Repair / maintenance of DG Set and other allied works at Site C, MES Complex, Milan Nagar, 3 AFSR area under GE (AF) Borjhar

Amount

a) Changing of engine oil and filter cartridges by adopting following processes :- Note:- Engine oil & filter cartidges will be measured and paid separately • Warm up engine and stop. • Drain engine oil. • Remove engine oil filter cartridges and clean lube oil centrifuge. • Remove sump bottom cover and clean engine oil suction strainer. • Replace screw plugs with new seals. • Fill the recommended new engine oil to ‘H’ mark on dipstick. • Clean seal seat and oil seat of new filter cartridge slightly. • Fill the new filter element with fresh oil up to full and tighten it to filter head quickly. • Screw filter cartridge until seal contacts and then tighten manually (do not use tools). • Crank the engine without starting until engine oil pressure is indicated while the manual stopping device is to be maintained in stop position.

b) Checking of V-belt, drive and tightness of nuts & bolts by following processes :-. Note:- If V-Belt replacement is reqd, the same will be measured and paid separately • V-belt tension can be checked by pressing with thumb, it shall be 1-2 cm. If it is not correct, readjustment shall be done. • Crank the engine for checking the V-belt all over for any sign of crack/wear. • Check tightness of all nuts and bolts. c) Greasing of water pump nipples by means of grease gun. d) Greasing of dynamo/ alternator (auxiliary) (as applicable) both ends ball bearings of the rotor. e) Check air and water hose piping, if any crack / leakage noticed; replace it immediately. f) Checking of coupling disc of fuel pump drive. g)Checking all external fasteners, especially those of manifolds, bends, turbocharger, engine mounting and rubber hoses etc. and detecting & rectifying leaks, if any. h) Cleaning of fuel tank thoroughly with diesel, removing sludges if any. (Do not use water for cleaning) j) Cleaning radiator externally by blowing pressurised air in the reverse direction of the flow of radiator fan, if it is more dirty taking the same in to the workshop. (Cleaning radiator in the outside workshop will be measured and paid separately) k) Checking the nozzle spray of FIP on nozzle tester, replacing the nozzle sealing washer and refit the nozzle and connect high pressure pipe.

l) Replacing of fuel filter cartridges by adopting following processes :- Note:- Filter cartidges will be measured and paid separately • Close fuel cock. • Unscrew centre bolt and remove cover. • Renew fuel filter elements. • Clean sealing surface on cover and housing with lint free cloth. • Provide new sealing rings under cover and centre bolt and tighten cover with centre bolt. m) Maintenance the battery of DG Set by following processes:- • Clean and check the battery connections. • Check the electrolyte level and topup with distilled water if required. • Check the Specific Gravity of the electrolyte. If it is less than 1210gm/l, recharge the battery. n) Check air and water hose piping for any crack / leakage. Replace if required. o) Replacing of Air filter elements by adopting following processes :- Note:- Filter elements will be measured and paid separately • Unscrew bolt and remove cover. • Renew Air Cleaner elements. • Clean sealing surface on cover and housing with lint free cloth. • Provide new sealing rings under cover and bolt and tighten cover with bolt.

p) Inspecting electrical unit i.e. starter, dynamo/ alternator, regulator etc, replacing worn out, defective parts and carbon brushes, pinion & Lubricating the same as reqd. q) Relay card, ECD card, CT, SPD, meters, battery chargers, fuse with base, control cable with wiring and other acessories if reqd during maintenance of AMF panel are deemed to be included in the rate of preventive maintenance of AMF panel

(a) DG Set of capacity 10 to 30 KVA with standard panel i) Location- 3 AFSR Sewage Installation, Make- KOEL, 10 KVA ii) Location- Kahikuchi Sewage Installation, Make- KOEL, 10 KVA

(b) DG Set of capacity 35 to 62.5/ 63.0 KVA with standard panel i) Location- MT Complex, Make- KOEL, 35 KVA

(c) DG Set of capacity 70 to 125 KVA with standard panel i) Location- MES Complex, Make- KOEL, 82.5 KVA

(d) DG Set of capacity 10 to 30 KVA with AMF panel i) Location- ASC, Make- KOEL, 30- KVA i) Location- 5 AFSB, Make- KOEL, 30 KVA iii) Location- 5AFSB (Temp) Make KOEL, 30 KVA

(e) DG Set of capacity 35 to 62.5 KVA with AMF panel i) Location- Pump House (Kahikuchi Area), Make- KOEL, 45 KVA

. Supply only following consumables for routine maintenance of 10 to 15 KVA DG Set

a) Lube Oil Filter & Fuel Filter Set

b) Air Cleaner Element Set

c) Fan Belt for radiator

d) Fan Belt for dynamo/ alternator (auxiliary)

e) Head Gasket Set

Supply only following consumables for routine maintenance of 30 KVA DG Set

a) Lube Oil Filter & Fuel Filter Set

b) Air Cleaner Element Set

c) Fan Belt for radiator

d) Fan Belt for dynamo/ alternator (auxiliary)

e) Head Gasket Set

Supply only following consumables for routine maintenance of 35 to 45 KVA DG Set

a) Lube Oil Filter & Fuel Filter Set

b) Air Cleaner Element Set

c) Fan Belt for radiator

d) Fan Belt for battery charger

e) Head Gasket Set

Supply only following consumables for routine maintenance of 82.5 KVA DG Set

a) Lube Oil Filter & Fuel Filter Set

b) Air Cleaner Element Set

c) Fan Belt for radiator

d) Fan Belt for dynamo/ alternator (auxiliary)

e) Head Gasket Set

S&F Starter Motor 12 V for 10 - 30 KVA Kirloskar/ Mahindra/ Cummins make Gen Set incl replacement of cable of suitable size complete all as specified and directed.

S&F Starter Motor 12 V for 35 - 63 KVA Kirloskar/ Mahindra/ Cummins make Gen Set incl replacement of cable of suitable size complete all as specified and directed.

S&F Starter Motor 12 V for 82.5 - 125 KVA Kirloskar/ Mahindra/ Greaves make Gen Set incl replacement of cable of suitable size complete all as specified and directed.

M&L for repair to 12 V starter motor for 10 to 30KVA DG Set by adopting following process: a) Disconnect the battery cable & stripping the starter motor b) Repair/ maintenance of armature & field coils as required c) Replace the carbon brushes & bushes of starter motor d) Replace the pinion if required e) Replace the solenoid if required f) Assembling, connection, testing & checking etc complete

M&L for repair to 12 V starter motor for 35 to 62.5/ 63 KVA DG Set by adopting following process: a) Disconnect the battery cable & stripping the starter motor b) Repair/ maintenance of armature & field coils as required c) Replace the carbon brushes & bushes of starter motor d) Replace the pinion if required e) Replace the solenoid if required f) Assembling, connection, testing & checking etc complete

M&L for dismantling the radiator assembly incl hose/ pipe/ clamps etc after shut off the diesel genrator set of 10 to 30 KVA capacity and taking out the same at workshop and cleaning/ servicing the same by following process:- a) Spray the hot water or steam to remove dirt, dust, or even insects which are accumulated in the radiator. b) Descaling the radiator by using rust removing acid solution and water or mixture of water, caustic soda, and kerosene as per the recommendation of the manufacturer of the generator set c) Transportation to the installation, reconnection, testing & checking etc complete Note:- Minor repairing such as brazing or soldering, replacement of hoses, pipe, clamps etc are deemed tobe included in the coated rate.

M&L for dismantling the radiator assembly incl hose/ pipe/ clamps etc after shut off the diesel genrator set of 35 to 62.5/ 63 KVA capacity and taking out the same at workshop and cleaning/ servicing the same by following process:- a) Spray the hot water or steam to remove dirt, dust, or even insects which are accumulated in the radiator. b) Descaling the radiator by using rust removing acid solution and water or mixture of water, caustic soda, and kerosene as per the recommendation of the manufacturer of the generator set c) Transportation to the installation, reconnection, testing & checking etc complete Note:- Minor repairing such as brazing or soldering, replacement of hoses, pipe, clamps etc are deemed tobe included in the coated rate.

M&L for dismantling the radiator assembly incl hose/ pipe/ clamps etc after shut off the diesel genrator set of 82.5 KVA to 125 KVA capacity and taking out the same at workshop and cleaning/ servicing the same by following process:- a) Spray the hot water or steam to remove dirt, dust, or even insects which are accumulated in the radiator. b) Descaling the radiator by using rust removing acid solution and water or mixture of water, caustic soda, and kerosene as per the recommendation of the manufacturer of the generator set c) Transportation to the installation, reconnection, testing & checking etc complete Note:- Minor repairing such as brazing or soldering, replacement of hoses, pipe, clamps etc are deemed tobe included in the coated rate.

M&L for dismantling the radiator assembly incl hoses/ clamps etc after shut off the diesel genrator set of 100 KVA capacity and fixing new radiator assembly with new hoses & hose clips etc complete all as specified & directed. DG Set Make- KOEL/ Kirloskar Bliss/ Greaves Cotton

M&L for dismantling the radiator assembly incl hoses/ clamps etc after shut off the diesel genrator set of 100 KVA capacity and fixing new radiator assembly with new hoses & hose clips etc complete all as specified & directed. DG Set Make - KOEL/ Kirloskar Bliss/ Greaves Cotton

M&L for repair to battery charging alternator for 10 to 30 KVA DG Set by adopting following process: a) Disconnect the cable & stripping the alternator b) Clean the rotor ring with a soft cloth and degreasing agent. If there are visible traces of burning on the surface due to sparking, the surface of the rings should be sanded with fine sandpaper that does not leave deep scratches. c) Replace the carbon brushes of alternator d) Replace the rotor bearing if required e) Clean the stator winding with a soft cloth and degreasing agent. f) Replace the rectifier assembly if required g) Assembling, connection, testing & checking etc complete

M&L for repair to battery charging alternator for 35 to 62.5/ 63 KVA DG Set by adopting following process: a) Disconnect the cable & stripping the alternator b) Clean the rotor ring with a soft cloth and degreasing agent. If there are visible traces of burning on the surface due to sparking, the surface of the rings should be sanded with fine sandpaper that does not leave deep scratches. c) Replace the carbon brushes of alternator d) Replace the rotor bearing if required e) Clean the stator winding with a soft cloth and degreasing agent. f) Replace the rectifier assembly if required g) Assembling, connection, testing & checking etc complete

Supply only engine oil 20W 40 for diesel engine driven generator in 50 ltrs container . Make - KOEL (Type- Premium)/ Eqvt to Castrol/ Indian Oil

Supply only coolant for diesel engine driven generator in 26 ltrs container . Make - KOEL (Type- K-Cool)/ Eqvt.

Supply only distilled water for battery of diesel engine driven generator set.

Supply & replacement of water pump for 10 to 45 KVA DG Set incl taking down old unsv one. Make of DG Set- KOEL/ Greaves Cotton/ Mahindra/ Cummins

Supply & replacement of water pump for 62.5/ 63 to 100/ 125 KVA DG Set incl taking down old unsv one. Make of DG Set- KOEL/ Greaves Cotton/ Mahindra/ Cummins

M&L for repairing of FIP for 10 to 45 KVA DG Set through FIP repair kit, incl replacement of valve and element (where ever reqd) and calibration all as specified and directed. Make of DG Set- KOEL/ Greaves Cotton/ Mahindra/ Cummins

M&L for repairing of FIP for 62.5/ 63 to 100/ 125 KVA DG Set through FIP repair kit, incl replacement of valve and element (where ever reqd) and calibration all as specified and directed. Make of DG Set- KOEL/ Greaves Cotton/ Mahindra/ Cummins

M&L for fixing of stop solenoid switch for 10 to 45 KVA DG Set as per existing make & type incl taking down old unsv one all as specified and directed.

M&L for fixing of stop solenoid switch for 62.5/ 63 to 125 KVA DG Set as per existing make & type incl taking down old unsv one all as specified and directed.

M&L for replacement of old unsv fuel pipe with new fuel pipe ( main & over flow ) through pipe clamp etc complete all as specified & directed.

Supply and installation with modification (as reqd) for Indicators of AMF panel complete all as specified & directed. Make-Siemens/ L&T/ Eqvt

Supply and installation with modification (as reqd) for push button of AMF panel complete all as specified & directed. Make-Siemens/ L&T/ Eqvt

S&F On-Load Manual Change Over Switch (in sheet steel enclosure) 63 Amps 415 Volts, 4 pole after disconnecting all electrical connection incl. taking down old unsv one complete all as specified and directed. Make - L&T/ Siemens/ABB

S&F power contactor 50 Amps 415 Volts, conforms to IS / IEC 60947-4-1 with spreader links after disconnecting all electrical connection incl. taking down old unsv one complete all as specified and directed. Make - L&T/ Siemens/ABB

M&L for taking down old unsv LT AMF Panel for 82.5 KVA DG Set after disconnecting all electrical connection complete.

Supply, install, testing, commissioning of LT AMF Panel for 82.5 KVA DG Set , IP-54 type (manufactured from Greaves Cotton or KOEL authorised manufacturer, necessary documents must be submitted prior approval of drawing from accepting officer) out door type made out of 2 mm thick CRCA sheet supported and fixed on structural frame, factory made duly fixed on the ground by PCC foundation (1:2:4 Type B-1) all as specified and directed. The panel box should have enamelled danger notice plate of 1.6 mm thick, duly painted with two coats of enamel paint over a coat of red oxide primer (internally & externally) on the surface all as specified and directed by Engr-in-Charge. The feeder pillar box is cubicle shaped, roof canopy type, with special type of heavy duty stainless steel door hinges and totally enclosed dust proof and vermin proof front and back opening with locking arrangements incl necessary control circuit connection and necessary cable connection by lugs and glands incl provision to accommodate battery separately and the following electrical items :-

(a) Microprocessor based Control and annunciator Unit or Genset Controller Unit for auto or manual starting of diesel generating set & to enemerate alarm to protect the generator against out of range voltage, out of range frequency, over load, low oil pressure, high temperature, low battery voltage incl necessary control circuit connection / probe connection from DG Set to control panel. 01 No Make - Deep Sea/ KOEL

(j) Hooter - 01 No (k) Battery Chargers Unit - 01 No (l) Remote Monitoring Unit - 01 No (m) Fuses with Fuse base (As required) (n) Control/ Power Cables - FRLS Type, Copper, 1100 V ( sizes as per requirement but not less than 2.5 sqmm) (As required) (o) MCB SP (DC) (As required) - L&T/ Havells/ Eqvt (p) Moulded case circuit breaker 125 Amps 415 Volts (Vertically Placed), 25 KA, 4 pole Make-Legrand/ Havells/ L&T/ Eqvt - 02 Nos

(q) Power Contactor 3 phase 125 A, 415 V, 4P Make-ABB/ Schneider/ L&T/ Eqvt - 02 Nos Note :- (i) Contractors should check the DG Set before submission of bid, any other spares for both engine and alternator side required for functioning of DG AMF panel are deemed to be included in the quoted rate. (ii) Any other accessories such as connectors, printed ferrules, slives, gromet, neoprene gasket, PVC channel, DIN rail etc which are not mentioned above are deemed to be included in this rate. (iii) Manufacturer should submit drawing of panel, power/ control circuit diagram in laminated paper in duplicate after necessary approval of the same from competent authority before procurement action from manufacturer.

Supply, fixing of expansion bellow pump for 10 to 45 KVA DG Set incl taking down old unsv one. Make of DG Set- KOEL/ Cummins

Supply, fixing of turbo charger for 10 to 45 KVA DG Set incl taking down old unsv one. Make of DG Set- KOEL/ Cummins

Supply, fixing of turbo charger for 62.5/ 63 to 125 KVA DG Set incl taking down old unsv one. Make of DG Set- KOEL/ Cummins/ Greaves Cotton

Supply and fixing of rectifier assembly set for 10 to 45 KVA DG Set incl taking down old unsv one. Make of DG Set- KOEL/ Cummins

Supply and fixing of AVR assembly set for 10 to 82.5 KVA DG Set incl taking down old unsv one. Make of DG Set- KOEL/ Cummins/ Greaves Cotton

KUNDAN ENGINEERS AND BUILDERS