REPAIR/MAINT/PERIODICAL SERVICING OF GENERATION SYSTEM DG SETS, DG CONTROL PANELS, DG COOLING SYSTEM AND ALLIED WORKS AT BVY, HQ 34 WEU AND OTHER CONNECTED AREAS UNDER AGE E/M-I OF GE MINNIEBAY

Amount

M&L for repair of DG Set 750 KVA of Cummins & Model No KTA 38 by dismantling the sub-assemblies such as fuel pump, fuel injection, governor, turbo-charger, radiator, oil cooler, engine heads, rocker arms, self starter, dynamo-engine wiring, terminal contacts and safety controls etc., including replacement of spare parts as required and re-assembling the sub-assemblies after carrying out necessary repairs including testing and commissioning complete all as directed by Engineer-in-Charge. Note : (a) Supply only spare parts required shall be measured and paid separately under relevant items of schedule 'A' (b) Repairs and calibration of sub-assemblies shall be measured and paid seperately under relevant items of schedule 'A'.

M&L for repair & calibration of turbo charger as per calibration procedure and norms as per manufacturer's standard including replacement of turbo supply & discharge hoses and clamps and de-scaling of turbo charger complete all as specified and directed for the DG Set 750 KVA of Cummins & Model No KTA 38 Note : Spares will be measured seperately under relevant schedule.

Supply only the following spare parts as required during repair of DG Set 750 KVA of Cummins & Model No KTA 38 series as under:-

Upper Engine gasket

Lower Engine gasket

Cylinder liner with O rings

Ring set of piston

Main bearing

Bearing connecting rod

Seal and seat water pump

Seal oil water pump

Ball bearing for water pump

Fuel pump repair kit

Barrel & plunjer injector

Valve intake

Exhaust valve

Insert Exhaust

Insert intake

Collet valve

Screw adjusting

Exhaust manifold having 3 parts

Turbo repair kit

Turbo mounting capscrew & nut

Clamp V band

Hose plain

Hose elbow

Clamp set

Cap filler

Push rod valve

Push rod injector

Fuel hose

Lube oil hose

Tube water transfer

Thermostat

Seal thermostat

Hose turbo supply

Thrust washer camshaft

M&L for Inspection, maintenance and servicing of following capacity DG Sets for 'B' check once in a 03 month or 250 hrs whichever is earlier of the engine for smooth functioning and carrying out the complete checks as per the manufacturers instructions or in case of emergency maintenance requirement all as specified and directed by the Engineer-in-Charge for following DG sets:- (a) Replace the lubricating oil. (b) Replace lubricating oil filter element. (c) Replace lubricating oil by pass filter element. (d) Replace the fuel filter element. (e) Check engine coolent. (f) Check the crank case breather. (g) Check turbo charger (for turbo fitted engine). (h) Draining out unserviceable engine oil from sump. (i) Checking & adjusting fan belts. Note. Filters, Engine oil & coolant shall be measured and paid separately under relevent item of this schedule

750 KVA DG Set of Make Cummins 02 Nos installed at BVY & MAP DG set

250 KVA DG Set of Make Cummins- 01 No installed at HQ 34 WEU and 200 KVA DG Set of Make Kirloskar - 01 No installed at Pump House.

50 KVA of Make Kirloskar 01 No installed at HQ 34 WEU

Supply only following spares suitable for cummins 750 KVA Engine Model No KTA 38 for carrying out repairs under Item No.4.00 above for:-

Water separator filter bearing Cat Part No 3873233 or equivalent (2 Nos for each engine)

Air filter bearing Cat Part No 8200015 or equivalent (2 Nos for each engine)

Fuel filter bearing cat part No FF5511 or equivalent(2 Nos for each engine)

Fuel filter bearing cat part No LF516 or equivalent (4 Nos for each engine)

Lube oil filter LF16029 or equivalent (2 Nos for each engine)

Supply only following spares suitable for cummins 250 KVA Engine Model No QSB6.7G23 for carrying out repairs under Item No.4.00 above for :-

Water separator filter bearing Cat Part No WS5029422 or equivalent (1 Nos for each engine)

Air filter bearing Cat Part No 8200796 or equivalent ( 1 Nos for each engine)

Air filter bearing Cat Part No 8200797or equivalent ( 1 Nos for each engine)

Fuel filter bearing cat part No 5031739 or equivalent (1 Nos for each engine)

Lube oil filter 5031315 or equivalent (1 Nos for each engine)

Supply only following spares suitable for Kirloskar 200 KVA Engine Model No KG 254 M1 for carrying out repairs under Item No.4.00 above for :-

Water separator filter bearing Cat Part No WF2152 or equivalent (1 Nos for each engine)

Air filter bearing Cat Part No F6.729.01-00 or equivalent ( 1 Nos for each engine)

Fuel filter bearing cat part No 48.117.04.0.00 or equivalent (1 Nos for each engine)

Fuel filter bearing cat part No 48.117.05.0.00 or equivalent (1 Nos for each engine)

Lube oil filter 06.436.01.0.00 or equivalent (1 Nos for each engine)

Supply only following spares suitable for Kirloskar 50 KVA Engine Model No KG 204D for carrying out repairs under Item No.4.00 above for :-

Air filter for Kirloskar 50 KVA Engine Model No KG 204D or equivalent ( 1 Nos for each engine)

Fuel filter bearing cat part No 04.296.01.0.10 or equivalent (1 Nos for each engine)

Lube oil filter 04.270.01.0.00 or equivalent (1 Nos for each engine)

Supply and filling of coolant concentrate for radiator of DG Set of any capacity and make compete all as specified and as directed.

M&L for dismantling self starter from engine, carryingout repairs to the self starter, replacement of carbon brushes, service kit, brush holder asssembly, terminals, varnishing complete for DG set capacity 200 KVA complete all as specified and as directed

M&L for dismantling self starter from engine, carryingout repairs to the self starter, replacement of carbon brushes, service kit, brush holder asssembly, terminals, varnishing complete for DG set capacity 50 KVA complete all as specified and as directed

M&L for dismantling self starter from engine, carryingout repairs to the self starter, replacement of carbon brushes, service kit, brush holder asssembly, terminals, varnishing complete for DG set capacity 750 KVAcomplete all as specified and as directed

M&L for dismantling the battery charge alternator from engine, carryingout repairs by replacement of carbon brushes, rectifier kit, diodes, varnishing the coils, replacing bearing, regulator, fixing back in the engine and connecting electrical system complete for DG set capacity 200 KVA complete all as specified and as directed.

M&L for dismantling the battery charge alternator from engine, carryingout repairs by replacement of carbon brushes, rectifier kit, diodes, varnishing the coils, replacing bearing, regulator, fixing back in the engine and connecting electrical system complete for DG set capacity 750 KVA complete all as specified and as directed.

M&L for repair, calibration, testing and commissioning of PT fuel pump for DG set capacity 200 KVA including the replacement of all service kits complete all as specified and as directed.

M&L for repair, calibration, testing and commissioning of PT fuel pump for DG set capacity 200 KVA including the replacement of all service kits complete all as specified and as directed.

M&L for repair, calibration, testing and commissioning of PT fuel pump for DG set capacity 50 KVA including the replacement of all service kits complete all as specified and as directed.

M&L for dismantling, transporting, repair and reconditioning of water pump assembly of 200 KVA DG set, by replacing water pump shaft, impeller, water seal and seat, oil seal, bearings, O ring, gaskets,etc, fixing back to the engine, testing and commissioning including the replacement of all service kits complete all as specified and directed.

M&L for dismantling, transporting, repair and reconditioning of water pump assembly of 750 KVA DG set, by replacing water pump shaft, impeller, water seal and seat, oil seal, bearings, O ring, gaskets,etc, fixing back to the engine, testing and commissioning including the replacement of all service kits complete all as specified and directed.

S&F in repair AVR suitable for 750 KVA DG set complete all as specified and as directed.

S&F in repair AVR suitable for 200 KVA DG set complete all as specified and as directed.

S&F as in repair the lead acid battery 12 V DC 180 AH including the initial charge, terminals connector complete all as specified and as directed.

S&F in repair fuel hose set for supply/return fuel of DG Set 200 KVA complete all as specified and as directed.

S&F in repair lub oil hose set of capacity 200 KVA complete all as specified and as directed.

S&F in repair lub oil hose set of Kirloskar DG Set of capacity 50 KVA complete all as specified and as directed.

S&F in repair coolant hose set of Cummins DG Set 750 KVA complete all as specified and as directed.

S&F in repair coolant hose set of Cummins DG Set 200 KVA complete all as specified and as directed.

S&F in repairs Lub oil pressure transducer for Cummins DG Set 750 KVA complete all as specified and as directed.

S&F in repairs Magnetic pick up for Cummins DG Set 750 KVA complete all as specified and as directed.

S&F in repairs Low lub oil pressure safety switch for Cummins DG Set 750 KVA complete all as specified and as directed.

S&F in repairs High water temperature trip safety switch of Cummins DG Set 750 KVA complete all as specified and as directed.

S&F in repair fan belts of Kirloskar DG Set 200 KVA complete all as specified and as directed.

S&F in repair fan belts of Cummins DG Set 750 KVA complete all as specified and as directed.

S&F in repair dynamo belt of Cummins DG Set 750 KVA complete all as specified and as directed.

S&F in repair shutdown valve of Cummins DG Set 750 KVA complete all as specified and as directed.

M&L in repair and rewinding the excitor rotor assembly of DG Set 750 KVA by taking out complete burnt coils, cleaning and rewinding the same by supper enamel copper wire existing guage , insulalting the coils with nomex paper, milinex sheet, heating and varnshing by varnish materials and applying one coat of bectol anti rust protection, fixing back in to the alternator, connecting the cables, starting and testing complete all as specified and as directed.

M&L in repair AUX 105 controller for 750 KVA Cummins DG Set complete all as specified and as directed.

M&L in repair mother board suitable for PCC 3300 controller for 750 KVA Cummins DG Set complete all as specified and as directed. Note: Software calibration if required will be measured and paid separately.

M&L for calibration of microprocessor based PCC 3300/PCC 1302 controller with OEM software including reloading corrupted software , setting parameters etc for functionality of DG set complete all as dierected starting and testing the DG set on load complete all as specified and as directed. Note: Quoted rate inclusive of software, PC/laptop and other T&P for carrying out job complete

M&L for servicing of air circuit breaker rating 1250-1600 Amps, dismantling from the DG set panel by taking out the defective moving contact unit with fingers and its connected accessories, dismantling and servicing the defective moving contact with fingers, under voltage trip, shunt release trip, assembling and fixing back in to the panel and locking properly and testing on load complete all as specified and as directed.

M&L for taking down unserviceable solenoid switch from starter motor of 750 KVA DG Set, opening and removing bunrt defective parts, replacing by new solenoid switch and connecting with contacts and testing complete all as specified and as directed.

M&L for taking down unserviceable solenoid switch from starter motor of 200 KVA DG Set, opening and removing bunrt defective parts, replacing by new solenoid switch and connecting with contacts and testing complete all as specified and as directed.

M&L for taking down unserviceable solenoid switch from starter motor of 50 KVA DG Set, opening and removing bunrt defective parts, replacing by new solenoid switch and connecting with contacts and testing complete all as specified and as directed.

S&F in repair rotating rectifier kit diode set of Cummins DG Set 750 KVA complete all as specified and as directed.

S&F in repair rotating rectifier kit diode set of Cummins DG Set 200 KVA complete all as specified and as directed.

Supply only engine oil for topping up in engine oil sump with suitable grade oil SAE-15W-40 complete all as specified and as directed.

Supply and filling engine oil for topping up in engine oil sump with suitable grade oil SAE-20W-40 complete all as specified and as directed.

S&F in repairs of low coolant water level sensor suitable for Cummins DG Set 750 KVA complete all as specified and as directed.

S&F in repairs radiator out let pipe along with hose and clamp sets of Cummins DG Set 750 KVA by taking out corroded pipes from radiator assly, fixing new pipes, hose and clampset, starting and testing complete all as specified and as directed.

M&L for fuel leakage rectification in 750/650 KVA DG set by complete dismantling of engine turbo charger connections, intake manifolds in both banks, removing STC fuel manifold along engine injectior fuel rail manifiolds along with connected hoses and accessories, replacement of set of fuel manifold O rings, STC O rings, fixing back all removed parts of manifolds and its connected items, carrying out valve and injector settings, starting and testing complete all as specified and as directed.Note : Each turbo charger with manifold will be measured as one job

Supply and fix in repair Human Machine interface suitable for PCC 3300 controller comprising of intuitive operator interface panel that allows for complete genset control as well as system metering, fault annunciation, configuration and diagnostics. The interface shall ihave following features:- (a) LED indicating lamps:- genset running, remote start, not in auto, shutdown, warning, auto, manual and stop, Circuit breaker open, Circuit breaker closed. (b) 320 x 240 pixels graphic LED backlight LCD (c) Four tactile feel membrane switches for LCD defined operation. (d) Seven tactile feel membrane switches dedicated screen navigation buttons for up, down, left, right, ok, home and cancel (e) Six tactile feel membrane switches dedicated to control for auto, stop, manual, manual start, fault reset and lamp test/panel lamps (f) Two tactile feel membrane switches dedicated to control of circuit breaker (g) Communications shall include PC tool interface with RS-485 communication port to allow the HMI to communicate with a personal computer running InPower and the HMI to communicate with the main control board Make: Cummins Power Command HMI 320 or equivalent.

M&L for cleaning the radiator assembly of 750 KVA DG Set of any model with the help of chemical and water through high pressure water pump at site complete including testing complete all as specified and as directed Note: Radicool wash as recommended by manufacturer as required shall be measured and paid seperately

M&L for cleaning the radiator assembly of 200 KVA DG Set of any model with the help of chemical and water through high pressure water pump at site complete including testing complete all as specified and as directed Note: Radicool wash as recommended by manufacturer as required shall be measured and paid seperately

Supply and filling of Radicool wash for radiator cleaning of DG Set of any capacity and make compete all as specified and as directed.

S&F in repair engine intake air temperature sensor for Cummins DG Set 750 KVA complete all as specified and as directed.

M/L for diesel exhaust fluid compatible with all SCR systems suitable for CPCB IV+ diesel engines. Make: Kirloskar/TATA/Cummins/CG or equivalent

Supply and fixing in repair automatic voltage regulator of model AS440 of Stamford or equivalent in kirloskar suitable for the DG Set 200 KVA complete all as directed by Engineer-in-Charge.

Supply and fixing in repair Deep sea engine controller suitable for the DG Set 200 KVA of Kirloskar complete all as directed by Engineer-in-Charge.

Supply and fixing in repair Cummins Governor cord suitable for the DG Set 200 KVA of Kirloskar complete all as directed by Engineer-in-Charge.

Supply and fixing in repair 3.15mm thick CRCA sheet panel with necessary auxiliaries, relay cord, emergency stop button, control supply on/off button etc for the DG Set 200 KVA of Cummins and Spare compartment for fixing engine controller, AVR, Governor card complete all as directed by Engineer-in-Charge. Note : The spares engine controller, AVR, Governor card will be measured and paid separately

M&L for injector and valve settings by adjusting the clearances according to engine firing orders, cleaning the prefilter cap, checking and adjusting the belts, checking and adjusting the mounting pads including replacement of unserviceable valve door gasket complete all as specified and as directed for DG set of capacity 750 KVA.

S&F in repair fuel pressure monitoring sensor for Cummins DG Set 750 KVA complete all as specified and as directed

Supply and fixing in repair Governor cord for the DG Set 750 KVA of Cummins complete all as specified and as directed.

S&F in repair wiring harness for the DG Set 750 KVA of Cummins complete all as specified and as directed.

Supply only cotton waste of good quality complete all as specified and as directed.

M/L for cleaning out HSD fuel tank of capacity above 2000 Ltrs upto 3000 Ltrs by disconnecting inlet pipe connections, flushing out sediments/deposits with high pressure air, arresting leakages if any, refixing the pipes including replacement of defective inlet valves and painting the tank with two coats of synthetec enamel paint over a coat of red oxide after preparation of surfaces complete all as directed.

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