SECTION-V

TECHNICAL SPECIFICATION
(SCOPE OF WORK & SPECIAL TERMS AND CONDITIONS)

Scope of Work and Special Terms and Conditions : NIT NO : 9900214352

Name of work: Overhauling of boiler pressure parts, APH, DUCT, MILL,

Burners, Fans, hanger supports & associated works in one units of NTPC Lara
STPP in 2020-21

1|Page
Name of The Work: Overhauling of boiler pressure parts, APH, DUCT, MILL, Burners, Fans, hanger
supports & associated works in one units of NTPC Lara STPP in 2020-21

SCOPE OF WORK
NIT NO : 9900214352
Page 1 of 39
Annexure-III
Purpose and Boiler is very critical equipment for power generation process. Boiler
Intent of the Work pressure part is one of the areas where utmost attention is required to carry
out huge amount of work of highest possible quality standards at great speed.
Therefore, NTPC Ltd. has much expectation from the agency, who undertake
this work. It is necessary that the prospective bidders understand the purpose
and intent of this contract. Therefore, bidders are advised to take note of the
following:

1.0 It is the intent of this contract that the unit must run without a tube
leakage from overhaul to overhaul. For this neither a defective/weak tube
is to be left in the boiler nor should any new defect be introduced in the
boiler during overhauling.
2.0 Therefore, the agency is required to assist NTPC in inspection work so
that all such tubes are identified early in the shutdown period and
replaced during overhaul.
3.0 It is also the intent of this contract to achieve “ZERO DEFECTS” during
maintenance. So, the maintenance work done in the boiler needs to be of
highest possible quality standards. The maintenance work must not
induce any defect in the boiler which may result in to tube leakage or
other problems. This means the quality of tube cutting, edge preparation,
fit up and welding must be world class. The agency must deploy skilled
and competent manpower and supervisors. The agency shall be
accountable for achieving these objectives.
4.0 The agency shall establish a proper supervision and quality assurance
system in consultation with NTPC Engineers.
5.0 Agency shall deploy sufficient number of working gangs, Skilled
manpower like HP welders, Key resources like welding machines,
radiography sources and supervisors so that the work is done in even
pace and last minute rush is avoided.
6.0 Agency shall deploy adequate T&P to maintain the pace of work.
7.0 The agency shall take all the precaution to ensure safety at work so that
the activities are not hindered by any incident or accidents.
8.0 Similarly, all other works must also be done with due care and according
to guidelines issued by NTPC Engineers.
Brief Description This scope of work (SOW) of the contract consists of all boiler components in
of the work first pass (furnace), Vestibule and second pass/cage areas.
Broad area in first pass and vestibule area are: Hopper walls, Spiral Walls,
Vertical Walls, Water wall sling tubes, rear arch, Pent house, Platen super
heater, Final Super heater, Final Re-heater, etc. (including attachments,
sealing, coverings and supports), Furnace Roof tubes, vestibule floor &
vestibule wall tubes.

Broad areas in second pass are cage front, rear, side wall tubes, sling tubes,
Divisional wall, Primary super heater coils, Economizer coils, primary re-
heater coil banks with associated roof and Structures.

For this work, once the First award letter is issued to the agency, he is
expected to start mobilizing on top priority, before the date of the shut
down, so as to achieve the targets set by EIC. Adequate mobilization of key
resources of right quality is the most vital input to the successful execution
of this work. Agency shall fully understand the targets to be obtained by
Name of The Work: Overhauling of boiler pressure parts, APH, DUCT, MILL, Burners, Fans, hanger
supports & associated works in one units of NTPC Lara STPP in 2020-21

SCOPE OF WORK
NIT NO : 9900214352
Page 2 of 39
him from the EIC for the pre shut down work, mobilize accordingly and
complete the activities before shut down. Generally, the mobilization
period shall be 10 days (intimation to shut down) for the unit to be
executed in the contract. Once the unit is shut down, the agency shall
arrange to do the preliminary cleaning and then start the scaffolding
works. Stage – wise, as the scaffolds start becoming ready, he shall arrange
for further cleaning, illumination, local approach and preparation of
surface for inspection / thickness survey / NDT checks and offer such areas
for EIC’s inspection.

Agency shall provide assistance as identified, for (during) these inspections
/ surveys / checks.

EIC and his representatives shall carry out the inspection/ checks /
thickness survey, and identify the sections to be replaced / repaired /
protected/ re – cleaned/ re-prepared /illumination to be augmented/
approach to be modified or extended, which actions are then to be carried
out by the agency, and offered again for check after completion / readiness,
taking care to comply with “Hold Points” specified by the EIC, if any.

EIC, may at his discretion (based on past history / experience) may also
identify some works like radiography or weld joints or replacements etc
before inspection it self, for the agency to start work on these, immediately
after approach and illumination are ready.

The scope for one boiler overhaul extends, briefly, till all identified works
are completed, scaffolds are dismantled, Boiler hydraulic test got
witnessed by the Boiler Inspector, all men and material are removed from
the boiler inside and out side, boiler boxed – up, etc. and trial run support
is given.

The agency shall depute his resident engineer and site – in – charge
regularly as specified by the EIC to meet him, to submit programs and
reports, to discuss strategies and to receive instructions / guidelines, etc.

Overall responsibility for coordinating with all the associated/concerned
agencies including EIC and to carry out a successful overhaul of the boiler
pressure parts, while abiding quality and safety norms and achieving a
defect free defect liability period of 90 days from date of synchronization
after each unit overhaul shall be in the scope of the agency.

In case of any ambiguity/ dispute in any schedule of scope of work, special
terms and conditions etc. decision of EIC shall be final and binding on
agency.

This contract is awarded to cater the Boiler Pressure Parts Overhauling

For One Units Of Lara: 2x800 MW, as per the enclosed scope of work and
terms & conditions of the contract. Accordingly, the vendor has to
mobolize its resources for overhauling of one-unit boiler pressure parts
as per instruction of the engineer-in–charge.
The scope of work is given for overhauling of one unit only.
Name of The Work: Overhauling of boiler pressure parts, APH, DUCT, MILL, Burners, Fans, hanger
supports & associated works in one units of NTPC Lara STPP in 2020-21

SCOPE OF WORK
NIT NO : 9900214352
Page 3 of 39

Sch. No. / Service Br Broad Detail of Works

Code:-
Title of Work
Sch. 10.10/ Pre & Post Shutdown works 1st & 2nd pass AND Vestibule area, etc. of one
Service Code: boiler :
BMMSW00OH001 :-
Misc Works (<>) OH A. Pre – shut down Works:

1) Initial Mobilisation:-

a) Submit Form – IV and take form – V from NTPC Ltd.

b) Arrange Labour license: License is required for about 250 persons. Arrange
comprehensive workmen insurance, which should cover all risks encountered
in such a job, including working at heights (up to 100 meters for 800 MW
boilers). The policy paper shall mention the name of the work and the location
(NTPC Ltd, Lara), besides the number of persons covered.
c) Agency must have the valid certificate of recognition from directorate of
steam boilers for boiler repair of pressure parts of special class for any
pressure.
d) Obtain the permission of the Chief Inspector of Boilers, Raipur,
Chhattisgarh, for the work and for doing the work with approved HP
welders.
e) Liasoning with Boiler Inspectorate for permission of work, radiography
approval, ground inspection, Hydraulic test, etc.
f) Depute Resident engineer, Site – in – charge and key supervisory and skilled
personnel to interact with EIC and his representatives, for understanding the
detailed resource requirements of the work (Staff, T&P, Consumables etc), to
understand the anticipated quantum of work, to make PERT net work, to work
out group – wise distribution of work, to work out day – wise and group –
wise program of the work and to understand the quality and safety
requirements. Considering the importance of the work as given at the
beginning of the SOW, the indicated resources of right quality shall be
mobilized, prior to the actual shut down.
g) To conduct briefing sessions for the various groups to ensure that the
understanding percolates to the bottom most level.
h) To arrange Photo gate passes/CLIMS gate pass for workers, staff and gate
passes for vehicles.
i) To arrange medical check – up for the workers to ensure fitness for work.
j) To make arrangements for accommodation / conveyance / food /
refreshments etc.
k) To transport T&P, radiography sources & consumables to inside Plant
premises with due entry at gate.

2) T&P’s Testing: -
Name of The Work: Overhauling of boiler pressure parts, APH, DUCT, MILL, Burners, Fans, hanger
supports & associated works in one units of NTPC Lara STPP in 2020-21

SCOPE OF WORK
NIT NO : 9900214352
Page 4 of 39
a) To arrange for testing of T&P (Lifting tools with competent person of state
Govt., Electrical tools at electrical repair shop of NTPC and Safety gadgets by
Safety cell of NTPC).
b) Testing/ checking of agency’s T&P and electrical equipment’s inside plant
premises:
i. This testing / checking is in addition to whatever tests / checks the agency
might have got done before entry in to plant premises.
ii. Shifting of T&P like chain pulley blocks, winches, hook chucks, slings, wire
ropes etc (all T&P for which periodic testing is a must as per Factories act
/ or is required to ensure their safe performance) to testing site.
iii. Shifting of weights / loads / other items required for testing purpose to
the test location & also return back the same after testing.
iv. Arrange for the testing of the T&P beforehand (to be witnessed by
competent person recognized as per factories act). NTPC representative
shall also witness the test as per the direction of EIC. It shall be the
responsibility of the agency to inform adequately in advance about the
testing venue and time so that witness can be done. Agency shall keep a
record of the tests carried out.
v. Submit copies of the test certificates issued by the competent person
based on tests carried out as above to EIC. Failed T&P shall be sent out of
plant premises.
vi. Shifting of electrical equipments like welding machines, grinding
machines, chop saw machines etc to electrical repair shop for checking /
testing to ensure healthiness. Assist Repair shop personnel for checking /
testing of the equipments.
vii. Only such T&P, Electrical equipments and Safety Gadgets, which are
certified to be OK, shall be deployed during overhaul.
viii. Arrangement of and payment for the competent person (as recognized by
the factories act) shall be done by the agency only.
ix. In case of notice of deployment of any T&P / electrical equipment which
has not been tested within plant premises, or, for which, the validity of
such a test has expired, a penalty of at least RS. 1000/- shall be imposed
for each such occasion in addition to penalties imposed by NTPC safety
department.
x. To arrange for testing of argon gas (Purity shall be 99.99%) at NTPC
site/lab. However, the test certificates to be produced by the agency from
the argon gas suppliers.

3) Welders Test:-
To arrange for testing of skilled manpower, as given below:
a) All HP welders engaged for the job must have valid license with IBR
Endorsement for HP welding. Copy of these shall be submitted to Engineer in
charge/FQA before the start of work.
b) All HP welders shall be tested by NTPC in 6G position. (Alloy and / or SS).
(Visual, RT & Bend tests)
c) All attachment welding/Fin welding shall be done by HP Welders only.
d) Only those welders, who pass the tests, shall be engaged on the job.
e) The welders shall always carry (when on job) and produce when demanded,
the photo identity card issued by NTPC – FQA.
f) If the welders / persons to be deployed had already been tested by NTPC –
Projects earlier and possess valid identity cards, then such welders/ persons
shall be eligible to be deployed even without doing a repeat test till the
validity of the earlier identity card expires.
g) Gas cutters and Grinder men shall be tested by representative of EIC (Visual
Name of The Work: Overhauling of boiler pressure parts, APH, DUCT, MILL, Burners, Fans, hanger
supports & associated works in one units of NTPC Lara STPP in 2020-21

SCOPE OF WORK
NIT NO : 9900214352
Page 5 of 39
and verbal).

4) Safety at Site:-

a) Safety supervisor shall be tested verbally by EIC / safety officer of NTPC Ltd.
b) Arrange safety training to all the workers and staff at NTPC safety cell.
c) No worker shall be allowed to work without safety induction process by NTPC
safety dept.

5) Site Set-up:-
i) Shift to location / platform on boiler: T&P, Consumables, Spares, Scaffold,
Materials (other than cup lock), Baking and holding ovens etc.
ii) Carry out pre – assembly works as identified by EIC. These can be weld joints,
radiographs, steel fabrication etc which are payable against respective
schedules of the contract. Make extra platforms if any, as identified by EIC, to
facilitate the work. (Payment shall be in the item “Steel fabrication”)
iii) Chalk out the movement path of major materials from and in to the boiler.
iv) Set up and commission: Computers/laptops, Radiograph evaluator, Baking
and Holding ovens, Electrical machines etc at site
v) Attend safety survey defects
vi) Quarter / Half shield fabrication (if any), grinding of edges / burrs etc.
vii) Set up electrical connections, shift feeder pillar boards, Cables, external Flood
lighting etc as required / as specified by EIC.
viii) Shift scaffolding pipes and wooden/metallic planks to respective Locations.
ix) Make site store / office ready for use.
x) Check welding and lighting supplies.
xi) Set up winch for lifting / lowering of materials to work location.
xii) Ensure all persons to be deployed are adequately skilled for the job.
xiii) Ensure all persons to be deployed are adequately trained in safety.
xiv) Prepare registers and formats for use during the work.
xv) Arrange procurement of leak - proof ash disposal bags.
xvi) Arrange radiography sources, driers, Films, cassettes etc. and set up
Processing lab.
xvii) Cleaning of the boiler tube spool pieces by blowing compressed air / steam
as per instruction of EIC.
xviii) Honey comb removal from work area, if required.
xix) Any other relevant work as per direction of engineer - in – charge.

6) Submission of Documents: -

Submit the following documents to EIC (Pre shut down) before the start of
shutdown:
a) Labor license specific to the contract.
b) ESI codes under ESI act (Employees' State Insurance Act). Contractor shall
give copy of TIC (Temporary Identification Certificate)/ Pehchan Card
registered with ESIC(Employees' State Insurance Act) for all workers working
under this contract.
c) List of T&P brought into plant premises along with their serial nos. and dates
/ year of purchase / manufacture.
d) Agency must have the valid certificate of recognition from directorate of
steam boilers for boiler repair of pressure parts of special class for any
pressure.
Name of The Work: Overhauling of boiler pressure parts, APH, DUCT, MILL, Burners, Fans, hanger
supports & associated works in one units of NTPC Lara STPP in 2020-21

SCOPE OF WORK
NIT NO : 9900214352
Page 6 of 39
e) Test certificates of T&P’s and appliances to be used. If agency fails to submit
the Test certificates of T&P, then penalty of 25% of the respective BOQ rate
shall be imposed.
f) List of consumables brought into plant premises along with their serial nos.
and dates and year of purchase where ever applicable.
g) Permission from CIB, Chhattisgarh for carrying out the job. (certificate of
recognition from directorate of boiler of 'special class boiler repairer')
h) Test certificates of HP Welders duly endorsed by IBR (CIB,Raipur).
i) Authorization / Permission from BARC for the use and movement of
radiography sources.
j) Test certificates from gas agencies to prove the purity of argon gas being used.
Gas purity may also be verified at site in NTPC lab/facility.
k) Batch certificate of cutting wheels’ / grinding wheels where self life period is
involved.
l) Mobilization formats (which shall be issued by EIC) duly filled up.
m) Details of supervisory staff to be deployed, in the format specified.
n) Details of workers to be deployed with name, age, permanent address,
category, medical fitness and their family /dependents.
o) Authorization letter for receipt of material from NTPC, for signing of
measurement books, etc.
p) Safety undertaking.
q) Submission of New gate passes, cancelled gate passes and renewed gate
passes.

B. Post Shut down Works:

1) Post Overhaul housekeeping: -

Clearing of the Boiler of all debris, scrap, left – over spares, T&P, consumables
etc.

2) Post overhaul Defect Rectification: -

a) Deploy manpower for assisting in light-up activities of boiler up to achieving
first full load of the unit.
b) Deploy manpower for attending to defects if any during the initial running
period of 6 days from light – up.
c) Attend to defects due to poor workmanship / negligence / omission up to 90
days from 1st synchronization of the unit after overhaul.
d) Erection and operation of Sky climber if required for attending defect (if any)
in 1st pass from start of overhaul to 90 days from 1st synchronization after
overhaul of the unit.
e) In case of non-requirement of any defect rectification, the payment towards
the Post Overhaul defect rectification shall be released to the party as a
reward for the quality work.

3) Return of Materials: -
a) Return of NTPC material as directed. Stacking / arranging the returned items
as specified.
b) Reconciling measurements and materials with EIC.
c) Servicing and return of NTPC’s issued T&P used during the job to make ready
for next work.

4) Submission of documents: -
Name of The Work: Overhauling of boiler pressure parts, APH, DUCT, MILL, Burners, Fans, hanger
supports & associated works in one units of NTPC Lara STPP in 2020-21

SCOPE OF WORK
NIT NO : 9900214352
Page 7 of 39
Submit the following documents in report form within 07 days from
synchronization of the unit after the overhaul / shutdown work is completed
or before release of running bills:
a) Details of work executed.
b) Measurements against different schedules in compiled form.
c) Material issue details.
d) Material consumption details.
e) Material return detail.
f) Weld joint – wise report for different sections / zones/ areas of boiler along
with RT report reference
g) Radiography reports along with repair details of defective joints.
h) DPT protocols.
i) Protocols of other hold points like “water wall air – charging before spool fit –
up, Check of fit – up and weld procedure of critical welds, SR charts” etc.
j) Copies of wage sheet of workmen along with duly filled up additional format
specified by EIC.

5) SCRAP HANDLING AND TRANSPORTATION: -

Steel scrap return:
a) The overhaul work shall generate scrap like old boiler tubes, shields, baffles,
bends, plates, rods, etc
b) Collect all the steel scrap at one place. Do not mix – up scraps of different
types.
c) Show to EIC and obtain his clearance for loading on to the disposal truck.
d) Load on to truck / trailer and return to NTPC stores, as specified by EIC.
e) All steel scrap return shall be completed within the time target set by EIC.

6) Debris disposal / light scrap return:

a) The overhaul work shall also generate scrap like aluminum sheets, mineral /
rock wool debris, ropes, gaskets, cable pieces, broken lights etc
b) Collect the following scrap separately
i. Aluminum scrap alone – separate place
ii. Ropes, gaskets, cable pieces, broken lights and miscellaneous items
separately
iii. Debris – wool, refractory and muck – separate
c) Show to EIC and obtain his clearance for loading on to truck / trailer.
d) Aluminum scrap is to be returned to NTPC store and weighed.
e) Other debris and scrap load on to truck and dispose at identified place(s).
f) Payment shall be done only after disposal of all debris and return of all scrap
to the satisfaction of EIC.
g) All the scrap return works shall be completed within given time target as per
instruction of EIC.

C. Mode of payment:

1) Pre – shut down works:

75% of the lump sum rate of Pre & Post S/D works in 1st & 2nd pass (Item 10 of
Schedule of rate). Break-up of 75% payments will be as follows: -
a) Initial Mobilization – 30%
b) T&P’s Testing – 10%
c) Welders Test – 5%
d) Safety at Site – 10%
Name of The Work: Overhauling of boiler pressure parts, APH, DUCT, MILL, Burners, Fans, hanger
supports & associated works in one units of NTPC Lara STPP in 2020-21

SCOPE OF WORK
NIT NO : 9900214352
Page 8 of 39
e) Site Set-up – 10%
f) Submission of Documents – 10%

This payment shall be released by EIC, if all identified pre shut down works are
completed to the satisfaction of EIC before PTW is issued.

If all identified pre shut down works are not completed to the satisfaction of EIC till
PTW issue and if the lapse is for reasons attributable to the agency, deduction as
decided by EIC depending upon the work not done shall be deducted. However, if
the final boiler box – up time target is met by putting in extra efforts, and without
leaving any of the identified works or inspections and without violating quality
norms to the satisfaction of the EIC, then this deduction may be waived by the EIC.

2) Post shut down works:

25% of the lump sum rate of Pre & Post S/D works in 1st & 2nd pass (Item 10
of Schedule of rate). Break-up of 25% payments will be as follows: -
a) Post Overhaul housekeeping and return of scrap – 10%
b) Post overhaul Defect Rectification – 7%
c) Return of Materials – 5%
d) Submission of documents including gate pass docs – 3%
The payment will be released by EIC, If all identified works including stacking
of QES (excluded in SOW of item 10.30) etc. are completed within 96 hours
after light – up (excepting attending to defects up to 90 days)
OR
In case boiler light – up is delayed by more than one week from scheduled
date, then all identified works including stacking of QES etc. shall be
completed within 96 hours after dismantling of Aluminum based quick erect
scaffolding.
All identified works including stacking of QES etc are not completed within
stipulated time period as mentioned above and the reason for the delay is
attributable to the agency then suitable penalty shall be imposed as decided
by Engineer-In-charge and same will be final and binding on Agency.

D. PENALTY:
a) Penalty for non return of scrap and non disposal of debris etc. as per
satisfaction of EIC will attract penalty of Rs.5000 for each instance.
b) If the debris / other scrap is returned / disposed at a place other than the
those identified by EIC, then a penalty of Rs. 5000 shall be imposed for each
instance.
c) Penalty for delay in submission of load testing documents for T&P before
schedule date of start of unit overhauling: Rs. 500 per day from date of start of
unit overhauling.
Sch. 10.20/ Scope of work includes cleaning of Heat Transfer Surfaces of 800 MW Doosan
Service Code: make Boiler First and Horizontal pass (Vestibule) of one Boiler.
BMBLR02GN353 1) The steam generator is a Doosan Power System India Pvt., Ltd. make
:- balanced-draft, once-through, supercritical, single reheat, dry bottom, indoor
BOILER >200MW# type. It is designed for sliding pressure operation, with a balanced draft
HPW Jet Cleaning furnace capable of firing pulverized coal. The steam generator will produce
steam flow to a turbine generator with boiler outlet conditions of main steam
flow of 2550T/h,(800MWe) SH Steam Temperature 568°C @ 258 kg/cm2(g)
and RH outlet steam flow of 2041.43 t/h, RH Steam Temperature 596°C @
51.34 kg/cm2(g).
Name of The Work: Overhauling of boiler pressure parts, APH, DUCT, MILL, Burners, Fans, hanger
supports & associated works in one units of NTPC Lara STPP in 2020-21

SCOPE OF WORK
NIT NO : 9900214352
Page 9 of 39

800 MW Doosan Make Boiler consists of Water walls, Super heaters, Re-
heaters, Vestibule wall & rear arch, sling tubes etc. The work area is as
mentioned below:

a) Spiral water wall tubes including hopper walls and vertical water wall tubes
forms furnace of 800MW boiler. Size of Furnace is 23,567 mm width, 19,427
mm depth, and Volume of 28,737 m3. Spiral wall forms furnace from EL.12640
mm to EL.58200mm. Thereafter vertical wall forms the furnace up to roof at
EL. 85042 mm.

b) Platen Super-heaters consists of 24 panels with 24 tubes in each panel in

boiler front and 24 panels with 24 tubes in each panel in boiler rear arranged
vertically in the Radiant zone of the furnace hanging from roof up to 64542
mm elevation.

c) Final Re-heater Panel consists of 67 assembly panels each arranged behind

platen super-heaters in Rear Arch, hanging vertically from roof. Height and
width of each panel’s area approx. 19 m and 3.40 m respectively.

d) Final SH panel consists of 101 assembly having 10 tubes each in inlet & outlet,
arranged above vestibule wall, hanging vertically from roof. Height and width
of each panel area approx. 16.8 m and 2.612 m respectively.

e) Rear arch, vestibule wall & floor

2) Following activities shall be carried out by the party: -

a) Boiler internal water washing for removal of ash of first pass, gooseneck &
second pass to be carried out, before furnace sealing/ Eco hopper sealing.
b) Transportation of 6 sets of High Pressure and High capacity Jet cleaning
machines along with accessories and 8 nos. of nozzles with approx. 140 m of
hose each to site location. The High Pressure Jet Pumps, nozzles, hoses and
other accessories required for cleaning of heat transfer surfaces will be in the
scope of agency.
c) Pumps should have a discharge pressure of 300 Kg/Sq.cm. All Pumps should
have the capability of delivering minimum two no’s of Jets each.
d) Installation of machines at identified location by Engineer-in–charge and
electrical & water line connections.
e) 4 nos. of jet pumps to run with 8 nos. of nozzles. 2 nos. of pumps are to be kept
in ready standby condition. There should be no time delay attributable to
pump failure.
f) It is mandatory for the Agency to bring at least 4 Nos. of High pressure
(Min.) jet pumps of capacity (Min.) with 8 Nos. of nozzles of equivalent
capacity. Incase agency fails to mobilize above number of pumps, the
penalty shall be imposed for balance number of jet pumps not brought at
site at the rate of Rs. 10,000/- (Rs. ten thousand only) per jet pump per
overhaul.
g) Installation and testing of pumps and nozzles at work location to be done at
least 1 day in advance of start of work. Agency has to show the operability of
their pumps and nozzle to EIC.
h) All 8 nozzles with hose should be in working condition.
Name of The Work: Overhauling of boiler pressure parts, APH, DUCT, MILL, Burners, Fans, hanger
supports & associated works in one units of NTPC Lara STPP in 2020-21

SCOPE OF WORK
NIT NO : 9900214352
Page 10 of 39
i) Complete cleaning by jet & scrubbing of all four sides Furnace water walls
from roof of the Boiler to sealing platform at 62 m location.
j) Thorough and complete cleaning of Platen Superheater, Final Reheater & Sling
tubes, Final Super heater and rear arch by water jet and manual scrubbing.
k) Thorough and complete cleaning by jet & scrubbing of all four Furnace water
walls from sealing platform to Spiral water wall panels bottom.
l) Thorough cleaning of 2nd pass including debris removal of eco hopper bottom.
m) After cleaning of heat transfer surfaces by jet cleaning, the mud and scales to
be cleaned from boiler quick erect scaffold platforms by the use of fire water
jet.
n) The debris shall be collected and disposed off to specified location. The above
work shall be carried out with extra safety to avoid any accident as it involves
working at height.
o) Failing to clean the debris as mentioned above shall attract heavy penalty @
10% of the BOQ rate.
Note:

1) PAYMENT BREAK-UP :
The payment of one No. BOQ under this schedule shall be considered only after
completion of all the above mentioned activities to the satisfaction of EIC in one
overhauling. The unit breakup of the one BOQ is mentioned below:

Payment/ deduction for the work shall be made as per the following
percentage.
a) Platen Superheater –10%
b) Final Superheater - 12%
c) Final Reheater – 8%,
d) Water washing by fire water jets in first pass & second pass-10%
e) All four water walls from sealing platforms at 62 m to roof at 83 m - Total-
15% (4% for front & rear WW each and 3.5% for left & right WW each)
f) All four water walls from sealing platforms at 62 m to burner top at 40 m –
Total 15% (4% for front & rear WW each and 3.5 % for left & right WW
each))
g) All four water walls from burner top at 42.5 m to spiral water wall panel
bottom at 13.5 m – Total 15% (4% for front & rear WW each and 3.5% for
left & right WW each).
h) Cleaning of mud and scales from QES platforms and other scaffolding
platforms from boiler roof to 12.5 m with water washing to the satisfaction
of EIC: 15%
i) A penalty of 10% of the BOQ rate shall be imposed if it is felt that there is
delay in initial mobilization for carrying out works mentioned in this
schedule. Decision of EIC shall be final and binding on the contractor.

Note:1
Time period permitted for cleaning of one 800 MW unit as per above scope of work
shall be a maximum of 60 Hrs. Agency should accordingly mobilize necessary nos.
of machines & other resources like nozzles, hoses and manpower (minimum pumps
required for operating 8 nos. nozzles simultaneously) and other T&P’s for the work.
The agency should bring sufficient high pressure hoses and guns so that 8 set of
nozzles can be simultaneously operated at various areas as mentioned above in
first pass of 800 MW up to roof.
Note: 2
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Payment shall be made proportionate to the work carried out as per above scope.
Note: 3
If jet washing is not completed within 60 hours, Penalty of Rs.500/- per hour will
be deducted. Also, if the cleaning is not satisfactory, EIC may take decision on
extension of jet washing cleaning time, with a penalty as mentioned above.

Sch. 10.30/ Erection of Quick - Erect scaffolding for one boiler:

Service Code: 1) The scope of erection shall cover Spiral water wall panels, Furnace, Burners,
BMSFL00OH001 Platen SH, Final RH up to Furnace Roof.
:- 2) Important: The scaffolding components are Aluminum based tailor made and
SCAFFOLDING (<>) are very costly items. They are supplied in fixed quantity for erection; hence
OH utmost care shall be taken during shifting and erection of scaffolding materials
to avoid its failure/ damage and loss. The loss of scaffolding materials or its
damage during shifting and erection shall attract heavy penalty.
3) Shift complete material of quick erect scaffolding from containers / another
unit zero meter to zero meter of the unit planned for overhaul.
4) Servicing of scaffolding: Application of rust remover in various components of
QES and make all the joints/moving members of scaffolding free to be easily
assembled at height. Cleaning of dirty components of scaffolding by water and
air before shifting to various locations of boiler.
5) Shift the material to respective locations of Boiler, as per break – up to be taken
from EIC.
6) Make suitable platforms (temporary, if required) at zero meter, 12.6 M and
other location for material shifting during erection and dismantling of QES.
Pulling and lifting arrangement such as winches, pulleys, wire ropes etc. shall
be arranged for erection & dismantling of QES.
7) Works like Shifting of materials to location, preparation of platforms shall be
carried out before start of erection. Complete material of scaffolding must be
shifted to the respective boiler floors before the start of erection.
8) There shall be at least four people per group and at least fifteen groups of
erector in each shift for erecting scaffolding with the help of winches. Working
shift will be of 8 hrs only.
9) Each group of erecting personnel shall demonstrate for safety and correct
erection of QES components in front of EIC/Representative of M/s Instant
Upright Ltd./NTPC safety personnel before start of work of each day prior to
commencement of erection of QES inside boiler. In case it is found that
manpowers are not trained for erecting this QES, same to be replaced
immediately. During erection, if it is found that erection is not being carried out
properly which cause safety hazard, then erection may may be stopped as per
instruction of EIC and erecting groups shall be replaced with trained manpower
or mobilized for training. Time lost during above mobilization and training will
be included in erection timing and agency cannot claim for the delay on the
account of above.
10) As Lighting of boiler is under the scope of agency, hence agency shall arrange
enough halogen/LED lights including 24V DC lights to avoid delay in erection
and dismantling of QES on the account of illumination of boiler. Portable
Emergency lights shall be kept with each group during erection and
dismantling of QES so as to keep themselves safe during short power failures.
Penalty of Rs. 500/- per instance shall be imposed incase illumination of
boiler is not improved immediately during erection & dismantling of QES.
11) Agency shall keep their electricians round the clock for assistance in
maintaining lights, power supply etc. for avoiding delay in erection and
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dismantling of QES. These electricians shall get all the information of electrical
supply systems from NTPC-EMD Department before start of QES.
12) Agency must deploy their manpower 10 days before start of work for shifting of
QES material to the site and also to various elevations of boiler as per the plan
provided by the NTPC.
13) Truck, Trolley etc. required for shifting of scaffolding shall be in the scope of
Agency. However, depending on availability, NTPC may provide, on free of
charge, but the same shall not be an excuse for delaying the work.
14) As winches will reduce time for erection and dismantling of QES, Erection &
Dismantling shall be carried out with the help of winches only, hence it is
mandatory for agency to bring at least 7 Nos. of remote controlled operated
portable winches of capacity :
0.5 Ton to One ton Capacity with pulley and wire ropes-Qty. 5 Nos.
2 Ton capacity with pulley & wire ropes –Qty. 2 Nos.

The winches shall be in healthy and running condition with all required
certificates. In case agency do not bring specified number (minimum 7
Nos.) of winches or brings less than specified number of winches before
start of erection of Aluminum based QES, then they will be penalized. The
penalty shall be imposed for balance number of winches not brought at
site at the rate of Rs. 25,000/- (Rs. twenty thousand only) per winch per
overhaul.
15) Erect the Sealing platform at Spiral water wall hopper panels at 12.6 meters.
Make this scaffold completely sealed by covering it with sheets, asbestos cloth
and insulation / refractory at the sides.
16) Erect the quick erect scaffold as per drawing and following the directions of EIC
if any. The drawings shall be taken from EIC before commencement of erection
of QES. Erection of QES up to 23.5m is very critical for successful erection of
QES upto furnace roof; hence every care shall be taken during erection of QES
up to 23.5m.
17) The quick erect scaffolding will be erected under strict supervision of the EIC/
M/s Instant UpRight Ltd (if available) to ascertain the erection as per drawing.
The erector shall be responsible for receiving all the drawings of QES from EIC
before starting erection of QES.
18) Necessary temporary platforms, inside furnace, if required will be erected
under the guidance of EIC / M/s Instant Up Right Ltd.
19) Hold point: EIC clearance shall be obtained to proceed further with erection,
once the scaffold reaches a level of 23.5 meters (Level 0). It is to be noted that
erection of whole structure will depend upon quality of erection of scaffolding
upto 23.5 m. Hence agency shall take extreme care for erection of QES upto this
level of scaffolding. EIC clearance shall be obtained once again to proceed
further erection, up to 44.7 meters (Level 10).
20) Bracings, stairs, railings for platforms, railings for stairs, corner planks tie – ups
etc. shall also be scrupulously done concurrently with the erection of the
scaffold, by deploying separate groups for these works.
21) Additional levels/Shifting of Levels to be done if necessary as per work
requirement. P/D brasses and spacer brasses shall be erected at correct
locations.
22) Staircases with railings must be made in parallel to the peripheral platforms to
allow start of water wall works as soon as possible.
23) Corner pieces of peripheral platforms must be fitted. In case of any fitting
problem, same is to be rectified as per EIC instruction.
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24) There will be sealing platform / dancing floor at around 56 meters (level 18).
25) Take care not to overload the sealing platform with excess materials / debris /
ash etc.
26) Beam Trusses for sealing platforms shall be erected as per drawing.
Modification if any in erection shall be carried out as per direction of EIC.
27) Safety net shall be erected across whole boiler furnace at level 6 and level 12 as
per direction of EIC. Safety net shall be erected around periphery (towards
furnace) of level 8, level 9, level10, level 11and level 12 as per instruction of
EIC. Required safety net shall be provided by NTPC free of cost on returnable
basis. Care shall be taken not to damage safety net during handling etc. Suitable
penalty equal to 1.2 times of PSL rate of safety net or higher amount as decided
by EIC shall be imposed on agency if same is found to be damaged during
handling etc.
28) Hold Point: After erection of sealing platform is completed, same shall be
shown to EIC/Representative of M/s Instant UpRight Ltd. Any confusion during
erection of sealing platform may be immediately addressed to EIC/
Representative of M/s Instant UpRight Ltd to avoid wrong erection and further
delay in erection. EIC clearance shall be obtained to proceed further with
erection of QES in Platen Super heater & Final Reheater area
29) Erect scaffold for Upper Furnace, Platen Super heater, Final RH areas as per
drawing / direction of EIC. Any modification as instructed by EIC shall be
carried out immediately.
30) Approach ladder to be erected for the platforms in platen Super-heater and
final Re-heater area to access each tubes of respective coils.
31) Ensure access to all heat transfer surfaces in above areas up to roof.
32) Shifting of towers, relocation of span decks / platforms in a tower as per
requirement, dismantling and re - erection of towers for carrying out work in
platen super heater, Final reheater, Vertical Water wall/ Upper furnace shall be
done as per instruction of EIC. No extra payment shall be given for this
work.
33) Dismantle in reverse sequence after obtaining clearance from EIC.
34) Shift to zero meter and to store / location specified by EIC.
35) Storage of Scaffolding shall be done in containers as per direction of EIC.
36) Servicing of scaffolding before stacking and storage: Scaffolding material shall
be cleaned, washed with detergent and dried with air before keeping in
containers. All snap outs shall be made free and oiling of its joints shall be done
before its storage. All defective scaffolding materials shall be separated out and
defects shall be rectified before its storage inside containers. Preservatives etc
will be used on scaffolding materials before storage.
37) The scaffolding material shall be counted and verified by NTPC representative
during shifting inside containers. In case any scaffolding material found missing
or damaged, agency shall be suitably penalized for the same. The penalty
amount as decided by EIC and other decisions of EIC will be final and binding
on agency.
38) Scaffolding material shall be stacked properly in each container to the
satisfaction of EIC. If stacking is not proper, then restacking had to be carried as
per instruction and satisfaction of EIC.
39) The above mentioned activities are minimum activities to be done in this
schedule. However further activities, as required, may be carried out for
successful completion of erection, dismantling, servicing, shifting etc. of QES for
which no extra payment will be given to the agency.
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Mode of Payment:
1) The payment of one BOQ under this schedule shall be considered only after
completion of all the above mentioned activities in all respects to the
satisfaction of EIC in each overhaul. The breakup of one BOQ for payment under
this schedule is given below:

a) Shifting of scaffolding material from store to unit zero meter : 2.5 %

b) Shifting of scaffolding material from unit zero meter back to store and its
proper stacking inside container: 12.5 %
c) Shifting from zero meter to respective locations on boiler & back: (2 X 5 =
10%)
d) Erection and dismantling up to bottom level of Burners : 20%
e) Erection and dismantling up to sealing platform/dancing floor level (62
meters, Level 18) : 30%
f) Erection and dismantling up to roof including for PLSH & Final SH: 25 %
g) Sealing scaffold at 62 M manhole door is to be made within 80 hours from
PTW issue. Scaffold up to boiler roof tubes of first pass including sealing at 62
M to be completed within 120 hours from PTW issue. Dismantling of scaffold
is to be done in 96 hours in Boiler. If these time targets are not met due to
reasons attributable to the agency, a deduction of Rs.75,000/- shall be done
from the payments due to the agency. However, if the final boiler box – up
time target is met by putting in extra efforts, and without leaving any of the
identified works or inspections and without violating quality norms to the
satisfaction of the EIC, then this deduction may be waived by the EIC.
Sch. 10.40/ Miscellaneous scaffolds for one Boiler -1st & 2nd pass:
ServiceCode: 1) Scaffolds covered by this schedule for repair and inspection are:
BMSFL00GN400 2) Below furnace hopper front and rear panels, for work on trough seal plate,
:- scallop welds (from inside), SS woven wire mesh, falling slag etc. Complete
sealing in trough seal area is to be done. If scaffolding is done in periphery, only
SCAFFOLDING (<>) 50% payment of scaffold below furnace hopper panel area will be made.
Instal/Remove 3) Pent house (inside / outside) for DPT, repairs etc. as per EIC.
4) Scaffold for Final super heater, Primary RH and Primary Re-heater headers.
5) For access to attachment welds of LHS and RHS WW inside the wind box/ buck
stays/ backstay attachments outside Boiler, wherever necessary.
6) Near Water wall Inlet header drain pipes.
7) For checking of water wall inlet header scallop weld by DP test (from hopper in-
side/ out-side as required).
8) Final Super heater 8 levels (Min.) of scaffold from bottom to top (with planks
between all panels) with both front and rear walk ways at all the levels.
9) As directed by EIC, if required, certain modification in Aluminum based QES
may be carried out by using planks and scaffolding pipes in all 5 levels of Quick
erect scaffold in Platen SH and Final Re-heater.
10) Final SH Front & Rear 7 levels (Min.) of scaffold from bottom to top (with planks
between all panels) with both front and rear walk ways at all the levels.
11) Approach from Final SH to Final Re-heater and to Platen SH peripheral
platforms at all 7 levels for easy movement of men and materials.
12) Spacer/Tie tubes: Platform shall be erected all along spacer tubes up to furnace
roof.
13) Sling tubes of water wall(vestibule area)/SH side cage sling tubes/Primary
reheater side sling tubes/cage front wall screen tubes/Division wall screen
tubes: 7 levels of scaffold up to roof for complete inspection of tubes. Complete
platform around the tubes just below the roof to be made for inspection of roof
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tubes. In addition, scaffolding to be made at all attachments areas of respective
tubes as mentioned above.
14) Primary RH terminal tubes, Sling tubes: 5 levels for complete inspection of
tubes. Complete platform around the Primary RH & Primary SH terminal tubes
just below the roof to be made for inspection of roof tubes.
15) Scaffold between Economizer 1st bank & Primary RH bottom bank for
inspection of PRH tubes, Primary RH inlet header and ECO sling tubes.
16) Below Economizer 1st bank(RH Side) & below Economizer 2nd bank (SH side)
for inspection of ECO bank bottom tubes .
17) Complete ECO Hopper for sealing below Eco inlet header.
18) External scaffolds on boiler (first pass areas, excluding piping) for works on
tubes, supports etc:
19) External scaffolds for second pass Back pass wall, buck stays, Back pass bottom
ring headers, drains etc.
20) Removal of all the scaffolding in this BOQ as per schedule given by EIC.
21) Any other scaffold as specified by EIC.
22) Erect the scaffolds specified.
23) Scaffolding work shall be as per safety norms.
24) Dismantle after obtaining clearance from the EIC.
25) Scaffolding in Platen SH, Final SH, Water Wall sling and Final Re-heater shall be
erected in parallel with Main boiler access scaffolding (QES).
Mode of Payment:
The payment of one BOQ under this schedule shall be considered only after
completion of all the above mentioned activities to the satisfaction of EIC in each
overhaul. The breakup of one BOQ for payment under this schedule is given below:
Break-up of total 100% payment for this schedule is as follows:-
a) Scaffold below Spiral wall hopper Panels – 10%
b) Wind box and Penthouse – 5%
c) Sling tubes of water wall(vestibule area)/SH side cage sling tubes/Primary
Re-heater side sling tubes/cage front wall screen tubes/Division wall screen
tubes– 20%
d) Final SH – 15%
e) Primary RH Coil Terminal Tubes & Sling tubes upto Back pass Roof – 15 %
f) ECO, Space Between ECO & Primary RH, ECO hopper sealing – 25%
g) External Scaffolding – 10%

If the required scaffold as specified by EIC is not erected within scheduled time
frame, an amount of Rs. 30,000/- per location shall be deducted from the amount
due to the agency in addition to the non-payment of scheduled rate.
Sch. 10.50/ Boiler area Illumination for one boiler:
Service Code: 1) Work should to be done as per the lighting plan as decided by EIC.
BMMSW00GN553 2) Minimum 70 Halogen or LED Lamps/ Flood Light fittings are to be set up (fixed
:- position) and to be maintained without interruption during the entire course of
Misc Works (<>) the overhaul work. These are in addition to the portable hand lamps of 24V
Lighting Services which are to be used for on – the – spot inspections / works etc.
In case, it is found that above number of lamps are not working, then penalty of
Rs.100/- per halogen/LED per instance shall be levied on the agency. And
agency will be instructed to immediately replace defective halogen/LED lamps
with new halogen/LED lamps. In case lamps are repeatedly found not working
at same location for more than 24 hours, then penalty of Rs. 1500 /- per
halogen/LED per instance shall be levied on the agency. All the sub- connections
to be taken from NTPC designated lighting boards only. All extension boards
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used to extend the power inside furnace must have ELCB(Earth leakage circuit
breaker) provision. Cables are to be routed properly with fabricated
conduits/galleries only.
3) Only 24V hand lamps shall be used inside boiler/other confined spaces for on
the spot inspections and other works. The above shall be followed strictly. In
case, it is found that agency is using lamps of higher voltage then penalty of Rs.
200/- per instance shall be levied on the agency.
4) Light fittings along with cable and accessories are in the scope of agency. Light
fittings (with limited cable and without lamps as per availability) may be issued
by NTPC to the agency on returnable basis. A rent of Rs. 1000/- per fitting per
overhaul will be charged from the agency in case of issue of fittings with lamp, if
available.
5) 50 nos. extension boards with 100 m. cable each is to be maintained. A rent of
Rs. 1000/- per board per overhaul will be charged from the agency in case of
issue of boards from NTPC as per availability.
6) Deploy adequate number of electricians round the clock along with suitable
helper support to achieve above.
7) Any material issued from NTPC should be returned in good condition or else the
cost will be recovered from agency’s bill.
8) The payment of one BOQ under this schedule shall be considered only after
completion of all the above mentioned activities to the satisfaction of EIC in each
overhaul.
Sch. 10.60/ This Schedule covers Assistance in boiler tube thickness survey:
Service Code: 1) Cleaning of tubes for Thickness survey.
BMBLR00GN911 2) Assistance during thickness survey.
:- 3) Noting down the values as per the formats given by EIC/area engineer
BOILER 4) Arranging access to the location of survey
(<>)THICKNESS 5) Arranging spot lighting at the location of the survey
M'MENT 6) Arrangement of 08 set D-meters along with Data Logger accessories
7) Scope includes all heat exchanging pr. Parts.
8) Major areas of survey are water wall tube in 1st pass:
a) Near Wall blowers &
b) LRSB openings bends,
c) View glass bends
d) Burner bends,
e) Spiral water wall,
f) Platen SH Panel tubes,
g) Spacer/Tie tubes, RH & SH tubes.
9) In 2nd pass,
a) cage wall tubes near LRSB and other areas,
b) all sling tubes of cage area
c) Economizer and Primary SH & RH coils
d) Other tubes in the cage area as decided by EIC.
10) Before starting of thickness survey, all sling tubes of cage area (Case to Case
Basis) have to be marked with paint/marker so as to identify the tubes
afterwards.
11) Thickness survey is to be carried out as per the plan and drawings submitted
by NTPC.
12) Identification of eroded length of tube.
13) Logging of thickness data in the data logger with proper identification of tube
and location. Submission of thickness survey report with 3 hard copies as well
as soft Copies to NTPC & downloading of data into computer/laptop.
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14) Payment against this BOQ will be made only after submission of report (In both
hard & soft form).
15) All arrangements like necessary area lighting, couplant required for thickness
survey, cleaning agents etc. to be done by contractors.
16) Each point should be a representation of minimum thickness of at least half
meter span.
17) Rough Copy of readings has to be submitted to concerned Site Engineer on
daily basis in order to plan necessary work in affected location.
18) Each point of measurement taken and recorded will be considered as one unit
for measurement.
19) In case of use of grease as a couplant during thickness survey, minimum grease
shall be applied in the area of measurement and same shall be wiped out and
cleaned immediately after completion of thickness measurement of that area.
20) Agency scope
Carrying 10 nos. bags / boxes (to be arranged by the agency), each of which
shall contain,
i. D-meters(10 Nos.)
ii. Skilled manpower
iii. Laptop/computer
iv. Emery papers (coarse grit)
v. Marking cloth
vi. Grease Bottle with screwable lid
vii. Hand lamps (two sets)
viii. Spare 24V Bulbs (2 nos.)
ix. Chalks
x. Permanent white markers
21) All the D-Metres are to be taken to NTPC/FQA Dept. for getting the calibration
certificate. Only after the approval of the NTPC/FQA , necessary work shall be
started in the boiler area.
Sch. 10.70/ Weld Joints – Normal :
Service Code: 1) All weld joints except those done in Platen SH, Final SH, Roof panels and Final
BMBPR00OH001 Reheater and those for replacing burner panel tubes / bends, water wall
:- reducers, cage area screen tube reducers shall be deemed as Normal weld
Blr PP Weld JTS Joints.
(<>) OH) 2) Range of common tubes sizes is 31.8 to 70 mm & thickness from 4 mm to 7.5
mm. If larger welds are to be done, equivalent joints shall be calculated as per
formula given in this schedule.
3) Weld joints will be required to be done in following cases based on boiler
condition:
a) Tube replacement as identified by EIC (before / after inspection).
b) Repair of defective Old weld joints identified through radiography.
c) Repair of fresh weld joints identified through radiography.
d) Repair of eroded / damaged welds identified by EIC.
e) Repair of defects found during DP / NDT tests
f) Hand hole welds.
g) Tube to header stub welds
h) Header girth welds / Header End cap welds.
i) Pre – assembly welds.
j) Fill – up of Dents / localized damaged portions.
k) Pipeline welds.
l) Provision of access doors etc as specified by EIC.
m) Any other work specified by EIC that requires weld jointing to be done.
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4) The weld joints can be butt welds, fillet welds or fillet cum groove welds.
5) Welding to be carried out by TIG only.
6) Tubes to be replaced shall be identified by EIC or his representative.
7) Make approach / access for the tube to be replaced.
8) All cut / removed items / attachments for making the approach / access for tube
removal are to be restored after the work, as per original.
9) Tube cutting shall be done by grinding or by hack saw/saber saw. All vertical
tubes are to be first cut by grinding at bottom. Then a suitable plate shall be
inserted to avoid any foreign material ingress. Only after this the upper joint
shall be cut by grinding.
10) Hold point: Once the bottom side of a vertical tube is cut by grinding and a
plate shall be inserted in to the gap, this shall be shown to EIC / his
engineers and signature obtained, for clearance to cut the top side of the
tube by grinder.
11) All fin cutting shall be done by saber saw/grinder, only after the bottom of the
tube piece being removed is sealed at bottom as mentioned above.
12) After removal of tube piece, the opening of tubes should be immediately
covered by metallic/plastic tube caps.
13) All stainless steel tubes shall be cut exclusively by grinding and hack saw.
14) Cutting of tubes/fins by cutting electrodes is prohibited.
15) Use of gas cutting for tube/fin cutting is not permitted.
16) In case of difficulty in cutting through above method, the agency shall approach
EIC and obtain permission to use gas cutting method.
17) New spools shall be prepared by cutting with chop saw only.
18) New spools shall be cleaned by blowing air / steam thru them before fit – up.
19) Edge preparation shall be as per approved profile for the weld joint. (refer
relevant code)
20) For all butt welds, care shall be taken to match the IDs of the tubes being welded
together.
21) Care shall be taken to ensure that the new segment of tube / pipe / attachment
being installed is of the correct material, in consultation with EIC.
22) Hold point: All new alloy steel tube segments being installed to be got checked
by EIC or his representative (and signature obtained) for correctness of steel
grade.
23) In no case shall the edge be prepared in part or full using gas cutting.
24) Tube fit – up shall be done taking due care to avoid extra stress on the welds.
25) Root gap shall be maintained as per relevant code.
26) Welding of joint shall be done by deploying NTPC tested (and passed) HP
welders, having valid IBR approved licenses only. Welder performance is to be
monitored on daily basis and in case of bad workmanship / poor progress / bad
discipline, EIC shall have the right to refuse permission for the deployment of a
tested and passed welder as well. This shall be applicable for other skilled man
power and supervisory staff also.
27) Correct consumables and procedures as per relevant code shall be employed for
the welding.
28) EIC or his representative shall carry out random checks on the quality aspects.
These aspects are also mentioned elsewhere in the contract, for the reference of
the agency.
29) Whenever tubes / bends in SHs or RHs are cut, ensure that the gaps between the
tubes / bends in the bottom portion of the panel are maintained as per original
after restoration.
30) Each instance of notice of violation of quality norms or procedures shall attract
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a penalty of Rs. 5000/-.
31) Violation of quality norms shall also disqualify the agency for waiver of
penalties with respect to delays if any, even if the boiler box – up time target is
met.
32) Weld joint spatter and slag shall be thoroughly removed and joint prepared for
radiography.
33) Take care to achieve a smooth recommended profile of the external surface of
the weld with proper reinforcement.
34) After radiography, in case defect is found in the weld, the weld shall be repaired
/ redone till the radiograph becomes acceptable. There shall be no additional
payment for doing this repair work. Penalty will be imposed suitably as
mentioned in penalty clause.
35) Preheating of all joints as per procedure shall be carried out as per instruction
of EIC. PWHT to be carried out after welding, if applicable. Payment against
PWHT shall be in the respective BOQ(BOQ No.10.330) .

36) Mode of Payment:

a) Fresh weld: Payable after it is cleared by radiography. One weld joint of Tube
of OD 31.8 mm to 70 mm and thickness up to 7.5 mm will be considered as
one BOQ for payment after joint is cleared in radiography.
b) Spool piece provided for removing a defective weld joint done by the agency
shall be taken as 1 joint only for the purpose of measurement.
c) If a joint done by the agency fails in hydraulic test then the same shall be
replaced free of cost. However if any old joint fails during hydraulic test then
the repair / replacement shall be treated as fresh joint.
d) In exceptional cases where, non completion of radiography or Re-radiography
is not attributable to the agency, and if the agency makes a written request
giving suitable justification, the EIC may waive the requirement for
radiography / Re – radiography, and clear the payment for the weld joint.
e) Old Welds: In case of partial repair/ grind & fill up of defective weld joint,
detected during radiography or visual inspection of old welds, 50 % payment
of one Weld joint shall be made after the repair done by the agency is cleared
thru re-radiography. The same shall be applicable for repair of defects found
in DP / NDT Checks.
f) Old welds: In case of major defect in the weld requiring cut and re welding of
the weld, payment for full weld joint shall be made, after it is cleared thru
radiography. The same shall be applicable for repair of defects found in DP /
NDT Checks.
g) Fill – up of Dents / damaged localized areas on tubes / headers etc: Welding
shall be done as per specified procedure. Payment shall be 25% of the weld
joint rate for each such spot irrespective of size of weld.
h) Hand hole cutting, removal and welding of water wall headers: This is to
be done as per procedure prescribed by the EIC. Payment shall be done
as per clause 36(l) of this BOQ.
i) For replacement of mis – aligned tubes of SHs / RHs, only weld joints are
covered in this schedule. Balance works are payable against the schedule
“Alignment of tubes” under BOQ 10.110.
j) The weld joints which fails in radiography shall be repaired/re welded/
replaced free of cost. Re-radiography will be done for the repaired joints.
k) Repair of weld joints which fails in re-radiography shall be done free of cost.
Agency has to carryout repair/replacement of weld joint till it is acceptable in
radiography. A penalty of the amount of the rate per joint in this schedule will
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be levied if a weld joint fails in re-radiography after first repair.
l) Bigger size welds: In case of bigger size welds (OD greater than 70 mm),
number of equivalent welds, for rate purpose shall be calculated as given
below:
No. of equivalent weld Joints = {(OD of the Big tube or pipe X Thickness of the big
tube or pipe) / (70 X 7.5)} rounded off to the nearest integer. Rate per joint shall be
normal or difficult depending upon the area in which this big weld is located.

Sch. 10.80/ Weld Joints – Difficult :

Service Code: 1) All weld joints those done in Platen SH, Final SH, Roof panels and Final Reheater
BMBPR00GN972 and those for replacing burner panel tubes / bends, water wall reducers, cage
:- area screen tube reducers/P91/T91/SS/DMW shall be deemed as difficult weld
Blr PP Weld JTS (<>) Joints
WELDING 2) Range of common tubes sizes is 31.8 to 70 X 7.5 mm. If larger welds are to be
done, equivalent joints shall be calculated as per formula given in this schedule.
3) Weld joints will be required to be done in following cases based on boiler
condition:
a) Tube replacement as identified by EIC (before / after inspection)
b) Repair of defective Old weld joints identified thru radiography.
c) Repair of fresh weld joints identified thru radiography.
d) Repair of eroded / damaged welds identified by EIC.
e) Repair of defects found during DP / NDT tests
f) Hand hole welds
g) Tube to header stub welds
h) Header girth welds / Header end cap welds.
i) Pre – assembly welds
j) Fill – up of Dents / localized damaged portions
k) Pipeline welds
l) Provision of access doors etc as specified by EIC.
m) Any other work specified by EIC that requires weld jointing to be done
n) The weld joints can be butt welds, fillet welds or fillet cum groove welds.
4) Tubes to be replaced shall be identified by EIC or his representative.
5) All welding joints of boiler tubes shall be done by TIG (Tungsten Inert
Gas) welding only. Welding by Shielded metal arc welding (SMAW) is NOT
permitted for carrying out pressure part boiler tube joints. Accordingly,
welders shall be deployed for carrying out tube joints
6) Make approach / access for the tube to be replaced by cutting the skin casing,
crown plate, peg fins etc. No separate payment shall be made for this.
7) All cut / removed items / attachments for making the approach / access for
tube removal are to be restored after the work, as per original.
8) Tube cutting shall be done by grinding or by hack saw. All vertical tubes are to
be first cut by grinding at bottom. Then a suitable plate shall be inserted to
avoid any foreign material ingress. Only after this the upper joint shall be cut by
grinding.
9) Hold point: Once the bottom side of a tube is cut by grinding and a plate
has been inserted in to the gap, this shall be shown to EIC/his engineers
and signature obtained, for clearance to cut the top side of the tube by
grinder/ saber saw.
10) All fin cutting shall be done by saber saw/ grinder, only after the bottom of the
tube piece being removed is sealed at bottom as mentioned above.
11) After removal of tube piece the opening of tubes should immediately covered
by metallic/plastic tube caps.
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12) All stainless steel tubes shall be cut exclusively by grinding and hack saw.
13) Cutting of tubes/fins by cutting electrodes is prohibited.
14) Use of gas cutting for tube/fin cutting is not permitted.
15) In case of difficulty in cutting thru above method, the agency shall approach EIC
and obtain permission to use gas cutting method.
16) New spools shall be prepared by cutting with chop saw only.
17) New spools shall be cleaned by blowing air / steam thru them before fit – up.
18) Edge preparation shall be as per approved profile for the weld joint. (refer
relevant code)
19) For all butt welds, care shall be taken to match the IDs of the tubes being
welded together.
20) Care shall be taken to ensure that for the new segment of tube / pipe /
attachment being installed is of the correct material, in consultation with EIC.
21) Hold point: All new alloy steel tube segments being installed to be got checked
by EIC or his representative (and signature obtained) for correctness of steel
grade.
22) In no case shall the edge be prepared in part or full using gas cutting.
23) Tube fit – up shall be done taking due care to avoid extra stress on the welds.
24) Root gap shall be maintained as per relevant code
25) Welding of joint shall be done by deploying NTPC tested (and passed) HP
welders, having valid IBR approved certificates only. Welder performance is to
be monitored on daily basis and in case of bad workmanship / poor progress /
bad discipline, EIC shall have the right to refuse permission for the deployment
of a tested and passed welder as well. This shall be applicable for other skilled
man power and supervisory staff also. The agency shall make good the short
fall arising out of such an action, so that the work is not affected.
26) Correct consumables and procedures as per relevant code shall be employed
for the welding.
27) EIC or his representative shall carry out random checks on the quality aspects.
These aspects are also mentioned elsewhere in the contract, for the reference of
the agency.
28) Whenever tubes / bends in SHs or RHs are cut, ensure that the gaps between
the tubes / bends in the bottom portion of the panel are maintained as per
original after restoration
29) Each instance of notice of violation of quality norms or procedures shall attract
a penalty of Rs 5000/-
30) Violation of quality norms shall also disqualify the agency for waiver of
penalties with respect to delays if any, even if the boiler box – up time target is
met.
31) Weld joint spatter and slag shall be thoroughly removed and joint prepared for
radiography.
32) Take care to achieve a smooth recommended profile of the external surface of
the weld with proper reinforcement.
33) After radiography, in case defect is found in the weld, the weld shall be repaired
/ redone till the radiograph becomes acceptable. There shall be no additional
payment for doing this repair work.
37) Preheating of all joints as per procedure shall be carried out as per
instruction of EIC. PWHT to be carried out after welding, if applicable.
Payment against PWHT shall be in the respective BOQ(BOQ No.10.330) .
34) Mode of Payment:
a) Fresh weld: Payable after it is cleared by radiography. One weld joint of Tube
of OD 31.8 mm to 70 mm and thickness upto 7.5 mm will considered as one
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BOQ for payment.
b) Spool piece provided for removing a defective weld joint done by the agency
shall be taken as 1 joint only for the purpose of measurement.
c) If a joint done by the agency fails in hydraulic test then the same shall be
replaced free of cost. However if any old joint fails during hydraulic test then
the repair / replacement shall be treated as fresh joint.
d) In exceptional cases where, non completion of radiography or Re-radiography
is not attributable to the agency, and if the agency makes a written request
giving suitable justification, the EIC may waive the requirement for
radiography / Re – radiography, and clear the payment for the weld joint
e) Old Welds: In case of partial repair/ grind & fill up of defective weld joint,
detected during radiography or visual inspection of old welds, 50 % payment
of one Weld joint shall be made after the repair done by the agency is cleared
thru re-radiography. The same shall be applicable for repair of defects found
in DP / NDT Checks.
f) Old welds: In case of major defect in the weld requiring cut and re welding of
the weld, payment for full weld joint shall be made, after it is cleared thru
radiography. The same shall be applicable for repair of defects found in DP /
NDT Checks.
g) Fill – up of Dents / damaged localized areas on tubes / headers etc: Welding
shall be done as per specified procedure. Payment shall be 25% of the weld
joint rate for each such spot irrespective of size of weld
h) Hand hole cutting, removal and welding of all headers except water wall
headers: This is to be done as per procedure prescribed by the EIC. Payment
shall be done as per clause 35(l) of this BOQ.
i) For replacement of mis – aligned tubes of SHs / RHs, only weld joints are
covered in this schedule. Balance works are payable against the schedule
“Alignment of tubes”.
j) The weld joints which fails in radiography shall be repaired/re welded/
replaced free of cost. Re-radiography will be done for the repaired joints.
k) Repair of weld joints which fails in re-radiography shall be done free of cost.
Agency has to carryout repair/replacement of weld joint till it is acceptable in
radiography. A penalty of the amount of the rate per joint in this schedule will
be levied if a weld joint fails in re-radiography
l) Bigger size welds: In case of bigger size welds, number of equivalent welds, for
rate purpose shall be calculated as given below:
No. of equivalent weld Joints = {(OD of the Big tube or pipe X Thickness of the big
tube or pipe) / (70 X 7.5)} rounded off to the nearest integer. Rate per joint shall be
normal or difficult depending upon the area in which this big weld is located.

Sch. 10.90/ Radiography :

Service Code: 1) Two radiography sources of each minimum of 8 curies shall be mobilized for
BMBLR02GN801 carrying out the work depending upon requirement.
:- 2) Agency should have proper documentation for movement of radiography
BOILER >200MW# sources and should have permission from competent authority such as BARC for
Radiography the radiographic sources.
3) Radiography work shall be coordinated by qualified NDT Level – 2 supervisors
only.
4) If two sources are used then there shall be three teams for carrying out the
radiography work; one each for the RT work with each source and one for the
parallel developing of films. Supervisors shall get the RT done, prepare the
reports and also coordinate for quick evaluation and communication to site
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engineers and for getting repairs and re-radiography done.
5) Radiography reports shall be submitted in excel printed format along with a soft
copy.
6) Radiography shall be done as per procedure / appropriate code.
7) Space for dark room shall be provided by NTPC.
8) Agency shall arrange all inputs required for this work and set up the dark room
/ processing lab. e.g. Drier, illuminator, chemical tanks Etc.
9) Identification numbers for weld joints / bends shall be as per system to be
obtained from EIC.
10) Film size for bends shall be decided based on the size of the bend portion to be
covered.
11) Prepare cassettes loading with films of adequate size.
12) Films of the make such as KODAK – AA 400, OR, AGFA – LAZER – D7 are only
acceptable
13) Ensure sensitivity meter and identification number are fixed properly to the
cassette.
14) Display “Radiation Hazard – Radiography in progress – Keep Away“sign
boards all around the periphery of the likely radiation zone.
15) Ensure RT is being done as per priority given by EIC
16) Ensure RT film is being fixed to the right weld joint.
17) After the films are exposed, these shall be developed and submitted to NTPC
for evaluation.
18) The joints marked for repair shall be re-radio-graphed after carrying out
repairs.
19) The joints marked re-shoot have to be re-radio-graphed after eliminating the
mistakes that occurred in taking the earlier radiographs.
20) The agency shall maintain joint wise record of radiography carried out, the
result, the repairs done and final result. The record must be compiled in a
register everyday and to be submitted to EIC. Cross checking of register shall
be carried out every day with NTPC Engineers.
21) All the radiography report shall preferably be reconciled before internal hydro
test.
22) All the radiography reports shall be submitted to NTPC before start of removal
of quick erect scaffold in first pass and 12 hrs before boiler box up in the areas
other than QES applicable areas.
23) The reports, which are submitted after the due time as above, shall not be
accepted and shall not qualify for any payment.
24) Agency shall arrange at least one radiograph evaluator for use at site.
25) Hold Point: Prioritization of available weld joints for doing RT shall be
obtained daily from EIC or his representatives along with signature. This
specified priority shall be strictly adhered to. After each session of RT is
complete, the actual status of RT done along with reasons for violating
specified priority/exception report, if any, shall be intimated to EIC.
26) Radiographs taken during night time shall be developed and submitted by
10.00 am in the morning, and those taken during lunch hours (13-14 hours)
shall be developed and submitted by 1500hours in the afternoon to EIC for
forwarding to FQA for evaluation.
27) Check radiography: EIC shall ask the agency to take re-shot of few weld
joints identified by him (for which the agency had already submitted
radiographs). The agency shall carry out re-radiograph of such welds (under
witness of EIC’s representative) and submit the developed films for matching
with the original films submitted by him earlier. In case of mismatch of these
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check films with the original films, a deduction of 1% of contract value per each
such not matching film shall be made from the payments due to the agency.

28) Mode of Payment:

a) Fresh weld joints:

i. For one fresh weld joint, payment shall be made for one BOQ only
irrespective of the number of shots taken. Agency will be qualified to get
this payment only if the joint is acceptable in quality. No payment for
radiography shall be made if the joint is not radio-graphed after repair.
ii. Payment shall be made for acceptable radiographs only.
iii. Payment for radiograph shall also be made for those welds for which re-
radiography is waived off by EIC.
iv. For radiographs of Bends, the rate shall be 1.50 times the rate for
radiographs of the weld Joints.
b) Old Weld Joints:
i. Radiography of all acceptable joints is admissible for payment
ii. In case defect is observed in the first radiograph of an old joint, the same is
to be repaired and re-radio graphed. Payment for both radiographs shall be
made in case defect is eliminated but no payment shall be applicable for any
of the radiographs if defect is not eliminated.
iii. Payment for 1st radiograph shall also be made for those welds for which re-
radiography is waived off by EIC
29) Radiography shortfall:
a) 100 percent of the fresh welds done during the overhaul shall be
radiographed.
b) All the old welds identified by EIC shall be radiographed.
c) All welds (fresh or old) in which a defect has been identified shall be re-
radiographed after eliminating the defect.

d) Short fall in any of these shall attract deduction as below:

(1) Fresh weld:
(a) No payment for the weld
(b) Deduction of Rs 1000/- per weld
(2) Old Weld:
(a) Deduction of Rs 500/- per weld
(3) Re-radiography after repair:
(a) No payment for the weld (in case of fresh weld)
(b) No payment for the 1st or intermediate radiographs with
repair
(c) Deduction of Rs 500/ per weld
e) EIC, may, at his discretion, arrange to identify “Must – Do” repairs, out of the
repairs to be done. If these repairs or their re-radiography, is not completed,
then
(1) No payment for the weld (in case of fresh weld)
(2) No payment for the 1st or intermediate radiographs with repair,
and,
(3) Deduction of Rs 5000/- per weld
f) If EIC waives of the requirement of radiography / re-radiography for some of
the shortfall quantity, then for such quantity, the above deductions shall not
be applicable.
Sch. 10.100/ Fins/Membrane/scallop bar/Sacrificial pad:
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Service Code: 1) Shift material to location.
BMBLR19GN972 2) Cut and fabricate to required size / shape.
:- 3) Fit accurately in the gap for fin / over the tube to be protected by shield.
BOILER (FINS) 4) Rectification of old damaged / left – over / burnt fins shall also be done under
WELDING this schedule.
5) Rectification of old damaged/ left – over scallop bar shall also be done under
this schedule.
6) Fabrication of studs/ anchors of 50mm (min.) (for refractory application) from
rods or 6mm to 8mm plates or bolts or studs as provided and welding the same
on fins. These anchors shall be welded before refractory application. Welding of
anchors on fins and in other areas shall be carried out by SMAW process.
However, if required the welding can be done GTAW process for which decision
shall be taken by EIC which will be final and binding on the agency.
7) Fin/Membrane welding, attachment welding etc. shall be smooth and without
voids. Fin welding shall be done by TIG welding (GTAW) only. Fin shall be
welded from inside and outside on each tube by TIG only. SMAW welding shall
not be allowed for Fin welding. Fin /attachment welding shall be done by HP
welders only. Agency shall get the fin welds checked by EIC or his
representative, before installing insulation mattresses.
8) Where buck stay is existing, the fin welding shall be done from inside, taking
care to seal the top and bottom voids (where the fin changes from outside to
inside and vice versa).
9) 2.5 mm dia electrodes only shall be used for shield fixing. Fins/Membrane shall
be welded by filler wires only.
10) Also, this BOQ shall be applicable for continuous welding like WB Sleeve
welding, Protection shield full welding (In burner or any other area as per Site
requirement), Scallop, Seal Box or any other areas inside Boiler. This BOQ shall
also include cutting & removal of cage bottom headers box. Length of box
cutting in running meters shall be paid in terms of equivalent fins welding.

11) Mode of Payment:

a) For measurement total length of fin welding will be considered for payment,
i.e. length of fin multiplied by two.
b) New Fins: Welding of 1 meter of Fin/Membrane fin shall be given 2 BOQ for
payment. If fin welding is done by SMAW process, welding of 1 meter of fin
shall be given 1 BOQ.
c) Removal of scallop bar and fixing of new scallop bar including fabrication of
new scallop bar and its welding for 1 m length by GTAW process only: 3 times
BOQ
d) Removal and re-fixing of old scallop bar including its preparation and welding
by GTAW process only: 2 times of BOQ.
e) Fabrication of Studs/ Anchors and welding for 40 pieces: One BOQ for welding
by SMAW process and 2 times of BOQ for welding by GTAW process.
f) If only welding of stud/anchors are carried out for 40 pieces: 0.5(half) of BOQ
for welding by SMAW process and 1.5(one and half times) BOQ for welding by
GTAW process.
g) Old Fin rectification / fill – up of voids etc: 40% of the rate per each of such
voids.
h) Payment of part length shall be done on pro-rata basis.

Sch. 10.110/ Alignment of Final Re-heater/Platen SH Coils/Final SH Coils /Sling tubes of All
Service Code: horizontal banks of second pass, Roof tubes, etc.:
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BMR/H51GN003 1) This is for correction of tube sagging / bowing / misalignment in Final re-
:- heater /Platen SH/Final SH/ sling tubes of all horizontal banks in second pass
Reheater (COIL) /Radiant Roof tubes.
ALIGNING 2) Alignment of Final Re-heater/Platen SH/Final SH/ coils/Sling tubes:
a) Cutting of male-female connectors. Cutting of male & female connectors shall
be carried out by grinding machine. No gas cutting set shall be used
b) Aligning with the help of aligning channels and tightening.
c) Re welding of male-female connectors after alignment. Male and female
connectors shall be re welded at just above or below existing connectors. Only
GTAW welding by certified HP Welders is permitted for welding of connectors
in SH and RH and other welding works.
d) Replacement of Band spacer, if required for alignment in final SH.
e) The above activities are indicative only and agency shall carry out extra
activities if required for alignment of coils.
f) Agency shall carryout all activities carefully as tubes of special materials are
used in SH and RH areas. In case of puncture/ extra grinding of tubes are done
by agency without permission of EIC, then same shall be restored immediately
at the free of cost by agency. If above defects is repeated by agency, then they
shall be penalized suitably by EIC which shall be binding on agency.
g) Carryout alignment for Sling tubes as per procedure and instruction from EIC.
3) Roof tube alignment:
i) Make access by removing skin casing, peg fins and refractory
ii) Pull up with suitable fixture and relock in to correct position. In case of
major sag, tubes shall be replaced.
iii) Restore the fins and refractory. Allow the refractory to cure.
iv) Restore the skin casing.
4) Agency shall take care of not damaging any tube during alignment. If any tube
or location is damaged while carrying out alignment, same has to be restored
immediately free of cost to the satisfaction of EIC. Also suitable penalty as
deemed fit shall be imposed on the Agency and same shall be final and binding
on the Agency.
5) Works on Economiser coils / Primary RH coils / Primary super heaters
coils including fixing of Binders and alignments of Primary RH, Primary
super heater & Economiser coils in boiler 2nd pass/Cage area
a) Obtain the list of Economizer / Primary RH Coils /Primary super heater
coils on which these works are to be done, from EIC.
b) Arrange adequate number of Chain pulley blocks for lifting / lowering the
coils / pairs.
c) Understand from EIC, the extent of the coil / pair that requires to be
exposed for inspection / work after lifting / lowering. In most cases this will
be full.
d) Remove obstacles, if any the path of movement of the coils / pairs.
e) Ensure that the cutting is done at the appropriate location to achieve the
specified result with minimal effort and work.
f) Lock the Coils / Pairs after specified position is reached.
g) Ensure that the locking is checked by site – supervisor and safety supervisor
for correctness. No work on these coils / pairs is to be started unless this is
ensured.
h) Fix required scaffold / planks etc for taking up the works on these coils /
pairs.
i) Make the coils ready for the intended works.
j) Obtain clearance from EIC for restoring the Coils / pairs.
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k) Restore the coils / pairs after the intended work, ensuring that the
alignment is maintained.
l) Works can be done either by lifting / lowering of the coils / pairs or by
creating of gaps between the coils / pairs as specified by EIC.
m) Fixing of binders along with alignment in Primary RH & Primary super
heater coils. The fixing of binders and alignment of Primary RH coils will not
require lifting of Primary RH coils above its position. Following are
minimum activities to be carried out for fixing of binder and alignment of
Primary RH coils.
i. Shift SS plates and rods to location.
ii. Cut SS plates to required length and fabricate binders.
iii. Erect the binders in Primary RH/Primary SH coils and Economizer coils.
Weld stoppers below the binders as per instruction of EIC.
iv. If required, scaffolding may be erected with pipe and planks for carrying
out above work.
v. The alignment of Primary RH coils shall be carried out by cutting and
welding of coil tube bends (if required), creating gaps between coils etc.
and fixing of binders.
vi. The above are minimum activities and are not exhaustive and agency
shall carry out extra activities for complete alignment of coils.
6) Mode of Payment:
a) For complete alignment of one number coil of final Re-heater/Platen SH
Coil/Final SH shall be considered as one BOQ for payment.
b) For roof tube, two tubes alignment will be considered as one BOQ for
payment.
c) For Cage Wall Screen tubes/Division wall Screen tubes, alignment of 5
numbers of rows shall be considered as one BOQ for payment.
d) Payment for the weld joints and radiographs done to achieve the alignment
shall be made in the respective schedules.
e) Payment for fins, refractory etc shall be under respective schedules.
f) No separate payment for cutting and welding of skin casing, crown plate etc.
done for roof tube alignment shall be made.
Mode of payment for point No.5
i. One pair of Economiser coil=Lifting of One coil of all three banks of
Economiser together(SH Side).
ii. One pair of Economiser coil(RH side)= Lifting of One coil of one bank of
Economizer (RH Side).
iii. One pair of Primary RH coil= Lifting of One coil of all Three banks
together.
iv. One pair of Economizer coil(RH side)= Lifting of One coil of one bank of
Primary Super heater (RH Side).
v. If more or less coils are handled in one set, payment shall be
proportionate.
vi. For example, if one eco coil only is handled as a single unit (instead of
pair), it shall qualify for half of the payment for one set.
vii. If the intended works are got done by creation of gaps between coil –
pairs, then the payment will be considered under coil pulling schedule
under BOQ 10.120
Sch. 10.120/ LIFTING,INSPECTION & LOWERING OF ECO / Primary SH & Primary re-heater
Service Code: COILS ASSEMBLY:
:- 1) Scope includes lifting / lowering of Economiser, Primary SH, Primary reheater
BMECO11GN556 coils by cutting hanger tube and header connections and inspection.
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Eco (COILS) 2) Locking of coils.
LIFTING 3) Total length of the coil has to be pulled out of the bank for visual inspection.
Cassette baffle at both ends of the Coil has to be removed & all tubes / bends
have to be cleaned thoroughly for proper visual Inspection.
4) All consumables and T&P’s, chain pulley with long lift for lifting of coil in
contractor’s scope.
5) Only tested chain block and hook chuck (testing of lifting tools is in contractor’s
scope) should be put into use.
6) For measurement each pair of coil assembly (All Banks) will be considered as
one unit of measurement. All Economizer, Primary SH, Primary reheater coils
are in pairs. Economizer has Four banks, Primary SH has one bank & Priamry
Reheater has three banks. So, when one complete pair of economizer coil is
pulled (with all three banks(SH Side)) it will be measured as One unit. Coils
have to be pulled in separate banks or in groups as per direction of E.I.C. If
more or less coils are handled in one set, payment shall be proportionate(Pro-
rata basis).
7) Attachments cut /damaged for replacement of tubes in lifted Coils have to be
restored back to Original. However, separate Payment shall not be paid to the
Agency for restoration of these attachments.
8) Scope includes removal of Cassette baffle & Inspection of Boiler tubes & bends
inside it and again fitting of Cassette baffle in its original position after
necessary repair, if reqd.
9) The Cassette baffles, as identified by Site Engineer have to be removed after
cutting top & bottom clits. Then tubes & bends inside the cassette baffle have to
be cleaned thoroughly to ensure proper inspection.
10) After removal, cassette baffles have to be kept in safe position in order to
prevent its falling.
11) If any damage is found in any cassette baffle, local repair has to be done by the
Agency by patch welding.
12) Joints made for restoration of the Coil assembly is separately payable.
13) Utmost care has to be taken by Agency men while cutting or welding of
attachments in Coils so as to ensure no harm to Coil tubes which may lead to
Tube failures in future.
Sch. 10.130/ Economiser coils inspection by making gaps by coil pulling
Service Code: 1) Arrangement for pulling of Economizer Coil at the middle bank of Rear Pass of
BMECO11GN402- Cage.
Eco (COILS) 2) Pulling to be done to inspect the coil from front to rear of the coil so as to
INSPECTION provide access to all the tubes of the coil.
3) Pull the coil by Chain pulley block / any other mechanical pulling machine and
maintain gap for a man to inspect the coil tubes inside the bank. NTPC may
provide Inflatable jacks (Air balloon) and air compressor for making gap
between coils free of cost. Agency has to arrange the air hose and small
fittings for operating the inflatable jacks. Also, if required, Agency has to
fabricate Mechanical Spacer arrangement for maintaining gap between pair of
Coils after creating gap by pneumatic Inflatable Jack.
4) After pulling the coil, mechanically lock the coil, as per the direction of NTPC
Engineer.
5) Arrangement of scaffolding inside the coil so that manual inspection of tubes
inside is possible.
6) Assist in inspecting the coil & carry out thickness survey.
7) Normalize the coil after inspection & repair.
8) For measurement purpose, Pulling of each pair of coil assembly (All three
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banks) will be considered as one unit of measurement. In ECO, coils are in pairs.
Economizer has four banks. So, One Unit of this BOQ shall be paid for pulling of
Upper, Middle & Lower Bank of same Coil located in Primary super heater side.
9) One Economiser bank (1 st bank) is located in Reheater side, which can also be
inspected by similar method as explained above.
10) In case of single bank pulling, Payment shall be made proportionately.
11) Utmost care has to be taken by agency workmen while cutting or welding of
attachments in Coils so as to ensure no harm to Coil tubes which may lead to
Tube failures in future.
Sch. 10.140/ Primary SH Coil/ Primary Re-heater coils inspection by making gaps by coil
Service Code: pulling
BMLTS02GN402-
LTSH (<=210MW#) 1) Arrangement for pulling of Primary SH Coil /Primary RH Coils at the middle
INSPECTION bank.
2) Pulling to be done to inspect the coil from front to rear of the coil so as to
provide access to all the tubes of the coil.
3) Pull the coil by Chain pulley block / any other mechanical pulling machine and
maintain gap for a man to inspect the coil tubes inside the bank. NTPC may
provide Inflatable jacks (Air balloon) and air compressor for making gap
between coils free of cost. Agency has to arrange the air hose and small fittings
for operating the inflatable jacks. Also, if required, Agency has to fabricate
Mechanical Spacer arrangement for maintaining gap between pair of Coils after
creating gap by pneumatic Inflatable Jack.
4) After pulling the coil, mechanically lock the coil, as per the direction of NTPC
Engineer.
5) Arrangement of scaffolding inside the coil so that manual inspection of tubes
inside is possible.
6) Assist in inspecting the coil & carry out thickness survey.
7) Normalize the coil after inspection & repair.
8) For measurement purpose, pulling of each pair of coil assembly (All Banks) will
be considered as one unit of measurement. In Primary RH, coils are in pairs.
Primary RH has three banks. So, One Unit of this BOQ shall be paid for pulling of
upper, middle & lower Bank of same coil. In case of single bank pulling, Payment
shall be made proportionately.
9) Primary SH has one bank only. Hence 1/3 rd payment shall be considered for
inspection of each pair by pulling.
10) Utmost care has to be taken by Agency men while cutting or welding of
attachments in Coils so as to ensure no harm to Coil tubes which may lead to
Tube failures in future.
11) Cassette baffle needs removal before inspection of the coil. Hence same to
be removed which shall be paid in respective schedule (BOQ).
Sch. 10.150/ DP test / MPI:
Service Code: 1) The agency shall arrange level-2 personnel in LPI/MPI for conducting the test.
BMBPR00GN900 Copy of certificate to be submitted before start of work.
:- 2) DPT kit/ MPI Kit is in the scope of the agency.
Blr PP Weld JTS 3) The DP test kit brought by the agency shall be Chlorine free.
(<>) Testing 4) Make approach including scaffolding to the place where DPT/MPI is to be
carried out.
5) Clean out the surface where DPT/MPI is to be carried out.
6) Light grinding / polishing of surface may be required to ensure good quality
test.
7) Carry out DPT/MPI in the presence of EIC or his representative, as per specified
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procedure.
8) Make a protocol / list of locations or welds tested by DPT/MPI and obtain the
signature of EIC or his representative against the record of the test of each such
weld. Payment shall be admissible for properly done DP/MPI test as identified
in above protocol only
9) Locations for arranging DPT/MPI test shall be obtained from EIC prior to and
during the shutdown.
10) DPT/MPI kit used should be within expiry date.
11) Mode of payment:
a) Pipe/Tube welds: The rates under this schedule will be applicable for max.
70 mm OD Tube i.e., the max weld length of 4 x 70 mm. In case of higher
pipe sizes, the payment shall be done as per following formulae: -

Payable Quantity = (Pipe OD in mm/ 70).

b) Half welds: In case only half portion of a weld joint is tested (as in case of
scalloped plate welds) then it will be treated as half joint for the purpose of
payment.
c) Fin weld and attachment welds: In case of fin welds and attachment welds a
length of 240 mm shall be considered as 1 BOQ for payment. In case of
longer or shorter welds payment shall be done on pro-rata basis.
d) In case DP/MPI Kit is provided to the agency by NTPC / any other agency
engaged by NTPC, then 50 % of the rate of DP test/MPI shall be admissible
for the payment. In that case also all manpower required for the DP
test/MPI , surface preparation and providing all other consumables except
DP Kit shall be in agency’s scope.
Sch. 10.160/ Fabrication of bends:
Service Code: 1) Shifting of straight tubes to the location.
BMBLR22GN250 2) Make the bends using either cold bending machine or by hot bending.
:- 3) Stress relieving of the bend(s) shall be done if specified by EIC, as per
BOILER (TUBE procedure. (Payment for stress relieving is covered under the schedule:” Stress
BENDS) Relieving”)
Fabrication 4) Offer the bends for visual inspection of EIC and obtain his clearance for use of
the bends.
5) Offer the bends for NDT (DPT & MPI) inspection at FQA also, if instructed by
EIC.
6) Adequately skilled persons to be deployed for this work to minimize wastage of
tube(s).
7) Mode of Payment:
a) Payment is admissible for all bends of acceptable quality.
b) Payment for “2 Nos. of bends made in one plane” in a single boiler tube shall
qualify for one BOQ. For more than two bends made in one plane in a single
boiler tube, payment shall be made on pro - rate basis over and above 2 bends.
c) In case of compound / complex bends, the number of bends in a piece shall
qualify for separate full payment. 3D Bends i.e., tube bends coming in two
planes or more than two planes are qualified for compound bends. In case of
any dispute regarding complexity of bends, decision of EIC shall be final and
binding on the agency.
d) In case of poor quality of fabrication of boiler tube bends resulting in non
acceptance of any bends thereby resulting in wastage of boiler tubes, then
penalty of two times the PSL rate of boiler tube shall be imposed on agency for
wasted boiler tubes.
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Sch.10.170/ Service FIXING OF PROTECTION SHIELDS:
Code:
BMBLR16BD800- 1) Scope of fixing protection shield is as follows
BOILER (SEGMNT a) In Economiser coil banks/primary reheater/Primary super heater coil
SHIELD) Repl banks
b) sling tubes of all coil banks /tie tubes & tie tube bends and cage
wall/Division wall screen tubes as per NTPC direction.
2) Removal of any damaged shield for fixing this new shield if required has to be
done.
3) NTPC scope: -welding electrodes & protection shield of length 1.5 to 2 mtr.
Length along with clamps.
4) Each shield fixed with min. two nos. of clamps will be considered as one unit.
5) Payment for Scaffolding for the above job will be considered under BOQ 10.40
Sch.10.180/ FABRICATION OF PROTECTION SHIELDS:
Servcice code: 1) Required quantity of SS straight shield 3.15mm thick is to be drawn from store.
BMBLR16GN250- 2) Marking and cutting as per the requirement of the drawings/ tube or shield
BOILER (SEGMNT sample.
SHIELD) Fabrication 3) Grinding and smoothening the cut edges.
4) SS shields are to be bent half round over the profile of the tubes of ECO 90 deg
bend, LRSB bends, manhole door bends, etc., as per the profile of the tubes of
respective area to be made.
5) After bending the gaps in shield have to be filled with welding with suitable
electrode.
6) Shield fabricated for fixing on one bend will be considered as one unit for
measurement.
Sch.10.190/Service FIXING & WELDING OF ATTATCHMENTS TO COILS/PANELS
code: 1) The scope includes welding of attachments strips of Stainless steel / Alloy Steel
BMBLR28GN972- material. If reqd., S.S wire mesh may be fitted in Platen SH /Economizer Coils,
(FIXING & WELDING which shall also be covered under this BOQ.
OF ATTATCHMENTS 2) The scope will cover fixing of Male & Female flexible connectors, anti rubbing
ON COILS): strips, protection plate BETWEEN rubbing coil parts, spacer tube clits and
clamps, Vibration arrestors etc on coils.
3) These strips to be fitted over the boiler tubes, welded by IBR welder only.
4) For measurement purpose, each S.S.Wire mesh of 2M X 1M size shall be
considered as One Unit and in case of attachment, each set shall be considered
as One Unit. For Example, in case of flexible connector welding, one female &
two male connector welding shall be taken as One Unit.
10.200 The scope of work includes restoration of Drip shield plates/ SS woven wire
BMBLR23BD801- mesh/ SS woven wire mesh below S panel in Bottom Ash Hopper:
BOILER(SEAL 1) Drip shield plates/ SS woven wire mesh/ SS woven wire mesh installed in
PLATE) Repair Furnace Bottom Hopper. All damaged Drip shield plates/ SS woven wire mesh
are required to be replaced with new plates and fasteners, Tack welding of all
Drip shield plates/ SS woven wire mesh shall be carried out.
2) The fabricated Drip shield plates/ SS woven wire mesh will be provided by
NTPC. In case fabricated Drip shield plates are not provided by NTPC, then Drip
shield plates shall be fabricated by Agency for which no extra payment shall be
made to agency.
3) For fabrication of Drip shield plates:
a. Shifting of Stainless Steel plates to the site from store.
b. Cutting of scallop bar of required size and shape from SS plates.
c. Cutting of Drip shield plates of required size and shape from SS plates.
4) Erection of scaffolding inside bottom ash hopper upto bottom of S panel for
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replacement of Drip shield plates/ SS woven wire mesh.
5) Removal of Old worn-out/damaged Drip shield plates/ SS woven wire mesh.
6) Inspection of scallop bar used for holding drip plates. DPT of scallop bar shall
be carried out after removal of drip shield plates/ SS woven wire mesh.
Damaged scallop bar should be replaced with new scallop bar. Welding of
scallop bar to the bottom portion of S panel tubes shall be carried out by TIG
(GTAW) welding only.
7) Spacers on scalloped bar shall be welded by TIG (GTAW) welding only.
8) Locking of Drip shield plates/ SS woven wire mesh with scallop bar by SS
fasteners.
9) Locking of Drip shield plates/ SS woven wire mesh will be carried out as per
drawing and instruction of EIC.
10) Carryout Tacking of SS Nut with SS Bolts.
11) Cutting of SS plates by cutting electrodes, Gas etc. is not permitted. SS plates
shall be cut by plasma cutting machine (to be provided by NTPC) or
cutting/grinding machine.
12) EIC or his representative shall carry out random checks on the quality aspects.
These aspects are also mentioned elsewhere in the contract, for the reference
of the agency.
13) Required electrodes/filler wire, SS fasteners and SS plates will be provided by
NTPC.
14) Mode of Payment:
a) Payment for all activities except scaffolding, required for restoration of Drip
shield plates/ SS woven wire mesh below S panel shall be carried out in this
schedule only. Payment for Scaffolding erection shall be given in separate
BOQ “Miscellaneous Scaffolding 1st Pass & 2nd Pass”.
b) Replacement of Total Drip shield plates/ SS woven wire mesh with
scalloped bar of one boiler shall be considered as one BOQ for payment. In
case Total Drip shield plates/ SS woven wire mesh are not replaced, the
payment shall be made on prorate basis with following formulae:
i. Payment for partial replacement of D.S. plates = No. of D.S. plates/ SS
woven wire mesh replaced x BOQ amount/Total D.S. plates/ SS
woven wire mesh.
ii. Incase Tacking of fasteners are not carried out, penalty of Rs.200/-
will be imposed for each untracked fasteners.
Sch.10.210 Pent house: Inspection & Repair:
Service code" 1) The whole of pent house are in the scope of the agency (Not just first pass
BMP/H00BD801 alone).
:- 2) Make big openings in pent house enclosure as specified by EIC.
Penthouse/Dead 3) Ensure fast cooling of the enclosure by setting up and maintaining blowers,
Chamber(<>)- pedestal fans etc. These equipments are to be issued from NTPC.
4) Trouble shooting in these cooling / ventilating equipments, if required.
Repair
5) Cleaning of ash deposit from these areas manually, filling up in bags. Ensure
proper disposal of collected ash to avoid its spillage in nearby areas.
Weighment as per LMI? In case of spillage, penalty of Rs.5000/- will be imposed
for each instance at discretion of EIC.
6) Ensure use of nose masks and hand gloves by all persons engaged in this work.
7) Ensure that the ash deposits have cooled adequately before asking persons to
enter these areas.
8) Deploy adequate number of persons round the clock to clear the areas of ash as
per time targets mentioned below.
9) Cleaning of ash from top of pent house.
10) Cleaning of ash and insulation debris from inside pent house.
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11) Inspection of skin casing and enclosures in all these areas.
12) Inspection of insulation seal around hangers as well as in the sides and corners.
Repair the same if found in damaged condition.
13) Inspection of hangers of headers and tightening / repair of loose / damaged
hangers.
14) Welding of broken supports. Repair of supports, beams and stays. If steel is
required for the repair work, then payment shall be under the schedule” Steel
fabrication”.
15) Repair of skin casing and enclosures.
16) Fitting and welding of U type expansion pieces at crack – prone locations, as
specified by EIC.
17) Restoration of Sky climber wire – rope conduits up to roof top. Provision of
flanged dummy plates at the top of these conduits.
18) Fixing / restoration of meshes inside Top vent – out doors in roof of pent house.
19) Fixing of new / loosened thermo couple pads on tubes / headers
20) Repair/replacement of expansion joints of pent house.
21) Local access / approach / scaffold required for inspection of header stubs,
headers, DESH, internal pipelines etc.
22) The ash collected in bags shall be put in to an ash evacuation pipe whose
opening is near penthouse, along with water.
23) Repair leakages if any in the ash evacuation pipe.
24) Any other work related to pent house, ash evacuation pipe etc involving steel
fabrication shall also be payable under the schedule “Steel Fabrication”
25) For safety during erection/dismantling of cup-lock scaffolding special purpose
anchor ropes shall be used to tie with safety belts. For this purpose, few
locations in skin casing are to be cut and pipes/ boxes with flanged connections
are to be welded over these holes through which anchor ropes are to be
inserted. These holes shall be extended up to the pent house roof through
conduits if required as per instruction of EIC.
26) Repair of insulation of penthouse roof / enclosure including replacement /
repair of cladding sheet.
27) Time target for pent house ash & insulation debris clearing: 135 hours from
PTW issue.
28) Deduction for delay: Rs 1000 per hour.
29) The above deduction may be waived off by EIC, if by making extra efforts, all
identified works and inspections are done by the agency without violating
quality norms to the satisfaction of EIC, and if Boiler box – up time target is met
as specified by EIC.
30) Damaged refractory to be removed & re-poured as per procedure.
31) Mode of Payment:
The payment of one BOQ under this schedule shall be considered only after
completion of all the above mentioned activities to the satisfaction of EIC in
each overhauling. The breakup of the one BOQ is mentioned below:
a) Pent house ash cleaning: 30%
b) Skin casing repair: 20%
c) Sky Climber rope and anchor rope conduits up to roof: 10%
d) Balance works: 40%
e) Refractory works: as per refractory schedule.
Sch.10.220 INSPECTION, RECTIFICATION OF PIPING HANGERS of MS, CRH, HRH, BOILER
Service code: INTER CONNECTION PIPING IN BOILER
BMHGR00OH001:- 1) Scaffolding should be erected for hangers which are inaccessible.
HANGER (<>) OH 2) Erect scaffolding during unit running time i.e. 10 days before shut down of unit.
3) Record hot readings of all hangers before the unit is shut down for overhauling.
4) Read cold readings of all hangers after the unit is shut down, drained & cooled
sufficiently.
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5) Reset the cold value. Designed Cold value of hanger will be supplied by NTPC.
6) Check hot value after synchronization as per the direction of E.I.C.
7) Cold and hot reading has to be recoded and protocol to be made.
8) All the hangers in MS, CRH, HRH, HP & LP Bypass and Feed water lines from
boiler to turbine, boiler interconnecting piping & Boiler hangers & supports
above pent house, hanger & supports of S panels, bottom Ring headers, Dead
chambers will be considered as one unit of measurement. 25% payment for hot
reading before Unit Shut down and after unit shut down and 75% payment for
cold readings and repair. Total no of hangers will be approximately 300 nos.
10.230 The scope covers Refractory Removal, Application of Refractory & Making of
BMBLR17GN800- Refractory Blocks etc.:
BOILER 1) Obtain the list of locations where the refractory is to be removed, restored or
(REFRACTORY) redone fully from EIC.
Remove & Apply 2) Arrange access, approach and local lighting.
3) Shift materials (castable, pourable & plastic refractory etc.) to location.
4) Ensure that while removing, the removed pieces do not fall on lower elevations.
5) Ensure that the removed pieces are carefully stuffed in to disposal bags and
shifted to identified location as per EIC.
6) Ensure that the area to be covered is thoroughly cleaned and cleared of old
refractory pieces, powder, debris or any other loose material.
7) Fix retaining meshes, rods, stiffeners, anchors, studs etc as per advice to be
obtained from EIC, over the surface / area to be covered by refractory. Payment
for welding of anchors, rods, studs shall be done in schedule for fin/ membrane
welding additionally.
8) Ensure all crevices, gaps, constricted spaces etc are thoroughly filled up with
the new refractory. Ram if needed. Agency must provide rubber hand gloves to
the person who is engaged for refractory job. Karni, bucket, tasla & spade to be
also arranged by party.
9) Ensure high quality surface finish.
10) Plastic refractory is to be applied at corners of Z panels, soot blower openings,
burner bends, LRSB openings, HRSB openings etc. Application of plastic
refractory is to be done by adequately skilled manpower. Provide proper safety
PPE to the manpower during preparation and application of plastic refractory
i.e. rubber hand gloves, gum boot etc.
11) Offer to EIC for visual inspection. Obtain clearance to go ahead with curing
process.
12) Cure/heating the refractory as per specified procedure. Protect the area during
curing time.
13) Do the refractory casting works sufficiently in advance to have adequate curing
time during the overhaul.
14) Refractory application should be smooth and to be carried out by skilled
personnel only. Uneven application of refractory will be rejected and rework to
be done free of cost till it is acceptable by EIC.
15) Mode of Payment:
a) Preparatory work for refractory: 20%
b) Refractory casting: 50%
c) Curing work: 30%
For Plastic refractory, the rate shall be 1.50 times the normal refractory.
Weight of refractory material (excluding its other mixtures) applied in tonnage will
be considered for measurement. Refractory work of manhole doors shall not
covered under this schedule. Unit of Measurement of this BOQ item is MT(Metric
Tonne)
Sch. 10.240/ Removal and installation of Insulation Pads and Aluminum Sheeting:
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Service Code: 1) Erection of scaffolding (if required).
BMPDI02GN800 2) Removal of Aluminum sheeting at desired location as per instructions of EIC.
:- 3) Removal of insulation layers and disposal as per EIC instructions. Ensure that
Pad Insulation disposal of damaged insulations shall be done properly to avoid spillage of
(250MM THK) insulation in the boiler. If spillage of insulation is found, penalty of Rs. 5,000/-
Remove & Appl will be imposed for each instance.
4) Installation of New insulation after clearance from EIC.
5) Welding of insulation holding pins. Utmost care should be taken to avoid any
welding of insulation holding pins to boiler tubes.
6) Welding of Insulation holding washers.
7) Installation of Aluminum sheeting.
8) Removal and disposal of old insulation.
9) Fixing/Replacement of Aluminum sheeting:
a) The scope covers installation of new aluminum sheeting and fixing of old
loose aluminum sheeting in various areas of boiler.
b) The agency shall remove old aluminum sheeting and fix it by screws. Incase
aluminum sheeting is missing in an area; then new aluminum sheeting has
to be installed in missing area.
10) Payment:
a) Removal and installation of 1 square meter of insulation of 250mm
thickness with fixing of Al. cladding sheet shall be taken as one BOQ for
payment. Payment of Insulation of thickness and area other than this shall
be done on Pro-rata basis.
b) Payment for Fixing/ Replacement of only Aluminum sheeting (clause 9 of
this schedule): Fixing/ replacement of 16 square meter of aluminium
sheeting shall be taken as one BOQ for payment.
c) Payment for Scaffolding if any shall be done in schedule 10.40.

Sch. 10.250/ Stress relieving per cycle:

Service Code: 1) Stress Relieving shall be done for following:
BMBLR02GN861 a) Bends fabricated at site as decided by EIC.
:- b) Header to tube joints.
BOILER >200MW# c) Weld overlay work on header.
STRESS RELEIVING d) Butt welded joints as per applicable code
e) Dis-similar weld joints, if applicable.
2) In one cycle of stress relieving more than one Bend/ Joint etc. can be covered
as decided by EIC.
3) SR shall be done as per procedure laid down in relevant codes / as per the
direction of engineer in charge.
4) The measurement shall be per cycle of Stress relieving OR No. of Tube joints.
5) The agency shall have to arrange all the equipment necessary to carry out SR
like heating source, heating coil, control panel, thermo couple, recorder etc.
6) Only calibrated equipment shall be deployed.
7) Whenever header is involved, the SR shall be done for a circumferential band
with the weld located at the middle.
8) Electrical resistance heating shall be done for SR. However, on instruction from
EIC, Induction heating shall be carried out for Stress relieving. Induction
heating machine will be in the scope of NTPC for the purpose.
9) Adequate nos. of thermocouples shall be mounted for proper measurement of
temperature and rates of heating and cooling.
10) SR Cycles are to be properly recorded and graphs submitted to the EIC.
11) For payment :
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a) One SR cycle= 1 BOQ if SR. is carried out by resistance heating. If SR is
carried out by induction heating, then one SR cycle shall be paid halve (0.5)
the BOQ rate.
OR
b) In case of multiple butt welded tube joints around one location, SR of up to 8
Nos. of Tube joints = 1 BOQ. If SR. for more than 8 Nos. tubes are carried out
in one SR. Cycle after getting permission from EIC, then payment shall be
made on pro-rate basis for additional tubes above 8 Nos. of tubes.
c) For S.R. of loose boiler tube bends: minimum 8 Nos. boiler tubes shall be
stress relieved in one cycle. Accordingly, agency shall be paid one BOQ for
S.R. of 8 Nos. boiler tube bends. If S.R. for more than 8 Nos. boiler tube bends
are carried out in one S.R. Cycle after getting permission from EIC, then
payment shall be made on pro-rate basis for additional tube bends above 8
Nos. of tube bends. Incase boiler tube bends for S.R. are less than 8Nos., then
agency shall get permission from EIC before proceeding for S.R. and
payment shall be given one BOQ for one SR cycle.
Sch. 10.260/ Cassette Baffles Work
Service Code: 1) This schedule covers the following works:
BMBLR15OH001 a) Replacement of cassette baffles of ECO / Primary RH/Primary SH Coils.
:- b) Complete removal of cassette baffle from a coil and re-fixing it after repair,
BOILER (CASSET on same or other coil.
BAFFLE) OH c) Repair of top cover sheets, stiffeners, clamps etc of the cassette baffle in
position. In this case, such repair of 02 cassette baffles shall be considered as
equivalent to replacement of one cassette baffle.
d) Cleaning of ash deposition inside Cassette Baffles.
2) Shift the cassette baffles along with its accessories to location.
3) Pre – assemble the cassette baffles with accessories as per guidance to be
obtained from EIC.
4) All welding of cassette baffles shall be Full (not stitch / tack).
Sch. 10.270/ ATTENDING MISC. JOBS IN BOILER PRESSURE PARTS & NON PP AREA
Service Code: One No. indicates deployment of gang of 1 skilled fitter, 1skilled welder, 1 semi-
BMDEP00GN602 skilled person and 1 helper for a normal working day of eight hours. The gang
:-
to be deployed in evening or night shifts as per requirement. For job carried
out on round the clock basis, contractor shall deploy his manpower in shifts. Part
payment will be made on pro rata basis based on actual manpower deployed.
General T&P except special tools required for the work shall be in the scope
of the contractor and is included in the scheduled rate.
1) If the contractor fails to deploy specified manpower, penalty for the shortage
equal to double the awarded rate shall be imposed.
2) The deployment of manpower can be for any job not covered under in the BOQ
and scope of this contract and this deployment can be anywhere in the plant.
The decision of EIC in this regard will be final.
3) For emergency jobs, as decided by NTPC, agency has to deploy manpower
for 24 Hrs basis and agency should provide all amenities like food to the
workmen.

Jobs which may be carried out are as follows:

a) Preservation of boiler tube/ coils etc. At site.
Name of The Work: Overhauling of boiler pressure parts, APH, DUCT, MILL, Burners, Fans, hanger
supports & associated works in one units of NTPC Lara STPP in 2020-21

SCOPE OF WORK
NIT NO : 9900214352
Page 37 of 39

b) Sorting and stacking of boiler tube and other items at various locations.
c) Colour coding of various tubes etc.
d) Assistance in material mix up checks of boiler tubes and bends.
e) Attending of defective vane diffuser of oil gun.
f) Assistance in HVT probe operation.
g) Assistance in burner related, SADC problems other than in above schedules.
h) Assistance for repair and salvaging of NTPC T&P like hydraulic jacks,
electrical winches, chain blocks etc.
i) Fixing of buck-stay pins / repair work for arresting vibrations.
j) Minor repair of railing / toe guards / small opening in floors. Steel required
for this work shall be issued through dept. stores to the contractor.
k) General housekeeping /beautification and proper stacking of spares in areas
pertaining to deptt. Stores. As specified by EIC.
l) Assistance in issue and shifting of general materials related to pressure parts
and soot blowers from different stores.
m) Assistance in inspection, surface preparation and DP testing of scaffolding
material.
n) BRP discharge pumps valve operation.
o) Shifting of sump pump/submersible pump as per instruction of EIC.
p) Repair of submersible pumps.
q) Assistance in auxiliary boiler furnace inspection & other works.
r) Cleaning of steam traps etc.
s) Works on HFO heaters and coolers if any.
t) Replacement of hoses in HFO unloading area.
u) Works on Plate Type Heat exchangers for Equipment cooling, if required.
v) Assistance during boiler hydrotest for installation of gauges, valves
tightening and etc.
Sch. 10.280/ Misc. works, doors, structure servicing/repair for 1st &2nd pass:
Service Code: 1) Boiler Doors:
BMSTR00OH000 i) All doors of the Boiler (as defined for this contract) are included in the scope.
:- These are:
Structures (<>) a) Peep Hole doors
Serv b) Manhole doors / Access doors
c) Scaffold doors at 10 m and 56 m
d) Pent house roof top Vent – out doors and other openings in penthouse
e) Any other openings
ii) Works to be done for these doors are:
a) Servicing them to make them freely operable
b) Replacing the ropes / gaskets / nuts and bolts to make the doors air –
ingress free.
c) Repair of the components of the doors if required.
d) Replacement of the peephole door assemblies if required.
e) Replacement/ repair and fixing of cooling air hoses from service air
points to peep hole.
f) Replacement of doors if required
iii) Works to be done specifically for scaffold doors of Boiler
1) 62 m doors:
Name of The Work: Overhauling of boiler pressure parts, APH, DUCT, MILL, Burners, Fans, hanger
supports & associated works in one units of NTPC Lara STPP in 2020-21

SCOPE OF WORK
NIT NO : 9900214352
Page 38 of 39
(1) Dismantling and re – erection after completion of work
(2) Replace with pre – fabricated doors.
(3) If pre – fabricated door is not available, carry out the following
activities (For these activities, steel used shall be payable against
“Steel Fabrication” and refractory work shall be payable against
“Refractory” schedule.)
(a) Chip out all old refractory
(b) Cut and remove all damaged rods, plates, stiffeners, side
plates, back – up plate etc.
(c) Replace the removed components with new items
(d) Carry out full welding
(e) Install grid of stiffeners
(f) Clean thoroughly and recast refractory/ block casting.
2) 13 m doors & Second pass manhole doors: (For these activities, steel
used shall be payable against “Steel Fabrication” and refractory work
shall be payable against “Refractory” schedule.)
(a) Dismantling and re – erection after completion of work
(b) Chip out all old refractory
(c) Cut and remove all damaged rods, plates, stiffeners, side
plates, partition plates, back – up plates etc
(d) Replace the removed components with new items
(e) Carry out full welding
(f) Install grid of stiffeners
(g) Clean thoroughly and recast refractory blocks.
2) Boiler structures:
i) All boiler structures of boiler first pass and all structures above Separator
level are covered in this schedule.
ii) Works to be done are:
1) Cleaning of all the structures including buck stays, beams, guides etc
2) Inspection of the structures
3) Attending to defects noticed in the structures as specified by EIC
4) Restoration of missing buck stay pins
5) If any new steel sections are used for this work, the same shall be
payable against the schedule “Steel Fabrication”
3) Other miscellaneous works:
i) Provision of Expansion indicators, marking of scale on the rods, locking the
rod and punching of the plate diagonally below the expansion rod.
ii) Installation of ASLD (Acoustic Steam Leak Detector) points (32 nos.) in boiler
1st and 2nd pass. The work consists of removal of insulation, cutting of
fins/casing/removal of peep hole, welding of ASLD pipe, restoration of fins/
membranes and restoration of insulation.
iii) Restoration of damaged Drip shield/wire mesh plates. Damaged scalloped bar
plate to be removed carefully without damaging boiler tubes. New plate to be
cut as per required dimensions and to be welded properly. If any boiler tube is
found damaged during replacement of these plates, penalty of 5 times of BOQ
per joint of schedule 10.60 will be deducted
iv) Seal plate, repair and maintenance. Damaged bolts & nuts to be cut and they
are to be replaced. Damaged plates to be repaired.
v) Conducting inspection and attending to defects in hydraulic tests after the
overhaul. Hydraulic test may be done at least twice after the works are carried
out. Defects attended shall be payable, as per respective schedules if they are
not from the works done by the agency. Defects observed in works done by
Name of The Work: Overhauling of boiler pressure parts, APH, DUCT, MILL, Burners, Fans, hanger
supports & associated works in one units of NTPC Lara STPP in 2020-21

SCOPE OF WORK
NIT NO : 9900214352
Page 39 of 39
the agency shall be attended by him free of cost.
vi) Conducting inspection and attending to defects in Vacuum pulling tests after
the overhaul. Defects attended shall be payable, as per respective schedules if
they are not from the works done by the agency. Defects observed in works
done by the agency shall be attended by him free of cost.
vii) Conducting inspection and attending to defects in Air Tightness tests, before
and after the overhaul. Defects attended shall be payable, as per respective
schedules if they are not from the works done by the agency. Defects observed
in works done by the agency shall be attended by him free of cost.
viii) Collection of tube samples from boiler, trimming them as specified, assisting
in packing, marking etc
ix) Any other work as directed by EIC.
x) Air line leakage arrested by welding.
xi) Mode of Payment:
The payment of one BOQ under this schedule shall be considered only after
completion of all the above mentioned activities to the satisfaction of EIC in one
overhauling. The unit breakup of the one BOQ is mentioned below:

Break – up percentages in case of non – execution:

(1) Doors:30%
(a) Scaffold doors: 40%
(b) Access Doors: 25%
(c) Peephole doors and others: 35%
(2) Structures:30%
(a) Cleaning: 60%
(b) Other works:40%
(3) Other Miscellaneous works:40%
 NIT NO : 9900214352
Annexure-IV
Name of the Work: Overhauling of boiler pressure parts, APH, DUCT, MILL, Burners, Fans,
hanger supports & associated works in one units of NTPC Lara STPP in 2020-21

SCOPE OF WORK(Burner & Oil Guns):

The scope of work envisages “Burner Assembly/Coal Compartments replacement and associated
jobs during O/H and Reconditioning of Coal Compartment and Coal Nozzle Tips after O/H,
duct/dampers/ APH/ FAN of one unit of NTPC Lara STPP in 2020-21” as described in detailed
scope of work and as per the instructions of Engineer–In–Charge.
Brief Description of the work
The overhauling works includes following activities:

(a) Dismantling cleaning, inspection and repair/ replacement of burner elbows.

(b) Dismantling, cleaning inspection and repair / replacement of coal burner pipes / nozzles.
(c) Servicing of air registers.
(d) Dismantling cleaning, servicing and repair / replacement of oil burners, guide assemblies,
protection of pipes, impeller holding pipes etc.
(e) Dismantling of 45 nos./ unit of igniter guns, oil guns cleaning, cleaning and replacement of
peephole glasses, view glasses etc.,
(f) Reconditioning of damaged burner assemblies.
(g) The payment for different items will be as per applicable BOQ.

DETAILED SCOPE OF WORK WITH SPECIAL TERMS & CONDITIONS

20.10 Removal & Fixing of Coal pipe elbows & gates: BMPFB56BD800
A) Removal of thermal insulation on the wind box so as to expose the welding joints of burner and
the wind box
B) Arresting of coal pipes with temporary supports/chain blocks as per the instruction of NTPC’s
Engineer. This job may involve cutting/fabrication and welding of ISMC 150 or available size,
on average 3 to 4 nos. for each pipe.
C) Removal and shifting of coal pipe elbows (along with pneumatic gates) to safe location.
D) Marking the match marks with paint of all elbows before dismantling.
E) Removal/dismantling of coal pipes/elbows and pulling out using suitable lifting arrangements.
Place it on the floor available in the respective elevation. Placing should be such that these pipes
should not obstruct the path for other works to be carried out during overhauling.
F) Replacing all the packing ropes/Gaskets with new ones while fitting back.
G) Fixing of coal pipe elbows in location after clearance of coal compartment jobs.
H) For measurement purpose one coal pipe elbow along with gate will be considered as one unit.

20.20 Removal & Fixing of Burner Assembly/ Coal Compartments : BMPFB01OH000

Removal:-
A) Removal of all C & I related equipments and obtaining clearance from C & I to Proceed further.
B) Removal of Scanner /oil gun hoses and keeping away from burner area as indicated by E.I.C

Page 1 of 30
 C) Removal of oil gun/Igniter assembly by marking the burner location on each assy.
D) Prepare and install lifting devices for burner which is installed at front wall side from boiler
ground level to burner floor level approx. Make erection path with trial lifting of one burner.
Similar arrangements have to be made for rear burners also.
E) The burner numbers and swirl pattern arrangement drawing must be obtained by area in
charge.
F) Removal of all the fasteners and pulling of burner assembly out of the windbox using suitable
lifting arrangements. Place it on the floor available in the respective elevation. Placing should be
such that these burners should not obstruct the path for other works to be carried out during
overhauling.
G) For lowering of coal compartment to zero meter, the agency has to install two nos. of Electric
winches (of min 5 Ton Capacity) and obtain safety clearance for the same.
H) Marking and shifting to Zero meter and then to identified area (max. within ½ Km from the
unit).
I) After removal of the burner, Burner housing to be cleaned thoroughly. If burner housing found
damaged, it is to be repaired.
J) If the burner requires repairing work, the same shall be done as per the direction of the area
engineer. The repair work shall be covered separately under BOQ : BMPFB54GN803
Fixing:-
K) Lifting of Burner/ coal compartments by Electric winch to various elevations and shifting to
the particular location as per the number marked on it. Ensure that the right style of burner is
lifted to the right place.
L) Final inspection of complete Burner/coal compartments and rectification of any defect
observed there in.
M) Inserting coal compartment along with internals into original position.
N) Centering of coal compartment within the burner box.
O) Each Burner should be installed by centre of burner throat. Burner should be maintained
horizontal. However, it is acceptable that PF side upper than furnace side under the angle of 0.5
Deg and vice versa is not acceptable.
P) While adjusting height and centre of burner, welding should be processed step by step at wind
box inside/outside, as per the direction of area engineer.
Q) Proper tightening of all fasteners.
R) Cleaning of the area after work and restoring of the safety provision provided.
S) For measurement: One burner assembly/ coal compartment along with its internals shall be
taken as one-unit replacement.

20.30 In-situ removal / replacement of swirler of oil guns/collector castings /core air
tube/Flame holder assy: BMPFB55OH001
A) Removal of damaged swirler of oil guns and repair/ replacement of the same.
B) Removal of damaged collector castings and replacement with new one
C) Removal of damaged core air tubes and replacement with new one.
D) All the points in A, B, C are to be carried out with proper care during removal and installation
with proper welding procedures with suitable welding rods as per the direction of E.I.C. or
NTPC’s Engineer.
E) Checking and repairing of core air damper/total air damper /total air swirler / adjusting pull

Page 2 of 30
 rods of secondary air/tertiary air and total air dampers.
F) Boxing up.
G) Disposal of the scrap after the job & cleaning of the area.

20.40 Inspection of All Wind Box Dampers(SADC) & Attending its Defects:
BMSDD00OH001
The secondary air control dampers are situated at each end of the wind box on each burner Row
List of SADC dampers:
LEFT RIGHT
ROW A 10HLE11AA071 10HLE12AA071
ROW B 10HLE21AA071 10HLE22AA071
ROW C 10HLE31AA071 10HLE32AA071
ROW D 10HLE41AA071 10HLE42AA071
ROW E 10HLE51AA071 10HLE52AA071
ROW F 10HLE61AA071 10HLE62AA071
ROW G 10HLE71AA071 10HLE72AA071
ROW H 10HLE81AA071 10HLE82AA071
ROW J 10HLE91AA071 10HLE92AA071
List of Core air dampers
LEFT RIGHT
ROW A 10HLE11AA071 10HLE12AA071
ROW B 10HLE21AA071 10HLE22AA071
ROW C 10HLE31AA071 10HLE32AA071
ROW D 10HLE41AA071 10HLE42AA071
ROW E 10HLE51AA071 10HLE52AA071
ROW F 10HLE61AA071 10HLE62AA071
ROW G 10HLE71AA071 10HLE72AA071
ROW H 10HLE81AA071 10HLE82AA071
ROW J 10HLE91AA071 10HLE92AA071
List of OFA dampers:
LEFT RIGHT
FRONT 10HLA15AA071 10HLA35AA071
REAR 10HLA25AA071 10HLA45AA071

A) Arranging scaffolding for proper and safe approach to all dampers.

B) Disconnecting from power cylinder after obtaining clearance from C&I department.
C) Freeness of all dampers has to be checked at various locations as listed above and protocol
has to be made.
D) Freeing the actuator link if required and fitting back after checking.
E) Opening and closing of manholes for inspection purposes.
F) For measurement purpose, inspection & repair (if reqd.) of all dampers of all four corners of
the wind boxes of the boiler in one unit (Total 40 dampers per unit) will be considered as
one Unit.
G) Removal and fixing back of actuator.

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 H) Clearing mechanical Jamming of damper for full free movement.
I) Freeness will be checked by NTPC and protocol has to be made.
J) In case of any problem in operation with Power cylinder, the contractor has to again attend
the problem till it operates satisfactorily & without any additional cost.
K) Fabrication of damaged/eroded flaps / shaft & replacement, if required.
L) Opening and closing of manholes. Proper Cleaning in wind box area has to be done after
providing suitable lighting in the entire area.

20.50 Repairing & reconditioning of coal nozzle/ burner assy.: BMPFB54GN803

A) Dismantling and cleaning of all the parts of coal compartment assembly i.e. burner assembly,
core air tube assembly, primary air cartridge, front plate assembly, secondary air barrel &
damper assembly, tertiary air barrel & damper assembly.
B) Metal filling by Arc welding on eroded portion of coal compartment to original thickness up of
the plate or equal to uniform thickness available.
C) Providing external patch on holes / crack on coal nozzle wherever required, metal filling from
inside by Arc welding to original thickness.
D) Any warped portion of the in-nozzle front, wherever required is to be cut and removed and to
be replaced from similar portion from condemned nozzles.
E) Painting of nozzle body with one coat of red oxide primer.
F) Removing any broken studs / nuts and cleaning of studs / nuts holes by tapping, providing of
new studs, bolts and nuts as per requirement.
G) Fixing of identification plate in prescribed format by tack welding to nozzle body.
H) Secondary air damper adjust pull rods/secondary swirler adjust pull rods/total air damper
pull rods are to be straightened / repaired and to be fixed with the coal compartment. If
required these pull rods are to be replaced with new ones if not possible to repair in the assy.
I) Damaged portion of coal nozzle tip plates are to be cut and replaced with fabricated SS plates
by Arc welding after edge preparation.
J) Any crack in the existing weld is to be ground in "V" shape and re-welded as per welding
procedure.
K) Correction of any warpages either by straightening or by replacement of plates.
L) If plate bending M/C is not available the contractor has to carry out the bending by gas
heating, for which no additional payment will be made.
M) Fixing of Guide vanes to the corresponding compartment body by welding.
N) Any damages or warpages on guide vane plates & pull rods are to be corrected / repaired /
replaced and re fixing with nozzle body.
O) Assemble the parts like core air tube assy. primary air cartridge, secondary air barrel, and
tertiary swirler assembly as whole. After complete assy., the movement of all the dampers
and swirlers has to check and rectified if found any problem.
P) Afterwards, the assembled coal compartments have to be numbered and stacked at the place
identified by the Engineer-In-Charge.
Q) For measurement purpose, all the above works carried out for one coal compartment (As
given in sub heading A to P) will be considered as one Unit.

20.60 Servicing of oil guns and oil gun forward/retract check : BMOLG52OH000
ATTENDING MISC. JOBS IN BURNER AREA

Page 4 of 30
One No. indicates deployment of gang of 1 skilled fitter, 2 Rigger, 1 Grinder and 2 helpers for a
normal working day of eight hours. The gang to be deployed in evening or night shifts as per
requirement. For job carried out on round the clock basis, contractor shall deploy his manpower
in shifts. Part payment will be made on pro rata basis based on actual manpower deployed.
General T&P except special tools required for the work shall be in the scope of the contractor and
is included in the scheduled rate.
1) If the contractor fails to deploy specified manpower, penalty for the shortage equal to double
the awarded rate shall be imposed.
2) The deployment of manpower can be for any job not covered under in the BOQ and scope of
this contract and this deployment can be anywhere in the plant. The decision of EIC in this
regard will be final.
3) For emergency jobs, as decided by NTPC, agency has to deploy manpower for 24 Hrs basis
and agency should provide all amenities like food to the workmen.

A) Servicing of oil guns and oil gun forward/retract check

1) Disconnect all steam and oil hose connections.
2) cylinder assembly disconnection, removal of oil gun, removal of oil gun holder tube,
removal of oil burner, repairing of the same by welding using suitable electrodes,
replacement and reconnection of flexible hose pipes, replacement of impeller carrying
tubes, booster holder tube, view pipe, oil burner and seal air connections shall be done if
required.
3) Remove all guns’ advance-retract mechanisms
4) Cleaning, servicing and repairing of oil guns advance-retract mechanisms are to be done
5) Replace the damaged components like Teflon seals, graphite rings etc.
6) Servicing of gun assembly and replacement of parts as per EIC direction.
7) Cleaning/replace the hoses as directed by EIC.
8) Refitting the assemblies in position and checking the operation of the same.
9) The contractor shall provide the manpower during the initial commissioning of the gun
assemblies
B) Jobs which may be carried out are as follows:
1) Assistance in Temp. probe servicing & operation.
2) Assistance in burner related, SADC problems other than in above schedules.
3) Assistance for repair and salvaging of NTPC T&P like hydraulic jacks, electrical winches,
chain blocks etc.
4) Minor repair of railing / toe guards / small opening in floors. Steel required for this work
shall be issued through dept. stores to the contractor.

Page 5 of 30
 5) General housekeeping /beautification and proper stacking of spares in areas pertaining to
dept. Stores. As specified by EIC.
6) Shifting of sump pump/submersible pump as per instruction of EIC.
7) Repair of submersible pumps.
8) Assistance in auxiliary boiler furnace inspection & other works.
9) Cleaning of steam traps etc.
10) Replacement of hoses in HFO unloading area.

SCOPE OF WORK(APH area):

Page 6 of 30
 GENERAL INSTRUCTIONS & SCOPE OF WORK

01) Before starting the work or entering into the equipment for any maintenance job, the agency
must ensure the following.

1) The relevant PTW for the work has been collected from EIC/representative.
2) Availability of sufficient and safe illumination through 24 volts inside confined space.
3) Availability & use of personal protective equipment.
4) Availability of suitable hand gloves for handling hot objects.
5) Availability of leather hand gloves for handling sharp objects.
6) In case of fire, take instructions from E.I.C. before opening the equipment.

02) After completion of the maintenance work and giving clearance for trial operation / Return of
PTW, ensure the following.

1) The equipment is cleaned and area cleared from scrap, debris.

2) Men and materials have been removed from the equipment.
3) Manhole and inspection doors are closed.

03) During assembling of the components / system, matching of the new spares with the
corresponding parts may be required to be done. For this, any minor cleaning, cutting / welding /
grinding / finishing with emery paper / coir rope may be required to be done and this is to be
considered as included in the respective jobs.

JOB NO. 20.70: (BMBAP02GN402) (Bisector APH >200MW INSPECTION)

CLEANING AND INSPECTION ACTIVITIES (PER APH)

1. Removal of ash accumulated at the air heater ducting portions below the expansion joint, rotor
post and sector plates.
2. Cleaning of ash accumulated over heating elements. Water washing/ air cleaning of baskets.
3. Opening of all the manhole doors including sector plate doors and cleaning the ash inside and
outside APH including expansion bellow over the sector plate, centre section etc.
4. Inspection of APH internals, for damage of bypass, axial, radial rotor post seals and ducting etc.
5. Record seal gap before overhauling.
6. Replacement of all manhole doors packing rope as per requirement.
7. Attending leakages during trial from all the identified locations etc.
8. Servicing of oil carryover probes
9. Removal of oil carryover probe from location (in case of bend in probe duct to be cut for removal
max. 100 x 100 mm size)
10. Cleaning of probe. Repair / replace damage probes / pipe
11. Correct bending, if any, in the probe.
12. Check healthiness of CW hoses. Replace if necessary.
13. Charge water and check for leakages. Attend if any.
14. Refit probe in position.

JOB NO. 20.80: (BMBAP18BD800) (Bisector APH (GUIDE BRG) Repl)

GUIDE BEARING REPLACEMENT (SAPH / PAPH) (PER APH)

Page 7 of 30
 1. Locking of rotor
2. Complete draining of lube oil from guide bearing housing.
3. Removal of lube oil lines and draining of lube oil.
4. Removal of guide bearing cover.
5. Clean guide bearing assembly for inspection.
6. Inspect guide bearing and measure clearance and record.
7. Measure guide bearing housing level and record.
8. Level it if found beyond permissible limit if replacement of guide bearing is not required.
9. Check condition of sealing tube for any leakage.
10. Repair/replace sealing tube.
11. Box up guide bearing housing top cover if and only replacement is not required.
12. Removal of guide bearing housing along with guide bearing.
13. Removal of guide bearing assembly.
14. Cleaning of housings and other parts.
15. Blue matching of adopter sleeve.
16. Assembling of new guide bearing assembly in guide bearing housing.
17. Complete box up of guide bearing assembly.
18. Guide bearing housing levelling.
19. Record readings in front of NTPC representative.
20. Refitting of lube oil lines.
21. Refilling of lube oil in the lube oil system.
22. During trail run of APH, guide bearing’s vibration, sound and other CMG parameter should be
normal.
23. Attend defect if any
NOTE:
IN CASE BEARING NOT REPLACED, PAYMENT MAY BE MADE 20% OF SERVICE VALUE FOR
INSPECTION ONLY AND ANOTHER 20% IF LEVELLING DONE.

JOB NO. 20.90: (BMBAP17BD800) Bisector APH (SUP.BRG) Repl

SUPPORT BRG REPLACEMENT/INSPECTION (SAPH / PAPH) (PER APH)

1. Draining of lube oil from support bearing housing.

2. Removal of lube oil lines and lube oil system if required.
3. Removal of support bearing cover/collar.
4. Clean support bearing assembly for inspection.
5. Inspect support bearing and measure clearance and record if possible.
6. Measure support bearing housing level and record, if possible.
7. Level it if found beyond permissible limit if replacement of support bearing is not required.
8. Check condition of sealing tube for any leakage.
9. Box up support bearing housing top cover if and only replacement is not required.
10. Removal of hot end and cold end radial and rotor seal as per requirement.
11. Making approach /scaffolding as per requirement and shifting of gang jacks pump and supporting
blocks to site.
12. Arresting of rotor to avoid tilting of rotor
13. Jacking of rotor with gang jack.
14. Removal of support bearing housing and lowering it to the service floor.
15. Removal of support bearing from housing.
16. Cleaning of all parts properly.
17. Assembling of all parts including new support bearing in housing.

Page 8 of 30
 18. Assembling of housing in position.
19. Levelling of support bearing housing.
20. Lowering of rotor after unlocking of rotor.
21. Flashing of support bearing properly with light oil.
22. Filling of lube oil in housing.
23. Restoration of lube oil system.
24. Take trial run.
25. Attend defects if any.

NOTE:
EXTRA PAYMENT FOR SCAFFOLDING AS PER BOQ.
IN CASE BEARING NOT REPLACED, PAYMENT MAY BE MADE 20% OF SERVICE VALUE FOR
INSPECTION ONLY AND ANOTHER 20% IF LEVELLING DONE.

JOB NO. 20.100: (BMBAP31GN558) Bisector APH (ROTOR) LEVELLING

ROTOR LEVELLING OF SAPH / PAPH (PER APH)

1. Removal of radial seal fixing of master level.

2. Rotating the rotor and recording of previous level.
3. Removal of housing-lock at guide bearing.
4. Setting of rotor level by adjusting the jacking screws as per requirement.
5. Locking of housing by welding of stoppers.
6. Repair/new fabrication of stoppers if required.

JOB NO. 20.110: (BMBAP30BD801) Bisector APH (AIR SEAL ASSY) Repair

AIR SEAL HOUSING - (GUIDE BEARING AND SUPPORT BEARING) (PER APH)

1. Ash cleaning of air seal housing area.

2. Removal of insulation and refractory near air seal housing area.
3. Opening of air seal housing, removal of packing ropes and KAO-wool. Repair as required.
4. Packing of air seal housing with new packing ropes and KAO-wool, and fixing back of cover. Any
minor modifications in the air seal housing is also to be carried out if required.
5. Casting of refractory or insulation at the air seal housing area as per requirement.
6. Fabrication / repair /cleaning of seal boxes in-side the air heaters below guide bearing, static
seals and also at cold end air seal housing.

JOB NO. 20.120: (BMLOS00OH000) Lube Oil System (<>)-Serv

LUBE OIL SYSTEM SERVICING (BOTH GUIDE AND SUPPORT BEARINGS) (PER APH)

1. Servicing of lube unit of one guide bearing and one support bearing, oil draining from cooler,
filters and piping.
2. Cleaning of coolers & filters. Hydraulic testing of coolers. Attending defects or replacement as per
requirement.
3. Checking freeness of oil and water line valves and servicing/providing new valves as per
requirement.
4. Checking pump, coupling and alignment and replacement / adjustment if required. Minor
modification of lube oil lines for better approach / accessibility wherever required as per

Page 9 of 30
 direction of engineer-in-charge. Lube oil lines and water lines upto root valves connecting with
cooling water header are also to be cleaned by cutting / welding as per requirement. If required
lines are to be replaced.
5. Oil flushing by light oil. Oil top-up in guide and support bearings, trial of lube oil system,
adjustment of pressure by relief valve setting and attending leakages if any. Return used/dirty oil
to identified place

JOB NO. 20.130: (BMBAP34GN865) Bisector APH (DRIVE ENGMT) SETTING

DRIVE GEAR BOX AND PIN RACK (PER APH)

1. Opening of pinion cover and inspection of pins and pinion condition.

2. Clean accumulated ash
3. Opening of inspection covers of gear box & internal inspection of gear box. Oil draining, flushing
and filling with new oil.
4. Greasing of bearings. Pinion /taper lock bush are to be removed & their condition is to be
checked and are to be replaced if required & as per directions of EIC.
5. Checking and adjustment of pinion root gap (after rotor levelling).
6. Putting back pinion cover by providing proper packing rope.
7. Servicing checks of air motor and associated valves. Oil replacement in air motor gear box &
lubricator. Re-lubricate coupling of air motor. Check healthiness of grid spring/coupling. Replace
if required.
8. Check over grid coupling; service or replace as requirement.
9. Checking for healthiness of overrunning clutches. Repair /replace if reqd.
10. Check the condition of oil seals and replace if required.
11. Check shaft condition; using speedy sleeve if required.
12. Do minor servicing and repair work
13. Alignment of both main & auxiliary (air) drive to recommended limits.

JOB NO. 20.140: (BMBAP34BD800) Bisector APH (DRIVE ENGMT) Repl

MAIN DRIVE GEAR BOX REPLACEMENT (SAPH / PAPH) (Nos)

1. Removal pinion cover.

2. Removal of motor from foundation after decoupling and removal of fluid coupling.
3. Removal of air motor.
4. Removal main drive gear box from foundation.
5. Removal of main drive pinion from gear box.
6. Check condition of pin rack assembly, if required replace. (fixing as per drawing)
7. Shifting of new/serviced gear box to drive foundation.
8. Fitting of pinion with taper lock bushing, check pinion level and record axial & radial gap of rack
& pinion.
9. Fixing of electrical motor and air motor on foundation.
10. Coupling of electrical motor with fluid coupling.
11. Fixing of pinion cover.
12. Take trial run.
13. Attend defects if any.
14. Dismantling of removed gear box and removal of damaged bearings, gaskets and oil seals.
15. Assembling of gear box with new bearings, gaskets and oil seals.
16. Proper storing of gear box as per direction of EIC/area-engineer.
NOTE:

Page 10 of 30
 • 50% PAYMENT SHALL BE MADE IF ONLY GEAR BOX ASSEMBLY REPLACED.
• 50% PAYMENT SHALL BE MADE IF RACK AND PINION ASSEMBLY CHANGED.

JOB NO. 20.150: (BMBAP38BD801) Bisector APH (ROTOR POST SEAL) Repair

STATIC SEAL AND ROTOR POST SEAL WORKS (PER APH)

1. Removal/pocket cutting of static seal plates, inspect and rectify/adjust as per requirement
repair/refitting /replacement of seal plates at both hot and cold ends.
2. Inspection and repair of static spool by patch welding at both hot and cold ends if required.
3. Repair/replacement of rotor post seal at both hot and cold ends if required.

JOB NO. 20.160: (BMBAP14BD800) Bisector APH (T BAR) Repl

T-BAR & ROTOR ANGLE REPAIR WORKS (PER HOT END OR COLD END)
(PER UNIT= PER HOT END /COLD END OF T-BAR OR ROTOR ANGLE OR BYPASS ANGLE)

1. Repair/replacement of T bar support angles & by pass seal support angles at hot end / cold end
as per requirement.
2. Replacement of T-bar and rotor angle bolts as per requirement.
3. Providing T-bar cleats and tabs as per requirement.
4. Check circularity of T-bar/rotor angle/ bypass angle both radially and axially (at both CE & HE)
rectify if required.

NOTE:
30% PAYMENT SHALL BE RELEASED IF REPAIR IS DONE IN PLACE OF REPLACEMENT.

JOB NO. 20.170: (BMBAP03BD801) Bisector APH (PRIMARY) Repair

ROTOR REPAIR WORKS (PER APH)

1. Repair of eroded rotor drum portion by patch welding.

2. Repair of diaphragm plates by metal build-up and grinding or by cutting and patch welding as per
requirement.
3. Inspection and welding of stay plates with diaphragm plates at damaged portions. Stay plates are
to be cut and patch welded if found eroded.
4. Welding of diaphragms with shell as per requirement.

JOB NO. 20.180: (BMBAP22BD800) Bisector APH (GRATING) Repl

REPAIR OF COLD END GRID MEMBERS-MAIN APH (ONE SET=ONE SECTOR OF APH)

1. Cleaning of cold end grills thoroughly.

2. Repairing /replace of damaged grills by replacing damaged portions of CE grills by cutting
damaged parts and grafting new plates as per requirement.
3. Check support blocks. Replace if required.
4. Repair diaphragms wherever found damaged.

JOB NO. 20.190: (BMBAP24BD800) Bisector APH (AX. SEAL PLATE ASSY) Repl

Page 11 of 30
AXIAL SEAL PLATE LEVELLING OF SAPH / PAPH (SERVICE QTY. ONE NUMBER = ONE AXIAL SEAL
PLATE, i.e. EACH APH HAS 2 AXIAL SEAL PLATES)

1. Fixing of finger tabs at HE & CE

2. Recording of previous setting of axial seal.
3. Repair axial seal plate if required.
4. Replace axial seal plate:
5. Transfer new axial seal plate from store.
6. Remove axial seal plate cover.
7. Remove damaged axial plate.
8. Re-fix new axial seal plate.
9. Check seal plate adjusting bolt, replace/ repair if required.
10. Replace axial seal cover.
11. Leveling of axial seal plate as per quality plan/drawing.
12. Record readings.
13. Repairing/replacement of adjusting mechanism, if required.
14. Locking of axial seal plates after completion of leveling.

NOTE;
70% PAYMENT IS FOR REPLACING AXIAL SEAL PLATE AND LEVELLING.
30% PAYMENT IF ONLY REPAIR WORK IS DONE AND LEVELLING

JOB NO. 20.200: (BMBAP23GN558) Bisector APH (SECT.PLT) LEVELLING

RADIAL SECTOR PLATE LEVELLING (PER HOT END OR COLD END) (NOS)

1. Checking & adjusting the t bar runout and marking of high point of T-bar.
2. Providing seal tab and measuring the gap at in-board and out board of radial seal plates.
3. Adjustment of sector plates to maintain gap within limits and locking the same.

JOB NO. 20.210: (BMBAP20BD801) Bisector APH (RD.SEAL) Repair

HOT/COLD END RADIAL SEAL REPAIR/SETTING OF PAPH/SAPH (PER HOT END OR COLD END
RADIAL SEAL) 1 QTY=HOT END=COLD END

1. Fixing of straight edge to set seals at pre-determined seal gap.

2. Loose all fasteners to set seals.
3. Replace all worn out/damaged fasteners and seals by new one.
4. Set all seals one by one & tighten bolts & nuts & locking thereof.
5. Record seal gap.
6. Check seal clearance and free rotation of rotor through air motor.
7. Attend defects, if any.
JOB NO. 20.220: (BMBAP15GN865) Bisector APH (BYP SEAL) SETTING

BY PASS SEAL REPLACEMENT AND SETTING (COLD END/HOT END OF SAPH / PAPH) (NOS)

1. Erection of scaffolding at the cold end to carry out the job.

2. Remove all worn out/damaged seals/holding strips.
3. Repair/replace damaged/worn out by pass seal holding angle.
4. Replace seals /holding strips/ fasteners with new one, maintaining seal gap as per norm.
5. Check seal clearance and free rotation of rotor through air motor.

Page 12 of 30
 6. Attend defects, if any.

JOB NO. 20.230: (BMBAP19GN865) Bisector APH (AX.SEAL) SETTING

AXIAL SEAL SETTING OF SAPH/PAPH (PER APH)

1. Fixing of straight edge to set seals at pre-determined seal gap.

2. Loose all fasteners to set seals.
3. Replace all worn out/damaged fasteners and seals by new one.
4. Set all seals one by one & tighten bolts & nuts & locking thereof.
5. Check seal clearance and free rotation of rotor through air motor.
6. Attend defects, if any.

JOB NO. 20.240: (BMBLR00GN972) BOILER (<>) WELDING

TABS WELDING (PER UNIT)

Welding of 12 nos of TAB in any location of the following:

1. Radial seal TABS in HE
2. Radial seal TABS in CE
3. Axial seal TABS in HE
4. Axial seal TABS in CE
5. Pin rack TABS
6. T-bar TABS and expansion clamps.

JOB NO. 20.250: (BMBAP23BD801) Bisector APH (SECT.PLT) Repair

REPAIR OF SECTOR PLATE (PER CE or PER HE of ONE APH) (NOS)

1. Inspection of sector plate.

2. Mounting of horizontal, beam inside APH, chain pulley blocks etc. For basket handling.
3. Removal of radial seals and removal of HE elements baskets in one sector (if required baskets in
opposite sector to be removed for maintaining balance)
4. Metal built up at all eroded position/cut and weld new plate at damaged position of the sector
plate. Grinding of the surface and matching with the template. Check for trueness, horizontality &
smoothness of the surface of the sector plate. Rectify wherever required.
5. Refit radial seals and reassemble baskets
6. Any other minor repairs/ jobs to complete the job.

JOB NO. 20.260: (BMBAP23BD800) Bisector APH (SECT.PLT) Repl

REPLACEMENT OF SECTOR PLATE (1unit = LHS or RHS) (NOS)

1. Left hand side and right hand side of sector plate will be considered as separate unit.
2. Cutting ducts supports at suitable locations as per requirement to facilitate removal of old sector
plate.
3. Making lifting arrangement inside.
4. Cutting/ removing old sector plat supports.
5. Taking out old sector plate.
6. Drawl/ transportation of new sector plate to location at APH floor.
7. Fixing new sector plate, level and alignment adjustments as per design.

Page 13 of 30
 8. Closing of duct opening and normalizing the supports.
9. Levelling of sector plate.
10. Lock sector plate.
11. Rectify any defect if arise.

JOB NO. 20.270: (BMBAP13BD800) Bisector APH (HE BASKT) Repl

REPLACEMENT OF APH HOT END / HOT INTERMEDIATE BASKETS (incl transportation) (Per
Basket)

1. Identification of damaged hot end/hot intermediate baskets. Shift the baskets to boiler zero meter
from working platform. Transporting the damaged baskets to identified location/scrap yard.
Loading & shifting of new baskets from main store to site
2. Unloading of new baskets at site. Care to be taken to avoid damage of baskets while handling.
3. Cleaning of new hot end/hot intermediate baskets.
4. The new basket individually, has to be dipped in NAOH solution in one tank for effective cleaning.
5. The basket has to be further dipped in water in second tank.
6. The new element (basket) has to be placed vertically on wooden sleepers and clean thoroughly
with steam and water jet to remove preservation oil and dirt completely.
7. After cleaning the basket have to be properly stacked and covered for storing till loading.
8. All the handling arrangements are in scope of the contractor.
9. Lifting back to position on to working platforms near APH.

NOTE:
20% PAYMENT FOR SHIFTING OLD BASKET TO SCRAP YARD/IDENTIFIED AREA

JOB NO. 20.280: (BMBAP11BD800) Bisector APH (CE BASKT) Repl

REPLACEMENT OF APH COLD END BASKETS (incl transportation) (Per Basket)

1. Identification of damaged cold end baskets. Shift the baskets to boiler zero meter from working
platform. Transporting the damaged baskets to identified location/scrap yard loading & shifting
of new baskets from main store to site
2. Unloading of new baskets at site. Care to be taken to avoid damage of baskets while handling.
3. Cleaning of new cold end baskets.
4. The new basket individually, has to be dipped in NAOH solution in one tank for effective cleaning.
5. The basket has to be further dipped in water in second tank.
6. The new element (basket) has to be placed vertically on wooden sleepers and clean thoroughly
with steam and water jet to remove preservation oil and dirt completely.
7. After cleaning the basket have to be properly stacked and covered for storing till loading.
8. All the handling arrangements are in scope of the contractor.
9. Lifting back to position on to working platforms near APH.

NOTE:
20% PAYMENT FOR SHIFTING OLD BASKET TO SCRAP YARD/IDENTIFIED AREA

JOB NO. 20.290: (BMBAP13GN400) Bisector APH (HE BASKT) Instal/Remove

REMOVAL AND REFITTING OF HOT END/HOT INTERMIDIATE END BASKETS (SAPH/PAPH)

(1QTY=1HE BASKET=1 HOT INTERMEDIATE BASKET)

Page 14 of 30
 1. Opening of basket removal door.
2. Fixing of basket handling beam and chain pulley block/electrical hoist in APH.
3. Installation of electrical winch as per requirement for basket handling, if required.
4. Removal of baskets from rotor and shifting it to servicing bay.
5. Cleaning through high pressure jet and repairing of side plates of baskets as per requirement.
6. Fitting of baskets in rotor.
7. Removal of basket handling beam and chain pulley block/electrical hoist from APH.
8. Closing of basket handling door & paint it. Paints/thinner will be provided by NTPC free of cost.
NOTE:
PAYMENT FOR HIGH PRESSURE JET CLEANING WILL BE PAID EXTRA AS PER BOQ.

JOB NO. 20.300: (BMBAP11GN400) Bisector APH (CE BASKT) Instal/Remove

REMOVAL AND REFITTING OF COLD END BASKETS (PAPH/SAPH) (PER BASKET)

1. Opening of basket removal doors.

2. Installation of electrical winch as per requirement for basket handling.
3. Removal of baskets from rotor and shifting it to servicing bay.
4. Cleaning through high pressure jet and repairing of side plates of baskets as per requirement.
5. Repairing of diaphragms if any.
6. Fitting of baskets in rotor
7. Closing of doors.
NOTE:
PAYMENT FOR HIGH PRESSURE JET CLEANING WILL BE PAID EXTRA AS PER BOQ

JOB NO. 20.310: (BMBAP13GN353) Bisector APH (HE BASKT) HPW Jet Cleaning

HE/HIE BASKET JET CLEANING (PER BASKET)

1. Deployment of HP jet cleaner with HP water jet nozzle at hot end basket area for HE and IE basket
cleaning. HP water jet pressure 200bar and above is required.
2. Remove HE & IE basket. Baskets removal & baskets cleaning both activities are performed
simultaneously; therefore, deploy HP jet cleaner as directed by EIC or his representative.
3. Baskets should be cleaned in such a way that there should be no ash deposit left after cleaning.
4. Final clearance for baskets cleaning completion will be given by EIC or his representative after
inspection of the same. If ash deposition is found in any of HE & IE baskets, re-cleaning of the
same will have to be carried out.

NOTE:
HP JET M/C IS IN CONTRACTOR’S SCOPE.

JOB NO. 20.320: (BMBAP11GN353) Bisector APH (CE BASKT) HPW Jet Cleaning

CE BASKET JET CLEANING (PER BASKET)

1. Deployment of HP jet cleaner with HP water jet nozzle at cold end basket area for basket cleaning.
HP water jet pressure 200bar and above is required.
2. Remove CE basket. Baskets removal & baskets cleaning both activities are performed
simultaneously; therefore, deploy HP jet cleaner as directed by EIC or his representative.
3. Baskets should be cleaned in such a way that there should be no ash deposit left after cleaning.

Page 15 of 30
 4. Final clearance for baskets cleaning completion will be given by EIC or his representative after
inspection of the same. If ash deposition is found in any of CE baskets, re-cleaning of the same will
have to be carried out.
NOTE:
HP JET M/C IS IN CONTRACTOR’S SCOPE.

JOB NO. 20.330: (BMMAT00GN350) MATL (<>) Hndlg & Tptn

TRANSPORTATION OF STEEL FROM CENTRAL STORES, RETURN OF SCRAP TO CENTRAL STORES

(MT)

1. Loading of material at source; site store, central store, steel yard, boiler etc.
2. Transportation to the destination site; work site, scrap yard, etc.
3. Unloading at destination site.
4. Proper placement of material at store/destination location.
5. Clean the material and site if required.
6. Scrap shifting from the site to scrap yard/steel yard.

Note: Contractor has to arrange trailer/truck for the material transportation at his own cost.

JOB NO. 20.340: (BMSFL00GN800) SCAFFOLDING (<>) Remove & Apply

SCAFFOLDING ERECTION AND REMOVAL (SCAFFOLDING MEASURING FOOTPRINT AREA OF 10 SQ.

MTR AND UPTO A HEIGHT OF EVERY 05 MTR FROM BASE) (NOS)

1. Shifting of scaffolding materials from store to site.

2. Erection of safe scaffolding with planks by proper tie-up/welding and providing handrails for
working at height.
3. Dismantling of scaffolding safely after completion and return of scaffolding material to store.

NOTE:
PAYMENT: 60% FOR ERECTION AND 40% FOR REMOVAL.

JOB NO. 20.350: (BMASB00BD000) APH S/Blower (<>)-Attend Defect

SERVICING OF SOOT BLOWER ASSEMBLY (COLD END) INCLUDING SPEED RECUCERS (PAPH/SAPH)

1.Complete cleaning of soot blower system.

2.Removal/replacement of soot blower nozzle and cleaning.
3.Complete/part replacement of soot blower arm in case of damage/leakage.
4.Replace soot blower assembly with new if required, as per NTPC rep. Direction.
5.Servicing of speed reducer including replacement of coupling and spiders.
6.Soot blower travel checking and setting.
7.Alignment of motor.
8.Trial run and attending defects if any.
9.Paint soot blower area as per instruction of EIC. Paints/thinner will be provided by NTPC free of
cost.
NOTE:
5% OF BOQ VALUE WILL BE DEDUCTED IF PAINTING WORK NOT DONE.
40% OF BOQ VALUE WILL BE DEDUCTED IF NEW SOOT BLOWER ASSEMBLY NOT USED I.E.
REPLACEMENT NOT DONE.

Page 16 of 30
JOB NO. 20.360: (BMBAP02OH000) Bisector APH >200MW Serv

CENTERE SECTION: CLEANING AND REPAIR

1. Clean center section area (remove ash, dust, dirt, insulation etc.).
2. Clean guide bearing area.
3. Repair damage duct.
4. Draw steel/materials from store and shift the same to site
5. Inspect duct plate thickness & erosion and cut worn out portion in ducts.
6. Cover any hole or damage portion of duct after cutting
7. Replace and weld cutout portion by grafting with 8mm/10 mm/12mm plates or as per
instructions of EIC. Use plates of the size of box.
8. Weld plates (8mm to 12 mm) on complete center section area. Weld plates completely from all
sides.
9. If asked apply refractory over first layer.
10. Weld second layer of plates over box and refractory.
11. Welding of each layer of the plates should get inspected and approved by NTPC rep.
12. Attend leakages/defects if any after ATT(Air Tightness Test). Contractor has to assist in ATT,
which is included in this scope.

NOTE:
FOR CLEANING OF CENTRE SECTION 20% OF THE BOQ PAYMENT; FOR LAYER#1 OF PLATE
ERECTION 60% OF BOQ AND FOR LAYER #2: 20 % OF THE BOQ PAYMENT WILL BE
RELEASED.

JOB NO. 20.370: (BMIDA52GN106) Axial ID Fan (BEARING) Checking

ID/FD/PA (SERVICING) FAN BLADE BEARING /BLADE HOLDER/BLADE SHAFT SERVICING

A. SCOPE OF WORK FOR ID FAN SERVICING:

ID FAN (100% BOQ)

1. Open all manhole doors after confirmation of PTW.

2. Decouple fan from motor.
3. Remove diffuser suction & discharge side flange joint & NMEJ bolt to facilitate diffuser drag-out.
4. Remove all lube oil/airline connection with proper marking by permanent paints.
5. Shifting fan diffuser towards discharge side to facilitate fan impeller.
6. Remove impeller casing top cover for blade removal and remove impeller cover with proper
marking.
7. Remove all blades and shift it to the blade handling platform.
8. Remove hydraulic cylinder from impeller hub & rotary union.
9. Thoroughly clean all the blades for DPT test. NTPC approved new DPT kit will be arranged by
contractor & no extra charges will be provided by NTPC. Blade DPT test witness by NTPC FQA &
BMD department jointly.
10. Remove all bearing cap, blade holder assy. Blade shaft, control arm etc. and thoroughly clean it.
11. Freeness checking of all blade holders, control arms etc., replace damage items if required and
replace blade bearing/blade as per instruction of EIC & apply lubrication on all blades bearing
and blade shaft etc. if required. Blade weight to be taken and record it replace blade if required.
12. Fit all blade holder assy. Control arm, blade shaft, bearing cap etc. onto the impeller.

Page 17 of 30
 13. Clean lubrication point passage
14. Apply lubrication to blade bearing assembly from lubrication point.
15. Fix impeller cover apply metal putty on impeller cover inside/outside.
16. Fix hydraulic cylinder & rotary union with impeller.
17. Tight diffuser suction & discharge side bolt.
18. Change NMEJ if found damaged & fix it in-between diffuser and outlet duct.
19. Fixing all lube oil lines and control oil lines and check oil leakage after lube oil trial run and rectify
if any oil leakages observed.
20. Fix blades with proper blade gap setting with impeller hub as well as with impeller ring as per
drawing and record it in presence of NTPC personal.
21. Servicing of main motor coupling.
22. Alignment of motor with fan & check it in presence of NTPC personal.
23. Stop lop and remove hydraulic system hose for alignment checking of rotary union in presence of
NTPC personal.
24. Connect oil line hoses and check blade full open/close position and record it as per drawing.
25. Couple fan with motor.
26. Painting to be done at fan area as per direction of EIC. (Paints/primer will be provided by NTPC
free of cost).
27. Clean fan internal and after thorough checking, close all manhole doors & box-up the fan.
28. Take fan trial run and rectify defects if any.

B. SCOPE OF WORK FOR PA/FD FAN SERVICING (60% OF THE BOQ)

1. Open all manhole doors after confirmation of PTW.

2. Decouple fan from motor.
3. Remove impeller casing manhole for blade removal.
4. Remove fan blade from impeller & thoroughly clean it for DPT test.
5. NTPC approved new DPT kit will be arranged by contractor & no extra charges will be provided
by NTPC.
6. Blade DPT test witness by NTPC FQA & BMD department jointly. If required, blade weight to be
taken and record it. Replace blade if required.
7. Remove blade bearing cap, blade shaft, from impeller & clean it. Replace damaged blade
bearing/bearing cap etc. and apply lubrication on blade bearing/blade shaft.
8. Freeness checking of all blade holders, control arms etc., replaces damaged items if required.
9. Check NMEJ & replace damaged part.
10. Clean lubrication point passage
11. Apply lubrication to blade bearing assembly from lubrication point.
12. Fix blades with proper blade gap setting with impeller hub as well as with impeller ring as per
drawing and record it in presence of NTPC personal.
13. Alignment of motor with fan & record it in presence of NTPC personal.
14. Trial run of lop for leakage checking.
15. Stop lop and remove hydraulic system hose for alignment checking of rotary union.
16. Connect oil line hoses and check blade full open/close position and record it as per drawing.
17. Clean fan internal and after thorough checking close all manhole doors & box-up fan.
18. Painting to be done at fan area as per direction of EIC. (Paints/primer will be provided by NTPC
free of cost).
19. Take fan trial run and rectify defects if any.

NOTE:-
1. FOR PA/FD FAN SERVICING 60% OF BOQ WILL BE RELEASED.
2. FOR SERVICING OF HYDRAULIC CYLINDER PAYMENT AS PER BOQ NO BMFDA52BD800

Page 18 of 30
 3. PAYMENT FOR NMEJ FITTING IS EXTRA AS PER RESPECTIVE BOQ
4. PAYMENT FOR BLADE PITCH SETTING IS EXTRA AS PER RESPECTIVE BOQ

JOB NO. 20.380: (BMPAA53OH001) Axial ID/PA/FD Fan (BRG) OH

COMPLETE OVERHAUL OF ID/PA/FD FAN

A. SCOPE OF WORK FOR ID/FD FAN COMPLETE OH (100% BOQ VALUE FOR ID FAN OH AND
70% BOQ VALUE FOR FD FAN OH)

1. Open all manhole doors after confirmation of PTW.

2. Decouple fan from motor and take initial reading by dial gauge and record it.
3. Remove diffuser suction & discharge side flange joint & NMEJ bolt to facilitate diffuser drag-out.
4. Remove all lube oil/airline connection with proper marking by permanent paints.
5. Shifting fan diffuser towards discharge side to facilitate fan impeller.
6. Remove impeller casing top cover for blade removal.
7. Remove all blades and shift it to the blade handling platform.
8. Remove hydraulic cylinder from impeller hub & rotary union.
9. Thoroughly clean all the blades for DPT test. NTPC approved new DPT kit will be arranged by
contractor & no extra charges will be provided by NTPC. Blade DPT test witness by NTPC FQA &
BMD department jointly.
10. Remove impeller cover with proper marking.
11. Remove all bearing cap, blade holder assy. Blade shaft, control arm etc. and thoroughly clean it.
12. Remove impeller from fan shaft by necessary tools and shifted it to the reclamation yard.
13. Remove fan bearing support from its pedestal and shifted it to the reclamation yard.
14. Clean impeller thoroughly by compressed air and replace plain bearing & suction side seal ring
etc. If required, blade weight to be taken and record it. Replace blade if required.
15. Freeness checking of all blade holders, control arms etc., replace damage items if required and
replace blade bearing as per instruction of EIC & apply new grease on all blades bearing and blade
shaft etc.
16. Fit all blade holder assy. Control arm, blade shaft, bearing cap etc. Onto the impeller as per
drawing.
17. Change all bearing if necessary, on bearing support.
18. Shift assembled bearing support to the bearing pedestal & bolted it.
19. Clean lubrication point passage.
20. Apply lubrication to blade bearing assembly from lubrication point.
21. Shifts impeller to the casing area & fix it with bearing support and fix impeller cover and apply
metal putty on impeller cover inside/outside.
22. Fix hydraulic cylinder & rotary union with impeller.
23. Shifting diffuser to its original position.
24. Tight diffuser suction & discharge side bolt.
25. Change NMEJ if found damaged & fix it in-between diffuser and outlet duct.
26. Fixing all lube oil lines and control oil lines and check oil leakage after lube oil trial run and rectify
if any oil leakages observed.
27. Connect C& I connection on bearing support.
28. Fix blades with proper blade gap setting with impeller hub as well as with impeller ring as per
drawing and record it in presence of NTPC personal.
29. Servicing of main motor coupling.
30. Alignment of motor with fan & check it in presence of NTPC personal.
31. Stop lop and remove hydraulic system hose for alignment checking of rotary union in presence of
NTPC personal.

Page 19 of 30
32. Connect oil line hoses and check blade full open/close position and record it as per drawing.
33. Couple fan with motor.
34. Painting to be done at fan area as per direction of EIC. (Paints/primer will be provided by NTPC
free of cost).
35. Clean fan internal and after thorough checking, close all manhole doors & box-up the fan.
36. Take fan trial run and rectify defects if any.

B. SCOPE OF WORK FOR PA FAN COMPLETE OH (70% BOQ VALUE FOR PA FAN OH)

1. Open all manhole doors after confirmation of PTW.

2. Decouple fan from motor.
3. Remove casing/diffuser suction & discharge side flange joint & NMEJ bolt.
4. Remove all lube oil/airline connection, blade & C&I point.
5. Remove fan casing manhole door to facilitate impeller and bearing housing assembly.
6. Shifting fan diffuser towards discharge side to facilitate fan discharge side impeller.
7. Remove hydraulic cylinder & rotary union from impeller.
8. Remove discharge side impeller from fan shaft & shift it to reclamation yard.
9. Shifting casing bottom part including bearing housing towards discharge side and remove suction
side impeller.
10. Servicing of all blade bearing, blade holder assy. Control arm and main bearing and replace
damaged items. Apply lubrication on all blade bearing.
11. Serviced impeller with bearing housing shifted to site and fitted it with foundation.
12. Tighten all foundation bolts.
13. Fix discharge side impeller with fan shaft and connect hydraulic cylinder /rotary union.
14. Thoroughly clean all blades for DPT test. Blade DPT test will be witnessed by NTPC
representative and agency will arrange NTPC approved DPT kit and no extra charges will be
provided by NTPC. If reqd. Blade weight to be taken and record it. Replace blade if reqd.
15. Fix blades with proper blade gap setting with impeller hub as well as with impeller ring as per
drawing and record it in presence of NTPC personal.
16. Shifting diffuser to its original position and connect suction and discharge side NMEJ/flange joint
bolt.
17. Fixing all lube oil lines and control oil lines and check oil leakage after lube oil trial run.
18. Connect C& I connection on bearing housing.
19. Alignment of motor with fan and record reading in presence of NTPC personal.
20. Servicing of main motor coupling.
21. Stop lop and remove hydraulic system hose for alignment checking of rotary union for fan.
22. Connect oil line hoses and check blade full open/close position for fan and record it as per
drawing.
23. Box up fan.
24. Clean fan internal and after thorough checking close all manhole doors.
25. Take fan trial run and rectify defects if any.

NOTE:-
1. FOR FD FAN SERVICING 70% OF BOQ WILL BE RELEASED.
2. IF MBA SERVICING IS NOT DONE THEN RATE OF BOQ ITEM 10.330 WILL BE CONSIDERED
FOR PAYMENT PURPOSE FOR ID/FD/PA FAN.
3. FOR SERVICING OF HYDRAULIC CYLINDER PAYMENT AS PER RESPECTIVE BOQ
4. PAYMENT FOR NMEJ FITTING IS EXTRA AS PER RESPECTIVE BOQ
5. PAYMENT FOR BLADE PITCH SETTING IS EXTRA AS PER RESPECTIVE BOQ
6. HEAVY VEHICLES LIKE CRANE/HYDRA/TRUCK/ANY OTHERS TOOLS REQD. FOR
IMPELLER/BEARING SUPPORT REMOVAL/FITTING WILL BE ARRANGE BY NTPC SUBJECT TO

Page 20 of 30
 AVAILABILITY. HOWEVER DUE TO NON-AVAILABILITY OF ANY ABOVE MENTIONED
EQUIPMENT/TOOLS WILL BE ARRANGE BY AGENCY ON HIS OWN COST AND NO EXTRA
CHARGES WILL BE PROVIDED BY THE NTPC.

JOB NO. 20.390: (BMLOS00BD801) Lube Oil System (<>) Repair

LUBE OIL SYSTEM OVERHAULING OF PA/FD/ID FAN

1. Drain lube oil from tank and properly storage it cleaned drum.
2. Thoroughly clean all filter & tank internal portion and paint if necessary inside tank.
3. Check all valve/hose pipe/oil pipeline/pump/spider/bell housing etc. & replace/rectify damage
items.
4. Thoroughly clean PHE cooler by cold jet water and box up it.
5. Fill fresh/collected oil inside tank after getting clearance from NTPC personal.
6. Trial run of pump for leakage checking and attained any defect.
7. Painting to be done all pipeline & valves & tank. (NTPC input paints/primer).

JOB NO. 20.400: (BMSAF00BD800) Seal Air Fan (<>) Repl

SEAL AIR FAN OVERHAULING

1. Removal of ducts, diffuser etc. To facilitate impeller removal after confirmation of PTW.
2. Removal of impeller from shaft without damaging impeller.
3. Removal of shaft assembly along with bearing assembly from foundation after decoupling.
4. Removal of coupling half from shaft.
5. DPT of impeller, replace if required. NTPC approved DPT kit will be provided by agency and no
extra charges will be provided by NTPC.
6. Minor repair work of impeller, if required.
7. Cleaning & polishing of impeller, motor shaft key etc. To facilitate smooth mounting of impeller
on shaft.
8. Dismounting of bearing assembly from shaft.
9. Clean all parts of bearing assembly including bearings and replace all worn out and damaged
parts.
10. Re assemble bearings and associated parts on shaft.
11. Clean and inspect bearing housing and replace if required with proper blue matching with
foundation.
12. Assemble bearing housing with shaft, bearing and associated parts.
13. Mounting of impeller on shaft and locking of the impeller with conical cover plate and lock nut
and washer.
14. Fixing of diffuser and related ducts along with labyrinth seal & rope.
15. Align fan w.r.t motor in presence of NTPC representative & record reading.
16. Taking successful trial run.
17. Defect rectification, if any.

NOTE:
60% PAYMENT OF BOQ VALUE WILL BE RELEASED ONLY FOR CHECKING OF IMPELLER &
BEARING HOUSING AND MOTOR ALIGNMENT WORK. REMAINING 40% WILL BE RELEASED
FOR BEARING/IMPELLER REPLACEMENT WORK IF REQUIRED, AS PER FAN BEARING
/IMPELLER CONDITION.

JOB NO. 20.410: (BMB/F00OH000) BLWR/FAN (<>) Serv

Page 21 of 30
GATE/DAMPERS BLOWER & AC/DC SCANNER AIR FAN / PURGE AIR FAN SERVICING

FAN/GD GATE AREA BLOWER AND AC/DC SCANNER AIR FAN / PURGE AIR FAN SERVICING AND
SEAL AIR FAN DYNAVANE FILTER CLEANING.

FOR BLOWER/AC/DC SCANNER AIR FAN / PURGE AIR FAN

1. Removal of all fan/blower casing covers & checks internal parts.
2. Thoroughly clean all bearing housing and apply fresh grease.
3. Check suction and discharge side duct NMEJ & replace/rectify it. If duct modification is required
then same has to done by agency.
4. Filter cleaning by compressed air.
5. Fan/blower impeller replacement if required.
6. Check suction and discharge side damper/foundation blot and rectify defect if required.
7. Painting to be done at fan/blower area as per direction of EIC (NTPC input paints/primer).
8. Trial of fan & defect rectification.

FOR SEAL AIR FAN DYNAVANE FILTER CLEANING

1. Open filter manhole door after confirmation of PTW.
2. Remove locking element and filter element & thoroughly clean all elements by water/air.
3. Refit all filter element with proper locking and close manhole door with rope & holdtite.

JOB NO. 20.420: (BMFDA52BD800) Axial FD Fan (SERVOMOTOR ASSY) Repl

HYDRAULIC CYLINDER REPLACEMENT OF PA/FD/ID FAN

1. Open discharge side manhole door. Remove rotary union and all hose pipe with proper marking
after confirmation of PTW.
2. Remove all bolts to facilitate hydraulic cylinder & remove it.
3. Change all oil seal on hydraulic cylinder.
4. Fit serviced hydraulic cylinder on impeller.
5. Fit rotary union & alignment it in presence of NTPC representative.
6. Connect all lube oil line & take trial run of lop & rectify defect if any.
7. Close all manholes.

JOB NO. 20.430: (BMFDA53GN100) Axial FD Fan (SILENCER) Cleaning

SILENCER CLEANING FOR PA/FD FAN

FOR PA/FD FAN:-

1. Opening of all manholes of the fan including servomotor door.
2. Provide proper scaffolding for movement inside suction chamber and outside roof.
3. Clean silencer from inside as well as outside thoroughly.
4. Clean both suction chamber and discharge duct up to discharge gate.
5. Repair roof support and wire mesh, canopy, suction chamber if required.
6. Remove all scaffolding material from inside/outside.
7. Clean all debris from inside fan chamber and dispose it to a suitable location as decided by EIC.
8. Close manhole door properly by providing packing ropes and fasteners.
FOR ID FAN:-
1. Opening of all manholes of the fan including servomotor door.
2. Provide proper scaffolding for movement inside suction chamber.

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 3. Clean id fan suction side and check all internals thoroughly.
4. Clean both suction chamber and discharge duct up to discharge gate and ash thoroughly.
5. Repair suction support and suction chamber if required.
6. Remove all scaffolding material from inside.
7. Clean all debris from inside fan chamber and dispose it to a suitable location as decided by EIC.
8. Close manhole door properly by providing packing ropes and fasteners.

JOB NO. 20.440: (BMMSW00GN758) Misc Works (<>) PERF. TESTING

BLADE PITCH SETTING ID/FD/PA FAN

1. Connect all lube oil connection.

2. Insure sufficient control oil pressure.
3. Operate blade pitch.
4. Check blade pitch operation at various locations.
5. Check full open and full close position and set blade pitch as per manual.
6. Take measurement of blade tip clearance, blade pitch etc. As per manual.
7. Record reading at 0% and 100%.
8. Ensure readings are under permissible limit.
9. Set blade pitch as per manual.
10. After final setting; make arrangement for inspection by NTPC representative.
11. Box-up after clearance from NTPC representative.

***************************************************************************************************

SCOPE OF WORK(DUCT area):

GENERAL INSTRUCTIONS & SCOPE OF WORK

Page 23 of 30
01) Before starting the work or entering into the equipment for any maintenance job, the agency
must ensure the following.

a. The relevant PTW for the work has been collected from EIC/representative.
b. Availability of sufficient and safe illumination through 24 volts inside confined space.
c. Availability & use of personal protective equipment.
d. Availability of suitable hand gloves for handling hot objects.
e. Availability of leather hand gloves for handling sharp objects.
f. In case of fire, take instructions from E.I.C. before opening the equipment.

02) After completion of the maintenance work and giving clearance for trial operation / Return of
PTW, ensure the following.

a. The equipment is cleaned and area cleared from scrap, debris.

b. Men and materials have been removed from the equipment.
c. Manhole and inspection doors are closed.

03) During assembling of the components / system, matching of the new spares with the
corresponding parts may be required to be done. For this, any minor cleaning, cutting / welding /
grinding / finishing with emery paper / coir rope may be required to be done and this is to be
considered as included in the respective jobs.

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Schedule No. 20.450 : BMDGD00BD800 Duct Damper/Gate (<>) Repl

Damper flap replacement

1. Remove old damaged flap.
2. Shift new flap to site.
3. Make scaffolding as per requirement.
4. Erect new flap.
5. Fit seals at flap edge if required.
6. Ensure proper fitment.
7. Shift old flap to scrap yard/ site store / any other location as per instruction of EIC.

Note: Extra payment for scaffolding as per respective BOQ.

Schedule No. 20.460 : BMMSW00GN972 Misc Works (<>) WELDING

Welding work
1. Re-welding of existing plates, bracings wherever old welding is eroded is included in this scope.
2. Hard facing of duct plates, vanes, if required are to be done.
3. This schedule is not applicable for welding works of all other schedules, as the scope is included
in respective schedules.

Schedule No. 20.470: BMDCT00GN100 Duct(<>)-Cleaning

Duct Cleaning
1. Open all manhole doors after confirmation of PTW.
2. Accumulate all the deposited ash and scrap in one location as desired by EIC.
3. Pack all the ash in gunny bags.
4. Safely remove, shift and unload the ash filled gunny bags to a location as desired by EIC.
5. If required, final cleaning of ducts with water jets may have to be carried out.
6. Post work cleaning: After completion of duct repair work- clean the duct again-remove all
scraps.
7. Proper lighting arrangement is to be made for inspection and contractor / his representatives
have to assist NTPC representative in carrying out inspection.

Complete duct system is divided into following parts for cleaning work and each part will be
considered as 1 BOQ quantity.

Duct system consists of following parts:

1. Economizer outlet to APH Inlet (1 BOQ)
2. PAPH-A/SAPH-A outlet to ESP inlet(A-B-C pass)(1 BOQ)
3. PAPH-B/SAPH-B outlet to ESP inlet (D-E-F pass)(1 BOQ)
4. ESP outlet A-B-C pass to ID fan–A inlet (1 BOQ)
5. ESP outlet D-E-F pass to ID fan–B inlet (1 BOQ)
6. ID fan A and B outlet to chimney (1 BOQ)
7. Cold Primary Air duct (1 BOQ)
8. Hot Primary Air duct (1 BOQ)
9. Cold Secondary Air Duct (1 BOQ)
10. Hot Secondary air duct (1 BOQ)

Schedule No. 20.480: BMG/B00OH000 Gear Boxes (<>) Serv

Page 25 of 30
 GEAR BOX SERVICING
1. Damper/Gate is to be locked mechanically before start of work.
2. Removal of Gear Box from Gate/Damper.
3. Disassembly of Gear Box and Cleaning of Grease etc.
4. Inspection/Replacement of bearing.
5. Check if any gear is damaged, replace damage gear.
6. Greasing and Re assembly of Gear Box.
7. If required replace gear box.
8. Repair connecting rods.
9. Fixing of Gear Box and trial operation of Damper/Gate.

Schedule No. 20.490: BMDCT00BD800 Duct(<>)-Repl

DUCT REPAIR WORK / BRACING REPAIR/ GUIDE VANE REPAIR

1. Assistance in ATT before OH (as per requirement), Deploy the manpower and required
resources for ATT.
2. Draw steel/materials from site store, steel yard, central store, etc. and shift the same to site.
3. After the internal inspection; conduct thickness survey of Duct, marking will be made for
replacement of plates based upon erosion and thinning. Assistance is to be extended for
thickness survey by providing sufficient manpower.
4. Inspect duct plate thickness & erosion and cut worn out portion in ducts. Make approach
/scaffolding as per requirement.
5. Replace and weld cutout portion by grafting with 6mm/8mm/10 mm/12mm plates or as per
instructions of EIC.
6. First new plates are to be cut as per marked dimensions and this can be used as template for
the old plate cutting and removal for proper fitting. Replaced plates are to be welded from
both sides as per availability of approaches. Putting additional layer is also included in scope.
7. Attend leakages/defects if any after ATT. Contractor has to assist in ATT (as per
requirement), which is included in this scope.
8. All guide vanes and baffles replacement are also covered in this scope. The guide vanes &
baffles are to be fitted as per the drawing/ sketch provided by the EIC.
9. Bracing replacement:
a. Drawl and shifting of the material from store to site.
b. Repair worn out/ damaged bracing pipes/beams by replacing part/whole of the
pipe/beam or shielding it.
c. Replacement of pipe/beam if required.
d. Shielding of bracing pipe with angles / channels and stitch welding to pipes.
e. Replace gusset plate if required.

Note: Payment for scaffolding if scaffolding erected and steel transportation from steel yard to site will
be made separately.

Schedule No. 20.500: BME/J02BD801 Expansion Joints (NON-METALLIC) Repair

REPAIR/REPLACEMENT OF NMEJ FABRIC

1. Shifting of fabric cloth from store to site.
2. Removal of bolts and nuts.
3. Removal of damaged expansion joint’s fabric cloth
4. Place new piece of fabric cloth.
5. Positioning of new fabric cloth at the joint.
6. Joining of two ends of the fabric.

Page 26 of 30
 7. Full tightening of bolts and nuts.

Note: Erect scaffolding for installation of non-metallic expansion joint if required. Payment for
scaffolding will be made separately.

Schedule No. 20.510: BME/J01BD800 Expansion Joints (METALLIC) Repl

FABRICATION, INSTALLATION /REPAIR OF METALIC EXPANSION JOINT or NON METALIC

EXPANSION JOINT
1. Shifting sheet from steel yard to site.
2. Fabricate die, if required, as per size of expansion joint /drawing given by EIC.
3. Fabricate plate as per drawing.
4. Fabricate 90 degree bend.
5. Cut the duct position & erect the expansion joint after confirmation of PTW.
6. Erect scaffolding for installation of metallic expansion joint.
7. Proper welding to be done on expansion metallic sheet to duct.
8. Remove scaffolding material from duct.
9. Attend defects if any after ATT.

Note: 1) Extra payment for scaffolding as per respective BOQ.

Extra payment for steel transportation as per respective BOQ
2) For payment purpose:
a) Fabrication of metallic joint - 20% of service value.
b) Erection and welding of metallic joint - 80% of service value.
c) Repair work at existing joint– 40% of service value.

Schedule No. 20.520: BMDGD00BD000 Duct Damper/Gate (<>) Attend Defect

Cleaning, inspection and lubrication of duct Damper/Gate.

1. Open required manhole doors after confirmation of PTW and erect scaffolding wherever
required.
2. Clean chains and sprockets thoroughly for gates.
3. For damper lubricate all bushes. Check flaps position in full close & full open condition.
4. Check all gate seals for any erosion or damage and for damper check individual damper flap
and shaft for any erosion.
5. Clean gate/damper movement slot for deposition of ash or debris.
6. Take trial operation of the gate/damper for smooth full opening and closing. Rectify defects if
any.
7. Clean surroundings.
8. Mark full open and close position clearly with paint.
Note:
Extra payment for scaffolding as per respective BOQ.

Schedule No. 20.530: BMDGD00OH001 Duct Damper/Gate (<>) OH

Major servicing/ Overhauling of Damper /OR/

Major servicing/ Overhauling of Guillotine damper/Gate /OR/
SCAPH Cleaning

Major servicing/ Overhauling of Damper

1. Open manhole door.

Page 27 of 30
 2. Arrange proper lighting and clean the damper area.
3. Check operation of damper from full open to full close.
4. Lever distances are to be adjusted, if required.
5. All flaps are to be cleaned.
6. Support gate flap with the help of chain pulley block and erect scaffolding wherever reqd. for
servicing of dampers.
7. Removal of damper bearings, side retainers and cleaning and greasing. Cleaning of bearing
bushes, pins etc. and replacing the damaged parts.
8. After removing bearing bushes, shafts are to be cleaned.
9. Inspect shaft and damper flaps for any defect. Repair them.
10. Replace shaft or service old shaft
11. Replace damper flaps if required.
12. Ensuring full range operation of dampers i.e. full close and open, both in cold and hot
condition.
13. Open / close markings externally on shafts are to be done if required.
14. Reassemble damper flaps, bearings, bushes and link
15. Fix link to actuator for damper.
16. Remove scaffolding.
17. Clean surroundings.
18. Mark full open and close position clearly with paint.
Note:
1) Extra payment for scaffolding as per respective BOQ.
2) Payment for Damper flap replacement- extra as per respective BOQ.
3) For payment purpose schedule is divided as-
Servicing - 70 %,
Operation checking and assistance during commissioning– 30%,

/OR/

Major servicing/ Overhauling of Guillotine damper/Gate

1. Arrange proper lighting and clean the gate area.

2. Check operation of gate- full open to full close.
3. Clean gate.
4. Clean chains and sprockets thoroughly for gate. Replace of pins/coupling bolts of chains, if
required.
5. Gate chains are to be cleaned and chain covers to be positioned.
6. Replacement of seals (partial/full), replacement of chains/bearing blocks with bearing,
shafts etc. Check all gate seals for any erosion or damage repair/replace if required.
7. Repair chain /bearing and sprocket guards if required.
8. Provide/replace guide angles.
9. During operation/commissioning activities if the chain fails, the gate is to be lifted using
pulley blocks.
Note:
1. For measurement purpose the twin gates shall be considered as two separate gates.
2. For payment purpose: Payment of seals replacement/repair is extra as per respective
BOQ
3. For payment purpose schedule is divided as-
Servicing - 70 %,
Operation checking and assistance during commissioning– 30%,

Page 28 of 30
 /OR/

SCAPH Cleaning

1. Open all manhole doors & duct drain point after confirmation PTW.
2. Clean SCAPH by water jet.
3. Inspect SCAPH and remove water from duct if stored inside of duct.
4. Close all manhole doors & drain point.

Schedule No. 20.540: BMHAG00BD798 Hot Air Gate (<>) RPL-M-SEAL

GATE SEAL REPLACEMENT

1. Check isolation of gate.
2. Remove seal holding plate
3. Remove old worn out seals
4. Check all gate seals for any erosion or damage repair/replace if required.
5. Replace seals (partial/full)
6. Fit seal holding plates.
7. Check full operation of gate after seal replacement.

Note: Extra payment for scaffolding as per respective BOQ.

Schedule No. 20.550: BMBLR20BD000 BOILER (PEEP/MANHOLE) Attend Defect

Duct door/Manhole repair

1. Open manhole door.
2. Remove old rope.
3. Apply Holtite or equivalent chemical.
4. Replace the rope.
5. Tight the fasteners of Manhole door.
6. Replace damaged fasteners.
7. If required replace the door.
8. Apply liquid glass.
9. Check for leakage after normalization of system.
10. Attend if any leakage is there.

Schedule No. 20.560: BMBLR02GN353 BOILER >200MW# HPW Jet Cleaning

Higher pressure water jet cleaning of Gates in duct

1. Deployment of HP jet cleaner with HP water jet nozzle at flue gas gates as directed by EIC.
2. Duct gates casing is to be lifted or fabrication of windows in gate casing. After lifting this
casing, HP jet cleaning is to be done as directed by EIC or his representative.
3. Cleaning may be required at rack & pinion after removing the cover.
4. Final clearance for FG gates cleaning completion will be given by EIC or his representative
after inspection of the same.
Note:
1. Duct gates are located at different location from eco-outlet to ID fan outlet (Chimney inlet);
therefore, it is advised to contractor to arrange three to four set of portable jet cleaning
machine so that shifting of machine from one FG gate to another gate will be easier.
2. Contractor has to arrange his own HP jet machines which can develop more than 200ksc
Pressure jet at least 2 nozzles.

Page 29 of 30
 3. The party shall be fully responsible for the safety of their manpower and equipment.
4. All persons deployed by contractor should be medically fit.
5. Party must deploy skill and experienced manpower.
6. NTPC may issue HP jet machine on chargeable basis, if contractor’s machine fails to meet
desired parameter or contractor fails to bring machine in proper condition subjected to
availability.

---------------x-----------------x-------------------x------------------------------x-------------------------X---------------------

Page 30 of 30
Overhauling of boiler pressure parts, APH, DUCT, MILL, Burners, Fans, hanger supports
& associated works in one units of NTPC Lara STPP in 2020-21

NIT NO : 9900214352

SPECIAL TERMS & CONDITIONS (Annexure-V)

1. GENERAL The works to be done shall conform to the detailed specifications

mentioned in scope of work as described in schedule of
quantities and further details as per the instructions of Engineer-
In-Charge. If there is any dispute about the scope of work, the
decision of Engineer-In-Charge shall be final and binding on the
contractor.

The quantity given in the schedule of quantities is indicative &

approximate only and may vary according to the actual
requirement. The contractor shall have no extra claim in this
regard.

The work shall be executed on firm price basis throughout the

contract period and during extended period also, if any.

Contractor shall pay central minimum wages with all statutory

benefits, which are revisable from time to time are to be paid to
the labor engaged in the work during the contract period and its
extended period with no extra cost to NTPC.

NTPC reserves the right to ban the party from the business if the
party withdraw the offer after becoming the lowest valued bidder
and also if the party does not execute the order after placement
of purchase order.
2 Contract period The period of contract shall be twelve (12) months from the
date of commencement of work. However, the contract can
further be extended for a period of six (6) months at the same
rate, terms and conditions. The Corporation reserves the right to
reduce the period at the time of award of contract itself at their
discretion. During the currency of contract, the Corporation
reserves the right to reduce the period/terminate the contract at
its own discretion without assigning any reasons whatsoever &
contractor will not have any claim on account of the same. The
corporation further reserves the right to extend the contract on
the same terms and conditions for a further period and the
Contractor shall be bound to execute the works during the
extended period also, at the same rates, terms & conditions as
awarded.

The contract can be summarily terminated if the quality of work

and pace of work are so bad that, in the view of NTPC,
continuation of the contractor’s work shall lead to deterioration
of the equipment or loss to NTPC. The balance work then shall be
got done at risk and cost of the contractor.

However actual overhauling work of individual boiler as per

schedule of contract has to be completed within 30 days or as per
schedule from actual date of start of Boiler overhauling. The

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NIT NO : 9900214352
actual date of start of shutdown will be intimated by the EIC 10
days in advance.

Time is the essence of contract and if you fail to maintain

required progress in terms of conditions of contract or complete
the work and clear the site on or before the contract or extended
date / period of completion, provision of clauses of G.C.C
regarding liquidated damage shall be applicable.
3 PRICE BASIS The contract for the entire scope of work shall be executed on
FIRM PRICE basis. GST shall be extra at actual.

You will execute all extra items of work, which may crop up
during execution on mutually agreed rates as per provision of
G.C.C.
4 Defect Liability The contractor shall guarantee the work done by him against any
Period for defects of poor workmanship, negligence or omission for a period
Individual of 90 days from the date of first synchronization after completion
Boilers of individual boiler overhauling. This is for such type of defects,
Overhauled which are likely to cause load reduction, or stoppage of the unit.
For other defects, which are not likely to cause unit shut down, or
load reduction, the defect liability period shall be thirty days only
from the date of first synchronization after the overhaul. Any
defects observed during this period shall be rectified by you at no
extra cost.
5 Mode Of The works shall be measured in terms of the unit indicated in the
Measurement Schedule of Quantities. Payment will be made for the actual
quantity of work executed at the unit rates specified in the
Schedule of Quantities.
6 Safety at and of General safety clauses
Work
The contractor shall be fully responsible for the safety of their
workmen and shall take necessary precautions and provide
protective PPE to avoid any accidents.

As the basic slogan of safety at NTPC Lara is NO ENTRY

WITHOUT PPES, the workers being engaged by the agency
inside the plant premises are required to compulsorily use the
basic PPEs like Safety Shoes, Safety Helmets, Full body Harness
and Safety reflective jackets.
After purchase but before issue to the workers by the contactors,
all PPEs are required to be inspected by NTPC safety & EIC for its
acceptance and approval. The cost of all safety items used by the
contractor for issue to his workers will be reimbursed to the
contractor on producing documents. The items are to be
purchased of NTPC approved brands only.

Apart from the above Basic PPEs, other PPEs like Hand gloves,
safety glasses, Ear Plugs, Nose Masks and grinding goggles etc.,
are also to be used by the workers on functional basis at work
locations as per requirement.

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Overhauling of boiler pressure parts, APH, DUCT, MILL, Burners, Fans, hanger supports
& associated works in one units of NTPC Lara STPP in 2020-21

NIT NO : 9900214352
After issuing required PPEs by the contractor, it is also the
agencies/contractors responsibility to ensure regular usage of
PPEs by their workers working at site.

If any contract worker found working without PPEs by NTPC, his

gate pass shall be seized immediately and agency shall be
penalized as per terms and conditions of the contract. On
repeated violations for three times by the same worker, he shall
be removed from the site permanently and his gate pass shall be
cancelled and returned to NTPC with RED MARK on it.

The performance of the agency (in regard to safety practices)

shall be continuously evaluated and properly recorded. Such
evaluations shall be used as important criteria for considering
any future contracts for the same agency. Any agency / worker(s)
with exemplary safety record may also be considered for suitable
certification. However, agency with poor safety track record shall
be disqualified for future contracts.

Contractor shall also take care of the safety of machines/

materials of NTPC in the vicinity.

The contractor must deploy trained and qualified safety

supervisors during the working period of the contract.

All the workmen deployed by the party must undergo the safety
training given by safety department of NTPC.

Only those workmen, who have undergone training by NTPC

safety department and possess the card issued by them in proof
of this, shall be engaged by the contractor for this work.

24 volts hand lamps and 24 volts transformer should be provided

by the contractors for any lighting required for the job. Each
portable electric supply board shall have the over current circuit
breaker (MCB) & earth leakage circuit breakers for protection
against electrical shock and equipment damage.

All T&P like lifting and pulling machines, chain pulley blocks,
slings and D-shackles etc should be maintained in proper
working condition. There should be at least 02nos U - Clamps in
hand spliced portion of each sling.

Valid test certificate for all lifting tools / tackles being deployed
shall be submitted.

Rubber hand gloves and rubber boots shall be provided to

electricians. Proper record of issue of PPE is to be maintained.

All scaffolding should be inspected for soundness and strength.

Only tubular scaffolding materials should be used.

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Overhauling of boiler pressure parts, APH, DUCT, MILL, Burners, Fans, hanger supports
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NIT NO : 9900214352
The planks used for making scaffolding should be effectively
secured by good quality binding wire. The binding wires shall be
checked for damages by contractor’s safety supervisor on regular
basis.

The approach platforms made to reach the plank should be safe

with hand rails and toe-boards.

As per standard practice the verticals and horizontals should be

cross-braced for good stability.

In no case the width of the working platform shall be less than

60cms if the platform is used only for footing/walkway. As far as
possible head room of at least 1.8 meters shall be maintained.

No board or plank of the working platform shall project behind

its support to a distance exceeding four times the thickness of the
board or plank.

Any scaffolding shall be constructed with a minimum of three

supports as per safety norms for a standard length plank.

The contractor’s labors should be medically fit to work smoothly

at sites.

All welding machine connections shall be made with welding

receptacles only. Return earthing to be done at job directly from
welding machine.

Violation of any safety norms shall draw the deduction as per the
safety clauses of NTPC.

Proper illumination shall be provided in working area.

Hand railings/toe guards etc. wherever removed shall be

restored as soon as possible after completion of work.

DA carrying hoses should be kept away from the welding cables.

The hoses should be healthy with proper clamping to prevent
chances of gas leaks.

Gas cylinders should not be rolled on the ground or carried in

bicycles etc. Trolleys should be used for their transportation.
Proper cages should be used for lifting and lowering cylinders.
Anchoring at the valve portion of the cylinder should be avoided,
as the valve is delicate portion of the cylinder, which is liable to
break causing serious accident.

Welding cables should have proper insulation. No bare cable

should be exposed.

No loose material shall be left at heights as material falling it may

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cause serious injuries.

All workers working at a height of more than two meters or any

other location fall from where is likely to cause injuries must use
safety belts / Safety harness.

All portable hand lamps shall have insulated handle, cage

guard/cover over the bulbs.

All electrical cable shall be of double insulated type and joints in

electric power supply cables should be avoided to the extent
possible. In case joints are unavoidable, these should be
minimum and the joint should be properly insulated.

Inserting bare terminals in plug sockets is prohibited. Proper

plug tops should be used for connection with switch boards. At
least 03 core wires are to be used in electrical fittings.

All welding machines, grinding machines, drilling machines etc.

Should have their bodies properly earthed.
All gas cylinders must have the proper protection caps to protect
the nipples

All welders must use the protective helmets / glass specially

meant for welding and gloves.

All gas cutters and grinder men must use the safety goggles and
hand gloves.

All electrical connections and electrical jobs shall be done only by

the electrician.

All lifting and pulling tackles shall be duly tested by authorized

person and contractor shall submit the valid certificate to EIC
prior to using the tackles.

Grinding wheel and cutoff wheels used by the contractor shall

have expiry date mentioned over it and no grinding wheel /cutoff
wheel can be used after expiry date.

Spark/welding bits/cutting metal generated during gas

cutting/welding should not be allowed to fall below, which may
cause fire hazard at work site.

No scrap/materials shall be kept over temporary platforms

erected inside boiler

Safety precaution related to sky climber works:

1. All nut and bolts of sky climber are to be tightened properly.
Their tightness is to be checked daily.
2. All stirrup rods (for hoist mounting) are to be tightened with
double nut.

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3. All railings including end rails must be installed.
4. Before receiving the wire ropes, these should be checked
visually for any damage like broken strands etc.
5. In no case less than 3 dog jaw clamps should be used for
making eye at the end of rope.
6. All ropes must be properly protected against damage by
sharp metal edges, hot cutting metal, hot weld metal, and
welding arc etc.
7. The sky climber deck shall be separately earthed at the time
of any welding work. Only qualified operators shall deploy
for operation of sky climber.
8. Never send inexperienced workers alone on the sky-climber.
9. Ensure that all persons going on sky climber use safety belts
and tie its life line.
10. In no case any person working on sky climber deck should
lean over the railings.
11. In no case people should sit on the railing or stand on toe-
guards.
12. In no case sky-climber should be operated without safety
rope.
13. Function of sky climber safety devices should be tested daily
by the supervisor of the contractor. Once in three days
Contractor’s site in charge should check all these things
randomly.
14. Do not overload the sky climber. Follow the guide lines
given by EIC about safe working load
15. Do not operate the sky climber unless the operating
procedure and safety precautions are fully understood.
16. Do not try to release the safety lock when the safety rope is
under tension or the hoisting rope is very loose. Release
safety lock only when the safety rope is slightly slack and
hoisting rope is in tension.
17. No person working on sky climber should ever try to rest
against water wall as this will push the sky climber away
from the wall and cause an accident.
18. Whenever it is required to work for longer duration at some
elevation, the sky climber deck shall be tied by a chain /
manila rope taken through the peep hole and whose other
end is securely tied with some fixed object.
19. Never take off safety helmet while working inside furnace as
the lumps of slag deposited on walls and Super heaters may
fall any time.
20. Do not sleep on sky climber.
21. Use independently suspended safety lines to tie safety belts.
22. Insulate at the anchoring point of sky climber ropes shall be
ensured by wrapping Non-asbestos cloth at anchor point to
avoid earthing thru’ the ropes.
23. Rubber wheels shall be provided at sky climber assembly.

Safety during radiography:

1. Whenever radiography is done, the contractor shall ensure
that the radiographer is equipped with radiation meter.

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2. Danger tag shall be displayed after ascertaining the range of
harmful radiation to prevent people from entering this zone.
Contractor shall ensure that no man shall remain in exposure
zone of radiation while taking the radiography.
3. Whenever two or more radiography sources are used, it must
be ensured that no radiography source or the approach to it
comes under the zone of harmful radiation of other source.
4. Safety clauses related to Quick Erect scaffold erection &
removal:
5. All base trusses, platforms, wing trusses, beam trusses are
kept and secured properly to the satisfaction level of EIC.
6. All platforms shall have proper railing.
7. In case of no movement, door of Trap door platforms shall be
kept closed. Corner platforms shall be erected along with
peripheral platforms.
8. Spacer Brace and plan diagonal Braces shall be secured
properly for giving necessary strength to QES.
9. No loose material shall be kept on the platforms.
10. All the persons must use the safety gadgets properly. Safety
belts and safety harnesses must be used by all persons
working at heights above 2 meters from z-panel platform.
11. Only skilled manpower shall be engaged for this work.
12. Adequate supervision shall be provided by the contractor
throughout the erection / dismantling work.
13. Sufficient skilled manpower shall be deployed by the
contractor so that manpower can be deployed in shifts and
the workmen get rest period.
7 Engineer – In - AGM (O&M – BMD) shall be the Engineer In charge for this work.
Charge

8 Mobilization Mobilization period (after intimation for shut down) shall be 10

Period days after receipt of communication from the EIC. The period
shall be counted from the date of intimation about the work to
the date of shut down. This contract consists of Overhauling Of
Boiler Pressure Parts, Mills, Burner, APH, Fan, Duct & Associated
Works For One Unit Of 800MW Boilers AT NTPC-LARA STPP.

Against this order the agency has to mobilize its resources for
ONE Unit separately for overhauling works.

Communication of shutdown for each unit shall be intimated by

the EIC 10 days in advance for each unit separately. However,
contractor should be in a position to ensure mobilization even
within a short period to start the work if need so arises. The
contractor has to mobilize the required manpower after receiving
the notice of the job and works should be executed round the
clock without interruption, as per site requirement.

Contractor should be in a position to ensure mobilisation even

within a short period to start the work if need so arises. No extra
claim shall be entertained by NTPC either for idle labour or
reduced mobilization period.

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10 Tentative Unit As communicated by the EIC within the contract period
shutdown date
11 Tentative shut
30 days or as per schedule.
down durations of
The above indicated period is from De - Synchronization of the
Individual Unit unit before overhaul to Re- synchronization of the unit after
overhaul. The duration can be changed by NTPC if required.
12 Broad Plan of Generally, the time duration of the shut down is spent in Pressure
work during the Parts overhaul in the following manner:
shut down 1. Cooling of Boiler
2. Internal Washing
3. Scaffolds / Start of pre – identified works
4. Illumination
5. Cleaning
6. Surface preparation
7. Inspection & Thickness survey
8. Identification of tubes to be replaced
9. Tube cutting, fitting of new spools and welding of joints
10. Radiography, repairs, Re-radiography.
11. Internal hydraulic Test before Synchronization or as decided
by EIC.
12. Scaffold removal & protection works: 3 days
13. External (IBR) hydraulic test before Boiler Light - up
14. Boiler Box-up & Light-Up: After External (IBR) hydraulic test
before Synchronization
15. Safety valve floating
16. Synchronization
17. In case activities like chemical cleaning etc are taken up,
then the time for actual work can be further reduced.
18. Contractor shall keep the above broad plan in mind while
assessing the resource requirement for successful
completion of the works.
19. Duct Cleaning
20. Duct thickness measurement.
21. Replacement/repair of damage duct portion.
22. Bracing support replacement/repair.
23. All Gate/Damper servicing
24. NMEJ repair.
25. APH all basket removal and cleaning then reinserting/
Basket replacement.
26. APH seal repair/ change and setting.
27. APH Guide bearing/ support bearing servicing/replacement.
28. APH drive system servicing/replacement.
29. APH sector plate, axial seal plate, T-bar, rotor angle, gratings
etc. repair/replacement.
30. APH soot blower, water washing, and firefighting etc. repair
/ replacement.
31. APH center section, air seal housing, etc. repair.
32. APH rotor level, Guide & support bearing inspection, seal
gap setting.
33. ID/FD/PA fan impeller, main bearing assembly, hydraulic
cylinder and rotary oil seal, Lube oil system etc.

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servicing/replacement.
34. Seal air fan servicing/ Replacement.
35. Scanner air/ Purge air/ Pent house fan/ gate blower
servicing/replacement.
36. Removal and fixing of coal compartment assembly
37. Reconditioning and repairing of coal nozzle compartment
assy.
38. Inspection of All wind box dampers & Attending its defects
39. All checks during and after O/H works shall be performed in
front of NTPC representative.
Note:
1. The above list is not exhaustive; Contractor has to perform
all the works required for successful completion of Duct
system overhauling.
2. The work shall be done round the clock in all the 3 shifts on
all days including Sundays and holidays.
3. The contractor shall arrange adequate work force to take
care of above schedule so that proper rest period is available
for workmen.
4. Contractor’s Site in charge and site supervisor etc. shall
consult with EIC and his representatives in the initial phase
of mobilization (before the shutdown) and understand the
likely requirements of different resources, group – wise
deployment for different works etc. These requirements
shall be drawn up and signed by the contractor for further
monitoring by EIC for compliance.
13 Work Timings The work shall be done round the clock in all the 3 shifts on all
days including Sundays and holidays. Radiography shall
preferably be done during night / early hours to avoid radiation
hazard to other persons.
The contractor shall arrange adequate work force to take care of
above so that proper rest period is available for workmen.
14 Liasoning with Liasoning with the Boiler Inspectorate to
Boiler . Obtain approval / permission for the envisaged works,
Inspectorate . For ground inspection of materials, Hydraulic test.
. Approval of Radiography & NDT reports etc shall be in the
scope of the contractor.
15 Issue & Materials shall be issued from any of the NTPC stores/ locations
transportation of inside plant premises. Their lifting, transportation to site and
materials back and re–stacking the returned items at store/ identified
location as specified by EIC shall be done by the contractor.
16 Quality of Work Maintaining quality in general shall be responsibility of the
contractor. Guide lines for maintaining quality of works shall be
given to the contractor from time to time during execution of
work. Where appropriate quality plan / Hold points have been
incorporated in contract, same shall be complied.
Contractor shall comply following procedures in addition to the
procedures and rules as per IBR / ASME norms while carrying
out the overhauling work of Boiler pressure parts.
Skilled manpower Tests:
As soon as the contract is awarded the contractor shall get his

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skilled personnel tested by FQA / executing department of NTPC.
(If the welders / persons to be deployed had already been tested
by NTPC –LARA earlier and possess valid identity cards, then
such welders/ persons shall be eligible to be deployed even
without doing a repeat test till the validity of the earlier identity
card expires.) The contractor shall make arrangement for the
test. Tubes for testing shall be supplied by NTPC. Details of the
tests are given below:

1 HP Welders – carbon Radiography, visual and bend

steel and alloy steels test: 6G
2 HP Welders – Radiography, visual and bend
stainless steel test: 6G
3 Attachment welders Visual and / or radiography:4G /
4F
4 Gas cutters Visual and verbal
5 Grinder men Visual and verbal

Only tested skilled manpower shall be deployed for the work.

Tests shall be got done before the start of shut down.
Tube Cutting:
Tube cutting shall be as per specified method only, which shall
be obtained from EIC.
Ingress of foreign materials into pressure parts:
All specified care shall be taken to prevent entry of foreign
materials in side pressure parts. No plain & straight rod to be
used while doing the pressure parts job. If used it may have the
“T” shape.

Welding
Baking of electrode shall be done as standard procedures. Carry
ovens shall be used to carry baked electrodes to location.
Only special purpose filler wires shall be used for welding of Pr.
Parts tubes, metallic expansion bellows, Fin welding with tubes,
Stopper for shields etc. Electrodes and filler wires will be used for
shielding as per requirement. List of Some of the filler wires and
electrodes are given below:
Rutox A (Stab)/ Superinox-1B/ SS-347 for shielding work.
TGSM filler wire for TIG welding of CS tubes
TGS 1CM for TIG welding of T-11, T12 tubes
TGS 2CM for TIG welding of T-22 tubes
For T91, T92, SUPER304H and other special material tubes as
per NTPC recommendations.
ERNiCr-3 for dissimilar metal welding of Alloy Steel to SS.

Full TIG shall be used to weld all Alloy steel & stainless steel
boiler tubes, dissimilar joints, fins, stopper for shields etc.

Contractor must keep at least six thermal chalks of 93 deg C,
120 Deg C, 150 deg C and 200 deg C each for maintaining
preheat temperature during welding where ever required by
code. (Flame heating for T22 tube joints and Electric heating
for T91 and header/pipe joints).

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Wrapping of non-asbestos cloth after welding of alloy steel
tube is compulsory to ensure slow cooling. Before start of TIG
welding the preheating must be done. If welding of alloy steel
tube is interrupted, then preheating is to be done once again
before restarting the welding.

Specified procedures of preheating, welding and post heating
shall be obtained and done in consultation with the EIC.

Each weld is to be identified by welder Name/Number and
welder’s performance shall be kept under check.

The contractor shall bring high purity argon gas with purity
more than 99.995%. The argon gas brought by the contractor
is to be got checked in chemical lab for moisture and oxygen.

The weld joints should be free from undercuts. Under filling
and excessive weld reinforcement should be avoided. Correct
weld profile / crown should be maintained. All welding must
confirm to relevant ASME / IBR codes
RADIOGRAPHY:

Check radiographs shall be taken as specified in SOW.

100% radiography shall be done for all butt weld joints in
first pass (as defined). In second pass (as defined), all butt
weld joints except connection welds of coils and drain welds
shall be radiographed 100%. In Connection welds and drain
welds of second pass, 50% of the fresh welds are to be
radiographed. These 50% shall be those specified / selected
by EIC only, and shall be as per his priority, which shall be
daily obtained from him by the contractor.

All the joints where repair has been performed after 1st
radiography shall be re-radiographed.

The contractor shall have to maintain joint wise record of
radiography carried out, the result, the repairs done and final
result. The record must be compiled in a register everyday
and to be submitted to NTPC EIC.
Shielding:

At-least 3 clamps shall be provided on all shields longer than
0.5 m.

Locking strip/rod shall be used for preventing dislocation of
shields.
Cassette Baffles: (Applicable for Second Pass work only)

Sections of cassette baffles shall be joined by full welding and
not by stitch welding.

Suitable locking arrangement shall be provided for preventing
movement of baffles.
Casting of refractory:

The surface where refractory has to be cast should be cleaned.

Proper anchoring arrangement like wire netting / mesh,
reinforcement rods as instructed by EIC should be provided,
to hold the refractory in position.

Refractory should be first mixed properly to get an even
mixture and then water should be added around 10 to 15 %
by weight in the refractory and then mix once again the
refractory mortar thoroughly.

While applying refractory, mortar should be gunned on the

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surface so as to avoid air pockets or looseness of the
refractory and outer surface of the refractory should be
smooth and of required contour as per the instruction of EIC.

Applied refractory should be cured by sprinkling water on the
surface once in 8 hrs.

Correct grade of refractory should be applied as per
instruction of EIC.

Procedure can be different for other grades of refractory.
Removal of Insulation:
Any sheets / mattress or plates removed for removing of
insulation shall be properly stored & screws are to be packed in
cloth. Waste insulation to dispose at a space specified for disposal
as per EIC.
17 Quantity of Work This being a maintenance contract, the quantity of work is
predominantly dependant upon the inspections done after the
unit is stopped and is made ready for inspection by the
contractor.

Hence the contractor shall make all efforts to make the different
areas ready for inspection with adequate scaffold, approach,
lighting, cleaning and surface preparation, at the very earliest, so
that the works can be identified early and greater time is
available for the execution.

Further, the exact quantities of different works that are required

in different units shall depend upon the individual machine
conditions, as obtained during the inspections. Therefore, it is not
possible to predict these quantities with a high accuracy in
advance. Therefore, the contractor shall keep him self ready for
much higher or lower quantities.

On the basis of past experience some works may be identified by

the EIC, even prior to the shut down it self. Contractor shall
invariably tune his mobilization to attend to these identified
works plus for the further works that are likely to come up based
on inspection after the boiler is stopped and made ready for
inspection.

Contractor’s RE and Site in charge etc shall sit with EIC and his
representatives in the initial phase of mobilization (before the
shut down) and understand the likely requirements of different
resources, group – wise deployment for different works etc.
These requirements shall be drawn up and signed by the
contractor for further monitoring by EIC for compliance.

Works to be done shall be obtained in writing from the EIC or his

representative in duplicate books / work registers /
communication register / letters etc. All identified works shall be
completed to the satisfaction of EIC before Boiler box – up. All
tube works, including radiography, repairs and attachments shall
be completed before first hydraulic test.

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18 Site – The contractor shall deploy resident engineer, site – in – charge,
Organization of engineers and supervisors as specified in the clauses given below.
the contractor
The site – in – charge is expected to organize the external inputs
and generally oversee the work in whole.

The site – in – charge shall be available at boiler and plant

premises and look after the overhaul work with the help of
engineers and supervisors reporting to him.

The contractor shall establish a contact point in LARA where he

or his representative can be contacted during the validity period
of the contract.

The contractor shall keep functional mobile phones with his

engineers / supervisors etc.

Contractor shall designate one site in charge for the contract

period.

He shall duly submit a signed daily progress report and a signed

daily safety checks report as per the format given by EIC.

Site – in – charge shall attend a daily review meeting with EIC at a

mutually convenient time and venue. They shall come prepared
with day and cumulative progress of various activities,
constraints, and zone – wise plans for next 24 hours etc for the
meeting.

Two numbers safety supervisors (01 each in day and night) shall
be deployed. No work shall be taken up without the concerned
shift – safety - supervisor having checked and given clearance as
to the safe method and compliance to safety norms. These checks
have to be noted down in a register for verification by EIC.

The contractor should give due importance to housekeeping of

the area in which the works are being done and he shall not
keep/leave any job/items disturbing the walking /inspection
/working of the areas.

The contractor should clear/clean the working area immediately

after completion of the job. All scrap materials have to be
disposed to the scrap yard/dump yard, as per instruction of
NTPC engineer-in-charge.

The contractor shall submit the list of T&Ps, which has been
mobilized for this job, to the EIC before start of the work.

Erection of approach platforms wherever required and

dismantling the same as required. If any platform/ handrail/ toe
guard is cut, the same is to be restored.

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All the electrical connection should be done as per electrical
safety standard including use of proper quality power cables for
distribution board, safety lamps, 24 volt bulbs etc.

The contractor has to nominate and intimate NTPC in writing

who shall be present during the execution of the work and will be
responsible to ensure full implementation of all the relevant
safety practices at site.

Materials shall be issued from NTPC stores / locations inside

plant premises. Their lifting, transportation to site and back and
re – stacking the returned items at store / identified location/
repairing yard as specified by EIC shall be done by the contractor.
19 Expected The contractor shall deploy site–in–charge and supervisors as
Mobilization of specified in the clauses given below.
resources – Staff
& Manpower Site-In-charge is expected to organize the external inputs and
generally oversee the work in whole.

The site – in – charge shall be available at boiler and plant

premises and look after the overhaul/reclamation work with the
help of supervisors reporting to him.

The contractor shall establish a contact point in site where he or

his representative can be contacted during the validity period of
the contract.

The contractor shall keep functional mobile phones with his Site-
In-Charge & supervisors etc.

Contractor shall designate one site in charge for the contract

period.

Site – in – charge shall attend a daily review meeting with EIC at a

mutually convenient time and venue. They shall come prepared
with day and cumulative progress of various activities,
constraints, and zone – wise plans for next 24 hours etc. for the
meeting.

Contractor should be in a position to ensure mobilisation even

within a short period to start the work if need so arises. No extra
claim shall be entertained by NTPC either for idle labour or
reduced mobilisation period.

Following activities as directed by EIC shall be carried out in

advance of start of work:

Mobilizing all key personnel, including supervisors, site in charge,

skilled manpower and arrangement of gate passes after
submitting labour insurance policy/documents, labour license, if
required etc.

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Make site store / office ready for use. No payment for the
purpose shall be made for these. However, material can be issued
for the same free of cost and during closing of contract, office
should be handed over to NTPC. For this office only power source
shall be provided by NTPC. All other electrical items to be
arranged by the party itself at its own cost. Site Store/Office may
be provided by NTPC if available. Same is to be returned back to
NTPC at the end of the contract in good condition.

Ensure all persons to be deployed have necessary qualification

and are adequately skilled for the job and have got safety training
from safety department.

The contractor shall keep one electrician for assisting in

managing their electrical equipment’s, general lighting in boiler
etc. as a part of their site mobilization and preparedness.
Ensure all persons to be deployed have necessary qualification
and are adequately skilled for the job and have got safety training
from safety department.

This list is indicative and not exhaustive and contractor shall

have to mobilize all other additional resources, which will be
required for successful and timely completion of the job.
 Site – in – charge: 01
 Engineers: 08
 Welding & NDT: 01
 Day works: 02
 Night work: 02
 APH & Fan area- 01
 Burner & Mills- 01
 Duct area- 01
 Documentation: 01
 Radiography Teams: 03
 Experienced Skilled Supervisors: 11
 Welding & NDT: 02
 Day Works: 07
 Night Works: 02
 Computer Operator: 01
 Electricians: 02 in day and 01 in night
 Safety Supervisor: 01 in each shift
 Supervisor for administrative Jobs: 01
 Supervisor for materials arrangement: 01 in each shift
 HP Welders: 09 per shift.
 Attachment welders: 8 per shift for Pr. Parts
: 6 per shift for Duct & Other area.
 Gas Cutters: 09 per shift.
 Grinder men: 15 per shift.
 Thickness survey assistants: Minimum 10 for first pass
work; Minimum12 for Second pass work. However total
strength should not be less than 22 numbers.
 Quick Erect scaffold in first pass: (Minimum)60 persons per

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shift
 Riggers :80 in second pass
RE & Site in charge shall be at least Diploma Engineers/ highly
skilled supervisors with 5 Years’ experience.

Engineers shall be at least Diploma with 1 or 2 years experience

or highly skilled supervisors with high level of relevant
experience.

Supervisor shall be at least Diploma with 1 or 2 Years experience

or highly skilled supervisors with high level of relevant
experience.

EIC may, at his discretion waive above criteria in case of well

deserving experienced persons.

The above deployments are mainly for the shut down duration.
Partial mobilization as per instruction to be obtained from the
EIC shall suffice for the pre – shut down /post shut down periods.
This partial mobilization shall however meet the requirement of
the pre - shut down / post shut down works identified. Also key
persons shall be mobilized invariably before the shut down to
participate in the planning process.

Mobilization of following categories shall be submitted /

verification facilitated on daily basis to the EIC as specified by
him:
 RE
 Site – in – Charge
 Engineers
 Supervisors
 Electricians
 HP welders
 Thickness / NDT assistants
 Radiography teams
 Computer operator
 Safety supervisors
Mobilization of above shall be taken note of and shortfall
affecting the work shall attract deduction at the rate of Rs 1000/-
per day per person for all categories except RE & SIE, in whose
case, the deduction shall be Rs. 5000 per day per person.

However, no deduction shall be made if by putting extra efforts,

all inspections and works identified by the EIC are completed
before boiler box – up to his complete satisfaction and no
violations / compromises have been made in terms of safety or
quality.

Contractor has to make his own arrangements for lodging and

boarding for his workmen at his own cost.
20. Expected Contractor shall mobilize resources (indicative) as given below.

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Mobilization of This list is not exhaustive and contractor shall have to mobilize
resources – T&P all other additional resources, which will be required for
and Consumables: successful and timely completion of the job.
Contractors’
Inputs All items mentioned in contractor’s input shall be in good and
safe working condition along with due legal / statutory validity /
permission for use. Testing of lifting T&P, electrical, safety
gadgets is in agency scope. Electrical equipments like welding
machines, grinding machines, chop saw machines tested by
electrical deptt of NTPC to ensure healthiness. Contractor shall
keep the record of the tests carried out & submit a copy of test
certificates submitted to NTPC. If required T &P should be tested
in plant premises and witnessed by NTPC and Competent
authority, arrangement for the same and payment for the
competent person (as recognized by the factories act) shall be
done by the contractor only.

The rates quoted by the contractor shall be inclusive of, but not
limited to, the inputs covered under the head of contractors input
/ expected mobilizations indicated, and at no extra cost to NTPC
for successful completion of the work.

If the contractor fails to provide any input covered in his scope,

NTPC may at its discretion, provide this to the contractor on
identified / prevailing Charges / Rates. However non-availability
of any such input from NTPC cannot be a basis for delay in
completion of work.

At the time of mobilization, contractor shall enquire from EIC if

there are any preferred features / brands for the consumables /
inputs being arranged by him for this work. In case such a
preference is intimated, the same shall be complied.

1. Safety appliances for all workmen and staff, as per safety

norms.
2. Binding wires
3. Welding Generators with minimum leakage current as
specified by EMD of NTPC :16nos
4. Welding rectifiers with minimum leakage current as
specified by EMD of NTPC : 08nos
5. Chain pulley Blocks - 3MT & Long lift: 20nos,
6. Chain pulley blocks - 5MT & long lift: 12nos,
7. Electric Winches remote operated for scaffolding: 0.5MT to
1 MT: 08 Nos.
8. Electric Winches of 2 to 5Ton capacity-02 nos.
9. Radiography sources: 08 to 12 Curies Only: 02nos
10. Gas Cutting Sets with flash back arresters: 20 nos
11. Grinding machines: 30 nos
12. Saber saw with 6” blade for metal cutting. : 04 nos.
13. Buffing Machine – 6 nos.
14. FF2 Grinder: 03 nos
15. Milling Cutters-Cylindrical, conical, round each 12 pieces.

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16. Chop Saws: 04 nos
17. Tube beveling/ Chamfering machines: 04 nos
18. Baking Oven (Large): 01 no.
19. Portable oven: 16 nos
20. 4 Core Lighting Cable: 2000 meters
21. Welding cable: 2000 meters
22. Electric cables: 3 core, Double insulated type.
23. Halogen lamp with fittings – 70 nos.
24. Extension Boards with circuit breakers – 50 Nos.
25. Grinding wheels with valid shelf life
26. Cut – off wheels with valid shelf life
27. Chop saw wheels with valid shelf life
28. Pistol Drilling machines: 03nos
29. General tools like spanners & screw drivers etc
30. Pulling & lifting machines, Ratchets etc: 06nos
31. Radiography film of make Kodak – AA 400, or, AGFA –
LAZER – D7
32. Radiography film cassettes, films and chemicals
33. High quality 24 volts hand lamps with flexible 3 core cables
and holders
34. General purpose electrodes (E6013) for steel fabrication,
and other works other than for HP welding.
35. All welding accessories including TIG Sets, welding cables,
holders, etc
36. Consumables like cotton waste, marking cloth, hacksaw,
emery paper, and wire brush, circulating wire brush, and
holdtite liquid.
37. Argon gas of 99.99% purity. Certificate for purity of argon
gas shall be submitted for checking.
38. DA & Oxygen gases
39. Fire water hoses with nozzles and couplings: Length 250
meters approx
40. All measuring instruments like Vernier, tape or any other
instrument required for executing the work under this
contract.
41. Truck / Tractor trolley / Trailer for quick transportation of
material
42. Jeep / Bus for conveyance of staff and workmen
43. Non-Asbestos cloth for wrapping alloy steel joints
44. Thermal chalk for monitoring pre/post heating
temperatures
45. Lap top computer or Personal computer with windows XP
and office 2000 (or later versions) with printer: 01 Set
46. Pen Drive: 02 nos
47. Portable illuminator for quick viewing of radiography films:
01 set
48. Tarpaulin for partition/protection during welding process.
49. Hose pipe for compressed air
50. Flood light lamps and cables
51. Stress relieving equipment with accessories
52. All portable electric hand tools shall be of double insulated
construction with fiber body.

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53. All lifting tools and tackles shall be in good condition and the
same shall be tested in the presence of NTPC representative
prior to overhaul.
54. All extension boards must necessarily have earth
connections.
55. All portable hand lamps should be of 24 volts.
56. Any other item required for successful completion of the
work.
57. Double end ring spanner for preferred metric up to A/F 36
mm (Total 6 nos / set)
58. Double end open jaw spanner preferred metric up to A/F 36
mm (Total 6 nos / set)
59. Single end De spanner A/F 41 to 70mm ( Total 4 nos / set)
60. Slugging spanner A/F 36 to 70 mm (Total 5 nos / set)
61. General purpose socket set (metric, preferred) A/F 12 to 32
mm (Total 10 nos/set)
62. Allen key up to metric preferred up to A/F 24 mm (Total 9
nos / set)
63. Slide wrench 12"
64. Pipe wrench 18"
65. Paint brush and spray guns, hoses for painting.
66. At least 5 numbers of high pressure jet machine or 8 nozzles
such that pressure at each nozzle should be above 200 bars
67. Feeler gauge (0.05 to 1 mm)
68. Wire rope Sling (3T, 5T)
69. D shackle (3T, 5T)
70. Torch light with batteries
71. Copper rod (dia 60 to 80 mm, length>300 mm)
72. Welding m/c min 250 Amp, 50 M cable, welding helmet,
electrode holder, Welding Generators/ rectifiers: 10nos.
73. Chain pulley Blocks: 3MT: 10 m Long lift: 8 nos.
74. Chain pulley blocks: 5MT: 15 m Long lift: 8 nos.
75. Gas cutting set consisting of DA, 02 regulator, 40 M hoses,
cutting torch with Flash back arrestor: 04nos
76. Portable grinding machine for wheel dia. 125 or 100 mm: 04
nos.
77. 4 Core Lighting Cable: 200 meters
78. Welding cable: 400 meters
79. Electric cables: 3 core, Double insulated type.
80. Grinding wheels with valid shelf life
81. Pulling & lifting machines, Ratchets etc: 06nos
82. High quality 24 volts hand lamps with flexible 3 core cables
and holders – 18 nos.
83. General Purpose MS Electrode for repair work.
84. Consumables like cotton waste, marking cloth, hacksaw,
emery paper, and wire brush, circulating wire brush,
85. All measuring instruments like Vernier, Bevel Protector,
tape or any other instrument required for executing the
work under this contract.
86. Truck / Tractor trolley / Trailer for transportation of
material.
87. Pulley sleeve for lifting.

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88. Flood light lamps and cables

All portable electric hand tools shall be of double insulated

construction with fibre body.

All lifting tools and tackles shall be in good condition and the
same shall be tested in the presence of NTPC representative prior
to overhaul. These shall have valid load test certificates issued by
factory inspector.

All extension boards must necessarily have earth connections.

Also output connections from the electric board for equipment’s
shall be taken via suitable tops.
All Types of torque wrenches
21. NTPC Inputs Free of Cost Items:
1. Power supply
2. Electrodes and Filler wires for HP welding. Other electrodes
(E6013) like structural welding shall be in contractor’s
scope.
3. All sealing materials except holdtite.
4. Consumables like diesel /rustoline / CTC/Aquasole purge
paper which become part of the machine after application or
working as cleaning agents for components.
5. All spares for the equipment of NTPC.
6. Refractory.
7. Compressed air, steam and water at fire hydrant for
cleaning.
8. Non-Asbestos ropes, Non-asbestos cloths and gaskets.
9. Fasteners, wire meshes.
10. Grease etc. for thickness survey.
11. Free of Cost – returnable items (subject to availability):
12. Quick erect scaffold materials for first pass work.
13. Fire extinguishers, if required.
14. Fibro scope, MPI kit, D-meters.
15. Male plug for taking supply from welding receptacle.
16. All materials for scaffolding except coir ropes and binding
rope.
17. Work shop facility if available. Contractor to provide
assistance.
18. 24 volts Transformers for lighting thru hand lamps.
19. Hydra, BOT, Truck shall be given subject to availability.

However, contractor cannot refuse any work on the ground of

non availability of above and contractor have to arrange the
same without any extra cost to NTPC to complete the work
immediately.

Chargeable Basis (Subject to availability):

Accommodation to staff / workmen.

Contractor has to submit reconciliation statement for all the free

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issue materials.
22. Rate schedule for 1. Welding machine: Rs 500 per day
issue of T&P / 2. Chain pulley Blocks: Rs 350 per day
consumables / 3. Argon / DA / Oxygen gas: 2.60 X PSL price
Accommodation 4. Fire Hoses with nozzles and couplings: Rs. 5000/- per
to Contractor overhaul
(subject to 5. Electric Winch: Rs 1,000 per day or Rs 15,000 per overhaul
availability) whichever is less.
6. Large Oven: Rs 250 per day
7. Truck, Trailer, Hydra, Accommodation etc: As per NTPC’ s
prevailing rates
8. Chop Saw without cutting wheel: Rs 250 per day
9. Any other consumable item: 1.30 X “PSL price or escalated
LPP”
10. Any other returnable item: @1% of PSL price per day
11. Electrical fittings and Halogen lamp: Rs. 1000 per fitting per
overhaul.
23. Time targets of At the beginning of the shut down, the time targets related to the
Work particular unit’s overhaul shall be obtained by the contractor
from the EIC. The contractor shall tune his resource mobilization
and strategy inline with these targets, and in consultation with
the EIC. Besides the final targets like internal and external
hydraulic tests, boiler box – up and light up etc, various
intermediate targets identified in scope of work or by EIC shall
also be met by the contractor.
24. Inspection The Engineer-In-Charge or his authorized representative shall
have free access to inspect the work at any point of time during
the execution of the work to ensure that the works is carried out
properly and to the required quality.

The contractor shall adhere to the quality plans of NTPC enclosed

/ available with NTPC for successful completion of work in all
respects.
25. Penalties / Any penalty covered in this contract shall be levied, if the cause of
Deductions for the lapse is attributable to the contractor only. Further, in case of
Individual Boiler combination of causes, it shall be levied only to the extent that
Overhaul the lapse is attributable to the contractor. EIC’s decision in this
regard shall however be final and binding.

Also, penalties / deductions against delay in different identified

intermediate time targets can be waived by the EIC, if by putting
extra efforts, all identified works and inspections are got
completed by the contractor before the final boiler box up time
target, with no compromise / violation with respect to quality or
safety norms to the full satisfaction of the EIC.

In case of non-compliance to any safety practice or safety rules /

norms set by NTPC, penalty as decided by NTPC safety
department or as per GCC shall be recovered from agency.

1. In case of any breakdown of equipment, the agency shall

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mobilize the gang within 4hrs of intimation from EIC, failing
which a penalty of Rs 3000/- per day will be levied and same
will be deducted from contractor’s bill.
2. The agency shall mobilize sufficient manpower to complete
the breakdown and other works and delay in completion of
work in the given time by E.I.C will attract a penalty of Rs
3000/- per day.
3. Absence of supervision by competent supervisor on any day
will attract a penalty of Rs 1000/- per day.
4. Lack of proper T&P and lifting / rigging equipment, affecting
the work will attract a penalty of Rs 1000/- per day.
5. Failure to remove scrap around maintenance areas will
attract a penalty of Rs 500/- day.
6. Stoppage of work or failure to mobilize in case of exigencies
as per the direction of E.I.C, hampering of work by the agency
for factors not attributable to NTPC shall attract penalty of Rs
5,000/ per day.
7. Safety / quality / other norms violation: Rs 500/- to Rs
5000/- for notice of each instance of such an occurrence
depending upon the severity of the violation, as decided by
EIC. This shall also include violation / non – adherence to
aspects of organization and execution of the work spelt out in
the contract or by EIC.
8. For fatal accident / injury causing death: Penalty @ 10% of
contract value or Rs. 5 lakh which ever is less for each fatal
accident / injury causing death in addition to the
compensation payable to the injured
9. Major injury or accident causing 25% or more permanent
disablement to workmen: penalty @ 2.5 % of contract value
or Rs. 1 lakh which ever is less for each disablement injury in
addition to the compensation payable to the injured

Poor workmanship:
Applicable for defects caused due to poor workmanship,
omission or negligence on the part of the contractor. This
deduction is decided on the twin criteria of nature of defect and
the date of shut down due to the defect. Notice of poor
workmanship, not likely to cause unit shutdown / load reduction:
Rectification free of cost if noticed during defect liability period of
30 days. Notice of poor workmanship, that may cause unit
shutdown / load reduction:
Up to 30 days from first synchronization of the unit: Rectification
free of cost plus deduction of 5% of executed contract value for
each such instance. NTPC may also, at its discretion, decide to get
the rectification work done by other contractor and debit the cost
to the contractor.
The contractor shall maintain a contact point in LARA under
intimation to NTPC, so that the noticing of such defects can be
informed to him without loss of time.
The contractor shall commence the work of rectification within 4
hours from the time of intimation of the defect, (unless allowed
higher period by EIC), not necessarily in writing.

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If the contractor fails to mobilize within the specified time or is
not available for intimation, then NTPC may engage another
contractor to get the rectification job done at the risk and cost of
the contractor.
Associated jobs like erection of scaffolding /sky climber in other
areas for inspection / attending of other defects etc, during the
shut down taken for attending the defect due to the contractor's
poor workmanship shall also be his responsibility. Maximum
deduction under this poor workmanship clause shall be limited
to 10 percent of the total executed value of the contract.
Non – completion / Leaving of Work:
Not replacing an identified tube / bend required to be done for
ensuring boiler reliability: Rs 25,000 per tube / bend
Radiography, repair etc: As given in Scope of Work
Any work, for which deduction is not specifically mentioned in
scope of work, or else where in the contract: At double the
awarded rate. If awarded rate is not directly linked to the left out
work, then at a rate of Rs 500/- to Rs 5000/- per each such work
depending upon the severity of the left out work to boiler
reliability as decided by EIC.
Delay in time target achievement:
1. Internal Hydraulic test: Rs 5,000 per hour
2. External Hydraulic test: Rs 10,000 per hour
3. Boiler Box – up and Light up Clearance: Rs 10,000 per hour
4. Damage to machines & other equipments /tools
/consumables/ spares:
1.3 x cost of damaged component after applying escalation @
10% per year from year of purchase.
5. The items received under a package or as a mandatory spares
and whose prices are not available or reasonable, deduction
for such items shall be done @ 1.3 times of current year
budgetary offer rate.
6. There shall be no claim of the contractor on damaged items.
Deductions shall not be made for damages occurring due to
normal wear and tear associated with usage.
7. Non provision of lap top / personal computer with printer
along with operator for report generation during shut down
period. To be brought 3 days before start of overhaul and
maintained till 3 days after the overhaul. (Reports to be
submitted in computerized system only)

Non provision of portable illuminator for viewing radiographic

films during shut down period: Rs 100 per day.
26. Payment to
Payment to workers shall be done in the presence of NTPC
workers: representative.

The contractor shall intimate the day of payment at least 2
days in advance in writing along with copies of the pay sheets
and the attendance cards.

Wages shall constitute minimum or agreed wages, over time
wages, earned leave, PF, Bonus, Leave wages etc as applicable.
All workmen shall be covered by PF rules irrespective of the

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period of employment.

Payment shall be made inside the plant premises during office
hours of NTPC.

Payment shall be done generally on monthly basis, preferably
before the 7th of succeeding month but not later than 10th of
succeeding month.

Contractor shall issue PF slips to the workmen.

Contractor shall submit the “all dues received” format
specified by EIC, with due signatures of his employees.
27. Compliance of STATUTORY ACTS:
STATUTORY ACTS
The bidder shall comply with PF Acts and all other statutory
requirements. Copy of Implementation of Statutory requirements
circular dtd.13.9.2017 enclosed.

COMPLIANCE OF ESI:

The contractor/ tenderer shall submit a copy of ESI code number

allotted to the agency along with the bid or before start of the
work upon award of contract. Otherwise NTPC reserve the right
to reject their bid or terminate the order, as the case may be. The
contractor shall be liable to pay Employer’s contribution and the
employees’ contribution to the State Insurance Corporation in
respect of all labour employed by him for the period of execution
of the contract, in accordance with the provisions of “The
Employees State Insurance Act 1948". The contractor should
submit the returns/ forms as required to ESI Corporation under
ESI Act, from time to time. In case the contractor fails to comply
with the provisions of the ESI Act, the Engineer-in-Charge shall
recover from the running bills/SD/EMD/ISD etc. amounts of
contributions including damages and interest etc. as assessed by
ESI and should deposit the same with ESI, as principal employer.

Compliance of statutory provisions whether mentioned in this

contract or not (if any) shall be binding on contractor.

If there is any change in labor laws after the contract has been
awarded, then the new law shall be automatically being binding
on the contractor.

The contractor shall comply with requirements of Pradhan

Mantri Jeevan Jyoti Yojna and Pradhan Mantri Suraksha Bima
Yojna for contract labors employed by him.

28. Payment to
Contractor’s running bill shall be cleared for the payment by
contractor the EIC within seven days after presentation if it is clear in all
respects. Payment of the work shall be on actual
measurement basis The bill shall be accompanied by the
following documents:

Proof of disbursement of wages / benefits to the workmen.

Proof of remittance of PF for the work period covered by

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previous bill, if any. The proof shall be in the form of
countersigned blank challans along with duly filled form-12,
or as specified by the EIC.

Details of materials drawn from and returned to site / central
stores and the consumption of the same.

Details of measurements, checks and protocols.

Protocol of site clearing after overhaul.

Proof of compliance of other statutory obligations like labor
license, PF, ESI code for contractor etc.

Indemnity bond for materials under issue to contractor

Security deposit of 10% shall be deducted from every bill
other than final bill. It shall be released to the contractor after

Defect liability period is completed.

Contractor has cleared all his liabilities towards his workmen
engaged for this work.

The contractor has cleared all his liabilities towards NTPC for
this work.

The works shall be measured in terms of the unit indicated in
the Schedule of Quantities. Payment will be made for the
actual quantity of work executed at the unit rates specified in
the Schedule of Quantities.
29. Safe up keep of Safe upkeep of dismantled components, issued materials etc shall
Dismantled be contractor’s responsibility. Any loss or damage to them shall
components and be recoverable from the contractor in full.
issued materials
30. Separate stacking Contractor shall ensure that the scraps, debris etc generated
/ piling of scrap / during the work are stacked / piled neatly, as specified by the
debris etc EIC, in separately identified spaces, till they are finally disposed.
31. Off loading of Contractor’s performance shall be regularly monitored. In case it
work is found that the quality or progress of work is not satisfactory,
then NTPC shall have the liberty to engage another contractor for
part of the job, at the risk and cost of the contractor, after 24
hours have been elapsed since the contractor has been cautioned
in writing and no visible signs of improvement are seen.
Under exceptional circumstances, not attributable to the
contractor, NTPC at its own discretion may decide to off load part
of the work. However, the same shall not be at the risk and cost of
the contractor.
32. Special clauses to
The following points are to be ensured by the contractor for
ensure ensuring environmental improvement.
environmental
Contractor shall ensure that environmental related awareness
improvement training has been given to his employees at the time of start of
new contract.

During the activities of maintenance/ overhauling / cleaning
waste generated is to be disposed as follows:
 Before start of work, contractor should ensure availability
of following in the place of work.
 Drum / jerry cane / trays for waste lubricating oil.
 Drum / jerry cane / trays for waste liquid cleaning agent.
 Identified container for waste jute.
 Identified container for waste gasket / Non-asbestos /

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rubber.
 Identified container / sacks for keeping waste insulations
wool.

Funnels, hoses and strainers in sufficient quantity for transfer
of oil.

During the maintenance activity waste generated shall be
kept in identified storage area.

Waste insulations wool shall be kept in sacks / identified
drum.

Metallic scrap should be kept in sacks / identified place as per
instruction of EIC. It is to be ensured by the contractor that at
the time of disposal of the waste material proper segregation
is done by his workers to avoid mixing of material.

Sufficient care shall be taken by the contractor / his personnel
to avoid any spillage leakage of oil / cleaning agent, spillage of
grease during replacement maintenance and transportation.
Waste shall be kept in drums and shall be shifted to identified
area. In case of spillage of oil, the oil is to be cleaned and
waste jute disposed as mentioned above.

Empty aerosol canes of DPT & cleaners shall be kept at
separate containers.

All the above waste material is to be place for further
disposal. It is to be ensured by the contractor that spillage
should not take place due to overfilling during transportation.

Proper safety equipments are to be provided to the workers
by the contractor. Safety helmets and shoe is must for all
workers. Gloves, goggles, dust mask, ear muffs etc. are to be
provided by the contractor as per job requirements.

Prompt corrective action shall be taken by the contractor for
any of his activities, which may lead to environmental impact.
33. Quantity Clause for variation in quantity and contract price: As per GCC
Variation OF O&M WORKS , OVERHAULING CATEGORY

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QUALITY PLAN FOR THE WORK OF BOILER PRESSURE PARTS (INDICATIVE):

Sl Description Characteristics Class Type of Quantu Reference Format of

of check / check m of document / record
operation check acceptance norms
1 HP welder 1. No C Visual 100% ASME Section 9 Test report
test significant defect RT
2. Strength Bend test
2 Attachment 1. No C Visual 100% ASME Test report
welder tests significant defect RT Fully aware of safety
2. Safety Verbal norms for the work
precautions
awareness
3 Gas cutter 1. Skill level C Visual 100% Quality cut, in terms Test report
test (not 2. Slag Verbal of level, evenness
permitted insertion Minimal insertion of
for cutting of 3. Safety slag
boiler tubes) precautions Fully aware of safety
awareness norms for the work
4 Grinder men Skill level C Visual 100% Skilled doing the Test report
test Profile of edge Verbal work
for tube butt Conforms with
weld specified profile
Safety precaution Fully aware of safety
awareness norms for the work
5 Cutting of Conformity with C Visual 30% Quality procedures Witness
tubes as per specified specified in contract record
specified procedure
quality
procedure
6 Tube fit – up Conformity with C Visual, 30% Quality procedures Witness
for weld joint specified dimension specified in contract record
procedure al
7 Coil lifting Conformity with C Visual 100% for Safety norms for Witness
arrangement safety norms arrange material handling record
Conformity with ment & given in contract
handling method random and else where
specified by EIC for coil Specification given
by EIC
8 RT of weld No significant C RT 100% ASME Radiography
joints defect films, test
reports

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