NTPC Limited

(A Government of India Enterprise)

Korba Super Thermal Power

NOTICE INVITING TENDER (NIT)

FOR

OVERHAULING OF FIRST PASS OF BOILER PRESSURE PARTS OF STAGE-I,II & III(2 X 200MW & 2 X

500MW) UNITS 2015-16.

(Domestic Competitive Bidding)

NIT No: 40041922	Date:20.07.2015
Bidding Document No: KS/CS/O&M/153057

1.0NTPC invites on-line bids from eligible Bidders for aforesaid package, as per the scope of work briefly mentioned hereinafter:

2.0Brief Details

NIT No.	40041922
NIT Date	20.07.2015
Document Sale Commencement Date & Time	20.07.2015 17:30:00
Document Sale Close Date & Time	08.08.2015 17:00:00
Source of IFB/NIT	Korba Super Thermal Power
Contract Classification	Services
Last Date and Time for Bid submission	09.09.2015 10:00:00
Technical Opening Date & Time	09.09.2015 10:30:00
Bid Opening Date & Time	11.09.2015 10:30:00
Cost of Bidding Documents in INR	2,500.00
EMD in INR	354000.00
Pre-Bid Conference Date & Time (if any)
Last Query Date (if any)	18.08.2015

3.0 Bid Security and Integrity Pact (if applicable) shall be submitted in a sealed envelope separately offline by the stipulated bid submission closing date and time at the address given below. Any bid without an acceptable Bid Security and Integrity Pact (if applicable) shall be treated as non-responsive by the employer and shall not be opened.

4.0 A complete set of Bidding Documents may be downloaded by any interested Bidder on payment (non-refundable) of the cost of the documents as mentioned above in the form of a crossed account Payee demand draft in favour of NTPC Ltd., Payable at KORBA or directly through the payment gateway at our SRM Site (https://etender.ntpclakshya.co.in/sap/bc/gui/sap/its/bbpstart). For logging on to the SRM Site, the bidder would require vendor code and SRM user id and password which can be obtained by submitting a questionnaire available at our SRM site as well as at NTPC tender site (www.ntpctender.com). First time users not allotted any vendor code are required to approach NTPC at least three working days prior to Document Sale Close date alongwith duly filled in questionnare for issue of vendor code and SRM user id/password.

5.0Brief Scope of Work & other specific detail

First pass, for the purpose of this SOW, consists of all boiler components (including attachments, sealings, coverings and supports) from water wall bottom ring headers up to Screen tubes in horizontal pass. Broad area heads are: Ring headers, Boiler Drum, Down comers, Water walls, Pent house (all components above, inside & enclosure) Platen super heater, Reheater and Screen, Extended walls up to screen, Roof up to screen, Boiler Piping, Structures and all dead chambers in 200 MW Boiler: It consists of all the above plus Divisional SH & Wall Reheaters in 500 MW Boiler.

Purpose and Intent of the Work:

Boiler is very critical equipment for power generation process. Boiler pressure part is one area where utmost attention is required to carry out huge amount of work of highest possible quality standards at great speed. Therefore NTPC Ltd has much expectation from the contractors who undertake this work. It is necessary that the prospective bidders understand the purpose and intent of this contract. Therefore bidders are advised to take note of the following:

1.0 It is the intent of this contract that the unit must run without a tube leakage from overhaul to overhaul. For this neither a defective/weak tube is to be left in the boiler nor should any new defect be introduced in the boiler by maintenance.

2.0 Therefore the contractor is required to assist NTPC in inspection work so that all such tubes are identified early in the shutdown period and replaced during overhaul.

3.0 It is also the intent of this contract to achieve #ZERO DEFECTS# during maintenance. So, the maintenance work done in the boiler needs to be of highest possible quality standards. The maintenance work must not induce any defect in the boiler which may result in to tube leakage or other problems. This means the quality of tube cutting, edge preparation, fit up and welding must be world class. The contractor must deploy skilled and competent manpower and supervisors. The contractor shall be accountable for achieving these objectives.

4.0 The contractor shall establish a proper supervision and quality assurance system in consultation with NTPC Engineers.

5.0 Contractor shall deploy sufficient number of working gangs, Skilled manpower like HP welders, Key resources like welding machines, radiography sources and supervisors so that the work is done in even pace and last minute rush is avoided.

6.0 Contractor shall deploy adequate T&P to maintain the pace of work.

7.0 The contractor shall take all the precaution to ensure safety at work so that the activities are not hindered by accidents. 8.0 Similarly all other works must also be done with due care and according to guidelines issued by NTPC Engineers. Brief Description of the work

For this work, once the FAL is issued to the contractor, he is expected to start mobilizing on top priority, so as to achieve the targets set by EIC under schedule 1.0, before the date of the shut down. Adequate mobilization of key resources of right quality is the most vital input to the successful execution of this work. Contractor shall fully understand the targets to be obtained by him from the EIC for the pre shut down work, mobilize accordingly and complete the activities before shut down. The general mobilization period (intimation to shut down) shall be 07 days .

Once the unit is shut down, the contractor shall arrange to do the preliminary cleaning and then start the scaffolding works. Stage # wise, as the scaffolds start becoming ready, he shall arrange for further cleaning, illumination, local approach and preparation of surface for inspection / thickness survey / NDT checks and offer such areas for EIC#s inspection.

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

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

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

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

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

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

a) Pre # shut down Works:

i)Submit Form # IV and take form # V from NTPC Ltd

ii)Arrange Labor license: License is required normally for about 250-300 persons for overhauling of Boiler.

iii)Arrange comprehensive workmen insurance/ ESI registration from ESI corporation, which should cover all risks encountered in such a job, including working at heights (up to 65 meters for 200 MW Boilers and up to 100 meters for 500 MW boilers). The policy paper shall mention the name of the work and the location (NTPC Ltd, Korba), besides the number of persons covered.

iv)Obtain the permission of the Boiler Inspectorate, Chattisgarh, for the work and for doing the work with approved HP welders.

v)Depute Resident engineer, Site # in # charge and key supervisory and skilled personnel to interact with EIC and his representatives, for understanding the detailed resource requirements of the work (Staff, T&P, Consumables etc), to understand the anticipated quantum of work, to make PERT net work, to work out group # wise distribution of work, to work out day # wise and group # wise program of the work and to understand the quality and safety requirements. Considering the importance of the work as given at the beginning of the SOW, the indicated resources of right quality shall be mobilized, prior to the actual shut down.

vi)To conduct briefing sessions for the various groups to ensure that the understanding percolates to the bottom most level.

vii)To transport T&P, radiography sources & consumables to inside Plant premises with due entry at gate ( As mentioned in clause 15 of STC-II)

viii)To arrange Photo passes for workers, staff and passes for vehicles

ix)Ensure that the workers engaged for work are medically fit

x)To make arrangements for accommodation / conveyance / food / refreshments etc

xi)Safety supervisor shall be got tested verbally by EIC / safety officer of NTPC Ltd

xii)Arrange safety training to all the workers and staff at NTPC safety cell. And to submit the record regarding the completion of safety training of all the workers from our Safety department.

xiii)Shift to location / platform on boiler: T&P, Consumables, Spares, Scaffold materials (other than cuplok), Baking and holding ovens etc

xiv)Chalk out the movement path of major materials from and in to the boiler.

xv)Set up and commission: Computer, Radiograph evaluator, Baking and Holding ovens, Electrical machines etc at site.

xvi)Insulation survey before shut down and making of list of locations. To start work immediately after shut down under intimation to EIC.

xvii)Make arrangement for drinking water to work site.

xviii)Set up electrical connections, shift feeder pillar boards, Cables, external flood lighting etc as required / as specified by EIC.

xix)Shift racks or tree shaped rack to zero meter of overhauling unit for proper storing/identification of boiler tubes.

xx)Check welding and lighting supplies.

xxi)Set up winch for lifting / lowering of materials to work location.

xxii)Ensure all persons to be deployed are adequately skilled for the job and trained in safety.

xxiii)Prepare registers and formats for use during the work.

xxiv)Arrange procurement of leak - proof ash disposal bags.

xxv)Arrange radiography sources, driers, Films, cassettes etc. and set up processing lab.

xxvi)Carry out pre # assembly works as identified by EIC. These can be weld joints, radiographs, steel fabrication etc which are payable against respective schedules of the contract.

xxvii)Make extra platforms if any, as identified by EIC, to facilitate the work.(Payment shall be in the item #Steel fabrication#)

xxviii)Cleaning of the spool pieces by blowing compressed air.

xxix)Any other work as per direction of engineer - in # charge.

xxx)Following documents must be submitted with in two days of shutdown to EIC :

1)Labour license specific to the contract.

2)Insurance policy for the workers to be deployed in this contract. ESI registration obtained from ESI corporation, Bilaspur.

3)List of T&P brought into plant premises along with their serial nos. And dates / year of purchase / manufacture.

4)Test certificates of T&Ps and appliances to be used.

5)List of consumables brought into plant premises along with their serial nos. And dates and year of purchase where ever applicable.

6)Permission from CIB, Chhattisgarh for carrying out the job.

7)Test certificates of HP Welders duly endorsed by IBR

8)Authorization / Permission from BARC for the use and movement of radiography sources.

9)Test certificates to prove the purity of argon gas being used.

10)Batch certificate of cutting wheels / grinding wheels where shelf life period is involved.

11)Mobilization formats duly filled up

12)Details of supervisory staff to be deployed, in the format specified

13)Details of workers to be deployed with name, age, permanent address, category, medical fitness and their family /dependents.

14)Authorization for receipt of material from NTPC, for signing of measurement books etc.

15) Details of safety training of workers.

b) Post Shut down Works:

i)Clearing of the Boiler of all debris, left # over spares, T&P, consumables etc. within 96 hours after light # up (payment for clearing of scrap against respective schedule)

ii)Deploy manpower for attending to defects if any during the initial running period of 48 hours from light # up.

iii)Return of NTPC material as directed. Stacking / arranging the returned items as specified.

iv)Reconciling measurements and materials with EIC.

v)Servicing and return of NTPC#s T&P used during the job to make ready for next work.

vi)Attend to defects due to poor workmanship / negligence / omission up to 30 days from 1st synchronization of the unit after overhaul.

vii)Submit the following documents in report form within 07 days from synchronization of the unit after the overhaul / shutdown work is completed or before release of running bills:

1) Details of work executed.

2) Measurements against different schedules in compiled form.

3) Material issue details.

4) Material consumption details.

5) Material return detail.

6) Weld joint # wise report for different sections / zones/ areas of boiler along with RT report reference 7) Radiography reports along with repair details of defective joints.

8) DPT protocols.

9) Protocols of other hold points like #water wall air # charging before spool fit # up, Check of fit # up and weld procedure of critical welds, SR charts, Eco coil lifting protocol# etc

10) Copies of wage sheet of workmen along with duly filled up additional format specified by EIC.

Notes to Scope of Work:

a)All temporary items erected / installed / fixed for the purpose of the work are also to be dismantled (whether separately mentioned or not) under the same schedule, in which the erection / installation / fixing is mentioned, at no extra cost, unless specified other wise.

b)Opening and closing of doors is in the contractor#s scope whether mentioned separately or not.

c)The description given in the scope of work is only a broad outline of the job. Detailed and more specific instructions shall be obtained from EIC from time to time during the course of the work. The contactor shall have to perform all additional associated jobs (whose description may not neces-sarily be there in the scope of work given above) which are considered necessary for successful completion of overhaul of boiler pressure part without any additional charge.

d)In the description of scope of work of various schedules / items of scope of work, it is possible that the mention of some jobs has been made which actually become payable as per rates applicable against other schedules (For example, weld joints, steel fabrication, refractory etc). Their mention in the description of the other schedules is for the purpose of continuity of scope of work and clarity only. The contractor, at the time of quoting must understand that though such a mention is given in these other schedules, these works for the purpose of measure-ments and payments shall be treated as respective items and not as part of those other schedules, in whose description, their mention has been made. Thus the rates quoted for those other schedules shall be exclusively for works other than those for which separate item rates exist in the contract.

e)During the work, additional cleaning of first pass areas using HP Jetting machine may be got done thru some other agency by NTPC. This agency shall use the scaffolds etc made by the contractor for this work. The contractor shall keep the lighting and other power supplies in off condition inside the boiler, in the areas where the HP jet cleaning water is likely to fall, for the duration of the HP jet cleaning work. Also, work may be affected in some of the areas for the duration of the HP jet cleaning (which can be from 2 to 3 days maximum), for which there shall be no claim from the pressure parts contractor.

f)Contractor has to make all necessary arrangements for the inspection of all drain and vent bends.

g)Contractor has to supply manpower required for the assistance to KT members.

h)Clause for variation in quantity and contract price:

i)This clause supersedes all other clauses related with variation in quantity/ variation limits of contract price given else where in the contract.

ii)This being a Overhauling maintenance contract, the quantities given in SOQ are tentative.

iii)Variation may occur in the quantities of individual items, required to be executed, depending on the condition of machine. iv) The variation limits for each schedule are given in Annexure # I.

v)Therefore the variation in quantities of individual items shall not be limited to +/- 20% of the SOQ quantity. The contractor shall have to execute the work irrespective of quantity.

vi) However if due to variation in executed quantities of individual items, the executed value of contract goes beyond that of L2 contractor (based on item rates of L2 contractor during tendering and the executed quantity under this contract) i.e. L1/ L2 positions

are changing, then the contractor shall have to give a discount which will maintain his L1 position.

vii)The contractor shall not have a right to refuse the execution of quantities on the ground that this will change L1/ L2 position and shall have to execute all works as directed by EIC.

viii)Beyond +20% variation in contract price, NTPC reserves the right to call the contractor for renegotiation of discount after the completion of work in accordance with relevant provisions of GCC.

ix)Variation limits for each schedule is too large only due to fluctuating overhauling schedule of the units.

x)In case a situation arises, where, the progress of work in one part (i.e. first pass / second pass of the boiler) is such, that the EIC feels that the mobilization in that part is to be increased, then he may, at his discretion, ask the contractor who is entrusted with the jobs of the other part, to take up some of the works in the first (lagging) part as well.

y)Following Works To Be Carried Out After Light-Up:

a)Clearing of the Boiler of all debris, scrap, left # over spares, T&P, consumables etc. within 96 hours after light # up (payment for clearing of scrap against respective schedules)

b)Deploy manpower for attending to defects if any during the initial running period of 48 hours from light # up.

c)Return of NTPC material as directed. Stacking / arranging the returned items as specified.

d)Reconciling measurements and materials with EIC.

e)Servicing and return of NTPC#s T&P used during the job to make ready for next work.

f)Attend to defects due to poor workmanship / negligence / omission up to 30 days from 1st synchronization of the unit after overhaul.

g)Submit the following documents in report form within 07 days from synchronization of the unit after the overhaul / shutdown work is completed or before release of running bills:

1) Details of work executed.

2) Measurements against different schedules in compiled form.

3) Material issue details.

4) Material consumption details.

5) Material return detail.

6) Weld joint # wise report for different sections / zones/ areas of boiler along with RT report reference 7) Radiography reports along with repair details of defective joints.

8) DPT protocols.

9) Protocols of other hold points like #water wall air # charging before spool fit # up, Check of fit # up and weld procedure of critical welds, SR charts# etc

10) Copies of wage sheet of workmen along with duly filled up additional format specified by EIC.

6.0 Prospective bidders from U.P. State are compulsorily required to provide TIN number at the time of purchase of bidding documents.

7.0Qualifying Requirements for Bidders:

7.1A complete set of Bidding Documents may be downloaded by any interested Bidder on payment (non-refundable) of the cost of the documents as mentioned above in the form of a crossed account Payee demand draft in favour of NTPC Ltd., Payable at Korba or directly through the payment gateway at our SRM Site.

7.2Bidder may request for any clarification to the bidding documents prior to the specified last date for clarification. Bidders shall be required to furnish a No Deviation Certificate (as per format enclosed) confirming full compliance to the terms, conditions and Technical Specifications of Bidding Documents and Amendment(s)/Clarification(s) (if any) in a separate sealed envelope, failing which bids shall be rejected and returned to the bidder without being opened.

7.3All bids shall be accompanied by a Bid Guarantee (EMD) as mentioned above. Bids not accompanied by the requisite guarantee in a separate sealed cover or bids accompanied by bid guarantee of inadequate value shall not be entertained and in such cases bids shall be returned to the bidders without being opened.

7.4QUALIFYING REQUIREMENTS FOR BIDDERS:

P.F. compliance is compulsory for above package. Bidder should submit documentary evidence of having registered and having independent Provident Fund Code Number of their establishment with the Regional Provident Fund Commissioner.

7.4.1 QUALIFYING REQUIREMENTS [QR]:

i. The bidder should be manufacturer of boilers of 200 MW or above capacity. OR

The bidder should have successfully executed work (s) of Overhauling/ Modification/ Erection of Boiler pressure parts in at least two (02) units of 200 MW or above capacity

Deviation Certificate (as per format enclosed) confirming full compliance to the terms, conditions and Technical Specifications of Bidding Documents and Amendment(s)/Clarification(s) (if any) in a separate sealed envelope, failing which bids shall be rejected and returned to the bidder without being opened.

(b)ENVELOPE NO. 2: (To be submitted off line only) (i) SHOULD CONTAIN THE EARNEST MONEY DEPOSIT AS PER OUR ADDITIONAL CONDITIONS OF EMD ENCLOSED.

(ii)LETTER OF UNDERTAKING ON NON-JUDICIAL STAMP PAPER WORTH Rs.50/- PURCHASED IN THE PARTY#S NAME AS PER ENCLOSED FORMAT OF NTPC.

(iii)SHOULD CONTAIN AN UNDERTAKING THAT YOU WILL COMPLY ESI RULES AND FURNISH ESI CODE/SUB CODE FROM RAIPUR IN THE EVENT OF BECOMING L1 BEFORE AWARD OF CONTRACT.

(iv) QUALIFYING REQUIREMENT DATA DETAILS I & II.

(v)ALL TECHNICAL CREDENTIALS AND ALL OTHER DOCUMENTS ISSUED WITH THIS TENDER. ALL THE DOCUMENTS TO FULFILL NIT QR ALONGWITH LIST (SEE NIT DETAILS).

(c)* PRICE BID : (To be submitted on line only)

BIDDER SHALL HAVE TO SUBMIT PRICE BID AT NTPC SRM E-TENDER SITE (ON LINE) ONLY. HOWEVER PRICE BID OF ONLY SUCCESSFUL BIDDER (W.R.T. QR AND TECHNICALLY) SHALL BE OPENED ON LATER DATE WITH PRIOR INTIMATION.

(d) The credentials of the parties shall be examined by NTPC with reference to QR & the price bid of only successful bidders i.e. who fulfill QR criteria and submits EMD, LOU, ESI undertaking and Qualifying Requirement Data details I & II. All Technical Credentials and all other Documents issued with this Tender shall be opened on later date with prior intimation.

7.8Submission of Bids under joint venture route are not permitted for this tender.

7.9NTPC reserves the right to assess independently the capacity and capabilities of the bidders to carryout the work.

7.10NTPC reserve the right to accept or reject late/delayed tenders and also to reject any or all tenders without assigning any reason thereof.

7.11A complete set of Bidding Documents may be downloaded by any interested Bidder on payment (non-refundable) of the cost of the documents as mentioned above in the form of a crossed account Payee demand draft in favour of NTPC Ltd., Payable at Korba or directly through the payment gateway at our SRM Site (https://etender.ntpclakshya.co.in/sap/bc/gui/sap/its/bbpstart). For logging on to the SRM Site, the bidder would require vendor code and SRM user id and password which can be obtained by submitting a questionnaire vendor code are required to approach NTPC at least seven working days prior to Document Sale Close date alongwith duly filled in questionnaire for issue of vendor code and SRM user id/password.

7.12Issuance of bid documents to any bidder shall not construe that such bidder is considered to be qualified. Bids Envelope 1 & 2 shall be submitted in tender box placed and opened at bid opening room at the address given below in the presence of bidder#s representatives who choose to attend the bid opening#.

8.0Issuance of Bidding Documents to any bidder shall not construe that bidder is considered qualified.

9.0 NTPC reserves the right to reject any or all bids or cancel/withdraw the NIT for the subject package without assigning any reason whatsoever and in such case no bidder/intending bidder shall have any claim arising out of such action.

10.0Address for Communication

AGM(CS), CONTRACT SERVICES, NTPC-KORBA, 2ND FLOOR, VIKAS BHAWAN,

PO-VIKASH BHAWAN (JAMNIPALI), DISTT. KORBA, CG-495450 Fax. 07759- 237199, Phone # 07759-237036

Email: bcsahoo02@ntpc.co.in

A. ANY BIDDER WHO IS HAVING VENDOR CODE IN SAP BUT NOT IN SRM, THEY SHOULD CONTACT WITH FOLLOWING DETAILS IMMEDIATELY IN ABOVE ADDRESS JUST AFTER PUBLICATION OF NIT.

1.VENDOR CODE

2.CONTACT PERSON NAME

3.CONTACT PERSONE DEGIGNATION IN FIRM

4.CONTACT NO. i.e. MOBIL NO., FAX NO. etc.

5.EMAIL ID

B. ANY BIDDER WHO IS NOT HAVING VENDOR CODE IN SAP (ALSO IN SRM) SHOULD CONTACT IMMEDIATELY IN ABOVE ADDRESS JUST AFTER PUBLICATION OF NIT. THEY HAVE TO SUBMIT COPY OF PAN CARD, CANCELLED CHEQUE, ADDRESS PROOF, EFT FORM AND DETAILS AS IN SR. NO. 2 TO 5 OF A AS ABOVE.

Websites: https://etender.ntpclakshya.co.in/sap/bc/gui/sap/its/bbpstart or www.ntpctender.com or www.ntpc.co.in