Bids Are Invited For Custom Bid for Services - NDT OF TG AREA PIPING IN NTPC Farakka - Area of execution of work Stage 2 (2x500MW)-U4&5 and Stage 1 (3x200MW)-Units of NTPC FARAKKA TG area piping which includes warmup piping, drain piping, high energy drain line, vent piping, impulse lines, thermowells, deaerator & FST, LP heaters extraction line metallic expansion joints, emergency drain lines etc. Scope of Work: Detailed Scope Of Work and BOQ Item wise description Scope of Work: The work against this contract includes jobs of Insitu Dissimilar metal checking, thickness measurement, hardness testing of welds/pipes and DPT of TG area piping of Stage 2 (2x500MW)-U4&5 and Stage 1 (3x200MW)-U3 of NTPC FARAKKA during the contract period at different OH times over a period of two years. JOB Sr NO: 10.10 10.10 – Dissimilar metal checking (NDT (MATL MIXUP) Checking) The work against this job include deployment of skilled and experienced manpower for checking of dissimilar metal using XRF analyser (PMI) of TG area piping from Zero meter to deaerator floor. The dissimilar metals are to be checked in all bends/pipes/socket couplings and other identified points of TG high energy drain piping/warm-up piping /impulse piping of Main turbine/ MS/ CRH/ HRH/ HPBYPASS/ LPBYPASS lines, steam extraction lines, FW lines, Gland steam lines & any other lines as instructed by the EIC. The party has to make plan for the activities of a particular day in consultation with the EIC in one day advance, so that maximum area can be covered in a particular day in an organized manner and all preparatory work as fixing of scaffolding if required, removal of insulation from the pipe and surface preparation for dissimilar metal checking to be done well in advance. The party has to submit testing reports on a daily basis to the EIC for recording his observations and the same shall be witnessed by the EIC in charge. Marking of each point and line shall be done and the same shall be maintained in the report along with the composition and material for easy identification and rectification work. The XRF analyser (shall be of reputed make and to be approved by EIC) along with calibration checking block for above work is in vendors scope. As the work is to done in OH & there are lot of points to be measured, sufficient teams/analysers shall be deployed as per instructions of EIC. One measurement team shall consist of minimum 2 members & 1 no. analyser. Grinding/Buffing in the scope of vendor for PMI Check (other service item). Note: In UOM (Unit of Measurement) 01 no is considered as 01 spot. JOB Sr NO: 10.20 10.20 - Thickness-(Survey/Study), Tube thickness of TG area piping is to be surveyed with the help of calibrated D Meters for all bends/pipes/socket couplings and other identified points of TG drain piping/warm-up piping /impulse piping/Emergency drain lines of Main turbine/ MS/ CRH/ HRH/ HPBYPASS/ LPBYPASS lines, steam extraction lines, FW lines, Gland steam lines & any other lines as instructed by the EIC. The thickness survey shall be done by skilled and experienced manpower. The agency shall deploy minimum 3(Three) Nos of calibrated thickness gauges of reputed make and necessary consumables such as emery paper, wire brush, cleaning cloths, greases etc. Tube surface grinding/buffing at hard scale/clinker formed areas to be done. Before start of thickness measurements, visual inspection of the area to be done for abnormality such as pitting, cut, Ovality, erosion and dents etc as per instruction of EIC. The readings are to be tabulated in the prescribed format and submitted to NTPC on daily basis. Marking of each point and line shall be done and the same shall be maintained in the report for easy identification and rectification work. For timely completion of job, party has to maintain minimum 2 teams during each overhaul and each team consisting of 2 persons for tube thickness measurement. One team will consist of one skilled technician and one helper. Random inspection will be carried out by the NTPC representative to counter check the readings recorded. Agency has to arrange reputed make of ultrasonic thickness gauge (D-Meter). Make and model of D- Meter machines to be approved by EIC prior to start of work. Instruments must be having display resolution 0.1 mm or better. The thickness survey to be done during overhauling of units & to be completed within overhauling schedule. Tentative Overhauling program of units shall be provided to the agency well in advance, the actual program shall be intimated 3 days in advance. Accordingly, agency has to mobilize for the work. As per the requirement of job, Agency may be required to deploy manpower round the clock, for which no extra payment shall be made. Agency shall be fully responsible for the safety of his manpower and strictly adhere to NTPC safety norms. Agency may be asked to provide one group for cross checking of readings, if desired by NTPC Engineer. In this account no extra payment shall be made. Note: In UOM (Unit of Measurement) 01 no is considered as 01 spot. Grinding/Buffing in the scope of vendor (other service item). JOB Sr NO: 10.30 10.30 - DP Testing The scope of work shall include DPT of all welds and other identified points of TG drain piping/warm- up piping /impulse piping/Emergency drain lines of Main turbine/ MS/ CRH/ HRH/ HPBYPASS/ LPBYPASS lines, steam extraction lines, FW lines, Gland steam lines & any other lines as instructed by the EIC. DPT shall also be done in Deaerator & FWST, Condenser metallic expansion joints, Main turbine Lube oil/control oil piping as per the instruction of EIC. Cleaning of tube surface/welding during DPT with cloth/buffing/grinding (grinding & buffing in the scope of vendor (other service item) to be done by the agency as per requirement. The contractor shall deploy three gangs (each gang shall consists of 1 level-2 operator & 1 helper) in each overhaul to carry out the DPT and to evaluate & prepare reports in the prescribed format. Reports shall be submitted to EIC on daily basis. Marking of each point and line shall be done and the same shall be maintained in the report for easy identification and rectification work. Payment for carrying out DPT shall be made on man hour rate (MHR) basis vide this job. One MHR shall be deemed to be equivalent to one gang working for one hour. DPT kit is in the scope of agency (DPT kit, Cleaner, Penetrant, Developer shall be of same make and have proper validity). Payment for DPT shall be made on man hour rate (MHR) basis, no idle charges whatsoever, shall be paid to the agency. UOM: MHR One MHR shall be deemed to be equivalent to one DPT Testing gang along with DPT kit working for one hour. JOB Sr NO: 10.40 10.40 – Scaffolding erection & removal Necessary scaffolding are to be made to carry out the inspection/testing/survey jobs of Sno.: 10.10, 10.20, 10.30 & 10.60. Party has to bring the scaffolding material for the work on returnable basis. Since NDT testing Jobs (SN:10.10,10.20,10.30 & 10.60) of piping are to be done from TG zero meter to till Deaerator Floor (30m EL), scaffolding work shall be done in above mentioned area as per requirement for the work. After work completion, scaffolding to be removed and area to be cleaned. All manpower for fixing of scaffolding and removal of same is in the agency scope. The same erected scaffolding will be used by NTPC for rectification work of defects if any in the item nos. 10.20, 10.30, 10.10 & 10.60. There shall be a minimum of 2 gangs, each gang consisting of 6 members during each overhaul. NTPC may ask for erection/removal of scaffolding of works other than related to this contract work in this service item. There shall be a minimum of 400 scaffolding pipes – each of 6 mtrs(if required, pipes has to be cut), 2000 fixed clamps, 500 rotating clamps & required metal planks for working during each overhaul. This number is tentative and qty to be decided before overhaul. . Note: UOM (Unit of Measurement) 01 No Payment of one BOQ will be made against this schedule for the erection of platforms of approximate size of 9 square metres up to height of 10 Mtrs. from the base If platforms of bigger size or smaller sizes are made, then payment shall be made on pro-rata basis. JOB Sr NO: 10.50 10.50 - Scaffolding Transportation Transportation of scaffolding material from vendor’s store to NTPC Farakka plant & vice-versa. Unloading of scaffolding material at plant. Loading of scaffolding material into trucks after work completion mobilisation/demobilisation of workers/staff Note: UOM 01 No shall be payable for 1 no. to & fro transportation. JOB Sr NO: 10.60 10.60 – Hardness checking (Hardness Checking) The work against this job include deployment of skilled and experienced manpower for checking of Hardness of TG area piping from Zero meter to deaerator floor. The hardness is to be checked in all welding / piping & fittings of P91 bends/pipes/socket couplings and other identified points of TG drain piping/warm-up piping /impulse piping of Main turbine/ MS/ HRH/ HPBYPASS/ LPBYPASS lines, & any other lines as instructed by the EIC. The party has to submit testing reports on a daily basis to the EIC for recording his observations and the same shall be witnessed by the EIC in charge. Marking of each point and line shall be done and the same shall be maintained in the report along with the Hardness for easy identification and rectification work. The hardness testing machine (NTPC APPROVED) duly calibrated of latest model of reputed make, accessories, consumables, calibration block are in the scope of contractor. As the work is to done in OH & there are lot of points to be measured, sufficient teams/Hardness testers shall be deployed as per instructions of EIC. One measurement team shall consist of minimum 2 members & 1 no. tester/CONSUMABLES. Grinding/Buffing in the scope of vendor (other service item). Note UOM: D (Day) One D (Day) shall be deemed to be equivalent to one Hardness Testing gang along with equipment working for one day JOB Sr NO: 10.70 10.70 – Insulation/cladding removal cum reapplication The work against this job include deployment of skilled and experienced manpower for removal/reapplication of insulation cum cladding There shall be minimum of three gangs during each overhaul. Each gang shall consist of 4 members. Removal & installation tools in the scope of vendor. Consumables like screws, wire for tagging in the scope of vendor. Insulation & cladding to be removed in a manner that the same shall be used again. In case of new requirement, NTPC will provide the same. Note UOM: NO. 1 NO. IS FOR 1 GANG (4 MEMBERS(2 NOS. SKILLED PLUS 2 NOS. SEMISKILLED) FOR 1 DAY JOB Sr NO: 10.80 10.80 Welding visual inspection cum engineer – Quality Engineer-2nos. and Engineer-1n0. During each overhaul The work against this job include deployment of 2 nos. Highly-skilled and experienced manpower during each overhaul for quality checks coordination with FQA & report generation on daily basis. All weldings visual inspection and report preparation. All pipes/elbows/socket couplings visual inspection for overheating, erosion & wherever it is doubtful, hardness/thickness to be checked & report to be prepared. The work against this job include deployment of 1nos. Highly-skilled and experienced manpower during each overhaul for overall coordination of work and report generation on daily basis. Note UOM: 1 MD FOR 1 ENGINEER FOR 1 DAY JOB Sr NO: 10.90 10.90 – Manpower cum tools for grinding/buffing/cleaning/cutting The work against this job include deployment of 4 nos. gangs of skilled and experienced manpower during each overhaul for grinding/buffing/cleaning/cutting works for checking against item nos. 10.10, 10.20, 10.30 & 10.60. All grinding tools such as grinding machines(AG7/AG5/AG4) with consumables such as buffing wheels, grinding wheels, cutting wheels, Electrical connections items such as JBs, power cable etc. for connection from nearest power supply and any other items required for conducting all checks mentioned in the contract. Note UOM: 1 NO. FOR 1 GANG WHICH CONSISTS OF 1 GRINDER AND 1 HELPER ALONG WITH GRINDING MACHINE/CONSUMABLES/ ELECTRICAL CONNECTIONS ITEMS AND ANY OTHER ITEMS REQUIRED FOR WORK FOR 1 DAY JOB Sr NO: 10.100 10.100 – Stay of workers & staff 1) Agency has to arrange the accommodation of their expert and representative as per their scope. Only stay charges will be paid by NTPC limited to Rs. 500 per staff per day & Rs. 300 per worker per day on the submission of invoices. If stay is provided by NTPC at free of cost, no charges will be paid. Provision of stay at NTPC depends on availability and situations prevailing at that time. Note UOM: 1no. – 1 time charges for 1 overhaul Special Terms & Conditions : The above job will be taken up in Stage 2 (2x500MW)-U4&5 and Stage 1 (3x200MW)-U3 of NTPC FARAKKA during Unit overhauling. So, party has to mobilise three times as per unit overhauling schedule during the contract period. Actual date of overhauling will be intimated by NTPC in the due course of time. Party shall be informed minimum 3- 4 days in advance before start of the work. Deviation of Contract: As per O&M GCC i.e. (+)100 % / (-)100 % for each line items. The Party shall report within 3-4 days from the date of intimation by EIC for starting the work. Fooding of deployed manpower and party’s representative is in vendors scope. Agency has to arrange the accommodation of their expert and representative as per their scope. Only stay charges will be paid by NTPC limited to Rs. 500 per staff per day & Rs. 300 per worker per day on the submission of invoices. Local TO & FRO transport from Hotel/Room to plant during the work will be in vendors scope. If stay is provided by NTPC at free of cost, no charges will be paid. Provision of stay at NTPC depends on availability and situations prevailing at that time. NTPC shall provide free power for charging of his machines / instruments. However, charger for instruments shall be arrangement by the agency at his own cost. After completion of total job, the service engineer shall submit his detail job report within 7 working days to EIC. The submitted report must have the isometric drawing of tested pipelines for clear and easy picturisation of above jobs (Thickness, Dissimilar metals test points, HARDNESS and DPT). The Party shall take all necessary safety precautions while working at site. The agency shall be responsible for the safety and necessary insurance of all workmen cum engineers while working at site. No gate pass will be issued without valid insurance at NTPC Farakka. Party must ensure strict adherence to field safety plan as follows by NTPC FIELD SAFETY PLAN. The personnel of Agency has to follow the NTPC safety rules and regulations, otherwise fine as deemed fit will be imposed for each incidence of non-compliance and the amount will be deducted from the Bill. Traveling expenses of deployed manpower Expert/Experienced manpower and vendors representative from their Head quarter to NTPC Farakka and back to head quarter is in the scope of party Party has to mobilise three times during the contract period as per unit overhauling schedule. All working manpower deployed for the work shall 100% COVID vaccinated. If NTPC requires RAT/RT-PCR certificate at the time of gate-pass creation, charges shal1 be borne by vendor As per NTPC new guidelines, the contractor shall necessarily take Workmen Compensation Policy and Third Party Liability Policy. Value to be insured shall be: Total/ Aggregate amount during the currency of Contract: Rs. 50.00 Lakhs or #110% of Contract value (Excluding GST)# whichever is lower. For any one occurrence: 50% of Total aggregate amount. Amount linked to Safety/Compliance of safety rule: minimum: 3.5% of contract value is linked to safety and it will be released after full compliance of safety as mentioned in contract and certification of EIC. A Contract agreement copy of Stamp Rs 1000 is to be submit before execution of Job. All other terms & conditions which is not mentioned in this contract will be as Per GCC of NTPC IDLE CHARGES OF WORKMEN CUM STAFF SHALL NOT BE PAID IF THE REASON IS ATTRIBUTABLE TO CONTRACTOR Work shall be done more than 8 hours depending on the requirement of EIC as the work is to be done in 20 days time. Quantity variation: As per O&M GCC List of minimum Tools and Plant & Consumables: Insulation, cladding, power supply, water in the scope of NTPC Owner’s issue material: All special tools required shall be brought by Vendor SAFETY: Supervisory nature contract Amount linked to safety compliance shall be minimum of 3.5% of total contract value 1 no. safety engineer shall be deployed all safety items like safety helmet, safety shoe, nose mask, hand gloves, ear plugs, safety goggles, safety harness, safety jackets for workers, safety dangree for staff etc to be ensured by party NTPC safety circular no. 789 shall be followed Quality: As per NTPC FQA. Total Quantity :
