Tender For Repair/ Maintenance Of Dg Sets And Connected Works At Af Stn Adampur; 1 Servicing & maintenance of DG sets as per manufacturersmaintenance reference to the entire satisfaction of Engineer-in-Chargeof the under mentioned parts for the following capacity :- (i)Draining out engine/lubrication oil, flushing and pouring new engine oil to DG set including supply and replacement of oil pan/chamber gasket (ii)Supply and fix, primary and secondary fuel filter element Make Bosh complete with gasket/rubber ring, in replacement as per existing sample. (iii) General servicing of DG set by opening of tappet cover/top cover, tappet clearance setting with injector timming adjustment, re-fixing of tappet/top cover including supply and replacement of tappet cover packing set, fixed with shellac/bostic tube. (iv)Tightening of all electrical connections, AVR connections, alternator connections and panel connections (v) Tightening of all the hoses, fuel connections. (vi) Opening of Battery terminals negative and positive,cleaning of posts negative and positive of batterywith ambri paper/regmaar,applying petrolium jelly over the posts,refixing the battery terminals properly.(vii) Filling of coolant to radiator as per required level (viii) Testing of Engine on load for 30 Minutes own cost of contractor. 2 20 KVA to 40 KVA 3 62.5 KVA to 82.5 KVA 4 100 KVA to 140 KVA 5 160 KVA to 200 KVA 6 320 KVA to 400 KVA 7 Repair / Overhauling of DG setRemoving tappet cover and cylinder heads gaskets from DG set, Grinding and polishing of cylinder heads, grinding of valve seats, grinding of inlet and exhaust valve after fixing new seals, calibration of injector, refitting cylinder head and tappets cover, changing of oil and replacement of the under mentioned parts for the following capacity :- (i) Bearing in fan body (ii) Inlet and exhaust valve pair (iii)Valve sheet insert (iv) Inlet and exhaust valve guide (v)Cylinder liner with joint ring (vi)Gasket for head (vii)Gear oil seal (viii) Oil seal all (ix) Thermostate element (x)Hose set (xi) Lub oil Pressure gauge (xii) Flexible pipe (xiii)Starter ring (xiv)Water Pump assy (xv) radiator pipe (xvi) Fuel Pipe (xvii) Branded wrapped belt (xviii) Testing the DG sets on load 8 20 KVA to 40 KVA 9 62.5 KVA to 82.5 KVA 10 100 KVA to 140 KVA 11 160 KVA to 200 KVA 12 200 KVA to 400 KVA 13 Repairing, decarburizing manifolds exhaust system and connected items DG setsincluding replacement of unserviceable asbestos rope on exhaust muffler/silencer including necessary nuts, bolts & washer etc with necessary masonry work as required for the following capacity :- 14 20 KVA to 40 KVA 15 62.5 KVA to 82.5 KVA 16 100 KVA to 140 KVA 17 160 KVA to 200 KVA 18 320 KVA to 400 KVA 19 Repairing, cleaning/servicing of radiator assembly DG setsincluding descaling of tubes with solution, chemicals and compressed air blast including soldering/gas welding of leaking tubes including cutting welding of rusted MS tubes with new tubes, making it leak proof, & re-fixing after testing, for the following capacity :- 20 20 KVA to 40 KVA 21 62.5 KVA to 82.5 KVA 22 100 KVA to 140 KVA 23 160 KVA to 200 KVA 24 320 KVA to 400 KVA 25 Calibration of fuel injector assembly at authorize workshop including replacement of cup, barrel and plunger injector washer etc, and re-fixing to its original position including necessary Service as required, including transportation to workshop and back for the following capacity :- 26 20 KVA to 40 KVA 27 62.5 KVA to 82.5 KVA 28 100 KVA to 140 KVA 29 160 KVA to 200 KVA 30 320 KVA to 400 KVA 31 S&F, Rubber hose pipe set with clamps suitable for the size of DG sets IN REPLACEMENT offollowingcapacity:- 32 20 KVA to 40 KVA 33 62.5 KVA to 82.5 KVA 34 100 KVA to 140 KVA 35 160 KVA to 200 KVA 36 320 KVA to 400 KVA 37 Servicing of alternator / AVR of DG setof any make and type by disconnecting all connecting all electric connections and removing dust from alternator/AVR and checking of wiring complete if burnt replace the wire with same size of conductor and making connection of all components for the following capacity :- 38 20 KVA to 40 KVA 39 62.5 KVA to 82.5 KVA 40 100 KVA to 140 KVA 41 160 KVA to 200 KVA 42 320 KVA to 400 KVA 43 S&F, Oil filter cartage element with O ring of DG set complete IN REPLACEMENTas per existing sample as following capacity:- 44 20 KVA to 40 KVA 45 62.5 KVA to 82.5 KVA 46 100 KVA to 140 KVA 47 160 KVA to 200 KVA 48 320 KVA to 400 KVA 49 S&F, Air filter (both outer & Inner) elementIN REPLACEMENT with O ring forDG set complete as following capacity:- 50 20 KVA to 40 KVA 51 62.5 KVA to 82.5 KVA 52 100 KVA to 140 KVA 53 160 KVA to 200 KVA 54 320 KVA to 400 KVA 55 Cleaning of diesel tank of any size/capaity including replacement of worn-out pipe line and measuring scale and make it leak proof, replacement of connection fuel inlet drain with bush, re-fixing in original position with necessary clamps, nut & bolts, complete all as specified & directed.. 56 S&F, Turbo Charger as per the existing including testing, IN REPLACEMENT complete for the following capacity :- 57 20 KVA to 40 KVA 58 62.5 KVA to 82.5 KVA 59 100 KVA to 140 KVA 60 160 KVA to 200 KVA 61 320 KVA to 400 KVA 62 S&F, Common spare parts of DG setsIN REPLACEMENT complete as following:- 63 Engine oil 15 W 40. 64 Brass terminal heavy duty for battery. 65 Distrilled water 66 Acid mixed water 67 Water temperature gauge sensor 68 Injector overflow pipe 69 Thermostat 70 Fuel feed baby pump 71 Asbestos rope superior quality on exhaust silencer pipe 72 Oil pressure gauge as per existing sample & capacity 73 Temprature gauge for oil / water 74 Fuel/oil pipe lines (High pressure rubber pipe covered with steel armoured) 75 Oil temprature gauge 0-130º C 76 Water temprature gauge 0-130º C 77 DC ammeter 0-50Amps 78 AC ammeter 0-500Amps 79 DC Voltmeter 0-50Amps 80 AC Voltmeter 0-500Amps 81 Frequency meter 82 Tachometer cable 83 Ignition switch DC with Key 84 Oil pressure gauge 0-7 Kg/Sqcm (Cat Part No 46.244.01) 85 Self starter for 12 Volts DC 86 Self starter for 24 Volts DC 87 Stopper 12 v 88 S&F, Rubber Hose pipe different size for radiator,air cleaner to turbo, turbo to sump,injector to filter,filter to tank,filter to tank 89 S&F, Copper battery lead connection IN REPLACEMENT suitable for 2 x 12 V,180 A H battery 1.2 mtr long each for positive & Negative connections and 0.5 mtr long for battery inter connection lead duly pre soldering and fixingof lugs and end copper terminal and testing complete. 90 S&F, Relay 12Volts 25 Amp Cat 111x2-12-60 IN REPLACEMENT complete. 91 S&F, Engine Safety control unit 20 KVA to 140 KVA IN REPLACEMENT complete. 92 S&F, Safety control Unit-ECR-19 A for 160 KVA to 400 KVA IN REPLACEMENT complete. 93 S&F, Maintnance free battery with initially charged 12 volt with 24 months warrenty IN REPLACEMENT as following capacity. 94 88/90 AH 95 150 AH 96 180 AH 97 S&F, Autocut electrical battery charger of10 Amp Unit SMPS with Constant Voltage output with Battery charging Transformer and moulded type rectifier unitIN REPLACEMENT as following capacity. 98 12 DC 99 24 DC 100 S&F, Coolant for DG sets as per DG set Manufacturers recommendations IN REPLACEMENT complete. 101 S&F, Door hinges suitable for DG set sound proof enclosure, of any capacity & make, for smooth opening & closing as IN REPLACEMENT complete. 102 S&F, Door Locks suitable for DG set sound proof enclosure, of any capacity & make, for smooth opening & closing as IN REPLACEMENT complete. 103 S&F, Door Handles suitable for DG set sound proof enclosure, of any capacity & makefor smooth opening & closing as IN REPLACEMENT complete. 104 Repair / overhauling ofDC Alternator by dismantling from the DG set after taking out the fan belt and pulley, replacement of armature coil, carbon etc and re-fixing the same, testing complete for DG set of capacity 20-400KVA, complete. 105 S&F, Fan belt set as per existingIN REPLACEMENT complete. 106 Servicing of self starter assembly of DG setby disconnecting the self starter assembly from the engine and dismantling , cleaning, all accessories,replacing worn-out parts like carbon brushes, penion of existing teeth, bendex bushes, armature, solenoid assy 12 Volt contact plates etc and rewinding the u/s feild coil etc and varnishing complete as following capacity:- 107 12 Volt 108 24 Volt 109 MAINTENANCE / REPAIR WORKS TO AMF PANEL OF DG SETS 110 Maintenance, repair, servicing of automatic mains failure panel 24Volt DC and 440Volt AC supply operated system by locating faults and replacement of userviceable parts and components, complete all as specified and directed, as per following:- (a)Repair of faulty worn out control wiring DC/AC for engine starting and off, with adequate and suitable size copper conductor wire, connected with proper copper lugs & terminals through protection pipe/casing. (b)Repair of worn out/faulty internal wiring of controls and timers, indicating/measuring instruments through various control fuses and relays with suitable and adequate size of copper conductor wire, connected with suitable copper lugs and terminals. (c)Replacement of worn out small control fuses, indicating lamps, various type of copper lugs, thimbles terminals all as deemed necessary or directed including minor spare parts and components in order to make system serviceable and perfectly in working order (d)Testing of system on load. NOTE:- Spare parts IN REPLACEMENT will be measured and paid for separately under respective item of BoQ. 111 S&F, Solid state electronic engine starting relay 12/24 volts DC 112 S&F, Alternator voltage monitor relay 3 phase 415 Volt 113 S&F, Main voltage monitor relay 3 phase 415 Volt 114 S&F, Under voltage monitor relay 3 phase 415 Volt 115 S&F, Solid state electronic timer 0-60 second,24 volts DC 116 S&F, Electronic earth fault relay for alternator protection 24volts DC 117 S&F, Electronic over load relay for alternator protection 24volts DC 118 S&F, Mode selector switch auto/manual test 24 volts DC 119 S&F, Power Contactor MCX 03 catNo. CS 97011, rating 32 Amp , 3 phase 4 pole, 415 volt 120 S&F, Power Contactor MCX 13 catNo. CS 97015, rating 80 Amp , 3 phase 4 pole, 415 volt 121 S&F, Power Contactor MCX 33 catNo. CS 97021, rating 200 Amp , 3 phase 4 pole, 415 volt 122 S&F, Power Contactor MCX 41 catNo. CS 97023, rating 325 Amp , 3 phase 4 pole, 415 volt 123 S&F, Front mounting aux contact block 2 NO + 2 NC catNo. CS 94114, rating 32 Amp , 3 phase 4 pole, 415 volt 124 S&F, VMR relay 125 S&F, Tyre Nylone 16 ply with tube inner of size 6.00-16 for trolly mounted DG sets IN REPLACEMENT complete. 126 Opening / dismantling and taking outexisting unserviceable alternator from DG set and transporting to civil workshop, taking out burnt out winding of stator & rotor and other defective parts from the alternator & includingre-winding of stator with superenamalled copper wire of existing size, H class & re-winding of rotor mainfield coil with superior quality copper strip of existing size, H class including required insullation material viz hardner, varnish, sleeve, mechanical lathework, re-winding of rotary rectifier including all other minor unforseen parts of alternator rrequired in the re-winding and transporting back to site and re-fixing the same in DG set, testing the DG set to entire satisfaction Engineer-in-charge of following capacity/ rating as under: - 127 20 KVA to 40 KVA 128 62.5 KVA to 82.5 KVA 129 100 KVA to 140 KVA 130 160 KVA to 200 KVA 131 320 KVA to 400 KVA 132 S&F, Front operated onload Change over switch200 Amp 4 pole ie-400A ue 415V,AC -23B, ui-1000 A,IS-13947 (P-3) IEC-60947 (P-3) B-10330 as per existing fitted in AMF panel IN REPLACEMENT complete. 133 S&F, Front operated onload Change over switch400 Amp 4 pole ie-400A ue 415V,AC -23B, ui-1000 A,IS-13947 (P-3) IEC-60947 (P-3) B-10330 as per existing fitted in AMF panel IN REPLACEMENT complete. 134 M&L for Spray painting of DG set, Alternator, Panel ,diesel tank and base frame etc. with two coat of synthetic enemel paint as per MES colour code after reparing to broken parts of body with gas welding ,cleaning of old painted surface by rubbing/removing of old paint and making surface reddy for painting to theDG set ofbcapacity upto 400 KVAcomplete all specified and directed. 135 S&F, Battery charger for DC batteries of range 6 Volts to 48 Volts provided with selector switch and with fast and slow charging system, IN REPLACEMENT, etc complete all specified and directed. 136 M&L for Earthing with and including copper earth plate electrode 3.15 mm thick of size 600 mm x 600 mm with 20 mm x 3 mm copper earthing strip complete all as shown in electrical plate No. 3 and as specified in Particular Specifications clause 19.1.2 of contract, IN REPLACEMENT complete all as specified and directed . NOTE: (a) The unit rate includes earthing lead and protection pipe upto 7.5 metre from top of earth plate. (b) Factory made PCC pit with cover shall be fixed at least 500 mm away from earth pit. (c) Earth resstance shall be less than 2 ohm. In case the test results are not found less than 3 ohm, complete earthing shall be redone by the contractor without any extra cost to Govt. 137 NOTES APPLICABLE TO SERAL ITEM NO. 1 TO 34 :- (i) To maintain utmost security at AF Station, contractor will arrange his workmen along with T&P in a manner that nonfunctional DG Set / AMF Panel is made functional swiftly within 24 hour of receiving of complaint from the MES, during entire contract period. (ii) Not withstanding with the provision of Compensation for Delay envisaged under condition 50 of IAFW-2249, General Conditions of Contracts, additional compensation@ Rs. 500/- day will be charged from contractor in case he fails to make the DG Set / AMF Panel functional to the entire satisfaction of Engineer-in-Charge within 24 hour of receiving of complaint from the MES regarding non working DG Set. 138 Note :Amount ofcredit for retrieved materials is mentionedintender documents in pdf form which will be deducted while acceptance of tender offline.
