Service Contract for overhauling job of U3 ESP500MW BHEL make 04 passes72 Nos.ESP Fields under AHPEM StgII at SGTPP WBPDCL

U#3 ESP OVERHAULING JOB:

Dry cleaning work. Dry cleaning of ESP starting from ESP inlet funnel to ESP outlet funnel , all ESP hoppers, Gas distribution Screens, all emitting electrodes and collecting plates and other allied zones. Suspension zone in between CERM/EERM Frame and ESP ceiling to be checked and cleaned properly. After de-synchronization of Unit, all hopper doors (288 Nos.) are to be opened for smooth removal of ash and after completion of total overhauling job, all hopper manholes has to be boxed up by replacement of new gasket replacement (100%). Stipulated Period of Work: Day-2 to Day-4- 04 Number of separate manpower gangs to be engaged for working at a time in 04 ESP Passes. Report to be submitted to department by 4th day evening or 5th day morning.

Water Jet Cleaning work. HP Water Jet washing of ESP internals (72 nos Fields), including all hoppers, collecting plates, emitting electrodes and other allied zones. At the time of water washing if any chocking found in the hoppers, the choking shall be cleared immediately. All arrangements including hose and booster pump having discharge pressure of 4-5 Kg/sq.cm for the job will be in party's scope. Suspension zone in between CERM/EERM Frame and ESP ceiling to be checked and cleaned properly. Stipulated Period of Work: Day-3 to Day-9 - 02 separate groups of manpower should be working at a time round the clock strictly to finish within stipulated time. Each day Job progress and simultaneous checking report to be submitted within 48 Hrs of Unit De-sync andsimultaneous information to party sufficient number HP Hose and 04 number HP Pumps must be available at site for working at a time from 04 different Water outlet points

Internal checking & rectification work. Field gauging of each Collecting Plate to maintain a gap of 400 mm by Go Gauge (72 nos of ESP fields in A, B, C & D Path).Job to be carried out by specialized separate manpower ,experienced to perform identical job at ESP. Re-fitting of newspacers if required. Stipulated Period of Work: Day -6 to Day-20. Each day finding report and simultaneous rectification report to be submitted. Rectification job to be strictly carried out as perreports/findings of expert engaged by departmental authority

CERM system. Checking and rectification of Collecting rapping system of all the ESP fields thoroughly. Replacement/Fitting of missing components / Repair & Alignment of rapping shafts, bearings, Pin wheel, hammer assembly of all the rapping mechanism, if required after checking for ESP Fields .Rectification/Replacement of shock Pad, Anvil Bar and corresponding fasteners, Shock Bar Guide Plate, Guide angle, PL attachments of Rapping and non-rapping sides. Stipulated period of Work: Day -6 to Day-20 - The teams are separate than the manpower engaged in field gauging job. Each day finding report and simultaneous rectification report to be submitted. Rectification job to be strictly carried out as per reports/findings of expert engaged by departmental authority.

EERM System. Checking and rectification of Emitting rapping system of all the ESP fields thoroughly. Replacement /Fitting of missing components/ Repair & Alignment of rapping shafts, bearings, Pin wheel, thrust pad, bottom bearing, hammer assembly of all the rapping mechanism, if required after checking for ESP Fields. Stipulated Period of Work: Day -6 to Day-20 -Simultaneous work to go on in 02 passes at a time by two separate expert team. These teams are separate than the manpower engaged infield gauging job. Each day finding report and simultaneous rectification report to be submitted. Rectification job to be strictly carried out as per reports/findings of expert engaged by departmental authority.

GDRM System. Checking and rectification of GD Screen rapping system thoroughly. Replacement / Repair & Alignment of rapping shafts, bearings, hammer assembly of all the rapping mechanism, if required after checking. Stipulated Period of Work: Day -10 to Day-16 Each day finding report and simultaneous rectification report to be submitted. Rectification job to be strictly carried out as per reports/findings of expert engaged by departmental authority.

Shaft insulator system. Replacement / Repair & Cleaning of Shaft Insulator and its Heater. Proper box up after the job with gasket replacement if found damaged. Cleaning of shaft insulators to be done in 02 phases(after water washing and again before final box up by petrol). Stipulated Period of Work: Day -8 to Day-18 - Thorough cleaning by petrol washing to ensure full dryness. Separate group of electrician is to be engaged for heater checking Each day finding report and simultaneous rectification report to be submitted. Rectification job to be strictly carried out as per reports/findings of expert engaged by departmental authority.

Support Insulator system. Cleaning of Support Insulator and its Heater. Proper box up after the job with gasket replacement if found damaged. Cleaning of support insulators to be done in 02 phases(after water washing and again before final box up by petrol). Stipulated Period of Work: Day -8 to Day-18 - Thorough cleaning by petrol washing to ensure full dryness. Separate group of electrician is to be engaged. Each day finding report and simultaneous rectification report to be submitted. Rectification job to be strictly carried out as per reports/findings of expert engaged by departmental authority.

Hopper Heater. Hopper heater replacement / Repair & Cleaning of Hopper Heater. Checking and repairing of heater jackets for any ash accumulation and damage followed by repairing of the same. Stipulated Period of Work: Day-10 to Day-20. Same electrician group to be engaged as for Support & Shaft insulators. Each day finding report and simultaneous rectification report to be submitted. Rectification job to be strictly carried out as per reports/findings of expert engaged by departmental authority

Guide vane. (ESP INLET FUNNEL) Checking , Repair/Replacement and strengthening of Guide Vane of ESP Inlet Duct. A separate/dedicated group of manpower to be engaged for the job apart from the groups working inside the ESP. Each day finding report and simultaneous rectification report to be submitted. Rectification job to be strictly carried out as per reports/findings of expert engaged by departmental authority.

CERM,EERM & GDRM Gearboxes. CERM,EERM & GDRM Gear Boxes. Lubrication of Collecting and Emitting rapping motor and its gearbox. Each day finding report and simultaneous rectification report to be submitted. Rectification job to be strictly carried out as per reports/findings of expert engaged by departmental authority.

Insulation Testing of ESP Fields.Insulation Testing of ESP Fields. After completion of aforesaid jobs, Meggaring of each field to be carried out until it comes to its desired value. Stipulated period of Work: From Day-22 to till desired result is achieved

ESP TR sets. The entire Transformer # Rectifier units should be checked thoroughly and cleaned body only including checking of oil level and changing of silica gel depending upon the condition then. Each day finding report and simultaneous rectification report to be submitted. Rectification job to be strictly carried out as per reports/findings of expert engaged by departmental authority.

HV Safety Breakers/Disconnecting Switche Alignments of all the safety breakers, 72 Nos. (1 for each field) should be checked & rectified. These must also be cleaned. All Pin Insulators (216 Nos) along with copper tubes to be checked cleaned and if required replaced. All Disconnecting switch boxes door rubber gasket replacement is mandatory and to be supplied by SgTPP authority. Through cleaning by petrol wash to ensure full dryness. Each day finding report and simultaneous rectification report to be submitted. Rectification job to be strictly carried out as per reports/findings of expert engaged by departmental authority

ESP MCC panels. All the MCC panels (LTMSB-A,B,C & D) of ESP fields & its ACP (A,B,C & D) Panels, HD & TB Panels also the EC Panels (72 nos), including 11 KV/ 415V Dry type Transformers (08 Nos.) to be cleaned & tightness checked. Strictly electrician group having adequate knowledge of electrical switchgear system to be engaged for the job. Report to be furnished with megger value

ESP manhole doors.Inspection and repair of all manhole Doors of A-path, B-path, C-path & D-path by replacement of Door sealing gasket for 100% doors. Stipulated Period of Time: Subject to completion of above mentioned jobs.

Painting work Painting of all outdoor equipments of ESP.(Gear Boxes, Doors, Disconnecting Switch Boxes, Shaft & Support Heater enclosures). Surface preparation by manual cleaning, de-rusting by Sand paper etc, then applying one coat of Bison H/B zinc phosphate primer + two coats of synthetic enamel finish paint (Make-Berger paints). The job has to be completed as directed by concerned departmental representative.

Repairing of Gas Distribution Screen. Repairing of Gas Distribution Screen based on report after checking. Repairing / Replacement to be done by necessary scaffolding which is under the Scope of Party. Inspection and patch repair of gas distribution box nozzles at the inlet funnel of ESP. Fabrication and replacement of nozzles of gas distribution box is limited to 20 Nos. Stipulated period of Work: Within Day 21. Each day finding report and simultaneous rectification report to be submitted. Rectification job to be strictly carried out as per reports/findings of expert engaged by departmental authority.

Checking & Calibration of ALI Checking and calibration of all Ash Level Indicators (ALI) are to be done. If required, ALI to be replaced (total # 144 nos.).Along with RF type probe checking and replacement if required.

Any type of fabrication job To set right the ESP internal and leakage rectification of ESP Roof Top and ESP Wall to resist water and air ingress in ESP if required, are also within the scope of the party. Each day finding report and simultaneous rectification report to be submitted. Rectification job to be strictly carried out as per reports/findings of expert engaged by departmental authority

ESP Hopper Repairing Job If any damage to hopper body/door, internal found for all 144 number ESP Hoppers, required rectification to be done.

Replacement of shock bar Replacement of 25 Nos. shock bar along with scaffolding work, dismantling & erection of shock bar, ESP Field gauging, checking & alignment of C13 Field at ESP, U#3. If required, the shock bar guide of rapping side & non rapping sides has to replaced.

Replacement of Support Insulator ,Repairing and strengthening of Support Insulator Housing.