Save Energy For The Benefit Of Self And Nation

Transcript

GSECL TPS SIKKA Page 1 of 27 “ Save Energy for the Benefit of Self and Nation ” Tender Invited for Work of overhauling of Air Pre Heater of Boiler Unit No. 1 during AOH at STPS Chief Engineer (Gen.) Gujarat State Electricity Corporation Ltd., Thermal Power Station, Sikka – 361 141 (Dist. Jamnagar) invites “On line Tenders” (e-tendering) for the work of above subject item. Tender Papers & Specifications may be down loaded from Web site http://gsecl.nprocure.com (For view, down load and on line submission) and GUVNL / GSECL web sites www.guvnl.com / www.gseb.com & www.gsecl.in (For view & down load only.) Tender fee may be paid along with submission of tender in EMD cover, for respective tender. “All the relevant documents of tenders to be submitted physically will be received only by Registered Post A.D. or Speed Post addressed to Chief Engineer (Gen.) Gujarat State Electricity Corporation Ltd., Thermal Power Station, Sikka – 361 141 (Dist. Jamnagar) Superscribing the envelope with Tender No. and Description. “No Courier Service or Hand Delivery” will be accepted. Tender No. 09 / 01 / 2014 (BMD - 28086) Estimated Cost of the tender items. Rs. 884052.00 Earnest Money Deposit Amount Rs. 8841.00 Tender Fees Amount (Non-Refundable) Rs. 750.00 Security Deposit 5 % of Order Value before placement of order Online (e-tendering) tender / offer submission last date up to 17:30 Hrs. only (this is mandatory) As per E-Tender Notice No. 09 Physical receipt of all the relevant documents last date up to 15:00 Hrs. By RPAD or Speed Post only As per E-Tender Notice No. 09 Date of opening of Tender Fee, EMD Cover and Technical Bid physical as well as on line opening at 15.30 Hrs. As per E-Tender Notice No. 09 Tentative date of on-line opening of price bid (if possible) at 15.30 Hrs. Will be intimated to technically qualified parties only. Time Limit 11 Months Validity of Tender 04 Months from the Opening of Technical Bid Class of Registration --- GSECL TPS SIKKA 01. 02. 03. 04. Page 2 of 27 All the relevant documents as per requirement of the Tender must also be submitted physically along with the Tender Fee in EMD sealed cover so that the same is received in this office on OR before the due date and time. All such documents should be strictly submitted by RPAD / speed post only. Otherwise the offer will not be considered and no any further communication in the matter will be entertained. Any deviation found in Data / Details / Documents between on line offer (etendering) and physically submitted documents (Tender document fee, bidder, offer of the same bidder) will not be considered and no any further communication in the matter will be entertained. Further bidders are requested to submit price – bid (Schedule-B) on-line only and not to submit the price bid in physical form. This is mandatory. If price bid is submitted in physical form, same will not be opened and only on-line submitted price bid will be considered for evaluation. Further if the quantity quoted differs in the any of the technical bid forms and in price bid forms, it is at the discretion of CE Committee / ED Committee – GSECL to consider the quoted quantity. It is mandatory for all the bidders to submit their tender documents by both forms viz. on – line (e-tendering) and physically in schedule time. Tender documents submitted in only any one, say either by on line or physically, in that case the same tender will not be considered. Any technical questions, information and clarifications that may be required pertaining to this enquiry should be referred to the Chief Engineer (Gen.) Gujarat State Electricity Corporation Ltd., Thermal Power Station, Sikka – 361 141 (Dist. Jamnagar). GSECL reserve the rights to accept / reject any or all tenders without assigning any reasons thereof. Signature of Contractor with Place / Date / Firm Seal / Stamp For, Gujarat State Electricity Corporation Ltd. Sd/Chief Engineer Thermal Power Station, Sikka. GSECL TPS SIKKA Page 3 of 27 DETAILS OF BIDDER 01. Name of Firm & Contact Person 02. Full Postal Address Phone/Fax No. Mobile No. E-mail Address : 03. GST / CST / ECC / TIN No. 04. Status of the firm with supporting documents Proprietary / Partnership / Pvt. / Public Limited. 05. Name of Agencies / Directors if not prop. Name of owner, if propriety, with phone / Fax Nos. 06. Registration certificate No. with GSECL 07. SSI No. (Notarized copy) 08. Labour License No. 09. P.F. A/C. Code No. 10. Service Tax No. 11. PAN No. 12. Latest bank solvency certificate at least 20 % of estimated cost (Not more than One year old) 13. Tender fee Amount DD No. & Date 14. EMD Amount DD No. & Date IMP ORT A NT N OT E 01. 02. This tender should be submitted duly signed without removing a single page. Otherwise the tender is liable to be rejected. For SUPPLY TENDER, TIN number should be invariable mentioned in their technical bid otherwise your offer will be ignored and price bid will not be opened. Signature of Contractor with Place / Date / Firm Seal / Stamp For, Gujarat State Electricity Corporation Ltd. Sd/Chief Engineer Thermal Power Station, Sikka. GSECL TPS SIKKA Page 4 of 27 E - TENDER GENERAL TERMS & CONDITIONS 01. 02. 03. 04. 05. 06. Tender Fee Paid Details (Tender Fee is COMPULSARY & there is no Exemption for Tender Fee). SSI / NSIC Firm also have to pay Tender Fee. Tender Fee & Earnest Money Deposit - will be accepted by D.D. in favour of Gujarat State Electricity Corp. Ltd., payable at State Bank of India, Sikka TPS Branch only (Branch Code No. 60417). Cheque are not accepted & Tenders submitted without tender fee / EMD will not be accepted. Tender “Technical Bid” Cover Packing & EMD + Tender Fee… Earnest Money Deposit is to be paid as per Tender Advertisement. Subject & Tender Notice No. & Item No. Clearly written on all covers. (01) EMD + Tender Fee DD Cover (02) Technical Bid Cover Also clearly mention on the covers. DD for payment of EMD & Tender Fee Demand Draft must be placed in the cover super scribing “EMD & Tender Fee” along with requisite documents as mentioned in the Condition. EMD + Tender Fee both should be kept in one separate cover & should be submitted with Technical Bid Covers. The Tender documents are to be submitted in namely Technical Bid with all enclosures of the tender documents respective covers accordingly along with the tender number. Technical Bid : The technical bid shall comprise of all the technical details of the stores / materials offered in accordance with the Corporation guaranteed technical particulars and conditions, etc. The Technical Bid shall be opened at 15.30 Hrs. on Due Date (If Possible), in the presence of those tenderers who wish to be present. If the Authorized Representative is likely to be present then he must submit the authorization letter of the representing company at the time of opening of Bids and this is compulsory. Only One authorized Representative shall be allowed. Please note that the required documents should be invariably submitted with tender copy. And tender without documents is liable to be ignored. Price Bid : Bidders are requested to submit Price Bid (Schedule-B) on-line only and not to submit the price bid in physical form. This is mandatory. If price bid is submitted in physical form, same will not be opened and only on-line submitted price bid will be considered for evaluation. Further if the quantity quoted differs in the any of the technical bid forms and in price bid forms, it is discretion of Committee – GSECL to consider the quoted quantity. Any technical questions information and clarifications that may be required pertaining to this Tender should be referred to The Chief Engineer, GSECL, TPS, Sikka, who also reserves the right to reject any OR all tenders without assigning any reasons thereof. Experience of Criteria Condition for Pre-qualification in Technical Bid… (Civil Works) The bidder should produce evidence of having experience of execution of similar nature of works for Rehabilitation work of high rise structures in Government / Semi Government / GSECL / State / Central / Railway with the documentary evidence, preferably certified copy of work order and satisfactorily work completion certificate from respective department thereof. “Technical Bid” duly filled must be accompanied by the following documents…. The reputed contractors with sound engineering back ground, experience and financial capability, fulfilling qualifying requirement stated hereunder at Sikka TPS, Gujarat. (a) Registration of appropriate class with State / Central Government / Railway / Electricity Board etc. (for Civil Works) GSECL TPS SIKKA Page 5 of 27 (b) 07. Experience certificate for execution of similar works of the magnitude (as specified in Special Note for Pre qualification) successfully completed by the contractor. (c) Solvency Certificate for 20 % value of the estimated cost of any Nationalized Bank. (d) Certificate of separate provident fund account number. (Only for works and if works to be carried out in premises of STPS.) (e) Details of Tools, tackles, equipments and personals available with firm. (f) Tenderer should down load the tender documents from the above Website and submit the same as per instruction therein by RPAD / Speed Post only. (g) The tenders duly filled in sealed covers will be received by RPAD / Speed Post at “The Chief Engineer, Gujarat State Electricity Corporation, Thermal Power Station, Sikka – 361 141, Dist. Jamnagar” Up to 15.00 hrs. on last date of submission and will be opened at 15.30 hrs. on the scheduled date (if possible) in the presence of bidders who wish to remain present. (h) Tender Fee and EMD will be accepted by DD only in favour of GSECL payable at Sikka TPS. No cheques or FDR will be accepted. Tenders received without EMD & Tender Fee are liable for rejection. (i) Tenderer should quote the reference of payment of EMD & Tender Fee i.e. DD No. & Date for EMD - DD No. & Date for Tender Fee on cover page of Technical Bid otherwise Bid will not be considered for opening. Tenderer should also certify as “unconditional tender” on tender cover it self. (j) Gujarat State Electricity Corporation, reserves the right to accept or to reject any or all the tender without assigning any reasons thereof. (k) Contractor shall have to submit the attested copy of EPF Code No. Certificate received from RPFC without fail otherwise tender will not be opened. Other Condition…. (a) The detailed description and full particulars will be available in the Tender Copy (Non transferable) (b) EMD at 1 % of the estimated cost is to be paid by D.D. in favour of Gujarat State Electricity Corporation Ltd. payable at State Bank of India, Sikka. Tenders without EMD are liable for rejection. The SSI / NSIC will be accepted for exemption of EMD for supply of subjected material only, otherwise tender / offer will be ignored. The Xerox copy submitted for SSI / NSIC shall be notarized only. SSI / NSIC submitted other than indented material will not be accepted for waival of EMD / SD and without payment of EMD, tender will be rejected out rightly without intimation to the party. No correspondence will be entertained further in the matter. (c) Security Deposit : Lowest party shall have to pay Security Deposit as, 5 % in case of Works & 10 % in case of Supply of order value before placement of order. (d) Small, Cottage and tiny industrial units of Gujarat State having the registrations numbers for production of goods and having the registration numbers from Govt. of Gujarat to submit Security Deposit and performance guarantee as under. (01) Wherever in the purchase policy, the Security Deposit and Performance Bank Guarantee rate of 5 % is stipulated, the same be considered at 3 % for Small, Cottage & tiny industrial units of Gujarat State. (e) (02) Wherever the rate of Security Deposit & performance Bank Guarantee of 10 % is stipulated in the purchase policy, the same be considered as 6 % for Small, Cottage & tiny industrial units of Gujarat State. (03) Security Deposit and Performance Bank Guarantee shall not be insisted concurrently and therefore Security Deposit may be converted into Performance Bank Guarantee or once PBG is submitted, SD will be refunded Technical bid should contain legible and attested copies of requisite documents like……. (01) Necessary Experience of the work / supply of similar nature. (02) Satisfactory completion certificate of work / supply orders executed. (03) Conditional tenders are liable for rejection. GSECL TPS SIKKA Page 6 of 27 (04) (f) (g) (h) (i) (j) (k) (l) Party should submit office, factory, and residence address with phone, fax and mobile number. (05) Class of Registration certificate. (06) Solvency certificate for 20 % of estimate cost. (07) Labour Licence from Govt. Dept. (08) P.F. Registration No. & Service Tax Registration No. (09) Last three years balance sheet, PAN No. & I. T.Return. (10) Sales Tax Registration certificate etc. at the time of application. (11) The rates may invariably be filled up in Corporation’s schedule form only. N.B.: The submission of documents 5, 6, 7, 8, 9 above will not apply for supply order. The submission of documents 10 above will not apply for work order, in case of less than 1.00 crores. This office will not responsible for postal delay on either ways. Sealed Tenders Super scribed with the Tender Notice No., Sr. No., Details of Work / Supply and Due date of opening and detail of D.D. No of EMD will be accepted on or before due date and time through Registered Post only. Corporation does not take any responsibility for delay of the tenders sent under RPAD on the due date at local post office. Gujarat State Electricity Corporation Ltd. reserves the right to itself not to accept or reject any or all the offers at any stage of the process and /or modify the process without assigning any reason whatsoever thereof. Gujarat State Electricity Corporation Ltd. reserves the right to accept / reject / cancel any or all tenders, extend dates and / or re-advertise tender without assigning any reasons thereof. Subletting of tender is not permitted. Opening of price bids will be decided on evaluation of technical bids and only eligible parties will be informed / intimated. Part order has to be accepted by party. - Arbitration clause for indivisible (i.e. combined supply and works orders / tenders….) “ All questions, disputes or differences, whatsoever which may at any time arise between the parties to this contract in connection with the contract or any matter arising out of or in relation thereto, shall be referred to the Gujarat Public Works Contract Dispute Arbitration Tribunal as per the provisions of the Gujarat Public works Contract Disputes Arbitration Tribunal Act, 1992”. Signature of Contractor with Place / Date / Firm Seal / Stamp For, Gujarat State Electricity Corporation Ltd. Sd/Chief Engineer Thermal Power Station, Sikka. GSECL TPS SIKKA Page 7 of 27 > TECHNICAL BID < No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. Description of Item Work of Checking / Inspection / Recording / Repair / Replacement and setting of radial, axial and by pass seals, including of repair / replacement of all static seals at cold end & hot end in APH - A & B as per SOW & instruction of EIC. Work of Repair / Rectification of all sector plates at Hot End and Cold End sides by weld repair / flush grinding in APH-A & B as per SOW & instruction of EIC. [ 01 Set = 03 Hot & 03 Cold Total 06 Sector Plates]. Work of Alignment / Setting of sector plates at Cold End and Hot End sides of APH-A & B as per SOW & instruction of EIC. [ 01 Set = 03 Hot & 03 Cold Total 06 Sector Plates]. Work of Repair / Rectification / Alignment / Setting of axial seal plates with respect to sector plates and seals of APH-A & B as per SOW & instruction of EIC. Work of Repair / Rectification of spool piece for tracking system of hot end side including repair of centre section below guide bearing & air seal assembly to arrest gas leakages as per SOW & instruction of EIC. Work of KAO wool filling and refitting in all static seals to sector plate, axial seal plate and spool piece at Hot End and Cold End sides of APH-A & B as per SOW & instruction of EIC. Work of Repair / Rectifications of APH housing and internal truss supports at Hot End and Cold End sides by replacing eroded housing plates and support pipes of APH-A & B as per SOW & instruction of EIC. Work of Repair / Replacement of Cold End side basket support grating[Inner & Outer] by cutting and fixing new support bars there in all sections in APH-A & B (1 Set=24 Nos.) as per SOW & instruction of EIC. Work of Servicing of main drive gear box including replacement of oil / grease in gear box / coupling etc. and servicing of air motor; pinion housing of drive mechanism of APH-A & B as per SOW & instruction of EIC. Work of Repair / Rectification/ replacement of T-bar at Hot End and Cold End sides including replacement of eroded hex bolts and T bar holding angles APH-A & B as per SOW & instruction of EIC. Work of Checking and alignment of guide and support bearings including oil replacement and flushing of both end side bearing with filling of new oil APHA & B as per SOW & instruction of EIC. Work of Repair / Rectification / Replacement of soot blower and water washing systems including servicing oiling/ greasing of its drive system of APH-A & B as per SOW & instruction of EIC. Work of Overhauling / servicing and replacement of guide bearing assembly / oil level tube / adapter sleeve / bearing housing / packing ropes, etc. in either in APH- A or APH- B, if required as per SOW & instruction of EIC. Work of Overhauling / servicing and replacement of Support bearing assembly / oil level tube / adapter sleeve / bearing housing / packing ropes, etc. in either in APH- A or APH- B if required as per SOW & instruction of EIC.. Work of the repairing of APH housing with door as per SOW & instruction of EIC. Work of Replacement of pinion wheels & pin rack with pins of APH - A & B as per SOW & instruction of EIC. Work of removing/ replacement/ repairing / cleaning/ reversing of HOT end Qty. 2 Unit Set 2 Set 2 Set 2 Set 2 Set 2 Set 2 Set 2 Set 2 Number 2 Set 2 Set 2 Set 1 Set 1 Set 250 2 Running Meter Set 144 Number GSECL TPS SIKKA 18. 19. 20. 21. 22. 23. Page 8 of 27 basket of APH - A & B as per SOW & instruction of EIC. Work of removing/ replacement/ repairing/ cleaning/ reversing of HOT intermediate end basket aof APH - A & B as per SOW & instruction of EIC. Work of removing/ replacement/ repairing/ cleaning/ reversing of Cold End basket of APH - A & B as per SOW & instruction of EIC. Work of rectification / replacement of flappers, sealing angles, partition plates, shafts and servicing of all bushes, links and O/H of gear box of GD 1A & 1B as per SOW & instruction of EIC. Work of Repair / rectification / replacement of I/L Damper Frames by cutting / removing old damaged frame parts and fabrication, erection and fitting, also repair & fabrication of supports at above & below APH flue gas duct in Unit-1 Work of cutting of corroded / eroded Damper frames and supports as per the instruction of EIC and SOW. Providing and fixing of MS hexagonal bolts / nuts / washer / stud / self locking nut etc. of required size confirming to IS-1363, grade - 4.6 as per SOW & instruction of EIC. 144 Number 216 Number 2 Number 5 Metric Ton 3 Metric Ton Kilogram 500 The Rates are Exclusive of Service Tax. Service Tax at prevailing rate, if applicable will be paid by GSECL extra on production of paid evidence/challan. The contractor shall at his own expense comply with all labour laws and keep the board indemnified in respect thereof. Some of the major liabilities under various labour and industrial laws which the contractor shall comply which are as under. 1) Payment of contributing of way of Employer’ s contribution towards provident fund, family pension scheme, deposit linked insurance scheme, administrative charges etc, at the rates made applicable from time to time by Government of Gujarat / Government of India or other Statutory Authorities. 2) Payment of deposit in respect of each contract labour at rate of Rs. 30/- with the office of Commissioner of labour as per contract labour (Regulation and Abolition) Act. 3) License as prescribed under the contract labour (Regulation and Abolition) Act, and rules farmed there under depending upon the number of workman employed by the contractor License is compulsory if ten or more labours engaged during day. 4) Identity cards as prescribed under the factories Act, with photo affixed there to the same for identification. 5) Payment of retrenchment compensation, Notice pay and other liabilities as per Industrial Disputes Act. Payment to the contractor’s employees arising out of any claim or disputes under the industrial Disputes Act. 1947 or any other labour laws. 6) Payment of compensation in case of accidental injury. 7) Provision of Creche if female labour employed is more than 30 numbers. 8) Maternity leave as per the provision of the Maternity Benefit Act. REQUIREMENTS FOR TECHNICAL BID: The bidders are requested to submit with their technical bid (in soft and hard) with the following credentials for technically qualification for the subject work tender. 01. Experience/Performance certificate for similar work [APH] executed in past of 120 MW or more capacity units of GSECL/NTPC/other State Electricity Boards and details of orders executed for last 03 years. 02. Mobilization period. 03. Details of minimum tools, tackles and equipment in possession relevant to the job. 04. Assurance for unconditional tender. Conditional tender is liable to be rejected. Withdrawal or insertion of conditions unilaterally after opening of tenders will not be permitted unless it so desired by the GSECL. 05. Details of P.F. Code no. from appropriate authority. 06. Latest Bank Solvency Certificate of minimum 20% of estimated cost from any Nationalized Bank. Details of registered partnership deed in case of partnership firm and activities of association and GSECL TPS SIKKA 07. 08. Page 9 of 27 memorandum of association in case of company. Party should have to submit the details of the registration number regarding Service Tax along with Technical Bid (i.e. Copy of Service Tax Registration). The tender shall be opened of the paid EMD & Tender Fee only. TECHNICAL TERMS & CONDITIONS 01. 02. 03. 04. 05. 06. 07. 08. 09. 10. 11. 12. 13. All the General terms & conditions shall be applied to party as per GSECL rules and regulation. Transportation of the material from main store /sub store to site, loading /unloading is in party's scope. The Balance good / unused material & scrap to be credited to main store only. As the work is to be completed in stipulated time period, Contractor should have to depute only qualified and experienced work force for the job. Qualified welder will be deployed by contractor for repairing work. Party shall have to co-ordinate and co-operate with the other agencies working near to their work place to avoid any accident. Contractor shall be responsible for any kind of damage of surrounding equipment / components. The contractor shall make his own full proof arrangement of storage of spares / consumables, tools tackles, etc. equipment to be overhauled and repairing works and shall be responsible for safe custody of such items at his site/store. In case of theft / lost / damage of such items while in possession of contractor, such materials are to be arranged & replaced, free of cost by the contractor to the GSECL. After completion of work in all respect, surrounding area is to be cleaned as per instruction of EIC. Party shall have to credit all eroded, removed and miscellaneous scrap etc. and balance good/ unused material to Main store Only. Contractor should attend any defect contributory to their faulty workmanship during the trial run and re-commissioning of equipment / system / unit, and rectify without any extra charges to the GSECL. If rectification is not carried out in time as instructed by Engineer-In-charge, the same shall be carried out by GSECL by engaging GSECL staff or any other agency and cost of which will be recovered including supervision charges from the contractor's bill as per Corporation's rules. MOBILIZATION PERIOD: 03 [Three] Days shall be allowed from the date of receipt of telephonic/fax /letter/E-mail for mobilization of contractor?s men, T&P etc. for carrying out the said work. WORK COMPLETION PERIOD : The period for completion of complete overhauling work of unit shall be as under excluding the mobilization period failing which the penalty at the rate of 0.5% of the contract value per week to the extent of 10% of contract value will be levied and will be recovered from party's bill [a] 25 days for COH [b] 18 days for AOH, [c] 03 Months if the work is to be carried on piece-meal basis on as & when required during RSD Or Forced / Planned Outage period. Resources/ Manpower are to be arranged accordingly to complete all the work positively in any one of above conditions. Executive Engineer (BMD) GSECL, Sikka TPS, shall be the Engineer in charge for the works. Defects observed shall be intimated by the contractor in writing to Engineer-in charge. GUARANTEE :- Party shall give guarantee for a period of 90 ACTUAL RUNNING DAYS(i.e. 2160 running hours) OF BOILER OR 18 MONTHS WHICHEVER IS EARLIER from the date of commissioning, an amount of 5 % of order value shall be retained for the same. SAFETY : Party has to observe & adopt all the safety laws strictly. GSECL will not be held responsible for any fatal / non-fatal, electrical / mechanical accident take place while execution of work. Only party will be responsible for such occurrence for compensation and compliance of legal matter. All safety measures shown elsewhere in this contract as well as factory rules, shall have to be observed strictly by contractors and penalty will be imposed for violation of such rules as & when pointed out by SAFETY OFFICER. Penalty will be deducted from your Running RA Bill; amount of penalty will be decided by 'Competent Authority' and conveyed to you. Unsatisfactory progress of work:- At any time if GSECL feels that progress of work is unsatisfactory and work force of contractor is inadequate or not as per the terms of contract; GSECL TPS SIKKA 14. 15. 16. Page 10 of 27 GSECL reserve right to cancel the contract at your risk & cost. The work order overall validity will be for 11 months and same may be extended unilaterally if required by GSECL for further 06 [Six] months or more with the same rates and Terms & Conditions of the work order. Quantity shown in work order is approximate and is liable to change. Payment will be made according to actual measurement quantity of work done on R.A. Bill Basis. Party has to provide the following documents along with the bill : [a] Bill in Triplicate [b] P.F. Challan copy [c] Material Statement. [d] Copy of C.R. of Scrap crediting. SCOPE OF WORK [A] General Scope of Work [a] The scope of work generally to carry out Overhauling / servicing and repairing of APH are as under, a) Checking and setting of rotor level by master level to the required tolerance. b) APH all seals clearance checking. c) Checking of pins and pin racks with run out measurement. d) APH gear box alignment checking and setting with its pin rack motor and grid couplings. e) Checking and setting level and run out of T-bars at Hot End & Cold End. f) Checking and measuring sector plates and axial seal plates gap with rotating seals and setting thereof. g) Checking and setting of trunnion shaft run out at guide bearings, leveling of guide bearings. h) Checking and setting of post seals gaps at Hot End & Cold End. i) Checking and setting of soot blowers lance travel over specified cordial distance. [b] Checking and recording of various APH clearance, level run out etc., with help of precision spirit level, finger tab etc. as per the direction of E.I.C. and standard practice / OEM recommendation. a) Checking plate level. b) HE sector plate level. c) CE sector plate level. d) HE T bar radial run out. e) CE T bar radial run out. f) Axial seal plate co-centricity. g) HE Radial seal clearance. h) CE Radial seal clearance. i) Axial seal clearance. j) Rotor post seal. k) Pin rack run out. l) Bypass seal Hot and Cold end. 1. ALL TYPE OF SEAL CHECKING /SETTING / REPAIRING / REPLACEMENT WORK :(A) HE RADIAL SEAL SETTING: Either old but good conditional seals are to be set by loosening bolts, nuts & eroded, damaged seals are to be removed by removing seals bolts & new seals are to be installed & set. But in any case aluminum straight edge is to be used for seal setting worn out bolts are to be replaced and all bolts are to be tightened. End seal tab are to be installed as per instruction of EIC. (B) COLD END RADIAL SEAL SETTING: old eroded & damaged seal are to be replaced eroded seal bolts are to be replaced. All seals are to be set by using straight edge & bolts to be tighten straight is to be set to specified limit. (C) AXIAL SEAL SETTING: Old worn out & damaged seals are to be replaced by new seals. Worn out bolts nuts are to be replaced. All seals are to be adjusted with the help of straight edge. Bolts & nuts are to be tightened. The seal ends are to be locked by sealing tab. (D) HE AND CE ROTOR POST SEAL: old worn out rotor post seals are to be cut, removed. GSECL TPS SIKKA (E) (F) (G) (H) Page 11 of 27 The weldment metal is to be removed by grinding. New seals are to be set as per instruction of EIC & welded with rotor post. STATIC SEAL: damaged eroded static seals are to cut, removed from HE & CE sector plate, axial seals are to be prepared by grinding. New seals are to be fabricated from MS plate & same are to be welded as per instruction of EIC. The static seal ends are to be properly fabricated and installed so as to prevent gas leakage. This also includes KAO WOOL filling. BYPASS SEAL: Eroded and worn out bypass seals are to be removed by opening bolts. New seals are to be installed and adjusted. Bolts are to be properly tightened with lock nut. ROTOR POST STATIC SEALS: The eroded rotor post static seal (Drum) is to be cut and removed. The residual of cutting are to be grounded and finished. New static seal with rotor post is to be full welded. REPAIR/REPLACEMENT OF DIAPHARM OF APH SECTOR: Eroded plates of sector diaphragm should be cutting & grinding properly. New plates should be welded with full welding at both sides & if required new holes should be drilled as per existing radial seals dimensions & as per instruction of EIC. 2. REPAIRING / RECTIFICATION OF HOT/COLD END SECTOR PLATE: Damaged sector plate is to be repaired by removing eroded piece and grinding the surface. New piece to be welded from inside and outside in level with sector plate face and grinding to be done. Pitting surface of sector plate should be filled up by welding. Grinding to be done to make in level with sector plate. Face of repaired portion adjuster rod/ tie rod and locking pin should be repaired/ rectified as per instruction of EIC and if required sector plate should be taken out from the position for repairing and relocating after repairing as per EIC instruction. The repairing of sector plate can be done by removing if required & instruction of EIC. 3. HOT/COLD END SECTOR PLATE ALIGNMENT / SETTING:a) b) c) ROTOR LEVEL: Rotor level is to be adjusted within specified limit with the help of adjusting bolts at guide bearing If required, seal air housing to be loosened. Any other work required to carry out leveling work must be done. HE SECTOR PLATE LEVEL: HE sector plate is to be adjusted within specified limit with the help of tracking and adjusting rod. If required, tracking rod assemblies are to be removed and same is to be locked again after completion of work. CE SECTOR PLATE LEVEL: Tracking rod assembly locking is to be removed. CE Sector plate is to be leveled with the help of all three tracking rod assemblies. Cleaning the ash from sector plate is also included in scope of work. After completion of work tracking rod assembly is to be locked. Contractor has to arrange for scaffolding and same has to be dismantled after completion of work. 4. AXIAL SEAL PLATE SETTING / REPAIRING: Axial seal plate concentricity is to be set with the help of four adjusting bolt assembly also included in the scope of work. The concentricity is to be adjusted to the specified limit and as per instruction of EIC. The bolt protecting cover is to be removed before starting & reinstalled after completion of work 5. REPLACEMENT OF TRACKING ROD/ADJUSTOR ROD ASSEMBLY & CENTER SECTION: a) The damaged/eroded sector plate tracking and adjustor rod assembly is to be removed. New assembly is to be fixed and properly tack welded. b) REPAIRING OF APH HE & CE CENTER SECTION: Center section plates of hot end and cold end side are provided with wear plate on either side and same should be repaired by welding and grinding skillfully or replaced by new machined plate if damage is irreparable. The decision of EIC shall remain binding to the contractor in this case. c) REPAIRING OF APH HE & CE CENTRE SECTION: * This includes all three center section at APH hot end & cold end. The complete plate of center section is to be cut and removed. New plates are to be cut accurately and welded in the position. The center section plate should be welded on both the sides and kerosene test of each joint is to be taken. The repairing is to GSECL TPS SIKKA * * Page 12 of 27 be carried out as per the instruction of EIC. Cleaning/removal of all patch repair/refractory/insulation work etc., throughout the length of existing plate and replacement with new plate as per shape and size with leak proof Welding on horizontal and adjacent side base as per instruction of GSECL EIC. Necessary air cleaning of system piping and providing new asbestos rope is part of scope of Contractor without any extra cost. SEAL AIR HOUSING AT HE : Seal air housing of Hot end is to be repaired/replaced by welding grinding. New rope is to be fixed. Deflector plates is to be repositioned/fixed, adjuster rod glands are to be re-installed. Seal air housing fixing bolts, studs are to be welded and seal air housing is to be properly clamped. If sealing is required to be replaced, the same must be done. All the work is to be carried out in such a way that there should not be any leakage from and around this area. 6. CAO WOOL :- Axial seal plate KAO wool box repairing work includes checking and filling the KAO wool in the box. CAO Wool to be provided as per OEM and instruction of EIC. 7. REPAIRING OF APH COMPONENTS: a) Repairing of APH housing and door: The eroded housing plates are to cut, removed and new plates are to be welded. The eroded portion and size of plates will be decided by EIC. The welding will be checked by Kerosene test. All the welding joints must be fully welded. The housing includes the position of housing from inlet expansion joints to APH outlet expansion joint. This does not include repairing of center section. Also eroded housing doors are to be repaired by welding and grinding to achieve zero leakage from housing door. b) REPAIRING OF SEAL AIR HOUSING & ROTOR POST APH DIAPHRAGMS AND ROTOR SHELL. i) SEAL AIR HOUSING AT H.E.: Seal air housing of the hot end are to be repaired by welding & grinding. New rope is to be fixed. Deflector plates are to be repositioned / fixed. Adjuster rod glands are to be reinstalled. Seal air housing fixing bolts studs are to be welded and seal air housing is to be properly clamped. If sealing is required to be replaced same must be done. All the work is to be carried out in such a way that there should not be any leakage from and around this area. ii) REPAIRING OF ROTOR POST: The damaged rotor post is to be repaired by welding, filling & grinding. If packing ring is damaged than it is to be replaced. iii) REPAIRING OF APH DIAPHARM: The eroded APH diaphragms are to be repaired by welding, filling and grinding before installation of rotor seals. This includes repairing of all diaphragms at C.E. and H.E. and axial seal fitting position. iv) REPAIRING OF ROTOR: The eroded portion of rotor shell plate is to be repaired by welding, filling and grinding only. Any puncture observed in rotor shell must be filled up and ground finished only. 8. CE BASKET GRATING REPAIRING/REPLACEMENT: When CE baskets are to be removed for works; each grating segments are to be checked for damage. The excessively damaged grating segment is to be replaced by new grating. The worn out support block are to be replaced. The damaged redial seal diaphragm plates are to be repaired by welding, filling and grinding. The work is to be carried out as per instruction of EIC. 9. OH/SERVICING/REPAIRING OF ROTOR DRIVE UNIT: APH MAIN DRIVE: This includes servicing of main drive gear box, air motor, and gear flex coupling including replacement of Gear flex coupling. Motor to gear box alignment etc. as per directives of EIC. a. b. Remove the high speed coupling grid member connecting the electric motor side in the units fitted with gear flex coupling Install finger gauge to measure radial run out of pin in pin rack. GSECL TPS SIKKA c. d. e. f. g. h. i. j. k. l. m. n. Page 13 of 27 Turn rotor and locate outermost pin. Mark pin for future identification. Using the same procedure, check the axial run of pin rack bar as follows. Find the area or point of lower bar that is closest of the pinion gear, mark for reference. Find the flatness as per or point on the surface of the end pin rack bar and set pinion gear in this area or point to dimensions. Adjust pinion and drive assembly to clearance shown on rotor drive assembly. Check pinion teeth for line contact with pins of pin rack by applying blue shim and adjust as required to full tooth contact record pinion on check sheets. For proper installation of taper lock pinion. Approximately 50 liters of oil will be required for the speed reducer rotor drive. Carbon ring packing gland assembly must be installed. Pinion cover and transition piece must be installed. Alignment of gear box to be carried out with main drive and auxiliary drive. Loose spares like carbon ring, packing etc. are to be fitted for proper sealing. Gear box to be flushed & new oil to be topped up. Mounting bolts of gearbox to be tightened to specified limit. 10. T BAR :a) HE T BAR REPLACEMENT AND SETTING RUN OUT: worn out and eroded T bars are to be removed by opening bolts and nuts, cutting and tag welding etc. If any new T bar are to be installed in radius of 4441 mm. New T bars run out to be adjusted within specified limit only. Rotor Angle is to be ground and cleaned before reinstallation of T bar Tag welding of T bars at time of T bar setting is not permitted. Bolts nuts are to be tightened to specify limit care must be taken that T bar ends does not consider with rotor diaphragm. Axial run out of T bar is to be got as per specified limit by cutting grinding etc., as per requirement. Axial & Radial on T bar. b) CE T BAR SETTING: Old CE T bars are to be removed by cutting welding tag, removing bolts & nuts. Rotor angle is to be cleaned & ground before installing new/ old T bar. CE T bars should be set with reference to hot end T bars. T bar is to set within specified unit. All the bolts and nuts are to be tightened. 11. GUIDE & SUPPORT BEARING O/H :a) Guide and support bearing are to be checked after draining oil from the bearing assemblies and cleaning the same guide bearing Clearance is to be measured with filler gauge. Also if the position of guide bearing is found disturbed same has to be repositioned. b) Support bearing levels are to be measured by using a precision level of accuracy 0.02mm/m on bearing. Flange bearings housing top to sleeve flange distance is to be measured. Guide bearing levels are to be measured by dial gauge at eight [08] different points on bearing flanges by rotating rotor and are to be as per design value. Gland packing is to be replaced at both ends. c) GUIDE BEARING AND SUPPORT BEARING LUB OIL SYSTEM: The system consists of oil pump coolers, various valves, flange joints piping and water circuit for oil cooler. The work includes arresting oil leakage & servicing of pump and valves, arresting oil leakage, servicing of pump and valves, cleaning of pump oil cooler and valve replacement with pipe modification as per instruction of site engineer. Piping insulating material will be provided by GSECL free of cost. 12. APH SOOT BLOWER SYSTEM: The system consist of steam lines, steam isolating valves, soot blower drain valves flange joints, orifice in the line, soot blowing nozzle swivel joints, pedestals swiveling mechanism gear box etc. The valves are to be overhauled / replaced as per the instruction of site engineer. Pedestals are to be cleaned. Any dry lubricant is to be applied to pedestal for easy movement of soot blowing gear boxes are to be serviced. Soot blowing nozzles are to be replaced if found eroded, any puncture in steam line is to be repaired by patch work or replacing spool piece of tube on replacement of complete steam tube. The trial of steam is to be taken after completion of work. The soot blower setting is to be done as per BHEL specification. GSECL TPS SIKKA Page 14 of 27 12.a. APH WATER WASHING SYSTEM: The work includes providing replacing APH water washing valves replacing water washing nozzles are repairing of water washing header. 13. GUIDE BEARING ASSEMBLIES REPLACEMENT WORK: Guide and support bearing are to be checked after draining oil from the bearing assemblies and cleaning the same. Guide bearing clearance is to be measured with filter gauge. Also, if the position of guide bearing has disturbed, same has to be repositioned. Support and trunion bolts are to be cleaned. Gap between trunion flanges and trunion bolts are to be checked. Gap between trunion flanges and end or rotor post must be checked by 0.05 mm feeler gauge to ensure trunion sealing, for this activity if required the housing or cover plates is to be opened and box up after completion of work. [a] PROCEDURE TO INSTALL FOR GUIDE BEARING TAPER LOCK BUSHING: Remove bushing if unit is already assembled and carefully clean taped surfaces, shaft bearing and outside of bushing and bore of hub, or adaptor sleeve. Remove any oil leakage or dirt. Remove any burrs which may be formed on the end of shaft or end of bushing. Place bushing in hub or adaptor. I. Oil thread and under head of cap screw, please screw loosely in holes shown thus in diagram. II. Make sure bushing is free in hub or adapter sleeve slip assembly on to shaft and locate in position desired. III. Tighten screws alternately and every until all are pulled up very tightly wrench up to 17 kg/m IV. Hammer against large end of bushing using hammer and block or sleeve of soft metal such as brass to avoid damage. Screws cannot be turned a little more using the specified wrench torque. Repeat this alternate hammering and screws retightening until the specified wrench torque no longer turns the screws after hammering. Screws must be kept at all times till other holes with grease to exclude dirt. 14. SUPPORT BEARING ASSEMBLIES REPLACEMENT WORK: Support bearing levels are to be measured by using a precision level of ordinary 0.02 mm/m. on bearing flanges and to be adjusted by leveling the bearings. Bearing housing top to sleeve flange distance is to be adjusted. Guide bearing levels are to be less than 2 mm. same has to be adjusted. Guide bearing levels are to be measured by dial gauge at eight [08] different points on bearing flange by rotating rotor and level is to be set as per design value gland packing to be replaced at both ends. * RECOMMENDED JACKING PROCEDURE OF SUPPORT BEARINGS: Remove bearing housing cover water shield and trunion and sealing cover. Place jacking beams on jack stands. Place four hydraulic RAMS on the jacking beams and line the rams up to that they are under a trunion bolt. Raise the RAMS, jacking on the trunion bolts, to relieve the bearing block between the jacking beams and rotor post and plate with four [04] Nos. of 100 mm diameter or rectangular bars. Release RAMS allowing pins to support the load. Remove the radial thrust bearing and unbolt the support bearing housing allowing bearing to be removed. Be sure that runner is removed at the same time as the bearing housing and bearing assembly. RAMS are activated by a single hydraulic pump. 15. SR. NO. 16 :- PIN & PIN RACK ASSLY :- After inspection of the same, party has to replace the pinion and pin/pin rack assly. as per instruction of EIC. If the pinion teeth of pin rack is excessively worn out, then the pinion must be reversed after taking out from gear box shaft and refitting the same. If gear box is required to be removed from base for work, same is included in the scope of work. The gear box aligned and placed in position. 16. SR. NO. 15, 17, 18 & 19 :- APH BASKET REPAIRING/ REVERSING / REPLACEMENT :a) Reversing of APH Hot & Hot Intermediate and Cold End Basket :- Removing & Reversing of APH Hot End Basket Elements handling beam is to be installed before starting work after hot end basket removal door. The hot end baskets are removed reversed GSECL TPS SIKKA b) Page 15 of 27 and inter change as per instruction of EIC. During reversing of heating element minor repairing of diaphragm plate is included in the scope. Elements handling beam is to be removed before closing the hot end basket removal door. All the cold end basket is to be removed after opening cover. The baskets are to be water washed by pressurized water jet. Each basket is to be inspected for damage. Damaged baskets are to be repaired by welding. The cleaned baskets are to be refitted in sector. The broken studs are to be replaced by new studs. Flange (COVER) are to be refitted by bolt tightening. The cleaning of the chocked baskets is to be carried out first by water washing even if the chocking of the elements persists, the baskets shall be cleaned by opening the frame and brushing and cleaning the each elements individually. After cleaning the basket same shall be assembled as per original and put in service. Replacement of APH Heating Elements [Baskets] :- After inspection of the basket?s condition by EIC, it will be jointly decided for replacement of the same. If decided to replace the baskets, party has to collect the same from the main store and lifting to the site. Complete set / damaged/ worn out / individual baskets (heating element) are to be replaced by new elements as per instruction of EIC. Elements handling beam is to be installed before starting work after hot end basket removal Door. If extra platform / structures required to be erected for convenience of work, same has to be arranged by Contractor, Corporation will provide only steel material for the same. The contractor shall have to find out and segregate the required type of hot end basket at Main store from the boxes by means of crane for speedy work. Required types of hot baskets are to be loaded in tractor trolley by means of crane. Same are to be transported at site near working place and unloaded by means of crane. Baskets of required type are to be lifted to platform of APH by means of electric winch machine. All the lifting tools & tackles (i.e. winch machine, slings, rope etc.) required to carry out the job shall have to be arrange by the Contractor at their own cost. Minor repairing, rectification of elements shall also have to be carried out by contractor including cutting, welding if necessary for replacement of baskets (heating element). Elements handling beam is to be removed before closing the hot end basket removal door. All the new baskets to be cleaned by pressure jetting of steam / water depending upon the availability of steam. Party has to note down the weight of each new basket and to be submitted to EIC for further evaluation of replacement span. After replacement work, party has to credit the removed/ scraped baskets to the Main Store or as per instruction of EIC. Details of APH basket [heating elements] is as under: Sr. No. Type of Baskets Quantity/APH 1 HOT END 72 Nos. 2 HOT Intermediate End 72 Nos. 3 Cold End 108 Nos. 17. Height of Basket 450 MM 850 MM 300 MM Basket per Unit 144 Nos. 144 Nos. 216 Nos. Sr. No. 20, 21 & 22 :- Repairing of Flapper/ Gear Box/ Damper frame /supports etc. a) REPAIR / RECTIFICATION OF FLUE GAS DUCT: The scope of work consists of cutting / dismantling / fabrication and re-erection of duct wall plates, supports, stiffeners, truss-support, and housing of APH Hot end / Cold end / Soot blower housing of APH and ECO to APH duct. The scope of work also includes covering of MS plates, angles, pipe, beam etc. The repair re-erection / rectification work is to be done in position and inside of ducts by cutting / welding and finishing the same within stipulated time. All work / arrangements have to be made by contractor without claiming extra cost. b) Repairing of APH housing and door: The eroded housing plates are to cut, removed and new plates are to be welded. The eroded portion and size of plates will be decided by EIC. The welding will be checked by Kerosene test. All the welding joints must be fully welded. The housing includes the position of housing from inlet expansion joints to APH outlet expansion joint. This does not include repairing of center section. Also eroded housing doors are to be repaired by welding and grinding to achieve zero leakage from housing door. c) RECTIFICATION / SERVICING, O/H OF INLET GAS DAMPERS OF APH: GSECL TPS SIKKA 1. 2. 3. 4. 5. 6. 7. 8. 9. 18. Page 16 of 27 Removal of all worn out flappers, sealing angles, partition and side plates by gas cutting and shifting to ground level. Repairing / rectification / replacement of flappers, sealing angles, partition plates, shafts and servicing of all bushes, links and overhauling of gear box as per the requirement and as per instruction. Repairing / replacement of damper frames as per the existing configuration of dampers. Providing of new supports and gusset plates etc as per the requirement. Dismantling of linkages, gear box for complete servicing work. Transportation of steel material from store to site and then fabrication, erection and fitting of frame, flappers, sealing angles, partition plates, pipe supports etc as per original configuration. Servicing of individual flappers shaft link and alignment of the all links with actuator and assembly thereof. Trial operation for ensuring smooth open close manually. The work is for inlet and outlet dampers of APH-1A, 1B of Unit-1. SR. NO. 23 : Supply of Nut/Bolt/Washers: Contractor shall have to supply the required size of bolts / nuts / washers / stud / self-locking nuts etc., as required quantity to carry out and complete the wok. Contractor shall have to make entry at main gate of STPS on Challans and one copy of Challan shall have to be submitted to the section. The supplied materials shall have to be inspected by EIC prior to utilization. The payment shall have to be made as per actual quantity of material supplied / utilized only. PRECAUTIONS TO BE TAKEN BY CONTRACTORS: 1. Repair / Welding are to be done with certified / qualified welders only. 2. Kerosene test is to be carried out for all weld joints leakages of air and seepages of flue gases. 3. Tightening of bolts with required torque. 4. Rotation of APH in correct direction. 5. Keeping of records of all reading before and after major repair job. 6. Do not allow any foreign material such as electrodes bits, slag, wools etc. to enter into heating elements during repair job. 7. All alignment / rectification are to be done as per instruction of BHEL check list. 8. Before proceeding to make any weld in the rotor earth rotor nearest to welders to prevent arcing through the bearings. 9. Attach a piece of angle iron (50X50X6.4 /50 mm long) to one outer diaphragm to use as a support for a precision level check rotor level at maximum number of location. Also level the rotor to within 0.1 mm/meter by adjusting the jack screw in guide bearings. 10. Lower rotor assembly on support trunnion using jacks to avoid jerk to the bearings. 11. Oil level is to be maintaining in support and guide bearings when the oil circulating unit is not in operation. 12. Element installation must progress in manner preventing excess unbalance of the rotor otherwise, permanent rotor distortion will result. 13. T-bar alignment is to be done with loaded condition of rotor. 14. After the radial seals are set, the rotor must not be turn backward, otherwise radial seals will be damaged. ALLOWABLE LIMITS FOR ADJUSTMENTS: Sr. DESCRIPTION ALLOWABLE LIMIT 1 Support bearing level tolerance : 0.1 mm / meter 2 Guide bearing housing top to sleeve flange distance allowable variation. : +/- 2.0 mm 3 Guide bearing allowable tolerance [Face run out on housing sleeve is 0.2 mm] : 0.25 meter 4 Verticality of rotor post, allowable variation. : 0.1 mm / meter 5 Rotor level ? total allowable tolerance. : 0.1 mm / meter 6 Pin rack run out : Total allowable limit in radial reading : 3.0 mm Max. mm / GSECL TPS SIKKA 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 [B] 01. 02. 03. 04. 05. 06. 07. 08. 09. 10. [C] 01. 02. 03. 04. 05. 06. 07. Page 17 of 27 Sector plate setting, Hot end out Board with T bar axial high point : 12.0 mm +/- 1.5 mm. Sector plate setting, Cold end out Board with T bar axial high point : 22.0 mm +/- 1.5 mm Sector plate setting, Cold end in Board with bottom total variation : 1.0 mm Cold and Hot end sector plate level, Allowable in Board total variation : 1.0 mm Cold and Hot end sector plate level, Allowable out Board total variation : 1.0 mm Pinion level normal to rotor, allowable limit : 0.1 mm / meter Height of pinion bottom face from bottom flange of pin rack : 10.0 mm radial clearance of pin with pinion : 13.0 mm +/- 3.0 mm Maximum allowable deviation in radial reading of T-bar : 3.0 mm Axial seal setting, Specified value at Hot end top : 6.11 mm (+ 0.0 mm/-1.5mm) Axial seal setting, Specified value at Cold end bottom. : 3.47 mm (+ 0.0 mm/-1.5mm) Bypass seal radial clearance, between T-bar and bypass seal at Hot end. : 4.17 mm +/- 0.25 mm Axial clearance between `T’ bar upper edge (LP) and bypass seal edge at Hot end. : 76 mm to 89 mm Axial clearance between `T’ bar upper edge (LP) and bypass seal edge at Cold end. : 12 mm Min. Radial seal clearance at Hot end in Board. : 0.0 mm Radial seal clearance at Hot end out Board. : 0.0 mm Radial seal clearance at Cold end in Board. : 0.0 mm Radial seal clearance at Cold end out Board. : 9.82 mm GSECL Will Provide: The following items shall be Provided by GSECL free of cost : All spare parts, refractory, insulation etc. required to complete the work. However, the contractor shall submit the requisition Two [02] days in advance. Gaskets and packing ropes. Steel material such as MS plates, angles, pipe, beam etc. for repairing of APH & Dampers. Nuts, bolts and other hardware etc. All lubricants and grease, hold-tight, lapping compound. Water, Air & Power for lighting / grinding machine and welding sets etc. at one location at one elevation, free of cost. Necessary extension from released supply, air and water points are to be done by contractor without any extra cost. Work shop facility will be provided by GSECL, if required and available. Open space plot area for storing the spares and site office purpose. Special T&P provided by manufacturer of the plant, if available, shall be provided free of cost. The contractor shall be responsible for the safe and proper use of the same. Cost of T&P loaned to contractor will be recovered in case of lost/damages to the same. For transportation of heavy material [ baskets, sector plates] crane /hydra will be provided. Following to be arrange by the CONTRACTOR : It will be the responsibility of the contractor to supply the following items, for which no additional payment over and above the quoted rates, will be made to him on account of these items. All consumables like cotton waste, cloth, kerosene, diesel, petrol, rustolene, cutting gas, argon gas etc. All consumables items required for effective cleaning [fire hoses and nozzles], Cleaning equipment such as soft wire brushes, jute ropes, gunny bags, ordinary cleaning brushes, brooms, water and air hoses and fittings. Lighting accessories such as switch board, 24 V welding Transformer, lighting cables, bulbs etc. to be arranged by party. All materials for erecting scaffolding, including scaffolding piping clamps, wooden planks, and special type of cup lock scaffolding etc. All normal T&P like welding sets, grinders, safety belts and PPE, hand tools, motor operated winch, EOT crane, pulleys, pulling and lifting machines, cutting and brazing torches, safety appliances, Tig welding equipment with consumables etc. All general purpose electrodes, Oxygen & acetylene gas. All the measuring instruments, like precision level with 0.02mm. Least count, micrometer, venire, Aluminum channel, finger tab, lifting and pulling machine, jack, sling, D-shackle, GSECL TPS SIKKA 08. Page 18 of 27 All other items not listed but required to carry out and complete this work. Signature of Contractor with Place / Date / Firm Seal / Stamp For, Gujarat State Electricity Corporation Ltd. Sd/Chief Engineer Thermal Power Station, Sikka. GSECL TPS SIKKA Page 19 of 27 GENERAL SAFETY RULES / NORMS TO BE OBSERVED BY THE CONTRACTORS All the contractors working at Sikka Thermal Power Station shall have to strictly observe the following safety rules. The contractors shall be responsible for informing and observing these rules by their supervisors / employees / labours as well as the supervisors / employees / labours of their sub agencies / sub contractors engaged, if any. Prior to commencement of the work, contractor shall have to submit a written assurance on their letter head to the concerned sectional heads / Engineer In charge that they have thoroughly gone through these rules, have educated their employees / employees of their sub contractor and will strictly observe the said rules while execution of work under work contract awarded to them. They will have to indemnify the Corporation for any loss or damage / accident / injury to the Corporation’s property / employees or employee of their own in default of non observing these rules. Persons to be employees for carrying out the work shall possess required qualification, be fully trained and conversant for works to be done. All persons should have gate pass, register consisting the full details [i.e. address, phone no. details of nearest relative etc] of all persons is to be maintained. During the work execution, one trained and competent supervisor should always remain present at site. The contractor shall take all the required safety measure prior to commencement of work on dangerous substances, machineries or area at which cautionary notice is displayed and obtain “Line Clear” or “Work Permit” through the concerned department / section. Prior to carry out welding, gas cutting, furnace heating or any other hot work job, the contractor shall remove al the inflammable material lying at or nearby worksite or cover it properly by suitable protective covering. Also, special care shall be taken before carrying out such job and see that all possible contributing factors to set fire shall be removed / vanished prior to commencement of the work. Advance intimation shall be given to concerned section / fire section to commence the work in fire prone areas. They should also keep ready all the first aid fire extinguishers / equipment and fire extinguishing media / material like sand / water buckets or other appropriate equipment at such place. While carrying out work in confined space or inside vessel, the contractor shall obtain necessary “Confined Space / Vessel Entry Permit” from concerned department prior to commencement of the work. Fire lighting in such areas, only 24 volt [ISI certified and with proper guard] hand lamp shall be used. For taking care of the persons working inside the confined space / vessel, a supervisor / person capable to keep continuous watch on person [s] working inside, assist them incase of emergency or arrange to get immediate outside help, shall remain present at entry joint and shall use full body safety belt without fail. While working inside sewage, trench, or in depth, a person to warn outsiders / entrants / passers etc. shall remain available near entry point or the entry point shall be cordoned by a barricaded tape with a cautionary notice. After completion of the works, all the lids / covers / grills / grits opened, shall be re-fixed / replaced in the original position as it were prior to commencement of the work and leave the work place in safe condition in all respect, so as to prevent accident to fellow workers. The contractor shall see that he / his persons do not block [by stacking materials, spares parts, tools-tackles, equipment etc] any passages / walkways / gangways / aisles / staircases / ladders / lifts or any other approaches / roads / leading to plant or its auxiliaries, on which there is a traffic movement or possible traffic movements in case of emergency. Such passages are meant for safe escape in the event of emergency. If it is utmost necessary to carry out work in such area with blocking. Passage, prior permission of competent authority or the Engineer-In-charge shall be obtained. To demarcate / declare the area of UNSAFE, cordon it using barricading tape and display suitable caution notice or keep a person to restrict / divert the traffic on this route through other safe passage Prior to use power electrically operated hand tools / equipment / machines / gadgets like welding machine, hand grinder, hand drill etc. ensure for its safe operation and use it only if it is found safe to use. Do not use defective, unsafe or improperly maintained equipment. The electrical power supply required to run such equipment shall not be taken directly at their own, but shall be obtained through concerned electrical maintenance departments, or their authorized persons or under their observation / guidance only. The electrical section shall provide temporary electrical connection up to contractor’s mains board on which it is compulsory to install mains switch, ELCB and fuses of adequate GSECL TPS SIKKA Page 20 of 27 capacity. All such equipments shall invariably be earthed adequately to prevent electrical shock, sparking, short circuit etc. Power cord to be used shall be of adequate capacity, without any joint and shall consist of earth wire also. Hence, it is necessary to use adequate capacity 3-wire power cord for single and 5-wire power cord for three phase power connections. The plugs, receptacles pins, holders etc. shall be of adequate capacity and safe to use. All electrical / mechanical equipment / tools – tackles viz. welding machine, cutting machine, grinder, drill, chain pulley blocks, hook, chooks, etc. equired to be used during work execution shall be of standard make and bear ISIcertification mark on it. The consumables like welding electrodes, grinding wheels / discs etc. which has specific life span shall not be used in any case if its expiry dates is over. It is compulsory to use standard make Personal Protective Equipment [PPEs] as per the job requirement. Do not work without use of required PPEs. Contractor is responsible to provide standard make [ISI approved]. Personal Protective Equipment / Safety gadgets suitable to give sufficient protection against hazards involved in their work / job to their staff, as per the job requirement and insist / enforce their staff to put on the same while at works. The ongoing work is liable to be stopped at any time if the contractor’s staff is found working without PPEs. Following is the list of various PPEs to beused for arious works / worksites. LIST OF SAFETY EQUIPMENTS 01 Industrial Safety Helmet 02 03 Safety Goggles [Grinding, Welding etc] Face Shield [Half of full] 04 Earplug / ear muffs 05 Apron [Rubber / PVC / Asbestos / Leather / Cotton] Gloves [Rubber / PVC / Asbestos / Leather / Electrical shock proof] Safety / Leather / Asbestos shoes / gum boots etc] Safety belt [full body] / rope / life line / fall prevention system etc. Dust respirator / scarf Chemical cartridge respirator Canister gas mask Air supply respirators 06 07 08 09 10 11 12 For protection of head against falling objects or during fall of person from height. For protection of eyes against flying particles / dust / chemical splash , spark, arc flashover etc. For protection of face against flying particles / dust, chemicals splash, spark arc, flashover etc. For ear / hearing system protection while working in high noise level area. For body protection against chemicals / oils / sharp, edged objects, heat, hot objects etc. For protection of hands against chemicals, oils, sharps edges object, heat hot metals / objects, electrically etc. For protection of leg / feet against falling objects / sharp edges objects, heat, hot metals / objects, electrically etc. For all prevention while working at heights or in depth, working in vessel or in confined space. Protection of respiratory system against dust. Protection against chemical fume / vapor etc. Protection against toxic / poisonous fumes / gases. Working in Oxygen deficient zone. Before using lifting machines / tackles like [C.P.Bs, Hooks, chooks, winch, forklift, mobile crane, EOT crane etc] and its attachments [like D-shackles, slings, U-clamp, eye bolts or any fixtures] it shall be checked and used only if found safe to use. Also, ensure that, these are tested, examined and certified in form no.9 / 10 by competent person as per the Factory act 1948 and its validity is not expired. Further, it shall be fixed properly and firmly prior to lifting he weight. Scaffoldings to be used for working at height shall be adequate size and capacity. Obtain the work permit when working at height. While climbing on such scaffolding or working on any structure at height, use of full body safety belt and helmet is compulsory. It is also necessary to fasten chinstraps of the helmet. Contractor or their employees shall not interfere n day to day routine plant activities / works except the work assigned to them, shall not loiter in the areas other than their work jurisdiction, as well as shall not temper / operate / touch the machineries / equipment / auxiliaries with which they are not concerned. Also, the contractor shall strictly instruct their staff not to sit or take rest at / near / below running plants, auxiliaries, system or any place which is risky, hazardous and prone to accident. GSECL TPS SIKKA Page 21 of 27 The cylinders containing poisonous / toxic or inflammable / explosive gas like Oxygen, Acetylene, LPG, Hydrogen, Ammonia, Chlorine, CO2 etc. shall be handled safely taking due care. To handle / shift such cylinders a special trolley / cage meant for it must be used but in no case it should be rolled. Domestic LPG cylinder shall not be used / permitted. On completion of the work, cotton waste, spilled oil / grease, pieces of welding rod and other waste material shall be removed from work site and the area shall be left safe, neat and clean. In case of any injury / accident while working, it shall immediately reported to Safety Department through concerned sectional head / engineer. The prescribed form no.21 may be obtained from concerned section or Safety officer. For any incident occurred, but have no injury to any person should also be informed to Safety Officer as “Near Miss Incident”. In all risky jobs, before starting the work, contractor should obtain General safety works permit from concerned section well in advance. In case of noticing smoke or fire during their work execution, they shall make immediate efforts to extinguish / control it and simultaneously inform the Fire Brigade on phone no. 444 / 421, shall shift the casualty to nearby hospital after rendering first aid in case of accident Over and above these, contractor shall have to follow all the safety requirement / rules and regulations / norms and legal provision laid down in various statutes, particularly the provisions of the Factories Act 1948 and the Gujarat State Factories Rules 1963 [amended up to date] shall be followed strictly. The contractor shall also obey the rules / regulations / instructions of the local competent authority for safety requirement. No women or young person shall be allowed to clean, lubricate or adjust any part of primer mover or of any transmission machinery, while the rime movers or transmission machine is in motion. Examination or operation of motion machinery shall be made or carried out only by a specially trained adult male workers wearing tight fitting clothing as per section 22 of factories act 1948. No women or your person shall be employed or permitted to work in Lead Compound area like battery room etc. as per schedule –IV of Gujarat Factory Rule 1963. All the relevant labour and industrial laws shall also be followed compulsorily. It is felt necessary to deploy safety officers / safety supervisors by contractors / agencies involved in carrying out hazardous activities / operations inside TPS to have better and constant supervision in terms of Health, Safety and Environment activities. In case, it comes to the notice of GSECL Sikka TPS management that, the safety guidelines / safety rules / safety norms are not being followed then a minimum sum of Rs.1,000/- [Rs. One thousand only] shall be penalized on the contractor / agency and for subsequent such violation, a severe penalty / action as deemed fit shall be imposed which may please be noted. The above rules shall be scrupulously followed and where required, they may contact the Safety Officer for any ambiguity / further guidance in this regard. For performance evaluation of contractor, safety factors of work, accident, first incident and near miss accident will be considered. Steps can be taken to review the job assignment up to cancellation for negligence. Signature of Contractor with Place / Date / Firm Seal / Stamp For, Gujarat State Electricity Corporation Ltd. Sd/Chief Engineer Thermal Power Station, Sikka. GSECL TPS SIKKA Page 22 of 27 DEVIATION FROM BIDDER (IF ANY) NOTE:1. GSECL does not bind to accept the deviation offered by bidder for evaluation of tender. 2. If there is any deviation from bidder, it should be clearly mentioned on this page. 3. Deviation mentioned on other page should not be considered and order will be placed according to the tender documents. 4. If there is no any deviation from bidder, than it must be clearly mentioned in this page “NO DEVIATION OFFERRED” Signature of the Contractor With seal GSECL TPS SIKKA Page 23 of 27 > ANNEXURE < TENDER FOR SUPPLY OF ____________________________________________________ ON FIRM'S LETTER HEAD I / We_______________________________________________________________ Authorised signatory of M/s._____________________________________________ here by certify that… M/s._______________________________________________________________ is not related with other firms who have submitted tenders for the same items under this Tender. Seal of the Firm : Place : Signature of the Tenderer : Date with Designation : GSECL TPS SIKKA Page 24 of 27 GUJARAT STATE ELECTRICITY CORPORATION LTD. INTEGRITYPACT OUR ENDEAVOUR To create an environment where Business Confidence is built through Best Business Practices and is fostered in an atmosphere of trust and respect between providers of goods and services and their users for the ultimate benefit of society and the nation. GSECL’S COMMITMENT PARTY’S COMMITMENT % To maintain the highest eithical standards % Not to bring pressure recommendations in business and professions. from outside GSECL to influence its decision. % Ensure maximum transparency to the % Not to use intimidation, threat, inducement satisfaction of stakeholders. or pressure of any kind on GSECL or any of it’s employees under any circumstances. % To ensure to fulfill the terms of agreement / % To prompt and reasonable in fulfilling the contract and to consider objectively the contract, agreement, legal obligations. viewpoint of parties. % To ensure regular and timely release of % To provide goods and / or services timely as payments on due dates for work done. per agreed quality and specifications at minimum cost to GSECL. % To ensure that no improper demand is made % To abide by the general discipline to be by employees or by any one on our behalf. maintained in our dealings. % To give maximum possible assistance to all % To be true and honest in furnishing the Vendors / Suppliers / Service Provider information. and other to enable them to complete the contract in time. % To provide all information to Suppliers / % Not to divulge any information, business Contractors relating to contract / job which details available during the course of facilitate him to complete the contract / job business relationship to other without the successfully in time. written consent of GSECL. % To ensure minimum hurdles to vendors / % Not to enter in to carter / syndicate / suppliers / contractors in completion of understanding whether formal / non-formal agreement / contract / work order. so as to influence the price. Seal & Signature (GSECL’s Authorized Signatory) Name : Designation : Seal & Signature (Party’s Authorized Person) Name : GSECL TPS SIKKA SCHEDULE - B Page 25 of 27 PRICE BID (RFQ NO. 28086) Work of overhauling of Air Pre Heater of Boiler Unit No. 1 during AOH at STPS Sr. 1. 2. 3. 4. 5. 6. 7. 8. 9. Description Work of Checking / Inspection / Recording / Repair / Replacement and setting of radial, axial and by pass seals, including of repair / replacement of all static seals at cold end & hot end in APH - A & B as per SOW & instruction of EIC. Work of Repair / Rectification of all sector plates at Hot End and Cold End sides by weld repair / flush grinding in APH-A & B as per SOW & instruction of EIC. [ 01 Set = 03 Hot & 03 Cold Total 06 Sector Plates]. Work of Alignment / Setting of sector plates at Cold End and Hot End sides of APH-A & B as per SOW & instruction of EIC. [ 01 Set = 03 Hot & 03 Cold Total 06 Sector Plates]. Work of Repair / Rectification / Alignment / Setting of axial seal plates with respect to sector plates and seals of APH-A & B as per SOW & instruction of EIC. Work of Repair / Rectification of spool piece for tracking system of hot end side including repair of centre section below guide bearing & air seal assembly to arrest gas leakages as per SOW & instruction of EIC. Work of KAO wool filling and refitting in all static seals to sector plate, axial seal plate and spool piece at Hot End and Cold End sides of APH-A & B as per SOW & instruction of EIC. Work of Repair / Rectifications of APH housing and internal truss supports at Hot End and Cold End sides by replacing eroded housing plates and support pipes of APH-A & B as per SOW & instruction of EIC. Work of Repair / Replacement of Cold End side basket support grating[Inner & Outer] by cutting and fixing new support bars there in all sections in APH-A & B (1 Set=24 Nos.) as per SOW & instruction of EIC. Work of Servicing of main drive gear box including replacement of oil / grease in gear box / coupling etc. and servicing of air motor; pinion housing of drive mechanism of APH-A & B as per SOW & instruction of EIC. Unit Qty. Rate Amount Set 2 66339 132678 Set 2 10084 20168 Set 2 6187 12374 Set 2 4515 9030 Set 2 14693 29386 Set 2 3916 7832 Set 2 8452 16904 Set 2 5797 11594 Number 2 3491 6982 GSECL TPS SIKKA 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. Page 26 of 27 Work of Repair / Rectification/ replacement of Tbar at Hot End and Cold End sides including replacement of eroded hex bolts and T bar holding angles APH-A & B as per SOW & instruction of EIC. Work of Checking and alignment of guide and support bearings including oil replacement and flushing of both end side bearing with filling of new oil APH-A & B as per SOW & instruction of EIC. Work of Repair / Rectification / Replacement of soot blower and water washing systems including servicing oiling/ greasing of its drive system of APH-A & B as per SOW & instruction of EIC. Work of Overhauling / servicing and replacement of guide bearing assembly / oil level tube / adapter sleeve / bearing housing / packing ropes, etc. in either in APH- A or APH- B, if required as per SOW & instruction of EIC. Work of Overhauling / servicing and replacement of Support bearing assembly / oil level tube / adapter sleeve / bearing housing / packing ropes, etc. in either in APH- A or APH- B if required as per SOW & instruction of EIC.. Work of the repairing of APH housing with door as per SOW & instruction of EIC. Work of Replacement of pinion wheels & pin rack with pins of APH - A & B as per SOW & instruction of EIC. Work of removing/ replacement/ repairing / cleaning/ reversing of HOT end basket of APH A & B as per SOW & instruction of EIC. Work of removing/ replacement/ repairing/ cleaning/ reversing of HOT intermediate end basket aof APH - A & B as per SOW & instruction of EIC. Work of removing/ replacement/ repairing/ cleaning/ reversing of Cold End basket of APH A & B as per SOW & instruction of EIC. Work of rectification / replacement of flappers, sealing angles, partition plates, shafts and servicing of all bushes, links and O/H of gear box of GD 1A & 1B as per SOW & instruction of EIC. Work of Repair / rectification / replacement of I/L Damper Frames by cutting / removing old damaged frame parts and fabrication, erection and fitting, also repair & fabrication of supports at above & below APH flue gas duct in Unit-1 Work of cutting of corroded / eroded Damper frames and supports as per the instruction of EIC and SOW. Providing and fixing of MS hexagonal bolts / nuts / washer / stud / self locking nut etc. of required size confirming to IS-1363, grade - 4.6 as per SOW & instructin of EIC. Set 2 3916 7832 Set 2 2015 4030 Set 2 4898 9796 Set 1 39415 39415 Set 1 56358 56358 Running Meter 250 118 29500 Set 2 37504 75008 Number 144 602 86688 Number 144 642 92448 Number 216 360 77760 Number 2 26783 53566 Metric Ton 5 7360 36800 Metric Ton 3 3301 9903 Kilogram 500 116 58000 GSECL TPS SIKKA Page 27 of 27 The Rates are Exclusive of Service Tax. Service Tax at prevailing rate, if applicable will be paid by GSECL extra on production of paid evidence / challan. TOTAL RS…. 884052.00