REPAIR/ROUTINE MAINTENANCE, TOP OVER HAULING OF DG SET AND AMF PANEL AT AF STATION CHANDIGARH UNDER GE (AF) CHANDIGARH

Amount

Servicing & maintenance of DG sets of capacity 15 KVA to 30 KVA through authorised representative of company to the entire satisfaction of Engineer-in-Charge complete as per following:- (i) Draining out engine/ lubrication oil, flushing and pouring new engine oil after repair of DG set including supply and replacement of oil pan/chamber gasket.(Engine oil shall be measured and paid under respective items). (ii) Supply and replacement of oil filter element. (iii) Supply and replacement of fuel filter element. (iv) Supply and replacement of fuel water separator. (v) Supply and replacement of element air cleaner/ filter. (vi) General servicing of DG set by opening of tappet cover/top cover, tappet clearance setting with injector timing adjustment, re-fixing of tappet/top cover including supply and replacement of tappet cover packing set, shellac/bostic tube. (vii)Checking of auto programming & manual processing. (viii)Tightening of all electrical connection, AVR connections, alternator connection and Panel connections. (ix) Tightening of all the hoses, Fuel connections. (x) Tightening/ adjustment of 'V' belts. (xi) Cleaning of silencer muffler. (xii) Checking & adjustment of battery terminals & taking out defective for replacement. (xiii) Cleaning of radiator with appropriate means as per standard practice. (xiv) Supply and topping up /filling up of radiator with K cool. (xii) Testing of Engine on load for 12 hours as per Particular Specification.

All as per item No. 1.00 above but DG set of capacity exceeding 50 KVA but not exceeding 63 KVA.

All as per item No. 1.00 above but DG set of capacity exceeding 100 KVA but not exceeding 160 KVA.

All as per item No. 1.00 above but DG set of capacity exceeding 160 KVA but not exceeding 250 KVA.

All as per item No. 1.00 above but DG set of capacity exceeding 250 KVA but not exceeding 320 KVA.

Supply only lubricant oil (Engine oil) of viscosity grade SAE 20W/40for filling in DG set of any capacity installed at different locations in situ at site including draining out existing oil complete all as specified and directed.

Supply, install, connecting & commissioning 180AH, 12 Volts maintenance free, factory charged, ready to use battery including disconnecting and taking out existing battery complete all as specified and directed.

Supply, install, connecting & commissioning 150AH, 12 Volts maintenance free, factory charged, ready to use battery including disconnecting and taking out existing battery complete all as specified and directed.

Supply, install, connecting & commissioning 100AH, 12 Volts maintenance free, factory charged, ready to use battery including disconnecting and taking out existing battery complete all as specified and directed.

Supply and fix in replacement automatic voltage regulator, 415volts, AC suitable for 63KVA to 200KVA DG set complete all as specified and directed.

Supply and fix in replacement automatic voltage regulator, 415 volts, AC suitable for 250KVA to 320KVA DG set complete all as specified and directed.

M&L for rewinding of self-starter 12 volts, including armature winding ,plunger , carbon bushes, spring and other connected acessories as fixed in position & testing including dismantling & opening complete all as specified and directed.

M&L for rewinding of self-starter 24 volts, including armature winding ,plunger , carbon bushes, spring and other connected acessories as fixed in position & testing including dismantling & opening complete all as specified and directed.

Supply & replacement of battery leads of PVC insulated sheathed multi core copper conductor 25Sqmm (nominal area) heavy duty cable 1.5m long with copper lugs duly crimped & soldered in one side and battery terminal on other side complete all as specified and as directed.

Supply and fixing battery terminal of aluminium with marking (+)/(-) fixed in position and testing, including taking down and removal, complete all as specified and as directed.

Supply and filling engine coolant in radiators of DG sets as per Manufacturer's recommendations installed at different locations brought at site in sealed packets complete all as specified and directed. Make:- SERVO, GOLDEN CRUISER, SHEEL, TOTAL, BPL.

Supply and filling distilled water in batteries of DG sets at different locations, brought at site in 40 litre plastic sealed containers complete all as specified and directed.

Supply and replacement self starter 12 volts fixed in position and testing complete all as specified and directed. Make: LUCAS or equivalent.

Supply and replacement self starter 24 volts fixed in position and testing complete all as specified and directed. Make: LUCAS or equivalent.

Supply and fixing Automatic Transfer Switch (ATS), 4pole, 415 Volts , with inbuilt time delay, with enclosures of rating 160 Amp, confirming IEC-60947-1 and IEC-60947-6-1, including taking down old and removal, complete all as specified and directed. Make: Havells/ L&T/Indoasian/ABB

Supply and fixing Automatic Transfer Switch (ATS), 4pole, 415 Volts , with inbuilt time delay, with enclosures of rating 200 Amp, confirming IEC-60947-1 and IEC-60947-6-1, including taking down old and removal, complete all as specified and directed. Make: Havells/ L&T/Indoasian/ABB

Supply and fixing Automatic Transfer Switch (ATS), 4pole, 415 Volts , with inbuilt time delay, with enclosures of rating 400 Amp, confirming IEC-60947-1 and IEC-60947-6-1, including taking down old and removal, complete all as specified and directed. Make: Havells/ L&T/Indoasian/ABB

S&F in replacement for power contactor 4 pole type 80/ 100 Amp including all accessories like auxiliary contacts etc. complete all as specified and directed. Make: L&T or equivalent.

S&F in replacement for power contactor 4 pole type 160 Amp including all accessories like auxiliary contacts etc. complete all as specified and directed. Make: L&T or equivalent.

S&F in replacement for power contactor 4 pole type 200/ 250 Amp including all accessories like auxiliary contacts etc. complete all as specified and directed. Make:L&T or equivalent.

S&F in replacement for power contactor 4 pole type 400 Amp including all accessories like auxiliary contacts etc. complete all as specified and directed. Make: L&T or equivalent.

S&F in replacement of MCCB , 04 Poles ,125 Amps, 25 KA, 50Hz,415 volts , Ics= 75 % of Icu Adjustable Thermal & Adjustable Magnetic type complete all as specified and directed.

S&F in replacement of MCCB , 04 Poles ,160 Amps, 25 KA, 50Hz,415 volts , Ics= 75 % of Icu Adjustable Thermal & Adjustable Magnetic type complete all as specified and directed.

S&F in replacement of MCCB , 04 Poles ,200 Amps, 25 KA, 50Hz,415 volts , Ics= 75 % of Icu Adjustable Thermal & Adjustable Magnetic type complete all as specified and directed.

S&F in replacement of MCCB , 04 Poles ,250 Amps, 25 KA, 50Hz,415 volts , Ics= 75 % of Icu Adjustable Thermal & Adjustable Magnetic type complete all as specified and directed.

S&F in replacement of MCCB , 04 Poles ,400 Amps, 36 KA, 50Hz,415 volts , Ics= 100 % of Icu Adjustable Thermal & Adjustable Magnetic type complete all as specified and directed.

S&F in replacement door hinges suitable for 63 KVA to 320 KVA DG set of existing type including welding and made to shape all as per specified and directed.

S&F in replacement V-Belt ISI marked, complete all as specified and as directed.

S&F in replacement oil pressure gauge ISI mark, complete all as specified and as directed.

S&F in replacement oil temperature gauge ISI mark, complete all as specified and as directed.

S&F in replacement fuel gauge meter ISI mark, operated on 12/24V DC all as specified and directed.

S&F in replacement high temperature diesel hose pipe of 1000 PSI for connecting from diesel tank outlet to engine complete with banjo bolt & washer suitable for DG set of capacity upto 100 KVA all as specified and directed.

S&F in replacement high temperature diesel hose pipe of 1000 PSI for connecting from diesel tank outlet to engine complete with banjo bolt & washer suitable for DG set of capacity 125 to 320 KVA all as specified and directed.

M&L for dismantling of exhaust pipe of silencer, cleaning of silencer to remove carbon deposit inside exhaust pipe and refixing including replacement of worn out rubber gasket packing and nuts, bolts etc. complete all as specified and directed.

M&L for scraping out old paint from DG set of upto 160 KVA including chassis, radiator and exhaust pipe washing with caustic soda to wipe out greasy material and applying two coats of heat resistant paint using spray gun including writing SM/ MES No. of engine and the alternator with total alphabets not exceeding 20 No. with white signal paint complete all as specified and directed.

All as per item No 40.00 above but of capacity 160 to 320 KVA.

Supply and installation in replacement controller meter of DG sets suitable for 62.5/ 100 KVA alongwith the new display panel specifications complete all as directed.

Supply and fixing in replacement battery charger unit for 20 to 125 KVA DG Set suitable for 12 V 180 AH complete with 2m copper leads -02 Nos & brass clamps complete all as specified and directed.

M&L for taking out FIP from DG set of capacity 63 to 100 KVA, transportation to authorized service centre for overhauling and recalibration and refixing to DG set including replacement of spare parts such as delivery valves, plunger, 'O' rings spring etc. complete all as directed.

M&L for taking out FIP from DG set of capacity 125 to 320 KVA, transportation to authorized service centre for overhauling and recalibration and refixing to DG set including replacement of spare parts such as delivery valves, plunger, 'O' rings spring etc. complete all as directed.

M&L cleaning of diesel tank of DG set of any capacity including replacement of worn out pipe line and measuring scale and fixing in original position and make it leak proof with necessary clamps complete all as specified and directed.

Supply and fixing in replacement radiator hose pipe for DG Set, complete all as specified.

M&L for replacement of change over switch off load side operated of capacity 200 Amp complete all as specified.

M&L for replacement of change over switch on load side operated of capacity 200 Amp complete all as specified.

Attending day to day complaints of the DG sets of various capacities including all major/ minor repairs as per the scope of the contract all as directed by Engineer-in-Charge. Notes: (a) The complaint shall be attended by the auth rep of the manufacturer by an experienced and professional mechanic. (b) The complaint shall be attended on the same day. (c) Non functioning of any DG set will be sole responsibility of the contractor and a penalty of Rs. 500/- for each hour of non running will be levied on the contractor. (d) The mechanic shall make a visit on all the generators on weekly basis.

Supply, laying, jointing and testing LT XLPE cable insulated, screened, PVC bedded, galvanized steel strip or wire armoured, electric power cables (heavy duty) 1100 volts grade with stranded aluminium conductor of size 95 sqmm 3½ core laid in trenches/ passing through GI tubing etc. including taking out existing LT XLPE cable complete as specified and directed.

Supply, laying, jointing and testing LT XLPE cable insulated, screened, PVC bedded, galvanized steel strip or wire armoured, electric power cables (heavy duty) 1100 volts grade with stranded aluminium conductor of size 70 sqmm 3½ core laid in trenches/ passing through GI tubing etc. including taking out existing LT XLPE cable complete as specified and directed.

Excavation in trenches in soft/ loose soil not exceeding 1.5 mtr wide and not exceeding 1.5 mtr in depth for foundation of pole, laying of cable etc. and getting out complete all as specified and directed.

Returning and filling in excavated soil in layer not exceeding 25cm thick in including spreading, levelling, watering and well ramming in soft/ loose soil complete all as specified and directed.

Removing excavated surplus soil to a distance not exceeding 50 mtrs and depositing where directed at a level not exceeding 1.5mtrs above the starting points complete all as specified and directed.

M&L for sand cushioning to cables with a layer of sand 8cm deep before laying the cable and 15cm depth after laying & stretching of cable) complete all as specified. Note: Punned thickness overall 18cm shall be measured & paid.

Supply and laying old size sub class ‘B’ bricks as in protection of cable laid dry flat perpendicular to direction of cable abutting each other complete all specified and directed.

M&L for earthing complete with GI earth plate electrode of size 600mm x 600mm x 6mm thick burried directly in ground vertically at a depth not less than 2.25m below normal ground level with top edge of earth plate not less than 1.5m below normal ground level, earth plate surrounded from all sides by 15cm thick packed alternate layers of charcoal dust and common salt, electrode connections using galvanized iron strip of size 32mm x 6 mm thick (upto body of equipment) by means of nuts, bolts, check nuts & GI washers connected to main switch board or main control board or test point, protected by galvanized iron pipe light grade 40mm dia bore, and watering pipe 20mm dia bore GI light grade with funnel & wire mesh including all necessary excavation & earth work, PCC chamber in PCC (1:2:4) type B-1, RCC cover, all as shown in electrical plate No 3 of MES Schedule Part-I (2009), testing on completion, including taking out old u/s earthing materials complete all as specified and directed. Note(s) :- (i) RCC pit cover shall be pre-cast of RCC (1:1½:3) type B-1, 80mm thick reinforced with XPM not less than 4Kg/Sqm. (ii) PCC chamber shall be constructed 500 mm away from the edge of earth pit. (iii) Rate shall include GI strip and protection pipe of length 7.5m, excess beyond 7.5m length required at site shall be measured and paid separately. (iv) Earth resistance shall be less than 3Ohm. In case test results are not found below 3Ohm, complete earthing will be re-done without any extra cost to Govt.

M&L for cleaning of radiator fins of DG set of capacity 63 KVA to 160 KVA by blow pressurized air through radiator fins in reverse direction to the fan flow including internal cleaning by filling K-clean to remove contaminants like scale, oil, grease or unwanted materials; K-clean to be added in ratio 375ml for every 16 litre capacity of radiator and solution to be drained out after running of engine for minimum of 30 minutes and repeating the process till the contentious, scale are completely removed including filling the radiator with genuine coolant premix (Supply only of coolant to be measured and paid separately) including soldering/ welding work to radiator fins if found leaked including transportation to civil workshop and fixing back fixing the same in position complete all specified and directed.

All as per item No. 59.00 above but but radiator of DG set of capacity 250 KVA to 320 KVA.

M&L for taking out alternator assembly of DG set of capacity 63 KVA to 125 KVA with the help of puller and opening the cover of alternator assembly for varnishing the winding, cleaning the stator/ rotor assembly using tetra chloride solution to wash unwanted contents on the winding and applying two coats of ‘F’ class varnish in the winding of DG set, drying the same using heating arrangement or hot blower complete all as specified and directed.

M&L for isolating the main supply from the DG set of capacity 125 KVA, dismantling the complete engine by taking out head, sump piston assembly, water sleeves, connecting rod, big end bearing, main end bearing, tapped assembly, inlet and outlet valves etc. including drainage out engine oil and keeping in container, Reassembly of engine after replacement of required accessories and testing the engine after making connection with alternator on load to the satisfaction of Engineers-in-Charge. Labour charges for replacement of new parts shall be deemed to be included in this item. However, supply of items required to be replaced will be paid separately. Parts where grinding, calibration or lapping is required at workshop will be measured and paid separately. Accessories required for overhauling of DG set shall be measured and paid separately.

M&L for decarburization of valve heads of DG of capacity 125 KVA and job making the surface free from carbon contents and lapping of inlet and outlet valve 12 No’s complete all as directed.

M&L for complete overhauling of fuel injecting pump of DG set of capacity 125 KVA and replacement of plungers, delivery valve and spring washer, cam shaft, pump, rack & pinion and testing the same after carrying out the job work from authorized workshop complete as specified and directed by Engineer-in-charge.

M&L for repair of injector nozzle of DG set of capacity 125 KVA and testing the injector assembly- 6 No. for proper delivery of the fuel including replacement of any parts like spring washers, plunger and barrel spring required complete as specified and directed by Engineer-in-charge.

Supply only the following parts for DG set of capacity 125 KVA:-

Liner assembly

Piston ring set

Gasket set complete for lower and upper parts

Water pump assembly

Thermo-state

Turbo charger repair kit

Fan belt

Diode assembly 1000 volt, 40Amp

Air Filter

Fuel filter

Oil filter

Hose pipe set

M&L for repairing/ rewinding the alternator of DG Set 63 to 350 KVA complete with taking out unserviceable alternator with disconnecting the electrical connections and rewinding the burnt alternator with appropriate size of copper wire, leatherised rubber and opening the coil complete with vanishing the coils & making connections all as specified and directed by the Engineer-in-Charge.

(p) CT Coil 200/5 - 03 Nos (q) DC Amp Meter 0-15 A -01 No (r) Trickle /Boost switch 0-15A - 01 No (s) Auto/Mannual Switch - 01 No (t) Start and stop Push button - 02 Nos (u) Frequency Meter - 01 No (v) Power contactor 200A 3 pole 415V for DG - 01 No (w) Power contactor 200A 3 pole 415 V for Main - 01 No (x) MCCB 250 A 25 KA 3 pole - 02 Nos (y) Fuse Base 250A - 06 Nos (z) Control Relay - 01 Set (aa) Over load Relay 2.5-4A. - 01 No

(p) CT Coil 200/5 - 03 Nos (q) DC Amp Meter 0-15 A -01 No (r) Trickle /Boost switch 0-15A - 01 No (s) Auto/Mannual Switch - 01 No (t) Start and stop Push button - 02 Nos (u) Frequency Meter - 01 No (v) Power contactor 125A 3 pole 415V for DG - 01 No (w) Power contactor 125A 3 pole 415 V for Main - 01 No (x) MCCB 160 A 25 KA 3 pole - 02 Nos (y) Fuse Base 160A - 06 Nos (z) Control Relay - 01 Set (aa) Over load Relay 2.5-4A. - 01 No

Maintenance, repair, servicing of Automatic Mains Failure panel 24Volt DC and 440Volt AC supply operated system by locating faults and replacement of unserviceable parts and components, for DG set 63KVA to 125KVA, 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) Material and labour, painting of AMF panel metallic body surface with one coat of superior quality synthetic enamel paint of approved colour and 1st quality including replacement of worn out rubber beading. (e) Testing of system on load. Note : Supply & fix, spare parts for replacement where required, shall be measured and paid separately.

All as per Serial Item No. 70.00 here-in-before but capacity 160KVA to 320KVA, complete all as specified and directed.

S&F in replacement Voltage monitoring relay door mountable 3 phase with 2 relay potential free outputs 7 segment display, 415 volt under and over voltage protection, 3 pole all as specified and directed.

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