PHL/CO/ENGG/5600 28 th Jan 2010 Tender Enquiry No.PHL/CO/ENGG/5600/TE-92 dated 28 th Jan 2010 We are presently operating a fleet 26 Dauphin, 3 Bell 206 L4, 4 Bell 407 and two MI-172 helicopters. Our MI-172 helicopters are installed with VR-14 Main Gear Boxes which are designed by JSC Klimov. Series production of the gearbox is carried out at Perm by M/s JSC Reductor PM, Russia & at St. Petersburg, Russia by Krazny Octiabr. One of our VR-14 gearboxes sl no. 1040141503025 has operated 2999 hrs since new. The gearbox was under inspection for TBO extension from 2910.hrs to 3160 hrs by technical specialists from M/s.JSC Klimov. However, the extension on the gearbox was not granted due to considerable wear of teeth joints reaching around 1.0 mm in the NS- 39M Pump Shaft and 0.5 mm in the GT40PC8V generator shaft. The technical specialist assessed the condition of the gearbox as unsatisfactory and recommended removal of the gear box for repair and overhaul. Detailed Technical report submitted by the specialist alongwith the history of operation of the gearbox is attached as Appendix A to this tender. We therefore, invite sealed quotes only from designers i.e. M/s. JSC Klimov and manufacturers i.e. M/s.JSC Reductor PM and M/s.Krasny Octiabr for repair and overhaul of VR-14 gearbox sl no. 1040141503025 as per our following terms and conditions. 1. Rates quoted for overhaul must be firm, fixed and on CPT New Delhi (Insurance Policy No. 31180/43/09/90114 of NEW INDIA ASSURANCE COMPANY LTD., INDIA) basis. Payment by PHHL for repair and overhaul overhaul will be made through Letter of Credit. Bank charges outside India, if any, will be borne by manufacturer/designer. 2. PHHL can accept or reject any offer received against the tender enquiry without assigning any reason whatsoever. 3. Service life of the VR-14 gearboxes sl no. 1040141503025 should be increased to at least 6000 hrs after overhaul and TBO assigned after overhaul should be at least 1500 hrs/06 years. 4. Guarantee of at least 500 hrs or 12 months from the date of installation on the helicopter or 18 months from the date of delivery, whichever occurs first, will be assured after repair/overhaul. Bidder will bear all expenses including transportation for items failed within guarantee period validity. 5. Turn around time for carrying out the job mentioned above should be specified for above VR-14 gearbox. Liquidated Damages @ 0.5% of the cost of equipment overdue for each of the first four full weeks and then @ 1% for each subsequent full week of the delay thereafter will be applicable for delay in delivery due to reasons attributable to the repair agency. However, total amount of Liquidated Damages shall not exceed 10% of the cost of the equipment delayed. Should the delay in delivery is of more than three months; Pawan Hans Helicopters has the right to cancel unfulfilled part of the contract.
6. All Mandatory modifications issued by designers/manufacturers applicable on VR- 14 Gearbox will be complied during overhaul. 7. The wax sealed quotation should be submitted before the last date i.e. 1500 hrs on 26 th Feb 2010. 8. The date of tender opening will be 1600 hrs on 26 th Feb 2010. The sealed envelop be super scribed Quotation for repair/overhaul of Main Gear Box VR-14 due at 1500 hrs on 26 th Feb 2010 and to be opened at 1600 hrs on 26 th Feb 2010. The envelop should be addressed to Dy General Manager (Tech Supp) Pawan Hans Helicopters Ltd. Corporate Office Safdarjung Airport New Delhi 110 003. INDIA. Fax : 91 11 24652516 Agencies will be selected on lowest quote basis. If all our terms and conditions are acceptable, we hereby invite you to quote your charges for repair and overhaul of VR-14 Gear Box sl no. 1040141503025. Please confirm your acceptance of all our terms and conditions in the quote. Details of this tender are also available on our website www.pawanhans.nic.in Regards, (M S Boora) Dy General Manager (Tech Supp)
Appendix A LIST of fulfilled works on the assessment of the technical state of the main gear box VR-14 No.1040141503025 as per the Programme No. 78I-1081P Technical documentation Name of the work Assessment results Technical Maintenance Manual Checking of the implementation of the scheduled technical maintenance work of the gear box at 100 hours and other works as per the current Bulletins. Implemented 84.10.00 d Maintenance schedule manual 84.10.00 v Technical 84.10.00 е Technical Programm 84.10.00 i Technical 84.10.00 g Technical Programm Helicopter Technical User Manual External inspection of the main gearbox (MGB) Checking of Oil level of MGB Inspection of Oil system of MGB Inspection of mechanism of smooth rotation of MGB and function of free wheel Inspection and check of functions of magnetic detector plugs Inspection and cleaning of MGB oil filter Measuring of the radial clearance of fan driven shaft in vertical and horizontal axis. Inspection of the condition of the fan driven shaft In normal standards As per the standards Engine Technical User Manual Inspection of alignment of MGB with the engines As per the Engine Technical User Manual 84.10.00 c Technical Oil analysis As per the technical standards Helicopter Technical User Manual 84.10.00 n Technical 84.10.00 p Technical Inspection of the conditions of the shaft teeth on the units Ground Test of MGB Flight Test of Helicopter Identified wear of the shaft teeth of the units NSh39M and GT40PCh8V (see the Act) Parameters are as per the Technical Maintenance Guidelines Parameters are as per the Technical Maintenance Guidelines
Appendix A TECHNICAL REPORT on the examination of the technical state of the main gear box VR-14 1040141503025 1. The main gearbox manufactured on 16.05.1995 by JSC Reductor PM with service time of 500 hrs till the first overhaul and service life of four years and full service life of 2000 hours. The MGB was in operation in India on the helicopter MI-172with the factory serial No.356c03 and Registration No. VT-ASM of the Indian company Pawan Hans Helicopter Ltd. In September 1999, the MGB was sent for overhaul due to the presence of metal particles on the oil filter and magnetic plugs at the time since new of 96 hrs. 2. Number of overhaul carried out: one. 3. The overhaul was carried out by JSC Krasniy Oktyabr on 20.11.2000 г. And the TBO was set for 1000 hours till the scheduled overhaul and a service life of 8 years and a full service time of 3000 hours. 4. After the overhaul, the MGB was stored in the packing of the supplier for a period of 3 years and four months. 5. From 04.04.2004 the MGB is in operation in India on the helicopter MI- 172with the factory No.356c07 and Registration No. VT-PHG of the Indian company Pawan Hans Helicopter Ltd Мi-172 with the engines TV3-117VМ series 2 and factory serial No. К788020139 (left) and No.К788020152 (right). After finishing the set service time of 1500 hours for the engines there were periodical replacements of the engines. - Engine No.К788020152 was replaced by the engine No. TV3-117VМ Serial 02 No.7087882602081 on the helicopter and was in operation during the period from 08.05.2004 to 16.12.2007. - Engine No К788020139 was replaced by the engine No. TV3-117VМ of series 02 factory serial No 7087882302075 on the helicopter and was in operation during the period from 12.11.2004. to 16.12.2007. During the period from November 2005 to September 2006 the helicopter was under overhaul in JSC KVZ in Russia as due for overhaul.
6. After completion of the set service life period of 1000 hours the operation of the MGB service life was extended as per the technical conditions till the scheduled overhaul by the JSC Klimov. 07.09.2005 extension of TBO up to 1250 hours as per the Bulletin No.14026-БЭ-Г. 10.08.2007 extension of TBO up to 1500 hours as per the Bulletin No.6.180.43BEЭ- АБ. 04.11.2007 extension of TBO up to 1750 hours as per the Bulletin No.6.180.43БЭ-АБ. 09.03.2008 extension of TBO up to 2000 hours as per the Bulletin No.6.180.43БЭ- АБ. 11.08.2008 extension of TBO up to 2250 hours as per the Decision No.769-14-08-0014РЕ. 19.01.2009 extension of TBO up to 2500 hours as per the Decision No. 769-14-09-0018РЕ. 19.01.2009 extension of service life up to 9 years (up to 19.11.2009) as per the Bulletin No. 6.180.43БЭ-АБ. 16.06.2009 г. extension of TBO up to 2750 hours as per the Decision No. 769-14-09-0031РЕ. 04.10.2009 г. extension of TBO up to 2910 hours 26 minutes as per the Decision No.769-14-09-0031РЕ. 04.10.2009 г. extension of service life up to 10 years (up to 20.11.2010) as per the Bulletin No. 6.180.43БЭ-АБ. 7. As per the status on 19.12.2009 the time since last overhaul of the MGB amounts to 2903 hours 19 minutes during the service life of 9 years 1 month, including: on the take of regime 8 hours 54 minutes, on nominal regime 64 hours 35 minutes. The equivalent service on takeoff and nominal regime operation amounts to 1.15% of the total service time since last overhaul and does not exceed the permitted 2.76 % as per the Decision No. 769-14-09-0031РЕ. And the time since new of the MGB amounts to 2999 hours 19 minutes. 8. On the basis of the Addendum-3 to the Agreement No. 765.78.5.313-09 dated 07.04.2009 in accordance with the Decision No.769-14-09-0031РЕ on the possible stage by stage life extension of the MGB VR-14 No. 1040141503025 up to 3500 hrs the MGB VR-14 No. 1040141503025 was inspected as per the Programme No.78И-1081П from 19 to 22 December 2009 at the service time of 2903 hours 19 minutes since last overhaul. The List of works and the assessment results are given in the Annexure No.1 to the present Report. During the examination of the MGB Log Book it has been established that the MGB Log Book is original, the form and the content of which corresponds to the established model. The rules of maintaining the Log Book by the operating organization corresponds to the established requirements. As per the result of the analysis of the operational documents and of the running operation of the MGB and the helicopter shows the following: did not reveal rough landing of the helicopter, damages of the main rotor blades, sudden stoppage of main rotor blades due to hit on the blades during the rotation, change of engines with incomplete service life, overspeed of the mrb rotation, alarm warning for the presence of metal particles in the oil, on the oil filter and on the magnetic plugs, adjustments of the pressure regulator of the MGB.
The technical operation of the MGB was being carried out in accordance with the requirements of the prevailing documentation of the MGB. Scheduled works and the technical maintenances during storage were carried out as per the required periodicity. As per the status on 19.09.2009 there are no remarks on the operation of the MGB. The results of the examination established the following: - The scheduled 100-hour scheduled work was fulfilled on 20.12.2009 at the service time of 2903 hours 19 minutes since the last overhaul. - The operation of the MGB is with the use of the mobile jet oil II. The last change of oil was done on 29.09.2009 at the service time of 2651 hour 58 minutes since last overhaul. As per the status on 19.12.2009 the service time of the oil amounts to 251 hours 21 minutes. The results of the analysis of the oil, taken from the MGB at the service time of 70 and 209 hours, corresponds to the technical standards and is attached to the present Report. - The measured radial play of the fan drive shaft in vertical plane - 0.24 mm, in horizontal plane 0.26 мм, does not exceed the threshold figure of 0.7 мм as established in the Programme. - Engine-MGB alignment is within the permitted limits Rear view 1.95 18.95 1.95 2.00 2.20 2.20 25 Left engine Right engine - During the examination of the gear teeth joints of the unit on the gearbox at the left side by the rear view wear up to 1.0 мм of the teeth is identified on the shaft of the gearbox unit НS39М No. N312Е217 and up to 0.5 mm in the front generator unit GТ40PC8V No. 4024211. Photos of the wear of the teeth are attached to the present Report. For further operation the coupling of the unit NS-39М No. N312Е217 is changed. - The MGB parameters on ground run and test flight of the helicopter on 21.12.2009 corresponds to the requirements of the Technical User Manual. Regime NR (%) Oil Pr. Oil Тemp. Eng. Comp. r.p.m. (Кgс/см2) ( С) left (%) right (%) Take off 92.0 3.8 72 100.0 100.0 Nominal 96.0 3.8 70 97.0 97.0 Cruising 96.0 3.7 70 95.2 95.2 Idle 67.0 3.0 50 77.0 74.0 Outside air temperature: +20 С. Atmospheric pressure: 1021 G.Pascal
Conclusion 1. The results of the works done on the main gearbox VR-14 No. 1040141503025, in shafts of the pump NS-39М No. N312Е217 and generator GТ40PC8V No. 4024211 showed considerable wear of the teeth joints reaching around 1.0 mm in the pump shaft and 0.5 mm in the generator shaft. Technical condition of the main gearbox VR-14 No. 1040141503025 is assessed as unsatisfactory. 2. In accordance with the Decision No.769-14-09-0031РЕ the main gearbox VR-14 No. 1040141503025 is to be removed from further operation due to technical condition as completed the established service time of 2910 hours 26 minutes, and it has to undergo repair.