COMPREHENSIVE MAINT OF 10 MW CAPACITY CAPITIVE POWER PLANT CPP AT NAVAL BASE KARWAR

M& L for servicing of Turbocharger comprising of following works & Dynamic balancing of the Rotor Shaft to be carried out by qualified team of engineers from Manufacturers Authorised Repair Workshop complete as specified and directed by Engineer in Charge :- i) Dismantling the turbocharger from the installed position & removing , loading, transporting the turbocharger cartridge to OEM authorised & approved workshop for dynamic balancing. ii) Mechanical cleaning , assesmment & working condition evaluation of the turbocharger iii) Complete overhaul & servicing of the turbocharger iv) Dismantling of the Cartridge , Mechanical cleaning of the rotor and Assessment of the rotor shaft & condition evaluation v) Replacement of Standard Overhaul Spare parts as required at site and directed by GE. vi) Dynamic balancing of the rotor shaft & balancing of the rotor complete vii) Re Assembling the complete cartridge & transporting back to the site viii) Re Assembling the complete turbocharger with the cartridge, re- installing & commisioning of turbocharger assembly with the DG sets complete as per OEM Standards ix) Documentation & submission of the service & test reports as per prescribed format.

M & L for Maint/ Servicing of 62.5 KVA DG set , removing tapped cover after removing inlet / outlet pipe removing engine head replacing unserviceable valve seat & valve guide inlet & outlet as required replacing engine main gasket sheet cleaning the oil sump, cleaning/ replacement of fuel oil filter, cleaning of air filter, repair to the self starter assembly,Replacement of the fuel injection nozzles, repair and caliberation of the FIP, cleaning & checking of all diesel hose pipes, replacement of engine oil, repalcemet of battery terminals & battery leads, servicing of self starter dynamo by replacing carbon brushes beairngs & bushes and reassembling the engine head & tappered cover in original possition including all as specified in 'C' check of engine manufacturer and as specified and directed by Engineer in Charge Note :- Rate quoted includes cost of new items for replacement The engine oil for filling/topup will be meausued and paid seperately.

M & L for Maint/ Servicing of diesel engine of air compressor type DA 16, BHP 16.2 cylinder , removing tappet cover after removing inlet / outlet pipe removing engine head replacing unserviceable valve seat & valve guide inlet & outlet as required replacing engine main gasket sheet cleaning the oil sump, cleaning/ replacement of fuel oil filter complete all as specified and as direted by Engineer-in-Charge Note :- Rate quoted includes cost of new items for replacement The engine oil for filling/topup will be meausued and paid seperately.

M & L for Servicing of Lube Oil Coolers by dismantling,condition evaluation, transporting to workshop, thorough mechanical /ultrasonic mechanical cleaning the copper tube by steel brush, replacement of worn out parts like Synthetic rubber rings, Gaskets, O rings , nuts and bolts etc., assessment of leakages through pressure testing, reinstalling in original position & tetsing as per OEM standards. Note :- Rate quoted includes cost of new items for replacement.

M & L for Servicing of Starting Air Compressor 12.5 HP by disconnecting electric motor & outlet piping, transporting the air compressor to work shop, dismantling air compressor, replacing worn our parts such as piston Ring, Oil Ring, Gas Ket Set, Bearings, Greasing Oiling & Reinstalling air compressor in original position including replacement of unserviceable soloniod coil, pressure switch etc , testing & comissioning all as specified and directed. Make ELGI, Model HP 12300 max working pressure 30 Bar, RPM 1100 of Air compressor. Note :- Rate quoted includes cost of new items for replacement

M&L for servicing of the safety valve of air receiver capacity 0.50m3 , working pressure 30 kg/cm2, Design pressure 33 kg/cm2 & test pressure 50 kg/cm2 all as specifed & directed.

S & F in replacement of air drain valve max. Working pressure 35 kg/cm2, end can size 0.5 BSP, Max. Working temp. 75degee C. For air receiver complete all as specifed & directed.

M/L for servicing of DG control panel installed in CPP control room involving Calibration of the DE/NDE Sensors (01 set ie 02 nos, Ground protection Relay (01 no). ABB REM 543. 110v AC.Aux,V:24vdc. 7CT,2PT Input (01 no.), Gen. ROTOR Earth fault relay ( 01 nos.), Gen. STATOR Earth fault relay (1 nos.), Triping Relay & Dead Bus Relay (2 nos) all as specifed & directed.

M & L for Servicing of Local sensor Stand (LSS) PANEL .incl Calibration of the Pressure switch & 02 no. Temperature Switch ( HT &LT water ) 06 nos of Pr. Gauge. (HT & LT inlet and outlet Lube oil temp inlet and outlet pr )and replacement of defective parts all as specifed & directed.

M & L Servicing of Lighening Arrestor Protection Transformer (LAPT) PANEL incl Calibration of Droop CT (01 no), Droop PT(01no), & Distribution Lightning arrestor CT(01no.) surge arrestor CT(01 no) core balance CT(01no) , & DROOP Transformers. (01no) and replacement of defective parts all as specifed & directed.

M & L for Servicing of Neutral Grounding Resistance (NGR) PANNEL incl Calibration of Protection CT (01 no).CBCT (1 nos) , Differential CT (03 nos) and replacement of defective parts all as specifed & directed.

M&L for dismantalling the pump set from foundation and motor unit opening complete pump set , cleaning, replacing unserviseable parts such as gun metal bushes, rubber packing, ms nuts,bolts,rubber coupling , (spider) bearings, air valve etc. With approved makes. Reassembling, reinstalling,testing for satisfactory running complete all as directed by EIC for the following pumps including transporting pumpsets to workshop for machininig work/ obtaining proper/suitable spares complete for:-

Lub. Oil priming pump set 7.5 HP.

HT water pump set 3 HP.

LT water pump set 10 HP.

M & L for rewinding of electric motors 3 phase 50Hz 415 volt comprising of following activities for motor of following capacity complete all as directed & specified & as per manufactures instructions Notes:- i) Disconnecting & removing the electric motor from installed position & loading, unloading, including transporting. ii) Dismantling existing burnt winding from the motor, prepare for & including rewinding complete with super enamelled copper winding wire of existing guage including all material such as insulated paper, sleeves, tape, varnish etc. complete for class F insulation, keeping in hot air oven for drying, packing & reassembling complete. iii) Reinstalling in position & in alignment including electric connection, commissioning & testing in actual working condition to check designed RPM performance complete. iv)Replacement of Ball bearings & bushes of existing size with exisisting make.

Elect motor 0.5 to 1 HP

Elect motor 3 HP

Elect motor 4 HP

Elect motor 5 HP

Elect motor 7.5 HP

Elect motor 10 HP

M & L for Servicing of Plate Heat Exchanger by dismantling, assessment & condition evaluation, transporting to workshop, thorough mechanical cleaning repairing , conducting DP test, replacement of worn out parts like Field Gaskets, Ring Gaskets, Pressure Guages, Spools gasketting, Pressure testing for leakages & reinstalling the PHEs in original position & testing & commissioning as per OEM standards.

Labour only for carrying out servicing of DG sets( through authorised service rep/OEM) of capacity 2500 KW, 11 KV and Engine Make KOEL, Type 9PA 61-280 with rated BHP 3600 & all other connected equipments forming part of CPP including routine maintenance, replacement of engine oil, Engine oil leakage arresting,water pipe leakage arresting,fuel pipe leakage arresting, leakage arresting & binding with new asbestos rope on silencer/Exhaust pipes and replacement of defective / unserviceable spare parts as per site requirement including testing of DG sets after servicing so as to provide uninterrupted power supply as directed by EIC. Note :-The engine oil for filling/topup and other materials / spare parts will be measured and paid seperately under respective items

A) CYLINDER HEAD : a) Visual inspection of the rocking gear. b) Adjustment valve backlash on cold engine. c) Inspection of the starting air valve flaps & rings. d) Strip opening of the cylinder Head e) Visual inspection of the Inlet and exhaust Valves f) Inspection of the Valve rocker assembly g) Inspection of the rocking gear assembly h) Inspection of the cylinder head assembly j) caliberation of the tappet settings k) Timing gear caliberation/setting

B) FUEL INJECTION : a) Check calibration Atomization & the tightness of the injector. b) Replacement of injector nozzles if required c) Checking of the sliding of the injection pump racks. d) Replacement of the Anti splash screws. e) Inspection of Fuel injection pump

C) CRANK CASE - BEARINGS - CRANK SHAFT : a) Carry out the crankcase inspection. b) Measurement of the crankshaft deflection c) Inspection of the bearing shells of two main bearings

D) COUPLING - VIBRATION DAMPER : a) Check the resilient segment of the coupling and inspection of relilient material.

E) FLUID SYSTEM: a) Checking of the pneumatic starter . b) Inspection of the Air distributor disk. c) Inspection of the Main starting valve. d) Inspection & cleaning of the self cleaning fuel filter. e) Inspection of the oil pump safety valve. f) Inspection of the oil pressure control valve. g) Inspection & cleaning of the self cleaning oil filter. h) Inspection of centrifugal oil purifier j) Replacement of the filtering elements of self cleaning SOFRON k) Inspection of fuel feed pump l) Cleaning of lube oil MOTI filter

F) GOVERNING - OVER SPEED - SAFETY – WIRING SYSTEM: a) Replacement of hydraulic governor or actuator oil. b) Run the electronic overspeed test. c) Inspection & calibration of the electric actauator of electronic governor and calibration of same d) preperation of the governor connected with DG set of cap 2.5MW speed and frequency as required by the existing synchronising panels all as specified.

Supply only following spare parts for overhauling of KOEL DG sets as mentioned in item Ser No 16.00 here-in-before. Note: Parts replaced shall be of OEM as per the Cat part given against each.

ROCKING GEARS

Screw with expanded tappet cat part No. 79.033.28.0.00

Special nut cat Part No. 79.033.35.0.00 .

Fuel INJECTORS

Helicoflex Sealing Joint Cat Part No. 27.067.16.0.00

Copper Washer ( 20 x 27) Cat Part No. 50.508.20.000

O RING D-8, 21A7, L120C7 Cat Part No 74.466.02.000

Cap nut cat Part No. 79.041.03.0.00

Ring D164 3.5D NSE6.531 60C7, Cat Part No.79.041.15.000

Injector gasket Cat Part No. 79.041.18.0.00

Bush Viton Cat Part No. 79.041. 19 .000

O RING D135 3D NSE6. 531 60C7 Cat Part No 74.041.21.000

Injector Nozzle Assembly 9x0.50x140 cat part. 27.067.05.000

Gasket cat part. 79.034.77.000

FUEL FILTER

Fuel Filters Element Cat Part No.79.352.06.0.00

O Ring Filter cover (2.5 x 160, 21502) cat part No. 30.300.18.000

O Ring Filter cover (3.5 x 112, 21502)cat part No. 30.300.28.000

COUPLING

O Ring DIA 17 x DIA 4x4 (20401) Cat Part No 70.657.33.0.00

O Ring (20301) 4x460 Material -Nitri Cat Part No 80.356.13.0.00

STARTING AIR VALVE

Copper Washer (30 x 38) Cat Part No 50.508.35.000.

Conical Spring Washer (M 14) Cat Part No 50.527.10.000.

Spring Cat Part No 79.040.03.0.00

Washer Cat Part No 79.040.04.0.00

Ring Cat Part No 79.040.06.0.00

Snep Nut,(BINX NUT) HM10, Cat Part No 79.040.08.0.00

O - Ring, MS29-513/126, 21A7, NSE 6.531, Cat Part No 79.040.10.0.00

GOVERNOR DRIVE

Key Cat Part No 50.402.08.025.

Circlip External-30 MM Cat Part No 50.501.30.000.

Circlip internal - 62 MM Cat Part No 50.502.62.000.

Circlip internal- 80 MM Cat Part No 50.502.80.000.

O Ring No AN58NSE 6.5, 21 A7 Cat Part No. 79.049.24.0.00

Lub oil cooler and chrger cooler

Set of Gasket and O Ring for Lub Oil Cooler Cat Part No 79.425.59.0.00

EXHAUST MANIFOLD

Gasket cat part No. 72.328.13.000

Flexible joint cat part No. 79.078.07.000

Exhaust gas temp sensor cat part No. 81.068.02.000

Flexible joint cat part No. 27.052.21.000

THERMOMETER/ SWITCHES

Thermometer 0- 100 to Suit M18X1.5 Cat Part No79.277.02.0.00

Thermometer 0- 200 to Suit M18X1.5 Cat Part No79.277.03.0.00

Supply Only lubricants.

Lubrication oil system 68 for alternator bearings.

ELGI Air lube oil for air compressors .

lube oil SERVO Marine-10-40Grade.

Material and Labour required for complete dismantling of existing burnt out 11 KV lightning arrestors and replacing the same with lightning arrestors suitable for 11 KV diesel generator.

Supply & Fix in repairs heating element as existing on site of capacity 6 KW complete all as specified and directed by Engr-in-charge.

M&L for caliberation of governor assembly of the DG set of cap 2.5 MW, 11 KV for desired output inorder to maintain the voltage and frequency of the DG set witin the limit of +/-1% of Voltage-11KV and frequency of 50HZ during all the time and dismantling of the governor assembly from the engine head and transporting the same to the OEM/authorized workshop and strip opening the governor assembly nad carrying out the requisite repair required to rectify the defects and assembling the governor assembly and refiiting the same with the DG set and testing the output of the DG set in the presence of the Engr-In-Chrage and rectifying the defects if any noticed complete all as specified and directed.

Material & Labour required for servicing of air pressure control system mounted on 2.5 MW DG set by replacing old air reciever bottle of Cap 30 Kg/CM, drain valves , pressure control system complete including replacement of nuts and bolts assembly,cleaning of pipe line connected from DG set head to system be cleaned and made choke free complete as all as specifed and directed by Engineer-in-charge.

M&L for preparation of old painted steel surfaces of 2.5 MW DG sets including alternator, support channels complete with the all connected equipments complete and painting with two coats of approved colour synthetic enamel paint complete all as directed. Note:-1. Painting should be done with existing colour codes and painting should apply with the help of spary gun using air compressor. 2. Quotated rate shall deemed to be included for preparation of old painted surface and applying zinc chrome primer over rusted portion all as directed.

M&L for preparation of old painted steel surfaces of 62.5 KVA DG sets including alternator, support channels complete with the all connected equipments complete and painting with two coats of approved colour synthetic enamel paint complete all as directed. Note:-1. Painting should be done with existing colour codes and painting should apply with the help of spary gun using air compressor. 2. Quotated rate shall deemed to be included for preparation of old painted surface and applying zinc chrome primer over rusted portion all as directed.

M&L for cleaning of diesel tank (Day Tank) of capacity 600 ltrs carefully by drining out fuel in the tank and disconnection from fuel system, descaling the diesel tank with water pressure and removing the complete sludge deposited, drying the tank, repair to any leakage, cleaning and testing of fuel line upto Fuel Pump inlet and preparation of old painted surfaces of diesel tank (Day Tank) of capacity 600 ltrs including all inlet and outlet pipes any of size, support channels complete with the all connected accessories complete and painting with two coats of approved colour synthetic enamel paint complete all as directed. Note:-1. Painting should be done with existing colour codes and painting should apply with the help of spary gun using air compressor. 2. Quotated rate shall deemed to be included for preparation of old painted surface.

M&L for cleaning of diesel tank (Drip Tank) of capacity 500 ltrs carefully by drining out fuel in the tank and disconnection from fuel system, descaling the diesel tank with water pressure and removing the complete sludge deposited, drying the tank, repair to any leakage, cleaning and testing of fuel line upto Fuel Pump inlet and preparation of old painted surfaces of diesel tank (Drip Tank) of capacity 500 ltrs including all inlet and outlet pipes any of size, support channels complete with the all connected accessories complete and painting with two coats of approved colour synthetic enamel paint complete all as directed. Note:-1. Painting should be done with existing colour codes and painting should apply with the help of spary gun using air compressor. 2. Quotated rate shall deemed to be included for preparation of old painted surface.

M&L for cleaning of Chemical mixing tank of capacity 600 ltrs - 01 No, Pre heating tank module 100 ltrs with heaters - 04 Nos and balance water tank 150 ltrs -04 Nos carefully by drining out chemical mixed water in the tank and disconnection from high temperature water circulation system system, descaling the all tank with water pressure and removing the complete sludge deposited, drying the tank, repair to any leakage, cleaning and testing of water line upto engine and preparation of old painted surfaces of Chemical mixing tank of capacity 600 ltrs - 01 No, Pre heating tank module 100 ltrs with heaters - 04 Nos and balance water tank 150 ltrs -04 Nos including all inlet and outlet pipes any of size, support channels complete with the all connected accessories complete and painting with two coats of approved colour synthetic enamel paint complete all as directed. Note:-1. Painting should be done with existing colour codes and painting should apply with the help of spary gun using air compressor. 2. Quotated rate shall deemed to be included for preparation of old painted surface.

M&L for preparation of old painted surfaces of air circulation System of 2.5 MW DG Set comprising of Diesel engine driven compressor-01 No, Electric driven compressor-01 No and air reciever bottle of Cap 30 kg/CM -04 Nos including all inlet and outlet pipes any of size, support channels complete with the all connected accessories complete and painting with two coats of approved colour synthetic enamel paint complete all as directed. Note:-1. Painting should be done with existing colour codes and painting should apply with the help of spary gun using air compressor. 2. Quotated rate shall deemed to be included for preparation of old painted surface and applying zinc chrome primer over rusted portion all as directed.

M&L for adding Chemical KEM Water treatment 107 M for water softening purpose into the Chemical mixing tank all as directed.

M&L for cleaning of diesel tank of CPP (Storage Tank) of capacity 60000 ltrs carefully by draining out fuel in the tank and disconnection from fuel system, descaling the diesel tank with water pressure and removing the complete sludge deposited, drying the tank, repair to any leakage, cleaning and testing of fuel line upto Fuel Pump inlet and preparation of old painted surfaces of diesel tank ((Storage Tank) of capacity 600 ltrs including all inlet and outlet pipes any of size, support channels complete with the all connected accessories complete and painting with two coats of approved colour synthetic enamel paint complete all as directed. Note:-1. Painting should be done with existing colour codes and painting should apply with the help of spary gun using air compressor. 2. Quotated rate shall deemed to be included for preparation of old painted surface.

M & L for Servicing of fuel centrifugel module flame proof electric motor 3 KW filtration system of CPP by dismantling of motor & outlet piping, transporting the motor to work shop for winding, GasKet Set, Bearings, Greasing Oiling & Reinstalling fuel centrifuge module flame proof electric motor 3 KW filtration system in original position, replacement of unserviceable meterals/spare parts for the fuel centrifuge module flame proof electric motor 3 KW filtration system of CPP and comissioning all as specified and directed. Note :- Rate quoted includes cost of new items for replacement

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