DIESEL GENERATOR NO.9 OVER HAUL SERVICE AND MAINTENACE LOCATION: TATA CHEMICLAS MAGADI POWER STATION (LAKE MAGADI)

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1 DIESEL GENERATOR NO.9 OVER HAUL SERVICE AND MAINTENACE ENGINE NO. 84HESL8MK ENGINE MAKE/MODEL: MIRRLEES BLACKSTONE (ATAMFORD) TYPE ESL8MK2 KW LOCATION: TATA CHEMICLAS MAGADI POWER STATION (LAKE MAGADI) SAFETY MEASURES AND REQUIREMENTS i) A thorough site risk assessment to be done before commencement of work. ii) All personnel involved in the job to be taken through safety induction for familiarization with the scope of work and the risks involved. iii) A risk assessment board to be availed on site furnished with the permit to work, risk assessment form, hot work permit and job procedure. iv) Ensure all electrical connections have been isolated and a Lock out, Try out, Tag out procedures have been followed before taking over the plant for the job. v) A tool box talk to he held before commencement of every shift to highlight on the new risks encountered or expected and how to mitigate them. vi) A person in charge of safety to be identified and be known to all the personnel during every shift. vii) A first aid kit to be availed on site at all times and a shift first aider identified. viii) All oxy-acetylene sets to be inspected and tested for leakages before use and hoses to be clear of falling hot material, sharp edges and dropping debris. ix) All personnel shall wear the mandatory PPE at all times and ensure use of other relevant PPE depending on the nature of work and condition of the work site. x) Housekeeping to be done at every stage of work and thoroughly at every close of shift. TOOLS REQUIRED

2 i) Vendor to provide his/her own tools during service EQUIPMENT (TATA TO PROVIDE) i) 15 tone chain block ii) Trolley CONSUMABLES REQUIRED (TATA TO PROVIDE) i) 10 kg Cotton rags ii) Lube oil iii) Turbo charger oil (Presila 68) iv) Degreaser TASKS TO BE CARRIED OUT The following are the tasks that need to be carried out during the service according to the engine manufacturer specifications (EMS) 1. Pre-service inspection. Inspect and identify all the required spares and consumables in store in readiness for the service. 2. Service all auxiliary motors and pumps Cooling tower, water jacket, lube oil priming pump and secondary water pump. 3. Servicing of the turbo charger Inspect and service the turbo charger, clean the air intake and oil governor, replenish the oil. 4. Cleaning and inspection of the alternator Inspect and clean the alternator and confirm and adjust the air gap accordingly to the stipulated limits. 5. Servicing and resetting of the speed governor Inspect service and lubricate the speed governor.

3 6. Serving of the exhaust valve cages. Remove all the exhaust valves, inspect, repair, service. a. Clean and decarbonizes all the cages b. Replace all the valve guides with new ones c. Wrap and match the valve seats with the correct exhaust valve. 7. Servicing and calibration of the fuel injectors a. Remove inspects and services the injector pumps b. Replace worn out nozzles with the new ones c. Test all the nozzles and set at the required bar as required. 8. Serving and calibration of the injector pumps. Service, clean and calibrate the pumps. Replace any worn-out parts with new ones. 9. Lube oil cooler and jacket cooler. Inspect, clean and assemble the coolers in their respective positions. 10. Cleaning of the H.F.O heater and checking of the electrical system a. Clean the H.F.O housing and replace all filter elements. b. Service and test the electrical heating system. 11. Cleaning of the engine lube oil sump gallery and the filters. a. Clean the engine lube oil sump gallery b. Clean the filter elements c. Top up the engine with fresh lube oil. 12. Engine testing and commissioning

4 Run the engine on both light fuel and heavy furnace oil gradually to full load. Take readings of the following: a. Cooling water pressure. b. Lube oil pressure c. Lube oil temperature. d. Exhaust temperatures ( C) at various loads. e. Crankshaft deflection readings in MM 13. Cylinder head Inspect clean and service 14. Cooling tower Clean the pond and piping system, replace if worn out. 15. Engine protection system. Inspect service and confirm the engine protection system conditions. Reset according to required working conditions. 16. Prepare a service report including all the spares used and consumables plus their quantities. 17. Commission the generator and leave it in a normal running operation. 18. Warranty 200 running hours in a stable condition without any breakdown related to the previous jobs done during the service.

5 TECHNICAL EVALUATION Quantitative Technical Criteria Tender Returnable Proof Criteria Criteria Sub Description Format Weighting Weighting 1 TECHNICAL CRITERIA 80% 1 Your company must be certified in power generation and high voltage handling and registered with the relevant authority. Attach current Certificate 10% The bidder shall submit 2 The vendor MUST have done similar jobs (Installation and servicing of generators of the same class) copy of completion certificates/ un-priced P.O. copies in support of above. If required purchaser may visit the 30% client 3 Vendor site visit Site visit is mandatory 10% Attach a detailed work 3 Show detailed preparation and execution work plan schedule for the activities in scope (Gantt Chart 30% with manning levels. SAFETY CRITERIA 20% 4 Does your company have competent, trained, safety conscious, and insured personnel Attach a valid WIBA for your staff 20% TOTAL 100%

6 A minimum overall score of 70% will be used to deem the renderer technically acceptable and anything below 70% will deem the renderer technically unacceptable FINANCIAL EVALUATION DESCRIPTION QTY UNIT PRICE SCOPE FOR GENERATOR NO.9 SERVICE 1 LUMP SUM 1. Mobilization and Demobilization cost 1 LUMPSUM SUB TOTALS VAT TOTAL Payment Terms Site visit on 19 th July 2017

SPECIFICATIONS FOR MOTOR OPERATED VALVES

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