting work. Medical fitness certificate
of sand blasting person to be submitted in advance.
6. All safety PPEs like safety helmet, safety shoes, ear plugs, safety goggles, safety belt, hand gloves,
apron, face shield etc. are in contractor scope.
7. Contractor shall depute their safety team for ensuring safe work. Contractor shall follow all safety
precautions as per JSW standard.
8. CONTRACTOR should work in the defined workplace only. The work area to be cordoned off and
entry to the area shall be restricted to authorized persons only.
9. All cleaning of Turbine inside and outside surfaces to be done with banyan cloth only. Cotton jute
is totally prohibited in Turbine overhaul work.
10. CONTRACTOR has to carry out all work in a safe and proper manner following industry standard
good engineering practices. Any damages caused to machinery due to negligence / poor
workmanship in performing contracted jobs will have to be rectified / put right at the cost and
risk of CONTRACTOR.
4. DELIVERABLES:
1. All DPRs and equalizing valves, DPRs of Seal oil system trouble free. Unit vibrations and
temperature with as per OEM standards at load of 130 MW.
2. H2 Leakage as per OEM recommendations.
3. No oil leaks in turbine, generator, HP bypass, Control, JOP, Seal oil and Lube oil system.
4. Zero oil leaks, steam and water leaks.
5. All hangers and Supports at Turbine and Generator Intact from control & stop valve and
cross over piping.
6. Turbine heat rate to be improved.
7. Vibrations of the turbine should be <100 microns.
8. Bearing temperatures of all the bearings should maintain below 90 deg c.
9. Zero Steam leak near front and rear gland area of HP-IP turbine.
5. JSW ENERGY SCOPE:
1. Drawings, Manuals, Special tools & tackles will be arranged for overhauling of the
equipment Which are supplied by OEM [Rotor/casing: HIP/LP lifting sling, Rotor lifting and
bearing removal tools only].
2. Equipment’s spare parts will be provided for replacement wherever required based on
condition of equipment.
3. Single point power source will be provided by JSW however load requirement to be given by
contractor.
4. Single point water source will be provided by JSW and additional multiple points to be
arranged by contractor as per requirement.
5. Area will be allotted for store and office for the contractor engineers.
6. EOT cranes will be used during course of outage.
7. Escort crane / Till Crane will be arranged by JSW for shifting of spares / tools based on
availability.
8. JSW has all the rights to accept and reject, penalize contractor if found not fit for the job.
9. Any damages to equipment and its parts due to inexperience, negligence or due to skill are
not acceptable and may lead to severe penalties as decided by JSW.
10. JSW safety and Area Engineer/In charge/HOD has all rights to stop/evaluate and question
the Safety of all personnel who are working inside JSW premises.
11. Consumable provided to contractor by JSW will be on chargeable basis.
6.CONTRACTOR SCOPE:
1. All types of NDT agencies with testing kits & consumables are to be mobilized by
overhauling contractor.
2. Balancing of the complete train after overhauling to be done by the contractor all the values
must be within OEM recommendations for warranty period.
3. Aluminum grit blasting on the HIP Rotor and top half, bottom half of inner casing till
required finish and cleanliness of deposits. Running unit’s maintenance bay openings must
be covered with tarpaulins.
4. Residual magnetism at journal areas has to be checked after MPI and de-magnetized by the
contractor after job completion. Same has to be witnessed by customer. To be ensured by
proper meter/instrument.
5. Round the clock shift basis team should be engaged by overhauling contractor.
6. Refining work shall be done by the contractor.
7. Condition monitoring of turbine prior to stoppage of machine shall be done by the
contractor to study the performance of the machine (including vibration level and process
parameter) before and after the COH and to find out necessary input before opening the
turbine to focus on specific area for improvement/addressing the problem.
8. Commissioning engineer shall be available for recording the full load parameter to access
the performance and efficiency of Turbo generator before and after COH. He shall be
available from prior shutdown to till machine full load operation.
9. EOT operators’ deputation by COH contractor at round the clock, (JSWEL has 2 EOTs in
operable condition the same will be allotted for TG COH)
10. Certified IBR welders, Stress relieving (SR) is in scope of contractor. JSW will approve the
welder after test weld.
11. Support requirements like scaffolding, welding cutting for agencies engaged in Electrical /
Instrumentation / Mechanical tests within the TG area are in scope of CONTRACTOR.
12. Support requirements like fabrication of fixtures, scaffoldings, working platforms, ladders,
welding, cutting for works.
13. Skilled and certified EOT crane operators are in scope of contractor (min. two operators
round the clock basis).
14. Temporary platform, scaffolding, 2 numbers of sand blasting shed with duct & exhaust fan
provision where ever required shall be prepared by contractor as per safety standard and
ensuring the safety clearance from JSW safety dept.
15. Loading, Unloading and shifting of all the spares, consumables tools and tackles from JSW
specified location to site and vice versa.
16. Removal and segregation of scrap generated during work from workplace and shifting to
JSW scrapyard is in scope of contractor. Workplace shall be made neat and clean after
completion of work.
17. All open pipes and internal to be checked before box up and no parts to be left inside and
may be ensured by Borescope
V. Scope of services
1. Quality of manpower:
The contractor shall have detailed plan of expertise engineers and skilled manpower deployment
(Site mobilization chart and manpower deployment chart area wise). The same shall be submit the for the
approval of JSWEL. The plan shall consist of below expertise and team of skilled manpower having hands
on experience in M/s BHEL make turbine and generator of capacity more than 100 MW.
Sl
Qty
No Resource Description
OEM Excution Team
1 OEM Site Engineer 1
2 OEM Turbine Engineer 3
3 OEM Generator Engineer 1
4 OEM Turbine Valve Engineer 1
5 OEM Turbine Oil System 1
6 OEM Safety Engineer 2
7 OEM Quality Engineer 1
8 OEM Condition monitoring expert 1
11
Sub Vendor Team
1 Site Incharge 1
2 Supervisor TG 4
3 Turbine Foremen (Preferably 15 to 20 COH) 2
4 Generator Foremen (Preferably 15 to 20 COH) 2
5 Turbine Governing valves Foremen 2
6 Turbine MWF 6
7 Generator MWF 4
8 Oil System MWF 3
9 General Fitter 10
10 Sarangai 4
11 HP Welder 1
12 LP Welder 2
13 EOT Operator 4
14 Rigger 6
15 Cutter/Grinder 4
16 Helper 50
17 Safety Manager 3
18 Electrician 2
110
Need Base Team
1 Sand Blasting Technician 6
2 NDT/NFT Technician 4
3 Generator Testing Expert 4
4 Bolt Heating Technician 4
5 SR/RT Technician 2
20
Total 141
Note : The above manpower are indicative based on the site requirement manpower to be mobilised
2. Tools and other Equipment’s:
1. All necessary T&P including wire rope slings, nylon sling belts, mechanical, hydraulic lifting,
pulling tools, jacks, hydro test pumps, IMTE, wooden sleepers etc for proper assembly and
alignments to be provided by contractor.
2. Lapping/seat cutting tool must be arranged prior to shut down.
3. All lifting tools and tackles chart with test certificate.
4. Eye bolts up to M56 standard pitch, each type minimum 4nos.
5. All measuring tools up to 600mm out-side and 1000mm inside micrometer, depth
micrometer, axial gap measuring tools, bore gauges, venires, Magnetic base with dial gauge
20nos, Dial gauge range 5mm pressure and also plunger type dial gauge with calibration
certificate chart.
6. All special welding electrodes, filler wires with requisite ovens required during overhaul for
repairing, material build up, tack welding, stitch welding; replacement etc. is in scope of
contractor.
7. Digital taper gauges to be arranged by contractor for flow path measurements of different
sizes.
8. Calibrated Master level to be arranged by contractor for recording all levels & journal
slopes.
9. Gas Cutting torch with flash back arrestor minimum 4 sets.
10. Brazing tool with deposit materials for making jack bolts.
11. All types of burr cutters, carbide tip drill bits and tap sets for removal of broken studs/bolts.
12. Chain pulley blocks from 1T to 20 tons minimum 2nos each size.
13. Coupling rotation slings with eye bolts suitable to 130 MW turbine.
14. Alumina grit and blasting tools.
15. Scaffolding pipes, clamps for complete overhauling.
16. Air & oil and water hoses for flushing and cleaning.
17. Tarpaulins for covering open areas, making sand blasting shed etc.
18. All material handling trolley will be arranged by CONTRACTOR for shifting of spares / tools.
19. All test equipment shall be calibrated & calibration certificates should be submitted to
JSWEL before starting the testing.
20. Dry air blowers / dehumidifiers and similar arrangements for Generator winding to remove
the moisture is in scope of CONTRACTOR.
21. Wooden sleepers & Scaffolding pipes is in contractor’s scope. Wooden scaffolding is strictly
prohibited.
22. Bolt heating induction machine along with teams (2 no) to be available well in advance at
site.
23. Sling to thread out Generator Rotor is to be arranged by the contractor.
24. Radiography, Stress relieving and IBR welder will be in the contractor scope.
25. All tools, tackles, lifting tools, slings for the above activities to be arranged by contractor
(Load Test certificate to be submitted in advance before starting of work).
26. All jacks including Gang jack with 100 Ton capacity (4 nos) is in scope of CONTRACTOR for
Generator alignment and button jacks.
27. Dry air blowers / de-humidifiers for Generator winding to remove the moisture.
28. All mechanical and electrical testing equipment’s relating to NDT are to be arranged by
contractor as a part of overhauling.
29. Fabrication of temporary dust bins for overhauling period.
30. All tools and testing kits for Turbine, Generator NDT, NDT and Testing works. Also the
required consumables.
31. All scaffoldings, structure, temporary platforms which are required during course of
overhauling are to be provided by contractor with safety certification.
32. Magnetic drilling machine with carbide tip drill bits of different sizes to suit Angle ring of
HPCV & IPCV.
33. Drilling [Minimum 200 to 250mm length carbide tip drill bits up to 12mm size is required.]
34. Measuring tools up to Vernier 600mm and inside micrometer 1000mm with calibration
certificate.
35. Hydraulic jacks from 5ton to 200ton 4nos each type to complete the job. [OEM not provided
Hyd Jacks]
36. Pre heat and Stress relieving coils with temperature monitors for piping, blades, fasteners,
casing, and valves welding.
37. Hand reamers for Generator and exciter bases taper /straight to complete the work.
38. HIP, LP, TV casing stud’s induction heating machine with 2 heaters all round the clock for
complete duration of annual shut down. All consumables and hoses [Up to 50mtr length]
must be included.
39. Hydraulic and Pneumatic tools/torque wrenches to be arranged by COH contractor [not
supplied by OEM] with drives, sockets to speed up the works and to avoid over tightening.
For fasteners Sizes and range of torque refer OEM drawings.
40. Loading, Unloading and shifting of all the spares, consumables tools and tackles from JSW
specified location to site and vice versa.
41. Stress reliving & RT Equipment’s.
42. All 24 V DC transformers and required lighting equipment’s.
43. All required tools & tackles like welding machine, grinding machines etc.,
3. Safety, Health and Environment:

1. Contractor has to ensure his workmen under gone safety induction and issuing of PPE. The
induction will be conducted for 8 hours.
2. Contractor has to maintain PPE issue register.
3. Contractor has to submit workmen compensation policy and labor license copy to HR-JSW.
4. All access platforms for safety of all personnel are to be arranged by contractor.
5. Access platform, scaffoldings for I and c/Electrical requirements & man power support within
contractor allotted area.
6. No smoking/chewing of tobacco/alcohol is allowed near work area /in-side the plant same to be
complied strictly by contractor. If any such incidents will be reported immediately to safety for
further action.
7. All tools & equipment’s are to be offered & get certified from JSWEL before commencement of
work.
8. JSWEL has CWMS (Contractor work men management system), hence all formalities shall be done
accordance to this. Normally gate procedure will take two days’ time including health checkup &
safety induction.
4. Material shifting and storage:

1 Excess tools and spares, consumables must be returned to stores with proper Tagging and
preservation.
2 Any special arrangements, extension or accessory to the existing arrangement, additional
arrangements for safety of people are in the scope of contractor and are to be handed over to
store with proper tagging & preservation.
5. Consumables:
Following tentative list of consumables are to be arranged by contractor for executing the overhauling
activities. (Any other consumables as & when required shall be made available by contractor only)
Sl No Description
1 Hylomar,
2 LOCKTITE 242 THREAD LOCKER
3 LOCKTITE CHIESEL GASKET REMOVER
4 LOCKTITE 406, 587 blue RTV gasket maker(each 5 tubes)
5 WD-40 - 400ml
6 SILICON CARBIDE-MEDIUM
7 DIAMOND PASTE-COARSE
8 DIAMOND PASTE-MEDIUM
9 DIAMOND PASTE-FINE
10 PLASTIC STEEL 5 MIN PUTTY
11 SILASTIC SELANT 732 RTV-100g.
13 TEFLON TAPE 1"
14 MOLYKOTE 1000 ANTISIZE THREAD COMPOUND
15 Birkosit/stag B steam sealing compound
16 EMERY PAPER GRADE100
17 EMERY PAPER GRADE 200
20 Teflon tape 1/2 – Champion
21 EMERY PAPER ROLL GRADE 250
23 Smooth Emery Roll Cloth
24 OIL PAPER 0.5 MM
25 Cutting wheel AG-7 175 mm
28 ALUMINA GRIT
29 Cleaning sponge 150mmX80mmX70mm
30 1 NYLON BRAIDED PVC FLEXIBLE HOSE
31 HACKSAW BLADE s (1/2”)
32 6 mm dia Nylon Brush for cooler Tubes cleaning
34 10,12 and 14 mm dia Nylon Brush for cooler Tubes cleaning
35 GRINDING WHEEL 100 X 4 X 16 A36 HI CUT
36 GRINDING WHEEL 125 X5 X22.23 A36 HI CUT
37 GRINDING WHEEL 180 X 7 X 22.23 HI CUT
38 MS Buffing wheel dia 4 X 1/2 width
39 MS Buffing wheel dia 6 OD X 1 thick X 5/8 Bore
40 FF2 Cutting wheel Size: 62X2.5X10
41 ELECTRODE E6013, 3.15MM
45 Brown fused alumina, Grit – F90 (Minimum of 10 tons required)
46 FILLER WIRE 90 S B3
47 ELECTRODES E 9018
48 TAP SETS
49 DA and Oxygen gas for cutting till completion of work
50 Varnish for generator
51 Paint required for LP,Generator, exciter, Bearing housing and Valves
VI. Quality assurance & Deliverables

1. Contractor must provide relevant detailed QAP, tentative work matrix and NDT matrix well in
advance.
2. Contractor Must support or get support from OEM or OEM decisions if required to move the work
smoothly and scientifically.
3. No work shall be performed without notice of JSW.
4. Engineers, workmen and specialists must be having through knowledge & work experience on
BHEL supplied Turbo-generator.
5. All the technical decision must be taken by contractor/expert in consultation with JSW/OEM. Any
quality related to workman, lack of expertise, tools and tackles are not acceptable and to restored
to original condition.
6. Complete overhauling must be closely supervised 24x7and
Engineer/foreman/millwright fitters must be thorough in their work. Any deviation will be noticed
immediately and work may be stopped if required by JSW.
7. Contractor should have the ability to complete the job within schedule or as per the time decided
by JSW without compromising the quality.
8. Once the shutdown is taken all the jobs must be carried by contractor.
9. Equipment defect liability will be for the period of twelve months from the day of synchronization
with full load operation. Contractor has to rectify the defects without any cost implication.
10. All operational and condition monitoring parameters performance will be the main criteria for the
contractor liability.
VII. Measurement sheets & Reporting Procedure.

1. Daily progress report soft copy and concerns must be mailed to JSW. All requirements must be
addressed well in advance for smooth flow of execution.
2. Detail report of the observations, work execution, spares consumed, spares recommended are to
be submitted by contractor along with the photographs & supporting documents in 3 sets.
3. Previous data of equipment’s and system, defects and root cause analysis prior to shut down well
in advance.
4. Site log book submission before start of unit which consisting of initial and final
clearances/measurements/dimensions of parts taken during complete overhaul for future
references of JSW and for history.
5. Man power and any other welding/cutting at contractor allotted area for I&C and Elect Dept works
are in the scope of Contractor. This is required to avoid external agency to create any unknown
errors in critical areas.
6. All coordination points to JSW I and c and Electrical must be informed or planned document must
be provided well in advance.
7. Studying and referring OEM doc which is provided by JSW in prior to shut down and thorough
about the system and equipment.
8. All reference OEM manuals and Drawings which are provided for shut down activity must be duly
returned to TMM.
9. Daily report and concerns must be recorded on daily basis and soft copy must be mailed to JSW
TS, TMM, EM, I&c, OM Head,VP
10. Any holds or plan must address immediately to section in charge /HOD for smooth execution and
completion.
11. All NDT plan and daily report must be shared to JSW on daily basis for taking any decision.
12. Openings of HIP, LP, MS TV, GV, RSV, LP openings must be covered immediately after opening to
avoid any foreign particle entry.
13. It is totally contractor’s responsibility to ensure his work man and engineers including external
sources not to enter unknown zones and put intentionally or un intentionally foreign parts inside
any openings.
14. EOT crane operators, electricians are to be deputed by contractor to take care of round the clock
activity.
15. Transportation of all assembly spares from ware house to assembly area by the contractor. 16
Electricians are to be deputed for round the clock
Defect liability
1. Equipment defect liability will be for the period of twelve months from the day of synchronization
with full load operation. Contractor has to rectify the defects without any cost implication.
contractor liability.
3. The machine condition monitoring parameters shall be as per the OEM limits are less than the present
values.
4. All the equipment’s should not having oil leaks, water leaks and steam leaks.
B.SBU-1 130 MW TURBINE COH INSULATION WORKS
A) Detailed Scope of Work:
This scope of work is laid out for approximately 160 sqm. of thermal insulation works related
to carry out 2 X 130 MW Turbine COH activity. We will issue two different orders for supply and
service. The work force and supervision shall have hands on experience on steam turbine, Model:
K30-16 + N30-2 x 3.2, Make: BHEL, (or) shall have carried out similar units more than 100 MW units.
The scope includes supply, removal & re erection of thermal insulation works, making pads of
required size, for the below major component,
1. Turbine casing except exhaust hood

2. Combined HP/IP turbine, stop/control valve left & right
3. HP Bypass & LP Bypass valves
4. Cross over piping, Main steam & HRH Strainer
The complete removal of existing pad insulation and proper cleaning to enable dismantling
of turbine and its components. The vendor shall erect & ensure safe standard scaffolding for
proper approach to the satisfaction our safety department to get clearance. The vendor shall
cover side by equipment’s like Boiler Feed pumps & generator with t arpaulins, also avoid spread
of insulation matters in air by proper barricading work area. After completion of removal any
scaffolding or material has to be removed which shall hinder main work, and shall not create any
dispute.
The erection of new pads shall start as soon as completion of Turbine COH works. The erection
pads also to be carried out properly as like removal.
The insulation finishing works to be well aesthetic and functionally proper and to be done to the
satisfaction of SEI.
The welding / grinding and any other works related to hooks or scaffolding is in the scope of
contractor. The consumables & tools used like electrode, grinding wheels, welding machines, other
required tools and PPE are to be offered for inspection to JSWEL staff for certification.
The vendor shall mobilize the manpower, T&P well in advance to carry out the preparatory
works related to the work. The vendor shall also consider two man days for gate pass formalities,
medical checkup, safety induction etc.,
Thorough inspection of shall be carried out along with JSWEL and make punch points for
trouble free operation and better performance. The crew shall be available till reaching the full
load operation. Minor removal & re-erection of wool to be done till 15 day of full load operation
if any problem arises in the equipment. The detailed technical report to be submitted for clearing
of Bill. The report shall consist of QA documents, Manpower utilization and time line details, area
of application and dimensional reports.
Other Details:
1. HP-IP Turbine (diameter) = 7 mts and length = 5 mtrs

2. Cross over pipe dia = 600 mm, Length = 20 mtrs
3. Other pipes like main steam, CRH, HRH lines, MS & HRH Strainers are also to be considered
for insulation
Equipment to be QTY Surface Area POS Temp C Outer Dia of Type

insulated In (Sq. mtr) No Pipe (mm) Insulation
Nos Per Total Max At No (See
Piece load Note.2)
Run
Outer casing with 1 40 40 1 300 325 - A
end seal
HP Valve casing 2 6 12 2 545 - - A
IP Valve Casing 2 8 16 3 546 - - A
Cross around 2 - - 4 302 325 Dia 762/717 B
piping ( L = 7.1 M
EACH )
LP Bypass valve 2 3.6 7.2 5 546 - - B
casing
Gland steam supply 2 - - - 300 - Dia 114.3 ( B
pipe(LP turbine) L= 1 M Each)
Gland steam Leak 2 - - - 300 - Dia 88.9 ( L= B
off pipe(LP turbine) 3.5 M Each)
B) Division of Responsibilities (DOR)
JSWEL Scope:
1. Work Permit.
2. Power supply point in case of any equipment used.
3. Air supply point if required.
Contractor Scope:
1. Complete scaffolding including pipes, platform and clamps for insulation removal and
application. Welding of fixtures and fins if any.
2. Removal Insulation of HIP outer top and bottom casing.
3. Removal insulation of HPCV, IPCV, HPSV & IPSV, LP Bypass stop & control valves,
Interconnecting piping etc.,
4. Welding /grinding/cutting/drilling machine with tools and consumables.
5. The power supply extension boards, 24 V DC lighting with transformers/switch board, lamps
are in scope of vendor.
6. Required air hose and other consumables are in the scope of vendor.
7. Preparation of blankets and shifting to the application area including T&P.
8. Welding electrodes, hooks fixing for insulation holding rod welding or fixing all type of
insulation holding/binding materials supplied by reputed vendor
9. PPEs for all workers and supervisors.
10. Before shut down material quality and bill of quantity verification to avoid any delay due to
shortage of material.
11. Accommodation, food and travelling is in the scope of vendor.
12. Application and removal of insulation on the basis of 24hrs as per JSW requirement.
13. Material shifting along with required manpower from stores to site and wastage removal on
daily basis to designated place shown by JSW.
14. Tarpaulins for covering to avoid dusting during removal and wastage removal.
15. Safety of all personnel.
16. Warranty and guaranty certificate for 1 year after application against heat radiation/delta T
due to improper application or poor quality of work.
17. Insulation removal and application during any emergency/steam leaks/oil leaks till unit
stabilization from synchronization to 15days.
18. Application of Insulation which is available at JSW ware house having equivalent
specification to avoid wastages.

1 Mobilization of manpower, tools and tackles at site for necessary arrangements
like gate passes, Accommodation etc.
necessary documents
Note: Documents for Gate Pass formalities 1, Aadhar Card, 2, Passport photos for gate pass
4Nos, 3, ESI 4, PF 5) Experience certificate.
processing.
C) Performance measure parameter/Deliverables:
1. Success full trail run & trouble free operation of equipment up to full load.
2. QA & BOQ documents
3. One-year warranty for material & workmen ship.
4. The surface temperature shall be within 50 to 70 Deg C.
5. The difference in metal temperature between upper & lower halves of both HP&IP casing
shall not be more than 15 Deg C during normal and stable operating conditions at rated
load of turbine.
6. Time line schedule – Removal shall be done in one day & application shall be done in 48
Hours.
7. Mobilization shall Manpower to be done three days before the commencement of work
for gate pass and safety induction.
D) Tentative Schedule of annual overhaul:
1. Will be intimated one week before commencement of work.
Tentative Manpower required for the Job:
Sl
Qty
No Resource Description
OEM Excution Team
1 Site Supervisor 1
2 Insulation Fitter 2
3 Insulation Helper 16
4 Welder 2
5 Grinder 1
6 Rigger 1
7 23
C.RLA WORKS ON TURBINE & GENERATOR (130 MW)
Validity of the contract

1. The contract validity shall be 31st Dec 2024.
2. The RLA work shall be completed as per the scheduled overhaul plan within 25 days. (Barring
stop to TG on barring). For the mobilization of necessary resources, the contractor shall be given
intimation 15 days prior to the scheduled outage.
3. Contractor to submit the bar chart indicating major activities to be carried out to complete the
work as specified above along with offer.
RLA WORKS ON TURBINE & GENERATOR:
List of tests, inspection. Checks to be carried out on 130 MW Turbine & Generator.
A. MAIN TURBINE & ITS COMPONENTS

The tests shall be covered as per the below given table:
RLA SCOPE OF WORK

LIST OF TESTS / INSPECTION / CHECKS TO BE CARRIED OUT ON 130 MW TURBINE
I.TURBINE ROTOR: (HP, IP, LP)
Component / Location VE DIM DPT MPI UT RPL NFT HB Remarks
A GLAND AREAS Y Y Y
B HP BLADES Y Y Y
C IP BLADES Y Y Y
D LP BLADES Y Y Y Y Y
E JOURNALS Y Y Y Y
F THRUST COLLARS Y Y Y Y
2 TURBINE INNER CASING: HP, IP LP
A INNER SURFACE Y Y Y Y Y
B STEAM CHEST Y Y Y Y Y
C NOZZLE CHAMBER Y Y Y Y Y
D PARTING PLANE Y Y Y Y
E STUDS AND COUPLING BOLTS Y Y Y Y
3. TURBINE OUTER CASING (HP, IP, LP)
A GUIDE BLADE CARRIERS y Y Y Y Y
B CASING WELDS & y Y Y Y Y
C PP STUDS Y
4 ESV, CONTROL VALVES & HPQCs
A BODY Y Y Y Y Y
B STEM& BUSHING Y Y Y Y
C VALVE CONE & SEAT Y Y Y Y
D STEAM CHEST &flanges Y Y Y Y Y
E VALVE SEAT &SEAT WELD Y Y Y Y
F STRAINER BODY & ELEMENTS Y Y Y Y
5 TURBINE BEARING
A BEARINGS Y Y Y Y
B THRUST PADS Y Y Y Y
C BEARING PEDESTALS Y Y Y Y
6 .CRITICAL PIPING MAIN STEAM INLET,GLAND STEAM PIPES AND EXTRACTION PIPES.
A WELD Y Y Y Y Y
B PIPES Y Y Y Y
7. Prediction of the Residual life of turbine components and assembly.
1) REMNANT LIFE ASSESSMENT —of rotor & casings shall be carried out by Finite Element Method (FEM).
2) Reporting of major deteriorations, if any, of the above components detected during Investigations at site.
Recommendations regarding repair / replacement / modifications / Remedial measures.
B. GENERATOR STATOR SCOPE OF WORK FOR ELECTRICAL TESTING OF 130MW 10.5KV GENERATOR
a) Disconnection Normalization of flexible for testing and necessary scaffolding arrangement for
flexible removal shall be in Contractor Scope
b) Tools & Tackles, testing kits and its accessories required for carrying out the below test are in
Vendor scope. All the testing activity has to be carried in presence of JSWEL Engineer.
1) ELECTRICAL TEST ON GENERATOR STATOR
1. Measurement of Insulation resistance and PI test.

2. Wedge Tightness, Slot Wedge deflection test (Check should cover not less than 35% of the
total slot wedges in helical configuration)
3. DC Winding Resistance measurement test.
4. Measurement of Tan delta and capacitance Test.
5. Electromagnetic Core Imperfection Detection test (ELCID Test)
6. Partial discharge test & Corona test.
7. DC HV step voltage & leakage current test
8. Measurement of Resistance of RTD’s and RTD healthiness checking.
9. Natural frequency test.
10. Ultrasonic test for core clamping.
11. Boroscopic Inspection [Based on condition]
A. GENERATOR ROTOR
2. DC Winding Resistance measurement test.
3. 3AC Impedance test.
4. Voltage Balance Test.
5. DPT, UT and MPI Microstructure Test.
6. Boroscopic inspection.
7. Recurrent Surge Oscillography (RSO) test.
B. GENERATOR EXCITOR.
2. 2 DC Winding Resistance measurement test.
C. VISUAL TESTS
1. To identify gross dimensional changes, corrosion pitting, breakage, cracks, ventilating holes’
blockage, glass sleeve tying, carbon layer accumulation, insulating packer’s tightness, HGL
bracers tightness, inter bar HGL spacers tightness, eye spacers tightness, stator holding
down bolts tightness.
Note:
DPT=Dye Penetrant Test,

MPl=Magnetic Particle Inspection
UT=Ultrasonlc Test
FEM: Remnant Life Assessment by Finite Element Method
NFT= Natural Frequency Test.
RPL= Metallography Replica Test.
LIST OF TESTS / INSPECTION / CHECKS TO BE CARRIED OUT ON 130 MW TURBINE:

I. VISUAL EXAMINATION.
II. DYE PENETRANT TEST.
III. WET FLUORESCENT MAGNETIC PARTICLE EXAMINATION.
IV. ULTRA-SONIC EXAMINATION.
V. MICROSTRUCTURE AND HARDNESS ON
VI. ELECTRICAL TESTS ON GENERATOR ROTOR AND STATOR
General terms & conditions of the contract
3. QUALIFYING REQUIREMENTS:
1.The bidder should have the RLA experience of capital overhauling M/s BHEL supplied 130 MW of
TG set.
2.The experience claimed by the bidder shall be considered, if the said experience is in the name of
the bidder directly and not by subletting the contract. Satisfactory work completion certificate is
furnished by the firm. During the work period, the successful bidder has to depute well conversant
experienced manpower for the RLA of the 130 MW Turbine-generator.
3.The agency shall have proven track record in maintaining similar type of equipment’s of coal
based thermal power plants of capacity more than 130 MW TG set of BHEL units & similarly he
has to submit job completion certificate from user of last 03 numbers of unit major RLA of Turbine
of said specification.
4.Bidder has to submit the proof about the qualification and experience of labor and engineer
deputed for maintenance work along with tender documents such as copy of appointment letters
or P.F. submission challans, for last 2 years along with qualification of personnel’s who will be
deputed for Overhaul work.
5.Vendor to provide List of manpower with names of Main Persons for Turbine, Valves, Generator
RLA experience.
NOTE: Bidder to complete the attached checklist.
Check List for Vendor
s.no Requirement from Bidder Remarks
a) W.O. copies for the last three years. a) Yes / No

b) Experience of capital Overhaul of Turbine-generator of 130 b) Yes / No.
MW of BHEL supplied TG set c) Attached / Not Attached.
1
c) Work completion certificate attached. d) Attached / Not Attached.
d) Proof of PF challans for previous years.
(Note : Above documents to be submitted along with offer)
2 Scope of Work Accepted / Not Accepted
3 Key performance Indicator Accepted / Not Accepted
4 Special Terms and conditions Accepted / Not Accepted
5 Minimum Manpower Deployment Detailed sheet to be attached
6 Works Penalty Clause Accepted / Not Accepted
7 Consumables Accepted / Not Accepted
8 Safety, Health and Environment Accepted / Not Accepted
The break up period is as under for Unit-2 (130MW) Turbine and Generator Tentative time
Schedule for Individual activity
DAY OF COMPLETION OF
Sr.
COMPLETION ACTIVITY ACTIVITY FROM THE DATE OF
No.
UNIT OUTAGE.
PRE OVERHAUL PLANNING: Pre-overhauling survey to be carried out by Vendor for all TG related parameters
capturing for analysis to rectify during capital overhauling.
05 days before actual start of

1 Mobilization of manpower, tools and tackles at site for necessary
OH works with necessary
arrangements like gate passes, Accommodation etc.
documents for gate pass
Note: Documents for Gate Pass formalities 1, Aadhar Card, 2, Passport processing.
photos 4Nos, 3, ESI 4, PF 5)Experience certificate
Identification and shifting of special tools, fixtures, jigs, etc. before 04 04 Days before actual start of
2
days withdrawal of unit. OH works
UNIT WITHDRAWL
Description
Recording of measurements, logged in Protocol & documentation 30 days from De-synchronization
Ø Dismantling observation report, Protocol signed with JSWEL EIC to synchronization of unit.
Ø Test report NDT (UT and DPT) report/ NFT/MPI of blades
1
Ø Assembly observation report, assembly Protocol signed with JSWEL EIC
100%
Ø Recommendation if any, for future action.
Within 15 days from Notice to
2 Complete site mobilization in terms of manpower, T&P etc.
proceed.
3 Mobilization for any unforeseen incidental / accidental repair. Within 12 hrs
4 Expertise M/s BHEL Engineer supervision required in case Non-OEM Round O’clock.
awarded for capital overhauling job.
Availability of sufficient T&P’s, temporary platform materials,
5 100%.
scaffoldings etc. to execute parallel activities simultaneously.
6 No delay due to
Safe storage of dismantled parts at site in proper manner, tagging with
missing/unmatched
name and numbering.
component.
Safety compliances.
Ø All the measuring instruments should have calibration certificate. Ø All
lifting devices should have load test certificate.
7 100% as per standard.
Ø All Electrical appliances should be provided with ELCB(30mA) and
other safeguard provisions.
Ø All hydraulic jack operation must be approved by JSWEL.
Ø Induction heating machine must be checked in prior to overhaul
and enough spares to be kept ready to avoid work delays.
Ø PPE’s to be used as per the standard.
Housekeeping of working area:
Ø Proper handling of lube oil & storage.
8 On Daily / Shift Basis
Ø Proper disposal of Hazardous/non Hazardous waste to designated
place within RLA schedule
Development of spares drawing through reverse engineering as per site
9 As per site Requirement.
requirement shall be provided to JSWEL on free of cost.
HR compliance-
A. ESIC/Pf registration of company with MS
10 100% Required for gate pass
B.ESIC/Pf challan to be submitted for the workers working at JSWEL
processing.
site
4. GENERAL TERMS
The scope of work envisages, RLA of complete HIP- LP and Generator Jobs for 130 MW Thermal power
plant as per the schedule of quantities. The Turbine & generator is supplied by M/s BHEL & operating
efficiently. Detailed scope of work is described hereunder. Stipulated overhauling outage duration is 30
days’.
1. Barring gear will be stopped on 5th day of unit shutdown.
2. Machine barring gear will be stopped on 5th day (HP-IP shaft mean temperature < 100 Deg C) &
effective working days will be 25 days (The detailed scope is shown below).
3. During course of outage, all dismantling, assembly activities, and dimensional inspection need call
JSW for inspection.
4. Job involves high care and precision; no parts shall be damaged during dismantling or assembly due
to poor workman ship, negligence and improper tools application etc.
5. Spares and consumables should not be misused on account of negligence.
6. All the work force working over equipment and nearby must be free from loose parts inside shirt
pockets to avoid any objects falling inside the opened equipment that could lead to complete damage
of equipment; any such thing must be reported immediately to JSW area Engineer in charge.
7. All small tools, measuring instruments shall be properly Gripped/ tied to avoid falling. It is vendor
responsibility to control and ensure its work force acts, healthiness of tools and safe technical working
procedure.
8. Before entering any confined space safety clearance shall be ensured and stand by person with life
line/tied rope must accompany outside the manhole till the completion of work.
9. No smoking/chewing of tobacco/alcohol is allowed near work area same to be complied strictly by
vendor. If any such incidents will be reported immediately to safety for further action.
10. Housekeeping of area daily separation of Food waste, oil waste to designated places.
11. Maintaining safety and integration at residing company premises of JSWEL/JSWSL . .
12. Shifting of all spares, handling tools, machining assistance at work shop, installation, removal and
returning/storing safely as per JSW engineer in charge.
13. Submission of Shut down report in 3 sets and check list/protocol within 7 days after shut down.
14. Oil spillage/wastage/mixing with water/mixing with soil is not permitted, proper trays, bucket/cans
to be arranged by contractor.
15. Air/Water/oil hoses for cleaning/flushing is under the scope vendor.
5. JSW ENERGY SCOPE:
1. Drawings, Manuals, Special tools & tackles will be arranged for RLA of the equipment Which are
supplied by OEM [Rotor/casing: HIP/LP lifting sling, Rotor lifting and bearing removal tools only].
2. Equipment’s spare parts will be provided for replacement wherever required based on condition of
equipment.
3. Single point power source will be provided by JSW however load requirement to be given by vendor.
4. Single point water source will be provided by JSW and additional multiple points to be arranged by
vendor as per requirement.
5. Area will be allotted for store and office for the vendor engineers.
7. Escort crane / Till Crane will be arranged by JSW for shifting of spares / tools based on availability.
8. JSW has all the rights to accept and reject, penalize vendor if found not fit for the job.
9. Any damages to equipment and its parts due to inexperience, negligence or due to skill are not
acceptable and may lead to severe penalties as decided by JSW.
10. JSW safety and Area Engineer/In charge/HOD has all rights to stop/evaluate and question the
Safety of all personnel who are working inside JSW premises.
11. Liquidate & damaged will be applicable as per the PO terms.
6. VENDOR SCOPE:
1. All types of NDT agencies with testing kits & consumables are to be mobilized by RLA vendor.
2. All necessary design / documentation to be arranged by vendor to ensure smooth working
3. Residual magnetism at journal areas has to be checked after MPI and de-magnetized by the vendor
after job completion. Same has to be witnessed by customer. To be ensured by proper
meter/instrument.
4. All mechanical and electrical testing equipment’s relating to RLA are to be arranged by vendor as a
part of overhauling.
5. DPT, UT, NFT, MPI, RLA, and Replica tests are to be carried out at respective locations including
chemicals for all kind of tests and disposal after completion. .
6. Support requirements like scaffoldings, welding cutting to Electrical/Instrumentation/Mechanical
coming under TG area are to be executed by TG RLA vendor.
7. Round the clock shift basis team should be engaged by RLA vendor.
VIII. Scope of supply
The vendor shall have detailed plan of expertise engineers and skilled manpower deployment. The
same shall be submit the for the approval of JSWEL. The plan shall consist of below expertise and team of
skilled manpower having hands on experience in M/s BHEL make turbine and generator of capacity more
than 100 MW.
Sl No Resource Description
1 Site In charge 1 NO
RLA Expert for turbine & its components (Preferably Ex BHEL, 15
2 to 20 COH) – 1 NO
RLA Expert for Generator & its components (Preferably Ex BHEL,
3 15 to 20 COH) – 1 NO
4 Team for carrying out NFT, Turbine RLA – 2 Teams
5 Team for carrying out Generator Testing’s & RLA - 2 teams
6 Safety officer – 2 no
7 EOT Operators – 2 no
8 SR & RT Team – 1 no
9 Electrician – 2 no
7. Tools and other Equipment’s:

1. All necessary T&P including pneumatic operated, wire rope slings, nylon sling belts, mechanical,
hydraulic lifting, pulling tools, jacks, hydro test pumps, IMTE, wooden sleepers etc for proper assembly
and alignments to be provided by vendor.
2. Lapping/seat cutting tool must be arranged prior to shut down.
3. All lifting tools with test certificate.
4. Eye bolts up to M56 standard pitch, each type minimum 4nos.
5. All measuring tools up to 600mm out-side and 1000mm inside micrometer, depth micrometer, axial
gap measuring tools, bore gauges, venires, Magnetic base with dial gauge 20nos, Dial gauge range
5mm pressure and also plunger type dial gauge.
6. Digital taper gauges to be arranged by vendor for flow path measurements of different sizes.
7. Calibrated Master level to be arranged by vendor for recording all levels & journal slopes.
8. Gas Cutting torch with flash back arrestor minimum 4 sets.
9. Brazing tool with deposit materials for making jack bolts.
10. All types of burr cutters, drill bits and tap sets for removal of broken studs/bolts.
11. Chain pulley blocks from 1T to 10 tons minimum 2nos each size. .
12. Scaffolding pipes, clamps for complete turbine side.
13. Air & oil and water hoses for flushing and cleaning.
14. Tarpaulins for covering open areas, making sand blasting shed etc.
15. Fabrication of temporary dust bins for overhauling period.
16. All tools and testing kits for Turbine, Generator RLA, NDT and Testing works. Also the required
consumables.
17. All scaffoldings, structure, temporary platforms which are required during course of overhauling are to
be provided by vendor with safety certification.
18. EOT operators’ deputation by RLA vendor at round the clock, (JSWEL has 2 EOTs in operable condition
the same will be allotted for TG COH)
19. Magnetic drilling machine with drill bits of different sizes to suit Angle ring of HPCV & IPCV.
20. Drilling [Minimum 200 to 250mm length drill bits up to 12mm size is required.]
21. Measuring tools up to Vernier 600mm and inside micrometer 1000mm with calibration certificate.
22. Hydraulic jacks from 5ton to 200ton 4nos each type to complete the job. [OEM not provided Hyd
Jacks]
23. Pre heat and Stress relieving coils with temperature monitors for piping, blades, fasteners, casing, and
valves welding.
24. Hand reamers for Generator and exciter bases taper /straight to complete the work.
25. HIP, LP, TV casing stud’s induction heating machine with 2 heaters all round the clock for complete
duration of annual shut down. All consumables and hoses [Up to 50mtr length] must be included.
26. Hydraulic and Pneumatic tools/torque wrenches to be arranged by COH vendor [not supplied by OEM]
with drives, sockets to speed up the works and to avoid over tightening. For fasteners Sizes and range
of torque refer OEM drawings.
27. Loading, Unloading and shifting of all the spares, consumables tools and tackles from JSW specified
location to site and vice versa.
28. Stress reliving & RT Equipment’s.
29. All 24 V DC transformers and required lighting equipment’s.
30. All required tools & tackles like welding machine, grinding machines etc.,
8. Safety, Health and Environment:

9. Vendor has to ensure his workmen under gone safety induction and issuing of PPE. The induction will
be conducted for 8 hours.
10. Vendor has to maintain PPE issue register.
11. Vendor has to submit workmen compensation policy and labor license copy to HR-JSW.
12. All access platforms for safety of all personnel are to be arranged by vendor.
13. Access platform, scaffoldings for I and c/Electrical requirements & man power support within vendor
allotted area.
14. No smoking/chewing of tobacco/alcohol is allowed near work area /in-side the plant same to be
complied strictly by vendor. If any such incidents will be reported immediately to safety for further
action.
15. All tools & equipment’s are to be offered & get certified from JSWEL before commencement of work.
16. JSWEL has CWMS (Contractor work men management system), hence all formalities shall be done
accordance to this. Normally gate procedure will take two days’ time including health checkup &
safety induction.
9. Material shifting and storage:

preservation.
arrangements for safety of people are in the scope of vendor and are to be handed over to store with
proper tagging & preservation.
10. Consumables:
Following tentative list of consumables are to be arranged by vendor for executing the RLA
activities. (Any other consumables as & when required shall be made available by vendor only)
Sl No Description
1 Kerosene
2 Methyl Alcohol ( AR/CR grade )
3 CTC commercial
4 Concentrated HCL acid
5 WD-40 - 400ml
7 Conventrated nitric acid
10 Lint free cloth
21 SS. HOSE CLAMP 1"
IX. Quality assurance & Deliverables
11. Vendor must provide relevant detailed QAP well in advance.
12. Vendor Must support or get support from OEM or OEM decisions if required to move the work
smoothly and scientifically.
13. No work shall be performed without notice of JSW.
14. Engineers, workmen and specialists must be having through knowledge & work experience on BHEL
supplied Turbo-generator.
15. All the technical decision must be taken by vendor/expert in consultation with JSW/OEM. Any quality
related to workman, lack of expertise, tools and tackles are not acceptable and may lead to penalty as
decided by JSW.
16. Complete RLA must be closely supervised 24x7and
Engineer/foreman/millwright fitters must be thorough in their work. Any deviation will be noticed
immediately and work may be stopped if required by JSW.
17. Vendor should have the ability to complete the job within schedule or as per the time decided by JSW
without compromising the quality.
18. Once the shutdown is taken all the jobs must be carried by vendor.
19. Equipment defect liability will be for the period of twelve months from the day of synchronization with
full load operation. Vendor has to rectify the defects without any cost implication.
vendor liability.
21. All the tools, tackles, equipment’s, kits, consumables shall be of superior quality. And shall have proper
legal and quality certification as per the relevance. The certificate & items shall be offered for
inspection to JSW.
X. Measurement sheets & Reporting Procedure.
16. Daily progress report soft copy and concerns must be mailed to JSW. All requirements must be
17. Detail report of the observations, work execution, spares consumed, spares recommended are to be
submitted by vendor along with the photographs & supporting documents in 3 sets.
18. Previous data of equipment’s and system, defects and root cause analysis prior to shut down well in
advance.
19. Site log book submission before start of unit which consisting of initial and final
clearances/measurements/dimensions of parts taken during complete overhaul for future references
of JSW and for history.
20. Man power and any other welding/cutting at vendor allotted area for I&C and Elect Dept works are in
the scope of Vendor. This is required to avoid external agency to create any unknown errors in critical
areas.
21. All coordination points to JSW I and c and Electrical must be informed or planned document must be
provided well in advance.
22. Studying and referring OEM doc which is provided by JSW in prior to shut down and thorough about
the system and equipment.
23. All reference OEM manuals and Drawings which are provided for shut down activity must be duly
returned to TMM.
24. Daily report and concerns must be recorded on daily basis and soft copy must be mailed to JSW TS,
TMM, EM, I&c, OM Head,VP
25. Any holds or plan must address immediately to section in charge /HOD for smooth execution and
completion.
26. All NDT plan and daily report must be shared to JSW on daily basis for taking any decision.
27. Openings of HIP, LP, MS TV, GV, RSV, LP openings must be covered immediately after opening to avoid
any foreign particle entry.
28. It is totally vendor’s responsibility to ensure his work man and engineers including external sources not
to enter unknown zones and put intentionally or un intentionally foreign parts inside any openings.
29. EOT crane operators, electricians are to be deputed by vendor to take care of round the clock activity.
30. Transportation of all assembly spares from ware house to assembly area by the vendor. 16 Electricians
are to be deputed for round the clock
D. SHUT DOWN WORKS ON TURBINE AUXILIARIES (130 MW)
The scope of work envisages internal Cleaning &, tubes inspection of Condenser, Deaerator, HP heaters,
Turbine side valves and Painting work of condenser, Inspection of Flash Tank and CBD tank, Servicing of
ACW Pumps, Replacement of ACW pipe line, High pressure valves servicing & replacement, High pressure
valves gland packing replacement, BFP & Booster, BFP lub oil coolers, PUMP Condenser Vacuum Pump
Inspection of Hangers and rectification on Turbine side. These jobs are to be carried out for SBU#1 Unit-
1, 130 MW Make :M/S.BHEL Thermal power plants TG Building as per the schedule of quantities & as per
Instruction of Engineer-In-Charge. Detailed scope of work is described hereunder.
DESCRIPTION: SHUTDOWN WORKS ON HOT WELL & CONDENSER
Specification of Condenser: It is a surface condense having shell & tube nest arrangement with divided
water boxes. The steam side of the surface condenser is connected to the exhaust hood of turbine. The
condenser are roller expanded in the tube plate to form a water tight joint. To prevent damage of the
tubes due to vibrations during operation, a number of support plates are provided along the pipe length
of the tubes at suitable intervals.
Type: SCD 2 - 818,

Make: BHEL,
Total Number of tubes: 16118
Design pressure: 1.1 Bar & Vacuum,
Quantity of steam: 275520 Kg/hr,
Quantity of cooling water: 15500 m3/hr,
Cooling surface are: 8180 Sq. mtr,
1.HIGH PRESSURE JET CLEANING OF CONDENSER TUBES

1. Avail safety permit with detailed risk assessment & job safety analysis.
2. Cleaning of condenser tubes (16000 numbers) by high pressure jet cleaning method.
3. Required number of Specially Designed high pressure jet pump to clean the condenser tubes to
be supplied by vendor.
4. Specially designed nozzles with accessories to clean the condenser tubes.
5. Required manpower to carry out the job.
6. Mobilization of men and materials at site and back.
7. Job will be carried out round the clock basis.
2.EDDY CURRENT TESTING OF THE CONDENSER TUBES
1. Avail safety permit for the work
2. Cleaning of leakage area if required.
3. Conducting eddy current test as per ASME Procedure Section V article 8 & appendix I to assess the
thinning wall reduction of Condenser tubes by certified ASNT Level – II manpower.
4. Testing to be done with INSIS –EC advanced multi-frequency Eddy Current Testing machine or
upgraded version with proper calibration certificate.
5. Submission of report with detailed recommendation, the report shall consist which proper
identification of tubes which are to be replaced.
6. The Eddy current test team member shall be present till the shutdown is complete to guide and
identify the correct tube. Shall ensure 100% co-ordination.
7. Housekeeping after completion of work.
8. Eddy current test report to be submitted immediately after completion of the work.
9.All the invoices to be submitted along with the proofs and valid dates.
5. Equipment defect liability will be for the period of twelve months from the day of synchronization with
6. Zero leakage of condenser tube is the main criteria for the quality.
Drawing if any: Tube layout, Drawing No: 1-160-10-00612

CONDENSER DETAILS
TYPE SCD 2 – 818, MAKE: BHEL

SHAPE RECTANGULAR
TOTAL NO. OF TUBES 16000
SIZE OF TUBE (OD x Thk x Lgth ) 22 X 18 BWG X 7500 mm
NO. OF TUBE IN AIR COOLING 1610
ZONE
WATER CHEMBER DIVIDED
NO. OF WATER SIDE PASSES TWO
WATER CHEMBER DIGN. PR. 5 atg
STEAM SIDE DIGN PRESSURE atg 1.1ksc & VACUUM
WATER SIDE DESIGN TEMP. 65 Deg. C
STEAM SIDE DESIGN. TEMP. 120Deg. C
QUANTITY OF STEAM 275520 Kg/hr
CONDENSER VACUUM 0.098 ksc
ENTHALPY OF CONDENSING 577.5 Kcal/kg
STEAM
FREE OXYGEN IN COND. 20 PPB
COOLING SURFACE AREA 8180 SQ.M
QUANTITY OF COOLING WATER 15500 CU.M./ Hr
COOLING WATER I/L TEMP. 32 Deg. C
COOLING WATER O/L TEMP. 42Deg. C
VELOCITY. OF COOLING WATER 1.8 M/ Sec
RESISTANCE ON WATER SIDE 5 mwc
HOT WELL CAP. (NWL TO LLWL) 3 Min
MATERIALS.
SHELL,DOME,HOTWELL C.S. SA 516 GR. 70
CHANNEL&WATER BOX C.S. SA 516 GR. 70
TUBE SHEET C.S. SA 516 GR. 70
TUBE AL.BRASS SB111UNS 687 /SS.SA 249 TP
304
BOLTS & NUTS SA 193 B7/ SA194ZH
PACKING CAF-9
3.GENERAL SCOPE OF WORK
1. Erection of platform with proper clamping system on both outer and inside the Condenser water box
man-holes and hot well man-holes. (Condenser outside Platform shall be erected prior to the
stoppage of the unit). Required Scaffolding materials are in the scope of Contractor.
2. Shifting of the material from store to the location.
4. Proper lighting adequate to inspect the water boxes and associated piping.
5. Floor openings should be noted and proper coverings should be installed to allow for safe
maneuverability throughout both water boxes.
6. Water box drains should be inspected to assure they are in proper working condition and no
obstructions exist Opening of all Water box and Hot-well man holes.
7. Preliminary Inspection of Water Box and Hot-Well .
8. Thorough Cleaning of tubes, Tube Sheet and internal surfaces of cooling water side and DM Water
side.
9. Replacement of Cooling water side Partition gasket if found damaged.
10. Inspection of Sacrificial Anodes and replacement of damaged/Eroded anodes with arrangement to fix
anodes.
11. Inspection (Visual &DPT) of condenser connected bellows (Cooling water side and DM water side).
12. Making arrangements for Condenser flood test including locking/ unlocking of condenser bottom
springs, measurements.
13. Carrying out of Flood Test on Shell side by filling of Water up to the Condenser Neck and identifying
of the damaged tubes & Plugging of the same.
14. Rectification of welding/gasket leaks observed during condenser flood test.
15. Painting of CW water box inner surfaces with Epoxy paint. (Paint is in the Scope of Contractor)
16. Servicing or replacement of drain/vent valves.
17. Cleaning of all Condenser Stand pipes.
18. Inspection of CW lines at condenser inlet thru Manholes & required patch welding (Quantity: 10 Nos,
Size: 250x250 mm)
19. Replacement of all Man holes Gaskets/T-rubber and box up.
20. Installation of dewatering pump in sump & discharge pipe line connection.
21. Attending all air leakage points if found or persisting.
22. Normalizing of Bottom Loading Springs After flood test and ensure the original readings of the
compression.
23. Assistance during condenser charging and attending of leaks if found.
24. Thorough Cleaning of Condenser outer surface area after completion of the work.
27. Scraps generated have to be removed & shifted to location as per SEI and Good Hose keeping to be
maintained at work place.
28. Arrangement of proper illumination (Hand Lams (24 V & 230V), Halogen Lamps at every location of
works as per the instruction of SEI. All materials like hand lamps, 24 V Transformers, Switch boards,
Cables, scaffolding, & other T&P are in the scope of contractor etc.
performance measure parameter/Deliverables

1. Completion of work as per scope within the shutdown period (which is communicated
accordingly).
2. Submission of detailed report with recommendations.
3. No leak from the manhole doors.
The vendor shall have detailed plan of expertise engineers and skilled manpower deployment. The
same shall be submit the for the approval of JSWEL. The plan shall consist of below expertise and team of
skilled manpower having hands on experience in M/s BHEL make condenser of capacity more than 100
MW.
Sl No Resource Description
1 Works Manager
2 Site In charge
3 High pressure jet cleaning Team
4 Eddy current Testing Team
Assistance Team for dismantling & scaffolding works including
5 Fitters, Riggers, Welders and Technicians
Description: SHUTDOWN WORKS ON DEAREATOR

SCOPE OF WORK:
3. Opening of Both Deaerator and Storage Tank man holes. & water wash on internal surface.
4. Inspection of Spray nozzles and trays.
5. DPT of deaerator internals.
6. Repair/Replacement of nozzles and trays.
7. Cleaning of Stand pipes.
8. Gasket replacement of all safety valves.
9. Repair of safety valve flange faces.
10. Replacement of pipes and fitting if any in Deaerator area.
11. Replacement of Manhole gaskets and tightening of Manholes.
12. Attending the Leaks observed during Charging of the Deaerator.
15. Scraps generated have to be removed & shifted to location as per SEI and Good Hose keeping
16. Arrangement of proper illumination (Hand Lams (24 V & 230V), Halogen Lamps at every location of
works as per the instruction of SEI. All materials like hand lamps, 24 V Transformers, Switch boards,
Cables etc., for the lighting arrangements are in the scope of contractor and they shall be inspected
by JSW Energy safety before use.
17. The required scaffolding, lighting & other T&P are in the scope of contractor.
18. Continuous stand by man power for monitoring and registering confined space entry & exit of
manpower.
Description: FLASH TANK & IBD INSPECTION

SCOPE OF WORK:
1. Removal of Man hole Door of both flash tank & IBD.
2. Internal Inspection and Cleaning.
3. Fabrication & Rectification of internals.
4. Replacement of Man-hole gaskets.
Description: BFP AND BOOSTER PUMP ALIGNMENT, MECHANICAL SEAL COOLER, WORKING OIL & LUB
OIL COOLERS CLEANING, SUCTIONS STAINER CLEANING
SCOPE OF WORK:
1. Removal of Coupling guard and Coupling Intermediate Piece by loosening Coupling Bolts of Motor
to voith and Voith to Pump
2. Coupling elements Inspection, DP Test (Inspection of element & Element Bushes, Coupling bolts
etc.) and replace.
3. Motor to Voith and Voith to Pump Alignment Check and Correction.
4. Alignment of all three no booster pump with motor.
5. Motor cooling mesh cleaning.
6. ACW pipe line replacement.
7. Inspection of fusible plug replace it.
8. Cleaning of all mechanical seal coolers of BFP & Booster pump.
9. Cleaning of hydraulic coupling breather replacement.
10. Servicing or replacement of valves (Oil or Water).
11. Motor bearings housing oil replacement.
12. Cleaning of all Booster pumps suction strainer.
13. Strainer cover fasteners DPT.
14. Trail run of the equipment.
15. Attend any defects related to this job.
16. Dismantling the working and lube oil coolers from its position; opening the end covers.
17. Remove cooler tube bundle; cleaning the tubes with nylon wire brush, and water.
18. Testing the coolers hydraulically and blanking the leaking tubes.
19. Assembling back the working and lube oil coolers with new end seal and flange gasket.
20. Draining of lube oil and hydraulic coupling oil tank, cleaning and filling fresh oil through the
filtering machine as per requirement.
21. Cleaning of lube oil filters.
22. Servicing or replacement of Lube Oil cooler / filter three-way ball valve.
23. Servicing or replacement of valves (Oil or Water).
24. Attending of all lube oil / working oil leaks.
DESCRIPTION: SERVICING OF ACW PUMP
SCOPE OF WORK:
3. Complete Dismantling of Pump and its components.
4. Cleaning of all the components by buffing or as directed by SEI.
5. Inspection and recording dimension of old & new parts.
6. Replacement of damaged components viz., Impeller & casing wear rings, Bearings, bearing
housing, impeller, pump shaft, shaft sleeve, gland packing / mechanical seal, etc.
7. Record of clearances, runouts and correction by machining.
8. Assemble back all the parts as per SEI.
9. Epoxy Painting of Pump, Suction and Discharge lines (Paint is in the Contractors Scope).
10. Inspection and Cleaning of Suction Strainer.
11. Replacement of pump discharge bellow.
12. Alignment Correction and Coupling replacement.
13. Trail Run of the Equipment up to full load operation and attending of problems if persisting.
boards, Cables etc., for the lighting arrangements are in the scope of contractor and they shall be
inspected by JSW Energy safety before use.
17. The required scaffolding, lighting & other T&P are in the scope of contractor.
DESCRIPTION: SERVICING OF VACUUM PUMP
SCOPE OF WORK:
2. Ensure necessary PTW & Safety clearance
3. Drive coupling inspection and repair/replace as required.
4. Pump and motor alignment checking and correcting.
5. Pump bearing inspection and greasing bearing replacement.
6. Pump Teflon port plate gasket inspection and Replacement.
7. Check Port Plate Clearances.
8. Motor bearing inspection and greasing.
9. Separator tank inspection and cleaning.
10. Low level and high level float inspection and servicing.
11. Pump inlet line filter cleaning.
12. Pump gland packing inspection and replacement.
13. Gauge glass cleaning.
14. Pump cooler cleaning.
15. Separator tank out let line valve servicing.
16. Scraps generated has to be removed & shifted to location as per SEI and Good Housekeeping to
boards, Cables etc., for the lighting arrangements are in the scope of contractor and they shall
be inspected by JSW Energy safety before use.
18. Required scaffolding, lighting & other T&P are in the scope of contractor.
Description: HANGERS INSPECTION & RECTIFICATION
SCOPE OF WORK:
1. Supply of Ex- BHEL Engineer Hangers & Supports export for recording TG side Hot readings
before unit shutdown, Cold reading during shutdown, Rectification of hanger supports,
Record Hot Readings after Shutdown of the Unit.
2. The Ex- BHEL Engineer should have hands on experience on High pressure pipe line support
& hangers.
3. The Ex- BHEL Engineer should submit BHEL experience certificate along with identity card for
the service tenure.
4. Required tools, tackles & scaffoldings for the above mentioned work in point 1.
5. Required fabrication works for correcting the hanger readings.
6. Inspection of hangers include Main Steam Line, Hot Reheat Line, Cold Re-Heat Line, Feed
water Line hangers for strength, verticality, tightness etc., and identify & any deviation to be
corrected in consultation with SEI. This includes fabrication works. Total Available Hangers in
Turbine Side.
7. All the Readings are to be Well Documented and to be submitted in Proper Format.
8. Supply of Safety supervisor along with the working manpower & ensure all safety standards
are followed.
1. OVERHAULING VALVES, ACW PIPE REPLACEMENT, CT RAISER VALVES SERVICING, CW DISCHARGE

VALVES SERVICING, HP HEATERS INSPECTION, MAINTENANCE OF CT FANS Etc., OF SBU-1, UNIT#1
(130MW)-TURBINE SIDE
The scope of work envisages “OVERHAULING VALVES, ACW PIPE REPLACEMENT, CT RAISER VALVES,
CW DISCHARGE VALVES SERVICING Etc.,” OF SBU-1, UNIT-1 (130MW)-TURBINE SIDE FOR 130 MW
SBU-1 UNIT-1 JSW ENERGY LTD" as described here under, as per the schedule of quantities and as per
the instructions of Engineer-In-Charge.
Description: REPLACEMENT OF ACW PIPE LINE
SCOPE OF WORK:
1. Obtain external PTW for preparatory works.
2. Survey of ACW line before shutdown.
3. Cut and remove the old pipe line & replace the pipe with new.
4. Required Welding of pipe and fittings.
5. Edge preparation of removed pipes and fittings.
6. Fabrication of reducer and bends.
7. Patch welding of pipe as per instructions of the Engineer.
8. Required welding electrodes for the welding work is in the scope of vendor.
9. Painting (01 Coat Red Oxide and 02 Coats enamel paint) the line (paint is in the scope of
contractor).
10. Shifting of removed pipes and scrap & left over new pipes etc., to Ware house is in the scope
of contractor.
11. DPT of 10% weld joints of each size to be done as per SEI.
12. The required scaffolding shall be provided as per safety standards. The scaffolding materials
are in the scope of work.
13. Assistance for isolation & normalization of ACW pipe line.
14. Doing necessary arrangement for isolation of lines.
15. Necessary temporary arrangements are to be done by Contractor.
16. The work shall be carried out 24x7 to complete the work before internal hydro test.
Description: SERVICING/REPLACEMENT OF CT RAISER VALVES
SCOPE OF WORK:
1. Removal of Valve from Position after Loosening of flange Bolts.
2. Dismantling all valve internals and cleaning all the internals.
3. Inspect the internals with DPT.
4. Replacement of valve internals where ever required.
5. Replacement of valve Seat Ring and Conducting of Water Fill Test.
6. Setting full open & full closing of valve.
7. Servicing of Gear Box.
8. Replacement of flange gaskets & Positioning of Valve and tightening of flange Bolts.
9. Ensure the valve is free to operate with hand.
The scope of work envisages “OVERHAULING OF VALVES FOR 130 MW SBU-1 UNIT-1 JSW ENERGY LTD"
as described here under, as per the schedule of quantities and as per the instructions of Engineer-In-
Charge.
Description: SERVICING OF 1/2" TO 14" class up to 2500 CLASS all VALVES

(Extraction, Feed water, condensate, Aux steam, Heater drains, flash tank, MAL)
1. Ensure the permit for the work.
2. Assistance for draining, isolation, normalization & charging.
3. Dismounting / Mounting of the electrical or Pneumatic actuator includes repair and
replacement of actuator where ever.
4. Removal of insulation as per required area for valve dismantling. (excess removal will have
accounted)
5. Complete dismantling of the valve and assessment.
6. Replacement of damaged parts.
7. Inspection for erosion on the seat /wedge and the same to be repaired by welding and
machining.
8. Necessary in-Situ seat cutting / Lapping tools and tackles to be in the scope of the contractor.
9. Seat lapping and checking blue contact. Leak test / Hydro test to be conducted.
10. Replacement of all gaskets, soft packing of bonnet, gland, flange, trim sets as a mandatory.
11. Seat cutting & lapping tools to be provided by vendor for quality work.
12. Seat repair by cutting, welding, machining to be done as per requirement.
13. Necessary precaution has to be taken up to avoid entry of any foreign material into the piping
/ equipment.
14. Joint inspection before boxing up the valve.
15. Pneumatic actuators servicing to be carried out for extraction drain, hot well make up system,
Condensate, Aux PRD system. Replacement of diaphragms, gland seal, etc.
16. Actuator servicing to be done. O-ring replacement with proper lubrication.
17. Ensuring of Free manual and remote operation of the valve, Valve stroking, Operational
checks after assembly.
18. Necessary co-ordination during Hydraulic test of boiler and attending the problems observed.
19. Co-ordination works (installation and removal of Test plugs, Gagging of the valves etc) for
Hydraulic test and Pressure setting of Safety valves.)
20. Replacement of valve gland packing where ever required.
21. Hot tightening to be done for all valves.
22. Post commissioning defects rectification to be carried out.
23. Round the clock manpower availability to be ensured by vendor for continuous 72Hrs full load
operation.
24. During commissioning, all filters, strainers cleaning to be carried out to ensure smooth
operation.
25. Man power assistance to dismantling & assembling of MOV actuators and gear boxes. (which
includes the contract without additional claim.)
26. Manpower assistance to operation for system isolation & normalization (like valve
commissioning, stocking) which includes the contract without additional claim.
27. Required consumables, tools and tackles (Lapping paste & Emery like Coarse, fine, Medium &
Grit, grinding & cutting wheels, buffing wheels, Electrodes, Blue, Valve lapping machine, Seat
leveling and seat cutting machine etc.) in the scope of contractor.
28. Submit daily progress report on daily basis.
Tentative BOQ is mentioned below:
DESCRIPTION OF WORK Qty UOM

Servicing Valves Up To 4 Inch (800 Class and Below) 8 EA
Servicing Valves Above 4 Inch To 10 Inch (800 Class And Below) 3 EA
Servicing Valves 10 Inch to 25” (800 Class and Below) 2 EA
Servicing Valves Up to 4 Inch (Above 800 Class) 10 EA
Servicing Valves above 4 Inch to 10 Inch (Above 800 Class) 2 EA
REPLACEMENT VALVES UP TO 4 INCH (800 CLASS AND BELOW)

Replacement of valves (Gate, Globe, Control, Ball valves & Safety valves)
1. Shifting of material from store to location; check and compare dimensions with existing
valve.
2. Ensure the necessary PTW & Safety clearance.
4. Removal of insulation & cladding sheet as per the requirement.
5. Storage of insulation in gunny bags to ensure the insulation is not polluting the surrounding
working area.
6. Includes necessary removing & restoration of lines / structure which obstructing the
replacement where ever required.
7. Removal of electrical / pneumatic actuator and remounting the same to new valve where
ever required.
8. Pre heating to be done as per the requirement; Reports shall be submitted well before
hydraulic test of boiler.
9. Cut and remove the existing valve by grinding or gas cutting (if valve is butt / socket
welded) as per the instruction of SEI. If valve is flanged end open the bolts and replace with
new gasket.
10. Edge preparation of pipe line and valve for butt joints.
11. Weld the joints as per welding procedure given or instruction of SEI. Valve shall be welded
in valve open condition.
12. Remove the clits and grind the weld joint properly.
13. Stress relieving (S-R) and radiography are to be done as per the requirement; Reports shall
be submitted well before hydraulic test of boiler.
14. All the required T&P and approved agency required for preheating, stress relieving and
radiography is in the scope of contractor.
15. Proper scaffolding for valve replacement to be arranged. And all scaffolding materials are
in the scope of contractor.
16. All the required resource for Pre heating, stress relieving, radiography is in the scope of
vendor.
REPLACEMENT VALVES ABOVE 4 INCH TO 10 INCH (800 CLASS AND BELOW)

1. Shifting of material from store to location; check and compare dimensions with existing valve.
working area.
ever required.
9. Cut and remove the existing valve by grinding or gas cutting (if valve is butt / socket welded)
as per the instruction of SEI. If valve is flanged end open the bolts and replace with new
gasket.
11. Weld the joints as per welding procedure given or instruction of SEI. Valve shall be welded in
valve open condition.
13. Stress relieving (S-R) and radiography are to be done as per the requirement; Reports shall be
submitted well before hydraulic test of boiler.
15. Proper scaffolding for valve replacement to be arranged. And all scaffolding materials are in
the scope of contractor.
vendor.
Replacement Valves above 10 Inch to 16 Inch (800 Class and Below)

working area.
ever required.
gasket.
vendor.
SHUTDOWN- REPLACEMENT VALVES UP TO 4 INCH (ABOVE 800 CLASS)

working area.
ever required.
gasket.
vendor.
REPLACEMENT VALVES ABOVE 4 INCH TO 10 INCH (ABOVE 800 CLASS)

working area.
ever required.
gasket.
vendor.
Description: CLEANINING, INSPECTION AND REPAIR OF HP HEATER 5&6
SCOPE OF WORK:
1. Shifting of the material from store to the location
3. Loosening of HP Heater flange bolts and Removal of flange.
4. Cutting of inspection door dummy with grinding.
5. Cleaning of Feed water box inner surface.
6. Required tap set for thread of flange bolts cleaning is to be arranged by contractor.
7. Water box partition plate &Tube Sheet inspection and necessary repair of partition plate.
8. Conducting water fill test on shell side and plugging of damaged tubes.
9. Welding of inspection door cover.
10. UT of the weld area.
11. Replacement of flange gasket & tightening of flange bolts.
12. Replacement of pump discharge bellow.
13. All the necessary insulation removal and re lagging of insulation.
14. Required electrodes 7018 A1 for welding of man hole doors.
18. Arrangement of proper illumination (Hand Lams (24 V & 230V), Halogen Lamps at every
location of works as per the instruction of SEI. All materials like hand lamps, 24 V
Transformers, Switch boards, Cables etc., for the lighting arrangements are in the scope of
contractor and they shall be inspected by JSW Energy safety before use.
19. The required scaffolding; lighting & other T&P are in the scope of contractor.
2.19 DESCRIPTION: SERVICING OF CW PUMP, MNTN:PMP;CW PMP VERTICAL,EA,NRML,VENDOR

Vendor Scope of Work:
1. Shifting of the spares & required material to the location.
3. Installation of dewatering pumps in the sump for pump internal inspection and recording
clearances.
4. Pump discharge flange shall be fixed with dummy plate.
5. Fixing of temporary pipe for diversion of leakage water.
6. Motor removal from position for pump servicing.
7. Dismantling of motor.
8. Cleaning of motor internals.
9. Recording dimension & readings as per checklist.
10. Replacement of worn out parts.
11. Replacement of Motor bearings.
12. Assembly of motor.
13. Complete Dismantling of Pump and its components.
14. Cleaning of all the components by buffing or as directed by SEI.
15. Inspection and recording dimension of old & new parts.
16. Required DPT consumables are in the scope of Vendor.
17. Replacement of damaged components viz., Impeller & casing wear rings, Bearings, impeller, shaft,
shaft sleeves, gland packing etc.,
18. Record of clearances, runouts and correction by machining if required.
19. Checking dimensions of the pump spares. If required checking dimensions of multiple spare of a
single replaceable part.
20. Job involves fabrication & replacement works. It also includes work at height & confined space.
21. Assemble back all the parts as per SEI.
22. Supply and apply of Epoxy Paint (Paint 40 liters should not exceed the expiry date) of Pump,
Suction and Discharge lines (Paint, thinner and primer JSW/Berger make is in the Contractors
Scope).
23. Discharge flange gasket replacement.
24. Discharge pipe inspection manhole door removal and gasket replacement.
25. Positioning of motor.
26. Alignment Correction and Coupling replacement if required.
27. Trail Run of the Equipment up to full load operation and attending of problems if persisting.
maintained at work place on day to day basis.
29. Work shall be carried out round the clock.
30. The allocated work shall be completed as per given target by the SEI.
31. Overhauling report shall be submitted by the vendor within 7 days after overhaul.
32. Housekeeping of the area shall be carried out day to day basis.
33. EOT operator round the clock.
34. Assistance for Isolation and normalization.
35. No smoking/chewing of tobacco/alcohol is allowed near work area same to be complied
strictly by vendor. If any such incidents will be reported immediately to safety for further
action.
36. All the alignment fixtures related to rotating equipment’s has to be fabricated prior to
overhauling by vendor itself.
37. All lube oil lines and bearing lube oil openings must be covered immediately after dismantling
by proper means. No foreign particles should fall inside, if any must be immediately brought
to notice of JSW area Engineer In-charge.
38. Oil spillage/wastage/mixing with water/mixing with soil is not permitted, proper trays,
bucket/cans to be arranged by contractor.
39. All dummies/sheets must be recorded and removed from oil lines /openings before final
assembly.
40. During execution of work if any damage is caused by the resources provided by the vendor,
then the vendor shall repair the same at free of cost immediately.
41. Excess tools and spares, consumables must be returned to stores with proper Tagging and
preservation
42. All the technical decision must be taken by vendor/expert in consultation with JSW. Any
quality related to workman, lack of expertise, tools and tackles are not acceptable and may
lead to penalty as decided by JSW.
44. DP test of spares
45. Other than Scope of JSW Energy Limited Mentioned below everything else for execution of
the job is in the vendor’s scope.
GUARANTEE/DEFECTS LIABILITY:
1. The contract shall stand guarantee for workmanship and quality of material supplied and incorporated
in the works for a period of Six (06) months from the date of completion and acceptance of work by
JSWEL. Any defects observed during this period shall be rectified by you at no extra cost.
Special terms & condition:

Vendor Scope:
A) Lifting tools and other equipment’s:
1 All scaffoldings / structure which are required during course of overhauling are to be provided by
vendor.
2 Magnetic drilling machine with drill bits of different sizes to suit GV and IV coupling pins
drilling.[Minimum 200 to 250mm length drill bits up to 12mm size is required.]
3 The required scaffolding supply and erection as per OSHAS Standards.
1 Supply of lighting equipment’s like halogen lamps, switch boards, flood lights, 24-volt transformer,
24-volt bulb etc. Are in contractor scope.
4 Required Tools & PPEs for the complete scope mentioned above are in the scope of vendor.
5 Tools should be with required test certificates.
6 All necessary T&P, wire rope slings, nylon sling belts, mechanical, hydraulic lifting, pulling tools,
jacks, hydro test pumps, Induction Heater, wooden sleepers etc for proper assembly and
alignments to be provided by vendor.
7 All lifting tools with test certificate.
8 Eye bolts up to M56 standard pitch, each type minimum 4nos.
9 All measuring tools up to 400mm out-side and 400mm inside micrometer, depth micrometer,
axial gap measuring tools, bore gauges, venires, Magnetic base with dial gauge- 20nos.
10 Calibrated micro level to be arranged by vendor for recording all levels & journal slopes.
11 Gas Cutting torch with flash back arrestor 4 sets.
12 Brazing tool with deposit materials for making jack bolts.
13 All types of burr cutters, drill bits, reamers and tap sets for removal of broken studs/bolts.
14 Chain pulley blocks from 1T to 10 ton minimum 2nos each size.
15 Coupling rotation slings with eye bolts suitable to BHEL supplied 130MW turbine.
16 Scaffolding pipes, clamps for complete turbine side.
17 Air/oil and water hoses for flushing and cleaning.
18 Tarpaulins for covering open areas, making sand blasting shed etc.
19 Fabrication of temporary dust bins for overhauling period.
20 Tentative Tools for the above mentioned work is mentioned as below:
1. Magnetic stand 1no

2. Vernier caliper – 0 - 200 mm 1no
3. Vernier caliper – 0 – 630 mm 1no
4. Dial indicator – 0.01 mm accuracy 1no
5. Measuring Tape – 5M 1no
6. Open-end & ring spanner - 18-19 1no
7. Open-end, ring & slugging spanner - 30-32 2no
10. Open-end & ring spanner - 24-26 2no
11. Open-end, ring & slugging spanner – 55 2no
12. Copper rod 2no
13. Allen key set 6 to 17 mm 2each
14. Ball peen Hammer - 500 grams 2no
15. Sledge hammer 2no
16. Flat scraper 2no
17. Flat file - 12 " 1no
18. Needle file set 1no
19.Engineers screwdriver – 300 L 2no
21.Gas cutting set 1set
22.Welding machine 1no
23.Chain block - 2 or 3 tone capacity 2no
24.Slings 2T, 5T and 10 Tonne capacity 2each
25.Deshackles 2T, 5T &10Tonne capacity 2 to 4each
26.M12, M24 & M30 eye bolts 2 to 4each
B) Consumables in vendors scope:
2 All GP electrodes, Carbon steel electrodes and gases of approved brands by JSWEL along with test
certificates is in contractor scope.
3 All consumables required for the job like Bannian Cloth, Marking Cloth, Diesel, Kerosene, Emery
Papers, emery wheels, rotary cutters, grinding, cutting Wheels, Hylomar (Gasket & jointing
compound), SILASTIC SEALANT 732 RTV, Birkosit -Steam Sealing, Persian blue, DP kits, WD-40 or
Rustoline, holdtite etc, are in Contractor Scope.
Following tentative list of consumables are to be arranged by vendor for executing the overhauling
activities.( Any other consumables as & when required shall be made available by vendor only)
Sl No Description
1 Hylomar, Gasket & jointing compound
5 WD-40 - 400ml
13 TEFLON TAPE 1"
24 OIL PAPER 0.5 MM
25 Cutting & grinding wheel AG-7 175 mm
45 ELECTRODE E7018-A1, 2.50 to 4 MM
46 Oxygen Gas
47 DA gas
48 DP Kit
49 Molykote 100
50 Hold tite
51 Filler Wire ER70S-2, Make Esab
JSW Scope:
1. Drawings, Manuals, Special tools & tackles will be arranged for overhauling of the equipment which
are supplied by OEM.
equipment.
6. Hydra / jumbo trolley will be arranged by JSW for shifting of spares / tools.
7. JSW safety and Area Engineer/In charge/HOD has all rights to stop/evaluate and question the safety
of all personnel who are working inside JSW premises.
8. Consumable provided to vendor by JSW will be on chargeable basis.
9. Required spares, which goes into the equipment.
10. Steel including MS plate, MS sheet, MS angles, tie rods.
11. Bracing pipes (MS) and steel required for the job.
12. Fire extinguishers
13. Supply of service Air
Equipment Specifications:
Description: SERVICING OF BUTTERFLY VALVE SIZE 1800 NB FOR CW PUMP DISCHARGE VALVE
SCOPE OF WORK:
1. Removal of CW PUMP discharge valve from position.
2. Removal of valve disc from position.
3. Repair valve gland area.
4. Assembly of valve after repair.
5. Replacement of Butterfly valve (1600 NB gasket) rubber seal ring.
6. Operational Check.
7. Servicing of actuator and replacement.
8. Scraps generated have to be removed & shifted to location as per SEI and Good Housekeeping
to be maintained at work place.
9. EOT crane operator round the clock.
boards, Cables etc., for the lighting arrangements are in the scope of contractor and they shall
be inspected by JSW Energy safety before use.
11. Required scaffolding, lighting & other T&P are in the scope of contractor.
DESCRIPTION: CW Trash Screen Cleaning & Sump Inspection
SCOPE OF WORK:
3. Installation of dewatering pumps in the sump for pump internal inspection and recording
clearances.
4. Fixing dummy gate at position.
5. Removal of Trash screen from position.
6. Repair trash screen frame.
7. Replace SS Trash screen.
8. Required Welding of pipe and fittings.
9. Required welding electrodes SS 309 for the welding work is in the scope of vendor.
10. Painting (01 Coat Red Oxide and 02 Coats EPOXY PAINT) the line (paint is in the scope of
contractor).
11. DPT of 10% weld joints of each size to be done as per SEI.
12. The required scaffolding shall be provided as per safety standards. The scaffolding materials
are in the scope of work.
13. Deployment of EOT Crane operator Round the clock for the work.
14. Necessary temporary arrangements are to be done by Contractor.
15. Fixing trash screen at position.
16. Job involves fabrication & replacement works. It also includes work at height & confined
space.
17. Deployment of EOT crane operator round the clock to execute the work.
18. Scraps generated & left over items have to be removed & shifted to location as per SEI and
Good Hose keeping maintained at work place on day to day basis.
DESCRIPTION: OVH,CT FANS OVERHAULING WORKS.
1. 10 CT fans nozzle inspection and replacement. Water distribution checking.

2. Hot water channel cleaning.
3. Fan blade angle check/correction and replacement if any.
4. Check for oil leak & replace input shaft oil seal.
5. Coupling alignment check/correction.
6. Gear box lub oil & vent line replacement.
7. Drift eliminators cleaning and realignment.
8. Replacement of corroded fasteners.
9. Installation of dewatering pumps in CT basin.
10. Repair of Platform required for fan maintenance works.
DESCRIPTION: PAINTING, EQPT, MNL, SYN ENM,02, VENDOR
1. The Contractor shall depute qualified supervisory personnel for safety & Execution of
work.
2. Contractor shall depute sufficient number of skilled & unskilled personnel who have
adequate experience on painting.
3. Safety of its entire working crew (providing PPE’s etc.) is the responsibility of the
contractor.
4. Surface preparation of the area to be painted
5. Painting of pipes & bends as per SEI (site engineer in-charge).
6. 1 Layer primer & 2 Layers of Synthetic Enamel Paint with smooth surface finish.
7. Supply of required Synthetic Enamel Paint, Thinner & primer.
8. All the required tools, tackles & consumables for painting like spray gun, hoses, paint
brush, Emery wheel, grinding machine, emery paper, cloth etc.
9. Ensure surrounding area is clean while paint. Ensure Paint does not fall on surfaces
other than the fabricated pipe. Immediate cleaning of the paint if it falls on other than
the fabricated Pipes.
10. Shifting of required materials from warehouse to the location including transportation
will be under contractor Scope.
11. Shifting of scrap to identified area on day to day basis including transportation will be
under contractor Scope.
12. Its Contractor’s responsibility to maintain housekeeping of the surrounding area till end of the
job.
13. Repaint if any defects observed.
14. Painting area will be calculated 1 SQR MTR for painting 1 SQR MTR with 3 layers (1 coat of
primer & 2 coats of enamel paint)
DESCRIPTION: EPOXY PAINTING OF EQUIPMENTS
work.
contractor.
6. 1 Layer primer & 2 Layers of epoxy Paint with smooth surface finish.
7. Supply of required Synthetic Enamel Paint, Thinner & primer.
other than the fabricated pipe. Immediate cleaning of the paint if it falls on other than
the fabricated Pipes.
job.
14. Painting area will be calculated 1 SQR MTR for painting 1 SQR MTR with 3 layers (1 coat of
primer & 2 coats of Epoxy paint)
PRDS TEE 2 NOS Repair/replacement works,
5. Record supports & Hanger readings before starting any work on the pipe line TEE elevation
within 3 mtrs.
6. Providing supports & lock the pipe line before cutting the weld joints.
7. Removal & restoration of lines / structure which obstructing the replacement where ever
required.
8. Cut and remove the existing TEEs by grinding as per the instruction of SEI.
9. Edge preparation of pipe line as per Engineer in charge.
10. Joint details:
Size of TEE is (UNEQUAL TEE 273X6.35/89.9X6.02, MOC SA 234 WP11)
Size of TEE is (EQUAL TEE 273X6.35, MOC SA 234 WP11)
11. Weld the joints as per welding procedure given or instruction of SEI.
12. Required Welding Electrodes (9018 B3 & 8018 B2) are in the scope of vendor.
13. DP test of weld joint. (DP kit is on the scope of vendor)
15. Pre heating, Post heating & Stress relieving (S-R) and radiography are to be done as per the
requirement; Reports shall be submitted well before hydraulic test of boiler.
16. Remove the additionally provided supports.
17. Check the pipe line supports & hanger readings. Rectify any correction required as per
Engineer in charge.
19. Any leaks observed after line charging shall be attended at free of cost as per above scope of
work.
performance measure parameter/Deliverables

1. Completion of work as per scope within the shutdown period (which is
communicated accordingly).
2. Submission of detailed report with recommendations.
3. NO leak from the weld joint for 1 year. Weld joint shall be repaired at free of cost
if any leak observed from any of the weld joints.
3. SHUT DOWN WORKS ON CT RAISER PIPES REPLACEMENT (130 MW)
3.1 Description: - FAB, MITRE BND 600 - 1000 MM; FAB AND EREC
1. As per Site measurements 10 no’s of 600 NB MITRE bend to be fabricated by using -600 NB CS
ERW Pipe as per site measurement.
CONTRACTOR SCOPE: -
1. Contractor shall execute fabrication of the MITRE bends as per SEI (site engineer in-
charge). Contractor shall depute qualified supervisory personnel for safety & Execution
of work.
adequate experience in the MITRE bend fabrication and Critical Pipe Erection.
contractor.
4. Continuous work supervision and progress report to be submitted on daily basis to the
Work Charge Engineer.
5. All General consumables like DPT Kit, cleaning agents, welding electrodes / machines with
cables, oxygen & acetylene cylinders, cotton & Banyan cloth, diesel, cutting and grinding
wheels/ machines switch board, lights power cables etc. are under Contractor scope, and should
be from the reputed supplier.
6. Supply of necessary tools and tackles. Prior to work, all the test certificates of the tools
& tackles shall be submitted to JSW for the approval.
9. After completion of each welding, joint inspection by JSW & Contractor with Visual /
DPT to be Carried, and any defects to be attended.
job.
11. Attend any leaks observed after charging the pipe line.
JSWEL Scope:
1. Obtaining PTW.
2. Provide Power Supply Point.
3. Supply of 600 NB CS ERW Pipe.
4. Lifting & moving equipment like hydra, Crane, Trailer Etc.
3.2 Description: - EREC,PIPING ,VENDOR

1. As per Site measurements Apx 18 MT of 600 NB CS ERW pipe shall be fabricated and erected at
SBU-1 cooling tower Raiser pipe. Each raiser pipe requires apx 1.7 MT of 600 NB CS ERW pipe
including bend.
2. Tentative Drawing is attached for reference.
CONTRACTOR SCOPE: -
1. Contractor shall execute fabrication & erection of the supplied pipe as per the drawing
given by SEI (site engineer in-charge). The Contractor shall depute qualified supervisory
personnel for safety & Execution of work.
2. Existing pipe in the concrete wall of cooling tower has to be repaired internally (it
requires pipe patching throughout circumference inside the existing pipe without
damaging existing pipe) & it has to be joint with newly erected pipe from hot water
channel of cooling tower. It is confined space.
adequate experience on pipe line fabrication & Erection of Critical Piping.
4. The work man should have adequate experience on working at height & confined space.
contractor.
7. All General consumables like DPT Kit, cleaning agents, welding electrodes / machines with cables,
oxygen & acetylene cylinders, cotton & Banyan cloth, diesel, cutting and grinding wheels/
machines switch board, lights power cables etc. are under Contractor scope, and should be from
the reputed supplier.
8. Supply of necessary tools and tackles for erecting pipe without crane. Prior to work, all
the test certificates of the tools & tackles shall be submitted to JSW for the approval.
11. After completion of each welding, joint inspection by JSW & Contractor with Visual / DPT
to be Carried, and any defects to be attended.
job.
13. Attend any leaks observed after charging the pipe line.
JSWEL Scope:
1. Obtaining PTW.
3. Supply of the 600 NB CS ERW Pipe.
4. Lifting & moving equipment like hydra, Crane, Trailer etc. for shifting purpose only.
3.3 Description: - DISMANTL, PIPE-DN600; MNL; VENDOR;0-40M

1. As per Site measurements Apx 10 MT of 600 NB CS ERW pipe shall be dismantled at SBU-1
cooling tower Raiser pipe. Each raiser pipe requires apx 1.7 MT of 600 NB CS ERW pipe
including bend.
2. Tentative Drawing is attached for reference.
CONTRACTOR SCOPE: -
1. Contractor shall execute dismantling of the existing pipe as per the drawing given by SEI
(site engineer in-charge). The Contractor shall depute qualified supervisory personnel for
safety & Execution of work.
adequate experience on pipe line fabrication & Erection of Critical Piping.
3. The work man should have adequate experience on working at height & confined space.
contractor.
6. All General consumables like oxygen & acetylene cylinders, cutting and grinding wheels/
machines, switch board, lights power cables etc. are under Contractor scope, and should be
from the reputed supplier.
7. Supply of necessary tools and tackles for dismantling pipe without crane. Prior to work,
all the test certificates of the tools & tackles shall be submitted to JSW for the approval.
job.
JSWEL Scope:
1. Obtaining PTW.
3.4 Description: - SCFD,MS PI,CLMP AND P/FRM,0-50MTR
Scaffolding for Apx 508 CUM volume at SBU-1 Cooling tower raiser pipe. Each pipe requires Apx.
49.5 CUM Scaffolding. Lenght-2.15 Mtrs, Width:2.15 Mtrs, Height: 11 Mtr
CONTRACTOR SCOPE: -
work.
contractor.
4. Provide stable & rigid Scaffolding at SBU-1 Cooling tower raiser pipe as safety standard.
5. To provide plates on loose surface.
6. To provide excess ladder at all the working platforms.
7. Provide hand rail at the working platform.
8. All the required tools, tackles & consumables for erecting scaffolding including, switch
board, lights & power cables etc.
job.
JSWEL Scope:
1. Obtaining PTW.
2. Provide Power Supply Point
3.5Description: - OVH,EPXY PAINTING OF EQUIPMENTS

1. Epoxy Painting of Apx 3000 SQR FEET of 600 NB CS ERW pipe . Area of each pipe is Apx. 250
Sqr feet. Max height of work is 10 Mtr.
CONTRACTOR SCOPE: -
work.
contractor.
1 Layer primer & 2 Layers of Synthetic Epoxy Paint with
smooth surface finish.
6. Supply of required epoxy Paint (Color sea green), Thinner & primer.
other than the fabricated pipe. Immediate cleaning of the paint if it falls on other
than the fabricated Pipes.
9. Shifting of required materials from warehouse to the location including
transportation will be under contractor Scope.
10. Shifting of scrap to identified area on day to day basis including transportation will
be under contractor Scope.
11. Its Contractor’s responsibility to maintain housekeeping of the surrounding area till end
of the job.
JSWEL Scope:
1. Obtaining PTW.
2. Provide Power Supply Point
3. Required scaffolding.
QUALIFYING REQUIREMENTS:
1. The experience claimed by the bidder shall be considered, if the said experience is in the name
of the bidder directly and not by subletting the contract. Satisfactory work completion
certificate is to furnished by the firm. During the work period, the successful bidder has to
depute well conversant experienced manpower for the specified works like bullet cleaning,
Eddy current test and re-tubing.
2. The agency shall have proven track record of specified job accomplishment & similarly he has
to submit job completion certificate from user of last 03 numbers of unit.
3. Bidder has to submit the proof about the qualification and experience of labor and engineer
deputed for maintenance work along with tender documents such as copy of appointment
letters or P.F. submission challans, for last 2 years along with qualification of personnel’s who
will be deputed for Overhaul work.
4. Vendor to provide List of manpower with names and experience, NDT Certifications.
5. Vendor to provide List of Tools and instruments that will be used for the work to access the
quality of work.
MOBILIZATION
The estimated mobilization required for Servicing / Replacement of Valves as per the following per shift
and to be available for the round the clock. Expected Completion Period to be 20 days
ESTIMATED FOR CONTRACTOR MOBILIZATION CHART DURING OVERHAUL
Sl
DESCRIPTION QTY
No
1 Work supervisors 4
2 Safety supervisors 2
3 Millwright Fitter Pumps 2
4 Valve and Actuator MWF 3
5 General Fitter 6
6 Insulation Fitter 2
7 Fabricator 4
8 Rigger 8
9 Helper 53
10 Insulation Helper 6
11 HP Welder 2
12 LP Welder 6
13 Gas cutter 4
14 Grinder 4
15 Actauator Third Party Expert 1
16 SR/RT Technician 2
17 Hanger Expert 1
TOTAL 110
Manpower Mobilization requirement for CT raiser pipes replacement

Sl. No: DESCRIPTION DEPLOYMENT
1 Work Supervisor 2
2 Safety Supervisor 2
3 Fabricator 4
4 Rigger 4
5 Grinder 4
6 Helper 16
7 Welder -6G 4
8 Gas Cutter 4
9 Painter 4
TOTAL 44
Manpower Mobilization requirement for CW pump & motor overhauling

DESCRIPTION Quantity
SL.NO:
01. Work supervisors 2
02. Millwright Fitter 2
03. Rigger 4
04 Helper 12
05 HP Welder 1
06. Welder 2
07 Gas cutter 2
08 Grinder 2
09 Painter 1
10 Safety Supervisor 1
11 EOT operator 2
12 Foreman 2
TOTAL 33
The above scope of work is indicative only & not exhaustive & all works necessary for completion of
above works during individual Units overhaul are deemed to have been included in the scope of work
and the contractor is responsible for the same without any extra claim. The contractor shall deploy
sufficient experienced skilled manpower required for the execution of work.
NOTE 1: Above man power should have competency to perform the above specified works with a
specified Quality and safety manner.
General Terms & Conditions:
The scope of work envisages, annual shutdown jobs for 130 MW Thermal power plant as per the schedule
of quantities. The Turbine is supplied by M/s BHEL & operating efficiently. Detailed scope of work is
described hereunder.
1. Stipulated annual shutdown duration is 30 days.
2. The works to be done shall conform to the detailed specifications here under, scope of work as
described in schedule of quantities and further details as per the instructions of Engineer-In-Charge.
If there is any dispute about the scope of work the decision of Engineer-In-Charge shall be final and
binding on the contractor.
3. During course of outage, all dismantling, assembly activities, and dimensional inspection need call
JSW for inspection.
4. Job involves high care and precision, no parts shall be damaged during dismantling or assembly due
to poor workman ship, negligence and improper tools application etc.
5. Spares and consumables should not be misused on account of negligence.
6. All the work force working over equipments and nearby must be free from loose parts inside shirt
pockets to avoid any objects falling inside the opened equipment that could lead to complete
damage of equipment; any such thing must be reported immediately to JSW area Engineer in charge.
All small tools, measuring instruments shall be properly gripped/ tied to avoid falling.
7. It is vendor responsibility to control and ensure its work force acts, healthiness of tools and safe
technical working procedure.
8. Before entering any confined space safety clearance shall be ensured and stand by person with life
line/tied rope must accompany outside the manhole till the completion of work.
9. No smoking/chewing of tobacco/alcohol is allowed near work area same to be complied strictly by
vendor. If any such incidents will be reported immediately to safety for further action.
10. All lube oil lines and bearing lube oil openings must be covered immediately after dismantling by
proper means. No foreign particles should fall inside, if any must be immediately brought to notice
of JSW area Engineer In-charge.
11. All dummies/sheets must be recorded and removed from oil lines /openings before final assembly.
12. Shifting of all spares, handling tools, machining assistance at work shop, installation, removal and
returning/storing safely as per JSW engineer in charge.
13. Submission of Shut down report in 3 sets and check list/protocol within 7 days after shut down.
14. Empty oil drums shifting from stores and returning waste oil /empty drums.
15. Hydraulic testing hand pumps for all the coolers must be maintained with necessary hoses and
connectors.
16. Oil spillage/wastage/mixing with water/mixing with soil is not permitted, proper trays, bucket/cans
to be arranged by contractor.
17. All the alignment fixtures related to rotating equipments has to be fabricated prior to overhauling by
vendor itself.
18. Air/Water/oil hoses for cleaning/flushing is under the scope vendor.
20. EOT crane operators for round the clock operation for 2 cranes are to be arranged by Vendor.
21. The quantity given in the schedule of quantities are indicative & approximate only and may vary
according to the actual requirement. The contractor shall have no extra claim in this regard.
22. The work shall be executed on firm price basis throughout the contract period and during extended
period also, if any.
23. Unless specified to the contrary in the bid, the rates are inclusive of all Taxes [Except Service Tax
(Please see note below)], Duties, Royalties and other Statutory levies and shall be paid by the
Contractor. No dispute shall be raised at a later stage in this regard by the contractor.

1 Mobilization of manpower, tools and tackles at site for necessary arrangements
like gate passes, Accommodation etc.
necessary documents
Note: Documents for Gate Pass formalities 1, Aadhaar Card, 2, Passport photos for gate pass
4Nos, 3, ESI 4, PF 5) Experience certificate.
processing.
Special terms & condition:

JSW Scope:
14. Drawings, Manuals, Special tools & tackles will be arranged for overhauling of the equipment which
are supplied by OEM.
equipment.
18. Area will be allotted for store and office for the vendor engineers.
20. Hydra / jumbo trolley will be arranged by JSW for shifting of spares / tools.
21. JSW has all the rights to accept and reject, penalize vendor if found not fit for the job.
22. Any damages to equipment and its parts due to inexperience, negligence or due to workmanship are
not acceptable and may lead to severe penalties as decided by JSW.
23. JSW safety and Area Engineer/In charge/HOD has all rights to stop/evaluate and question the safety
of all personnel who are working inside JSW premises.
24. Liquidate & damaged will be applicable as per the PO terms.
25. Vendor accommodation will be provided by JSW on chargeable basis subject to availability / vacancy.
26. Consumable provided to vendor by JSW will be on chargeable basis.
27. Required spares, which goes into the equipment.
28. Steel including MS plate, MS sheet, MS angles, tie rods.
29. Bracing pipes (MS) and steel required for the job.
30. All special electrodes of Alloy steel and Stainless steel.
31. Consumables in use should be with in expiry period.
Vendor Scope:
C) Tests and scope
1 All types of NDT agencies with testing kits & consumables are to be mobilized by overhauling
vendor.
2 All necessary design / documentation to be arranged by vendor to ensure smooth working
3 Balancing of the complete train after overhauling to be done by the vendor all the values must be
within OEM recommendations for warranty period.
4 Dry air blowers / de-humidifiers for Generator winding to remove the moisture.
D) Lifting tools and other equipments:
21 All scaffoldings / structure which are required during course of overhauling are to be provided by
vendor.
22 EOT operator round the clock, [JSW has 3 EOTs in operable condition.]
23 Magnetic drilling machine with drill bits of different sizes to suit GV and IV coupling pins
drilling.[Minimum 200 to 250mm length drill bits up to 12mm size is required.]
24 Loading, Unloading and shifting of all the spares, consumables tools and tackles from JSW specified
location to site and vice versa.
25 Safety Supervisor required for the complete job is in the scope of vendor.
26 The required scaffolding, lighting & other T&P are in the scope of contractor.
27 Required Tools & PPEs for the complete scope mentioned above are in the scope of vendor.
28 Tools should be with required test certificates.
E) Work instructions/reporting:
1 Daily progress report soft copy and concerns must be mailed to JSW. All requirements must be
2 Detail report of the observations, work execution, spares consumed, spares recommended are to
be submitted by vendor along with the photographs & supporting documents in 3 sets.
3 Previous data of equipment’s and system, defects and root cause analysis prior to shut down well
in advance.
4 Man power and any other welding/cutting at vendor allotted area for I&C and Elect dept works are
in the scope of Vendor. This is required to avoid external agency to create any unknown errors in
critical areas.
5 All coordination points to JSW I&C and Electrical must be informed or planned document must be
provided well in advance.
6 Studying and referring OEM doc which is provided by JSW in prior to shut down and thorough
about the system and equipment.
7 All reference OEM manuals and Drawings which are provided for shut down activity must be duly
returned to TMM.
8 Daily report and concerns must be recorded on daily basis and soft copy must be mailed to JSW
TS, TMM, EM, C&I, SIC, AGM OM, AVP
9 Any holds or plan must address immediately to section in charge /HOD for smooth execution and
completion.
10 All NDT plan and daily report must be shared to JSW on daily basis for taking any decision.
11 Openings of Bearing Housing, LP openings must be covered immediately after opening to avoid
any foreign particle entry.
12 It is totally vendor’s responsibility to ensure his work man and engineers including external sources
not to enter unknown zones and put intentionally or un-intentionally foreign parts in side any
openings.
13 EOT crane operators, electricians are to be deputed by vendor to take care of round the clock
activity.
14 Transportation of all assembly spares from ware house to assembly area by the vendor.
15 Electricians are to be deputed for round the clock
F) Quality of manpower:
1 Vendor must provide relevant detailed QAP well in advance.

2 Engineers, workmen and specialists must be having through knowledge & work experience on
BHEL supplied Turbo-generator.
3 All the technical decision must be taken by vendor/expert in consultation with JSW. Any quality
related to workman, lack of expertise, tools and tackles are not acceptable and may lead to penalty
as decided by JSW.
4 Complete overhauling must be closely supervised 24x7and Engineer/foreman/millwright fitters
must be thorough in their work.
5 Vendor should have the ability to complete the job within schedule or as per the time decided by
JSW without compromising the quality.
6 Once the shutdown is taken all the jobs must be carried by vendor until unless huge qty of
manpower and cost is involved.
7 Equipment defect liability will be for the period of six months from the day of synchronization with
8 System vacuum and TG valves performance will be the main criteria for the vendor performance/
liability.
G) Tools:
1 All necessary T&P, wire rope slings, nylon sling belts, mechanical, hydraulic lifting, pulling tools,
jacks, hydro test pumps, Induction Heater, wooden sleepers etc for proper assembly and
alignments to be provided by vendor.
2 Lapping/seat cutting tool must be arranged prior to shut down.
3 All lifting tools with test certificate.
4 Eye bolts up to M56 standard pitch, each type minimum 4nos.
5 All measuring tools up to 400mm out-side and 400mm inside micrometer, depth micrometer, axial
gap measuring tools, bore gauges, venires, Magnetic base with dial gauge- 20nos.
6 Calibrated micro level to be arranged by vendor for recording all levels & journal slopes.
7 Gas Cutting torch with flash back arrestor 4 sets.
8 Brazing tool with deposit materials for making jack bolts.
9 All types of burr cutters, drill bits and tap sets for removal of broken studs/bolts.
10 Chain pulley blocks from 1T to 10 ton minimum 2nos each size.
11 Coupling rotation slings with eye bolts suitable to BHEL supplied 130MW turbine.
12 Scaffolding pipes, clamps for complete turbine side.
13 Air/oil and water hoses for flushing and cleaning.
14 Tarpaulins for covering open areas, making sand blasting shed etc.
15 Fabrication of temporary dust bins for overhauling period.
H) Safety, Health and Environment:
1 Vendor has to ensure his workmen under gone safety induction and issuing of PPE.
2 Vendor has to maintain PPE issue register.
3 Vendor has to submit workmen compensation policy and labour license copy to HR-JSW.
4 All access platforms for safety of all personnel are to be arranged by vendor.
5 Access platform, scaffoldings for I and c/Electrical requirements & man power support within
vendor allotted area.
6 No smoking/chewing of tobacco/alcohol is allowed near work area /in-side the plant same to be
complied strictly by vendor. If any such incidents will be reported immediately to safety for further
action
I) Material shifting and storage:
preservation.
arrangements for safety of people are in the scope of vendor and are to be handed over to store
with proper tagging & preservation.
3 All the materials which are being supplied by M/s. JSWEL on free of cost & returnable basis,
after execution of the work balance materials should be returned in good working condition
within Seven (7) days after completion of work. Failing to return within the period, hire
charges for the delayed period as described by M/s. JSWEL shall be recovered from
contractor’s bill.
J) Consumables in vendors scope:
4 Supply and application of Epoxy paint is in contractor scope.

5 Supply and application with anticorrosive black paint is in contractor scope.
6 The contractor shall arrange all the required tools & tackles including transportation of spares,
other owner issue materials, etc., from central stores / O&M Sub-stores. Arrangement of trailer
and Crane is in contractor scope.
7 All scaffolding materials including relevant clamping fasteners shall be in the scope of contractor.
8 All GP electrodes, Carbon steel electrodes and gases of approved brands by JSWEL along with test
certificates is in contractor scope.
9 All consumables required for the job like Bannian Cloth, Marking Cloth, Diesel, Kerosene, Emery
Papers, emery wheels, rotary cutters, grinding, cutting Wheels, Hylomar (Gasket & jointing
compound), SILASTIC SEALANT 732 RTV, Birkosit -Steam Sealing, Persian blue, DP kits, WD-40 or
Rustoline, Drill bits and reamers, tap sets high temperature molykote Compound, lapping paste,
holdtite etc, are in Contractor Scope.
10 Supply of lighting equipments like halogen lamps, switch boards, 24 volt transformer, 24 volt bulb
etc. Are in contractor scope.
11 Disposal of scrap is in contractor scope.
12 The contractor should provide Electrician for attending Hoist and welding M/c problems during
Execution of the work.
13 The Contractor should deploy manpower for each particular job as mentioned in table with Gas
cutting, welding machines, grinders etc., to work parallel in all activities of the unit under
overhaul as per requirement and instructions of Engineer-In-Charge and the contractor shall
deploy one supervisor exclusively to look after safety aspects and for ensuring the
implementation of all safety precautions by contract workmen.
Following tentative list of consumables are to be arranged by vendor for executing the overhauling
activities.( Any other consumables as & when required shall be made available by vendor only)
Sl No Description
1 Hylomar, Gasket & jointing compound
5 WD-40 - 400ml
13 TEFLON TAPE 1"
15 Birkosit steam sealing compound
24 OIL PAPER 0.5 MM
40 OXYGEN GAS CYLINDERS
41 DA GAS CYLINDERS
42 ARGON CYLINDER
44 ELECTRODE E6013, 2.5 to 4 MM
45 ELECTRODE E7018, 2.5 to 4 MM
46 ELECTRODE E7018-A1, 2.50 to 4 MM
47 Filler Wire ER70S-2, Make Esab
48 Filler Wire ER80S-B2, Make Esab
49 Filler Wire ER90S-B3, Make Esab
50 ELECTRODE E8018-B2, 2.50 to 4 MM
51 ELECTRODE E9018-B3, 2.50 to 4 MM
52 ELECTRODE E309 2.50 to 4 MM
PERIOD OF CONTRACT:
1. The period of contract shall be SIX (06) MONTHS from the date of commencement of work. However,
the Corporation reserves the right to reduce the period at the time of award of contract itself at their
discretion. During the currency of contract, the Corporation reserves the right to reduce the
period/terminate the contract at its own discretion without assigning any reasons whatsoever &
contractor will not have any claim on account of the same.
2. The corporation further reserves the right to extend the contract on the same terms and conditions
for a further period and the Contractor shall be bound to execute the works during the extended
period also, at the same rates, terms & conditions as awarded.
3. During the course of validity period of contract, JSWEL may assign the said contract to any other
agency, and said agency, being the assignee shall operate the contract and engagement for the
purpose of execution, supervision, payment, extension/renewal etc on the same terms and conditions
of the contract, and the contractor shall have no right to raise any objection, whatsoever, on
assignment of the contract by JSWEL as referred to above.
4. Time is the essence of contract and if you fail to maintain required progress in terms of conditions of
contract or complete the work and clear the site on or before the contract or extended date / period
of completion, provision of clauses of G.C.C regarding liquidated damage shall be applicable.
GUARANTEE/DEFECTS LIABILITY:
2. The contract shall stand guarantee for workmanship and quality of material supplied and incorporated
in the works for a period of Six (06) months from the date of completion and acceptance of work by
JSWEL. Any defects observed during this period shall be rectified by you at no extra cost.
PENALTY CLAUSE:
1. The contractor has to maintain one supervisor during overhauls who will supervise the works during
day / night. Proper supervision is to be ensured to safely execute the work.
2. All the lifting tools and tackles should have valid test certificate and all the lifting tools and tackles are
to be marked for identification and should be certified by JSWEL Safety Incharge.
3. All gas cutting sets should be provided with flash back arresters on cylinder side as well as torch side.
All gas hoses & regulators should be of good quality and in good condition.
4. The agency supervisor has to ensure that all the workers are working with proper safety gadgets,
PPEs like helmet, shoes, goggles, full body harness, fall arrestors, and 24-volt hand lamps in confined
space, etc. Suitable penalty will be imposed for not ensuring this.
5. Access platforms are to be properly fixed for rigidity and adequate illumination be provided.
6. Supply to electrical equipments is to taken from ELCBs. Welding generators and other electrical hand
tools should be certified by Electrical Maintenance department.
7. All the statutory safety rules should be followed strictly followed. Suitable penalty for any violation
of the above will be levied by EIC per instance.
8. The agency shall complete all the works given to him by the EIC in the stipulated time by proper
coordination of resources. Failure to complete the work as per schedule will attract penalty.

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JSW ENERGY LIMITED

THERMAL POWER PLANT

JSW ENERGY LIMITED,

Vijaynagar, Village. & P.O.: Toranagallu,

Dist.: Bellary, Pin.: – 583123,

Bid document consists of the following:

II. Equipment details

III. Validity of the contract

IV. Scope of work

V. General terms & conditions of the contract

VI. Scope of services

VII. Quality assurance

VIII. Measurement sheets & Reporting Procedure.

IX. Defect liability

a) Capital overhaul of Steam Turbine, Generator & Connected valves / Strainers.

II. Equipment details:

Tandem compounded, Two Cylinder reheat condensing turbine.

e) Reheat Stop &Control valve

f) Bypass stop and control valve

III. Work schedule

F. STEAM STRAINERS INSPECTION

J. HYDROGEN COOLER INSPECTION.

a) Machining of valve cones if stucked in the valve casing.

b) U seal rings machining after replacement

e) Casing, valve mating faces/bodies welding and repair works.

Following tests are to be done on the Generator Rotor

1. Slip Rings surface is to be checked

A. TURBINE & GENERATOR AUXILARIES (U1, 130 MW)

DESCRIPTION: SHUTDOWN WORKS ON CONTROL OIL SYSTEM

DESCRIPTION: SHUTDOWN WORKS ON HP- BYPASS SYSTEM

DESCRIPTION: SHUTDOWN WORKS ON SEAL OIL SYSTEM

IV. General terms & conditions of the contract

NOTE: Bidder to complete the attached checklist.

3. TECHNICAL TERMS AND CONDITIONS:

3. Safety, Health and Environment:

4. Material shifting and storage:

VI. Quality assurance & Deliverables

VII. Measurement sheets & Reporting Procedure.

1. Turbine casing except exhaust hood

1. HP-IP Turbine (diameter) = 7 mts and length = 5 mtrs

Equipment to be QTY Surface Area POS Temp C Outer Dia of Type

B) Division of Responsibilities (DOR)

08 days before actual

C) Performance measure parameter/Deliverables:

1. Will be intimated one week before commencement of work.

Tentative Manpower required for the Job:

C.RLA WORKS ON TURBINE & GENERATOR (130 MW)

Validity of the contract

RLA WORKS ON TURBINE & GENERATOR:

A. MAIN TURBINE & ITS COMPONENTS

RLA SCOPE OF WORK

1) ELECTRICAL TEST ON GENERATOR STATOR

1. Measurement of Insulation resistance and PI test.

DPT=Dye Penetrant Test,

LIST OF TESTS / INSPECTION / CHECKS TO BE CARRIED OUT ON 130 MW TURBINE:

General terms & conditions of the contract

NOTE: Bidder to complete the attached checklist.

Check List for Vendor

s.no Requirement from Bidder Remarks

a) W.O. copies for the last three years. a) Yes / No

05 days before actual start of

7. Tools and other Equipment’s:

8. Safety, Health and Environment:

9. Material shifting and storage:

TG ,RLA & AUXILARIES SCOPE OF WORK FINAL 01.02.2024 (1)

TG ,RLA & AUXILARIES SCOPE OF WORK FINAL 01.02.2024 (1)