COMPREHENSIVE REPAIR, MAINT OF DG SETS AND ALLIED WKS AT AF STN SURATGARH

Supply and fix Diesel water separator filter of Make mahindra / Kirloskar/ cummins/ ashok leyland for the following capacities of

Supply and fix lubrication oil filter element with 'O' ring of Make MICO / Kirloskar / ashok leyland/mahindra as required at site for following capacities of DG Sets

Supply and fix Air filter element inner and outer as required at site with 'O' ring of Make MICO / Kirloskar / ashok leyland as required at site for following capacities of DG Sets :-

Supply and fix fuel filter element with 'O' ring of Make MICO / Kirloskar / Ruston as required at site for following capacities of DG Sets

Supply and fix fan belt of Make - Finner/ Dunlop/Kirloskar as required at site for the following capacities of DG Sets

Labour for carrying out Servicing of DG Sets from OEM for the following DG sets of Make: Cummins/Kirlosker/Greaves/ Mahindra powerol/ Ashok leyland as per manufacturer recommendation/ particular specification including replacement of required necessary spares and Replacement of Filters such as Fuel filter and lub oil filter complete sets along with rectification of minor defects, and cleaning of air filters/ breather,coolant tank with Blower and labour for filling/topping up and replacement of Engine oil/coolant and tuning of engine for DG set as given below Note :- Material required for DG servicing / repair will be paid separately under relevant items.

DG Set capacity up to 35 KVA

DG Set Capacity from 50 KVA to 82.5 KVA

DG Set Capacity from 100 KVA to 125 KVA

DG Set Capacity from 160KVA to 200 KVA

DG Set Capacity from 320 KVA to 400 KVA

Labour for D check of 50 KVA DG set ( Make : Kirloskar), removing all accessories required for repair & replacement, cleaning, lathe work , washing & greasing of all the parts and reassembling the engine after repair & replacement of defective engine parts and commissioning testing on full load complete. (Loc 05 Runway End) Notes for item No-7:- Engine parts required for major repair will be paid separately.

Material & labour for cylinder assembly including rings of 50 KVA DG Set

Material & labour for Piston assembly including piston rings of 50 KVA DG Set

Material & labour for Valve pair / tapet of 50 KVA DG Set

Material & labour for Valve guide of 50 KVA DG Set

Material & labour for Wire snap ring of 50 KVA DG Set

Material & labour for Valve stem Material of 50 KVA DG Set

Material & labour for Oil Seal ( Main & timing) of 50 KVA DG Set

Material & labour for PUSH ROD KIT & Rocker arm of 50 KVA DG Set

Material & labour for SET OF JOINTS of 50 KVA DG Set

Material & labour for Con Rod Bearing & Bushes of 50 KVA DG Set

Material & labour for Small End Bush U/B of 50 KVA DG Set

Material & labour for Lube oil Pump assembly of 50 KVA DG Set

Material & labour for Bonjo Bolts/ eye bolts/ set bolts of 50 KVA DG Set

Material & labour for Lube oil filter of 50 KVA DG Set

Material & labour for Primary air cleaner of 50 KVA DG Set

Material & labour for Disel filter kit of 50 KVA DG Set

Material & labour for Head Gasket of 50 KVA DG Set

Material & labour for Engine block of 50 KVA DG Set

Material & labour for Engine crank of 50 KVA DG Set

Material & labour for Connecting rod of 50 KVA DG Set

Material & labour for Spray nozzles of 50 KVA DG Set

Material & labour for Cam shaft , bushes of 50 KVA DG Set

Material & labour for Safety element for air cleaner of 50 KVA DG Set

Material & labour for FIP/INJECTOR PARTS of 50 KVA DG Set

Supply and fix only solenoid switch in repair suitable for any capacity DG set all as directed

Supply & fixing in replacement of VMR of suitable size , supply voltage 415 v , 50Hz, output contacts, 2 SPDT(C-N/O-N/C) relays, rating 5A at 250 VAC with digital indication complete all as per specified and directed.

Supply and fix only flexible braided hydraulic hose 5/8" dia x 600 mm length including suitable check nuts & washers

Supply and fix only ignition switch with key in repair for DG sets of any capacities all as directed by Engineer-in-charge.

Supply only radiator coolant of synthetic grade. Make Castrol/Gulf/ Kirloskar care

Supply and fix in replacement lead acid 12 V 180 AH battery and initial charging complete including inbuilt charger including required electrolyte /distilled water etc and fixing as required at site to the concerned DG Set all as directed by engineer-in-charge.

Supply and fix in replacemet lead acid 12 V 110 AH battery and initial charging complete including inbuilt charger including required electrolyte /distilled water etc and fixing as required at site to the concerned DG Set all as directed by engineer-in-charge. Note :- Min Warranty of batteries for item No 13 & 14 is not less than 36 months.

M&L for replacement of battery cable of 50 sqmm PVC insulated multi stranded copper conductor single core cable with necessary lugs

M&L for taking out radiator with intercooler of any capacity of DG sets from engine taking it to work shop repair of leakage pipes, cleaning the radiator by using degreasing compound, re-assembling to the engine complete.

Supply and fixing in replacement of fuel level gauge of any capacity of DG sets

Supply and fixing in replacement oil pressure assy with sensor

Supply and fixing in replacement coolant temperature sensor.

M&L for taking out fuel tank of any capacity of DG sets and Clean the sludge/ sediments and rinse the tank with small amount of clean diesel complete all as directed at site.

Taking down unserviceable fuel pump from any type/ capacity DG set, carrying to workshop and M&L for repairing including necessary spares and calibration, refixing the same duly repaired to its original position and testing for its serviceability at site complete all as specified and directed by Engr-in-Charge.

Supply and fix only battery terminal heavy duty as per sample made of brass with bolts and washers all as required at site.

Material and labour for replacement of electronic automatic voltage regulator ( AVR) of 100 V , 8 Amps suitable to DG Set of capacity upto 100 KVA including necessary terminals' sleeves etc as required at site of any type and make of DG Sets. (Make of AVR shall be same as supplied by the DG manufacturer with new DG set.)

Material and labour for replacement of electronic automatic voltage regulator (AVR) of 50 V , 16 Amps suitable to DG Set of capacity from 160 KVA to 400 KVA including necessary terminals' sleeves etc as required at site of any type and make of DG Sets.(Make of AVR shall be same as supplied by the DG manufacturer with new DG set.)

Supply & fix in repair of Self starter assy 24 V complete for DG set of 320 to 400 KVA 24 Volts DC including , complete fixing & testing .

Supply & fix in repair of Self starter assy 12/24 V for DG set of 125 to 200 KVA 12/24 Volts DC including , complete fixing & testing.

Supply & fix in repair of self starter assy 12/24 V for DG set of 50 to 100 KVA 12 volts DC including, complete fixing and testing.

Supply & fix in repair of self starter assy for DG set of 15 to 35 KVA 12 volts DC including, complete fixing and testing.

Taking out unserviceable alternator from DG set, taking to workshop, rewinding with existing size copper conductor, varnishing, drying, refixing, connecting and testing complete all as specified as directed by Engr-in-Charge.

50 to 82.5 KVA alternator

100 to 200 KVA alternator

S&F Rubber hose set for DG set radiator by replacing the unserviceable hose set complete.

15 to 100 KVA DG Set

110 KVA to 200 KVA DG set

380 to 400 KVA

M&L for making smooth surface by scratching the old paints and rubbing with emery paper, filling putty in dents, where required, apply one coat of red oxide primer then apply two coats of synthetic enamel smoke grey DUCO paint with spraying process. The following capacities of DG sets.

30 KVA to 100 KVA DG set

110 KVA to 200 KVA DG set

Supply and fix in replacement of turbo charger of capacity 100 to 200 KVA.

M&L for opening/dismantling and disconnecting all the connections from panel to terminal box, repair/replacing the field coils to the alternator, refixing the field coils to the alternator after drying the varnish and making the electric connections to terminal box with proper brass nut bolts and washers testing and commissioning for satisfaction for the following capacities of DG sets.

15 KVA to 100 KVA DG set

110 KVA to 200 KVA DG set

320 KVA to 400 KVA DG set

Material and labour for complete servicing Auto Mains failure system for operation , control and protection of DG set by complete servcing/ carring out repairs of the power contctors , control contactors, timer units, SMPS units, rectifier units including replacement of worn out control wiring , fuses and testing out out for complete operation of the dg set and AMF system Note:- Spare parts required shall be measured and paid separately or issued by the department.

Supply and fix only electronic timer 12 volt (0-60 sec) suitable for AMF panels in respect of serial item No 34 here-in-before. .

Supply and fix only electronic timer 24 volt (0-60 sec) suitable for AMF panels in respect of serial item No 34 here-in-before. .

Supply and fix only AC timer (O-60 sec) 230 volt AC suitable for AMF panels in respect of serial item No 34 here-in-before.

Supply and fix only thermal overload relay 3 PH, 415 Volt (0-300 Amp) suitable for AMF panels in respect of serial item No 34 here-in-before. .

Supply and fix only cranking relay 12/24 volts DC 8/11 stage suitable for AMF panels in respect of serial item No 34 here-in-before. .

Supply and fix only cranking relay 220 volts AC 8/11 stage suitable for AMF panels in respect of serial item No 34 here-in-before.

Supply and fix only start stop relay card 12/24 volt suitable for AMF panels in respect of serial item No 34 here-in-before.

Supply and fix only indicator lamp assembly LED type with red/green/blue for phases R,Y,B complete all as specified suitable for AMF panels in respect of serial item No 34 here-in-before.

Labour only for identification of breakdown of any type and rectification of minor defect of DGs of any capacity and make with proper record mentioning date and nature of defect duly signed by JE E/M and AGE E/M. Notes for item No-44:- (1.) Spares required for major repair will be paid separately. (2) This items pertains to attending complaints of DG Sets and reqiured necessary T&P and safety equipments will be the responsibility of contractor etc.

Supply & fix only 4 Pole power contactor with AC coil 400 Amps, 3 phase 415 volt 50 HZ suitable for AMF panels all as specified and directed. Make:-Havells/GE/L&T/Siemens

Supply and fix only 4 Pole power contactor with AC coil 250 Amps, 3 phase 415 volt 50 HZ suitable for AMF panels all as specified and directed. Make:-Havells/GE/L&T/Siemens

Supply and fix only 4 Pole power contactor with AC coil 200 Amps, 3 phase 415 volt 50 HZ suitable for AMF panels Make:-Havells/GE/L&T/Siemens

Supply and fix only AC coil 230/440 V suitable for 200 Amps , 3 phase 415 volt 50 HZ power contactor

Supply and fix only AC coil 230/440 V suitable for 400/500 Amps , 3 phase 415 volt 50 HZ power contactor

Supply and fix only multifunction meter suitable for AMF panels.

Supply and fix only engine start relay 12 volt DC suitable for AMF panels .

Supply and fix only engine start relay 24 volt DC suitable for AMF panels .

Supply and fix in replacement benzo pipe of standard size 17x17mm,19x19mm &17x19mm from tank to diesel pump of dg set all as directed.

M&L for Painting to outdoor/indoor type AMF panel box internally as well as external surfaces complete with two coat of synthetic enameled paint over a coat of red oxide primer of approved colour including of preparation of old surfaces of Panel complete all as specified and as directed.

M&L for control wiring with single core copper cable of size 2.5 sqmm from AMF panel to DG set all as specified and directed.

M&L for control wiring with five core copper cable of size 2.5 sqmm from AMF panel to DG set all as specified and directed.

S&F Battery charger( automatic type) 12 V 10 A ( DG Capacity up to 160 KVA) for AMF panel mounted operating on 230 V single phase 50 Hz supply having automatic cut off facility after charging of battery, by replacing unserviceable charger.

S&F Battery charger ( automatic type) 24 V 10 A ( DG Capacity 200 KVA to 400 KVA) for AMF panel mounted operating on 230 V single phase 50 Hz supply having automatic cut off facility after charging of battery, by replacing unserviceable charger.

Supply and fix in replacement of DG Controller of capacity 110 KVA -125 KVA of existing make 12 volt complete all as directed by Engr-in-charge.

Supply and fix in replacement of DG Controller of capacity 160 KVA - 200 KVA of existing make 12/24 volt complete all as directed by Engr-in-charge.

M&L earthing complete with GI earth plate electrode 600mmx600mmx6mm thick, buried directly in ground (earth pit not less than 2.25 metres deep below ground level) with top edge of earth plate not less than 1.5 mtrs below normal ground level connected with GI earth strip 32x6mm thick and copper bolts, nuts, etc and protected by GI pipe light grade 40mm bore and 20 mm dia GI tubing light grade with funnel for watering, connecting to busbar, all as shown in electrical plate No.3 of SSR Part I incl necessary earth work and excavation in any type of soil, PCC earth chamber with RCC cover slab, salt, charcoal and MS hook, ane provn of test point complete.

"Supply, installing, testing and commissioning in replacement of factory made AMF Panel CPRI approved for 100 KVA capacity DG set indoor type platform mounted, suitable for accommodating all MCCBs with input voltage 415 volts 3.5 phase 4 wire, 50 Hz AC supply system complete all as specified and directed having aluminium bus bar installed on DMC/Epoxy insulators. The panel shall be dust and vermin proof, IP-65 class protection and made of 2mm thick CRCA MS sheet with front and rear opening type with double door shutter and locking arrangement (including provision of lock with 2 keys), powder coated finish over a coat of red oxide, primer on outside and two coats of red oxide primer on inside surface. The panel is installed over a platform of suitable size with PCC 1:3:6 type C-2 using with 40mm crushed stone aggregate 20cm in thick in foundation and of height upto 0.5 mtr, complete all as directed at site. All interconnections between the main bus bar as well as outgoing feeders shall be carried out with TPN aluminium bus bar of rating not less than 1.5 times rated capacity of individual MCCB and should be insulated with shrinkable PVC sleeves. The MCCB should be adjustable type. The scope of work includes provision of following. (Note:- The item includes control cabling from DG set to AMF Panel as per requirement)" ( Loc 275 SU)

Note:Team for repairing of DG and AMF panel should be ready at every time with all necessary equipments during working hours and repair action should be started within 2 hrs after complaint intimation to contractor/ superwiser through phone call or text message or by any other means. 1000 Rs penalty shall be imposed at each violation of above direction.

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