REPAIR, MAINT AND OVERHAULING OF VARIOUS CAPACITY DG SETS, LT SERVO VOLTAGE STABILIZER INSTALLED AT AF STN MOHANBARI UNDER GE (AF) MOHANBARI

Amount

Labour charge for disconnecting of LT connection, earthing lead and taking down carefully defective servo controlled voltage stabilizer of capacity 75 KVA, 3 Phase, 415 Volts, dismanteling all internal electric connection from auto transformer, variac and voltage correction motors after draning out of transformer oil storing the oil in oil barrel of capacity 210 litres for refuse and opening the top cover of the servo controlled voltage stabilizer by removing nuts, bolts, washers etc and repair to core/ winding after removing internal electrical connections by unscrewing nuts, bolts etc and cleaning entire housing of stabilizer and dismantling complete primary and secondary winding from the limb and removed the entire tape insulation from the existing copper winding wire and installing the servo controlled voltage stabilizer to its original position after complete repairs including connection of all electric cables wires and earthing connection complete all as specified and directed by the engg-in-charge. Note:- (i) Rate for minor parts like insulation tape, nut bolts, washers,screws and lugs are inclusive. (ii) Spare parts shall be measured and paid for saperately under respective items here in after as "supply only" (iii) Repairs to DG set will be carried out by authorised agent as approved by GE

Supply only the following items for 75 KVA servo voltage stabilzers :-

LED indicator as per colour scheme (Red/Yellow/Blue/Green)

Oil capacitor of capacity 1.5 Mfd

MCCB, TP, 63 Amps,16kA, 415Volts AC, 50Hz

OV/UV Protector ranging 110 VAC to 440 VAC

connector 4 pole suitable for connecting 25 Sqmm copper cable

Material and labour for dehydration and filteration of transformer oil by dehydration plant (bringing plant at site) including testing of sample before and after dehydration and filteration to achieved 40 KV at 2.5 mm gap complete all as specified and as directed. Note: (a) The filtration of the transformer oil shall be carried out at different locations of Air Force Station Mohanbari. (b) The report before filtration and after filtration to be submitted by contractor. (c) Transformer oil for topping up will be measured and paid separately.

Supply and toping up of new transformer oil (in sealed barrel) confirming to IS 335 Std having dielectric strength 40KV at 2.5mm gap after initial dehydration complete all as specified and as directed. Make : Gulf/Power oil/Savita oil.

Material and labour for repairing / replacement of burnt and damaged control wiring of 75 KVA servo voltage stabilizer with new wiring complete to make fully functional complete all as specified and directed by the engg-in-charge.

Labour charges for finding out defects of fully Auto Mains Failure Panel (AMF) of DG set capacity 45/50 KVA, Makes : Kirloskar/Ashok Layland DG Set and taking out burnt interconnection wiring including U/S and serviceable components for reuse including rewiring of panel using existing size of copper cable, ferrule, lugs, insulating material, nut bolt washers of various sizes refixing serviceable items any make and part No and testing complete all as specified and directed by the engg-in-charge. Note:- (i) Minor parts like control cables, fuse, nuts bolts, washers, screws are inclusive in above rates (i) Spare parts shall be measured and paid for saperately under respective items here in after as "supply only" (ii) Repairs to AMF Panel of DG set will be carried out by authorised agent as approved by GE.

Supply only the following items for AMF panel of DG set capacity 45/50 KVA:-

Generator controller suitable for 45 KVA DG Set Make: Kirloskar Model No KG934V

Generator Display Panel suitable for 50 KVA DG Set Make: Ashok Leyland Maodel No GC 1202

Power contactor Type MCX 12 415 Volts with add on block Model MNX -A1

MCB TPN 63, 415 Volts

VMR 3P (REL) Model No PR-07

4 Pole connector suitable for AMF Panel

MCB SP 6 to 32 Amps, C curve , 240 Volts

Labour charges for dismatling and reassembling of DG set, taking out the unserviceable parts and replacement of unserviceable parts with new one, conforming to their respective part Nos for the DG set of capacity 82.5 /100 KVA, Makes: Cummins/ Kirloskar DG Set complete all as specified and directed by the engg-in-charge Note:- (i) Machining of various parts like cylinder head and nut bolts and washers, and small washers are inclusive in above rates (ii) Spare parts shall be measured and paid for saperately under respective items here in after as "supply only" (iii) Repairs to DG set will be carried out by authorised agent as approved by GE.

Supply only the following items for 82.5 /100 KVA capacity DG set :-

Cylinder liner assembly

Piston

Piston ring

CR Bearing

Main Bearing

Water Pump

Head Gasket

Set of Joint

By Pass Hose

Turbo Pipe

Hose clamp

Valve

Valve seat insert

Valve seat exhaust

valve Guide

Valve oil seal

Fuel pipe (inlet & outlet pair)

Material and Labour for disconnecting the oil cooler of any make / any model from the existings locations duly removing of all mechanical connections and taking down from the engine for complete servicing, opening into parts and cleaning throughly by using with chemical cleaning and pressure testing, refixing back to its original positions with 'O rings / gasket complete for the DG sets upto 75 to 100 KVA capacity all as specified and directed by Engr-in-charge.

M & L for decoupling the alternator from the engine , taking down from the foundation, transportation to civil workshop, dismantling complete to take out the rotor assembly, properly cleaning of alternator /stator windings/bearings etc with blower & dry cloth, varnishing & drying up of the windings in suitable furnace to improve insulation value, greasing of the bearings with high quality grease, tightening of terminal connections incl replacing worn out sleeves/ nuts/bolts/washers etc, re-assembling complete, shifting back & refixing at original position, making perfect alignment with the engine assembly and testing all as specified and as directed for the DG set of Capacity 15 to 35 kVA

M&L for reparing the doors of sound proof encloser of DG Set any size /any make/ any capacity for proper closing and locking using new SS hinges/door handles / in built locks complete all as per existing and as directed

Material and labour for Painting to the DG Sets of 15 to 100 KVA capacities by preperation of old painted surfaces, cleaning & removing of existing rust grease oil spot etc, priming with aluminium red-oxide and then applying 1st grade of synthetic enamelled spray paint (two coat) of approved make, brand and colours (includes cost of paint) including fuel tank, foundation base, exhaust pipe and panel board incl writing SM/MES Number in approved style and color complete all as specified and directed. Make : ASIAN PAINT/BERGER/NEROLAC Note: Contractor will apply one layer of grease over specification plate / any written letter before painting and clean same after painting. Rates for same is deemed to be included into item quoted rates.

Supply and fixing in repairs heavy duty copper cable battery leads (Red and black ) complete all as specified and as directed.

Supply and fixing in repairs heavy duty brass terminals (as per sample) suitable for battery terminals complete all as specified and as directed.

Supply and replacing LED type indicator lamp red, yellow or blue complete all as specified and as directed.

M&L for draining out the engine oil from the sump, opening the sump cover cleaning properly to remove old oil stucked to the surfaces, replacing the worn out gaskets/nuts/bolts/washers & refixing the sump cover complete all as directed for 750 KVA capacity DG set engine complete all as directed.

All as per item No 17 here in before but 75 to 100 KVA capacity DG set.

All as per item No 17 here in before but 35 to 62.5 KVA capacity DG set.

All as per item No 17 here in before but 15 to 30 KVA capacity DG set.

Material and Labour for dismantling turbocharger assembly from the DG set, transportation to work shop for repair, cleaning and carrying out inspection of each components/ spares segregation of serviceable spares for reuse including decarbonising machine, cutting, grinding polishing etc. and re-assembling the turbocharger with replacement of spares parts and refixing on existing position complete all as directed for 75 to 100 KVA capacity DG set engine complete all as directed.

All as per item No 21 here in before but 15 to 30 KVA capacity DG set.

Supply and filling engine oil grade 15W40 premium grade complete all as directed . Make :- Castrol/HP/Servo

Supply and filling distilled water in batteries for top up complete all as directed .

M&L for draining out old coolant from the engine radiators of DG Sets of any capacity and make, flushing the radiator tubes with distilled water and filling with new coolant, refixing the drain plug properly and filling the complete radiator with new pre mixed coolant complete all as specified and as directed.Make: Servo/HP/Castrol

Supply and replacing V belt set (for fan & alternator) for 750 KVA DG set engine of make Kirloskar/CG/Cummins etc all as per existing complete all as specified and directed

All as per item No 26 here in before but 75 to100 KVA capacity DG set.

All as per item No 26 here in before but 35 to 62.5 KVA capacity DG set.

All as per item No 26 here in before but 15 to 30 KVA capacity DG set.

Disconnecting and taking down the defective self starter of any make from the DG set , transporting to civil workshop dismantling the same to take out defective parts and repairing by replacement of carbon brushes, armature coil, field coil, bush, bearings and bendix pinion, clutch assembly and other related components, reassembling & shifting to original location, refixing on the DG set , making all connections and testing for smooth functioning complete all as directed for DG set of capacity 15 KVA to 30 KVA. Note :- Self starter of same type and capacity shall be arranged by the contractor and fixed at the DG set for the duration the original one is under repairs. Unit rate quoted will be deemed to include the expenditure for the same and no extra payment shall be made on this part.

All as per item No 30 above but capacity 35 to 62.5 KVA

All as per item No 30 above but capacity 75 to 100 KVA

All as per item No 30 above but capacity 750KVA

Supply and replacement of ( AVR ) automatic voltage regulator Diode forward and reverse, rotating rectifier assembly, half wave phase controlled thyristor type, complete all as per existing type & size for DG set of capacity 15 to 30 kVA.

All as per item No 34 above but 35 to 62.5 kVA

All as per item No 34 above but capacity 75 to 100 KVA

Disconnecting and taking down the leaking radiator from DG set engine assembly, transporation to civil workshop for repairs , cleaning the complete radiator for detecting the leakage and repairing the leaking portion (Tubes/fins/tank etc) by soldering/brazing ,cleaning of all water tube with suitable cleansing agent & water preasure & removing the complete sludge and dust from inside the tank, replacing worn out hose pipes & clamps etc, shifting & refixing at original site and testing for proper working complete all directed for the DG set with capacity 15 to 30 kVA

All as per item No 37 above but 35 to 62.5 kVA

All as per item No 37 above but capacity 75 to 100 KVA

Disconnecting and taking down the defective dynamo from the DG set engine, shifting to civil workshop for repairs, strip opening to remove unserviceable parts , repairing by replacing of armature coil, carbon brush, field coil, clutch patti bearing, refixing magnetic steel laminates, replacing pole head and pole shoe, bearings of shaft ball/roller/sleeve type, and other related items of the assembly , re-assembling and refxing the same on original position and testing complete for the DG set of capacity 15 to 30 kVA

All as per item No 41 above but 35 to 62.5 kVA

All as per item No 42 above but capacity 75 to 100 KVA

Servicing of DG Set 750 KVA capacity of Make :- Cummins , taking down worn out replaceable parts such as fuel filters (Primary and secondary) , by pass filters, lube oil filters, air cleaner filters, water separators filters,lube oil flexible pipe, hose pipes, clamps etc and replacing the same with same size, make and capacity of parts, and including testing complete all as specified and directed. Note:- (i) Spare parts shall be measured and paid for saperately under respective items here in after as "supply only" (ii) Servicing will be carried out by authorised agent as approved by GE.

Supply only the following items for 750 KVA capacity DG set :-

Fuel filter assembly with 'O' rings

Lube filter assembly with 'O' rings

Bypass filter assembly with 'O' rings

Water separator with 'O' rings.

Air cleaner element set.

All as per item No 44 here in before but 75 to 100 KVA capacity, Make : Kirloskar/Cummins DG set

Supply only the following items for 75 to 100 KVA capacity DG set :-

Fuel filter assembly with 'O' rings.

Lube filter assembly with 'O' rings.

Bypass filter assembly with 'O' rings.

Water separator with 'O' rings.

Air cleaner element set.

All as per item No 44 here in before but 35 to 62.5 KVA capacity, Make : Kirloskar/Ashok Layland DG set

Supply only the following items for 35 to 62.5 KVA capacity DG set :-

Fuel filter assembly with 'O' rings.

Lube filter assembly with 'O' rings.

Bypass filter assembly with 'O' rings.

Water separator with 'O' rings.

Air cleaner element set.

All as per item No 44 here in before but 15 to 30 KVA capacity, Make Ashok Leyland/Kirloskar DG set

Supply only the following items for 15 to 30 KVA capacity DG set :-

Fuel filter assembly with 'O' rings.

Lube filter assembly with 'O' rings.

Bypass filter assembly with 'O' rings.

Water separator with 'O' rings.

Air cleaner element set.

Disconnecting and taking down the fuel pump from the DG engine assembly, transporting to civil workshop and repair & calibration of FIP of DG Set including replacement of plungers, washer manifold, injection nozzles etc all as required and testing after refixing on engine and setting the rated RPM all as specified and directed for DG set of capacity 75 to100 kVA

All as per item No 52 above but 15 to 30 kVA

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