ROUTINE DAILY MAINTENANCE INSPECTION AND INSITU ESSENTIAL REPAIRS OF DRY DOCK CAISSON GATES/ FLAP GATES OF VARUNA AND SURYA DOCK AT NAVAL DOCKYARD VISAKHAPATNAM UNDER GE (I) (DM) VISAKHAPATNAM

Amount

M&L for routine maintenance (chipping, cleaning, greasing and overhauling) for rod gearing arrangement (of different length with Dia between 25-45mm, head stock with bevel gears) of valves of various sizes of caisson gates / flap gates and associated accessories including universal joints and bushes with minor defect rectifications, if any (Standard/ Specification – SS 316, MS, EN 8 for bevel gear).complete all as specified & directed. The scope of the work in this item is as under:- (a) Checking the rod gearing system from the gear box to the valves spindle to be checked every operation visually. (b) All the knuckle joints of the rod gearing system shall be lubricated thoroughly before every operation. (c) Visually checking the rod gearing system at every welding joints / knuckle joints any crack / bend / deflection if any found shall be rectified. (d) The meatering scale of the rod gearing system/pedestal shall be inspected and defect if any observed shall be rectified. (e) Marine gears shall lubricated for all bevel gear system. (f) The material (i.e. SS316 / M.S. / EN8) required for repairing for the rod gearing system knuckle shall be supplied by contractor . (Note:- (i) All the material and /T&P etc. required for undertaking the maintenance/ repairs is contractor's supply (ii) One unit job shall be measured as the works mentioned above for one rod gearing arrangement during every operation of docking / undocking).

M&L for Visual inspection and INSITU maintenance / minor repairs (if any) for Sluice valves of Size NB 600 including joints, nut and bolts with washers, stuffing box, connecting pipes, rubber gasket, seals and associated fittings as per IS specifications for the system complete all as specified and directed . The scope of the work in this item is as under:- (a) Checking and rectifying the leakage through stuffing box / gland, body-demo, dome – stuffing box and side flange gaskets. (b) Checking and rectifying noise / vibrations while opening or closing the valve (c) Checking and rectifying condition of body seat / wedge seat ring faces scratches, dent marks, intactness. (d) Checking and rectifying the defects of any minor nature of spindle & spindle nut / yokes sleeve threads. (e) Close the by-pass valve, disconnecting the extension year rod connection, Try to flush away the external object by opening & closing the valve & creating flow to flush it away. Open flanged joint to reach the object and remove it manually. (f) Replace the graphite gland packing rings / body wedge seat rings. (g) Tighten the gland gradually and uniformly. (h) Replace the gland packing. (i) Tighten the joint fasteners gradually and uniformly body dome/dome stilting box gaskets.

(j) Replace the nitrile rubber gaskets. (k) Re-tighten the flanged joint. (l) Remove parallel/angular gap between valve and pipe flanges and rectify (m) Replace spindle nut, spindle may also be replaced if the thread are excessively worn-out or damaged (n) Disconnection the damnatory joint all these procedures requires the upstream and downstream piping and removal of the valve from the gate. (Note:- (i) All the material and /T&P etc. required for undertaking the maintenance/ repairs is contractor's supply (ii) One unit job shall be measured as the works mentioned above for one Valve only)

All as per item No.2.00 above, but for NB 300mm dia, valves.

All as per item No.2.00 above, but for NB 350mm dia, valves.

All as per item No.2.00 above, but for NB 450mm dia, valves.

All as per item No.2.00 above, but for NB 250mm dia, valves.

All as per item No.2.00 above, but for NB 150mm dia, valves.

All as per item No.2.00 above, but for NB 80mm dia, valves.

M&L for visual inspection, Overhauling / repair / renewal for three way cock of variable sizes including associated system, joints and accessories complete all as specified and directed.(Standard/ Specification –SS 316). (Note:- (i) All the material and / T&P required for undertaking the maintenance/ repairs is contractor's supply (ii) One unit job shall be measured as the works mentioned above for one three way cock of any size)l

M&L for surface preparation, cutting, fabrication, fixing and welding of 12mm and above thick MS plate including fabrication of associated structures such as T channels, rolled sections, angles etc. followed by DP test confirming to IS standards complete all as specified and directed. Note: (i) Renewal of structural/steel plates is to be carried out in very restricted area inside the gate tanks such as scuttle air/water tidal chambers etc.(ii) Contractor shall submit the DP test certificate for obtaining the approval from DS Dept . (iii) Marking, cutting and welding etcshall be inspected during execution and contractor shall obtained approval from DS dept).(iv) MS Plate will be issued by MS dept free for fixing. (v) All T&P and other fit-out required for executing the repairs work is contractor's supply)

M&L 40 mm dia steel water tube medium grade galvanised used for ladders, framed balusters, walkways, railing, frame work of water tanks and similar works including necessary welding bolting as required in site complete all as specified and directed including taking out old unserviceable one

Supply and fixing the 600mm dia (ID), 12 mm wall thickness MS ERW flooding pipe lines in the air chamber inside gate. The work involves the following activities:- (a) Fabrication / Rolling of pipe :- Pipe shall be rolled out of 12 mm thick plate confirming to IS 2062 as per site requirement, (b) Transportation, lowering into the gate chambers. (c) Cutting, unscrewing bolts from 600mm dia. Sluice valve securing the valve in position, fabricate as per actuals, including necessary cutting bending and welding with 600 mm dia (ID) flanges etc,. (d) Renewing of 10mm thick nitrile gasket, bolts, nuts and washers including assembling of 600mm dia sluice valve all as directed. [Note:- The above works are to be carried out at -10 MRL from dock floor level Inside the gate, the entire systems to be tested and proved. Working area is limited & restricted necessary ventilation, blowers, oxygen to be included in the scope].

All as per item No.12.00 above, but for NB 450 mm dia (ID) 12mm wall thickness MS ERW Pipe

All as per item No.12.00 above, but for NB 300 mm dia (ID) 9.27mm wall thickness MS ERW Pipe

All as per item No.12.00 above, but for NB 250mm dia (ID) 9.27mm wall thickness MS ERW Pipe

All as per item No.12.00 above, but for NB 350mm dia (ID) 9.27mm wall thickness MS ERW Pipe

All as per item No.12.00 above, but for NB 150 mm dia (ID) 7.11 wall thickness MS ERW Pipe

All as per item No.12.00 above, but for NB 80 mm dia (ID) 5.74mm wall thickness MS ERW Pipe

All as per item No.12.00 above, but for NB 50 mm dia (ID) 3.91mm wall thickness MS ERW Pipe

Material and labour for Sea Chest Grills of Caisson gates fabricated from MS plate confirming to IS 2062 /structural steel sections including nut bolt washers welding bending cold or hot drilling holes for bolts in any shape or size as indicated or directed including dismantling of old one complete all as specified and directed.

M&L for valve operation of Caisson gates/flap gates (Surya and Varuna Caisson gates, No. of valves in the gates required to be operated during the operation – 26) during docking/ undocking operations in Varuna and Surya Dry-dock including all associated activities required to be undertaken prior operation as per SOPs. (a) all associated valves in the ‘C’ deck ‘B’ deck air chambers are checked visually for the fitness of the operation of the gate (b) Pre-operational procedures/a trail run in the dry condition. (c) Repair & rectifying the defects observed in the findings. (d) Check the measuring scale is closed condition/opening conditions as required for the operation of the gate. (e) The operation may go upto round the clock and that labours over time. Contractor's quoted rate includes whatever extra payment for the overtime duty of workers.No additional payments are allowed for this operation. Contractor should arrange his workers considering this aspect. (f) All the above work is to be carried out as per the instructions user / ND(V) and also user Dept will monitor the work and work is to be done as per the instructions given by MDS/rep of ND(V) (g) Overtime for the Firm personnel’s involved in Valve operations during evolutions is contractor liability. (h)) Material, T&P and equipment required for undertaking the checking prior valve operation is included the quoted rate. (j) Operation of 26 nos. of valve during each operation shall be measured as one Job

Supply and fix musical note neoprene rubber water seal bar extruded of size 50mm dia. bulb 225mm web X 50mm flange and as per site requirement including removing old rubber seal along with wooden fenders and re fixing the same , applying sealing compound for ensuring leak proof complete all as specified and directed including taking out old one

Supply, fix, install testing and commissioning both ends flanged 150 mm bore CI Sluice valve class PN 1.6 conforming to IS-14846 (2000) with iron wheel head and SS spindle including necessary nuts bolt, washer, rubber/fibre board gasket complete all as specified and directed including taking down old one. The following works are also in the scope of the work in this item i (a) All connected pipeline and 150mm dismantling joints are to be removed and reinstalled, necessary bolts, nuts & are include in the quoted rate for dismantling joint. (b) Transportation, lowering into the gate chambers. (c) Removing & renewing of 10mm thick nitrile gasket, bolts, nuts and washers for flange to flange of valves including assembling of 150mm dia. sluice valve along with pipe line all as directed. [Note:- The above works are to be carried out at -10 MRL from dock floor level Inside the gate, the entire systems to be tested and proved. Working area is limited & restricted necessary ventilation, blowers, oxygen to be included in the scope].

Supply, fix, install testing and commissioning both ends flanged 600 mm bore CI Sluice valve class PN 1.6 conforming to IS-14846 (2000) with iron wheel head and SS spindle including necessary nuts bolt, washer, rubber/fibre board gasket complete all as specified and directed including taking down old one. The following works are also in the scope of the work in this item i (a) All connected pipeline and 150mm dismantling joints are to be removed and reinstalled, necessary bolts, nuts & are include in the quoted rate for dismantling joint. (b) Transportation, lowering into the gate chambers. (c) Removing & renewing of 10mm thick nitrile gasket, bolts, nuts and washers for flange to flange of valves including assembling of 600 mm dia. sluice valve along with pipe line all as directed. [Note:- The above works are to be carried out at -10 MRL from dock floor level Inside the gate, the entire systems to be tested and proved. Working area is limited & restricted necessary ventilation, blowers, oxygen to be included in the scope].

Supply, fix, install testing and commissioning of submersible pump of capacity 40 TPH with starter panel (40 TPH) including all associated accessories and join connection in air chambers complete all specified and as job directedincluding dismantling / taking out old one. Head- 15 mtrs, pump wt <50kgs, motor rating-5HP, (Make Mody/Lubi or equivalent)

Supply, fix, install testing and commissioning of submersible pump of capacity 20 TPH with starter panel (20 TPH) including all associated accessories and join connection in air chambers complete all specified and as job directedincluding dismantling / taking out old one. Head- 15 mtrs, pump wt <50kgs, motor rating-5HP, (Make Mody/Lubi or equivalent)

M&L for Routine Daily Maintenance Inspection And In-Situ Essential Repairs Of Dry Dock Caisson Gates/Flap Gates Namely Varuna Flap/Caisson Gate Surya Flap/Caisson Gate In Respect of the following items of work (a) Visual inspection and Easing of rod-greasing mechanism of valves including greasing of bolts, rod gearing arrangements of all Valves, Spindles of all valves and checking for full closing and opening positions etc. (b) Visual inspection & minor defect rectification in respect of Wooden Fenders, Bearing Surfaces, Guard Rails, Ladders, Landing Plates, Manhole Hatches, Covers Etc.. (c) Visual inspection & minor defect rectification in respect of Tidal Chambers, End Tidal Chambers, Access Chambers, Scuttle Tanks, Drainage Tanks Etc. (d) Inspection and minor defect rectification of all manholes to ensure water tightness including conduct of Chalk Impression Test. (e) Inspection and operation of valve with full closing and opening of all intake and discharge valves, LP Air Line and Pressure Gauges, Eye hooks on side shells, Bollards etc.. (f) Removing And lubricating the 600mm/800mm dia pulleys fitted on the Flap Gate and refixing the same including necessary grease, worn out bolts, nuts and washers etc. All As Specified And Directed (Unit 01 Nos = Completion of above scope in one day) Note: (i)The above items of work shell be carried out with the following minimum numbers of tradesmen: Pipe Fitters 3 No’s, Valve/Engine Fitters 03 No’s, Cutter 1No, Fabricator 02 No’s, Welder 03 No’s, Helper 3 No’s, With Connected Equipment Like Gas Cutting Equipment, Welding Machine & Grinding All Related Equipment

(ii) The steel plates required for welding upto 1 Sqm Shall be arranged by MDS Dept. The size of plate required more than 1 Sqm shall be procured by the contractor and the same shall be measured and paid under relevant Item of BOQ. (iii) Replacement Of Bolts, Nuts Washers etc. Shall Be Measured And Paid Under Relevant Items (iv) Contractor's quoted rates are inclusive of (a) Grease required for one day work (which is about 1kg), (b) welding electrode suitable for welding plate thickness of 10mm to 20mm -70nos ( one pack) per day, (c ) gland packing – 1kg, (d) rubber gasket (v) Safety gear, safety tallies as per international norms required for the above operation in progress shall be arranged by the contractor and the cost shall be include in the rate quoted.

Supply only MS flange (single) 150mm dia pipe. made out of 16 mm thick MS plate IS 2062 complete all as specified & directed

Supply only MS flange (single) 100mm dia. pipe. made out of 16 mm thick MS plate IS 2062 complete all as specified & directed

Preparation of old steel surfaces of any description by Hydro jet blasting (3000psi) surface preparation (chipping, cleaning) and applying the following paints on the prepared surfaces complete all as specified & directed (a) 1 coat of Primer (Zinc Chrome primer) (Dft. 1 X 50 micron Dry film Thickness (Dft)) (b) 2 coats of A/C (Anti Corrusive paint) (. 2 X 200 micron Dft) (c) 3 coats of A/F (Anti Fouling paint), (3x150 microns Dft) Note:- Paints will be issued by ND(V) as free for applying. (Make of paints :- Akzo Nobel/ Jotun/ Sigma)

Preparation of old steel surfaces of any description by Hydro jet blasting (3000psi) surface preparation (chipping, cleaning) and applying the following paints on the prepared surfaces complete all as specified & directed (a) 1 coat of Primer (Zinc Chrome primer) (Dft. 1 X 50 micron Dry film Thickness (Dft)) (b) 2 coats of A/C (Anti Corrusive paint) (. 2 X 150 micron Dft) (c) 1 coats of Tie (. 1 X 125 micron Dft) (d) 3 coats of A/F (Anti Fouling paint), (3x150 microns Dft) Note:- Paints will be issued by ND(V) as free for applying. (Make of paints :- Akzo Nobel/ Jotun/ Sigma)

Inspection of Underwater areas of gate with Qualified diving team with safety supervision for identification of damaged area with Videography of the required location and submission the report in CD to users complete all as specified & directed.

Sealing of gate leakages by suitable quantity of Cotton/Oakum fibres to arrest leakages by underwater diving post docking operations to prevent dock wall deterioration. (1 Nos = Arresting of entire leak throughout gate length and height post closing of gate post operation will be considered as one Job)

NOTE: The unit rate quoted for all the above items includes working in a confined area/required Hiring of services for OSHAS compliant scaffoldings and necessary safety gears.

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