Refurbishing of Unit-III (100MW) Generator of Kadamparai Power House

Amount

Charges towards removal of 12 Nos. rotor poles from rotor spider

Charges towards dismantling the Generator by decoupling the turbine and threading out the rotor

Charges towards removing the 198 Nos top and 198 Nos bottom coils by removing end insulations & end caps, de-wedging the wedges, de-brazing the connection & non-connection end ferrules ( released stator coils should be hand over to TNGECL).

Charges towards de- brazing and removal of 18 Nos. bus bars on both phase and neutral sides and 72 Nos. of Jumpers with suitable thermal protection and removing 4 Nos. surge ring.

Charges towards dismantling the entire core, handing over the old stampings to TNGECL Stores, procuring the raw materials for making 100% new laminations, making a punching tool, punching the stampings, removing the burrs, re-varnishing and conducting following tests on the sample. a. Xylol Test b. Mandrel Test c. 7H Pencil Hardness Test d. Insulation Resistance Test by applying 110 V AC between 10 Nos. stampings clamped together with a lamp series. The lamp should not glow.Transporting the core to the site, re- staggering and restacking, maintain the core back thickness, locking the core by insulating core bolts, locking plates and checking the IR value of core bolts

Charges towards conducting the ELCID and 100% Flux loop test to ascertain the integrity of insulation of stator core and find out the hot spot and the same to rectified.

Charges towards cleaning and polishing the stator core pack slot for ready to install new stator coils.

Charges towards supply of new stator bars with Class F insulation (top -198 Nos & bottom-198 Nos.) as per the sample bars.

Tests on stator coils as per relevant IS standard: 1. Dimensional check 2. Coil Resistance Measurement 3. Inter strand IR value test at 110 V AC for 3 sec 4. IR value at 5 KV before and after HVAC test for 1 minute 5. HVAC test at 26 KV for 1 minute 6.Tan delta test at 2.2 KV, 6.6 KV, and 11 KV

Charges towards procurement of the required quantity of glass epoxy class “F” liners, wedges and binding card, mouth block, end cap, coil overhang support epoxy spacer, tape and resin etc.,

Charges towards re-insulating both top and bottom side overhang surge ring -4 nos., 18 Nos. Bus bars, 72 Nos. jumpers in the stator assembly with class ‘F’ insulation.

Charges towards replacement of 27 Nos. RTD for measuring winding, tooth & core temperature, with temperature scanner.(including wiring)

Charges for installing the tested new bottom & top coils with using fresh liners, wedges, end banding the overhang portion with fiber tapes and cards using the binding cement of epoxy resin, soldering the non-connection and connection side end ferrules, bus bars and jumpers and insulating the jumper joints & providing end caps.

Charges towards transporting of 12 Nos. rotor poles for re-insulating from KPH to vendor works and back.

Charges towards re-insulating of 12 Nos. rotor pole coils with Class H insulation and testing. Tests on rotor pole coils: 1. Coil resistance measurements 2. IR value at 2.5 KV before and after HVAC test 3. HVAC test at 2.5 KV for minute 4. AC pole drop test 5. AC impedance test 6. Surge comparison test at 3 KV 7. Polarity test

Charges towards assembly of all 12 nos. rotor poles,coupling of rotor and turbine, assembling with the Generator.

Supply of spare new Top Coil with Class F insulation as per sample

Supply of spare new rotor pole coils with H class insulation as per sample.

Supply of spare new rotor pole core as per sample

Charges towards drying out, final testing. The following tests after completion of stator winding. i) IR value at 5 KV before and after HVAC test. ii) AC High voltage test at 23 KV, 50Hz for 1 minute. iii) PI value iv) Winding resistance v) Tan delta test at 11 KV in steps of 0.2, 0.4, 0.6VL Rotor: 1. DC resistance measurement 2. IR value at 500V 3. AC pole drop test

Charges for relocation of HPLOP system (Pump and motor- 2sets with connected pipelines) from the existing position with all accessories and extend its pipeline to the safe position to avoid oil spillage into the Generator.

Charges for reconditioning of Top Guide bearing Supporting ring with all blocks -10Nos. and replacement of necessary essentials bolts and spares(if any)

Charges for replacement of pipe and pipe fitting accessories for LPLOP system in unit-III of Kadamparai Power House. (As per Annexure –A under Section-VI Technical)

Charges for rehabilitation of CGLS (centralised Grease Lubrication System) for the use of mechanical rotating parts such as Guide vane Top and Bottom points- 24 Nos., MIV system, etc. including the replacement of damaged PVC hoses and servicing of distribution system)

Complete Re-alignment of the whole unit (Comprising of Generator, Rotor, Turbine, Turbine shaft, Intermediate shaft and all the Rotating parts with the Existing static components and fixed References of the unit-3.) by removing all allied accessories and placing shims (if required).After re-alignment, all allied parts to be reassembled. The Values achieved in leveling, Rotor centering, Run-outreadings, throw, Labyrinth and bearing clearances by theRe-alignment have to be as per BHEL recommended standards. i.e UGB, LGB, TGB radial clearance is within 0.2mm; Turbine Labyrinth clearance within 1.0mm; lower wearing ring axial clearance to be within 10mm + 1mm; TGB radial throw within 0.09mm; LGB radial throw within0.03mm. ( As per Annexure-B under Section VI - Technical)

Dynamic Balancing of the whole Rotor assembly of the Unit to achieve the accepted vibration Levels, as per I.S. (Vibration in Top Bracket and in all the three GTGB, GBGB and TGB Bearings have to be proved to be within the Limits as furnished in Special condition Point– a) and Successful Commissioning of the Unit-3 of Kadamparai power house, for a continuous running of 72 Hours with full load. (within prescribed Parameters as furnished in Special condition Point – b under Section VI - Technical).

CGST in % (For Bidders inside TamilNadu)

SGST in % (For Bidders inside TamilNadu)

IGST in % (For Bidders outside TamilNadu)

Coral rewinding India Private Limited (BID ID -1463177)

Evans Electric Limited (BID ID -1465635)

ABB INDIA LIMITED (BID ID -1484652)