SPECIAL REPAIR TO MEWR SIMA AC PLANT INCLUDING COMPREHENSIVE MAITENANCE AND OUTSOURCING FOR MANNING AND OPERATION OF AIR CONDITIONING PLANT IN NSRY AT NAVAL BASE KARWAR UNDER GE SB KARWAR

Amount

(PART - I - SPECIAL REPAIR)

Notes:- The unit-rate quoted for Air conditioning work shall deemed to be included for taking down of existing false ceiling and any other usable material carefully and to preserve it in safe conditions for refixing after completion of work complete all as specified and as directed.

Dismantling and taking down old central AC plants various type comprising compressors-03 Nos, Chillers - 03 Nos, condenser pumps -03 Nos,Chilled water pump - 03 Nos, cooling tower - 03 Nos, AHU- 07 Nos, with control switches, condenser water pipe lines, etc. and all connected items including demolition of foundation, 450 TR ( 3 x 150 TR) Plant for faciliating replacement of BER plants with new plants and removing from site all as directed. Notes:- (i) The items obtained from dismantling i.e from item No.2 to 26 & 28 shall be deposited to MES store yard.AC duct shall be removed up to plenum level and AC ducting inside building shall not be dismantled. (ii) Dismantling of AC plant units to be planned as directed by Engineer in charge / GE to ensure that there is no disruption to the AC services

Supply, Installation, Testing & Commissioning of VFD enabled water cooled screw chiller units total 03 Nos (2 working + 1 standby) each having minimum capacity 155 TR with screw compressor energy efficient and eco friendly R-134 A refrigerant ,condenser with microprocessor control . The Unit shall have compressor mounting arrangement on rubber Grommets with metal sleeves, Water cooled shell & tube type condenser , evaporator duly insulated, Thermostatic expansion valve . Unit shall have filter dryer, pressure switch i.e. HP/LP, Electronic Thermostat Flow switch at chiller, Integral Refrigerant Piping & wiring, Accessories as required and called for, automatic and safety control mounted in central console Electronic microprocessor with soft starter panel central overloaded protector including comprising of following accessories/ facilities:

(a) 155 TR (with premissible variation of +/- 2.5 % ) semi hermetic screw type compressors with R134 A refrigerant gas ,electrically operated on three phase 415 volts +/- 10 %, 50 Hz ,AC power supply complete with automatic step less capacity control from 100 % to 35 % for each compressor with slide valve mechanism,solenoid valves,in built oil separator,oil pressure safety switch ,crank case heater etc (b) Evaporator and condenser as per OEM standards. (c) Electronic Expansion Valves. (d) Microprocessors based control panel suitable for remote on/off operation and BMS connectivity with mod bust RTU protocol, panel shall be capable to store last 100 alarm/trip status and 1024 readings for each parameters (e) Touch screen type colour graphics display with minimum resolution of 128x68 pixels shall indicate chilled water inlet/outlet and condenser water inlet/outlet (f) Necessary interconnecting copper piping complete with fitting valves etc with required safety controls. (g) Initial charge of eco friendly non CFC refrigerant R 134A and synthetic oil for the complete plant. (h) One Set of differential pressure switch to prevent operation of chiller at low chilled water flow. (j) Electrical control panel with VFD starter.

(A) Mode: (i) Auto/Manual (ii) Single Phasing Protection. (iii) Compressor Restart Protection. (iv) 10- Sec Time Delay between System. (v) Short Circuit Protection 5°C - Anti Freeze Protection. (vi) Display on Micro control indicating . (vi) Display on Micro control indicating compressor on, (vii) Crankcase Heater ON/Off, Entering/Leaving water Temp (B) Refrigerant: (i) R-134A or any other non CFC/non HCFC gas. (ii) Actual capacity as per Ambient condition. (C) Chiller (i) Chilled water Inlet Temp. 12˚ C. (ii) Chilled water outlet Temp. 7˚ C (iii) Chilled water flow rate: 400 USG PM (iv) Max Operating pressure : 150 psig (water side) (v) Fouling Factor: 0.0000176 m².K/W (vi) Chilled water pressure drop maximum 4 MWC (vii) Cop at design condition :Not less than 5.00 (viii) COP at ARI 550/590 condition: It shall be 0.66 KW/TR (ix) NPLV at ARI 550/590 condition : Not less than 5.00

(D) Condenser (i) Condenser water Inlet Temp. 32˚C (ii) Condenser water outlet Temp. 36˚ C. (iii) Fouling Factor : 0.000044 m².K/W (iv) Condenser water flow rate: 500 USGPM Notes for Item No.2: (i) Plant offered by the tenderer must confirm to meet the desired condition as per the data sheet attached as annexure I. (ii) The water flow rate in Gin are appropriate & minor variation as per OEM design of the chiller is acceptable while meeting other criterias. (iii) Inlet & Outlet temperature conditions for the condenser water are appropriate & minor variation as per the deisgn of equipment by OEM is allowed. (iv) The system integration shall be done & achieve the deisgn condition as per given data sheet

Material & Labour for PCC foundation, anti vibration pad, and modification of pipe line by cutting, welding for existing pipe line of suitable size and shape for chiller unit complete all as specified and as directed by Engineer-in-charge. Notes : (i) Size of PCC foundation as per site conditions and as per manufacturers instructions. (ii) Sound engineering practice shall be employed for construction of foundation. (iii) Any item not mentioned above but essential required for installation ,commissioning & integration in existing location/system is deemed to be included in the quoted rates and no extra charges shall be admissable on the account.Bidder is advised to visit the site of work in advance to ascertain & aquint with scope of work and condition of work

Supply & Fixing in replacement FRP Induced draft rectangular counter flow type Cooling Tower with FRP basin of capacity 550 USGPM and inlet/outlet/wet bulb temperature 36/32/27.8 ˚ C with squirrel cage, vertical flange mounted extended thread shaft type, induction motor with totally enclosed weather proof enclosure, connecting the inlet & outlet existing pipelines including PVC Fills, Eliminator, FRP Fan Deck, Hardware etc having minimum cooling capacity of 680 KW complete on existing platform of following capacities after removing old cooling tower as specified in OEM manual & as directed by Engineer-in-charge.

Supply & Fixing in replacement condenser water mono block pump of capacity 35 Lps ,head 16 to 30 m having C.I body,SS shaft & bronze impeller suitable for three phase 50 Cycle, 433V, AC supply complete all as specified and directed by Engineer-in-charge

Supply & Fixing in replacement chilled water mono block pump of capacity 26.5 Lps ,head 24 to 30 m having C.I body,SS shaft & bronze impeller suitable for three phase 50 Cycle, 433V, AC supply complete all as specified and directed by Engineer-in-charge

Taking down old unserviceable/deteriorated insulation from any surface such as pipelines , cleaning the steel surfaces by using wire brush etc and supply & fix nitrile rubber insulation one layer of 19mm thickness sticking on the chilled water surfaces/pipes by using approved adhesive and sealing the joints by weather proof tape duly cladded with aluminium foil including all accessories as required all as directed by Engineer-in-charge.

Material & Labour for duct insulation with Armaflex sheet 19 mm thick insulation with 26 gauge Aluminium cladding and including the following:- (a) Cleaning the duct surface (to be insulated) by scrapping carefully with wire brush etc to make the surface completely free of miss scale, dirt, dust, grease and other foreign materials, taking special care so that all duct joints are sealed against any leakage. (b) Applying rubber based adhesive CPRX Compound. (c) Sealing of all longitudinal joints and circular overlaps with and including aluminum foil tape 50mm wide, to make the insulation leak proof. (d) Securing the insulation with and including mechanically fastened nylon/steel straps of size 12mm/50mm at maximum intervals of 1.2 m.

Supply, installation, testing and commissioning of fire damper complete with smoke detector/thermister, fusible link etc. and actuator as required for operation. The fire dampers shall be spring activated on melting of fusible link having melting point 67.13° C. The fire damper shall be located in the SA/RA ducts, at all fire rated crossovers (shafts, walls, etc.). The control panel shall be located in such a way that the reset can easily be done. These combination smoke and fire dampers shall be interlocked with the building management system for the fire detection or HVAC and shall trip/close in the event of fire/smoke in the respective zone. Fire damper shall be tested as per ULL- 555 and certified by CBRI. The fire-damper shall be of at least 120 minutes fire-rating complete all as specified and as directed.

Supply, Fabrication, Installation, Testing and Commissioning of ducting for supply/Return made out of Gl steel metal 22 & 24 gauge, Zinc coated complete with all standard accessories, flanges, GI Hardware, Self Adhesive elastomeric foam gasket, support etc as per IS-655, complete all as specified and as directed

Taking down old unserviceable existing M.S. Pipes & supply and fix MS pipe heavy grade with all fittings laid in floors or fixed to walls and ceilings including cutting,welding & matching to existing pipe etc of sizes as shown as per specification and as required complete all as specified and as directed.

(a). For size 250 mm

(b). For size 150 mm

(c). For size 125 mm

(d). For size 100 mm

(e). For size 80 mm

(f). For size 65 mm

(g). For size 50 mm Note:- The Pipes size 150 mm & below shall be M.S. ‘C’ class as per IS : 1239 and pipes size above 150 mm shall be welded black steel pipe heavy class as per IS: 3589, from minimum 6.35 mm thick M.S. Sheet for pipes up to 350 mm dia. and from minimum 7mm thick MS sheet for pipes of 400 mm dia and above.

Taking down old unserviceable CI butterfly valve of any make and size and Supplying, fixing, testing and commissioning of butterfly Valve(Manual) with C I body SS Disc, Nitrile rubber Seal & O- Ring PN 1.6 pressure rating for chilled water circulation, in the chilled water plumbing duly insulated to the same specifications as the connected piping and adequately complete all as specified and as directed

(a). For size 150 mm

(b). For size 125 mm

(c). For size 100 mm

(d). For size 80 mm AHU connection

(e). For size 65 mm AHU connection

(f). For size 50 mm AHU connection

Supply, installation, testing and commissioning in replacement of AHU for operation of supply and return air application suitable capacity, indoor type, draw through type of sectionalized construction, factory made, having total static pressure should be 80mm with GI casing of thickness 0.6 mm outside layers and 0.6 mm inside layer injected with CFC free polyurethane foam (PUF) of 40 kg/cum density insulation complete with blower section, chilled water cooling coil section, filter section with muffler and access door to attend the motor/fan with lighting provisions and all accessories of following capacities in CFM including necessary PCC foundation with vibration isolators all as specified and as directed including comprising of following :-

(i) Cooling coil of 6 row deep copper tube with aluminium fins with automatic controlled+ anti-freeze thermostat . (ii) Blower section complete with blower having forward curved centrifugal fan for weather maker suitable for desired static pressure as specified , with minimum 2 bends GSS eliminators with suitable capacity TEFC squirrel cage induction motor (IP-55 and class F insulation VFD compatible) for operation on 3 phase 415 volt 50 HZ AC supply with belt driven pulley. (iii) 50 mm thick washable type pre-filters with filter element made out of synthetic non woven media supported by HDPE mesh on both side including stitching in diamond pattern complete including frame and suitable for efficiency 90% down to 10 micron EU-4 Type complete with mounting frame work. (iv ) Fine Filters section with 305 mm thick secondary dry type cleanable and easily maintainable air filter supported by GI wire and folder to form accordion plate having an efficiency of 99% down to 5 micron EU-5 TYPE complete with mounting frame works. (v) Drain connection, stainless steel (20 G SS-304 Grade) tray duly insulated with 13 mm closed cell nitrile insulation drain pan and with necessary GI pipe for drain out the condensate to the open drain of the building. (vi) Humidification system complete with heating coil/strip heaters to maintain required RH at site with fully automatic arrangement for operation with humidistat for the following capacities as under

(a) 18000 CMH(10588 CFM)

(b) 22000 CMH(12941 CFM)

(c ) 30000 CMH(17647 CFM)

(d) 29000 CMH(17059 CFM)

(e ) 41000 CMH(24118 CFM)

(f) 10990 CMH(6471 CFM)

(g) 19000 CMH(11177 CFM)

Material and labour for suspended false ceiling with 12mm thick perforated gypsum board / tiles for insulation and acoustic purposes, 60 x60 cm in size, fixed with staples on snap grid, in a grid of hot dip GI exposed pre coated suspension system with GI frame work for seamless ceiling comprising of GI perimeter channel, unequal flange and web etc of suitable size duly suspended with 6mm dia GI bar hanger fixed with steel dash fasteners or iron purline from the roof with adjustment clip providing positions for light fixtures, air conditioning diffuser and ducts, sprinkler, smoke detectors etc. the main runners to be secured to structural soffits by hanger@1220 mm maximum c/c. the last hanger at the end of each main runner should not be placed at more than 450mm from the adjacent wall, flush fitting 1220mm cross tee to be interlocked between main runners@ 610mm c/c, so as to form 600mm x 600mm grid complete all as specified and directed

Supply, installation, testing and commissioning in replacement of Three Way Control Valve in a single body equipped with electronic modulating actuator working on 0-10 V DC, 4- 20 mA electric signal. The minimum close off Pressure of actuator must be 1.5 times shut off head of pump as per specifications of following sizes. The valve shall be complete with digital type modulating thermostat (with NTC sensors) which will have provision of setting room temperature. The valve system shall be complete with necessary control cabling between control transformer, valve and standalone thermostat. The valve shall be suitable for the following pipe sizes complete all as specified and as directed

(a). 100 mm dia

(b). 80 mm dia

(c). 65 mm dia

(d). 50 mm dia

M & L for earthing complete with GI earth plate electrode of size 60cmx60cmx6 mm thick, buried directly in ground (earth pit not less than 2.25m deep below normal ground level) with top edge of the earth plate not less than 1.5m below normal ground level connected with GI strip 32 x 6 mm by means of bolts, nuts, check nuts and washers of galvanised iron or steel including necessary excavation and earth work in any type of soil, removing surplus soil to a distance not exc 50m, with and including PCC chamber in PCC(1:2:4) type B1, using (20 mm graded stone aggregate),"mild steel angle iron frame" made out of MS angle iron of size 40x40x6 mm thick duly painted with two coats of synthetic enamel paint over one coat of red oxide zinc chrome primer hinged with and including 10 mm thick CI cover with handle, watering arrangement with funnel internally secured with wire mesh with 20mm dia medium grade GI pipe for watering, 40 mm dia light grade, GI pipe for lead protection in & including alternate layers of charcoal dust and common salt complete all as shown in electrical "Plate No-3 of SSR Part-I-2009" and connected to earthing test point all as specified and as directed including testing on completion. Note: GI earth strip 32 x 6 mm upto 7.5 RM is included in the unit rate quoted

Supplying, fixing, testing and commissioning in repair of NON - RETURN VALVE with dual plate of C I body SS plates vulcanized NBR seal flanged end & PN 16 pressure rating for chilled water/condenser water circulation of size 150 mm, in the chilled/condensor water plumbing duly insulated to the same specifications as the connected piping and adequately supported as per specifications complete all as specified and as directed.

Supplying, fixing, testing and commissioning in replacement of Balancing Valve with built in measuring facility with C I body flanged construction with EPDM coated disc with long pitch with protected out pipe insulation & PN 16 pressure rating for chilled water circulation, in the chilled/hot water plumbing duly insulated to the same specifications as the connected piping and adequately supported as per specifications complete all as specified and as directed.

(a) For 150 mm dia

(b) For 100 mm dia

(c) For 80 mm dia

(b) For 65 mm dia

(c) For 50 mm dia

Supplying, fixing, testing and commissioning in repair of Y - Strainer of Ductile CI Body flanged ends with stainless steel strainer for chilled water circulation of size 150 mm, in the chilled/hot water plumbing duly insulated to the same specifications as the connected piping and adequately supported as per specifications complete all as specified and as directed.

Supply and fixing in replacement in position the industrial type pressure gauges with gun metal / brass valves complete as required complete all as specified and as directed.

Supply & fixing in replacement in position the mercury in glass with industrial type thermometers complete all as specified and as directed.

Supply & fixing digital display thermometer for measuring return air temp to be installed in each AHU of return air duct including sensor,wiring ,connection,fixing & all work as required.The thermometer will be prominantly display in AHU room complete all as specified and as directed.

Supply and fixing in replacement in position the following Ball Valves 40 mm dia for makeup line as per specifications complete all as specified and as directed Note :Ball valve shall be screwed type brass/bronze lever operated, quarter turn ball valve (screwed type) of full flow with bronze /forged brass hard chrome plated ball with setting & gland of superior quality of preferably PN 1.6 rating complete all as specified and as directed.

Supply & Fixing in replacement water flow switch in chilled/ condenser water pipe line complete all as specified and as directed.

M & L in replacement for Insulation of M S Pipe with PUF slab 30 mm thick with and including applying bituminous compound and GI cladding with 26 gauge GI sheet complete of sizes as shown as per specifications and as required complete all as specified and as directed

(a) 50 mm dia. CHW Pipe

(b) 65 mm dia. CHW pipe

M & L in replacement for Insulation of M S Pipe with PUF slab 40 mm thick with and including applying bituminous compound and GI cladding with 26 gauge GI sheet complete of sizes as shown. as per specifications and as required complete all as specified and as directed

(a) 150 mm dia

(b) 100 mm dia

(c) 80 mm dia

Providing and fixing Auto air vents (Brass MOC) of 25 mm dia complete all as specified and as directed

M & L in repair of closed expansion tank will be of M.S. construction with interchangeable EPDM-BUTYL rubber membrane. The expansion tank shall be complete with safety relief valve and pressure gauge. The tank will be of pressure rating to suit the system pressure and will be sized to adequately compensate for water expansion due to operating temperature variations. For chilled water application, it will be insulated with 50 mm thick insulation to the specifications and cladded with 26G-aluminum cladding. The expansion tank shall be supplied along with pressurization unit. The pressurization unit shall consist of two nos.(1 working+1 stand-by) high pressure pumps of suitable pressure rating mounted on M.S. frame, complete with interconnecting piping, isolation valves, NRV, Y-strainer, Pressure gauge, pressure transmitter, auto-logic panel(IP 55) with dry-run protection, electrical MCB and interconnecting wiring. The unit shall be housed in powder-painted canopy suitable for external installation, if required. 500 Liters approx. capacity tank (on chilled water system main header) complete all as specified and as directed

Providing and placing on terrace (of plant room) polyethylene water storage tank of capacity 2000 ltrs , IS : 12701 marked, with cover and suitable locking arrangement and making necessary holes for inlet, outlet and overflow pipes but without fittings and the base support for tank complete all as specified and as directed Note: The arrangement for the makeup soft water shall be made by the client to fulfil the makeup water requirement.

Supply, installation, testing and commissioning of GI volume control duct damper of 1.2 mm thick sheet complete with neoprene rubber gaskets, nuts, bolts, screws linkages, flanges etc, as per specifications & as required complete all as specified and as directed

Supply, fabrication, installation and testing of non-porous flexible connections constructed of fire resistance flexible, double canvas connection with resistoflex material as per the approved shop drawings complete all as specified and as directed

Supply and fixing of powder coated extruded aluminium supply / return air grills with aluminium volume control dampers as per specifications complete all as specified and as directed

Supplying, installing, testing and commissioning of Fresh Air powder coated Anodized extruded aluminium construction fresh air louvers (50 mm deep) (Fresh air louver with VCD , bird screen & rattle-free) complete as per specification complete all as specified and as directed

Supplying ,laying , fixing & testing of following sizes of XLPE insulated,armoured heavy duty electric cable with aluminium conductor,1100 volts grade complete as required and as directed

(a) 3 ½ Core- 70 sq mm

(b) 4 Core- 25 sq mm

(c) 4 Core- 10 sq mm

(d) 4 Core- 6 sq mm

(e) 3.5 Core- 120 sq mm

(f) 3.5 Core- 50 sq mm

Manning and Operation round the clock of chilled water type central AC plants of capacity 3x 150 TR for a total period of 60 (Sixty months) [for three shifts of eight hours duration (0600 hrs to 1400 hrs, 1400hrs to 2200 hrs & 2200 hrs to 0600 hrs)] by one Ref Mech (Skilled) per shift for all days in a week including sundays & holidays with all instruments and controls complete all as specified as under and as directed by Engineer-in-charge.

(a) First (11 months after completion of Phase I test)

(b) Second (11 months after completion of 38 (a) here in before

(c) Third (11 months after completion of 38 (b) here in before

(d) Fourth (11 months after completion of 38 (c) here in before

(e) Fifth (11 months after completion of 38 (d) here in before

(f) Sixth (05 months after completion of 38 (e) here in before Notes :- (a) 24 Hour period will be considered as a day, AC Plant shall be operated as and when needed and as directed and the same shall be operated in three shifts of 08 hours each i.e, 1st shift 0600 to 1400 Hours, 2nd shift 1400 Hours to 2200 Hours and 3rd shift from 2200 Hours to 0600 Hours of the next day as directed by Engineer-in-Charge. Contractor shall employ one operator (skilled) per shift. (b) Daily maintenance as per manufacturer's instr for AC plants (c) Log sheet for recording daily running hours run shall be provided / maintained by the contractor in their respective installation and same will be checked by the Engineer-in-charge periodically and daily by JE.

(d) General cleanliness / removing of vegetation of respective installation surrounding area to be done regularly and the cost of the same deemed to be included in the quoted rate. (e) Cleaning of the cooling tower, package unit, compressor, condenser complete, cleaning of all parts with brush, washing with detergent powder refit all parts after cleaning and making good the disturbed area. The cleaning shall be carried out twice in whole contract as directed. The same shall deemed to be included in the rate quoted for above mentioned central AC plants. (f) The rates quoted shall be inclusive of all taxes ,cess, levies etc as applicable including GST (g) The prevailing rate,wage,contribution etc shall be as applicable as on the bid submission end date.

(h) In view of COVID-19 alerts various restrictive instructions issued concerned authorities from time to time. Hence additional precautions essential for the work shall be taken by the contractor by way of provisioning of masks, hand sanitizers, gloves etc to workmen and all local instructions issued by the Concerned Authorities and Station Authorities shall be complied with all relevant safety precautions covered under Model Rules for the protection of health and sanitary arrangement for workmen (Annexure ‘C’) of IAFW-2249) shall be strictly followed. Nothing extra is admissible on this account (j) The contractor shall also deploy additional man power as relief against weekly off,leave,holidays etc all as per existing Labour Act and shall substitute the operator accordingly for which no extra payment admissible. The unit rate quoted against items in Schedule ‘A’/BOQ shall be inclusive of this provision also. (k) The contractor shall pay the wages to the operator through e-payment i.e Aadhar linked bank accounts and Credit to their bank account. The wages shall not be less than prevailing minimum wages fixed by state Govt or central Govt whichever is more.

(k) In the case of absence of operator, penalty will be charged as doubled as quoted rate or Rs 1000/-per shift whichever is higher besides any loss/damages occurring during the period which will have to be made good by the contractor without any extra cast. (l) The contractor shall provide 02 uniforms to each operators & helper and design of uniform shall be got approved from GE. In case of failure, a penalty of Rs 100/- per day per operator will be levied and recovered from dues. (m) It is responsibility of contractor to deposit the employees provident fund (EPF) to the concerned authority as per the prevailing scales as laid down by the Ministry of labour for all Electrician/operator/helper (as applicable) and necessary proof to this regard shall be submitted to Engineer-in-Charge for verification and records. The quoted rate shall be deemed to be included of above provisions. In case contractor fails to produce the proof of EPF, he shall be liable for action as deemed fit. Decision of GE in this regard shall be final and binding. (n) The contractor shall maintain all the registers under various labour law rules, 2017 and shall be produced to GE and as well as officers detailed by labour department.

(PART - III COMPREHENSIVE MAINTENANCE)

Comprehensive maintenance comprising of routine, preventive & breakdown maintenance of chilled water type central air conditioning plant of capacity 3X 150 TR installed , comprising of all devices and accessories through out 12 months on all days including sundays & holidays for a period of 03 years i.e after expiry of defects liability period of 24 months after completion of all phase II tests) complete all as specified and as directed and shown below:-

(a) First year (12 months ) after expiry of defect liability period

(b) Second year (12 months) after completion of 39 (a) here in before

(c) Third year (12 months) after completion of 39 (b) here in before Notes:- (i) The comprehensive maintenance for a period of 36 months wef satisfactory completion of guarantee (defects liability period) for the work (ii) The Contractor shall be responsible for periodical maintenance including renewal / replacement of parts, fittings/fixture filling of refrigerant gas etc required for smooth functioning of the plant as per manufacturer's instructions. (iii) The cost of spare parts, consumable items, repair/replacement of equipments/machinery with labour charge for carrying out comprehensive maintenance are deemed to be included in the unit rate quoted by the contractor above.

Pneumatic Engineers Pvt. Ltd.

somnath engineering corporation

DURGAI ELECTRICALS

Parksons Engineering Company Pvt Ltd

C R R CONSTRUCTIONS