REPAIR AND MAINTENANCE OF DG SETS AND AMF PANELS UNDER

Amount

M & L for Inspection and carrying out B-Checks of 500 KVA DG Set Once in Six months or 300 Hours of Run whichever is earlier installed at various locations by representative / authorised Service Engineer of OEM of the DG Set including inspection, maintenance, changing all types of filters and servicing of DG Set including Alternator, Non AMF / AMF Panels connected to DG Sets for routine check-up including routine / preventive maintenance checks, checking up of engine and alternator for the smooth functioning as per the Manufacturer’s instructions including checking of Engine Oil Level, Oil Bath Cleaner Oil Level, Draining Sediments from Fuel Tank, checking of Pre Cleaner Dust Pan, Air Cleaner Restriction, Coolant Level, Recording Oil Pressure, Checking / Tightening of all Bolts / Nuts of Engine and Alternator, checking of AVM Pads, Diaphragm Coupling, Air Piping, cleaning of Oil Bath Air Cleaner Tray Screen, check / adjust Belts, checking Battery Voltage, Water Level and apply Jelly on Terminals, checking Fan Hub / Air Blower Hub and Water Pumps, cleaning of electrical connections with CTC solution, checking of safety controls, cleaning of Cooling System, cleaning of Engine and Radiator Assembly, including cleaning of Air Filter using Pressure Air, Corrosion Inhibitor, O Ring, Gaskets, Screws etc. and draining out old engine oil from oil chamber and removing deposited material including applying Grease, CRC in moving parts and draining out water from radiator assembly and refilling new after mixing with coolant including tightening of all inlet and outlet connections and replacing minor items such as Hose Clamp, Screws, Washers etc., cleaning of Roof, Floor of the DG Set Room complete all as specified and as directed.

Item No. 1 Continued....... Note: The B Check includes carrying out preventive maintenance including replacing minor unserviceable / worn out spares to keep the DG set for trouble free functioning. The rate quoted is deemed to be including all the minor spares such as screws, clips,washers, distilled water, electrolyte, etc. All other spares , engine oil will be measured and paid seperately as supply only under relevant items of this schedule, Contractor has to attend the break down at any time and place during the contract period. General maintenance is indicative only contractor has to carryout other necessary maintenance task also as required and directed

All as per item no. 1 here in before but DG set of capacity 250KVA

All as per item no. 1 here in before but DG set of capacity 200KVA

All as per item no. 1 here in before but DG set of capacity 160 KVA

All as per item no. 1 here in before but DG set of capacity 100 KVA

All as per item no. 1 here in before but DG set of capacity 82.5 KVA

All as per item no. 1 here in before but DG set of capacity 62.5 KVA

All as per item no. 1 here in before but DG set of capacity 50KVA

All as per item no. 1 here in before but DG set of capacity 30KVA/40KVA

All as per item no. 1 here in before but DG set of capacity 15KVA

All as per item no. 1 here in before but for diesel engine coupled to fire fighting pump of capacity 43 HP / 10 HP

Supply of oil filter for the DG set of capacity 500 KVA

Supply of oil filter for the DG set of capacity 250 KVA

Supply of oil filter for the DG set of capacity 200 KVA

Supply of oil filter for the DG set of capacity 160 KVA

Supply of oil filter for the DG set of capacity 100 KVA

Supply of oil filter for the DG set of capacity 82.5 KVA

Supply of oil filter for the DG set of capacity 62.5 KVA

Supply of oil filter for the DG set of capacity 50 KVA

Supply of oil filter for the DG set of capacity 30 /40 KVA

Supply of oil filter for the DG set of capacity 15 KVA

Supply of oil filter for engine coupled to fire fighting pump of capacity 43 HP / 10 HP

Supply of fuel filter for the DG set of capacity 500 KVA

Supply of fuel filter for the DG set of capacity 250 KVA

Supply of fuel filter for the DG set of capacity 200 KVA

Supply of fuel filter for the DG set of capacity 160 KVA

Supply of fuel filter for the DG set of capacity 100 KVA

Supply of fuel filter for the DG set of capacity 82.5 KVA

Supply of fuel filter for the DG set of capacity 62.5 KVA

Supply of fuel filter for the DG set of capacity 50 KVA

Supply of fuel filter for the DG set of capacity 30 / 40 KVA

Supply of fuel filter for the DG set of capacity 15 KVA

Supply of fuel filter for engine coupled to fire fighting pump of capacity 43 HP / 10 HP

Supply of coolant filter for 500 KVA DG set installed at main power house

Supply of coolant filter for 200/160 KVA DG set installed at Likabali Auditorium/MAP

Supply of coolant filter for 250 KVA DG set installed at TA Batallion

Supply of by pass filter for 500 KVA DG set installed at main power house

Supply of by pass filter for 200/160 KVA DG set installed at Likabali Auditorium/MAP

Supply of by pass filter for 250 KVA DG set installed at TA Batalian

Supply only Fuel Water Separator Filter suitable for 250 KVA DG set installed at TA Battalion complete all as specified and as directed.

M & L for repair and reconditioning of battery charge alternator cummins make including taking out the defective alternator from 15 -100 KVA capacity DG set , complete dismantling and repair and replacing the carbon brushes, rectifier diode set, bearing and bush, regulator control, refixing the same in the DG set and connecting with the circuit including all required items, starting and testing all as specified and directed

M & L for repair and reconditioning of battery charge alternator cummins make including taking out the defective alternator from 82.5 - 500 KVA capacity DG set , complete dismantling and repair and replacing the carbon brushes, rectifier diode set, bearing and bush, regulator control, refixing the same in the DG set and connecting with the circuit including all required items, starting and testing all as specified and directed

S & Fixing in repair and rewinding the excitor stator assembly of 500 KVA by takingout complete burnt coils, cleaning and rewinding the same by supper enamel copper wire SWG 18, insulalting the coils with nomex paper, milinex sheet, heating and varnshing by varnish materials and applying one coat of bectol anti rust protection, fixing back in to the alternator, connecting the cables, starting and testing all as specified and directed

Supply only coolant for radiator suitable for DG set 15-500 KVA Make- Cummins/ Kirloskar/ Ashok Leyland green,all as per manufacturers recommendations

M & L for supply and fixing engine fuel hose assly along connector for 500 KVA DG set by taking out the detoriated hoses from engine, replacing and connecting starting and testing all as directed

Supply and fixing engine Lube oil hose assly along adaptor for 500 KVA DG set by taking out the detoriated hoses from engine, replacing and connecting starting and testing all as directed

Supply and fixing in replacement of fan belt set in 200 KVA DG set cummins part no. 178611 all as specified and directed

Supply and fixing in replacment of belt for water pump in 200 KVA DG set cummins part no.200328 all as specified and directed

Supply and fixing of fan belt in 500 KVA DG set cummins part no.3001660 all as specified and directed

Supply and fixing of belt for battery charging dynamo in 500 KVA DG set cummins all as specified and directed

Supply and fixing of fan belt in 30/ 50 / 62.5/ 100 KVA DG set all as specified and directed

Supply and fixing in repairs High water temperature trip safety control part no. 3408624 make Cummins in DG set and connecting with DG set system of 500 KVA/200 KVA all as specifiied and directed

S & Fixing in repairs Low lub oil pressure safety control part no. (3408607) 3408614 make Cummins in DG set and connecting with DG set system of 500 KVA/200 KVA all as directed.

Supply and fixing fuel oil pressure sensor Cummins make 500 KVA DG set all as directed.

Supply and fixing and testing DG set stop solenoid switch in 100 / 30 KVA by taking out the defective switch from the DG set, replacing by new and aligning, connecting with circuit, starting and testing all specified and directed

Supply and fixing in repair coil electrical in STC control valve under make Cummins part no.4963341 in 500 KVA DG set as specified and directed.

Supply and fixing in repair shutdown valve under make Cummins part no. 3239599 in 500 / 200 KVA DG set as specified and directed.

Supply and fixing in repairs magnetic pick up part No. 3875360 make Cummins suitable for 500 / 200 KVA DG set by taking out the defective unit from engine , replacing the same and adjusting the gap setting. Connecting in the circuit all as specified as directed.

Supply and fixing low coolant water level sensor Cummins make 500 KVA DG set all as directed.

Supply and fixing in repairs battery charger 230 V AC input and output 12 V DC 10 amps charging rating with fully auto control in charging and floating with boost system all as specified and directed.

Supply and fixing in repairs battery charger 230 V AC input and output 24 V DC 10 amps charging rating with fully auto control in charging and floating with boost system all as specified and directed.

Supply and lay 3 core 1.5 Sqmm PVC insulated and FR PVC Round Sheathed, Copper Conductor (flexible) industrial cable, 1100 Volts, conforming to IS: 694 including taking down old cable complete all as directed and as specified.

S & fix in repair Rigid non-metallic PVC conduit of dia 20mm exclusive of boxes (junction/ terminal) but inclusive of all tees, bends,elbows, reducers, bell mouth tube ends and fixing accessories such as couplers, lock nuts, saddles, pipe hooks etc. all as directed and as specified

M & L for taking out old electrical contactor, supply and fixing electrical contactor of main supply contactor in 50KVA/40KVA/30 KVA AMF DG set all as specified and directed

Supply and fixing 4 Pole contactor 415 V AC, Amps rating 200, 415/240 V coil supply voltage all as specified and as directed

Supply and fixing spare coil 415V/240 V AC suitable for contactor 415 V AC,Model MCX 33, Make: L&T/C&S

Supply and fixing of Air filter of 100 KVA / 82.5 / 62.5 KVA / 50 KVA DG set cummins part no. all as specified and directed.

Supply and fixing of Air filter of 500 KVA DG set cummins part no.4020551 all as specified and directed.

M & L for repair and reconditioning the starting motor 12 V DC system including taking out the defective starter from 15-100 KVA capacity DG set , complete dismantling and repair and replacing the carbon brushes with holder, solenoid switch assly, bushes, commutator unit, starting coil, etc refixing the same in the DG set and connecting with the circuit including all required items, starting and testing all as specified and directed

M & L for repair and reconditioning the starting motor 24 V DC system of kirloskar make including taking out the defective starter from 500 KVA / 250/ 200 KVA capacity DG set , complete dismantling and repair and replacing the carbon brushes with holder, bushes, starting coil, etc refixing the same in the DG set and connecting with the circuit including all required items, starting and testing all as specified and directed.

Supply and fixing of AMF Logic controller (Microprocessor based type) by taking out the defective unit from 200KVA/ 62.5 KVA /50KVA/ 30 KVA capacity DG set complete checking the panel and its connection circuit in the panel board, providing prper interlink connection with DG set including all required items, starting and testing all as specified and directed. Make: C & S / L&T/Cummins

Supply, installation and commissioning of AVR in 30 KVA/ 50 KVA / 100 KVA / 200 KVA DG set by taking out the defective AVR from DG set alternator from its control circuit, fixing the new AVR and connecting in the circuit, thorough checking and testing the DG set on load all as directed. make Kirloskar / Altex

Cleaning/descaling of radiator /CAC core of 500 KVA DG Set externally by applying cleaning agents as per manufacturer's recommendation, pressurised water and removing carbons, oil wet dirts, etc all as directed.

Supply and fix PCC 3300 genset control assembly with Cummins part No 0327-1601-1 suitable for 500 KVA DG set including taking down old PCB from the control panel all as directed

Supply and fix in repair Human Machine interface for PCC 3300 comprising of intuitive operator interface panel that allows for complete genset control as well as system metering, fault annunciation, configuration and diagnostics. The interface shall ihave following features:- (a) LED indicating lamps:- genset running, remote start, not in auto, shutdown, warning, auto, manual and stop, Circuit breaker open, Circuit breaker closed. (b) 320 x 240 pixels graphic LED backlight LCD (c) Four tactile feel membrane switches for LCD defined operation. (d) Seven tactile feel membrane switches dedicated screen navigation buttons for up, down, left, right, ok, home and cancel (e) Six tactile feel membrane switches dedicated to control for auto, stop, manual, manual start, fault reset and lamp test/panel lamps (f) Two tactile feel membrane switches dedicated to control of circuit breaker (g) Communications shall include PC tool interface with RS-485 communication port to allow the HMI to communicate with a personal computer running InPower and the HMI to communicate with the main control board Make: Cummins Power Command HMI 320 or equivalent

Supply and fix in repair compact multifuntion microprocessor based synchronising controller cum load manager and protection package suitable for managing load sharing and parallel operation of 500 KVA DG sets. It shall have over current, over voltage, over frequency, under frequency, over load, unbalanced current/ voltage, loss of excitation, over excitation, reverse power protection. Make: Wood ward model no Easy Gen relay 2000 series / DE IF model no AGC 200

Material and labour for replacing Control Cables XLPE Insulated, PVC tape innersheathed with Solid Copper conductor of size 2.5 sq.mm x 6 core including necessary clamps if fixed on wall all as specified as directed.

Taking out ACB breaker for repair and servicing by disconnecting and dismantling the ACB breaker rating 2000 Amps / 1000 Amps make L&T by carrying out repair/ servicing , checking and renewing the defective shunt trip coil & UV trip 230 V AC , checking and rectifying the defective CTs and rectifying the mechanism operation including spring charge system, reinstalling the same in the panel and providing necessary line and connections all as directed

Supply only shunt release coil 240 V AC all as per sample and as specified

Supply only Closing coil 240 V AC all as per sample and as specified

Supply only undervoltage coil 240 V AC all as per sample and as specified

Supply only spring charging motor suitable for fixing in ACB of make L&T C Series operated in 240 V AC supply all as specified

Supply only microprocessor based protection release for ACB all as specified and as directed

Supply and fixing in repairs phase indicator lamps R, Y, B LED type

Material and labour for replacement of battery lead 1.50m long consisting of multistranded copper conductor PVC insulated single core cable of 50 Sqmm size connected with 1 No battery terminal clamp at one end and copper lug at other end all as directed.

Supply and fixing in repair and commissioning battery charging alternator, (Make Cummins Part No. 3236504) in 500 KVA DG sets all as directed .

Supply and labour for carrying out repairs in the rotating rectifier kit diode sets in 500 KVA capacity stamford alternator by taking out the defective parts from DG set, fixing new rectifier kit set in the alternator and connecting with circutis, starting and testing the DG set on load complete all as specified and directed .

Material and labour for carrying out repairs in the rotating rectifier kit diode sets in 250 / 200 / 100 KVA DG set by taking out the defective parts from DG set, fixing new rectifier kit set in the alternator and connecting with circuits, starting and testing the DG set on load complete all as specified and directed .

Inspecting the autosynchroniser panel for its proper operation and carrying out the following (a) Tracing out faults caused by defective components including relays, contactors, connectors, battery charger etc by taking down the old components and replacing with new one. (b) Checking the control wiring for any defects, tightening the connections and securing any open point with insulation tape. (c) Inspecting the synchronising controller for alarms caused by faults within the system and addressing the faults. Checking the settings of the synchorising controller for its proper functionality. Note: The components required replacement shall be measured and paid separately under relevant items of the schedule.

Supply only Emergency off push buttons with mushroom head, push-turn fuction with 1NO and 1 NC all as specified

Supply only Push button flush head type of red/green colour suitable for operation in24 VDC/ 220V AC all as specified and as directed

Supply only miniature plug in relay 24 V DC, 6 A all as specified and as specified

Supply only sockets 10 A rating for plug-in type relays with mixed contact terminal arrangement and screw connector all as directed and as specified

Supply only auxiliary contactor 16A, 4 Pole suitable for operation in 24V supply all as specified and as directed.

Material and labour for carrying out repairs in the Electronic Governor Control (EGC) in 500 KVA DG set by taking out the defective parts from DG set, fixing new controller in the engine and connecting with circuits, starting and testing the DG set on load complete all as specified and directed .

Supply and fixing in replacment of belt for water pump in 500 KVA DG set cummins all as specified and directed.

Supply, installation and commissioning of AVR module in 500 KVA DG set by taking out the defective AVR module from DG set control circuit, fixing the new AVR Module and connecting in the circuit, thorough checking and testing the DG set on load all as directed

Supply, installation and commissioning of Actuator in 500 KVA DG set by taking out the defective Actuator from enginet, fixing the new Actuator and connecting in the circuit, thorough checking and testing the DG set on load all as directed

Supply,in fixing lub oil pressure sensor in 100/ 82.5/ 62.5 / 30 KVA DG set by taking out the defective sensor from engine,, fixing the new pressure sensor and connecting all connection, thorough checking and testing the DG set on load all as directed

Supply, installation and commissioning of Radiator assly in 62.5 KVA DG set by taking out the defective radiator from engine,, fixing the new Radiator assly Module and connecting all connection, thorough checking and testing the DG set on load all as directed

Supply and fixing Anti Vibration Mounting Pad ( AVM ) in 200 KVA DG set by taking out the defective AVMs from enginet, fixing the new AVM pads and carrying out alignment, thorough checking and testing the DG set on load all as directed

M & L for taking down unserviceable starting motor from the engine 500 KVA / 200 KVA and supply and fixing starter assly under part no. 5256026 and connecting with circuit and testing complete all as directed.

Supply & fixing in PT fuel pump of 500 KVA DG set by taking out the defective defective fuel pump, renewing the worn out parts, seals, o rings, governor weight carriers, carryingout repair and calibration of PT fuel pump and fixing back in the engine and testing on load all as directed

M& L for complete scraping of existing paints from DG set of 500 /200 KVA installed at Prothrapur power house, thorough cleaning the surface from oil wet, rusted areas, applying 1 coat of metal primer and followed by two coats of synthetic enamel heat resistant paint by air compressor spray 2 coating all as specified including writing the SM / MES Nos. all as directed

M & L for taking down unserviceable starting motor from the engine 30 / 40 / 62.5 / 82.5/ 100 KVA and supply and fixing starter assly under part no. and connecting with circuit and testing complete all as directed.

Supply & fixing in solid state potentiometer under cummins part no. 3877372 in 500 KVA in prothrapur pump house and testing as specified and directed

Supply and fixing the wiring harness under Cummins Part no. 4021160 in 500 KVA DG set in Prothrapur pump house all as directed

Supply and fixing water pump under Cummins Part no.4955707 in 500 KVA DG set by taking out defective pump from engine, cleaning and checking drive gears play aand end play, fixing new pump, gaskets, O ring, connecting radiator suction pipes, hoses and clamps, starting and testing DG set all as directed

Repair and servicing of cylinder head assembly of 500 KVA DG Set by taking out the acoustic enclosure doors on both sides, removing the intake and exhaust connection pipes, disconnecting radiator fan assembly, decoupling the alternator, removing the lube oil sump, dismantling complete 1 No cylinder head, 1 No cylinder liner along with piston aasembly and connecting Rod assembly by lifting and tilting from its mounting place, thorough inspection and cleaning the inspection block, replacing the defective components of cylinder liner, piston, ringset with connecting rod assembly, fixing cylinder head and injectors and fixing back all the disconnected parts and kits and coupling the alternator back and checking alignment, adjusing engine valve and injector timing starting and testing on load. Note:- All the required spares will be measured and paid separately as supply only in subsequent items.

Supply only engine cylinder head assembly suitable for 500 KVA DG set of of existing model at power house

Supply only Injector STC Assembly suitable for 500 KVA DG set of of existing model at power house

Supply only Push rod valve suitable for 500 KVA DG set of of existing model at power house

Supply only Push rod injector suitable for 500 KVA DG set of of existing model at power house

Supply only cylinder liner with seal rings suitable for 500 KVA DG set of of existing model at power house

Supply only Piston assembly suitable for 500 KVA DG set of of existing model at power house

Supply only ring set for piston suitable for 500 KVA DG set of of existing model at power house

Supply only connecting rod suitable for 500 KVA DG set of of existing model at power house

Supply only bearing for connecting rod suitable for 500 KVA DG set of of existing model at power house

Supply only cross head suitable for 500 KVA DG set of of existing model at power house

Supply only upper engine gasket set for 500 KVA DG set of of existing model at power house

Supply only turbo charger assembly suitable for 500 KVA DG set of of existing model at power house

Supply only gasket for lube oil sump suitable for 500 KVA DG set of of existing model at power house

Supply only clamp V band suitable for 500 KVA DG set of of existing model at power house

bansal construction

A. R. ELECTRICALS