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| 1 | HP AIR COMPRESSOR Make - BURCKHARDT,Model - S5W212L,MT - 35172 Skilled manpower to be deployed to carry out the following HP AIR Compressor overhauling works,and satisfactory trials to be shown to the ship/naval trial agencies |
| 2 | A) HPAC MER-35183,HP AIR COMPRESSOR Make - BURCKHARDT,Model - S5W212L,MT - 35172 |
| 3 | Check set points of all safety trips:(a) High lub.oil temperature switch (Set Point - 80 C), Qty - 01(b) High water temperature switch (Set Point - 54 C), Qty -01(c) High discharge air temperature switch (Set Point - 20.5 C), Qty - 01(d) Low lub oil pressure switch (Set Point - 2.5 bar), Qty - 01(e) High discharge air switch (Set Point - 215 bar ), Qty -01(f ) Low water pressure switch (Set Point - 1.4 bar), Qty -01 |
| 4 | Check mechanical seal of water pump. Check the thickness of carbon ring, replace if worn more than 3 mm. (Part No of mechanical seal of water pump - 129 002 300 654) |
| 5 | Replace crankshaft oil seals if found damaged. ( Crank Oil Seal - 129 086 505 101) |
| 6 | Before assembly of cylinder head check oil throw from the cylinders. On completion assemble with new cylinder head gaskets |
| 7 | Clean lub oil cooler. Pressure test on completion. Inspect and replace elastomers during assembling. (Working Pressure : 3 to 6 bar) |
| 8 | Replace all piston rings and oil scrapper rings.(a) Ist Stage (129 000 801 603) ,Qty - 10(b) IInd Stage (129 000 801 903) , Qty - 5(c) IIIrd Stage (129 000 803 003) , Qty - 8(d) IVth Stage (129 000 804 103) , Qty - 10(e) Vth Stage (129 000 805 005), Qty - 12 |
| 9 | Check cylinder liners and cylinder bore for wear. Replace defective liners |
| 10 | Check weardown of Main Bearings and Con Rod Bearings.Note: Replace if weardown is beyond permissible limit.(a) Main bearing (129 002 300 116) , Qty - 04(b) Big end bearing (129 002 300 303) , Qty - 03(c) Needle Roller Bearing (129 002 300 306) , Qty - 03(d) Big end bearing dowell (129 002 300 305), Qty - 06 |
| 11 | Check piston for wear.Replace defective piston.(a) Piston dia 125 mm (129 000 831 601), Qty - 02(b) Piston dia 110 mm (129 002 331 903), Qty - 01(c) Piston dia 70 mm (129 002 333 035), Qty - 01(d) Piston dia 42 mm (129 002 334 135), Qty - 01(e) Piston dia 25 mm (129 002 335 035), Qty - 01 |
| 12 | Check oil pump (housing internal+rotors & gear) and water pump.Carry out Overhauling of pumps. |
| 13 | Carryout chemical cleaning of water cooler. Pressure test on completion (Working Pressue : 3 to 6 bar, Test Pressure - 9 Bar) |
| 14 | Replace concentric valve internals, Sub- microfilters, Micro filters, activated carbon filter and pre filter elements |
| 15 | Carry out alignment of Metaflex Coupling (where fitted) between compressor and motor as per JIC 35172/4000H10. |
| 16 | Safety valve: Check the function of the safety valves. Adjust the pilot air with the pressure reducer 1st stage to 16 bar and check if the safety valve opens at 16 bar.Replace defective safety valves |
| 17 | Non- return valve block: Inspect the components of the non-return valve block. Replace defective valve block |
| 18 | F/W cooler to be removed, Carryout chemical cleaning of cooler, pressure tested to 38 KG/CM2 (from S/W side) Renew MS protectors.Total Qty - 04 |
| 19 | Carry out functional checks and calibration of all instrumentation. Replace defective component.(a) Temp Gauge; Working Range : 0-100 C; Qty - 08(b) Pressure Gauge; Working Range : 0-10 bar, Qty - 08(c) Pressure Gauge; Working Range : 0-25 bar, Qty - 02(d) Pressure Gauge; Working Range : 0-60 bar, Qty - 01(e) Pressure Gauge; Working Range :0-100 bar, Qty - 01(f) Pressure Gauge; Working Range :0-400 bar, Qty - 03(g) Differential Pressure Gauge; Working Range :0.2 to 1.0 bar, Qty - 03(h) Pressure Gauge; Working Range :0-16 bar, Qty - 01 |
| 20 | Undertake sequential trials of compressor. Rectify defects. |
| 21 | Undertake comprehensive checks of control system. Rectify defects. |
| 22 | Undertake checks for blow down (auto drain) system. Rectify defects. |
| 23 | Carry out performance trial of the SW cooling pump(BWL 416) including parameter checks(suction/discharge pressure), vibration trials, insulation/SPM checks on motor, motor startingrunning current checks etc |
| 24 | Overhau and Carry out performance trial of the SW cooling pump(BWL 416) including parameter checks(suction/discharge pressure), vibration trials, insulation/SPM checks on motor, motor startingrunningcurrent checks etc. |
| 25 | Calibrate all instrumentation.Replace defective gauge.(a) Pressure Gauge 0 to 6 bar , Qty - 01 |
| 26 | B) HPAC FWD,35183 HP AIR COMPRESSOR Make - BURCKHARDT,Model - S5W212L,MT - 35172 |
| 27 | Check set points of all safety trips:(a) High lub.oil temperature switch (Set Point - 80 C), Qty - 01(b) High water temperature switch (Set Point - 54 C), Qty -01(c) High discharge air temperature switch (Set Point - 20.5 C), Qty - 01(d) Low lub. oil pressure switch (Set Point - 2.5 bar), Qty - 01(e) High discharge air switch (Set Point - 215 bar ), Qty -01(f) Low water pressure switch (Set Point - 1.4 bar), Qty -01 |
| 28 | Check mechanical seal of water pump. Check the thickness of carbon ring, replace if worn more than 3 mm. (Part No of mechanical seal of water pump - 129 002 300 654) |
| 29 | Replace crankshaft oil seals if found damaged. ( Crank Oil Seal - 129 086 505 101) |
| 30 | Before assembly of cylinder head check oil throw from the cylinders. On completion assemble with new cylinder head gaskets |
| 31 | Clean lub oil cooler. Pressure test on completion. Inspect and replace elastomers during assembling. (Working Pressure : 3 to 6 bar) |
| 32 | Replace all piston rings and oil scrapper rings.(a) Ist Stage (129 000 801 603) ,Qty - 10(b) IInd Stage (129 000 801 903) , Qty - 5(c) IIIrd Stage (129 000 803 003) , Qty - 8(d) IVth Stage (129 000 804 103) , Qty - 10(e) Vth Stage (129 000 805 005), Qty - 12 |
| 33 | Check cylinder liners and cylinder bore for wear. Replace defective liners. |
| 34 | Check weardown of Main Bearings and Con Rod Bearings. Replace if weardown is beyondpermissible limit.(a) Main bearing (129 002 300 116) , Qty - 04(b) Big end bearing (129 002 300 303) , Qty - 03(c) Needle Roller Bearing (129 002 300 306) , Qty - 03(d) Big end bearing dowell (129 002 300 305), Qty - 06 |
| 35 | Check piston for wear.Replace defective piston.(a) Piston dia 125 mm (129 000 831 601), Qty - 02(b) Piston dia 110 mm (129 002 331 903), Qty - 01(c) Piston dia 70 mm (129 002 333 035), Qty - 01(d) Piston dia 42 mm (129 002 334 135), Qty - 01(e) Piston dia 25 mm (129 002 335 035), Qty - 01 |
| 36 | Check oil pump (housing internal+rotors & gear) and water pump.Carry out Overhauling of pumps. |
| 37 | Carryout chemical cleaning of water cooler. Pressure test on completion(Working Pressue : 3 to 6 bar, Test Pressure - 9 Bar) |
| 38 | Replace concentric valve internals, Sub- microfilters, Micro filters, activated carbon filter and pre filter elements. |
| 39 | Carry out alignment of Metaflex Coupling (where fitted) between compressor and motor as per JIC 35172/4000H10. |
| 40 | Safety valve: Check the function of the safety valves. Adjust the pilot air with the pressure reducer 1ststage to 16 bar and check if the security valve opens at 16 bar.Replace defective safety valves |
| 41 | Non- return valve block: Inspect the components of the non-return valve block. Replace defectivevalve block. |
| 42 | F/W cooler to be removed, Carryout chemical cleaning of cooler, pressure tested to 38 KG/CM2 (fromS/W side) Renew MS protectors.total Qty - 04 |
| 43 | Carry out functional checks and calibration of all instrumentation. Replace defective component.(a) Temp Gauge; Working Range : 0-100 C; Qty - 08(b) Pressure Gauge; Working Range : 0-10 bar, Qty - 08(c) Pressure Gauge; Working Range : 0-25 bar, Qty - 02(d) Pressure Gauge; Working Range : 0-60 bar, Qty - 01(e) Pressure Gauge; Working Range :0-100 bar, Qty - 01(f) Pressure Gauge; Working Range :0-400 bar, Qty - 03(g) Differential Pressure Gauge; Working Range :0.2 to 1.0 bar, Qty - 03(h) Pressure Gauge; Working Range :0-16 bar, Qty - 01 |
| 44 | Undertake sequential trials of compressor. Rectify defects |
| 45 | Undertake comprehensive checks of control system. Rectify defects. |
| 46 | Undertake checks for blow down (auto drain) system. Rectify defects. |
| 47 | Carry out performance trial of the SW cooling pump(BWL 416) including parameterchecks(suction/discharge pressure), vibration trials, insulation/SPM checks on motor, motor startingrunningcurrent checks etc. |
| 48 | Overhau and Carry out performance trial of the SW cooling pump(BWL 416) including parameter checks(suction/discharge pressure), vibration trials, insulation/SPM checks on motor, motor startingrunningcurrent checks etc. |
| 49 | Calibrate all instrumentation.Replace defective gauge.(a) Pressure Gauge 0 to 6 bar , Qty - 01 |
| 50 | C) HPAC AFT 35183 HP AIR COMPRESSOR Make - BURCKHARDT,Model - S5W212L,MT - 35172 |
| 51 | Check set points of all safety trips:-(a) High lub.oil temperature switch (Set Point - 80 C), Qty - 01(b) High water temperature switch (Set Point - 54 C), Qty -01(c) High discharge air temperature switch (Set Point - 20.5 C), Qty - 01(d) Low lub. oil pressure switch (Set Point - 2.5 bar), Qty - 01(e) High discharge air switch (Set Point - 215 bar ), Qty -01(f) Low water pressure switch (Set Point - 1.4 bar), Qty -01 |
| 52 | Check mechanical seal of water pump. Check the thickness of carbon ring, replace if worn more than 3 mm. (Part No of mechanical seal of water pump - 129 002 300 654) |
| 53 | Replace crankshaft oil seals if found damaged. ( Crank Oil Seal - 129 086 505 101) |
| 54 | Before assembly of cylinder head check oil throw from the cylinders. On completion assemble with new cylinder head gaskets |
| 55 | Clean lub oil cooler. Pressure test on completion. Inspect and replace elastomers during assembling.(Working Pressure : 3 to 6 bar) |
| 56 | Replace all piston rings and oil scrapper rings.(a) Ist Stage (129 000 801 603) ,Qty - 10(b) IInd Stage (129 000 801 903) , Qty - 5(c) IIIrd Stage (129 000 803 003) , Qty - 8(d) IVth Stage (129 000 804 103) , Qty - 10(e) Vth Stage (129 000 805 005), Qty - 12 |
| 57 | Check cylinder liners and cylinder bore for wear. Replace defective liners. |
| 58 | Check weardown of Main Bearings and Con Rod Bearings. Replace if weardown is beyondpermissible limit.(a) Main bearing (129 002 300 116) , Qty - 04(b) Big end bearing (129 002 300 303) , Qty - 03(c) Needle Roller Bearing (129 002 300 306) , Qty - 03(d) Big end bearing dowell (129 002 300 305), Qty - 06 |
| 59 | Check piston for wear.Replace defective piston.(a) Piston dia 125 mm (129 000 831 601), Qty - 02(b) Piston dia 110 mm (129 002 331 903), Qty - 01(c) Piston dia 70 mm (129 002 333 035), Qty - 01(d) Piston dia 42 mm (129 002 334 135), Qty - 01(e) Piston dia 25 mm (129 002 335 035), Qty - 01 |
| 60 | Check oil pump (housing internal+rotors & gear) and water pump.Carry out Overhauling of pumps |
| 61 | Carryout chemical cleaning of water cooler. Pressure test on completion (Working Pressue : 3 to 6 bar, Test Pressure - 9 Bar |
| 62 | Replace concentric valve internals, Sub- microfilters, Micro filters, activated carbon filter and pre filterelements |
| 63 | Carry out alignment of Metaflex Coupling (where fitted) between compressor and motor as per JIC 35172/4000H10 |
| 64 | Safety valve:Check the function of the safety valves. Adjust the pilot air with the pressure reducer 1ststage to 16 bar and check if the security valve opens at 16 bar.Replace defective safety valves |
| 65 | Non- return valve block: Inspect the components of the non-return valve block. Replace defective valve block. |
| 66 | F/W cooler to be removed, Carryout chemical cleaning of cooler, pressure tested to 38 KG/CM2 (from S/W side) Renew MS protectors.total Qty - 04 |
| 67 | Carry out functional checks and calibration of all instrumentation. Replace defective component.(a) Temp Gauge; Working Range : 0-100 C; Qty - 08(b) Pressure Gauge; Working Range : 0-10 bar, Qty - 08(c) Pressure Gauge; Working Range : 0-25 bar, Qty - 02(d) Pressure Gauge; Working Range : 0-60 bar, Qty - 01(e) Pressure Gauge; Working Range :0-100 bar, Qty - 01(f) Pressure Gauge; Working Range :0-400 bar, Qty - 03(g) Differential Pressure Gauge; Working Range :0.2 to 1(h) Pressure Gauge; Working Range :0-16 bar, Qty - 01 |
| 68 | Undertake sequential trials of compressor. Rectify defects |
| 69 | Undertake comprehensive checks of control system. Rectify defects |
| 70 | Undertake checks for blow down (auto drain) system. Rectify defects |
| 71 | Undertake checks for blow down (auto drain) system. Rectify defects |
| 72 | Carry out performance trial of the pump including parameter checks(suction/discharge pressure),vibration trials, insulation/SPM checks on motor, motor starting-running current checks etc |
| 73 | Overhaul and Carry out performance trial of the pump including parameter checks(suction/dischargepressure), vibration trials, insulation/SPM checks on motor, motor starting-running current checks etc. |
| 74 | Carry out functionality checks of all instrumentation and calibrate.(a) Trips(i) Low L/O Pressure Switch (Set Point: 2.5 bar), Qty - 01(ii) High Discharge Air Pressure (Set Point: 2.5 bar), Qty - 01(iii) Final Stage Discharge Air Temp (Set Point: 150 C), Qty - 01(b) Relief Valve 1st Stage (Set Point: 4- 28 bar), Qty - 01(c) Relief Valve 2nd Stage (Set Point: 13-46 bar), Qty - 01(d) Relief Valve 3rd Stage (Set Point: 44-96), Qty - 01(e) Relief Valve 4th Stage (Set Point: 96-115), Qty - 01(f) Relief Valve 5th Stage (Set Point: 220 bar), Qty - 01 |
| 75 | Undertake capacity trials of the compressors and rectify defects observed |
| 76 | Remove soot from the exhaust silencer and clean exhaust piping. |
| 77 | Check all safety devices and carryout calibration,replace defective component.Alarms:(a) Engine RPM (Set Point: 1650), Qty - 01(b) Low lub Oil Pressure Alarm (Set Point: 2.0 bar), Qty - 01(c) High lub Oil Temp (Set Point: 120 C), Qty - 01(d) Fuel leakage (Yes/No), Qty - 01Trips:(a) Low lub Oil Pressure Alarm (Set Point: 1.5 bar), Qty - 01(b) High lub Oil Temp (Set Point: 130 C), Qty - 01 |
| 78 | Alarm hooter of HPAC (FWD) operating intermittently without any signal. DIDR to be undertaken |
| 79 | Auto drain solenoide valve of HPAC (AFT) found to be malfunctioning and operating intermittently.Carry out serviceability checks. Replaced if found defective |
| 80 | D) HPAC MER Drier,35183 HP AIR COMPRESSOR Make - BURCKHARDT Model - S5W212L |
| 81 | Tank level indication of HPAC (Aft) showing erratic values in display panel. Suspect sensormalfunctioning. Carry out calibration of sensor. Replace if found defective |
| 82 | MER HPAC Main Valve (4 Way Change Over/ Valve V1/V2) of drier unit not operating/malfunctioning. Carry out serviceability checks and defect rectification. Replace if found defective |
| 83 | Air leakage observed from HPAC needle valves of Drier unit. Carry out overhaulig of Valves.Replaced if found BER.Make – Beko, Model - AC300HP300, Valve type - Needle valve, Dia - 1/4', PN -400 Bar Qty- 10 |
| 84 | DD HPAC - COMPRESSOR 351101 DIESEL DRIVEN HP AIR COMPRESSOR |
| 85 | Lub oil viscosity of engine observed at the lower end of permissible limit. Suspect lub oildialution.DI/DR to be undertaken |
| 86 | DDHPAC exhaust system isolating valve not holding. Carry out overhauling of valve. Replaced iffound BER.Valve Type – Gate Valve - Dia 80 MM, Mat - MS |
| 87 | DIESEL ENGINE HP AIR COMPRESSOR 452016 (HA 694) |
| 88 | BASCCA compressor not charging upto 300 bar. Suspect Pressure Regulating Valve defective.Undertake calibration/ overhauling of PRV .Make- Goenka, model -9 CFM, Qty- 01 |
| 89 | Third stage PRV valve of BASCCA compressor found operating during charging . Suspect PressureRegulating Valve malfunctioning. Undertake calibration/ repair of PRV .Make- Goenka, model -3 CFM,Qty- 01 |
| 90 | DD BASCCA compressor staring recoil asembly found jammed duing starting. Undertake repair/renewal of recoil asembly. Make- Goenka, model -3 CFM, Qty- 01Spare required for undertaking the job (not limited to) - Recoil assembly Please Enable Macros to View BoQ information |
