COMPREHENSIVE MAINTENANCE OF DG SET UNDER GE NAVY CHENNAI

Change the engine oil and all filters as per scheduled intervals or requirement.

Drain water from the fuel tank to present contamination and consider cleaning it.

Check and clean or replace the air filter element.

Inspect for leaks and ensure it is securely attached.

Check and tighten electrical connections and components.

Checking the coupling bolts and adjustment checking the self starter and Dynamo

Checking the battery distilled water levels and topping upto the required level.

Checking the panels (Manual as well as AMF) attached to the DG set for loose connections, defects if any in the panel Board and replacement of spares all as directed.

Check and adjust the valve clearance if necessary.

Clean the radiator fins and hoses thoroughly.

Clean the fuel tank to remove any accumulated water or contaminates

NOTES:- (i) Control switches , MCCB's, contactors, multi display meters , Engine control unit shall be out of scope of the item of work and the rate quoted shall be exlusive for servicing/ maintenance of the above item of work.

(ii) Servicing of DG set alongwith connected Alternator and Panel Board including 'A' check of the Engine shall be carried out once in every month (Except during the month when 'B' check is carried out) as directed by the Engineer-in-Charge and the Contractor shall carry out periodical inspections during the maintenenace period and shall be responsible for the smooth functioning of the DG set for a period of 30 days from the date of service and shall also attend all the maintenence / breakdown repairs as and when required in that period except in case of major repairs.

(iii) Spare parts required for replacement during the maintenance period shall be measured and paid separately at supply only rates and cost of labour for fixing these spares shall be deemed to be inluded in the rate quoted .

(iv) Cost of all consumables required during the maintenance period shall be deemed to be included in the rate quoted for this item.

(v) List of checks to be carriedout under 'B' & 'C' check is attached to the Particular specifications.

Checking the tappet clearance and adjustment of valve including replacement of tappet gasket for following DG Sets :-

DG Set of capacity 10 to 15 KVA

DG Set of capacity 40 to 75 KVA

DG Set of capacity 100 to 125 KVA

DG Set of capacity 160 KVA.

DG Set of capacity 320 KVA.

Supply & replacement fuel filter pre and secondary including rubber gasket for following DG sets

DG Set of capacity 10 to 15 KVA

DG Set of capacity 40 to 75 KVA

DG Set of capacity 100 to 125 KVA

DG Set of capacity 160 KVA.

DG Set of capacity 320 KVA.

Supply & replacement only lube oil filter including rubber gasket for following DG sets

DG Set of capacity 10 to 15 KVA

DG Set of capacity 40 to 75 KVA

DG Set of capacity 100 to 125 KVA

DG Set of capacity 160 KVA.

DG Set of capacity 320 KVA.

Supply & replacemet air filter element including rubber gasket for following DG sets

DG Set of capacity 10 to 15 KVA

DG Set of capacity 40 to 75 KVA

DG Set of capacity 100 to 125 KVA

DG Set of capacity 160 KVA.

DG Set of capacity 320 KVA.

Supply & replacement fan belt of existing size for following DG sets

DG Set of capacity 10 to 15 KVA

DG Set of capacity 40 to 75 KVA

DG Set of capacity 100 to 125 KVA

DG Set of capacity 160 KVA.

DG Set of capacity 320 KVA.

Supply & replacement Radiator hose with clip of existing size for following DG sets.

DG Set of capacity 10 to 15 KVA

DG Set of capacity 40 to 75 KVA

DG Set of capacity 100 to 125 KVA

DG Set of capacity 160 KVA.

DG Set of capacity 320 KVA.

Supply & replacement rubber coupling of existing size for following DG sets

DG Set of capacity 10 to 15 KVA

DG Set of capacity 40 to 75 KVA

DG Set of capacity 100 to 125 KVA

DG Set of capacity 160 KVA.

DG Set of capacity 320 KVA.

Supply and toping up the following items for the DG Sets

Engine oil 20 W 40

Distilled water.

Battery acid

Coolant Make :

Benzo bolt with washer.

Jubilee clamp for fuel pipe

Fuel Flexible pipe with brass or GM adaptor.

Oil Flexible pipe with brass or GM adaptor.

Flexible reinforced pressure pipe 3/8" dia.

Flexible reinforced pressure pipe 1/2" dia.

Flexible reinforced pressure pipe 1" dia.

Supply and Cladding with glass/rock wool and aluminium sheets of exhaust manifold for following DG sets including removing of existing asbestos rope or any other type of insulation.

DG Set of capacity 10 to 15 KVA

DG Set of capacity 40 to 75 KVA

DG Set of capacity 100 to 125 KVA

DG Set of capacity 160 KVA.

DG Set of capacity 320 KVA.

Supply and fixing of Expansion bellow for exhaust manifold for following DG sets including removing of existing

DG Set of capacity 10 to 15 KVA

DG Set of capacity 40 to 75 KVA

DG Set of capacity 100 to 125 KVA

DG Set of capacity 160 KVA.

DG Set of capacity 320 KVA.

Draining the engine oil from sump removing the sump cover cleaning the sludge and refixing the same including replacement sump gasket and filling oil for the following Gen sets as per manufactures instructions

DG Set of capacity 10 to 15 KVA

DG Set of capacity 40 to 75 KVA

DG Set of capacity 100 to 125 KVA

DG Set of capacity 160 KVA.

DG Set of capacity 320 KVA.

Dismantling the fuel pump from the Engine, transportng to the service center and complete servicing and overhauling of the pump including replacement of service kit ,element, delivery valve, plunger, copper washer etc all as required including re-calibration, refixing and testing complete.

DG Set of capacity 10 to 15 KVA

DG Set of capacity 40 to 75 KVA

DG Set of capacity 100 to 125 KVA

DG Set of capacity 160 KVA.

DG Set of capacity 320 KVA.

Dismantling the water pump from the Engine and supply and fixing new water pump of existing size and testing complete.

DG Set of capacity 10 to 15 KVA

DG Set of capacity 40 to 75 KVA

DG Set of capacity 100 to 125 KVA

DG Set of capacity 160 KVA.

DG Set of capacity 320 KVA.

Dismantling the fuel pump from the Engine and supply and fixing new fuel AC pump of existing size and testing complete.

DG Set of capacity 10 to 15 KVA

DG Set of capacity 40 to 75 KVA

DG Set of capacity 100 to 125 KVA

DG Set of capacity 160 KVA.

DG Set of capacity 320 KVA.

Draining out the diesel tank, cleaning / washing out the sludge and re-filling with diesel for following DG set:-

DG Set of capacity 10 to 15 KVA

DG Set of capacity 40 to 75 KVA

DG Set of capacity 100 to 125 KVA

DG Set of capacity 160 KVA.

DG Set of capacity 320 KVA.

Taking down radiator, servicing, cleaning of with suitable reagent, washing thoroughly,arresting leakage if any by welding / brazing and refixing the same (Necessary coolant and distilled water required will be measured and paid seperately under relevant item herein before).

DG Set of capacity 10 to 15 KVA

DG Set of capacity 40 to 75 KVA

DG Set of capacity 100 to 125 KVA

DG Set of capacity 160 KVA.

DG Set of capacity 320 KVA.

Removing and replacing of Fuel injector pipe for following DG set

DG Set of capacity 10 to 15 KVA

DG Set of capacity 40 to 75 KVA

DG Set of capacity 100 to 125 KVA

DG Set of capacity 160 KVA.

DG Set of capacity 320 KVA.

Supply and replacement of anti vibration mounting pad for following DG sets including removing of existing .

DG Set of capacity 10 to 15 KVA

DG Set of capacity 40 to 75 KVA

DG Set of capacity 100 to 125 KVA

DG Set of capacity 160 KVA.

DG Set of capacity 320 KVA.

Supply and replacement of the following items for DG set any capacity

Oil pressure gauge.

Battery terminal socket GM including soldering.

Battery terminal leads complete with brass connector

Radiator Cap

Fuel Tank Cap with Lock.

Door lock of any type and size complete Set.

Door gasket of any type and size complete set.

Carbon brushes for charging alternator

PT Pump repair Kit

AVR Suitable for 62.5 to 125 KVA Alternators

AVR Suitable for 10 to 40 KVA Alternators

AVR Suitable for 160 KVA Alternators

AVR Suitable for 320 KVA Alternators

Supply and replacement of the following items for DG set control panel of any capacity.

AC Ammeter digital type

AC Volt meter digital type 0 to 500 volt.

Frequency meter

DC Volt meter 0 to 24 V

lgnition switch with key for on, off and run.

DIN Rail for fixing MCB

MCB SP 6-32 Amps

MCB 4P 40 Amp

Indicator lamp for panel board as per existing size.

No Volt Coil suitable for 3 phase power contactor 160-200 Amps ratings.

Dash board pilot lamp.

Control cable 2.5 sqmm copper Multistranded.

Control cable 4 sqmm copper Multistranded.

Toggle Switch 15 Amps.

AMF Relay 12 Volt DC.

Battery charging alternator 12 Volt.

Temperature Gauge with sensor.

Electronic governor.

RPM Meter.

Door hinges.

Oil Pressure Sensor.

AMF Panel relay.

Battery charger AC to DC.

Single phase preventor.

Speed control sensor.

Contactor 4 P ole 200 A.

Removing dismantling and overhauling of 12 volt starter motor, replacement of armature coil, field coil, bush bearing etc to make the starter motor serviceable complete all as specified and as directed.

Removing dismantling and overhauling of 24 volt starter motor, replacement of armature coil, field coil, bush bearing etc to make the starter motor serviceable complete all as specified and as directed.

Spray painting of diesel generating set of capacity 10 to 40 KVA with acoustic enclosure with one coat of synthetic enamel paint including writing of SM/MES No on engine and alternator, body colour shall be apple green, black for foundation base frame, red for all guards, all as specified and as directed.

Spray painting of diesel generating set of capacity 62.5 to 125 KVA with with acoustic enclosure one coat of synthetic enamel paint including writing of SM/MES No on engine and alternator, body colour shall be apple green, black for foundation base frame, red for all guards all as specified and as directed.

Spray painting of diesel generating set of capacity 160 KVA open type with one coat of synthetic enamel paint including writing of SM/MES No on engine and alternator, body colour shall be apple green,black for foundation base frame, red for all guards for all as directed.

Spray painting of diesel generating set of capacity 320 KVA open type with one coat of synthetic enamel paint including writing of SM/MES No on engine and alternator, body colour shall be apple green,black for foundation base frame, red for all guards for all as directed.

Removing and replacing the old unserviceable lead acid battery of size 12 Volt , 100 AH of reputed make including charging and shifting & depositing old battery to MES all as specified as directed ( Make : Amaron, Exide)

Removing and replacing the old unserviceable lead acid battery of size 12 Volt , 130 AH of reputed make including charging and shifting & depositing old battery to MES all as specified as directed ( Make : Amaron, Exide)

Removing and replacing the old unserviceable lead acid battery of size 12 Volt , 180 AH of reputed make including charging and shifting & depositing old battery to MES all as specified as directed ( Make : Amaron, Exide)

M & L for PCC (1:3:6) type C2 (using 40mm graded crusehd stone aggregate ) as in foundation/Copping of pole including necessary form work complete all as specified and directed.

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