REPAIR AND MAINTENANCE OF DG SETS AND AMF PANELS AT AFS HAKIMPET UNDER GE(AF) HAKIMPET

Amount

Material and Labour for servicing of DG set by carrying out the following maintenance including testing on completion for a period of 02 hours at connected load complete all as specified and directed for the DG set of capacity 180 KVA. Make - Cummins DG Set installed at ATC DG set Room in AFS Hakimpet area:-

Notes: Rate qouted for above item shall includes for the following:- (a) Draining out engine oil from the sump by removing drain plug, cleaning the sump thoroughly and refilling the sump with new engine oil to required level(Engine Oil will be measured and paid under relevant supply only item of BOQ). (b) Draining out of diesel from tank and storing in cleaned containers, cleaning the tank thoroughly by removing sediments settled at the bottom and refilling the drained out diesel duly filtered. (c) Supply and replace complete set of fuel filters, engine oil filters and air cleaner element. (d) Draining out complete coolant water mixture from the radiator and re-filling the radiator with new coolant and water mixture with proportionate ratio. (Coolant will be measured and paid under relevant supply only item of BOQ). (e) Check and top up the electrolyte/distilled water in starting batteries to maintain the required specific gravity. Cleaning of battery terminals & applying petroleum jelly to battery poles & brass connectors. (f) Tightening all the fasteners of complete DG set to the required torque.

All as per item No.01 here-in-before but for DG set of capacity 125 KVA Make – Kirloskar/Greaves installed at various locations in AFS Hakimpet.

All as per item No.01 here-in-before but for DG set of capacity 100 KVA Make – Kirloskar/Greaves/Ashok Leyland installed at various locations in AFS Hakimpet.

All as per item No.01 here-in-before but for DG set of capacity 70/ 75 KVA Make – Kirloskar installed at various locations in AFS Hakimpet.

All as per item No.01 here-in-before but for DG set of capacity 62.5/63 KVA Make – Kirloskar/Ashok Leyland installed at various locations in AFS Hakimpet.

All as per item No.01 here-in-before but for DG set of capacity 40/50 KVA Make – Kirloskar/Greaves/Ashok Leyland installed at various locations in AFS Hakimpet.

All as per item No.01 here-in-before but for DG set of capacity 20/25 KVA Make – Kirloskar / Ashok Leyland installed at various locations in AFS Hakimpet.

All as per item No.01 here-in-before but for DG set of capacity 15 KVA Make – Kirloskar / Ashok Leyland installed at various locations in AFS Hakimpet.

Attending of complaint duly finding of fault or defects in enging/alternator/ AMF panel and rectification of defects including checking microprocessor based AMF control panel and connected programmed safety features, safety switches/ cut-outs / thermostats etc, removing and re-terminating the burnt wires, checking of all contactors/contacts for proper auto functioning and rectifying the faults/ faulty components by replacing with new spares and setting the relays setting of programming of operating parameters and safety limits ( if required) etc complete all as specified and directed. Note :- Spare parts required to make serviceable will be measure and paid separately under respictive items of BOQ.

Supply only engine oil 10W40/20W40/20W50/15W40 against Item Nos. 1 to 8 for oil change of Generator set (As per the recommendation of Manufacturers) complete all as specified and directed.

Supply only generator radiator coolent Concentrate Blue against Item Nos. 1 to 8 complete all as specified and directed.

Supply and replace the following spare parts suitable for DG sets of various capacities:-

Wire braided fuel pipe

Leak off pipe

Fuel pipe from feed pump to fuel filter inlet

Fuel pipe from fuel filter out to fuel pump inlet

Fuel pipe from tank to feed pump(upto length 1.70m)

Hose for water outlet manifold

Thermostat bypass hose

Hose for drain pipe

Bypass hose

'V' belt cogged of suitable size as per site requirement

Poly 'V' belt

De-scaling of radiator assembly by carefully by removing from the engine, transporting to the workshop and removing the sediments, scales and rust etc by means of acid cleaning, high pressure water washing and air cleaning, arresting the leakages by gas welding / soldering with suitable material, re-assembling the same with new gaskets including replacement of radiator cap(wherever required) and transporting to the site, fixing to the engine for DG Set of capacity from 100 KVA to 180 KVA complete all as specified and directed.

All as per item No.13 here-in-before but for DG Set of capacity from 62.5 KVA to 75 KVA.

All as per item No.13 here-in-before but for DG Set of capacity upto 50 KVA.

Dismantling the defective water pump assembly and Supply and fix new water pump assembly for DG set of capacity from 100 KVA to 180 KVA complete all as specified and directed.

All as per item No. 16 here-in-before but of capacity 63 KVA to 75 KVA.

All as per item No. 16 here-in-before but of capacity 40 KVA to 50 KVA.

Dismantling the defective fuel injectors & fuel injection pump from the engine and M&L for repair/calibration of fuel injectors & fuel injection pump including replacement of barrel plunger, cups & ‘O’ rings etc. for DG Set of capacity 100 KVA to 180 KVA complete all as specified and directed.

All as per item No.19 here-in-before but for DG set of capacity 62.5 KVA to 75 KVA.

All as per item No.19 here-in-before but for DG set of capacity 40 KVA to 50 KVA.

Taking down unserviceable fly wheel gear ring and Supply and fix fly wheel gear ring set suitable for DG set of capacity 100 KVA to 180 KVA complete all as specified and directed.

All as per item No. 22 here-in-before but for DG set of capacity 25 KVA to 75 KVA.

Dismantling the fly wheel coupling between engine and alternator and Supply and replace complete set of bullet rubber bushes, coupling nuts & bolts including proper alignment of engine & alternator for smooth running for DG set of capacity 100 KVA to 180 KVA complete all as specified and directed.

All as per item No. 24 here-in-before but for DG set of capacity 62.5 KVA to 75 KVA.

Taking down unserviceable engine wiring and M&L for rewiring of engine safety control system from control panel to engine control gadgets like shut down valve, dynamo & self-starter etc, for DG set of capacity from 100 KVA to 180 KVA complete all as specified and directed.

All as per item No. 26 here-in-before but for DG set of capacity from 62.5 KVA to 75 KVA.

All as per item No. 26 here-in-before but for DG set of capacity upto 50 KVA

Dismantling the defective self starter assembly 12V/24V carefully from the DG set and carryout repair and servicing by cleaning all accessories with suitable cleaning agent and supply and replace commentator, carbon brush set, carbon brush holder, king pin holder, armature choke nut, body screens, clutch plate assay and solenoid etc re-assembling and re-fixing the same and testing on completion for DG set of capacity from 100 KVA to 180 KVA complete all as specified and directed.

All as per item No. 29 here-in-before but for DG set of capacity from 40 KVA to 75 KVA.

All as per item No. 29 here-in-before but for DG set of capacity from 15 KVA to 25 KVA

Dismantling the defective battery charging alternator carefully and carryout repair and servicing by cleaning all accessories with suitable cleaning agent and supply and replace carbon brush, brush holders, bushes/bearings, varnishing etc, re-assembling and re-fixing the same and testing on completion complete all as specified and directed.

Supply and fixing RPM Meter / Hrs meter as per existing make & size suitable for existing panel board for connection of cable for DG Set including taking down of existing unserviceable meter complete all as specified and directed.

Supply and fix Oil Pressure Gauge suitable for DG Sets including taking down existing unserviceable gauge complete all as specified and directed.

Supply and fix Water Temperature Gauge suitable for DG Sets including taking down existing unserviceable gauge complete all as specified and directed.

Supply and Connection battery lead (1.50m long each made of PVC Insulated Plain/Striped Automobile Cables with high conductivity bright annealed copper conductor bunched together, insulated with dielectric grade PVC compound (impervious to oils, greases, acids, petrol and water) conforming to IS 2465 of size 25 sqmm soldered one end with copper/brass connector with nuts and bolts for battery pole and the other with copper lug for self starter terminal including taking down of existing u/s battery lead with connector and lug of any description complete all as specified and directed.

Supply and wrap asbestos rope of 8/10mm thick over silencer of DG sets including taking down of existing unserviceable rope complete all as specified and directed. Note: Straight length of silencer is measured for the purpose of payment

Taking down unserviceable Automatic Voltage Regulator of any description from alternator and supply and fix new Automatic Voltage Regulator of suitable model for existing alternator of capacity 180 KVA complete all as specified and directed.

All as per item No.38 here-in-before but for DG set of capacity from 15 KVA to 125 KVA.

Supply and fix maintenance free battery 12V, 150 AH for DG set including initial filling & Charging complete all as specified and directed.

All as per item No. 40 here-in-before but of rating 12V, 180 AH.

All as per item No. 40 here-in-before but of rating 12V, 80/90/100 AH.

Dismantling the defective alternator from DG set, transporting to civil work shop, separating the stator and rotor from alternator housing, cutting and removing burnt winding of stator completely, cleaning the slots and rewinding the stator with existing gauge of super enameled copper wire with suitable insulation, applying varnish and heating in heating chamber till completely dried and reassembling the alternator, transporting back to site and re-fixing to the DG set including proper alignment for smooth running and testing on completion for DG set of capacity 100 KVA to 180 KVA complete all as specified and directed.

All as per item No. 43 here-in-before but for DG set of capacity 63 KVA to 75 KVA.

All as per item No. 43 here-in-before but for DG set of capacity 40 KVA to 50 KVA.

All as per item No. 43 here-in-before but for DG set of capacity 15 KVA to 25 KVA.

Supply and fix MCCB 3 Pole, 415 V, fixed type, 25 to 100 Amps with breaking capacity 16 KA including taking down unserviceable MCCB of any description complete all as specified and directed.

All as per item No. 47 here-in-before, but of 125 Amps

Supply and fix MCCB 3 Pole, 415 V, Adjustable type, 160 Amps with breaking capacity 36 KA including taking down unserviceable MCCB of any description complete all as specified and directed.

All as per item No. 49 here-in-before but of 200 Amps

All as per item No. 49 here-in-before but of 250 Amps

Supply, erection, testing and commissioning indoor type factory made powder coated AMF Panel Board suitable for DG set 180 KVA capacity, with 400 Amps bus 4 Nos. aluminium bus bar, having locking arrangments floor mounted free standing weather proof panel with IP-54 protection fabricated out of suitable sized angle iron and flats and covered with 3 mm thick CRCA sheet duly pretreated in seven tank process for de-greasing , de-rusting & phosphated painted with 2 coats of primer paint then the panel surface shall be finished and then painted with final coat of epoxy based powder coated paint.Panel shall be compartmentrised with rubber gasketed hinged door. Panel shall be having only front opening for installation of separate cable alleys, busbar chamber and switchgear compartments. Provision in cable alleys to be kept for bottom cable entry for incoming & outgoing cables. Panel have CT 5/400 Amps - 03 Nos, Digital Ammeter 0-500 Amps, Digital Voltmeter 0-500 Amps, Phase Indicator LED (RYB) - 03 Nos. A clear space of 200mm to be kept from floor level for switchgear compartment. Extended busbar links/ terminals to be provided for connecting cables. Air ventillation louvers to be provided for heat dissipation with earthing terminal at each end of the panel. Suitable sized knock-out holes consisting of the following and taking down of existing old unserviceable panel, complete all as specified and directed:- a) Power contactor-4 pole, of suitable current rating with thermal overload relay - 02 Nos (for alternator and mains) b) HRC fuse of suitable current rating for short circuit protection c) Microprocessor based AMF module incorporating functions:- - Supply failure timer - Restoration timer - 3 Impulse automatic engine start/ stop logic - Mains/ Generator Voltage & Frequency sensing d) Aluminium bus bars of suitable capacity with incoming/ outgoing terminals e) Instrument fuses duly wired and ferruled f) MCCB of suitable rating 4 pole with overload and short circuit protections - 02 No's (for alternator & mains) g) Current Transformers of suitable rating

Servicing of AMF panel of DG sets of capacity from 15 KVA to 180 KVA installed at AFS Hakimpet Area by cleaning the complete panel with suitable cleaning agent and checking the controller relays, timer, contactors for proper functioning, replacing defective spare parts, replacement of defective wires of existing size, tightening of all connections and applying jelly on contactors complete all as specified and directed:- Note : Spares required will be measured and paid separately as 'Supply Only' but cost of wires and labour shall be included in the quoted rate.

Supply only of following spare parts of existing make & modelsuitable for existing DG set AMF Panels, 3 Phase, 415 Volts, 50 Hz:-

4 Pole Power Contactor of rating 32 Amps

4 Pole Power Contactor of rating 63 Amps

4 Pole Power Contactor of rating 100 Amps

4 Pole Power Contactor of rating 160 Amps

4 Pole Power Contactor of rating 200 Amps

4 Pole Power Contactor of rating 325 Amps

Control relay

Timer

Battery Charging Unit 12 Volts

Battery Charging Unit 24 Volts

AMF Logic controller relay complete assembly

Auto / Manual switch complete assembly

Indicaton lamp of existing model

Engine start/stop push button

Volt /Amp meter of existing model

M&L for painting of DG set to match with existing color complete including engine, alternator and all iron structure with two coats of syntetic enamel paint of capacity 100 to 180 KVA complete all as specified and directed.

M&L for painting of DG set to match with existing color complete including engine, alternator and all iron structure with two coats of syntetic enamel paint of capacity upto 50 KVA complete all as specified and directed.

Comprehensive maintenance and servicing of lift (10 passengers), electricaly operated like checking of ropes, door movements, limit switch, alignment of ropes and lift, lubrication, break panel, cable checking, normal and routine maintenance including renewal / replacement of defective parts for the complete contract period that i.e. 10 months, complete all as specified and directed. Make :- Johnson Notes :- (i) Comprehensive maintenance includes all minor, major and consumeble repairs and replacement of spare parts/parts etc. (ii) Comprehensive maintenance does not include repair / replacement of car door/car cabin. (iii) Oil level to be checked in every month and if there is any leakage observed , it must be arrested. Again oil should be filled correctly.

kaushikbrothers

Haasith constructions