GE (P) AF/GUR-46/2021-22 REPAIR, MAINTENANCE, OF DG SETS ENGINE, ALTRNATOR, OVER HEAD ELECTRIC CRANE AND OTHER CONNECTED WORKS AT AF STN GURGAON UNDER GE (P) AF GURGAON

Amount

M&L for Serviceing and periodical maintenance of DG sets of following capacity including cleaning internal parts thoroughly , replacement of oil filter, fuel filter, air cleaner, turbo charger etc and making smooth valve seats of inlet and exhaust valves including replacement of minor parts such as nut, bolts, washers, benjo nut, bolts, washers, locking nuts, circlips, `O’ Rings, Gasket, main cylinder head joint screws, stud small springs as deemed necessary or ordered complete and reassembling after replacement of unserviceable parts including painting with one coat of syntheteic enamemled paint of existing colour after removing dust, dirt and oil by castic soda etc, commissioning and testing on connected load complete all as specified and directed by Engineer-in-Charge of the following DG Sets:- (Note : The quoted rates of the contractor includes for fixing the serviceable parts in position and replacement of unserviceable parts with new parts. The new replaced spare parts which are catered in BOQ for supply only shall be measured and paid for separately . However essential minor parts/work which is required for sound engineering practice shall be deemed to include in the coated rate of this item):-

10/15/20 KVA DG Set.

25/30/40 KVA DG Set.

60/63/75 KVA DG Set.

100 KVA DG Set.

400 KVA DG Set.

Supply only of Lubricant oil filter element complete with plane washer, 'O' ring etc. complete all as specified and as directed by Engr-in-charge to incorporate in DG Sets repairs against items No 1 here-in-before for the following:- (Make-Mico/Flit Guard/ Donalson)

10/15/20 KVA DG Set.

25/30/40 KVA DG Set.

60/63/75 KVA DG Set.

100 KVA DG Set.

400 KVA DG Set.

Supply only of Fuel filter element complete with plane washer, 'O' ring etc. complete all as specified and as directed by Engr-in-charge to incorporate in DG Sets repairs against items No 12 here-in-before for the following:- (Make-Mico/Flit Guard/ Donalson)

10/15/20 KVA DG Set.

25/30/40 KVA DG Set.

60/63/75 KVA DG Set.

100 KVA DG Set.

400 KVA DG Set.

Supply only of Air filter element complete with plane washer, 'O' ring etc. complete all as specified and as directed by Engr-in-charge to incorporate in DG Sets repairs against items No 1 here-in-before for the following:- (Make-Mico/Flit Guard/ Donalson)

10/15/20 KVA DG Set.

25/30/40 KVA DG Set.

60/63/75 KVA DG Set.

100 KVA DG Set.

400 KVA DG Set.

Draining-out old spoiled lubrication oil from DG Sets of 10 to 400 KVA capacity of any make, cleaning thoroughly the same including supply and filling lubrication oil SAE-40 into the chamber/sump complete all as specified and directed Engineer-in-Charge. Make SERVO OF IOC/HINDUSTAN PETROLEUM/BPCL

Supply only flexible pipe, filter to lub oil cooler including banjo bolt washers, copper asbestos washer, spring washer nuts and bolts etc for following DG sets :-

10/15/20 KVA DG Set.

25/30/40 KVA DG Set.

60/63/75 KVA DG Set.

100 KVA DG Set.

Supply only V Belt to incorporate in DG Sets against item No 1 here-in-before complete all as specified and directed by Engineer-in-Charge for the following DG Sets :-

10/15/20 KVA DG Set.

25/30/40 KVA DG Set.

60/63/75 KVA DG Set.

100 KVA DG Set.

Draining out the diesel tank, cleaning / washing out the sedimentation using Kerosine and re-filling with diesel upto 400KVA DG sets (Note: Diesel will be provided by the department)

M&L for rewinding of alternator with approved copper wire including replacement of bearings etc if required, transportation from site to workshop and back after repairing and refixing the same in DG set with testing complete all as per specified and directed by Engr-in-charge of the following DG Sets:-

10/15/20 KVA DG Set.

25/30/40 KVA DG Set.

60/63/75 KVA DG Set.

M & L for overhauling of DG sets upto 100KVA capacity including cleaning internal parts thoroughly , replacement of oil filter, fuel filter, air cleaner, turbo charger etc and making smooth valve seats of inlet and exhaust valves including replacement of minor parts such as nut, bolts, washers, benjo nut, bolts, washers, locking nuts, circlips, `O’ Rings, Gasket, main cylinder head joint screws, stud small springs as deemed necessary or ordered complete and reassembling after replacement of unserviceable parts including painting with one coat of syntheteic enamemled paint of existing colour after removing dust, dirt and oil by castic soda etc, commissioning and testing on connected load complete all as specified and directed by Engineer-in-Charge of the following DG Sets:- (Note : The quoted rates of the contractor includes for fixing the serviceable parts in position and replacement of unserviceable parts with new parts. The new replaced spare parts which are catered in BOQ for supply only shall be measured and paid for separately . However essential minor parts/work which is required for sound engineering practice shall be deemed to include in the coated rate of this item):-

Supply only in replacement of Piston set complete all as specified and directed by Engineer-in-Charge.

Supply only in replacement of Piston Ring complete all as specified and directed by Engineer-in-Charge.

Supply only in replacement of piston linear with linear ring complete of complete all as specified and directed by Engineer-in-Charge.

Supply only in replacement of CR bearing set of complete all as specified and directed by Engineer-in-Charge.

Supply only in replacement of Piston set of complete all as specified and directed by Engineer-in-Charge.

Supply only in replacement of Cylinder Head complete all as specified and directed by Engineer-in-Charge.

Supply only in replacement of Cylinder liner complete all as specified and directed by Engineer-in-Charge.

Supply only in replacement of Cylinder Head Valve complete all as specified and directed by Engineer-in-Charge.

Supply only in replacement of Cylinder Head Seat of complete all as specified and directed by Engineer-in-Charge.

Supply only in replacement of Cylinder Head guide of complete all as specified and directed by Engineer-in-Charge.

Supply only in replacement of Wall Seal of complete all as specified and directed by Engineer-in-Charge.

Supply only in replacement of Push Guide Box of complete all as specified and directed by Engineer-in-Charge.

Supply only in replacement of Front and Rear Oil Seal of complete all as specified and directed by Engineer-in-Charge.

Supply only in replacement of unserviceable Oil Pump with oil pump gear for all all as specified and directed by Engr-in-Charge. Make - Bosch

Supply only in replacemet of Push Rod of DG complete all as specified and directed by Engineer-in-Charge.

Supply only in replacement of Turbo Kit for upto 100 KVA complete all as specified and directed by Engineer-in-Charge.

Supply only in replacement of Fly Wheel Ring for rating complete all as specified and directed by Engineer-in-Charge.

Supply and fix nozzle assembly (MICO NO 9430 0 ) complete with washer, banjo, bolt, copper washer etc suitable for 100 KVA DG set diesel engine set complete all as specified and directed by Engineer-in-Charge.

Supply and fix leak off pipe assembly for nozzle assembly complete all as specified and directed by Engineer-in-Charge.

M&L for disconnecting and taking down fuel filter assembly, cleaning thoroughly fuel filter housing complete and replacement of the fuel filters/fuel pipe etc complete all as specified and directed by Engineer-in-Charge. (Supply of item measured and paid seperately).

Supply only of Prefilter insert with sealing ring Make Mico Cat No 9451037404 complete all as specified and as directed by Engr-in-charge.

Supply only of Micro super filters element with sealing ring Make Mico,Cat No 9451037405 complete all as specified and as directed by Engr-in-charge.

Supply only of Flexible fuel pipe cat No 34035030 complete all as specified and as directed by Engr-in-charge.

M&L for disconnecting and taking down old unserviceable self starter, 12/24Volt and dismantling complete for repair and replacement of the Following parts :- (a) Armature – 01 No (b) Solenoid switch – 01 No. (c) Field coil – 01 No. (d) Commentator – 01 No. (e) Carbon brush – 02 Nos. (f) Bendex assembly – 01 No

S&F in replacement of water Temp sensor of upto 400KVA DG set complete all as specified and as directed by Engr-in-charge.

Disconnecting and taking down old unserviceable worn out 12/24 volts dynamo from the DG set, supply and fix, test new alternator A-115, 12/24 V with and incl. complete accessories such as connection , wiring, Nuts, Bolts Bracket for alteration, plain washer, spring washer, screws etc all as specified and directed. Make: LUCAS/Kirloskar/Cumins.

M&L for disconnecting and taking down old unserviceable water pump assembly for repair and over hauling, dismantling the complete water pump assembly filling metalling, grindings and turning the bearing housing and impeller housing including replacement of minor spares such as nuts, bolts, plain washers, spring washers, circlips, spacer, oil seal, joints etc. including assembling the water pump assembly, fixing back at removed place, testing and commissioning complete all as specified and directed by Engineer-in-Charge. Note :- Other spare parts shall be measured and paid for separately under relevant item hereinafter).

Supply only following spare parts for water pump assembly as repaired complete all as specified and directed by Engineer-in-Charge:-

Ball bearing –SKF-6203

Ball bearing –SKF-6303

Shaft for water pump

Bronze Impeller

Supply and fix battery leads, heavy duty copper stranded conductor with brass terminal and thimble 1.5 mtr long complete all as specified and directed by Engineer-in-Charge.

Supply and fix brass terminal for batteries including taking out and removing existing unserviceable terminals complete all as specified and directed by Engineer-in-Charge.

Supply and fix in replacement of complete radiator assembly suitable upto 100 KVA, KIRLOSKAR BLIS DG Set with all accessories such as Joints hoses, hose clip, nuts, bolts, washer, spring washers spacer, Fan guard, anti-vibration pad, screw sets etc complete all as specified and directed by Engineer-in-Charge.

Dismantling the radiator of following DG sets, cleaning and de-scaling of chocked water tubes and jackets of radiator, cleaning the fins of radiator with acid and Jet spray including brazing of worn out copper tubes, body and for removing all chocked from the pipes by pressure washing and by using suitable solutions, checking for leakage, arresting leakage if any do welding / brazing, fusing, drying and refixing including replacement of the worn out minor spares such as Joint Hose Pipe, plain washers, spring washers, screws nuts, bolts, joints, rubber hoses with clip etc complete all as specified and directed of the following DG sets:-

10/15/20 KVA DG Set.

25/30/40 KVA DG Set.

60/63/75 KVA DG Set.

100 KVA DG Set.

400 KVA DG Set.

Supply and filling Coolant complete all as specified and directed by Engineer-in-Charge. Make : Castrol/HP/Power Oil

Supply and fix in replacement of unserviceable AVAR for 15 to 40 KVA GEN SET, complete all as specified and directed by Engineer-in-Charge.

Supply and fix in replacement maintenece free battery (24 months replacement warranty) duly initial charged 12 volt 180 AH complete all as specified and directed by Engr -in-charge. Make: Exide/Amron/TATA Green.

Supply and fix in replacement maintenece free battery (24 months replacement warranty) duly initial charged 12 volt 90 AH complete all as specified and directed by Engr -in-charge. Make: Exide/Amron/TATA Green.

S&F in replacement Automatic transfer switch(ATS) Confirming to IEC: 60947-1 and IEC: 60947-6-1, four pole, AC-33A, 50 Hz 440 volt automatic/manual with in built time delay of capacity 200 Amps, complete all as specified and directed by Engineer-in-Charge.

S&F in replacement Voltage monitor relay (3 phase ) AC : 110/ 415Volt Setting 75 -100/300 - 400 V, complete all as specified and directed by Engineer-in-Charge. Make :- Teknika Type TE 211 flush or of the existing make.

Supply and fix in replacement Over current relay definite time Non directional ,definite time & current adjustable setting 0.5 -5A 1-10A /0.1-1A time 0-10 sec, complete all as specified and directed by Engineer-in-Charge. make :- Teknika Type TE 510 internal or of the existing make.

Supply and fix in replacement Battery Volt relay 12/24 volt DC, complete all as specified and directed by Engineer-in-Charge. Make :-Teknika or of the existing make.

Supply and fix in replacement Timer AC/DC on delay -sec, complete all as specified and directed by Engineer-in-Charge. Make :- Teknika TE 100 internal or of the existing make.

Supply and fix in replacement Battery charger 12 volt complete all as specified and directed by Engineer-in-Charge.

Supply only shut down coil suitable upto 400 KVA DG SET complete all as specified and directed by Engineer-in-Charge.

Taking out Unsv MCCB and supply and fix new Moulded Case Circuit Breaker (MCCB) AN frame of capacity 100 Amps, Four pole, 415 volts, 35 KA fixed thermal & fixed magnetic setting complete all as specified and directed by Engineer-in-Charge.

Taking out Unsv MCCB and supply and fix new Moulded Case Circuit Breaker (MCCB) AN frame of capacity 200 Amps, three pole, 415 volts, 25 KA fixed thermal & fixed magnetic setting complete all as specified and directed by Engineer-in-Charge.

Earthing of machinery/equipment installed at power house / substation , using 32 X 3 mm GI strip and GI plate of size 600 X 600 X 6 MM as earth electode directly in ground (earth pit not less than 2.25 m deep below) ground with top edge of plate not less than 1.5m below normal ground level earth plate surrounded by 15 cm thick packed layer of charcoal. and strip protected by GI pipe 15 mm dia bore and 50 mm dia GI pipe light grade for watering 180 cm long bottom and kept on earth plate top end threaded and pluged with removeable cap or plug including 3 Nos 5 mm dia hole at ground level and PCC 1:2:4 block 30 cm x 30 cm x 30 cm for protection flushing with ground level complete all as specified and directed by Engineer-in-Charge.

S&F Earth continuity conductor or main earthing lead fixed to wall on batten or recess or chases or buried in ground or drawn in conduit/pipe or fixed to poles or any other indicated situation for loop earthing etc. as required 25x4mm galvanised iron strip complete all as specified and directed by Engineer-in-Charge.

Supply and fix in replacement Solenoid switch 12 volt, complete all as specified and directed by Engineer-in-Charge.

Supply and fix in replacement of HRC Fuse Link 125/100 A, 415 V AC, DIN Type, 100 KA. complete all as specified and directed by Engineer-in-Charge.

S&F in replacement Changeover switchs of capacity 200Amps operated 415V , 50 Hz conforming IS/IEC 60947-1 & 3 complete all as specified and directed by Engineer-in-Charge.

S&F in replacement Changeover switchs of capacity 160 Amps operated 415V , 50 Hz conforming to IS/IEC 60947-1 & 3, complete all as specified and directed by Engineer-in-Charge.

S&F in replacment 3 Pole power contractor - Type MNX 110 of AC 1 current rating 160 Amp and AC3 rating 110 Amp with auxilary contact 2NO + 2 NC, complete all as specified and directed by Engineer-in-Charge. Cat Part No CS 94137 of make L&T or equivalent out of makes specified in list of makes.

S&F in replacment 3 Pole power contractor - Type MNX 95 of AC 1 current rating 160 Amp and AC3 rating 95 Amp with auxilary contact 2NO + 2 NC, complete all as specified and directed by Engineer-in-Charge. Cat Part No CS 94137 of make L&T or equivalent out of makes specified in list of makes.

Supply and fix in replacement of Kit Kat fuse/cylindrical fuse link 32 Amp, 415 volt complete all as specified and directed by Engineer-in-Charge. Make L&T or equivalent out of makes specified in list of makes.

M&L for painting of DG Sets (upto 400 KVA) with two coats of synthetic enamel paint of approved quality and shade over one coat of red oxide primer after preparing the surfaces (inner and outer) complete all as specified and directed by Engineer-in-Charge.

Supply and fix in replacement of HRC Fuse Link 125/100 A, 415 V AC, DIN Type, 100 KA. complete all as specified and directed by Engineer-in-Charge.

Supply and fix in replacement of Engine Safety Unit (ESU) of any KVA rating of DG Set in 54 ASP complete all as specified and directed by Engineer-in-Charge. . Existing Make- Intex -V2-04 or equivalent out of makes specified in list of makes.

M&L for repair and testing of Control Panel/AMF Panel of any type and 20 to 100 KVA rating of DG set capacity including programming , full copper wiring complete with washer, banjo, bolt, copper washer etc . (This includes the item involved in the repair and programming and S&F of other related items) complete all as specified and directed by Engineer-in-Charge.

Supply and fix in replacement of new Lock System set for multiple door DG Set complete of any KVA rating and any make complete all as specified and directed by Engineer-in-Charge.

Supply and fix in replacement of VAF Meter complete all as specified and directed by Engineer-in-Charge. Make-Nippon or equivalent out of makes specified in list of makes.

Supply and fix in replacement of RPM Indicator complete all as specified and directed by Engineer-in-Charge. Make-Nippon or equivalent out of makes specified in list of makes.

Supply and fix in replacement of unserviceable AVAR for 63 to 100 KVA GEN SET, complete all as specified and directed by Engineer-in-Charge.

S&F in replacement of unserviceable Feed Pump for any KVA DG set all as specified and directed by Engr-in-Charge. Make - Bosch

S&F in replacement of unserviceable Thermostat Valve for any KVA DG set all as specified and directed by Engr-in-Charge.

S&F Distilled Water for Batteries all as specified and directed by Engr-in-Charge.

M&L in replacement of door hinges of upto 100KVA DG set complete all as specified and directed by Engr-in-Charge.

Supply, laying and testing LT XLPE insulated screened PVC bedded galvanized steel strip or wire armoured electric power cable, heavy duty, 1100 Volts grade with stranded aluminium conductor of size 120 Sq mm, 3.5 core on pole, under floor, in pipe complete all as specified and directed by Engineer-in-Charge.

Supply, laying and testing LT XLPE insulated screened PVC bedded galvanized steel strip or wire armoured electric power cable, heavy duty, 1100 Volts grade with stranded aluminium conductor of size 70 Sq mm, 3.5 core on pole, under floor, in pipe complete all as specified and directed by Engineer-in-Charge.

Excavation over area not exceeding 1.5M wide and not exceeding 1.5M in depth for foundation etc or for shafts, wells, cesspits, manholes, pier holes etc not exc 10 Sqm on plan/hard standing and not exc 1.5M in depth and getting only out in hard soil/standing complete all as specified and directed by Engineer-in-Charge.

Excavation in trenches in soft/loose soil , not.exc 1.5 mtr wide and not.exc 1.5 mtr deep and getting out in soft/loose soil for laying of cable/foundation of pole and stay etc, complete all as specified and directed by Engineer-in-Charge.

Removing excavated materials to a distancd not exceeding 50 mtr and depositing where directed at a level not exceeding 1.5 mtr above ground level from starting point, complete all as specified and directed by Engineer-in-Charge.

Returning, filling in including spreading, levelling, watering and well ramming in layers n.exc 25 cm thick complete all as specified and directed by Engineer-in-Charge.

M&L for sand cushioning in trenches for protection of LT under ground cable including watering and consolidation ( to the thickness 18cm) complete all as specified and directed by Engineer-in-Charge.

Supply and laying well burnt sub class ‘B’ bricks, locally available in trenches for protection of underground cable vertically, complete all as specified and directed by Engineer-in-Charge.

M&L for Comprehensive Maintenance and repair of Electrical Overhead Gantry Cranes of Capacity 2 Tonne by Lubrication matting gears, Chain and Spockets arrangements in every quarter through out the year and repair / replacement all unserviceable parts, so that motion limiting devices are functioning properly, such as hoisting, limiting devices, cross-traverse and long travel limiting devices and pendent controllers with acceleration control with electrical protective devices complete all as specified and directed by the Engr-in-Charge. Note :- All New parts required for replacement are deemed to be included in the item rate except major parts which will be measured & paid seperately under relevant items here-in-after.

Load Testing of all Gantry cranes as per IS code with no load and with 2 Ton load on halfyearly basis by an authorized company complete all as specified and directed by Engineer-in-Charge. Note: T&P required for shifting of load from one place to another is also included & test certificate will also be provided.

Supply only following Spare Parts of Gantry Cranes installed at different locations of Air Force Station Gurgaon, complete all as specified and directed by Engineer-in-Charge:-

Pendent Control Station Starter.

Contactor for Long Traverse Motor.

Contactor for Cross Traverse Motor.

Contactor for Hoisting(Lifting / Lowering) Motor.

Spocket Chain for Lifting and Lowering.

Spocket Main Gear drive by Chain as per Sample.

Bearing for E O T Crane of 2 Ton Capacity.

Labour and T&P for Shifting of DG Set by Hydra and related required accessories within 54 ASP Domestic area, G Block and Technical area as specified and directed, complete all as specified and directed by Engineer-in-Charge.

M & L for complete servicing of spike barrier by taking out old oil and replacement with new HP oil and IS quality grease in barrier including welding work ,disposel of soil and junk acumulated arounds spikes complete all as specified and directed by Engineer-in-Charge.

M&L in replacement of rewinding of electric motor 3000 RPM, 80 watt S.N 1015083629, Single phase oil dip motor with super enameled copper winding wire including bearing and bushes and other accessories required to make motor functional and testing on load complete all as specified and directed by Engineer-in-Charge.

M&L for replacement rack and pinion complete unit assembly complete all as specified and directed by Engineer-in-Charge.

M&L for repair to Programming control panel complete unit for spike barrier complete all as specified and directed by Engineer-in-Charge.

M&L for Rewinding of Hoisting Motor of 10 HP by super enamelled Copper winding wire of same gauge as of existing one including heating, varnishing and testing after completion, complete all as specifed and directed by Engr-in-charge.

M&L for Rewinding of Hoisting Motor of 5 HP by super enamelled Copper winding wire of same gauge as of existing one including heating, varnishing and testing after completion, complete all as specifed and directed by Engr-in-charge.

Supply , laying and fixing in replacement of HDPE pipe of 160mm dia of PE -63 material Black colour having 6kgf/cm2 pressure rating alongwith joint i.e. elbow,Tee,union.coupler, end cap etc with correct way of fusion joining as specified and directed by Engr-in-Charge. Make: Supreme/diplast/kisan

M&L for laying and fixing only for HDPE pipe of 50mm dia of 6kgf/cm2 pressure rating with correct way of fusion joining as specified and directed by Engr-in-Charge. Note: stores are issued as Schedule 'B' Items by the department

M&L for laying and fixing only for HDPE pipe of 110mm dia of 6kgf/cm2 pressure rating with correct way of fusion joining as specified and directed by Engr-in-Charge. Note: stores are issued as Schedule 'B' Items by the department

M&L for laying and fixing only for HDPE pipe of 160mm dia of 6kgf/cm2 pressure rating with correct way of fusion joining as specified and directed by Engr-in-Charge. Note: stores are issued as Schedule 'B' Items by the department

M&L complete for drilling hole under hard standing /road in different location as per site requirement (between 03 mtr to 12mtr maximum) for laying of pipe/cable by means of bookle and without disturbing the top surface and making good the disturbed surface if any complete all as specified and as directed by Engr-in-charge.

Note:- The amount of Rs 66,985/- against Schedule of Credit on Page No 119 to 121 shall be deducted from the total amount quoted against Sch 'A' while deriving the Contract Sum for Acceptance

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