OVERHAULING AND MAINTENANCE OF MAIN SEA AND DOCK FLOODING 1800MM DIA BUTTERFLY VALVE (BFV) ALONG GEAR BOX WITH EXTENSION MECHANISM WITH CONNECTED ACCESSORIES FOR BFV NO 1 2 3 4 5 3A 4A AND 5A FOR SOUTH DRYDOCK (SDD) PUMP HOUSE AT DRYDOCKS NAVAL DOCKY

Material & labour for PCC (1:2:4), type B1 (using 20 mm graded stone aggregate) as in pillar to support the pipe lines including necessary form work and finishing the exposed surfaces of concrete fair and even all as specified and directed

Comprehensive Overhauling an Maintenance of 1200mm & 1800mm dia BFV valve along with with extension rod-gear mechanism all as specified and directed. The unit rate quoted for Ser 2.00 should be considered with and including the following points mentioned below a) Lowering of existing blanking off plate (BOP) on sea side Butter-fly valves (BFV-1&2) in its position.(Note: Yard will provide BOPs and technical support for operating BOP. Firm shall employ divers for cocking to ensure water tight integrity from sea side and other misc. works). b) Open the valve and check for sea water ingress from other side of the valve to ensure water tight integrity of BOP. c) Cocking between BOP and its frustum from sea side by divers to arrest the ingress of sea water if any. d) Ensure the watertight integrity at all times during execution of the job

e) Disconnect the valve operating mechanism (gear box with extension rod) and overhaul/ repair of its components properly. f) Disconnect the dismantling joint and remove from its position and place in secure place.(if rubber seal/ connecting seal joint damaged during removal, replace with new one on assesmbling period) g) Disconnect and remove the Butter-Fly Valve from pipe line. h) Check the condition of shaft if required, fine tune by machining make key way slots for any modification (replace shaft if damaged/warnout) j) check the condition of dowel pins on disc if warnout replace with new one set. k) Water tight seals and O rings to be repalce mandatory where ever necessary. m) Replace the warnout bushes and sleeves. n) Replace valve internal fasteners as to mandatory. p) Check the valve body issue make modifiuaction/machining/cutting /welding/ and fit the valve disc properly inside body.

q) Supply and fix to valve body Non return stopper of SS Stopoper support frame with one manual adjustment bolt with double nut to avoid over closing of valve disc. r) Check the condition of bearing and replace. s) Mandatory to replace the valve disc seal EPDM material with disc cover and SS fasteners t) Repalace any worn/ damaged seals, o-rings, fasteners, sleeves, bearings, bushes, etc. spares additionally required to make operational is mandatory supply and provide without additional cost as suggested and directed to by Engineer In-Charge u) If the disc seal itself significantly worn, consider replace it. v) Clean all components with suitable solvents, to remove debris and contaminents.

Overhauling/ maintenance of Gear Box butterfly valve as follows: a) Inspect the Gear and gear-shaft and do the requisite maintenance with suitable solvents and founnd any damaged parts, to be replaced with new items. b) Water tight seals and O-rings to be repalced mandatory. c) Replace warnout bushes and bearings if necessary. d) Replace the gear box stopper bolts with SS fasteners. e) Replace the valve indicator cover with new visual marking of of 1/8th, 1/4th, 1/2, 3/4th and full Open ,full close postions to be embosed with brass plate on Gear-Box cover with the supervision of user department. f)Required Nut,bolt fasteren etc to be included in the overhauling.

Overhauling and maintenance of Extension rod worm gear mechanism as follows: a) Overhaul the shaft and found any damages to on the surface of the shaft, to be metal buildup, machining, tuning etc. to be carried upto the mark to suit the site conditions. b) Replace the shaft bushes & sleeves and keys by new items and make key slot surface as new item suited and should not hynderance to the existing system. c) Replace the seals and O-rings and gaskets mandatory. d) If found any damage for external pipe of extension rod to be modified as site suited.

M & L for pressure testing of BFV system with the follwing a) Perform a Hydro test by external test equipment setup by providing additional dummy plate for Body and Seat cover to maintain the standard as per BS EN 12266-1 to test upto 1.5 MPa/ 15.30 Kg/cm2 duration of 5 mins b) Clean and prepare the mating surfaces/ flanges of pipes on both sides and its surrounding properly. Fit the gaskets on pipe flanges and secure them properly. c) Fit the Overhaluled Butter-fly valve in its position and secure with one end pipe flange properly with new set of fasteners d) Fit the gear box with electrical operated acuator of the valve with extension rod mechansim and check for its operation both manually and with power properly. e) Check free condition of the dismantling joint and prepare for lowering in its position.

f) Remove the cocking material between BOP and its frustum from sea side by divers and ensure no waste material in that Vicinity. Fill up the water in the cavity between BF valve and BOP to reduce the seaside pressure on BOP. g) Lift the blanking off plate (BOP) and secure it properly. h) Carry out final trails of the valves during dry dock operation After test proven, install the whole BFV Valve, Gear Box with Extension mechanism in correct order ensure correct alignment and mounting and do the actual Sump test by charging the sump through sea water. j) Supply and applying of one coat primer and two coats of anti corrosion paint on Internal & external surface of pipelines and flanges

Note: Firm to supply and position sufficient lighting, ventilation provision and a 100 TPH submerible pump in the pits separetly with all associated panels, discharge pipe to discharge from pump house (minus 20 Mtrs) to sea (Jetty level) so as to ensure that residual water in the pits is nill at all points of time. The pump head should be sufficient to discharge the water outside the pump house towards the sea. Pump house at a level of -18m below sea level. Firm is not to depend on the availability of the pump house stripping pumps and should make its own arrangements for removal of water from the pits and pipelines. Any delay in work with regards to presence of water in the pits/ pipelines is attributable to firm. Firm should own ararangements of crane and lifting assesories for lift and overhaul of valve and associated parts.

Supply only the following spare parts as required shall be measured and paid separately under relevant items of Sch'A' during repair of BFV Valve complete all as specified and directed.

Supply only EPDM valve disc seal of 1800mm dia/ suited to site conditiona and Shore hardness of 60 -70 to suite Valve disc Complete all as specified and as directed.

Supply only EPDM/ Nitrile rubber gaskets of 10 mm thick and Shore hardness of 60 -70 to suite mating surface of flanges.Complete all as specified and as directed.

Supply only 36mm dia X 180mm long SS 316 grade studs with 03 in Nos. Hex. nuts for each stud complete all as specified and as directed.

Supply only 36mm dia X 690mm long SS 316 grade studs with 05 in Nos. Hex. nuts for each stud complete all as specified and as directed.

Supply only 36mm dia X 155mm long SS 316 grade studs with 02 in Nos. Hex. nuts for each stud.Complete all as specified and as directed.

M&L for Cross arms,underneath supports, Reducers of heavy duty C-Class material of MS, and brasings, supports, clapms and back plates fabricated from structural steel suctions, including nuts and bolts and washers, welding, bending cold or hot, drilling holes for bolts, in any shape or size as indicated or directed and inclusive of one primer coat and one under coat and one finishig coat of paint at galleries and under sump pits and pumphouse sumps conncted lines, complete all as specified and directed

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