Tender For Repair/Maintenance To Dg Sets In Aor Of Mph And Other Location Under Ge (U) Udhampur.; 1 Material and labour for carrying out‘B’ check for various capacity DG setby replacing the following accessories of DG set, complete all as specified and directed by Engr-in-Charge.(a) Oil filter.(b) Air filter.(c) Fuel filter.(d) By pass filter.(e) Engine oil .(f) coolent.Note :-(i) B checks shall be carried out by OEM of company .Certification of the same shall be submitted.(ii) Engine oil & coolent shall be measured and paid separately.(iii) Labour & transportation shall be arranged by contractor and quoted rate deemed to be inclusive in the unit rate.Make of DG set shall be repaired : KIRLOSKER/ CUMMINS /GREAVES. 2 Description all as per item No.1.00 here-in-before but for 160 to 250 KVA DG set, complete all as specified and directed by Engr-in-Charge. 3 Description all as per item No.1.00 here-in-before but for 100 to 125 KVA DG set, complete all as specified and directed by Engr-in-Charge. 4 Description all as per item No.1.00 here-in-before but for 30 to 75 KVA DG set, complete all as specified and directed by Engr-in-Charge. 5 Description all as per item No.1.00 here-in-before but for 10 to 30 KVA DG set, complete all as specified and directed by Engr-in-Charge. 6 Taking out the existing battery of DG setand repair/replacement ofunserviceable/faulty lead acid Battery of capacity 150 AH, 12V including connecting to DG set, complete all as specified and directed by Engr-in-Charge. 7 Description all as per item No. 2.00 here-in-before but of 180 AH, 12V including connecting to DG set, complete all as specified and directed by Engr-in-Charge. 8 Renewal/ repairs/supply of unserviceable automatic voltage regulator (AVR) 10 to 75 KVA DG set including all spares, testing, complete all as specified and directed by Engr-in-Charge.Make:- As per OEM approved make. 9 Renewal/ repairs/supply of unserviceable automatic voltage regulator (AVR) above 100 KVA and upto 250 KVA DG set including all spares, testing, complete all as specified and directed by Engr-in-Charge.Make:- As per OEM approved make. 10 Dismantling of exhaust pipe of the DG set 63 KVA to 250 KVA capacity by unscrewnuts and bolts and taking down the pipe with muffler, cleaning the silencer,welding works if required ,painting and fixing the same in its original position, complete all as specified and directed by Engr-in-Charge . 11 Disconnecting all the incoming and outgoing rubber hoses and draining out the water from the choked radiator assembly of the existing make and model and various capacitiesDG sets and taking down the radiator assembly by unscrewing all mechanical/electrical connections from the existing mounting, transporting the same to civil workshop for carrying out servicing, opening the top and bottom covers ofradiator assembly, cleaning thoroughly the chocked pipe of the radiator by using chemical detergent, lime caustic soda, cotton etc., cleaning of all the deposited sediments in the pipes/tubes including arresting of leakage by means of soldering, brazing and transporting back to site and refixing the same in its original position with suitable size nuts, bolts and washers and Anti vibrating mounting(AVM) pads as required as per OEM recomendation etc., for the DG set of capacity up to 250 KVA, complete all as specified and directed by Engr-in-Charge. 12 Renewal /supply of battery cable leads of copper conductor and with brass lugs terminal, for the 12V, 150/180 /200 AHbatteries to self stater as that of existing size and length, complete all as specified and directed by Engr-in-Charge. 13 Taking down the U/S belt from the DG set Supply ,test and commissioning of belts suitable for fan, alternator, dynmo, radiator of the DG Set of following capacity, complete all as specified and directed by Engr-in-Charge :- (a) 10 KVA to 250 KVA. 14 Engine oil 15W/40 for toping up upto the required level and service,complete all as specified and directed by Engr-in-Charge.Make :- CASTROL/ INDIAN OIL/ SERVO 15 Replacement /supplyof Line Voltage Monitors (LVMS) of existing make of DG set of 100 KVA to 250 KVA capacity listed parameters including testing, complete all as specified and directed by Engr-in-Charge.Make :- OEM recommended 16 Replacement/supply of Line Voltage Monitors (LVMS) of existing make of DG set capacity up to100 KVAcapacity listed parameters including testing, complete all as specified and directed by Engr-in-Charge.Make :- OEM reccommended 17 Drain out the fuel from the fuel tank of DG set of any size/capacity and keeping it in separate container safely, disconnecting all the fuel lines and other mechanical connections and taking out the fuel tank for cleaning, internally and externally by removing all the accumulated dirt/ sediment, leak testing the tank and welding/ brazing including one coat ofsynthetic enamel paint, refixing the tank in its original position, replacing the drain plug and PVC pipe, calibrating the fuel tank, refilling the drained out fuel back into the tank and marking of liters in gauge and provision of locking arrangements, complete all as specified and directed by Engr-in-Charge. 18 Drain out the fuel from the fuel tank of capacity 24 KL Diesel tank and keeping it in separate container safely, disconnecting all the fuel lines and other mechanical connections and taking out the fuel tank for cleaning, internally and externally by removing all the accumulated dirt/ sediment, leak testing the tank.incltwo coat of synthetic enamel paint,refilling the drained out fuel back into the tank and marking of liters in gauge and provision of locking arrangements, complete all as specified and directed by Engr-in-Charge. 19 Removing the defective charging dynamo/alternator of capacity 12/24 Volt DC any make, model, ofcapacity 10 to 100 KVA and opening it by removing all nuts and bolts, cleaning with necessary cleaning agent and overhauling, lubricating of therewinding the damaged winding of field coilswith super enameled copper wire suitable forsame existing size/guage & reconnecting the same, refixing back in original position including making all necessary electrical/mechanical connections,testing and commissioning, complete all as specified and directed by Engr-in-Charge. 20 Removing the defective charging dynamo/alternator of capacity 12/24 Volt DC any make, model, ofcapacity 100 to 250 KVA and opening it by removing all nuts and bolts, cleaning with necessary cleaning agent and overhauling, lubricating of therewinding the damaged winding of field coilswith super enameled copper wire suitable forsame existing size/guage & reconnecting the same, refixing back in original position including making all necessary electrical/mechanical connections,testing and commissioning, complete all as specified and directed by Engr-in-Charge. 21 Inhibitor corrosion (coolant additive concentrate) required for top up, complete all as specified and directed by Engr-in-Charge. 22 Supply and topping up of acid mixture suitable for lead acid batteries of 12 volts, complete all as specified and directed by Engr-in-Charge. 23 Supply and topping up of distilled water suitable for lead acid batteries of 12 volts, complete all as specified directed by Engr-in-Charge. 24 Supply and fix Battery brass terminaland jelly, complete all as specified and directed by Engr-in-Charge. 25 Calibration ofthe U/S Fuel injection pump assy ,Test & commisioning ofFuel injection pump assy after calibrationinclusive of injector system for following DG set, complete all as specified and directed by Engr-in-Charge :-Note :- Calibration shall be performed before erection of FIP.(a) 10 KVA to 250 KVA 26 Repair and replacement of the U/S Fuel injection pump assy install ,Test & commisioning ofFuel injection pump assy inclusive of injector system for following DG set, complete all as specified and directed by Engr-in-Charge :-Note :- Calibration shall be performed before erection of FIP.(a) 10 KVA to 160 KVA 27 (b) 160 KVA to 250 KVA 28 Overhauling of injector nozzles of capacity 125 KVA to 250 KVA test & commisioning of injector nozzles inclusive of injector system, complete all as specified and directed by Engr-in-Charge. 29 Overhauling of injector nozzles of capacity 40 KVA to 100 KVA test & commisioning of injector nozzles inclusive of injector system, complete all as specified and directed by Engr-in-Charge. 30 Overhauling of injector nozzles of capacity 10 KVA to 40 KVA test & commisioning of injector nozzles inclusive of injector system, complete all as specified and directed by Engr-in-Charge. 31 Repair to Self starter Motor, 12/24 volts, suitable for existing DG set above 10 KVA to 100 KVA capacity including making all necessary electrical/mechanical connection as per recomendation of OEM of DG Set & dismantling/taking out old unserviceable self starter Motor from existing position, complete all as specified and directed by Engr-in-Charge.Make :- Approved by OEM of DG set. 32 Repair to Self starter Motor, 12/24 volts, suitable for existing DG set above 100 KVA to 250 KVA capacity including making all necessary electrical/mechanical connection as per recomendation of OEM of DG Set & dismantling/taking out old unserviceable self starter Motor from existing position, complete all as specified and directed by Engr-in-Charge.Make :- Approved by OEM of DG set. 33 S & F Diesel benjo Hose pipes of 1.0 Meter length with both edges brass clampsof existing modelsuitable to DG Set of capacity up to 125 KVA including taking down old unserviceable one, complete all as specified and directed by Engr-in-Charge. 34 S & F Diesel benjo Hose pipes of 1.0 Meter length with both edges brass clampsof existing modelsuitable to DG Set of capacity above 125KVAup to 250 KVA including taking down old unserviceable one, complete all as specified and directed by Engr-in-Charge. 35 Repairs to Alternator of following DG Sets, transporting the same to theOEM authorised service center/work shop and carrying out the repairs such as taking out the burnt out winding and rewinding the alternator with copper wire of same guage turns and weight, checking of commentator, brushescomplete and refixing the same in its existing position after transporting back to the site and connecting up electric connections with suitable lugs complete and testing ,complete all as specified and directed by Engr-in-Charge :-Note: Copper winding material will be measured and paid seperately under relevant Item 36 (a) DG set Upto 100 KVA capacity. 37 (b) DG Set of capacity 100KVA to 250 KVA. 38 Supply only High conductivity copper conductor winding material including necessary insulation material required, complete all as specified and directed by Engr-in-Charge. 39 Overhauling ofTurbo Charger Assemblyduly disconnecting the mechanical and electrical connections from for the following DG sets, opening and thoroughly checking to carry out repairs complete to the Turbo Charger Kit and spares as required at site including any mechanical and reassembling and refixing the same after repair to its original position and reconnecting the same including testing, complete all as specified and directed by Engr-in-Charge:- 40 (a) DG Sets of capacity10 to 100 KVA. 41 (b) DG Sets of capacity 100 KVA to 250 KVA. 42 Supply and fix newTurbo Charger Assembly(In replacement) duly disconnecting the mechanical and electrical connections from for the following DG sets, opening and thoroughly checking to carry out repairs complete to the Turbo Charger Kit and spares as required at site including any mechanical and reassembling and refixing the new turbo charger assembly to its original position and reconnecting the same including testing, complete all as specified and directed by Engr-in-Charge:- 43 (a) DG Sets of capacity10 to 100 KVA. 44 (b) DG Sets of capacity 100 KVA to 250 KVA. 45 Dismantling & disconnecting all connection of upper and lower engine, cylinder heads,lines,thrust valve,valve seat inlet and exhaust,main bearing set,inlet valve and exhaust valve,head gasket,CR bearing,hose set,ring set,valve seal,liner O ring,oil seal set,O rings kit,Crank shaft ,Connecting roads,Push roads,Value Guides, Valves seats,piston assy and all connecting items like ring ,washer,gasket etcfrom diesel engine and sent to OEM authorised Service center for calibration and repairs by replacing the all above said spares such as cylinder heads,lines,thrust valve,valve seat inlet and exhaust,main bearing set,inlet valve and exhaust valve,head gasket,CR bearing,hose set,ring set,valve seal,liner O ring,oil seal set,O rings kit,Crank shaft ,Connecting roads,Push roads,Value Guides, Valves seats ,piston assy and all connecting items like ring ,washer,gasket etc and re-assembling to its original position with necessary fittings and O rings for the following capacities including testing, complete all as specified and directed by Engr-in-Charge.Note : Any minor or major spares other than above is included in the quoted rates. 46 (a) DG Sets of capacity10 to 100 KVA. 47 (b) DG Sets of capacity100 to 250 KVA. 48 Earthing complete with GI earth plate electrode 60cmx 60cmx 3mm thick buried directly in ground earth pit not less than 2.25 mtr deep below normal ground level) with top edge of plate not less than 1.5m below ground level, connecting to the Aluminium earth strip 32 x 6mm dia, by means of nuts, bolts,check nuts and washer etc of galvanised iron and earth lead protected by provision of GI pipe medium grade 40mm bore from earth elelctrode to test pointincl provn of concrete pit in PCC (1:2:4) type B-1 using 20mm graded stone agagregates with 40mm thick cover of RCC (1:2:4) reinforced with XPM sheet (weight not less than 4Kg/Sqm) and frame of angle iron 25 x 25 x 6mm with lugs 2 Nos and with 8mm dia MS bar handle made to shape, GI pipe medium grade 20mm bore pipe for watering perforated at bottom 1.75 mtr long placed on top edge of earth plate, common salt and charcoal filling test point with fixing arrangement, funnel, wire mesh and earth work in hard/dense soil, returning in and removal of surplus soil to a distance not exceeding 50mtr, complete all as specified in electrical plate No 3 of SSR Part I and connection to earth test point including testing on completion, complete all as specified and directed by Engr-in-Charge. Note:- Item of earthing includes cost of 7.5m long aluminiumstrip of 32 x 6mm size and protection pipe of 40mm bore GI medium grade. 49 Supply and fix tappet cover for DG set of 10 KVA to 100 KVA capacity with all listed parameters as per OEM recommendation including testing, complete all as specified and directed by Engr-in-Charge. 50 Supply and fix tappet cover for DG set of 100 KVA to 250 KVA capacity with all listed parameters as per OEM recommendation including testing, complete all as specified and directed by Engr-in-Charge. 51 Replacement of controller display suitable to DG set controlls/commands of 10 KVA to 100 KVA capacity with all listed parameters as per OEM recommendation including testing, complete all as specified and directed by Engr-in-Charge. 52 Replacement of controller display suitable to DG set controlls/commands of 125 KVA to 250 KVA capacity with all listed parameters as per OEM recommendation including testing, complete all as specified and directed by Engr-in-Charge. 53 Replacement of microprocessor based control unit suitable to DG set controlls/commands ofup to 100 KVAcapacity with all listed parameters as per recomendation including testing, complete all as specified and directed by Engr-in-Charge. 54 Replacement of microprocessor based control unit suitable to DG set controlls/commands of 100 to 250 KVA capacity with all listed parameters as per OEM recommendation including testing, complete all as specified and directed by Engr-in-Charge. 55 Replacement of microprocessor based Display unit(HMI) suitable to DG set controlls/commands of 10 KVA to 250 KVA capacity with all listed parameters as per OEM recommendation including testing, complete all as specified and directed by Engr-in-Charge. 56 Replacement of Actuator suitable to DG set controlls/commands of 10 KVA to 125 KVA capacity with all listed parameters as per OEM recommendation including testing, complete all as specified and directed by Engr-in-Charge. 57 Replacement of Actuator suitable to DG set controlls/commands of 125 KVA to 250 KVA capacity with all listed parameters as per OEM recommendation including testing, complete all as specified and directed by Engr-in-Charge. 58 Supply and mounting AVM(anti vibration) pads for Engine,radiator and alternator of DG set of any capacity including labour charges for proper mounting and all necessary misc accessroies, complete all as specified and directed by Engr-in-Charge. 59 Supply and fix Asbestos rope suitable for existing DG set including,complete all as specified and directed by Engr-in-Charge. 60 Supply and fixing battery charger 230 V AC input and output 24 V / 12 V 10 amps charging rating IMPS type with fully auto control in charging and floating with boost system, complete all as specified and directed by Engr-in-Charge. 61 Supply and fix fuel tank lock and key suitable for existing DG set including removing old un seviceable one, complete all as specified and directed by Engr-in-Charge. 62 Supply and fix Door lock and keywith door rod assy in side the door suitable for existing DG set including removing old un seviceable one, complete all as specified and directed by Engr-in-Charge. 63 Supply and fix Door hinges suitable for existing DG set including removing old un seviceable one, complete all as specified and directed by Engr-in-Charge. 64 Taking down the U/S control cable from DG set & AMF panelSupply ,install ,Test & commisioning ofcontrol cable from DG set alternator unit to AMF unit offollowing sizeDG set, complete all as specified and directed by Engr-in-Charge :-(a) 120 sq mm 65 (b) 150 sq mm 66 Replacement of on load change over switch, 63 Amps capacity, suitable for 3 phase, 4 pole, 415 Volts,front handle operated suitable in open execution type for fixing in existing panels including necessary lugs,glands.,nuts,bolts inclduing taking down old unserviceable one, complete all as specified and directed by Engr-in-Charge. 67 Replacement of on load change over switch, 125 Amps capacity, suitable for 3 phase, 4 pole, 415 Volts,front handle operated suitable in open execution type for fixing in existing panels including necessary lugs,glands.,nuts,bolts inclduing taking down old unserviceable one, complete all as specified and directed by Engr-in-Charge. 68 Replacement of on load change over switch, 250 Amps capacity, suitable for 3 phase, 4 pole, 415 Volts,front handle operated suitable in open execution type for fixing in existing panels including necessary lugs,glands.,nuts,bolts inclduing taking down old unserviceable one, complete all as specified and directed by Engr-in-Charge. 69 Supply and fix Contactor Assembly &PLCs wtih under+ over voltage relay for existing DG set AMF panel of capacity up to 100 KVA including removing old un seviceable one, complete all as specified and directed by Engr-in-Charge. 70 Supply and fix Contactor Assembly &PLCs wtih under+ over voltage relay for existing DG set AMF panel of capacity 100 to 250 KVA including removing old un seviceable one, complete all as specified and directed by Engr-in-Charge. 71 Servicing to AMF panel of capacity10 KVA to 100 KVA fromthe Circuit systemby checking the following parameters for proper functioning, complete all as specified and directed by Engr-in-Charge :-a) Checking / fault diagnosis of Isolator ,Battery charger,Auto/Manual selector switch & Current Transformer. b)Checking the Electronic circuit boards with phase indication lamp 220 V. c) Checking the functionality& caliberation of Power Relays (Cranking Relays).d) Checking the Mechanism of isolator module and vcb moduleNote :- Rates of all spares and Parts including repair and replace are included in quoted rate. 72 Servicing to AMF panel of capacity100 KVA to 250 KVA fromthe Circuit systemby checking the following parameters for proper functioning, complete all as specified and directed by Engr-in-Charge :-a) Checking / fault diagnosis of Isolator ,Battery charger,Auto/Manual selector switch & Current Transformer. b)Checking the Electronic circuit boards with phase indication lamp 220 V. c) Checking the functionality& caliberation of Power Relays (Cranking Relays).d) Checking the Mechanism of isolator module and vcb moduleNote :- Rates of all spares and Parts including repair and replace are included in quoted rate. 73 Supply and fix Copper lugs 120 sqmm to 150 sqmm suitable for 1100 Volt copper cable suitable for existing DG set including removing old unserviceable one, complete all as specified and directed by Engr-in-Charge. 74 Taking down the U/S primary diesel feeder pump assy from DG set Supply ,install ,Test & commisioning of primary diesel feeder pump assy inclusive of all spare and parts system for following DG set, complete all as specified and directed by Engr-in-Charge :-Note :- Calibration shall be performed before erection of pump.(a) 10 KVA to 125 KVA 75 Taking down the U/S primary diesel feeder pump assy from DG set Supply ,install ,Test & commisioning of primary diesel feeder pump assy inclusive of all spare and parts system for following DG set, , complete all as specified and directed by Engr-in-Charge :-Note :- Calibration shall be performed before erection of pump.(a) 125 KVA to 250 KVA 76 Complaint/Inspection & visit the power house for checking the fault occure in DG set of any capacity ,Rectify the fault at own arrangement and report to JE /Engr in charge after rectifying the fault and proper testing and commissioning of DG. All spare abd parts will be paid and measured separately at site, complete all as specified and directed by Engr-in-Charge. 77 Supply and fix Hour meter operating on 240 V suitable for existing DG set including removing old un seviceable one, complete all as specified and directed by Engr-in-Charge. 78 Supply and fix garage mats for floor absorbe liquides oil drips pan with waterproof Rubber backing layer for protection of floors. Size of mat2 mtr x 4 mtr forDG set at substation, complete all as specified and directed by Engr-in-Charge.
