SE/G/TIN/GL/SPECN.No.12/25-26

Transportation charges for to-and-fro transportation (round trip) of the entire runner shaft with runner blade assembly between the powerhouse and the work site, including loading, unloading, and safe handling, along with charges for design, fabrication, and preparation of a suitable supporting stand/cradle to ensure safe and stable transportation of the runner shaft assembly of approximately 9m length and 10 ton`s weight.

Rectification of a 360° circumferential crack, as detected by Ultrasonic Testing (UT), in the runner shaft flange of 800 mm outer diameter and 200 mm thickness, located near the centre bore, where the crack depth is non-uniform and ranges from approximately 10 mm to 50 mm, with maximum crack propagation observed above the centre bore region, comprising complete excavation of the cracked zone by controlled grinding and gouging until sound parent metal is achieved, proper edge preparation of uneven and extensive crack areas using appropriate V-groove or U-groove profiles based on material thickness and accessibility, thorough cleaning of the prepared surfaces to remove oil, grease, moisture, rust, carbon deposits, and other contaminants, grinding of the flange surface to eliminate forging laps and surface discontinuities, followed by refilling of the excavated area through controlled micro-welding using approved welding procedures and consumables, and final grinding and profiling after welding to restore the original flange geometry, including preparation of the flange groove area and eight (8) flange bolt bore locations affected by cracking.

Charges for carrying out Ultrasonic Testing (UT), run-out measurement, face-out measurement, and dynamic balancing of the entire shaft assembly, comprising the A-shaft and B-shaft coupled with the runner blade assembly, including all necessary instruments, setups, and measurements to ensure compliance with specified tolerances and operational requirements

ASSEMBLING (i) Labour charges for assembling the LOS unit complete with the gearbox unit, including positioning, leveling, and preliminary alignment. (ii) Labour charges for assembling the runner shaft and intermediate shaft, including fitting of all associated accessories, keys, fasteners, and mounting hardware. (iii) Labour charges for assembling the intermediate shaft with roller bearings, including bearing installation, seating, and connection with turbine-side components. (iv) Labour charges for assembling the runner shaft with runner and coupling, including proper tightening, locking arrangements, and inspection. (v) Labour charges for assembling and fixing the slow-speed coupling and high-speed coupling, including coupling alignment checks. (vi) Labour charges for assembling and refixing the turbine head covers along with all related accessories, gaskets, and sealing arrangements (vii) Labour charges for turbine-side alignment with the runner shaft (including runner) and precision alignment with the intermediate shaft. (viii) Labour charges for coupling the runner shaft and intermediate shaft, ensuring correct alignment with the gearbox input shaft. (ix) Labour charges for gearbox alignment with turbine shaft, alignment of associated turbine accessories, and refixing/ alignment with the respective generator. (x) Supply and replacement of damaged or unserviceable bolts, nuts, and fasteners required during assembly. (xi) Labour charges for vibration analysis calibration through TNGECL, performance monitoring, and successful commissioning, including completion of a continuous 72-hour trial run test.

Fabrication of Shaft A and B coupling bolt (As per sample)