TENUGHAT VIDYUT NIGAM LIMITED
HINOO, DORANDA, RANCHI-834002
BILL OF QUANTITY
PART-I (TECHNICAL)
NIT NO-0028/C&I/W/TVNL/ RAN/2011-12
Due on-16.11.2011
Sub:- Annual rate contract (ARC) for Preventive/ Breakdown/ annual maintenance of all
instruments of C&I circle of 2x210MW units of TTPS, Lalpania.
Details to be furnished by the Tenderer (enclose separate sheets if required).
1.
Name and Address of the firm
:(Along with phone no. if any)
2.
Name of the proprietor/ partner of the firm
(Attach copy of ownership/ partnership deeds)
:-
3.
Name and qualification of the site-in-charge
:-
4.
Experience in respective field of 210MW
(Attach copy of work orders of related field)
:-
5.
Financial credibility/ capacity
(Attach Bank solvency certificate)
:-
6.
Annual Turn Over
:-
7.
Labour license no.
(Attach copy of registration)
:-
8.
P.F. Code No(Attach copy of registration)
:-
9.
Character certificate of the head of the firm
(Issued from not below the rank of Magistrate)
:-
10.
PAN
(Attach copy in proof)
:-
11.
Sales Tax clearance certificate, if any
:-
12.
Details of Earnest Money Deposit Amount
:-
TENUGHAT VIDYUT NIGAM LIMITED
HINOO, DORANDA, RANCHI-834002
NIT NO-0028/C&I/W/TVNL/ RAN/2011-12
Due on- 16.11.2011
Sub:- Annual rate contract (ARC) for Preventive/ Breakdown/ annual maintenance of all
instruments of C&I circle of 2x210MW units of TTPS, Lalpania.
SCOPE OF WORK
1
1.
1
"PART-A" : SCOPE OF WORK FOR ROUTINE
MAINTENANCE JOBS.
Maintenance of actuators (solenoid operated)
Major operation:
If any of the following items under this group is executed or carried out,
it is treated as one operation
a)
b)
Removal of actuator from site and mounting the same in position.
Actuator dismantling and servicing, changing of seal kit or spare parts
and assembling the same.
1.
2
Minor operation
If any of the following items under this group is executed or carried out,
it is treated as one operation
a)
PREVENTIVE MAINTENACE OF SOLENIOD OPERATED
ACUATORS
External cleaning of actuators to be done. Air leakage if any has to be
attended. Checking of related cables for
dressing and healthiness and terminal tightening to be done in the JB.JB
cleaning and JB sealing glands and
solenoid glands if required has to be done. Limit switch operation
checking and actuator operation checking
has to be done.
b)
c)
d)
2
2.
1
a)
b)
c)
a)
b)
c)
2.
2
a)
Removal of solenoid from site, dismantling and servicing with changing
of spare parts and fixing the same
back in position and checking for proper operation of the actuators.
Changing /replacement of limit switches and adjustment for proper
operation.
Repair and servicing of limit switches.
Maintenance of actuators (pneumatic controlled MEDIUM
SIZE
{Diaphragm size less than 300 mm}) and hydraulic
system.
Major operation:
HYDRAULIC SYSTEM: If any of the following items under this group is
executed or carried out, it is treated
as one operation.
Servicing of one servo valve including removal dismantling and
mounting the same in position.
Servicing of blocking unit and its solenoid valves including removal and
mounting the same in position.
Control Valve calibration, including feedback transmitter calibration or
any other job for satisfactory
operation of the control valve as directed by the EIC.
PNEUMATIC ACTUATORS: If any of the following items
under this group is executed or carried out, it is
treated as one operation.
Diaphragm replacement of the pneumatic actuator (medium size) and
checking its operation
Servicing positioner including dismantling and mounting.
Servicing of pneumatic controllers.
Minor operation: If any of the following items under this
group is executed or carried out, it is treated
as one operation
PREVENTIVE MAINTENACE OF HPBP HYDRAULIC SYSTEM: Checking and
tightening of piping /tubing
joints for leakage etc, cleaning externally of all parts, tightening actuator links,
external cleaning of oil filter,
checking for proper operation, adjustment of limit switches, (if required), sealing
of required
JB covers and glands (if required), checking of cable dressing and its healthiness,
checking of nitrogen
/oil pressure in one oil unit and any other minor operation required for
satisfactory operation of the
b)
c)
d)
actuator. These jobs have to be carried out for all the four HPBP control actuator
in one unit.
Jobs mentioned in 2.2 (a) for the main pressure reducing valves shall be done for
all the four spray valves
and two block valves of HPBP system.
Line filter cleaning of two control valves in HPBP SYSTEM including removal and
mounting the same in
position.
PREVENTIVE MAINTENACE OF SEAL/LEAK STEAM VALVE: Checking and tightening
of
piping/tubing joints for leakage etc cleaning externally of all parts, tightening
actuator links, cleaning of
oil filters, checking of proper operation, adjustment of limit switches (if
required), sealing of related JB
covers and glands (if required), checking of cable dressing and its healthiness.
e)
Servo valve filter cleaning including removal of filter from servo valve and putting
it back in position for
satisfactory operation. These jobs shall be carried out for two servo valves.
f)
PREVENTIVE MAINTENACE OF PNEUMATIC ACTUATORS: This include externally
cleaning of
the actuator, tightening the actuator links, checking of any air leakege, and
arresting the same, air pressure
checking in air pressure regulator, checking and dressing of related control
cables. These jobs have to be
carried out for 6 pneumatic actuators to constitute one unit of operation.
g)
Assistance in Calibration of pneumatic control valves including feedback
transmitter and positioner.
MAINTENANCE OF LARGE SIZE ACTUATORS.
(Diaphragm size more than 300 mm)
This job includes servicing of the actuator. (Dismounting the actuator from the
location, Dismantling the
actuator, Replacing of diaphragm (if required) cleaning the actuator, changing the
seals or spares (as required
and assembling the same, mounting the same back in position and testing the
same for satisfactory operation.
Major operation :If any of the following items under this
group is executed or carried out, it is
treated as one operation.
Diaphragm replacement of the pneumatic actuator (medium size) and checking
its operation
Servicing positioner including dismantling and mounting.
3
3.
1
a)
b)
c)
3.
2
a)
b)
4
4.
1
a)
b)
c)
d)
e)
4.
2
a)
Servicing of pneumatic controllers.
Minor operation
PREVENTIVE MAINTENACE OF PNEUMATIC ACTUATORS: This include externally
cleaning of
the actuator, tightening the actuator links, checking of any air leakege, and
arresting the same, air pressure
checking in air pressure regulator, checking and dressing of related control
cables. These jobs have to be
carried out for 6 pneumatic actuators to constitute one unit of operation.
Calibration of pneumatic control valves including feedback transmitter and
positioner.
Maintenance of instruments
Major operation
If any of the following items under this group is executed or carried out, it is
treated as one operation
Instrument calibration at site/lab.
Type of instruments to be covered
Pressure /Temp/Level and other local gauges
Pressure /Temp/Level/position and other transmitters.
Pressure /Temp/Flow/Level and other switches.
EP converters/PRV /Positioners etc
UCB instruments like recorders and indicators
Temp scanners, analytical instruments or any other equipment as directed by
EIC.
belt sway, Pull cord ,Zero speed
Field instruments of AHP
Air filter regulator removal, servicing and fixing back in position and checking for
proper operation of
actuators.
Assisting in calibration of electronic cards.
Removal of TSI instruments, Assistance in calibration and fixing them
back
Cleaning of rotameters , in PT and CW chlorination plant.
Minor operation
If any of the following items under this group is executed or carried out,it is
treated as one operation
Removal from site the following type of instruments /equipment cleaning and
carrying to C&I workshop
/lab for repair /calibration carrying back to site and fixing them
back.
Pressure /Temp/Level and other local gauges
Pressure /Temp/Level/position and other transmitters
Pressure /Temp/Flow/Level and other switches, analytical instruments
b)
c)
d)
e)
f)
g)
h)
i)
j)
5
5.
1
5.
2
5.
3
Temp scanners ,power supply units.
Air filter regulators /EP converters /solenoid valves / positioners.
UCB instruments like recorders ,indicators switch assemblies etc.
Any other instruments which is reqired & as directed by EIC.
JB cleaning and tightening terminals of JB, sealing of JB covers and glands.
Replacement of temperature element like RTD or
Thermocouple.
Replacement of air filter regulators /EP converters/ positioners/ Pneumatic
controllers
Removal of hoses and fixing it back for one HPBP or SCDS control valve actuator
or HPBP spray or
HPBP block valve.
Replacement of servo valve for HPBP control valve actuators or SCDS AA or AN
or ANB control valve
actuator.
Cleaning of rotameters in DM plant and pretreatment
plant.
One RTD or one Thermocouple terminal tightening at the element head and
JB.
Cleaning and mounting of CHP crusher belt protection
switches.
Cleaning of bunker level indicators, JBs and processor
cabinets.
Maintenance of PA station
Checking of signal cables
Each cable (size 8x.0.50mm)in the signal loops to be opened at both ends,
individual cores to be tested with
meggers(500V) for fault with respect to other cores and ground and resistance to
be measured with one amp
current for possible fault /breakage etc.
Checking of power cables.
Each cable (size3x2.5 mm)in the power loops to be opened at both the ends and
individual cores to be tested
with meggers (500V) for faults with respect to other cores and ground and
resistance to be measured with ten
amp current for possible fault breakage etc.
Overhauling of PA system.
5.
4
6
7
7.
1
7.
2
External and internal cleaning of PA station ,Functional checking of all features
(page in ,page out PVT in
,PVT out ,PVT busy indication gong etc )checking of signal levels and setting if
required ,loading stations and
any other faults to be identified and rectified ,replacement of faulty parts and any
other operation that may be
required for satisfactory and reliable functioning of entire PA station as a
whole.
Major operation (monthly PM)
External cleaning of PA installation, functional checking of all features and
recording of status, setting of
volume, replacement of faulty parts (Hand sets,front panel ,driver unit or voice
coils)and any other minor
operations may be required for satisfactory and reliable operation of the PA
station.
Maintenance of Belt weigher
External cleaning of belt weigher panel, checking and recording of calibration
constants before and after
calibration, calibration of zero by empty running of the belt, calibration of span if
required by putting dead
weight and balancing the bridge if required and any other operation required for
satisfactory weighing of
conveyed coal including its remote indication and
totalisation.
Maintenance of Opacity Monitors.
External cleaning and lens cleaning filter cleaning
checking for proper operation ,calibration whenever
required and any other operation required for proper measurement of opacity.
Opacity monitor (miscellaneous)
If any one of the following is executed or carried out it is treated as one operation.
a)
b)
c)
d)
8.
1
Removal and refixing of electronics Module
Removal and refixing of shutter Assembly.
Replacement of filter.
Telescope alignment.
Cleaning of Panels.
If any of the following items under this group is executed or carried out, it is
treated as one operation External
and internal cleaning with blower/vacuum cleaner/solvents of the CER/UCB/LIE
and remote panel without
removal of the cards /equipments as per the requirement and as directed by the
EIC.
8.
2
9
9.
1
9.
2
10
11
.1.
11
.2
Cleaning of Panel cards/equipments
If any of the following items under this group is executed or carried out, it is
treated as one operation Removal
of panel cards /equipments from panel cleaning the cards /equipment /connector
/slots with blower /solvents
/brush for removal of dust /deposits and proper contact ,refixing in position
complete as per requirement and
as directed by the EIC.
Laying of GI pipes / M
Laying of GI pipes of sizes 1/2"
Laying of GI pipes of sizes 1"
Laying of GI pipes as mentioned above, required pipe and fittings shall be
supplied by TVNL at central store.
Necessary support & and consumables for proper laying to be provided by the
contractor.
Servicing & calibration of Instruments in Lab.
The Scope includes shifting of instruments from one place to another place or as
directed by EIC, external and
internal cleaning and assistance during calibration of instruments like pressure
Transmitter, Temperature
gauges, pressure gauges, pressure switches, electro pneumatic converters etc.
SOX ,NOX , CO, CO2 Preventive maintenance (weekly)
The Scope includes the following.
Probe filter cleaning.
Checking the fine filter element.
Checking the sample flow.
Checking for leakages in the sample line.
SOX,NOX Breakdown Maintenance
If any one of the items mentioned below is executed it is treated as one operation.
a)
b)
c)
d)
11
.3.
Probe Heater replacement.
Probe Filter replacement.
Sample pump diaphragm replacement.
Solenoid valve replacement.
SOX,NOX Sample line cleaning.
The Scope includes identification of choking in the sample line and cleaning the
same to ensure free flow of
sample in the sample line & in case of any leakage in the sample line the same has
to be attended.
12
12
.1
12
.2
13
a)
b)
c)
d)
14
a)
b)
15
a)
b)
01
(a)
i)
Transportation of Material.
Bringing light material from store.
Bringing heavy material from store.
Scope of work for 12.1 and 12.2:
The contractor shall provide the required manpower for bringing any C&I spare or
consumables or any other
materials from store. The nature of job shall be handling of the material at the
store like loading in the vehicle
or the trolley. Unloading of the material from the vehicle /trolley at service
building and carrying the same to
site store and keeping in location. In case of TTPS vehicle is not available and it
is possible to carry the
material by hand the same shall be brought from store manually. In case manual
trolley is used the trolley
shall be driven manually.
Support during light up & Synchronization.
The scope includes the following.
Any process measurement disturbance to be attended.
To ensure opening of all Extraction NRVs of Turbine System.
To ensure Smooth operation of all control valves (both pneumatic and
Hydraulic).
To attend problems of field instruments related to permissives, interlock and
protections, as directed by
concerned engineer.
Support during interlock and protection checks.
The scope includes the following.
All problems related to field instrument feedbacks (like opening/closing of
manifolds if required,
attending loose connections etc.)
And any other support required at control room to be
provided.
Tele Phone EPABAX
To attend Telephone defect in colony or plant
To provide new telephone connetion, cable and
telephone set will be provided by TVNL
"PART-B" : SCOPE OF WORK FOR PREVENTIVE MAINTENANCE
JOBS.
SCANNERS
Job Description :Removing Scanner and poking of guide pipe.
ii)
iii)
iv)
v)
vi)
vii
)
viii
)
ix)
x)
xi)
01
(b)
Blasting Guide Pipe with Instrument air (Cornerwise) and blanking during scanner
cleaning.
Clean Scanner Head.
Check Fibre-Optic cable condition. Replace if scratches are observed.
Carry on candle test and observe full intensity indication in metering output card
and remote meter.
Check frequency setting dip switches for coal & Oil Scanner.
Check Scanner Air Hose tightness.
Check scanner cable tightness in JB.
Remove blanking & fix the Scanner.
Associated JB cleaning.
Ensure JB covers are closed,no dust ingress inside,if necessary replace gasket and
seal cable glands.
FIRING ELEVATIONS..(LEVEL 1 & 2)
Job Description:
Cleaning all actuators of Nozzle V/V, Atomising V/V and Scavange
i)
V/V.
External cleaning of all limit switches and local gauges appearing in each
ii)
corner.
iii) Check for air leakages and attending those if observed.
iv) Functional checking of air filter regulators.
Tightening of all termination points in local if required.
v)
vi) Ensure JB,limit switch covers are closed,no dust ingress inside,if necessary replace
gasket and seal cable
glands.
vii If condition permits, physical assistance is required during checking of all
associated corner valves by
)
physically bringing the elevation into service and carry out limit switch
adjustment if found disturbed after
checking.
viii In case of Elevation-1. & Elevation-2, carry out the same jobs for light oil system
also.
)
ix) Associated Junction Boxes cleaning.
02 IGNITORS CLEANING MAINTENANCE (Elevation wise, 4
.(a per elevation)
)
Total population ‐ 4 in each Elevation.
Job Description.
i)
External cleaning of power Cylinder & Limit switches.
ii) Removal and cleaning of spark Tip. If defective‐replace spark tip.
iii) Check spark Gap tube. If defective ‐ replace it.
iv) Check flexible cable ‐ replace if necessary.
v)
vi)
Check spark intensity, spark rotation of tip and spark frequency.
Check air connection and tighten carefully if required. Arrest air leakage if
any.Check air filter regulator.
vii Operate ignitor Advance/Retract Mechanism and adjust limit switch if necessary
)
and if permitted.
viii Associated JB cleaning.
)
ix) Ensure JB covers are closed,no dust ingress inside,if necessary replace gasket and
seal cable glands.
02 FIRING ELEVATIONS.PER ELEVATION (LEVEL 3&4 )
(b)
.
Job Description:
i)
Cleaning all actuators of Nozzle V/V, Atomising V/V and Scavange V/V.
ii)
External cleaning of all limit switches and local gauges appearing in each corner.
iii)
iv)
v)
vi)
Check for air leakages and attending those if observed.
Functional checking of air filter regulators.
Tightening of all termination points in local if required.
Ensure JB,limit switch covers are closed,no dust ingress inside,if necessary
replace gasket and seal cable
glands.
vii If condition permits, physical assistance is required during checking of all
)
associated corner valves by
physically bringing the elevation into service and carry out limit switch
adjustment if found disturbed after
checking.
viii In case of Elevation‐1. & Elevation‐2, carry out the same jobs for light oil system
)
also.
ix) Associated Junction Boxes cleaning.
03 ID Fan
.(b
)
Job Description:
i)
Externally clean local instruments including hydrocoupling local rack.
ii)
iii)
iv)
03
.(c
Clean local rpm indicator and its control box.
Clean all Local JB's.
Ensure the covers of JBs and doors of Local panels are closed,no dust ingress
inside,if necessary replace
gasket and seal the cable glands.
FD FAN
)
i)
ii)
03
.(d
)
i)
ii)
03
.(e
)
A.)
(i)
(ii)
(iii
)
(iv
)
(v)
(vi
)
(vi
i)
(vi
ii)
Job Description:
Externally clean local instruments/junction boxes.
Ensure the covers of JBs and Blade pitch positioners/position transmitter are
closed,no dust ingress inside, if
necessary replace gasket and seal the cable glands.
PA FAN
Job Description:
Clean all local instruments/junction boxes.
Ensure the covers of JBs and Blade pitch positioners/position transmitter are
closed,no dust ingress inside, if
necessary replace gasket and seal the cable glands.
AUX.PRDS SYSTEM.
Constituents of the systems:‐
Aux. PRDS System
Job Description:‐
Clean actuator and positioner externally & associated junction
boxes.
Observe for proper copper‐tube connection. If any air leakage observed, obtain
proper PTW and arrest the
same.
Check air filter regulator and air lock relay condition. If required, carry out
servicing of these after proper
isolation.
Check and clean all local instruments.
Tight position transmitter links and mounting screws.
Check feedback link condition. If required, tighten the same.
Observe for any leakage in the system. If any leakage is observed, arrest the
same.
Ensure the covers all JBs and all instruments are closed,no dust ingress inside,if
necessary replace gasket
and seal the cable glands.
03 MILL DAMPER (PISTON TYPE PNEUMATIC ACTUATOR)
.(f) (06 dampers per mill to be considered as 1 no.)
Job Description:‐
i)
Cleaning the actuator /power cylinder externally.
ii) Check & arrest all air leakage from pneumatic
connection.
iii)
iv)
v)
vi)
Clean associated air line instruments/positioner /limit switch/feed back
transmitter/EP converter/ air lock
relays.
Ensure healthiness of positioner pressure gauge.
Wherever possible check operation, if permitted.
Ensure correct indication of position feedback , limit switch (if any) in UCB.
vii Check tightness of feedback lines & its healthiness.
)
viii Check air filter regulator & its set point . Drain it through the drain plug & ensure
)
that no more water is
present inside.
04 SADC(SECONDARY AIR CONTROL DAMPER) (ELEVATION
.(b WISE, 4 PER ELEVATION)
)
Job Description:‐
(i) Clean positioners and pneumatic actuators. Clean all junction boxes.
(ii)
(iii
)
(iv
)
(v)
(vi
)
(vi
i)
04
.(c
)
Check feedback link tightness. If feedback found bent, replace it.
Clean D.P. Switches and D.P. Transmitters associated with the systems.
Check all limit switch status and confirm as per physical condition of the dampers.
Check limit switch
actuating lever tightness and roller tightness.
Observe for proper modulation of the secondary air dampers.
Check for air leakages if any and arrest the same.
Ensure the covers of all JBs, all positioners /feedback transmitter and limit
switches are closed, no dust
ingress inside,if necessary replace gasket and seal the cable glands.
BURNER TILT
System consists of 04 Burner Tilt actuator/elevation.
Job Description:‐
(i) Clean externally pneumatic power cylinders/junction
box.
(ii) Clean Positioner Units, limit switches and position feedback transmitters.
(iii
)
(iv
)
Check feedback link tightness and healthiness.
Check position feedback transmitter indication and ensure its compatibility of
reading with respect to physical position at the field.
(v)
04
.(d
)
i)
ii)
iii)
iv)
v)
vi)
Ensure the covers all JBs,positioner,position transmitter and limit switches are
closed,no dust ingress
inside,if necessary replace gasket and seal the cable glands.
APH
Job Description :‐
Clean all local instruments/Local JB's.
Clean and check air filter regulator, check oil lubricator level, top up oil if
required.
Carry out test sequence for APH Rotor Stoppage Alarm System and observe for
normal functioning.
Carry out test sequence for APH Hot‐Spot detection system and observe for
normal functioning.
Check associated alarms.
Ensure the covers and doors of all JBs, Local panels, all instruments are closed, no
dust ingress inside, if
necessary replace gasket and seal the cable glands.
Clean the local cabinets/local panels associated with the systems.
vii
)
viii Check APH Air Motor System. Clean solenoid and check whether air pressure is
)
sufficient to operate air
motor system or not. Check pressure switch status. Check lubricator Oil level and
top‐up if necessary.
Permit Requirement:‐ No isolation required. Permission to test APH Rotor
Stoppage Alarm System and APH
Hot‐Spot Detection System is required.
05 OIL STATION
.(a
)
Job Description:
i)
Cleaning of Actuators of all HFO and Light oil valves.
ii) Check for air Leakages. In case any Leakage is observed, obtain proper permit for
attending the same.
iii) Check proper functioning of Solenoid Valves.
iv) Clean all limit switches, position transmitters and local controllers and adjust the
limit switch if it is found
disturbed.
v) Check all air regulators for correct functioning and
setting.
vi) Check junction box cable tightness/Cleaning Junction Boxes.
vii Check functioning of local gauges pertaining to the system.
)
viii Checking of Oil Recovery Tank level Measurement system, tightening of
)
terminations, cleaning ‐ etc.
ix) Ensure JB covers are closed, no dust ingress inside; if necessary replace gasket
and seal cable glands.
05 FAP(FIREMANS AISLES PANEL)
.(b
)
Job Description:
(i) Clean all local gauges.
(ii) Observe for fittings leakage. If any leakage is observed, arrest the same with
proper isolation.
(iii Ensure that all the lines are in charged condition after job completion.
)
(iv Check local panel power supply.
)
(v) Clean local panel/Local JB's.
(vi Ensure the panel cover is closed, no dust ingress inside, if necessary replace
)
gasket and seal the cable glands.
05 SCANNER COOLING & GUN SEALING AIR SYSTEM
.(c
)
Job Description:‐
(i) Clean limit switches & check link tightness in dampers.
(ii) Clean all local instruments/local JB's.
(iii Check for leakages from different hoses of each corner.
)
(iv Clean damper actuators externally.
)
(v) Ensure that the corners of all JBs and instruments are closed, no dust ingress
inside, if necessary replace the
gasket & seal the cable glands.
6
MILL SYSTEM WITH FEEDERS
U#1 : 2nd week of every month.
U#2 : Last week of every month.
Permit Requirement:‐
i) Mill Shutdown Required.
(ii)
ii) Permit to operate following dampers from local.
(i) Pneumatic gates/drives involved in the system of each mill.
(ii) Mill seal Air system ON/OFF & control Dampers (03 nos./mill).
(iii Tube Mill Reducer Lubricating Unit Temp. Control Valve. (01
)
no./mill).
(iv Tube Mill Bearing Lubricating Unit Temp. Control Valve. (01
)
no./mill).
(v) Mill DP Level Control System.
(vi Local Instruments of each mill.
)
(vi Tube Mill Bearing Lubricating oil circuits of each mill.
i)
(vi Mill D.P. Controllers of each mill.
ii)
Time requirement for jobs
6.
SUBSYSTEM‐A
1
1 day for each Mill
1
Classifier outlet valves
2
Fire fighting system
3
Purge Air Dampers
6. SUBSYSTEM‐B
2
1 day for each Mill
1
Cold Air gate
2
HOT AIR GATE Air Gate
3
NOISE
4
Mill DP
5
Feeders
6. SUBSYSTEM‐C
3
1 day for each Mill
1
Seal AIR System
2
Local Instruments
3
Girth Gear Greasing System
4
Lub Oil System
5
Blowdown control System
JOB IN MILLS
(i) Check pneumatic actuator operation and observe for leakages/passing in
pneumatic cylinders if any.
(ii) Clean all actuators and associated equipments.
(iii Check feedback link tightness.
)
(iv Clean all limit switch & check lever tightness.
)
(v) Clean all local instruments.
(vi Check purging system in D.P. Control system and confirm for correctness of
)
operation.
(vi Clean noise sensors,if permitted.
i)
(vi Clean all local equipments/Local Panels & Junction
ii)
(ix
)
Boxes.
Check all temperature points associated in the system and check for JB tightness
and element head
tightness of cable.
(x) Clean all temp. elements and local gauges externally.
(xi Clean and Check air filter regulators of the system and observe whether water is
)
present in instrument air
line or not. If required, drain it, check oil level in the lubricator, top up oil if
required.
(xii Ensure the covers and doors of all JBs, Local panels, all instruments are closed,
)
no dust ingress inside, if
necessary replace gasket and seal the cable glands.
(xii Physical assistance during checking of all valve, damper, gate limit switch
i)
checking and rectification of
fault if found defective during checking.
(xi Ensure Nucleonic source isolation and clean Scintillation Detector.
v)
JOBS IN FEEDERS:
(i) Clean Tacho unit.
(ii) Clean local JB's
(iii Functional checking of speed sensors.
)
(iv Cleaning of flap switches and observe for freeness of actuating mechanism.
)
(v) Observe for termination tightness for all cables.
(vi Ensure the covers and doors of all JBs, Local panels, all instruments are closed,
)
no dust ingress inside, if
necessary replace gasket and seal the cable glands.
7
Assistance in feeder calibration
i)
open side gate of feeder
ii) Count no. of teeth of feeder belt
iii) mount calibration probe
iV) normalising feeder after calibration.
08 CONTROL Desk CLEANING
.(a
)
(i) Cleaning of control desk (internal & external).
08 CLEANING OF LIR (LOCAL INSTRUMENT RACK) ALONG
.(b WITH LOCAL INSTRUMENTS
)
i)
Clean the local instrument rack and instrument associated with it.
ii) Check any looseness of fitting if any, then tighten with care.
iii) Check impulse line leakage (including condensing pot) , if any take PTW to work
by isolation.
iv)
Clean the junction box with care & check presence of any loose connection.
v)
Ensure that no dust ingress inside the J.B. If necessary, replace the gaskets & seal
cable glands.
Close the JB cover firmly.
PM of SWAS Sample Table.
vi)
08
.(c
)
i)
ii)
iii)
iv)
v)
vi)
09
.(a
)
i)
ii)
iii)
Ensure all the samples are coming to sample table with adequate pressure and
flow. Isolate and purge the
sample lines with compressed air if required.
Arrest all the leakage.
Ensure all the rotameters are working properly. Clean/Service/Replace the
defective rotameters.
Check all the pressure and temperature gauges. If any of the gauges found
defective, remove for
calibration or replace if the gauge is not repairable.
Ensure grab sample availability in the sample tray.
Clean the panel interior and exterior and removal logged water from the panel
floor.
OXYGEN ANALYSER
Clean the oxygen analyser cabinets(Electronic & sequencer units).
Check the oxygen cylinder calibration gas pressure is within 10‐130kg/cm2. Note
down the pressure
reading & inform the concerned engineer.
Check & adjust the output pressure from the calibration gas cylinder at 15 PSI.
iv)
Check that flow of calibration gas in the flow meter is 2‐3 ltr/min.(during
calibration).
v) Check that there is adequate air supply in the air filter regulator (10 PSI) . If not
adjust it.
vi) Check that flow of reference air is set at 1 lit/min in the flow meter if not adjust
it.
vii Note the display of %O2 in the analyser electronic
)
module.
viii Ensure that there is no loose connection in the terminal blocks inside the cabinet
)
Tighten if required.
ix) Ensure that the cable from the analyser to the electronic unit is healthy & does
not touch the flue gas duct.
x) Air supply connection & Gas supply connection should be tightened.
xi)
Close the analyser & ensure no air leakage inside these cabinets, if necessary
replace the gasket and seal
the cable glands.
xii) Lock the analyser & return the work permit.
09 CLEANING OF LIE (LOCAL INSTRUMENT ENCLOSURE)
.(c ALONG WITH LOCAL INSTRUMENTS.
)
i)
Clean the internal of the local instrument enclosure.
ii) Clean the instruments.
iii) Check any looseness of the fittings if any, then tighten with care.
iv) Check impulse line leakage if any(including that at condensing pot & drain
catchpot), Take ptw to work
by isolation.
v) If water is accumulated in the LIE, drain it.
vi) Check the purge air filter regulator pressure & drain air filter regulator if water is
there.
vii Clean the junction box of LIE ensure that door of the JB is closed.
)
viii Ensure that no dust ingress inside the LIE & J.B. If necessary, replace the gaskets
)
& seal cable glands.
ix) Close & lock the LIE.
09 PM OF ANALYTICAL INSTRUMENTS
.(d
)
(I) PM OF SILICA ANALYZER
i)
Clean (or replace if required) the reagent bottle and sample tubing.
ii) Clean colorimeter cell.
iii) Inspect the sample conditioning system. Verify the sample pressure is in the
renage of 2 to 8 psig. If not,
adjust the pressure within this range. Clean the sample strainer. Check the
sample temperature. If more
than 45 deg.C, check the cooler and bring the temp. within the permissible
range.
iv) Check for any leakage in the reagent and sample line and arrest those leakage.
Replace the defective tubes
and fittings if required.Calibrate the analyzer and ensure that it's reading
matches with the lab analysis
result.
v) Check the healthiness of alarm signals in annunciation facia and CRT.
vi)
Ensure that the recorder and CRT readings match with the analyzer reading.
(II) PM OF LOW‐LEVEL SODIUM MONITOR
i)
Ensure the sample flow rate is between 35 and 45
ml/min.
ii)
Inspect the unit thoroughly for leakage and arrest if any leakage found.
iii)
Check the reference electrolyte solution is adequate. If required, refill the bottle
with solution upto
adequate level.
iv) Clean/replace the filter element.
v) Replace reagent, diffusion tubing and flow manifold face o‐rings.
vi) Condition sodium electrode with etch solution.
vii Calibrate the analyzer and ensure that the displayed reading matches with the
)
lab analysis result.
viii Check the healthiness of alarm signals in annunciation facia and CRT.
)
ix) Ensure that the recorder and CRT readings match with the analyzer reading.
(III
)
i)
ii)
iii)
iv)
v)
vi)
HYDRAZINE ANALYZER
Ensure the sample flow rate is between 90 and 110 ml/min.
Ensure the sample temperature doesn't exceed 35 deg.C.
Check whether there is any leakage in the sample line. If any leakage is detected,
arrest it.
Remove the hydrazine cell and thermistor from the chemistry block and clean the
block.
Fill the hydrazine cell with gel.
Calibrate the analyzer and ensure that the displayed reading matches with the
lab analysis result.
Check the healthiness of alarm signals in annunciation facia and CRT.
vii
)
viii
)
(IV
)
i)
ii)
iii)
iv)
v)
Clean the photocell window and turbiditymeter body.
Ensure the sample flow rate is between 250 and 750 ml/min.
Ensure the sample temperature doesn't exceed 40 deg.C.
Check the standardization of the analyzer and calibrate if required.
Ensure that the displayed reading matches with the lab analysis result.
vi)
Check the healthiness of alarm signals in annunciation facia and CRT.
vii
)
viii
)
(V)
i)
Ensure that the recorder and CRT readings match with the analyzer reading.
Ensure that the recorder and CRT readings match with the analyzer reading.
TURBIDITYMETER
Check the healthiness of alarm signals in annunciation facia and CRT.
LOW‐LEVEL DISSOLVED OXYGEN MONITOR
Ensure the sample flow rate is between 300 and 500 ml/min.
ii)
iii)
iv)
v)
Ensure the sample temperature doesn't exceed 40 deg.C.
Check the dessicator. If colour is found pale pink, then replace it.
Calibrate the analyzer and ensure that the displayed reading matches with the
Lab analysis result.
Check the healthiness of alarm signals in annunciation facia and CRT.
vi)
Ensure that the recorder and CRT readings match with the analyzer reading.
(VI
)
i)
ii)
iii)
PH ANALYZER
iv)
v)
vi)
vii
)
(VI
I)
i)
ii)
Ensure the sample flow rate is approx. 100 ml/min.
Ensure the sample temperature doesn't exceed 40 deg.C.
Ensure the reference electrode filling solution is adequate.
Clean the electrodes.
Calibrate the analyzer and ensure that the displayed reading matches with the
Lab analysis result.
Check the healthiness of alarm signals in annunciation facia and CRT.
Ensure that the recorder and CRT readings match with the analyzer reading.
CONDUCTIVITY METER
iii)
Clean the conductivity cell.
Calibrate the analyzer and ensure that the displayed reading matches with the
lab analysis result.
Check the healthiness of alarm signals in annunciation facia and CRT.
iv)
Ensure that the recorder and CRT readings match with the analyzer reading.
09
.(e
)
i)
ii)
PNEUMATIC CONTROL VALVE
iii)
iv)
v)
vi)
vii
)
Cleaning the actuator externally.
Check & arrest all air leakage from pneumatic
connection.
Clean associated air line instruments/positioner /limit switch/feed back
transmitter/EP converter/ air lock
relays.
Ensure healthiness of positioner pressure gauge.
Wherever possible check operation of the valve.
Ensure correct indication of position feedback , limit switch (if any) in UCB. Check
tightness of feedback
lines & its healthiness.
Check air filter regulator & its set point . Drain it through the drain plug & ensure
that no more water is
10
.(a
)
(I)
i)
ii)
iii)
iv)
v)
vi)
10
.(b
)
i)
ii)
iii)
10
.(c
)
i)
ii)
iii)
iv)
v)
11
(a)
(i)
present inside.
PM OF PRINTERS AND HARDCOPIER
PM OF PRINTERS
Remove power supply and interface cable from the printer.
Clean the printer interior and exterior thoroughly. Remove paper pieces, dirt and
grease from the cabinet.
Clean the printer table and Link‐CP.
Clean the print‐head and guide‐rod. Grease the guide‐rod and gears with silicon
grease/oil.
Restore power supply and connect the interface cable.
Load printer paper and put back the printer to service.
FIELD JB CLEANING & TIGHTNESS CHECKING:
Different JBs are to be cleaned externally & internally with air/clot
h.
Terminals to be tightened with a screwdriver.
If any abnormal TB, lug or ferrule is observed it is to be rectified.
PANEL TERMINATION TIGHTNESS CHECKING
Obtain PTW.
Tighten the 100V a.c, 100V d.c connections.
Tighten the connections on the reverse side of DAM unit.
Tighten 48V & 24V connections.
Return PTW.
REMOVAL OF PRINTER PAPER:
Printer paper for all the printers available at CER room, DAS room, UCB and C&I
shift Engr.'s room are to be
collected marked and kept at location identified by representative of EIC.
(ii) Replacement of paper werever necessary.
(iii Cleanliness of printer, table & sorroundings to be ensured.
)
(iv Bringing of printer papers from stores if required.
)
11(b) TESTING OF ANNUNCIATION LAMPS:
(i) Press lamp test button & check all annun. windows are flagging or not.
(ii)
11
(c)
(i)
(ii)
(iii
)
12
i)
ii)
13
.(a
)
i)
ii)
iii)
iv)
v)
vi)
vii
)
viii
)
13
.(b
)
i)
ii)
iii)
iv)
v)
vi)
vii
)
viii
)
Replace bulb if necessary. Check whether LT card is inserted or
not.
ROUTINE CHECKING OF SWAS ON LINE ANALYSER
Check whether all analysers are in service or not.
Check for any leakage & attend if any.
Check whetrher all samples are coming or not. If not, attend.
REMOTE OPERATION CHECKING & IDENTIFICATION OF
PROBLEMS FOR ONE NO. OF
MODULATING DRIVE.
Command to be given from UCB under the guidance of TVNL personnel.
Feedback of associated modulating drive is to be checked at UCB & at local under
the supervision of
TVNL personnel & attend simple problems.
POKING OF AEROFOIL IMPULSE LINE IN MILL AREA
Obtain proper isolation & PTW.
Isolate the transmitter from manifold.
Poke all the aerofoil impulse lines with a rod.
Check purge air is coming in the impulse line at the bottom of the aerofoil.
Ensure that there is no choking.
If manhole is open, clean all the hole in the aerofoil.
Check & ensure that purge air is coming in all the hole.
Restoration of the system & return the permit.
POCKING OF AEROFOIL IMPULSE LINE IN SECONDARY AIR
FLOW MEASUREMENT
Obtain proper isolation & PTW.
Isolate the transmitter from manifold.
Poke all the aerofoil impulse lines with a rod.
Check purge air is coming in the impulse line at the bottom of the aerofoil.
Ensure that there is no choking.
If manhole is open, clean all the hole in the aerofoil.
Check & ensure that purge air is coming in all the hole.
Restoration of the sytem & return the permit.
14
(i)
(ii)
(iii
)
(iv
)
(v)
(vi
)
a)
b)
c)
(vi
i)
(vi
ii)
(ix
)
(x)
15
a)
b)
c)
d)
16
a)
b)
c)
d)
e)
17
PM FOR UNIT LIGHT UPS
Job Description
Checking of operation and feedback of all oil corner valves (Nozzle v/v, Atomising
v/v, Scavenging v/v)
and igniter and attending the defects if any.
Checking of all igniters (20 nos) for sparking. In case if the sparking is not healthy,
then the problem is to
be identified and the defective rod or tips are to be replaced.
Preventive checking of scanners and replacement of defective scanner, card or
cable etc.
Checking of operation of all mill gate (PC gate, check valve, Purge damper, mixed
air gate, cold air gate,
seal air discharge damper) and attending the defects if any.
Checking of operation of all control dampers (Main PA, Bypass damper, Hot air &
cold air dampers) in all
the mills and attending defects if any.
Checking of operation of following actuators and attending any problems thereof.
Aux PRDS valves
Oil station valves
HFO & LDO PCV at FOPH.
Checking of operation and preventive maintenance of Low Load control valve,
BFP‐A, B & C and recirculation valves,
HFO & LDO control valves.
Checking of operation of ITSH/ HTSH/RH spray pneumatic block valves and
attending the defects if any.
Preventive checking of mill DP impulse lines.
Checking of instrument cooling fans of OLCS, CLCS and DPIO cabinets and
replacement of defective
fans, if any.
PM of UPS and Battery
cleaning of batteries wiping and air blowing
terminal cleaning &tightness
measurement of terminal voltage
Panel cleaning and thorough checking of panel
PM of Bunker level indicator
cleaning of probe by removing cover
checking of purge air line and arresting leakage if
required
checking of Remote display unit
terminal tightness
cleaning of local cabinet
PM of Ash hopper level indicator/ unit
a)
b)
c)
d)
cleaning of local cabinet and terminal tightness
cleaning of annunciation Panel and its terminal
checking the functioning of probe.
checking of transmitter and relay card.
PART-"C" : SCOPE OF WORK FOR BREAKDOWN
MAINTENANCE JOBS
01
.(a
)
SERVICING,REMOVAL,REFIXING OF AIR FILTER
REGULATORS/LUBRICATOR
Job details:
(i) Removal of air filter regulators/lubricators from site.
(ii) Disassembly at servicing Lab.
(iii Thorough cleaning/replacement of diaphragm(if
)
required)
(iv Functional checking/pressure setting at pneumatic test
)
bench.
(v) Refixing at site.
01.(b) REMOVAL,SERVICING,REFIXING OF PR.SWITCHES,
TEMP.SWITCHES
Job details:
(i) Removal of switches from site after proper isolation.
(ii) Thorough cleaning.
(iii Carrying the instrument to the lab/calibration area.
)
(iv Carrying the instrument back to the field after
)
calibration.
(v) Fixing repaired/new switch at site.
(vi Charging process and observe for leakage.If any, arrest the same.
)
01 REMOVAL/NORMALISATION OF AIR CONNECTION OF
(c) PNEUMATIC ACTUATORS/DAMPERS.
(i) Obtain PTW.
(ii) Isolate all pneumatic connections.
(iii Disconnect all pneumatic connection from the actuators & its accessories.
)
(iv Remove the actuator from its location if necessary.
)
(v) Refix the actuator on its location & normalise all pneumatic connections.Check
the desired air supply
availability.
(vi Return the PTW.
)
2
(i)
(ii)
(iii
)
(iv
)
(v)
(vi
)
03
.(a
)
i)
ii)
iii)
iv)
v)
03
.(b
)
(i)
(ii)
(iii
)
(iv
)
(v)
03
.(c
)
a)
b)
c)
d)
REMOVAL,SERVICING,REFIXING OF PRESSURE
GAUGES,TEMP.GAUGES
Removal of gauges from site after proper isolation.
Thorough cleaning.
Carrying the instrument to the lab/calibration area.
Carrying the instrument back to the field after
calibration.
Fixing repaired/new gauges at site.
Charging process and observe for leakage.If any, arrest the same.
REMOVAL, CLEANING, TRANSPORTATION TO & FROM
LAB, REFIXING OF E/P CONVERTORS,
PNEUMATIC POSITION ERS, PNEUMATIC POSISTIONERS, LOCAL CONTROLLER/
TRANSMITTERS, AIR LOCK RELAY ,
PILOT VALVE SERVICING
Obtain proper PTW and isolation.
Removal of transmitter and clean it.
Handover to C&I for Calibration and/or repair.
Change transmitter if it is faulty.
Fix the transmitter back and ensure proper fitting is used and attend leakages if
any at the minifolds etc.
SERVICING,REMOVAL,REFIXING OF AIR FILTER
REGULATORS,AIR LOCK RELAYS
Job details:
Removal of air filter regulators from site.
Disassembly at servicing Lab.
Thorough cleaning/replacement of diaphragm(if
required)
Functional checking/pressure setting at pneumatic test
bench.
Refixing at site.
EXTERNAL CLEANING & POKING PER PAIR IMPULSE LINE :
Blow down panel to be cleaned.
Union joint to be removed at different locations (manholes to be removed if
required) of the impulse lines.
Different lines to be poked with air hose/flexible wire.
Lines to be pressurized with high pressure nitrogen if required (cylinder to be
taken at site.)
03
.(d
)
(i)
(ii)
(iii
)
(iv
)
03
.(e
)
(i)
(ii)
(iii
)
(iv
)
(v)
03
.(f)
i)
REPLACEMENT OF SOLENOID VALVE
Isolation of Power after obtaining proper PTW.
Removal of solenoid.
Fixing of the new solenoid valve at its location.
Restoration of power and operation checking.
LIMIT SWITCH/PROXIMITY SWITCH ADJUSTMENT
Removal of Limit Switch after power isolation.
Cleaning contacts with anti‐rust spray.
Cleaning and checking spring mechanism, roller etc.
Operate drive (with proper PTW) and checking status changeover at required
position. Adjust if required.
Reconnection & restoring the system.
LEVEL SWITCH BREAKDOWN JOB:
Obtainproper PTW & ensure proper isloation or simulation as required.
ii)
iii)
iv)
v)
Remove the level switch from the location.
Clean the float of the level switch thoroughly.
Clean the micorswitch with contact cleaner check its healthiness.
After assembling check the healthiness of the switch by actuation of the float.
vi)
03
.(g
)
i)
ii)
Mount the level switch properly & normalise the wiring.
CABLE/WIRING CHECKING(PAIRWISE):
iii)
iv)
v)
03
.(h
)
i)
ii)
iii)
Obtain proper PTW & ensure proper isolation.
Check the continuity of the course from the local control panel, related JBs to the
field equipment.
If found defective search the spare core at both the end and connect them.
Check the healthiness after connection.
Normalise everything after the replacement.
REMOVAL & FIXING OF TEMP, ELEMENT LIKE T/C, RTD
ETC.
Obtain proper PTW.
Remove the faulty thermocouple/RTD.
Refix a new thermocouple/RTD.
iv)
v)
vi)
vii
)
03
.(i)
i)
ii)
iii)
iv)
v)
03
.(j)
.
i)
ii)
iii)
iv)
v)
03
(k)
i)
ii)
iii)
iv)
v)
vi)
vii
)
viii
)
03
.(l)
.
i)
ii)
iii)
iv)
v)
Connect the cable & insure that there is no loose
connections.
Check reading and dress the thermocouple/RTD cable.
Aslo check the tightness at JB,CJC, Marshalling end.
Return the PTW after normalization.
TRANSMITTER MANIFOLD REPLACEMENT
Close the process root valves.
Remove the defective manifold.
Connect the new manifold.
Charge the process root valve.
Attend leakages if any.
REMOVAL AND FIXING OF SAMPLE COOLERS
Isolate the cooler from cooling water and sample side.
Clean the cooler interior and remove rust/dirt
deposition.
Bring new cooler to site if required.
Mount the cooler and restore process connections.
Charge the cooler and ensure it is cooling the sample effectively.
REPLACEMENT OF ELECTRODES OF LOW‐LEVEL
DISSOLVED OXYGEN MONITOR/LOW‐LEVEL SODIUM
MONITOR/CONDUCTIVITY METER/PH ANALYZER/HYDRAZINE ANALYZER
Bring new electrodes to site.
Isolate P/S and sample from the analyzer.
Remove the electrical connections of old electrode.
Remove the old electrode.
Mount the new electrode.
Restore electrical connections to new electrode.
Restore P/S and sample to the analyzer.
Calibrate the analyzer with the new electrode and ensure that it's reading
matches with the Lab analysis result.
REPLACEMENT OF COLORIMETER LAMPS/ELECTRONIC
MODULE/SOLENOID VALVES/REAGENT TUBES OF SILICA
ANALYZER.
Isolate P/S and sample from the analyzer.
Bring the new item to be replaced to site.
Remove the electrical connections of old item.
Remove the old item.
Install the new item.
vi)
vii
)
viii
)
04
(a)
(i)
(ii)
(iii
)
04
.(b
)
(i)
(ii)
(iii
)
(iv
)
(v)
04
(c)
(i)
(ii)
(iii
)
(iv
)
(v)
(vi
)
5
05
.(a
)
05
.(b
)
05
.(c
Restore electrical connections to new item.
Restore P/S and sample to the analyzer.
Calibrate the analyzer with the new item and ensure that it's reading matches
with the Lab analysis result.
CLEANING AND FIELD CALIBRATION OF ITEMS
MENTIONED AT SL.NO.03.(A) LIKE VARIOUS
TRANSDUCERS E/P
CONVERTER PNEUMATIC POSITIONER, LOCAL CONTROLLERS ETC.
Obtain PTW.
Clean the instruments/transducer to be calibrated.
Check the calibration at field of the instruments/transducer for 0%, 25%, 50%,
75% & 100% input & record it.
CALIBRATION OF PNEUMATIC & ELECTRICAL
ACTUATOR(INCLUDING POSITION TRANSMITTERS).
Obtain proper PTW and isolation.
Externally clean the actuator.
Feed singal (4‐20MA or 0.2 ‐1 kg/cm2) calibrate the final control
element.
Calibrate position transmitter.
Restoration of the system and returning PTW.
CHECKING OF IGNITOR SPARK TIP/CORNER
Obtain PTW.
Give advance command to ignitor from local.
Observe for sparking command from local.
If sparking does not take place, replace the tip.
Again check for spark.
Return PTW.
MAINTENANCE OF FOLLOWING DIAPHRAGM TYPE
ACTUATOR:
Diaphragm replacement(Small actuators)
Diaphragm replacement (large actuators)
Actuator servicing (Small)
)
05
.(d
)
6
06
.(a
)
(i)
(ii)
(iii
)
(iv
)
(v)
(vi
)
06
.(b
)
(i)
(ii)
(iii
)
(iv
)
(v)
(vi
)
06
.(c
)
(i)
(ii)
(iii
)
06
.(d
)
(i)
(ii)
Actuator servicing (Large)
BREAKDOWN JOBS IN PISTON TYPE PNEUMATIC ACTUATORS:
Total population of piston type actuators can broadly be categorised into three
groups,
SMALL ACTUATORS:
Ignitor Advance/Retract Mechanism.
HFO/LDO system corner Nozzle valves, Atomising Valves, Scavange valve etc.
Burner check valves.
Purge Air Dampers.
Seal Air ON‐OFF Dampers.
PA/Bypass/Cold Air Dampers of mill.
MEDIUM ACTUATORS:
HFO/LDO Trip Valves.
Flame TV insertion system actuator.
MS PRDS Pressure control valve.
SADC Dampers/Overfiere Dampers.
Scanner Air Dampers.
Hot air Dampers of mill.
LARGE ACTUATORS.
Mill system ‐Mixed Air Gates, Cold Air Gates, Raw coal gate.
Burner Tilt Mechanism.
BFO Damper.
SERVICING JOB OF PISTON TYPE ACTUATOR.
Isolation of the system.
Delinking.
(iii
)
(iv
)
(v)
(vi
)
7
07
.(a
)
a)
b)
c)
d)
e)
f)
g)
07
.(b
)
a)
b)
c)
d)
e)
07
.(c
)
(i)
a)
b)
c)
d)
e)
08
.(a
)
(i)
Removal of Power Cylinder from worksite to pneumatic laboratory.
Disassembly of the actuator.
Replacement of damaged seal kits.
Reassembly and linking at site.
MILLING SYSTEM BREAKDOWN JOB:
TACHO UNIT REPLACEMENT :
Electrical & mechanical isolation to be done after obtaining PTW.
New tacho unit to be carried from store to the site.
Faulty tacho unit to be removed.
New tacho unit to be installed.
Electrical wiring to be done.
tacho unit trial to be taken.
Faulty tacho unit to be carried to the LAB/Workshop.
TACHO UNIT REPAIRING :
Faulty Tacho unit to be carried to the workshop.
Tachounit to be dismantled under the supervision of TVNL maintenance
Engineer.
Driving & non‐driving bearings are to be inspected
thoroughly.
Check the healthiness of primary & secondary coils, if found faulty, replace it.
Assemble all parts under the supervision of TVNL maintenance
engineer.
BLOWDOWN SYSTEM POKING:
FROM MILL INTERNAL
Mechanical isolation to be done after getting PTW.
Lighting arrangement to be done inside the Mill.
All 8 lines are to be poked from the mill internal after removing the nozzle.
Grinding/Drilling to be done if needed.
Restoration of the system.
MECHANICAL ADJUSTMENT OF FLOW SWITCH
Obtain PTW
(ii)
(iii
)
08
.(b
)
(i)
(ii)
08
.(c
)
i)
ii)
iii)
iv)
08
.(d
).
i)
ii)
iii)
iv)
v)
vi)
08
.(e
).
i)
ii)
iii)
iv)
v)
vi)
08
.(f)
9
09
.(a
)
Isolate flow switch line. Check the status of the flow switch contact. If contact not
OK, then adjust.
Put the flow switch line in service. Checking status changeover at required
position. Adjust if required.
MECHANICAL ADJUSTMENT OF LIMIT
SWITCH/PROXIMITY SWITCH
Obtain PTW
Operate drive and checking status changeover at required position. Adjust if
required.
PNEUMATIC LINE ISOLATION VALVE REPLACEMENT
Isolate the air line.
Remove the defective valve.
Connect the new valve.
Charge air & check for satisfactory valve operation.
REMOVAL AND FIXING OF PRINTER/ LINK‐CP/MULTI RS/
PLOTTER/ HARDCOPIER/ CONSOLE/ RECORDER
Removal P/S from the faulty item.
Remove electrical connections.
Take the defective CRT/MS clock to C&I Lab.
Bring repaired/new item to site.
Mount the repaied/new item.
Restore electrical connections and P/S and ensure normal operation of the item.
REPLACEMENT/SERVICING OF ROTAMETERS/SAMPLE
FILTERS
Isolate and remove process connections from the rotameter.
Dismantle and clean the rotameter interiors.
Assemble the rotameter.
Mount the rotameter and restore process connections.
Charge the rotameter and ensure it's proper functioning.
Ensure that the flow control knob is working properly.
BREAKDOWN JOB OF FLAME SCANNER
Scope of job as per PM description alongwith replacement/rectification of spare
parts.
Breakdown jobs of following instruments:
SERVICING/SEAL KIT REPLACEMENT OF SOLENOID
VALVES
a)
(i)
(ii)
(iii
)
(iv
)
(v)
09
.(b
)
i)
ii)
iii)
iv)
v)
vi)
09
.c)
i)
ii)
iii)
iv)
v)
vi)
vii
)
10
10
.(a
)
(i)
(ii)
(iii
)
(iv
)
10
(b)
i)
Servicing job involves.
Isolation of Power after obtaining proper PTW.
Removal of solenoid.
Servicing and functional checking thereafter (including seal replacement).
Fixing the solenoid valve at its location.
Restoration of power.
AIR PREHEATER FIRESENSING DETECTOR BREAKDOWN
JOB:
Obtain proper PTW & ensure proper isolation.
Check the healthiness of the sensor,Temp. switch and the light from local panel
and local JB.
If found defective change the sensor by opening corresponding manhole.
Normalise everything after the replacement.
check the healthiness of the detector from the local panel.
Cancel the PTW.
FLOW SWITCH MAINTENANCE.:
Necessary isolation to be done after getting PTW.
Flow switches are to be removed from the flanged joint & carried to be Lab.
Flow switches are to be cleaned thoroughly.
Flow switch indicator & relay are to be checked by operating the target (after
applying proper supply).
Rectification to be done if needed.
Flow switch is to be refixed & restoration to be done.
Flow switch is to be calibrated on line
Maintenance of the following instruments:
REPLACEMENT/ADJUSTMENT OF LIMIT
SWITCH/PROXIMITY SWITCH
Obtain PTW.
Removal of Limit Switch after power isolation.
Operate drive and checking status changeover at required position. Adjust if
required.
Reconnection & restoring the system.
TRANSMITTER IMPUILSE LINE PURGING FOR AIR & FLUE
GAS SERVICE.
Isolate the transmitter.
ii)
iii)
Remove the purge line.
Apply instrument air to high‐pressure line of the transmitter through purge line.
iv)
Apply instrument air to low pressure line of the transmitter through purge line.
v)
vi)
10
.(c
)
(i)
(ii)
Connect the purge line back.
Charge the transmitter.
POSITION FEED BACK TRANSMITTER CALIBRATION OF
PNEUMATIC VALVE/DAMPER
(iii
)
10
.(d
)
i)
ii)
iii)
11
.(a
)
i)
ii)
iii)
iv)
v)
vi)
11
.(b
)
12
i)
ii)
iii)
Obtain proper PTW and isolation.
Operate the valve/damper from 0 to 100% & check the position feed back
transmitter output. If not OK, Calibrate.
Restoration of the system and returning PTW.
CALIBRATION OF TEMP. TRANSMITTER IN HPBP& APRDS:
Temp. signal to be simulated by a mV source at MFT & APRDS panel.
Feedback of associated parameter is to be observed at EWS/UCB.
Minor adjustment to be done if required.
HEALTHINESS CHECK FOR TEMP. ELEMENT LIKE T/C,RTD
ETC. AT ELEMENT HEAD LOCAL JB END & AT
MARSHALLING
CABINET , TERMINAL TIGHTNESS IF REQD.
Obtain proper PTW.
Check wheter the concerned thermocouple /RTD is faulty or not.
If faulty change with new thermocouple /RTD.
Tighten loose connections if not faulty. Check reading and dress the
thermocouple/RTD cable.
Also check the tightness at JB, CJC & marshalling cabinet.
Return the PTW after normalization.
HEA Ignitor
Scope of job includes cheking of healthiness of HEA igniter, its required necessary
repair of the same.
TARGET FLOWMETER CALIBRATION
This includes LDO flow meter, HFO flow meter & HFO return flow
meter.
Standard weight to be prepared with the help of a standard weigh machine.
Flow meter to be drained after proper isolation.
Standard weight to be hanged to check the proper
biasing.
iv)
v)
13
i)
ii)
iii)
iv)
v)
vi)
14
i)
ii)
iii)
iv)
v)
15
i)
ii)
iii)
iv)
v)
Standard weight to removed & calibration to be carried out with help of
calibration kit.
Restoration of the system.
RECOVERY OIL TANK LEVEL SENSOR BREAKDOWN JOB:
Obtain proper PTW & ensure proper isolation.
Check the healthiness of the sensor from the local control panel
If found defective change the sensor .
Normalise everything after the replacement.
check the healthiness of the detector from the local control panel.
Cancel the PTW.
VIBRATION PROBE CHECKING REPLACEMENT(FANWISE)
Obtain proper PTW.
Check the continuity of the cable and the healthiness of the porobe from the
panel and local JBs .
If the prove is found defective replace the probe.
After replacement check the healthiness of the probe by electrical or mechanical
simulation.
Normalise everything and cancel the PTW.
OXYGEN ANALYZER
Removal of the faulty analyzer from the stack .
Changing of faulty diffuser element if failed.
Changing of heating element or cell if failed.
Fixing & calibration of the cell.
Calibration gas pressure checking and changing of the same if empty.
16.
i)
ii)
iii)
iv)
TRANSMITTER ZERO CHECKING.
Isolate the transmitter.
Open the vent plug of the transmitter.
Check "Zero" of the transmitter by connecting an ammeter.
If the reading is not 4 mA. adjust to make the current 4 mA using "Zero"
screw.
v) Reconnect the vent plug.
vi) Charge the transmitter.
17 REMOVAL AND FIXING OF CRT/MS CLOCK
i)
Isolate the power supply/necessary electrical connection for CRT/MS clock..
ii)
iii)
iv)
18
.(a
).
i)
Remove the CRT/MS clock from the locations.
Fix the new CRT/MS clock in location.
Normalise the power supply/electrical connections.
REMOVAL AND FIXING OF RESIN COLUMNS
Isolate the resin column from the process.
ii)
Remove the process connections and hand over the column to the Chemistry
personnel for regeneration.
Restore the process connections to the regenerated column.
Charge the column and ensure no leakage.
REPLACEMENT OF MODULES/LAMPS.
iii)
iv)
18
(b)
i)
Replace the faulty lamps.
ii) Replace the faulty modules.
19 REPLACEMENT OF ELECTRONIC MODULE/DIFFUSION
TUBES OF LOW‐LEVEL SODIUM MONITOR.
i)
Isolate P/S and sample from the analyzer.
ii) Bring the new item to be replaced to site.
iii) Remove the electrical connections of old item.
iv) Remove the old item.
v) Install the new item.
vi) Restore electrical connections to new item.
vii Restore P/S and sample to the analyzer.
)
viii Calibrate the analyzer with the new item and ensure that it's reading matches
)
with the Lab analysis result.
20 PLC
If any of the following items under this group is executed or carried out, it is
treated as one operation
a) changing faulty component of power supply system
b) changing faulty relay
c) checking and replacement of RG11 coaxial cable, BNC & connectors
d) checking and replacement of back plane of PLC system
21 VFD in CHP
a) Replace ment of VFD module
b) Replacement of power supply component
PART-D: CABLING AND
MISCELLANEOUS JOBS
1. CABLING JOBS (FOR ITEM SL.NO 1 TO 7 OF BOQ)
(i) Arrangement of cable transportation from Main store /C&I store to the location
of work (Vehicle will be provided
free of cost by TVNL).
(ii) Cable laying through cable trays.
(iii Cable dressing through the tray/near termination points.
)
(iv Fixing cable glands of proper size (Gland will be provided by TVNL).
)
(v) Cable termination & checking as per direction of EIC/representative of EIC (lugs
and ferrules to be provided by TVNL).
(vi
)
(vi
i)
Running the cable through flaxible /rigid conduit as per requirement.(conduit to
be provided by TVNL).
Cable of different size and type shall be supplied by TVNL free of charge. Lugs,
ferrules & conduits will be provided by TVNL free of cost to the contractor.
2
i)
ii)
SEALING WORK OF CABLE GLANDS :
Obtain proper PTW & ensure proper isolation.
Seal the different cable glands of the JBs, control panel, local panels, CJCs, limit
switches, PR. switches, PRTXs Temp
switches, Temp TXs , Proximity switches etc. with silicon sealant.
Normalise everything and cancel the PTW.
LEAKAGE ARRESTING FROM IMPULSE LINES
Without welding requirement: Leakage which can be arrested without welding
(with Cu‐washer, Teflon tape etc.)
With welding requirement (including cutting, grinding,
surface preparation etc.)
COPPER TUBING UPTO 1/2"
Remove the old tube.
Take measurements for the new tube.
Bend the tube as per requirement & conect it.
LAYING OF SS TUBES (UPTO ½ INCH)
Take measurement of the area where SS tube (up to ½") to be laid.
Note down the bend and angles.
Carry out bending in tube bender.
iii)
3
i)
ii)
4
i)
ii)
iii)
5.
(i)
(ii)
(iii
)
(iv
)
(v)
6
6.
1
6.
2
6.
3
7.
8.
8.
1
8.
Install clamps as and where required.
Connect and tighten with proper fittings, ferrules, teflon tape etc.
PHYSICAL ASSISTANCE OF THE FOLLOWING MANPOWER
SHIFT MAINTENANCE JOBS & OTHER MISC. JOBS:
Supply of Engineer on hourly basis
Supply of Technician‐I on hourly basis .
Supply of Technician ‐II on hourly basis .
Shift Engineer for DAS. Supply of consumable such as
cartridge, paper, keyboard , mouse, BNC connector,RJ45
cable, CD.
Maintenance of Software & hardware of computers and its networking installed
in various departments.
Supply of Engineer on hourly basis
Supply of Technician‐I on hourly basis .
2
PART-E: ANNUAL OVER HAULING
1.(a) REMOVAL,SERVICING,REFIXING OF PR.SWITCHES,
TEMP.SWITCHES
Job details:
(i) Removal of switches from site after proper isolation.
(ii) Thorough cleaning.
(iii Carrying the instrument to the lab/calibration area.
)
(iv Carrying the instrument back to the field after
)
calibration.
(v) Fixing repaired/new switch at site.
(vi Charging process and observe for leakage. If any, arrest the same.
)
1. FLOW SWITCH MAINTENANCE.:
b)
i)
Flow switches are to be removed from the flanged joint & carried to be Lab.
ii)
iii)
iv)
v)
1.(
c)
i)
ii)
iii)
iv)
v)
1.(
d)
(i)
(ii)
(iii
)
(iv
)
(v)
1.(
e)
Flow switches are to be cleaned thoroughly.
Flow switch indicator & relay are to be checked by operating the target (after
applying proper supply).
Rectification to be done if needed.
Flow switch is to be refixed & restoration to be done.
LEVEL SWITCH MAINTENANCE:
Remove the level switch from the location.
Clean the float of the level switch thoroughly.
Clean the micorswitch with contact cleaner check its healthiness.
After assembling check the healthiness of the switch by actuation of the float.
Mount the level switch properly & normalise the wiring.
LIMIT SWITCH MAINTENANCE
Removal of Limit Switch after power isolation.
Cleaning contacts with anti‐rust spray.
Cleaning and checking spring mechanism, roller etc.
Operate drive (with proper PTW) and checking status changeover at required
position. Adjust if required.
Reconnection & restoring the system.
REMOVAL & FIXING OF TEMP, ELEMENT LIKE T/C, RTD
ETC.
i)
ii)
iii)
iv)
v)
Checking healthiness of thermocouple/RTD
Also check the tightness at JB,CJC, Marshalling end.
Remove the faulty thermocouple/RTD.
Refix a new thermocouple/RTD.
Connect the cable & insure that there is no loose
connections.
Vi) Check reading and dress the thermocouple/RTD cable.
1(f REMOVAL,SERVICING,REFIXING OF PRESSURE
)
GAUGES,TEMP.GAUGES
(i) Removal of gauges from site after proper isolation.
(ii) Thorough cleaning.
(iii Carrying the instrument to the lab/calibration area.
)
(iv Carrying the instrument back to the field after
)
calibration.
(v) Fixing repaired/new gauges at site.
(vi Charging process and observe for leakage.If any, arrest the same.
)
1( POKING OF AEROFOIL IMPULSE LINE IN MILL AREA
g)
i)
Isolate the transmitter from manifold.
ii) Poke all the aerofoil impulse lines with a rod.
iii) Check purge air is coming in the impulse line at the bottom of the aerofoil.
iv)
v)
vi)
1(
h)
A
1(i
)
i)
ii)
iii)
iv)
v)
vi)
1(j
)
Ensure that there is no choking.
open manhole & clean all the holes in the aerofoil.
Check & ensure that purge air is coming in all the hole.
ELECTRONIC TRANSMITTER
Removal from site the following type of instruments /equipment cleaning and
carrying to C&I workshop
/lab for repair /calibration carrying back to site and fixing them
back.
Pressure /Temp/Level/position and other transmitters
TRANSMITTER MANIFOLD REPLACEMENT/SERVICING
Close the process root valves.
Clean the impulse line and Manifold by Rustonil/Petrol
Remove the defective mainfold.
Connect the new manifold.
Charge the process root valve.
Attend leakages if any.
Cleaning of Panels.
1(
k)
1(I
)
a)
b)
2
a)
(i)
(ii)
(iii
)
(iv
)
(v)
3
4
i
ii
iii)
iv)
iv)
5
i)
ii)
iii)
iv)
v)
6
i)
ii)
iii)
External and internal cleaning with blower/vacuum cleaner/solvents
of the of panel in C&I Equipment room and remote
panel
removal of the cards /equipments as per the requirement and as directed by the
EIC.
HEA Ignitor
Scope of job includes cheking of healthiness of HEA igniter, its required necessary
repair of the same.
Power cylinder of Raw coal gate,PA I/L gate & hot air
gate
Removal of actuator from site and mounting the same in position.
Actuator dismantling and servicing, changing of seal kit or spare parts
and assembling the same.
SERVICING/SEAL KIT REPLACEMENT OF SOLENOID
VALVES
Servicing job involves.
Isolation of Power after obtaining.
Removal of solenoid.
Servicing and functional checking thereafter (including seal replacement).
Fixing the solenoid valve at its location.
Restoration of power.
REMOVAL OF CONNECTION OF ELECTRICAL ACTUATOR
AS PER REQUEST OF E/M AND RECONNECTION
MAN POWER ASSISTANCE DURING OVERHAULING OF PNUMATIC/HYDRAULIC
ACTUATORS THROUGH OEM
Keltron Make pneumatic actuator
MIL Make Pneumatic valve
IL make Valve and Power cylinders
HP & LP Bypass
Leak and seal gland stem valve
DCCSP and ACCSP
Isolation of Power
Cleaning of panels through air blower
Terminal tightness
Checking of contactor
Checking of change over ckt.
Generator signaling panel
checking of microprocessor based alarm unit.
terminal tightness
cleaning of panel
7
(i)
(ii)
(iii
)
(iv
)
(v)
(vi
)
(vi
i)
8
i)
ii)
iii)
iv)
v)
SADC(SECONDARY AIR CONTROL DAMPER) (ELEVATION
WISE, 4 PER ELEVATION)
Job Description:‐
Dismentalling of Power cylinders and positioners
Clean positioners and pneumatic actuators.
Check feedback link tightness. If feedback found bent, replace it.
Clean D.P. Switches and D.P. Transmitters associated with the systems.
Check all limit switch status and confirm as per physical condition of the dampers.
Check limit switch
actuating lever tightness and roller tightness.
Observe for proper modulation of the secondary air dampers.
Check for air leakages if any and arrest the same.
Ensure the covers of all JBs, all positioners /feedback transmitter and limit
switches are closed, no dust
ingress inside,if necessary replace gasket and seal the cable glands.
Replacement of Damaged JUNCTION BOX ( per 10 pair
TB)
Tagging/marking of cable
removal of wire from terminal, opening the gland of
cable
Dismentaling of Junction box and fixing new one
glanding of cable, termination of wire, cable dressing
Sealing work of junction box
TENUGHAT VIDYUT NIGAM LIMITED
HINOO, DORANDA, RANCHI-834002
NIT NO-0028/C&I/W/TVNL/ RAN/2011-12
Due on-16.11.2011
SPECIAL TERMS AND CONDITIONS
1. ENGAGEMENT OF MAN POWER- The qualification and experience of the man-power
engaged should be as per job. The contractor shall replace the person not found suitable for
the job by the Engineer-in-charge. The contractor must deploy skilled technicians only
for execution of this contact. The contractor or it’s nominated representative &
technicians must have adequate knowledge of different instruments, like pneumatic
ON/OFF & regulated actuators (up to large size), pneumatic positioners, electronic
transmitters, solenoid valves, limit switches, pressure switches, E/P converters,
temperature switches, flow meters, analytical instruments, air filter regulators etc.
So that the contractors or his representative can guide/ supervise the workforce
independently. Knowledge of calibration/ servicing of various instruments is
essential.
2. DEPLOYMENT OF MAN POWER- Deployment of man- power engaged may be
changed by the Engineer-in-charge or his representative as per the requirement of the job.
No extra payment will be made by TVNL for the work beyond normal working hours,
Sundays and Holidays.
3. TOOLS AND PLANTS The contractor shall have to arrange tools and tackles like grease
gun, lubricating can, ladders, torches, gun-boots, hand gloves, boxes for keeping tools, rain
coat, D-spanner set, box spanner set, Ring spanner set, slide wrench, pipe wrench, 5MT
pulling lifting machine, hammers, different sizes of files, pliers, different sizes of screw
drivers and Allen key sets etc. at their own cost. However special tools and plants will be
supplied by the department.
4. SPARES & LUBRICANTS- All spares and lubricants will be supplied by the
department.
5. CLEANING OF WORK SITE- All the debris, scraps, unserviceable materials and
temporary scaffolding will be removed by the contractor from the work site after the
completion of maintenance work.
6. PREMATURED TERMINATION OF THE CONTRACT- If the performance of the
contractor is not found satisfactory, the contract may be terminated after one month’s
notice.
7. STATUTORY REGISTER:- The contractor must
maintain systematically the
following registers :a) Register of leave with wages in form no.-15
b) Register of payment in form no.-13
c) Overtime muster roll in from no.-10
d) Issue Register of personal protective equipment & safety appliances.
8. PENALTY CLAUSE:a) Rs. 200.00 for each occasion on unsafe working.
b) Rs.200.00 per day as not providing personnel safety gadgets per person.
c) Rs. 500.00 per day if the site is not cleared of scrap on daily basis.
d) Rs. 1000.00 per day in absence of engineer without intimation and permission.
e) Rs.1000.00 per occasion for insufficient and poor quality of tools & tackles
welding m/c etc.
f) Rs. 500.00 per day for delay above ½ hour in site activity after receipt of work
permit.
g) Rs. 500.00 per day for absence of supervisor from job.
h) Rs. 400.00/day/manpower in case sort supply of workforce below permissible
level.
i) Cost of consumable in case of improper storage of consumable. 2XLPP+30%
overhead charge if the consumable in the contract scope is provided by TVNL
equipment or its part.
9. Availability of the man power:- Breakdown jobs in C&I are normally emergency
in nature. It requires deployment of manpower at odd hrs. Within a very short
notice. The contractor or his representative (nominated by him) must agree to stay in
the TTPS/TVNL Township on chargeable basis subject to availability with their
own mobile, Telephone numbers so that he can be contacted by EIC/ his
representative at any moment. He must be prepared to mobilize his workforce to
attend emergencies at any time within a very short notice.
10. PROGRESS MONITORING:- Job progress shall be monitored at the end of the
day by the EIC or his representative. So the contractor must maintain logbook for
PM & Breakdown jobs for every month. These log book duly certified by TVNL
personnel concerned has to be submitted to the EIC. The performance of the
contractor shall be reviewed by TVNL after three months. If found Not satisfactory,
the contract may be terminated by TVNL by giving ONE month notice. In the mean
time alternate arrangement will be explored.
In case both the units are put under shut-down for a period of more than two months the contract
may be suspended temporarily or cancelled on prior notice.
TENUGHAT VIDYUT NIGAM LIMITED
HINOO, DORANDA, RANCHI-834002
NIT NO-0028/C&I/W/TVNL/ RAN/2011-12
Due on-16.11.2011
GENERAL TERMS AND CONDITIONS.
1. The tender shall be submitted in duplicate in two parts (Part-I (Technical) and Part-II
(Commercial)).
2. The rate to be quoted in Price Part (Part-II) shall be in figure and in words both.
3. The Tenderer must quote definite rates. Tenders with variable rates shall be considered
invalid. The period of contract shall be normally for a period of one year. The rate quoted
by the Tenderers shall remain firm during the entire tenure of contract agreement.
4. The quoted rate should be workable rate.
5. The quoted rate shall be inclusive of all fringe benefits to laborers under labor laws. Any
escalation in the rate of minimum wages or VDA or any other allowance during the
contract period will have to be borne by the contractor.
6. Earnest money- The Tenderers are required to deposit Earnest Money as indicated
against the tender notice in the shape of Bank Draft issued by any Nationalized Bank in
favour of “TENUGHAT VIDYUT NIGAM LIMITED”, Payable at Ranchi. The Bank
Draft must be enclosed with the Technical Part of the tender. Tender without or with
inadequate Earnest Money will be rejected out rightly.
7. Agreement-The successful Tenderer will have to execute an agreement in prescribed
format on a non-judicial stamp paper with concerned Electrical Superintending Engineer
within 15 days of the receipt of the work order. The successful Tenderer is required to
deposit initial security money @5% of the ordered value before executing the agreement.
The earnest money deposited with the tender shall be adjusted towards initial security
deposit. Further 5% security money will be deducted from the running bills of contractor
to raise the security deposit up to 10%. The entire amount so deposited/ deducted against
security deposit shall be released after successful execution of the contract.
8. Engineer-in-charge- The concerned Electrical Executive Engineer will be the Engineerin- charge of the work.
9. Paying Authority - The Accounts officer, TTPS, Lalpania will be the paying authority.
10. Payment- The bill in triplicate will be submitted by the contractor to the Engineer-incharge of the work for verification and onward transmission to the paying authority for
payment.
11. Safety- All the safety rules prescribed for the particular job shall strictly be followed by
the contractor and safety appliances have to be provided by them to their staff at their
own cost.
12. Consumables- Consumables such as lubricating oil, grease, bolts and nuts, gaskets, oil
seals etc will be supplied by the department free of cost, if available. However,
consumables such as Kerosene oil, cotton waste, mark-in cloth, emery cloth paper, DA,
Oxygen gas, Welding electrodes etc will have to be supplied by the contractor at their
own cost.
13. Tools and Plants - All Tools and Plants required for the work shall be arranged by the
contractor at their own cost.
14. The contractors will have to follow the guidelines laid under the labour laws in respect of
salary payment and other service conditions. In the event of any accident/ casualty to the
employees of the contractor, the compensation payable to the employees shall be borne
by the contractor only and TVNL will not be responsible in any way.
15. The work shall be executed in accordance with the specifications, drawings, designs etc.
as per direction of Engineer-in-charge for the work. In case of any work for which there
is no specification mentioned, such work shall be carried out as per the instructions and
requirements prescribed by the Engineer-in-charge of the work. The Engineer-in-charge
may make any alteration/ addition in the scope of work and to the specifications,
drawings, designs etc, if necessary during the progress of work and the contractor shall
have to carry out the work accordingly. Anything not mentioned herein shall be decided
by the Engineer-in-charge of the work and shall be binding to the contractor.
16. In case of any damage to the equipments and plants due to mishandling during
maintenance by the employee of the contractor, the damage would be made good by
them.
17. The carriage, loading and unloading of materials to be brought at site have to be arranged
by the contractor at their own cost and no claim for the same will be entertained.
18. facilities to be provide by TVNL :i. Unfurnished accommodation for office with water and electricity inside the
power house will be provided. If available.
ii. Guest house facilities shall be provided to visiting Engineers/ officers of the
contractor on chargeable basis, if available.
iii. Medical facilities to the working personnel will be provided at TTPS Hospital to
the extent it is available. No payment shall be made for any medicine
purchase of for ant treatment done outside the hospital.
iv. Unfurnished accommodations to the contractor and their employees for the
contract work shall be provided in the township, if available on chargeable
basis. Electricity supply will also be chargeable as per tariff rates.
v. Conveyance facility for working personnel will not be provided except in
emergency calls.
vi. The contractor shall be allowed to avail the facilities available at our chemical
laboratory at TTPS.
19. Any other matter not mentioned above shall be mutually discussed and settled. In case
any dispute the decision of the General Manager cum Chief Engineer, TTPS, Lalpania
will be final.
20. Legal jurisdiction- All suits and proceedings in connection with this contract will be
under the jurisdiction of the court at Tenughat (Bermo) in the district of Bokaro,
Jharkhand only.
21. The Tenderer should go through all the terms and conditions and technical specifications
and sign in all the papers of the tender.
22. The Tenderer who are agreeable to the above terms and conditions should only submit
their offer.
TENUGHAT VIDYUT NIGAM LIMITED
HINOO, DORANDA, RANCHI-834002
BILL OF QUANTITY
PART-II (PRICE-PART)
NIT No-0028/C&I/W/TVNL/ RAN/2011-12
Due on-16.11.2011
SUB:- Annual rate contract (ARC) for Preventive/ Breakdown/ annual maintenance of all
instruments of C&I circle of 2x210MW units of TTPS, Lalpania.
Sl No
A.
1.
1.1
1.2
2.
Description
Population Job/yrs
ROUTINE
MAINTENANCE
WORK
Maintenance
of
actuators
(solenoid operated)
96
48
Major operation
Minor operation
96
384
Maintenance
of
Actuators
(Pneumatic controlled MEDIUM
SIZE (Diaphragm size less than
300mm) and hydraulic system.
Major operation
52
Minor operation
52
39
208
3.1
3.2
Maintenance of large size actuators
(Diaphragm size more than
300mm)
Major operation
24
Minor operation
24
18
96
4.
4.1
4.2
Maintenance of Instruments
Major operation
Minor operation
1000
1000
500
2000
5.
5.1
5.2
5.3
5.4
Maintenance of PA station
Checking of Signal cables
Checking of Power cables
Overhauling of PA system
Major operation (monthly PM)
100
100
100
100
200
25
150
12
6.
Maintenance of Belt weigher
2
12
7.
7.1
Maintenance of Opacity Monitors
External cleaning and lens cleaning 4
filter cleaning, checking for proper
operation, calibration whenever
required and any other operation
2.1
2.2
3.
12
Rate
Amount
7.2
required for proper measurement
of Opacity
Opacity monitor (miscellaneous)
4
8.1
8.2
Cleaning of Panels
Cleaning
of
Panel
/equipments
9.
9.1
9.2
Laying of GI pipes/M
Laying of GI pipes of sizes ½”
Laying of GI pipes of sizes 1’’
10.
Servicing
&
calibration
Instruments in Lab
11.1
11.3
SOX, NOX, CO, CO2 Preventive 2
maintenance weekly
SOX,
NOX
Breakdown 2
maintenance
SOX, NOX Sample line cleaning
2
12.
12.1
12.2
Transportation of material
Bringing light material from store
Bringing heavy material from store
13.
Support during
synchronization
14.
Support during interlock
protection checks
15.
a)
Tele phone EPABX
To attend telephone defect in 500
colony or plant
To
provide
new
telephone 100
connection, cable and telephone set
will be provided by TVNL
11.2
b)
light
90
cards 90
up
49.8
75.7
of 970
-----
48
180
90
400
200
1500
96
12
48
120
30
& ---
48
and ---
48
1200
24
B
PREVENTIVE
MAINTENANCE
01(a)
01(b)
SCANNERS
Firing elevations (level 1 &2)
2
2
48
48
02(a)
36
02(b)
Ignitors cleaning maintenance 6
(elevation wise, 4per elevation)
Firing elevation (level 3 &4)
4
03(a)
ID fan
48
4
48
03(b)
03©
03(d)
03(e)
FD fan
PA fan
Aux PRDS System
Mill
Damper
(Piston
type
pneumatic actuator) (06 dampers
per mill to be considered as 1no)
04(a)
SADC (Elevation
elevation)
Burner tilt
APH
04(b)
04©
wise,
4
6
8
6
4per 24
48
72
96
72
288
2
4
24
48
05(a)
05(b)
05©
Oil station
2
FAP (fireman Aisles Panel)
2
Scanner cooling & Gun sealing 2
system
24
24
24
6.
6.1
6.2
6.3
Mill system with feeders
Subsystem-A
Subsystem-B
Subsystem-C
6
6
6
72
72
72
7.
Assistance in feeder calibration
12
144
08(a)
Control Desk cleaning
2
24
08(b)
Cleaning of LIR (Local Instrument 20
Rack) along with local instruments
20
08©
PM of SWAS sample table
2
80
9(a)
Oxygen Analyser
10
120
9(b)
Cleaning of LIE (Local Instrument 50
Enclosure) along with local
instruments
100
9©
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
PM of Analytical Instruments
PM of Silica Analyzer
PM of Low Level Sodium Monitor
Hydrazine Analyzer
Turbidity meter
Low level dissolved oxygen
monitor
PH Analyzer
Conductivity meter
9(d)
Pneumatic Control valve
2
2
2
2
4
24
24
24
24
48
15
18
180
216
80
960
10(a)
PM of Printers & Hard copier
10(b)
Field JB cleaning & tightness 200
checking
200
10©
Panel
termination
checking
280
11(a)
Removal of Printer paper
10
120
11(b)
Testing of annunciation lamps
2
96
11©
Routine checking of SWAS on line 2
analyzer
24
12.
Remote operation checking & 400
identification of problems for one
no of modulating drive
Poking of Aerofoil impulse in mill 24
area
800
16
14.
Pocking of aerofoil impulse line in 4
secondary air flow measurement
PM for Unit light ups
2
15.
PM of UPS and Battery
8
16
16.
PM of Bunker Level Indicator
1
12
17.
PM of Ash hopper level indicator/ 2
unit
24
C.
BREAKDOWN
MAINTENANCE
1 (a)
SERVICING REMOVAL
REFIXING OF AIR FILTER
REGULATORS/LUBRICATOR
REMAVAL SERVICING
REFIXING OF PR SWITCHES
TEMP SWITCHES
REMOVAL /NORMALISATION
OF AIR CONNECTION OF
PNEUMATIC ACTUATORS/
DAMPERS
REMOVAL SERVICING
REFIXING OF PRESSURE
GAUGES. TEMP. GAUGES
REMOVAL CLEANING
13(a)
13(b)
1 (b)
1 (c)
2.
3(a)
10
tightness 140
120
48
48
500
125
800
400
150
300
400
800
400
800
3(b)
3(c)
3(d)
3(e)
3(f)
3(g)
3(h)
3(i)
3(j)
3(k)
3(l)
4(a)
4(b)
TRANSPORTATION TO& FROM
LAB, REFIXING OF E/P
CONVEYORS, PNEMATIC
POSITIONERS, PNEMATIC
POSITIONES LOCAL,
CONTROLLER/TRANSMITTERS
AIR LOCK RELAY, PILOT
VALVE SERVICING
SERVICING REMOVAL OF AIR
FILTER REGULATORS AIR
LOCK RELAYS
EXTERNAL CLEANING &
POKING PER PAIR IMPULSE
LINE
REPLACEMENT OF SOLENOID
VALVE
LIMIT SWITCH/PROXIMITY
SWITCH ADJUSTMENT
LEVEL SWITCH BREAKDOWN
JOB
CABLE/ WIRING CHECKING
(PAIRWISE
REMOVAL &FIXING OF TEMP
ELEMENT LIKE T/C RTD ETC
TRANSMITTER MANIFOLD
REPLACEMENT
REMOVEAL AND FIXING OF
SAMPLE COOLERS
REPLACEMENT OF
ELETRODES LOW LEVEL
DISSOLVED OXYGEN
MONITOR /LOW LEVEL
SODIUM, MONITOR
/CONDUCTIVITY METER/PH
ANALYZER /HYDRAZINE
ANALYZER
REPLACEMENT OF
COLORIMETER LAMPS
/ELECTRONIC MOUDLE
/SOLENOID VALVES REGENT
TUBES OF SILICA ANALYZER
CLEANING AND FIELD
CALIBRATION OF ITEMS
MENTIONED AT SL NO. 03 (A)
LIKE VARIOUS
TRANSDUCERS E/F
CALIBRATION OF
PNEUMATIC & ELETRICAL
ACTUATOR (INCLUDING
500
125
400
800
240
120
260
130
60
30
------
120
480
120
400
36
24
8
60
24
2
10
80
160
80
160
4(c)
5.
(a)
(b)
(c)
(d)
6.
6(a)
06(b)
06(c)
06 (d)
POSITION TRANSMITTERS )
CHECKING OF IGNITOR
SPARK TIP /CORNER
MAINTEANACE OF
FOLLOWING DIAPHRAGM
TYPE ACTUATOR
Diaphragm replacement (small
actuators)
Diaphragm replacement (large
actuators)
Actuator servicing (small)
Actuator servicing (large)
BREAKDOWN JOBS IN PISTON
TYPE PNEUMATIC
ACTUATORS
Total population of piston type
actuators can broadly be
categorized into three groups
SMALL ACTUATORS
MEDIUM ACTUATORS
LARGE ACTUATOR
SERVICING JOB PISTON TYPE
ACTUATOR
7.
07(a)
07(b)
07(c)
Milling system Breakdown job
TACHO UNIT REPLACEMENT
TACHO UNIT REPAIRING
BLOWDOWN SYSTEM
POKING FROM MILL
INTERNAL
08(a)
MECHNICAL ADJUSTMENT
OF FLOW SWITCH
MECHNICAL ADJUSTMENT
OF LIMIT SWITCH
/PROXIMITY SWITCH
PNEUMATIC LINE ISOLATION
VALVE REPLACEMNET
REMOVAL AND FIXING OF
PRINTER/ LINE CP/ MULTI
RS/PLOTTER/ HARDCOPIER/
CONSOLE /RECORDER
REPLACEMENT /SEVICING OF
ROTAMETRES/SAMPLE
FILTERS
BREAKDOWN JOB OF FLAME
SCANNER
08(b)
08(c)
08(d)
08(e)
08(f)
6
144
96
20
24
10
96
24
96
24
72
72
24
42
18
18
24
20
6
6
6
6
12
24
9
18
260
600
96
48
10
10
30
60
40
160
9.
09(a)
Breakdown jobs of following
instruments
SERVICING /SEAL KIT
REPLACEMENT OF SOLENOID
VALVES
AIR REHEATER FRESHING
DETECTOR BREAKDOWN JOB
FLOW SWITCH MAINTEANCE
240
240
4
24
9
18
260
55
75
450
80
320
8
32
HEALTHINESS CHECK FOR
TEMP ELEMENT LIKE T/C RTD
ETC AT ELEMENT HEAD
LOCAL END JB END &
MARSHALING, HEAD LOCAL
JB & AT MARSHALING
CABINET, TERMINAL
TUGHTNESS IF REQD.
HEA IGNITOR
TARGET FLOWMETER
CALIBRATION
This includes LDO flow meter,
HFO flow meter &HFO return
flow meter
200
1200
24
10
72
40
13.
RECOVERY OIL TANK LEVEL
SENSOR BREAKDOWN JOB
4
8
14.
VIBRATION PROBE
CHECKING REPLACEMENT
(FANWISE)
14
56
15.
OXYGEN ANALYZER
10
40
09(b)
09(c)
10.
10(a)
10(b)
10 (c)
10(d)
11(a)
11(b)
12.
Maintenance of the following
instruments:REPLACEMENT /ADJUSTMENT
OF LIMIT SWITCH PROXIMITY
SWITCH
TRANSMITTER IMPULSE LINE
PURGING FOR AIR FLUE GAS
SERVICE
POSITION FEEDBACK
TRANSMITTER CALIBRATION
OF PNEUMATIC VALVE
/DAMPER
CALIBRATION TEMP.
TRANMITTER IN HPBP &
APRDS
16.
TRANSMITTER ZERO
CHECKING
340
1360
17.
REMOVAL AND FIXING OF
CRT/MS CLOCK
10
100
18(a)
REMOVAL AND FIXING OF
RESIN COLUMNS
REPLACEMENT OF
MODULES/LAMPS
REPLACEMENT OF
ELECTRONIC MODULE /
DIFFUSED TUBES OF LOW
LEVEL SODIUM MONITOR
8
16
-----
1400
2
8
20.
PLC
2
24
21.
VFD in CHP
24
48
D.
CABLEING AND
MISCELLANCEOUS JOBS &
DEPLOYMENT OF REGULAR
MANPOWER
CABLING JOBS FOR ITEM SL.
NO. 1 TO 7 OF BOQ
---
1000
18(b)
19.
1.
2.
SEALING WORK OF CABLE
GLANDS
---
2000
3.
LEAKAGE ARRESTING FROM
IMPULSE LINES
---
50
4.
COPPER TUBING UPTO ½”
---
125
5.
LAYING OF SS TUBES (UPTO
½ INCH
---
25
6.
PHYSICAL ASSISTANT OF
FOLLOWING MANPOWER
SJIFT MAINTENANCE JOBS &
OTHER MISC. JOBS.
Supply of engineer on hourly basis
Supply of Technician –I on hourly
basis
Supply of Technician-II on hourly
basis
1
1
-----
2
---
1
---
6.1
6.2
6.3
7.
Shift Engineer for DAS, supply of
consumable such as cartridge,
paper, keyboard, mouse, BNC
connector ,RJ45 cable, CD
8.
8.1
8.2
E.
1(a)
1(b)
1(c)
1(d)
1(e)
1(f)
1(g)
1(h)
1(i)
1(j)
1(k)
1(l)
Maintenance of Software &
hardware of computers and
networking installed in various
departments
Supply of engineer on hourly basis
Supply of Technician –I on hourly
basis
ANNUAL OVER HAULING
REMOVAL, SERVICING,
REFIXING OF PR. SWITCHES,
TEMP. SWITCHES
FLOW SWITCH
MAINTENANCE
LEVEL SWITCH
MAINTENANCE
LIMIT SWITCH
MAINTENANCE
REMOVAL & FIXING OF TEMP
ELEMENT LIKE T/C RTD, ETC
REMOVAL SERVICING
REFIXING OF PRESSURE
GAUGES, TEMP. GAUGES
POKING OF AEROFOIL
IMPULSE LINE IN MILL AREA
ELECTRONIC TRANSMITTER
TRANSMITTER MANIFOLD
REPLACEMENT / SERVICING
CLEANING OF PANELS
HEA IGNITER
Scope of job includes checking of
healthiness of HEA igniters its
requirement necessary repair of the
same
POWER CYLINDER OF RAW
COAL GATE, PA I/L GATE &
HOT AIR GATE
1
1
-----
---
312
---
24
---
52
---
376
---
960
---
558
---
24
-----
500
100
-----
126
24
---
36
2.
SEVICING /SEAL KIT
REPLACEMENT OF SOLENOID
VALVES
---
110
3.
REMOVAL OF CONNECTION
OF ELECTRICAL ACTUATOR
AS PER REQEST OF E/M AND
RECONNECTION
---
400
4.
MAN POWER ASISTANCE
i)
ii)
iii)
iv)
v)
DURING OVERHAULING OF
PNEUMATIC / HYDRULIC
ACTUATORS THROUGH OEM
Keltron make pneumatic actuator
MIL make pneumatic valve
IL make valve and power cylinders
HP& LP Bypass
Leak and seal gland stem valve
-----------
28
64
38
10
4
5.
DCCSP AND ACCSP
---
4
6.
GENERATION SIGNALING
PANEL
---
2
7.
SADC(SECONDARY AIR
CONROL DAMPER )
(ELEVATION WISE, 4 PER
ELEVATION )
---
48
8.
REPLACEMENT OF DAMAGED
JUNCTION BOX (PER 10 PAIR
TB)
---
100
TOTAL
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