Vol-Ii B936

TENDER PSER:SCT:SAL-B936:08
NO
VOLUME II TECHNICAL SPECIFICATION WITH SCC
JOB ERECTION, TESTING & COMMISSIONING OF BOILER

INCLUDING MILLS, ESP, ROTATING MACHINES &
PIPING ETC
PROJECT 1x250 MW UNIT # 1 BONGAIGAON THERMAL
POWER STATION SALAKATI, KOKRAJHAR,ASSAM
BHARAT HEAVY ELECTRICALS LIMITED

(A Govt Of India Undertaking)
POWER SECTOR – EASTERN REGION
PLOT – DJ 9/1, SECTOR II, SALT LAKE
KOLKATA – 700 091
INDEX
CLAUSE NO/ DESCRIPTION

ANNEXURE NO
1.0 Project Synopsis & General Information – See Common Conditions
2.0 SCOPE OF ENQUIRY.
3.0 HYDRAULIC AND OTHER TESTS.
4.0 PRE-COMMISSIONING TEST AND COMMISSIONING.
5.0 WELDING, HEAT TREATMENT AND RADIOGRAPHY.
6.0 DRUM LIFTING AND MISCELLANEOUS POINTS.
7.0 LINING AND INSULATION WORK.
8.0 FINISH PAINTING.
9.0 SCOPE.
10.0 EXCLUSIONS.
11.0 DEVIATIONS.
12.0 SERVICE TO BE RENDERED BY BIDDER.
13.0 GENERAL TECHNICAL REQUIREMENT (CODE AND PRACTICES).
14.0 PROTECTION.
15.0 ERECTION SCHEDULE.
16.0 CONTRACT MANAGEMENT.
17.0 CONSTRUCTION MANAGEMENT.
18.0 PROJECT PROGRESS REVIEW MEETING.
19.0 SITE ORGANIZATION.
20.0 Common
21.0 ERECTION SERVICES.
22.0 QUALITY ASSURANCE PROGRAM- See Common conditions
23.0 GENERAL REQUIREMENTS - QUALITY ASSURANCE - See Common
Conditions.
24.0 INSPECTION, TESTING AND INSPECTION CERTIFICATES - See
Common Conditions.
25.0 QUALITY CONTROL & QUALITY ASSURANCE- See Common
Conditions.
26.0 CERTIFICATE TOWARDS COMPLETION.
27.0 DEWATERING- See Common Conditions.
28.0 CONSUMABLES.
29.0 ELECTRODES AND GASES.
30.0 PROJECT MANAGEMENT.
31.0 Common
32.0 Common
33.0 IMTE.
34.0 TEST CERTIFICATE FOR TOOLS & PLANTS.
35.0 ISSUE OF TOOLS & PLANTS.
36.0 Common
37.0 Common
38.0 Common
39.0 Common
40.0 AREA REQUIREMENT.
41.0 CONSTRUCTION OF TEMPORARY OFFICE ETC.
42.0 TOOLS & PLANTS.
43.0 TOOLS & PLANTS TO BE PROVIDED BY BHEL (SHARED
MACHINERY).
44.0 TIME SCHEDULE.
45.0 CONSTRUCTION SCHEDULE.
46.0 RECTIFICATION/MODIFICATION.
47.0 EXTRA WORK FOR HIGH PRESSURE JOINTS.
48.0 EXTRA WORK FOR ALL CASES OTHER THAN HIGH PRESSURE
JOINTS.
TENDER NO. PSER:SCT:SAL-B936 :08
VOLUME-II TECHNICAL SPECIFICATION AND SPECIAL CONDITIONS OF
CONTRACT
49.0 TAXES AND DUTIES.

50.0 Common
51.0 Common
52.0 Common
53.0 TERMS OF PAYMENT.
54.0 REVISION OF ACCEPTED RATES.
55.0 RATE/PRICE.
56.0 Common
57.0 Common
ANNEXURE-A See Separate File
ANNEXURE-B See Separate File
ANNEXURE-C LIST OF TOOLS & PLANTS TO BE PROVIDED BY CONTRACTOR.
ANNEXURE-D LIST OF TOOLS & PLANTS TO BE MADE AVAILABLE BY BHEL FREE
OF ANY CRARGES.
ANNEXURE-E APPROXIMATE NUMBER OF ERECTION WELD JOINTS FOR
PRESSURE PARTS.
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CLAUSE DESCRIPTION
NO
1.0 PROJECT SYNOPSIS AND GENERAL INFORMATION
NTPC is setting up three units of 3x250 MW Thermal Power station (coal
based) at Bongaigaon , District- Kokrajhar , State of Assam..
The Plant site is located near Kumguri near Salakati in Kokrajhar district of
Assam. The nearest major town Bongaigaon is located at a distance of
about 20 Kms. from Project site.
Nearest Railway Station : Salakati Railway Station

( Approx. 4 KMs from the Plant)
Nearest Airport : Guwahati

( Approx. 220 KMs from the Plant)
Kokrajhar is district town located around 14KM away from the project site.
Bongaigaon is around 35KM away from the project site.
2.0 SCOPE OF ENQUIRY

The steam generator shall be natural circulation, drum type, double pass, water
tube, corner fired with tilting type burners using pulverized coal, single reheat,
suitable for outdoor installation
2.1 The intent of this erection specification of BONGAIGAON 250 MW Boiler is to
provide services for execution of the project according to most modern and
proven techniques and codes. The omission of specific reference to any method,
equipment or material necessary for the proper and efficient services towards
installation of the plant shall not relieve the contractor of the responsibility of
providing such services / facilities to complete the work or portion of work
awarded to him. The quoted / accepted rates / price shall deem to be inclusive of
all such contingencies.
2.2 This specification covers the complete work of handling including arranging the
issue of material, receipt from store/ yard, transportation to site, temporary
storage prior to erection, if required, cleaning, preservative painting, erection,
alignment, welding, leveling, adjustment, heat treatment, NDT, welding of
hooks, seal-plates etc., hydraulic test, insulation, chemical cleaning, all pre-
commissioning tests, start-up and trial run of individual equipment, final
commissioning, finish painting and trial run of the Boiler of BONGAIGAON 1
x 250 MW Unit up to handing over of the unit to BHEL/ NTPC including PG
test of the unit. In addition, unloading of the Boiler Drum from Trailor to work
site is also included under the scope of this specification. The work shall conform
to dimensions and tolerances given in various drawings and documents that will
be provided during erection. If any portion of works is found to be defective
in workmanship and not conforming to drawings / documents or other
stipulations, the contractor shall dismantle and re-do the work duly replacing
the defective materials at their own cost, failing which recoveries, as determined
by BHEL, shall be effected from contractor's bills.
2.3 It is not the intent of this specification to specify herein all the details of erection
and commissioning. However, the system shall conform in all respects to high
standards of quality and workmanship for performing the required duties in a
manner acceptable to purchaser who will interpret the meaning of drawings and
specifications and shall be entitled to reject any work or material, which in his
judgments is not in full accordance herewith.
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2.4 The omission of specific reference to any fabrication / erection method,

equipment or material necessary for proper and efficient working of the plant
shall not relieve the tenderer of the responsibility of providing such facilities to
complete the work at quoted rates. Any mismatch/ defect found due to mistake
in fabrication / erection shall have to be rectified by the vendor free of cost.
Inspection by BHEL/Customer does not relieve vendor of his responsibility of
executing quality erection.
2.5 The work covered under this specification is of highly sophisticated nature,
requiring the best quality workmanship, supervision, engineering and construction
management. The contractor should ensure proper planning and successful and
timely completion of the work to meet the overall project schedule. The
contractor must deploy adequate quantity of tools & plants, modern / latest
construction aids etc. He must also deploy adequate trained, qualified and
experienced supervisory staff and skilled personnel.
2.6 Contractor shall erect and commission all the equipments and auxiliaries as per
the sequence & methodology prescribed by BHEL depending upon the technical
requirements. Availability of materials and fronts will decide this. BHEL Engineer’s
decision regarding correctness of the work and method of working shall be final
and binding on the contractor. No claims for extra payment from the contractor
will be entertained on the ground of deviation from the methods / sequence
adopted in erection of similar sets elsewhere.
2.7 The boiler shall be erected as per relevant provisions of latest Indian boiler
regulations and amendments / addendums thereof, if any.
2.8 Following shall be the responsibility of contractor and have to be provided within
finally accepted rates / prices:
2.8.1 Provision as required of all types of labour, supervisors, engineers, watch and
ward, tools & tackles, calibrated IMTEs (Inspection, measuring and testing
equipment) as specified and otherwise required for the work, consumables for
erection, testing and commissioning including material handling.
2.8.2 Achieving Proper out-turn / Turn-over as per BHEL plan and commitment.
2.8.3 Completion of work as per BHEL Schedule.
2.8.3 Good quality and accurate workmanship for proper performance of the
equipment.
2.8.4 Repair and rectification.
2.8.5 Preservation / Re-conservation of all components during storage / erection /
commissioning till handing over.
2.9 The work to be carried out under the scope of this specification shall broadly
comprise of but not to be limited to the following:
2.10 Foundation and other necessary civil works for supporting structures, equipment
etc, will be provided by BHEL. The dimensions of the foundation and anchor bolt
pits shall be checked by contractor for their correctness with respect to the above
access as per the erection drawings. Further, top elevation column foundations
shall be checked with respect to bench-mark etc. All minor adjustment of
foundation levels dressing and chipping of foundation surfaces etc up to 50 mm
as may be required for the erection of equipment/plants will be carried out by the
contractor without any extra cost. All foundations and anchor points required for
installing drum lifting winches shall be cast by the contractor using his own
materials at his cost as per the sketches provided by BHEL engineer. Installation
of starters, distribution etc, shall be done by the contractor while only incoming
supply to the common isolating switch will be arranged by BHEL. Grouting of all
columns, column base encasings, equipment base plates, anchor bolt holes etc
are included in the scope. The grouting mixture shall be composed either of port
land cement or ready mix grout of proven quality. However, in both the cases
Vendor has to supply portland cement and ready mix grout component
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respectively within his quoted rate. Application of the two options will
depend on drawing/specification/ instruction of BHEL Engineer. The contractor
shall arrange for sand, stone-chips, gravels, anti shrink compound,
plasticizer, shuttering, grout mixing machine, labours etc at his cost. The
contractor shall prepare the required test pieces/test cubes to ensure the
strength of grout and get the same tested in approved laboratory at his cost. Test
cube shall also be taken during grouting for testing in the laboratory and shall be
tested at his cost.
2.11 The contractor shall take delivery of material/equipment at projects store/yard.
As soon as the material is issued to the contractor, all responsibility of proper
handling and storage shall be the responsibility of the contractor and thereafter
any loss/damage to the equipment and material due to faulty handling and
storage or any other reason attributable to contractor, shall be made good by the
contractor at his own cost.
2.12 The contractor shall check, tally and inspect all material consignment issued to
him and shall maintain proper record or the receipt of material received and
such reports shall be produced by the contractor to the Engineer for verification.
Any deviation from packing list or damage to any component noticed during
receipt of material should be immediately brought to the notice of BHEL
engineer. Any claim in this regard after receipt of material by the contractor will
not be entertained.
2.13 The contractor shall arrange for unloading of Boiler Drum from special trailor
and transportation of the same to work place within his quoted price. For
unloading operation, two cranes of 75T/100T/150T capacity to be used in
tandem. The Cranes will be arranged by BHEL and provided to the contractor.
2.14 Pre-assembly of equipment at the pre-assembly yard for inspection, checking and
erection. It is to be noted that BHEL will provide only reasonably leveled open
space for pre-assembly yard. The contractor has to arrange desired leveling of
the area at their cost. The fixtures, steel structures required for temporary
supporting for pre-assembly, checking, and welding for lifting and handling during
pre-assembly and erection shall be arranged by the contractor at his own cost.
Steel for such work if required shall be arranged by the contractor.
2.15 It shall be the responsibility of the contractor to provide ladders on columns for
initial work till such time stairways are completed. For this, the ladder should not
be welded on the column and should be pre-fabricated clamping type ladders. No
temporary welding on any structural member is permitted except under special
circumstances with the approval of BHEL. In case it is necessary then the
contractor shall cut the temporary structure and rectify the column as directed by
the engineer.
2.16 The contractor is strictly prohibited in using the Boiler / Auxiliary Components for
any temporary supporting or scaffolding works etc. In case of such misuse a sum
of as determined by Engineer will be recovered from contractor’s bills.
2.17 Suspensions for ducting will be supplied in running lengths, which shall be cut to
size and adjusted as required. Ducts / expansion bellows are dispatched to site in
loose walls plates / pieces and these are to be assembled and welded at site
along with stiffeners etc., before erection within the finally accepted rates. All
joints connecting duct expansion piece and dampers shall be seal welded on
inside as well as on outside.
2.18 The headers are provided with hand holes. The contractor, shall as per
requirement, carry out removal and re-fixing of hand hole plates within finally
accepted rates.
2.19 Burner tilt mechanism will be checked for freeness, serviced and adjusted, if
necessary to obtain optimum tilt before installation.
2.20 Contractor shall carry out kerosene testing of all bearing housings of various
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rotating equipment like pumps, fans etc., as per BHEL engineer’s instructions.
Performance of hydro test of oil coolers of rotating machines and hydro test of
SCAPH and other equipment as per BHEL engineer’s instructions is included in the
scope of work.
2.21 Certain rotating machinery after initial runs and commissioning of the equipment
have to be hot aligned as per the instructions of BHEL engineer. Cleaning air pre-
heater, fans, boiler ducting etc., free of extraneous steel, scaffolding materials
electrodes, all foreign materials etc., before trial run of rotating machinery, and at
various stages of pre-commissioning activities as per BHEL engineer’s instruction,
is within the scope of work.
2.22 Some of the rotating equipment and electrical motors are provided with
protective greases only. Contractor shall arrange for cleaning of the same with
kerosene or some other reagent. If necessary, dismantling some of the parts of
the equipment would be necessary. He shall arrange for re-greasing / lubricating
them with recommended lubricants and for assembling back the dismantled parts,
within their finally accepted quoted price. No additional payment shall be made
for such type of work. Lubricating Oil will, however, be supplied free of
cost by BHEL.
2.23 The contractor shall fabricate pipe, special bends etc., threading and welding as
required for installing lube oil system and carry out the acid cleaning of the
fabricated piping. The contractor shall also service the lube oil system, carrying
out the hydraulic test of oil coolers etc
2.24 Erection of Ceralin tiles, their glue application, fixing of weld plugs and their
welding for the tube mills is to be carried out by contractor at no extra cost to
BHEL.
2.25 Packer plates supplied may have to be machined to the correct dimensions. It
may also be necessary to blue match the same with each other/ with equipment /
with foundations as per BHEL instructions.
2.26 Contractor shall arrange changing of preservative oil in the gearboxes, journal
and other bearing assemblies of rotating equipment when in storage areas or
after erection of equipment as the case may be as per the instructions of BHEL
engineer. Necessary lubricating oil will be supplied by BHEL and the same will be
drawn by contractor from BHEL / customer’s stores and transporting to site. No
additional payment will be made for such works even though supply of
lube oil might have been made under regular despatchable unit (DU) number
against product group main assembly (PGMA) and appearing in the shipping list.
Prior to the commissioning of the equipment, oil should be drained and collected
in drums provided by BHEL and returned to BHEL / customer’s stores.
2.27 All the works such as cleaning, touch up painting, checking, aligning,
assembling, temporary erection for alignment, dismantling of certain equipment
for checking and cleaning, surface preparation, fabrication of tubes and pipes,
ducts, supports, as per general engineering practices at site cutting, grinding,
straightening, chamfering filing, chipping, drilling, reaming, rapping, shaping,
filling up etc and other works, as may be applicable in such erection works
which are treated as incidental to the erection works and are necessary to
complete the work satisfactorily, shall be carried out by the contractor as part
of the work. All consumables including Paints for touch up painting shall have to
be supplied by the contractor.
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2.28 Normally, the High Pressure Valves will have prepared edges for welding. But if it
becomes necessary, the contractor will prepare new edges or re-condition the
edges by grinding or chamfering to match the corresponding tubes and pipes. All
fittings like T Pieces, weld neck flanges, reducers etc, shall be suitably matched
with pipes for welding. The valves will have to be edge- matched, checked,
cleaned and overhauled in full or in part before erection, after chemical cleaning
and during commissioning, by the contractor as part of the scope of work.
2.29 Minor adjustments like removal of ovalities in pipes and opening or closing the
fabricated bends of high pressure piping to the layout shall be considered part of
the work and the Contractor is required to carry out such work free of cost with
specified heat treatment procedures.
2.30 Suspension for ducting, piping, etc. will be supplied in running lengths which
shall be cut to suitable sizes and adjusted as required secondary steel for
hangers etc shall be supplied by BHEL. Ducts/expansion bellows are likely to be
despatched to site in walls/plate/loose pieces and those are to be assembled and
welded at site, before erection. This involves intensive seal welding / full welding
on ducts and same shall be included in the scope of work of the contractor.
2.31 Suspension for entire Boiler system will have to be finally tightened by using a
calibrated torque wrench. The torque wrench for the purpose has to be arranged
by the contractor at his own cost and calibrated as per specification listed in
various drawings. Calibration is to be done from a recognised body and
certificate is to be submitted to BHEL.
2.32 Complete penetration of water wall (Panel to Panel) welding shall be achieved
either by one side or both sides welding.
2.33 All the motors and equipment shall be suitably doweled after alignment of shafts
with taper / parallel machined dowels as per the direction of the Engineer. Dowel
pins required are be machined by the contractor at his own cost. However the
materials for dowel pins shall be issued by BHEL free of cost.
2.34 Forced lube oil systems including lube oil piping of drives, rotating equipments
etc. form part of the work under these specifications. Hydraulic test of oil coolers,
oil piping etc. are in the scope of work. Where required cooler may have to be
dismantled for hydraulic test and re-erected thereafter as part of work.
2.34 Even though rotating machines may be grouted to foundation using non-shrink
grout mix, blue matching of packer plates / shims with foundation / between
packers / equipment base should be done as incidental to work wherever
instructed by BHEL Engineer.
2.35 The HT motor bearings shall be blue matched at site and checked for bearing
clearances. The contractor if required shall carry out scraping of bearing housing.
No extra claim for blue matching up to 1mm initial gap will be entertained.
2.35 Actuators / drives of valves, dampers, gates, powered vanes etc. may have to be
serviced, lubricated, before erection, during pre-commissioning & commissioning,
including carrying out minor adjustments required as incidental to the work.
2.36 Certain instruments like pressure gauges, pressure transmitters, temperature
gauges, flow switches and indicators, etc., are received in assembled condition as
integral part of equipment. Contractor shall be responsible for safe receipt,
installation and custody of these instruments supplied mounted on skids /
equipment. BHEL will get these instruments calibrated. The contractor for this
scope of work shall assist and co-ordinate for the same with the agency engaged
by BHEL to calibrate such instruments.
2.37 Contractor shall install piping in such a way that no excessive or destructive
expansion forces exists in either the cold condition or under conditions of
maximum temperature and pressure. All bends, expansion joints and any other
special fittings necessary to take care of proper expansion shall be incorporated
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as per the advice of Engineer. During installation of expansion joints, anchors,

care must be taken to see that full design movement is available at all times from
maximum and minimum temperature.
2.38 The hanger assemblies shall not be used for attachment of rigging to hoist the
pipes into position. Other means shall be used to securely hold the pipe in
position till pipe supports are completely assembled and attached to the pipe and
building structure.
2.39 The contractor shall carry out the tightening of the field bolts on the equipment
and piping covered under this specification by using either the calibrated torque
wrench method or the turn of part method. The methods used the tools and the
equipment deployed shall be subject to the approval of Engineer. The competent
technicians shall carry out the bolting work.
2.40 The commissioning of all pneumatic actuators is excluded from the scope of this
contract. However assistance in mechanical work associated with the
commissioning power cylinders, valves, valve actuators etc., coming under
various groups shall be provided by contractor within the finally accepted rates.
The contractor may have to draw the materials. Any damage / loss in their
custody will be the contractors account.
2.41 The erection of all pneumatic power cylinders for the burner-tilt mechanism and
SADC is included in the scope of this contract. Assistance in mechanical work
associated with the commissioning power cylinders, valves, valve actuators etc.,
coming under various groups shall be provided by contractor within the finally
accepted rates.
2.42(a) The Erection, testing and commissioning of all electrically operated valves,
actuators and dampers is covered within the scope of this specification.
2.42(b) The Structural Job of making Platform,Pedastal,Ladder etc to facilitate installation
of Open type /Close type Instrument Rack and approach to Instrument Tapping
are included in the scope of this contract. However Structural Materials shall be
provided by BHEL on free of cost.
2.43 Extra lengths in various fabricated ducts and piping given as erection allowance,
shall have to be cut to suit site conditions. Fabricated pipes are sent in standard
lengths and will be cut to suit the site conditions and the layouts. Tubes or pipes
wherever deemed to be convenient will be sent in running lengths with
sufficient bends. For any mismatch while matching the joints in tubes cutting,
adjusting, re-welding, addition of spool pieces should be done by the contractor
to match site condition without any extra payment.
2.44 The contractor shall install as part of the work at unit rate of non-pressure
parts for erection of all platforms ladders , and approaches wherever required to
facilitate operation of equipment/instrument but not specifically shown in the
drawings/bill of materials. However raw materials for the same shall be provided
by BHEL.
2.45 Extra portions of fins in water-wall panels has to be smooth ground for
making panels to panel joints. Also panel to panel tube joint alignment may
require some amount of fin cutting and edge preparation/adjustment of panel.
Such works shall be carried out by the contractor to the desired accuracy as part
of the scope of work. Complete penetration of water wall (panel to panel) fin
welding shall be achieved either by single side or double side welding.
2.46 Panel to panel welding in water-wall panels shall be carried out by the contractor
as part of the scope of work. This shall be carried out by approved high
pressure welders only.
2.47 Attachment welding of necessary seal boxes inspection windows. Instrument
tapping points, thermocouple pads, root valves, condensing valves, flow nozzles
and control valves etc., both for regular measurement and performance testing
to be provided on boiler, its auxiliaries or pipelines covered within the scope of
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this tender, will also be the responsibility of the contractor and the same will
be done as per the instructions of BHEL Engineer. The erection and welding of
all above items will be the contractor's responsibility, within their quoted rate
even if:
2.47.1 Product groups (PG) under which these items are released are covered in the
scope of this tender.
2.47.2 Items supplied by an agency other than BHEL are covered in the scope of this
tender..
2.48 The inside of all tubes, pipes, valves and fittings shall be free from dirt, and loose
scales. Before being erected, all pipelines shall be thoroughly blown and/or
flushed; the ball and sponge test shall be carried out. All the above works shall be
carried out by the contractor as part of the scope of work. A system for recording
all such operations shall be developed and maintained in a manner to ensure that
no obstructions are left inside the tubes/pipes and no tubes/pipes are left un-
cleaned and untested.
2.49 The contractor shall bend, cut, prepare ends and route the pipes as per the
equipment layout, for the pipes which shall be supplied in random straight
length. The contractor shall complete the terminal joint at either ends for all
the piping schemes covered in this scope of work.
2.50 Installation of all supports and hangers including concreting or welding of these
supports as necessary, required for piping in this scope of work have to be
carried out by the contractor.
2.51 Fabrication of supports wherever required, shall also be carried out by the
contractor without any extra cost. Any additional support if required for
effective completion of work, as advised by BHEL engineer, shall be fabricated
and erected by the contractor at no extra cost. However, the raw material
required for such additional supports shall be supplied by BHEL. Adjustment of all
hangers supports erected and providing cold pull in the piping wherever
required is included in the scope of the contractor.
2.52 Fabrication and Erection of Auxiliary supports required for supporting the
main hangers and supports shall have to be carried out by the contractor as part
of the scope of work. However, secondary steel required for the above shall be
provided by BHEL free of cost. However in case the contractor is required to
supply it , they are asked to quote separately the unit rate of supplying the
same.
2.53 The hanger assembly shall not be used for attachment of rigging to hoist any
equipment into position. Other means shall be used to securely hold the
equipment into position till the equipment supports are completely assembled and
attached to the pipe and building structure, and the spring support is set to
accommodate the pipe-sway. Spring suspension/constant load hangers have to
be pre assembled and adjusted for the required loading and erected as per the
instructions of BHEL Engineers. Any adjustments, removal of temporary arresters
/ lockers etc have to be carried out as and when required.
2.54 During hydraulic testing of the pipe system, all pressure parts having variable
spring type supports shall be held securely in place by temporary means while
constant spring type supports shall be pinned or blocked solid during test.
2.55 All drain points shall be laid by the contractor to the drain pit as advised by BHEL
Engineer, as part of the scope of work.
2.56 All rotating machinaries and equipment under the scope shall be cleaned,
lubricated, checked for their smooth rotation if necessary by dismantling and
refitting before erection. If, in the opinion of the BHEL Engineer, the equipment is
to be checked for clearances, tolerances at any stage of the work or during
commissioning period, facilities for dismantling, cleaning, lubricating and refitting
shall be provided by the contractor. All consumables required shall be supplied
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by the contractor.
2.57 All the flap valves, dampers of ducts shall be serviced and lubricated to the
satisfaction of BHEL Engineer, before erecting the same.
2.58 All attachment, welding, fixing hooks, supports, anchors, studs, plates, angles
and other steel components to support insulation and refractory over the
pressure parts components erected shall have to be carried out by the
contractors as specified in the drawings and as per instructions of the Engineer.
welding of supports shall be done by high pressure welders only.
2.59 In case of any class of work for which there is no such specification laid down in
this specification but subsequently given in the drawing released by
manufacturing unit, such as welding of stainless steel parts, such work shall be
carried out including supply of consumables in accordance with the instructions
and requirements of the Engineer at no extra cost.
2.60 All lifting tackles including wire-ropes slings, shackles, used by the contractor,
shall be got approved by BHEL Engineer. It will be the responsibility of the
contractor to ensure safe lifting of the equipment taking due precautions to
avoid any accidents and damages to other equipment and personnel. Test
certificates and periodical calibration of lifting appliances from a recognised body
are to be submitted to BHEL site office, as per requirement of BHEL/ISO system.
Expenditure on such works forms a part of the scope of work.
2.61 Fine fittings, boiler drain piping, oil system & other small bore piping have to be
routed according to site conditions and hence shall be done only in position. As
such, layout of small bore piping in boiler and oil system including bending,
cutting edge preparation etc. shall be done as per site requirement. Necessary
sketch for routing these lines should be got approved from BHEL by the
contractor. There is a possibility of change in routing the above pipelines even
after completion, to suit the site condition which shall have to be done by the
contractor at no extra cost. On completion of piping erection Vendor should
submit `AS-BUILT’ drawings with RTF for necessary record.
2.62 For pipes nominal size 2’’ and below routing shall not be shown in piping layouts
or in isometrics and the same to be routed / connected as shown in schematics.
For the above sizes if the routing is shown in layouts it is only for guidance and
the same shall be routed and supported as per site requirement / convenience as
per site Engineer’s advice. Piping below size 2’’, valves, flanges, fittings etc., shall
be supplied as commercially available. Hence fit-ups, edge preparation including
welding of stubs, shall be included in the contractor’s scope.
2.63 All site-fabricated pipes will be issued in running metres as straight length. These
are to be cut and edge prepared at site to required length to suit layout as given
in the erection drawing. In some cases attachments like lugs, stoppers, cleats
etc., will be supplied as loose items and to be cut and welded to the pipes at site
as per erection drawing Necessary drilling of holes on main pipe for welding stubs
shall also be done at site by the contractor.
2.64 For some low pressure application system, Piping covered under various
drains & vents, various fittings like bend, Tee etc. need to be fabricated at
site from the supplied straight lengths though their sizes are greater than
2’’ ( Two inches ). No separate price for such fabrication will be entertained
by BHEL and this is to be done by the Vendor within his quoted rate /
price.
2.65 Oil system main lines supports shall be supplied at random lengths and
fabrication, erection etc of these supports shall be included in the scope of the
contractor within the quoted rates.
2.66 Pulverised fuel piping from coal mill / Mill discharge valve outlet up to burner
with necessary supports and fittings.
2.67 The air heater baskets have to be thoroughly cleaned by compressed air and
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preservative to be spread as part of responsibility of the contractor.

2.68 The contractor shall erect scaffoldings/Temporary platforms supports etc
required during erection before the permanent supports are erected. These
should be of adequate capacity and shall never be overloaded. These should be
replaced when not found suitable during erection work. All structure materials
required for the above shall be arranged by the contractor at his own cost. No
such material shall be supplied by BHEL in any case. No temporary supports shall
be welded on the pressure parts or piping. Welding of temporary supports, cleats
etc on the boiler columns shall be avoided. In case of absolute necessity,
contractor shall take prior approval from BHEL Engineer. Further, any cutting or
alteration of member of the structure or platform or other equipment shall not be
done without specific prior, approval of BHEL Engineer.
2.69 The contractor shall carry out the trial run of motors including checking of the
direction of rotation in the uncoupled condition, checking alignment and re-
coupling the motor to their respective driven equipment. Before starting the
motor IR Value of the motor shall be recorded and if found necessary dry
out operation shall be carried out by the contractor to make up the IR Value to
normal, as per the advice of BHEL Engineer within the quoted rate.
2.70 Proper account of the packing wood and steel supports forming part of
packing will be kept by the contractor and returned to BHEL stores from time
to time.
2.71 The contractor shall carry out burner alignment and Burner nozzle setting as
directed by BHEL Engineer. Burner tilt mechanism will be checked for freeness,
serviced and adjusted, if necessary to obtain optimum tilt before and after
installation for which all necessary arrangement for providing safe approach
inside the furnace has to be taken care of by the bidder.
2.72 All piping coming under the purview of IBR is included in Bidder’s Scope. The
contractor shall arrange / organize for stage inspection of Boiler/IBR Components
by Statutory Authority/Boiler Directorate. It will be the sole responsibility of the
Vendor to arrange visit of the inspecting authority for conducting stage inspection
of the components based on the Drawings / documents supplied by BHEL. Vendor
is also expected to carry out the liaison work for expediting the process
of Lay-out drawing approval by State Boiler Directorate / Guwahati. Only
technical clarification, if required during drawing approval or inspection, will be
extended by BHEL. The Vendor should inform in advance about the inspection
schedule for putting up formal invitation through Owner. Necessary inspection
fees of Assam Boiler Directorate only will be paid by BHEL / OWNER in this
regard. All other incidental expenditures need to be borne/absorbed
by the vendor within his quoted price.
2.73 Temporary blanking of ducts / equipment for commissioning, if required, has to
be done by contractor free of cost. Main Steam Line & Hot Reheat line Strainers
bodies, CRH NRV are erected first by other agency and the lines will be erected
by the contractor. All the connecting joints are to be welded by the
Contractor adopting special precautions. After Hydraulic Test, the strainer
elements are to be fixed. During trial operation, if required, the strainers are to be
removed for inspection of debris & cleaning. During all these operation piping
contractor shall extend all assistance by providing necessary manpower, T&P and
required materials.
2.74 Non specified jobs at the interface / terminal points like bolting welding, gasket
changing etc. have to be done by the contractor within the quoted price.
2.75 Welding of Duct with at terminal point of chimney is to be done by the
contractor within the quoted rate.
2.76 Instrument tapping coming on the Ducts to be welded/fitted on the Duct to be
done by the contractor within the quoted price.
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2.77 Erection of total trim piping system coming under various Product groups - 21,
24, 42 & 80. Erection will cover total Welding Radiography, NDT and fixing of
hangers and support.
2.78 For site routed piping based on schematic drgs, no layout drgs. will be provided.
Contractor to deploy specially skilled manpower for these type of piping for
drawing optimum advantage in laying with minimum joint and maximum
flexibility. On completion of such piping, contractor should submit the ‘AS-BUILT'
drgs. For record purpose.
2.79 Overhead piping shall have a minimum overhead clearance of 2.3 Meters above
walkways and working areas and 6 Meters above roadways unless otherwise
approved by the BHEL Engineer.
2.80 For field run piping, contractor shall fabricate and erect all hangers and supports
as required with due regard to general arrangement layout of other pipes,
hangers, cable trays, ducting, structural members, etc.
2.81 The following works shall also be in the scope of this contract :
2.82 Cutting of suspension for piping etc., to suitable sizes and adjustment as
required.
2.83 Matching of expansion / walls / places/ pieces, their assembly bolting and
welding.
2.84 Pre-assembly of spring suspension / hangers and shock absorber for the required
load of piping etc.
2.85 Cutting of extra length of fabricated pipes or addition of spool piece to suit site
conditions and layout and tie rods threads checking / length adjustment if any
including rethreading.
2.86 Locking of spring hangers during erection, removal of locking, adjustment of
spring tension for cold and hot condition and subsequent adjustment and final
adjustment wherever required. Logging of spring tension readings.
2.87 For maintaining the slopes as given in the drawings for larger thickness and larger
dia pipelines, edge preparation for welding may have to be altered suitably to
achieve the slope.
2.88 It may become necessary to make temporary spool pieces for the location of
valves, flow measurement devices, delicate equipment etc. Contractor’s scope
shall include preparation, erection and dismantling of such spool pieces without
any additional payment.
2.89 In pipelines like CRH lines, extraction lines, etc., the NRVs will be erected by other
erection agency. Alignment of these valves to match the pipe ends (Both sides),
welding, heat treatment and NDE etc., shall be carried out by the contractor
within their quoted rates.
2.90 All temporary lines required for Chemical Cleaning of Pre-Boiler system,
Condensate piping, Heater Drip system etc. ,Hydraulic testing, etc., shall be
supplied in ‘As is Where is’ condition. The contractor shall arrange to carryout the
required dressing, grinding, cleaning, cutting, edge preparation etc., while
carrying out erection. No extra claim on this account will be entertained. For
human protection, temporary insulation over piping to be applied at no extra cost.
2.91 Before laying the piping on supports, the coordinates and elevations of all
supports shall be checked by the contractor for correctness. Discrepancies from
the execution drawings, if any, shall be promptly brought to the notice of BHEL
engineer in writing and correction shall be carried out as per his instructions.
2.92 Total Fuel oil system piping is included in the contract scope and this will cover
entire piping from existing fuel oil pump house to burners of boiler. A separate
and complete pressurizing unit, with all piping up to the new boiler, shall be
supplied to cater for the proposed plant. The function of the fuel oil handling
equipment is to provide a continuous supply to the ignition and support firing oil
burners, at the desired flow rate, temperature and pressure. The Fuel Oil suction
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lines from the storage tanks shall be equipped with the following items:
2.92.1 • Means for isolating the fuel oil lines.
2.92.2 • Fuel oil suction strainers.
2.92.3 • Fire valves (for quick isolation of the system in case of a fire).
2.93 Required trestles, if any, for supporting / laying the pipe lines are not in scope
of the bidder.
2.94 All temporary piping required for chemical cleaning and Steam blowing
operation of the Unit including pre-boiler system have to be carried out by
the vendor under the scope of this specification. While the erected
tonnage of the temporary piping will be paid as per Rate applicable
for Non-Pressure Parts, all other allied works incidental to conductance
of chemical cleaning & Steam blowing operation need to be carried out by
the vendor within his quoted rate.
2.95 The tank required for pouring and mixing the chemicals need to be
fabricated by the vendor within his quoted rate. The approx. Tank
size will be about 3m x 3m x 2m. However, the exact size will be
communicated before fabrication at site and required Plate for fabrication
of the tank will be supplied free of charges. Similarly the Steel required
for supporting the tank will be supplied free of charges. Vendor to take
special note of the fact that no charges towards fabrication and
supporting / dismantling and return of the tank will be paid by
BHEL and the same need to be executed within the quoted rate
of the vendor. The vendor is also expected to dismantle the facility and return
the material to BHEL stock-yard.
2.96 On completion of the specified commissioning activities vendor shall have
to dismantle all the temporary piping and other facilities (established for
carrying out the operation ) within his quoted rate.
2.97 Chemical circulating pumps, motors. Starter etc. Will be supplied by BHEL. All
these are required to be installed after due servicing within the quoted rate of the
vendor.
2.98 The gadgets like apron, gum-boot, hand-gloves, face-mask etc. required for
handling chemicals by the workmen need to be provided by the vendor
within his quoted rate.
2.99 While carrying out the sheeting work at Boiler roof and Burner operating
floor special safety precautions need to be adopted. Required sheets and
fixing hardwares would be supplied under regular supply. The minor
hardwares like Bitumen washers, Putty etc. are required to be supplied by
the vendor within his quoted rate.
2.100 Instrument tapping coming on the ESP to be welded/fitted by the contractor
within the quoted price.
2.101 ESP collecting electrode may require straightening and repair due to minor
transportation damage before erection and spot heating in position to get correct
alignment. Contractor shall carry out this within his quoted rate.
2.102 Layer of insulation mattress on roof top of ESP (inner roof) shall be applied before
outer roof is placed.
2.103 Fixing of deflection plates in the inlet screen sheet of ESP as per flow model
report drawing. However, adjustment / re-positioning of the plates may be
required to be done by the contractor during gas distribution test within the
quoted rate.
2.104 All the collecting and emitting frames are to be checked in dimension and pitches
before erection. All the readings are to be logged. Straightening of frames
distorted during transportation shall be carried out by the contractor within
quoted price.
2.105 Erection of electrical equipment like high voltage rectifier transformer,VFDs,
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heating elements, rapping gear motor etc. are included in the scope of the
contractor. Filtration of the Transformer oil also , if required, need to be done
by the vendor within his quoted rate and for carrying out the same ,
vendor must deploy one 500 LPM oil filtration unit. However, erection of
panels, Laying of cables, cable trays, termination of cables, glanding of control
panels etc. are excluded from the scope of the vendor.
2.106 Removal of all temporary supports , foreign materials, scraps, debris etc. from
inside of the ESP and other erected components and thorough cleaning to achieve
clearance / IR values between collecting and emitting system shall be done by the
contractor.
2.107 For all plate welding , seal welding from inside and stich welding from other side
is to be followed as per drawing.
2.108 Roof top sheeting & side cladding over ESP pent house to be done by
the vendor within his quoted price. Required corrugated sheets and fixing
hardwares will be supplied by BHEL under regular supply. Minor
consumables like bitumen washers, putty etc. need to be arranged by the
vendor within his quoted price.
2.109 Minor straightening of plates of inner / outer roof, funnels, GD screen sheets,
hopper panels damaged during transportation shall be carried out by the vendor
within his quoted rate.
3.0 HYDRAULIC AND OTHER TESTS
3.1 The contractor shall carry out the required tests up to the battery limit on the
boiler and the pipelines such as hydrostatic test of the main boiler, gas tightness
test for ducts by appropriate methods, furnace pressure tightness test etc. It
may be required to do the gas tightness test of ducting and boiler furnace by
filling up air and pressurizing with the help of compressor / Fan. The installation
of Fans/Compressors (if required) shall e within the scope of the bidder without
any extra cost to BHEL. All the above tests shall be repeated till the successful
completion of tests is certified by BHEL as a part of the work.
3.2 Contractor shall lay all necessary temporary piping with valves, pressure gauges;
blank plate’s supports at the duct & pipes terminals etc and install the pumps
required for the test. After the test all the temporary piping, pumps etc will be
removed and returned to BHEL stores.
4.0 PRE-COMMISSIONING TESTS AND COMMISSIONING
4.1 Commissioning of the boilers will involve Pre-commissioning checks, test running
of individual equipment or system, trial runs of all the equipment erected,
lighting up of the boiler for refractory drying, alkali boil-out of boilers,
acid/chemical cleaning, floating of safety valves, flushing of all the lines by air,
acid/chemical, oil or steam as required and any other works incidental to pre-
commissioning & commissioning. Contractor shall supply adequate supervisory
manpower, labour, tools and consumables except those to be provided by BHEL
as per this specification for all these activities without any extra cost
4.2 Chemical cleaning will involve cutting of some of the existing valves or removal of
caps of some stubs, placing the rubber wedges in the boiler drum, and cutting
of hand-hole plugs of bottom ring header. Boiler drum internals also shall be
removed before chemical cleaning within the quoted price.
4.3 Re-welding of the hand-hole plugs or stubs and the valves which were cut, re-
fixing of boiler drum internals etc after completion of chemical cleaning shall be
done by the contractor at his cost.
4.4 In case any defect is detected during tests / trial runs, loose components, undue
noise or vibration, strain on connected equipment etc, the contractor shall
immediately attend to these defects and take necessary corrective measures. If
any re-adjustment and re-alignment are necessary, the same shall be done as
per BHEL Engineers instruction. If any part of the boiler needs repair,
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rectification and replacement due to poor workmanship of the vendor, the

same shall be done by the contractor at his cost. The parts to be replaced shall
be provided by BHEL.
4.5 Commissioning of ESP shall involve carrying out of all required tests on ESP & its
auxiliaries such as air leak test, gas distribution test, motor no load test, rapping
mechanism trial runs, ESP interlock tests, centrifuging of transformer oil,
charging of transformer fields, commissioning of all electrical equipment / panels,
heaters and their proper tuning etc. as per instruction of BHEL Engineer. The
contractor shall provide all consumables, labour, scaffoldings and items required
for satisfactory testing.
4.6 Commissioning of the boiler will involve trial run of all the equipment erected,
lighting up for refractory drying, alkali boil out, acid cleaning, passivation,
preservation, steam blowing and floating of safety valves, flushing of all the lines
by air, oil or steam as the case may be, trial run of the boiler, servicing of valves
and any other works incidental to commissioning. Contractor shall supply
manpower round the clock, consumables (other than which are to be provided by
BHEL free of charges) and T&P for all these works shall from part of work.
4.7 Contractor has to provide all categories of labours including necessary tools,
consumables and supervision during the period of commissioning of boiler till
handing over.
4.8 Cleaning and servicing of all the filters / strainers, toppings of oils coming in the
system / equipment shall be done by the contractor within the accepted price.
This activity will start from pre-commissioning check of equipment / system and
will continue till the equipment or system is handed over to customer.
4.9 It shall be specifically noted that the above employees of the contractor may
have to work round the clock along with BHEL commissioning Engineers and
hence over time payment may be involved. The contractor's quoted rate shall
be inclusive of all these factors also.
4.10 During commissioning, opening of valves, changing of gaskets, realigning of
rotating and other equipment, attending to leakage and minor adjustments of
erected equipment may arise. The quoted rate of contractor shall be inclusive of
all such works.
4.11 In case, any rework is required because of contractor’s faulty erection which is
noticed during commissioning, the same has to be rectified by the contractor at
his cost. If during commissioning any improvement or rectification due to design
requirements is involved, the same shall be paid extra. For this purpose, daily
labour report indicating therein, nature of work carried out, consumables used
etc, shall be maintained by the contractor and get the same signed by BHEL
Engineers every day.
4.12 Performance of guarantee test : The final performance and guarantee
tests of the unit to establish the guaranteed parameters shall be carried out
by BHEL. Contractor shall assist BHEL by providing required manpower tools and
consumables for carrying out the above tests. All preparatory works and
temporary connections required for performing the above tests shall be carried
out by the contractor. The man-power deployed for this purpose shall be made as
per rate schedule.
4.13 Contractor to provide necessary commissioning assistance from pre-
commissioning stage onwards and up to continuous operation of the unit &
handing over to customer. The category of personnel to be strictly as per site
requirement and to be in consonance with the various pre-commissioning and
commissioning programs made to achieve the schedule agreed with customer. It
may be noted by the bidder that they will have to provide sufficiently experienced
engineer/supervisor in adequate numbers so that the equipment / system can be
commissioned with just overall supervision from BHEL.
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4.14 DELETED
4.15 It shall be specifically noted that the contractor may have to work round the clock
during the pre-commissioning period along with BHEL Engineers and hence
considerable overtime payment is involved. The contractor’s quoted rates shall be
inclusive of all these factors.
4.16 Hanger adjustment / re-adjustment during erection, before and after Hydraulic
Test, before and after steam blowing, during and after full load operation, are to
be carried out by the contractor within Quoted Rate.
4.17 The contractor has to provide required supervisory and skilled man power
assistance during pre-commissioning and commissioning checks of motor
operated valves, actuators, control valves etc without any extra charges.
4.18 After the start of continuous operation with coal firing, the commissioning tests
and maintenance activities will continue. It shall be the responsibility of the
contractor to provide the following category of workers with necessary
consumables, tools and tackles and supervision till handing over of the unit to the
customer.
4.18.1 Pipe Fitters / General Fitters / Millwright Fitters - 2 nos.
4.18.2 Rigger / unskilled workers - 5 Nos.
4.18.3 Electricians - 2 Nos.
4.18.4 Supervisor - 1 No.
4.18.5 Valve Technician - 1 No.
4.18.6 HP Welder - 1 No.
4.19 The above figures shows only minimum required over and above labour required
for completing pending erection commissioning works and clearing check and
punch lists. Contractor has to provide number of personnel of various categories
as per work demand and necessity at site. These skeleton staff are required after
synchronization of the unit for attending to commissioning, post commissioning,
operation and maintenance problems and no over run charges will be payable for
providing these services unless left over jobs are also done during this period and
the delay in the completion of these jobs is not attributable to the contractor.
4.20 It shall be specifically noted that above employees of the contractor may have to
work round the clock along with BHEL Commissioning Engineers involving
considerable payment of overtime.
4.21 During commissioning, opening of valves, changing of gaskets, checking,
resetting of hangers, realigning of rotating and other equipment, attending to
leakages in valves etc., and adjustments of erected equipment may arise. All the
valves shall be serviced and lubricated to the satisfaction of BHEL Engineer
during the erection and commissioning as per BHEL Engineer’s instructions.
5.0 WELDING, HEAT TREATMENT & RADIOGRAPHY
5.1 The pressure parts shall be erected in conformity with the provisions of
Indian Boiler Regulations and as may be directed, as per other
standard/specification in practice in BHEL. The method of welding (Viz) are,
TIG or other methods as indicated in the detailed drawing or as instructed by
BHEL Engineer shall followed. BHEL Engineer will have the option to change the
method to suit site conditions. All the prepared/matched edges will have to be
suitably protected to prevent rusting or foreign material ingression.
5.2 Welding of high tensile structural steel and pressure parts shall be done by using
certified welders, who posses requisite certificate and who are approved BHEL
Engineer.
5.3 All welders shall be tested and approved by BHEL Engineer before they are
actually engaged on the work even though they may posses the requisite
certificates. BHEL reserves the right to reject any welder without assigning any
reasons. The welder identification code as approved by the BHEL Engineer shall
be stamped by the welder on each joint done by them. The contractor will be
responsible for the periodic renewal, re-testing of the welders as demanded by
BHEL/statutory requirements.
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5.4 BHEL Engineer is entitled to stop any contractor's welders from his work if his
work is unsatisfactory for any technical reason or there is a high percentage of
rejection of joints welded by him, which, in the opinion of BHEL Engineer, will
adversely affect the quality of welding. Even though the welder has earlier passed
the tests it does not relieve the contractor from his contractual obligations, to
check the performance of the welders.
5.5 All charges for testing of welders including destructive and non-destructive tests,
if conducted by BHEL or by the inspecting authority shall have to be borne by the
contractor. Adequate pipe material and the welding filler as provided in the
document will be arranged by BHEL and all testing facility shall be made available
by contractor. If any additional pipe/welding filler is required, the same have to
be arranged by contractor at his cost.
5.6 All welded joints shall be subjected to acceptance by BHEL Engineer / statutory
body / customers. Joints coming under the purview of IBR need to be cleared by
Testing laboratory of Assam Boiler Directorate. Contractor has to arrange for
such regular evaluation of radiographs without accumulation of any backlog.
Necessary evaluation fees only will be reimbursed by BHEL / Customer in this
regard on production of due documentary evidences.
5.7 Preheating, post-heating and stress relieving after welding are part of erection
work and shall be performed by the contractor in accordance with the
instructions of BHEL Engineer. Contractor shall arrange to supply heating
equipment with automatic recording devices. Also the contractor shall have to
arrange for the labour, all heating elements, thermocouples, compensating
cables, insulation materials like mineral wool, asbestos cloth, ceramic beads,
asbestos rope, etc., required for the heat treatment and stress relieving works.
During preheat/stress relieving operations, the temperature shall be measured at
one or more points as required by attaching thermocouples and recorded on a
continuous printing type recorder. All the recorded graphs for the heat treatment
works carried out shall be got signed by the BHEL Engineer prior to the
commencement of each cycle and handed over to BHEL on completion. The
graphs will be the property of BHEL. The contractor has to provide thermal
chalks, temperature recorders, thermocouple attachment units, graph sheets,
etc., required for the job and maintain them in good condition. All temperature
recorders should be calibrated by WB Boiler Directorate approved agency before
use and validity renewed at appropriate intervals, Required fees to be paid for
initial and periodic calibrations should be borne by the contractor.
5.8 All low hydrogen electrodes shall be baked and dried up to 350 deg C for an
hour in an electric electrode drying oven and to be kept at 150 deg C before they
are used in erection work, and all welders including high pressure welders shall
have a portable electrode drying oven at the work spot.
5.9 All butt joints of high pressure tubular system of boiler and piping shall be carried
out by TIG root-run and subsequent runs by arc welding. Full TIG welding,
wherever necessary shall be carried out within the quoted rates. For oil system
piping, root run of all the butt joints shall be carried out by TIG welding only.
While all the filler wires required for TIG welding of Boiler tubular joints will be
supplied by BHEL free of cost, Filler wires required for the Piping works to be
arranged by the Vendor within his quoted price.
5.10 The technical particulars, specifications and other general details of work shall
be in accordance with AWS 0.1.1.72 clause 6.11. or ASME Section IV, V & IX
and IBR or ISO as specified by BHEL.
5.11 Contractor shall note that 100 % radiography shall be done at the initial stages
on all the high pressure welding joints. Subsequently, on the basis of quality of
welding, radiographic inspection shall be done on the following basis.
Welded tube/pipe Minimum % of weld
to be rediographed
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5.11.1 Pipe & tube having bore up to 178 mm 10 %

5.11.2 Pipe & tube having bore of 178 mm and above. 100 %
5.12 The percentage given above are tentative, which may be increased depending
upon the quality of joints at the discretion of BHEL.
5.13 Low speed high contrast fine grain films (D-7 or equivalent) in 10 cm width only
should be used for weld joint radiography. Film density shall be between 1.5 to
2.0.
5.14 All radiographs shall be free from mechanical, chemical or process marks to the
extent they shall not confuse the radiographic image. Radiography should be
taken only after removal of cleats etc. by grinding from tubes wall for getting
better image.
5.15 Penetrameter as per ASME/ISO, shall be used for all exposures.
5.16 Lead numbers and letters (generally of 6 mm size) are to be used for identification
of radiographs. Contract no, joint identification, source used, welders
identification, SFD used are to be noted down in the paper cover of radiography.
Load intensifying screens for front & back of the film shall be used as per the
instructions of BHEL Engineer.
5.17 The weld joint is to be marked with permanent mark A, B, C, etc to identify the
segments. For this, a low stress stamp shall be used to stamp the pipe on the
down stream side of the weld. For multiple exposure on pipes, on Overlap of
about 25 mm of film shall be provided.
5.18 The contractor shall be fully equipped with radiography equipment, films,
chemicals and other dark room facility. There must be a number of radio-graphic
personnel with sufficient experience and certified by BARC for field radiographic
inspection. Further, the contractor must follow strictly the safety rules laid down by
BARC, from time to time. Necessary storage pit also to be prepared by the vendor
for storing the radio-active isotopes in compliance with the norm decided by
BARC. Contractor's radiographers shall also be registered with BARC for film
badge service. Contractor shall provide all skilled and unskilled workmen
required for the job, which will include Engineers, supervisors, operators, as
required for timely and satisfactory execution of radiography work. For
preliminary evaluation of radiographic films, the contractor must deploy competent
personnel having at least ASNT / ISNT Level-II certification. He should also
ensure compliance of all statutory requirements with respect to health hazard in
handling the radiographic sources. The contractor shall also furnish along with
their offer, the names of approved high pressure welders in TIG welding and alloy
steel arc welding possessing current valid certificate from CIB / ASSAM in their
rolls and also to be deployed in this project.
5.19 If the contractor does not carry out radiography work in time due to non-
availability of film, chemicals, etc, BHEL may get the work done through some
other agency at the risk and cost of the contractor.
5.20 All the radiographs shall be properly preserved in air-conditioned rooms and shall
become the property of BHEL.
For erection & welding of SA335 P91 material please refer the “PROCEDURE
FOR ERECTION & WELDING OF SA335 P91 MATERIALS” given in this
specification.
In the case of P-91 Piping NDT requirement, since no radiography is possible,
alternatively Ultrasonic Test has to be carried out apart from other NDE.
5.21 The defects as pointed out by BHEL engineer/inspecting shall be rectified
immediately to the satisfaction of Engineer and re-radiographed. The decision
of Engineer regarding acceptance or otherwise of the joint shall be final and
binding on the contractor.
5.22 Radiography of joints shall be so planned after welding that the same is done
either on the same day or next day of the welding to assess the performance of
high pressure welders. If the performance of the welder is unsatisfactory, he
shall be replaced, immediately.
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5.23 Wherever radiographs are not accepted on account of poor exposure, joints
shall be re-radiographed and new films submitted for evaluation. Radiographs
shall be taken again on joints after carrying out repairs. However, if the defect
persists after first repair as per radiograph, carrying out radiography shall be
repeated till the joint is made acceptable. In case the joint is not repairable, the
same shall be cut, re-welded and re-radiographed at Contractor's cost. The
statutory evaluation charges in respect of such repeated evaluation shall have
to be borne by the contractor.
5.24 The contractor shall also be equipped for carrying out other NDT, like liquid
penetrant inspection, magnetic particle inspection, etc as & when required for
work within the quoted rates.
5.25 Contractor has to make his own arrangements for air-conditioned dark room to
process the radiographs.
5.26 For carrying out ultrasonic testing of welded joints large size tubes and pipes, it
will be necessary to prepare the surface by grinding to a smooth finish and
contour as desired by BHEL Engineer. The contractor's scope of work include
such preparation and no extra charges are payable for this.
5.27 It may also become necessary to adopt inter layer radiography/ MPT/UT
depending upon the site/technical requirement necessitating interruptions in
continuity of the work and making necessary arrangements for carrying out the
above work. The contractor shall take all this into account and quote the price
inclusive of all such work and radiography.
5.28 The welded surface irrespective of place of welding shall be cleaned of slag and
painted with primer paint to prevent corrosion at no extra cost towards this. Paint
for this purpose shall be provided by contractor.
5.29 It is obligatory on the part of the contractor to give daily feedback on progress
of completed HP joints, joints stress relieved etc.
5.30 The contractor shall carry out the edge preparation of weld and joints at site in
accordance with the details acceptable to BHEL Engineer. Machining or
automatic flame cutting shall be used only where edge preparation otherwise it's
impractical. All slags shall be removed from cuts and all hand cuts shall be
ground smooth to the satisfaction of BHEL Engineer.
6.0 DRUM LIFTING & MISCELLANEOUS POINTS
6.1 Boiler drum will be sent to BONGAIGAON Site through a special trailor
of BHEL / Trichy. Unloading of the same from trailor and subsequent
Transportation of the same to erection site for erection shall be within the
scope of work of the bidder.
6.2 Boiler Drum of the unit is planned to be lifted in conventional method by using
two number of electrical winches and multi-sheave pulley blocks. These two
items only will be arranged by BHEL free of any hire charges. However, all
other items shall have to be arranged by contractor within his quoted rate.
In the event contractor wants to use some modern method like Strand Jack
arrangement for lifting the drum, The Vendor shall have to furnish, along with
the tender, the details of arrangement with the probable sub-vendor with their
credentials for carrying out the above job. The details w.r.t having completed the
lifting job for boiler drum or any other heavy equipment by the above Sub-vendor
shall be furnished along with the bid.
6.3 Overhauling and servicing of drum lifting winches, pulley blocks, etc., both
mechanical and electrical parts including application of preservative coating on
wire ropes and changing of ropes or any spare parts are also included in
contractor's scope of work. Ropes and Spare parts for the same shall be
supplied by BHEL free of cost. Necessary preservative shall be arranged by the
contractor.
6.4 Temporary structures required for Drum lifting operation shall have to be
fabricated by the contractor at site according to drawing / instruction of BHEL
engineer. Necessary steel for the same shall be issued by BHEL free of charges.
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However, Fabrication and erection of the same shall have to be carried out
by the contractor within his quoted rate. After completion of drum lifting,
erection and alignment, the drum lifting arrangements shall be dismantled by the
contractor and materials returned to BHEL store.
6.5 HSFG bolts of boiler supporting structure are to be tightened, by turn of nut
method, as per the instructions of BHEL Engineer. The bolted joints should be
jointly checked by the BHEL/Customer and contractor's personnel for the required
tightness and re-tightened wherever necessary. The tightened bolts should be
identified by colour paints. Facility for random checking with calibrated torque
wrenches (with required capacity) shall also be provided by contractor.
6.6 Assistance for calibrating/ testing the power cylinders, valves gauges,
instruments etc, and setting of actuators coming under various group shall be
provided by contractor within quoted rates.
6.7 Headers are provided with hand holes for cleaning. The holes are closed with
hand hole plates by seal welding prior to boiler operation. The periodical removal
and re-welding of the hand hole plate will have to be done as part of the contract.
6.8 Skin casing sheet for covering the boiler roof panels, rear arch tubes and other
areas will be supplied as per BHEL standard of practice. Any cutting and
fabrication to suit the site conditions shall be carried out within the quoted rates.
6.9 It is the responsibility of the contractor to engage his workmen in shifts or on
overtime basis for achieving the desired progress and target set by BHEL. The
contractor's quoted rate shall include all those contingencies.
6.10 The contractor is strictly prohibited from using any of the boiler components like
angles, channels, hand-rails for any temporary supporting or scaffolding work
or for making pre-assembly bay. In case of such misuse, a sum as determined by
BHEL shall be recovered from contractor's bills. Also the contractor will be
responsible for the safe custody and proper accounting of all materials issued in
connection with the work. If the contractor has drawn materials in excess of the
work/design requirements, recoveries will be affected for such excess drawls at
the rates prescribed by manufacturing units.
7.0 LINING AND INSULATION WORKS
7.1 Application of various types of Refractory and insulation materials, welding/fixing
iron components to support insulation materials, outer sheet casing etc are
included in the scope of this specification.
7.2 Refractory materials include castables standard and shaped firebricks, refractory
mortar, cement plaster etc. The work of chipping and cutting of firebricks to suit
the site conditions is the responsibility of the contractor.
7.3 Insulation materials include insulation bricks, slabs, their mortar, insulation
wools, readymade wool mattresses, asbestos materials like mouldable
insulations, their mortars, mouldable insulation in powdered form. Cutting and
shaping of insulation materials to suit site conditions is contractor's
responsibility.
7.4 Steel components include all reinforcing steel components for refractory and
insulation like small hooks, long hooks, studs, supporting plates, sheets,
angles, wire mesh, expanded metal, threaded steel items, lugs, binding wires,
rods etc cutting bending, welding, riveting, screwing etc to suit the site
conditions wherever necessary for the purpose of application of insulation and
refractory materials shall be carried out by the contractor as part of the scope of
work.
7.5 Providing necessary shuttering and centering for refractory and insulation works,
curing the castable refractory etc shall form part of this work.
7.6 Wool insulation covers both application of readymade wool mattresses and
preparation and application of specified thickness and shaped mattresses like
single layer or multi layers out loose wool, with one side or all sides wire-mesh, as
may be directed by BHEL Engineers. Wool insulation also covers execution of
removable type of insulation at expansion joints, valves and other fittings special
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type insulation for bends, steam tracing, flanges, steam traps etc for controls
and instrumentation. These gaps have to be finished as per drawings at a later
date. The lined surfaces which may be dismantled at different places for
inspection and checking while erection and commissioning of boiler shall also be
done by contractor at his own cost.
7.7 Certain gaps and openings are to be left in the Refractory and insulation for
fixing gauge glasses and after fittings.
7.8 Sheet metal cladding over insulation is also integral part of the erection work.
Only experienced tin smiths shall be engaged for such work. Metal cladding will
consists of plain steel sheets, GI sheets, plain/ribbed/corrugated aluminum
sheets. The sheets will be supplied in standard lengths and width. Cutting them
to required sizes, fabricating bends, boxes etc. for proper covering shall be done
by the contractor under this specification.
7.9 All the machines, equipment, tools and tackles required for sheet metal work,
preparation and application of refractory materials shall be provided by the
contractor within the quoted rates.
7.9.1 Scaffolding pipes shall be used for usage in boiler and ducting areas to avoid fire
hazards. The necessary scaffolding pipes shall be arranged by the contractor at
his cost.
7.10 Painting of the inside surface of sheet metal cladding with two coats of
anticorrosive black bituminus paint shall be carried out by the contractor. Paints
required for the above shall be supplied by the contractor within quoted rate.
7.11 If during erection & commissioning of boiler, any of the boiler parts to be
temporarily fixed and then replaced by permanent ones at a later date or if some
parts are to be opened for inspection, the same may necessitate removal & re-
application of refractory, insulation, which shall be done by the contractor and
the rate quoted shall be inclusive of all such contingencies.
7.12 The damages, wastage and loss to the individual items of refractory, insulation
materials shall not exceed 5 % of the design quantities of individual items.
7.13 All the metal surfaces where castable / pourable refractory are to be laid, two
layers of black bituminus paints are required to be applied before applying of
refractory within the quoted rate. Paints requried for the above shall be supplied
by the contractor within the quoted rates.
8.0 FINISH PAINTING
8.1 All exposed metal parts of the equipment, structure, auxiliaries, piping, and other
items (covered within the scope of this contract) after installations are to be
painted. The surfaces are to be thoroughly cleaned of all dirt, rust, scales,
grease, oils and other foreign materials by wire brushing, scrapping, any other
method as per requirement of BHEL. The same will be inspected and approved
by the engineer before painting.
8.2 Mostly the equipment / items/ components will be supplied with one coat of primer
paint and one coat of finish paint. However during storage and handling, the
same may get peeled off / deteriorate. All such surfaces are to be thoroughly
cleaned and to be touch up painted with suitable approved primer and finish paint
matching with shop paint / approved final colour. Besides above two coats of
approved primer paint is to be applied on all the bare / unpainted surfaces. The
gas cut stubs would require being ground and rounded.
8.3 After applying the primer paints, wherever required, all structure / equipment /
items, shall be finish painted with Alkyd / alloyed resin machinery enamel
paints / Synthetic enamel as specified by BHEL engineer. The number of coats
/ paint thickness shall be as indicted in the drawing / documents. However at least
two coats of finish painting is to be applied. In case proper finish is not obtained in
two coats, the contractor shall apply additional coat (s) till proper finish / paint
thickness is achieved. Certain equipment / Items are required to be painted with
approved quality heat resistant paint. After completion of painting all bright spots
shall be cleaned to the satisfaction of Engineer.
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8.4 Certain equipment like control panels, valves etc. shall require spray painting. The
contractor shall make arrangements of the required equipment for spray painting
at his own cost. Spray painting at the job site shall be permitted only at times and
locations approved by Engineer.
8.5 Contractor at no extra cost to BHEL shall apply all paints, primers; arrange tools
and other consumables including scaffolding materials required for finish painting.
Required Paint and Primer need to be supplied by Vendor within his quoted
rate. The paint need to be sourced from reputed BHEL vendor and quality of the
paint shall be checked by BHEL prior to application. In the event of failure in
supply of the paint by the vendor of proper quality and quantity as per
requirement, BHEL shall supply the paint and recover the cost with due BHEL
overhead from the very next payable bills of the Vendor.
8.6 The contractor may be required to fill up dents / marks by applying putty before
final painting of equipment. All materials and arrangements have to be made
within quoted price / rates.
8.7 The contractor shall provide legends with direction of flow on equipment and
piping in size specified by Engineer. Letter writing shall be done in Hindi / English
or in both languages.
8.8 The painters have to under go test and only qualified painters will be allowed to
work.
9.0 SCOPE – Equipment / System descriptions
The scope of work of the contractor for each package of Boiler and auxiliaries
will be inclusive but not limited to following:
9.1 Boiler Steam Drum with internals and fittings.
9.2 Complete water cooled furnace wall system including header drains, drain
funnels, drain pipelines up to & including blow down tank and necessary stubs for
chemical cleaning , nitrogen purging and wet lay up.
9.3 Complete circulating system including down comers, headers, riser tubes etc.
9.4 Complete super-heater system, including headers connecting pipes, vents,
drains, drain, funnels, pipelines up to Blow down tank nitrogen connections,
safety valves, sampling connections, start up lines etc.
9.5 Complete Re-heater system including headers, connecting pipes, coils drains,
drain funnels, drain pipes up to Blow down tank, safely valves etc.
9.6 De-super-heater system for super-heaters & re-heater steam temperature
control, pneumatically operated diaphragm type control valves with isolating
valves, block valves and bypass valves.
9.7 Economiser system including connecting pipes,headers & economiser re-
circulation system.
9.8 Rotary Air heater
9.9 Steam Coil air pre-heater ( SCAPH ) with accessories.
9.10 All Boiler integral piping valves & fittings, including check valves, motorised
isolating valves, motorised stop valves, motorised startup valves, blow-down
valves, safety valves, and electromatic safety valves, for drum, super-heater and
re-heater, safety valve escape piping with silencers. Complete steam and
water sampling lines with sample coolers & collectors. Chemical feed line. IBD
& CBD lines, vents, RH/SH spray control station, Eco re-circulation etc.
9.11 All approaches to valves and mountings including platforms.
9.12 Boiler refractory and application of insulating materials along with required
fixing material for the equipment.
9.13 Boiler inner casing wherever necessary.
9.14 Boiler outer sheet steel casing (MS) Aluminium sheet casing/ Insulation jacket
for equipment including hot air/Flue ducts etc.
9.15 Air & Gas duct work with necessary expansion joints with protection
against ash erosion insulation wherever required, dampers gates, supports,
access doors etc. and support steel work.
9.16 All the ash hoppers for boiler, economiser, air-heater stainless steel dip plates
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for bottom ash hopper and shield plates with refractory. The fly ash hoppers
shall be provided with suitable vibration and heating arrangement to prevent ash
build up.
9.17 Boiler roof mountings including access / inspection doors for boiler /
furnace, air-heater, economiser, and ducts etc and also access for power
operated maintenance platform.
9.18 Complete soot blower and wall blower system with drains, entire piping and
fittings including control valves.
9.19 All drain lines including trap discharge outlet with drain funnels/drain receivers
and pipelines from funnels discharge up to the nearest plant drainage system.
9.20 Temperature measuring probe for start up (at furnace outlet) along with its
starter cum control panel.
9.21 Complete boiler and auxiliaries supporting structural steel, walkways,
platforms, ladders and gratings, hand rail, stair cases at both sides of the boilers
including inter connecting walkways between steam generator operating floor
and main building and connecting platform for boiler and elevator including
chequered plates, kicker / toe-guard plates wherever required, foundation bolts,
nuts, fasteners, inserts, anchor channels, base plates, packers, shims, pipe
sleeve for equipment and columns under scope.
9.22 Erection of Elevator structure including it’s bracings, connecting members and
cladding.
9.23 Erection of LDO, pumps, motors, heaters etc. along with applicable piping.
9.24 Erection of burner block, guns, ignitor, ignitor fans etc.
9.25 Erection of scanner air fan with motor and its ducting upto burners.
9.26 Structural steel material & purlin for boiler roof, drum level and burner operating
floor.
9.27 Boiler roof sheeting and weather protection sheeting at Burner platform.
9.28 Complete buck stays and tie bars for pressure part system.
9.29 Complete erection of Pulverized fuel piping including supports from Mill Outlet
Valves to Burner Block.
9.30 Erection of total Fuel Oil line covering suction lines from the storage tanks to
Fuel oil pump house and discharge line from Pump house to Burner floor is
included in the scope of this tender.
9.31 Erection of total Electro-static Precipitator. However, erection of Electrical
System , other than rectifier transformers, is excluded from the erection
scope of the vendor.
9.32 Erection of all radial and axial fans covering F.D, I.D, P.A. and Seal Air
fans.
9.33 Erection of Pulveriser and motors with their handling devices, monorails etc.
9.34 Erection of Raw coal Feeders, Row coal bunker outlet gates and raw coal
piping of stainless steel, from banker to feeders with one number MD gate at
each bunker outlet and one number mutually operation get at feeder inlet.
Stainless steel piping from feeder to mill with couplings supports etc.
9.35 All pipe-work shall be designed, manufactured and erected conforming to the
regulations and recommendations of the Indian Boiler Regulations and an
Internationally recognized standard such as ANSI B31.1. and materials are
selected accordingly. Pipe-work shall be subject to the Independent Inspection
Authority and Engineer for approval prior to Erection.
9.36 Tentative tonnage of critical/power cycle piping is around 721 MT. The tonnage
covers the weight various Piping, Valves & fittings, Tanks, Vessels, Insulations,
Pumps, gauges etc. Supplied under PG-80 and 81.
9.37 In the piping scope, the following major system will be covered under the piping,
supplied against PG 80:
9.37.1 Main steam system from boiler super heater header to Turbine including ESV,
equalising line and branchings for Aux. PRDS, HP By-Pass etc.
9.37.2 Hot re-heat system from HRH Header at Boiler end to I.P Turbine including I.V ,
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LP Bypass Piping up to L.P. Bypass Valve.

9.37.3 Total feed discharge system piping including H.P heater by-pass, Group
protection Valve and Boiler feed re-circulation up to Deaerator.
9.37.4 Cold re-heat system from Turbine end to CRH at Boiler end including CRH
NRV, re-heat De-super-heater, connection to Deaerator and HP bypass.
9.37.5 Total auxiliary steam system piping including Header / inter-connection /
supply to various equipment like SCAPH, AH Soot blower, Fuel oil atomisation,
Steam Ejectors, Gland seals, Steam to F.O. Pump house, Aux. steam to
Deaerator, F.O. tracing and other miscellaneous users.
9.37.6 Extraction Steam Piping to Deaerator, H.P Heater-1 & H.P Heater-2.
9.37.7 Spray Water Piping to HP Bypass, Aux. PRDS, Boiler SH DESH & RH DESH.
9.37.8 Boiler Filling Line.
9.37.9 Total Fire water, Wash water and Cooling water piping related to Boiler & its
Auxiliaries.
9.37.10 Total compressed air system including service and instrument air related to Boiler
& its Auxiliaries.
9.37.11 Erection of total chemical dosing system including installation of Pumps, motors,
tanks and related piping works.
9.37.12 Oil system piping supplied under PG-80 including oil suction piping from
F.O. Storage Tank to F.O. Pump House.
9.37.13 Erection of various tanks, vessels, drains and vents
9.37.14 Erection of HPBP oil system covering valves, Oil unit and it’s Piping.
9.37.15 Erection of all temporary piping required for chemical cleaning & steam blowing
operation.
9.38 Complete auxiliary
Main Steam Strainers, Hot re-heat strainers and CRH NRVs will be erected
by TG erection vendor. However welding of these items to be carried by
the Vendor within his quoted price.
9.39 Dismantling and restoration of valves , Strainers during the pre-
commissioning / commissioning stage to be done by the contractor within
his quoted rate
9.40 All hanger components, spring cage assembly, constant load hanger and aux.
steel structure will be supplied as loose items. Contractor shall pick up the correct
components pertaining to a hanger, assemble the component at site and erect as
per the drawing/ document. Necessary cutting of rods and aux. steel structure to
the reqd. lengths shall be done at site by the contractor within his quoted rate.
9.41 Welding, radiography, heat treatment of piping joints will be as per specification
enumerated in the relevant clause.
9.42 Application of Finish Paint on all erected components covered under the
scope.
10.0 EXCLUSIONS
The following main items are specifically excluded from the subcontractor's
scope:
10.1 Boiler civil Foundations.
10.2 Mill bay structures, bunkers.
10.3 Items appearing in product Group 95, 96 & 97. However some items appearing
in 95, 96 & 97 PG related to pressure parts welding like soot blower orifice,
metal temp pads and clamps etc are in the scope of the contractor. seal welding
of screwed type thermowells and socket type thermo wells have to be done by
the contractor without any extra cost.
10.4 Erection of Cable trays, Cablings, Panels of ESP.
10.5 All concrete floors in boiler area (including concrete roofs at firing and feeder
floors etc).
10.6
11.0 DEVIATIONS
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The bidder is required to submit with his offer in the relevant schedule/format list
of any deviation taken by him without any ambiguity. Any assumptions,
presumptions, deviations etc indicated or implied anywhere by the bidder;
excepting those indicated in the deviation schedule / format, will not be
recognized and will not form a part of consideration/offer. In the absence of such
filled-up schedule/format it will be understood and agreed that the bidder's offer
is based on strict conformance to the specification and no negotiation would be
allowed in this regard. BHEL reserves the right not to recognize any/all
deviations submitted after opening of the bid.
12.0 SERVICES TO BE RENDERED BY THE BIDDER
Services for construction, fabrication, equipment erection testing as well as trial
run & commissioning of various equipment and accessories under the contract
shall include but not be limited to the following:
12.1 Issuing materials from store/open yard from time to time for erection as per the
construction program. The Contractor shall be the custodian of all the
materials issued till the plant/equipment is officially taken over by the owner /
BHEL after complete erection any successful trial run & commissioning.
12.2 Transport of material to their respective places of erection and erection of the
complete plant & equipment as supplied under this specification.
12.3 Trial run and commissioning of individual equipment / sub-systems to the
satisfaction of Owner / BHEL.
12.4 Deployment of all skilled and unskilled manpower required for erection,
supervision of erection, watch & ward, commissioning and other services to the
rendered under this specification.
12.5 Deployment of all erection tools & tackle, construction machinery, transportation
vehicles and all other implements in adequate number and size, appropriate for
the erection work to be handled under scope of this specification except otherwise
specified.
12.6 Supply of all consumables, eg welding electrodes, cleaning agents, diesel
oil, lubricant etc as well as materials required for temporary supports,
scaffolding etc as necessary for such erection work, unless specified other wise.
12.7 Providing support services for the contractor's erection staff eg construction of
site offices, temporary stores, residential accommodation and transport to work
site for erection personnel, watch and ward for security and safety of the
materials under the Contractor's custody etc. as required.
12.8 Maintaining proper documentation of all the site activities undertaken by the
Contractor as per the proforma mutually agreed with BHEL, Submission of
monthly progress reports and any such document as and when desired by
BHEL/owner, including taking approval of all statutory authorities i.e Boiler
Inspector, Factory Inspector, Inspector of Explosives etc , as applicable for
respective portions of work fall under the jurisdiction of such statutes of laws.
12.9 Any other service, although not specifically called for but required for a contract of
the size and nature indicated in the specification.
13.0 GENERAL TECHNICAL REQUIREMENTS (CODES AND STANDARDS)
13.1 Except where otherwise specified, the plant/equipment shall comply with the
appropriate Indian Standard or an agreed internationally accepted Standard
Specification as mentioned elsewhere in contract specifications, each
incorporating the latest revisions at the time of tendering. Where no
internationally accepted standard is applicable, the Bidder shall give all particulars
and details as necessary, to enable BHEL to identify all of the plant/equipment
in the same detail as would be possible had there been a Standard Specification.
13.2 Where the Bidder proposes alternative codes or standards he shall include in
his tender one copy (in English) of each Standard Specification to which
materials offered shall comply. In such case, the adopted alternative standard
shall be equivalent or superior to the standards mentioned in the specification.
13.3 In the event of any conflict between the codes and standards referred above,
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and the requirements of this specification, the requirements which are more
stringent shall govern.
13.4 Tools used during erection and commissioning shall not be accepted except with
the specific approval of the Engineer.
14.0 PROTECTION
14.1 Equipment having anti-friction or sleeve bearings shall be protected by
weather tight enclosures. Coated surfaces shall be protected against impact,
abrasion, discoloration and other damages. Surfaces which are damaged shall
be repainted.
14.2 Electrical equipment, controls and insulations shall be protected against moisture
and water damages. All external gasket surfaces and flange faces, couplings,
rotating equipment shafts, bearings and like items shall be thoroughly cleaned
and coated with rust preventive compound and protected with suitable wood,
metal or other substantial type covering to ensure their full protection. All
exposed threaded parts shall be greased and protected with metallic or other
substantial type protectors.
14.3 All piping, tubing and conduit connections on equipment and equipment
openings shall be closed with rough usage covers or plugs. Female threaded
openings shall be closed with rough usage covers or plugs or forged steel
plugs. The closures shall be taped to seal the interior of the equipment. Open
ends of piping, tubing and conduit shall be sealed and taped.
14.4 All erected equipment / components to be preserved as per the preservation
recommendation of BHEL. For this type of presentation, contractor shall engage
an exclusive team of 5 persons for meeting the continuous requirement.
However, the required preservatives will be supplied to the contractor free of
cost. All other consumables including wire brush, emery papers, painting brush
etc to be supplied by the contractor within the quoted rate.
15.0 ERECTION SCHEDULE
15.1 In order to achieve the overall completion schedule, the contractor shall provide
BHEL all information covering erection sequence, testing and commissioning
activities. These schedules may be based on the recommended erection
procedures and will be subject to discussions/agreements with the owner/ BHEL
subsequent to the award of contract.
15.2 The successful bidder shall have to provide all the above schedules in a tabular
form in addition to that in the form of network and these shall necessarily include
information not limited to the earliest and latest dates for various
activities/submissions and also any related constraints.
16.0 CONTRACT MANAGEMENT
The Contractor should also submit Network program for the erection and
commissioning of various items. These networks shall show the Owner / BHEL
hold points(CHP) which have to be cleared by Owner/BHEL or their authorised
representative(s) before further erection/commissioning can take place. These
program for the erection and commissioning would clearly identify
responsibilities of the Contractor and Owner/ BHEL. Networks shall be submitted
within 4 weeks of the date of finalisation of award of work / placement of LOI for
approval of BHEL.
17.0 CONSTRUCTION MANAGEMENT
17.1 Based on the PERT Network program, within one (1) month of the award of the
Contract, the Contractor shall submit a program of construction / erection /
commissioning, for the implementation. These program would be amplified
showing start of erection and subsequent activities and shall form the basis for
site execution and detailed monitoring, The three monthly rolling program with
the first month's program being tentative based on the site conditions would
be prepared based on these program . The Contractor shall also be involved
along with the Owner/BHEL to tie up detailed resource mobilisation plan over
the period of time of the contract matching with the performance targets.
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17.2 The program would be jointly finalised by the site in-charge of the contractor with
BHEL/owner's project coordinator as well as the site planning representative.
The erection program with also identify the sequential erectable tonnages.
18.0 PROJECT PROGRESS REVIEW MEETINGS
18.1 Periodic progress reviews on the entire activities of execution in respect of supply
& works in scope of bidder will be held once in a month at Calcutta/site. These
meetings will be attended by reasonably higher officials of the Contractor and will
be used as a forum for discussing all areas where progress needs to be
speeded up. Actions will be placed on the concerned agencies and decisions will
be taken to expedite/ speed up the progress. Minutes of such meetings will be
issued reflecting the major discussions and decisions taken and circulated to all
concerned for reference and action. The contractor shall be further responsible for
ensuring that suitable steps are taken to meet various targets decided upon such
meetings.
18.2 In addition to the above and to streamline the construction and erection at site a
suitable frequency and forum of periodic meetings between the contractor and
the Owner/BHEL will be decided upon as part of erection coordination procedure.
19.0 SITE ORGANISATION
19.1 The contractor shall maintain a site organisation of adequate strength in respect
of manpower, construction machinery and other implements at all times for
smooth execution of the contract. This organisation shall be reinforced from time
to time, as required to make up for slippage from the schedule without any
commercial implication to BHEL. The site organisation shall be headed by a
competent construction manager having sufficient authority to take decisions at
site.
19.2 On award of contract, the contractor shall submit to BHEL site organisation
chart indicating the various levels of experts to be deployed on the job. BHEL
reserves the right to reject or approve the list of personnel proposed by the
Contractor. The persons, whose bio-data have been approved by BHEL, will
have to be posted at site and deviations in this regard will not generally be
permitted.
19.3 The Contractor should also submit to BHEL for approval a list of construction
equipment, erection tools, tackle etc. prior to commencement of site activities.
These tools & tackles shall not be removed from site without written permission of
BHEL.
19.4 The organisation chart for site should indicate the various levels of experts to
be posted for supervision in the various fields in erection, commissioning etc as
applicable. For proper supervision of the work, the vendor shall ensure
providing one qualified supervisor against deployment of 15 workmen.
20.0 GENERAL GUIDELINES FOR FIELD ACTIVITIES
20.1 The contractor shall execute the works in a professional manner so as to achieve
the target schedule without any sacrifice on quality and maintaining highest
standards of safety and cleanliness.
20.2 The contractor shall co-operate with the Owner/BHEL and other Contractors
working in site and arrange to perform his work in a manner so as to minimize
interference with other contractors works. BHEL's engineer shall be notified
promptly of any defect in other contractors works that could affect the
contractors work. If rescheduling of contractors work is requested by the
Owner's/ BHEL's engineer in the interest of overall site activities, the same shall
be compiled with by the contractor. In all cases of controversy, the decision of
BHEL shall be final and binding on the contractor without any commercial
implication.
20.3 The Engineer shall hold weekly meeting of all the contractors working at Site
at a time and a place to be designated by the Engineer. The Contractor shall
attend such meetings and take notes of discussions during the meeting and the
decisions of the Engineer and shall strictly adhere to those decisions in
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performing this work. In addition to the above weekly meeting, Engineer may call
for other meetings either with individual contractors or with selected number of
contractors and in such a case the contractor, if called will also attend such
meetings.
20.4 Time is the essence of the contract and the contractor shall be +responsible for
performance of his work in accordance with the specified construction schedule.
If at any time the contractor is falling behind the schedule, he shall take
necessary action to make good of such delays by increasing his work to
comply with the schedule and shall communicate such action in writing to the
Engineer, satisfying that his action will compensate for the delay. The
contractor shall not be allowed any extra compensation for such action.
20.5 The Engineer shall however not be responsible for provision of additional labour
and or materials or supply of any other services to the contractor except for the
co-ordination work between various contractors as set out earlier.
20.6 The works under execution shall be open to inspection & supervision by BHEL's
/ Owner's engineer at all times. The contractor shall give reasonable notice to
BHEL before covering up or otherwise placing beyond the reach of inspection
any work in order that same may be verified, if so desired by the Owner / BHEL.
20.7 Every effort shall be made to maintain the highest quality of workmanship by
stringent supervision and inspection at every stage of execution. Manufacturer's
instruction manual and guidelines on sequence of erection and precautions shall
be strictly followed. Should any error or ambiguity be discovered in such
documents the same shall be brought to the notice of BHEL's Engineer.
Manufacturer's interpretation in such cases shall be binding on the contractor.
20.8 The contractor shall comply with all the rules and regulations of the local
authorities, all statutory laws including Minimum wages, workmen
compensation etc. All registration and statutory inspection fees, if any in respect
of the work executed by the contractor shall be to his account.
20.9 All the works such as cleaning, checking, leveling, blue matching, aligning,
assembling, temporary erection for alignment, opening, dismantling of certain
equipment for checking and cleaning, surface preparation, edge preparation,
fabrication of tubes and pipes as per general engineering practice at site,
cutting grinding, straightening, chamfering, filling, chipping, drilling, reaming,
scrapping, shaping, fitting-up, bolting/welding, stainless steel welding etc. as
may be applicable in such erection and necessary to complete the work
satisfactorily, are to be treated as incidental and the same shall be carried out by
the contractor as part of the work.
20.10 It is the responsibility of the contractor to do the alignment etc if necessary,
repeatedly to satisfy Engineer, with all the necessary tools & tackles, manpower
etc. The alignment will be complete only when jointly certified so, by the
contractor's Engineer and BHEL. Also the contractor should ensure that the
alignment is not disturbed afterwards.
20.11 Equipment and material which wrongly installed shall be removed and
reinstalled to comply with the design requirement at the contractor expense, to
the satisfaction of BHEL/Owner/Consultant.
20.12 After identification of erection materials by BHEL at BHEL's store/storage
yard, it shall be the responsibility of the contractor to take delivery of materials
from BHEL's store/storage yard by contractor's own T&P/manpower and re-
stack the leftover materials as per erection sequence at BHEL store at their
own cost. The entire activities are to be carried out under supervision of BHEL's
MM engineer.
21.0 ERECTION SERVICES
21.1 As part of the overall project management activity, the contractor shall be
responsible for proper co-ordination of erection activities during various phases
of execution of the contract. The contractor shall identify a person designated as
construction manager, with whom BHEL shall interact on matters related to
execution of the contract. The construction manager shall be the single point
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contract person on behalf of the contractor. BHEL shall interact with the
construction manager only on all matters on co-ordination between BHEL and
the contractor.
21.2 The contractor shall confine all his field operations to those works which can be
reformed without subjecting the equipment and materials to adverse effects,
during inclement weather conditions, like monsoon, storms etc. and during
other unfavorable construction conditions. No field activities shall be performed
by the contractor under conditions which might adversely effect the quality and
efficiency thereof, unless special precautions or measures are taken by the
contractor in proper and satisfactory manner in the performance of such works
and with the concurrence of the engineer. Such unfavorable construction
conditions in no way relieve the contractor of his responsibility to perform the
works as per the schedule.
21.3 The contractor shall supply all the skilled workmen H.P. welders, gas cutters,
electricians, riggers, sarangs, erectors, carpenters, fitters, masons, laggers, tin-
smiths, instrument machines etc, in addition to other skilled, semi-skilled and
unskilled workmen required for all the works of handling and transportation from
site store to erection site, erection, testing and commissioning contemplated
under this specification. Only fully trained and competent men with previous
experience on the job shall be employed. They shall hold valid certificates
wherever necessary. BHEL reserves the right to decide on the suitability of the
workers and the other personnel who will be employed by the contractor.
BHEL reserves the right to insist on removal of any employee of the contractor at
any time, if they find him unsuitable and the contractor shall forthwith remove him.
21.4 The supervisory staff employed by the contractor shall be technically qualified and
experienced in the area of work. They shall ensure proper out turn of work and
discipline on the part of labour put on the job by the contractor and in general
see that the works are carried out in a safe and proper manner and in
coordination with other labour and staff employed directly by BHEL or other
contractors of BHEL and BHEL's client/consultant.
21.5 The contractor shall also furnish daily labour report showing by classification the
number of employees engaged in various categories of work a progress report of
work as required by BHEL Engineer.
21.6 The work shall be executed under the usual conditions affecting major power
plant construction and in conjunction with numerous other operations at site. The
contractor and his personnel shall co-operate with other personal, and other
contractors, coordinating his work with others and proceed in a manner that shall
not delay or hinder the progress of work as a whole.
21.7 The contractor's supervisory staff shall execute the work in the most substantial
and workman like manner in the stipulated time. Accuracy of work and aesthetic
finish are essential part of this contract. The contractor shall be responsible to
ensure that assembly and workmanship conform to the dimensions and tolerance
given in the drawing / instruction given by BHEL Engineer from time to time.
21.8 It is the responsibility of the contractor to engage his workman in shifts or on
overtime basis for achieving the target set by BHEL during erection,
commissioning and testing period. Contractor's quoted rate shall include all these
contingencies.
21.9 For rendering commissioning assistance during running of the unit till
handing over of the set, a dedicated gang of Six persons along with an
exclusive supervisor need to be deployed by the vendor to attend the
incidental works of commissioning as per the instruction of BHEL
commissioning engineer. The total gang will report to BHEL and will follow
instruction of BHEL’s Commissioning Engineer. This gang with supervisor shall
be separate and will be their besides other personnel to provided by the vendor
for his day –to-day work. The gang need to be provided during Day & Night
shift also whenever required by BHEL commissioning engineer. They shall be
equipped with all necessary hand-tools to attend all the incidental works
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during commissioning.
21.9.1 In the event of failure of the contractor to provide necessary commissioning
assistance indicated above as per requirement for a continuous period of 15 days
or more, BHEL reserves the right to recover the amounts at the following rates
and organize the services :
21.9.2 @ Rs 12,000/- (Twelve thousand) /month for Supervisor
21.9.3 @ Rs 8000/- ( Eight thousand ) / month for each persons.
22.1 The organisation structure and qualification data of key personnel for the
management and implementation of the proposed quality assurance programme.
22.2 System for site erection control including process controls and fabrication and
assembly controls.
22.3 Control of non-conforming items and system for corrective actions.
22.4 Inspection and test procedure for all site related works.
22.5 Control of calibration and testing of measuring and testing equipment.
22.6 System for quality audit.
22.7 System for indication and appraisal of inspection status.
22.8 System for maintenance of records.
23.0 GENERAL REQUIREMENTS - QUALITY ASSURANCE
23.1 All materials, components and equipment covered under this specification
shall be erected, commissioned and tested at all the stages, as per a
comprehensive Quality Assurance Programme.
23.2 Field Quality plans will detail out for all the equipment, the quality practices and
procedures etc to be followed by the contractor site quality control organisation.
During various stages of site activities from receipt of materials/ equipment at site.
23.3 Quality audit/approval of the results of tests and inspection will not prejudice the
right of BHEL to reject an equipment not giving the desired performance after
erection and shall not in no way limit the liabilities and responsibilities of the
Contractor in earning satisfactory performance of equipment as per specification.
23.4 Repair/rectification procedures to be adopted to make any job acceptable shall be
subject to the approval of BHEL/ Owner.
24.0 INSPECTION, TESTING AND INSPECTION CERTIFICATES
24.1 The Engineer, his duly authorised representative and/or an outside
inspection agency acting on behalf of the BHEL/Owner shall have access at all
reasonable times to inspect and examine the materials and workmanship of the
works during its manufacture and if part of the works is being manufactured or
assembled on other premises or works, the Contractor shall obtain for the
Engineer and for his duly authorised representative permission to inspect as if
the works were manufactured or assembled on the Contractor's own premises
or works. Necessary arrangement for carrying out inspection including supply
of labour, IMTEs, area illumination and scaffolding, if required will be
contractor’s responsibility and same has to be carried out within the quoted
price.
24.2 To facilitate advance planning of inspection in addition to giving inspection
notice the contractor shall furnish quarterly inspection programme indicating
schedule dates of inspection at customer hold point and final inspection stages.
Updated quarterly inspection plans will be made for each 3 consecutive months
and shall be furnished before beginning of each calender month.
25.0 QUALITY CONTROL & QUALITY ASSURANCE
Contractor's Engineers and supervisors shall be adequately qualified and also
inclined to do a quality job. The quality assurance Engineer shall co-ordianate
all aspects of quality control, inspection, implemention of quality assurance
procedures laid down in Quality Plan and technical specification by BHEL. He
shall fillup quality assurance logsheets / formats and submit to BHEL for joint
inspection and acceptance.
26.0 CERTIFICATE TOWARDS COMPLETION
The work under the scope of the contractor will be deemed to be completed in
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all respects only when so certified by BHEL. The decision of BHEL shall be final
and binding on the contractor.
27.0 DEWATERING
Contractor shall ensure at all times that his work areas & approach/access
roads are free from accumulation of water, so that the materials are safe and
the erection/progress schedule are not affected. No separate claim in this
regards shall be admitted by BHEL. No separate payments for dewatering of
subsoil or surface water if required at any time during execution of the work
including monsoon period shall be considered by BHEL .
28.0 CONSUMABLE
28.1 The contractor shall provide within finally accepted price / rates, all consumables
like all welding electrodes (including alloy steel and stainless steel), filler wires, all
gases (inert, welding, cutting), soldering material, dye penetrants, radiography
films. Other erection consumables such as tapes, jointing compound, grease,
mobile oil, M-seal, Araldite, petrol, CTC / other cleaning agents, grinding and
cutting wheels are also to be provided by the contractor. Steel, H&S, packers,
shims, wooden planks, scaffolding materials hardware items etc required for
temporary works such as supports, scaffoldings are to be arranged by him.
Sealing compounds, gaskets, gland packing, wooden sleepers, for temporary
work, required for completion of work except those which are specifically supplied
by manufacturing unit are also to be arranged by him.
28.2 All the shims, gaskets and packings, which go finally as part of equipment, shall
be supplied by BHEL free of cost to the extent supplied by the manufacturing
units. Requirement in excess, shall have to be met by the vendor within his
quoted rate.
28.3 It shall be the responsibility of the contractor to plan the activities and store
sufficient quantity of consumables. Non-availability of any consumable materials
or equivalent suggested by BHEL cannot be considered as reason for not
attaining the required progress or for additional claim.
28.4 Only TIG filler wire, as supplied by BHEL’s manufacturing units as part of regular
supply, shall be supplied by BHEL free of cost. Required quantity as arrived at by
calculation / standards will only be supplied. It would be the contractors'
responsibility to account for the consumption of these filler wires. Additional
requirement beyond standard / calculated quantity will be at cost recovery basis
only unless and otherwise accounted for. Surplus quantity of TIG filler wire, if
any, shall be properly stored and returned to stores.
28.5 It shall be the responsibility of the contractor to obtain prior approval of BHEL,
regarding suppliers, type of electrodes etc before procurement of welding
electrodes. On receipt of electrodes at site these shall be subjected to inspection
and approval by BHEL. The contractor shall inform BHEL details regarding type
of electrodes, batch number, date of expiry etc and produce test certificate for
each lot / batch with correlation of batch / lot number with respective test
certificate. No electrode without a valid test certificate will to be used.
28.6 BHEL reserves the right to reject the use of any consumable including electrodes,
gases, lubricants / special consumables if it is not found to be of the required
standard / make / purity or when shelf life has expired. Contractor shall ensure
display of shelf life on consumable wherever required and records maintained.
28.7 In case of improper arrangement for procurement of any consumable, BHEL
reserves the right to procure the same from any source and recover the cost from
the Contractor's first subsequent bill at market value plus the departmental
charges of BHEL from time to time (30% at present). Postponement of such
recovery is normally not permitted. The decision of Engineer in this regard shall
be final and binding on the Contractor.
28.8 All lubricants and chemicals required for cleaning, pre-commissioning,
commissioning, testing, preservation and lubricants for trial runs of the equipment
shall be supplied by BHEL / BHEL’s client free of cost. All services including
labour and T&P will be provided by the contractor for handling, filling, emptying,
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refilling etc. the consumption of lubricants / chemicals shall be properly accounted

for. Surplus material if any shall be properly stacked / packed and returned to
stores.
28.9 Transportation of oil drums, from stores, filling of oil and filling of oil for flushing,
first filling of oil and subsequent changeover or topping / making up till the unit is
fully commissioned and handed over to customer is included in scope of this
contract. The contractor shall have to return all the empty drums to BHEL /
BHEL's client store at no extra cost. Any loss / damage to above drums shall be
to contractor's account.
29.0 ELECTRODES AND GASES
29.1 All electrodes required for MS, carbon steel, stainless steel, alloy and other
metals required for pressure parts as well as non-pressure parts shall be
supplied by the contractor after due approval of BHEL and as per design
requirement within this quoted rate. It shall be the responsibility of the contractor
to obtain prior approval of BHEL, before procurement regarding suppliers, type of
electrodes etc. on receipt of the electrodes at site, it shall be subject to inspection
and approval by BHEL. The contractor shall inform BHEL details regarding type
of electrodes, batch number and date of expiry etc.
29.2 Only TIG filler wire, as supplied by BHEL’s manufacturing units as part of regular
supply, shall be supplied by BHEL free of cost. Required quantity as arrived at by
calculation / standards will only be supplied. It would be the contractors'
responsibility to account for the consumption of these filler wires. Additional
requirement beyond standard / calculated quantity will be at cost recovery basis
only unless and otherwise accounted for. Surplus quantity of TIG filler wire, if
any, shall be properly stored and returned to stores.
29.3 Supply of filler wires will be restricted to the welding of Boiler Pressure-
parts and Critical / power cycle piping only. The utilisation of the supplied filler
wires of pressure-parts shall be duly accounted for exercising maximum care
and ensuring economical usage for minimum wastage. If during erection, it is
found that the consumption of filler wire is more than the actual requirement by
improper usage, the cost for the additional quantity so consumed shall be
recovered from the contractor.
29.4 Storage of electrodes shall be done in a air-conditioned / controlled humidity form
as per requirement, at his own cost by the contractor.
29.5 In case of improper arrangement for procurement of above electrodes, BHEL
reserves the right to procure the same from any source and recover the cost
from the contractor's first subsequent bill at market value plus the departmental
charges of BHEL communicated from time to time. Postponement of such
recovery is not permitted.
29.6 BHEL reserves the right to reject the use of any electrodes at any stage, if
found defective because of bad quality improper storage, quality date expiry,
unapproved type of electrodes etc. It shall be the responsibility of the contractor
to replace at his cost without loss of time.
29.7 Contractor shall submit weekly / fortnightly / monthly statement /report regarding
consumption and the stock available of all types of electrodes for cost analysis &
preventive measure.
29.8 All the required gases like oxygen, acytelene, LPG, argon, nitrogen required for
work shall be supplied by the contractor at his cost. It shall be the responsibility
of the contractor to plan the activities and store sufficient quantity of these
gases. The contractor shall submit weekly/fortnightly/monthly statement report
regarding consumption of the above gases for cost analysis purposes. Safe
keeping of inflammable cylinders, distribution using gas manifolds shall be
contractors responsibility. BHEL reserves the right to reject the use of any gas in
case required purity is not maintained.
29.9 The contractor shall arrange all packing plates / shims required for erection of all
auxiliaries and rotating equipment under the scope of this tender specification
other than these supplied by manufacturing units at his own cost.
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29.10 Sufficient quantity of test plates and pipes, as considered adequate, for testing
contractor's High pressure Welders will be supplied by BHEL. Additional pipes,
if required, and all other expenses in conducting the tests shall be borne by the
contractor within his quoted rate.
29.11 All temporary piping material necessary for conducting Hydraulic test, will be
provided by BHEL. However, servicing, erection and dismantling of the same and
depositing at BHEL stores is the responsibility of the Contractor without extra
charges.
30.0 PROJECT MANAGEMENT
The successful bidder will have to establish computerised project management
system and the following are the essence of the system.
30.1 Still colour photography (matt paper, post card size, max 10 nos per month of the
contract execution period) depicting progress of the work, damage to the
machine parts (if any) as directed by BHEL site Engr is to be arranged by the
successful bidder.
30.2 Receipt and issue of Boiler components will be managed through totally
computerized SOMS ( Site Operating Management System ) and to facilitate
issue of Boiler material and reconciliation of the same at regular
periodicity. The bidder will have to install 1 nos. PCs (MULTIMEDIA PC WORK
STATION (Pentium Duo-Processor, 1GHz OR ABOVE), 80 GB HDD & 1GB
RAM, 100 Mbps LAN card, 4 Nos. USB Port, Built-in MODEM, External Speakers,
17” Monitor, DVD-R/CD-RW Drive, Mouse with Mouse Pad, of
HCL/COMPAQ/ZENITH OR EQUIVALENT MAKE WITH WINDOW XP (SP-2)
O/S AND REQUIRED SOFTWARE LIKE MS OFFICE XP PROFESSIONAL,
AUTOCAD2005, PAGEMAKER 7.0, Adobe PDF writer, ETC.) with LASER JET
printers COMPATIBLE FOR A3 SIZE PRINTING with Power backup at places, as
per instruction of BHEL from the beginning of the contract for exclusive use by
BHEL. The bidder is also to provide 500 Sheets of A4 Sized Paper and 200
Sheets of A3 Size Paper per month from the time of installation of the printers.
The required ink cartridges or Toner cartridges as per requirement is also to be
supplied by the bidder. This computer/printer shall remain Contractor’s property
and shall maintain it to the satisfaction of BHEL and they will be allowed to take
out the same after completion of the works under this tender specification. The
contractor shall provide data / information etc. in prescribed formats for periodical
updating of the progress reports, material management reports, updating of
network pertaining to the contractor’s scope of work etc. The contractor shall also
provide One computer operators and Two service staffs for miscellaneous service
for BHEL’s use at site / Kolkata for reconciliation, progress review & day-to-day
planning, documentation purpose right from start of work.
30.3 In the event of failure of the contractor to provide computer/printer/Operator
Service staff as per requirement for a continuous period of 15 days or more,
BHEL reserves the right to recover the amounts at the following rates and
organize the services :
30.3.1 @ Rs 8000/- (eight thousand) /month for each computer operator.
30.3.2 @ Rs 8000/- (eight thousand )/month for each computer with printer.
30.3.3 @ Rs 6000/- ( six thousand ) / month for each service staff.
30.4 The successful bidder has to arrange for printing & binding of the Protocol and
/ or Report and / or Data, pertaining to the scope of the bidder. Contents,
Layout Design, Quality of paper/cover, No. of copies etc of such printing
and/or binding will be decided by BHEL.
30.5 The successful bidder shall have provide BHEL with all erection / work schedule
and or progress report, protocol, test report in floppies (compatible to BHEL
software) and also in requisite number of hard copies. The input & output data
for all such schedule shall be furnished to BHEL in a manner compatible with
BHEL software available at site. A copy of the progress report must be
submitted to Project Manager / Calcutta latest by 7th of every month covering
the detailed progress achieved in the previous month.
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31.0 GENERAL
It is imperative on the part of the contractor to join and effectively contribute in
joint measures such as tree plantation, environment protection, contributing
towards social upliftment, conversion of packing woods to school furniture,
keeping good relation with local populace etc.
32.0 COMMUNICATION
Intercom (one line) shall be provided by BHEL free of cost at contractor's site
office. Maintenance of the same shall be arranged by the contractor at his cost.
P&T line, Fax etc, as required by the contractor, is to be installed by the

contractor at his cost after obtaining necessary approval from the
purchaser/BHEL.
33.0 IMTE
Contractor shall ensure deployment of reliable and calibrated IMTEs (Inspection
measuring and testing equipment). The IMTEs shall have test / calibration
certificates from authorized / Government approved / accredited agencies
traceable to National / International standards. Each IMTE shall have a label
indicating calibration status i.e. date of calibration, calibration agency and due
date for calibration. A list of such instruments deployed by contractor at site with
its calibration status is to be submitted to BHEL Engineer for control. Re-
testing/re-calibration shall also be arranged by the contractor at their own cost
at regular interval during the period of use as advised by BHEL.
34.0 TEST CERTIFICATE FOR T&P
Contractor shall ensure deployment of serviced and healthy T&Ps including
cranes, lifting tackles, wire ropes, manila ropes, winches and slings etc. History
card and maintenance records for major T&Ps will be maintained by the
contractor and will be made available to BHEL Engineer for inspection as and
when required. Identification for such T&Ps will be done as per BHEL Engineer's
advice. All T&Ps, lifting tackles, pulling devices, wire rope and slings to be
deployed by the contractor must bear valid/latest test certificates for their
suitability, and the documents shall be preserved at site.
35.0 ISSUE OF T&P
35.1 In the event of BHEL issued T&P, measuring instruments etc the contractor
and BHEL shall maintain joint protocol about the condition of all T&P,
instruments etc taken from BHEL's custody and return to BHEL after use. The
contractor shall not use these equipment for purposes other than the scope of
work given in this tender document.
35.2 It is the responsibility of contractor to keep these equipment always in working
condition and ensure their safe return in working condition to BHEL's store
subject to normal wear & tear.
35.3 After use of T&P items issued by BHEL the same shall be returned to BHEL in
good working condition subject to normal wear & tear failing which recoveries at
the book value of the item or the market rate prevailing at the time of returning
the items, whichever is higher shall be made from the payments due to the
contractor from BHEL from this contract or from any other contract.
36.0 INSURANCE
The contractor shall make available the original insurance cover(s) taken by
him, against his T&P, assets and workmen compensation and any other cover
as may be pertinent to his works and obligatory in terms of law, to BHEL for
necessary verification in regard to their adequacy, before commencement of
work. However, irrespective of such verification/ acceptance, the responsibility
to maintain adequate insurance coverage at all times during the period of the
contract shall be of the contractor alone. Such insurance covers to be taken
shall be in the joint names of the owner and the contractor. The contractor shall
however be authorized to deal directly with the Insurance company(s) and shall
be responsible in regard to maintenance of such insurance covers. Insurance
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covers to be taken by BHEL/ Customer shall be as stipulated under relevant

clause of this specification. However, third party liability shall also be in
BHEL/customer's scope.
37.0 LAND
37.1 Only limited land can be provided free of cost for construction of temporary office,
stores, fabrication area etc. within the project premises.
37.2 Land can not be provided for Labour Colony inside / outside the project premises
to the contractor to construct labour colony/hutment. The bidder must visit the
plant & surrounding areas to assess the situation so that they can make some
arrangement nearby to the project premises in consultation with NTPC/BHEL
37.3 The contractor will be responsible for handing back all lands, as handed over to
him for his temporary use, to BHEL as per the instruction of BHEL Engineer.
38.0 WATER
38.1 BHEL will provide construction water free of cost at one point within 500 Mtrs.
from given work premises.
38.2 BHEL will provide free of cost one Drinking water point within 500 Mtrs. from
given work premises.
38.3 Further distribution beyond above mentioned points to be arranged by the
contractor at his own cost within the working areas.
38.4 Water will be supplied 2 to 3 times in a day. Contractor will have to arrange for
storage of water to meet the day to day requirement. BHEL will however arrange
for adequate supply of construction water to meet the requirement of water during
major concreting.
38.5 The availability of water at BONGAIGAON project is limited. Contractor shall
ensure that no water is wasted. In this regard the contractor shall take all
necessary measure towards preservation of water.
38.6 BHEL shall not be responsible for any inconvenience or delay caused due to
any interruption of water supply and no compensation for delay in work for such
interruption shall be claimed by the contractor.
39.0 ELECTRICITY
39.1 BHEL will provide construction power on Free of charges at 415 V at single point
near work premises within 500 Mtr of 1st row Boiler Column. Further distribution
(including maintenance of the distribution lines) beyond this point to be arranged
by the contractor at his own cost. Any other voltage if required shall be arranged
by the contractor from power supply as above. Contractor will have to provide
necessary calibrated meters (tamper proof, suitably housed in a weather proof
box with lock & key arrangement) at each point of power supply along with
calibration certificate from authorized / accredited agency for working out the
power consumption at his own cost. In case of re-calibration required for any
reason the necessary charges including replacement by calibrated meters is to be
borne by the contractor. Supply of electricity shall be governed by Indian
Electricity Act and Installation Rules and other Rules and Regulation as
applicable.
39.2 BHEL shall not be responsible for any inconvenience or delay caused due to
any interruption of power supply and no compensation for delay in work can be
claimed by the contractor due to such non-supply on the grounds of idle labour,
machinery or any other grounds.
39.3 The Contractor should ensure that the work in critical areas is not held up in the
event of power break-down and for the same he should have suitable standby
arrangement at his cost. As a part of the bid, a specific proposal in this regard
has to be submitted by the contractor. In the event of breakdown in the electric
supply, if the progress of work is hampered, it will be the responsibility of the
Contractor to step up the progress of work after restoration of electric supply so
that overall progress of work is not affected.
39.4 The contractor shall have to make arrangements at their own cost for area
illumination that will be required in the working areas for execution of the work.
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40.0 AREA REQUIREMENT

The contractor shall furnish the estimated area required for the construction of his
office, stores, etc. separately. The same will be reviewed by BHEL and allotted to
the extent available/considered necessary, depending upon the area availability.
No claim whatsoever can be made by the contractor in case the area allotted to
him is less than his proposal.
41.0 CONSTRUCTION OF TEMPORARY OFFICE ETC
The contractor shall arrange at his own cost the construction of his temporary
office, stores, etc and also the watch and ward of all the above.
42.0 TOOLS AND PLANTS
42.1 The contractor is required to provide all necessary tools and plants, (other
than those specified to be provided by BHEL) measuring (calibrated)
instruments and handling equipment for timely completion of the total works as
per contract. The quoted rate shall be inclusive of such requirements. However
the contractor shall submit deployment plan of all T&Ps along with tender bid.
42.2 In the event of any failure of the part of the contractor, BHEL may at his discretion
also terminate the contract on this ground and take out any or whole amount of
the contract from the scope of the contractor. Decision of BHEL in this regard will
be final and binding on the contractor.
42.3 The T & Ps to be arranged by the contractor shall be in proper working condition.
42.4 The list of T&P indicated in relevant annexure are the minimum expected to be
provided by the contractor.
42.5 All other tools and plants required for the work including cranes, electric /hand/
pneumatic winches, tractor-trailors, Air compressors, trucks, welding
generators/transformers, jacks, slings, pulley blocks, TIG/ARC welding
equipment, heat-treatment equipment, temperature recorders, electrode drying
ovens, pipe chamfering machines, hydraulic pipe bending machines etc and
small tools and plants like chisels, scrappers, spanners, files, screw drivers,
electrical tools kits etc required for timely completion of work shall be arranged
by the contractor at his own cost. The contractor shall give a list of such
equipment to be deployed by them giving details like nos available with them, nos
to be deployed, capacity etc of each item in the format enclosed in the annexure
for General information about the contractor and the same shall be binding on
the contractor during to execution contract. It may be specifically noted that the
above items and those in annexure have been mentioned just to give a broad
idea to the contractor about the requirement of T&P for such works. However,
all T&P's required for smooth and timely completion of work shall be arranged by
the contractor at his own cost and BHEL project manager's decision regarding
the requirement of a particular item shall be binding on the contractor. The
equipment once deployed at site shall not be removed from site without the
written consent of BHEL, Construction Manager.
42.6 Sufficient quantities of Guy ropes shall be arranged by the contractor for
erection/alignment of columns.
42.7 All tools & plants deployed by the contractor shall be as per the specification
approved by BHEL Engineers.
42.8 All the T&P, lifting tackles including wire ropes, slings, shackles and electrically
operated equipment shall be approved by BHEL Engineer before they are
actually put on use.
42.9 The list of major T&P required to be deployed in indicated in annexure. The
list is minimum and not exhaustive but anything required over and above these
to suit the site condition/rate of progress/nature of work shall be arranged by
contractor at his own cost.
42.10 For the movement of crane, etc, it may become necessary to lay sleeper bed
or any other material for obtaining levelled safe approach, for usage of
equipment. It shall be contractor's responsibility to arrange for necessary
materials for this.
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42.11 All the T&P arranged by contractor including electrical connections wherein
required shall be reliable/proven/tested with necessary test certificate.
43.0 TOOLS & PLANTS TO BE PROVIDED BY BHEL (SHARED MACHINERY )
43.1 The machineries as prescribed in relevant annexure will be provided to the
contractor on free of cost basis on availability. The list is only indicative and BHEL
is not committed to provide the same.
43.2 The contractor shall ensure that machinery provided to him is kept in good
running condition, all along it's use by contractor and after use is returned to
BHEL in good condition. BHEL's decision regarding condition evaluation shall
prevail.
43.3 BHEL will provide one 250 T Class or Higher Capacity mobile crane free of
charges on sharing basis including operator, fuel and other consumables
for lifting of Boiler / ESP top components only. The crane will be available at
Unit-1/BONGAIGAON Site for a maximum period of Four (4) months
starting from 2nd /3rd month from date of start of Boiler erection. However
allotment of the Crane amongst various erection vendors will be decided by
BHEL engineer considering its priority and necessity. The maximum
working period of the crane will be 12 hours / day with one hour recess in-
between. Engagement of the crane beyond this period will be on chargeable
basis (the charge will be the actual hiring / extra payment made to the crane
agency for this purpose). Since the crane will be arranged on sharing basis,
vendor has to inform well in advance the exact schedule of requirement
based on which allotment will be done by BHEL on availability.
43.4 BHEL will also provide a 75T crane free of all charges on sharing basis to the
bidder. The bidder has to arrange operator & fuel for the portion of the usage by
him. Since the crane will be arranged on sharing basis, vendor has to
inform well in advance the exact schedule of requirement based on which
allotment will be done by BHEL on availability. In case this (75T) crane is not
available to the contractor during his requirement due to reasons attributable to
BHEL, BHEL may provide a lesser capacity crane if found suitable for the
intended purpose (and this lesser capacity is available at site) on the same terms
and condition. Maintenance assistance (if required) for the crane provided under
this clause shall be provided by the vendor. Decision of BHEL’s Site-In-Charge in
this clause shall be final.
43.5 BHEL shall also provide 4 Nos. of Induction Heating Equipment for P-91 piping on
free of charge basis. Receipts of these items including all accessories are to be
shifted from site store to erection places and installed by the bidder. Power supply
cables to these equipments are to be provided by the bidder. Entire erection
commissioning, shifting from one place to another and day to day maintenance is
the scope of the bidder. The bidder will have to include these charges within the
quoted rate.
43.6 BHEL shall provide Drum Lifting winches with wire rope and 10 sheave pulley
blocks free of charges. Receipts of these items including all accessories are to be
shifted from site store to erection places and installed by the bidder. Power supply
cables to these equipments are to be provided by the bidder. Entire erection
commissioning, including securing/grouting wherever required and day to day
maintenance is the scope of the bidder. The bidder will have to include these
charges within the quoted rate.
43.7 All arrangements, including providing & laying of sleeper beds, backfilling of
approaches wherever necessary for safe movement of the cranes/ T&P as
directed by BHEL shall be the responsibility of the contractor. Sleepers for this
purpose shall be provided by the contractor.
43.8 During use of cranes issued by BHEL, the activities like boom reduction,
extension for their use and restoration to previous state or as directed by BHEL
after the use shall be the contractor’s responsibility without any extra charge.
43.9 Any damage/breakdown maintenance of the machinery arising out of improper
handling by contractor shall be to the account of the contractor. BHEL shall
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reserve the right of repairing the same to its own satisfaction at contractor's cost.
During such outage of the machinery, BHEL shall not be responsible to provide
any alternative. The contractor shall arrange for such alternative arrangement at
his own cost.
43.10 The contractor shall return BHEL equipment / T & Ps issued to him in good
condition as and when desired by BHEL. If the return is delayed, hire charges, as
applicable shall be levied by BHEL.
43.11 In case of any machinery ( given to contractor) remaining idle without any valid
reason, BHEL shall withdraw the equipment immediately for allotment to the
contractor next in priority.
43.12 In case any machinery (given to contractor) is idle and/or in case of exigency of
work, BHEL reserves the right to withdraw the same and no compensation shall
be entertained on this account by BHEL.
43.13 In case the total work under scope is split, the tools and plants to be provided by
BHEL shall be shared amongst the contractors as per discretion of BHEL.
43.14 All the above equipment issued to contractor will be inspected periodically by
BHEL engineer. In case contractor fails to make good the damages caused,
BHEL will do the same at the cost of the contractor.
43.15 The above T&P shall be available with project manager, BHEL. The T&P shall
be shared by all contractor working for BHEL at the site and distribution of these
shall be done at the discretion of project manager, BHEL on the
requirement/priority of the job and the availability of these items.
43.16 In the event of any damage or theft occurring to these items while in use with the
contractor due to their negligence, the same shall be repaired/replaced by the
contractor at their own cost within the time stipulated by project manager, BHEL.
Contractor’s failure to do so shall entitle BHEL to get the above done through
other agency and the cost so incurred by BHEL shall be recovered from the
contractor's bill.
43.18 The above are for general guidance only. Except the above mentioned items, the
contractor have to deploy all other tools & plants required for proper & satisfactory
completion of the job. The number of such item will be as per requirement.
44.0 TIME SCHEDULE
44.1 The entire work of erection and commissioning for Boiler, ESP, Piping etc as
detailed in this tender shall be completed within a period of 30 months from
the date of start of work.
44.2 The erection and commissioning will be deemed to be completed in all respects,
only when the trial runs of individual equipment and testing including floating of
safety valves is over and the unit is handed over to customer after successful
trial operation with MCR. The decision of BHEL in this respect shall be final and
binding on the contractor.
44.3 The contractor should arrange to mobilize and start the erection work within 15
days from the date of LOI from BHEL. Erection of first column will be deemed
as start of work of unit at site.
However, in case of occurance of any non-sequential situation, The month
of first RA bill to be considered as ZERO MONTH, subject to discretion of
Construction Manager, BHEL.
45.0 CONSTRUCTION SCHEDULE
45.1 The schedule of major milestone activities shall be as under
45.1.1 Start of Boiler erection – Zero month.
45.1.2 Drum lifting - 04 Months from start of erection.
45.1.3 Hydraulic test - 12 Months from start of erection.
45.1.4 Light up - 16 Months from start of erection.
45.1.5 Chemical cleaning - 16 Months from start of erection.
45.1.6 Steam Blowing Completion - 16 Months from start of erection.
45.1.7 Synchronisation/Coal Firing of the Unit - 21 months from start of erection.
45.1.8 Completion of works/COD – 24 Months from start of erection including full
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loading, final painting & handing over.

45.1.8.1 Liquidation of pending points and site demobilization – 30 months from start of
erection.
45.2 The following fronts to be released by the contractor within the stipulated time
period for facilitating other agency to commence their work as per schedule:
Furnace bottom ash hopper – 12 Months from start of work.

Mill Bay area clearance – after Drum Lifting.
45.3 It may be noted that the above schedules are tentative. The exact dates shall be
decided based on project requirement. The decision of BHEL in this regard is final
and binding.
46.0 RECTIFICATION / MODIFICATION

46.1 All rectification/modifications and reworks required for any reasons not due
to fault of the contractor on works already completed, which require less than or
upto 50 man hours shall be considered as minor and shall be carried by the
contractor free of cost.
46.2 BHEL may consider payment for extra works on man hour basis for such of
those works which require mojor revamping / rework and is totally unusual to
normal erection or commissioning work which are not due to contractor's faulty
erection. The decision of BHEL in this regard shall be final and binding on the
contractor. The contractor may submit his extra claim bills (specifically agreed by
BHEL Engineer) along with the labour sheet duly certified by BHEL Engineer at
site. But BHEL has also got the option to get these works done trough other
agencies, if they so desire.
46.3 All the extra work, if any, carried should be done by a separate gang which
should be identified prior to start of work for certification of man-hours. Daily
labour sheets should be maintained and should be signed by contractor's
representative and BHEL engineer. Signing of labour sheet does not
necessarily mean the acceptance of extra work. Only those works which are
identified as not usual to normal erection and certified so by the construction
manager only will be considered for payment.
46.4 BHEL has got the option of executing work related to this package but
added subsequently on technical requirement / detailed engineering / customer’s
recommendation either adopting clause through quoted tonnage rate ( upto the
limit of + 20% of the given tonnage ) or by adopting either of the following
clauses on H.P. joints and man-hr rates at the discretion of BHEL.
47.0 EXTRA WORK RATE FOR HIGH PRESSURE JOINTS
47.1 The following are all inclusive rates will be applicable for
rectification/modification/rework involving welding of high pressure joints.
47.2 Unit rate per equivalent water wall joint of size OD 63.5 mm x 6.3 mm thick.
Type of material Average rate per joint
Carbon steel Rs 200.00
Alloy steel Rs 250.00
47.3 Not withstanding the equated rate that can be derived from clause no 53 of terms
of payments, extra work rate for HP joints shall be as per the above only.
47.4 The rate indicated above and below are firm and are not subject to any
escalation during the contractor period till the completion of work unit rates for
welding are inclusive of joint preparation, cutting, edge preparation, welding and
stress relieving, radiography with all consumables , tools and plants, supervision
etc.
47.5 For additional radiography, if so desired by BHEL, payment @ Rs 6.00 per cm
length of film (100 mm wide) exposed and accepted by site engineer and further
certified by site Engineer that the length of film exposed is minimum required for
carrying out the radiography shall be paid.
48.0 EXTRA WORK RATE FOR ALL CASES OTHER THAN HIGH PRESSURE
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JOINTS
The following manhour rates will be applicable for modification / rectification
work, excluding pressure part joints.
48.1 Average single man-hour rates including overtime if any supervision use of tools
& tackles and other site expenses and incidentals including consumables for
carrying out rework/revamping as certified by site as may arise during the
course of erection testing and commissioning -- Rs 40.00 (Forty) per man-
hour.
48.2 Average single man-hour rates including overtime if any supervision use of tools
and tackles and other site expenses and incidentals excluding consumables for
carrying out rework/ revamping as certified by site as may arise during the
course of erection testing and commissioning -- Rs 25.00 (Twenty Five) per
man-hour.
NOTE: The above man-hour rates towards extra work shall be firm and not
subject to any variation during execution of the work.
49.0 TAXES AND DUTIES
49.1 All taxes, charges, royalties, duties, octroi etc and other taxes for materials
obtained for the work and for the execution of the contract shall be borne by the
contractor and shall not be payable extra (except service tax).
49.2 Service tax including Educational Cess (as applicable), shall be reimbursed at
actual against submission of documentary evidence to the satisfaction of BHEL.
As such, the bidder’s quoted rate shall not be inclusive of the service tax. Any
changes in service tax rules (by Government) shall be complied with.
49.3 Vendor should be registered under State VAT Act of the respective State. They
should produce their Registration No and copy of Registration certificate as proof
of registration and a clause should be included in the contract to read as “sub-
contractor shall produce sufficient proof of payment of VAT” so that BHEL as
main contractor can get the benefit of deduction of subcontracting value from the
contractual transfer price under state VAT Act and CGVAT Act.
49.4 In the states like Orissa and Bihar where the State VAT Act does not permit
deduction of subcontracting value from contract value, contractor’s price shall be
inclusive of Work Contract Tax as per VAT Act. Contractors should produce Tax
Invoice and other necessary documents to BHEL as required under VAT Act/
Rules so that BHEL can avail input credit under VAT Act.
50.0 MOBILISATION ADVANCE
Not applicable.
51.0 RATE REVISION
Not applicable.
52.0 RESPONSIBILITY OF THE CONTRACTOR IN RESPECT OF SAFETY OF
MEN, EQUIPMENT, MATERIAL ETC
52.1 Before commencing the work, the contractor shall appoint / nominate a
responsible officer to supervise implementation of all safety measures and liaison
BHEL / customer.
52.2 The contractor shall submit a “safety plan” to BHEL. The safety plan shall indicate
in detail the measures that would be taken by the contractor to ensure safety of
men, equipment, material etc. during execution of the work. The plan shall take
care to satisfy all requirements specified hereunder. BHEL shall have right to
review and suggest modifications in the safety plan. Contractor shall abide by
BHEL’s decision in this respect.
52.3 The contractor shall take all necessary safety precautions and arrange for
appropriate protective gears as per direction of BHEL or it’s authorized person to
prevent loss of human lives, injuries to men engaged and damage to property etc.
Code for safety management at construction site shall also be referred to.
52.4 The contractor shall provide to his work force & ensure the use of the following
personal protection equipment as found necessary and as directed and advised
by BHEL officials.
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52.4.1 Safety helmets conforming to IS 2925 / 1984 (1990)

52.4.2 Safety belts conforming to IS 3521 / 1989
52.4.3 Safety shoes conforming to IS 1989 part – II / 1986 (1992)
52.4.4 Eye and face protection devices conforming to IS 2573 / 1986 (1991),
52.5 IS 6994 / 1973 part – I (1991), IS 8807 / 1978 (1991), IS 8519 / 1977 (1991).
52.6 53.4 All tools, tackles, lifting appliances, material handling equipment,
scaffolds, cradles, safety nets, ladders, equipment etc. used by the contractor
shall be of safe design and construction. Wherever applicable test certificates for
the fitness of these shall be furnished. BHEL will have the right to ban the use of
any item found unsuitable.
52.7 All electrical equipment, connections and wiring for construction power, its
distribution and use shall conform to the requirements of Indian Electricity Act and
rules. Only electricians licensed by the appropriate statutory authority shall be
employed by the contractor to carry out all types of electrical works. All electrical
appliances including portable electric tools used by the contractor shall have safe
plugging system to source of power and be appropriately earthed.
52.8 For the work in confined spaces, lighting shall be arranged with power source of
not more than 24 volts. Alternatively, proper protection shall be provided for use
of higher voltage source.
52.9 The contractor shall adopt all fire safety measures as laid down in the “code for
fire safety at construction sites” of BHEL and as per directions of BHEL official. A
copy of the above referred “code for fire safety at construction sites” shall be
made available by BHEL to the contractor for reference.
52.10 Where it becomes necessary to provide and / or store petroleum products,
explosives, chemicals and liquid or gaseous fuel or any other substance that may
cause fire or explosion, the contractor shall be responsible for carrying out such
provisions and / or storage in accordance with the rules and regulations laid down
by the relevant government acts, such as petroleum act, explosives act,
petroleum and carbides of calcium manual of the chief controller in all such
matters.
52.11 The contractor shall arrange at his cost (wherever not specified) appropriate
illumination at all work spots for safe working when natural day light may not be
adequate for clear visibility.
52.12 The contractor shall be held responsible for any violation of statutory regulations
(local, state or central) and BHEL instructions that may endanger safety of men,
equipment, material and environment in his scope of work or another contractors
or agencies. Cost of damage, if any, to life and property arising out of such
violation of statutory regulations and BHEL instructions shall be borne by the
contractor.
52.13 In case of a fatal or disabling injury / accident too any person at construction sites
due to lapses by the contractor, the victim and / or his / her dependents shall be
compensated by the contractor as per statutory requirements. However, if
considered necessary, BHEL shall have the right to impose appropriate financial
penalty on the contractor and recover the same from payments due to the
contractor for suitably compensating the victim and / or his / her dependents.
Before imposing any such penalty, appropriate enquiry shall be held by BHEL
giving opportunity too the contractor to present his case.
52.14 In case of any damage to property due to lapses by the contractor, BHEL shall
have the right to recover cost of such damages from payments due to the
contractor after holding an appropriate enquiry.
52.15 In case of any delay in the completion of a job due to mishaps attributable to
lapses by the contractor, BHEL shall have the right to recover cost of such delay
from payments due to the contractor after notifying the contractor suitably and
giving him opportunity to present his case.
52.16 If the contractor fails to improve the standards of safety in its operation to the
specification of BHEL after being given a reasonable opportunity to do so, and / or
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to provide necessary safety devices and equipment or to carry out instructions

regarding safety issued by the authorized BHEL official, BHEL shall have the right
to take corrective steps at the risk and cost of the contractor after giving a notice
of not less than seven days indicating the steps that would be taken by BHEL.
52.17 The contractor shall submit report of all accidents, fires and property damage,
unsafe occurrences to the authorized BHEL official immediately after such
occurrence but in any case not later than twelve hours of the occurrence. Such
report shall be furnished in the manner prescribed by BHEL. In addition, periodic
reports on safety shall also be submitted by the contractor to BHEL.
52.18 Scaffolding
The Contractor shall take all precautions to prevent any accidental collapse of
scaffolding or fall of persons from scaffolding. The Contractor should ensure that
scaffolding are designed by a competent person and it erection and repairs should
be done under the expert supervision. The scaffolding shall meet the required
strength and other requirements for the purpose for which the scaffold is erected.
The material used for scaffold should conform to the BIS / International standards.
52.19 Working at Heights
All working platforms, ways and other places of construction work shall be free from
accumulations of debris or any other material causing obstructions and tripping.
Wherever workers are exposed to the hazard of falling into water, the Contractor
shall provide adequate equipment for saving the employees from drowning and
rescuing from such hazards. The Contractor shall provide boat or launch equipped
with sufficient number of life buoys, life jackets etc. manned with trained personnel at
the site of such work.
Every opening at elevation from ground level through which a building worker,
vehicle, material equipment etc. may fall at a construction work shall be covered
and/or guarded suitably by the Contractor to prevent such falls. Wherever the workers
are exposed to the hazards of falling from height, the Contractor shall provide full
harness safety belts fitted with fall arresting systems to all the employees working at
higher elevations and life line of 8 mm diameter wire rope with turn buckles for
anchoring the safety belts while working or moving at higher elevations. Safety nets
shall also be provided for saving them from fall from heights and such equipment
should be in accordance with BIS standards. Wherever there is a possibility of falling
of any material, equipment or construction workers while working at heights, a
suitable and adequate safety net should be provided. The safety net should be in
accordance with BIS Standards. The Contractor shall provide standard prefabricated
ladders on the columns where the workers are required to use them as an access for
higher elevations till permanent staircase is provided. The workers shall be provided
with safety belts
fitted with suitable fall arresting system (Fall arrestors) for climbing/getting down
through ladders to prevent fall from height.
52.20 If the Contractor fails in providing safe working environment as per the Safety Rules
of BHEL/NTPC or continues the work even after being instructed to stop the work by
the Engineer I/C , the Contractor shall be penalized at the rate of Rs. 25,000/- per
day or part thereof till the instructions are complied with and so certified by the
Engineer
I/C. However, in case of accident, the provisions contained in Sub-Clause below
shall also apply in addition to the penalties mentioned in this sub-clause.
II If the Contractor does not take all safety precautions and / or fails to comply with the
Safety Rules as prescribed by the Employer or under the applicable law for the safety
of the plant and equipment and for the safety of personnel and the Contractor does
not prevent hazardous conditions which cause injury to this own employees or
employees of other Contractors, or BHEL/NTPC's employees or any other person
who are at the Site or adjacent thereto, the Contractor shall be responsible for
payment of penalty to BHEL/NTPC as per the following schedule:-
a) Fatal injury or accident causing death: Penalty @10% of contract value
or
Rs. 5,00,000/- per person, which ever is less.
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b) Major injuries or accident causing 25% or more permanent disablement

to workmen or employees Penalty @2.5% of contract value or Rs.
1,00,000/- per person which ever is less.
Permanent disablement shall have the same meaning as indicated in The
Workmen's Compensation Act' 1923. The penalty mentioned above shall be in
addition to the compensation payable to the workmen / employees under the relevant
provisions of the Workmen's Compensation Act' 1923 and rules framed there under
or any other applicable laws as applicable from time to time.
52.21 If two or more fatal accidents occur at same site under the control of Contractor
during the period of contract and he has
(1) not complied with keeping adequate PPEs in stock or
(2) defaulted in providing PPEs to his workmen
(3) not followed statutory requirements / NTPC safety rules
(4) been issued warning notice/s by NTPC head of the project on non
observance of safety norms
(5) not provided safety training to all his workmen, the Contractor can be debarred
from getting tender documents for two years from the date of last accident.
The safety performance will also be one of the overriding criteria for evaluation of
overall performance of the Contractors by BHEL/NTPC. The Contractor shall submit
the
accident data including fatal / non-fatal accidents for the last 3 years where he has
undertaken the construction activities Projects-wise along with the tender
documents. This will also be considered for evolution of tender documents. If the
information given
52.18 Nonconformity of safety rules and safety appliances will be viewed seriously and
the BHEL has right to impose fines on the contractor as under:
Sl no Safety Fine (Rs)
01. Not wearing safety helmet. 50/-
02. Not wearing safety belt. 100/-
03. Grinding without goggles. 50/-
04. Not using 24 V supply for internal work. 500/-
05. Electrical plugs not used for hand machines. 100/-
06. Not slinging properly. 200/-
07. Using damaged sling. 200/-
08. Lifting cylinders without cage. 500/-
09. Not using proper welding cable with lot of joints and not 200/-
insulated properly.
10. Not removing small scrap from platforms. 200/-
11. Gas cutting without taking proper precaution or not using 200/-
sheet below gas cutting.
12. Not maintaining electric winches which are being 500/-
operated dangerously.
13. Improper earthing of electrical T&Ps. 500/-
53.0 TERMS OF PAYMENT
53.1 The contractor shall submit his monthly on account bill (RA bill) once in a month
at the end of each month covering progress of work on all respects and areas
from 25th of prevuious calander month to 24th of the current month. The RA bill,
complete in all respects accompanied by BHEL engineer's certificate / jointly
signed measurement sheet will be paid within 30 days of submission of the bill,
subject to its completeness & correctness in all respects. The measurement will
be taken by BHEL engineer as per relevant clause of GCC and certify regarding
the actual work executed in the measurement book and bills for work.
53.2 Out of break-up for progressive payment indicated below, 5% will be retained
from each RA bill which will be released on completion of guarantee period of
12 months. However, this balance 5% can be released against submission of
performance bank guarantee in the prescribed 'form' which shall be kept valid for
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the specified period (guarantee period) subject to receipt of certificate that all
works are completed in all respects. This bank guarantee is separate from the
bank guarantee towards security deposit and the bank guarantee towards
security deposit cannot be utilized for this purpose. The security deposit will be
refunded as per GCC.
53.3 STAGES OF PROGRESSIVE PRO-RATA PAYMENTS
53.3.1 Subject to the deduction & retention as indicated above, which BHEL may be
authorized to make under the contract, the contractor shall, on the certification of
the engineer at site, be entitled for payment as explained here under:
53.3.2 For erection, testing & commissioning of boiler and auxiliaries as detailed in the
tender document, progressive payment shall be made as above on the basis of
contract price as per rate schedule. The above break-up is only for the purpose
of progressive payment and should not be construed as total scope of work.
53.3.3 The quoted rates per MT for different groups indicated in rate/price schedule shall
be distributed in the following manner for releasing payments against RA bills:
Stages of payment Payment break up
Pr Rotating Non-pr ESP Piping
parts/Tr machine parts (incl. P-
im 91)
Piping
53.3.3.1 Completion of pre-assembly 15% ---- 15% 15% 15%
53.3.3.2 Placement in position 25% 40% 25% 20% 20%
53.3.3.3 Alignment, grouting & welding 35% 45% 40% 40% 35%
including bolting as required
53.3.3.4 Completion of non destructive 10% ---- ---- ---- 13%
examination & stress relieving
/ heat treatment
53.3.3.5 Bolting & completion hangers ---- ---- 05% ---- 05%
& supports etc. wherever
necessary
53.3.3.6 Completion of Hydraulic test 04% ---- ---- ----- 04%
(drainable)
53.3.3.7 Completion of air & Gas ---- ---- 01% 04% ----
tightness test for equipment
53.3.3.8 Gas distribution test ---- ---- ---- 03% ----
53.3.3.9 Charging of all field of ESP ---- ---- ---- 05% ----
53.3.3.10 Boiler light up and ABO 02% 05% 01% 03% ----
53.3.3.11 Completion of acid / chemical 02% ---- 02% ---- ----
cleaning
53.3.3.12 On completion of steam 02% ---- ---- ---- 3%
blowing & Safety Valve
floating
53.3.3.13 Coal firing 01% 04% 04% 05% ----
53.3.3.14 Full loading -- 03% 03% 02% 01%
53.3.3.15 Submission of as-built 01% ---- ---- ---- 01%
drawings.
53.3.3.16 Liquidation of pending points 01% 01% 02% 01% 01%
53.3.3.17 Reconciliation of issued 01% 01% 01% 01% 01%
materials
53.3.3.18 Completion of all contractual 01% 01% 01% 01% 01%
Obligation and de-
mobilization of site office.
Total 100% 100% 100% 100% 100%
53.3.4.1 In case the PG Test assistance is not required, the payment towards this will not
be considered.
53.3.4.2 The above billing break up is applicable for the main boiler and the auxiliary
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boiler.
53.3.4.3 100% payment shall be released for sl. Nos. 9.0 & 10.0 (i.e. for Unloading of
boiler drum & shifting to place of erection and PG Test assistance) on completion
of the respective activities.
53.3.4.4 For all items of work as per Volume-III, Price Schedule, interim payment shall be
limited to 95 % of the gross value of interim bill on item rate basis. All admissible
recovered/ adjustments etc shall be made from the interim payable amount. The
balance 5 % shall be payable as per Clause No. 16.8
53.3.4.5 Out of above mentioned 95 % of gross bill value, 1.5 % of gross bill amount shall
be paid in the following manner on certification by BHEL engineer after
compliance of each of following activity in each month. In case of non-fulfilment of
respective activity by vendor in each month, no payment shall be made by BHEL
against corresponding activity and no claim of bidder at a later date, whatsoever,
in this regard shall be entertained by BHEL.
53.3.4.6 0.7 % shall be paid on compliance of house keeping of vendor’s working area and
store/ office areas.
53.3.4.7 0.3 % shall be paid on compliance of general illumination of vendor’s working
area and stores, office area.
53.3.4.8 0.2 % shall be paid on compliance of applicable OHSAS requirement as per
guidelines of BHEL/ PSER and as specified in the tender.
53.3.4.9 0.3 % shall be paid on compliance of applicable Safety requirement as per
guidelines of BHEL/ PSER and as specified in the tender.
53.3.4.10 5% will be retained from each RA bill which will be released on completion of
guarantee period. However, this 5% payment can be released against submission
of performance bank guarantee valid for the guarantee period as stated above in
prescribed proforma subject to receipt of certificate that all works are completed in
all respects. The submission of bank guarantee towards performance guarantee
is separate and the bank guarantee towards security deposit cannot be utilized for
this purpose. The security deposit will be refunded as per GCC.
53.3.4.11 BHEL at their discretion, may further split up the above percentages and effect
payment to suit the site condition, cash flow requirement and according to the
progress of work.
53.3.4.12 Bidder may please note that payment shall be made through e–mode for which
Bank details are to be furnished as per format given in Annexure-K of VOL – IE
of tender.
54.0 RATES/PRICE
54.1 The bidder shall quote their rate as per rate schedule given in Volume-III of this
specification only.
54.2 Quoted/accepted rates shall remain valid for +/- 20 % variation in total weight
indicated in relevant annexure of weight schedule. Actual tonnage as detailed in
the documents of manufacturing units shall be considered for the purpose of
billing and payment at accepted unit rates.
55.0 LIQUIDATED DAMAGE : If the contractor fails to maintain the required progress
of work as per contract or to complete the work and clear the site within the time
prescribed by the Contract (Contractual Completion period), he shall without
prejudice to any other right or remedy of BHEL on account of such breach, the
contractor agrees to pay compensation (penalty) to BHEL. The above agreed
compensation shall be a penalty equivalent to 0.5% of the contract price for
delay of every one (1) week if the reasons for delay is attributable to
contractor, subject to a maximum of 5 % of contract price (irrespective of
lump sum or item-rate contract or others) excluding elements of EXCISE DUTY
and Sales Tax (if quoted by the contractor separately)
56.0 PERFORMANCE BOND : Not Applicable.
57.0 PRICE VARIATION/ADJUSTMENT FORMULA FOR SERVICE JOBS
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57.1 After the `Base Date’, and/ or during the progress of work, the monthly price
adjustment amount of the contract price will be computed as per the formula
given below. The base date shall be reckoned as latest due date of submission
of offer.
57.2 ER = ER1 – ERo.
57.3 ER1 will be computed as follows.
L1
ER1 = ERo (0.15 + 0.85 ---), where
Lo
ER = Adjustment to contract price payable to the contractor for each billing.
ER1 = Adjusted amount payable/recoverable to the contractor of contract
price for each billing.
ER0 = Value of work done in the billing period.
57.4 The payment of price adjustment amount so computed shall be made against a
separate invoice linking the corresponding invoice (gross RA bill amount) after
retaining the prorate amount due on completion of guarantee/ final bill (as per
payment terms of tender). The amount so retained shall be paid on successful
completion of guarantee/ final bill (as per payment terms of tender).
L0 = All India Consumer Price Index for Industrial Workers (All India Average)
as published by Labour Bureau, Simla, Government of India as on base
date.
L1 = All India Consumer Price Index for Industrial Workers (All India Average)
as published by Labour Bureau, Simla, Government of India for the
month of work done.
57.5 Total PVC payable / recoverable against the contract shall have an overall
ceiling of 15 % of the contract price for original contract completion period of 30
months.
57.6 The quantum of such price variation amount per month shall be restricted to the
ceiling percentage for each RA Bill amount. The final adjusted amount of PVC
will be paid along with the final bill.
57.7 The contractor shall produce necessary Government Notifications/ RBI Bulletins
of above component for receiving payment from BHEL/ refund to be made to
BHEL, as required, in the formula mentioned above.
57.8 The contractor will be required to raise bills for PVC payment on monthly basis
along with RA Bill irrespective of the fact whether, any increase/ decrease in
price/ index has taken place or not.
57.9 PVC shall be admissible up to the original completion period of tender.
58.0 ORC (OVER RUN COMPENSATION)
58.1 In case, due to reasons not attributable to the contractor, the work gets extended
beyond original completion period, stipulated in tender, the contractor shall be
entitled for over run compensation (ORC).
58.2 ORC shall be applicable as per following.
58.3 The rate/ price of balance part of job beyond normal completion period shall be
revised by 10 % from 1st month of extended period. This revised rate shall
remain valid for one year.
58.4 The above revised rate shall be further revised by 10 % per year in the
subsequent years and this re-revised rate shall remain valid for one year and so
on till completion of contract.
58.5 During the extended period, contractor shall maintain their resources as per
mutually agreed program. However, the contractor have to deploy additional
resources, if required, to complete the job within the re-scheduled completion
period.
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58.6 Payment of ORC shall be subject to compliance to following condition.

58.7 Contractor shall maintain minimum resources as per agreed program and
certified by BHEL.
58.8 Contractor shall achieve the target as per agreed program.
58.9 The example is indicated below:
Rate/Price of Balance job on contractual completion date = A, Say
Revised Rate during the 1st Year after contractual completion date = 1.1 A
Revised Rate during Second Year after contractual completion date

PLUS One Year = 1.21 A
And so on for subsequent period if applicable.
NOTE:
(a) Enhanced rate shall not be applicable during the period in extension
where reasons for delay are attributable to vendor as explained below :
Contract period extended - 8 Months, say
(Out of 8 Months delay, supposing vendor is responsible for 3 months delay and
BHEL is responsible for 5 months delay)
Revised Rate 1.1 A shall come into effect on expiry of contract period
plus 3 months.
Revised rate 1.1A shall be in force for One Year thereafter.
(b) For further extension if any, for application of ORC, above logic shall be
applicable after evaluating the reasons of delay.
That is, the revised rate for 2nd year shall come into effect on expiry of
delay period attributable to the vendor during first year. i.e, extended
period.
Contract Period + Vendor Delay (3Month in above case) + One year +
Vendor delay during one year extended period.
This revised rate 1.21A shall remain in forces for one year thereafter.
And so on.
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ANNEXURE-1
(PROCEDURE FOR ERECTION & WELDING OF SA335 P91 MATERIAL)
Prior to erection, supplied pipes shall be inspected thoroughly and if any

defect like crack, lamination, deposit noticed, the same shall be confirmed
by Liquid Penetrant Inspection. If confirmed, same shall be referred to
supply unit of BHEL for required repair.
16a EDGE PREPARATION AND FIT UP.
I. Cutting of P-91 material shall be done by hand saw / hack saw /

machining / plasma cutting / grinding only.
II. Edge preparation shall be done only by machining and the required
edge preparation machine shall be arranged by contractor at his
cost. In extreme cases, edge can be prepared by grinding with
prior approval of BHEL. During edge preparation care should be
taken to avoid excessive pressure to prevent heating up of the
pipe edges.
III. All edge preparation done at site shall be subjected to Liquid

Penetration Test. Weld built-up on edge preparation is prohibited.
IV. The weld fit-up shall be carried out properly to ensure proper
alignment and root gap. Neither tack welds nor bridge piece shall
be used to secure alignment.
V. Partial root weld of minimum 20mm length by GTAW and fit-up by

a clamping arrangement is recommended. Use of site manufactured
clamps for fit-up is acceptable. The necessary pre-heat and purging shall
be done. The fit-up shall be as per drawing. Root gap shall be 2 to 4
mm. Root mismatch shall be within 1 mm. Suitable reference
punch marks shall be made on both the pipes ( at 200 mm
from the EP ) at least on four axis to facilitate U. T on weld joint.
16b FIXING OF THETMOCOUPLES AND HEATING ELEMENTS

DURING PRE-HEATING AND POST WELD HEAT TREATMENT.
No pre-heating is required for fixing T/Cwith resistance spot welding. Following

are the equipment / facilities for heating cycles.
1. Heating Method : Induction Heating
2. Thermo couples : Ni-Cr / Ni – Al of 0.5 mm gauge size.
3. Temp. Recorder : 6 Points / 12 Points.
16c ARRANGEMENT FOR PURGING :
I. Argon gas with requisite quality shall be used for purging the root
side of weld. The purging dam ( blank ) shall be fixed on either
side of the weld bevel prior to Pre-heating. The dam shall be fixed
inside the pipe and it shall be located away from the heating
zone. Purging is to be done for root welding (GTAW) followed by
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two filler passes of SMAW in case of butt welds. Purging is not

required in case of nozzle and attachment welds, when they are
not full penetration joints. The Argon gas to be used shall be dry.
The flow rate is to be maintained during purging is 10 to 25 litres
/ minute and for shielding during GTAW is 8 to 14 ltres / minute.
II. Start purging from inside of pipe when root temperature reaches
220 deg. Centigrade. Provide continuous and adequate Argon gas to
ensure complete purging in the root area. The minimum pre-
flushing time for purging before start of welding shall be 5
minutes, irrespective of the pipe size. Wherever possible, solid
purging gas chambers are to be used which can be removed after
welding. If not possible, only water soluble paper is to be used.
Plastic foils that are water soluble are not acceptable.
16d WELDERS QUALIFICATION
Only qualified welding procedures are to be used. Welders qualified as per

ASME Section – IX and IBR on P-91 material shall only be engaged.
Welders logbook to be maintained and welders performance shall be
monitored by BHEL site welding engineer / Quality assurance engineer.
16e PREHEATING
Prior to start of pre-heating ensure that surfaces are clean and free from
grease , oil and dirt. Pre-heating temperature shall be maintained at 220
deg. Centigrade by using induction heating. The temperature shall be
ensured by using a calibrated autographic recorder and two calibrated
thermocouples fixed at 0 and 180 degree positions on both pipes 50 mm
away from the edge. The thermocouples shall be welded with spot
welding machine. The pre-heating arrangement shall be inspected and
approved by BHEL engineer.
Alternate arrangements shall be made during power failure. Two additional

square thermocouple are to be fixed for emergency use. Gas burners shall
employed to maintain the temperature until the power resumes.
16f WELDING
Root welding shall be done using GTAW process ( as per WPS ) five
minutes after the start of Argon purging. Filler wires shall be clean and
free from rust or oil. Argon purging shall be continued minimum two filler
passes of SMAW. Argon gas to be used both for purging as well as shielding
shall be of 99.99 purity level conforming to IS 5760-1998.
16g STORAGE OF WELDING CONSUMABLES :
I. Welding consumables are received with proper packing and marking

which includes the relevant batch number for easy identification.
II. Electrodes are stored in their original sealed containers / packages

until issued and kept in dry and clean environment taking care of
shelf life.
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III. Welding filler wires are received with proper packing and marking
which includes the relevant batch number for easy identification.
IV. The filler wires are stored in original packages until issued and
kept in dry and clean environment.
V. The electrode GTW wires issued to the welders should be

controlled through issue slips. SMAW electrodes used must be dried
in drying ovens with calibrated temperature controller. The drying
temperature shall be as recommended by the electrodes
manufacturer. The drying temp. shall be 200 – 300 deg. Centrigrades
for two hours if it is not specified by manufacturer. Portable
flasks shall be used by the welders for carrying electrodes and
shall be kept at 100 deg. Centrigrades. Welding shall be carried out
with short arc and stringer bead technology.
VI. The inter-pass temperature shall not exceed 350 deg. Centigrades.
After completion of welding bring down the temperature to 80 –
100 deg. C and hold it at this temperature for one hour minimum.
The PWHT shall commence after completion of one hour of
soaking.
16h POST WELD HEAT TREATMENT :
I. A minimum of four thermocouples shall be placed such that at

least two are on the weld and the other twoon the base material
on either side of the weld within the heating band at 180 deg C
apart about 50 mm from the weld joint. One stand by thermocouple
shall also be provided on the weld in case of any failure of the
thermocouple. The width of the heated circumferential band on
either side of the weld must be al least 5 times the thickness of
the weld. In case of fillet joints the heating band shall be six
times the thickness of the base material. An insulation of about
10mm thickness shall be provided between the cables and the weld
joints.
II. Obtain the clearance for post weld heat treatment cycle from BHEL
QAE / welding engineer. The PWHT temp. for P-91 with P-91
material shall be 760 + 10 Deg. C and the soaking time shall be
2.5 minutes per mm of weld thickness, subject to a MINIMUM OF
TWO HOURS. All records shall be reviewed by BHEL welding
engineer prior to PWHT clearance. Heating shall be done by
Induction heating only. The rate of Heating / Cooling :
Thickness up to 50 mm 110 deg.

Centrigrades
Thickness up to 50 – 75 mm 75 deg.
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Centrigrades / hr. ( max )
Thickness more than 75 mm 55 deg.

Centrigrades / hr. ( max )
III. The width of the insulation beyond the heating band shall be at
least two times the heating band width on either side of the
weldment.
IV. The recording of time and temperature shall be continuously

monitored with a calibrated recorder right from pre-heating. This
shall be ensured at every one hour by a site authorized personnel.
16i PREVENTIVE MEASURES DURING POWER FAILURE AND NON-

FUNCTIONING OF EQUIPMENT :
No interruption is allowed during welding and PWHT. Hence all equipment

for the purpose of power supply, welding, heating etc. shall have
alternative arrangements, ( Diesel generator for providing power to the
welding and heating equipment, reserve thermocouple connections, gas
burner arrangement for maintaining temperature etc. ). Following preventive
measures shall be adopted until normal power supply or backup power
supply through diesel generator is restored.
(a) During start of pre-heating :
Weld fit-up arrangement shall be immediately covered with

insulation along with complete circumference of the pipe and
maintained at the temperature 80 to 100 deg. C until the power
resumes. The temperature shall not be allowed to fall below 80
deg. C. Gas burners shall be employed to maintain the temperature
till the power resumes. Preheating may be continued after power is
resumed / alternate arrangement is made.
11. During GTAW / SMAW
Use gas burner arrangement to maintain the temperature at 80 to

100 Deg C up to a length of 50 mm on either side from weld
center line along the complete circumference of the pipe. Root
welding shall be continued after power is restored and preheating
temperature is raised to 220 deg. C. During the above period
temperature shall be recoded through contact type theromometer.
(c) During cooling cycle after SMAW welding to the holding

temperature at 80 to 100 deg. C for one hour.
(d) During post weld heat treatment the following shall be followed
During heating cycle ---- The whole operation to be repeated from

the beginning.
During soaking cycle ----- Heat treat ( soak ) subsequently for the
entire duration.
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During cooling ( above 335 deg. C ) --- Reheat to soaking

temperature and cool at the required rate.
In all the cases mentioned above the temperature measurement on the
weld joint by means of contact type calibrated temp. gauges shall be
employed to record the temperature at regular interval of 15 minutes.
16j TEMPERATURE MONITORING
The welding and heat treatment chart shall be recorded for the
following details. The actual PWHT chart shall be monitored for the
following :
a) Pre-Heating
b) Interpass Temperature ( GTAW + SMAW )
c) Cooling and holding at 80-100 deg. C for minimum one hour.
Start PWHT after minimum one hour of soaking.
d) Heating to PWHT.
16k CAUTION
The PWHT temperature shall not deviate from the values specified in
the chart range since any deviations to the specified holding
temperature range, will adversely affect the mechanical properties of
the weldment and may lead to rejection of the weldment. The weld
joints should be kept dry. Under no circumstances any water / liquid is
allowed to come in contact with weld as well as pre-heated portion of
the pipe.
16l CALIBRATION
All equipment like recorder, thermocouple, compensating cable, oven,

thermostat etc. should have valid calibration carried at BHEL
approved labs. The calibrated reports should be reviewed and
accepted by calibration In-charge at site prior to use.
16m NON DESTRUCTIVE EXAMINATION
I. Non destructive examination shall be done after PWHT. Prior to

testing all welds shall be smoothly ground.
II. All welds ( Butt and Fillet ) shall be subjected to MPI. In addition
to MPI, butt-welds and all full penetration welds shall be examined
by UT.
III. LPI penetrant material ( Dye penetrant, Solvent cleaner & developer )
and medium ( dry / wet particles ) used in MPI shall be of BHEL
approved brands only.
IV. For Ultrasonic Testing calibration blocks used shall be of the same
material specification, dia and thickness.
V. The UT equipment shall be calibrated prior to use and should be
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of digital type -- Krautkramer model USN 50 or equivalent , capable

of storing calibration data as well as ultrasonic results.
VI. All recordable indications will be stored in memory of digital flaw

detector and PC for review at a later period.
VII. The equipment calibration data for specific weld as well as the hard
copy of ‘Static echo-trace pattern’ - showing the flow echo
amplitude with respect to DAC, flaw depth, projection surface,
distance and beam – path shall be attached to UT test report. This
hard copy of echo-trace with equipment calibration data will form
part of test documentation.
VIII. The examination as well as evaluation shall be performed by a

qualified Level – II personnel and a test report shall be submitted.
Any defect noticed during NDE shall be marked with a marker.
16n REPAIR OF WELD JOINTS
(a) WELD REPAIR AT ROOT

On visual examination during root welding if it reveals any
surface defects, the same shall be removed by grinding
maintaining temperature 80 – 100 deg. C and rewelded with
GTAW maintaining 220 deg. C before starting SMAW.
(b) WELD REPAIR ON COMPLETION

Any defect observed on the weld shall be brought to the notice
of Quality Assurance Engineer. The size and nature of the
defect shall be reviewed. Any repair on weld to be carried out
on their approval. If some defects are noticed on fully
completed joint while performing UT after completion of PWHT,
the same may be assessed in order to find the seriousness of
the defect and to locate where exactly the defect lies from the
weld outside the surface. The defect area shall be marked and
repaired as below:
1) The weld shall be removed by grinding ( gouging not

permitted ) such that the area for repair welding is free from
sharp corners and provided with sufficient slope towards the
weldface sides. Incase of cut and weld joints HAZ will have
to be removed by grinding.
2) Surface examination ( MPI/ LPI ) on the ground weld area to

be performed to ensure a sound base material before
depositing weld layers using SMAW.
3) The temperature of the weld is to be maintained at pre-

heat temperature.
4) Carry out SMAW using the same procedure as that of

welding.
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5) All the specified precautions with respect to welding

consumables, heating cycles, post weld heat treatment etc.
as followed for original welding shall be strictly adhered.
6) The NDE shall be conducted for the entire weld joint.
7) If any further defects are observed on the repaired weld,

the same may be further reworked as mentioned above.
16o HARDNESS SURVEY

The equipment recommended to measure the hardness are
EQUOTIP or MICRODUR make or equivalent portable equipment,
which is to be arranged by the bidder at their cost. The
equipment used for the hardness measurement shall be calibrated
as recommended by the manufacturer and also on a P-91
calibration block provided by BHEL. The surface shall be cleaned
and prepared as per hardness test instrument manufacturer’s
recommendation prior to hardness survey. Hardness survey shall be
done at each joint at three locations along the circumference. At
each location three ratings on weld and parent material shall be
carried out. All the hardness values shall be recorded. The maximum
allowable hardness at weld and parent metal shall be 300 HV10.
Joints having hardness above 300 HV shall be re-heat treated and
hardness shall be checked again. If hardness is still more, refer
the case to Unit.
16p COMBINATION WELDING

For the combination of material like P-22 with P-91 and X-22 with
P-91 the WPS as approved by WTC shall be given by PC for
adoption.
Material Temperature Soaking Time
P-91 + P-22 745 + 15 deg. C 2.5 Minutes / mm
( minimum 1 Hr. )
P-91 + X-22 750 + 10 deg. C 2.5 Minutes / mm
Minimum 2 hour for thickness
up to 50 mm and 4 hrs. for
thickness more than 50 mm.
Precautions as required for P-91 shall be fully taken care of.
16q SPECIFIC TRAINING FOR WELDERS

I. The qualified welders who will be engaged in P-91 welding shall
be given training on pipe joints simulated with P-91 welding and
heating cycle conditions.
II. The acquaintance on welding positions, as applicable shall be given

using P-91 pipes and P-91 welding consumables, Welding techniques
and instructions on Dos and DON’T’s of P-91 welding. Welders who
are qualified only on P-91 welding shall be engaged. Welders shall
have to undergo all the training all the training above. It may be
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required that the welders shall have to be tested and and qualified
at BHEL / WTC / TRICHY. Contractor shall arrange for the same and
entire expenditure towards this shall be borne by the Contractor.
16r CONTROL ON WELDERS
The welders during welding at site shall follow the correct
procedures. The welders shall interact with the HT operator (
Induction / Resistance equipment operator ) to ensure that preheat
and inter-pass temperature during welding are maintained as per
requirement. The welders shall not mix the welding electrodes with
that of the other welder. At the end of the shift, the unused
electrodes shall be returned to the stores.
16s PERSONNEL ENGAGED FOR HEATING CYCLE ( HT OPERATOR
)
Contractor shall deploy adequate no of heat treatment operator /
technicians and electricians exclusively in shifts, who shall have
adequate heat treatment experience on P-91 or similar material. HT
operator shall be aware of the followings :
1. The equipment used and its working principle.
2. The procedure to be followed in using heating equipment.
3. Procedures to be followed in case of power failure or

equipment non-functioning.
4. Calibration of equipment
5. Method of fixing the thermocouples and compensating

cablesleading to HT recorder.
6. Fixing of heating pads or elements on the pipe joints and

also in maintaining the temperature within the specified
limits.
16t NDE PERSONNEL QUALIFICATIONS
All the Non-Destructive Examinations shall have to be performed by
Qualified NDE personnel only. Ultrasonic Testing , Magnetic Particle
Inspection and Liquid Penetrant Inspection shall be carried out by
ASNT / ISNT Level – II qualified personnel only.
16u SUPERVISION
Contractor shall deploy exclusive Engineer and Supervisor who will
be responsible for the completion of all activities from weld fit-up
to final clearance of weld joints after satisfactory NDE and
acceptance by BHEL / Customer / IBR.
16v DO’S AND DON’T’SDURING P-91 WELDING, HEAT TREATMENT

AND NDE AT CONSTRUCTION SITE.
DO’S :
1. Cutting by Band saw / Hack saw / Machining / Plasma cutting.
2. Pipe edge preparation by machining. Machining shall be done
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without excessive pressure to prevent heating up of pipe.
3. Grinding may be done on exceptional cases taking adequate

care to prevent overheating.
4. Thermocouple wire ( hot / cold junctions ) shall be welded with

condenser discharge portable spot-welding equipment.
5. Reserve thermocouples shall be made available, in case of failure

of connected thermocouple elements.
6. Ensure adequate Argon gas for complete purging of air inside

the pipe before starting GTAW root welding.
7. Ensure preheating at 220 deg. C minimum before GTAW root

welding.
8. Start preheating only after clearance from welding engineer /

Quality assurance engineer for weld fit-up and alignment of the
joint as well as fixing of Thermocouples ( for Induction heating ).
9. Do visual inspection on root weld maintaining weld preheat

temperature.
10. Continue Argon purging until the GTAW root welding followed by
minimum two filler passes of SMAW is complete.
11. Perform partial root welding to facilitate fit-up, if necessary.
12. Ensure that only one layer of root welding using TGS 2CM filler
wire is deposited wherever necessary.
13. Ensure proper use of TIG wires as identified by colour coding

or suitable hard punching.
14. Keep the GTAW wires in absolutely clean condition and free
from oil , rust etc.
15. Dry the SMAW electrodes before use.
16. Ensure inter-pass temperature is less that 350 deg. C.
17. Hold at 80-100 deg. C for a period of minimum 1 Hr. before

start of PWHT.
18. Record entire heating cycle on chart through recorders.
19. Exercise control during grinding of weld and adjoining base

metal while removing surface surface / sub-surface defects or
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during preparation of NDE.
20. Ensure no contact with moisture during preheat, welding , post

heat and PWHT of weld joints.
21. Ensure removal of Argon purging arrangements after welding.
22. Use short Arc only. The maximum weaving shall be limited to
1.5 times the dia of the electrode.
23. Obtain WPS from equipment / piping supplier ( combination

welding ) for welding of Pipe with equipment.
DON’T’S
1. Avoid Oxy-Acetylene flame cutting.
2. Avoid weld-build up to correct the weld end or to set right the lip
of the weld bevel.
3. Avoid Arc strike on materials at the time of weld fit-up during

welding.
4. Do not tack weld the thermocouple wires with manual ARC / TIG
welding.
5. No GTAW root welding without thorough purging of root area.
6. Do not use Oxy-Acetylene flame heating for any heating

requirement.
7. Do not use thermal chalks on the weld groove.
8. Do not stop Argon purging till completion of GTAW root welding

and two layers of SMAW.
9. No tack welding or Bridge piece welding is permitted.
10. Do not use unidentified TIG wires or electrodes.
11. Do not exceed the maximum inter-pass temperature indicated in WPS.
12. Do not allow moisture, rain, water, cold wind, cold draft etc. to come
in contact with the weld zone during the entire cycle from preheat to
PWHT.
13. Do not exceed the limits of PWHT soaking temperature.
14. Do not interrupt the welding / heating cycle except for unavoidable
power failures.
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15. Do not use uncalibrated equipment for temperature measurement during

heating, welding, post-weld heat treatment etc.
16w FACILITY TO BE PROVIDED BY BHEL FOR P-91 WELDING,
FREE OF CHARGES:
1. Required No. of Induction Heating Machines with
accessories.
2. The following consumables :
(i) Annealing Cables
(ii) Compensating Cables
3. Welding electrodes for P-91 welding.
4. Digital Temperature indicator.
The Induction heating equipment shall be drawn from BHEL stores,
transported, installed and commissioned wherever required at site. For
routine and breakdown maintenance, Contractor shall have to deploy
sufficient Manpower, Tools & Plants within his quoted rate.
The contractor shall provide electrical cables and switches required. All the
equipment shall be protected by providing covers or sheds at site by the
contractor within the quoted rate. Any loss / damage of equipment / tools
by the contractor shall be recovered from the contractor.
16x FACILITY TO BE PROVIDED BY THE CONTRACTOR FOR P-91
WELDING
1. Required numbers of operators / technicians / electricians for
installation, commissioning and operation continuously.
2. Gas burner arrangement with required gas for maintaining

temperature in the event of power failure.
3. Ultrasonic flaw detector with recording Device & Complete

accessories ( Digital Type - Krautkramer model
USN 50 or equivalent ) capable of storing calibration data. All
recordable indications will be stored in the memory of the
digital flaw detector and in PC ( to be arranged by contractor
within his quoted rate ) for review at a later period.
4. Spot welding Machine for fixing Thermo-couples.

5. EQUOTIP or MICRODUR make or equivalent portable
hardness tester.
6. MPI & LPI kit with required consumables.
7. DG Power supply within 500 mtrs. From Boiler (Only for
power failure during welding) including necessary cables and
switches etc.
8. Consumables :
(i) Glass Fibre Cloth - 1 mm x 1000 mm - Temperature
rating 1260 deg. C.
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12. Glass Fibre cord - Dia 3 mm ( Twisted ) - Temperature rating -

1260 deg. C.
13. Ceramic Fibre Blanket - RT Grade, Density 96 KG / Cub. M -

Temperature rating - 1260 deg. C.
(iv) Ceramic Fibre rope - Fibre glass braided, dia 12mm -

Temperature rating 1260 deg. C.
(v) K- Type Thermocouple - 0.5 mm Dia single strand

individual fibre glass insulated.
(vi) Heavy duty TC connectors for K- Type Thermocouples

– Size 0.5 mm dia single strand individual fibre galss
insulated.
(vii) All other consumables / equipment required to carry

out the work.
16y TECHNICALLY APPROVED BRANDS BY BHEL / HPBP / TRICHY.

Liquid penetrant , penetrant remover ( solvent cleaner) and Aerosol
Developer from the same manufacturer considered as a family
group.
VENDOR PENETRANT BRAND
PENETRANT DEVELOPER
REMOVER
ITW SIGNODE (I) LTD. STOPCHECK STOP CHECK STOP CHECK

SKL – SP SKC – 1 SKD – S2
P – MET CO. FLAW CHECK FLAW CHECK FLAW CHECK

I) PP – 15 I) PP- 21
I) PP - 31A
II) PP – 110 II) PP – 120
II) PP – 131A
CHECKMATE CHEM. CHECKMATE CHECKMATE

CHECKMATE
PVT. LTD. SUPER SUPER
SUPER
PT – 97 CL – 96 DV –
98
PRADEEP METAL FLAW GUIDE FLAW GUIDE

FLAW GUIDE
TREATMENT GP GP
GP
FERRO CHEM CRACK CHECK CRACK CHECK CRACK CHECK

FC – 911 FC – 911
Page 59 of 65
CONTRACT
FC – 911
DRY MAGNETIC POWDER :
1. MAGNAFLUX - PRODUCT GREY , 8A -- RED
2. FERROCHEM PRODUCT NO. 256
3. K – ELECTRONICS PRODUCT -- RD -- 200 ( SPECIAL )
NON – FLOROSCENT MAGNETIC INK

( PREPARE BATH AS INSTRUCTED BY SUPPLIER )
1. MAGNAFLUX -- PRODUCT 9C RED WITH MX/MG

CARRIER II OIL VEHICLE.
2. FERROCHEM -- PRODUCT NO. 146A WITH OIL

VEHICLE ( WITH HIGH FLASH POINT 92
DEG. C. )
3. SARDA MAGNA CHECK INK WITH OIL VEHICLE ( WITH HIGH

FLASH POINT 92 DEG. C )
FLUOROSCENT MAGNETIC INK

( PREPARE BATH AS INSTRUCTED BY SUPPLIER )
1. MAGNA FLUX -- PRODUCT 14 A WITH MX/MG CARRIER II OIL

VEHICLE.
2. MAGNA FLUX -- PRODUCT 14 AM - PREPARED BATH OF 14

A
AND MG / MX CARRIER-II READY TO
USE WITHOUT MEASURING AND MIXING
IN AEROSOL CONTAINER WITH MX/MG
CARRIER-II OILL VEHICLE.
Page 60 of 65
CONTRACT
ANNEXURE-C
LIST OF T&P TO BE PROVIDED BY CONTRACTOR
Contractors may please note that this list is not exhaustive & given for guidance purpose.
The contractor may be required to deploy additional T&Ps not mentioned in this list at their
own cost for proper execution of the job.
01 a) 75 T Crwler Crane 1 no.
b) 40T / 25 T Mobile crane 1 no
c) 18T Mobile Crane 1 no.
02 Crane 12 T Hydra 2 no
03 Passenger cum goods elevator (within 4 months of LOI) 1 no
04 Tractor-trailor 30T (with long bed) 1 no
05 Tractor-trailor 12T/15T (with long bed) 2 no
06 Truck 10T 1 no
07 Wheel barrows 1 no
08 Electrical winch 8T 2 no
12 Chain pulley block 10T As per
13 Chain pulley block 5T, 3T, 2T requirement
14 Pull lift 6T, 5T, 3T, 1.5T
15 Multipurpose pulling and lifting m/c 5T, 3T, 1.6T
16 Hydraulic jack 100T, 50T, 20T, 10T, 5T
17 Single sheave snatch pulley 10T, 5T
18 Double sheave snatch pulley 10T, 5T
19 D shackles 10T, 20T, 50T
20 Turn buckles 3T, 5T, 8T, 10T, 15T, 20T
21 Welding generator K320
22 Oil cooled welding transformer 300 amp, 450 amp
23 Air cooled welding transformer 300 amp
24 Stress relieving transformer 600 amp
25 TIG welding torch air cooled
26 Tig welding torch water cooled
27 High frequency unit
28 Oxygen regulator
29 Acetylene regulator
30 Cutogen 5
31 Oxygen hose 10 mm
32 Acetylene hose 10 mm
33 Electrode drying oven
34 Portable electrode drying cabinet
35 Copper welding cable 600 amp, 400 amp
36 Aluminium cable 600 amp, 400 amp
37 Temperature recorder
38 Thermochalk 100 deg C to 800 deg C
39 Air compressor 250 cfm, 80 cfm
40 Stationery compressor 350 cfm
Filling pump 80 M head, 15 ltr/sec (at least one month prior to Hydraulic
41
test)
42 Electrode baking oven
43 Vernier theodolite - 1 sec accuracy
44 Dumpy level
45 Spirit level 12 inch, 0.1 mm accuracy As required
Page 61 of 65
CONTRACT
46 Combination squares
47 Micrometers of different sizes
48 Vernier callipers of different size
49 Dial guage
50 Flood light with bulb
51 Step down transformer
52 Drilling m/c of different sizes
53 Megger
54 Tong tester
55 Grinding m/c of different sizes
56 Chamfering m/c of different sizes
57 Trip torque wrench
58 Aluminium telescopic ladder
59 Manila ropes of different sizes
60 Steel wire ropes of different sizes
61 Drawing board
62 Radiography equipment
63 Moving platform
64 Magnetic particle test equipment
65 Ultrasonic flaw detector
66 Dye Penetrant test kit
67 Sheet grooving m/c for outer sheet casing
68 Sheet bending m/c for outer sheet casing
Recordable ultrasonic test equipment (UFD Krauft Kammer make 1 Set.
69
USN-50 or higher version to meet the requirements )
70 Radiography arrangement including source- IR 192 1 Set.
Mechanized hydraulic pipe bending machine with die of various 1 Set.
71
sizes
72 Gas burner arrangement 1 Set.
73 Hardness tester 1 Set.
74 Spot welding machine 1 Set.
NOTE:-
1. In case the bidder fails to mobilize the above T&P as per requirement and the work
progress/safety is affected for non-mobilization of any required T&P, gadgets,
equipment, system; BHEL shall inform the bidder writing that BHEL shall provide
the required items and recover the actual cost of providing such item / system plus
BHEL’s overhead as per rule.
2. The Make of these items has to be approved either by BHEL or by NTPC. The
same has to be tested/calibrated/certified by statutory authorities as the case may
be.
Page 62 of 65
CONTRACT
ANNEXURE - D
LIST OF T&P TO BE MADE AVAILABLE ON SHARING BASIS BY
BHEL FREE OF ANY CHARGES
Sl no Item Capacity Quantity
250 MT or higher
1 Crawler crane 1 no
capacity
2 Crawler Crane MID-RANGE 1 no
GENERAL 1 no
Crawler Crane PURPOSE
(100T OR EQV.)
2 Crawler crane 75 T capacity 1 no
3 Drum lifting winch 10 T 2 no
4 10 Sheave pulley block As Reqd. 2 set
Induction Heating Equipment along with
accessories with High Frequency cable
As required 4 SETS
between equipment to capacitor Panel
with Annealing Cable.
5 EOT crane in TG hall (if required) As installed 1 No.
6 Hydro test pump 0-450 kg/sqcm 1 no
7 Chemical circulating pumps As required As required
8 Air Blower As required 1 no.
9 Huck Bolting Machine As required 1 no.
Note:-
The above T&Ps will be made available for the project. Contractor may make
01
use of the T&Ps as per the provision of tender document.
All other T&Ps required for proper execution of the job shall be provided by the
02
contractor.
All the T&P listed above shall be issued and used as per relevant clause in the
03
contract.
___________
Page 63 of 65
CONTRACT
ANNEXURE-E
APPROXIMATE NUMBER OF ERECTION WELD JOINTS FOR
PRESSURE PARTS
A. Circulation System
Sl
no Size Material Specification Quantitiy
1 D457.2 x 40.0 SA106 Gr.C + SA106 Gr.C 50

2 D406.4 x 40.0 SA106 Gr.C + SA106 Gr.C 8
3 D406.4 x 55.0 SA106 Gr.C + SA106 Gr.C 4
4 D63.5 x 5.6 SA210Gr.C + SA210 Gr.C 3500
5 D76.1 x 7.1 SA210Gr.C + SA210 Gr.C 350
6 D127.0 x 12.5 SA106 Gr.C + SA106 Gr.C 460
7 D127.0 x 20.0 SA106 Gr.C + SA234 WPC 20
B. SH System
1 D127.0 x 12.5 SA106 Gr.C + SA106 Gr.C 100
2 D51.0 x 5.0 SA213 T11 + SA213 T11 400
3 D323.9 x 40.0 SA106 Gr.B + SA106 Gr.B 2
4 D44.5 x 4.5 SA210 Gr.C + SA210 Gr.C 1450
5 D273.0 x 40.0 SA106 Gr.C + SA106 Gr.C 4
6 D127.0 x 20.0 SA106 Gr.C + SA234 WPC 2
7 D47.63 x 5.0 SA210 Gr.C + SA210 Gr.C 1100
8 D47.63 x 5.0 SA210 Gr.C + SA213 T11 550
9 D47.63 x 5.0 SA213 T11 + SA213 T11 1100
10 D368.0 x 40.0 SA335 P12 + SA335 P12 14
11 D47.63 x 8.0 SA213 T11 + SA213 T22 30
12 D47.63 x 6.0 SA213 T11 + SA213 T11 210
13 D47.63 x 8.0 SA213 T22 + SA213 T22 240
14 D406.4 x 65.0 SA335 P12 + SA335 P12 4
15 D406.4 x 50.0 SA335 P12 + SA335 P12 4
16 D47.63 x 8.0 SA213 T22 + SA213 T22 380
17 D47.63 x 10.0 SA213 T22 + SA213 T22 380
18 D44.5 x 4.0 SA210 Gr.C + SA210 Gr.C 10
19 D44.5 x 4.0 SA210 Gr.C + SA213 T11 4
20 D44.5 x 5.0 SA213 T11 + SA213 T11 20
21 D51.0 x 5.6 SA213 T11 + SA213 T11 2
22 D44.5 x 5.6 SA213 T11 + SA213 T11 2
C. RH System
1 D63.5 x 4.0 SA213 T11 + SA213 T11 65
2 D47.63 x 8.6 SA213 T11 + SA213 T11 325
3 D54.0 x 4.0 SA213 T22 + SA213 T22 390
4 D47.63 x 6.0 SA213 T91 + SA213 T91 130
5 D57.0 x 5.0 SA213 T91 + SA213 T91 260
D. Eco System
1 D368.0 x 48.0 SA106 Gr.C + SA106 Gr.C 2
2 D368.0 x 32.0 SA106 Gr.C + SA106 Gr.C 1
3 D323.9 x 40.0 SA106 Gr.C + SA106 Gr.C 1
4 D38.1 x 4.0 SA210 Gr.A1 + SA210 Gr.A1 1480
5 D44.5 x 4.5 SA210 Gr.C + SA210 Gr.C 1480
6 D323.9 x 35.0 SA210 Gr.C + SA210 Gr.C 2
7 D273.0 x 32.0 SA210 Gr C + SA210 Gr C 14
E. Soot Blowing System
1 Nb 15 To Nb 65 SA106 Gr C + SA106 Gr C 1400
F. Boiler Integral Piping
Page 64 of 65
CONTRACT
1 Nb 15 To Nb 65 Mixture of Carbon steel and Alloy 2200

2 Nb 100 To Nb 200 Steel 100
3 Above Nb 200 20
Note
01. The HP butt joints shown are applicable for boiler pressure parts only.
02. The size & thickness indicated in the above schedule are preliminary and may
undergo change.
03. The above no of HP butt joints of boiler area are approximate and may vary to any
extent. No additional payment whatsoever will be considered by BHEL in this regard
for any variation in the no. of joints.
04. For calculating the equivalent joint, BHEL's standard formula, given in the welding
manual, issued by FQA/Madras, will be adopted. The said manual will be available in
the office of BHEL, PSER and bidder may take reference of this manual while
quoting. No compensation whatsoever in this regard will be admissible by BHEL in
future.
05. All applicable joints under Piping category shall be assumed/ considered by bidder
while quoting rates and quoted rate shall be inclusive of such. No additional payment
whatsoever will be considered by BHEL in this regard.
Page 65 of 65
BONGAIGOAN UNIT 1 TENTATIVE WEIGHT.
Weight in (KGs)
Workorder Estimate PGMA Description
0397-059-1-04126 133151 Upper Drum Without I
0397-060-1-04136 4056 Upper Drum Internals
0397-061-1-04146 13793 Upper Drum Sspn Id 6
0397-259-1-05137 13800 Inlet Front Lower Ww
0397-261-1-05147 13800 Inlet Rear Lower Ww
0397-262-1-05155 16800 Inlet Side Lower Ww
0397-070-1-05175 1300 Inlet Extended Side
0397-071-1-05227 2800 Waterwall Rear Hange
0397-072-1-05229 5300 Waterwall Rear Scree
0397-062-1-05231 3800 Outlet Front Upper W
0397-063-1-05251 6900 Outlet Side Upper Ww
0397-196-1-06400 15840 Unclassified Burner
0397-104-1-06631 45440 Front Upper Ww Pnl
0397-157-1-06634 31300 Front Intermediate W
0397-231-1-06637 22200 Waterwall Lower Fron
0397-184-1-06644 47800 Rear Intermediate Ww
0397-232-1-06647 22920 Rear Lower Ww Pnl
0397-107-1-06651 64675 Side Upper Ww Pnl
0397-220-1-06655 66425 Side Lower Ww Pnl
0397-064-1-06670 8400 Extended Side Ww Pnl
0397-147-1-07108 65000 Down Comer Piping Up
0397-263-1-07109 88000 Down Comer Piping Lo
0397-185-1-07215 21000 Relief Tubes From Si
0397-186-1-07216 21000 Relief Tubes From Re
0397-187-1-07218 6600 Relief Tubes From Fr
0397-144-1-07223 23000 Furnace Screen Tubes
0397-145-1-07225 9700 Furnace Rear Hanger
0397-146-1-07226 16500 Furnace Rear Arch Tu
0397-313-1-07231 1800 Lower Corner Transit

0397-314-1-07232 550 Upper Corner Transit
0397-065-1-07401 21900 Waterwall Suspension
0397-197-1-07410 8300 Downcomer Suspension
0397-221-1-07420 3600 Downcomer Guides
0397-222-1-07431 2250 Riser Tube Support
0397-148-1-07500 350 Misc Components - Pr
0397-102-1-07501 2200 Furnace Insert Tubes
0397-374-1-07601 800 Pressure Seals
0397-066-1-07700 900 Bulked Bps Items For
0397-067-1-07992 100 Imported Electrodes
0397-068-1-07993 450 Consumables & Erecti
0397-105-1-08101 54000 Furnace Upper Buckst
0397-106-1-08104 45000 Furnace Intermediate
0397-251-1-08107 31000 Furnace Lower Buckst
0397-223-1-08111 2500 Furnace Rear Arch Bu
0397-264-1-08380 35000 Furnace Bottom Suppo
0397-265-1-08400 7200 Furnace Guide
0397-260-1-08500 65800 Furnace Back Pass Bu
0397-149-1-08700 500 Ex.Movement Measurem
0397-103-1-08900 3000 Furnace Key Buckstay
0397-188-1-09001 6720 Seal Boxes For Furna
0397-431-1-09002 1280 Seal Boxes For Instr
0397-441-1-09003 200 Material For Instrum
0397-233-1-10135 7197 Horizontal Spaced Sh
0397-116-1-10174 11297 Vertical Spaced Sh C
0397-075-1-10178 7367 Vertical Platen Sh 1
0397-198-1-10182 3750 Sh Rear Wall Inlet H
0397-117-1-10183 5330 Sh Frontwall Inlet
0397-160-1-10184 620 Sh Extended Side Wal
0397-199-1-10185 3680 Sh Rear Roof Inlet H
0397-076-1-10191 2858 Sh Radiant Wall Roof
0397-118-1-10235 8690 Horizntl Spaced Sh O

0397-119-1-10274 15575 Vertical Spaced Sh C
0397-077-1-10278 7991 Vertical Platen Sh O
0397-161-1-10283 4940 Sh Frontwall Outlet
0397-163-1-10687 3175 Sh Radiant Wall Junc
0397-164-1-11236 274260 Sh Hor Spaced Upper
0397-165-1-11237 105000 Sh Hor Spaced Inter
0397-166-1-11274 86200 Sh Vertical Spaced C
0397-234-1-11278 92000 Vert Platen Centre S
0397-200-1-11616 11000 Sh Rear Upper Panels
0397-201-1-11618 4960 Sh Rear Lower Panels
0397-168-1-11685 62000 Sh Front Wall Panels
0397-169-1-11686 9500 Sh Roof Panels
0397-120-1-11687 7500 Sh Rear Roof Panels
0397-170-1-11688 11700 Sh Center Roof Panel
0397-171-1-11694 1930 S.H.Extended Bottom
0397-121-1-12174 8200 Vertical Spaced Sh I
0397-266-1-12184 2250 Roof Inlet Sh Pipes
0397-267-1-12187 1250 Sh Inlet Rear Roof P
0397-122-1-12535 38100 Sh Hor Spaced Hanger
0397-172-1-12803 1100 Sh Steam Cooled Spac
0397-108-1-12805 5100 Super Heater Hanger
0397-173-1-12850 5300 Sh Conn Pipes-Satura
0397-202-1-12852 11200 Sh Desh Links
0397-203-1-12900 2350 Sh Desh
0397-174-1-12903 58800 5h Miscl Components
0397-175-1-12906 4700 Sh Suprts For Lines
0397-080-1-12914 650 Suspension Of Sh Rad
0397-123-1-12917 4000 Suspension Of Radian

0397-124-1-12924 13300 Suspension Of Sh Bac
0397-073-1-12927 2400 Suspension Of Rear R
0397-176-1-12928 5000 Suspension Of Sh Rea
0397-125-1-12944 1710 Suspension Of Sh Pla
0397-126-1-12948 18350 Suspension Of Vertic
0397-127-1-12954 4300 Suspension Of Vertic
0397-128-1-12968 15500 Suspension Of Platen
0397-315-1-12994 40 Port Inst For Insitu
0397-081-1-15174 6000 Reheater Vert Spaced
0397-082-1-15274 18000 Reheater Vert Spaced
0397-177-1-16275 145500 Rh Vertical Spaced F
0397-129-1-16277 9500 Vert Rear Platen Rhc
0397-083-1-17919 7700 Rh Front Suspension
0397-084-1-17929 13450 Rh Rear Suspension
0397-130-1-17992 50 Rh Site Electrodes I
0397-316-1-18001 10480 Furnace Roof Skin Ca
0397-317-1-18010 2100 Pr Pts Attachmnts In
0397-178-1-18020 320 Vibration Snubbers
0397-204-1-19124 110080 Coils And Supports O
0397-269-1-19701 6050 Inlet Eco Headers
0397-131-1-19702 4810 Outlet Eco Headers
0397-205-1-19753 2890 Headers Of Rear In
0397-206-1-19763 2900 Headers Of Front In
0397-207-1-19783 2900 Headers Of Centre In
0397-132-1-19802 13890 Eco Hanger Tubes
0397-270-1-19850 2895 Eco Feed Pipe
0397-271-1-19851 10260 Eco Links To Drum
0397-133-1-19904 15160 Eco Suprts & Suspens
0397-208-1-19905 12400 Eco Suprts & Suspens
0397-235-1-19906 740 Eco Suprts For Lines

0397-501-1-20051 23381 Long Retractable Soo
0397-384-1-20054 557 Wall Box Non Pressur
0397-502-1-20201 9143 Wall Deslagger Rw5e
0397-503-1-20511 112 Da Head Valve Assy
0397-385-1-20794 63 Wall Box Non 7ressur
0397-443-1-20972 1554 Temp Probe Duplex Po
0397-320-1-20998 8 Special Tools For So
0397-391-1-28220 4850 Doors
0397-548-1-28700 650 Bps Fasteners
0397-278-1-31010 3450 Skin Casing Comps We
0397-332-1-31102 1000 Fornace Bottom Skin
0397-333-1-31104 5450 Furnace Rear Arch Sk
0397-334-1-31105 300 Second Pass Skin Cas
0397-335-1-32010 7125 Fixing Comp For Blr
0397-451-1-32120 1400 Fixing Comp For Sb P
A PR PARTS 2532150
0397-386-1-21600 6800 Soot Blower Piping A
0397-387-1-21601 5600 Sootblower Piping Su
0397-388-1-21700 800 Bulked Bps Component
0397-389-1-21800 1000 Sb Valves (Bhel)
0397-444-1-21825 1600 Sb Valves (Sub Deliv
0397-445-1-21850 25 Soot Blower Safety V
0397-272-1-24200 34200 Boiler Trim Piping A
0397-273-1-24201 10000 Supports For Trim Pi
0397-534-1-24215 2000 Spray Water System
0397-390-1-24220 14400 Safety Valve Esc Pip
0397-134-1-24225 13300 Silencer Support-Saf
0397-135-1-24235 2500 Slncr&Suprt-Starting

0397-321-1-24240 650 Sample Cooler And Su
0397-274-1-24260 17000 Valves (Bhel) Rh U
0397-322-1-24265 7100 Valves & Fittings (S
0397-323-1-24273 250 Direct Water Level G
0397-275-1-24275 1600 Headers For Trim Pip
0397-324-1-24280 3800 Erv And Safety Valve
0397-085-1-24285 34000 Safety Valve/Erv Sil
0397-325-1-24316 6800 Rh Desh
0397-326-1-24350 600 Boiler Filling Pipin
0397-327-1-24351 400 Hangers And Supports
0397-447-1-24950 20 Special Tools
0397-448-1-24955 100 Lapping Tools For Sv
0397-449-1-24960 50 Lapping Tools For Co
0397-450-1-24994 225 Name Plates
0397-344-1-41350 1100 Air Cooled Oil Gun A
0397-345-1-41390 1100 Oil Gun Vice Assy An
0397-346-1-41500 650 High Energy Arc Igni
0397-510-1-42001 300 Pneumatic Fittings
0397-458-1-42002 2000 Steam Blow Materials
0397-511-1-42005 350 Instrument Fittings
0397-286-1-42010 6150 Lfo Pump Set
0397-287-1-42020 7000 Hfo Pump Set
0397-288-1-42030 21000 Hfo Heater Set
0397-347-1-42046 300 Drain Oil Pump-Motor
0397-348-1-42065 6000 Drain Oil Tank
0397-488-1-42070 2000 Burner Station Skid
0397-459-1-42120 9600 Piping, Pump House-F
0397-460-1-42128 600 Piping,Pump House St
0397-349-1-42150 4700 Piping, Operating Fl

0397-350-1-42152 900 Piping,Opr'G Floor L
0397-351-1-42154 2500 Piping,Opr'G Floor D
0397-352-1-42157 1200 Piping,Opr'G Floor A
0397-353-1-42158 2500 Piping,Opr'G Floor S
0397-405-1-42200 3240 Subdelivery Fuel Oil
0397-406-1-42300 3000 Bhel Valve F.O. Syst
0397-407-1-42358 2200 Bhel Valve,Opr'G Flo
0397-461-1-42700 1300 Bps Fasteners
TRIM PIPING 244965
0397-392-1-30103 2700 Seal Plate Assy
0397-393-1-30105 5050 Furnace Bottom Enclo
0397-328-1-30211 1950 Furnace Rear Arch En
0397-329-1-30212 8200 Furnace Extd Side Bo
0397-394-1-30215 3850 Main Boiler
0397-330-1-30219 41050 Vertical Roof Enclos
0397-331-1-30220 24650 Deck Support And Sea
0397-452-1-32310 28400 Fixing Comp For Air
0397-453-1-32410 6300 Fixing Comp For Ah A
0397-505-1-32510 50300 Fixing Comp For Id D
0397-506-1-32710 2000 Fixing Comp For Oil
0397-454-1-33021 75100 Blr Pr Parts Mineral
0397-455-1-33121 8800 Blr Mountings Minera
0397-456-1-33126 2650 Sb Pipes Mineral Woo
0397-457-1-33201 500 Main Blr Formed Refr
0397-427-1-33210 100000 Main Blr Castable Re
0397-336-1-33230 140000 Main Blr Pourable In
0397-396-1-33321 98000 Air Ducts Mineral Wo
0397-397-1-33421 20000 Air Heater And Gas D
0397-507-1-33521 34000 Id Ducts Mineral Woo
0397-508-1-33721 3600 Oil System Mineral W
0397-535-1-33924 200 Misc Eqpts Asbestos

0397-398-1-33970 5000 Misc Eqpts Expanded
0397-337-1-33971 700 Misc Eqpts Woven Wir
0397-509-1-33975 200 Misc Eqpts Sealing C
0397-001-1-35010 12000 Foundation Materials
0397-009-1-35110 260000 Main Columns Left
0397-010-1-35120 280000 Main Columns Right
0397-011-1-35130 160000 Main Columns Middle
0397-012-1-35140 134200 Auxiliary Columns-Le
0397-013-1-35150 64000 Auxiliary Columns-Ri
0397-042-1-35190 6000 Girder Pin Connectio
0397-043-1-35210 340000 Boiler Ceiling Struc
0397-026-1-35310 21000 Horizontal Bracing I
0397-029-1-35340 15000 Horizondal Bracing I
0397-046-1-35350 17000 Horizondal Bracing V
0397-047-1-35360 15000 Horizondal Bracing V
0397-030-1-35380 44000 Landing Platforms
0397-086-1-35390 56000 Platform At Drum Flo
0397-014-1-35441 116000 Horizontal Beams-Low
0397-048-1-35443 85000 Horizontal Beams-Upp
0397-015-1-35511 19000 Front Bracing-Lower
0397-049-1-35513 16000 Front Bracing-Upper
0397-016-1-35521 34000 Side Bracing-Lower
0397-050-1-35523 50000 Side Bracing-Upper
0397-017-1-35531 35000 Rear Bracing-Lower
0397-051-1-35533 27000 Rear Bracing-Upper
0397-074-1-35610 53000 Boiler Roof Structur
0397-094-1-35611 19000 Boiler Roof Sheeting
0397-018-1-35700 9500 Hsfg Fasteners For P

0397-031-1-35811 110000 Floor Grills And Gua
0397-032-1-35820 18000 Stairs
0397-033-1-35851 24000 Hand Rails And Posts
0397-087-1-35993 17300 Consumablesanderecti
0397-088-1-36110 37000 Columns Near Air Pre
0397-089-1-36310 44000 Main Mbl Floor 11th
0397-090-1-36311 48200 Main Floor I Mbl 1st
0397-091-1-36320 55000 Main Floor 12th Leve
0397-092-1-36321 96650 Main Floor Ii Mbl Is
0397-093-1-36322 42500 Main Floor Ii Mbl 2n
0397-137-1-36331 23100 Main Floor Iii Mbl 1
0397-138-1-36332 22200 Main Floor Iii Mbl 2
0397-140-1-36341 69200 Main Floor Iv Mbl 1s
0397-180-1-36351 23300 Main Floor V Mbl Ist
0397-181-1-36352 8800 Main Floor V Mbl Ii
0397-183-1-36361 36400 Main Floor Vi Mbl 1s
0397-209-1-36391 24700 Miscellaneous Platfo
0397-158-1-36612 17700 Weather Protection F
0397-212-1-36740 32500 Posts And Hangers
0397-213-1-36811 89600 Floorgrillsandguardp
0397-214-1-36853 36100 Handrails And Posts
0397-338-1-37010 8400 Blr Outer Casing Com
0397-399-1-37810 41600 Blr Outer Casing

0397-237-1-38110 50900 Lift Columns
0397-339-1-38210 10250 Inter Conn Platforms
0397-490-1-38299 51300 Mill Handling Monora
0397-340-1-38310 550 Conn Platforms To Mi
0397-279-1-38410 79000 Mill Maintanance Pla
0397-238-1-38510 34300 Lift Beams And Braci
0397-400-1-38610 15000 Elevator Cladding St
0397-401-1-38611 15000 Elevator Cladding Sh
0397-402-1-38710 4000 Lift Machine Room De
0397-280-1-38810 66000 Floorgrills And Guar
0397-281-1-38850 16000 Hand Rails And Hand
0397-549-1-38993 2700 Consumables And Erec
0397-239-1-39101 25450 Columns Frames Befor
0397-240-1-39102 54150 Columns Frames Befor
0397-215-1-39140 169400 Cols Frames Near I.D
0397-216-1-39150 308300 Col Frames Betn I.D.
0397-282-1-39300 139700 Platforms - External
0397-403-1-39301 4300 Struc And Platform F
0397-404-1-39302 8250 Struc For Motor Hood
0397-341-1-39303 239100 Monorail Beams For F
0397-342-1-39304 27500 Fan Handling Structu
0397-343-1-39305 22000 Fan Handling Structu
0397-283-1-39810 44800 Floor Grill
0397-284-1-39820 7400 Stairs
0397-285-1-39850 14550 Hand Rail And Hand R
0397-159-1-39993 12350 Consumables And Erec
0397-408-1-43004 2800 Assy Comp Scanner &
0397-513-1-43005 4300 Assy Comp Mill Seal
0397-409-1-43104 16200 M/C Comp Scanner & G
0397-514-1-43105 17200 M/C Comp Mill Seal A
0397-462-1-43200 10000 Subdel,Ignitor&Scann

0397-217-1-45220 60000 Wind Box Assembly 22
0397-354-1-45221 5000 Wind Box Support 22-
0397-355-1-47221 31000 Fuel Piping Supports
0397-289-1-47223 24300 Pipe Couplings,Orifi
0397-290-1-47229 280000 St Pipes,Shop Bends
0397-241-1-48012 66850 Rect Duct Bet F.D F
0397-242-1-48014 7000 Expn Piecesbet F.D F
0397-243-1-48015 7600 Supportsetcbet F.D F
0397-291-1-48112 72520 Rect Ducts Pri Fan T
0397-292-1-48114 2850 Expn Piecespri Fan T
0397-293-1-48115 10300 Supportsetcpri Fan T
0397-294-1-48141 21800 Seal Air Hag And Id
0397-244-1-48142 34400 Rect Duct Coldairbu
0397-295-1-48144 700 Expn Piecescoldairbu
0397-296-1-48145 3700 Supportsetccoldairbu
0397-553-1-48200 3400 Instrument Tappings
0397-356-1-48202 54300 Rect Ductsairheater
0397-357-1-48204 12700 Expn Piecesairheater
0397-358-1-48205 5200 Supportsetcairheater
0397-359-1-48207 9000 Flowmeters For Secon
0397-297-1-48212 16850 Wind Box Connecting
0397-298-1-48214 3300 Expn Pieceswindbox C
0397-245-1-48222 71000 Rect Duct-Airheater
0397-247-1-48225 6600 Supports For Hot P.A
0397-360-1-48382 92500 Rect Duct Economise
0397-361-1-48384 10900 Expn Pieceseconomise
0397-362-1-48385 3300 Supportsetceconomise
0397-363-1-48432 49110 Rect Duct Airheater
0397-365-1-48435 5300 Supportsetcairheater

0397-366-1-48462 265100 Rect Duct Boiler Ou
0397-367-1-48464 21000 Expn Piecesboiler Ou
0397-368-1-48465 29400 Bof To Ep Ducting Su
0397-248-1-48482 176600 Rect Ducts-Elec Prpt
0397-249-1-48484 10000 Expn Pieceselec Prpt
0397-250-1-48485 1050 Supportsetcelec Prpt
0397-299-1-48492 782770 Rect Duct Ind Draft
0397-300-1-48494 4000 Expn Piecesind Draft
0397-301-1-48495 60000 I.D.System Duct Supp
0397-302-1-48662 63250 Rect Duct Hot Air B
0397-303-1-48664 2200 Expn Pieceshot Air B
0397-304-1-48665 9300 Supports For Hot Pa
0397-305-1-48667 12600 Venturi-Primary Air
0397-219-1-48993 3850 Erection Materials
0397-595-1-67204 3060 Raw Coal Gates Needl
0397-587-1-67272 5760 Coal Valve-36 Inch M
0397-579-1-67276 5940 Raw Coal Gate Chain
0397-596-1-67283 7440 Feeder Outlet Isolat
0397-463-1-67801 12000 Down Spout
0397-536-1-67802 15500 Bunker Emptying Chut
0397-464-1-67803 17400 Feed Pipe To Mill
57010 7030 GATE FAN OUTLET
57013 4180 DAMPERS BET FD FAN &
57033 8930 DAMPERS AH BY PASS SE
57110 8835 GUILLOTENE GATE PA FA
57113 3990 DAMPERS BETWEEN PAFAN
57133 5082.5 DAMPER PA FAN TO COLD
57141 9500 SEAL AIR HAG AND ID F
57143 2185 DAMPER COLD AIR BUS(T
57160 8170 COLD AIRGATE, AIRBUS
57203 9832.5 DAMP APH TO WINDBOX D

57209 2660 LINKAGES FOR DAMPERS
57223 3895 DAMP APH PRIMARY SIDE
57383 20900 DAMPER ECONOMISER TO
57423 24035 DAMPER CASCADE EVOP G
57460 20425 GUILLOTENE GATE EP IN
57466 23750 PLATFORMS AND LADDERS
57470 20425 EP OUTLET GATE
57480 27550 GUILLOTENE GATE EP OU
57490 27550 GUILLOTENE GATE ID FA
57491 1425 BLOWER WITH MOTOR
57497 950 KNIFE GATE VALVE
57577 9500 ELECT ACTUATOR FOR GA
57660 12350 GATE HOT AIR BUS TO M
57663 5605 DAMPER HOT AIR BUS TO
57988 19 DUCTS COMMISSIONING S
NON PR PARTS-TOTAL 8237874
0397-578-1-65736 38200 36 Inch Gravimetric
50510 4275 STEAM COIL A P H
50610 5225 SCAPH-HORIZONTAL TYPE
52000 399.95 SPECIAL TOOLS/CONTRA
52010 340100 LARG AH-ROTOR ASSY
52011 14820 LARG AH-ROTOR POST
52012 3600.5 LARG AH-ROTORPINRACK
52013 4370 LARG AH-ROTORSEALS
52030 38966.15 LARG AH-ROTORHOUSING
52041 37697.9 HOT END CONN PLATE
52042 57095 COLD END CONN PLATE
52054 370.5 LARG AH-AXIAL SEAL
52055 836 LARG AH-BY PASS SEAL
52100 3705 LARGE AH ROTOR DRIVE
52211 646 LARG AH-AIRSEAL PIPE
52212 66.5 LARG AH-OBSER. PORTS

52217 4.75 LARG AH-STOP.ALARMS
52220 9737.5 LARG AH-GENS DETAILS
52261 2793 LARG AH-GUIDE BEARNG
52262 4047 LARG AH-SUPRT BEARNG
52271 484.5 OIL PIPING GUIDE BRG
52272 522.5 OIL PIPING SUPRT BRG
52274 1054.5 LUB OIL CIRCULN UNIT
52301 570 WASH MANIFLD GAS INL
52302 541.5 WASH MANIFLD GAS OUT
52326 323 CLEANG EQPT GAS OUT
52329 1482 CLE EQPT DRIVE UNIT
52360 33.25 FIRE SENSING SYSTEM
52600 114 LARGE AH E,C&I COMPON
52988 285 LARG AH COMMG SPARE
52997 150689 APH-MANDATORY SPARE
55011 1615 FD FAN FOUNDATION MAT
55017 95 FD FAN C&I ITEMS
55031 1280.6 PA FAN FOUNDATION MAT
55037 95 PA FAN C&I ITEMS
55084 2850 INITIAL FILL LUBRICAN
55214 14535 1REAC FDFAN1600-2000
55334 23244.6 2 REACT PA FAN
55810 807.5 AXIAL FDFAN COUPLING
55830 855 AXL PAFAN COUPLING
55910 4275 AXL FDFAN ACCESSORY
55911 29271.4 AXIAL FDFAN SILENCER
55916 1615 ADDITIONAL FD ROTOR
55930 4180 AXL PAFAN ACCESSORY
55931 28766 PA FAN SILENCER
55936 4180 ADDITIONAL PA ROTOR
56000 475 TOOLS & FIXTURE/CONT
56021 4989.4 ID FAN FOUNDATION MAT

56027 95 ID FAN C&I ITEMS
56077 95 SEAL AIR FAN C&I ITEM
56161 807.5 BAC 1 SUC SA FAN
56173 5890 BAC 1 SUC IGNTR FAN
56228 118940 BAC 2 SUC ID FAN
56670 1187.5 IGNITR FAN MOTOR
56820 95 RADL IDFAN COUPLING
56870 47.5 SEAL AIR FAN COUPLING
56920 3800 RAD IDFAN ACCESSORY
56926 30875 ADDITIONAL ID ROTOR
56988 9.5 RADIAL FAN COMMG SPA
56997 4750 RADFAN-MANDTRY SPARE
ROTATING M/C -TOTA 1012776.5
77901 14250 ROLL/SLIDE SUPPORTS
77905 950 ESP-SUB-DELIVERY COMP
77906 17100 INSULATOR HOUSING AS
77908 36100 GAS DIST. ASSY
77909 5946.05 GD-RAPPING MECHANISM
77910 404.7 GD_DRIVE ARRANGEMENT
77911 13775 GAS SCREEN-EP
77913 7410.95 EMIT SYST SUSPENSION
77914 2707.5 SUPPORT INSULATORS
77915 10987.7 EMITTING ELECTRODES
77916 13775 EMIT ELECT RAPP MECH
77917 11875 DRIVE ARGT. FOR EMIT.
77919 60325 COL ELEC SUSPENSION
77920 509352 COLLECTING ELECTRODE
77921 42275 EMIT SYS FRAME-TOP
77922 62700 EMIT SYS FRAME BOTOM
77923 7068 INSPECTION DOORS
77924 44599.65 SHOCK BARS
77925 34200 COLL ELECT RAPP MECH

77926 2429.15 COLL ELEC RAPP DRIVE
77928 61750 ESP ROOF PANELS
77930 5320 ELECTRICAL SD COMPTS
77931 6650 GEARED MOTORS FOR RAP
77932 90725 EMIT SYS FRAME-MIDLE
77937 950 JUNCTION BOX & PUSH B
77942 85500 OUTER ROOF-EP
77943 23750 HOPPER RIDGES
77944 128250 HOPPER UPPER PART
77945 125400 HOP MLD&LOWER PART
77946 31350 INSULATOR SUPP PANEL
77947 55100 ROOF PANEL ASSY
77948 147250 CASING STRUCTURE
77949 347868.15 CASING SHELL/PANEL
77950 80750 INLET-OUTLET FUNNEL
77955 114000 PENT HOUSE FOR E P
77957 9500 SPLITTER&GUIDE VANES
77959 29450 CONTROL ROOM-INSERTS
77960 80750 CABLE-CABLE RACKS
77961 475 EP PERF TEST EQUIPT
77962 44650 EARTHING,CABLE TRAYS,
77963 950 ASH LEVEL INDICATOR
77964 42750 MISCELLANEOUS ITEMS
77965 76000 APP PLATFORM-HOPPER
77966 3800 WATER WASHING SYSTEM
77967 136800 MIN WOOL FOR ESP INSU
77968 128250 FIXING COMP. FOR ESP
77972 950 INTERLOCKS-EP
77973 3800 ELECTRICALLY OPERTD H
77974 950 OPACITY MONITOR & ACC
77978 950 BAPCON & ACCESSORIES
77980 12350 FOUNDATION MATLS FOR

77981 275500 SUPPOTING STRUCTURES
77988 475 COMMISSIONING SPARES
77990 950 HEATING ELEMENTS
77991 9500 PANEL TYPE HOPPER HEA
77992 17100 AUXILIARY CONTROL PAN
77993 1140 RAPPER CONTROL PANEL
77994 950 STATCON PANEL
77996 190 TOOLS & TACKLES
89610 66500 EP GALLERIES&STAIRS
89611 9500 ESP ROOF HANDRAILS
ESP-TOTAL 3157023.85
0397-465-1-80342 5100 Aux Steam To Scaph
0397-466-1-80343 1250 Aux Steam To Sootblo
0397-467-1-80344 40000 Aux.Steam To F.O.Pum ROTARY M/C-TOTAL
0397-597-1-80351 8100 Aux Steam To Unliste
0397-468-1-80355 5000 Steam Tracing Line O
0397-554-1-80364 1550 Cbd Tank Vent To Sys
0397-598-1-80365 50 Cbd Tank Vent/Sv Exh
0397-515-1-80366 7400 Ibd Tank Vent To Atm
0397-428-1-80368 2350 Scaph Drain Tank Ven
0397-516-1-80395 650 Aux Steam To Fo Atom
0397-547-1-80399 28000 Steam Blowing
0397-599-1-80418 100 Ecection Materials F
0397-517-1-80450 4900 Cbd And Emergency Dr
0397-518-1-80451 3050 Boiler Integral Pipi
0397-555-1-80453 2300 Lp Piping Drains-Sg
0397-556-1-80454 4950 Scaph Drains
0397-600-1-80455 2400 Drain From Ulisted E
0397-469-1-80460 25800 Sg Aux Cooling Water
0397-601-1-80471 9200 Boiler Wash Water To
0397-470-1-80480 5200 Fire Water-Other Are
0397-471-1-80600 400 Hp Dozing

0397-432-1-80604 27000 Acid Cleaning
0397-472-1-80612 3350 Service Air For Unit
0397-473-1-80616 8600 Inst Air For Unit
0397-474-1-80650 45000 Heavy Fuel Oil Main
0397-519-1-80901 6000 Sd Valves&Specialiti
0397-475-1-80905 19250 Bhel Valves-Boiler L
0397-476-1-80917 5600 Tg Valves(Pem Engine
0397-477-1-80918 5200 Quick Cl.Nrvs For Ex
0397-520-1-80921 22600 H&S For Boiler Light
0397-429-1-80926 4100 H&S For Temp Piping-
0397-430-1-80927 6000 H&S For Temp Piping-
0397-478-1-81003 2450 Cont Blow Down Expan
0397-479-1-81009 6550 Inter Blow Down Expa
0397-522-1-81010 2600 Clean Drain Flash Ta
0397-539-1-81041 3000 Impure Condens Tank
0397-602-1-81042 8100 Make Up Water Store
0397-491-1-81128 3000 H P Dosing System
0397-382-1-81161 15000 Bcw Heat Exchanger
0397-433-1-81318 5600 Fix Comp For Insuln
0397-489-1-81325 35300 Mineral Wool Mattres
0397-523-1-81341 600 Sealing Compound-Ext
0397-524-1-81350 21100 Aluminium Sheet-Exte
0397-603-1-81411 550 Direct Gauges For St
0397-604-1-81412 350 Direct Gauges For No
0397-605-1-81414 100 Local Control Eqpt-N
0397-606-1-81415 500 Test Thermowell
0397-566-1-81422 2900 Sensing Elements In
0397-575-1-81435 8500 Field Junction Boxes
0397-576-1-81436 80 Lv Cables
0397-442-1-81437 400 Supervisory Control

0397-410-1-95088 300 Fsss Flame Scanner
0397-411-1-95089 50 Fsss Local Gun Maint
0397-412-1-95091 33000 Fsss Field Interconn
0397-413-1-95092 30000 Fsss Control Cables
0397-480-1-95191 1000 Sadc Field Interconn
0397-580-1-95485 2400 Gravimetric Feeder R
0397-581-1-95487 20 Gravi.Feeder Electro
0397-582-1-95488 1000 Feeder Mounted C&I E
0397-607-1-95489 120 Coal Flow Moniter
0397-583-1-95495 16000 Gravimetric Feeder F
0397-414-1-96087 750 Field Interconnectin
0397-481-1-96186 9000 Soot Blower Motor Co
0397-482-1-96187 40000 Soot Blower Cables &
0397-483-1-96188 100 Furnace Temparature
0397-532-1-96189 20 Soot Blower Local Co
0397-550-1-96193 200 Miscellaneous Starte
0397-558-1-96387 10000 Apdrs Control Cable
0397-559-1-96388 1000 Apdrs Field Intercon
0397-560-1-96389 1 Apdrs Field Instrume
0397-484-1-96485 1500 Ac Power Distributio
0397-537-1-96487 2000 Ac,Dc System Cables
0397-485-1-96588 2500 Electrical Actuators
0397-369-1-97088 3000 Elctronic Level Indi
0397-370-1-97097 1000 Instrumentation Fiel
0397-493-1-97099 1500 Acs Field Inter Conn
0397-415-1-97195 600 Pressure & Vessel An
0397-416-1-97196 15 Electrodes & Gaskets
0397-533-1-97282 400 Flowmeters
0397-371-1-97284 750 Field Gauges
0397-372-1-97285 100 Field Switches
0397-584-1-97287 100 Inst & Acc In Steam,
0397-373-1-97297 100 Mtm Clamps And Pads

0397-383-1-97298 2500 Mtm Thermo Couples &
0397-417-1-97577 100 Erv Control Equipmen
0397-585-1-97584 3000 Acoustic Pyrometer S
0397-538-1-97585 14000 Acoustic Steam Leak
0397-486-1-97588 1000 Cables & Glands
0397-487-1-97591 100 Miscellaneous Items
0397-525-1-97592 2800 Pneumatic Tubings &
0397-551-1-97593 15000 Elevator & Accessori
0397-577-1-97596 3000 Closed Circuit Telev
0397-418-1-97599 4000 Pneumatic Actuator I
0397-419-1-97960 2 Face Cutter Tool Ewl
0397-609-1-99099 100 Misc Chain Pully Blo
0397-526-1-99100 27500 Fan Handling Equipme
0397-527-1-99300 9000 Cir.Pump,Feed Pump,H
0397-567-1-99400 6000 Airheater,Steamcoil
0397-552-1-99502 6500 Pre.Parts Handling E
0397-528-1-99512 5000 Furnace Cradle 2 Wal
0397-565-1-99600 1200 Fo System Handling E
0397-005-8-20988 7 Sdot Blower Commissi
0397-012-8-21987 1 Commg Spares For Sb
0397-013-8-21988 1 Commg Spares For Sub
0397-006-8-24987 1 Commg Spares For Saf
0397-010-8-24988 5 Commg Spares For Imp
0397-007-8-24989 25 Commg Spares For Con
0397-002-8-41988 10 Oil&Gas Burner Commi
0397-008-8-42988 20 Oil&Gas System Commi
0397-003-8-95088 25 Fsss Flame Scanner
0397-011-8-95988 25 Fuel Firing Control
0397-001-8-97088 6 Elctronic Level Indi
0397-004-8-97196 2 Electrodes & Gaskets
0397-009-8-97585 10 Acoustic Steam Leak

0397-010-S-21825 100 Sb Valves (Sub Deliv
0397-007-S-24260 5000 Valves (Bhel) Rh U
0397-008-S-24265 1000 Valves & Fittings (S
0397-009-S-24280 800 Erv And Safety Valve
0397-001-S-41997 2500 Oil and Gas burner m
0397-002-S-42997 600 Oil System-Mandatory
0397-003-S-45997 15000 Coal Burner-Mandator
0397-004-S-47997 6000 Coal piping mandator
0397-005-S-65997 900 Feeder Mandatory Spa
0397-006-S-67997 750 Feeder Isolation g
80342 5,100 AUX STEAM TO SCAPH

80343 1,250 AUX STEAM TO AH SOOT BLOWERS
80344 40,000 AUX STEAM TO FO SYSTEM TP
80351 8,100 AUX STEAM TO UNLISTED USERS ‐ SG SCOPE
80355 5,000 STEAM TRACING PIPING
80364 1,550 CBD TANK VENT TO SYSTEM
80365 50 CBD TANK VENT/SV EXHAUST TO ATMOSPHERE
80366 7,400 IBD TANK VENT TO ATMOSPHERE
80368 2,350 SCAPH DRAIN TANK VENT/SV EXHAUST TO ATM
80395 650 AUX STEAM TO FUEL OIL ATOMISING
80399 28,000 STEAM BLOWING PIPING ‐ TEMPORARY
80450 4,900 CBD AND EMERGENCY DRUM DRAIN
80451 3,050 BOILER INTEGRAL PIPING DRAINS
80453 2,300 LP PIPING DRAINS ‐ SG SCOPE
80454 4,950 SCAPH DRAINS
80455 2,400 DRAIN FROM UNLISTED EQPT/VESSEL‐SG SCOPE
80460 25,800 SG AUX COOLING WATER UNIT SYSTEM
80471 9,200 BOILER WATER WASH TO & FROM UNIT
80480 5,200 FIRE WATER‐OTHER AREAS
80600 400 HIGH PRESSURE DOSING PIPING
80604 27,000 ACID CLEANING PIPING ‐ TEMPORARY
80612 3,350 SERVICE AIR FOR INDIVIDUAL UNITS
80616 8,600 INSTRUMENT AIR FOR INDIVIDUAL UNIT
80650 45,000 FUEL OIL SUPPLY AND RETURN PIPING
80901 6,000 SUB DELIVERY VALVES FOR LIGHT UP
80905 19,250 BHEL VALVES FOR LIGHT UP
80917 5,600 BHEL VALVE ‐ ACID CLEANING ALKALI FLUS‐TEMP
80918 5,200 BHEL VALVES ‐ TEMP PIPING FOR SB
80921 22,600 H&S FOR LIGHT UP STEAM LINE
80922 21,200 H&S FOR LIGHT UP NON STEAM LINES
80926 4,100 H&S FOR TEMPORARY PIPING ACID & ALKALI
80927 6,000 H&S FOR TEMPORARY PIPING ‐ STEAM BLOWING
80992 100 IMPORTED ELECTRODES
81003 2,450 CONTINUOUS BLOW DOWN EXPANDER‐D1500 MM
81009 6,550 INTERMITTENT BLOW DOWN EXPANDER‐D2500 MM
81010 2,600 CLEAN DRAIN FLASH TANK ‐ DIA 1000 MM
81128 3,000 HIGH PRESSURE DOSING SYSTEM
81161 15,000 BCW HEAT EXCHANGER
81041 3,000 IMPURE CONDENSATE TANK
81042 8,100 MAKE UP WATER STORAGE TANK BELOW 300 CUM
81318 5,600 FIX COM FOR MISCELLANEOUS PPG INSULATION
81325 35,300 MINERAL WOOL MATTRESS
81341 600 SEALING COMPOUND FOR INSL
81350 21,100 ALUMINIUM CLADDING FOR INSULATION
80300 10,000 MS FROM SH TO BOILER STOP VALVE
80301 75,000 MS FROM BOILER STOP VALVE TO ESV

80303 12,500 MS HEADER TO AUX PRDS
80304 5,000 MS HEADER TO HPBP VALVE
80310 115,000 HRH FROM REHEATER TO INTERCEPTOR VALVE
80311 11,500 HRH FROM INTERCEPTOR VALVE TO TURBINE
80312 33,000 LPBP VALVE UPSTREAM & DOWNSTREAM
80320 55,000 CRH FROM TURBINE TO REHEATER
80321 6,000 HPBP VALVE TO CRH PIPING
80324 1,200 CRH HEADER TO AUX.PRDS
80340 2,000 AUX STEAM HEADER
80341 45,000 AUX STEAM HEADER INTERCONN BETWEEN UNITS
80373 5,000 AUX STEAM HEADER SV EXHAUST
80418 1,300 ERECTION MATERIALS FOR INSTRUMENTS
80431 2,500 SPRAY WATER TO AUX PRDS
80452 5,000 HP PIPING DRAINS ‐ SG SCOPE
80453 700 LP PIPING DRAINS ‐ SG SCOPE
80920 6,000 H&S HYDRO TEST
80923 120,000 H& FOR STEAM BLOWING
80901 9,100 SUB DELIVERY VALVES FOR LIGHT UP
80902 600 SUBDELIVERY VALVES FOR STEAM BLOWING
80993 500 MISC ERECTION MATERIALS
81318 9,000 FIX COM FOR MISCELLANEOUS PPG INSULATION
81415 400 TEST THERMOWELLS
81416 1,200 PERFORMANCE GUARANTEE TEST MATERIALS
80307 1,500 HP & LP BYPASS WARM UP
80322 4,500 CRH PIPING TO DEAERATING HEATER
80331 5,000 EXTRACTION STEAM TO LP HEATER‐2
80332 5,500 EXTRACTION STEAM TO LP HEATER‐3
80335 7,000 EXTRACTION STEAM TO DEAERATING HEATER
80336 4,000 EXTRACTION STEAM TO HP HEATER NO.1
80337 2,000 EXTRACTION STEAM TO HP HEATER‐2
80345 2,000 AUX STEAM TO DEAERATING HEATER
80349 850 AUX STEAM TO GLAND SEALS ‐ TG SCOPE
80420 12,000 BOILER FEED PUMP SUCTION
80421 10,000 BOILER FEED PUMP RECIRCULATION
80423 44,000 BOILER FEED PUMP TO HPH INCLUDING BYPASS
80424 30,000 BFD BETWEEN HTRS & GROUP PROTECTION VLV
80425 55,000 BFD FROM FINAL HPH TO SG TP
80430 1,900 SPRAY WATER TO HPBP
80432 2,000 SPRAY WATER TO BOILER DESH UPTO SG TP
2096246
BONGAIGOAN AUXILARY BOILER TENTATIVE WEIGHT
Weight in (KGs)
PGMA Estimate PGMA Description
0497-032-1-04114 21667 Upper Drum + Intl Id
0497-033-1-04144 437 Upper Drum Sspn Id 4
0497-034-1-04210 8700 Lower Drum + Intl Id

0497-051-1-06609 2307 Corner Ww Pnl
0497-052-1-06614 6437 'D'Pnl Ww Pnl
0497-053-1-06616 3686 Baffle Ww Pnl
0497-054-1-06657 4104 Side Boiler Ww Pnl
0497-063-1-07211 15336 Boiler Bank Tubes
0497-064-1-07214 1652 Boiler Side Wall Shi
0497-119-1-07601 2728 Pressure Seals
0497-029-1-07989 55 Tools For Tube Expan
0497-074-1-09001 282 Seal Boxes For Furna
0497-151-1-09002 112 Seal Boxes For Instr
0497-159-1-09003 286 Material For Instrum
0497-047-1-10170 439 Vertical Sh Inlet Hd

0497-049-1-10270 438 Vertical Sh Outlet
0497-055-1-11170 728 Sh Vertical Coil Ele
0497-066-1-12850 1784 Sh Conn Pipes-Satura

0497-075-1-12900 687 Sh Desh
0497-046-1-12901 315 Sh Hngr,Suprts,Guide

0497-091-1-19850 121 Eco Feed Pipe
0497-160-1-20301 300 Rotary Soot Blower E
0497-178-1-20621 10 Blowing Element For
0497-179-1-20671 10 Blowing Element For
0497-161-1-20801 300 Long Retractable Soo
0497-103-1-20804 10 Wall Box Assembly Fo
0497-105-1-20998 10 Special Tools For So
0497-134-1-21600 350 Soot Blower Piping A
0497-135-1-21601 600 Sootblower Piping Su
0497-137-1-21800 125 Sb Valves (Bhel)
0497-106-1-24350 700 Boiler Filling Pipin
0497-107-1-24351 300 Hangers And Supports
0497-088-1-24600 1000 Boiler Trim Piping A
0497-089-1-24601 700 Boiler Trim Piping S
0497-182-1-24620 1300 Safety Valve Esc Pip
0497-048-1-24625 1000 Silencer Support-Saf
0497-212-1-24640 350 Sample Cooler And Su
0497-121-1-24660 800 Valves (Bhel) Pack

0497-122-1-24665 150 Valves & Fittings (S
0497-225-1-24673 250 Direct Water Level G
0497-123-1-24675 200 Headers For Trim Pip
0497-124-1-24680 180 Erv And Safety Valve
0497-050-1-24685 1300 Safety Valve/Erv Sil
0497-108-1-24991 3 Imported Electrode F

0497-164-1-24994 60 Name Plates
0497-133-1-41200 2500 Sv-Burner Assy With
0497-112-1-41500 100 High Energy Arc Igni
0497-196-1-42001 5 Pneumatic Fittings
0497-167-1-42002 200 Steam Blow Materials
0497-197-1-42005 200 Instrument Fittings
0497-095-1-42010 600 Lfo Pump Set
0497-113-1-42152 500 Piping,Opr'G Floor L
0497-141-1-42200 200 Subdelivery Fuel Oil
0497-142-1-42300 25 Bhel Valve F.O. Syst
0497-168-1-42700 60 Bps Fasteners

0497-138-1-28220 1500 Doors
0497-139-1-30215 650 Main Boiler
0497-094-1-31010 400 Skin Casing Comps We
0497-132-1-31301 1650 Miscellaneous Casing

PR-PARTS-TOTAL 94837
0497-165-1-33021 6500 Blr Pr Parts Mineral
0497-166-1-33201 7800 Main Blr Formed Refr
0497-110-1-33212 55000 Main Blr Castable Re
0497-009-1-35110 17900 Main Columns Left
0497-010-1-35410 12600 Column Frames-Front
0497-011-1-35510 13400 Column Bracings-Fron
0497-027-1-35810 4000 Temporary Structure
0497-044-1-36310 8000 Main Mbl Floor 11th
0497-019-1-36820 1200 Stairs And Ladders
0497-035-1-36850 4000 Handrails And Hand R
0497-111-1-37010 550 Blr Outer Casing Com

0497-140-1-37810 1000 Blr Outer Casing
0497-079-1-48082 5800 Sqduct,Cold Air Fdfo
0497-080-1-48084 250 Exppcs,Cold Air Fdfa
0497-065-1-48085 1300 Supportsetccold Air
0497-213-1-48200 200 Instrument Tappings
0497-114-1-48207 700 Flowmeters For Secon
0497-147-1-48332 5500 Sqduct,Boiler-Chimne
0497-148-1-48334 600 Support,Boiler-Chimn

0497-149-1-48335 700 Supportsetcfluegas D
57083 1425 DAMPER COLD AIR FD FAN
57577 172.9 ELECT.ACTUATOR FOR DAMP.
87010 1900 CHIMNEY FDN MATLS
87100 23275 CHIMNEY SHELLS
87150 1900 CHIMNEY STAKES
87200 475 PAINTER TROLLEY
87300 3800 PLAT FORMS & LADDERS
87930 475 AVIATION LAMPS
87950 5225 CHIMNEY INSULATION
87960 2850 CHIMNEY INS.FIX.COMPONENT
0497-205-1-81300 800 Fix Comp For Mainste
0497-180-1-81325 2200 Mineral Wool Mattres
0497-206-1-81341 10 Sealing Compound-Ext
0497-207-1-81350 1500 Aluminium Sheet-Exte
0497-240-1-81411 200 Direct Gauges For St
0497-241-1-81412 100 Direct Gauges For No
0497-242-1-81414 400 Local Control Eqpt-N
81300 800 FIX COM FOR MAIN STEAM PPG INSL


NON PR PARTS-TOTAL 62857.9
56000 161.5 FANS TOOS &F IXTURE
56011 368.6 FD FAN FOUNDATION MATLS
56017 47.5 FD FANC&I ITEMS
56113 6122.75 BAC 1 SUC FD FAN
56610 1472.5 RADIAL FAN MOTOR
56810 47.5 RADIAL FAN COUPLING
56911 1253.05 FD FAN SILENCER
ROTATING M/C-TOTAL 9473.4
0497-115-1-80300 900 Ms From Superheater
0497-169-1-80345 2100 Aux.Steam For Oil Li
0497-198-1-80366 700 Ibd Tank Vent To Atm
0497-226-1-80417 500 Boiler Feed Discharg
0497-239-1-80418 100 Ecection Materials F
0497-199-1-80420 700 Boiler Feed Pump Suc
0497-214-1-80421 200 Boiler Feed Pump Rec
0497-215-1-80446 500 Deaerating Heater Ov
0497-200-1-80450 300 Cbd And Emergency Dr
0497-201-1-80451 400 Boiler Integral Pipi
0497-216-1-80453 200 Lp Piping Drains-Sg
0497-170-1-80460 600 Sg Aux Cooling Water
0497-211-1-80473 600 Dm Water System
0497-171-1-80600 100 Hp Dozing

0497-172-1-80601 100 Lp Dozing
0497-173-1-80612 200 Service Air For Unit
0497-174-1-80616 400 Inst Air For Unit
0497-175-1-80650 500 Heavy Fuel Oil Main

0497-202-1-80901 600 Sd Valves&Specialiti
0497-116-1-80904 900 Bhel Valves-Boiler H
0497-176-1-80905 5500 Bhel Valves-Boiler L
0497-117-1-80920 2600 H&S For Boiler Hydro
0497-183-1-81005 2300 Inter Blow Down Expa
0497-184-1-81026 23200 Tray Type Deaerator
0497-162-1-81034 2800 Platform&Stairs For
0497-150-1-81104 3500 Boiler Feed Pump
0497-185-1-81127 3000 Lp Dosing System
0497-186-1-81128 3000 H P Dosing System
0497-187-1-96191 10000 Lt / Valve & Damper

0497-210-1-97282 120 Flowmeters
0497-118-1-97284 200 Field Gauges
0497-208-1-97592 1000 Pneumatic Tubings &
0497-146-1-97599 500 Pneumatic Actuator I

80300 900 MS FROM SUPERHEATER TO BOILER STOP VALVE
80345 2,300 AUX STEAM TO DEAERATING HEATER
80366 800 IBD TANK VENT TO ATMOSPHERE
80417 500 BOILER FEED DISCHARGE PIPING
80418 200 ERECTION MATERIALS FOR INSTRUMENTS
80420 700 BOILER FEED PUMP SUCTION
80421 300 BOILER FEED PUMP RECIRCULATION
80446 600 DEAERATING HEATER OVER FLOW AND DRAIN
80450 400 CBD AND EMERGENCY DRUM DRAIN
80451 400 BOILER INTEGRAL PIPING DRAINS
80453 300 LP PIPING DRAINS - SG SCOPE
80460 600 SG AUX COOLING WATER UNIT SYSTEM
80473 600 DEMINERALISED WATER SYSTEM
80600 200 HIGH PRESSURE DOSING PIPING
80601 80 LOW PRESSURE DOSING PIPING
80612 300 SERVICE AIR FOR INDIVIDUAL UNITS
80616 400 INSTRUMENT AIR FOR INDIVIDUAL UNIT
80650 1,000 FUEL OIL SUPPLY AND RETURN PIPING
80901 700 SUB DELIVERY VALVES FOR LIGHT UP
80904 1,000 BHEL VALVES FOR HYDRO TEST
80905 5,500 BHEL VALVES FOR LIGHT UP
80920 2,000 H&S FOR HYDRO TEST
80922 1,100 H&S FOR LIGHT UP - NON STEAM LINES
81005 2,400 INTERMITTENT BLOW DOWN EXPANDER-D1500 MM
81026 24,000 TRAY TYPE DEAERATOR BELOW 100 cuM/HR
81034 2,800 PLATFORM & STAIRS FOR FEED TANK & DEARTR
81104 3,600 BOILER FEED PUMP
81127 3,000 LOW PRESSURE DOSING SYSTEM
81128 3,000 HIGH PRESSURE DOSING SYSTEM
PIPING-TOTAL 141540
BHEL PIPING CENTRE, CHENNAI - PROJECT: BONGAIGAON TPS - 3 x 250 MW-- CUSTOMER : NTPC
USTOMER NO : U2/0397, 0497, P1/ 0690, 0693 - ZERO DATE 05 FEBRUARY 2008 - UNIT -
LIST OF APPLICABLE PGMAs
Wt/Boiler Activ
sl no. PGMA Description (Kgs) IBR Activity ity Remarks edited by pkdas
area ibr
1 80342 AUX STEAM TO SCAPH 5,100 I LU SG Intgrl. blr
2 80343 AUX STEAM TO AH SOOT BLOWERS 1,250 I LU SG Intgrl. blr
3 80344 AUX STEAM TO FO SYSTEM TP 40,000 I LU SG Intgrl. C blr
4 80351 AUX STEAM TO UNLISTED USERS ‐ SG SCOPE 8,100 I SN SG Intgrl. blr
5 80355 STEAM TRACING PIPING 5,000 I LU SG Intgrl. C blr
6 80364 CBD TANK VENT TO SYSTEM 1,550 I SN SG Intgrl. blr N
7 80365 CBD TANK VENT/SV EXHAUST TO ATMOSPHERE 50 N SN SG Intgrl. blr
8 80366 IBD TANK VENT TO ATMOSPHERE 7,400 N LU SG Intgrl. blr
9 80368 SCAPH DRAIN TANK VENT/SV EXHAUST TO ATM 2,350 N LU SG Intgrl. blr
10 80395 AUX STEAM TO FUEL OIL ATOMISING 650 I LU SG Intgrl. blr
11 80399 STEAM BLOWING PIPING ‐ TEMPORARY 28,000 N SB SG Intgrl. C blr
13 80450 CBD AND EMERGENCY DRUM DRAIN 4,900 I LU SG Intgrl. blr up to1st vlv
14 80451 BOILER INTEGRAL PIPING DRAINS 3,050 I LU SG Intgrl. blr up to1st vlv
15 80453 LP PIPING DRAINS ‐ SG SCOPE 2,300 I LU SG Intgrl. blr N
16 80454 SCAPH DRAINS 4,950 N LU SG Intgrl. blr
17 80455 DRAIN FROM UNLISTED EQPT/VESSEL‐SG SCOPE 2,400 N LU SG Intgrl. blr
18 80460 SG AUX COOLING WATER UNIT SYSTEM 25,800 N LU SG Intgrl. blr
19 80471 BOILER WATER WASH TO & FROM UNIT 9,200 N LU SG Intgrl. blr
20 80480 FIRE WATER‐OTHER AREAS 5,200 N LU SG Intgrl. blr
21 80600 HIGH PRESSURE DOSING PIPING 400 N LU SG Intgrl. blr
22 80604 ACID CLEANING PIPING ‐ TEMPORARY 27,000 N LU SG Intgrl. C blr
23 80612 SERVICE AIR FOR INDIVIDUAL UNITS 3,350 N LU SG Intgrl. blr
24 80616 INSTRUMENT AIR FOR INDIVIDUAL UNIT 8,600 N LU SG Intgrl. blr
25 80650 FUEL OIL SUPPLY AND RETURN PIPING 45,000 N LU SG Intgrl. C blr
26 80901 SUB DELIVERY VALVES FOR LIGHT UP 6,000 N LU SG Intgrl. blr
27 80905 BHEL VALVES FOR LIGHT UP 19,250 N LU SG Intgrl. blr
28 80917 BHEL VALVE ‐ ACID CLEANING ALKALI FLUS‐TEMP 5,600 N LU SG Intgrl. C blr
29 80918 BHEL VALVES ‐ TEMP PIPING FOR SB 5,200 N SB SG Intgrl. C blr
30 80921 H&S FOR LIGHT UP STEAM LINE 22,600 N LU SG Intgrl. blr
31 80922 H&S FOR LIGHT UP NON STEAM LINES 21,200 N LU SG Intgrl. blr
32 80926 H&S FOR TEMPORARY PIPING ACID & ALKALI 4,100 N LU SG Intgrl. C blr
33 80927 H&S FOR TEMPORARY PIPING ‐ STEAM BLOWING 6,000 N SB SG Intgrl. C blr
34 80992 IMPORTED ELECTRODES 100 N HT SG Intgrl. blr
35 81003 CONTINUOUS BLOW DOWN EXPANDER‐D1500 MM 2,450 I LU SG Intgrl. blr N
36 81009 INTERMITTENT BLOW DOWN EXPANDER‐D2500 MM 6,550 N LU SG Intgrl. blr
37 81010 CLEAN DRAIN FLASH TANK ‐ DIA 1000 MM 2,600 N LU SG Intgrl. blr
38 81128 HIGH PRESSURE DOSING SYSTEM 3,000 N LU SG Intgrl. blr
39 81161 BCW HEAT EXCHANGER 15,000 N LU SG Intgrl. tg
40 81041 IMPURE CONDENSATE TANK 3,000 N SN LU SG Intgrl. C blr
41 81042 MAKE UP WATER STORAGE TANK BELOW 300 CUM 8,100 N SN LU SG Intgrl. blr
42 81318 FIX COM FOR MISCELLANEOUS PPG INSULATION 5,600 N SB SG Intgrl. insulation
43 81325 MINERAL WOOL MATTRESS 35,300 N LU SG Intgrl. insulation
44 81341 SEALING COMPOUND FOR INSL 600 N LU SG Intgrl. insulation
45 81350 ALUMINIUM CLADDING FOR INSULATION 21,100 N LU SG Intgrl. insulation
Total SG Integral Piping 434,950
1 80300 MS FROM SH TO BOILER STOP VALVE 10,000 I HT PCP blr

2 80301 MS FROM BOILER STOP VALVE TO ESV 75,000 I SB PCP blr
3 80303 MS HEADER TO AUX PRDS 12,500 I SB PCP blr
4 80304 MS HEADER TO HPBP VALVE 5,000 I SB PCP blr
5 80310 HRH FROM REHEATER TO INTERCEPTOR VALVE 115,000 I SB PCP blr
6 80311 HRH FROM INTERCEPTOR VALVE TO TURBINE 11,500 I SB PCP blr
7 80312 LPBP VALVE UPSTREAM & DOWNSTREAM 33,000 I SB PCP blr
8 80320 CRH FROM TURBINE TO REHEATER 55,000 I SB PCP blr
9 80321 HPBP VALVE TO CRH PIPING 6,000 I SB PCP blr
10 80324 CRH HEADER TO AUX.PRDS 1,200 I SB PCP blr
11 80340 AUX STEAM HEADER 2,000 I LU PCP blr
12 80341 AUX STEAM HEADER INTERCONN BETWEEN UNITS 45,000 I LU PCP C blr
13 80373 AUX STEAM HEADER SV EXHAUST 5,000 N LU PCP blr
14 80418 ERECTION MATERIALS FOR INSTRUMENTS 1,300 N LU PCP blr
15 80431 SPRAY WATER TO AUX PRDS 2,500 I SN PCP blr
16 80452 HP PIPING DRAINS ‐ SG SCOPE 5,000 I LU PCP blr up to 1st vlv
17 80453 LP PIPING DRAINS ‐ SG SCOPE 700 I LU PCP blr up to 1st vlv
18 80920 H&S HYDRO TEST 6,000 HT PCP blr
19 80921 H&S FOR LIGHT UP STEAM LINE 9,000 N LU PCP blr
20 80923 H& FOR STEAM BLOWING 120,000 N LU PCP blr
21 80901 SUB DELIVERY VALVES FOR LIGHT UP 9,100 N LU PCP blr
22 80902 SUBDELIVERY VALVES FOR STEAM BLOWING 600 N SB PCP blr
23 80992 IMPORTED ELECTRODES 500 N HT PCP blr
24 80993 MISC ERECTION MATERIALS 500 N HT PCP blr
25 81318 FIX COM FOR MISCELLANEOUS PPG INSULATION 9,000 N SB PCP insulation
26 81325 MINERAL WOOL MATTRESS 160,000 N LU PCP insulation
27 81341 SEALING COMPOUND FOR INSL 500 N LU PCP insulation
28 81350 ALUMINIUM CLADDING FOR INSULATION 25,000 N LU PCP insulation
31 81415 TEST THERMOWELLS 400 N LU PCP blr
32 81416 PERFORMANCE GUARANTEE TEST MATERIALS 1,200 N SN PCP blr
Total PC Piping 727,500
1 80307 HP & LP BYPASS WARM UP 1,500 I SN SB TG&LP blr

2 80322 CRH PIPING TO DEAERATING HEATER 4,500 I SN SB TG&LP blr
3 80331 EXTRACTION STEAM TO LP HEATER‐2 5,000 I SN TG&LP blr N
4 80332 EXTRACTION STEAM TO LP HEATER‐3 5,500 I SN TG&LP blr N
5 80335 EXTRACTION STEAM TO DEAERATING HEATER 7,000 I SN SB TG&LP blr N
6 80336 EXTRACTION STEAM TO HP HEATER NO.1 4,000 I SN TG&LP blr N
7 80337 EXTRACTION STEAM TO HP HEATER‐2 2,000 I SN SB TG&LP blr up to 1st vlv
8 80345 AUX STEAM TO DEAERATING HEATER 2,000 I LU TG&LP blr
9 80349 AUX STEAM TO GLAND SEALS ‐ TG SCOPE 850 I SN SB TG&LP blr
22 80420 BOILER FEED PUMP SUCTION 12,000 N LU TG&LP blr
23 80421 BOILER FEED PUMP RECIRCULATION 10,000 I LU TG&LP blr
24 80423 BOILER FEED PUMP TO HPH INCLUDING BYPASS 44,000 I LU TG&LP blr
25 80424 BFD BETWEEN HTRS & GROUP PROTECTION VLV 30,000 I LU TG&LP blr
26 80425 BFD FROM FINAL HPH TO SG TP 55,000 I LU TG&LP blr
27 80430 SPRAY WATER TO HPBP 1,900 I SN LU TG&LP blr
28 80432 SPRAY WATER TO BOILER DESH UPTO SG TP 2,000 I SN LU TG&LP blr
Total TG &LP Piping
187,250
1 80300 MS FROM SUPERHEATER TO BOILER STOP VALVE 900 I HT Aux Blr blr
2 80345 AUX STEAM TO DEAERATING HEATER 2,300 I LU Aux Blr blr
3 80366 IBD TANK VENT TO ATMOSPHERE 800 N LU Aux Blr blr
4 80417 BOILER FEED DISCHARGE PIPING 500 I LU Aux Blr blr
5 80418 ERECTION MATERIALS FOR INSTRUMENTS 200 N LU Aux Blr blr
6 80420 BOILER FEED PUMP SUCTION 700 N LU Aux Blr blr
7 80421 BOILER FEED PUMP RECIRCULATION 300 I LU Aux Blr blr
8 80446 DEAERATING HEATER OVER FLOW AND DRAIN 600 N LU Aux Blr blr
9 80450 CBD AND EMERGENCY DRUM DRAIN 400 I LU Aux Blr blr up to 1st vlv
10 80451 BOILER INTEGRAL PIPING DRAINS 400 I LU Aux Blr blr up to 1st vlv
11 80453 LP PIPING DRAINS ‐ SG SCOPE 300 I LU Aux Blr blr up to 1st vlv
12 80460 SG AUX COOLING WATER UNIT SYSTEM 600 N LU Aux Blr blr
13 80473 DEMINERALISED WATER SYSTEM 600 N LU Aux Blr blr
14 80600 HIGH PRESSURE DOSING PIPING 200 N LU Aux Blr blr
15 80601 LOW PRESSURE DOSING PIPING 80 N LU Aux Blr blr
16 80612 SERVICE AIR FOR INDIVIDUAL UNITS 300 N LU Aux Blr blr
17 80616 INSTRUMENT AIR FOR INDIVIDUAL UNIT 400 N LU Aux Blr blr
18 80650 FUEL OIL SUPPLY AND RETURN PIPING 1,000 N LU Aux Blr blr
19 80901 SUB DELIVERY VALVES FOR LIGHT UP 700 N LU Aux Blr blr
20 80904 BHEL VALVES FOR HYDRO TEST 1,000 N HT Aux Blr blr
21 80905 BHEL VALVES FOR LIGHT UP 5,500 N LU Aux Blr blr
22 80920 H&S FOR HYDRO TEST 2,000 N HT Aux Blr blr
23 80921 H&S FOR LIGHT UP STEAM LINE 4,000 N LU Aux Blr blr
24 80922 H&S FOR LIGHT UP ‐ NON STEAM LINES 1,100 N LU Aux Blr blr
25 80992 IMPORTED ELECTRODES 30 N HT Aux Blr blr
26 81005 INTERMITTENT BLOW DOWN EXPANDER‐D1500 MM 2,400 N LU Aux Blr blr
27 81026 TRAY TYPE DEAERATOR BELOW 100 cuM/HR 24,000 I LU Aux Blr blr N
28 81034 PLATFORM & STAIRS FOR FEED TANK & DEARTR 2,800 N LU Aux Blr blr
29 81104 BOILER FEED PUMP 3,600 N LU Aux Blr blr
30 81127 LOW PRESSURE DOSING SYSTEM 3,000 N LU Aux Blr blr
31 81128 HIGH PRESSURE DOSING SYSTEM 3,000 N LU Aux Blr blr
32 81300 FIX COM FOR MAIN STEAM PPG INSL 800 N LU Aux Blr insulation
33 81325 MINERAL WOOL MATTRESS 2,300 N LU Aux Blr insulation
34 81341 SEALING COMPOUND FOR INSL 40 N LU Aux Blr insulation
35 81350 ALUMINIUM CLADDING FOR INSULATION 1,500 N LU Aux Blr insulation
Total Aux Boiler 68,350
C PGMA Common for all 3 Units. Covered in Unit-1 supply

NOTE- LU,HT of aux blr should be one month prior to the activity of main boiler

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TENDER PSER:SCT:SAL-B936:08

JOB ERECTION, TESTING & COMMISSIONING OF BOILER

BHARAT HEAVY ELECTRICALS LIMITED

CLAUSE NO/ DESCRIPTION

49.0 TAXES AND DUTIES.

Nearest Railway Station : Salakati Railway Station

Nearest Airport : Guwahati

2.0 SCOPE OF ENQUIRY

2.4 The omission of specific reference to any fabrication / erection method,

as per the advice of Engineer. During installation of expansion joints, anchors,

preservative to be spread as part of responsibility of the contractor.

rectification and replacement due to poor workmanship of the vendor, the

5.11.1 Pipe & tube having bore up to 178 mm 10 %

LP Bypass Piping up to L.P. Bypass Valve.

refilling etc. the consumption of lubricants / chemicals shall be properly accounted

P&T line, Fax etc, as required by the contractor, is to be installed by the

covers to be taken by BHEL/ Customer shall be as stipulated under relevant

40.0 AREA REQUIREMENT

loading, final painting & handing over.

Furnace bottom ash hopper – 12 Months from start of work.

46.0 RECTIFICATION / MODIFICATION

52.4.1 Safety helmets conforming to IS 2925 / 1984 (1990)

to provide necessary safety devices and equipment or to carry out instructions

b) Major injuries or accident causing 25% or more permanent disablement

58.6 Payment of ORC shall be subject to compliance to following condition.

Rate/Price of Balance job on contractual completion date = A, Say

Revised Rate during Second Year after contractual completion date

Prior to erection, supplied pipes shall be inspected thoroughly and if any

I. Cutting of P-91 material shall be done by hand saw / hack saw /

III. All edge preparation done at site shall be subjected to Liquid

V. Partial root weld of minimum 20mm length by GTAW and fit-up by

16b FIXING OF THETMOCOUPLES AND HEATING ELEMENTS

No pre-heating is required for fixing T/Cwith resistance spot welding. Following

1. Heating Method : Induction Heating

2. Thermo couples : Ni-Cr / Ni – Al of 0.5 mm gauge size.

3. Temp. Recorder : 6 Points / 12 Points.

16c ARRANGEMENT FOR PURGING :

two filler passes of SMAW in case of butt welds. Purging is not

16d WELDERS QUALIFICATION

Only qualified welding procedures are to be used. Welders qualified as per

Alternate arrangements shall be made during power failure. Two additional

16g STORAGE OF WELDING CONSUMABLES :

I. Welding consumables are received with proper packing and marking

II. Electrodes are stored in their original sealed containers / packages

V. The electrode GTW wires issued to the welders should be

16h POST WELD HEAT TREATMENT :

I. A minimum of four thermocouples shall be placed such that at

Thickness up to 50 mm 110 deg.

Centrigrades / hr. ( max )

Thickness more than 75 mm 55 deg.

IV. The recording of time and temperature shall be continuously

16i PREVENTIVE MEASURES DURING POWER FAILURE AND NON-

No interruption is allowed during welding and PWHT. Hence all equipment

(a) During start of pre-heating :

Weld fit-up arrangement shall be immediately covered with

11. During GTAW / SMAW

Use gas burner arrangement to maintain the temperature at 80 to

(c) During cooling cycle after SMAW welding to the holding

During heating cycle ---- The whole operation to be repeated from

During cooling ( above 335 deg. C ) --- Reheat to soaking

16j TEMPERATURE MONITORING

All equipment like recorder, thermocouple, compensating cable, oven,

16m NON DESTRUCTIVE EXAMINATION