Objectives

The primary objective of this tender is to appoint a qualified supplier capable of providing reliable, comprehensive, and cost-effective metal spraying services for Eskom Rotek Industries. The services aim to refurbish and protect turbine components such as gland box casings and rotor shafts by applying high-quality metal coatings, ensuring adherence to specified standards and tolerances.

Scope

The scope includes:

• Provision of metal spraying services for components with inside and outside diameters up to +700mm and lengths ranging from 150mm to 4m.
• Application of metal coatings up to +2mm thickness with a final surface finish of N6 (0.8 μm Ra).
• Execution of work both insitu (on-site) and at the contractor’s workshop facilities.
• Preparation, inspection, and certification of components before and after spraying, including NDT and bond testing.
• Adherence to detailed scopes of work, drawings, and approved inspection reports supplied by Eskom engineering.
• Refurbishment of components such as sleeves, piston blocks, and turbine parts as specified.

Technical Requirements

The technical requirements encompass:

• Use of thermal spraying techniques (Flame, Arc, HVOF, Plasma) conforming to relevant standards.
• Compliance with standards including EN 657, EN ISO 14923, EN 14616, EN 15311, EN 4665, EN ISO 17836, EN 1395 series, and ASTM/AWS guidelines.
• Facilities capable of handling components with diameters up to +700mm and lengths up to 4m.
• Application of coatings with specified thickness and surface finish, ensuring minimal distortion and tight dimensional tolerances (±0.01mm).
• Certification requirements including ISO 9001 certification.
• Qualified personnel with appropriate certifications for metal spraying and NDT procedures.
• Preparation of detailed Quality Control Plans (QCP) and inspection reports prior to work commencement.

Skills Requirements

The contractor must demonstrate:

• Qualified and certified personnel in metal spraying techniques and associated inspection methods.
• Capability to perform non-destructive testing (NDT) and bond testing on finished components.
• Experience in handling large and complex turbine components, with facilities suitable for both onsite and workshop operations.
• Ability to produce certified material and process documentation, including material certificates and inspection reports.
• Competence in adhering to international standards and client-specific specifications for thermal spray applications.