SPECIAL REPAIR REPLACEMENT OF DG SET NO 03 OF CAPACITY 1010 KVA11KV AT INS VAJRAKOSH AND STARTER CONTROLS OF WATER SUPPLY INSTALLATIONS AND CONNECTED WORKS AT SITE E UNDER GE SB KARWAR

Amount

M&L for taking down carefully complete acoustic insulation chamber of 1010 KVA,11 KV DG set and alternator by disconnecting electrically and mechanically in presence of a senior OEM authorised engineer taking to workshop for rewinding including removing of burnt out coils and insulating materials completely and cleaning with CTC and rewinding with the same guage winding wires all as per OEM specifications and varnishing, baking/ heating of main stator including checking of all accessories, painting of alternator bring back to site including installation, aligning and testing in the presence of OEM authorised engineer complete all as specified and as directed.

Detailed scope of work:- Preliminary Inspection:- a) Depute a senior engineer along with man power to site with all T&Ps for removal of acoustic, removal of coupling bolts, connections, loading to suitable vehicle. b) Preliminary inspection of stator , rotor, existing armature & existing field both electrical and mechanical and submission of relevant reports and photos. c) Checking of all accessories like RTD, BTD, space heater for the alternator. d) Cleaning of stator, rotor, existing armature & existing field along with related parts.

Stator rewinding a) Debrazing of end connections b) Removal of old copper coils from the stator slots. c) Conducting hot spot test on stator core and report of the same will be submitted. d) Preparation of new coils using 99.99% electrolytic grade copper conductor. e) Insertion of new coils in to slots locking of coils using existing specifications class F insulation scheme. f) End connections brazing providing HT cables for output leads. g) Pre heating in oven, carrying out global VPI and curing in oven. h) Carrying out gel coat on stator winding. j) Testing of complete stator winding after VPI and before final assembly of the alternator k) Through cleaning of rotor, existing armature and existing field. l) Gel coating m) Dynamic balancing of rotor. n) Final assembly and painting Testing a) IR measurement b)Winding resistance measurement c) HV test & surge comparison test d) Run test

Servicing of 1010 KVA DG set engine B check maintenance of make Cummins, by opening up the rocker and cover, adjusting the rocker arm tappet gap, removing & cleaning the inlet & outlet valves, replacement of tappet cover gaskets, checking & calibration of fuel injection system, removing the diesel feed pipes, cleaning thoroughly & pressure testing, removing the oil sump of engine, cleaning & replacement of Engine Oil , oil filters, fuel fitters, replacement of inlet manifold gasket, draining out diesel from diesel storage tank completely, cleaning the tank & drying, outlet & over flow pipes from tank to engine. including replacement of spare parts as require etc complete including PCB display calibration all as specified and as directed. Notes-:- (i) Servicing of DG setshall be done by authorised service engineer of cummins only. (ii) Spare parts required shall be measured and paid separately as "Supply only". (iii) Unit rate quoted shall be deemed to be included removing and fixing spare parts.

Supply only in repairs to the following items for 1010 KVA DG set :-

a) Element lubricating oil filter HSN/SAC- 84212300

b) Kit fuel filter and ring HSN/SAC- 84213100

c) Kit super bypass filter element HSN/SAC -84212300

d) Seal O ring HSN/SAC - 40169330

e) Valvoline Premium blue 7600/120 ltrs HSN/SAC - 27101980

f) Element air cleaner HSN/SAC - 84213100 ( v-series)

g) Inhibitor corrosion- 205 ltrs HSN/SAC -38200000

h) Display control HSN/SAC - 90329000

j) Card control HSN/SAC - 85439000

k) PCB assembly HSN/SAC - 85439000

l) Kit air cleaner element HSN/SAC - 84213100

m) Gasket Rocker lever to cover of Cat No. 3077198

n)Separator, Fuel water Cat No. 3231787

o)Belt , V Cat No. 210118

p)Gasket , Handhole Cat No. 3077199

q)Gasket , Handhole Cat No. 3078124

r)Battery , Pulse Lite 12 V , 160 AH Cat No. AX1012845

s) Bearing No. DE-NU230MC3

t) Bearing No.NDE-6322MC3

Preparation of the old existing external and internal steel surfaces of canopy/body of existing DG sets/Oil tanks/Panel etc. including removal of disintegrated & detorioted paint either but hand scraping or by blow lamps, applying necessary filler coat and stopping as required and applying two coats of synthetic enamel paint (match with existing colour or as approved/directed) with using spray machine over a coat of red oxide primer on old prepared surfaces complete all as specified and as directed Note : Rates quoted by the contractor shall be deemed to include for writing the MES/SM No and other relevant details with paint in the pattern and style (existing as same) as approved by the Engineer-in-Charge.

S&F Solenoid coil with complete assembly of DG set of capacity 1010 KVA all as specified and as directed. Note : As per sample and approved by the Engineer-in-Charge before incorporate in the work and after testing complete.

Taking down carefully existing old unserviceable 30 HP DOL starter and supply, installation, testing and commissioning of 30 HP DOL starter panels of size 500 mm x 500 mm x 300 mm, dust, moisture and vermin proof totally enclosed IP-55 factory made fabricated from 1.6 mm thick CRCA sheet duly powder coated in existing indoor LT panels floor mounted comprising of following accessories with incoming and outgoing connections as per site requirement complete all as specified and as directed :- (a) 63A 3P 25 KA MCCB, TMD Release, type : Easypact CVS -01 No. (b) Standard extended rotary handle for easy pact CVS 100/160/250 A. - 01 No. (c ) 6A 1P 10KA C curve MSB, type : xC60 - 01 No. (d) AC3: 50 AC1:70A 3P Power contactor, coil : AC, Aux. Contact : 1 NO+1NC - 01 No. (e) 37-50A Thermal overload relay Type IRE - 01 No (f) Auxiliary contact block, front mounting, contacts : 2NO+2NC for LC1E06-E630/LC1E0600-LC1E9500. (g) Red, yellow, blue indicating lamps (LED) 230 V AC - 03 Nos.

(h) Control fuse 2 A - 04 Nos. (j) Ammeter 5 A AC Input - 01 No. (k) Voltmeter 480V, AC input - 01 No. (l) 60/5A 1VA Acc CL-3 ABS insulated Current Transformer - 03 Nos. (m) Red mushroom head (40 mm) Trigger type, press to lock turn turn to release 22.5 mm push button (plastic)- 01 No. (n) Green Flush type 22.5 mm Push Button (Plastic) + NO - 01 No. (o) Red Flush type 22.5 mm Push Button (Plastic) + NC - 01 No. (p) ON/OFF/TRIP indication lamp- 03 Nos. (q) 0.5 Sq mm FR insulated 1 core unsheathed industrial flexible cable-35 RM. (r) 10 Sq mm FR insulated 1 core unsheathed industrial flexible cable-10 RM. (s) 2.5 Sq mm Feed thru screw clamp TB - 10 Nos. (t) 16 Sq mm Feed thru screw clamp TB - 08 Nos.

Taking down carefully existing old unserviceable 150 HP DOL starter and supply, installation, testing and commissioning of 150 HP DOL starter panels of size 700 mm x 700 mm x 350 mm, dust, moisture and vermin proof totally enclosed IP-55 factory made fabricated from 1.6 mm thick CRCA sheet duly powder coated in existing indoor LT panels floor mounted comprising of following accessories with incoming and outgoing connections as per site requirement complete all as specified and as directed :- (a) 250A 3P 25 KA MCCB, TMD Release, type : Easypact CVS -01 No. (b) Standard extended rotary handle for easypact CVS 100/160/250 A. - 01 No. (c) Spreaders (Set of 3) 3P for EasyPact CVS 100/160/250A (d) 6A 1P 10KA C curve MSB, type : Xc60 - 01 No. (e) AC3: 205 AC1:315A 3P Power contactor, coil : AC/DC, Aux. Contact : NA - 01 No. (f) 132-220A Electronic relay Type : LR9-F - 01 No. (g) Additional instantaneous Auxiliary contact block, from mounting, contacts : 2NO+2NC for F Model -LC1D09- LC1D150&LC1F

(h) Red, yellow, blue 22.5 mm indicating lamps LED (Blue Lens) 230 V AC - 03 Nos. (j) Control fuse 2 A - 04 Nos. (k) Ammeter 5 A AC Input - 01 No. (l) Voltmeter 480V, AC input - 01 No. (m) 60/5A 1VA Acc CL-3 ABS insulated Current Transformer - 03 Nos. (n) Red mushroom head (40 mm) Trigger type, press to lock turn turn to release 22.5 mm push button (plastic)- 01 No. (p) Green Flush type 22.5 mm Push Button (Plastic) + NO - 01 No. (q) Red Flush type 22.5 mm Push Button (Plastic) + NC - 01 No. (r) ON/OFF/TRIP indication lamp- 03 Nos. (s) 0.5 Sqmm FR insulated 1 core unsheathed industrial flexible cable-35 RM. (t) Auto/manual switch, Remote Control, Emergency Switch, High & Low pressure controller (5-7 kg) etc

Taking down carefully old defective LT UG cables of any size including cable protection pre cast concrete cover / bricks from the trenches and keeping aside for reuse/disposal complete all as specified and as directed.

Supply, laying, jointing and testing of LT underground XLPE insulated screened PVC bedded, armoured heavy duty electric cable with stranded aluminium conductor, 1100 volts grade of following cross-sectional area conforming to IS-7098 (Part-I) of 1988 laid in trenches/wall/floors/ducts etc fixed with saddle and clamps or passing through pipes complete with cable and connection with proper thimbles, nuts, bolts and washers all as specified and as directed. Note:- Excavation & earth work, sand cushioning and PCC cover for cable protection shall be measured and paid for separately

(a) 25 Sqmm 4 Core

(b) 35 Sqmm 3.5 Core

(c ) 70 Sqmm 3.5 Core

Excavation in trenches not exceeding 1.5m wide and not exceeding 1.5m depth for laying/taking out cable and getting out in soft/loose soil all as specified and as directed.

Returning, filling in soil including spreading leveling, watering and well ramming in layers not exceeding 25cm thick all as specified and as directed.

Removing excavated material not exceeding 50m and depositing where directed at a level not exceeding 1.5m above the starting point all as specified and as directed.

Supply and spread dry river sand in trenches for cable cushioning all as specified and as directed Note:- Punned thickness of sand shall be measured and paid

Supply and laying un-reinforced pre-cast concrete cable cover, class LV, type 1, flat, size 250mm x 150mm x 40mm complete all as specified and as directed.

S&F in repair MCCB 400 Amps 3 Pole 50 KA breaking capacity, 415 volts AC with adjustable thermal magnetic release complete all as specified and as directed.

S&F in repair MCCB 250 Amps 3 Pole 36 KA breaking capacity, 415 volts AC with adjustable thermal magnetic release complete all as specified and as directed.

S&F in repair MCCB 160 Amps 3 Pole 25 KA breaking capacity, 415 volts AC with adjustable thermal magnetic release complete all as specified and as directed.

S&F in repair MCCB 125 Amps 3 Pole 25 KA breaking capacity, 415 volts AC with adjustable thermal magnetic release complete all as specified and as directed.

S&F in repair HRC fuses of blade tag type of 2 to 16 Amps rated at 415 volts AC with breaking capacity of 80 KA all as specified and as directed.

S&F in repair HRC fuses of blade tag type of 20 to 32 Amps rated at 415 volts AC with breaking capacity of 80 KA all as specified and as directed.

S&F in repair HRC fuse link 100 Amps, 415 Volt all as specified and as directed.

S&F in repair HRC fuse link 250 Amps, 415 Volt all as specified and as directed.

S&F in repair HRC fuses holder for HRC fuses all as specified and as directed.

S&F in repair soft starter for 100 HP motor, 140-150 Amps, 415 Volt complete all as specified and as directed.

M/S MANOJKUMAR M NAGARKATTE

cooltech engineering services

ANKIT SHIP REPAIRERS AND SUPPLIERS