REPAIR, MAINT AND SERVICING OF DG SET INCL SERVICING OF AMF PANELS AND CONNECTED ITEMS AT AF STN BHUJ

Amount

Labour only for attending the emergent complaint of DG sets of 7.5 KVA to 320 KVA capacities installed at various locations of air force station bhuj. Carrying out general servicing and minor repairs and/or replacements, including following jobs whichever is required to make DG Set functional complete all as specified and directed by Engineer-in-Charge :- (i) Checking and cleaning of diesel filters & oil filters and making a list of filters required to be replaced. (ii) Checking of engine oil level and intimating the quantity of oil required for topping, if any. (iii) Checking, cleaning and servicing including oiling & greasing of engine and making list of repairs / replacements required, if any. (iv) Checking, cleaning, watering & general servicing of alternator battery including tightening of nuts, bolts, lugs and the like. Also making a list of repairs / replacements required, if any. (v) Checking the earthing connections of neutral and body of DG set, tightening of connections and making a list of repairs / replacements required, if any.

(vi) Checking of self starter and intimating Engr in charge if required to be repaired / specially serviced in workshop. (vii) Checking, cleaning and general servicing of AMF panel including replacement / tightening of nuts, bolts, lugs and other such minor parts, oiling & greasing and making list of repairs / replacements required, if any. (viii) Checking, cleaning & general servicing of instrument panel and making a list of repairs/ replacements required, if any. (ix) Checking, cleaning and general servicing of various parts of DG set such as timer, contactors , meters, etc. and making list of repairs / replacements required, if any. (x) Tightening / replacement of nuts, bolts, washers and the like of DG set all as directed. (xi) Checking for diesel leakage from any point and rectify if can be rectified by minor repairs / replacements. Else make list of repairs / replacements required, if any. (xii) Checking, cleaning and adjusting fan belt tension and making a list of replacements requirted, if any. (xiii) Checking, cleaning & general servicing of exhaust / silenecer including checking for leakage of smoke & rectify, if can be rectified by minor repairs / replacements. Else make a list of repairs / replacements required, if any.

(xiv) Checking, cleaning and tightenening of electrical connections including replacement of minor parts. (xv) Checking & cleaning of AVM pads, tightening / replacement of nuts, bolts, & washers and making a list of replacements required, if any. (xvi) Checking, cleaning & tightening of exhaust pipe, flange and lagging, tightening / replacement of nuts, bolts, washers and the like and making a list of repairs / replacements required, if any. (xvii)(a). Checking output of alternator and adjusting the same to specified values, in case of brush type (b) cleaning & servicing of the alternator, minor repairs & replacements and making list of alternators requiring complete overhauling (xviii) Checking, cleaning & tightening of all hose pipes, tightening / replacement of nuts, bolts, washers and the like and making a list of repairs / replacements required, if any. (xix) Checking, cleaning & servicing of air filter elements and making a list of replacements required, if any. (xx) Oiling, greasing and checking for proper functioning of DG set.

(Note - I. Rates quoted by the tenderer are also deemed to include the cost of supply & fix in replacement of minors parts like nuts, bolts, washers, lugs, etc., supply and applying oil & greasing and minor repairs to DG set. II. The work under this item is to be carried out as complaint recieved and as directed by the Engineer in charge. III. List of repairs / replacements prepared by the contractor shall be submitted to the Engineer in charge for verification. IV. The all mentioned above maintenance work carried out by contractor.

Material & labour for full servicing of DG Sets of capacity 7.5 KVA to 63 KVA complete all as specified and directed by Engineer-in-Charge as per following :- (i) Draining out engine/lubricant oil flushing including filling fresh oil afterdrain out old oil by skilled OEM trademan of DG set including replacement of oil pan /chamber gasket . (ii) Supply & fix in replacement lubricant oil filter element . (iii) Supply & fix in replacement fuel filter element. (iv) Supply & fix bypass filter element. (v) Checking and applying grease to battery terminals and checking its specific gravity including topping of distilled water /acid as required. (vi) General cleaning of oil/fuel spills, grease spots etc. (vii) Checking of belt tension and adjusting as per requirment. (viii) Check all electrical conditions. (ix)Check pollution level. (x) Change water separator and radiator cleaning with chemical. (xi) Change hydraulic governor oil, change aneroid oil, check aneroid adjustment, replace aneroid breather. (xii) Clean radiator externally, check fan hub/Idler and water pump/idler. (xiii) Inspect units, replace as required (Alternator/Generator,Starter etc), check air cleaner if required (Amount of air filter will be paid separately), evacuator valves change if required.

Material & labour for full servicing of DG Sets of capacity 70 KVA to 160 KVA complete all as specified and directed by Engineer-in-Charge as per following :- (i) Draining out engine/lubricant oil flushing including filling fresh oil afterdrain out old oil by skilled OEM trademan of DG set including replacement of oil pan /chamber gasket . (ii) Supply & fix in replacement lubricant oil filter element . (iii) Supply & fix in replacement fuel filter element. (iv) Supply & fix bypass filter element. (v) Checking and applying grease to battery terminals and checking its specific gravity including topping of distilled water /acid as required. (vi) General cleaning of oil/fuel spills, grease spots etc. (vii) Checking of belt tension and adjusting as per requirment. (viii) Check all electrical conditions. (ix)Check pollution level. (x) Change water separator and radiator cleaning with chemical. (xi) Change hydraulic governor oil, change aneroid oil, check aneroid adjustment, replace aneroid breather. (xii) Clean radiator externally, check fan hub/Idler and water pump/idler. (xiii) Inspect units, replace as required (Alternator/Generator,Starter etc), check air cleaner if required (Amount of air filter will be paid separately), evacuator valves change if required.

Material & labour for full servicing of DG Sets of capacity 200 KVA to 320 KVA complete all as specified and directed by Engineer-in-Charge as per following :- (i) Draining out engine/lubricant oil flushing including filling fresh oil afterdrain out old oil by skilled OEM trademan of DG set including replacement of oil pan /chamber gasket . (ii) Supply & fix in replacement lubricant oil filter element . (iii) Supply & fix in replacement fuel filter element. (iv) Supply & fix bypass filter element. (v) Checking and applying grease to battery terminals and checking its specific gravity including topping of distilled water /acid as required. (vi) General cleaning of oil/fuel spills, grease spots etc. (vii) Checking of belt tension and adjusting as per requirment. (viii) Check all electrical conditions. (ix)Check pollution level. (x) Change water separator and radiator cleaning with chemical. (xi) Change hydraulic governor oil, change aneroid oil, check aneroid adjustment, replace aneroid breather. (xii) Clean radiator externally, check fan hub/Idler and water pump/idler. (xiii) Inspect units, replace as required (Alternator/Generator,Starter etc), check air cleaner if required (Amount of air filter will be paid separately), evacuator valves change if required.

Material & labour for preparing old painted surface of DG sets (complete including engine, alternator, body & chases) by thoroughly cleaning the surfaces to remove dirt, dust, rust flakes and paint flakes, using wire brush or sand papers, damp cloth or as directed. Priming the surface with anti corrosive primers using suitable sprayers. Applying automotive paint using sprayers till glossy finish is obtained, complete all as per manufacturers instructions and writting MES Number in block capital letters complete all as specified and directed by Engineer-in-Charge.

Supply only lead acid battereies for DG set complete all as specified and directed by Engineer-in-Charge of following capacity:-(Maintenance free battery of 2 years warranty)

88 AH,12 Volt.

150 AH,12 Volt.

180 AH,12 Volt.

Repair and maintenance of FIP including replacement of Plunzers, Governer kit with pin, Nozzles P type,Head ball guide kit, Head sheet (set of 12 piece) rock rod, rollar bearing, oil seal, piston pin, gasket kit and sleeves complete all as specified and directed by Engineer-in-Charge DG set of following capacity:-

DG Set Upto 25 KVA

DG Set 30 to 50 KVA

DG Set 62.5 to 75 KVA

DG Set 82.5 to 100 KVA

DG Set 125 to 320 KVA

Material & labour for taking out radiator of DG set 7.5 KVA to 50KVA for repair, welding, brazing, leak testing, descaling & refixing to DG set to its original position and testing complete all as specified and directed by Engineer-in-Charge.

Material & labour for taking out radiator of DG set 62.5 KVA to 100 KVA for repair, welding, brazing,leak testing, descaling & refixing to DG set to its original position and testing complete all as specified and directed by Engineer-in-Charge.

Material & labour for taking out radiator of DG set 125 KVA to 320 KVA for repair, welding, brazing,leak testing, descaling & refixing to DG set to its original position and testing complete all as specified and directed by Engineer-in-Charge.

Taking out the charging alternator of DG Set of following capacity and shifting to workshop for rewinding of armature including replacement of rewinding unserviceable, bushes & minor parts & reinstalling the same after testing complete all as specified and directed by Engineer-in-Charge of following:-.

DG set of capacity upto 15 KVA

DG set of capacity 25 to 37.5 KVA

DG set of capacity 50 KVA

DG set of capacity 62.5/63 KVA

DG set of capacity 70 to 82.5 KVA

DG set of capacity 100 to 320 KVA

Supply & fix in replacement solenoid switch for 200 to 320 KVA DG set and testing complete all as specified and directed by Engineer-in-Charge for proper functioning.

Supply & fix in replacement solenoid switch for 160 KVA DG set and testing complete all as specified and directed by Engineer-in-Charge for proper functioning.

Supply & fix in replacement solenoid switch for 100 to 125 KVA DG set and testing complete all as specified and directed by Engineer-in-Charge for proper functioning.

Supply & fix in replacement solenoid switch for 70 to 82.5 KVA DG set and testing complete all as specified and directed by Engineer-in-Charge for proper functioning.

Supply & fix in replacement solenoid switch for 62.5/63 KVA DG set and testing complete all as specified and directed by Engineer-in-Charge for proper functioning.

Supply & fix in replacement solenoid switch for 15 to 50 KVA DG set and testing complete all as specified and directed by Engineer-in-Charge for proper functioning.

Supply & fix in replacement of AMF Relay suitable for DG sets complete all as specified and directed by Engineer-in-Charge.

Supply & fix in replacement of single phase preventor complete all as specified and directed by Engineer-in-Charge.

Supply & fix in replacement of PLA relay complete all as specified and directed by Engineer-in-Charge.

Supply & fix in replacement 3 pole power contactor 25 A,415 V complete all as specified and directed by Engineer-in-Charge.

Supply & fix in replacement 3 pole power contactor 40/45 A,415 V complete all as specified and directed by Engineer-in-Charge.

Supply & fix in replacement 3 pole power contactor 75 A,415 V complete all as specified and directed by Engineer-in-Charge.

Supply & fix in replacement 3 pole power contactor 110/115 A,415 V complete all as specified and directed by Engineer-in-Charge.

Supply & fix in replacement 3 pole power contactor 185/225 A,415 V complete all as specified and directed by Engineer-in-Charge.

Supply & fix in replacement of HRC fuse base of capacity 125 to 250 Amps complete all as specified and directed by Engineer-in-Charge.

Removing, transporting to workshop, repairing & servicing of self starter of DG set ranging from 7.5 KVA to 320 KVA including replacement of parts such as washer, nut, bolts, bush, solonoid, rotor etc., reassembling and testing complete all as specified and directed by Engineer-in-Charge.

Descaling of water jacket of engine by using descaling solution with pressure circulation pump,leak testing, soldering, brazing, checking for leaks and recirculating with clear water complete all as specified and directed by Engineer-in-Charge for following DG sets:-

Up to 63 KVA DG Set

70 KVA to 160 KVA DG Set

200 KVA to 320 KVA DG Set

Supply & fix in replacement "V" belt for radiator fan complete all as specified and directed by Engineer-in-Charge for following DG Set:-

Upto 50 KVA

62.5 to 82.5 KVA

100 to 320 KVA

Replacement / filling up/ top up of engine oil (20 W 40) suitable for DG sets complete all as specified and directed by Engineer-in-Charge.

Replacement / filling up/ top up of pre mix coolant suitable for DG Set complete all as specified and directed by Engineer-in-Charge.

Material & labour for cleaning of diesel tank of DG Set "tank cleaned on Date………..complete all as specified and directed by Engineer-in-Charge.

Supply & fix in replacement of anti vibration pad suitable for 25 to 320 KVA DG set complete all as specified and directed by Engineer-in-Charge.

Supply & fix in replacement of air cleaner filter for DG Set capacity 200 KVA to 320 KVA complete all as specified and directed by Engineer-in-Charge.

Supply & fix in replacement of air cleaner filter for DG Set capacity 70 KVA to 160 KVA complete all as specified and directed by Engineer-in-Charge.

Supply & fix in replacement of air cleaner filter for DG Set capacity 7 KVA to 63 KVA complete all as specified and directed by Engineer-in-Charge.

Supply & fix in replacement of hose pipe set suitable for following capacity of DG sets & complete all as specified and directed by Engineer-in-Charge for following.

Up to 63 KVA DG set

70 KVA to 160 KVA DG set

200KVA to 320 DG set

Supply & fix in replacement of AVR suitable for following capacity of DG Sets & complete all as specified and directed by Engineer-in-Charge for following.

Up to 50 KVA DG set

62.5 to 125 KVA DG set

160 to 320 KVA DG set

Supply & fix in replacement of battery lugs complete all as specified and directed by Engineer-in-Charge.

Supply & fix in replacement of ignition switch suitable for DG sets & complete all as specified and directed by Engineer-in-Charge.

Supply & fix in replacement of self starter suitable for up to 25 to 50 KVA DG Set 12 Volt complete all as specified and directed by Engineer-in-Charge.

Supply & fix in replacement of self starter suitable for 62.5 to 82.5 KVA DG Set 12 Volt complete all as specified and directed by Engineer-in-Charge.

Supply & fix in replacement of self starter suitable for 100 to 125 KVA DG Set 12 Volt complete all as specified and directed by Engineer-in-Charge.

Supply & fix in replacement of self starter suitable for 160 to 320 KVA DG Set 24 Volt complete all as specified and directed by Engineer-in-Charge.

Repair/replacement wiring (till 5 m) of DG Set/AMF panel upto 25 to 50 KVA complete all as specified and directed by Engineer-in-Charge.

Repair/Replacement wiring (till 5 m) of DG Set/AMF panel 62.5 to 100 KVA complete all as specified and directed by Engineer-in-Charge.

Repair/Replacement wiring (till 5 m) of DG Set/AMF panel 125 to 320 KVA complete all as specified and directed by Engineer-in-Charge.

Supply & fix in replacement of of battery charger of 6 Amps for 12 Volt battery complete all as specified and directed by Engineer-in-Charge.

Supply & fix in replacement of battery charger of 6 Amps for 24 Volt battery complete all as specified and directed by Engineer-in-Charge.

Supply & fix in replacement of water pump complete for 35 to 320 KVA DG set complete all as specified and directed by Engineer-in-Charge.

Supply & fix in replacement of diesel pipe filter to pump for DG set complete all as specified and directed by Engineer-in-Charge.

Supply & fix in replacement of diesel pipe filter to tank for DG set complete all as specified and directed by Engineer-in-Charge.

Supply & fix in replacement radiator up to 100 KVA DG set complete all as specified and directed by Engineer-in-Charge.

Supply & fix in replacement radiator from 125 to 200 KVA DG set complete all as specified and directed by Engineer-in-Charge.

Supply & fix in replacement DG set/AMF panel power controller up to 50 KVA DG set complete all as specified and directed by Engineer-in-Charge.

Supply & fix in replacement DG set/AMF panel power controller from 62.5 to 125 KVA DG set complete all as specified and directed by Engineer-in-Charge.

Supply & fix in replacement DG set/AMF panel power controller from 160 to 320 KVA DG set complete all as specified and directed by Engineer-in-Charge.

Supply & fix in replacement MCCB's,415 Volts , 3 / 4 pole , with adjustable thermal & fixed magnetic settings having complete all as specified and directed by Engineer-in-Charge. for following capacities :-

Upto 63 Amps 16 KA 3 Pole

100 Amps 25 KA 3 Pole

125 Amps 25 KA 3 Pole

160 Amps 36 KA 3 Pole

200 Amps 36 KA 3 Pole

250 Amps 36 KA 3 Pole

Supply & fix Diesel pump with pipe assembly to make it fully fuctional and fixing it to its original position of DG set in any capacity including replacement necessary element complete all as specified and directed by Engineer-in-Charge.

Material & labour for complete checking of AMF panel,finding the fault,servicing complete including as per site and replacement of unserviceable spares and testing complete for manual & auto operations complete all as specified and directed by Engineer-in-Charge. (Note:- Supply only of new items required for replacement will be measured & paid seperately under respective item of schedule.)

Supply & fix distiled water suitable for battery of DG set complete all as specified and directed by Engineer-in-Charge.

Opening the coupling of DG set of capacity 200 to 320 KVA , dismantling the outer cover & taking out the fly wheel ring and shifting to workshop for repair in and including replacement of fly wheel ring by pressing machine and reinstalled the same after repair to make it fully fuctional complete all as specified and directed by Engineer-in-Charge.

Opening the coupling of DG set of capacity 7.5 to 63 KVA, dismantling the outer cover & taking out the fly wheel ring and shifting to workshop for repair in and including replacement of fly wheel ring by pressing machine and reinstalled the same after repair to make it fully fuctional complete all as specified and directed by Engineer-in-Charge.

Opening the coupling of DG set of capacity 70 KVA to 160 KVA, dismantling the outer cover & taking out the fly wheel ring and shifting to workshop for repair in and including replacement of fly wheel ring by pressing machine and reinstalled the same after repair to make it fully fuctional complete all as specified and directed by Engineer-in-Charge.

Material & labour for calibration of fuel injector assembly of DG set of 70 KVA to 160 KVA capacity at authorised workshop including replacement of cup, barrel and plunger injector washer etc complete all as specified and directed by Engineer-in-Charge.

Material & labour for calibration of fuel injector assembly of DG Set of 7.5 KVA to 63KVA capacity at authorised workshop including replacement of cup, barrel and plunger injector washer etc complete all as specified and directed by Engineer-in-Charge.

Material & labour for calibration of fuel injector assembly of DG Set of 200KVA to 320 KVA capacity at authorised workshop including replacement of cup, barrel and plunger injector washer etc complete all as specified and directed by Engineer-in-Charge.

Supply & fix in replacement of bentex wheel complete suitable for self starter complete all as specified and directed by Engineer-in-Charge.

Supply & fix in replacement of battery copper cable red with plug of size 35 sqmm complete all as specified and directed by Engineer-in-Charge.

Supply & fix in replacement of battery copper cable black with plug of size 35 sqmm complete all as specified and directed by Engineer-in-Charge.

Supply & fix in replacement fan assembly along with hub suitable for DG Set of any cap complete all as specified and directed by Engineer-in-Charge.

Taking out the alternator of DG set of capacity 7.5 KVA to 320 KVA and shifting to workshop for rewinding of armature including replacement of rewinding unserviceable, bushes & minor parts & reinstalling the same after testing complete all as specified and directed by Engineer-in-Charge.

Material & labour for earthing complete with galvanized steel pipe electrode 50 mm bore, medium grade, 6 mtr length buried directly and preferably vertically in ground with top edge of the pipe not less than 0.3 meters below normal ground level, connected with 20 mm dia GI pipe by means of reducer and clamped with CI checknuts through 4.0 mm GI earth lead as shown in electrical plate No 2 (duly protected with 20 mm dia light grade GI pipe upto 7.5 m from the earth plate) and connected to GI steel earth pipe including charcoal, dust, common salt necessary excavation in soft/loose soil, returning filling in and removal of surplus soil to a distance not exceeding 50 m from the starting point, watering pipe 20 mm dia GI light grade treated with 1 No PGI funnel, pit of PCC 1:3:6 type C-1, RCC 1:2:4 type B-1 pit cover 75 mm thick reinforced with 6 mm dia bars @ 75 mm c/c both ways and with MS handle 12 mm dia complete connected to earth test point including testing complete all as specified and directed by Engr-in-Charge.

Complete overhauling of DG set capacity 82.5 to 125 KVA with dismantling of exhaust piping, fuel piping, HP pipes, inlet mainfold, hoses, Cy head, injectors and other related assessories and top overhauling CR bearing, con rod, piston, piston ring, cylinder liner and major overhauling charges watre pump, oil cooler HE, crank shaft, main bearing, thrust washer etc and reassembling with required torque tappet setting and trail and refixing of following items at original position etc complete all as specified and directed by Engineer-in-Charge.

Supply only cylinder liner complete all as specified and directed by Engineer-in-Charge.

Supply only piston complete all as specified and directed by Engineer-in-Charge.

Supply only piston ring complete all as specified and directed by Engineer-in-Charge.

Supply only inlet valve complete all as specified and directed by Engineer-in-Charge.

Supply only exhaust valve complete all as specified and directed by Engineer-in-Charge.

Supply only valve seat inlet complete all as specified and directed by Engineer-in-Charge.

Supply only valve seat exhaust complete all as specified and directed by Engineer-in-Charge.

Supply only valve guide complete all as specified and directed by Engineer-in-Charge.

Supply only HCT switch complete all as specified and directed by Engineer-in-Charge.

Supply only injector nozzle complete all as specified and directed by Engineer-in-Charge.

Supply only delivery valve complete all as specified and directed by Engineer-in-Charge.

Supply only pipe set complete all as specified and directed by Engineer-in-Charge.

Supply only connecting rod assly DL-4complete all as specified and directed by Engineer-in-Charge.

Supply only set gasket complete all as specified and directed by Engineer-in-Charge.

Supply only head gasket complete all as specified and directed by Engineer-in-Charge.

Supply only set of fuel flex complete all as specified and directed by Engineer-in-Charge.

Supply only con rod bush complete all as specified and directed by Engineer-in-Charge.

Supply only con rod bearing complete all as specified and directed by Engineer-in-Charge.

Supply only oil pressure guage complete all as specified and directed by Engineer-in-Charge.

Supply only water temp guage complete all as specified and directed by Engineer-in-Charge.

Supply only ammeter complete all as specified and directed by Engineer-in-Charge.

Supply only LLOP switch complete all as specified and directed by Engineer-in-Charge.

Supply only sealing ring complete all as specified and directed by Engineer-in-Charge.

Supply only AVM complete all as specified and directed by Engineer-in-Charge.

Supply only T/C KIT complete all as specified and directed by Engineer-in-Charge.

Supply only AVM for meter box complete all as specified and directed by Engineer-in-Charge.

Supply only nut M10 complete all as specified and directed by Engineer-in-Charge.

Supply only bolt 8x25 complete all as specified and directed by Engineer-in-Charge.

Supply only bolt 10x30 complete all as specified and directed by Engineer-in-Charge.

Supply only set of O ring complete all as specified and directed by Engineer-in-Charge.

Supply only set of hose clip complete all as specified and directed by Engineer-in-Charge.

Supply only set of hoses complete all as specified and directed by Engineer-in-Charge.

Material & labour of diod to be fixed in alternator complete all as specified and directed by Engineer-in-Charge.

Supply & fixing in replacement digital timer for ON/OFF to the perimeter lights/DG set complete all as specified and directed by Engineer-in-Charge.

Supply & fixing inverter type LED street light 30 Watt, PDC housing, IP-66 inbuilt battery backup On/Off/ Dimm incl connecting with min 2.5 mtr 1.5 Sqmm multistranded copper wire with necessary clamping arrangments complete all as specified and directed by Engineer-in-Charge.

Ahmed B Khatri

Mohshin Refrigeration & Electrical Services