INDEXTENTATIVESCOPEOFWORK

S.No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.

AREA
O/HBoiler&Aux.
O/HCleaningCondenserbyHighPressureJet,retubing
ChemicalCleaning(Boiler,Condenser,otherHeat
Exchanger)
ElectricalRepair&Installation
TurbovisoryandC&IJobs
O/HofallSteamTurbineExceptofKWUDesign
O/HofallSteamTurbineofKWUDesign
O/HofTurboGenerator
O/HofGasTurbineofSIEMENSdesign
Refractory&Thermalwoolpadinsulation&claddingof
boiler/pipingetc.
Sprayinsulation/CeramicPadInsulationofTurbineCasing
O/HofHydroTurbine
O/HofHydroGenerator
NonDestructiveTesting(U.T.,Radiography,MPI,DPTand
HeatTreatment)
ProvidingTechnicalManpowerforindependentsupervision
atsite
Fabrication/Repair/MachiningofthermalandHydro
TurbineComponents
Rebabitting&RefurbishmentofBearings

ANNEXURE
A
B
C

D
E
F
G
H
I
J
K
L
M
N
O
P
Q

Page1of1

AnnexureA
BOILERANDAUXILIARIES
1. Overhauling and minor repair of pressure parts viz. water walls, economizers and superheaters,
reheatersincludinghighpressurewelding.
2. Replacementofwaterwall,economizer,superheater,reheater,etc.
3. Servicing/minorrepairing/replacementofhighpressurevalves.
4. Overhauling/minorrepair/modificationofrotaryairheaters.
5. Replacementoftubularairheaterlower,middleandupperblocks,retubing.
6. Overhaulingoffans,pumps.
7. Overhaulingofballmills/tubemills.
8. Overhaulingofbowlmills/hammermills.
9. Overhauling/minorrepairofrawcoalfeedersandvariators.
10. Replacement/minorrepairofrawcoalfeedersrotaryandchaintypeandtheirvariators.
11. Overhaulingofpulverizedcoalfeedersandvariators.
12. Replacement/minorrepairofcoallinesstraightandbendportions.
13. Turnikets,screwconveyorcoalchutes,RCbunkers,PCbunkers,etc.
14. Replacementofoilandcoalburnernozzleboxes,connectingducts,tiltingmechanism,oilburnerandoil
system,etc.
15. Overhauling/minorrepairofairducts,gatesanddampers.
16. Minorrepair/overhaulingofmechanicalprecipitators.
17. Overhauling/revampingofelectrostaticprecipitators(mechanical).
18. Servicingofboilerdruminternals,gaugeglassesandconnectingvalves.
19. Replacement/minor repair of high pressure line drains and air vents, various connecting pipes, main
steamline,feedwaterlineandallotherlines.
20. Overhaulingofmuddrums,checking/replacementoforificeplates.
21. Overhaulingofcontrolledcirculationpumpsandtheirmotors.
22. Inspectionandminorrepairofallsupportsandhangersofpipes,ducts,etc.
23. Alltypeofrefractory,insulationandcladdingworks.
24. Varioustypesoffabricationworksincludingstainlesssteelfabrication.
25. Radiography,heattreatment,etc.ofhighpressureweldingjointsandtheirNDT.
26. Overhaulingofsootblowers.
27. Minorrepair/replacementofboilercasing,structure,etc.
28. Overhaulingofashhandlingsystem,slagconveyor,etc.

Page2of2

AnnexureB
OVERHAULINGANDCLEANINGOFCONDENSERBYHIGHPRESSUREJET,RETUBING,ETC.
1.
2.
3.
4.
5.
6.

Erectionofscaffoldingandopeningofgates.
Erectionandcommissioningoftemporaryhighpressurejetsystemincludingsupplyofallequipment.
Cleaningofthecondensertubesbyhighpressurejet.
Conductinghydraulictestandpluggingofleakingtubes.
Dismantlingofscaffolding,temporarysystemandnormalizing.
Condenserretubing:
Erectionofscaffoldinganddismantling.
Removalofolddamagedtubes.
Cleaningofholes.
Insertionoftubes,cutting,expansionandflaring.
Hydraulictesting.
Normalisationofsystem.

AnnexureC
CHEMICALCLEANINGOFCONDENSERSANDBOILERS
1.
2.
3.
4.
5.
6.
7.
8.

9.
10.
11.
12.
13.

Erectionofscaffolding/platforms.
Preparationofthecondenserforchemicalcleaningandnormalizingafterwards.
Erectionoftemporarysystem,includingsupplyofallequipmenti.e.pumps,pipelines,tank,etc.
Arrangementofchemicals,ifrequired.
Establishingatemporarytestingfacilityatsite.
Establishingsystemanddisposalofwasteasperstatutoryrequirements.
Normalisingofthesystem.
Preparationoftheboilerforchemicalcleaningandnormalizingafterwards.Thismayincludeopening
ofdrumandremovalofinternals,fixingofplugsinsuperheater/safetyvalveandotheropeningsin
thedrum,connectingtemporarysystemonthemainboilerafterremovalofinternalsofECONRV,
cuttingofhandholesinringheaders,etc.
Erectionoftemporarysystemincludingsupplyofallequipmentincludingpumps,pipelines,tank,etc.
Arrangementofchemicals,ifrequired.
Establishingatemporarytestingfacilityatsite.
Establishingsystemanddisposalofwasteasperstatutoryrequirements.
Normalisingofthesystem.

Page3of3

AnnexureD
ELECTRICALREPAIRANDINSTALLATION
A.
1.
2.
3.
4.
5.
6.
7.
8.
9.
B.
C.
D.
E.
F.
G.
H.
I.
J.
K.
L.
M.

TransformerJobs:
Dismantlingofterminalbushings.
Removaloftankcover.
Liftingofcorewindingassemblytofacilitateinspection/cleaning.
FabricationofspecialT&Pforundertakingrepairs.
Assistinfollowingactivitiesforrepairoftransformers:Unlacingandreplacementofcores,Replacement
ofdamagedcoilsbyspareones,Dismantlingandreassemblyofterminalgearassembly.
Takingoutofcoreandwindingassembly.
Dryoutbyvacuumpulling,inductionheating,oilcirculation.
Assemblyofterminalbushings.
Precommissionchecks,commissioning.
RewindingofHT/LTmotorsincludinginsulationofcoils.
Rewindingandrepairofpolecoilsofhydrogeneratorincludingreplacement/arrangementofinsulation
items.
Refurbishmentofpolecoilsofhydrogenerator.
RewindingofTurboGeneratorStator
Testingofelectromechanicalrelays,solidstaterelays,etc.
Stabilitytestofelectricalsystem.
Wiringofprotectioncircuit.
ServicingofMOCB,vacuumcircuitbreaker,ABCB,etc.
Servicingofisolator.
Hipottestingofcircuitbreakers.
Servicingofbatterychargerincludingreplacementofbattery,wiringthereof.
Powercablehipottesting.

AnnexureE
TURBOVISORYANDC&IJOBS
1. Removal/laying,dressing,glanding,ferrulingandterminationofPowerandControlCablesrequiredfor
HTandLTtransformers.
2. Erection/revampingofcontrolpanelsforsystemslikeexcitationsystemincludingAVR,furnacesafeguard
supervisory system (FSSS), turbine supervision system and removal of panels with mechanical work
connectedtothesystem.
3. Erection/testingoffieldinstruments.
4. Overhauling/calibrationandtestingofturbovisoryinstruments.
5. Mounting of control switches, relays, indicating lamp assemblies, annunciation system, indication and
recordinginstruments,etc.oncontrolpanel/controldesk.
6. Calibrationoftheindicatingandrecordinginstruments.
7. Precommissioningandcommissioningofthecontrolscheme.
8. SCADA,Onlinevibrationmonitoringsystem,Onlineconditionmonitoringsystem.

Essentialinstruments:
Digitaltongtester(ofgoodmakelikePhillipsMotwane)
Digitalmultimeter(ofgoodmakelikePhillipsMotwane)
Portablecalibrationsetupforfieldinstrumentsofpressure,etc.

Page4of4


AnnexureF
OVERHAULINGOFSTEAMTURBINEOTHERTHANKWUDESIGN
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.

Dismantlingandassemblyofcrossoverpipes.
LooseningofstudsofpartingplaneofLPC,liftLPcylinder.
Liftingofpedestalcoverandbarringgear.
Heat loosening of HP and MP outer cover parting plane studs / bolts, lift HP and MP outer casing.
HeatlooseningofHPandMPinnercasingpartingplanestuds/bolts.
LiftHPandMPinnercasinganduppercarriersofMPcylinders.
Dismantle/testLPHeaters.
DecoupleHP/MP,MP/LP,LP/GeneratorRotorsandcheckalignments.
Liftbearingtopsandcheckclearancesandinterference.
Checkrotorrunoutandjournalslopes.
Checksteamflowpathclearancesandthrustfloat.
LiftHP,MPandLProtors.
Removeallbottomdiaphragms,liners,etc.
Overturntopcasings.
Cleanallcasingpartingplanesandcheckthermaldistortionofindividualcasingbyhandscrapper.
Replacement of gland sealing fins on rotors. The job of rotor fin cutting is to be carried out with
safetyandproperprecautions.
Rectifythermaldistortion,ifany,andensureperfectmatchingofallindividualcasingpartingplane.
Clean all turbine parts including casing, rotors, diaphragms, etc. (Sand blasting will be carried out,
wherevernecessary).
UTandDPTofbearingsincludinggeneratorbearings(1to7).
Revisioning/reconditioning/colourmatchingofallsevenbearings,includingreplacement,wherever
required.
Alignment of rotors and finalising the position of bearings and slope checking including generator
bearings.
Assemblethrustbearingandcheck/adjustthrustfloat.
Centeringofalldiaphragmsandotherinternals.
Check/adjuststeamflowpathclearances,sealclearances,thermalclearances,etc.
BoxupLPcasingandtightenfasteners.
BoxupHPandMPinnercasingsandheattightenfasteners.
AssembleLPheatersintheLPcasing.
BoxupHPandMPoutercasingsandheattightenfasteners.
Check final alignment and do necessary corrections, if needed. Couple rotors after reaming, if
requiredincludinggeneratorandLPcouplingandgeneratorbearings.
OverhaulingofHPQC,IPQC,IVsandgoverningvalves,extractionNRVsincludingtheirservomotors.
Check/adjustbearingoilclearancesandinterferences.
RevisioningofMOPandgoverningsystem.
Cleaningandoverhaulingofoilinjector.
Overhaulingofturninggear.
Settingallsevenbearingsforoilflushingandnormalisingthereaftertoputmachineonturninggear.
Check/adjustgoverningcharacteristics.
Steamrollingandcheckingoverspeedprotections.
Trimbalancing,ifrequired.

Page5of5

AnnexureG
OVERHAULINGOFSTEAMTURBINEOFKWUDESIGN
HPMODULEOVERHAUL
1. Removal and disposal of thermal insulation from HP turbine. Dismantling of steam inlet and exhaust
piping.Openingofbreechnuts.LiftingofHPmodulefrompedestalsandplacingitonstands.
2. DismantlingofremovedHPmodule.LooseningofPPstuds.Cleaning/aluminablasting/sandblasting/wet
sandblastingofturbineinternals.Revisioningofrotorandcasing.
3. Centering of barrel in outer casing and assembly of the complete casing. Replacement of keys, as
required.Maintainingaxialandradialclearances.Machiningoffins,ifrequired.
4. Liftingthebarrelandplacingitinhorizontalposition,removaloflockingdevicesandsupportingtherotor
onfixture.Fittingofsealsandouterglands.ShiftingofHPmodulefromfixturetopedestals.
5. Connectionofallpiping.Rollcheck,bumpcheck,horndroptestandconnection.
HPMODULEREPLACEMENT
1. Liftingofoldmodulefrompedestalsandplacingitonfixture.
2. ShiftingofnewHPmoduletopedestalsafterremovingallpreservationcoatings/covers/capsoncasing
androtor.Removaloftransportationdeviceafterloadingtherotoronthebearings.
3. Removal of emergency governor shaft from the old module and its fitting / centering on rotor of new
moduleincludinginsituservicingofbothoverspeedstrikers.
4. Connectionofallpipingwithcasingtobecarriedoutincludinginsitudrillingoflocatingpinholesinthe
inletinsert.Horndroptest,rollcheckandbumpcheckofnewmoduletobecarriedoutbeforeandafter
connectionofpipingandcorrected.
IPMODULE
1. RemovalofcompleteIPturbineinsulationanditsdisposal.Dismantlingofinlet,glandsealingsteamand
extractionlinesoftopcasingafterproperlysupportingthem,includingcutting,ifrequired.
2. Dismantlingofexhauststeamlinesfromtopcasingandglands.Heatlooseningofjointboltsandliftingof
top half of IP inner and outer casings. Measure axial, radial and shaft seal clearances and radial, facial
runoutofIPcouplings.RemovalofIProtorandIPinnercasing.
3. Cleaning/alumina blasting/sand blasting/wet sand blasting of IP turbine internals. Checking of parting
planegapsofinnerandoutercasingandrectifications.Replacementofglandfins,asreqd.
4. BoxupofIPinnerandoutercasings,rollcheck,bumpcheckandheattighteningofjointbolts.Boxupof
front,glandboxes.Assemblyofinlet,glandsteam,extractionlinesandexhauststeampipes.
LPMODULE
1. Removal of LP gland box upper halves and checking of seal clearances. Loosening of LP casing parting
plane bolts and lifting of outer casing. Removal of LP innerouter and innerinner casing top halves.
CheckingandrectificationofaxialandradialclearancesofLPcasing/rotor.
2. LiftingofLProtorandplacementofrotoronstandsaftersupportingproperly.
3. Checking for looseness of lades of LP rotor and DP testing, wherever necessary. Rectification of loose
blades, if any. Inspection of LPT expansion bellows, LPT inlet pipe (LHS & RHS), bellow protection pipe
weldingseamsandLPcasingtopedestalexpansionbellowsbyDPT.
4. Cleaning/alumina blasting/sand blasting/wet sand blasting of LP turbine internals. Check parting plane
gapsandovalityofinnerinnerandinneroutercasingsandrectification.
5. Placement of LP rotor back in position after cleaning work. Boxup of LP innerinner and innerouter
casings, roll check and correction. Boxup of LP outer casing after complete inspection of condenser
internal (steam space). Setting of gland box clearances, key clearances and assembly of gland boxes
includingreplacementofsegments,ifrequiredandmakingofclearances.
BEARINGINSPECTION
1. Removalofbearing1to7pedestalcoversandbearingT/Haftercheckingyokekeyclearances.Coupled
andfreerunoutchecksofallrotorsandcouplings.
Page6of6

2. DecouplingofHP/MOP.OverhaulingofMOP.DPTandUTofMOPbearingsandreplacementofwornout
/damagedparts,reassembly,realignmentandcoupling.
3. Measurement of catenary of TG rotors using pot levels and corrections. Roll check and bump check of
HP,IPandLPcasings.SwingcheckatHPfront.DecouplingofHPIPandIPLProtors,measuringalignment
of rotors. Inspection, NDT and revisioning of all TG bearings. Inspection and rectification of contact
betweentorusandsupport.Revisioningofthrustbearing,adjustmentofthrustfloat.
4. AlignmentofHP/IPandIP/LProtors.Couplingofrotorsincludingreaming/honingandmachiningofnew
couplingbolts.Rollcheck,bumpcheck,horndroptestandcenteringofHP,IPandLPcasings.Adjustment
ofaxialandradialkeysandpackers,ifreqd,incl.machining,matchingandlubrication.
5. Resettingofallbearings,oilcatchersandpedestaloilguardrings,repair/replacementofsealingstripsas
perrequirement.Dismantling,overhaulandadjustmentofoverspeedtripdeviceandthrustbearingtrip
device.Barringgearnozzleremoval,repair/replacementoffinsandreassembly.
6. BoxupofTGbearings1to7.Preparationforoilflushing,cleaningofoilfilters,basketstrainers,duplex
filtersandresettingofthrottlesoncompletionoftheflushing.
7. Assistanceinsteamrollingandsynchronizationandattendingtoanydefectsobservedduringthesame.
Assistanceintrimbalancingofthemachine.
VALVESHP,IP,LPBYPASS,SPRAYVALVESANDSERVOMOTORS
1. Removalanddismantlingofthevalvesandactuatorassemblyaftermeasuringvalvetravel.
2. Cleaningandinspectionofvalves,valvestems,studs,bushesandpilotseatincludingNDTandchecking
ofvalvestemsrunout.Rectification/replacementofcomponents,ifrequired.
3. Inspectionofallsealingfacesatthevalvesets,backseat,sealingring,etc.andstopvalveservomotordisc
topandrectification,asnecessary.
4. Inspectionofbackseatbushings,spacerrings,glandpackingsandservomotoroilsealrings.
5. Assemblyofcompletevalvesincludingservomotorsandconnectionofallpiping.Checkingofvalvesfor
any leaks and proper functioning. Measurement of valve stem lifts/travel/compression. Adjustment of
valvesduringfinalsetting.
VALVESHPBYPASSANDSPRAYVALVESANDSERVOMOTORS
1. Removeinsulation,cuttingofspraylineanddecouplingofthevalve.Dismantlingofthevalve.
2. Checkconditionofthestrainer,valveconeandvalveseat.Repair/replacethewornout/damagedparts,
ifrequired.Lappingofseatinposition.Seatcutting,ifrequired.
3. Assemble the valve back and weld the spray line. Root run to be TIG welded. Revisioning of
servomotors/actuators and servovalves of the HPBP valves and spray valves including pilot valves.
Associatedoilpipingshallbetakenupforoilflushing.Couplingandcommissioningofthevalve.
MSANDHRHSTRAINERS
1. Cutting of strainer drain lines, dismantling of main steam and HRH strainers, inspection/NDT, cleaning
andrectification,replacementofgasketsandreassembly,TIGweldingofstrainerdrainlines,rectification
afterradiography,ifrequired.
GOVERNINGANDLPBYPASSRACKS
1. Revisioning of all the components, feedback assemblies, their inspection and cleaning. Replacement of
components, ORings, oil seals and other parts, if required. Commissioning and resetting of Governing
andLPBypassRacksvisvisrespectivestopandcontrolvalves,CRHNRVs,waterinjectionvalves,etc.to
designvalues.
CONDENSATEEXTRACTIONPUMPSANDCIRCULATINGWATERPUMPS
1. Complete dismantling of the pump including decoupling. Piping disconnection and recording of pre
dismantling float, etc. Cleaning, inspection and revisioning of all components. Check runout of shafts.
Clearancecheckingofstagesleeveandcutlassrubberbearings.
2. Clearance checking of stage bush and restriction bush. Repair/replacement of the wornout/ damaged
parts.Properlockingofwearrings,bearingbushes,etc.byscrews.Assemblyofthepumpandheadgear.
Checking of axial float and centering. Assembly of the bearing housing with bearings, oil filling after
flushingofthehousing.Boxingupofthepump.Assemblyofgland.Installationofthemotor,alignment
withpump,couplingandtrialrunofthepump.
Page7of7

AnnexureH
OVERHAULINGOFALLTURBOGENERATOR
1. Checkingcoupledrunoutandbearingyokeclearance.DecoupleandcheckLPGeneratoralignment.
2. Removal of oil pipelines. Dismantling of hydrogen seals of both sides and checking of seal liners.
Replacementofsealliners,ifrequired.
3. Removalofendshieldsandfanshieldsofbothsides.Removaloffanbladesofbothsides.
4. Removalofbrushgearassemblyandbearingno.7.Reassemblyofbearingno.7andbrushgearincluding
alignmentwithsliprings.
5. Threadingoutofgeneratorrotoraftercheckingairgap,magneticcentre&demagnetizationofrotor.
6. Removalofhydrogencoolers,cleaningoftubesandconductinghydraulictest.Facematchingofcoolers
andwaterbox.Reassemblyofthehydrogencoolersincludingreplacementofgaskets.
7. AssistanceincheckingofRTDsofstatorwinding/slot.ReplacementofRTDswhereverpossible.
8. Replacementofgeneratorstatorbushingandgaskets,ifrequired.Asbestosfibrecementingofterminal
bushing,ifrequired.
9. UT/DPtestingofbearingsandreplacement,ifrequired.
10. Rotorpurge test,airtightnesstestandreplacementofwashersofallthefourinnerandouter current
carryingbolts.Removal/refittingoffanhub.Replacementofslipring,ifrequired.
11. DPtestofrotorretainingrings.
12. Inspection,checking,tightnessofcorebarnutsandtheirlocking.Checkingandremovaloftechnological
bolts,ifany.
13. Checkingtightnessofoverhangbracketboltsandbusbarsupportbracketboltsandtheirlocking.
14. CheckingconditionofTeflontubes,waterheaderandinsulatingboxcoverandreplacement,ifreqd.
15. Inspectionofstatorwindingandmeasurementofradialdeflectionmovementofthestatorwedgesand
retightening,ifrequired.
16. Hydraulictestingofstatorwinding.Attendingtofailureofminornaturenoticed.
17. ELCIDtestonstatorcore.MinorrectificationandretestofELCID.
18. Clearingofblockagesinstatorwindingbyreverseflowofwaterinwinding.
19. PIvaluecheckinganditsimprovement,ifnecessary.
20. Epoxyinjectionontheoverhangportionofthestatorwindingandsprayvarnishonstatorandrotor.
21. Rotorthreadingin.InsertionofhydrogencoolersandfixingofUBends.
22. MeasurementandrectificationofLPGeneratorcouplingfacialrunout.
23. LPGenerator alignment and coupling including reaming/honing and machining of new bolts and
replacementofbolts,ifrequired.Checkingandcorrectionofcoupledrunout.
24. Measurementoffinalairgapandmagneticcentreandcorrection,ifrequired.
25. Mounting of fan blades and assembly of end shield, seal body, fan shields and seal body pipelines
includingreplacementofgasketsingasandoilsystemlinesconnectedtostatorbody.
26. Checkingofauxiliaryshaftrunoutandcorrection,ifnecessary.
27. Assembly of bearings. Checking of oil clearances of bearing and setting of bearing pad and yoke keys.
Boxupofbearingpedestals5,6and7.
28. RevisioningofDPRVA&Bandresttingofreliefvalvesofsealoilpumps.
29. Preparationforoilflushing.
30. Gastightnesstestofgeneratorafterfinalboxup.Thescopewillbelimitedtoinspectionofendshield
joints,sealbodyjoints,hydrogencoolers,flangesandprechambersonly.
31. Removalofbrushlessexciter,whereverprovided.
32. Electricalchecking/testingofdiodes,fusesandreplacement,etc.
33. Checkingofbearinginsulationandrectification,ifrequired.

Page8of8

AnnexureI
OVERHAULINGOFSIEMENSDESIGNGASTURBINES
1. Compressor/turbine washing. Mark and remove insulation. Spray/apply antiseize compound on bolts
andnuts.Openallmanholesandcheckforabnormalities.Disconnectfueloil/gaspipelines.Disconnect
electricalandinstrumentationequipment.Measurebacklashofturninggearandundoallblowoffpipes.
Measureradialclearancesofturbineblades.
2. Removal of intermediate shaft cover/suction cone/inlet. Check coupled runout of both the couplings.
Decouple turbine/intermediate shaft and intermediate shaft/generator, check alignment and conduct
bumpcheck.Providesupportsunderthecentrecasing.Takeoutallcentre/guidepins.
3. Removalofcombustionchambersafteropeningtheflangebolts.
4. Grindoffexhaustcasingliners.Openboltsofcentreandexhaustcasingsandliftingoftophalves.
5. Dismantle all piping connections and burners on both CCs. Take out all gas and oil valves. Conduct
pneumatictestingofallballvalves.OpeningofboltsofdomesofbothCCs.Liftofftopdomesandflame
tubesofbothCCs.Removediagonalswirlersandinspectfordamages.Inspectionofburnerinsertrings
fordamageandremovalofthesame,ifrequired.
6. Inspectionoftilesandtileholdersofbothflametubes.Replacementofdamagedtiles/tileholders.
7. Takeoutmixingchambersfromcombustionchambers,ifrequired.OpenKRingandliftofftophalf.
8. Apply/spray antirust compound on all blade carriers. Provision of jack bolts for the blade carriers.
Opening of bolts of carriers and lifting of the top halves. Lift off stuffing box and compressor/turbine
bearings.Measurementofaxial/radialbladeclearancesofturbine/compressorstages.
9. Fixinnercasingwithclampstorotor.Lifttheturbinerotorandshifttoupendingdevice.
10. Upendtherotorfromhorizontaltoverticalposition.Prepareplatformonallfoursides.
11. Unclamp/relieverotor.Recorddeflectionoftierod.Dismantlerotorincludinginnercasing.
12. Removetheintermediateshaft.Removetheturninggeardevicefromcompressorbearings.
13. Removecentreguidesofthelowerhalfcarriersandtakeoutthelowerhalves.Dismantlingoftheturbine
stationary/rotorbladesofstages1/2.Dismantlingcompressordiaphragmsfromtopcarriers.
14. NDTworksonbearings,tierod,compressorbladedrotordiscs,turbineblades,etc.includingsupplyof
DPtestkits,MPItestingkit,MPIfluidsandUTkits.
15. Repair/reconditioningoftheinnercasing,mixingchambersandflametubes.
16. Reconditioningandassemblyofturbine/compressorblades.
17. Assemblyofrotor&tighteningoftherotortierod.Assemblyofcompressordiaphragmsincarriers.
18. Overhaulofblowoffvalvesandoilpumps.Overhaulofturninggear/overspeedtrippingdevice.
19. Insert lower halves of turbine/compressor blade carriers. Install turbine/compressor bearings after
checkingclearances.Inserttheintermediateshaftinposition.InsertKRingbottomhalfinposition.
20. AssemblyofflametubeandtopdomesofbothCCs,assemblyofburnersandpipings.
21. TurnrotorfromverticaltohorizontalpositionandshifttoTGhallandinsertrotorinposition.Makeinner
casingfreefromrotor.Preparebearingsforjackingoil.Turnrotorandgrindturbineblades.
22. Bump check and measurement of axial/radial clearances. Boxup and assembly of the blade carriers.
Assembly of KRing. Assemble the shaft gland box and turbine bearings. Boxup and assembly of the
centrecasing/exhaustcasing.Assemblethecombustionchamberstocentrecasing.
23. Measurement of radial clearances and centering. Alignment of turbine, intermediate shaft, generator
rotors.Couplingofallrotorsincludingstretchingofboltsbyhydraulicdevice.
24. Assemblyofturninggear/overspeedtrippingdevice.Weldingofexhaustcasingliners.
25. Fixing of the instruments and adjustment of guide vanes. Fixing of air intake casing, suction cone and
intermediateshaftcover.Insertalllowercentreguides.
26. Lubeoiltankcleaning/oilflushing.
27. Fixingofblowoffvalves/pipes.Finalchecksandclosingofmanholes.
28. Insulationoftheturbineincludingsupplyandapplication.
29. Turninggearoperation/startup.
Page9of9

AnnexureJ

REFRACTORY/THERMALWOOL/PADINSULATION&CLADDINGOFBOILER/PIPING

1. Refractorybricklining,plastering,insulationbricklining,etc.ofboiler.
2. Thermalmineralwool/padinsulationwithproperaluminiumcladding.

AnnexureK

SPRAY/CERAMICPADINSULATIONOFTURBINECASING

1. Sodium silicate spray/calcium silicate type thermal insulation of HP, MP and LP cylinders and valves as
perBHEL/Manufacturersspecifications.
2. Thermal mineral wool/pad insulation with proper aluminium cladding of transfer pipe, omega pipes,
crossoverpipesand2metrelengthofallotherpipelinesconnectedwithturbinebottomcylinders.
3. Temperatureratingsoftransferandomegapipesis5350Candthatofcrossoverpipesis2500C.
4. Ceramicpadinsulationofturbinecasingsasperspecifications.

AnnexureL&M

OVERHAULINGOFHYDROTURBINES(FRANCIS,KAPLAN,PELTON)ANDGENERATORSAND
THEIRAUXILIARIES

1. Insiturepairofunderwaterpartsinhydroturbinesinvolvingcomponentslikerunnerblades,runnerhub,
runnerchamber,drafttubecone,guidevanes,pivotring,topcoverliner,shaftsealingsystem,etc.and
epoxygroutingofdrafttubeandrunnerchamber.
2. Insiturepairofstatorwindinginhydrogenerators.
3. Majoroverhauling/renovationofcompletehydrogeneratingsetsincludingturbineaswellasgenerator
and their auxiliaries that shall involve the general maintenance of all dismantled components besides
repair. Likely items earmarked for replacement are all rubber seals, Orings, all fasteners,
top/middle/bottom guide vane bushes, guide vane cup seals, neoprene rubber seals, grease lubricant
system,shearpins,shaftsleeve,looseinsulationmaterial,epoxypaints,etc.
4. Repairofoldturbinerunnerassembly.
5. Repairofoldguidevanes.
6. Overhaulingofgoverningsystem(bothelectricalandmechanicalcubicles).
7. Overhaulingofexcitationsystem.

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AnnexureN

NDTANDHEATTREATMENT

1.
2.
3.
4.
5.

RadiographyofHPweldingjointsoftubes/pipesupto400mm.
StressRelievingofHPweldingjointsoftubes/pipesupto400mm.
UT/DPT/MPIofvariouscomponentsandweldjoints.
Thicknessmeasurement/surveyofboilerpressureparts,casingsofhydroturbines,etc.
Preheating/stressrelievingofjoints/componentsusingresistance/inductionheatingwithrecorders.

AnnexureO

PROVIDINGTECHNICALMANPOWERFORINDEPENDENTSUPERVISIONATSITE

Providingtechnicalmanpowerforindependentsupervisionofsiteworkssuchas:

1. Boiler:
a) AirPreheater
b) Valvessafetyandconventional
c) Wallblowers
d) Pressureparts
e) Mills
f) Burners
2. Turbine:
a) KWUDesign
b) LMWDesign
c) Industrial
3. Generator
4. HydroTurbine
5. HydroGenerator
6. TransformerandBreaker
7. Watertreatment
8. EnergyAuditofPowerPlants

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AnnexureP

FABRICATION/REPAIR/MACHININGOFTHERMALANDHYDROMACHINECOMPONENTS
1. The parties interested to enroll for this area of work should have their own Machining facility (i.e.:
Factory/Machineshop,tieupforcastingfacilitywithreputedfirminIndia/abroad)
2. Transportationofthecomponentsto&froworksofthesubcontractor/vendor.
3. Transitinsurance&insuranceduringperformanceofcontractattheworksforasumassuredthatshall
beindicatedbyBHELoncasetocasebasis.
4. FABRICATION/REPAIR/MACHINING of various components of Steam Turbine ( Viz: Gland Body,
Diaphragm,Guidewheels,Labyrinth,Casingetc)asperdrawing/instructionofBHEL,Insitu/attheworks
ofthevendor.
5. FABRICATION/REPAIR/MACHININGofvariouscomponentsofSteamGenerator(Viz:Mills,Fans,Flanges,
Labyrinth,Casingetc)asperdrawing/instructionofBHEL,Insitu/attheworksofthevendor.
6. Reverse engineering of the components wherever required based on OGA Drawing, actual physical
configurationorinstructionsofBHELoncasetocasebasis.
7. FABRICATION/REPAIR/MACHINING of Hydro Turbine Runners (Francis, Kaplan, Pelton wheel) of the
rating6.0MWandabove,ashighas150MW.
8. FABRICATION/REPAIR/MACHININGofHydroTurbineComponents(Viz:TopCover,Labyrinth,PivotRing,
GuideVanes,Bushes,Bearingbody,SpiralCasing,MirrorDisc,ThrustBearingFramesetc)
9. FABRICATION/REPAIR/MACHININGofHydroTurbineshaftatvariouslocationsasperrequirement.
10. Heattreatmentofthecomponentswhereverrequiredasperprocedure.
11. Casting of Blades/Vanes and other Hydro machine components or tie up for the same with reputed
castingfirmsinIndia&abroad.
12. Machining/Fabrication/Repair/Castingetcshouldbedoneaspertheaccuracyspecifiedinthedrawing/as
perdirectionofBHEL.
13. Heattreatmentfacilityortieupforthesameshouldbeavailableattheirdisposal.
14. ThepartiesshouldbeabletoperformHVOFcoatingofComponentsthroughtheirownfacilityorthrough
tieupwithreputedfirmsinthisarea.
15. Theinterestedpartiesshouldhavetieupwiththirdpartyinspection(Viz:M/sLloyd,RITES,DNV,BVQI
etc)sothattheirservicescouldrequisitionedasperrequirementofBHEL.

The above scope is tentative, the interested parties should be capable of performing the Fabrication/
MachiningandrepairholisticallytoanyextentforSteamandHydroturbineComponents.

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AnnexureQ
REBABBITTINGANDREFURBISHMENTOFBEARINGS
1.
2.
3.
4.
5.

Transportationofbearingshellalongwithhousingto&frositetoworks.
TestingoftheBearingShellafterdemetallization.
RebabitingofbearingshellaspertechnicalSpecificationofBabbittmaterial.
Machiningofthebearingtosuitthediameter.
Ensurefollowingbeforemachiningofshell:
Partingplanematchingofbearingshell.
Tightnessofbearingshellwithhousing.
Redowellingofshell&bearinghousing.
Radial&facialrunoutofassembly
6. DPTestingandUltrasonictestingoftherebabbittedBearingstolookforsurfacecracks,porosity,
blowholes,lackofbonding,etc.andrectificationofthesameasperrequirement.TheNDTshallbe
carriedoutinthepresenceofourexperts.
7. ReverseengineeringoftheentirebearingsbasedonOGAdrawingsandshaftdiameter.
8. Completearrangementofbearingincludingmaterial(Babbittandhousingcasting)basedonreverse
engineeringdata/BHELSUPPLIEDDATAoncasetocasebasis.

TestcertificateofBabbittmaterialistobeprovidedbythesubcontractor.Inspectionofthebearing
willbecarriedoutbyBHELengineer.
Thesubcontractorwillgive12monthswarrantyofrebabittedbearingfromdateofreceiptatsite
towardsmaterial&workmanship.

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LIST OF EXPECTED MAJOR T &P & IMTEs

1. TORQUE WRENCH OF VARIOUS SIZES FROM :5PSI TO 150PSI.
2. SPANNERS : 5MM TO 95 MM WITH RATCHET FACILITY
D-SHAPE
SOCKETS
RING-SHAPE
3. HAMMERS: 1.2 KG TO 5 KG.
4. MALLETS/NYLON HAMMERS/WOODEN HAMMERS
5. SCREW JACKS: UPTO100MT
6. HYD-JACKS: 5MT TO 50 MT WITH PUMPING UNITS.
7. WELDING GENERATORS: UP TO 320AMPS CAPACITY.
8. WELDING TRANSFORMERS WITH RECTIFIER UNITS.
9. INSULATED WELDING TORCH & GADGETS.
10. GQ-4 GRINDING MACHINE.
11. AG-7, AG-5 GRINDING MACHINE.
12. FF-2/FLEXIBLE GRINDER.
13. PISTOL GRINDERS.
14. ELECTRIC WINCH CAPACITY:5MT & 10MT.
15. HAND REAMERS : DIA UPTO :25.0 MM
16. TAPSETS: UP TO M20 THREADED HOLE.
17. HAND DRILL MACHINE: UPTO Dia:10.00MM
18. MAGNETIC BASE-POST DRILL MACHINE: UPTO Dia : 40MM.
19. VERNIER CALLIPERS: UPTO 300 MM LENGTH.
20. INSIDE MICROMETERS: UPTO 1.5 MTRS LENGTH
21. OUTSIDE MICROMETERS: UPTO 500 MM
22. DEPTH MICROMETER
23. FEELER GUAGES :MIN:0.03MM TO 1.00MM
24. DIAL GUAGES-LEAST COUNT:0.01MM
25. CHAIN BLOCKS/PULLING DEVICE : MIN:2MT MAX:25MT
26. MULTI-SHEEVE PULLY UPTO 25 MT.
27. SLINGS UPTO PAYLOAD CAPACITY: 10 MT.
28. THEODOLITE
29. : ACCURACY: 0.5MM/MTR.
30. LEVEL INSTRUMENT: ACCURACY UPTO: 0.025MM/MTR
31. MEASURING TAPES: UPTO: 30MTR.
32. STEEL-SCALES: UPTO: 1MTR
33. LOW VOLTAGE (24VOLTS) POWER SUPPLY SOURCE.
34. INSULATED PLIERS FOR ELECTRICAL WORK
35. PLIERS
NOSE PLIER
CROCODILE PLIER
26 FILES OF ALL CATEGORY.
27 VICE : 100MM X 300 MM
28 CUTTING TORCH WITH ADAPTERS.
29 CRIMPING TOOLS
30 SCREW-DRIVERS: UP TO 8.0 MM.
31 SLIP GAUGE
32 DIAL BORE GAUGE
33 TELESCOPIC GAUGE
34 TAPER GAUGE

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