COMPREHENSIVE MAINTENANCE OF DG SETS AND CONNECTED ACCESSORIES, AMF PANELS REPAIR MAINTENANCE OF DG SETS INSTALLED AT VARIOUS PUM HOUSE AND SUB STATIONS WITH THEIR CONNECTED ACCESSORIES AT RCI TECHNICAL AREA, CARBON CARBON AREA ZONE-I UNDER GE I RND

Amount

Disconnecting all the incoming and outgoing rubber hoses and draining out the water from the chocked radiator assembly of the DG Sets of capacity 100/250/ 320/380/437.5 KVA and taking down the radiator assembly by unscrewing all mechanical connections from the existing mounting, opening the top and bottom covers of the radiator assembly, cleaning thoroughly the choked pipe of the radiator by using chemicals, servicing the radiator, cleaning of all the deposited sediments in the pipes, soldering/ brazing the leakage pipe, refixing the top and bottom covers after completion of above works, refixing the same to its original position with suitable size of bolts, nuts and washers etc., complete all as specified and as directed.

All as per item No. 1 above but DG Sets of capacity 500/625/750 KVA.

Disconnecting the electrical connections and taking down the self starter of capacity 24 volts, 180 AH from DG sets capacity of 320/437.5 KVA for carrying out repairs and complete overhauling the system including replacing the unserviceable parts like carbon brushes, bearings/ couplings, burnout coils, field coils, armature etc., with new ones, reassembling and refixing the self starter to its original position and connecting up complete all as specified and as directed.

All as per item No. 3 above but DG Sets of capacity 500/ 625/750 KVA.

Disconnecting all electrical cable connections and taking down the dynamo assembly from DG sets of capacity 320/437.5 KVA to carry out repairs and complete overhauling the dynamo including replacing the unserviceable parts like carbon brushes, bearings, armature, burnt out coils etc., reassembling and refixing the dynamo assembly to its original position and reconnecting all disconnected cable connections including testing complete all as specified and as directed.

All as per item No. 5 above but DG Sets of capacity 500/750/1010 KVA.

S&F panel mounting type battery charger with transformer diode operated, 24 Volts, 10 Amps, input range 170V to 270V including taking down old unserviceable one complete all as specified and as directed. Make : NHP/ELAK

S&F lead acid battery 180 AH, 12 Volts, 25 plates complete with first charge of battery including taking down old unserviceable one complete all as specified and as directed. MAKE: EXIDE EXPRESS/AMARON

Draining out fuel from the fuel tank of 1000 litres capacity and keeping it in separate container, disconnecting the outlet fuel lines and taking out the fuel tank for cleaning, both internally and externally by removing all the accumulated dust/ sediments, leak testing the tank and welding/ brazing, including painting the external surfaces of the tank with spray gun machine after preparation of old painted surface with one coat of black synthetic enamel paint and refixing the tank to its original position, replacing the drain plug and PVC pipe protected with steel flexible pipe including GI clamps, calibrating the fuel tank, marking the tank in white paint, arresting leakage in the GI delivery line by replacing the necessary GI fittings, refilling the drain out fuel back into the tank and provision of one Godrej make 7-lever pad lock complete all as specified and as directed.

S&F Start/stop push button for control panel necessary mounting arrangement including taking down old unserviceable one complete all as specified and as directed. Make of DG Set: Kirloskar, Cat part No. 454 03.147.19.0.00

S&F in 3 pole power contactor type of MNX 185 including taking down old unserviceable one complete all as specified and as directed. MAKE: L&T Catpart No. CS94139/C&S

S&F Lube oil cooler for DG SET including taking down old unserviceable one complete all as specified and as directed. Make of DG Set: KIRLOSKAR, Cat part No. 04.020.01.0.00

Maintenance of DG set of capacity 50 KVA and carrying out ‘B’ check and replacement of ‘B’ check kit filters such as oil filter, by-pass filter, fuel filter, CR element and CR plates complete with ‘O’ rings and draining of burnt out engine oil and topping up with the new engine oil complete including testing by Authorized dealer complete all as specified and as directed. Note: Engine oil shall be measured and paid separately under relevant items of this BOQ. Make of DG set: KIRLOSKAR/ CUMMINS /GREAVES

All as per item No. 13 above but DG Set of capacity 100 KVA.

All as per item No. 13 above but DG Set of capacity 200 KVA.

All as per item No. 13 above but DG Set of capacity 250 KVA.

All as per item No. 13 above but DG Set of capacity 300 KVA.

All as per item No. 13 above but DG Set of capacity 320 KVA.

All as per item No. 13 above but DG Set of capacity 380 KVA.

All as per item No. 13 above but DG Set of capacity 437.5 KVA.

All as per item No. 13 above but DG Set of capacity 500 KVA.

All as per item No. 13 above but DG Set of capacity 625 KVA.

All as per item No. 13 above but DG Set of capacity 750 KVA.

All as per item No. 13 above but DG Set of capacity 1010 KVA.

S&F safety air filter element and primary air filter element with necessary ‘O’ rings for the DG sets of capacity 320/437.5 KVA including taking down old unserviceable one complete all as specified and as directed. Make of DG Set: KIRLOSKAR, Catpart No. 6H.411.01.0.00 and 6H.411.02.0.00

S&F inner and outer air cleaning element with necessary ‘O’ rings for the DG sets of capacity 500/625 KVA including taking down old unserviceable one complete all as specified and as directed. Make of DG Set: KIRLOSKAR, Catpart No. D16.505.41.0.00 and D16.505.42.0.00

S&F inner and outer air cleaning element with necessary ‘O’ rings for the DG sets of capacity 750/1010 KVA including taking down old unserviceable one complete all as specified and as directed. Make of DG Set: KIRLOSKAR, Catpart No. DV2.506.62.0.00 and DV2.506.63.0.00

SUPPLY ONLY engine oil SAE 15W 40 for DG Set of any capacity. Make: SERVO/CASTROL/BHARAT

SUPPLY ONLY Coolant Additive Concentrate (CAC) ratio 1:4 for DG Set of any capacity Make: SERVO/FLEETGUARD

S&F Water pump assembly including taking out old unserviceable one complete all as specified and as directed. Make of DG Set: KIRLOSKAR, Cat part No. 38.207.40.0.00

S&F Lube Oil Pump assembly including taking out old unserviceable one complete all as specified and as directed. Make of DG Set: KIRLOSKAR, Cat part No. 3H.005.10.0.00

S&F Electric water temperature gauge of range 40° to 120°C, 24 Volts including taking out old unserviceable one complete all as specified and as directed. Make of DG Set: KIRLOSKAR, Catpart No. 46.066.02.0.00

S&F Electric water temperature gauge of range 40° to 120°C, 12 Volts including taking out old unserviceable one complete all as specified and as directed. Make of DG Set: KIRLOSKAR, Catpart No. 46.065.02.0.00

S&F in Lube oil temperature gauge ELE -40°-150°/160° C for DG sets including taking out old unserviceable one complete all as specified and as directed. Make of DG Set: KIRLOSKAR, Catpart No. 46.085.01.0.00

S&F fly wheel assembly including taking out old unserviceable one complete all as specified and as directed. Make of DG Set: KIRLOSKAR, Cat part No. 4H.037.10.0.00

S&F Digital hour meter 12 to 48 Volts DC with cable for DG sets including taking out old unserviceable one complete all as specified and as directed. Make of DG Set: KIRLOSKAR, Cat part No. 46.253.01.0.00

S&F water separator including taking out old unserviceable one complete all as specified and as directed. Make of DG Set: KIRLOSKAR, Cat part No. 47.278.010.0.00

S&F turbo charger K24 including taking out old unserviceable one complete all as specified and as directed. Make of DG Set: KIRLOSKAR, Cat part No. 4H.1308.09.0.00

S&F On load changeover switch 400 Amps capacity type CO4-400 including taking out old unserviceable one complete all as specified and as directed. MAKE: L&T, Cat part No -CO44000OOOO

S&F fuel return pipe to tank, rubber material, 1/2 inch dia including taking out old unserviceable one complete all as specified and as directed. Make of DG Set: KIRLOSKAR, Cat part No. 03.635.17.0.00

S&F fuel pipe 1/2 inch dia rubber material 7.5 14X14 B 700 wire braided for DG set including taking out old unserviceable one complete all as specified and as directed. Make of DG Set: KIRLOSKAR, Cat part No. 34.151.01.0.00

S&F 24 volts Starter Motor Assembly for DG sets including taking out old unserviceable one complete all as specified and as directed. Make of DG Set: KIRLOSKAR, Cat part No. AP1.006.10.0.00

S&F fuel pipe 1/2 inch dia iron material wire braided including taking out old unserviceable one complete all as specified and as directed. Make of DG Set: KIRLOSKAR, Cat part No. 34.174.01.0.00

S&F radiator fan plastic material for DG Set including taking out old unserviceable one complete all as specified and as directed. Make of DG Set: KIRLOSKAR, Cat part No. 6H.540.01.0.00

S&F Air delivery bend for DG set including taking out old unserviceable one complete all as specified and as directed. Make of DG Set: KIRLOSKAR, Cat part No. 4H.1712.15.0.00

S&F V-belt for water pump of 400/500/600 KVA DG set including taking out old unserviceable one complete all as specified and as directed. Make of DG Set: KIRLOSKAR, Cat part No. KV0.056.30.0.00

S&F fuel feed pump for DG including taking out old unserviceable one complete all as specified and as directed. Make of DG Set: KIRLOSKAR, Cat part No. CC1.073.02.0.00.

S&F MCCB, FP, 200 Amps with adjustable thermal and magnetic settings, 50Hz, 36KA, 415 volts, conforming to CSE 2NN250atm4P-* including provision of copper cable/ extended terminals of suitable ratings from MCCBs to busbar and connection of LT cables with MCCBs with suitable size aluminium lugs including taking out old unserviceable one complete all as specified and as directed. MAKE: HAVELLS/C&S/L&T

S&F MCCB, FP, 400Amps with adjustable thermal and magnetic settings, 50Hz, 36KA, 415 volts, conforming to CSE3N400ATM4P-* including provision of copper cable/ extended terminals of suitable ratings from MCCBs to busbar and connection of LT cables with MCCBs with suitable size aluminium lugs including taking out old unserviceable one complete all as specified and as directed. MAKE: HAVELLS/C&S/L&T

S&F MCCB, FP, 250Amps with adjustable thermal and magnetic settings, 50Hz, 36KA, 415 volt, conforms to CSE2NN250ATM4P-* including provision of copper cable/ extended terminals of suitable ratings from MCCBs to busbar and connection of LT cables with MCCBs with suitable size aluminium lugs including taking out old unserviceable one complete all as specified and as directed. MAKE: HAVELLS/C&S/L&T

S&F V-belt for fan drive size of B89 and pitch length 2300mm including taking out old unserviceable one complete all as specified and as directed. MAKE: NIRLON/FENNER/DUNLOP

S&F V-belt for fan drive size of C72 and pitch length 1880mm including taking out old unserviceable one complete all as specified and as directed. MAKE: NIRLON/FENNER/DUNLOP

S&F oil pressure transducer suitable for 320 KVA DG set including taking out old unserviceable one complete all as specified and as directed.

S&F battery terminal cable of size 50 Sqmm single core, multi stranded copper conductor including taking out old unserviceable one complete all as specified and as directed.

S&F brass/ copper lugs, open type, heavy duty, suitable for 50 Sqmm cable including taking out old unserviceable one complete all as specified and as directed.

S&F brass/ copper battery terminal, heavy duty, suitable for 180 AH, 12 Volts lead acid battery including taking out old unserviceable one complete all as specified and as directed.

M&L for preparation of old painted surfaces of body and MS channel foundation of diesel generating sets of 320 KVA to 750 KVA capacity and applying one coat of synthetic enamel paint (First quality) by spray painting over a coat of red oxide primer complete all as specified and as directed. Make of paint: Asian Paints/ Berger/Nerolac

S&F Stop solenoid 12 Volts for DG Set including taking out old unserviceable one complete all as specified and as directed. Make of DG Set: KIRLOSKAR, Catpart No. 34.188.03.0.00

S&F 3 pole poer contactor type MNX 225 including taking out old unserviceable one complete all as specified and as directed. MAKE: C&S, Catpart No. CS94140/L&T

S&F 3 pole poer contactor type MNX 250 including taking out old unserviceable one complete all as specified and as directed. MAKE: C&S, Catpart No. CS94141/L&T

S&F digital panel meter, multi function having the parameters of voltage, current, frequency, power factor, operated in 3 phase 415 volts AC with CTs including taking out old unserviceable one complete all as specified and as directed. Make : L&T/C&S

Disconnecting all water connections, exhaust connections and dismantling top of the head for DG Sets of 320KVA capacity and removing all unserviceable items, servicing of rocker arms, tappets, inlet valves, exhaust valves, injectors, push rods etc., replacement of intake gasket, head gasket, tappet cover gasket, rocker cover gasket, exhaust manifold gaskets, water manifold 'O' ring, grinding of valve seat, refixing the top head of DG sets including testing and checking of engine timing, calibration of injectors, calibration of fuel pumps complete all as specified and as directed.

Disconnecting all water connections, exhaust connections and dismantling top of the head for DG Sets of 380 KVA capacity and removing all unserviceable items, servicing of rocker arms, tappets, inlet valves, exhaust valves, injectors, push rods etc., replacement of intake gasket, head gasket, tappet cover gasket, rocker cover gasket, exhaust manifold gaskets, water manifold 'O' ring, grinding of valve seat, refixing the top head of DG sets including testing and checking of engine timing, calibration of injectors, calibration of fuel pumps complete all as specified and as directed.

S&F automatic voltage regulator (AVR) Model: TAVR-10/TAVR-20/TAVR-14 Cat part No. 2H.811.32.0.00 including testing complete all as specified and as directed. Make of DG set: CUMMINS/GREAVES/KIRLOSKAR

Disconnecting and taking out LT ACB draw out type, 630 to 1600 amps capacity of make ABB/MERLIN GERINN/CROMPTON GREAVES/SIEMENS/L&T/GE/ C&S from the existing LT panel boards, overhauling the ACBs including cleaning of contacts, removing the carbon deposits, conditioning of spring charge mechanism, taking down all defective accessories, repair/replacement of earth fault release, over current release, trip coil, under voltage coil etc., repair/overhauling of draw out mechanism, greasing and lubricating all moving and fixed parts, removing dust in the ACBs by means of air blowers and refixing and reconnecting the ACBs back in position in the panel board and testing complete all as specified and as directed. NOTE: Spare parts will be measured and paid separately as SUPPLY ONLY under relevant items of this BOQ.

SUPPLY ONLY closing coil, common for 630A-4000A capacity ACB. MAKE: As per Serial item No. 65 above

SUPPLY ONLY under voltage trip device without delay, common for 630A-4000A capacity ACB. MAKE: As per Serial item No. 65 above

SUPPLY ONLY shunt trip coil, common for 630A-4000A capacity ACB. MAKE: As per Serial item No. 65 above

SUPPLY ONLY spring charge induction switch. MAKE: As per Serial item No. 65 above

SUPPLY ONLY trip induction switch both manual and fault induction. MAKE: As per Serial item No. 65 above

SUPPLY ONLY position indication switch. MAKE: As per Serial item No. 65 above

SUPPLY ONLY main isolating contacts (jaw contacts) for ACB rating 16D/16N. MAKE: As per Serial item No. 65 above

SUPPLY ONLY main fixed contacts (upper terminals) for ACB rating 16D/16N. MAKE: As per Serial item No. 65 above

M&L for XLPE insulated, armoured, heavy duty electric cable with aluminium conductor of cross sectional area 3.5 core 185 Sqmm, 1100 volts grade complete all as specified and directed.

M&L for XLPE insulated, armoured, heavy duty electric cable with aluminium conductor of cross sectional area 3.5 core 240 Sqmm, 1100 volts grade complete all as specified and directed.

M&L for XLPE insulated, armoured, heavy duty electric cable with aluminium conductor of cross sectional area 3.5 core 150 Sqmm, 1100 volts grade complete all as specified and directed.

Checking & repairs to AMF panel up to 1000 KVA capacity such as faulty relays, contactors, logic units, HRC fuses and wiring connections and testing complete all as specified and as directed. NOTE: Spare parts will be measured and paid separately as SUPPLY ONLY under relevant items of this BOQ.

SUPPLY ONLY relays 24/12 volts for AMF panels. MAKE: L&T/SIEMENS/INDO ASIAN

SUPPLY ONLY relays 12/12 volts for AMF panels. MAKE: L&T/SIEMENS/INDO ASIAN

SUPPLY ONLY auxiliary contactors with logic units. MAKE: L&T/SIEMENS/HAVELLS

S&F in replacement of Line Voltage Monitors (LVMS) of existing make to DG set of 30 KVA to 250 KVA capacity listed parameters including testing complete all as specified and as directed.

M&L disconnecting & removing the unserviceable AC wiring from AMF panel of DG set of any type/any make/any model/any capacity and rewiring with the same with suitable new copper wire to existing guage wire by providing flexible pipe including making all electrical connections as per OEM recommendation for satisfactory completion of job & replacement of electrical/electronic spares and testing etc complete all as specified and directed. NOTE: (i) The unit rate quoted deemed to be inclusive of new copper wire. (ii) Electrical/Electronic spares shall be measured & paid separately under relevant items of this BOQ.

Supply only Over/Under voltage relay as per existing one. Make: L&T

Supply only Single phase preventer as per existing one. Make: Minilec/GIC

Supply only PLC based AMF relay unit as per existing one. Make: L&T

M&L for removing and shifting Fresh Water Pump of 500 KVA DG to Workshop for repairs and calibration by replacement of necessary spare parts and reconditioning, refixing back in its original position and testing complete all as specified and as directed

M&L for disconnecting all connections & removing the PT pump from engine of 500/ 625 KVA DG set and transporting to OEM authorised service center and calibration of PT pump for maximum efficiency by replacement of PT Pump kit, gear gasket etc., refixing and connecting back in its original position and testing complete all as specified and as directed

M&L for removing and shifting fuel injection pump from engine of DG set of capacity 30 KVA to 125 KVA to an authorised service centre for servicing, calibration and to adjust by replacing the un serviceable worn-out spares with new appropriate make of minor spares to tune up for maximum efficiency, refixing and connecting back in its original position and testing complete all as specified and as directed. NOTE: Major spares required shall be measured and paid separately under relevant items of this BOQ.

Supply only orfice for DG set of capacity 30 KVA to 125 KVA as per existing make and model.

Supply only Barrel and Plunger for DG set of capacity 30 KVA to 125 KVA as per existing make and model.

Supply only FIP bearing for DG set of capacity 30 KVA to 125 KVA as per existing make and model.

Supply only orfice for DG set of capacity 125 KVA to 250 KVA as per existing make and model.

Supply only Barrel and Plunger for DG set of capacity 125 KVA to 250 KVA as per existing make and model.

Supply only FIP bearing for DG set of capacity 125 KVA to 250 KVA as per existing make and model.

S&F self starter motor, 24 volts of make LUCAS or its equivalent approved by OEM suitable for DG set of capacity 100 KVA to 320 KVA including connecting electrically/ mechanically as per recommendations of OEM including taking out old unserviceable one complete all as specified and directed.

S&F self starter motor, 12 volts of make LUCAS or its equivalent approved by OEM suitable for DG set of capacity upto 100 KVA including connecting electrically/ mechanically as per recommendations of OEM including taking out old unserviceable one complete all as specified and directed.

M&L for disconnecting all electrical & mechanical connections, dismantling engine from 100 KVA to 250 KVA DG sets, transporting to OEM Authorised service center for complete overhauling, replacing unserviceable wornout spares with new appropriate make minor spares & major spares, refixing and connecting back in its original position and testing complete all as specified and as directed. NOTES: 1. The unit rate quoted is deemed to be including manpower required for dismantling, assembling, loading/unloading, Crane charges for transporting engine to workshop and back after repairs. 2. Major spares required shall be measured and paid separately under relevant items of this BOQ.

Supply only Gear fuel Pump

Supply only Total Gasket Set

Supply only Core & cooler set

Supply only Shaft rocker arm

Supply only Oil seal

Supply only Ball Bearing set

Supply only Main Bearing set (STD)

M&L for repairs to Alternator of 100 KVA DG Set, transporting the same to OEM authorised service center/work shop and carrying out repairs such as taking out burnt out winding and rewinding the alternator with super enamelled copper wire of same gauge, turns and weight, checking of commentator, brushes complete and refixing the same back in existing position after transporting back to site and connecting up electrically with suitable lugs and testing complete all as specified and directed.

S&F Speed Controller (Governor card) suitable for 380 KVA DG sets including taking down old unserviceable one complete all as specified and directed.

S&F Actuator suitable for 320 KVA DG sets including taking down old unserviceable one complete all as specified and directed.

S&F Fuel Sensor suitable for 380 KVA DG sets including taking down old unserviceable one complete all as specified and directed.

S&F in replacement of microprocessor based control unit suitable to DG set of any capacity with all listed parameters as per recommendation including testing complete all as specified and directed. Make : KIRLOSKAR /CUMMINS/GREAVES

S&F brass/ copper lugs, open type, heavy duty, suitable for 50 Sqmm cable including taking out old unserviceable one complete all as specified and as directed.

Dismantling of 750KVA alternator, removing and rewinding of Exiter field winding, reinsulation and varnishing with Dr.Beck elmothern F-50, preheating and baking in oven, gel coat apply to winding etc., and testing of DG set complete all as specified and directed.

Dismantling of 750KVA alternator removing and rewinding of Exiter rotor winding, reinsulation and varnishing with Dr.Beck elmothern F-50, preheating and baking in oven, gel coat apply to the winding etc., and testing of DG set complete all as specified and directed.

M&L for taking out injector from 500 KVA DG set for re-conditioning, transporting to OEM Authorised service center for complete overhauling, replacing unserviceable spares with new injectors (12 Nos), injector cup, O-rings, screen filter and all other spares required, calibrating and refixing and connecting back in its original position and testing complete all as specified and as directed.

S&F piston of engine of OEM suitable for 380 KVA DG including taking out old unserviceable one complete all as specified and as directed.

S&F piston ring set of OEM suitable for 380 KVA DG including taking out old unserviceable one complete all as specified and as directed.

S&F CR bearing set of OEM suitable for 380 KVA DG including taking out old unserviceable one complete all as specified and as directed.

S&F sump gasket 2 piece of OEM suitable for 320 KVA DG including taking out old unserviceable one complete all as specified and as directed.

S&F injector 'O' rings & copper cups of OEM suitable for 320 KVA DG set including taking out old unserviceable one complete all as specified and as directed.

S&F push rod valve of OEM suitable for 320 KVA DG including taking out old unserviceable one complete all as specified and as directed.

S&F push rod injector of OEM suitable for 437.5 KVA DG including taking out old unserviceable one complete all as specified and as directed.

S&F connecting rod assembly of OEM suitable for 437.5 KVA DG including taking out old unserviceable one complete all as specified and as directed.

S&F STC injector recon of OEM suitable for 437.5 KVA DG including taking out old unserviceable one complete all as specified and as directed.

S&F cylinder head assembly recon of OEM suitable for 625 KVA DG including taking out old unserviceable one complete all as specified and as directed.

S&F in replacement of Gen Set Control Panel for 1010 KVA Cummins DG Set Commissioning and testing of DG Set complte all as specified and directed . Engine controller panel MODEL No. PCC 3.3. MAKE: CUMMINS

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