Rectification of oil leak in runner assembly by dismantling the runner assembly in complete and Recommissioning of Unit3 of Tunnel Power House, Mettur Dam

Amount

1.DISMANTLING: Charges towards Draining the Runner Hub Oil, Dismantling of PMG, Oil Header assembly including Oil Rods, All Pipes Lines, Pilot and Main Exciter, Slip ring holder assembly including Covers, Doors and Bolts & Nuts with proper prior marking and transporting to repair bay.

Charges towards Dismantling of Upper bracket (77 Ton), Thrust Bearing, Upper Guide Bearing, Coupling Bolts and Nuts including Dismantling of Oil coolers, Oil bath, Cooling Water Inlet / Outlet Pipes, Oil drain Pipes and all instrumentation lines in complete, proper prior marking and transporting to repair bay.

Charges towards Dismantling of 330-Ton Generator Rotor Assembly in complete including Oil Rods, Generator Lower Guide Bearing assembly, Lower spider (27 ton) , Brake assembly and its allied oil/air lines including removal of Coupling Bolts & Nuts, Oil bath , pit ceiling and all instrumentation lines after proper prior marking and Transporting.

Charges towards Dismantling and realising of Turbine Pit De-Watering System, Leakage Oil System, Platforms, Wicket Gate Apparatus including Servo Motors, Regulating Ring and connectors including all impulse lines to gauges and instrumentation lines with proper prior marking and Transporting to Repair Bay.

Charges towards Dismantling of Turbine Guide Bearing, Grease feeding Lines, Bath cover seal arrangements, Upper & Lower Labyrinth including all instrumentation lines with proper prior marking and Transporting to Repair Bay.

Charges towards Dismantling and removal of Turbine Cover, 24Nos. Guide Vane, Seals and grease feeding lines and instrumentation line in complete with proper prior marking and Transporting to Repair Bay.

Charges towards providing support to entire Turbine Rotor, Releasing the Turbine Rotor from scaffolding with proper prior marking and Transporting to Repair Bay.

Charges towards removing the Turbine Shaft (Weight- 18 Ton ), removal of all Bolts & Nuts in 8Nos. Runner Blades including 32Nos. Seals etc., Runner Mechanism and Turning Gears including removal of all Bushes from Runner Body including Special tools and tackles as per site requirements with proper prior marking and transporting to Repair Bay.

Charges towards the hiring of Mobile crane to transport the materials in the out of approach area of Power house EOT Crane.

2.SUPPLY OF REPLACEMENT SPARES AND CONSUMABLES Supply of Bronze bushes, Bolts and Nuts and Rubber Cords required for the assembling of Runner Mechanism and Runner Blades as per drawing and standards after Reverse Engineering

Supply of Bolts and Nuts and Rubber Cords required for connecting the Turbine and generator shafts and assemble the Turbine cover, Turbine Guide Bearing and Bath cover seals as per drawing and standards after Reverse Engineering

Supply of Bronze Bushes, Bolts and Nuts, Rubber collars and Rubber Cords required for wicket gate apparatus as per drawing and standards after Reverse Engineering

Supply of Bolts and Nuts for the upper and lower spider as per drawing and standards after Reverse Engineering

Supply of various size fasteners, dowel pins, Rubber cords and O rings, consumables etc. Bolts and Nuts, for all other components as per drawing and standards

3.COMPLETE REASSEMBLING: Charges towards Complete Reassembling of Runner Mechanism and Runner Blades including the replacement of all the bushes and seals, Turbine Shaft, Turbine Cover, Turbine Guide Bearing , Shaft Seals assembly , Guide vanes and Grease feeding lines including the pressure test of Runner blade seals including transporting the materials from repair bay.

Charges towards Complete Reassembling of wicket gate apparatus including replacement of new Rubber collars, Bronze bushes in Top and Bottom of Guide vane housing, Grease feeding lines and instrumentation lines including transporting the materials from repair bay.

Charges towards reassembling of Turbine Pit De-Watering System, Leakage Oil system, Platforms, all the impulse and instrumentation lines including transporting the materials from repair bay.

Charges towards Complete Reassembling of Lower bracket, Brake assembly and its allied oil/air pipe lines, Generator Lower Guide Bearing, Generator Rotor, Upper bracket, Generator Upper and Thrust Bearings, Bearing Oil coolers, Oil bath, all Oil, Water Inlet/Outlet pipes and Drain pipe lines and Oil Rods and all the impulse and instrumentation lines including transporting the materials from repair bay.

Charges towards Complete Reassembling of Main and Pilot Exciters, Oil Header assembly, PMG Slip ring holder assembly and all Oil , Water Inlet/Outlet, Drain Pipe Lines and all the impulse and instrumentation lines including transporting the materials from repair bay.

Charges towards the hiring of Mobile crane to transport the materials in the out of approach area of Power house EOT Crane.

4.REALIGNMENT, DYNAMIC BALANCING AND RECOMMISSIONING: Charges towards the Alignment of Whole Unit comprising PMG, Oil Header assembly, Pilot Exciter ,Main Exciter, Generator Bearings, Generator Shaft ,Turbine Shaft, Turbine Guide Bearing , labyrinths and all the rotating parts with the fixed reference of the Unit-3.The values achieved in levelling, centering, Run Out, Throw, and Bearing Clearances by the realignment should be as per manufacture's recommended Standards.

Charges towards the Dynamic Balancing of the whole Rotor assembly of the Unit to achieve the accepted vibration level as per the manufacture's standard, successful commissioning of Unit 3, for a continuous running of 72 Hrs. with full load within the prescribed parameters.

SAMY CONSTRUCTION