MAINT/ REPAIRS TO DG SETS, AMF PANELS, LIGHTENING PROTECTION SYSTEM AND ALLIED WORKS AT AFAC UNDER AGE (I) (AF) COIMBATORE.

Amount

Comprehensive maintenance of DG sets for routine/preventive maintenance checks at least once in a month, checking up of engine and alternator for trouble free functioning and attending break downs/ complaints as and when required for smooth functioning, servicing (Oil Changing of DG sets once in contract period) as directed by Engineer-in-charge. The comprehensive maintenance includes the following works:-

Cleaning of air filter.

Checking and adjusting of valve tappet clearance.

Checking of Engine lubrication system, fuel system, air system, cooling system, mechanical adjustments/rectification and electrical system.

Changing of lubricant oil filter if necessary.

Changing/cleaning of fuel pre and fine filter.

Checking and tightening of bolts and nuts.

Checking of flexible rubber coupling.

Checking of charging system of the battery.

Checking of ‘V’ belt and adjusting the tension.

Checking of exhaust turbo charger.

Checking of fuel injector.

Checking and cleaning of breather pipe.

Checking of alternator terminals and cable lighteners etc.

Checking of safety controls operation.

Checking of speed governors and engine shut down for proper functioning.

Checking of proper functioning of self starter and battery charging.

Greasing of generator.

Carrying out preventive maintenance, checking as per manufacturer’s recommendations and to make proper functioning/serviceability of unserviceable RPM meter and hour meter and all engine parameters, gauges throughout the contract period all as directed by Engineer in Charge

The capacity and location of DG sets for which comprehensive maintance to be carried over are as under:-

100 KVA DG set (Raw water pump house).

82.5 KVA DG set ( AFNET).

82.5 KVA DG set (6AFH).

75 KVA DG set ( HQ Building).

40 KVA DG set (Fire fighting pump house).

25 KVA DG set (IT FACULTY).

25 KVA DG set (Raw water pump house for 43 S/O's).

7.5 KVA DG set (logistics section).

Note 1:-The comprehensive maintenance includes carrying out preventive maintenance including replacing all the unserviceable/ worn out minor/major spares to keep the the DG set for trouble free functioning.

Note 2:- Contractor's labour has to attend the breakdown at any time during the contract period.

Note 3:- The rate quoted deemed to include all the minor spares such as screws, clips washers, distilled water, electrolyte etc and other spares will be measured and paid separately under appropriate items of BOQ here in after.

Terms and conditions for item No 01 is as under:-

(a) Cleaning the DG set complete including panel boards with clean cotton wastes, checking of lubrication systems, checking of fuel systems, checking of air systems, checking of cooling systems and any other leakages.

(b) Top up the distilled water, apply petroleum jelly to battery terminals ,check acid density of the battery by means of hydrometer to recharge the battery if necessary and to run the engine and to watch sound level, noise and smooth functioning and to record the parameter like LOP, LOT, WT, AMPs, volts, Hz, RPM etc.

(c) The contractor’s service technician shall possess certificate from the industrial training institute of any state in Electrical and Mechanical Engineering and should have sufficient knowledge in the relevant field of DG set and AMF panel.

Supply only set of fuel pre-filters and fine filters as per sample and make of the following capacities of DG sets (fixing under srl item No 01). :- Note: Each set comprising of the complete pre/fine filters required at site.

100 KVA DG set (Raw water pump house).

75 KVA DG set ( HQ Building).

40 KVA DG set (Fire fighting pump house).

25 KVA DG set (IT FACULTY).

25 KVA DG set (Raw water pump house for 43 S/O's).

7.5 KVA DG set (logistics section).

82.5 KVA DG set (6 AFH & AFNET).

Supply only set of lub/engine oil filters as per sample and make of the following capacities of DG sets (fixing under srl item No 01) :-

100 KVA DG set (Raw water pump house).

75 KVA DG set ( HQ Building)

40 KVA DG set (Fire fighting pump house).

25 KVA DG set (IT FACULTY).

25 KVA DG set (Raw water pump house for 43 S/O's).

7.5 KVA DG set (logistics section).

82.5 KVA DG set (6 AFH & AFNET).

Supply only flexible fuel pipes with banjo bolts and nuts as per sample length and size to meet the requirement of site condition.

Supply only battery terminal clamp made up of brass with bolts and nuts.

M & L for servicing of radiator assembly complete for cleaning, cooling water spaces, and replace unserviceable rubber hose, pipes, circle, clamps, cleaning of radiator mix with appropriate cleaning agent, de-scaling by means of scale solvent as well as neutralizing agent to arrest leakages by means of brazing etc. all as directed by the Engineer-in-charge of following capacities: Note: These servicing includes necessary replacement of gaskets, sealing rings, cleaning agents etc all as directed by Engineer in Charge.

100 KVA DG set ( Raw water pump house)

82.5 KVA DG set (AFNET)

40 KVA DG set (Fire fighting pump house)

25 KVA DG set (Ra water pump house for 43 S/O's)

Supply only fan belts of following capacities of DG set as per sample size all as directed. (Make : Fenner/Dunlop) (Fixing under Sl Item No. 1). :-

100 KVA DG set (Raw water pump house)

75 KVA DG set ( HQ Building)

82.5 KVA DG set (Siruvani pump house & Siruvani pump house)

40 KVA DG set (Fire fighting pump house)

25 KVA DG set (IT FACULTY)

25 KVA DG set (Raw water pump house for 43 S/O's)

7.5 KVA DG set (logistics section)

M & L for checking/servicing and overhauling/ calibration of the fuel injection pump with injectors of following capacities of DG sets. Note: The rate is deemed to be included for necessary sealing rings, ‘O’ rings if needs replacement etc and render necessary test/servicing certificate from the authorized dealer.

100 KVA DG set (Raw water pump house)

82.5 KVA DG set (6 AFH)

75 KVA DG set ( HQ Building)

40 KVA DG set (Fire fighting pump house)

25 KVA DG set (IT FACULTY)

25 KVA DG set (Raw water pump house for 43 S/O's)

7.5 KVA DG set (logistics section)

Comprehensive maintenance of the Control panels/AMF panels/DG Panels, Alternator terminals, including routine/preventive maintenance checks at least once in a month for trouble free functioning and attending breakdowns/complaints as and when required . The type of work/ maintenance to be carried out during comprehensive maintenance are as under all as directed by Engineer-in-charge Note: Items required for replacement shall be measured under Sl Item No. 19 to 29 as supply only. Fixing, checking and testing charges of these items shall include in Comprehensive maintenance.

Checking, tightening all electrical connections.

Checking, tightening all contact points/Bus bars.

Checking, setting/replace timers (AC or DC).

Checking/replace push buttons.

Checking/ replace indicator lamps.

Checking/ replace main, auxiliary contactors, relays

Checking/replace contactor coils

Checking/replace volt/amp/energy /PF/KWH/ multifunction meters/CT's

Checking Auto/manual function.

Checking, tightening the screws, bolts and any other fastening accessories.

Checking battery charger and its output

Cleaning the panels, contactors, MCCB/ MCB terminals, removing the carbon deposits by using CTC as cleaning agent.

Checking/replace the alarms/hooters

Checking/replace control wiring, ferrules, lugs (copper/aluminium)

Proper settings of AVR/IEVR etc

To check insulation resistance test between phase and earth, phase to phase for starter and rotary windings and to apply appropriate insulating varnish if dried up etc.

The list of DG Sets whose panels to be serviced are as under:-

100 KVA DG set (Raw water pump house)

82.5 KVA DG set (6 AFH)

75 KVA DG set (HQ Bldg.)

40 KVA DG set (Fire fighting pump house)

25 KVA DG set (IT FACULTY)

25 KVA DG set (Raw water pump house for 43 S/O's)

7.5 KVA DG set (logistics section)

Note 2: The rate deems to include all other minor spares if any not reflected above to keep the panel in working condition.

Note 3: General maintenance is indicative only and the contractor has to do the necessary maint task over and above as mentioned and as directed by Engineer-in-charge.

Servicing/Overhauling of battery charging sets of capacity 2 x 12 volts of any make and model.

M & L for radiator anticorrosive coolant conditioner properly mixed up with the radiator water.

Supply and filling engine oil 20W - 40

M&L for drain out the diesel from the diesel tank thoroughly to clean the dirt/sedimentation in the tank , refilling the diesel to the tank and all as specified and directed by the Engineer-in-charge for the following capacities of DG sets:-

Note: (i) Container for drain out of DHPP to be provided by the contractor..

(ii) The rates deems to be inclusive of two coats of red oxide primer and one of coat of anti corrosive enamel paint including marking of level of tank.

100 KVA DG set (Raw water pump house)

82.5 KVA DG set (6AFH & AFNET)

75 KVA DG set ( HQ Building)

40 KVA DG set (Fire fighting pump house)

25 KVA DG set (IT FACULTY)

25 KVA DG set (Raw water pump house for 43 S/O's)

7.5 KVA DG set (logistics section)

M&L for servicing the 12 volts lead acid batteries 25 plates including reconditioning, replacing the old electrolyte, refilling the batteries with fresh electrolyte, recharging the batteries to its required specific gravity and re-fixing and testing all as directed by Engineer-in-charge.

M&L for servicing of self starter assembly of DG sets 24/12 volts of following capacities by disconnecting the self starter assembly from the engine and dismantling, cleaning all accessories, replacing worn-out parts like carbon brushes, bushes, contact plates,bentex, jumping levels etc and rewinding the unserviceable field coil and varnishing all as directed by Engineer-in-charge.

100 KVA DG set (Raw water pump house)

82.5 KVA DG set (6 AFH)

75 KVA DG set ( HQ Building)

25 KVA DG set (IT FACULTY)

25 KVA DG set (Raw water pump house for 43 S/O's)

7.5 KVA DG set (logistics section)

Repairing the dynamo after removing from the DG set of capacity 60 to100 KVA and transporting to an authorised service center including replacement of following parts :-

Armature of suitable size 1 No

Bearing bushes of suitable size 1 set

Dynamo Voltage regulator of suitable size

All as per item No 16 but capacity of 7.5 to 40 KVA DG set

Supply only Ignition key suitable for DG set panel/control panel

Supply only MCCB 63 amps breaking capacity 25 KA, 3 Pole suitable for for Control panel/AMF panel.

Supply only Main contactor suitable for 100 KVA AMF Panel

Supply only Main contactor suitable for 40 KVA AMF Panel

Supply only Main contactor suitable for 25 KVA AMF Panel

Supply only Main contactor suitable for 7.5 KVA AMF Panel

Supply only Auxiliary/Control contactors (2NO, 2NC) of suitable ratings for AMF Panels.

Supply only Plug in relay 12 V DC 8/11 pins suitable for for AMF Panels

Supply only battery charger (ie step down tfr)of ratings 100VA,220-240V/12-14-16 volts suitable for AMF Panels

Supply only battery charger (ie step down tfr)of ratings 200VA, 415 volts / 0-18 volts suitable for AMF Panels

Supply only Rheostat variable type suitable for old conventional type AMF Panel

Supply only multifunction digital meter (in lieu of voltmeter, ammeter, PF meter)suitable for new version AMF Panels

Supply only single phase preventer of suitable rating for Control panel/AMF panel

Supply only CT's of suitable rating for Control panel/AMF panel

Supply only fly wheel ring suitable for 100 KVA DG Set.

Supply only fly wheel ring suitable for 82.5 KVA DG Set.

Supply only fly wheel ring suitable for 25 KVA DG Set.

Supply and fix lead acid battery 12 V 150 AH, Make : Exide/Amaron

Supply and replacement of hinges of canopy door of DG set.

Supply and fix AVR (Automatic Voltage Regulator) of generator capacity 62.5 to 100 KVA of Kirloskar make suitable for existing specification complete all as specified and directed.

Supply and fix AVR (Automatic Voltage Regulator) of generator capacity 7.5 to 40 KVA of Kirloskar make suitable for existing specification complete all as specified and directed.

Strip opening and dismantling Cylinder head/ cylinder block of DG set 75 KVA carefully and taking out cylinder head/cylinder block for arresting oil leakage, cleaning , transporting to workshop for lathe work if required, replacing of Cylinder head gasket/Cylinder Block gaskets with new gasket sets and refixing the same after completion of repair work and testing complete all as specified and directed. Note:- Rate quoted by the contractor shall deemed to be included for stopping Oil leakage, rates for gaskets, nuts, bolts, washers, and gasket adhesive material included in quoted rate and nothing shall be paid extra on this account.

Dismantling, Removing the existing disturbed/displaced Copper/Aluminium/GI strips of any sizes from the roof/wall of building, and keeping in a safe custody for taking credit or for re-using serviceable strips in the work complete all as specified and directed.

. Fixing only serviceable Copper/Aluminium/GI strips of any size as retrieved from taking down item by straightening, removing the kinks along the length and refixing the same with and including new porcelain insulators/saddles/screws complete all as specified and directed by Engineer-in-charge.

Supply and fix in repairs Aluminium strip of size 25 x 3.15mm with saddles and fixing screws etc for roof conductors and down conductors above ground level all as specified and directed by Engineer-in-charge. Care should be taken by using all safety devices to ensure safety while working. Note : (i) Scaffolding work will be measured and paid separately under relevant items here in after. (ii) The work shall be carried out for a height varying from GL to 18 meter

. Supply and fix in repairs copper strip of size 20 x 3.15mm with saddles and fixing screws etc for roof conductors and down conductors above ground all as specified and directed by Engineer-in-charge.

. Supply and fix in repairs copper strip of size 32 x 6 mm burried in ground or fixed with wall complete all as specified and directed by Engineer-in-charge.

. Supply and fix in repairs Galvanised iron strip32x6mm with saddles and fixing screws etc for roof conductors and down conductors above ground all as specified and directed by Engineer-in-Charge

. Supply and fix in repairs Air Termination, single pointed Aluminium rod 12mm dia and 300mm long including taking down old unserviceable air termination rod, all as directed by Engineer-in-Charge.

Supply and fix in repairs Test Point terminal block made of gun metal or phosphorus bronze size 75x75x25mm drilled and screwed including 3 Nos 8mm dia 25mm long hexagonal head screw.

M&L for scaffolding work with iron frames welded and joined with suitable bolt nuts up to a height of 25 mtr above ground level for laying Aluminium strip all as directed by Engineer-in-charge. Note: (i) Special care shall be taken by using all safety devices to ensure safety while working. (ii) Materials utilized for scaffolding work shall be taken back by contractor after satisfactory work completion. (iii) Materials used for scaffolding may be their own materials or may be used by taking rent from outside at their own arrangement.

M&L for demolition of existing earth chamber including removing the demolished material to the distance not exceeding 50 mtr and deposited where directed at a level not exceeding 1.50 mtr above the starting point and construction of new earth chamber only in same location as per Electrical plate No.3 as shown in SSR Part I 2009 (Section-19) on Page No. 497 including excavation on any type of soil, returning filling, removal of surplus material to a distance of 50 metered with specification PCC 1:3:6 type C1 using 20mm graded stone aggregate for bed and chamber, RCC 1:2:4 type B1 using 20mm graded stone aggregate for earth Pit cover 50mm thick with 8mm dia TMT bars at 140mm C/C both ways (instead of CI cover) with lifting handle and fixing of funnel complete with colour code all as specified and directed by Engineer-in-Charge.

. Supply and lay PVC Insulated aluminium armoured cable 2 core 6 Sqmm on wall duly clamped all as directed by Engr-in-charge including taking down the old unserviceable cable.

Supply and fix in repairs LED Aviation Obstruction light fitting 302 LED with all accessories, brackets for fixing arrangements etc., on over Head Tank. Make: Bajaj, Model: BGAV 302 LED or equivalent in Philips/Crompton Greaves/Havells.

Supply, installation & testing of maintenance free chemical earthing of copper coated electrode pipe of length 3 mtr long and 76 mm dia, having terminal size 50x6 mm, the earth electrode pipe is tightly filled with Crystalline Conductive Mixture (CCM) and then sealed. The electrode shall be installed by making bore of 200 mm dia & 3 Mtr deep below normal ground level, after using & including 10 KG ground enhancing material, the electrode shall be surrounded by and including 60 KG Back Fill Compound (Chemical compound provided by manufacturer) complete including making earth pit chamber of size 30CM x 30 CM x 15 CM complete including taking out old unserviceable conventional type earthing complete all as specified and directed. Make: Innove Infra Solutions, Cat No. ELE-380-CU or equivelent in JMV LPS Ltd.

M&L for potassium nitrate , mixing in water, and pouring in existing earth pits in camp area to hold moisture in earth pits complete all as directed. Note: (i) Total quantity brought by contractor shall be deposited in MES store. (ii) The locations of earthing pits and quantity of potassium nitrate to be poured shall be directed by Engineer-in-charge/JE (E&M)

Rajapriyaconstruction

p.chinnasamy