REPAIRS MAINTENANCE OF DG SETS ALONG WITH AMF PANELS INSTALLED AT VARIOUS LOCATIONS OF NPOL KOCHI AND 14 ASC AF KAKKANAD UNDER AGEI RD KOCHI

Amount

Comprehensive Maintenance, Servicing and carrying out periodical service to DG set along with AMF panel or standard panel like carry out oil service and routine checkup/maintenance as per manufacturers schedule, checking complete system of lubrication, cooling systems, air intake systems, fuel systems, exhaust systems, DC/AC electrical systems in DG Set as well as in AMF/Stanadard Panel, tightening bolts and nuts in engine and alternator related systems, etc and repairs including material for renewal/ replacement of minor defective parts of like connectors, MCBs, phase indication lamps etc for following capacity of DG sets all as specified and directed by Engr in charge.

320 KVA with AMF Panel installed at Main Lab Central AC Plant.

250 KVA with AMF Panel installed at T Complex sub station

250 KVA with AMF Panel installed at Varuna Pump House

125 KVA with AMF Panel installed at Pump House at technical area.

125 KVA with AMF Panel installed at Hanger site at technical area.

75 KVA trolley mounted.

75 KVA /102 Hp Diesel engine fire pump installed at pump house in technical area

35 KVA with AMF Panel installed at Site 'A' area

15 KVA with AMF Panel installed at Pump House at UARF, Kulamavu.

35 KVA with AMF Panel installed at 14 ASC, AF Kakkanad

20 KVA with AMF Panel installed at 14 ASC

Note: The spares to DG Sets items as listed below as SUPPLY ONLY will be used whenever required only and it shall measured and paid separately under respective items.

The rate is inclusive of all items as required at site except those items as SUPPLY ONLY below to keep the DG Set along with AMF / Standard panel on monthly basis complete all as specified and as directed by Engr-in-Charge.

The contractor should attend any complaint / breakdown immediately on call basis and even no of times without any extra cost.

Contractor should submit the inspection / maintenance report of every visit inspite of no of visits during breakdown calls including mentioning the status of DG Sets and spares any replaced

The old unserviceable spares replaced under comprehensive maintenance i.e in sl No 02 of above BOQ is the property of contractor for which credit shall be deducted under respective items in schedule of credit.

All AMF panels and standard DG set panels should be well cleaned with CTC solution checking all the electrical connection and tighten for any loose connection.

Supply and replace of heavy duty diesel engine oil of 20W40 grade for DG Sets having capacities varying from 15 KVA to 320 KVA complete all as specified and as directed.

Supply only Lub Oil Filter for DG set up to 35 KVA

Supply only Lub Oil Filter for DG set 75 KVA to 125 KVA

Supply only Lub Oil Filter for DG set 250 to 320 KVA

Supply only fuel filter for DG set up to 35 KVA

Supply only fuel filter for DG set 75 KVA to 125 KVA

Supply only fuel filter for DG set 250 to 320 KVA

Supply only Oil pressure gauge for DG set of any size/make

Supply only Ignition switch for DG set 75 KVA to 320 KVA

Supply only battery charging alternator suitable for charging 12 V batteries upto 90 AH fixed to engine of DG set 75 KVA to 320 KVA capacity

Recharging of Battery 12 Volts , up to 90 AH any make / type by replacing electrolyte including replacement of unserviceable terminal posts, to the required standard complete all as specified and as directed .

Recharging of Battery 12 Volts , up to180 AH any make / type by replacing electrolyte including replacement of unserviceable terminal posts, to the required standard complete all as specified and as directed .

Supply only Diesel hose of size 5/16 all as directed.

Supply only Battery terminals one end socket and the other end clamp type including brazing work and applying jelly over the battery terminal and pole all as directed by the Engr in charge

Supply only Water hoses complete set of engine DG sets of cap up to 35 KVA

Supply only Water hoses complete set of engine DG sets of cap 75 to 125 KVA

Supply only Water hoses complete set of engine DG sets of cap 250 to 320 KVA

Repairs to 12 V self starter of DG set engine by dismantling, removing and replacing the old defective/worn-out bearings, servicing including replacement of carbon brush, bendix drive, cleaning commutator in armature etc assembling and testing for satisfactory function all as directed.

Repairs to 24 V self starter of DG set engine by dismantling, removing and replacing the old defective/wornout bearings, servicing including replacement of carbon brush, bendix drive, cleaning commutator in armature etc assembling and testing for satisfactory function all as directed.

Supply only auxiliary contactor suitable for AMF panel of up to 320 KVA DG set

Supply only power contactor suitable for AMF Panel of upto 320 KVA DG set

Supply only automatic Battery charger SMPS type suitable for 12 V fixed in AMF Panel

Supply only automatic Battery charger SMPS type suitable for 24 V 180 AH fixed in AMF Panel

Supply only digital multifunction meter VAF meter ELTRAC or equivalent

Supply only Auto cut off battery charger external with 12/24 V, transformer type

Supply and mixing water coolant in radiator water of DG Sets having capacities varying from 15 KVA to 320 KVA complete all as specified and as directed.

M&L for Repairs to door of acoustic enclosure of DG set cap 35 to 125 KVA by taking down and replacing the door hinges and door lock all as directed.

Supply and filling distilled water for inside the battery and charge properly to maintain battery voltage for 15 KVA to 320 KVA DG Sets in both technical & residential area complete all as specified and as directed.

M&L for dismantling of complete radiator assy from engine and taking out all, descaling rusty, sludge and mudy particles inside the radiator by using of sodium hydroxide with water pressure cleaning complete, changing of radiator fan belt if required and refixing the radiator assy on its existing position and testing complete for its satisfactory performance with entire satisfaction of Engineer-in-Charge for the following DG sets:-

For DG Set capacity 15KVA to 75 KVA

For DG Set capacity 125 KVA to 250 KVA

For DG Set capacity 320 KVA

Taking out old burnt out Automatic voltage regulator from DG set alternator and replace with new AVR and including testing and checking voltage regulation of the DG set on full load for its satisfactory performance complete all as specified and directed by Engineer-in-Charge:-

For DG Set capacity 15 KVA to75 KVA

For DG Set capacity 125 KVA to 250 KVA

For DG Set capacity 320 KVA

M&L for preparation of old painted surfaces of the DG set and fuel tank of following capacity by cleaning oilly and greasy spots using CTC and material and labour for one coat of synthetic enamel paint using spray machine to the fuel tank and one coat of heat resistance paint to Engine / alternator complete all as specified and directed. Note:- Colour code to be followed as under:-

(i) Engine body - OG. (ii) Alternator - Siemens grey (iii) Fly wheel guard - Red (iv) Radiator -Black (iv) DG set canopy/complete body with two coats of superior quality synthetic enamel paint using spray gun (Area of painting not exceeding 3 sqm) including writing of incoming/outgoing feeder with letters, MES/SM Nos etc complete all as specified.

For DG Set capacity 15 KVA to 75 KVA

For DG Set capacity 125 KVA to 250 KVA

For DG Set capacity 320 KVA

M&L for disconnection of Diesel Oil tank with inlet and outlet diesel pipe line hose/pipe and cleaning of complete oil tank and drain out slug, muddy oil particle complete and refixing after at the same place and connecting complete with existing system including marking of tank showing the capacity in Ltrs and replacement of transparent PVC pipe complete all as directed by Engineer-in-Charge:-

For DG Set capacity15KVA to 75KVA

For DG Set capacity 125 KVA to 250 KVA

For DG Set capacity 320 KVA

Supply & Fix in replacement AMF controller, three phases, 50 Hz, AC, auto/manual/test/off mode with necessary display complete all as specified.

Material & Labour for dismantling the alternator of DG Set of capacity 20 KVA to 75KVA from its base by using chain and pulley after removing the coupling with the engine, removing all nut, bolt with washer and all electrical connection of the alternator, shifting the alternator to workshop by crane and vehicle, opening into parts, checking all winding like main stator/rotor winding, exciter stator/rotor winding. Rewinding the main rotor and exciter rotor by using the “F” class insulation and existing gauge and type of magnet wire which was on original motor, varnishing, heating, drying, greasing the bearing including replacement unserviceable bearing ,refixing the complete including connection to the terminal box of the alternator at workshop and shifting the same to the site, fixing the alternator to its base carefully by using chain and pulley, connecting it with existing engine including checking the alignment of alternator with engine connecting all electrical connection of the alternator and testing the DG set “OFF/ FULL LOAD” , matching to the existing range of RPM of the engine output voltage for 415 volt and testing complete all as per the direction of Engineer In Charge.

All as per item No 35 but DG Set of capacity 125 KVA capacity complete all as specified.

All as per item No 35 but DG Set of capacity 250 KVA capacity complete all as specified.

All as per item No 35 but DG Set of capacity 320 KVA capacity complete all as specified.

Supply, install, testing & commissioning in repairs controller- Procom DGC-6D Auto Mains failure control Module including Display, replacing contactors/Connectors and making all electrical connections good and renewed for up to DG set 125 KVA as per existing make complete all as specified and directed by Engr-in-charge.

Supply, install, testing & commissioning in repairs controller- Procom DGC-6D Auto Mains failure control Module including Display, replacing contactors/Connectors and making all electrical connections good and renewed for DG set 200 KVA to 320 KVA as per existing make complete all as specified and directed by Engr-in-charge.

Supply & Fix in replacement fuel sensor for DG Set capacity 320 KVA complete all as specified..

Material & Labour for taking down pump assembly of DG sets upto 75KVA capacity from its existing position, opening into parts, overhauling the same at workshop with replacement of water pump repair kit, ball bearing (1No) (Make SKF/NBC), gasket seal, oil seal and re-assembling and re-fixing on the base including to and fro conveyance charge from site to workshop and back complete all as specified.

All as per item No 39 but water pump assembly of DG sets 75 to 125 KVA capacity

All as per item No 39 but water pump assembly of DG sets 320 KVA capacity

Material & Labour for taking down 12/24 Volts Dynamo suitable for DG set of any capacity from the existing position, shifting to the work shop, opening into parts, cleaning to sort out the unserviceable parts, replace by new one, rewinding and varnishing, heating of coil, reassembling and re-fixing to its base including to and fro conveyance charge from site to workshop and back complete all as specified.

Material & Labour for dismantling carefully fuel injection pump (FIP) upto 6 cylinders engine of DG set and transporting to workshop, opening into parts, for maintenance, servicing, overhauling, tuning and calibration, adjustment of nozzle pressure and other controls, replacement of unserviceable spares, re-assembling, re-fixing the FIP on its original position including to and from conveyance charge from site to workshop and back complete all as specified.

Supply only Radiator coolant coil suitable for DG set upto 125KVA as per existing make and model complete all as specified.

Supply only Radiator coolant coil suitable for DG set upto 320 KVA as per existing make and model complete all as specified.

Supply, install, testing & commissioning in repairs DC relay card/ PLA relay 12/24 volt DC for DG set any capacity including making all electrical connections and checking by running the DG set for 02 hours complete all as specified and directed by Engr-in Charge,

Supply & Fix in replacement MCB SP 6 - 32 Amp, C-curve, 415 volt AC complete all as specified.

Supply & Fix in replacement MCB SPN 6 - 32 Amp, C-curve, 415 volt AC complete all as specified.

Supply & Fix in replacement MCB TPN, 40 -63 Amp, C-curve, 415 volt AC complete all as specified.

Supply & Fix in replacement MCB TPN, 63 -100Amp, C-curve, 415 volt AC complete all as specified.

S&F in repair MCCB 100 Amp 4 pole 415 volt 36 kA breaking capacity adjustable type complete all as specified and directed.

S&F in repair MCCB 200 Amp 4 pole 415 volt 36 kA breaking capacity adjustable type complete all as specified and directed.

S&F in repair MCCB 630 Amp 4 pole 415 volt 36 kA breaking capacity adjustable type complete all as specified and directed.

S&F in repair on load change over switch as open execution 200 A, 415 V, complete all as specified and as directed

Supply & Fix in replacement Flexible pipe inlet as per existing size and type, complete all as specified.

Supply & Fix in replacement One meter long battery lead with stranded copper conductor of 200 Amp DC rating maximum upto 2 run x 1 metre with brass terminals on both end complete all as specified.

Material & Labour for taking down unserviceable heat insulation from exhaust piping and providing new heat insulation to exhaust pipe using 50 mm thick mineral wool inside the container & upto the exhaust stack. The insulation shall be cladded/ covered with 24G aluminium sheet. Pipe length shall be maximum up to 12 Metre long from engine including necessary welding works, cladding works with wire mesh and aluminium foil, replace unserviceable supporting MC, angle iron 50 mm X 50 mm X 6 mm, suitable size flange, nut, bolt and washers as required including weather cowl complete all as specified.

Material & Labour for dismantling exhaust manifold from the engine to detect the smoke leak, clean the manifold including welding works, replacement of unserviceable spares, packing, bellows, nut, bolt, washers, insulators, etc. reassembling and refixing on its base, testing by running the DG set No LOAD/FULL LOAD complete all as specified.

Supply & Fix in replacement LED indicator lamp (Red, Yellow, Amber and Green) including taking down old unserviceable indicator lamp complete all as specified.

Supply & Fix in replacement LED indicator lamp (Blue / white) including taking down old unserviceable indicator lamp complete all as specified.

Supply & Fix in replacement Standard push button, flush head, any colour complete all as specified.

S&F in repair digital three phase voltmeter 0-500 Volts of size 96x96mm complete all as specified and directed by Engr-in-Charge.

S&F in repair digital three phase Ampere meter 0-500 Volts of size 96x96mm complete all as specified and as directed by Engr-in-Charge.

S&F in repair solenoid switch upto 320 KVA DG set complete all as specified and as directed.

M&L for earthing complete with galvanised steel earth plate electrode 60cm x 60cm x 6 mm buried directly in ground level with top edge of earth plate at a depth not less than 1.5m below ground level connected to and including galvanised iron strip 25mm x 4mm as earthing lead by means of bolts, nuts, check nuts and washers etc made of GI and connected to earthing test point all as shown in electric plate No. 3 of SSR indicated and testing on completion including excavation and earth work in any type of soil/rock, PCC (1:3:6) type C-1 earthing chamber, precast RCC slab 50mm thick in cement concrete (1:2:4) type B-1 reinforced with welded steel wire babric (APM) weight not less than 4 Kg/Sqm, funnel with GI watering pipe of 20mm bore medium grade, wire mesh and lugs, GI protection pipe of 40mm bore medium grade 7.5 m long test point etc complete all as specified and as directed by Engr-in-Charge.

Providing and fixing 25mm x 5mm G.I strip in 40 mm Dia G.I pipe from earth electrode including connection with G.I Nut, bolt, Spring ,Waher excavation and refilling etc. as required.

S&F in repair 1.5 Sqmm three core PVC insulated, unsheathed multistranded copper conductor flexible cable 1100 volts grade complete all as specified and directed by Engr in Charge.

WELTRONENGINEERINGSERVICES

Omkar Manpower Consultancy