81375 REPAIRS/MAINTAINANCE OF DG SETS AND HT EXTERNAL SERVICES AND ITS CONNECTED WORKS AT PARUNDU UNDER GE TIRUNELVELI

Amount

Comprehensive maintenance for diesel engine drive generating set by carrying out routine 'A' check and 'B' check as recommended by the respective manufacture of following capacity DG sets complete including cost of minor items like petroleum jelly, grease, nut bolts etc during routine AMC checks once in every month and attending unlimited breakdown calls. Note:- (a) Engine oil, radiator coolant oil, filters required during the maintenance period shall be measured and paid separately at supply only rates and cost of labour for fixing those spares/filling of oils shall be deemed to be included in the rate quoted for this item. (b) Required T&P shall be arranged by the Contractor at site. (c) List of checks to be carried out under 'A' and 'B' Check is attached as

(a) 500 KVA DG sets at UAV Power house (Make & Model No. : Kirloskar DV 10TA )

(b) 250 KVA DG Set at UAV Power house (Make & Model No.-Kirloskar 6SL 1500 TA G3

(c) 160 KVA DG set at ATC power house (Make & Model No.- Ashok Leyland A9 NO 1100 )

(d) 100 KVA DG Set at NEW Adm Block (Make & Model No.- Ashok Leyland A9 NO 1400 )

(e) 82.5 KVA DG set at 7N DET (Make & Model No.- Ashok Leyland AL 412 TGI )

(f) 82.5 KVA DG Sets at DFO (Make & Model No.-Ashok Leyland AL 412 TGI )

(g) 15 KVA DG set at TS pump house (Make & Model No.-Ashok Leyland EA 20 )

(h) 35 KVA DG set at TS Pump House (Make & Model No.-Mahindra 4575 GM )

(j) 40 KVA DG set at TS Pump house (Make & Model No.-Ashok Leyland ALGPWO4DMK1E4 )

Dismantling the radiator and after cooler of following DG sets for removing all scales from the pipes by pressure washing and by using suitable solutions, checking for leakage, arresting leakage if any by welding / brazing, finishing, drying and refixing, filling coolant and testing complete all as required by Engr-in-charge.(Necessary coolant and distilled water required will be measured and paid seperately under respective item herein after

(a) 500 KVA DG sets at UAV Power house

(b) 250 KVA DG Set at UAV Power house

(c) 160 KVA DG set at ATC power house

(d) 100 KVA DG Set at NEW ADM Block

(e) 82.5 KVA DG set at 7N DET

(f) 82.5 KVA DG Sets at DFO

Supply and fix in replacement of battery 12 volt 180 AH including taking down old unserviceable item complete all as required by Engr-in-charge.

Supply and fix Battery terminal heavy duty 1mtr long standard copper cable with brass clamps, bolts,nuts,washers etc. including taking down old unserviceable item complete all as required by Engr-in-charge.

Supply only engine oil SAE 15W40 high quality suitable for Kirloskar make DG set Make: Kirloskar K-OIL

supply only engine oil SAE 15W40 high quality suitable for Ashok Leyland/Mahindra make DG set. Make: Servo super/Gulf Leypower XLL Diesel Engine oil

Supply only coolant oil heavy duty suitable for Kirloskar DG set. Make: Kirloskar K-cool

Supply only coolant oil heavy duty suitable for shook Leyland/Mahindra DG set. Make LEY power coolant 5000/TVS Girling vericool radiator coolant concentrate

Supply only distilled water suitable for DG set

Dismantling the fuel pump from the engine, transporting to the service center and complete servicing and overhauling of the pump including replacement of service kit element, delivery valve, plunger, copper washer etc all as required including re-calibration, refixing and testing complete

(a) 82.5 KVA/160 KVA/100 KVA DG set

Dismantling the water pump from the engine and supply and fixing new water pump of existing size and testing including taking down old unserviceable item complete

(a) 82.5 KVA/160 KVA/100 KVA DG set

(b) 500 KVA/250 KVA DG set

Draining out the diesel tank, cleaning / washing out the sludge using and re-filling with diesel for following DG set

(a) 500 KVA DG set at UAV Power house

(b) 250 KVA DG set at UAV power house

(c) 100 KVA DG set at New Adm Block

(d) 82.5 KVA DG set at 7N DET

(e) 82.5 KVA DG set at 7N DFO

(f) 15 KVA DGs et at TS pump House

Removing and replacing of fuel injector for following DG set 82.5 KVA DG set including taking down old unserviceable complete all as required by Engr-in-charge.

Heating and varnishing of alternator for DG set 100 KVA DG set complete all as required by Engr-in-charge.

Supply and replacement of the following items for DG set any capacity including taking down old unserviceable items

(a) Oil pressure gauge

(b) Radiator Cap

(c) Fuel Tank Cap with Lock

(d) Door lock of any type and size complete set

(e) Door gasket of any type and size complete set

(f) AVR Suitable for 15 to 120 KVA Alternators

(g)AVR Suitable for 120 to 200 KVA Alternators

(h) AVR Suitable for 250 to 500 KVA Alternators

(j) AC Ammeter analog type

(k) AC voltmeter analog type 0 to 500 volt

(m) Frequency analog meter

(p) Multifunction digital meter

(s) Ignition switch with key for on, off and run

(t) Shunt coil for MCCB

(u) Indicator lamp for panel board as per existing size

(v) No Volt coil suitable for 3 phase power contactor 300 Amps ratings

(w) AMF relay 12 Volt AC

(x) Battery charging alternator 24 volt

(y) Temperature guage with sensor

(z) RPM mater with connecting cable

(aa) oil pressure sensor

(ab) Contactor 4 pole 250 amps capacity

(ac) Thermostat

Removing dismantling and overhauling of 12 volt starter motor, replacement of armature coil, field coil, bush bearing etc to make the starter motor serviceable complete all as specified and as directed

Removing dismantling and overhauling of 24 volt starter motor, replacement of armature coil, bush bearing etc to make the starter motor serviceable complete all as directed

Spray painting of diesel generating set of following capacity with acoustic enclosure with one coat of synthetic enamel paint including writing of SM/MES No on engine and alternator, body colour shall be apple green black for foundation base frame, red for all guards, all as specified and as directed

(a) 82.5 KVA DG set

(b) 15KVA DG Set

Material and Labour for PCC 1:2:4 Type B2 using 40mm graded aggregate as in foundation, filling and mass concrete complete all as specified and as directed by the Engineer-in-charge

Material and Labour for shifting DG set from one location to another location using mechanical means including disconnection and reconnections complete all as specified and directed

Supply and replacement of auto 24V battery charger with wiring

Supply and replacement of canopy light 24V 18W with wiring

Supply and replacement of Battery top leg changing

Supply and replacement of Asbestos rope

Supply and replacement of Emergency stop switch

Supply and replacement of the following items for 82.5 KVA DG set including taking down old unserviceable items

(a) Alternator adopter box

(b) engine safety controller

(c) stop solenoid

(d) Oil pressure switch

(e) Temperature switch

(f) Engine safety complete wiring

(g) Power Panel complete wiring

(h) Engine ON/OFF relay

(j) Fan Belt

(k) Engine control panel controller and display with wiring

(m) Fuel filter

(n) Oil filter

(p) Air Filter assembly

(q) Fuel Tank indicator dial page

(r) Extension of exhaust pipe

Supply and replacement of the following items for 10KVA DG set including taking down old unserviceable

(a) Air Filter inner and outer set

(b) Oil filter

(c) Fuel filter with water separator

(D) Diesel Hose

(e) Diesel strainer

(f) Radiator hose set

(g) Water pump radiator belt

Supply and replacement of the following items for 500 KVA DG set including taking down old unserviceable item

(a) Extension of exhaust pipe

(b) air filter inner and outer set

(c) oil filter (2Nos)

(d) Diesel filter with water separator bowl and hand priming pump

(e) Diesel Hose set

(f) Radiator hose set

(g) Emergency stop switch

(h) Bus bar insulator

(j) Oil flasher unit

(k) Turbo charger compressor, turbine wheel and center housing

(m) Turbo charger turbine and compressor housing

(n) Turbo charger actuator and outlet elbow

(p) panel board glass with beading

(q) Radiator fan belt (3Nos)

(r) Breather hose

Supply and replacement of the following items for 250KVA DG set including taking down old unserviceable item

(a) Oil filter

(b) air filter inner and outer set

(c) Fuel filter

(d) Radiator fan belt

Supply and replacement of the following items for 15KVA DG Set including taking down old unserviceable item

(a) Emergency stop meter

(b) Oil pressure meter

(c) Oil filter

(d) Air filter

(e) Fuel filter

(f) 12V relay control board

Supply and replacement of the following items for 160 KVA DG set including taking down old unserviceable item

(a) Oil filter

(b) air filter inner and outer set

(c) Fuel filter

(d) Fan belt

(e) Diesel hose set (2 Nos)

Material and labour for earthing complete with galvanised steel earth electrode 60cmx60cmx6mm thick, buried directly in ground (earth pit not less than 2.25metres deep below normal ground level) with top edge of the plate not less than 1.5 metres below normal ground level, connected to 32x6mm GI strip as earthing lead by means of bolts, nuts, check nuts and washers of copper all as shown in electrical plate No.3 connected to earthing test point, including 20mm GI pipe (medium grade) for watering and 40mm GI pipe (medium grade) for protection of earth strip and etc., including testing on completion, PCC chambers in PCC 1:3:6 type C1, RCC M25 type cover slab 50mm thick with 8mm dia TMT HCR/CRS steel bars at 140mm C/C both way and lifting handle GI funnel & wire mesh, funnel, lugs and charcoal, salt etc all as applicable complete all as specified and as directed by the Engineer-in-Charge

Dehydration/filtration of transformer oil by employing on line filtration plant to achieve di-electric strength not less than minimum 50KV including following work services:- (a) Removal of all suspended particles such as dust,rust,scales,collided carbon oxidation sludge, etc upto <1 micron. (b) De-hydration of transformer oil under vacuum. (c) Circulation of heated oil and filling of treated oil in transformer tank. (d) Top up the transformer oil upto the level. NOTE:(i) Contractor shall use the vehicle mounted filtration plant with new suitable size heavy duty hose pipe. (ii) The transformer oil required for replacement/top up shall be measured and paid separately. (iii) Conducting field testing of di-electric strength of the transformer oil before and after filtration.

Material and Labour for transformer oil for top up in transformer Note: sealed container only will be brought at site with minimum BDV 60KV complete all as specified and as directed. Make:HP/Bharat petroleum/Power oil

Disconnecting HT/LT connection transformer, 11000/433V, 3Phase, 4wire system and opening up the top cover of transformer of capacity 250,KVA for checking the conditions to carryout repairs at site, including draining out oil from the transformer in suitable container(Container to be provided by the contractor) and repair to the transformer with replacement of parts(as required) checking the lead connection from winding to bus rods including necessary soldering/jointing etc and after complete repair refilling the dehydrated oil, replacing perished gasket with new gasket of same size and testing on full load after connecting the HT/LT connections complete all as directed by Engineer-in- charge. Note:(i) Major parts as under shall be measured and paid separately under relevant item of this BOQ (ii) Dehydration/filtration of transformer oil shall be measured and paid separately under relevant item of this BOQ (iv)T&P and minor parts will be arranged by the contractor and the cost there of shall be deemed to be included in the unit rate quoted against this item (v)Rate deemed to be inclusive of securing the cable on HT/LT side for tension free at cable entry box.

All as per item No.35 herein before but capacity of 100KVA complete all as specified and as directed

Disconnecting primary/Secondary connection of transformer,22000/11000V,3 phase system and opening up the top cover of transformer of capacity 400KVA for checking the conditions to carryout repairs at site, including draining out oil from the transformer in suitable container(Containers to be provided by the contractor) and repairs to the transformer with replacement of parts (as required) checking the lead connection from winding to bus rods including necessary soldering/jointing etc and after complete repair refilling the dehydration oil, replacing perished gasket with new gasket of same size and testing on full load after connecting the HT/LT connections complete all as specified and as directed Note: (i) Major parts as under shall be measured and paid separately under relevant item of this BOQ (ii) Dehydration/filtration of transformer oil shall be measured and paid separately under relevant item of this BOQ (iv)T&P and minor parts will be arranged by the contractor and the cost there of shall be deemed to be including in the unit rate quoted against this item (v)Rate deemed to be inclusive of securing the cable on Primary/Secondary side for tension free at cable entry box.

Material and Labour for Replacement of HT bushing of transformer 11/0.433 KV of capacity 250 KVA complete all as specified and directed

All as per item No 38 herein before but capacity of 100 KVA.

Material and Labour Replacement of LT bushing of transformer 11/0.433 KV of capacity 250 KVA complete all as specified and directed.

All as per item No 40 herein before but capacity of 100 KVA.

Material and Labour for Replacement of HT bushing of transformer 22 / 11 KV of capacity 400 KVA complete all as specified and directed.

Material and Labour for Replacement of LT bushing of transformer 22 / 11 KV of capacity 400 KVA complete all as specified and directed.

Material and Labour for Replacement of silica gel breather of 22/11 KV Out door type transformer capacity 400 KVA complete all as specified and directed.

Material and Labour for Replacement of silica gel breather of 11000/433 V transformer of capacity 400 KVA complete all as specified and directed.

All as per item No 45 herein before but capacity of 100 to 250 KVA.

Material and Labour for Replacement of silica gel breather of 433/230 V transformer of capacity 50 KVA complete all as specified and directed.

Material and Labour for Replacement of silica gel standard type complete all as specified and directed.

Supply and fixing in repairs Dial type Temperature gauge 0 to 1000 C range complete with suitable to any make type and capacity of transformer complete all as specified and directed.

Supply and fixing Gun metal gate valve of 25 mm dia, ISI Marked suitable for oil inlet/outlet valves of transformer including taking down old one complete all as specified and directed.

Supply and fixing Gun metal gate valve of 40 mm dia, ISI Marked suitable for oil inlet/outlet valves of transformer including taking down old one complete all as specified and directed.

Taking down the defective unserviceable transformer, step down, 22000/11000 V, 3 phase system, out door type, 400 KVA from the PCC foundation inside the fencing with the help of man power & chain pulley block or by crane etc including disconnecting all electrical and mechanical connections from the site and carrying to work shop for repair and replacement of old burnt unserviceable items and taking back to the site after complete testing including cost of transportation to and fro complete including meggaring, re- connecting HT cable end joint at Primary and Secondary side of the transformer and testing on no load and full load all as specified and directed by Engr-in-charge. Notes: (i) Major parts as under shall be measured and paid separately under appropriate item of this BOQ (ii) Dehydration/ filtration of transformer oil shall be measured and paid separately under relevant item of this BOQ’ (iii) T&P including loading & unloading and minor parts like gasket kits etc. will be arranged by the contractor and the cost thereof shall be deemed to be included in the unit rate quoted against this item (iv) Rate deemed to be inclusive of securing the cables on Primary/Secondary side for tension free at cable entry box and complete testing of transformer

All as per item No 52 herein before but 11000/433 V, 3 phase, 4 wire system, out door type transformer, capacity from 400 to 100 KVA.

Material and Labour for winding HT coil with DPC or enamelled copper wire of existing size & gauge winding wire for winding the transformer HT coil including insulating material complete all as specified and directed by Engr-in-charge.

Material and Labour for LT coil winding with DPC or enamelled copper wire strip of existing size & gauge winding for winding the transformer coil LT coil all as specified and directed by Engr-in-charge.

Material and Labour in repair for Single Post insulator, 22 KV with hardware fittings etc. complete all as specified and directed by Engr-in-charge.

Supply and Fixing in repairs 22 KV/33 KV Lightning Arresters expulsion type complete with all fittings, transmission class discharge capacity 65 kilo Amps etc as required including testing and commissioning complete all as directed Engineer-in-Charge.

Material and Labour in repair for ACSR Conductor of weasel type for HT connection complete all as specified and directed.

Material and labour for Danger notice plate of 1.6mm thick mild steel sheet, vitreous enamelled white, with letters, figures and conventional skull and bones in signal red colour and fixed with M.S. clamps, bolts and nuts of approved size, for HT, 25x20cm complete all as specified and directed.

Material and labour for preparation of old cement coated surface, cleaning the surface of the RCC HT pole above the ground level including coping area and painting with 2 coats of acrylic exterior emulsion paint over a coat of cement primer and applying one coat of zinc chromium primer and 2 coats of aluminium paint for cross arms any numbers of each pole incl clamps etc complete all as required by Engr-in-charge.

Material and labour for servicing of HT 11 KV VCB along with CTs/PTs of current rating upto 400 A, rupturing capacity 250/200 MVA of any make and type by drawing out breaker assembly from panel and carry out the following work:- (i) Cleaning/ decarburizing of all fixed and moving contacts, levers, springs using suitable cleaning agent and tightening of screws, nuts, bolts, spring etc, (ii) Adjust the trolley in and out mechanism , (iii) Lubricating/greasing of all operating mechanism and moving parts, switching & tripping mechanism, automatic shuttering system, necessary brazing, turning, polishing of main and auxiliary contact, demoisturing of insulators, etc to be done (iv) Testing of tripping performance of HT VCB by secondary current injection and testing of CT ratio and polarity, (v) Checking of tripping relay including interlocking if an25ements of the mechanical clearances of the operating mechanism, internal wiring circuit etc, tightening of all connections, replacement of HRC fuse, fuse carrier base (if any found u/s) including removing moisture deposit inside the VCB.

(vi) Checking all end terminals, tightening the nut bolt and washers, replace the unserviceable nut, bolt & washers, draw-in the breaker, put in position, engage the VCB with the supply system and testing for smooth functioning. NOTE : (i) The cost of cleaning materials, HT Tape, thinner, cotton waste, steel nut, bolt with double washers, HRC fuses, , fuse carrier base, shall deemed to be included in the quoted rate. (ii) Contractor shall isolate and earth the breaker before starting the work.

Supply and fixing, Closing Coil Assembly ( 24V/30V DC) as per existing size, type and suitable for 11 KV VCB including taking down old item complete all as specified and directed by Engineer in charge.

Supply and fixing ,of Tripping Coil Assembly ( 24V/30V DC) as per existing size, type and suitable for 11 KV VCB including taking down old item complete all as specified and directed by Engineer in charge.

Supply and fixing, of LED indicator of RED/GREEN/YELLOW/AMBER including taking down old materials, complete all as specified and directed.

Supply and fixing, of push button RED/GREEN/YELLOW/BLACK including taking down old materials complete all as specified and directed.

Supply and fixing in repair of Digital Volt Meter of approx. size 96 x 96 mm in square shape, capacity 0 to 500 Volts complete all as specified and as directed.

Supply and fixing in repair of Digital Ammeter of approx. size 96 x 96 mm in square shape, capacity as per existing complete all as specified and as directed.

Material and labour for Cleaning of old surface from dust, oil, rust from VCB and Calibration of protective relays both 02 Nos over current and 01 No earth fault relay of IDMT or any other type by using relay injection kit including necessary adjustment of over current / earth fault / earth leakage by secondary current injection test along with testing and calibration of pickup current, time setting multiplier, tripping delay time, auto resetting of time, etc for successful operation at the time of fault occurrence as required according to the connected load and all as directed. NOTE : (i) The rent of air compressor, T&P, etc shall deemed to be included in the quoted rate. (ii) Contractor shall ensure the safety of the Painter/Electrician/Supervisor/Engineer while working on HT electric system at his own risk.

Excavation in trenches not exceeding 1.5 mtrs wide and not exceeding 1.5 mtr deep in any type of soil for laying underground cables, laying pipes etc. complete all as specified and directed.

Returning filling in including spreading levelling watering and well ramming in layers not exceeding 25 cm thick in hard/ dense soil complete all as specified and directed.

Removing surplus soil to a distance not exceeding 50 m and depositing at a level not exceeding 1.5m above the starting point all as specified and directed.

Supply and spread riddled earth in trenches for cable cushioning on top and bottom of cable as specified for cable protection complete all as specified and directed. (Note: Only punned thickness of earth shall be measured)

Supplying and laying un-reinforced precast concrete cable cover, class HVP, Type 2 ,flat , size 450mm x 180mm x 40 mm , complete all as specified and as directed by the Engineer-in-Charge

Taking down burnout cable and Supply and laying, testing and commissioning HT 11KV XLPE cable, PVC insulated, screened PVC bedded galvanised steel strip or wire armoured electric power cable, heavy duty with aluminium conductor 11000 Volts grade (earthed), cable of size 3 core 185 sqmm laid in trenches / floor / duct / fixed on poles / through GI tubing including brass cable glands complete all as specified and directed.

Supply and fixing , cable jointing kit for 11 KV (Earthed) grade cable for straight through heat shrink type joint complete with jointing material and accessories suitable for XLPE armoured aluminium conductor cable of size 185 sqmm x 3 core including taking down old item, complete all as specified and directed.

Supply and fixing , cable jointing kit for 11 KV (Earthed) grade cable for indoor termination heat shrink type joint complete with jointing material and accessories suitable for XLPE armoured aluminium conductor cable of size 185 sqmm x 3 core including taking down old item, complete all as specified and directed.

Supply and fixing , cable jointing kit for 11 KV (Earthed) grade cable for out door termination heat shrink type joint complete with jointing material and accessories suitable for XLPE armoured aluminium conductor cable of size 185 sqmm x 3 core including taking down old item, complete all as specified and directed.

Supply and fixing , cable jointing kit for 22 KV (Earthed) grade cable for indoor termination heat shrink type joint complete with jointing material and accessories suitable for XLPE armoured aluminium conductor cable of size 185 sqmm x 3 core including taking down old item, complete all as specified and directed by Engr-in-charge.

Supply and fixing , cable jointing kit for 22 KV (Earthed) grade cable for out door termination heat shrink type joint complete with jointing material and accessories suitable for XLPE armoured aluminium conductor cable of size 185 sqmm x 3 core including taking down old item, complete all as specified and directed by Engr-in-charge.

M & L for earthing complete with copper plate electrode 60x60cm x3.15mm thick, buried directly in ground (earth pit not less than 2.25 metres deep below ground level) with top edge of the plate not less than 1.5 metres below normal ground level, connected to 25x3mm copper strip as earthing lead by means of bolts, nuts, check nuts and washers of copper all as shown in electrical plate No.3 connected to earthing test point, including 20 mm GI pipe (Medium grade) for watering and 40 mm GI pipe (Medium grade) for protection of earth strip and etc.. including testing on completion ,PCC chambers in PCC1:3:6 type C1, RCC M25 type cover slab 50mm thick with 8mm dia TMT HCR/CRS steel bars at 140mm C/C both way and lifting handle GI funnel & wire mesh ,funnel, lugs and charcoal, salt etc all as applicable complete Note : The unit rate shall also include for excavation, earth work in any type of soil, removal of surplus soil, PCC (1:3:6) type C1 for earth pit cover 6 Nos of 8mm dia CTD bar , RCC cover slab, GI funnel with 40 mm dia watering pipe, wire mesh, 15mm dia light grade GI protection pipe for earth lead etc., complete.

Materials and labour for mobilisation and fault finding of 11 kV HT UG cable of any size and length, in case of cable fault such as short circuit/ burn out or earth fault etc with using proper cable fault locating machine and marking the exact location of fault in the cable complete all as specified and directed.

All as per Sl item No 81 but for marking the exact location of next consecutive fault finding in the cable complete all as specified and directed.

Supply and fix in replacement of panel heaters ( Space heater 80 W) and Thermostat , including necessary wiring complete all as specified and directed.

Supply and fix in replacement 110V DC Electronic Hooter complete all as specified and directed.