REGULAR MAINTENANCE OF FLAP GATES AND CAISSON GATES OF VARUNA DRYDOCKS AT NAVAL DOCKYARD VISAKHAPATNAM UNDER GE (I) (DM) VISAKHAPATNAM

Routine maintenance (chipping, cleaning, greasing and overhauling) for rod gearing arrangement (of different length with Dia between 25-45mm, head stock with bevel gears) of valves of variable sizes of caisson gates and associated accessories including universal joints and bushes with minor defect rectifications, if any (Standard/ Specification – SS 316, MS, EN 8 for bevel gear) all as specified and directed. (a) Checking the rod gearing system from the gear box to the valves spindle to be checked every operation visually. (b) All the knuckle joints of the rod gearing system shall be lubricated (c) Visually checking the rod gearing system at every welding joints/knuckle joints any crack/bend/deflection to be rectified

(d) The meaning scale of the rod gearing system/pedestal to be verified the findings shall be rectified to measure the actual opening of the valve (e) Marine gears shall lubricated all bevel gear system. (f) The material (SS316/EN8) repaired for the rod gearing system knuckle shall be scope of the contractor. (Unit 01 Nos = Above scope for one rod gearing arrangement) Material and equipment’s required for undertaking the maintenance/ repairs is responsibility of the vendor.

Visual inspection and INSITU maintenance / minor repairs (if any) for Sluice valves of Size NB 600 including joints, nut and bolts with washers, stuffing box, connecting pipes, rubber gasket, seals and associated fittings for the system (IS specifications). The Maintenance of the valves to include the under mentioned :- (a) Check and rectifying the leakage through stuffing box/gland, body-demo, dome – stuffing box and side flange gaskets. (b) Check and rectifying noise/vibrations while opening or closing the valve (c) Check and rectifying condition of body seat/wedge seat ring faces scratches, dent marks, intactness (d) Check and rectifying if may minor condition of spindle & spindle nut/yokes sleeve threads. (e) Close by-pass valve disconnecting the extension year rod connection, Try to flush away the external object by opening & closing the valve & creating flow to flush it away. Open flanged joint to reach the object and remove it manually.

(f) Replace the graphite gland packing rings. (g) Tighten the gland gradually and uniformly. (h) Replace the gland packing. (i) Tighten the joint fasteners gradually and uniformly body dome/dome stilting box gaskets. (j) Replace the nitrile rubber gaskets. (k) Re-tighten the flanged joint. (l) remove parallel/angular gap between valve and pipe flanges and rectify (m) Replace spindle nut, spindle also may be replaced if the thread are excessively worn-out or damaged (n) Disconnection the damnatory joint all these procedures requires the upstream and downstream piping and removal of the valve from the gate. Note:- Spares for items shall be measured and paid separately Unit 01 Nos = Above scope for one valve)

All as per item No. 2.00 above, but for NB 300mm dia, valves.

All as per item No. 2.00 above, but for NB 350mm dia valves.

All as per item No. 2.00 above, but for NB 450mm dia, valves.

All as per item No. 2.00 above, but for NB 250mm dia, valves.

All as per item No. 2.00 above, but for NB 150mm dia, valves.

All as per item No. 2.00 above, but for NB 80mm dia, valves.

Visual inspection, Overhauling/ repair/renewal for three way cock of variable sizes including associated system, joints and accessories (Standard/ Specification - SS 316) all as specified and directed.

Surface preparation, cutting, fabrication, fixing and welding of 12mm and above thick MS plate including fabrication of associated structures such as T channels, rolled sections, angles etc. followed by DP test confirming to IS standards complete all as specified and directed. Note: (i) Renewal of structural/steel plates is to be carried out in very restricted area inside the gate tanks such as scuttle air/water tidal chambers etc., (ii) Contractor shall be submit the DP test certificate for obtaining the approval from DS dept (iii) Marking, cutting and welding etc shall be inspeted during execution and contractor shall obtained approval from DS dept (iv) MS plate will be issued by MS dept free for fixing. (v) All T&P and other fit-out required for executing the repairs work is contractor's supply.

Repair/ renewal of pipes for Railing of 40mm NB, 35mm, 4mm thick (MS Galvanised) frame work of water tanks and similar work complete confirming to IS 1239, medium grade complete all as specified and directed. Note :-Material and equipment’s required for undertaking the repairs is vendors liability

Supply and fixing the 600mm dia, flooding pipe lines in the air chamber inside gate. The work includes :- (a) Pipe is to be rolled as per site, make out of 20mm thick plate confirming to IS 2062. (b) Transportation, lowering into the gate chambers. (c) Cutting, unscrewing bolts from 600mm dia. Sluice valve securing the valve in position, fabricate as per actuals, cross and bend and welding with ID 600mm dia flanges etc,. (d) Renewing of 10mm thick nitrile gasket, bolts, nuts and washers including assembling of 600mm dia sluice valve all as directed. Note:- The above works are to be carried out at -10 MRL from dock floor level Inside the gate, the entire systems to be tested and proved. Working area is limited & restricted necessary ventilation, blowers, oxygen to be included in the scope.

All as per item No.12.00 above, but for NB 450mm dia pipes.

All as per item No. 12.00 above, but for NB 300mm dia pipes.

All as per item No. 12.00 above, but for NB 250mm dia pipes.

All as per item No. 12.00 above, but for NB 350mm dia pipes.

All as per item No. 12.00 above, but for NB 150mm dia pipes.

All as per item No. 12.00 above, but for NB 80mm dia pipes.

All as per item No. 12.00 above, but for NB 50mm dia pipes.

Material and labour in repair maintenance of Sea Chest Grills of Caisson gates, renewing the corroded MS rod and flanges as required at site and made out of MS plate confirming to IS 2062 complete all as specified and directed.

Valve operation of Varuna Caisson gates, No. of valves in the gates required to be operated during the operation – 26) during docking/ undocking operations in Varuna and Surya Dry-dock including all associated activities required to be undertaken prior operation as per SOPs. (a) All associated valves in the ‘C’ deck ‘B’ deck air chambers are checked visually for the fitness of the operation of the gate (b) Pre-operational procedures/a trail run in the dry condition. (c) Repair & rectifying the defects observed in the findings.

(d) Check the measuring scale is closed condition/opening conditions as required for the operation of the gate. (e) The operation may go upto round the clock and that labours over time and material in the scope of work. Whatever extra payment for the overtime for the labour and the materials shall be born by the contractor. (f) All the above work is to be carried out as per the instructions user/ND(V) and also user Dept will monitor the work and to be done as per the instructions given by MDS/rep of ND(V). Note: Overtime for the Firm personnel’s involved in Valve operations during evolutions is vendor’s liability. Material and equipment’s required for undertaking the checks prior valve operation is responsibility of the vendor.

Supply and fix musical note neoprene rubber water seal bar extruded of size 50mm dia. bulb 225mm web X 50mm flange and as per site requirement including removing old rubber seal along with wooden fenders and re fixing the same , applying sealing compound for ensuring leak proof complete all as specified and directed.

Supply and fix in repairs, installation and proving of submersible pumps in the capacity of 40 TPH along each with starter panel(40 TPH) each along with all associated accessories and join connection in air chambers complete all specified and as job directed. Head- 15 mtrs, pump wt <50kgs, motor rating-5HP complete all as specified and directed, Make :- Mody/Lubi or equivalent

Supply and fix in repairs, installation and commissioning of submersible pumps in the capacity of 20 TPH along each with starter panel(20 TPH) each along with all associated accessories and join connection in air chambers complete all specified and as job directed. Make :- Mody/Lubi or equivalent

Routine Daily Maintenance Inspection And In-Situ Essential Repairs Of Dry Dock Flap Gates Namely Varuna Flap Gate In Respect of the following items of work: (a) Visual inspection and Easing of rod-greasing mechanism of valves including greasing of bolts, rod gearing arrangements of all Valves, Spindles of all valves and checking for full closing and opening positions etc. (b) Visual inspection & minor defect rectification in respect of Wooden Fenders, Bearing Surfaces, Guard Rails, Ladders, Landing Plates, Manhole Hatches, Covers etc (c) Visual inspection & minor defect rectification in respect of Tidal Chambers, End Tidal Chambers, Access Chambers, Scuttle Tanks, Drainage Tanks etc… (d) Inspection and minor defect rectification of all manholes to ensure water tightness including conduct of Chalk Impression Test.

(e) Inspection and operation of valve with full closing and opening of all intake and discharge valves, LP Air Line and Pressure Gauges, Eye hooks on side shells, Bollards etc.. (f) Removing And lubricating the 600mm/800mm dia pulleys fitted on the Flap Gate and refixing the same including necessary grease, worn out bolts, nuts and washers etc. (Unit 01 Nos = Completion of above scope in one day) Note: (i)The above items of work shell be carried out with the following minimum numbers of tradesmen: Pipe Fitters 3 No’s, Valve/Engine Fitters 03 No’s, Cutter 1No, Fabricator 02 No’s, Welder 03 No’s, Helper 3 No’s, With Connected Equipment Like Gas Cutting Equipment, Welding Machine & Grinding all related equipment (ii) The steel plates required for welding upto 1 Sqm Shall be arranged by MDS Dept. The size of plate required more than 1 Sqm shall be produced by the contractor and the same shall be measured and paid under relevant Item of BOQ.

(iii) Replacement Of Bolts, Nuts Washers etc. Shall Be Measured And Paid Under Relevant Items (iv) Grease required for one day work is 1kg, welding electrode suitable for welding plate thickness of 10mm to 20mm -70nos( one pack) per day, gland packing – 1kg, rubber gasket and the same shall be include in the rate quoted by the bidder. (v) Safety gear, safety tallies as per international norms required for the above operation in progress shall be arranged by the contractor and the cost shall be include in the rate quoted.

Material and labour for MS flange (single) 150mm dia. made out of MS plate IS 2062 complete all as specified and directed.

Material and labour for MS flange (single) 100mm dia made out of MS plate IS 2062 complete all as specified and directed.

Hydro jet blasting (3000psi) of the above water area (external), surface preparation (chipping, cleaning) followed by application of paint scheme :- (a) 1 coat of Primer (Zinc chrome primer) (Dft. 1 X 50) (b) 2 coats of A/C (Anti Corrusive paint) (Dft. 2 X 200) (c) 3 coats of A/F paint (Anti Fouling paint), (Dft: 3x150 microns) Note :- Paints will be issued by ND (V) as free for applying (Make :-Akzo Nobel/ Jotun/ Sigma)

Hydro jet blasting (3000psi) of the internal tanks, surface Preparation (chipping, cleaning) followed by application of paint scheme :- (a) 1 coat of Primer (Zinc chrome primer) (Dft. 1 X 50) (b) 2 coats of A/C (Anti Corrusive paint) (Dft. 2 X 200) (c) 1 coat of tie coat (Dft : 1 x 125 microns) (d) 3 coats of A/F paint (Anti Fouling paint), (Dft: 3x150 microns) Note :- Paints will be issued by ND (V) as free for applying (Make :-Akzo Nobel/ Jotun/ Sigma)

Inspection of Underwater areas of gate with Qualified diving team with safety supervision for identification of damaged area with Videography of the required location as directed by the user. Unit (1 No = 6 hours of dived operation) complete all as specified and directed.

Sealing of gate leakages by suitable quantity of Cotton/Oakum fibres to arrest leakages by underwater diving post docking operations to prevent dock wall deterioration. (1 Nos = Arresting of entire leak throughout gate length and height post closing of gate post operation) complete all as specified and directed.

NOTE: The unit rate quoted for all the above items includes working in a confined area/required Hiring of services for OSHAS compliant scaffoldings and necessary safety gears.

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