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| 1 | Comprehensive maintenance including Repairs/ Refurbishment of 40 Ton Capacity Varuna Flap Gate Operating Winch operated systems includes 50 Ton Pusher and Power Pack complete system all as directed by Engr-in-charge.A. DAILY ROUTINES(i)Clean the winch & Hydraulic pusher pump free from dust, moisture, grease, oil etc.(ii) Check and maintain the minimum oil level in the hydraulic pump tank. If necessary top up with hydraulic oil.(iii) Turn the pump coupling & winch coupling by hand. Make sure both are free. B. WEEKLY ROUTINES(i)Check the earth connections and motor cables are not loose.(ii) Check that motor does not vibrate and does not make excessive noise whilst running.(iii) Check that motor operates satisfactorily in both the directions from the local control panel. |
| 2 | iv. Check and ensure that the EHT breaks operate satisfactorily.C. THREE MONTHLY ROUTINES(i) Check and record the insulation, resistance of motor EHT break, winch motor from the VFD drive/ bypass system, hydraulic motor, solenoid valve, contactor panel and control circuits.(ii) Check all connections for tightness in the ICTP switch gear contactor panel, local control panel, motor, EHT break.(iii) Check and eliminate leaks in the Hydraulic lines.(iv) Grease the moving parts and the wire ropes with the proper grease.(v) Check and make the pulleys free to operate. Check the condition of the rope physically.(vi) Clean the panels thoroughly |
| 3 | D. SEMI-ANNUAL ROUTINES(i) Performa detailed inspection of Winch components(ii) Replace worn or damaged seals and gaskets(iii) Check winch motor for signs of wear or damageE. ANNUAL ROUTINESi. Overhaul the winch, pushers & Hydraulic pump and its valves, as per makers hand book.a) Clean, chip and paint Winch & Pusher include primer and 02 coats of paintii. Overhaul the winch motor & hydraulic motor for:-a) Dismantle the motor & carry out the defecation.b) Clean all parts of the motor.c) Clean the stator windings thoroughly and impregnate with insulating varnish.d) Renew the bearings if necessary. |
| 4 | e) Clean the bearings & repack with the grease XG-274, ensuring that the bearings are not over greased.f) Renew all fasteners.g) Paint all parts of the motor.h) Reassemble the motor, fit the motor on the foundation & align with winch include transportiii. Overhaul the magnetic break for:-a) Dismantle the breakb) Clean the brake shoes and roughen them.c) Renew oil in the break as OEM recommendedd) Check & record the resistance value & resistance of the break solenoidse) Re-assemble & adjust the break and switch gear include transportiv. Overhaul the panels for:-a) Clean the panels thoroughly.b) Check all the contacts for wear and tear, replace all worn out contacts for by-pass arrangement and carryout calibration for VFD & PLC panels. |
| 5 | c) Clean all contacts and dress if necessary.d) Check all timers for correct operation.e) Check and calibrate the overload trip device.f) Paint all panels include primer and Paint as Marine suitedv. Overhaul the solenoid valves. Carryout trials of the valvesvi. Overhaul the Automation Systema) Servicing/ Overhaul & Calibrate the SCADA & PLC components b) Repair/ Replace & calibrate the different Sensors fitted to the flap gate & winch system for automationc) Renew & Replace the power & control cables if required as sufficient, suggested by user department.d) Servicing/ Repair 02 in no wired PCs and 03 in no wireless think pads and Calibrate which are connected to Automation system Note:-All routine work costfor item no.1 to 4 are inclusive of coated rate. |
| 6 | Comprehensive maintenance including Repairs/ Refurbishment of 25 Ton Capacity Surya Flap Gate Operating Winch Mechanism includes 40 Ton Pusher and Power Pack complete system all as directed. |
| 7 | Comprehensive maintenance including Repairs/ Refurbishment of PLC & SCADA Automation System includes starters and LT panels for 40 Ton Capacity Varuna Flap Gate Operating Winch Mechanism includes 50 Ton Pusher and Power Pack system alongwith the following items complete system all as directed by Engr-in charge.a) Servicing/ Overhaul & Calibrate the SCADA & PLC components b) Repair/ Replace & calibrate the different Sensors fitted to the flap gate & winch system for automationc) Renew & Replace the power & control cables if required as sufficient, suggested by user department.d) Servicing/ Repair 02 in no wired PCs and 03 in no wireless think pads and Calibrate which are connected to Automation system |
| 8 | A. Daily Maintenance i. Visual Inspection- Cech for damage, corrosion, or water on the load cell and cablesii. Verify calibration- Ensure the load cell is calibrated correctlyiii. Zero Checks - Verify the load cell reads zero when no load is appliediv. Check Connections- Ensure all electrical connection securedB. Monthly Maintenancei. Cleanliness- Clean the load cell and surrounding area to prevent dirt and moisture buildupii. Cable Inspection- Inspect cables for damage, wear, or corrosioniii. Electrical Checks- Verify electrical connections and wiringiv. Calibration Checks- Perform a calibration check to ensure accuracyC. Quarterly Maintenancei. Load Cell verification- Verify the load cell\"s accuracy using a known weight or calibration standard |
| 9 | ii. Temperature compensation- Verify temperature compensation is functioning properlyiii. Sensor Checks- Check the load cell\"s sensor for proper functionData logger check- Check data loggers for proper function and data accuracyD. Semi-Annual Maintenancei. Detailed inspection- Perform a detailed inspection of the load cell and surrounding componentsii. Calibration adjustment- Adjust calibration as needediii. Load cell cleaning- Clean the load cell\"s sensing areaiv. Electrical system check- Verify the electrical system is functioning correctly |
| 10 | E. Annual Maintenancei. Full calibration- Perform a full calibratin of the load cellii. Load cell replacement- Replace the load cell if necessaryiii. System upgrade- Consider upgradng the load cell systemiv. Maintenance records- Review and update maintenance records |
| 11 | Supply only the following Spares as required shall be measured and paid separately under relevant items of Sch \"A\" during trouble shooting/ breakdowns in any cases. View criticality & priority of the machinery, after finding the defect of material/ item/ spare, to be provided at site within a week & such kind of agreement to be taken in MOU if the firm is out of OEM. |
| 12 | VFD 75KW |
| 13 | Dynamic break resistor (Any Reputed Make suitable to site condition) |
| 14 | ROTARY HANDLE AND SPEADER LINKS |
| 15 | R Y B INDICATIONS |
| 16 | SELECTOR SWITCH |
| 17 | 75KW/160A CONTACTOR |
| 18 | 140-180A OLR |
| 19 | S/D TIMER |
| 20 | 160A SFU WITH FUSES SET |
| 21 | Wires and wiring terminations as site required |
| 22 | Aux Contactor |
| 23 | Hooter (Audio-Visual Alarm) |
| 24 | VFD 30KW |
| 25 | VFD 11.25KW |
| 26 | Dynamic break resistor for 30Kw (ANY REPUTED) |
| 27 | Dynamic break resistor for 11.25Kw (ANY REPUTED) |
| 28 | 63A 4P MCCB |
| 29 | 125A 4P MCCB |
| 30 | ROTARY HANDLE AND SPEADER LINKS |
| 31 | R Y B INDICATIONS |
| 32 | SELECTOR SWITCH |
| 33 | 30KW/40HP CONTACTORS |
| 34 | 26-50A OLR |
| 35 | S/D TIMER |
| 36 | 63A SFU WITH FUSES SET |
| 37 | Wires and wiring terminations as site required |
| 38 | Aux Contactor |
| 39 | 63A 4P MCCB |
| 40 | ROTARY HANDLE AND SPEADER LINKS |
| 41 | R Y B INDICATIONS |
| 42 | SELECTOR SWITCH |
| 43 | 11KW/40HP CONTACTORS |
| 44 | 50-636 OLR |
| 45 | S/D TIMER |
| 46 | 100A SFU WITH FUSES SET |
| 47 | Wires and wiring terminations as site required |
| 48 | Aux Contactor |
| 49 | ANALOG INPUT 4-20mA 16CH |
| 50 | ANALOG INPUT 0-10V 8CH |
| 51 | ANALOG OUTPUT 4-20mA 8CH |
| 52 | SMPS 230/24V DC,10AMPS |
| 53 | RELAYS 24V DC COIL VOLATGE 2C/O |
| 54 | TOUCH PANEL 10 OR 12 INCH HMI DISPLAY |
| 55 | FIBER OPTIC CABLE |
| 56 | FIBER OPTIC TO ETHERNET CONVERTOR |
| 57 | ETHERNET SWITCH FOR COMMUNICATION FROM PLC TO HMI AND MEDIA CONVERTER AND NECESSARY CONNECTED ITEMS MAKING THE UNIT COMPLETELY FUNCTIONAL COMPLETE ALL AS SPECIFIED AND DIRECTED |
| 58 | Supply only CPU Intel Core i9 14th Gen, 24GB Ram, 1TB SSD, RTX 4070 Graphic Card/ Latest upgraded |
| 59 | Supply only 27 to 34 Inch Visual Display Unit to support with CPU |
| 60 | Supply only Pointing Device (Mouse) to support with CPU |
| 61 | Supply only Input Device (Keyboard) to support with CPU |
| 62 | Supply only Split Screen/ Multi Screen Splitter along with power cord and HDMI/ VGA cables |
| 63 | WinCC SCADA system software LATEST UPDATED VERSION/ V7.5SP1, RC512 (512PowerTags), runtime /configuration software on DVD, Floating License, license key on USB flash drive, Class A, 5 languages (de, en, fr, es, it), Please observe product release: support. industry, siemens .comSIOSentryID:109772767 |
| 64 | PLC & VFD software Logic Development, SCADA screens animation (analog) development Alarm Trends, Graphs development Report system Development |
| 65 | Step7 V16/ LATEST VERSION, WinCC Professional Engineering Software & Starter Software |
| 66 | TIAA PLC programming software |
| 67 | LVDT sensors with Audio setup for pushers (02 in No for Each Flap Gate) |
| 68 | Load Cell (01 in No for each flap Gate) |
| 69 | Load Cell Indicator (Wired & wireless - Each Gate having 01 Wired & 01 Wireless) |
| 70 | Level sensor and associated Display Accessories (04 in No for each flap gate) |
| 71 | Serviceing/Overhaul the Local panel & Remote Panel for wich systemreplace all worn out contacts for by-pass arrangement and carryout calibration for VFD & PLC, overload trip device for panel andtwo coat painting complete all as specified and directed. |
