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| 1 | Comprehensive maintenance of capston units at drydock area by overhauling and servicing of capston gearbox, motor and other connected items complete as per OEM maintenance chart and employing one technician and one helper with tool and equipment required for maintaining the complete system.the following jobs are required to perform during maintenance period at varunasurya dock and EOC pocket.(Total-14 NOs.)a) Dismantling of complete Capstan Unit comprisingthe following This capstan to be landed in firm’s compelete workshop post dismantling.(i) Dismantling the platform(ii) Disconnection of the supply from the panel and the capstan motor. (iii) Draining of lubrication oil in container(iv) Loosening of all the foundation bolts(v) Lifting the complete unit which comprises of capstan motor, fluid coupling, braking system, reduction gear, drum and panels for controlling the capstan. |
| 2 | b) Assessment of the material of capston as per the activities specified.(i) Chipping of the loose rust of the gear box casing for all the capstans.(ii) The gauging of the plate thickness to be carried out and preparation of report for all the capstans.c) Civil foundation Assessment and foundation repairs as per the assessment/ survey report.(i) The civil structure survey of the foundation is to be carried out and assessment report is to be submitted along with suggestions on serviceability and fabrication of foundation.(ii) Repair/ Renewal of fondations along with renewal of foundation bolts (if required as suggested by user department) |
| 3 | d) Repair to Gear box and gear train to be carried out as per the activities specified.(i) Gear box sump inner surface to be painted as per the following paint scheme:Paint:(ii) Anti- Corrosive - 02 coats(iii) Top Coat - 01 coat (iv) Renewal of bearings of the gear train post inspection by the QC/ User rep of the NDV.(v) During assembly of the gear box following to be checked:The backlash, meshing of the gear’s impression.e) Overhauling of Electrical Motor & EHT Brake system includingThe one-time maintenance/ overhauling of the motors is to be carried out and the report is to be submitted.(i) Maintenance of Electro Hydro Thrust brake unit, motor, renews bearings to be carried out.(ii) Insulation test to be carried out and to be enhanced if found less by varnishing, hot air or baking. |
| 4 | (iii) The dynamic balancing of the rotating unit along with submission of report and calibration certificate of the balancing machine.f) Repair of Electric main starter & remote-control circuit panels:Renew/ Repair the main starter panel box and remote panel box of control circuit, repair/ renew all sub component of the control circuit.i) Renew/ Repair the main starter panel box and remote panel box of control circuit, repair/ renew all sub component of the control circuit. g) Dismantling of complete Capstan Unit comprisingthe following This capstan to be landed in firm’s compelete workshop post dismantling.(i) Dismantling the platform |
| 5 | (ii) Disconnection of the supply from the panel and the capstan motor. (iii) Draining of lubrication oil in container(iv) Loosening of all the foundation bolts(v) Lifting the complete unit which comprises of capstan motor, fluid coupling, braking system, reduction gear, drum and panels for controlling the capstan.h) Assembling of complete Capstan Unit:Assemble the capstan as complete unit with alignment of the fluid coupling.(i) Renewal of the brake liner & adjustment of the clearance and spring tension.(ii) Assembling of the capstan unit.(iii) Finish PCC work with white wash. |
| 6 | Load testing of capston Gear system including providing artifical load once in the contract period and furnishing test report by the certified testing agency to the department all as specified and directed.Note:- Artificial load shall be arrange by department. Handling and transporting of artifical load from the store yard to work site shall be arrange contractor. |
| 7 | M & L for painting of the external area of capston with one coat of enemal painting and two coat anti crrosive pant complete all as specifed and directed. |
| 8 | Provision of Synthetic Nylon water proof material covers to prevent the capstans from weather conditions for each Capstan.Customised weather proof enclosure to be provided as user convenient complete all as specified and directed. |
| 9 | Supply of following spares additionally to carryout the above mentioned jobs suggested by OEM manual/ user department to carryout periodical routine maintenance for each capstan as and when required as mentioned below :- |
| 10 | MAIN CONTACTORS, SIEMENS, 3TA 28 |
| 11 | OLR, THERMAL TYPE RANGE, 50-90 AMPS |
| 12 | HRC FUSES WITH BASE, 250A, 500V |
| 13 | HRC FUSES WITH BASE, BAKELITE, 10A |
| 14 | INDICATION LAMPS, BAKELITE, 10A |
| 15 | PUSH BUTTONS, (Each), 10A, 500V |
| 16 | PUSH BUTTONS, (NC), 10A, 500V |
| 17 | SELECTOR SWITCH, 2 WAY, 10A, 500V |
| 18 | CABLE CONNECTORS, 150A, 500V, 3 SLOTS |
| 19 | CABLE CONNECTORS, 10A, 500V, 10 SLOTS |
| 20 | CABLE CONNECTORS, 10A, 500V, 20 SLOTS |
| 21 | MOTOR BEARINGS, DE BEARING AS PER SAMPLE |
| 22 | CABLE LUGS, PIN LUGS(COPPER), 50 SQ.MM LUGS(COPPER) |
| 23 | MAIN SWITCH ISOLATOR, L & T, FN-125, 415V, 125A |
| 24 | MAIN CONTACTORS, SIEMENS, 3TA 28 |
| 25 | SINGLE PHASE PREVENTER, VSP 415V D1-MINELAC |
| 26 | AUX. CONTACTOR, 10A, 500V, 4NC+4Each, COIL 220V |
| 27 | AUX. CONTACTOR, 20A, 500V 4Each, 1NC+1Each COIL 220V |
| 28 | Current Transformer, CT\"S, 150/5A |
| 29 | DIGITAL AMMETER WITH INBUILT SELECTOR, 0-150, CONZERVE |
| 30 | DIGITAL VOLTMETER WITH INBUILT SELECTOR, 0-500V, CONZERVE |
| 31 | CONTROL TRANSFORMER, 415/220V, 1000VA |
| 32 | CONTROL TRANSFORMER, 415/220V, 500VA |
| 33 | SELECTOR SWITCH, 4 WAY, CHANGEOVER SWITCH, 32A,500V |
| 34 | MOTOR BEARINGS, NDE BEARING AS PER SAMPLE |
| 35 | RUBBER BUSH & PINS FOR ELECTROMAGNETIC BRAKE DRUM (COUPLING) |
| 36 | LONG BOLT WITH SPACER |
| 37 | OIL SEAL (GEAR BOX) |
| 38 | GEAR BOX BEARINGS, SKF-30228 |
| 39 | GEAR BOX BEARINGS, SKF-30226 |
| 40 | CIRCLIP (DIA 135*3) |
| 41 | GEAR HUB |
| 42 | SPUR GEAR (Z-69, DP-2.5, F-150) |
| 43 | OUTPUT SHAFT |
| 44 | INTERMEDIATE PINION (INTEGRAL WITH PINION-I) SHAFT (Z-22, DP-2.5, F-170) |
| 45 | HELICAL GEAR (Z-76, M-7, F-120) |
| 46 | FLANGE |
| 47 | CROWN WHEEL (Z-48) |
| 48 | LOCKING SLEEVE |
| 49 | TAIL Pinion (BEVEL TEETH) Z-7 |
| 50 | CIRCLIP |
| 51 | Bearing Holder circlip |
| 52 | PACKING RING |
| 53 | PACKING PIECE |
| 54 | COUPLING SET IN PAIRS |
| 55 | COUPLING RUBBER PACKING |
| 56 | FLUIDOMAT COUPLING (COMPLETE) |
| 57 | GEAR BOX BEARINGS, SKF-30228 |
| 58 | Drive power card 1GBTPCB of VFD 75 KW ,3 Ph 415 V Model ATV610DT5N4 of schineder or equivalent of ABB/ Siemens |
| 59 | Over voltage/under voltage relay |
| 60 | Temperature sensor |
| 61 | Fused terminal with 2A/6A fuse link. |
| 62 | Control transformer 415/110 VAC ,500 VA. |
| 63 | Space heater, 220VAC. |
| 64 | Rectifier unit (215-500V) precima PMG 480-s |
| 65 | Capston gear box Lubrication oil |
| 66 | Repair/maintinance ofmultiple section ofcapston Panel board busbar chamber, swich gear chamber, metering chamber cable termination/tray chamber after opening front/top/side/back cover by using forced air pressure andbrushes, cleaning of all dust/durt, complete cleaning of out side surface of panel board using suitable cleaning agents, tighting of all nuts & bolts of busbar/switchgear, repair/replacement to defective metering wiring from ACB/MCCB/CT to meter and replacement of defective meters, CTs, indicator lamp, metering terminal blocks, MCB, replacement of all aluminum cable lugs, nuts-bolts-washers, replacement of defective Panel knob/door knob and hinges and painting complete panel all as specified and directed |
| 67 | Note:- (i) Panel Meter, indicator lamp, MCB,busbarand CT will be measured and paid seperately as supply only. (ii) required aluminium cable lugs, metering cables and nuts-bolts-washers shall be inclusive of quoted rate. (iii) Servicing/maintinance of ACBs measured seperatelly. (iv) cable connection disconnection included inclusive of quoted rate. |
| 68 | Supply ,Installed and testing Of VVFD drive to operate 100 HP A.C.motor, 960 RPM speed,twin direction 415 Volt and 50Hz freequence complete suitable for capston motor controlsystem all as specified and directed. Make -ABB/schneider/siemens |
| 69 | M & L forXLPE insulated, screened, PVC bedded,galvanised steel strip or wire armoured,electric power cables (heavyduty) with aluminium conductor, 11000 volts Earthed, grade cross sectional area 240 sqmm 3 core complete all as specified and directed. |
