REPAIR RATE CONTRACT FOR REPAIR AND OVERHAULING OF ALTERNATORS UPTO 1.5 MW ONBOARD IN SHIPS FOR A PERIOD OF ONE YEAR AND EXTENDABLE UPTO TWO MORE YEARS

Amount

RATE SHEET 1: WJFACS- 80 KW/120 KW TILLANCHANG/TARASA/CANKARSO/KONDUL/KOSWARI/TRINKAT/KARUVA (Each Ship - 03 Nos, Total Ship – 07 Nos , Total DAs - 21 Nos)

Disconnecting of power and control cables, and Re-connecting of power and control cables

Decoupling and coupling of Alternator from Engine

Opening and Closing of Hatches

Shifting of DA from compartment to upper deck

Shifting of DA from upper deck to compartment

Transportation charges to and fro ship and workshop

Dismantling/Re-assembly of Alternators

Electrical and Mechanical inspection of alternators

Cleaning of main stator/ rotor, exciter stator/rotor and mechanical parts

Improvement of IR- Insulation Resistance (IR) value should be more than 10 M Ohms

Apply two coats of varnish as per the prescribed procedure and apply a topcoat of enamel

Electrical testing of main rotor and exciter rotor (Rotor drop test) (report to be submitted)

Inspection of both side bearing step and bearing housing

NDT/Ultrasonic test of shaft for trueness/anomaly and repairs if required (report to be submitted)

Dynamic balancing of rotor

Both end bearing renewal

Serviceability checks of Rotating Rectifier Assembly/ Revolving diode bridge

Painting

Serviceability checks of AVRs and Sensor cards/ replacement/ repairs (if required)

Alignment of Alternator (Laser alignment)

Harbour load trails (Load bank provided by Indian Navy)

Rewinding of Stator (H class insulation)

Rewinding of Rotor (H class insulation)

RATE SHEET 2: INS MAKAR 150 KW

Decoupling and Coupling of Alternator from Engine

Removal and Assembling of Connection

Opening and Closing of Hatches

Shifting of DA from DA Compartment to Upper Deck

Shifting of DA from Upper Deck to DA Compartment

Disassembly/Reassembly of Alternator

Electrical and Mechanical inspection of Alternator

Restagging of Stator Core and Core Varnishing

Restaggering of rotor core and core varnishing

Stripping and winding of main stator of alternator with Class H Insulation

Replacement of Rotor pole to pole supporting Fork Clamp

Stripping and winding of main rotor of alternator with Class H Insulation

NDT/Ultrasonic Test of Shaft for Trueness/Anomaly and repairs if required

Replacement of RTD

Dynamic Balancing of rotor@G1 Grade

Inspection of both side bearing step & bearing housing

Both end bearing renewal

Transportation Charges to and fro (Karwar to Hyderabad)

Alignment of Alternator (Laser alignment)

Harbour Load trails (Load Bank provided by Indian Navy)

Repair/Replacement of defective cards/components & Rewiring of Ex Panel for 150 KW Alternator

Painting

RATE SHEET 3: OPV Class 400 KW - INS SUVARNA/INS SUBHADRA

Disconnecting of power and control cables, and Re-connecting of power and control cables

Decoupling and coupling of Alternator from Engine

Opening and Closing of Hatches

Shifting of DA from compartment to upper deck

Shifting of DA from upper deck to compartment

Transportation charges to and fro ship and workshop

Dismantling/Re-assembly of Alternators

Electrical and Mechanical inspection of alternators

Cleaning of main stator/ rotor, exciter stator/rotor and mechanical parts

Improvement of IR- Insulation Resistance (IR) value should be more than 10 M Ohms

Apply two coats of varnish as per the prescribed procedure and apply a topcoat of enamel (Elmot manual)

Electrical testing of main rotor and exciter rotor (Rotor Voltage drop test ) (Report to be submitted)

Inspection of both side bearing step and bearing housing

NDT/Ultrasonic test of shaft for trueness/anomaly and repairs if required (report to be submitted)

Dynamic balancing of rotor

Both end bearing renewal

Serviceability checks of Rotating Rectifier Assembly/ Revolving diode bridge

Painting

Serviceability checks of AVRs and Sensor cards/ replacement/ repairs (if required)

Alignment of Alternator (Laser alignment)

Harbor load trails (Load bank provided by Indian Navy)

Rewinding of Stator (H class insulation)

Rewinding of Rotor (H class insulation)

Removal of cooler. The job includes the following:- (a) Disconnect/ isolate existing power supply incoming cables and degutting of pipes/cables/panels as required. (b) Remove all the system pipes. Job includes:- (i) Manufacturing of blanks. (ii) Fitment of blanks. (c) Remove the grating and its foundation by cutting. (Hot work as required). (d) Welding of suitable eye bolts for shifting and undertaking the job insitu.

Repair of cooler. The job includes the following:- (a) Pressure test the cooler for identification of the leaking tubes. (b) Repair the leaking tubes. (c) Undertake chemical cleaning of the cooler (d). Manufacturing and renewal of zinc plugs (Qty 02 each) (e) Insitu pressure testing of the cooler on completion of repairs/ cleaning in presence of yard and SS reps.

Fitment of the cooler. The job includes the following:- (a) Paint the corroded foundation base plate of the cooler. (b) Fitment of all system pipes. (c) Successful trials of the cooler.

RATE SHEET 4 : INS TEG/TRISHUL - 800 KW

Dismantling alternator coupling from engine, dismantle alternator foundation bolts, disconnecting and reconnecting of main power cables.

Replacement of defective Outer Flange.

Dismantling, cleaning and varnishing of windings followed by assembly of Alternator using varnish

Replacement of defective Inner Flange

Metalizing & Machining of NDE side Enshield housing cover

Re-winding (including Varnishing and baking with H class insulation ) of Main stator

Re-winding (including Varnishing and baking with H class insulation ) of Main Rotor

Re-winding (including Varnishing and baking with H-class Insulation) of Exciter stator

Re-winding (including Varnishing and baking with H-class Insulation) of Exciter Rotor

Rotor balancing in Shop Floor

Replacement of DE Bearing with SKF Bearing

Renewal of NDE bearing with SKF Bearing

Renewal of AVR, if required

Renewal of RRA, if required

Coupling and Alignment of Alternator to Engine (laser alignment)

Connectorisation of Alternator

Vibration Analysis (Report from vibration Analysis level 3 of ANSI classification

Full load trials post overhauling/repairs (ships load)

Painting

Removal of cooler. The job includes the following:- (a) Disconnect/ isolate existing power supply incoming cables and degutting of pipes/cables/panels as required. (b) Remove all the system pipes. Job includes:- (i) Manufacturing of blanks. (ii) Fitment of blanks. (c) Remove the grating and its foundation by cutting. (Hot work as required). (d) Welding of suitable eye bolts for shifting and undertaking the job insitu.

Repair of cooler. The job includes the following:- (a) Pressure test the cooler for identification of the leaking tubes. (b) Repair the leaking tubes. (c) Undertake chemical cleaning of the cooler (d). Manufacturing and renewal of zinc plugs (Qty 02 each) (e) Insitu pressure testing of the cooler on completion of repairs/ cleaning in presence of yard and SS reps.

Fitment of the cooler. The job includes the following:- (a) Paint the corroded foundation base plate of the cooler. (b) Fitment of all system pipes. (c) Successful trials of the cooler.

RATE SHEET 5: INS Aditya - 1 MW

Disconnect the cable from the alternator

Break and remove the chock fasting component under the alternator foundation

Turn the alternator from the place and keep it on the foundation

Remove the coupling of the alternator

Remove the NDE & DE side cover of the alternator

Remove the both bearing & NDE & DE and inspect the journals

Fit the coupling of the alternator

Turn the alternator in position

Carryout the DE bearing housing, over size, metalizing, grinding to suit the bearing

Fit both side bearing using SKF induction heater and fit the bearing housing (bearing replacement)

Carryout the alignment and offer the inspection to the QC on jack bolt.

Carryout the chock fasting under the alternator foundation.

Couple the engine with alternator

Carryout the alignment check once again and confirm

Carryout the connectorisation of the alternator

Harbor load trails (Load bank provided by Indian Navy), including vibration trials

Serviceability checks of AVRs and Sensor cards/ replacement/ repairs (if required)

Improvement of IR- Insulation Resistance (IR) value should be more than 10 M Ohms

Cleaning of main stator/ rotor, exciter stator/rotor and mechanical parts

Serviceability checks of Rotating Rectifier Assembly/ Revolving diode bridge

Painting

Rewinding of Stator (H class insulation)

Rewinding of Rotor (H class insulation)

Removal of cooler. The job includes the following:- (a) Disconnect/ isolate existing power supply incoming cables and degutting of pipes/cables/panels as required. (b) Remove all the system pipes. Job includes:- (i) Manufacturing of blanks. (ii) Fitment of blanks. (c) Remove the grating and its foundation by cutting. (Hot work as required). (d) Welding of suitable eye bolts for shifting and undertaking the job insitu.

Repair of cooler. The job includes the following:- (a) Pressure test the cooler for identification of the leaking tubes. (b) Repair the leaking tubes. (c) Undertake chemical cleaning of the cooler (d). Manufacturing and renewal of zinc plugs (Qty 02 each) (e) Insitu pressure testing of the cooler on completion of repairs/ cleaning in presence of yard and SS reps.

Fitment of the cooler. The job includes the following:- (a) Paint the corroded foundation base plate of the cooler. (b) Fitment of all system pipes. (c) Successful trials of the cooler.

RATE SHEET 6 : INS Vikramaditya 1.5 MW

Dismantling alternator coupling from engine, dismantle alternator foundation bolts, shifting of alternator

Material for dismantling , cleaning with compressed air and varnishing of windings followed by assembly of alternator

Dismantling, cleaning with compressed air and varnishing of windings followed by assembly of alternator

Removal of alternator cooler

Removal and alternator connections

Material for check bearing clearance of DE and NDE after QC checks of oil clearance (ii) lead wire test (iii) change bearing only if required

Check bearing clearance of DE and NDE after QC checks of oil clearance (ii) lead wire test (iii) change bearing only if required.

Coupling and Alignment of Alternator to Engine

Connectorisation of Alternator

AVR connections

Vibration Analysis (Report from vibration Analysis level 3 of ANSI classification

Check Rotor balancing in-situ by certified firms and furnish report (on two occasions , prior commencement of overhaul and poat overhaul

Full load trials post overhauling

Improvement of IR- Insulation Resistance (IR) value should be more than 10 M Ohms

Rewinding of Stator (H class insulation)

Rewinding of Rotor (H class insulation)

Painting

Degutting/ regutting of pipes/fittings etc for space to undertake dismantling of rotor from stator for checks/ repairs/ IR improvement/ bearing replacement

Removal of cooler. The job includes the following:- (a) Disconnect/ isolate existing power supply incoming cables and degutting of pipes/cables/panels as required. (b) Remove all the system pipes. Job includes:- (i) Manufacturing of blanks. (ii) Fitment of blanks. (c) Remove the grating and its foundation by cutting. (Hot work as required). (d) Welding of suitable eye bolts for shifting and undertaking the job insitu.

Repair of cooler. The job includes the following:- (a) Pressure test the cooler for identification of the leaking tubes. (b) Repair the leaking tubes. (c) Undertake chemical cleaning of the cooler (d). Manufacturing and renewal of zinc plugs (Qty 02 each) (e) Insitu pressure testing of the cooler on completion of repairs/ cleaning in presence of yard and SS reps.

Fitment of the cooler. The job includes the following:- (a) Paint the corroded foundation base plate of the cooler. (b) Fitment of all system pipes. (c) Successful trials of the cooler.

M/s Dynatron services Private Limited (BID ID -3107386)

ULTRA MARINE (BID ID -3106355)

M/S NIRAKAR ENGINEERING (BID ID -3100283)

MAKARAND MARINE SERVICES (BID ID -3102780)

nexa (BID ID -3093855)

Krasny Defence Technologies Limited (BID ID -3102656)