REPAIR MAINTOF DG SETS AND SERVO VOLTAGE STABILIZERS BY OEMs AT KHUNDRU KHANABAL KHUNMOH AND KHREW UNDER GE 861 EWS

Amount

M/L for Maintenance and servicing of standby DG Set complete including draining out of diesel from tank , cleaning the tank thoroughly and refilling the drained out diesel, draining out engine oil from the sump, cleaning the sump thoroughly and refilling the sump with new engine oil to it’s required level, replacing the fuel filter, lubricating oil filter , check & clean air cleaner , change air cleaner elements, check coolant level & make up the same ,drain the fuel filter & water separator ,filling the starting batteries with electrolyte/distilled water to maintain the required specific gravity, replace the u/s brass connectors for batteries, cleaning of battery terminals & applying petroleum jelly to battery terminal posts & brass connectors, including M & L for V Belts, checking of exhaust leakage, governor, breathers etc, adjust/set the same for proper functioning of DG Set, checking of fuel, oil and water/ coolant level etc, adjusting and keeping the fan belts to the desired tension, tightening all the bolts and nuts to the required torque etc, cleaning the DG Set with accessories as prescribed by the manufacturer and test for satisfactory running of DG set for two hour at connected load and record shall be made in respect of RPM , oil pressure , oil temperature , coolant temperature, voltage , frequency , load current , battery charging , fuel consumption etc complete all as specified and directed by Engineer in Charge for 10- 20 KVA D G set Make Kirloskar Note :- (a). Engine oil for refilling will be measured and paid for separately (b). Coolant for make up will be measured & paid for separately (c). Testing will be carried out in presence of Engineer - in - charge and DHPP consumption will be entered in PRRB. (d). The Make of Fuel filter , Oil Filter , V belt & component will be as per manufactures recommendations ( Rate of fuel filter, oil filter, air filter and V belt shall deem to be included in quoted rate.)

All as per item No.1 above but for 25 TO 35 KVA DG Set Make – KEC/ Kiloskar

All as per item No.1 above but for 40-50 KVA DG Set Make – CG /Greaves

All as per item No.1 above but for 63 KVA DG Set Make – Mahindra

All as per item No.1 above but for 82.50 KVA DG Set Make – Sudhir/ Ashok layland

All as per item No.1 above but for 100 KVA DG Set Make – 100 Make: Greaves

All as per item No.1 above but for 125 KVA DG Set Make – Kirloskar

All as per item No.1 above but for 160-200 KVA DG Set Make – Cummins

Supply only multi-grade 15W40 lubricating oil for DG Sets as per manufacturer’s recommendations, complete all as specified and directed. Make- IOC, Castrol, Hindustan Petroleum

Supply only coolant for radiator as per manufacturer’s recommendations, complete all as specified and directed. Make- Castrol, Servo, Cummins

Supply & fixing Hose pipe set & Clips of water / coolant cooled radiator system for following DG set:- (a) 10 to 20 KVA DG set

(b) 25 to 35 KVA DG Set

(c ) 40 to 50 KVA DG set

(d) 63 KVA DG set

(e) 82.50 KVA DG set

(f) 100 KVA DG set

(g) 125 KVA DG set

(h) 160 to 200 KVA DG set

Repairs & Overhauling of radiator assembly by dismantling from engine transporting to the workshop and removing the sediments and scales, corrosion etc by means of acid, cleaning and high pressure water washing and air cleaning, gas welding / soldering with good quality material for stopping the leakage etc, re-assembling the same with new gaskets and transporting to the site, fixing to the engine with hoses, clips complete to the entire satisfaction of engineer - in - charge as required for following DG Sets. (a) 10 to 20 KVA DG set

(b) 25 to 35 KVA DG Set

(c ) 40 to 50 KVA DG set

(d) 63 KVA DG set

(e) 82.50 KVA DG set

(f) 100 KVA DG set

(g) 125 KVA DG set

(h) 160 to 200 KVA DG set

Dismantling the water pump of the DG Set taking out the worn out parts, refixing the water pump in the same position after replacing the worn out parts with new water pump repair kit set for following DG set:- (a) 10 to 20 KVA DG set

(b) 25 to 35 KVA DG Set

(c ) 40 to 50 KVA DG set

(d) 63 KVA DG set

(e) 82.50 KVA DG set

(f) 100 KVA DG set

(g) 125 KVA DG set

(h) 160 to 200 KVA DG set

Dismantling & strip opening of self starter for 12 volt/24 volt inspecting /checking the complete parts & taking out worn out parts/unserviceable parts and making the self starter functional after replacing the new parts as required and directed. Note: Spare parts shall be measured and paid for separately under respective items of BOQ.

(a) Supply only Armature assembly 12 volt suitable for 92 to 150 Ah

(b) Supply only Solenoid switch 12 volts

(c ) Supply only Field coil 12 volts

(d) Supply only Bendex penion 12 volts complete

(e) Supply only Carbon brush

Supply & fixing the following items to self starter of existing make. (a) Armature assembly 24 volt suitable for 180 AH

(b) Solenoid switch 24 volts

(c ) Field coil 24 volts

(d) Bendex penion 24 volts complete

(e) Carbon brush

Material and labour for servicing battery charging alternators assembly of DG Set , by disconnecting from engine and dismantling the battery charging alternator assembly for following DG set cleaning all accessories and replacing with worn out parts like carbon brush, bush/bearing , jumping leads etc, and varnishing all as directed. (a) 10 to 20 KVA DG set

(b) 25 to 35 KVA DG Set

(c ) 40 to 50 KVA DG set

(d) 63 KVA DG set

(e) 82.50 KVA DG set

(f) 100 KVA DG set

(g) 125 KVA DG set

(h) 160 to 200 KVA DG set

Disconnection and dismantling the fuel injector pump assembly from its original position , Overhauling & servicing by cleaning / oiling/servicing of fuel injector pump assembly , removing and replacement with and including fuel injector pump, repair kit,fuel pipe and injectors including calibration & refixing the same complete all as directed by Engineer-in-charge for following DG set :- (a) 10 to 20 KVA DG set

(b) 25 to 35 KVA DG Set

(c ) 40 to 50 KVA DG set

(d) 63 KVA DG set

(e) 82.50 KVA DG set

(f) 100 KVA DG set

(g) 125 KVA DG set

(h) 160 to 200 KVA DG set

S&F in repair RPM meter of DG set complete all as specified and directed.

S&F in repair oil pressure Gauge on DG set complete all as specified and directed.

S&F in repair oil temperature Gauge on DG set complete all as specified and directed.

S&F in repair water temperature Gauge on DG set complete all as specified and directed.

S&F PVC insulated stranded copper conductor cable of 25 sqmm single core, of 2 Mtr length, souldered with 2 Nos gun metal battery terminals suitable for 60-180 Ah 12V DC battery, complete all as specified and directed. Make of cable : Plaza / Finolex / Gloster/National/ Polycab

Dismantling asbestos rope from silencer of DG set and supply & fixing asbestos rope (8/10mm thick) around silencers complete all as specified and directed.

M&L for preparation of old painted surface of DG Set complete (DG Set cap20KVA to 35 KVA) with fuel tank by scrapping / removing old paint / dust etc and painting with two coats of synthetic enamel paint (colour & tint as approved) over a coat of primer including caliberatation of capacity and marking/writing as follows:- (a) Tank capacity (b) Tank cleaned on (c) Due date.

All as per srl item No 68 above but for DG Set cap 50 KVA to 82.5 KVA.

All as per srl item No 68 above but for DG Set cap 100 to 125 KVA.

All as per srl item No 68 above but for DG Set cap 200 KVA.

Disconnecting, and taking out carefully unserviceable alternator, transformer and old pattern AVR of any make and any capacity of DG Sets , dismantling and strip opening of alternator for servicing, taking out and removing old burnt out winding and rewinding of alternator with existing gauge super enameled copper wire as approved by the Engineer-in-Charge with insulating material such as luminous paper, latherized paper, cotton tape, glass sleeves, insulating varnish etc, including reassembling and fixing the same in position and testing alternator assembly, complete all as specified and directed by the Engineer-in-Charge.

Taking out following defective parts from Alternator of DG sets and supply and fixing new parts in same position including testing, complete all as specified and directed by Engineer-in-Charge :- (a) AVR unit complete for 20 to 35 KVA DG Set

(b) AVR unit complete for 50 to 82.50 KVA DG Set

(c ) AVR unit complete for 100 to 125 KVA DG Set

(d) AVR unit complete for 160 to 200 KVA DG Set

(e) Terminal plate

(f) Silicon Rectifier assembly with metallic plate as existing covered with thin layer of selenium and inverted nut bolt , control wiring soldering complete

(g) Flexible rubber coupling star type capacity alternator coupled for 20 to 35 KVA , complete all as specified and directed

(h) Flexible rubber coupling star type capacity alternator coupled with Kirloskar or any other approved make of DG set for 50 to 82.50 KVA, complete all as specified and directed

S&F self Starter in repair 12 V for DG set 63 to 82.50KVA suitable for kirloskar, complete all as specified and directed.

S&F self Starter in repair 12 V for DG set 20 to 35 KVA suitable for Ruston, complete all as specified and directed.

S & F in repair flexible fuel pipe of 5 Mtr length including end hexa nut bolts etc, complete all as specified and directed.

S & F in repair ignition switch push button type, complete all as specified and directed.

S&F in repair lead acid battery maintenance free 12 Volt 180Ah, complete all aspecified and directed Make: Exide/Amaron

All as per srl item No.85 above but 12 Volts 150 Ah, complete all as specified and directed. Make: Exide/Amaron

All as per srl item No.85 above but 12 Volts 92/100 Ah, complete all as specified and directed.Make: Exide/Amaron

S & F brass terminal for batteries including taking out and removing existing unserviceable terminals, complete all as specified and directed.

S&F in replacement off load change over switch 4 pole 415 volts , 300 Amps rating side handle operated in sheet metal enclosure after dismantling and taking out old change over of any make and capacity, complete all as specified and directed.

S&F in replacement off load change over switch 4 pole 415 volts , 200 Amps rating side handle operated in sheet metal enclosure, complete all as specified and directed.

S&F in replacement off load change over switch 4 pole 415 volts , 125 Amps rating side handle operated in sheet metal enclosure, complete all as specified and directed.

S&F in replacement off load change over switch 4 pole 415 volts , 100 Amps rating side handle operated in sheet metal enclosure, complete all as specified and directed.

S&F in replacement off load change over switch 4 pole 415 volts , 63 Amps rating side handle operated in sheet metal enclosure , complete all as specified and directed.

Taking out U/S control wiring complete from servo controlled voltage stabilizer of any capacity and ofany make up to 50 KVA 3 phase 415 volts for unbalanced load. Providing wiring loom complete to the stabilizers made out of suitable size PVC insulated copper conductor cable including cables lugs, connectors, channels and fixing in replacement of any other worn out/unservicable items to make functiononal, complete all as specified and directed. Note:-Additional items required to make stabilizers serviceable will be measured separately under respective items

Taking out U/S control wiring complete from servo controlled voltage stabilizer of any capacity and ofany make up to 50 KVA to 100 KVA 3 phase 415 volts for unbalanced load. Providing wiring loom complete to the stabilizers made out of suitable size PVC insulated copper conductor cable including cables lugs, connectors, channels and fixing in replacement of any other worn out/unservicable items to make functiononal, complete all as specified and directed. Note:-Additional items required to make stabilizers serviceable will be measured separately under respective items

Taking out U/S control wiring complete from servo controlled voltage stabilizer of any capacity and ofany make up to 100KVA to 225 KVA 3 phase 415 volts for unbalanced load. Providing wiring loom complete to the stabilizers made out of suitable size PVC insulated copper conductor cable including cables lugs, connectors, channels and fixing in replacement of any other worn out/unservicable items to make functiononal, complete all as specified and directed. Note:-Additional items required to make stabilizers serviceable will be measured separately under respective items

Supply only voltmeter digital type 30 to 600 volts of size 96x96mm square type conforming to Cat Pt No WDS 101 FCV00 of L&T/ AE/C&S or equivalent, complete all as specified and directed.

Supply only printed control card circuit suitable for voltage stabilizer of make AE/ Blue Line /Paradise/Vintech/Electric Field/ Sheeba Info tech, complete all as specified and directed.

Supply only holder for printed control card circuit suitable for any make voltage stabilizer including connections by souldering , complete all as specified and directed.

Supply only micro switch (limit switch) suitable to cut off supply to control motors on high and low set limits as per sample held in sub divn, complete all as specified and directed.

Supply only auto manual toggle switch 2 way 5 amps 230 volts including connecting electrically, complete all as specified and directed.

Supply only synchronous motor single phase AC 230 volts suitable to work with voltage stabilizer up to 50 KVA cap any Make AE/Blue line /Paradise/Vintech/Electric field/ Sheeba Info tech with torque up to 5 Kg/cm2, complete all as specified and directed.

Supply only synchronous motor single phase AC 230 volts suitable to work with voltage stabilizer 50KVA to 225 KVA capacity of any Make AE/Blue line /Paradise/Vintech/Electric field/ Sheeba Info tech with torque above 5 Kg/cm2 up to 12 Kgcm2, complete all as specified and directed.

Supply only gear suitable for synchronous motors to operate the shaft for variable dimmer stat.

Supply only indicator with bulb, red, yellow or green 230 volts as per sample make L&T/C&S/AE

Supply only trigger (control) transformer with primary voltage 230 volts and secondary voltage any desired voltage between 12 volts to 60 volts to suit the control circuit of the stabilizer as per sample

Supply only push button any type and any size as per sample held in Sub Divn, suitable to operate the synchronous motor manually, complete all as specified and directed.

Supply only dimmer stat 28 amps rating suitable for voltage stabilizer of any cap up to 50 KVA per phase of any make to match with existing system, complete all as specified and directed.

Supply only dimmer stat 60 amps rating suitable for voltage stabilizer of any cap up to 100 KVA per phase of any make to match with existing system, complete all as specified and directed.

Supply only dimmer stat 100 amps rating suitable for voltage stabilizer of any cap up to 200 KVA per phase of any make to match with existing system, complete all as specified and directed.

Supply only drive assemby complete suitable for voltage stabilizers any make up to 100 KVA per phase all as per sample held in Sub Divn , complete all as specified and directed.

Supply only drive assemby complete suitable for voltage stabilizers any make above 100 KVA up to 200 KVA per phase all as per sample held in sub Divn, complete all as specified and directed.

Supply only carbon brush with holder as per sample held in Sub Divn suitable for voltage stabilizer of any make, any capacity upto 50 KVA, complete all as specified and directed.

Supply only carbon brush with holder as per sample held in Sub Divn suitable for voltage stabilizer of any make, any capacity 50 KVA to 200KVA, complete all as specified and directed.

Taking out main transformer of the voltage stabilizer for repair/rewinding and rewinding of the main transformer using super enameled copper winding wire of existing gauge including latherite paper, PVC sheets, sleeves etc all as required including varnishing complete with insulating varnish, drying and refixing to the stabilizer after testing, complete all as specified and directed.

Supply and fixing in replacement brass studs with nuts, washers etc complete including porcelain bushes as per sample held in Sub Divn suitable for voltage stabilizers upto 50 KVA cap any make all as required at site, complete all as specified and directed.

All as per item No.116 above but 50 KVA up to 100 KVA.

All as per item No.116 above but 100 KVA up to 225 KVA.

Scraping old paint from the voltage stabilizer 3 phase up to 50 KVA capacity and preparation of surfaces and re-painting the voltage stabilizers by spraying synthetic enamel paint of approved colour and make, writing SM/MES No and capacity with white paint all as required at site, complete all as specified and directed.

All as per item No.119 above but 50 KVA up to 100 KVA.

All as per item No.119 above but 100 KVA up to 225 KVA.

M&L for top overhauling of DG set 82 to 100 KVA Make : Cummins, KEC , Mahindra Greaves and kirloskar with and including of taking down of the old unsv parts such as inlet and exhaust valve mechanism, valve guide sheet, tappets, cylinder liners, pressure ring, oil rings, piston, connecting rod and gagen pin including lathe work as required for top overhauling and fixing the unservicable parts in same position, complete all as specified and directed. Note :- Spare parts shall be measured and paid for separately under respective items of BOQ as supply only. -

(a) Supply only Sleeves liner, complete all as specified and directed.

(b) Supply only Piston , complete all as specified and directed.

(c) Supply only Piston oil ring, complete all as specified and directed.

(d) Supply only Piston pressure ring, complete all as specified and directed.

(e) Supply only Inlet valve mechanism, complete all as specified and directed.

(f) Supply only Exhaust valve mechanism, complete all as specified and directed.

(g) Supply only Connecting rod bearing , complete all as specified and directed.

(h) Supply only Valve guide, complete all as specified and directed.

(j) Supply only connecting rod bush, complete all as specified and directed.

(k) Supply only Valve guide sheet, complete all as specified and directed.

(l) Supply only FIP calibration, complete all as specified and directed.

(m) Supply only Injectors, complete all as specified and directed.

(n) Supply only Inlet and exhaust valve spring, complete all as specified and directed.

(o) Supply only Head gasket set, complete all as specified and directed.

(p) Supply only injector sleeves, complete all as specified and directed.

M&L for top overhauling of DG set 50-63 KVA of Make Cummins, KEC, Mahindra, Greaves and kirloskar with and including of taking down of the old unsv parts such as inlet and exhaust valve mechanism, valve guide sheet, tappets, cylinder liners, pressure ring, oil rings, piston connecting rod and gagen pin and lathe work as required for top overhauling, including fixing all the necessary parts in postion, complete all as specified and directed. Note :- Spare parts shall be measured and paid for separately under respective items of BOQ as supply only.

(a) Supply only Sleeves liner, complete all as specified and directed.

(b) Supply only Piston, complete all as specified and directed.

(c) Supply only Piston oil ring, complete all as specified and directed.

(d) Supply only Piston pressure ring, complete all as specified and directed.

(e) Supply only Inlet valve mechanism, complete all as specified and directed.

(f) Supply only Exhaust valve mechanism, complete all as specified and directed.

(g) Supply only Connecting rod bearing , complete all as specified and directed.

(h) Supply only Valve guide, complete all as specified and directed.

(j) Supply only connecting rod bush, complete all as specified and directed.

(k) Supply only Valve guide sheet, complete all as specified and directed.

(l) Supply only FIP calibration, complete all as specified and directed.

(m) Supply only Injectors , complete all as specified and directed.

(n) Supply only Inlet and exhaust valve spring, complete all as specified and directed.

(o) Supply only Head gasket set, complete all as specified and directed.

(p) Supply only injector sleeves, complete all as specified and directed.

M&L for top overhauling of DG set 20-35 KVA Make : Cummins, KEC , Mahindra, greaves and kirloskar with and including of taking down of the old unsv parts such as inlet and exhaust valve mechanism, valve guide sheet, tappets, cylinder liners, pressure ring, oil rings, piston connecting rod and gagen pin and lathe work as required for top overhauling including fixing all the necessary parts in postion, complete all as specified and directed. Note :- Spare parts shall be measured and paid for separately under respective items of BOQ as supply only.

(a) Supply only Sleeves liner

(b) Supply only Piston

(c) Supply only Piston oil ring

(d) Supply only Piston pressure ring

(e) Supply only Inlet valve mechanism

(f) Supply only Exhaust valve mechanism

(g) Supply only Connecting rod bearing

(h) Supply only Valve guide

(j) Supply only connecting rod bush

(k) Supply only Valve guide sheet

(l) Supply only FIP calibration

(m) Supply only Injectors

(n) Supply only Inlet and exhaust valve spring

(o) Supply onlyHead gasket set

(p) Supply only injector sleeves General Note : The contractor will submit a scanned copy of Memmorudum of under standing from OEMs ( or authorised dealers) for the respective E/M installations. The details of OEMs are as under:- (a) DG Set (i) Kirlosker Green (ii) Crompton Greaves (iii) Sudhir (b) Servo Voltage Stablizer (i) Vinitek (ii) Electric field

Filtration of transformer oil of Voltage Stablizer oil type up to 150 KVA capacity installed at different sub stations/locations using filtration plant , dehydration and improving di-electric strength of the oil to withstand 40 KV for one minute including testing of oil as specified and directed. NOTE : Stablizer oil test kit shall be provided by the contractor at site for testing of oil.

Filling in with new Stablizer oil low viscosity of approved make as per IS-335 of 1992 and die-electric strength 20 KV when tested at 1mm gap incl submission of certificate fro IS approved lab for desired value of die-electric strength complete all as specified.

Supply, fixing testing and commissioning of Heat exchanger, consisting of two closely wound, helical, concentric coil arranged to give three passes on flue gas side and made of ERW tubes for hot water plant installed at Khrew station of cap 200000 kcal/hr including disconnecting of electrical connections, taking out out unservicable coil complete to the entire satisfaction of engineer in charge... Make AQUAMATIC AMW SERIES ( 2 LAKH KCAL/HR).

Supply, fixing testing and commissioning of Shell assembly consisting of a single jacket, enclosing the heat exchanger coil to serve as an integral " Combustion Chamber" duly insulated externally for hot water plant installed at Khrew station of cap 200000 kcal/hr complete to the entire satisfaction of engineer in charge... Make AQUAMATIC AMW SERIES ( 2 LAKH KCAL/HR).

Supply, fixing testing and commissioning of Mono-bloc burner suitable for HSD firing wit on-off control for hot water plant installed at Khrew station of cap 200000 kcal/hr complete to the entire satisfaction of engineer in charge... Make AQUAMATIC AMW SERIES ( 2 LAKH KCAL/HR).

Supply, fixing inrepair of extesting and commissioning of Dust protected, pre-wired control panel housing a set of contactors & MCB, motor protection and fuses, including set of water piping connecting the unit & Pump, colorifier (heat Exchanger) duly insulated and supplid with safety valve, pressure and temperature gauges and secondary water thermostat for hot water plant installed at Khrew station of cap 200000 kcal/hr complete to the entire satisfaction of engineer in charge... Make AQUAMATIC AMW SERIES ( 2 LAKH KCAL/HR).

Supply, fixing inrepair of expansion tank to take care of expansion due to thermal heating of water with level indicator, air vent, valves and stainer incl one set of water piping connecting the unit and calorifier for hot water plant installed at Khrew station of cap 200000 kcal/hr complete to the entire satisfaction of engineer in charge... Make AQUAMATIC AMW SERIES ( 2 LAKH KCAL/HR).

Dismantling the electric motor 3 phase 440 volts 2 to 3 HP opening cleaning of winding and varnishing and winding drying the same re assembling and fixing the same on existing position with pump reconnection checking the alignment incl replacement of foundation channel pad and testing on load for smooth running complete all as specified and directed by Engr in charge.

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