REPAIR/MAINTENANCE OF FREQUENCY CONVERTORS, HT DG SET AND ALLIED ITEMS UNDER C NO 60 0F NAVAL DOCKYARD, UNDER GE (NW) KUNJALI, MUMBAI

Amount

Material & Labour for decoupling of motor and generator set at site, including disconnection of all incoming and outgoing cables of 860 kW, 600 RPM, 6.6 kV capacity set.The work includes removal of pedestal bearings along with shims (thin liners of sheet metal of various thicknesses) placed under the pedestal bearings and feet of stator frames. Proper marking and diagrammatic records of shim positions shall be prepared and maintained as a reference for re-assembly.Levelling shall be carried out with high precision to ensure correct installation and smooth operation of the bearing and machine.Work shall be executed completely as specified and directed by the Engineer-in-Charge and carried out only through an authorised OEM agency only. Note- Details of OEM representative shall be kept of records and verfied by Engr-in-charge .

Material & Labour for shifting of motor and generator set of 860 kW, 6.6 kV capacity from Dockyard to OEM workshop for complete overhauling of the Frequency Converter (FC) set. Note : Work includes safe loading via cranes (if required), transportation and unloading at OEM workshop premises using a suitable heavy-duty loader. All activities shall be carried out in accordance with OEM guidelines and as directed by the Engineer-in-Charge.

Material & Labour for dismantling of motor, generator, and exciter (stator and rotor) for repair/overhauling of 860 kW, 600 RPM, 6.6 kV FC set. The work includes removal of bearing pedestals after inserting necessary shims; removal of upper half bearings; supporting the rotor with crane hook on coupling side during nut loosening; careful removal of oil rings; and proper extraction of the rotor. Pedestal bearing oil wells and bearing halves shall be cleaned thoroughly before reinstallation and coated with oil. Notes: (i) During work on stator frames, appropriate shims under stator feet shall be replaced per records/drawings, and board packing inserted in the air gap to prevent rotor–stator damage during transport. (ii) During work on dowel pins, it shall be ensured that existing dowel holes in stator frames and bearing pedestals align correctly with the base plate; all dowel holes must be in one line for accurate alignment. (iii) During work on bearings/rotor, insulating shims shall be provided under pedestals to prevent shaft current damage, placed next to steel shims. Insulated holding-down bolts of appropriate size shall be fitted.

Material & Labour for overhauling of 860 kW, 600 RPM, 6.6 kV Frequency Converter (FC) set by authorised OEM only, as per following schedule: (i) Check all fans/blowers for proper operation. (ii) Check door locks and interlock systems. (iii) Check indication lamps/lights. (iv) Check emergency stop switches. (v) Inspect for abnormal sound/noise from rectifier. (vi) Clean equipment and associated switchgear. (vii) Check all sensors. (viii) Remove dust using blower. (ix) Check ACB/MCCB contactors and tighten. (x) Clean all contacts with CTC solvent. (xi) Check voltage and current potentiometers. (xii) Check all bus bar fittings. (xiii) Tighten rectifier bridge fittings. (xiv) Verify meters, SPP, OL systems. (xv) Calibrate all meters via authorised agency and submit valid certificate. (xvi) Calibrate and test all safety equipment for satisfactory functioning. Note- Details of OEM representative shall be kept of records and verfied by Engr-in-charge .

Material & Labour for conducting static tests of windings using special tools/test jigs as per manufacturer’s recommendation: (i) Insulation resistance of windings. (ii) Winding resistance. (iii) Surge comparison test. (iv) Polarization index test. All testing to be carried out under OEM supervision and as directed by Engineer-in-Charge.

M&L for conducting of following test on all winding of motor generator, exciter stator and rotor of 860 KW FC Set, 6.6KV, 600RPM, complete all as specified and directed by Engr-in-Charge. (i) Dry ice (CO2) cleaning of winding of FC motor generator, exciter stator and rotor. (ii) pre-heating of windings in oven of FC motor generator, exciter stator and rotor. (iii) varnishing of all windings of FC motor generator, exciter, stator and rotor . (iv) curing of winding in oven of FC motor generator, exciter, stator, stator and rotor,

Material & Labour for dynamic balancing of generator rotor, synchronous motor rotor, and exciter rotor of 860 kW FC set.The work includes recording vibration readings on all sides of the rotors and ensuring correct alignment and permissible eccentricity limits. Note : Balancing shall be carried out as per OEM standards and directions of the Engineer-in-Charge.

Material & Labour for white-metal relining of one (01 No.) pedestal-type journal sleeve bearing with spherical seating of size 152.4 mm (Ø) × 228.6 mm (length) with 3.1 mm white-metal liner thickness. The process includes surface preparation, tin-plating, melting and pouring of white metal, controlled cooling, machining, and final inspection. Composition of white-metal alloy shall be tin-based as per OEM recommendation to ensure low-friction performance and long service life.

Material & Labour for repair of slip rings for generator and motor rated 230 A, fabricated from mild-steel rings shrunk onto epoxy-glass insulated steel sleeves pressed onto the shaft.Includes refitting of brush gear assembly on the adjacent bearing pedestal, adjustment of brush spring pressure, and machining of new helical grooves on slip-ring surfaces to match existing gauge and dimensions,Work to be executed as specified and directed by Engineer-in-Charge.

M&L for Re-assembly of motor generator & exciter unit of FC convertor 6.6KV, complete all as specified and directed by Engr-in-Charge. Note: (i) During assembling the machines, the air gap must be checked very carefully for eccentricity which should not be more than 5% of the avarage air gap.(ii) The frame should be effectively earthed by a connection of substantial cross section which should be mechanically and electrically sound.(iii) A careful inspection of the machine should be made before first running up. The connection should be tallied with the connection diagram supplied with each machine and all electrical connection tightened firmly. Checking of all clearance between live parts and earth. The bearing should be filled with oil to the correct level and oil ring should be revolves freely when the machine is running.(iv) The pedestral bearing oil well should be cleaned before reinstallation and lower half of the bearing should be cleaned, placed in position. The oil ring should be put in position and the top halves of the bearing liner should be oiled and assemble after checking that the oil rings revolve freely, insert the coupling bolts into the half cuplings and tighten the coupling side till the nuts are tightened.

Material & Labour for painting of the complete motor-generator-exciter set with one coat of primer and two coats of high-quality synthetic enamel paint (film thickness 75 – 125 microns) applied by spray method. Note :Work includes surface preparation, cleaning of old paint and rust, masking, and finishing in approved shade to satisfaction of Engineer-in-Charge.

Material & Labour for shifting of 860 kW, 6.6 kV motor-generator set from OEM workshop back to Dockyard site after completion of overhauling. Note : (a) Work Includes safe loading, transportation , unloading, and positioning at site using heavy-duty loader or equivalent lifting equipment. (b) All work to be carried out under supervision and direction of Engineer-in-Charge.

Material & Labour for unloading of FC set from transporter and positioning at its existing foundation using heavy-duty hydra/crane. Includes safe handling, alignment, and installation of motor, generator, and exciter units complete with bearings as specified and directed by Engineer-in-Charge.

Material & Labour for replacement of lubricating oil for bearings using Servo Prime 17 (conforming to BIS 489) including draining of old oil, cleaning of oil wells, and refilling to correct level as specified and directed by Engineer-in-Charge.

Material & Labour for complete functional and full-load testing of 860 kW, 6.6 kV FC set after overhaul. Includes measurement of bearing temperature, vibration levels, and checking for oil leakages, insulation, and clearances between live parts and earth. A detailed inspection shall be carried out before first running; test results to be recorded and certified by the Engineer-in-Charge/user department. Make: Siemens / BHEL, Note : Work to be executed by authorised OEM only, as specified and directed by Engineer-in-Charge.

Material & Labour for repair and overhauling of Frequency Converter set of capacity 1000 kW / 1250 kVA, 600 RPM, 6.6 kV, 50 Hz, 1494 RPM with output 7.2 kV.The work includes checking and rectification of cell failure, communication failure, and frequency failure in SMPS units; testing of fibre optic cables and plug connections; verification of DM110 functional software; rectification of frequent start-failure issues; and complete operational testing after repair. Note : Work to be executed by authorised OEM only, as specified and directed by Engineer-in-Charge.

Material & Labour for inspection and testing of all fans and blowers of VVVFD drive for proper operation, air flow, and cooling efficiency,Any defects to be reported and rectified as per OEM standards as specified and directed by Engineer-in-Charge..

Material & Labour for carrying out complete switching ON and OFF operations of Frequency Converter set and checking the performance parameters such as voltage, current, and system response during start/stop cycles complete all as specified and directed by Engineer-in-Charge. Note-All readings to be recorded and verified by Engineer-in-Charge.

Material & Labour for inspection and detection of abnormal sound or vibration from VVVFD drive and FC set during running condition, identification of cause, and rectification as directed by Engineer-in-Charge.

Material & Labour for checking and verifying proper working and functionality of all fans and blowers provided in Variable Voltage Variable Frequency Drive (VVVFD) systems complete as specified and directed by Engineer-in-Charge.

Material & Labour for conducting detailed visual inspection of all panels, drives, enclosures, and wiring for any physical damage, cracks, deformation, or loose fittings complete as specified and directed by Engineer-in-Charge.

Material & Labour for thorough cleaning of all electrical equipment, FC sets, and associated switchgear using approved methods complete as specified and directed by Engineer-in-Charge.

Material & Labour for checking and verifying functionality and calibration of all sensors fitted in the VVVFD, FC, and associated systems complete as specified and directed by Engineer-in-Charge. Note: Includes testing for continuity, feedback signal verification, and correction of loose terminations as directed by Engineer-in-Charge.

Material & Labour for checking of optical fibre cables and replacement of defective OFC cables with new cables of existing size and specifications complete as specified and directed by Engineer-in-Charge Note:Includes proper termination, routing, dressing, and verification of communication continuity.

Material & Labour for identifying corrupted software and updating the latest OEM-approved software version in the VVVFD and FC control systems as per user requirement complete as specified and directed by Engineer-in-Charge

Material & Labour for inspection and testing of all fuses, fuse carriers, and glass fuses in FC and VVVFD panels complete as specified and directed by Engineer-in-Charge

Material & Labour for cleaning of all control and power panels, drives, and switchgear assemblies using dry compressed air, blower, or industrial vacuum cleaner to remove dust and foreign particles complete as specified and directed by Engineer-in-Charge

Material & Labour for checking proper functioning of all SMPS modules installed in VVVFD system complete as specified and directed by Engineer-in-Charge

Material & Labour for checking and tightening all electrical connections of ACBs, MCCBs, and contactors fitted in FC and VVVFD panels complete as specified and directed by Engineer-in-Charge

Material & Labour for cleaning of all electrical contacts, contactor points, and bus-bar joints with CTC solvent or equivalent approved cleaner complete as specified and directed by Engineer-in-Charge

Material & Labour for checking and tightening of all terminal connections (control and power) in FC and VVVFD systems using calibrated torque tools complete as specified and directed by Engineer-in-Charge

Material & Labour for carrying out insulation resistance test for motor and alternator windings complete as specified and directed by Engineer-in-Charge .

Material & Labour for calibration of all electrical measuring instruments (voltmeters, ammeters, frequency meters, power-factor meters, etc.) through authorised and NABL-traceable agency complete as specified and directed by Engineer-in-Charge .

Material & Labour for calibration and testing of all safety tripping devices including overload relays, earth fault relays, and emergency tripping switches for satisfactory functioning as per OEM guidelines complete as specified and directed by Engineer-in-Charge . Note: All results to be recorded and certified by Engineer-in-Charge.

Material & Labour for painting of motor and generator with one coat of primer and two coats of high-quality synthetic enamel paint after surface preparation and removal of old paint, rust, and grease complete as specified and directed by Engineer-in-Charge . Note :(a) Paint film thickness: 75–125 microns. (b) Shade and finish to be approved by Engineer-in-charge.

Material & Labour for carrying out the routine maintenance of 1000 kW, 6.6 kV Frequency Converter (FC) set as per the following preventive-maintenance schedule. (a)All work shall be performed by authorised OEM personnel and under the direction of the Engineer-in-Charge. (b)Maintenance activities shall include visual inspection, tightening of connections, cleaning, measurement of insulation resistance, alignment, and vibration checks in accordance with OEM recommendations.

(A). Monthly Schedule (a) Check that all holding-down bolts, jointing bolts, and bolts in electrical connections are tight. (b) Clean the motor and generator thoroughly and ensure the equipment is dust-free. (c) Inspect for any loosened nuts, bolts, or fittings and rectify if found.

B. Quarterly Schedule (a) Blow the stator and rotor windings of the generator with dry, clean compressed air at a pressure not exceeding 2 bar. (b) Refill the recommended lubricant/grease in the bearing hubs of the motor and generator as per OEM specification.

C. Six-Monthly Schedule (a)Open the generator AVR cabinet; clean the HT bushings, CTs, and PTs; and tighten all electrical connections. (b)Measure and record insulation-resistance values of rotor and stator windings of motor and generator using a 5 kV Megger. (c)Check the temperature-measuring devices (for bearings and stator windings) for accuracy and correct functioning.

D. Annual Schedule (a) Alignment: Check alignment of motor and generator and compare readings with installation records. (b) Vibration: Measure vibration levels of motor and generator and compare with baseline data. (c) General: Inspect windings and cores for dust, oil, or foreign material; clean thoroughly as necessary. (d) Connections: Clean all power-cable terminals and verify tightness. (e) HT Bushings: Inspect motor and generator HT-cable termination bushings for cracks or physical damage. (f) Insulation: Measure and record insulation-resistance values of HT cables, motor, and generator windings, and document results.

Material & Labour for carrying out routine preventive maintenance of the Variable Voltage Variable Frequency Drive (VVVFD) system and associated Synchronizing Panel as per the following maintenance schedule.

A. Monthly Schedule (a) Clean the exterior and interior of VVVFD and synchronizing-panel cabinets to make them completely dust-free. (b) Remove and clean all filter pads of VVVFD and synchronizing panels; reinstall after drying and inspection.

B. Quarterly Schedule (a) Blow the transformer windings using dry and clean compressed air at a pressure not exceeding 2 bar to remove dust accumulation. (b) Fill or top-up the recommended grade of lubricant/grease in the bearing hub of the exhaust-fan motor as per OEM specification.

C. Six-Monthly Schedule (a) Open the VVVFD cabinet; clean HT bushings, power cells, SMPS modules, and tighten all electrical control and power connections. (b) Open the synchronizing panel; clean terminal blocks and check for signs of overheating or looseness. (c) Carry out detailed visual checks and tighten all control-cable terminations inside the synchronizing panel.

D. Annual Schedule (a) Clean and tighten all power-cable connection terminals in both VVVFD and synchronizing panels. (b) Inspect input and output HT-cable termination bushings for cracks, deformation, or any physical damage. (c) Measure and record insulation-resistance values of HT cables and transformer windings using 5 kV Megger; document results. (d) Conduct thorough inspection of all VVVFD and synchronizing-panel components for physical or electrical abnormalities. (e) Clean and tighten all control-cable terminals and verify continuity. (f) Calibrate all parameter-measuring meters, indicators, and gauges through authorised calibration agency; submit NABL-traceable certificates. (g) Check and verify software settings, record firmware version, and measure individual cell-capacitor values for deviation from OEM tolerance limits.

Taking down and replacement of unserviceable float cum boost charger 110 Volt and providing of new float and boost charger 110 volt/60 Amps with input 415 Vols, 17 Amps, out put-132 Volts, 60 Amps, Type BC60 complete all as specified.

Taking down and replacement of unserviceable float cum boost charger 110 Volt and providing of new float and boost charger 110 volt/30 Amps with input 415 Vols, 15 Amps, out put-132 Volts, 30 Amps, complete all as specified.

Material & Labour for dismantling and removing old unserviceable batteries and supplying, fixing, and commissioning new dry-type lead-acid batteries of capacity 2 V, 300 Ah each, including connectors, cleaning, and terminal protection complete as specified and directed by Engineer-in-Charge .

Material & Labour for dismantling and removing old unserviceable batteries and supplying, fixing, and commissioning new dry-type lead-acid batteries of capacity 2 V, 100 Ah each, including connectors, cleaning, and terminal protection complete as specified and directed by Engineer-in-Charge .

Material & Labour for taking out unserviceable Variable Frequency Drive (VFD) of 1250 kVA Frequency-Converter panel and supplying, installing, configuring, and testing a new 3-phase VFD suitable for 1250 kVA FC operation complete as specified and directed by Engineer-in-Charge .

Material & Labour for taking out unserviceable Variable Frequency Drive (VFD) of 750 kVA Frequency-Converter panel and supplying, installing, configuring, and testing new 3-phase VFD suitable for 750 kVA FC operation complete as specified and directed by Engineer-in-Charge.

Material & Labour for replacement of unserviceable carbon brushes of size 25.4 × 38 × 50 mm suitable for 60 Hz Frequency Converter system (HS Code 8545) installed at MSS complete as specified and directed by Engineer-in-Charge .

Supplying and fixing in repairsof new multifunction digital meter with RS-485 communication port (Model EM 6430 or equivalent) in existing control panel, including wiring, configuration, and operational testing complete as specified and directed by Engineer-in-Charge .

Material & Labour for replacing unserviceable bearing Pattern No. 620422/C with new bearing of identical dimensions and specifications complete as specified and directed by Engineer-in-Charge .

Material & Labour for replacing unserviceable pedestal-type journal sleeve bearing with spherical seating of size 152.4 mm (dia) × 228.6 mm (length), suitable for Frequency Converter sets of 860 / 750 / 1250 kVA capacity complete as specified and directed by Engineer-in-Charge .

Material & Labour for dismantling the old unserviceable digital display unit of Cummins DG Set Model 60 GAT / QSK-60-G4, and carrying out complete servicing, repair, and functional testing of the same to ensure proper operation and display accuracy. Work to include cleaning of display contacts, replacement of damaged components, software reloading, and testing to user satisfaction complete as specified and directed by Engineer-in-Charge . HSN Code: 998719 Make: Cummins

Material & Labour for dismantling the old unserviceable digital display unit and supplying, installing, and commissioning a new digital display suitable for Cummins DG Set Model 60 GAT / QSK-60-G4.Includes all wiring connections, configuration, parameter calibration, and testing for proper functioning under load complete as specified and directed by Engineer-in-Charge . HSN Code: 85318000 Make: Cummins

Material & Labour for servicing of Cummins 2000 kVA DG Set, Model 60 GAT / QSK-60-G4, to carry out “B-Check” level preventive maintenance.Work includes replacement of oil filter, fuel filter, inspection of air filter, cleaning of components, checking of coolant system, belts, wiring, lubrication, and adjustment of minor unserviceable parts,After servicing, complete operational testing shall be performed to the full satisfaction of the user complete as specified and directed by Engineer-in-Charge . HSN Code: 998719 Make: Cummins

Material & Labour for dismantling old unserviceable corrosion resistor and supplying, installing, and commissioning a new corrosion resistor suitable for Cummins DG Set Model 60 GAT / QSK-60-G4.Includes mounting, wiring, and performance testing after installation complete as specified and directed by Engineer-in-Charge . HSN Code: 8421990 Make: Cummins

Material & Labour for dismantling old unserviceable fuel–water separator and supplying, installing, and testing new separator unit suitable for Cummins DG Set Model 60 GAT / QSK-60-G4, including connection of fuel lines, leak testing, and commissioning complete as specified and directed by Engineer-in-Charge . HSN Code: 8421230 Make: Cummins

Material & Labour for dismantling old unserviceable lubricating oil filter and supplying, installing, and testing new oil filter suitable for Cummins DG Set Model 60 GAT / QSK-60-G4.Includes checking for oil leakage and ensuring proper sealing and flow after installation complete as specified and directed by Engineer-in-Charge . HSN Code: 8421230 Make: Cummins

Material & Labour for replacement of lubricating oil using Valvoline Premium Blue 7800 Plus, suitable for Cummins DG Set Model 60 GAT / QSK-60-G4.Includes draining of old oil, cleaning of sump, and refilling with fresh oil of required grade and quantity as per OEM specification complete as specified and directed by Engineer-in-Charge . HSN Code: 27101980 Make: Valvoline / Cummins

Material & Labour for replacement of engine oil with Valvoline Premium Blue 7800 Plus engine oil suitable for Cummins DG Set Model 60 GAT / QSK-60-G4, including draining of used oil, cleaning of tank and filler area, and refilling to specified level. Testing to be carried out under full-load condition after replacement complete as specified and directed by Engineer-in-Charge . HSN Code: 27101980 Make: Valvoline / Cummins

Material & Labour for dismantling old unserviceable battery and supplying, installing, and testing new Pulse Lite battery rated 12 V, 160 Ah, suitable for Cummins DG Set Model 60 GAT / QSK-60-G4 including proper connection, polarity verification, terminal greasing, and load testing complete as specified and directed by Engineer-in-Charge . HSN Code: 85071000 Make: Cummins

Material & Labour for servicing of all DG Set batteries including cleaning of terminals, applying petroleum jelly or conductive grease, checking terminal voltage and specific gravity, tightening of connections, and testing charging/discharging performance. Includes inspection of cables, nuts, and bolts for corrosion and replacement if required.Work shall be carried out under supervision of Engineer-in-Charge. HSN Code: 85071000 Make: Cummins

Note for item No 1 to 60 above : (a) All works shall be carried out by authorised OEM or their approved service partners only. (b) All replaced components shall be new, genuine, and of identical rating/specification. (c) Test certificates, alignment records, and calibration reports shall be submitted after completion. (d) Inspection and testing shall be carried out through a Rep of Accepting Officer before installations and amount for the same shall be included in the rate quoted by the bidder.

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