Tender For Comprehensive Maintenance Of Dg Sets At Various Locations At Af Stn Nal; 1 Labour only for servicing, preventive maintenance, checking, inspection and attending breakdown complaints of DG Set of capacity 400 KVA, including Engine, Alternator, Control Panel, AMF Panel and all associated accessories, complete for ensuring efficient and trouble-free functioning, all as specified and directed by Engineer-in-Charge. The work shall include replacement of unserviceable parts (spares will be measured and paid separately under relevant items).Notes:1. The contractor shall detail qualified technicians to attend to any breakdown of DG Set (Engine/Alternator/Control Panel/AMF Panel, etc.) within 24 hours of reporting. Failure to do so shall attract a penalty of Rs. 1000/- per day for each day of delay, including Sundays and holidays, recoverable from the contractor’s dues.2. Preventive maintenance shall be carried out as per manufacturer’s (OEM) recommendations and approved schedule. In addition to scheduled preventive maintenance, any other maintenance activity required for proper and reliable functioning of the system as per OEM guidelines shall be executed with prior approval of the GE.3. Preventive maintenance shall cover the complete DG Set, AMF Panel, Control Panel, Fire-Fighting Diesel Engine and all associated accessories installed at various locations.4. Maintenance shall be planned and executed in such a manner that overall functioning and availability of the system remain unaffected during the process. 2 Notes for item No. 01 above:5. All items/spares required for replacement shall be measured and paid separately under the relevant items of the Schedule.6. Payment for this item, if claimed during the currency of the contract, shall be released only on completion of each calendar quarter, on a pro-rata (proportional) basis as per satisfactory performance and certification by the Engineer-in-Charge.7. In case the contractor fails to execute any of the works as specified under this item, no payment shall be admissible. The contractor shall ensure availability of technicians to attend breakdowns of any type throughout the contract period, including Sundays and holidays.8. All items/spares required for replacement shall be measured and paid separately under the relevant items of the Schedule. (Reiterated for emphasis and clarity.)9. Minor parts, not specifically mentioned but essential for smooth operation, costing less than Rs. 500/- per job, shall be deemed included in the quoted rate.10. Spare parts and lubricants shall be measured and paid separately under relevant items.11. Labour charges for dismantling/taking down and replacement/refixing of new spare parts as and when required shall be deemed included in the quoted rate.12. Servicing shall be carried out after every 250 hours of DG Set operation or as per OEM recommendation, whichever is earlier.13. The quoted rate shall be inclusive of engine oil required for “B Check” of DG Set. 3 All as per serial item no. 1 above but capacity 250 KVA 4 All as per serial item no. 1 above but capacity 200 KVA 5 All as per serial item no. 1 above but capacity 166.25/ 160/ 180 KVA 6 All as per serial item no. 1 above but capacity 125 KVA 7 All as per serial item no. 1 above but capacity 100/ 110 KVA 8 All as per serial item no. 1 above but capacity 62.5 KVA 9 All as per serial item no. 1 above but capacity 50 KVA 10 All as per serial item no. 1 above but capacity 40 KVA 11 All as per serial item no. 1 above but capacity 30/ 20 KVA 12 Supply only following new spare parts conforming to the existing respective Cat part Nos for DG set of 400 KVA capacity- 13 Fuel filter Element inner with gasket and washer 14 Fuel filter Element outerwith gasket and washer 15 Air Filter Element inner with gasket and washer 16 Air Filter Element outer with gasket and washer 17 OilFilter Element inner with gasket and washer 18 Oil Filter Element outer with gasket and washer 19 Shell fuel filter, 20 Fuel Water Separator 21 Hose flexible 22 Hose Plain 23 V-Belt 24 Supply only following new spare parts confirming to the existing respective Cat part Nos for DG set of 250/ 200KVA capacity- 25 Fuel filter Element inner with gasket and washer 26 Fuel filter Element outerwith gasket and washer 27 Air Filter Element inner with gasket and washer 28 Air Filter Element outer with gasket and washer 29 OilFilter Element inner with gasket and washer 30 Cartridge lubricant oil filter element 31 Ring : Seal 32 Gasket oil pipe 33 Gasket water pipe 34 Hose rubber ring joint 35 Clamp hose ring type 36 Air cleaner bracket for air cleaner 37 Belt : V type 38 Fuel pipe of existing size as specified 39 Supply only following new spare parts confirming to the existing respective Cat parts Nos for DG set of 166.25/ 160/ 180 KVA capacity- 40 Fuel filter Element inner with gasket and washer 41 Fuel filter Element outerwith gasket and washer 42 Air Filter Element inner with gasket and washer 43 Air Filter Element outer with gasket and washer 44 OilFilter Element inner with gasket and washer 45 Oil Filter Element outer with gasket and washer 46 Shell fuel filter, 47 Fuel Water Separator 48 Hose flexible 49 Hose Plain 50 Sensor Temperature 51 V-Belt 52 Supply only following new spare parts confirming to the existing respective Cat parts Nos for DG set of 100/ 110/ 125 KVA capacity- 53 Fuel filter Element inner with gasket and washer 54 Fuel filter Element outerwith gasket and washer 55 Air Filter Element inner with gasket and washer 56 Air Filter Element outer with gasket and washer 57 OilFilter Element inner with gasket and washer 58 Oil Filter Element outer with gasket and washer 59 Spin on filter 60 Fuel filter kit 1.1 ltr 61 Rubber hose 62 V-Belt 63 Hose thermostat to radiator 64 Supply only following new spare parts confirming to the existing respective Cat parts Nos for DG set of 62.5/ 50 KVA capacity- 65 Fuel filter Element inner with gasket and washer 66 Fuel filter Element outerwith gasket and washer 67 Air Filter Element inner with gasket and washer 68 Air Filter Element outer with gasket and washer 69 OilFilter Element inner with gasket and washer 70 Oil Filter Element outer with gasket and washer 71 Hose flexible, 72 Hose Plain, 73 Sensor Temperature 74 V-Belt 75 Supply only following new spare parts confirming to the existing respective Cat parts Nos for DG set of 40/ 30/ 20/ 15 KVA capacity. 76 Oil Filter element iner/outer with gasket and washer 77 Fuel filter Element inner/outer with gasket and washer 78 Air filter element inner/outer with gasket and washer 79 Dismantling of radiator assembly from DG Set of capacity 400 KVA, cleaning the same thoroughly using caustic soda solution, carrying out necessary repairs including brazing of tubes in case of leakage, and re-fixing the radiator assembly in position after testing for proper functioning, complete all as specified and directed by Engineer-in-Charge. 80 All as per serial item no. 8 above but capacity 250 KVA 81 All as per serial item no. 8 above but capacity 200 KVA 82 All as per serial item no. 8 above but capacity 166.25/160/180 KVA 83 All as per serial item no. 8 above but capacity 125 KVA 84 All as per serial item no. 8 above but capacity 100/110 KVA 85 All as per serial item no. 8 above but capacity 62.5 KVA 86 All as per serial item no. 8 above but capacity 50 KVA 87 All as per serial item no. 8 above but capacity 40KVA 88 All as per serial item no. 8 above but capacity 30/20/15 KVA 89 Supply and filling of engine oil 20W/40 multigrade for top-up or refilling of DG Sets of various capacities, makes, models, and locations as specified, including necessary handling and testing for proper level and quality, complete all as specified and directed by Engineer-in-Charge. 90 Supply and filling of anti-corrosive / anti-freeze coolant, suitable for radiators of DG Sets of various capacities, makes, and models, conforming to the manufacturer’s (OEM) specifications and requirements, including necessary handling and testing, complete all as specified and directed by Engineer-in-Charge. 91 Supply and filling of distilled water / acid mixture as required for batteries and radiators of DG Sets of various capacities and makes, including necessary handling, testing and ensuring proper electrolyte level, complete all as specified and directed by Engineer-in-Charge. 92 Disconnecting the self-starter (24V) from the engine body, dismantling the same for inspection, identifying defective components, carrying out necessary repairs, reassembling after replacement/renewal of faulty spares (as required), and refixing the unit in its original position after testing for proper operation, complete all as specified and directed by Engineer-in-Charge.Note:Spares required for replacement shall be measured and paid separately under relevant items of the Schedule. 93 Supply only of the following spares against defective ones for self-starter (24V) suitable for the engine as per OEM fitted with DG Sets of capacities 400 KVA, 250 KVA and 200 KVA, complete all as specified and directed by Engineer-in-Charge. 94 Clutch assembly 95 Bendex pinion 96 Solenoid switch 97 Carbon Brush 98 Armature Field Coil 99 Bush 100 Self armature coil 101 Disconnecting the self-starter (12V) from the engine body, dismantling the same for inspection, identifying defective components, carrying out necessary repairs, reassembling after replacement/renewal of faulty spares (as required), and refixing the unit in its original position after testing for proper functioning, complete all as specified and directed by Engineer-in-Charge.Note:Spares required for replacement shall be measured and paid separately under the relevant items of the Schedule. 102 upply only of the following spares against defective ones for self-starter (12V) suitable for engine as per OEM fitted with DG Sets of capacities 50 KVA, 62.5 KVA, 100 KVA, 125 KVA, 160 KVA, and 180 KVA, complete all as specified and directed by Engineer-in-Charge. 103 Clutch assembly 104 Bendex pinion 105 Solenoid switch 106 Carbon Brush 107 Armature Field Coil 108 Bush 109 S&F (Supply and Fix) Automatic Voltage Regulator (AVR), 24 Volt, suitable for the following capacities of DG Sets, including taking down the old unserviceable unit and fixing the new one in position, testing for proper operation, complete all as specified and directed by Engineer-in-Charge.Make: As per existing make or as approved by the Engineer-in-Charge. 110 24 Volt, Suitable for 400 KVA DG Set, 3 Phase, 415 Volts 111 24 Volt, Suitable for 200/250 KVA DG Set., 3 Phase, 415 Volts 112 24 Volt, Suitable for 100/125/160 KVA DG Set., 3 Phase, 415 Volts 113 Supply, laying, connection, and testing of XLPE insulated, armoured, heavy-duty electric cable with aluminium conductor, 1100 volts grade, of size 70 Sqmm, 3.5 core, laid in trenches, ducts, or fixed to walls/poles as required at site, including all accessories, terminations, and connections, complete all as specified and directed by Engineer-in-Charge. 114 Supply and fixing in repairs of 3-pole power contactor, AC operated, of capacity 300 Amps, provided with auxiliary contacts (2 NO + 2 NC), including connections, testing and commissioning, complete all as per existing sample and as specified and directed by Engineer-in-Charge. 115 Supply and fixing in repairs of 3-pole power contactor, AC operated, of capacity 225 Amps, provided with auxiliary contacts (2 NO + 2 NC), including necessary connections, testing and commissioning, complete all as per existing sample and as specified and directed by Engineer-in-Charge. 116 Supply and fixing in repairs of 3-pole power contactor, AC operated, of capacity 185 Amps, provided with auxiliary contacts (2 NO + 2 NC), including necessary connections, testing and commissioning, complete all as per existing sample and as specified and directed by Engineer-in-Charge. 117 Supply and fixing in repairs of 3-pole power contactor, AC operated, of capacity 22 to 32 Amps, provided with auxiliary contacts (1 NO + 1 NC), including necessary connections, testing and commissioning, complete all as per existing make/type and as specified and directed by Engineer-in-Charge. 118 Supply and fixing in repairs of 3-pole power contactor, AC operated, of capacity 40 Amps, provided with auxiliary contacts (1 NO + 1 NC), including necessary connections, testing and commissioning, complete all as per existing make/type and as specified and directed by Engineer-in-Charge. 119 Supply and fixing in repairs of microprocessor-based controller, suitable for DG Sets of capacities 200 KVA, 250 KVA, and 400 KVA, including necessary wiring connections, configuration, testing and commissioning, complete all as specified and directed by Engineer-in-Charge. 120 All as per serial item no. 23 above but capacity 166.25/160/180 KVA 121 All as per serial item no. 23 above but capacity 125/100/110 KVA 122 All as per serial item no. 23 above but capacity 62.5/50 KVA 123 All as per serial item no. 23 above but capacity 40/30/20 KVA 124 Supply and fixing in repairs of AMF relay card, suitable for DG Sets of capacities 200 KVA and 250 KVA, including necessary connections, testing and commissioning, complete all as specified and directed by Engineer-in-Charge. 125 All as per serial item no. 24 above but capacity 166.25/160/180 KVA 126 All as per serial item no. 24 above but capacity 125/100/110 KVA 127 All as per serial item no. 24 above but capacity 62.5/50 KVA 128 All as per serial item no. 24 above but capacity 40/30/20 KVA 129 Supply only of heavy-duty battery terminals, made of brass, complete with bolts, nuts, and washers, conforming to the sample kept with AGE E/M, complete all as specified and directed by Engineer-in-Charge. 130 Supply only of ignition switch with key, suitable for DG Set as required at site, complete all as specified and directed by Engineer-in-Charge. 131 Supply and fixing in repairs of battery lead, 1.00 metre long, made of 25 Sqmm single core, PVC insulated, multi-stranded copper conductor cable, provided with copper lug on one end and brass battery terminal on the other, including necessary connections and testing, complete all as specified and directed by Engineer-in-Charge. 132 Supply and fixing in repairs of battery charger suitable for 12 Volt battery of AMF panel, including necessary connections, testing and commissioning, complete all as per existing make and as specified and directed by Engineer-in-Charge. 133 Supply and fixing in repairs of battery charger suitable for 24 Volt battery of AMF panel, including necessary connections, testing and commissioning, complete all as per existing make and as specified and directed by Engineer-in-Charge. 134 Supply and fixing in repairs of battery charger suitable for 12 Volt battery, housed in a sheet metal enclosure, complete with voltmeter and ammeter of capacity 10 Amps, and provided with two leads with terminal clamps, suitable for AMF panel, including all necessary connections, testing and commissioning, complete all as per existing make and as specified and directed by Engineer-in-Charge. 135 Supply and fixing in replacement of on-load changeover switch, AC-21 duty, side-handle operated, housed in sheet metal enclosure, four-pole, capacity 100 Amps, suitable for 415 Volts, 50 Hz AC supply, including necessary connections, testing and commissioning, complete all as specified and directed by Engineer-in-Charge. 136 Supply and fixing in replacement of on-load changeover switch, AC-21 duty, side-handle operated, housed in sheet metal enclosure, four-pole, capacity 200 Amps, suitable for 415 Volts, 50 Hz AC supply, including necessary connections, testing and commissioning, complete all as specified and directed by Engineer-in-Charge. 137 Supply and replacement of maintenance-free battery, 12 Volts, 180 AH capacity, including initial charging, connection with suitable DC cable, thimbles, nuts, bolts, and carrying out testing on completion, complete all as specified and directed by Engineer-in-Charge. 138 Supply and replacement of maintenance-free battery, 12 Volts, 150 AH capacity, including initial charging, connection with suitable DC cable, thimbles, nuts, bolts, and testing on completion, complete all as specified and directed by Engineer-in-Charge. 139 Supply and replacement of maintenance-free battery, 12 Volts, 88 AH capacity, including initial charging, connection with suitable DC cable, thimbles, nuts, bolts, and testing on completion, complete all as specified and directed by Engineer-in-Charge. 140 Material and labour for dismantling the dynamo (12 Volt DC) of DG Sets and transporting it to the workshop for overhauling, including replacement of all unserviceable spares, reassembling, refixing to the DG Set, making necessary connections, and testing on completion, complete all as specified and directed by Engineer-in-Charge. 141 Supply and replacement of rubber coupling, nuts, bolts, and washers suitable for DG Sets of capacities 20 KVA to 400 KVA, including alignment of DG Set engine with alternator after replacement, and testing on completion, complete all as specified and directed by Engineer-in-Charge.Note:The cost of tools and plants (T&P) required for dismantling of alternator and engine for replacement of rubber coupling shall be deemed to be included in the quoted rate. 142 Material and labour for repair to alternator of DG Sets of capacities 20 KVA to 100 KVA, including servicing, greasing, cleaning of dust and carbon deposits, replacement of defective rectifier of suitable capacity, and testing of alternator for proper output voltage and load performance, complete all as specified and directed by Engineer-in-Charge. 143 Material and labour for repair to alternator of DG Sets of capacities 110 KVA to 400 KVA, including servicing, greasing, cleaning of dust and carbon deposits, replacement of defective rectifier of suitable capacity, and testing of alternator for proper output voltage and load performance, complete all as specified and directed by Engineer-in-Charge. 144 Material and labour for repairing and welding of doors to main body / AMF panel board and making good the canopy of DG Set / panel board of any capacity, including surface preparation and painting with existing colour, to match the existing finish, complete all as specified and directed by Engineer-in-Charge. 145 Material and labour for dismantling defective alternator from DG Set of capacity 20 KVA to 400 KVA, by disconnecting all internal connections and opening coupling shaft, carefully removing rotor and windings, removing carbon brushes, replacing unserviceable brushes, nuts and bolts, cutting out burnt windings and rewinding the same with suitable size of super-enamelled copper wire as per existing gauge, insulating winding connections using fireproof sleeve and tape, applying varnish, and drying coils in sunlight or oven to remove moisture. The work shall also include painting the alternator body externally, marking MES/SM number, refixing the alternator with engine, ensuring proper alignment of coupling and shaft, reconnecting all electrical connections (internal and external) with suitable copper lugs, meggerring the alternator, and testing under load for satisfactory performance, complete all as specified and directed by Engineer-in-Charge.Notes:(i) Winding wire required for rewinding shall be measured and paid separately under the relevant item of the Schedule.(ii) The contractor shall submit a test report for each repaired alternator, duly signed by the Engineer-in-Charge.(iii) The cost of transportation of alternator from site to workshop and back shall be deemed to be included in the quoted rate. 146 Supply only of super-enamelled copper conductor wire of suitable gauge and size as required for rewinding of alternators of DG Sets of capacities 20 KVA to 400 KVA, complete all as specified and directed by Engineer-in-Charge. 147 M&L for repair and maintenance of AMF / non-AMF panel of any capacity and make of DG Set, including carrying out routine and preventive maintenance checks for ensuring trouble-free and efficient functioning, complete all as specified and directed. The scope of work shall include but not be limited to the following:–(a) Checking all electrical connections and carrying out rectification including necessary wiring as required for proper functioning.(b) Checking all contact points, busbars, and carrying out rectification as required.(c) Checking and replacement of timers (AC/DC type) as required.(d) Checking and replacement of push buttons as required.(e) Checking and repair of selector switches as required.(f) Checking and replacement of indicator lamps as required.(g) Checking, repair or replacement of main and auxiliary contacts/relays as required.(h) Checking and replacement of contact coils as required.(j) Checking and repair of voltmeters and ammeters as required.(k) Checking of auto/manual operating function and rectification if required.(l) Checking of battery charger output voltage and adjustment as required.(m) Cleaning of panel, terminals and associated components.Note: Replacement of unserviceable spares shall be measured and paid separately under relevant items of this schedule.
