Working Conditions

The contractor shall depute the service engineer as per the maintenance schedule defined in the contract at LTT /WB/CSTM for breakdown calls. Service Engineer shall report within reasonable time to the place where breakdown is reported on all days irrespective of holidays, Sundays.

The contractor shall keep trained service Engineers for the purpose of maintenance breakdown whenever the rake is available at LTT/WB/CSTM and shall depute promptly at locations like – Nasik Rd, Bhusaval, Itarsi, Jabalpur, Allahabad, etc. for the any breakdown. The time interval for attending breakdown shall be maximum journey period by first available train plus two hours.

The contractor shall keep all necessary tools, testing equipment, spare parts, sub-assemblies and consumables in the ready stock at LTT/WB/CSTM. The materials stocked at LTT /WB/CSTM will be in the custody of the contractor. Service Engineers of the contractor or their authorised representatives will be allowed to bring in take the materials out of the premises at any time without prior permission of Railways.

The contractor shall submit a list of service engineer, technicians and other staff deployed for this work along with their qualification and experience. It should be ensured that during the currency of the contract same set of staff are deployed for this. Necessary identity card shall be issued by the contractor duly signed by Railways officials for attending the power car, however this will not be used as traveling authority.

All the checks maintenance activities shall be carried out in the stable condition in the depot at LTT.

The contractor will make a suitable proforma in triplicate for all the schedules (A, B, C, D checks), indicating the activities to be carried out in each schedules/checks. The triplicate copy should be jointly signed by firms representative/Engineer and Railways authorized representative. One copy of the activities performed and duly signed should be submitted to Sr.DEE(Cog) CSTM  along with the bill.

Scope of Work for Control and distribution

1.0              Comprehensive maintenance contract for Control and Distribution systems.

    Cleaning, re-conditioning and testing e.g. fixed and moving auxiliary contacts, fixed and moving main contacts, operating shaft, tripping shaft, etc. for power panel.

After cleaning / reconditioning / replacement of the spare parts while reassembling the following jobs are also required to be carried out.

              i.          Greasing of mechanical components as per greasing schedules and use of grease as recommended by OEM manuals.

            ii.          Testing for closing and tripping mechanism including adjustments / repairs. If needed.

         iii.          Inspection / adjustment of fixed and moving auxiliary contacts.

          iv.          To check alignment and change if required fixed and moving parts of ACB and change over main isolating contacts, secondary isolating contacts, shutter assembly and telescopic.

            v.          Checking, tightening and changing if required of all accessories control wiring. Lugs terminals, CT, etc.

          vi.          Cleaning of the arc chutes and replacements if required.

       vii.          Testing and replacement of major parts if required of ACB and change over e.g. pole assembly, FRCD mechanism and ACB and change over terminals connected to bus bars links complete repairing of ACB and change over if damaged.

The works mentioned in schedule at item no. 5(i) to 5(ii) and 6(i) to 6 (ii) of Part-B are required to be carried out on need basis. The quantities specified are tentative and may vary as per actual requirement during the tenure of contract. The decision for replacement of these items shall be taken by Railway’s authorized representative based on the joint inspection made by contractor’s representative and Railway’s authorized representative. Payment for these items shall be made based on accepted rates in respective quarterly payment due.

Scope of work for Alternator

1.0      Comprehensive maintenance contract for alternator 500 KVA

2.1.             Maintenance of Alternator:

Depending on the individual site conditions frequent maintenance should be practiced. Before carrying out any maintenance work the generator should be stopped and isolated electrically from all external loads or supplies.

2.2.             General cleaning

Both interior and exterior of the machine (particularly the windings, bearing, ventilation opening, static exciter, etc. ) should be kept free from any oil or dust by blowing out frequently (Say every one months) with clear dry air at a pressure not exceeding 3.5 kg/cm². If the blowing is ineffective to remove oil or dust, the parts should be carefully cleaned with a rag lightly damped in white spirit.

2.3.             Connections

All the external and internal connections (including rotating rectifier assembly and excitation control unit) must be checked for tightness at joints and continuity. Fuse links shall make a good fit in the holders. All the hardware, including those of terminals should be tightened if necessary.

2.4.             Loss of Residual

If the generator residual is lost because of long storage or demagnetizing due to any mal operations, it will be necessary to disconnect the exciter field terminals at the exciter control unit and connect 12 volts battery directly across the field (with correct polarity) for a few seconds to re establish the residual.

2.5.             Rotating rectifier assembly

The health condition of the diodes cab be checked when required as follows:-

a.             The pig tail terminal of each diode is disconnected.

b.             At least 1.5 volts source (eg. AVO using 008, simpsong 200) on the appropriate range (say ohms x 1). The resistance of diode between stud and pig tail in both directions is measured.

2.6.             Diodes in good condition will show a low (up to a few 100 ohms) resistance in the forward direction and a very high resistance (up to 1 mega ohm) in the reverse direction. A high resistance in both directions or a low resistance in both directions indicates a faulty diode which should be replaced.

2.7.             Failure of surge suppressor can be detected by smell and appearance. Failure of fuses can be detected by checking its continuity using a multi-meter.

2.8.             Bearing

The roller bearing or ball bearing will run for long periods without any attention as the bearing housing is charged with right quantity of grease before dispatch. The bearings are to be lubricated with correct quantity of grease in the intervals stated on the name plate of the generator, in order to replenish any grease lost during running. Lithium based conforming to grade 3 / AP 3 (Castrol) / Mobilube no. 3 (Indian oil) or equivalent may be used. The bearings will be replaced under AMC if defective.  

2.9.             If the grease is caked before commissioning, it has to be completely replaced. Grease of different makes and grades should not be mixed. The original grease should be removed, unless it has become dirty, deteriorated or not caked.

2.10.           Unnecessary disturbance of the bearing cap should be avoided. Where disturbance is necessary great care must be exercised when handling the bearing and cover to avoid the ingress of dirt and moisture into the grease of bearing. When the machine has to be stationary for a long period, the rotor should be turned periodically to avoid settling of grease at the bottom of the housing.

2.11.           However, if alternator failure/winding burnt happens due to AMC negligence, same will be penalised. 

SCope of work for engine

1.1                   Carrying out four engine inspections, designated as A-check, B-check, C-check and D-check as per details brought at Annexure (Maintenance schedule – Diesel Engines) for M/s. Cummins make diesel engine, model no. KTA 1150G / 19G, M/S Crompton Greaves model no. TBD4, 500 KVA capacity of alternator of KEL & Kirloskar or other make installed in power cars.

1.2                   The technical specification, model number and make given in tender is only for reference. For other make, model of engine with their schedule as per OEM will be applicable and followed.

1.3                   A check or inspection is referred to as the NEW ENGINE PERFORMANCE INSPECTION. This check is required to be carried out at the time of putting engine into service or within 50 hours after engine is put into service. In any case ‘A’ check must be done within one month after the engine is put into service. ‘A’ inspection ensures trouble free service of the engine long life and efficiency of the engine. ‘B’ check inspection is required to be carried out after 300 hrs or 6 months of Engine operation, whichever is earlier. ‘C’ check is required to be carried out after every 1500 hrs or every one year of engine operation whichever is earlier. Further ‘D’ check is required to be carried out after every 6000 hrs. or 2 years of Engine operation, whichever is earlier. After every D check 1500 hrs. Checks is to be done as specified in chapter-V of tender.

1.4                   In case of crank shaft, ovality/jamming/breakage mixed or head of the piston damaged due to lubricant oil contamination / deficiency or due to wrong operation by AMC operator / escorting staff same shall be responsibility of contractor and any such demise will have to be rectified by the contractor at a own cost.  

1.5                   The activities to be carried out during ‘A’ check, ‘B’ check, ‘C’ check and ‘D’ check are brought in details given below :-

1.6                   During ‘A’ check a daily weekly report of Engine operation is to be prepared by company’s Engineer and Railway’s authorized Engineers incorporating checking of engine oil level, checking of belt, (inlet engine) water pump belts, inline engine water pump belts, fan drive belts, generator / alternator belts) belt insulation, re-adjusting new belts, check oil both cleaner oil level, check of damage, check engine coolant level, check sediment from fuel tanks, fuel / water filter separator. Further weekly check is also required during scheduled ‘A’ check item no. 1. During weekly maintenance check the work to be carried out are cleaning of pre-cleaner and dust fan, checking of inlet air restriction cleaning or replacement of air cleaner elements, cleaning and inspection of pre cleaner (heavy duty ) drain air tanks, drain sediment from fuel tanks.

1.7                   During ‘B’ check all the activities of ‘A’ check are to be repeated and some additional work to be carried out. The tenderer are required to replace the ‘B’ check kit, lubricating oil and air filter.

         

1.8                   Only schedule quantity of lubricant oil shall be paid, for additional consumption will mean poor maintenance which will be penalised.

1.9                   During ‘C’ check all the activities of ‘A’ check and ‘B’ check are repeated. In this check the contractor is required to repair / reconditioning the injector, PT pump, turbo charger and governor PSG. Payment towards this activity shall be made against schedule item no. 3.

1.10               During ‘D’ check all the activities of ‘A’, ‘B’ and ‘C’ check are required to be repeated and some additional works are to be carried out as per details. The contractor is required to repair / recondition the cylinder head, injectors, PT pump, turbo charger, ACC drive, governor PSG, water pump, lubricating oil cooler, cam flower, rocker arm HSG. Payment towards this activity shall be made against schedule item no. 4.