REPAIR/MAINT OF DG SETS AND CONNECTED WORKS OF POWER HOUSE NO-I AND II AREA

Comprehensive maintenance of 320 KVA DG sets consisting of normal repairs with periodical routine maintenance, attending breakdown as and when required and testing of DG set complete i.e. Engine, Alternator etc including all consumables items like cleaning cloth, waste cloth, degreasing/cleaning agent, anti-rust spray, grease, kerosene oil etc. Maintenance will be carried out all as directed by Engineer-in-Charge and comprising of the following :- (a) Change/top up engine oil. (b) Replacement of Oil Filter element, Fuel filter element, air filter element, fuel flexible pipe, fan belt/V-belt for water pump and alternator, cleaning of Fuel tank etc (c) Replacement of water filter element. (d) Adjusting valve tappet/governor clearence/timing (e) Injector pressure test cleaning and repairing, tightining fasteners and making lubrication leak proof Notes: 1. Engine oil/coolant will be measured and paid separately. 2. Labour charges for dismantling / taking down and replacement/refixing new parts as and when required is deemed to be included in unit rate quoted. 3. Spares (as per sample) and lubricant to be measured and paid separately under respective items here-in-after as supply only. 4. Minor consumables like oil filter gasket, Drain plug washer, O-rings & sealing washers, Gasket for fuel and air connections etc are included in the quoted rate. 4. All spare parts should be approved by Engr-in-Charge before fixing. 320 KVA DG Set Make : GREAVES

Supply only the following items against BOQ Item No 1.00 here-in-before ( to be measured and pain only when incorporated agaist the equipments)

Supply only Fuel Filter element for 320 KVA DG Set

Supply Engine Oil Filter element for 320 KVA DG Set

Supply only Primary Air Filter (Outer) for 320 KVA DG Set

Supply only Secondary Air Filter (Inner) for 320 KVA DG Set

Supply only Fan belt / V-belt for 320 KVA DG Set

Supply only Radiator hose (upper & lower) for 320 KVA DG Set

Supply only of fuel hose for 320 KVA DG Set

Supply only of Expansion Bellow for 320 KVA DG Set

Supply only of corrosion resistor for 320 KVA DG Set

All as per above item No 11.00 here-in-before but of capacity 100 to 125 KVA DG Set Make : Kirloskar/Cummins

Supply only the following items against BOQ Item No 3.00 here-in-before ( to be measured and pain only when incorporated agaist the equipments)

Supply only Fuel Filter element for 100 to 125 KVA DG Set

Supply only Engine Oil Filter element for 100 to 125 KVA DG Set

Supply only Primary Air Filter (Outer) element for 100 to 125 KVA DG Set

Supply only Secondary Air Filter (Inner) element for 100 to 125 KVA DG Set

Supply only Fan belt / V-belt for 100 to 125 KVA DG Set

Supply only Radiator hose (upper & lower) for 100 to 125 KVA DG Set

Supply only of fuel hose for 100 to 125 KVA DG Set

Supply only of Expansion Bellow for 100 to 125 KVA DG Set

Supply only of corrosion resistor for 100 to 125 KVA DG Set

All as per above item No 22.00 here-in-before but of capacity 62.5 to 82.5 KVA DG Set Make : Kirloskar/Cummins/Ashok Leyland

Supply only the following items against BOQ Item No 5.00 here-in-before ( to be measured and pain only when incorporated agaist the equipments)

Supply only Fuel Filter element for 62.5 to 82.5 KVA DG Set

Supply only Engine Oil Filter element for 62.5 to 82.5 KVA DG Set

Supply only Primary Air Filter (Outer) element for 62.5 to 82.5 KVA DG Set

Supply only Secondary Air Filter (Inner) element for 62.5 to 82.5 KVA DG Set

Supply only Fan belt / V-belt for 62.5 to 82.5 KVA DG Set

Supply only Radiator hose (upper & lower) for 62.5 to 82.5 KVA DG Set

Supply only of fuel hose for 62.5 to 82.5 KVA DG Set

Supply only of Expansion Bellow for 62.5 to 82.5 KVA DG Set

Supply only of corrosion resistor for 62.5 to 82.5 KVA DG Set

All as per above item No 33.00 here-in-before but of capacity 40 to 50 KVA DG Set Make : Kirloskar/Eicher

Supply only the following items against BOQ Item No 7.00 here-in-before ( to be measured and pain only when incorporated agaist the equipments)

Supply only Fuel Filter element for 40 to 50 KVA DG Set

Supply only Engine Oil Filter element for 40 to 50 KVA DG Set

Supply only Primary Air Filter (Outer) element for 40 to 50 KVA DG Set

Supply only Secondary Air Filter (Inner) element for 40 to 50 KVA DG Set

Supply only Fan belt / V-belt for 40 to 50 KVA DG Set

Supply only Radiator hose (upper & lower) for 40 to 50 KVA DG Set

Supply only of fuel hose for 40 to 50 KVA DG Set

Supply only of Expansion Bellow for 40 to 50 KVA DG Set

Supply only of corrosion resistor for 40 to 50 KVA DG Set

All as per above item No 45.00 here-in-before but of capacity 25 to 35 KVA DG Set Make : Kirloskar/Eicher

Supply only the following items against BOQ Item No 9.00 here-in-before ( to be measured and pain only when incorporated agaist the equipments)

Supply only Fuel Filter element for 25 to 35 KVA DG Set

Supply only Engine Oil Filter element for 25 to 35 KVA DG Set

Supply only Primary Air Filter (Outer) element for 25 to 35 KVA DG Set

Supply only Secondary Air Filter (Inner) element for 25 to 35 KVA DG Set

Supply only Fan belt / V-belt for 25 to 35 KVA DG Set

Supply only Radiator hose (upper & lower) for 25 to 35 KVA DG Set

Supply only of fuel hose for 25 to 35 KVA DG Set

Supply only of Expansion Bellow for 25 to 35 KVA DG Set

Supply only of corrosion resistor for 25 to 35 KVA DG Set

Supply & filling of Engine oil 20W40 to topup/replacement of all DG set of various capacity, model & location as mentioned here-in-before as per the standard practice, complete all as specified and directed.

Supply & filling of Coolant suitable for DG set of various capacity, model & location as mentioned here-in-before as per the standard practice complete all as specified and directed.

Supply and filling distilled water & acid mixture for battery and radiator, complete all as specified and directed.

S & F in repair battery, 12 Volt, 150 AH, complete all as specified and directed.

S & F in repair battery, 12 Volt, 88 AH complete all as specified and directed.

S & F in repairs Battery terminal cable, copper conductor multi strand, unsheathed, single core 16 sqmm, 1.2 mtr long fixed with copper terminals on both side suitable for 12 Volts & upto 150 AH battery both for positive and negative terminal all as specified and directed.

Repair/Maint of Automatic Battery Charger, I/P-230 Volt, AC, output volt 12 Volt DC, 10 Amps and replacement of burn out of electric circuit, unserviceable triodes, unserviceable rectifiers, unserviceable capacitors and resistance etc. after completion of repair work testing complete all as specified and directed. Note:- All the spares part deemed to be included in quoted rate.

Dismantling of radiator assembly of 320KVA from generating set and repair the tank/storage portion incl necessary welding/soldering & making leak proof of the tank, descaling the complete radiator with chemical agent and pumping set and assembling the radiator including replacement of all old rusted MS nuts, bolts washers & gasket sets including refixing and testing complete all as specified and directed.

Dismantling of radiator assembly of 125/100KVA from generating set and repair the tank/storage portion incl necessary welding/soldering & making leak proof of the tank, descaling the complete radiator with chemical agent and pumping set and assembling the radiator including replacement of all old rusted MS nuts, bolts washers & gasket sets including refixing and testing complete all as specified and directed.

Dismantling of radiator assembly of 75/82.5/62.5/63KVA from generating set and repair the tank/storage portion incl necessary welding/soldering & making leak proof of the tank, descaling the complete radiator with chemical agent and pumping set and assembling the radiator including replacement of all old rusted MS nuts, bolts washers & gasket sets including refixing and testing complete all as specified and directed.

Dismantling of radiator assembly of 50/40KVA from generating set and repair the tank/storage portion incl necessary welding/soldering & making leak proof of the tank, descaling the complete radiator with chemical agent and pumping set and assembling the radiator including replacement of all old rusted MS nuts, bolts washers & gasket sets including refixing and testing complete all as specified and directed.

Dismantling of radiator assembly of 25/35KVA from generating set and repair the tank/storage portion incl necessary welding/soldering & making leak proof of the tank, descaling the complete radiator with chemical agent and pumping set and assembling the radiator including replacement of all old rusted MS nuts, bolts washers & gasket sets including refixing and testing complete all as specified and directed.

S & F in repairs of radiator pump of any capacities installed at DG sets at different locations including replacement of all old rusted MS nuts, bolts washers & gasket sets including refixing and testing complete all as specified and directed.

S & F in repairs of radiator fan of any capacities installed at DG sets at different locations including replacement of all old rusted MS nuts, bolts washers & gasket sets including refixing and testing complete all as specified and directed.

Disconnecting the self-starter (12V/24V) from the engine body of 320 KVA DG set, dismantling the same, inspecting and identifying defective/faulty components, reassembling after replacement of unserviceable parts, wherever required, and refixing the self-starter to its original position, complete all as specified and as directed. Note: Spare parts required for replacement shall be measured and paid separately under the relevant items mentioned below as supply only

Supply only the following items against BOQ Item No 25.00 here-in-before ( to be measured and pain only when incorporated agaist the equipments)

Clutch assembly, complete all as specified and directed.

Bendix pinion, complete all as specified and directed.

Solenoid switch, complete all as specified and directed.

Carbon brush set, complete all as specified and directed.

Bushes/bearings (Front & Rear), complete all as specified and directed.

rewinding of field coil, complete all as specified and directed.

rewinding of armature coil, complete all as specified and directed.

Disconnecting the self-starter (12V/24V) from the engine body of 25 to 125 KVA DG set, dismantling the same, inspecting and identifying defective/faulty components, reassembling after replacement of unserviceable parts, wherever required, and refixing the self-starter to its original position, complete all as specified and as directed. Note: Spare parts required for replacement shall be measured and paid separately under the relevant items mentioned below as supply only

Supply only the following items against BOQ Item No 25.00 here-in-before ( to be measured and pain only when incorporated agaist the equipments)

Clutch assembly, complete all as specified and directed.

Bendix pinion, complete all as specified and directed.

Solenoid switch, complete all as specified and directed.

Carbon brush set, complete all as specified and directed.

Bushes/bearings (Front & Rear), complete all as specified and directed.

rewinding of field coil, complete all as specified and directed.

rewinding of armature coil, complete all as specified and directed.

Finding out defects of Fully Automatic Electric panel (AMF) suitable for 125/110/100KVA DG set and taking out burnt interconnection wiring including u/s sensor, relay etc and serviceable components for reuse including Rewiring of damaged portion of panel using existing size of copper cable, ferrule, lugs, insulating material, nut bolt washer of various sizes including supply and fix new relay of existing model, refixing serviceable items, calibration and testing complete all as specified and directed. Note:- All the spares part deemed to be included in quoted rate.

Finding out defects of Fully Automatic Main Failure panel (AMF) suitable for 82.5 to 50 KVA DG set and taking out burnt interconnection wiring including u/s sensor, realy etc and serviceable components for reuse including Rewiring of damaged portion of panel using existing size of copper cable, ferrule, lugs, insulating material, nut bolt washer of various sizes including supply and fix new relay of existing model, refixing serviceable items and testing complete all as specified and directed. Note:- All the spares part deemed to be included in quoted rate.

Dismantling /opening of alternator by disconnection of cable connections and flexible coupling, nuts/bolts and alternator foundation nut, bolts including taken back in temporary platform including strip opening of alternator and checking out burnt out parts for capacity 320 KVA Taking out burnt armature or burnt field coil or both. Rewinding armature coil or field coil or armature coil and field coil with super enamaled copper winding wire of existing guage, weight and turns including insulation of armature/field coil with Class ‘H’ insulation and Varnishing of armature/field coil winding and drying up to desired temperature. Reassembling alternator after rewinding and reasembling with engine including connection of cable connections and flexible coupling, nuts/bolts and alternator foundation nut, bolts etc.testing calibaration and commissioning complete all as specified and directed. Note : (i) Supply of winding wire & S&F of rectifier diode, AVR, if required, will be measured in respective items and paid separately. (ii) Replacement/refixing new minor parts like bearings, temperature sensors, terminal insulators excitor etc as and when required is deemed to be included in unit rate quoted. (iii) DG Set Make : Greaves Cotton/Kirloskar

All as per above Item No.90.00 here-in-before but for capacity 110 KVA to 125 KVA complete all as specified and directed.

All as per above Item No. 90.00 here-in-before but for capacity 62.5 KVA to 82.5 KVA complete all as specified and directed.

All as per above Item No. 90.00 here-in-before but for capacity 25 KVA to 50 KVA complete all as specified and directed.

Supply only armature, winding wire and rewinding of armature with super enameled copper winding wire of existing gauge for above wire for 25 KVA to 320 KVA DG sets. complete all as specified and directed.

Supply only of field coil with super enameled copper winding wire of existing gauge for 25 KVA to 320 KVA DG sets.complete all as specified and directed.

Supply and replacement of solid-state AVR suitable for DG set alternator of 320 KVA DG Set capacity, including testing, commissioning and all connected works, complete all as specified and directed.

Supply and replacement of solid-state AVR suitable for DG set alternator of 62.5 to 125 KVA DG Set capacity, including testing, commissioning and all connected works, complete all as specified and directed.

Supply and replacement of rectifier diode suitable for 320 KVA DG set alternator, including dismantling, refixing, testing and all connected works, complete.

Supply and replacement of rectifier diode suitable for 62.5 to 125 KVA DG set alternator, including dismantling, refixing, testing and all connected works, complete.

S & F On load Change Over switch rotary type panel mounted in existing panel rating of 160 A , 4 pole , 415 V including elecrical connection with proper lugs after dis connection of elecrical connection taking out old U/SChange Over switch complete all as specified and directed.

S & F On load Change Over switch rotary type with enclosure of rating of 200 A , 4 pole , 415 V including elecrical connection with proper lugs after dis connection of elecrical connection taking out old U/S Change Over switch complete all as specified and directed.

S & F On load Change Over switch rotary type with enclosure of rating of 250 A , 4 pole , 415 V including elecrical connection with proper lugs after dis connection of elecrical connection taking out old U/S Change Over switch complete all as specified and directed.

Taking out exhaust silencer box and pipe from the DG set of cap of 320KVA, decarburizing and cleaning the silencer box including replacement of nut, bolts, washers clamp/bracket and refixing and wraping with asbestos rope and powder complete all as specified and directed. (Note:- Asbestos rope and powder rate will be inclusive).

Taking out exhaust silencer box and pipe from the DG set of cap 62.5KVA to 125KVA, decarburizing and cleaning the silencer box including replacement of nut, bolts, washers clamp/bracket and refixing and wraping with asbestos rope and powder complete all as per specified and directed. (Note:- Asbestos rope and powder rate will be inclusive).

Taking out exhaust silencer box and pipe from the DG set of cap 25 KVA to 50 KVA decarburizing and cleaning the silencer box including replacement of nut, bolts, washers clamp/bracket and refixing and wraping with asbestos rope and powder complete all as per specified and directed. (Note:- Asbestos rope and powder rate will be inclusive).

Supply,designing ,install, testing & commission 3 phase and neutral, 415 volts outdoor type, CPRI type tested having certification of IEC-61439 , factory made , dust and vermin proof, cubical type LT panel of size 1.20m x 0.45m x 1.20m, with canopy fabricated from 3.00 mm thick CRCA sheet for outer shell and 2 mm thick for non load bearing with angle iron frame of 50 x 50 x 6 mm, double door, front and back openable type, double door system, hinged opening, rubber lining, locking arrangement, with anticorrosive coating and finally epoxy polyester power coating with pure polyster Siemens grey structural RAL-7032 shade, protection class IP-66 fully compartmentalize design with 4 Nos of bus bar made of copper 400 Amps rated (electrical grade aluminium complying with the requirements of latest BIS, colour coded), busbar extensions for cable connections of electrolytic grade . The busbars and Interconnecting links shall be insulated with heat shrinkable PVC sleeve with RYB & black colour coding. The bus bars shall be supported on unbreakable, non-hygroscopic SMC insulated pre-wired with suitable size of copper strip/copper wire with colour code for connecting out going MCCB/MCB's, including suitable aluminium earth strips conforming to IS with danger notice plate, necessary cable glands, cable connection with proper lugs, making electrical connection and circuit wiring for street light auto ON/OFF control timer by using desired electrical parameters PCC foundation and pedestal for fixing pillar feeder box/LT Panel with PCC 1:3:6, 15 cm thick in foundation, brick (Fly ash) / PCC block work in CM 1:6, rendering 1:6 on exposed surface and 100 mm thick PCC 1:3:6 type C1 using 20 mm graded stone aggregate as in padding on top and grounting bolts etc for panel. The platform shall be of 450 mm height above ground level all as specified with supply and fixing the following accessories including taking out the existing one :

M&L for complete overhauling of diesel engine of DG set of capacity 82.5 to 125 kVA, including dismantling of engine assembly, removal of cylinder head, piston, connecting rod, crankshaft, camshaft and all accessories, thorough cleaning with approved chemicals, inspection for wear and tear, replacement of worn-out/unserviceable parts, reconditioning of components wherever required, reassembly, testing, trial run on load and commissioning, complete all as specified and directed by Engineer-in-Charge. Note: Supply only items required to be replaced shall be measured and paid separately under respective item No 50 to 70

Supply only cylinder head gasket, suitable for DG set engine of specified capacity, complete all as specified and directed.

Supply only inlet and exhaust valves, complete set, complete all as specified and directed.

Supply only valve guide and valve seat, complete all as specified and directed.

Supply only rocker arm assembly including rocker shaft, bushes and springs, complete all as specified and directed.

Supply only cylinder liner (wet/dry type) of original make and specification, complete all as specified and directed.

Supply only piston complete with piston rings, gudgeon pin and circlips, complete all as specified and directed.

Supply only piston ring set (compression and oil rings), complete all as specified and directed.

Supply only connecting rod bearing (big end and small end), complete all as specified and directed.

Supply only main bearing shells, suitable for engine, complete all as specified and directed.

Supply only thrust washer for crankshaft, complete all as specified and directed.

Supply only front and rear crankshaft oil seals, complete all as specified and directed.

Supply only camshaft bearing/bushes, complete all as specified and directed.

Supply only timing gear / timing chain set including tensioner (if any), complete all as specified and directed.

Supply only tappets/lifters, complete all as specified and directed.

Servicing, calibration and testing of fuel injection pump (FIP), including replacement of minor parts if required, complete all as specified and directed.

Servicing and testing of injector nozzles including replacement of nozzle tip if required, complete all as specified and directed.

Supply only lubricating oil pump, complete all as specified and directed.

Supply only oil sump gasket, complete all as specified and directed.

Supply only water pump, complete all as specified and directed.

Supply only thermostat valve, complete all as specified and directed.

Supply only complete engine gasket set including O-rings and oil seals, complete all as specified and directed.

M&L for complete overhauling of diesel engine of DG set of capacity 320 kVA, including dismantling of engine assembly, removal of cylinder head, piston, connecting rod, crankshaft, camshaft and all accessories, thorough cleaning with approved chemicals, inspection for wear and tear, replacement of worn-out/unserviceable parts, reconditioning of components wherever required, reassembly, testing, trial run on load and commissioning, complete all as specified and directed by Engineer-in-Charge. Note: Supply only items required to be replaced shall be measured and paid separately under respective item Nos 72 to 92

Supply only cylinder head gasket, suitable for DG set engine of specified capacity, complete all as specified and directed.

Supply only inlet and exhaust valves, complete set, complete all as specified and directed.

Supply only valve guide and valve seat, complete all as specified and directed.

Supply only rocker arm assembly including rocker shaft, bushes and springs, complete all as specified and directed.

Supply only cylinder liner (wet/dry type) of original make and specification, complete all as specified and directed.

Supply only piston complete with piston rings, gudgeon pin and circlips, complete all as specified and directed.

Supply only piston ring set (compression and oil rings), complete all as specified and directed.

Supply only connecting rod bearing (big end and small end), complete all as specified and directed.

Supply only main bearing shells, suitable for engine, complete all as specified and directed.

Supply only thrust washer for crankshaft, complete all as specified and directed.

Supply only front and rear crankshaft oil seals, complete all as specified and directed.

Supply only camshaft bearing/bushes, complete all as specified and directed.

Supply only timing gear / timing chain set including tensioner (if any), complete all as specified and directed.

Supply only tappets/lifters, complete all as specified and directed.

Servicing, calibration and testing of fuel injection pump (FIP), including replacement of minor parts if required, complete all as specified and directed.

Servicing and testing of injector nozzles including replacement of nozzle tip if required, complete all as specified and directed.

Supply only lubricating oil pump, complete all as specified and directed.

Supply only oil sump gasket, complete all as specified and directed.

Supply only water pump, complete all as specified and directed.

Supply only thermostat valve, complete all as specified and directed.

Supply only complete engine gasket set including O-rings and oil seals, complete all as specified and directed.