REPAIR / MAINTENANCE OF DG SETS AND CONNECTED WORKS AT AF STN ADAMPUR

Amount

Servicing & maintenance of DG sets as per manufacturer's maintenance reference to the entire satisfaction of Engineer-in-Charge, complete as per following:- (i) Draining out engine/lubrication oil, flushing and pouring new engine oil to DG set including supply and replacement of oil pan/chamber gasket (ii) Supply and fix, primary and secondary fuel filter element Make Bosh complete with gasket/rubber ring, in replacement as per existing sample. (iii) General servicing of DG set by opening of tappet cover/top cover, tappet clearance setting with injector timming adjustment, re-fixing of tappet/top cover including supply and replacement of tappet cover packing set,fixed with shellac/bostic tube. (iv) Tightening of all electrical connections, AVR connections, alternator connections and panel connections (v) Tightening of all the hoses, fuel connections. (vi) Opening of Battery terminals negative and positive,cleaning of posts negative and positive of battery with ambri paper/regmaar,applying petrolium jelly over the posts,refixing the battery terminals properly. (vii) Filling of coolant to radiator as per required level (viii) Testing of Engine on load for 30 Minutes own cost of contractor.

20 KVA to 40 KVA

63 KVA to 82.5 KVA

100 KVA to 140 KVA

160 KVA to 200 KVA

320 KVA to 400 KVA

Repair / Overhauling of DG set Removing tappet cover and cylinder heads gaskets from DG set, Grinding and polishing of cylinder heads, grinding of valve seats, grinding of inlet and exhaust valve after fixing new seals, calibration of injector, refitting cylinder head and tappets cover, changing of oil and replacement of following parts & capacity :- (i) Bearing in fan body (ii) Inlet and exhaust valve pair (iii) Valve sheet insert (iv) Inlet and exhaust valve guide (v) Cylinder liner with joint ring (vi) Gasket for head (vii) Gear oil seal (viii) Oil seal all (ix) Thermostate element (x) Hose set (xi) Lub oil Pressure gauge (xii) Flexible pipe (xiii) Starter ring (xiv) Water Pump assy (xv) radiator pipe (xvi) Fuel Pipe (xvii) Branded wrapped belt (xviii) Testing the DG sets on load

20 KVA to 40 KVA

63 KVA to 82.5 KVA

200 KVA to 400 KVA

Repairing, decarburizing manifolds exhaust system and connected items DG sets including replacement of unserviceable asbestos rope on exhaust muffler/silencer including necessary nuts, bolts & washer etc with necessary masonry work as required, complete as following capacity:-

20 KVA to 40 KVA

63 KVA to 82.5 KVA

100 KVA to 140 KVA

160 KVA to 200 KVA

320 KVA to 400 KVA

Repairing, cleaning/servicing of radiator assembly DG sets including descaling of tubes with solution, chemicals and compressed air blast including soldering/gas welding of leaking tubes including cutting welding of rusted MS tubes with new tubes, making it leak proof, & re-fixing after testing, as following capacity:-

20 KVA to 40 KVA

63 KVA to 82.5 KVA

100 KVA to 140 KVA

160 KVA to 200 KVA

320 KVA to 400 KVA

Calibration of fuel injector assembly at authorize workshop including replacement of cup, barrel and plunger injector washer etc, and re-fixing to its original position including necessary Service as required, including transportation to workshop and back as following capacity:-

20 KVA to 40 KVA

63 KVA to 82.5 KVA

100 KVA to 140 KVA

160 KVA to 200 KVA

320 KVA to 400 KVA

Rubber hose pipe set with clamps suitable for the size of DG sets IN REPLACEMENT of following capacity:-

20 KVA to 40 KVA

63 KVA to 82.5 KVA

100 KVA to 140 KVA

160 KVA to 200 KVA

320 KVA to 400 KVA

Servicing of alternator / AVR of DG set of any make and type by disconnecting all connecting all electric connections and removing dust from alternator/AVR and checking of wiring complete if burnt replace the wire with same size of conductor and making connection of all components complete as following capacity:-

20 KVA to 40 KVA

63 KVA to 82.5 KVA

100 KVA to 140 KVA

160 KVA to 200 KVA

320 KVA to 400 KVA

Oil filter cartage element with O ring of DG set complete IN REPLACEMENT as per existing sample as following capacity:-

20 KVA to 40 KVA

63 KVA to 82.5 KVA

100 KVA to 140 KVA

160 KVA to 200 KVA

320 KVA to 400 KVA

Air filter (both outer & Inner) element IN REPLACEMENT with O ring for DG set complete as following capacity:-

20 KVA to 40 KVA

63 KVA to 82.5 KVA

100 KVA to 140 KVA

160 KVA to 200 KVA

320 KVA to 400 KVA

Cleaning of diesel tank of any size /capaity including replacement of worn-out pipe line and measuring scale and make it leak proof, replacement of connection fuel inlet drain with bush, re-fixing in original position with necessary clamps, nut & bolts, complete.

Turbo Charger as per the existing including testing, IN REPLACEMENT complete as following size:-

100 KVA to 160 KVA

200 KVA to 400 KVA

Common spare parts of DG sets IN REPLACEMENT complete as following:-

Engine oil 15 W 40.

Brass terminal heavy duty for battery.

Distrilled water

Acid mixed water

Water temperature gauge sensor

Injector overflow pipe

Thermostat

Fuel feed baby pump

Asbestos rope superior quality on exhaust silencer pipe

Oil pressure gauge as per existing sample & capacity

Temprature gauge for oil / water

Fuel/oil pipe lines (High pressure rubber pipe covered with steel armoured)

Oil temprature gauge 0-130º C

Water temprature gauge 0-130º C

DC ammeter 0-50Amps

AC ammeter 0-500Amps

DC Voltmeter 0-50Amps

AC Voltmeter 0-500Amps

Frequency meter

Tachometer cable

Ignition switch DC with Key

Oil pressure gauge 0-7 Kg/Sqcm (Cat Part No 46.244.01)

Self starter for 12 Volts DC

Self starter for 24 Volts DC

Stopper 12 v

Rubber Hose pipe different size for radiator,air cleaner to turbo,turbo to sump,injector to filter,filter to tank,filter to tank

Copper battery lead connection IN REPLACEMENT suitable for 2 x 12 V, 180 A H battery 1.2 mtr long each for positive & Negative connections and 0.5 mtr long for battery inter connection lead duly pre soldering and fixing of lugs and end copper terminal and testing complete.

Relay 12Volts 25 Amp Cat 111x2-12-60 IN REPLACEMENT complete.

Engine Safety control unit 20 KVA to 140 KVA IN REPLACEMENT complete.

Safety control Unit-ECR-19 A for 160 KVA to 400 KVA IN REPLACEMENT complete.

Maintnance free battery with initially charged 12 volt with 24 months warrenty IN REPLACEMENT as following capacity.

Autocut electrical battery charger of 10 Amp Unit SMPS with Constant Voltage output with Battery charging Transformer and moulded type rectifier unit IN REPLACEMENT as following capacity.

Coolant for DG sets as per DG set Manufacturer's recommendations IN REPLACEMENT complete.

Door hinges suitable for DG set sound proof enclosure, of any capacity & make, for smooth opening & closing as IN REPLACEMENT complete.

Door Locks suitable for DG set sound proof enclosure, of any capacity & make, for smooth opening & closing as IN REPLACEMENT complete.

Door Handles suitable for DG set sound proof enclosure, of any capacity & make for smooth opening & closing as IN REPLACEMENT complete.

Repair / overhauling of DC Alternator by dismantling from the DG set after taking out the fan belt and pulley, replacement of armature coil, carbon etc and re-fixing the same, testing complete for DG set of capacity 20-400KVA, complete.

Fan belt set as per existing IN REPLACEMENT complete.

Servicing of self starter assembly of DG set by disconnecting the self starter assembly from the engine and dismantling , cleaning, all accessories,replacing worn-out parts like carbon brushes, penion of existing teeth, bendex bushes, armature, solenoid assy 12 Volt contact plates etc and rewinding the u/s feild coil etc and varnishing complete as following capacity:-

MAINTENANCE / REPAIR WORKS TO AMF PANEL OF DG SETS

Maintenance, repair, servicing of automatic mains failure panel 24Volt DC and 440Volt AC supply operated system by locating faults and replacement of userviceable parts and components, complete all as specified and directed, as per following:- (a) Repair of faulty worn out control wiring DC/AC for engine starting and off, with adequate and suitable size copper conductor wire, connected with proper copper lugs & terminals through protection pipe/casing. (b) Repair of worn out/faulty internal wiring of controls and timers, indicating/measuring instruments through various control fuses and relays with suitable and adequate size of copper conductor wire, connected with suitable copper lugs and terminals. (c) Replacement of worn out small control fuses, indicating lamps, various type of copper lugs, thimbles terminals all as deemed necessary or directed including minor spare parts and components in order to make system serviceable and perfectly in working order (d) Testing of system on load.

NOTE:- Spare parts IN REPLACEMENT will be measured and paid for separately under respective item of BoQ.

Solid state electronic engine starting relay 12/24 volts DC

Alternator voltage monitor relay 3 phase 415 Volt

Main voltage monitor relay 3 phase 415 Volt

Under voltage monitor relay 3 phase 415 Volt

Solid state electronic timer 0-60 second, 24 volts DC

Electronic earth fault relay for alternator protection 24volts DC

Electronic over load relay for alternator protection 24volts DC

Power Contactor MCX 03 cat No. CS 97011, rating 32 Amp , 3 phase 4 pole, 415 volt

Power Contactor MCX 13 cat No. CS 97015, rating 80 Amp , 3 phase 4 pole, 415 volt

Power Contactor MCX 33 cat No. CS 97021, rating 200 Amp , 3 phase 4 pole, 415 volt

Power Contactor MCX 41 cat No. CS 97023, rating 325 Amp , 3 phase 4 pole, 415 volt

Front mounting aux contact block 2 NO + 2 NC cat No. CS 94114, rating 32 Amp , 3 phase 4 pole, 415 volt

VMR relay

Tyre Nylone 16 ply with tube inner of size 6.00-16 for trolly mounted DG sets IN REPLACEMENT complete.

Front operated on load Change over switch 400 Amp 4 pole ie-400A ue 415V, AC -23B, ui-1000 A,IS-13947 (P-3) IEC-60947 (P-3) B-10330 as per existing fitted in AMF panel IN REPLACEMENT complete.

Spray painting of DG set, Alternator, Panel ,diesel tank and base frame etc. with two coat of synthetic enemel paint as per MES colour code after reparing to broken parts of body with gas welding ,cleaning of old painted surface by rubbing/removing of old paint and making surface reddy for painting to the DG set ofbcapacity upto 400 KVA complete all specified.

Electric operated single phase 0.5 HP,230 volts AC copper winded, centrifugal self priming monoblock pump set 25 dia mm suction and 25 mm dia delivery make Havells/crompton suitable for drawing of fuel from barrels and filling to the DG sets at various locations comlete with suitble size of copper cable 20 mtrs long and heavy duty flexible rubber pipe 20 mm dia and 20 mtrs long etc comlete.

Hand operated rotary barrel pump 25 dia mm suction and 20 mm dia delivery suitable for drawing of fuel from barrels etc comlete.

Earthing with and including GI earth plate electrode 6 mm thick of size 600 mm x 600 mm with 32 mm x 6 mm GI strip earthing lead complete all as shown in electrical plate No. 3 and as specified in Particular Specifications of contract, IN REPAIR.

NOTES: - (i) The unit rate includes earthing lead and protection pipe upto 7.5 metre from top of earth plate. (b) Factoy fabricated precast PCC pit & cover shall be fixed at least 500 mm away from earth pit. (iv) Earth resistance should not be less than 3Ohm. In case the test results are not found below 3 Ohm, complete earthing will be redone without any extra cost to Govt.

NOTES APPLICABLE TO SERAL ITEM NO. 1TO 34.01:- (i) To maintain utmost security at AF Station, contractor will arrange his workmen along with T&P in a manner that nonfunctional DG Set / AMF Panel is made functional swiftly within 24 hour of receiving of complaint from the MES, during entire contract period. (ii) Not withstanding with the provision of "Compensation for Delay' envisaged under condition 50 of IAFW-2249, General Conditions of Contracts, additional compensation @ Rs. 500/- day will be charged from contractor in case he fails to make the DG Set / AMF Panel functional to the entire satisfaction of Engineer-in-Charge within 24 hour of receiving of complaint from the MES regarding non working DG Set.

Note : Amount of credit for retrieved materials is mentioned in tender documents in pdf form which will be deducted while acceptance of tender offline.

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