Government of India Ministry of Railways · (a) Analyze failures of GR/CGR/RGR, SMGR & TFP and...

of 11

Issued on 02-09-2016 IR Report No. RDSO/2016/QAE/RM/0001(Rev.‘0’)

Government of India Ministry of Railways

REPORT

OF

COMMITTEE FOR REVIEW OF MAINTENANCE PRACTICES

FOR NO-32 TAP CHANGER AND TRANSFORMER

FOR

CONVENTIONAL ELECTRIC LOCOMOTIVES

Report No. RDSO/2016/QAE/RM/0001 ( Rev. ‘0’)

September, 2016

Issued by Quality Assurance (Electrical) Directorate

Research, Designs and Standards Organisation Manak Nagar, Lucknow – 226 011

lR;eso t;rs

of 11


of 11


INDEX

S. No Descriptions Page No.

1.0 Background 4

2.0 Terms of Reference 4

3.0 Details of Locomotives Holdings 4-5

4.0 Age Profile of Tap Changers 5

5.0 Need for this Study 5-6

6.0 Failure Reported from Railways 6

7.0 Current Maintenance Schedules for Tap Changer: 6

8.0 Current Maintenance Schedules for Transformer: 6-7

9.0 Quality Audit of Sheds / Shops to review maintenance

practices for Tap Changer & Transformer

7

10.0 Product / Facility audit of OEMs of Tap Changer 7

11.0 Deliberations by the Committee 7-9

12.0 Recommendations 10-11

Annexure – Q1, Q2, Q3, Q4, X1 (BT design) & X2 (Ganz design) for AOH

Annexure – R1, R2, R3, R4, X3 (BT design) & X4 (Ganz design) for IOH

Annexure – S1, S2, S3, S4, X5 (BT design) & X6 (Ganz design) for POH

Annexure – 2A (List – A & B) for repair/rehabilitation BT design

Annexure – 2B (List – A & B) for repair/rehabilitation Ganz design

Annexure – Z1 (Critical Component to be replaced after 12 Years of Service)

Annexure – Z2 (Assemblies for un-schedule arising)

of 11


1.0 Background :

With increased production of Electric Locomotives for meeting the traffic demand, the holding of Electric Loco Sheds on

Indian Railways has been increasing steadily. Considering non-availability of the desired man power as per yard stick in sheds for holding these locomotives and increased number of

failures during the last few years, need has been felt to review the maintenance practices for N-32 Tap changer, SMGR and

Transformer for Conventional Electric Locomotives as advised by Railway Board.

Railway Board vide their letter No. 2002/Elect.

(TRS)/441/4 Pt.I dated 04.07.2016 has nominated a committee comprising ED/EM, RDSO (Convener), CWM (Western Railway), Dahod and CELE/Central Railway to look

into all the aspects of reliabilitypertaining to tap changer, SMGR & Transformer for Conventional Electric Locomotives.

2.0 Terms of Reference:

The terms of reference of the committee are as under:- (a) Analyze failures of GR/CGR/RGR, SMGR & TFP and

suggest remedial measures. (b) Audit maintenance practices of Tap changer, SMGR and

Transformer in various Sheds vis-à-vis the laid down

guideline of RDSO & suggest improvements, if any. (c) Examine testing facility, oil centrifuging, special tools,

DGA & availability of trained manpower and bring out

deficiencies for taking necessary action. (d) Spares with the Sheds/Shops & recommend in case of

deficiency. (e) Review the scope of work of AOH/IOH/POH/MTR for

theseequipment and suggest changes, if any.

(f) Examine the maintenance of Tap changer & SMGR by procurement of spares for AOH/IOH/POH and suggest

any improvement to improve reliability.

3.0 Details of locomotives holding:

Details of holding of electric locomotives:

SN Date Conventional locomotives

3-Ph locomotives

1 01.04.2013 4010 587

2 01.04.2014 4122 719

3 01.04.2015 4184 850

4 01.04.2016 4198 1027

of 11


From the above details, it is seen that there is increase of

74.95% of 3-ph IGBT locatives during last four years hence there is shifting from conventional to 3-ph loco. However, more & more staff are diverted towards maintenance of 3-ph loco

and as on date all locos are manufactured of 3-ph only.

4.0 Age profile of Tap Changer:

As per quality audit undertaken of 3 Loco Sheds, details of age

profile of Tap changers are as under:

SN Aging of Tap Changer ELS/MGS

ELS/BL

ELS/GZB

Total

1. Nos. of Tap Changer(01 to 03

years old)

43 66 08 117


years old)

43 45 20 108


years old)

24 36 23 83


years old)

03 21 - 24


years old)

33 13 22 68

6. Nos. of Tap Changer(more than17 years old)

51 10 - 61

7. Total 197 191 73 461

There are 27.98% of tap changer/transformer which are in service for more than 12 years. The residual life of these tap

changer/transformers is more than 20 years.

5.0 Need for this Study:

Indian Railway has been meeting the ever increasing freight

and passenger traffic demand throughout the length and breadth of country and the need for such increase is getting stiffer day by day in view of the projected growth and

development of the country. As per the recommendation of “National Transport Development Policy Committee Report” on

Indian Railways, it has been recommended that Indian Railway will require additional 28000 Locomotives up to 2031-32. As on date, Indian Railways have stoppedmanufacturing of

Conventional Electric Locomotives.

93 cases for loss of punctuality of mail & express train

have been reported between April 2015 to June 2016 of GR/RGR/CGR, SMGR and transformer failure for conventional

locomotive. There have been some stray cases (02 Nos.) of fire incidence also on account of GR/TFP oil splash which is a

of 11


cause of concern. This may have happened due to gradual

decrease of knowhow amongst Railway staff about maintenance of tap changer and transformer. The above causes are adversely affecting the reliability of conventional

locomotive which constitute 80% of IR fleet of electric locomotives.

It has been observed during recent past:

Some of the trained and expert manpower for maintaining conventional type locomotive have either retired or have

been redeployed in the maintenance of 3 phase locomotive.

Holding of electric locomotives has increased to 5225

locomotive against the sanctioned homing capacity of 4065 locomotive over IR. Electric loco holding is 28%

higher than its sanctioned homing capacity.

Failures on Tap Changer are increasing due to improper

maintenance. This is because of the age factor of tap changers have not been considered so far. Indian

Railways are following maintenance practices framed way back when conventional locomotive were produced regularly in full swing.

The conventional locomotives are ageing and so its equipment, especially tap changers.

Supply of spares is erratic and scanty.

Maintenance staff per loco has been decreased due to

increased holding of electric loco and reduced sanction of new staff for maintenance of the locos.

6.0 Complaints by user Railways:

Railways have reported failures of both Ganz& BT design Tap Changers. There are total nos. 54 failures last year (2015-16)

as reported by user Railways.

7.0 Current Maintenance Schedules for Tap Changer:

IA, IB, IC, AOH, IOH & POH schedules are being carried out

by sheds/workshops staff as per the scheduled prescribed by RDSO. The rehabilitation work also being carried out by sheds/workshops through outsourcing to OEMs following

scope of work as prescribed by RDSO.

8.0 Current Maintenance Schedules for Transformer:

IA, IB, IC, AOH, IOH & POH schedules are being carried out

by sheds/workshops staff as per the scheduled prescribed by RDSO. The rehabilitation work also being carried out by

of 11


sheds/workshops through outsourcing to RDSO approved

sources following scope of work as prescribed by RDSO.

9.0 Quality Audit of Sheds / Shops to review maintenance

practices for Tap Changer & Transformer for Conventional Locomotives:

The committee has formed two teams consisting each of a JAG officers of Railways and one officer of RDSO to conduct quality

audit of ELS/BL, ELS/MGS, ELS/GZB, ELW/BSL & LCW/DHD. Teams have conducted audit and submitted their reports to the committee. The committee have gone through

the key recommendations submitted by the teams and considered and deliberated the same.

10.0 Product / Facility audit of OEMs of Tap Changer:

The nominated teams have also visited the OEMs premises to see the process, jigs & fixtures, testing facilities etc. Teams have submitted their report to the committee. The committee

have gone through these reports and considered while deliberating the issue.

11.0 Deliberations by the Committee:

A. Tap changer: (i) Committee has scrutinized audit reports of sheds &

workshops by nominated teams. The committee also studied the suggestions given by Railways for addition of

items in overhauling kits issued by RDSO vide their letter No. EL/3.2.30 dated 12.05.2010. The maintenance practices of the sheds have also been scrutinized for

inspections and overhauls.

(ii) Existing overhauling kits needs to be revised due to

increase in periodicity of overhaul, suggestions by Railways and to improve the reliability in service.

(iii) During visit to maintenance sheds, it is observed that

some of the kits for overhauls are not available due to

delay in procurement etc. Hardware items are also not available due to non-availability of hardware items in existing overhauling kits, which leads to improper

maintenance during overhauling.

(iv) The requisite spares items and sub-assemblies are not available at sheds.

of 11


(v) Adequate skilled staff for undertaking overhauls and

unscheduled repairs are not available in sheds and workshops. Moreover, the holding of sheds and work load of workshop have increased in last few years

without increase in commensurate staff in tapchanger section.

(vi) The adequate jigs, fixtures and testing facilities for overhauling and un-schedule repairs are not available in

sheds and workshops to ensure proper maintenance and testing of tap changer during rehabilitation and overhauled.

Based on above, following have emerged:

(a) Some of the items such as silica gel,aux. switch in SMGR, contact tips for CGR etc. are required to be

replaced on condition basis in inspection schedules i.e. IA, IB& IC to ensure trouble free service on-line.

(b) Kits for major overhaul i.e. AOH, IOH, POH and rehabilitation needs to be revised keeping into the views

of audit teams and feedback from Railways. Some of the hardware item which were being procured by the Railways separately, which shall now be part of the

overhauling kits. These kits shall be procured from OEMs and RDSO approved sources. Some of the items are to be procured from respective OEM only. The revised

kits to be procured and used by sheds for AOH, IOH & POH shall be as per Annexure Q1, Q2, Q3& Q4 for AOH,

Annexure- R1, R2, R3 & R4 for IOH and Annexure- S1, S2, S3& S4 for POH.

(c) Looking to inadequacy of skilled manpower, lack of jigs & fixtures, testing facilities and increase in loco holding,

the Sheds & Workshops may have to go for outsourcing of overhaul activities. For such cases, the overhauling to be entrusted to the respective OEM considering the fact

that both type of tap changer do not have same design and items to be replaced. Hence, the overhauling kits for BT and Ganz type shall be as per Annexure- X1, X2 for

AOH, Annexure- X3, X4 for IOH, Annexure- X5, X6 for POH and Annexure- 2A (List-A & B), 2B (List-A & B) for

rehabilitation respectively. (d) Procedure need to be simplified for outsourcing of AOH,

IOH, POH & rehabilitation of tap changer by developing specifications and schedules, which may be done by

nodal agency viz. BSL or DHD Workshop which shall be

of 11


applicable to all the Railways. Till this process is

formulated, normal system of work shall continue. (e) Critical component/sub-assemblies of tap changer are to

be replaced as per maintenance manual of OEMs during their service period. It is observed that some of the tap changers have not gone for rehabilitation and they are

having residual service. For ensuring their reliability, it is suggested that few critical items/sub-assemblies should

be replaced in tap changer after completion of 12 years of service or more and not contemplated for rehabilitations.

(f) Tap Changer having major defects in their life time are required to be attended for replacement of major items/sub-assemblies. To attend such tap changer and

keep them healthy during their service life, major items/sub-assemblies have been identified which shall

be kept by sheds to meet un-schedule arising which will result decrease in down time of tap changer.

(g) To meet the requirement of tap changer during periodic overhauling, rehabilitation of tap changer and to meet

unforeseen situations, sheds will require sufficient rotational spares to avoid any interruption of service. The production of conventional locomotive at CLW has

stopped now. Hence, to maintain the fleet of around 4200 conventional locomotive to their residual service life, new tap changers shall be inducted to meet the

requirement.

B. Transformer:

Committee has gone through the contracts for repair/rehabilitation of transformer awarded by Railways. The

scope of work and technical specifications is varying from Railways to Railways. It is therefore necessary to standardize scope of work and technical specification so that all Railways

will follow the same. Committee has finalized the scope of work and technical specification for repair/rehabilitation of transformer of conventional Locos.

Sub kit AOH-1

Annexure- Q1

Drg. No. Item No. Description Drg. No. Part No. Description

1 1 9919000109001 G1519 Locking Cord (0.6m) SWT-435200-P1 S1519 Fibre glass cord. (0.6 m)

2 2 9910383917001 G3309 Seal AG-549697-P1 S3309 Gasket (for oil flow indicator)

3 2 9919000117001 G1306.2a/

G1306.5a

Seal AM-502840-P1 S1306.2/

S1306.5

Packing (For oil level indicator)

4 1 9910383456002 G1303 Sealing Gasket AG-207812-P2 S1303 Gasket

5 1 9910383599001 G1302.3 Seal AG-546167-P1 S1302.3 Gasket

6 2 9910383461004 G1320.1 Sealing Ring AG-544325-P4 S1320.1 Packing Ring (Safety Valve)

7 2 9910383528001 G1518 Insulated tube AM-500801-P1 S1518 Insulating tube

8 2 9910383534001 G1512 Insulating tube AG-546189-P1 S1512 Insulating pipe

9 6 9910383694001 G2529 Contact piece AG-540123-P1 S2529 Contact

10 2 9919000059002 G3270.3 Cup seal for oil pump SWT-435167-P2 S3270.3 Cup seal

11 2 9919000095004 G3225/G3

222

O ring SWT-435430-P4 S3225/S3

222

O ring

12 2 9919000059001 G3235/G3

233

Cup seal for oil pump SWT-435167-P1 S3235/S3

233

Cup seal

13 1 9919000095003 G3221 O ring SWT-435430-P3 S3221 O ring

14 2 9919000095002 G3224/G3

252

O ring SWT-435430-P2 S3224/S3

252

O ring



17 1 9919000197005 G31.1 Filter SWT-335066-P5 S31.1 Filter element

18 1 9989000293801 G3290.1 Locking Bolt Complete SWT-435490-R1 S3290.1 Locking Bolt Complete

Items required for carrying out AOH maintenance schedule of NO-32 type tap changer

1.Common Items/Components of NO 32 Tap Changer to be procured from REPL (BT type) or AAL (Ganz type) only

Sr. No. Qty. GANZ Type M/s AAL Make BT type M/s REPL Make

A) Selector (GR)

B) Circuit Breaker (CGR)

C) Oil Filtration unit (PHGR)

Page 1 of 2

Sub kit AOH-1

Annexure- Q1


Sr. No. Qty. GANZ Type M/s AAL Make BT type M/s REPL Make

19 1 9919000297001 G3290.2 Cup Seal SWT-435484-P1 S3290.2 Cup Seal

20 1 9919000294001 G3290.7 Piston SWT-435488-P1 S3290.7 Piston

21 2 9989000265801 G3280 Screw Plug Complete SWT-435158-R1 S3280 Screw Plug With Seal

22 4 9910383461006 M1213 Sealing ring SWT-435144-P2 A1213 Packing ring

23 4 9910383734002 M3108 Gasket AG-544441-P2 A3108 Gasket


254

9910383799001 M3206 Sealing Nipple AG-544411-P1 A3206 Valve Nipple

264

9980383790801 M3209 Push Rod with Seal AG-544415-R1 A3209 Valve Plunger Complete

27 4 9910185894002 M3203 Seal Ring AG-508472-P1 A3203 Packing

284

9910383787001 M3204 Compression Spring AG-544356-P1 A3204/

A4204

Compression Spring

2916

9910383855002 M6434/

M6331

Cam type Aux Switch AM- 400660-R1 A6434/

A6331

Cam type Aux Switch Compl.

30 900gm. 9919000207801 G3608 Silica Gel SWT-435501-R2 S4711 Silica Gel

31 60gm. 9989000206801 G3612 Cork Grain SWT-435543-R2 S4712 Cork Grain

32 1 Overhauling kit of PRV

(Seimeg)

Overhauling kit of PRV (Seimeg)

33 1 Set Set of Harwares 28 nos. as

per Annexure- AOH-HW-1

Set of Harwares 28 nos. as per

Annexure- AOH-HW-1

Total Items- 32+28(Hardware)=60

D) Air Motor (SMGR)

Accessories

Page 2 of 2

Annexure- AOH-HW-1


1 6 9910646720028 G2530 Socket HD cap screw MT-430956-P2109 S2530 Hex socket head cap screw

M8x30

2 6 9910646796014 G2524 Spring Washer-M8 SWT-435227-P1 S2524 Spring Washer

3 6 9910646720066 G2540 Flat Washer-M8 MT-430445-P2022 S2540 Washer8.4/13*0.5

4 3 9910383451065 G1411/

G1615/

G1522

Circlip A25 MT-430201-P25 S1411/S1615/

S1522

Circlip A25

5 72 9919000150008 G2407 Cu Gasket 6.5/11.2x1 MT-430152-P11 S2407 Cu Gasket 6.5/11.2x1

6 4 9919000150010 G3435 Gasket(Copper) MT-430152-P34 S3435 Gasket (for oil drain Socket)

7 2 9919000150011 G3433 Gasket(Copper) MT-430152-P34 S3433 Gasket (for oil piping complete)

8 1 9919000150021 G3268 Gasket 3EYC-400029-P1 S3268 Gasket

9 2 9919000150025 G3290.14 Gasket MT-430152-P18 S3290.14 Gasket

10 1 9919000150024 G3290.10 Gasket(Cu) MT-430152-P13 S3290.10 Cu Gasket

11 10 9919000150009 G3406/

G3422

Gasket MT-430152-P23 S3406/ S3422 Cu Gasket 14/20x1.6

12 18 9919000250013 G1204 Disc Washer M10 MT-430151-P26 S1204 Belleville spring washer

13 2 9919000150022 G3212 Gasket (copper)

22.8/30x1

MT-430152-P36 S3212 Gasket 22.8/30x1

14 2 9919000197004 G31.2 Cu Gasket MT-400428-P2 S31.2 Cu Gasket 14/18x1.6

15 4 9919000150027 G3270.4 Gasket (Coupper)

5.5/11x0.2

SWT-435249-P1 S3270.4 Shim

1.Common Hardware of NO 32 tap changer to be procured from REPL (BT type) or AAL (Ganz type) only

Sr.

No.

Qty. GANZ Type M/s AAL Make BT type M/s REPL Make

Page 1 of 2


Sr.

No.


16 4 9919000150020 G3242 Gasket (Copper) 5/10x1 MT-430152-P3 S3242 Cu Gasket 5/10x1

17 2 9910383796012 M3207 Internal Circlip 16X1 MT-430202-P16 A3207/A4207 Internal Circlip I16

18 12 9919000250008 M3110 Disc Washer M6 MT-430151-P22 A3110 Belleville Spring Washer 7.5x14

19 2 9910646780035 M1915 Hex. Nut M12x0.8d MT-430957-P114 A1915 Hex. Nut 0.8dxM12

20 2 9910646780031 M1913 Hex. HD Screw M12x45 MT-430872-P415 A1913 Hex. screw M12x45

21 2 9910646693005 G1320.4 Split Cotter Pin for Safety

Valve

MT-430405-P2364 S1320.4 Split cotter pin A2.5x28

22 12 9910646720027 G2532 Hex. Socket Hd. Screw

M6x20

MT-430956-P2007 S2532 Hex. socket hd. Screw M6x20

23 12 9910646796014 G2607 Spring Washer M8 SWT-435227-P1 S2607 Spring Washer B8

24 6 9910646795076 G2414 Spring Washer M12 MT-430197-P618 S2414 Spring Washer B12

25 12 9910646720073 G2511 Split Cotter Pin 2x20 MT-430405-P2211 S2511 Split Cotter Pin 2x20


27 1 9919000150023 G3290.17 Cu Gasket SWT-435491-P3 S3290.17 Cu Gasket

28 5 9919000150003 G3938a Gasket dia 20.8/28x1 for

Air Pressure Regulator

MT-430152-P33 S3938 Gasket Ø20.8/28x1(For Air

Pressure Regulator)

Total = 28

Page 2 of 2

Sub kit AOH-2A

Annexure-Q2

Sr.No. Qty. Drg. No. Item No. Description

1 2 9910379600025 M568 O ring

2 4 9910383757001 M586 Nylon Washer

3 4 9910383757002 M593 Washer

4 8 9910383754002 M594 Disc

5 4 9910383855002 M6464/M6331 Aux. Cam Switch complete

62

9919000124001 G3613 Rubber Gasket for 1 Kg Air

Drier

72

9910646257001 G3614 Rubber Gasket for 1 Kg Air

Drier

8 1 set Set of Harwares 02 nos. as per

Annexure- AOH-HW-2

Total - 7+2 (Hardware)= 09

2. Uncommon Items/Components for AOH specific to (Ganz type) Tap Changer to be

procured from M/s AAL only

Page 1 of 1

Annexure. AOH-HW-2

Sr. No. Qty. Drg. No. Part No. Description

1 2 9910383784013 M569 Internal Circlip 12x1

2 4 9910383813004 M2314.6.1a Split Pin 2x16

2.Un-common Hardware items of NO 32 Tap Changer to be procured from AAL (Ganz type)

only

Total -02

Page 1 of 1

Sub kit AOH- 2B

Annexure- Q3


1 2 AM-404742-P1 A4430.4 Packing Ring

2 2 AG-413762-P25 A4430.2 Damping Gasket

3 6 AG-544441-P1 A4120/A4430.19 Gasket

4 1 AM-501612-P1 A4540.4 Guide Pin

5 1 AM-401107-P1 A4540.7 Compression Spring

6 2 AG-544411-P1 A4206 Valve Nipple

7 2 AG-544415-R1 A4209 Valve Plunger Complete

8 2 AG-508472-P1 A4203 Packing

9 4 AG-544346-P1 A4430.14 Washer

10 2 3EYC-400037-R1 A2215 Spring with eyes

11 6 AG-544461-P1 A3208/A4208 Washer

12 2 AG-544356-P1 A4204 Compression Spring

13 1 AM-501613-P1 A4540.6 Guide Pin

14 2 RE-144023-P2 S4701.11 Rubber Gasket for 1 Kg Air Drier


161 set Sets of Hardware 10 nos. as per Annexure- AOH-HW-3

Total - 15+10(Hardware)=25

3. Uncommon Items/Components for AOH specific to BT type Tap Changer to be procured from M/s REPL only

Page 1 of 1

Annexure- AOH-HW-3


1 1 MT-430201-P10 A4514 External Circlip A10

2 4 MT-430405-P2209 A5317.9 Split PinA2x15

3 8 AM-400428-P1 A3113/A4426 Flat Gasket

4 12 AM-501808-P1 A4537 Packing Washer

5 1 MT-430189-P110 A4540.12 Roll Pin 2x12

6 4 MT-430202-P16 A3207/A4207 Internal Circlip I16

7 8 NB-435128-P6 A2314.6.1 Circlip(Imported)


9 4 MT-430189-P311 A4540-10 Roll Pin 4x14

10 2 A-430152-P19 A1952 Cu Gasket 11/17x1

3.Un-common Hardware items of NO 32 Tap Changer to be procured from REPL (BT type) only

Total - 10

Page 1 of 1

Sub Kit AOH-1 Annexure-Q4

1 4 SWT -435461 -P1 or

9910383748001 or

SKEL -3463, RDSO

SPEC/E-4/01

A2303 or M2303 Sealing ring or U-section

ring

Items required for carrying out AOH maintenance schedule of NO 32

type Tap Changer

Items to procured from sources approved as per RDSO vendor list

Page 1 of 1

Annexure- X1

Drg. No. Part No. Description

1 1 SWT-435200-P1 S1519 Fibre glass cord. (0.6 m)

2 2 AG-549697-P1 S3309 Gasket (for oil flow indicator)

3 2 AM-502840-P1 S1306.2/

S1306.5

Packing (For oil level indicator)

4 1 AG-207812-P2 S1303 Gasket

5 1 AG-546167-P1 S1302.3 Gasket

6 2 AG-544325-P4 S1320.1 Packing Ring (Safety Valve)

7 2 AM-500801-P1 S1518 Insulating tube

8 2 AG-546189-P1 S1512 Insulating pipe

9 6 AG-540123-P1 S2529 Contact

10 2 SWT-435167-P2 S3270.3 Cup seal

11 2 SWT-435430-P4 S3225/S3222 O ring

12 2 SWT-435167-P1 S3235/S3233 Cup seal

13 1 SWT-435430-P3 S3221 O ring

14 2 SWT-435430-P2 S3224/S3252 O ring

15 6 SWT-435430-P5 S3251 O ring

16 1 SWT-435430-P1 S3254 O ring

17 1 SWT-335066-P5 S31.1 Filter element

18 1 SWT-435490-R1 S3290.1 Locking Bolt Complete

BT type M/s REPL Make

A) Selector (GR)



Revised Must Change item of AOH for BT design NO 32 tap changer for outsourcing to M/s REPL

Sr. No. Qty.

Page 1 of 3

Annexure- X1


BT type M/s REPL MakeSr. No. Qty.

19 1 SWT-435484-P1 S3290.2 Cap Seal

20 1 SWT-435488-P1 S3290.7 Piston

21 2 SWT-435158-R1 S3280 Screw Plug With Seal

22 4 SWT-435144-P2 A1213 Packing ring

23 4 AG-544441-P2 A3108 Gasket

24 4 AG-544441-P1 A3111 Gasket



27 4 AG-508472-P1 A3203 Packing


29 16 AM- 400660-R1 A6434/ A6331 Cam type Aux Switch Compl.



32 6 AG-544441-P1 A4120/

A4430.19

Gasket

33 1 AM-501612-P1 A4540.4 Guide Pin




37 2 AG-508472-P1 A4203 Packing

38 4 AG-544346-P1 A4430.14 Washer


40 6 AG-544461-P1 A3208/A4208 Washer


D) Air Motor (SMGR)

Page 2 of 3

Annexure- X1


BT type M/s REPL MakeSr. No. Qty.

42 1 AM-501613-P1 A4540.6 Guide Pin



45 4 SWT-435461-P1 A2303 Sealing ring

46 900gm. SWT-435501-R2 S4711 Silica Gel

47 60gm. SWT-435543-R2 S4712 Cork Grain

48 1 Overhauling kit of PRV (Seimeg)

49 1 Set Set of Harwares 38 nos. as per Annexure-

HW-X1B


Accessories

Page 3 of 3

Annexure- HW-X1B


1 6 MT-430956-P2109 S2530 Hex socket head cap screw M8x30

2 6 SWT-435227-P1 S2524 Spring Washer

3 6 MT-430445-P2022 S2540 Washer8.4/13*0.5

4 3 MT-430201-P25 S1411/S1615/

S1522

Circlip A25

5 72 MT-430152-P11 S2407 Cu Gasket 6.5/11.2x1

6 4 MT-430152-P34 S3435 Gasket (for oil drain Socket)

7 2 MT-430152-P34 S3433 Gasket (for oil piping complete)

8 1 3EYC-400029-P1 S3268 Gasket

9 2 MT-430152-P18 S3290.14 Gasket

10 1 MT-430152-P13 S3290.10 Cu Gasket

11 10 MT-430152-P23 S3406/ S3422 Cu Gasket 14/20x1.6

12 18 MT-430151-P26 S1204 Belleville spring washer

13 2 MT-430152-P36 S3212 Gasket 22.8/30x1

14 2 MT-400428-P2 S31.2 Cu Gasket 14/18x1.6

15 4 SWT-435249-P1 S3270.4 Shim

16 4 MT-430152-P3 S3242 Cu Gasket 5/10x1


18 12 MT-430151-P22 A3110 Belleville Spring Washer 7.5x14

19 2 MT-430957-P114 A1915 Hex. Nut 0.8dxM12

20 2 MT-430872-P415 A1913 Hex. screw M12x45

21 2 MT-430405-P2364 S1320.4 Split cotter pin A2.5x28

22 12 MT-430956-P2007 S2532 Hex. socket hd. Screw M6x20

23 12 SWT-435227-P1 S2607 Spring Washer B8

24 6 MT-430197-P618 S2414 Spring Washer B12

Hardware list of AOH for BT design NO 32 tap changer for outsourcing to M/s

REPL

Sr.

No.

Qty. BT type M/s REPL Make

Page 1 of 2

Annexure- HW-X1B


Sr.

No.


25 12 MT-430405-P2211 S2511 Split Cotter Pin 2x20


27 1 SWT-435491-P3 S3290.17 Cu Gasket

28 5 MT-430152-P33 S3938 Gasket Ø20.8/28x1(For Air Pressure

Regulator)


30 4 MT-430405-P2209 A5317.9 Split PinA2x15

31 8 AM-400428-P1 A3113/A4426 Flat Gasket


33 1 MT-430189-P110 A4540.12 Roll Pin 2x12




37 4 MT-430189-P311 A4540.10 Roll Pin 4x14

38 2 A-430152-P19 A1952 Cu Gasket 11/17x1

Total - 38

Page 2 of 2

Annexure- X2

Drg. No. Item No. Description

1 1 9919000109001 G1519 Locking Cord (0.6m)

2 2 9910383917001 G3309 Seal

3 2 9919000117001 G1306.2a/G1306.5a Seal

4 1 9910383456002 G1303 Sealing Gasket

5 1 9910383599001 G1302.3 Seal

6 2 9910383461004 G1320.1 Sealing Ring

7 2 9910383528001 G1518 Insulated tube

8 2 9910383534001 G1512 Insulating tube

9 6 9910383694001 G2529 Contact piece

10 2 9919000059002 G3270.3 Cup seal for oil pump

11 2 9919000095004 G3225/G3222 O ring

12 2 9919000059001 G3235/G3233 Cup seal for oil pump

13 1 9919000095003 G3221 O ring

14 2 9919000095002 G3224/G3252 O ring

15 6 9919000095005 G3251 O ring

16 1 9919000095001 G3254 O ring

17 1 9919000197005 G31.1 Filter

18 1 9989000293801 G3290.1 Locking Bolt Complete

Revised Must Change item of AOH for Ganz design NO 32 tap changer for outsourcing to M/s AAL

Sr. No. Qty. GANZ Type M/s AAL Make


A) Selector (GR)


Page 1 of 3

Annexure- X2



19 1 9919000297001 G3290.2 Cap Seal

20 1 9919000294001 G3290.7 Piston

21 2 9989000265801 G3280 Screw Plug Complete

22 4 9910383461006 M1213 Sealing ring

23 4 9910383734002 M3108 Gasket

24 4 9910383734001 M3111 Gasket

25 2 9910383799001 M3206 Sealing Nipple

26 4 9980383790801 M3209 Push Rod with Seal

27 4 9910185894002 M3203 Seal Ring

28 4 9910383787001 M3204 Compression Spring

29 16 9910383855002 M6434/ M6331 Cam type Aux Switch

30 2 9910379600025 M568 O ring

31 4 9910383757001 M586 Nylon Washer

32 4 9910383757002 M593 Washer

33 8 9910383754002 M594 Disc

34 4 9910383855002 M6464/M6331 Aux. Cam Switch complete

35 2 9919000124001 G3613 Rubber Gasket for 1 Kg Air Drier


37 4 9910383748001 M2303 U section ring

38 900gm. 9919000207801 G3608 Silica Gel

39 60gm. 9989000206801 G3612 Cork Grain

40 1 Overhauling kit of PRV (Seimeg)

Accessories

D) Air Motor (SMGR)

Page 2 of 3

Annexure- X2



41 1 Set Set of Harwares 30 nos. as per

Annexure- HW-X2 A


Page 3 of 3

Annexure-HW-X2 A


1 6 9910646720028 G2530 Socket HD cap screw

2 6 9910646796014 G2524 Spring Washer-M8

3 6 9910646720066 G2540 Flat Washer-M8

4 3 9910383451065 G1411/

G1615/

G1522

Circlip A25

5 72 9919000150008 G2407 Cu Gasket 6.5/11.2x1

6 4 9919000150010 G3435 Gasket(Copper)

7 2 9919000150011 G3433 Gasket(Copper)

8 1 9919000150021 G3268 Gasket

9 2 9919000150025 G3290.14 Gasket

10 1 9919000150024 G3290.10 Gasket(Cu)

11 10 9919000150009 G3406/ G3422 Gasket

12 18 9919000250013 G1204 Disc Washer M10

13 2 9919000150022 G3212 Gasket (copper) 22.8/30x1

14 2 9919000197004 G31.2 Cu Gasket

15 4 9919000150027 G3270.4 Gasket (Coupper) 5.5/11x0.2

16 4 9919000150020 G3242 Gasket (Copper) 5/10x1

17 2 9910383796012 M3207 Internal Circlip 16X1

18 12 9919000250008 M3110 Disc Washer M6

19 2 9910646780035 M1915 Hex. Nut M12x0.8d

20 2 9910646780031 M1913 Hex. HD Screw M12x45

21 2 9910646693005 G1320.4 Split Cotter Pin for Safety

Valve

22 12 9910646720027 G2532 Hex. Socket Hd. Screw M6x20

23 12 9910646796014 G2607 Spring Washer M8

24 6 9910646795076 G2414 Spring Washer M12

25 12 9910646720073 G2511 Split Cotter Pin 2x20


27 1 9919000150023 G3290.17 Cu Gasket

28 5 9919000150003 G3938a Gasket dia 20.8/28x1 for Air

Pressure Regulator29 2 9910383784013 M569 Internal Circlip 12x1

30 4 9910383813004 M2314.6.1a Split Pin 2x16

Total = 30

Hardware list of AOH for Ganz design NO 32 tap changer for

outsourcing to M/s AAL

Sr.

No.

Qty. GANZ Type M/s AAL Make

Page 1 of 1

Sub kit IOH-1Annexure-R1


1 1 9919000109001 G1519 Locking Cord (0.6m) SWT-435200-P1 S1519 Fibre glass cord. (0.6m)

2 2 9910383917001 G3309 Seal AG-549697-P1 S3309 Gasket (for oil flow indicator)

3 1 9910383461005 G1421 Sealing ring AG-544325-P5 S1421 Packing ring

4 2 9980383530801 G1515 Contact roller AG-546151-R1 S1515 Contact roller complete

5 2 9910383461004 G1320.1 Sealing ring AG-544325-P4 S1320.1 Packing Ring

6 2 9919000118001 G1434/G1440 Oil seal SWT-435381-P1 S1434/S1440 Oil seal


8 2 9919000117001 G1306.2a/

G1306.5a

Seal AM-502840-P1 S1306.2/

S1306.5

Packing (for oil level

indicator)

9 4 9910383541001 G1514 Bearing AG-546150-P1 S1514 Bearing

10 1 9910383599001 G1302.3 Seal AG-546167-P1 S1302.3 Gasket

11 2 9910383528001 G1518 Insulated Tube AM-500801-P1 S1518 Insulating Tube

12 2 9910383534001 G1512 Insulating Tube AG-546189-P1 S1512 Insulating Pipe

13 2 9919000080001 G1513 Contact Roller Housing AM-300009-P1 S1513 Contact Roller Housing

14 1 9919000095006 G1601.1 Bushing double pole 'O'

ring

AG-432122-P7 S1601.1 Packing Ring


16 2 9910383533001 G1516 Roller Guide AG416382-P1 S1516 Roller Housing

17 2 9910383578001 G1435 Coupling Pin AG-546487-P1 S1435 Coupling Pin

18 08 9910383535001 G1517 Push Spring AG-405322-P1 S-1517 Push Spring


20 12 9910383693001 G2517 Insulated sleeve AM-502593-P1 S2517 Bush

21 6 9919000183001 G2502 Bush AM-502699-P1 S2502 Insuating Bush

22 12 9910646714001 G2505 Insulating Washer AM-502615-P1 S2505 Insulating Washer

23 6 9910383657002

9910383657003

9910646703002

9910646703001

G2151

G2144

G2146

G2154

Contact Bolt AG-547421-P2 S2151

S2144

S2146

S2158

Contact Bolt

Items required for carrying out IOH maintenance schedule of NO-32 type Tap Changer

1. Common Items/Components of NO 32 Tap Changer to be procured from REPL (BT type) or AAL (Ganz type) only

Sr. No. Qty. GANZ Type M/s AAL Make M/s BT type M/s REPL make

A) Selector (GR)


Page 1 of 3




24 139919000215001

9919000215002

G2152

G2147

Contact Nut M-12xTh-7 AG-547420-P1 S2152

S2147

Contact Nut

25 2 9910646720024 G2515 Needle Roller Bearing HAGT-443522-P1 S2515 Yoke type track roller 10/19x11.8

26 6 9989000314801 G2537 Spring Guide HAGT-443612-R1 S2537 Spring retainer complete

27 6 9919000187001 G2503 Bush AM-502618-P1 S2503 Bush

28 6 9919000317001 G2536 Compression Spring AG-540918-P1 S2536 Compression Spring

29 2 9919000059001 G3235/G3233 Cup seal for oil pump SWT-435167-P1 S3235/S3233 Cup seal

30 2 9919000095004 G3225/G3222 O ring SWT-435430-P4 S3225/S3222 O ring



33 2 9919000095002 G3224/G3252 O ring SWT-435430-P2 S3224/S3252 O ring



36 1 9919000197005 G31.1 Filter SWT-335066-P5 S31.1 Filter Element

37 2 9919000150026 G3290.12 Gasket (copper) MT-430152-P19 S3290.12 Cu gasket



40 10 9919000150009 G3422/G3406 Gasket MT-430152-P23 S3422/S3406 Cu gasket

41 1 9919000150023 G3290.17 Gasket (copper) SWT-435491-P3 S3290.17 Cu gasket

42

7

9919000150011

9919000150010

G3433/G3435Gasket MT-430152-P34 S3433/S3435

/S3428

Cu gasket

43 1 9919000297001 G3290.2 Cup Seal SWT-435484-P1 S3290.2 Cup Seal


45 2 9989000265801 G3280 Screw Plug complete SWT-435158-R1 S3280 Screw Plug Complete

46 1 9989000293801 G3290.1 Locking Bolt Compl. SWT-435490-R1 S3290.1 Locking Bolt Complete

47 1 9919000269001 G3253 Middle Piece SWT-335045-P1 S3253 Middle Piece




C) Oil Filteration Unit (PHGR) & CU Gaskets

D) Air Motor (SMGR)

Page 2 of 3




51 4 9980383790801 M3209 Push rod with seal AG-544415-R1 A3209 Valve plunger comp.

52 2 9910383799001 M3206 Sealing nipple (Valve 'A') AG-544411-P1 A3206 Valve nipple

53 3 9910646780048/

9910385081046

M1929.1/

G4212/

G4217

Roll pin (8X45) MT-430189-P471 A1929.1/

S4212/ S4217

Roll pin (8/45)

54 3 9910646780046/

9919000009014

M1929.2/

G4216/

G4218

Roll pin (5X45) MT-430189-P371 A1929.2/

S4216/ S4218

Roll pin (5/45)

55 4 9910185894002 M3203 Seal Ring AG-508472-P1 A3203 Packing

5635

9910383855002 M6434 Cam type Aux. Switch AM-400660-R1 A6434/ 5514/

A6331

Aux. cam switch compl.

57 2 9910383787001 M3204 Compression Spring AG-544356-P1 A3204 Compression Spring

58 8 9910383803002 M2313 Bearing Shell AG-545649-P2 A2313 Bearing Liner

59 141 9919000087001 G4415 Mica Washer KB-473201-P2 S4415 Mica Washer

60 3 9919000092001 G4416.2 Tube B-406533-P2 S4416.2 Samica Glass Tube

61 900gr. 9989000207801 G3608 Silica Gel SWT-435501-R2 S4711 Silica Gel


631

9919000150016 G3947a Copper Gasket 17/30x1 Gasket (For Inlet Side Nipple)

64

4

9919000150005 G3972a Copper Gasket 18/10x1 Gasket (Outlet from two way

solenoid valve to PHGR &

SMGR)

651 Set

G3933 Overhauling kit of PRV

(Seimeg)

S3933 Overhauling kit of PRV (Seimeg)

661 Set

Overhauling kit of

EVPHGR

Overhauling kit of EVPHGR

67

1 Set

Set of Hardware 47 nos.

as per Annexure -IOH-HW-

1

Set of Hardware 47 nos. as per

Annexure -IOH-HW-1

Total-66+47(Hardware)=113

E) ZSM Panel

E) Accessories for Stainless Steel Element

Page 3 of 3

Annexure-IOH-HW-1


1 2 9910383496001 G1442 Washer A-509828-P1 S1442 Washer 52/42x0.2

2 15G1523 Packing

Washer25.5/32x0.2

AG-544234-P3 S1523 Packing Washer25.5/32x0.2

3 1 9910383575012 G1436 Rolled Pin 3x25 MT430189-P216 S1436 Roll Pin 3x25

4 4 9910646698001 G1438 Locking SWT435084-P1 S1438 Spring Ring

52

9910385081046 G4212/ G4217 Roll Pin 8x45 MT430189-P471 S4212/ S4217 Roll Pin 8x45

62

9919000009014 G4216/ G4218 Roll Pin 5x45 MT-430189-P371 S4216/ S4218 Roll Pin 5x45

7 2 9910383546001 G1508 Fixing Plate AG544655P-1 S1508 Locking Washer

824

9910646796011 G2604 Hex Socket Hd cap

ScrewM6x25

MT-430956-P2008 S2604 Hex Socket Hd cap ScrewM6x25

9 369919000184001 G2508 Disc Washer M6 HAGT-443524-P1 S2508 Belleville Spring Washer 6.2/18x0.5

10 12 9910646720038 G2520 Split Pin 4x25 MT-430445-P2411 S2520 Split Cotter Pin 4x20

11 6 9910646720028 G2530 Socket HD cap screw MT-430956-P2109 S2530 Hex socket head cap screw M8x30

12 6 9910646796014 G2524 Spring Washer-M8 SWT-435227-P1 S2524 Spring Washer

13 6 9910646720066 G2540 Flat Washer-M8 MT-430445-P2022 S2540 Washer8.4/13*0.5

14 2 9919000197004 G31.2 Cu Gasket AM-400428-P2 S31.2 Cu Gasket 14/18x1.6

15 2 9919000150022 G3212 Gasket MT-430152-P36 S3212 Gasket 22.8/30x1

16 4 9919000150027 G3270.4 Gasket (Cu) 5.5/11x0.2 SWT-435249-P1 S3270.4 Shim

17 4 9919000150020 G3242 Gasket (Cu) 5/10x1 MT-430152-P6 S3242 Cu gasket 5/10x1

188

9910383911026 G3202 Spring washer M8 SWT-435227-P1 S3202 Split Type Spring Washer 8.1/12.7

19 1 9919000271005 G3236 Spring washer M12 MT-430197-P218 S3236 Spring Washer B12

20 1 9919000150021 G3268 Gasket 3EYC-400029-P1 S3268 Gasket

1. Common Hardware items of NO 32 tap changer to be procured from REPL (BT type) or AAL (Ganz type) only

Sr.

No.


Page 1 of 3

Annexure-IOH-HW-1


Sr.

No.


218

9919000250008 M3110 Disc Washer M6 MT-430151-P22 A3110 Belleville Spring Washer 7.5x14

22 4 9910383796012 M3207 Internal Circlip 16x1 MT-430202-P16 A3207 Internal Circlip I 16

23 4 9910383811011 M2301 Circlip MT-430201-P42 A2301 External Circlip A42

243

9910646780056 M1909a Hex HD screw M10x35 MT-430151-P26 A1909 Hex Screw M10x40

25 2 9910646780035 M1915 Hex nut M12x0.8d MT-430957-9114 A1915 Hex. Nut 0.8dxM12

26 2 9910646780031 M1913 Hex HD screw M12x45 MT-430872-415 A1913 Hex. Screw M12x45

27 29910646693005 G1320.4 Split Cotter Pin for

Safety Valve

MT-430405-P2364 S1320.4 Split cotter pin A2.5x28

2811

9910383470001 G1221 Special Bolt (For Inner &

Outer Insulating Ring)

AG-546084-P1 S1221 Special Bolt (For Inner & Outer

Insulating Ring)

29 229919000251001 G1220 Spring bronze washer-

M6

MT-430190-P116 S1220 Belleville Spring Washer

30 10 9919000222001 G1532 Shim Washer HAMT-405170-P6 S1532 Washer (For Contact Roller)

31 12 9910646796014 G2607 Spring Washer M8 SWT-435227-P1 S2607 Spring Washer B8

32 6 9910646795076 G2414 Spring Washer M12 MT-430197-P618 S2414 Spring Washer B12


34 12 9910647265002 G2516 Washer HAGT-443523-P1 S2516 Washer

3512

9910646796025 G2408/G2532 Hex. Skt. Dd. Screw

M6x20

MT-430956-P2007 S2408/S2532 Hex. socket hd. Screw M6x20

36 489910646796012 G2406 Hex Socket Hd cap

ScrewM6x30

MT-430956-P2009 S2406 Hex socket hd cap screw M6x30

3772

9919000150008 G2407 Cu Gasket 6.5/11.2x1 MT-430152-P11 S2407 Cu Gasket 6.5/11.2x1

383

9910383451065 G1411/G1615/

G1522

Circlip A25 MT-430201-P25 S1411/S1615/

S1522

Circlip A25

Page 2 of 3

Annexure-IOH-HW-1


Sr.

No.


3909

9919000150009 G2145/

G2161

Gasket MT-430152-P23 S2145/S2161 Cu Gasket 14/20x1.6

40 100 9919000250013 G1109/G1112/

G1204/G1305/

G1403/G1603/

G2117/G2134/

M2109

Disc Washer-M10 MT-430151-P26 S1109/S1112/

S1204/S1305/

S1403/S1603/

S2117/S2134/

A2109

Belleville spring washer 11/22

41 30 9919000250011 G1460/G1464/

G1611/G1614/

G2127/G2182/

M1907/M1936/


S1611/S1614/

S2127/S2182/

A1907/A1936/

Belleville spring washer 8.4/18

425

9919000150003 G3938a Gasket dia 20.8/28x1 for

Air Pressure Regulator

MT-430152-P33 S3938 Gasket Ø20.8/28x1(For Air

Pressure Regulator)

432

9910646780051 M1914a Helical Spring lock

washer M12

MT-430151-P28 A1914 Belleville spring washer 14/28

4412

9910646720027 G2532 Hex. Socket Hd. Screw

M6x20

MT-430956-P2007 S2532 Hex. socket hd. Screw M6x20

45 1 9919000180003 G3290.6 Internal circlip I35 MT-430202-P35 S3290.6 Internal circlip I35

46 12 9910646720066 G2539 Washer HAGT-443523-P2 S2539 Washer

47 2 9910646756059 2113 External Circlip A24 MT-430201-P24 A2113 External Circlip A24

Total- 47

Page 3 of 3

Sub kit IOH-2AAnnexure-R2


1 2 9980641450801 M553c Spring With Eyes

2 2 9910379600025 M568 O ring

3 7 9910383855002 M6331 Aux. Cam Switch compl.

4 2 9910646729001 M8605 Sequence Relay

5 3 9980647346801 M8604 Diode Comp.

6 4 9910383757001 M586 Nylon Washer

7 4 9910383757002 M593 Washer

8 8 9910383754002 M594 Disc

9 4 9910383761001 M590 Pressure Spring

10 4 9910383759001 M587a Armature



131 set Set of Hardware 06 nos. as per

Annexure -IOH-HW-2

Total- 12+06 (Hardware)=18

2. Uncommon Items/Components for IOH specific to (Ganz type) tap changer

to be procured from AAL only

Page 1 of 1

Annexure- IOH-HW-2



2 4 9910383813004 M2314.6.1a Split Pin 2x16

3 4 9910383755001 M596 Tab Washer

4 2 9910383750028 M570b Spring Washer M10

5 10 9910383750029 M570e Spring Washer M8

6 4 9910383755002 M578 Tab Washer

2. Un-common Hardware items of NO 32 Tap Changer to be procured from AAL

(Ganz type) only

Total - 06

Page 1 of 1

Sub kit IOH-2BAnnexure-R3


1 4 AG-544411-P1 A3206 Valve nipple


3 2 AM-404742-P1 A4430.4 Packing ring


5 1 AM-401107-P1 A4540.7 Compression spring

6 2 AG-544415-R1 A4209 Valve plunger comp.

7 6 AG-544441-P1 A4120/A4430.19 Gasket

8 1 AM-501612-P1 A4540.4 Guide Pin

9 2 AG-508472-P1 A4203 Packing

10 4 AG-544346-P1 A4430.14 Washer

11 2 AG-549177-P1 A4150.36 Armature


13 4 AG-544356-P1 A3204/A4204 Compression Spring


15 1 AG-546709-P1 A6102 Key

16 1 AM-300792-R2 A6103a Intermediate Gear Complete (Right)

17 1 AM-501613-P1 A4540.6 Guide Pin


19 1 AG-546709-P2 A1951 Key



22 2 AG-549804-R1 A4150.31 Adjusting screw complete

23 1 set Set of Hardware 17 nos. as per Annexure -

IOH-HW-3

Total-22+17(Hardware)=39

Set of Hardwares

3. Uncommon Items/Components for IOH specific to BT type tap changer to be procured

from REPL only

Page 1 of 1

Annexure- IOH-HW-3

Sr.

No.Qty. Drg. No. Part No. Description

1 2 SWT-439002-P2021 A4150.41 Locking Sheet

2 2 SWT-439002-P2023 A4150.4 Locking sheet 13,5

3 6 AG-544461-P1 A4208/A3208 Washer

4 4 MT-430189-P311 A4540.10 Roll pin 4 x 14

5 2 3EYC-400001-P1 A4516 Hex. screw M8x35

6 2 MT-430197-P613 A4543 Spring washer B8

7 1 MT-430189-P110 A4540.12 Roll Pin 2x12

810 AM-400428-P1 A3113/A4426/

A4424/A4123 Flat Wahser

9 2 MT-430202-P16 A4207 Internal Circlip I 16



12 4 MT-430405-P2209 A5317.9 Split PinA2x15



15 1 MT-430201-P12 A5150.22 External Circlip A12


17 2 A-430152-P19 A1952 Cu Gasket 11/17x1

3. Un-common Hardware items of NO 32 Tap Changer to be procured from REPL (BT

type) only

Total - 17

Page 1 of 1

Sub Kit-3 IOH Annexure-R4


1 4 SWT -435461 -P1 or

9910383748001 or

SKEL -3463, RDSO

SPEC/E-4/01

A2303 or M2303 Sealing ring or U-section ring

2 1 9980383467802 or AM-

200095-R2 or S1218/

SKEL- 4661

G1218 or S1218 Insulting Ring (Inner) or Insulating

Ring complete (Inner)

3 1 9980383467801 or AM-

200095-R1 or S1219/

SKEL- 4661

G1219 or S1219 Insulting Ring (Outer) or Insulating

Ring complete (Outer)

Total-03

Items required for carrying out IOH maintenance schedule of NO 32

type Tap Changer

Items to procured from sources approved as per RDSO vendor list

Page 1 of 1

Annexure-X3


1 1 SWT-435200-P1 S1519 Fibre glass cord. (0.6m)

2 2 AG-549697-P1 S3309 Gasket (for oil flow indicator)

3 1 AG-544325-P5 S1421 Packing ring

4 2 AG-546151-R1 S1515 Contact roller complete

5 2 AG-544325-P4 S1320.1 Packing Ring

6 2 SWT-435381-P1 S1434/S1440 Oil seal

7 1 AG-207812-P2 S1303 Gasket

8 2 AM-502840-P1 S1306.2/

S1306.5

Packing (for oil level

indicator)

9 4 AG-546150-P1 S1514 Bearing

10 1 AG-546167-P1 S1302.3 Gasket

11 2 AM-500801-P1 S1518 Insulating Tube

12 2 AG-546189-P1 S1512 Insulating Pipe

13 2 AM-300009-P1 S1513 Contact Roller Housing

14 1 AG-432122-P7 S1601.1 Packing Ring

15 3 AG-207812-P4 S1107 Gasket

16 2 AG416382-P1 S1516 Roller Housing

17 2 AG-546487-P1 S1435 Coupling Pin

18 1 AM-200095-R2 S 1218 Insulting Ring (Inner) or Insulating Ring

complete (Inner)

19 1 AM-200095-R1 S1219 Insulting Ring (Outer) or Insulating Ring

complete (Outer)

20 08 AG-405322-P1 S-1517 Push Spring

21 6 AG-540123-P1 S2529 Contact

22 12 AM-502593-P1 S2517 Bush

23 6 AM-502699-P1 S2502 Insuating Bush

24 12 AM-502615-P1 S2505 Insulating Washer

25 6 AG-547421-P2 S2151

S2144

S2146

S2158

Contact Bolt

26 13AG-547420-P1 S2152

S2147

Contact Nut

27 2 HAGT-443522-P1 S2515 Yoke type track roller

28 6 HAGT-443612-R1 S2537 Spring retainer complete

29 6 AM-502618-P1 S2503 Bush

30 6 AG-540918-P1 S2536 Compression Spring

Revised Must Change item of IOH for BT design NO 32 tap changer for outsourcing to

M/s REPL

Sr. No. Qty. M/s BT type M/s REPL make

A) Selector (GR)


Page 1 of 3

Annexure-X3



31 2 SWT-435167-P1 S3235/S3233 Cup seal

32 2 SWT-435430-P4 S3225/S3222 O ring

33 2 SWT-435167-P2 S3270.3 Cup seal

34 1 SWT-435430-P3 S3221 O ring

35 2 SWT-435430-P2 S3224/S3252 O ring

36 6 SWT-435430-P5 S3251 O ring

37 1 SWT-435430-P1 S3254 O ring

38 1 SWT-335066-P5 S31.1 Filter Element

39 2 MT-430152-P19 S3290.12 Cu gasket

40 2 MT-430152-P18 S3290.14 Cu gasket

41 1 MT-430152-P13 S3290.10 Cu gasket

42 10 MT-430152-P23 S3422/S3406 Cu gasket

43 1 SWT-435491-P3 S3290.17 Cu gasket

447

MT-430152-P34 S3433/S3435

/S3428

Cu gasket

45 1 SWT-435484-P1 S3290.2 Cup Seal

46 1 SWT-435488-P1 S3290.7 Piston

47 2 SWT-435158-R1 S3280 Screw Plug Complete

48 1 SWT-435490-R1 S3290.1 Locking Bolt Complete

49 1 SWT-335045-P1 S3253 Middle Piece


51 4 AG-544441-P2 A3108 Gasket

52 4 AG-544441-P1 A3111 Gasket



55 3 MT-430189-P471 A1929.1/

S4212/ S4217

Roll pin (8/45)

56 3 MT-430189-P371 A1929.2/

S4216/ S4218

Roll pin (5/45)

57 4 AG-508472-P1 A3203 Packing

5835

AM-400660-R1 A6434/ 5514/

A6331

Aux. cam switch compl.


60 8 AG-545649-P2 A2313 Bearing Liner




D) Air Motor (SMGR)

Page 2 of 3

Annexure-X3



63 2 AM-404742-P1 A4430.4 Packing ring




67 6 AG-544441-P1 A4120/A4430.19 Gasket

68 1 AM-501612-P1 A4540.4 Guide Pin

69 2 AG-508472-P1 A4203 Packing

70 4 AG-544346-P1 A4430.14 Washer

71 2 AG-549177-P1 A4150.36 Armature




75 1 AG-546709-P1 A6102 Key

76 1 AM-300792-R2 A6103a Intermediate Gear Complete (Right)

77 1 AM-501613-P1 A4540.6 Guide Pin


79 1 AG-546709-P2 A1951 Key




83 2 AG-549804-R1 A4150.31 Adjusting screw complete

84 141 KB-473201-P2 S4415 Mica Washer

85 3 B-406533-P2 S4416.2 Samica Glass Tube

86 900gr. SWT-435501-R2 S4711 Silica Gel


88 1 Gasket (For Inlet Side Nipple)

89 4 Gasket (Outlet from two way solenoid

valve to PHGR & SMGR)

90 1 Set S3933 Overhauling kit of PRV (Seimeg)

91 1 Set Overhauling kit of EVPHGR

92 1 Set Set of Hardware 64 nos. as per

Annexure-HW-X3 B

Total-91+64 (Hardware)=155


E) ZSM Panel

Page 3 of 3

Annexure -HW-X3 B


1 2 A-509828-P1 S1442 Washer 52/42x0.2

2 15 AG-544234-P3 S1523 Packing Washer25.5/32x0.2

3 1 MT430189-P216 S1436 Roll Pin 3x25

4 4 SWT435084-P1 S1438 Spring Ring

5 2 MT430189-P471 S4212/ S4217 Roll Pin 8x45

6 2 MT-430189-P371 S4216/ S4218 Roll Pin 5x45

7 2 AG544655P-1 S1508 Locking Washer

8 24 MT-430956-P2008 S2604 Hex Socket Hd cap ScrewM6x25

9 36 HAGT-443524-P1 S2508 Belleville Spring Washer 6.2/18x0.5


11 6 MT-430956-P2109 S2530 Hex socket head cap screw M8x30

12 6 SWT-435227-P1 S2524 Spring Washer

13 6 MT-430445-P2022 S2540 Washer8.4/13*0.5

14 2 AM-400428-P2 S31.2 Cu Gasket 14/18x1.6

15 2 MT-430152-P36 S3212 Gasket 22.8/30x1

16 4 SWT-435249-P1 S3270.4 Shim

17 4 MT-430152-P6 S3242 Cu gasket 5/10x1

18 8 SWT-435227-P1 S3202 Split Type Spring Washer 8.1/12.7


20 1 3EYC-400029-P1 S3268 Gasket

21 2 MT-430405-P2364 S1320.4 Split cotter pin A2.5x28

22 11 AG-546084-P1 S1221 Special Bolt (For Inner & Outer

Insulating Ring) 23 22 MT-430190-P116 S1220 Belleville Spring Washer

24 10 HAMT-405170-P6 S1532 Washer (For Contact Roller)

25 12 SWT-435227-P1 S2607 Spring Washer B8



28 12 HAGT-443523-P1 S2516 Washer

29 12 MT-430956-P2007 S2408/S2532 Hex. socket hd. Screw M6x20

30 48 MT-430956-P2009 S2406 Hex socket hd cap screw M6x30

31 72 MT-430152-P11 S2407 Cu Gasket 6.5/11.2x1

32 3 MT-430201-P25 S1411/S1615/S1522 Circlip A25

33 09 MT-430152-P23 S2145/S2161 Cu Gasket 14/20x1.6

34 12 MT-430956-P2007 S2532 Hex. socket hd. Screw M6x20

35 1 MT-430202-P35 S3290.6 Internal circlip I35

36 12 HAGT-443523-P2 S2539 Washer

37 5 MT-430152-P33 S3938 Gasket Ø20.8/28x1(For Air Pressure

Regulator)38 100 MT-430151-P26 S1109/S1112/S1204/

S1305/S1403/S1603/

S2117/S2134/ A2109


Hardware list of IOH for BT design NO 32 tap changer for outsourcing to M/s

REPL

Sr.

No.


Page 1 of 2

Annexure -HW-X3 B


Sr.

No.


39 30 MT-430151-P23 S1460/S1464/S1611/

S1614/S2127/S2182/

A1907/A1936/


40 8 MT-430151-P22 A3110 Belleville Spring Washer 7.5x14



43 3 MT-430151-P26 A1909 Hex Screw M10x40

44 2 MT-430957-9114 A1915 Hex. Nut 0.8dxM12

45 2 MT-430872-415 A1913 Hex. Screw M12x45

46 2 MT-430151-P28 A1914 Belleville spring washer 14/28



49 2 SWT-439002-P2023 A4150.4 Locking sheet 13,5

50 6 AG-544461-P1 A4208/A3208 Washer

51 4 MT-430189-P311 A4540.10 Roll pin 4 x 14



54 1 MT-430189-P110 A4540.12 Roll Pin 2x12

55 10 AM-400428-P1 A3113/A4426/

A4424/A4123Flat Wahser




59 4 MT-430405-P2209 A5317.9 Split PinA2x15



62 1 MT-430201-P12 A5150.22 External Circlip A12


64 2 A-430152-P19 A1952 Cu Gasket 11/17x1

TOTAL=64

Page 2 of 2

Annexure-X4


1 1 9919000109001 G1519 Locking Cord (0.6m)

2 2 9910383917001 G3309 Seal

3 1 9910383461005 G1421 Sealing ring

4 2 9980383530801 G1515 Contact roller

5 2 9910383461004 G1320.1 Sealing ring

6 2 9919000118001 G1434/G1440 Oil seal

7 1 9910383456002 G1303 Sealing Gasket

8 2 9919000117001 G1306.2a/

G1306.5a

Seal

9 4 9910383541001 G1514 Bearing

10 1 9910383599001 G1302.3 Seal

11 2 9910383528001 G1518 Insulated Tube

12 2 9910383534001 G1512 Insulating Tube

13 2 9919000080001 G1513 Contact Roller Housing

14 1 9919000095006 G1601.1 Bushing double pole 'O' ring

15 3 9910383456004 G1107 Sealing Gasket

16 2 9910383533001 G1516 Roller Guide

17 2 9910383578001 G1435 Coupling Pin

18 1 9980383467802 G1218 Insulting Ring (Inner) or Insulating

Ring complete (Inner)

19 1 9980383467801 G1219 Insulting Ring (Outer) or Insulating

Ring complete (Outer)

20 08 9910383535001 G1517 Push Spring

21 6 9910383694001 G2529 Contact piece

22 12 9910383693001 G2517 Insulated sleeve

23 6 9919000183001 G2502 Bush

24 12 9910646714001 G2505 Insulating Washer

25 6 9910383657002

9910383657003

9910646703002

9910646703001

G2151

G2144

G2146 G2154

Contact Bolt

26 139919000215001

9919000215002

G2152

G2147

Contact Nut M-12xTh-7

27 2 9910646720024 G2515 Needle Roller Bearing

28 6 9989000314801 G2537 Spring Guide

29 6 9919000187001 G2503 Bush

30 6 9919000317001 G2536 Compression Spring


32 2 9919000095004 G3225/G3222 O ring


A) Selector (GR)



Revised Must Change item of IOH for Ganz design NO 32 tap changer for outsourcing to M/s

AAL


Page 1 of 3

Annexure-X4



34 1 9919000095003 G3221 O ring

35 2 9919000095002 G3224/G3252 O ring

36 6 9919000095005 G3251 O ring

37 1 9919000095001 G3254 O ring

38 1 9919000197005 G31.1 Filter

39 2 9919000150026 G3290.12 Gasket (copper)

40 2 9919000150025 G3290.14 Gasket (copper)

41 1 9919000150024 G3290.10 Gasket (copper)

42 10 9919000150009 G3422/G3406 Gasket

43 1 9919000150023 G3290.17 Gasket (copper)

44

7

9919000150011

9919000150010

G3433/G3435 Gasket

45 1 9919000297001 G3290.2 Cup Seal

46 1 9919000294001 G3290.7 Piston

47 2 9989000265801 G3280 Screw Plug complete

48 1 9989000293801 G3290.1 Locking Bolt Compl.

49 1 9919000269001 G3253 Middle Piece

50 4 9910383461006 M1213 Sealing ring

51 4 9910383734002 M3108 Gasket

52 4 9910383734001 M3111 Gasket

53 4 9980383790801 M3209 Push rod with seal

54 2 9910383799001 M3206 Sealing nipple (Valve 'A')

55 3 9910646780048/

9910385081046

M1929.1/

G4212/

G4217

Roll pin (8X45)

56 3 9910646780046/

9919000009014

M1929.2/

G4216/

G4218

Roll pin (5X45)

57 4 9910185894002 M3203 Seal Ring

5835

9910383855002 M6434 Cam type Aux. Switch


60 8 9910383803002 M2313 Bearing Shell


62 2 9910379600025 M568 O ring

63 7 9910383855002 M6331 Aux. Cam Switch compl.

64 2 9910646729001 M8605 Sequence Relay

65 3 9980647346801 M8604 Diode Comp.

66 4 9910383757001 M586 Nylon Washer

67 4 9910383757002 M593 Washer

68 8 9910383754002 M594 Disc

D) Air Motor (SMGR)

Page 2 of 3

Annexure-X4



69 4 9910383761001 M590 Pressure Spring

70 4 9910383759001 M587a Armature

71 4 9910383748001 M2303 U-section ring



74 141 9919000087001 G4415 Mica Washer

75 3 9919000092001 G4416.2 Tube

76 900gr. 9989000207801 G3608 Silica Gel

77 60gm. 9989000206801 G3612 Cork Grain

781

9919000150016 G3947a Copper Gasket 17/30x1

79 4 9919000150005 G3972a Copper Gasket 18/10x1

801 Set

S3933 Overhauling kit of PRV (Seimeg)

81 1 Set Overhauling kit of EVPHGR

821 Set

Set of Hardware 53 nos. as per

Annexure -HW-X4 A

E) ZSM Panel



Page 3 of 3

Annexure- HW-X4 A


1 2 9910383496001 G1442 Washer

2 15 G1523 Packing Washer25.5/32x0.2

3 1 9910383575012 G1436 Rolled Pin 3x25

4 4 9910646698001 G1438 Locking

5 2 9910385081046 G4212/ G4217 Roll Pin 8x45

6 2 9919000009014 G4216/ G4218 Roll Pin 5x45

7 2 9910383546001 G1508 Fixing Plate

8 24 9910646796011 G2604 Hex Socket Hd cap ScrewM6x25

9 36 9919000184001 G2508 Disc Washer M6

10 12 9910646720038 G2520 Split Pin 4x25

11 6 9910646720028 G2530 Socket HD cap screw

12 6 9910646796014 G2524 Spring Washer-M8

13 6 9910646720066 G2540 Flat Washer-M8

14 2 9919000197004 G31.2 Cu Gasket

15 2 9919000150022 G3212 Gasket

16 4 9919000150027 G3270.4 Gasket (Cu) 5.5/11x0.2

17 4 9919000150020 G3242 Gasket (Cu) 5/10x1

18 8 9910383911026 G3202 Spring washer M8

19 1 9919000271005 G3236 Spring washer M12

20 1 9919000150021 G3268 Gasket

21 8 9919000250008 M3110 Disc Washer M6


23 4 9910383811011 M2301 Circlip

24 3 9910646780056 M1909a Hex HD screw M10x35

25 2 9910646780035 M1915 Hex nut M12x0.8d

26 2 9910646780031 M1913 Hex HD screw M12x45

27 2 9910646693005 G1320.4 Split Cotter Pin for Safety Valve

28 119910383470001 G1221 Special Bolt (For Inner & Outer

Insulating Ring)

29 22 9919000251001 G1220 Spring bronze washer-M6

30 10 9919000222001 G1532 Shim Washer

31 12 9910646796014 G2607 Spring Washer M8

32 6 9910646795076 G2414 Spring Washer M12


34 12 9910647265002 G2516 Washer

35 12 9910646796025 G2408/G2532 Hex. Skt. Dd. Screw M6x20

36 48 9910646796012 G2406 Hex Socket Hd cap ScrewM6x30

37 72 9919000150008 G2407 Cu Gasket 6.5/11.2x1

Hardware list of IOH for Ganz design NO 32 tap changer for


Sr.

No.


Page 1 of 2

Annexure- HW-X4 A


Sr.

No.


38 3 9910383451065 G1411/G1615/

G1522

Circlip A25

39 09 9919000150009 G2145/

G2161

Gasket

40 100 9919000250013 G1109/G1112/

G1204/G1305/

G1403/G1603/

G2117/G2134/

M2109

Disc Washer-M10

41 30 9919000250011 G1460/G1464/

G1611/G1614/

G2127/G2182/

M1907/M1936/

Disc Washer-M8

42

5

9919000150003 G3938a Gasket dia 20.8/28x1 for Air

Pressure Regulator

432

9910646780051 M1914a Helical Spring lock washer M12

4412

9910646720027 G2532 Hex. Socket Hd. Screw M6x20

45 1 9919000180003 G3290.6 Internal circlip I35

46 12 9910646720066 G2539 Washer

47 2 9910646756059 2113 External Circlip A24


49 4 9910383813004 M2314.6.1a Split Pin 2x16

50 4 9910383755001 M596 Tab Washer



53 4 9910383755002 M578 Tab Washer

Total - 53

Page 2 of 2

Sub kit POH-1Annexure-S1


1 16 9910383465005 G1216 Contact segment outer AM-501104-P1 S1216 Contact segment (outer)

2 1 9980383489801 G1480 Coupling shaft complete AG-405327-R1 S1480 Coupling shaft complete

3 1 9980383489802 G1481 Coupling shaft complete AG-405327-R2 S1481 Coupling shaft complete

4 33 9910383466001 G1217 Conical nut AG-544329-P1 S1217 Conical nut

5 17 9910383465006 G1215 Contact segment inner AM-501105-P1 S1215 Contact segment inner

6 2 9980383530801 G1515 Contact roller AG-546151-R1 S1515 Contact roller complete


8 66 9919000097001 G1212 Gasket AG-544327-P1 S1212 Gasket

9 66 9919000098001 G1213 Washer AG-544333-P1 S1213 Washer

10 4 9910383541001 G1514 Bearing AG-546150-P1 S1514 Bearing




14 33 9910383461001 G1211 Sealing ring AG-544325-P1 S1211 Packing ring

15 11 9910383470001 G1221 Special Hexagonal bolt AG-546084-P1 S1221 Special bolt

16 2 9910383512001 G1470.4 Actuating plug AG-545598-P1 S1470.4 Actuating plug

17 2 9910383578001 G1435 Coupling pin AG-546487-P1 S1435 Coupling pin

18 8 9910383535001 G1517 Push spring AG-405322-P1 S1517 Compression spring

19 22 9919000251001 G1220 Spring Bronze Washer -M6 MT-430190-P116 S1220 Belleville spring washer 6.4/14

20 1 9910383456005 G1444 Sealing Gasket AG-207812-P5 S1444 gasket

21 10 9910383520002 G1450 Distance Washer AG-544234-P2 S1450 Packing washer

22 2 9910383528001 G1518 Insulated Tube AM-500801-P1 S1518 Insulating tube

23 2 9919000118001 G1434/

G1440

Oil Seal SWT-435381-P1 S1434/

S1440

Oil Seal

24 2 9910383534001 G1512 Insulating pipe AG-546189-P1 S1512 Insulating pipe

25 10 9919000222001 G1532 Shim Washer HATM-405170-P6 S1532 Washer (for contact roller)

GANZ Type M/s AAL Make

1.Common Items/Components of NO 32 tap changer to be procured from REPL (BT type) or AAL(Ganz type) only

Tap Changer M/s BT Make

Items required for carrying out POH maintenance schedule of NO-32 type tap changer

Sr. No.

A). Selector (GR)

Qty.

1 of 5



GANZ Type M/s AAL Make Tap Changer M/s BT MakeSr. No. Qty.

26 3 9910383621014

9910383621014

9910646795024

G2104.1

G2110.1

G2210.1

Roll pin-Ø8x45 MT-430189-P471 S2104.1

S2110.1

S2210.1

Roll Pin (8x45)

27 3 9910383621015

9910383621015

9910646795025

G2104.2

G2110.2

G2210.2

Roll pin-Ø5x45 MT-430189-P371 S2104.2

S2110.2

S2210.2

Roll Pin (5x45)

28 1 9919000109001 G1519 Locking Cord (0.6m) SWT-435200-P1 S1519 Fiber Glass Cord (0.6M)

29 2 9910383461004 G1320.1 Sealing ring AG-544325-P4 S1320.1 Packing ring (for Safety valve)

30 2 9910383461001 G1320.2.3 Compression spring AG-546174-P1 S1320.2.3 Compression Spring31 1 9919000095006 G1601.1 Bushing double pole 'O' Ring AG-432122-P7 S1601.1 Packing Ring 32 2 9910383917001 G3309 Seal AG-549697-P1 S3309 Gasket (For Oil Flow Indicator)

33 4 9910646698001 G1438 Locking SWT-435084-P1 S1438 Spring Ring34 1 9910383577001 G1437 Coupling tube AG-416635-P1 S1437 Coupling Pipe35 1 9910383461005 G1421 Sealing ring AG-544325-P5 S1421 Packing Ring

36 1 9910383461002 G1476 Sealing ring AG-544325-P2 S1476 Packing Ring 37 2 9910646693005 G1320.4 Split pin Ø2.5x25 MT-430405-P2364 S1320.4 Split Cotter Pin38 1 9910383575012 G1436 Rolled pin Ø3x25 MT-430189-P216 S1436 Rolled Pin Ø3x25

392

9919000124001 G3613 Rubber Gasket (Big) RE-144023-P2 S4701.11 Rubber Gasket 1.0 Kg. Air Dryer

402

9910646257001 G3614 Rubber Gasket (Small) RE-144023-P1 S4701.15 Rubber Gasket 1.0 Kg. Air Dryer

412

9919000117001 G1306.2a/G1306

.5a

Seal AM-502840-P1 S1306.2/

S1306.5

Packing (For Oil Level Indicator)

42 1 9980643600169 G3902a Air pressure regulator 3EYC-400052-P1 S3902 Air Pressure Regulator43 1 9910383502011 G1471 Set screw M5x6 MT-430440-P2706 S1471 Slotted Head Grub Screw M5X6

44 1 9910383599001 G1302.3 Seal AG-546167-P1 S1302.3 Gasket45 2 9919000080001 G1513 Contact Roller Housing AM-300009-P1 S1513 Contact Roller Housing46 1 9989000191801 G1231 Flexible Cable Complete SWT-435531-R1 S1231 Flexible Cable Complete

47 6 9910646720024 G2515 Needle roller bearing HAGT-443522-P1 S2515 Needel Bearing Support Roller

48 36 9919000184001 G2508 Disc washer M6 HAGT-443524-P1 S2508 Belliville spring washer

B) Circuit Breakers -CGR

2 of 5




49 12 9910383693001 G2517 Insulated sleeve AM-502593-P1 S2517 Bush


51 6 9919000317001 G2536 Compression spring AG-540918-P1 S2536 Compression Spring

52 6 9919000315001 G2538 Bearing pins HAGT-443530-P1 S2538 Pin

53 6 9919000183001 G2502 Bush AM-502669-P1 S2502 Insulating Bush

54 12 9910646714001 G2505 Insulating Washer AM--502615-P1 S2505 Insulating Washer

55 12 9910646720073 G2511 Split pin ø2x20 MT-430405-P2211 S2511 Split Pin

56 1 9980383648803 G2160a Resistor assy. AG-313290-R1 S2160 Wire Wound Resistance assy.

57 4 9910383657002/

9910383657003/

9910646703002

G2151/ G2144/

G2146

Contact bolt AG-547421-P2 S2151/

S2144/

S2146

Contact Bolt

58 2 9910646703001 G2158 Contact bolt AG-547421-P1 S2158 Contact bolt

59 13 9919000215002/

9919000215001

G2152/ G2147 Contact nut M12 AG-547420-P1 S2152/

S2147

Contact nut

60 12 9910647265002 G 2516 Washer HAGT-443523-P1 S2516 Washer

61 6 9919000033001 G2531 Arc Horn AM-304070-P1 S2531 Arcing Horn

62 6 9919000187001 G2503 Bush AM-502618-P1 S2503 Bush

63 1 9910383491001 G2209 Bevel Wheel AM-301334-P1 S2209 Bevel gear

64 2 9980383933802 G3312/G3313 Connection Pipe AM-400010-R1 S3312/

S3313

Oil pipe complete

(for oil flow indicator)

65 1 9989000179801 G3290.11 Pipe assy. SWT-435498-R1 S3290.11 Pipe Compelete


67 2 9989000265801 G3280 Screw Plug Comp. SWT-435158-R1 S3280 Screw Plug Complete


69 10 9919000150009 G3422/G3406 Gasket MT-430152-P23 S3422/

S3406

Cu gasket

70 1 9989000293801 G3290.1 Locking bolt compl SWT-435490-R1 S3290.1 Locking Bolt Comp.

71 2 9919000059001 G3233/G3235 Cup seal for oil pump SWT-435167-P1 S3233/

S3235

Cup seal


73 7 9919000150011/

9919000150010

G3433/G3435 Gasket MT-430152-P34 S3433/

S3435/

S3428

Cu gasket

74 1 9919000297001 G3290.2 Cup seal SWT-435484-P1 S3290.2 Cup Seal

75 1 9919000286001 G3213 Compression spring SWT-435148-P1 S3213 Valve Spring

76 1 9919000197005 G31.1 Filter SWT-335066-P5 S31.1 Filter Element

C) Oil Filtration Unit-(PHGR & Oil Pump Device)

3 of 5




77 2 9919000095002 G3224/G3252 O ring SWT-435430-P2 S3224/

S3252

O ring

78 1 9919000287001 G3216 Compression spring SWT-435149-P1 S3216 Valve Spring

79 2 9919000095004 G3225/G3222 O ring SWT-435430-P4 S3225/

S3222

O ring

80 4 9919000150020 G3242 Gasket (Copper) 5/10x1 MT-430152-P6 S3242 Cu gasket 5/10x1



83 1 9919000288001 G3261 Spring SWT-435150-P1 S3261 Spring


85 2 9919000150021 G3268 Gasket (copper) 23.5/26.5x1 3EYC-400029-P1 S3268 Gasket


87 1 9919000150023 G3290.17 Gasket (copper) SWT-435491-P3 S3290.17 Cu gasket


89 1 9989000271801 G3230 Piston Complete SWT-435182-R1 S3230 Piston Complete

90 1 9989000048801 G3434 3 way cock SWT-335152-R1 S3434 Three Way Valve

91 1 9919000269001 G3253 Middle Piece SWT-335045-P1 S3253 Middle Piece

D) Air Motor -SMGR

92 4 9980383790801 M3209 Push rod with seal AG-544415-R1 A3209 Push rod with seal

93 35 9910383855002 M6331/ M5514/ M6434cam type aux. switches AM-400660-R1 A6331/ A5514/ A6434Aux. Cam Switch

Note:- in M/s B.T. Tap

Changer=35 Nos required

and in M/s AAL make Tap

Changer=42 Nos. required

94 8 9910383803002 M2313 Bearing shell half AG-545649-P2 A2313 Bearing liner


96 4 9910383799001 M3206 Sealing nipple (Valve 'A') AG-544411-P1 A3206 Valve nipple

97 4 9910383787001 M3204 Compression Spring AG-544356-P1 A3204 Compression Spring



100 2 9910383874001 M1916 Key AM-500224-P1 A1916 Key

101 3 9910646780048/

9910385081046

M1929.1/

G4212/

G4217

Roll pin-ø8x45 MT-430189-P471 A1929.1/S4212/S4217Roll pin (8/45)

4 of 5




102 3 9910646780046

9919000009014

M1929.2/

G4216/

G4218

Roll pin-ø5x45 MT-430189-P371 A1929.2/S4216/S4218Roll pin (5/45)

103 1 9910646299077 M2113 Circlip ext (24) MT-430201-P24 A2113 External circlip A24

104 4 9910185894002 M3203 Seal Ring AG-508472-P1 A3203 Nylon Washer (Packing)

105 141 9919000087001 G4415 Mica washer KB-473201-P2 S4415 Mica washer 21/50x2

106 3 9919000091001 G4416.2 Mica Tube B-406533-P2 S4416.2 Samica glass tube

107 3 9919000210001 G4416.1 Stud B-406533-P1 S4416.1 Stud

108 900gr. 9989000207801 G3608 Silica Gel SWT-435501-R2 S4711 Silica Gel


110 5 9919000150003 G3938a Gasket Ø20.8/28x1 MT430152-P33 S3938a Gasket Ø20.8/28x1 (For

replacement of air pressure

regulator)

111 1 9919000150016 G3947a Copper Gasket 17/30x1 MT-430152-P39 S3947 Copper Gasket 17/30x1

112 5 9919000150005 G3972a Copper Gasket 18/10x1 MT-430152-P18 S3972 Copper Gasket 18/10x1

1131 Set

Set of Hardwares 53 nos. as per

Annexure- POH-HW-1


Annexure- POH-HW-1

(E) Accessories for stainless steel element(If required)


F) ZSM Panel

5 of 5

Sub kit POH-1 Annexure-POH-HW-1


1 8 9910383496001 G1442 Washer A-509828-P1 S1442 Washer( For coupling shaft)2 10 G1523 Packing Washer 25.5/32x0.2 AG-544234-P3 S1523 Packing Washer(25.5/32x0.23 6 9910646720028 G2530 Socket hd cap screw - M8x30 MT-430262-P1213 S2530 Hex. Socket Head Cap Screw

4 18 9910646796014 G2524 Spring Washer - M8 SWT-435227-P1 S2524 Spring Washer5 6 9910646720066 G2540 Flat Washer M8 MT-430445-P2022 S2540 Washer 8.4/13x0.56 12 9910646720027 G2532 Socket hd. Cap Screw - M6x20 MT-430262-P1159 S2532 Socket hd. Cap Screw - M6x20

7 24 9910646796011 G2604 Hex Socket hd. Cap Screw -

M6x25

MT-430956-P2008 S2604 Hex socket hd.cap screw

8 48 9910646796012 G2406 Hex Socket hd. Cap Screw -

M6x30

MT-430956-P2009 S2406 Hex socket hd. cap screw M 6x 30

9 72 9919000150008 G2407 Gasket copper MT-430152-P11 S2407 Cu gasket 6.5/11.2x1

10 2 9919000182003 G2169 Shim SWT-435243-P1 S2169 Shim11 12 9910646720035 G2533 Flat Washer - M6 (Copper) MT-430152-P11 S2533 Cu washer12 2 9919000150022 G3212 Gasket MT-430152-P36 S3212 Gasket 22.8/30X1(P36)13 1 9919000197004 G31.2 Gasket (copper) AM-400428-P2 S31.2 Cu Gasket 14/18x1.614 2 9919000150015 G3606 Gasket (copper) AM-400428-P3 S3606 Flat Gasket15 8 9910383911026 G3202 Spring Washer - M8 SWT-435227-P1 S3202 Split type Spring Washer 8.1/1216 4 991900015027 G3270.4 Gasket copper SWT-4355249-P1 S3270.4 Shim17 1 9919000180003 G3290.6 Internal circlip I35 MT-430202-P35 S3290.6 Internal circlip I3518 12 9910646720066 G2539 Washer HAGT-443523-P2 S2539 Washer19 2 9910383579001 G1424 Locking Plate AG-546273-P1 S1424 Locking plate20 2 9910383546001 G1508 Locking washer AG-544655-P1 S1508 Locking washer21 3 9910383451065 G1522/G1615/

G1411

External Circlip A25 MT-430201-P25 S1411/S1615/

S1522

External Circlip A25

1. Common items required for carrying out POH maintenance schedule of NO-32 type tap changer

Required Hardware of NO 32 tap changer to be procured from REPL (BT type) or AAL (Ganz type) onlySr. No. Qty. GANZ Type M/s AAL Make Tap Changer M/s BT Make

1 of 3



Sr. No. Qty. GANZ Type M/s AAL Make Tap Changer M/s BT Make

22 77 9910383451043 G1108/G1304 Hex Screw M10x30 MT-430872-P2362 S1108/S1304 Hex screw M10x3023 100 9919000250013 G1109/G1305/

G1204/G1017/

G1910/F2109/

G4127/G1603/

G2120/G2134/

M2149/G2155/

G3426/G3453

Belleville Spring Washer 11/22 MT-430151-P26 S1109/S1305/

S1204/S2117/

A1910/ A2109/

A4127/ S1603/

S2120/

S2134/S2149/S21

55 /S3426/S3453


24 30 9919000250011 G1460/G1464/

G1611/G1614/

G2127/G2182/

M1907/M1936/


S1611/S1614/

S2127/S2182/

A1907/A1936/


25 3 9910383525004 G1507 Hex Bolt M8x75 SWT-439005-P321 S1507 Hex bolt M8x75/22

26 11 9910383635022 G2116 Hex Bolt M10x35 MT-430871-P363 S2116 Hex bolt M10x35/2627 45 9910383556001 G1623 Shim AG-547502-P1 S1623 Shim28 6 9910383547010 G1624 Split Cotter Pin A3.2x45 MT-430405-P2318 S1624 Split cotter pin A3.2x4529 9 9919000150009 G2145/G2161 Cu Gasket 14/20x1 MT-430152-P23 S2145/S2161 Cu gasket 14/20x130 24 9910646796025 G2408/G2532 Hex Skt Hd. Screw M6x20 MT-430956-P2007 S2408/S2532 Hex. socket hd. Screw M6x20

31 6 9910646795063 G2413 Hex Skt Hd. Screw M12x35 MT-430956-P2308 S2413 Hex soc hd screw M12x35

32 6 9910646795076 G2414 Spring Washer M12 MT-430197-P618 S2414 Spring Washer B1233 12 9910646796027 G2409 Flate Washer M6 MT-430151-P20 S2442 Belleville spring washer 6.4/1434 6 9919000685001 G2504 Stud M6 AM-502621-P1 S2504 Stud M635 12 9910646720072 G2510 Castle Nut M6 MT-430446-P2106 S2510 Castle nut M636 12 9910646720038 G2520 Split Cotter Pin 4x20 MT-430405-P2411 S2520 Split Cotter Pin 4x20

37 12 9910646796009 G2606 Hex Skt Hd Cap Screw M8x50 MT-430956-P2113 S2606 Hex socket hd cap screw M8x50

38 24 9910646796014 G2607 Spring Washer M8 SWT-435227-P1 S2607/S2411 Spring Washer B839 2 9919000150015 G3303 Cu Gasket 16/22 MT-430152-P27 S3303 Cu. gasket 16/2240 76 9919000040005 G4412 Puched Washer 9/17x1.6 MT-430827-P2015 S4412 Punched washer 9/17x1.641 38 9919000040006 G4413 Hex Nut 0.8dxM8 MT-430957-P112 S4413 Hex nut 0.8dxM842 38 9919000040016 G4420 Hex Screw M8x20 MT-430872-P2260 S4420 Hex screw M8x2043 8 9910646756027 M3109 Hex Bolt M6x70/18 SWT-439005-P270 A3109 Hex. bolt M6x70/18

2 of 3




44 8 9919000250008 M3110 Belleville Spring Washer 7.5x14 MT-430151-P22 A3110 Belleville spring washer 7.5x14

45 2 AN00000494 M1928/M1930 External Circlip A24 MT-430201-P24 A1928/A1930 External circlip A 2446 4 9910383811011 M2301 External Circlip A42 MT-430201-P42 A2301 External circlip A4247 4 9910383811007 M2314.2 Internal Circlip I 52 MT-430202-P52 A2314.2 Internal circlip I 5248 2 9910646780035 M1915 Hex nut M12x0.8d MT-430957-9114 A1915 Hex. Nut 0.8dxM1249 2 9910646780031 M1913 Hex HD screw M12x45 MT-430872-415 A1913 Hex. Screw M12x4550 1 9919000271005 G3236 Spring washer M12 MT-430197-P218 S3236 Spring Washer B1251 4 9910383796012 M3207 Internal Circlip 16x1 MT-430202-P16 A3207 Internal Circlip I 1652 3 9910646780056 M1909a Hex HD screw M10x35 MT-430151-P26 A1909 Hex Screw M10x4053 2 9910646780051 M1914a Helical Spring lock washer M12 MT-430151-P28 A1914 Belleville spring washer 14/28

Total - 53

3 of 3

Sub kit POH - 2A Annexure- S2

Sr. No. Qty. Drg. No. Item No. Description 1 2 9910379600025 M568 O' ring

2 4 9910185894002 M563 Sealing ring

3 1 9910389850006 M711.17 Cam discs -45/46

4 1 9910389849003 M711.25 Cam discs - 61/62

5 1 9910646286001 M711.29 Cam discs - 69/70

6 1 9910389850009 M711.36 Cam Discs - 83/84

7 1 9880383722801 M558n Link with pin

8 1 9910383853001 M726b pin

9 1 9910383837001 M720 Gear wheel

10 1 9910383835001 M725a Key

11 1 9910383835002 M8315 Key

12 2 9910383836001 M8406 Key

13 2 9910383836002 M8407 Key

14 6 9910646292012 M742 Circlip - internal ø40x1.75

15 2.2mtr. 9910643600142 M6602.5 /M6602.6 Sealing profile

16 6 9910646299040 M8440 Circlip External ø17x1



19 1 9910646299077 M8439 Circlip External ø24x1.2

20 1 9980383713801 M558a Nothcing comp.

21 7 9910383855002 M6331/ M5514/ M6434 Cam type aux. switch


23 10 9919000182002 M545b Shims (for crank shaft)

24 2 9980383796801 M535 Three way valve "A"

25 2 9980383784801 M536a Three way valve "B"

26 4 9910383755001 M596 Tab Washer

27 4 9910383755002 M578 Tab Washer

28 12 9910646292040 M740 Locking plate M8

29 4 9910383761001 M590 Pressure Springs

30 4 9910383760001 M589 Valve Lifter

31 4 9980646750801 M584 Coil Comp.

32 4 9910383757001 M586 Nylon Washer

33 3 9980647346801 M8604 Diode Comp.

34 1 9980383735802 M537 Air line Complete

35 2 9910646729001 M8605 Sequence Relay

36 8 9910383754002 M594 Disc

37 4 9910383759001 M587a Armature

38 1 Set Set of Hardware (11 nos.) as

per Annexure-POH-HW-2

2. Uncommon Items/Components for POH specific to (Ganz type) tap changer to

be procured from AAL only

Total - 37+11(Hardware)=48

1of1

Annexure- POH-HW-2



2 4 9910383813004 M2314.6.1a Split Pin 2x16

3 4 9910383753001 M595 Setting Screw

4 4 9910383756001 M597 Nut


6 2 9910383750026 M570c Hex. Hd. Screw M10x20

7 10 9910383750027 M570d Hex. Nut M8


9 4 9910383756002 M577 Nut

10 4 9910383757002 M593 Washer

11 2 9910383801001 M572 Guide Disc

2.Un-common Hardware items of NO 32 Tap Changer to be procured from AAL

(Ganz type) only

Total - 11

Page 1 of 1

Sub kit POH-2B Annexure-S3

Sr. No. Qty. Drg. No. Item No. Description



3 2 SWT-435385-R1 A4150.38 Coil Complete

4 1 AM-300449-R1 A4150.45 Diode Assy. Comp.

5 1 SWT-335030-P4 A6423.8A Cam Disc 83-84

6 1 SWT-435104-P1 A5506.11 Cam Disc 61-62

7 3 SWT-435237-P1 A2117 Shim

8 1 AM-400817-P1 A1934 Gasket Ring


10 1 AG-417258-R1 A2212 Notching Complete


12 1 AM-501612-P1 A4540.4 GuidePin

13 2 HAGT-144612-R1 A4430.3 Piston Complete

14 1 3EYC-400040-P1 A2217 Pin

15 6 AG-544441-P1 A4120/ A4430.19 Gasket

16 6 SWT-435063-P1 A1926.2 Coller Ring

17 4 Ag-549222-R1 A5317.8 Plunger Nut Complete

18 1 AM-400425-R2 A3114 Air Piping Complete

19 2 AG-549804-R1 A4150.31 Adjusting Screw Complete

20 4 AG-544461-P1 A3208 Washer

21 2 SWT-435398-P1 A4150.43 Plunger

22 2 AG-549177-P1 A4150.36 Armature



25 4 AG-508472-P1 A3203 Packing

26 6 MT-430704-P10 A6327/ A5509/

A5426

Bellivelle Spring Washer 32/48

27 1 AG-546491-P1 A5403.3 Pin


29 1 3EYC-400041-R1 A2216 Strap with pin Complete


31 2 AG-430510-P1 A4430.10 Compression Spring

32 2 Am-502322-P1 A2110 Shim

33 4 MT-430110-P2034 A6419 Locking Sheet

34 1 SWT-435056-P1 A6602.5 Rubber Cord

3. Uncommon Items/Components for POH specific to BT type Tap Changer to be

procured from REPL only

Page 1 of 2

Sub kit POH-2B Annexure-S3


35 2 MT-430189-P367 A4519 Roll Pin 5/28

36 1 AG-546709-P1 A6102 Key


38 1 Am-401107-p1 A4540.7 Compression Spring

39 1 AG-548990-P2 A6206 Key

40 1 AG-546709-P2 A1951 Key

412 SWT-439002-P2023 A4150.4/

A4150.18

Locking Sheet

42 3 AG-548990-P3A6120/A6406/

A5411Key

43 2 AG-544461-P1 A4208 Washer


45 2 AG-508472-P1 A4203 Packing


47 1 AM-500694-P1 A6105 Bearing Pin

48 1 AM-501613-P1 A4540.6 GuidePin

49 1 AM-500694-P1 A5407 Bearing Pin

50 1 SWT-435429-R1 A4518 Journal pin complete

51 1 AG-330565-R1 A3115 Air Piping Complete

52 1 SetSet of Hardware 25 nos. as per

Annexure-POH-HW-3


Page 2 of 2

Annexure-POH-HW-3


1 2 MT-430189-P110 A4540.12 Roll Pin 2x12

2 4 AG-544346-P1 A4430.14 Washer

3 10 AM-400428-P1 A3113/ A4426/

A4424/ A4123

Flat Washer

4 2 MT-430202-P16 A4207 Internal Circlip 16



7 1 MT-430201-P12 A5150.22 Circlip A12



10 2 MT-430201-P24 A2113 External Circlip

11 4 MT-430405-P2209 A5317.9 Split Pin


13 2 MT-430189-P110 A4430.7 Roll Pin

14 1 SWT-435211-P5 A4542 Spl. Locking Washer


16 2 MT-430892-P2263 A4544 Hex Screw M8x35

17 3 MT-430201-P10 A5404/A6403/

A6109


18 4 MT-430201-P17 A5523/A6310/

A6111

External circlip A17

19 2 MT-430511-P215 A4124 Hex. socket hd. screw M8x70/22

20 2 MT-430190-P118 A4125 Belleville spring washer 8.4/18

21 4 AG-544466-P1 A2314.6.2 Pin

22 1 MT-430189-P212 A5403.2 Roll pin 3x16

23 2 A-430152-P19 A1952 Cu Gasket 11/17x1

24 4 MT-430189-P311 A4540.10 Roll pin 4 x 14


3. Uncommon Hardware for POH specific to BT type Tap Changer to be procured

from REPL only

Total -25

Page 1 of 1

Sub Kit- 3(POH)Annexure-S4

Sr. no. Qty./ TC OEMs Drg. No. or RDSO' DRG. Item No. Description

1 4 SWT -435461 -P1 or 9910383748001

or SKEL -3463,

RDSO SPEC/E-4/01

A2303 or M2303 Sealing ring or U-section ring

2 1 9980383467802 or AM-200095-R2 or

S-1218/ SKEL- 4661

G - 1218 or S -1218 Insulting Ring (Inner) or Insulating Ring

complete (Inner)

3 1 9980383467801 or AM-200095-R1 or

S-1219/ SKEL- 4661

G - 1219 or S -1219 Insulting Ring (Outer) or Insulating Ring

complete (Outer)

4 1 AAL's drg No. 9980385081803 or

BT's drg. No. SWT -

135037 -R1 or RDSO drg. No.

S42/ /SKEL -4625

G42 or S42 MANUAL HAND DRIVE

or Manual Hand drive with operating

handle

5 1 AM-300792-R2 or RDSO-

A6103a/SKEL/4615

A6103a Intermediate gear complete (R.H)

6 1 AG-430172-P1 or RDSO-

A6313/SKEL/4617

A6313 Spur Gear

7 1 AM-500436-R1 or RDSO- A6401-

1/SKEL/4618

A6401 Pinion complate

8 2 AG-330676-P1 or RDSO- A6110-

1/SKEL/4616

A6110.1 Spur Gear

9 1 SWT-335050-P1 or 9919000140001

or SKEL-4664 Alt.1

S3933 / G3933 Solenoid Valve

10 2 AG-416382-P1 or 9910383533001 or

SKEL-4648

S1516 / G1516 Contact Roller Guide

11 6 HAGT-443612-R1 or 9919000314001

or SKEL-4649 Alt.1

S2537 or G2537 Spring retainer complete

12 2 AG-430129-R1 or SKEL-4639 Alt.1 A4150.30 3 way Valve MG 4/5A

Total- 12

Items to be procured from sources approved, as per RDSO vendor list

Tap Changer NO 32

Items required for carrying out POH maintenance schedule of NO-32 type tap

changer

Page 1 of 1

Annexure-X5


1 16 AM-501104-P1 S1216 Contact segment (outer)

2 1 AG-405327-R1 S1480 Coupling shaft complete

3 1 AG-405327-R2 S1481 Coupling shaft complete

4 33 AG-544329-P1 S1217 Conical nut

5 17 AM-501105-P1 S1215 Contact segment inner

6 2 AG-546151-R1 S1515 Contact roller complete

7 2 AG-207812-P3 S1202 Gasket

8 66 AG-544327-P1 S1212 Gasket

9 66 AG-544333-P1 S1213 Washer

10 4 AG-546150-P1 S1514 Bearing

11 3 AG-207812-P4 S1107 Gasket

12 2 AG-416382-P1 S1516 Roller housing (black)

13 1 AG-207812-P2 S1303 Gasket

14 1 AG-207812-P1 S1102 Gasket

15 33 AG-544325-P1 S1211 Packing ring

16 11 AG-546084-P1 S1221 Special bolt

17 2 AG-545598-P1 S1470.4 Actuating plug

18 2 AG-546487-P1 S1435 Coupling pin

19 8 AG-405322-P1 S1517 Compression spring

20 22 MT-430190-P116 S1220 Belleville spring washer 6.4/14

21 1 AG-207812-P5 S1444 gasket

22 10 AG-544234-P2 S1450 Packing washer

23 2 AM-500801-P1 S1518 Insulating tube

24 2 SWT-435381-P1 S1434/

S1440

Oil Seal

25 2 AG-546189-P1 S1512 Insulating pipe

26 10 HATM-405170-P6 S1532 Washer (for contact roller)

27 3 MT-430189-P471 S2104.1 S2110.1

S2210.1Roll Pin (8x45)

28 3 MT-430189-P371 S2104.2 S2110.2

S2210.2Roll Pin (5x45)

29 1 SWT-435200-P1 S1519 Fiber Glass Cord (0.6M)

30 2 AG-544325-P4 S1320.1 Packing ring (for Safety valve)

31 2 AG-546174-P1 S1320.2.3 Compression Spring32 1 AG-432122-P7 S1601.1 Packing Ring 33 2 AG-549697-P1 S3309 Gasket (For Oil Flow Indicator)

34 4 SWT-435084-P1 S1438 Spring Ring35 1 AG-416635-P1 S1437 Coupling Pipe36 1 AG-544325-P5 S1421 Packing Ring

37 1 AG-544325-P2 S1476 Packing Ring 38 2 MT-430405-P2264 S1320.4 Split Cotter Pin39 1 MT-430189-P216 S1436 Rolled Pin Ø3x25

40 2 RE-144023-P2 S4701.11 Rubber Gasket 1.0 Kg. Air Dryer 41 2 RE-144023-P1 S4701.15 Rubber Gasket 1.0 Kg. Air Dryer

Sr. No. Qty.

Revised Must change item of POH for BT design NO 32 tap changer for outsourcing to

M/s REPL


A). Selector (GR)

1 of 4

Annexure-X5


Sr. No. Qty. Tap Changer M/s BT Make

42 2 AM-502840-P1 S1306.2/S1306.5 Packing (For Oil Level Indicator)

43 1 3EYC-400052-P1 S3902 Air Pressure Regulator44 1 MT-430440-P2706 S1471 Slotted Head Grub Screw M5X645 1 AG-546167-P1 S1302.3 Gasket46 2 AM-300009-P1 S1513 Contact Roller Housing47 1 SWT-435531-R1 S1231 Flexible Cable Complete

48 1 AM-200095-R2 S1218 Insulting Ring (Inner) or Insulating Ring

complete (Inner)

49 1 AM-200095-R1 S1219 Insulting Ring (Outer) or Insulating Ring

complete (Outer)

50 6 HAGT-443522-P1 S2515 Needel Bearing Support Roller

51 6 HAGT-443612-R1 S2537 Spring retainer complete

52 36 HAGT-443524-P1 S2508 Belliville spring washer

53 12 AM-502593-P1 S2517 Bush

54 6 AG-540123-P1 S2529 Contact

55 6 AG-540918-P1 S2536 Compression Spring

56 6 HAGT-443530-P1 S2538 Pin

57 6 AM-502669-P1 S2502 Insulating Bush

58 12 AM--502615-P1 S2505 Insulating Washer

59 12 MT-430405-P2211 S2511 Split Pin

60 1 AG-313290-R1 S2160 Wire Wound Resistence assy.

61 4 AG-547421-P2 S2151/

S2144/

S2146

Contact Bolt

62 2 AG-547421-P1 S2158 Contact bolt

63 13 AG-547420-P1 S2152/

S2147

Contact nut

64 12 HAGT-443523-P1 S2516 Washer

65 6 AM-304070-P1 S2531 Arcing Horn

66 6 AM-502618-P1 S2503 Bush

67 1 AM-301334-P1 S2209 Bevel gear

68 2 AM-400010-R1 S3312/

S3313

Oil pipe complete

(for oil flow indicator)

69 1 SWT-435498-R1 S3290.11 Pipe Compelete

70 1 SWT-435488-P1 S3290.7 Piston

71 2 SWT-435158-R1 S3280 Screw Plug Complete

72 6 SWT-435430-P5 S3251 O ring

73 10 MT-430152-P23 S3422/

S3406

Cu gasket

74 1 SWT-435490-R1 S3290.1 Locking Bolt Comp.

75 2 SWT-435167-P1 S3233/

S3235

Cup seal

76 2 SWT-435167-P2 S3270.3 Cup seal

77 7 MT-430152-P34 S3433/

S3435/

S3428

Cu gasket

78 1 SWT-435484-P1 S3290.2 Cup Seal

79 1 SWT-435148-P1 S3213 Valve Spring

80 1 SWT-335066-P5 S31.1 Filter Element

81 2 SWT-435430-P2 S3224/

S3252

O ring

82 1 SWT-435149-P1 S3216 Valve Spring

83 2 SWT-435430-P4 S3225/

S3222

O ring



2 of 4

Annexure-X5



84 4 MT-430152-P6 S3242 Cu gasket 5/10x1

85 1 SWT-435430-P3 S3221 O ring

86 1 SWT-435430-P1 S3254 O ring

87 1 SWT-435150-P1 S3261 Spring

88 2 MT-430152-P19 S3290.12 Cu gasket

89 2 3EYC-400029-P1 S3268 Gasket

90 2 MT-430152-P18 S3290.14 Cu gasket

91 1 SWT-435491-P3 S3290.17 Cu gasket

92 1 MT-430152-P13 S3290.10 Cu gasket

93 1 SWT-435182-R1 S3230 Piston Complete

94 1 SWT-335152-R1 S3434 Three Way Valve

95 1 SWT-335045-P1 S3253 Middle Piece

96 4 AG-544415-R1 A3209 Push rod with seal

97 35 AM-400660-R1 A6331/ A5514/

A6434

Aux. Cam Switch

Note:- in M/s B.T. Tap Changer=35 Nos required

and in M/s AAL make Tap Changer=42 Nos.

required

98 8 AG-545649-P2 A2313 Bearing liner

99 4 AG-544441-P1 A3111 Gasket




103 4 AG-544441-P2 A3108 Gasket

104 2 AM-500224-P1 A1916 Key

105 3 MT-430189-P471 A1929.1/

S4212/

S4217

Roll pin (8/45)

106 3 MT-430189-P371 A1929.2/

S4216/

S4218

Roll pin (5/45)

107 1 MT-430201-P24 A2113 External circlip A24

108 4 AG-508472-P1 A3203 Nylon Washer (Packing)109 2 SWT-439002-P2016 A4150.33 Locking Sheet


111 2 SWT-435385-R1 A4150.38 Coil Complete

112 1 AM-300449-R1 A4150.45 Diode Assy. Comp.

113 1 SWT-335030-P4 A6423.8A Cam Disc 83-84

114 1 SWT-435104-P1 A5506.11 Cam Disc 61-62

115 3 SWT-435237-P1 A2117 Shim

116 1 AM-400817-P1 A1934 Gasket Ring


118 1 AG-417258-R1 A2212 Notching Complete

119 1 AM-501809-P1 A4515 Packing Washers

120 1 AM-501612-P1 A4540.4 GuidePin

121 2 HAGT-144612-R1 A4430.3 Piston Complete

122 1 3EYC-400040-P1 A2217 Pin

123 6 AG-544441-P1 A4120/ A4430.19 Gasket

124 6 SWT-435063-P1 A1926.2 Coller Ring

125 4 Ag-549222-R1 A5317.8 Plunger Nut Complete

126 1 AM-400425-R2 A3114 Air Piping Complete

127 2 AG-549804-R1 A4150.31 Adjusting Screw Complete

128 4 AG-544461-P1 A3208 Washer

129 2 SWT-435398-P1 A4150.43 Plunger

130 2 AG-549177-P1 A4150.36 Armature



D) Air Motor -SMGR

3 of 4

Annexure-X5



133 4 AG-508472-P1 A3203 Packing

134 6 MT-430704-P10 A6327/ A5509/ A5426 Bellivelle Spring Washer

135 1 AG-546491-P1 A5403.3 Pin


137 1 3EYC-400041-R1 A2216 Strap with pin Complete


139 2 AG-430510-P1 A4430.10 Compression Spring

140 2 AM-502322-P1 A2110 Shim

141 4 MT-430110-P2034 A6419 Locking Sheet


143 2 MT-430189-P367 A4519 Roll Pin 5/28

144 1 AG-546709-P1 A6102 Key


146 1 AM-401107-p1 A4540.7 Compression Spring

147 1 AG-548990-P2 A6206 Key

148 1 AG-546709-P2 A1951 Key

149 2 SWT-439002-P2023 A4150.4/ A4150.18 Locking Sheet

150 2 AG-430129-R1 A4150.30 Valve Complete MG4/5A

151 3 AG-548990-P3 A6120/A6406/

A5411

Key


153 2 AG-508472-P1 A4203 Packing

154 2 AG-544461-P1 A4208 Washer


156 1 AM-500694-P1 A6105 Bearing Pin

157 1 AM-501613-P1 A4540.6 GuidePin

158 1 AM-500694-P1 A5407 Bearing Pin

159 1 SWT-435429-R1 A4518 Journal pin complete

160 1 AG-330565-R1 A3115 Air Piping Complete

161 1 AM-300792-R2 A6103a Intermidiate Gear complete (Right)

162 1 AG-430172-P1 A6313 Spur Gear

163 1 AM-500436-R1 A6401 Pinion complate

164 2 AG-330676-P1 A6110.1/ A6411 Spur Gear


166 141 KB-473201-P2 S4415 Mica washer 21/50x2

167 3 B-406533-P2 S4416.2 Samica glass tube

168 3 B-406533-P1 S4416.1 Stud

169 900gr. SWT-435501-R2 S4711 Silica Gel


171 1 SWT-135037 -R1 S42 Manual Hand drive with operating handle

172 5 MT430152-P33 S3938a Gasket Ø20.8/28x1 (For replacement of

air pressure regulator)

173 1 MT-430152-P39 S3947 Copper Gasket 17/30x1

174 1 SWT-335050-P1 S3933 Two way solenoid valve EVPHGR

175 5 MT-430152-P18 S3972 Copper Gasket 18/10x1

176 1 Set Set of Hardware (78 nos.) as per

Annexure-HW-X5 B


TOTAL - 175+78 (Hardware)= 253

F) ZSM Panel

4 of 4

Annexure-HW-X5 B


1 8 A-509828-P1 S1442 Washer( For coupling shaft)2 10 AG-544234-P3 S1523 Packing Washer(25.5/32x0.23 6 MT-430262-P1213 S2530 Hex. Socket Head Cap Screw4 18 SWT-435227-P1 S2524 Spring Washer5 6 MT-430445-P2022 S2540 Washer 8.4/13x0.56 12 MT-430262-P1159 S2532 Socket hd. Cap Screw - M6x207 24 MT-430956-P2008 S2604 Hex socket hd.cap screw8 48 MT-430956-P2009 S2406 Hex socket hd. cap screw M 6x 309 72 MT-430152-P11 S2407 Cu gasket 6.5/11.2x1

10 2 SWT-435243-P1 S2169 Shim11 12 MT-430152-P11 S2533 Cu washer12 2 MT-430152-P36 S3212 Gasket 22.8/30X1(P36)13 1 AM-400428-P2 S31.2 Cu Gasket 14/18x1.614 2 AM-400428-P3 S3606 Flat Gasket15 8 SWT-435227-P1 S3202 Split type Spring Washer 8.1/1216 4 SWT-4355249-P1 S3270.4 Shim17 1 MT-430202-P35 S3290.6 Internal circlip I3518 12 HAGT-443523-P2 S2539 Washer

19 2 AG-546273-P1 S1424 Locking plate20 2 AG-544655-P1 S1508 Locking washer21 3 MT-430201-P25 S1411/S1615/ S1522 External Circlip A25 22 77 MT-430872-P2362 S1108/S1304 Hex screw M10x3023 100 MT-430151-P26 S1109/S1305/S1204/

S2117/A1910/

A2109/ A4127/

S1603/ S2120/

S2134/S2149/S2155

/S3426/S3453


24 30 MT-430151-P23 S1460/S1464/

S1611/S1614/

S2127/S2182/

A1907/A1936/


25 3 SWT-439005-P321 S1507 Hex bolt M8x75/22

26 11 MT-430871-P363 S2116 Hex bolt M10x35/2627 45 AG-547502-P1 S1623 Shim28 6 MT-430405-P2318 S1624 Split cotter pin A3.2x4529 9 MT-430152-P23 S2145/S2161 Cu gasket 14/20x130 24 MT-430956-P2007 S2408/S2532 Hex. socket hd. Screw M6x20

31 6 MT-430956-P2308 S2413 Hex soc hd screw M12x35

32 6 MT-430197-P618 S2414 Spring Washer B1233 12 MT-430151-P20 S2442 Belleville spring washer 6.4/1434 6 AM-502621-P1 S2504 Stud M635 12 MT-430446-P2106 S2510 Castle nut M636 12 MT-430405-P2411 S2520 Split Cotter Pin 4x20

37 12 MT-430956-P2113 S2606 Hex socket hd cap screw M8x5038 24 SWT-435227-P1 S2607/S2411 Spring Washer B8

Hardware list of POH for BT design NO 32 Tap Changer for outsourcing to M/s REPL

Sr.

No.

Qty. Tap Changer M/s BT Make

1 of 2

Annexure-HW-X5 B


Sr.

No.

Qty. Tap Changer M/s BT Make

39 2 MT-430152-P27 S3303 Cu. gasket 16/2240 76 MT-430827-P2015 S4412 Punched washer 9/17x1.641 38 MT-430957-P112 S4413 Hex nut 0.8dxM842 38 MT-430872-P2260 S4420 Hex screw M8x2043 8 SWT-439005-P270 A3109 Hex. bolt M6x70/1844 8 MT-430151-P22 A3110 Belleville spring washer 7.5x1445 2 MT-430201-P24 A1928/A1930 External circlip A 2446 4 MT-430201-P42 A2301 External circlip A4247 4 MT-430202-P52 A2314.2 Internal circlip I 5248 2 MT-430957-9114 A1915 Hex. Nut 0.8dxM1249 2 MT-430872-415 A1913 Hex. Screw M12x4550 2 MT-430151-P28 A1914 Belleville spring washer 14/2851 1 MT-430197-P218 S3236 Spring Washer B1252 4 MT-430202-P16 A3207 Internal Circlip 1653 3 MT-430151-P26 A1909 Hex Screw M10x4054 2 MT-430189-P110 A4540.12 Roll Pin 2x1255 4 AG-544346-P1 A4430.14 Washer56 10 AM-400428-P1 A3113/ A4426/

A4424/ A4123

Flat Washer

57 2 MT-430202-P16 A4207 Internal Circlip 1658 8 NB-435128-P6 A2314.6.1 Circlip(Imported)59 1 MT-430201-P10 A4514 External Circlip A1060 1 MT-430201-P12 A5150.22 Circlip A1261 12 AM-501808-P1 A4537 Packing Washer62 2 AM-501809-P1 A6106 Packing Washer63 2 MT-430201-P24 A2113 External Circlip64 4 MT-430405-P2209 A5317.9 Split Pin65 12 AM-501808-P1 A6118 Packing Washer66 2 MT-430189-P110 A4430.7 Roll Pin67 1 SWT-435211-P5 A4542 Spl. Locking Washer68 2 MT-430197-P613 A4543 Spring washer B869 2 MT-430892-P2263 A4544 Hex Screw M8x3570 3 MT-430201-P10 A5404/A6403/

A6109


71 4 MT-430201-P17 A5523/A6310/

A6111

External circlip A17

72 2 MT-430511-P215 A4124 Hex. socket hd. screw M8x70/2273 2 MT-430190-P118 A4125 Belleville spring washer 8.4/1874 4 AG-544466-P1 A2314.6.2 Pin75 1 MT-430189-P212 A5403.2 Roll pin 3x1676 2 A-430152-P19 A1952 Cu Gasket 11/17x177 4 MT-430189-P311 A4540.10 Roll pin 4 x 1478 2 3EYC-400001-P1 A4516 Hex. screw M8x35

TOTAL - 78

2 of 2

Annexure-X6


1 16 9910383465005 G1216 Contact segment outer

2 1 9980383489801 G1480 Coupling shaft complete

3 1 9980383489802 G1481 Coupling shaft complete

4 33 9910383466001 G1217 Conical nut

5 17 9910383465006 G1215 Contact segment inner

6 2 9980383530801 G1515 Contact roller

7 2 9910383456003 G1202 Sealing Gasket

8 66 9919000097001 G1212 Gasket

9 66 9919000098001 G1213 Washer

10 4 9910383541001 G1514 Bearing

11 3 9910383456004 G1107 Sealing Gasket

12 2 9910383533001 G1516 Roller Guide

13 1 9910383456002 G1303 Sealing Gasket

14 1 9910383456001 G1102 Sealing Gasket

15 33 9910383461001 G1211 Sealing ring

16 11 9910383470001 G1221 Special Hexagonal bolt

17 2 9910383512001 G1470.4 Actuating plug

18 2 9910383578001 G1435 Coupling pin

19 8 9910383535001 G1517 Push spring

20 22 9919000251001 G1220 Spring Bronze Washer -M6

21 1 9910383456005 G1444 Sealing Gasket

22 10 9910383520002 G1450 Distance Washer

23 2 9910383528001 G1518 Insulated Tube

24 2 9919000118001 G1434/

G1440

Oil Seal

25 2 9910383534001 G1512 Insulating pipe

26 10 9919000222001 G1532 Shim Washer

27 3 9910383621014

9910383621014

9910646795024

G2104.1

G2110.1

G2210.1

Roll pin-Ø8x45

28 3 9910383621015

9910383621015

9910646795025

G2104.2

G2110.2

G2210.2

Roll pin-Ø5x45

29 1 9919000109001 G1519 Locking Cord (0.6m)

30 2 9910383461004 G1320.1 Sealing ring

31 2 9910383461001 G1320.2.3 Compression spring32 1 9919000095006 G1601.1 Bushing double pole 'O' Ring

33 2 9910383917001 G3309 Seal

34 4 9910646698001 G1438 Locking35 1 9910383577001 G1437 Coupling tube36 1 9910383461005 G1421 Sealing ring

37 1 9910383461002 G1476 Sealing ring

38 2 9910646693005 G1320.4 Split pin Ø2.5x2539 1 9910383575012 G1436 Rolled pin Ø3x25

40 2 9919000124001 G3613 Rubber Gasket (Big)

Revised Must change item of POH for Ganz design NO 32 tap changer for


A). Selector (GR)


1 of 4

Annexure-X6



41 2 9910646257001 G3614 Rubber Gasket (Small)42

29919000117001 G1306.2a/G1306

.5a

Seal

43 1 9980643600169 G3902a Air pressure regulator44 1 9910383502011 G1471 Set screw M5x645 1 9910383599001 G1302.3 Seal46 2 9919000080001 G1513 Contact Roller Housing47 1 9989000191801 G1231 Flexible Cable Complete48 1 9980383467802 G1218 Insulting Ring (Inner) or Insulating Ring

complete (Inner)49 1 9980383467801 G1219 Insulting Ring (Outer) or Insulating Ring

complete (Outer)

50 6 9910646720024 G2515 Needle roller bearing

51 6 9919000314001 G2537 Spring guide

52 36 9919000184001 G2508 Disc washer M6

53 12 9910383693001 G2517 Insulated sleeve

54 6 9910383694001 G2529 Contact piece

55 6 9919000317001 G2536 Compression spring

56 6 9919000315001 G2538 Bearing pins

57 6 9919000183001 G2502 Bush

58 12 9910646714001 G2505 Insulating Washer

59 12 9910646720073 G2511 Split pin ø2x20

60 1 9980383648803 G2160a Resistor assy.

61 4 9910383657002/

9910383657003/

9910646703002

G2151/ G2144/

G2146

Contact bolt

62 2 9910646703001 G2158 Contact bolt

63 13 9919000215002/

9919000215001

G2152/ G2147 Contact nut M12

64 12 9910647265002 G 2516 Washer

65 6 9919000033001 G2531 Arc Horn

66 6 9919000187001 G2503 Bush

67 1 9910383491001 G2209 Bevel Wheel

68 2 9980383933802 G3312/G3313 Connection Pipe

69 1 9989000179801 G3290.11 Pipe assy.

70 1 9919000294001 G3290.7 Piston

71 2 9989000265801 G3280 Screw Plug Comp.

72 6 9919000095005 G3251 O ring

73 10 9919000150009 G3422/G3406 Gasket

74 1 9989000293801 G3290.1 Locking bolt compl



77 7 9919000150011/

9919000150010

G3433/G3435 Gasket

78 1 9919000297001 G3290.2 Cup seal


80 1 9919000197005 G31.1 Filter

81 2 9919000095002 G3224/G3252 O ring


83 2 9919000095004 G3225/G3222 O ring

84 4 9919000150020 G3242 Gasket (Copper) 5/10x1

85 1 9919000095003 G3221 O ring

86 1 9919000095001 G3254 O ring



2 of 4

Annexure-X6



87 1 9919000288001 G3261 Spring

88 2 9919000150026 G3290.12 Gasket (copper)

89 2 9919000150021 G3268 Gasket (copper) 23.5/26.5x1

90 2 9919000150025 G3290.14 Gasket (copper)

91 1 9919000150023 G3290.17 Gasket (copper)

92 1 9919000150024 G3290.10 Gasket (copper)

93 1 9989000271801 G3230 Piston Complete

94 1 9989000048801 G3434 3 way cock

95 1 9919000269001 G3253 Middle Piece

96 4 9980383790801 M3209 Push rod with seal

97 35 9910383855002 M6331/

M5514/ M6434

cam type aux. switches

98 8 9910383803002 M2313 Bearing shell half

99 4 9910383734001 M3111 Gasket

100 4 9910383799001 M3206 Sealing nipple (Valve 'A')


102 4 9910383461006 M1213 Sealing ring

103 4 9910383734002 M3108 Gasket

104 2 9910383874001 M1916 Key

105 3 9910646780048/

9910385081046

M1929.1/

G4212/

G4217

Roll pin-ø8x45

106 3 9910646780046

9919000009014

M1929.2/

G4216/

G4218

Roll pin-ø5x45

107 1 9910646299077 M2113 Circlip ext (24)

108 4 9910185894002 M3203 Seal Ring109 2 9910379600025 M568 O' ring

110 4 9910185894002 M563a Sealing ring

111 1 9910389850006 M711.17 Cam discs -45/46

112 1 9910389849003 M711.25 Cam discs - 61/62

113 1 9910646286001 M711.29 Cam discs - 69/70

114 1 9910389850009 M711.36 Cam Discs - 83/84

115 1 9880383722801 M558n Link with pin

116 1 9910383853001 M726b pin

117 1 9910383837001 M720 Gear wheel

118 1 9910383835001 M725a Key

119 1 9910383835002 M8315 Key

120 2 9910383836001 M8406 Key

121 2 9910383836002 M8407 Key

122 6 9910646292012 M742 Circlip - internal ø40x1.75

123 2.2mtr. 9910643600142 M6602.5

/M6602.6

Sealing profile


D) Air Motor -SMGR

3 of 4

Annexure-X6





127 1 9910646299077 M8439 Circlip External ø24x1.2

128 1 9980383713801 M558a Nothcing comp.

129 7 9910383855002 M6331/ M5514/

M6434

Cam type aux. switch


131 10 9919000182002 M545b Shims (for crank shaft)

132 2 9980383796801 M535 Three way valve "A"

133 2 9980383784801 M536a Three way valve "B"

134 4 9910383755001 M596 Tab Washer

135 4 9910383755002 M578 Tab Washer

136 12 9910646292040 M740 Locking plate M8

137 4 9910383761001 M590 Pressure Springs

138 4 9910383760001 M589 Valve Lifter

139 4 9980646750801 M584 Coil Comp.

140 4 9910383757001 M586 Nylon Washer

141 3 9980647346801 M8604 Diode Comp.

142 1 9980383735802 M537 Air line Complete

143 2 9910646729001 M8605 Sequence Relay

144 8 9910383754002 M594 Disc

145 4 9910383759001 M587a Armature

146 4 9910383748001 M2303 U-section ring

147 141 9919000087001 G4415 Mica washer

148 3 9919000091001 G4416.2 Mica Tube

149 3 9919000210001 G4416.1 Stud

150 900gr. 9989000207801 G3608 Silica Gel

151 60gm. 9989000206801 G3612 Cork Grain

152 1 9980385081803 G42 MANUAL HAND DRIVE

153 5 9919000150003 G3938a Gasket Ø20.8/28x1


155 1 9919000140001 G3933 Two way solenoid valve EVPHGR


1571 Set


Annexure-HW-X5 A

F) ZSM Panel



4 of 4

Annexure-HW-X6 A


1 8 9910383496001 G1442 Washer2 10 G1523 Packing Washer 25.5/32x0.23 6 9910646720028 G2530 Socket hd cap screw - M8x304 18 9910646796014 G2524 Spring Washer - M85 6 9910646720066 G2540 Flat Washer M86 12 9910646720027 G2532 Socket hd. Cap Screw - M6x207 24 9910646796011 G2604 Hex Socket hd. Cap Screw - M6x258 48 9910646796012 G2406 Hex Socket hd. Cap Screw - M6x309 72 9919000150008 G2407 Gasket copper

10 2 9919000182003 G2169 Shim11 12 9910646720035 G2533 Flat Washer - M6 (Copper)12 2 9919000150022 G3212 Gasket 13 1 9919000197004 G31.2 Gasket (copper)14 2 9919000150015 G3606 Gasket (copper)15 8 9910383911026 G3202 Spring Washer - M816 4 991900015027 G3270.4 Gasket copper17 1 9919000180003 G3290.6 Internal circlip I3518 12 9910646720066 G2539 Washer19 2 9910383579001 G1424 Locking Plate20 2 9910383546001 G1508 Locking washer21 3 9910383451065 G1522/G1615/ G1411 External Circlip A2522 78 9910383451043 G1108/G1304 Hex Screw M10x3023 100 9919000250013 G1109/G1305/

G1204/G1017/

G1910/F2109/

G4127/G1603/

G2120/G2134/

M2149/G2155/

G3426/G3453

Belleville Spring Washer 11/22

24 30 9919000250011 G1460/G1464/G1611/

G1614/G2127/G2182/

M1907/M1936/

Disc Washer-M8

25 3 9910383525004 G1507 Hex Bolt M8x7526 11 9910383635022 G2116 Hex Bolt M10x3527 45 9910383556001 G1623 Shim28 6 9910383547010 G1624 Split Cotter Pin A3.2x4529 9 9919000150009 G2145/G2161 Cu Gasket 14/20x130 24 9910646796025 G2408/G2532 Hex Skt Hd. Screw M6x2031 6 9910646795063 G2413 Hex Skt Hd. Screw M12x3532 6 9910646795076 G2414 Spring Washer M1233 12 9910646796027 G2409 Flate Washer M634 6 9919000685001 G2504 Stud M635 12 9910646720072 G2510 Castle Nut M636 12 9910646720038 G2520 Split Cotter Pin 4x2037 12 9910646796009 G2606 Hex Skt Hd Cap Screw M8x50

38 24 9910646796014 G2607 Spring Washer M839 2 9919000150015 G3303 Cu Gasket 16/2240 76 9919000040005 G4412 Puched Washer 9/17x1.641 38 9919000040006 G4413 Hex Nut 0.8dxM842 38 9919000040016 G4420 Hex Screw M8x2043 8 9910646756027 M3109 Hex Bolt M6x70/1844 8 9919000250008 M3110 Belleville Spring Washer 7.5x1445 2 AN00000494 M1928/M1930 External Circlip A24

Hardware list of POH for Ganz design No 32 Tap Changer for outsourcing to M/s AAL


1 of 2

Annexure-HW-X6 A



46 4 9910383811011 M2301 External Circlip A4247 4 9910383811007 M2314.2 Internal Circlip I 5248 2 9910646780035 M1915 Hex nut M12x0.8d49 2 9910646780031 M1913 Hex HD screw M12x4550 1 9919000271005 G3236 Spring washer M1251 4 9910383796012 M3207 Internal Circlip 16x152 3 9910646780056 M1909a Hex HD screw M10x3553 2 9910646780051 M1914a Helical Spring lock washer M1254 2 9910383784013 M569 Internal Circlip 12x155 4 9910383813004 M2314.6.1a Split Pin 2x1656 4 9910383753001 M595 Setting Screw57 4 9910383756001 M597 Nut58 2 9910383750028 M570b Spring Washer M1059 2 9910383750026 M570c Hex. Hd. Screw M10x2060 10 9910383750027 M570d Hex. Nut M861 10 9910383750029 M570e Spring Washer M862 4 9910383756002 M577 Nut63 4 9910383757002 M593 Washer64 2 9910383801001 M572 Guide Disc

TOTAL-64

2 of 2

LIST-A Annexure 2A

1) SELECTOR (G.R)

Sr. No. Part number Drawing number Description Qty/ TC

1 S1306.2/ S1306.5 AM-502840-P1 PACKING(OIL LEVEL 2

2 S3309 AG-549697-P1 GASKET ( OIL FLOW IND) 2

3 S1303 AG-207812-P2 GASKET 1

4 S1320.1 AG-544325-P4 PACKING RING (safety valve ) 2

5 S1434/S1440 SWT-435381-P1 OIL SEAL 2

6 S1421 AG-544325-P5 PACKING RING 1

7 S1218 AM-200095-R2 INSULATING RING (INNER ) 1

8 S1219 AM-200095-R1 INSULATING RING (OUTER) 1

9 S1102 AG-207812-P1 GASKET 1

10 S1107 AG-207812-P4 GASKET 3

11 S1202 AG-207812-P3 GASKET 2


13 S1212 AG-544327-P1 GASKET 66

14 S1213 AG-544333-P1 WASHER 66

15 S1437 AG-416635-P1 COUPLING TUBE 1

16 S1444 AG-207812-P5 GASKET 1


18 S1480 AG-405327-R1 COUPLING SHAFT COMPLETE 1

19 S1481 AG-405327-R2 COUPLING SHAFT COMPLETE 1

20 S1514 AG-546150-P1 BEARING 4

21 S2104.1/ S2110.1/

S2210.1

MT-430189-P471 ROLL PIN 8/45 3

22 S2104.2/ S2110.2/

S2210.2

MT-430189-P371 ROLL PIN 5/45 3

23 S1208.1 AG-416333-P3 CONTACT TERMINAL 1

24 S1231 SWT-435531-R1 FLEXIBLE CABLE COMPLETE 1

25 S1232 MT-430106-P2406 HEX SCREW M5 X 10 2

26 S1233 MT-430827-P2010 PUNCHED WASHER 2

27 S1234 MT-430197-P608 SPRING WASHER B5 2

28 S1215 AM-501105-P1 CONTACT SEGMENT INNER 17

29 S1216 AM-501104-P1 CONTACT SEGMENT OUTER 16

30 S1217 AG-544329-P1 CONICAL NUT 33

31 S1228 AM-401257-P1 COMPRESSION SPRING 1

32 S1306.3 AM-404045-P1 SIGHT GLASS 1

33 S1320.2.3 AG-546174-P1 COMPRESSION SPRING 2

34 S1230.2.5 MT-430575-P22 DISC SPRING 16

35 S1405.2/ S1410.2 STD-430041-P6205Z BALL BEARING 2

36 S1435 AG-546487-P1 COUPLING PIN 2

37 S1454 STD-430041-P6004 BALL BEARING 2

38 S15.1 AG-210303-R1 CONTACT ARM COMPLETE WITHOUT

STEPPING WHEEL

1

39 S1608 AG-207772-P2 CONTACT RING (INNER) 1

40 S1609 AG-207772-P1 CONTACT RING (OUTER) 1

41 S1225 AG-546099-R1 CONNECTING TERMINAL 33

42 S1408 AM-301334-P3 BEVEL GEAR 1

43 S1449 AG-314854-P1 BEVEL GEAR 1

44 S1467 AG-315296-R1 BEARING PIN COMPLETE 1

45 S1490 AM-401904-R1 BEVEL GEAR COMPLETE 1

46 S1401 AG-207813-P1 DRIVE SHAFT 1

47 S3607 SWT-335070-R1 AIR DRYER ASSEMBLY 1

48 S1604 SWT-335166-R1 FLEXIBLE CONNECTION 2

59 S1201 SWT-135013-P1 CONTACT PLATE 1

50 S1470 AG-416040-R1 LANTERN GEAR COMPLETE 1

51 S 1214 AG -544328-P1 Special nut 33

Items/ Components of Tap Changer N-32 (Bombardier Make) to be replaced

Compulsorily by new ones during rehabilitation / reconditioning by REPL

Page 1 of 5

LIST-A Annexure 2A

2) CIRCUIT BREAKERS (CGR)

Sr. No. Part number Drawing No. Description Qty/ TC

1 S2529 AG-540123-P1 CONTACT TIP 6

2 S2502 AM-502669-P1 BUSH 6

3 S2505 AM-502615-P1 INSULATING WASHER 12

4 S2508 HAGT-443524-P1 BELLEVILLE SPRING 36

5 S2511 MT-430405-P2211 SPLIT PIN 24

6 S2515 HAGT-443522-P1 NEEDLE BEARING SUPPORT ROLLER 6

7 S2516 HAGT-443523-P1 WASHER 24

8 S2517 AM-502593-P1 BUSH 12

9 S2536 AG-540918-P1 COMPRESSION SPRING 6

10 S2537 HAGT-443612-R1 SPRING RETAINER COMPLETE 6

11 S2538 HAGT-443530-P1 PIN 6

12 S2102 SWT-335194-R1 COUPLING SHAFT COMPLETE 1

13 S2108 STD-430045-P1305 BALL BEARING 2

14 S2160 AG-313290-R1 WIRE WOUND RESISTANCE 1

15 S2206 STD-430041-P6205ZZ BALL BEARING 2

16 S2220.1 AM-100257-R2 CAM DISC COMPLETE -I 1

17 S2220.2 AM-100257-R3 CAM DISC COMPLETE -II 1

18 S2220.3 AM-100257-R4 CAM DISC COMPLETE -III 1

19 S2416 AM-300075-P1 INSULATING BEAM 3

20 S2512 AM-401885-R2 FLEXIBLE CONNECTION COMPLETE 12

21 S2519 AM-401693-P2 BEARING PIN 6

22 S2610.2 AM-401046-P1 COMPRESSION SPRING 6

23 S2114 AM-200033-R1 INSULATING PLATE 1

24 S2131 AM-200034-R1 INSULATING PLATE 1

25 S2186 AM-400085-P1 INSULATING PLATE 1

26 S2531 AM-304070-P1 ARCING HORN 6

27 S2209,2103,S2109 AM-301334-P1 BEVEL GEAR 3

28 S2220.4 AM-300080-P1 SHAFT 1

29 S2115 AG-313288-P1 CONTACT ANGLE 1

30 S2158 AG-547421-P1 CONTACT BOLT 2

31 S2144//S2151 AG-547421-P2 CONTACT BOLT 4

3) OIL FILTRATION UNIT ( PHGR CIRCUIT)

Sr.

No.Part number Drawing No. Description Qty/ TC

1 S32 SWT-235033-R1 OIL PUMP COMPLETE 1

2 S3290 SWT-335196-R1 OIL PUMP DEVICE 1

3 S-31 SWT-335066-R1 OIL FILTER COMPLETE 1

4 S3434 SWT-335152-R1 THREE WAY VALVE 1

Page 2 of 5

LIST-A Annexure 2A

4)

Sr.

No.Part number Drawing No. Description Qty/ TC

1 A1213 SWT-435144-P2 PACKING RING 4

2 A2303 SWT-435461-P1 SEALING RING 4

3 A3108 AG-544441-P2 GASKET 4

4 A3111/A4120/ A4430.19 AG-544441-P1 GASKET 8

5 A4430.4 AM-404742-P1 PACKING RING 2

6 A4430.2 AG-413762-P25 DAMPING GASKET 2

7 A2209 SWT-435581-R1 SPRING WITH EYES 2

8 A4540.7 AM-401107-P1 COMPRESSION SPRING 1

9 A1929.1 MT-430189-P471 ROLL PIN 8/45 1

10 A1929.2 MT-430189-P371 ROLL PIN 5/45 1

11 S4212 MT-430189-P471 ROLL PIN 8/45 1

12 S4216 MT-430189-P371 ROLL PIN 5/45 1

13 S4217 MT-430189-P471 ROLL PIN 8/45 1

14 S4218 MT-430189-P371 ROLL PIN 5/45 1

15 A1916 AM-500224-P1 KEY 2

16 A1934 AM-400817-P1 GASKET RING 1

17 A1951 AG-546709-P2 KEY 1

18 A2210 AG-545485-R1 STRAP WITH PIN COMPLETE 2

19 A2313 AG-545649-P2 BEARING LINER 8

20 A4150.45 AM-300449-R1 DIODE ASSEMBLY 1

21 A4150.23 AM-400095-R1 PLATE COMPLETE 1

22 A4150.36 AG-549177-P1 ARMATURE 2

23 A4150.38 SWT-435385-R1 COIL COMPLETE 2

24 A4150.43 SWT-435398-P1 PLUNGER COMPLETE 2

25 A4430.3.2 AG-543463-P1 GASKET 2

26 A4430.10 AG-430510-P1 COMPRESSION SPRING 2

27 A4540.4 AM-501612-P1 GUIDE PIN 1

28 A5317.7 AM-500020-P1 COMPRESSION SPRING 4

29 A5514/A6331/A6434 AM-400660-R1 AUX. CAM SWITCH 35

30 A6120 AG-548990-P3 KEY 1

31 A6206 AG-548990-P2 KEY 1

32 A6327/A5509/ A6426 MT-430704-P10 BELLEVILLE SPRING WASHER 6

33 A6602.5/ A6602.6 SWT-435056-P1 RUBBER CORD 2

34 A1926.2 SWT-435063-P1 COLLAR RING 6

35 A4150.31 AG-549804-R1 ADJUSTING SCREW COMPLETE 2

36 A2212 AG-417258-R1 NOTCHING COMPLETE 1

37 A1911 SWT-235137-P1 SUPPORT 1

38 A2112 AM-401770-R1 FLY WHEEL COMPLETE 1

39 A2314.3 AG-416732-P1 PISTON 4

40 A2314.5 SWT-435529-P3 NEEDLE BEARING 4

41 A3115 AG-330565-R1 AIR PIPING COMPLETE 1

42 A3114 AM-400425-R2 AIR PIPING COMPLETE 1

43 A4150.10 SWT-435152-R1 TERMINAL COMPLETE 4

44 A4150.6 AG-430562-P1 COVER 2

AIR MOTOR (SMGR): Replacement of following components of SMGR

Page 3 of 5

LIST-A Annexure 2A

45 A4150.28 SWT-435153-P2 END PLATE 5

46 A4150.39 AG-549180-P1 CORE 2




50 A4518 SWT-435429-R1 JOURNAL PIN COMPLETE 1

51 A5150.6 AG-548990-P1 KEY 1

52 A5150.11 AM-200327-P1 ANNULUS 1

53 A5150.13 STD-430041-P6001Z RADIAL GROOVE BALL BEARING 1

54 A5150.14 STD-430041-P16005 RADIAL GROOVE BALL BEARING 3

55 A5150.15 AM-304006-P1 SUN GEAR 1

56 A5150.17 AM-400878-R1 BEARING RING COMPLETE 1

57 A5150.18.2 HAGT-443129-P3 NEEDLE BEARING 1

58 A5150.20 STD-430041-P6001 RADIAL GROOVE BALL BEARING 1

59 A5317.1 AG-549223-P1 STRAP 4

60 A5317.2 STD-430041-P625ZZ RADIAL GROOVE BALL BEARING 4

61 A5317.3 AG-549226-P1 PIN 4

62 A5317.8 AG-549222-R1 PLUNGER NUT COMPLETE 4

63 A5403.1 AG-549230-R1 RATCHET COMPLETE 1

64 A5407/A6105 AM-500694-P1 BEARING PIN 2

65 A5411 AG-548990-P3 KEY 1

66 A5503/A6208/A6314/

A6409

STD-430045-P1203 SELF ALIGNING BALL BEARING 7

67 A5506.1 TO A5506.14 __________ CAM DISC SET 14

68 A6101 AG-549199-P1 SPUR GEAR 1

69 A6103A AM-300792-R2 INTERMEDIATE GEAR 1

70 A6104 HAGT-443129-P1 NEEDLE BUSH 2

71 A6110.1/A6411 AG-330676-P1 SPUR GEAR 2

72 A6313 AG-430172-P1 SPUR GEAR 1

73 A6323.1 TO A6423.13 ___________ CAM DISC SET 8

74 A6401 AM-500436-R1 PINION COMPLETE 1

75 A6423.1 TO A6423.13A CAM DISC SET 13

76 A2103 STD-430045-P1205 SELF ALIGNING BALL BEARING 2

77 A2314.4 AG-546733-P1 PIN 4

78 A1201 AM-301050-P1 CYLINDER 4

79 A1924 AG-430155-P1 BEVEL GEAR 1

80 A1926.3 AG-330745-P1 BEVEL GEAR 1


82 A32 AG-417999-R1 VALVE COMPLETE 6/6A 4

83 A4150.30 AG-430129-R1 VALVE COMPLETE 4/5A 2

84 A4136 AG-330674-R1 BEARING PLATE COMPLETE 1

85 A4137 AG-330675-R1 BEARING PLATE COMPLETE 1

86 A4150.37 AG-430149-R1 YOKE PLATE COMPLETE 1

87 A4430.1 AM-301715-P1 CYLINDER 1

88 A5150.18 AG-548981-R1 PLANET GEAR COMPLETE 1

89 A5150.19 AM-200328-P1 PLANET RING WITH PINION 1

90 A5401a SWT-435196-P1 CONTROL DISC 1

91 A5150.2 AM-400877-P1 CAM DISC 4

92 A5502 AG-330678-P1 SHAFT 1

93 A6319 AG-330678-P1 SHAFT 1

94 A6422 AG-330678-P1 SHAFT 1

95 A5150.1 AM-304010-P1 SHAFT 1

96 A6602 SWT-235107-R3 AIR MOTOR COVER COMPLETE 1

Page 4 of 5

LIST-A Annexure 2A

5) ACCESSORIES

Sr.

No.

Part number Drawing No. Description Qty/ TC

1 S4415 KB-473201-P2 MICA WASHER 21/50/2 141

2 S4416.2 B-406533-P2 SAMICA GLASS TUBE 3

3 S4406.2 SWT-435218-P3 INSULATING TUBE 4

4 S4406.3 SWT-435218-P1 INSULATING WASHER BIG 8

5 S4406.4 SWT-435218-P2 INSULATING WASHER SMALL 8


1 S3933 SWT-335050-P1 TWO WAY SOLENOID 1

2 S3939 SWT-435352-R1 THREE WAY VALVE 1

3 S3902 SWT-335139-P1 PRESSURE REGULATOR 1

4 S3915 SWT-435152-R1 TERMINAL COMPLETE 24

5 S3916 SWT-435153-P2 END PLATE 26

6 S3917 SWT-235114-R1 ROTARY SWITCH COMPLETE 1

7 S3925 SWT-335181-R1 FOOT PEDAL SWITCH 1

a) For STAINLESS STEEL GRID ELEMENT RGR

b) CONTROL PANEL ( ZSM PANEL)

Page 5 of 5

LIST-B Annexure- 2 A

Sr.

No.Part No. Drawing No. Description Qty/ TC

1 S1607 AM-400019-R1 CARRIER PLATE COMPLETE 1

2 S1501 AM-100246-P1 STEP WHEEL 1

3 S1601 AG-207811-R1 CONDENSOR BUSHING 1

4 S2101/S2132 AM-100045-R1 SUPPORT 1

5 S2101 AM-100045-R1 SUPPORT 1

6 S1101 AG 106371 R1 MOUNTING FRAME COMPLETE 1

7 S1457 AG-207751-P1 DRIVE WHEEL 1

8 S 1453 AG-106335-R1 Gear box housing 1

Sr.


1 S2506 HAGT-340079-R1 CONTACT LEVER ASSEMBLY 6

2 S27 AGT-108794-R3 ARCING CHAMBER 3

3 S2401 AG-313525-R1 CARRIER STRIP 6

4 S2601 AG-313527-R1 BLOW OUT COIL COMPLETE 6

5 S 2135 AM-304092-P1 Connecting angle 3

Sr.


1 A2101 AG-106705-R1 CRANK SHAFT COMPLETE 1

2 A2314.6 AG-430278-R1 CONNECTING ROD COMPLETE 4

3 A4540 HAGT-225320-R1 CONTROL LEVER COMPLETE 1

4 A2102.a AM-301109-P1 Bearing plate 1

5 A2102.b AM-301109-P2 Bearing plate 1

6 A5501 AG-330673-R1 Bearing plate complete 2

7 A6315 AG-430171-R1 Bearing plate complete 2

8 A6428 AM-300226-R1 Bearing plate complete 2

9 A1101 AG-207783-P1 Base Plate 1

Sr.


1 S39 SWT-035002-R1 CONTROL PANEL COMPLETE 1

2 A6505 SWT-235118-R1 SELSYN TRANSMITTER 1

3 S40 SWT-235119-R1 RECEIVER SET 2

4 S42 SWT-135037-R1 MANUAL DRIVE 1

5 S4407 SWT-135041-R2 Transition resistance compl.(S.S.RGR) 1

Additional critical items (optional) of BT make NO-32 Tap Changer to

be replaced on condition basis by REPL

3) AIR MOTOR (SMGR)

2) CIRCUIT BREAKER ( CGR )

4) ACCESSORIES

1) SELECTOR (G.R)

Page 1 of 1

LIST-A Annexure-2 B

Sl.no. Part number Drawing number Description Qty/ TC

1 G1306.2a/G1306.5a 9919000117001 Seal 2

2 G3309 9910383917001 Seal 2

3 G1303 9910383456002 Sealing Gasket 1

4 G1320.1 9910383461004 Sealing ring 2

5 G1434/G1440 9919000118001 Oil seal 2

6 G1421 9910383461005 Sealing ring 1

7 G1218 9980383467802 Insulating ring (inner) 1

8 G1219 9980383468801 Insulating ring (outer) 1

9 G1102 9910383456001 Sealing gasket 1

10 G1107 9910383456004 Sealing gasket 3

11 G1202 9910383456003 Sealing gasket 2

12 G1211 9910383461001 Sealing Ring 33

13 G1212 9919000097001 Gasket 66

14 G1213 9919000098001 Washer 33

15 G1437 9910383577001 Coupling Tube 1

16 G1444 9910383456005 Sealing gasket 1

17 G1476 9910383461002 Sealing Ring 1

18 G1480 9980383489801 Coupling shaft complete 1

19 G1481 9980383489802 Coupling shaft complete 1

20 G1514 9910383541001 Bearing 4

21

G2104.1/

G2110.1/

G2210.1

9910383621014/

9910383621014/

9910646795024

Rolled pin- ø8x45 3

22

G2104.2/

G2110.2/

G2210.2

9910383621015/

9910383621015/

9910646795025

Rolled pin- ø5x45 3

23 G1208.1 9910383459005 Contact pin (at 16th notch only) 1

24 G1231 9989000191801 Flexible cable compl. 1

25 G1232 9910383451080 Hex screw-M5 2

26 G1233 9910383451081 Flat washer-M5 2

27 G1234 9910383451082 Spring washer-M5 2

28 G1215 9910383465006 Contact segment inner 17

29 G1216 9910383465005 Contact segment outer 16

30 G1217 9910383466001 Conical Nut 33

31 G1228

32 G1306.3a 9910642308001 Glass Tube 1

33 G1320.2.3 9910383484001 Compression spring 2

34 G1320.2.5 9910383485001 Disc Spring 12

35 G1405.2 9910383582002 Ball bearing 2

36 G1435 9910383578001 Coupling Pin 2

37 G1454 9910383514005 Ball bearing 2

38 G15.1 9980383526801 Contact arm without Stepping wheel 1

39 G1608 9910383465002 Contact ring inner 1

40 G1609 9910383465001 Contact ring outer 1

41 G1225 9980383472801 Connecting Terminal Assy. 33

42 G1408 9910383491003 Bevel wheel 1

43 G1449 9910383516001 Bevel wheel 1

44 G1467 9980383505801 Bearing journal 1

45 G1490 9989000004801 Bevel wheel Assy. 1

46 G1401 9910383581001 Drive shaft 1

47 G36a 9980646236801 Air Drier Assembly 1

48 G1604 9989000189801 Connection compl. 2

49 G1201 9910383458001 Contact Plate 1

50 G1470 9980383508801 Lantern gear pinion 1

51 G1214 9910383464001 Special nut 33

Items/ Components of Ganz(type) NO-32 Tap Changer to be replaced Compulsorily

by new ones during rehabilitation / reconditioning by AAL

not required as design is of Flexible cable complete

1) SELECTOR (G.R)

Page 1 OF 4

LIST-A Annexure-2 B



1) SELECTOR (G.R)2)

Sr. No. Part number Drawing number Description Qty/ TC

1 G2529 9910383694001 Contact piece 6

2 G2502 9919000183001 Bush 6

3 G2505 9910646714001 Insulating Washer 12

4 G2508 9919000184001 Dics washer M6 36

5 G2511 9910646720073 Split pin ø2x20 12

6 G2515 9910646720024 Needle roller bearing 6

7 G2516 9910647265002 Washer 12

8 G2517 9910383693001 Insulated sleeve 12

9 G2536 9919000317001 Compression spring 6

10 G2537 9989000314801 Spring guide 6

11 G2538 9919000315001 Bearing pin 6

12 G2102 9980383622802 Coupling shaft 1

13 G2108 9910383621010 Self aligning ball bearing 2

14 G2160a 9980383648803 Resistor assy. 1

15 G2206 9910383635020 Ball Bearing 2

16 G2220.1 9980383641801 Cam plate I 1

17 G2220.2 9980383641802 Cam plate II 1

18 G2220.3 9980383641803 Cam plate III 1

19 G2416 9910383702004 Insulated bar 3

20 G2512 9980646709801 Flexible Connection 12

21 G2519 9910640586001 Pin 6

22 G2610.2 9910383673001 Compression Spring 6

23 G2114 9980383646801 Insulated Plate Upper 1

24 G2131 9980383645801 Insulated Plate Lower 1

25 G2186 9910646701001 Protecting Wall 1

26 G2531 9919000033001 Arc horn 6

27 G2209/

G2103/

9910383491001/ Bevel wheel 3

28 G2220.11 9910383640001 Shaft 1

29 G2115 9910383656001 Connection bar 1

30 G2158 9910646703001 Contact bolt 2

31G2144/G2146

G2151

9910383657003/

9910646703002

9910383657002

Contact bolt 4

3)


1 G32 9980383911801 Oil Pump complete 1

2 G3290 9989000180801 Oil Pump device complete 1

3 G31 9989000197801 Oil filter 1

4 G3434 9989000048801 Three way cock 1

CIRCUIT BREAKERS (CGR)

OIL FILTRATION UNIT ( PHGR CIRCUIT)

Page 2 OF 4

LIST-A Annexure-2 B



1) SELECTOR (G.R)4)


1 M581 9910383726001 Pin 1

2 M539e 9910383731001 Cylinder stud 2

3 M539d 9910383731002 Cylinder stud 2

4 M725a 9910383835001 Key 1

5 M8315 9910383835002 Key 1

6 M720 9910383837001 Gear wheel 1

7 M8314 9910383883001 Bevel wheel on air motor 1

8 M2103 9910646756040 Ball bearing 2

9 M2107a 9910647134001 Spl.screw 4

10 M2216 9980383722801 Link with pin 1

11 M553c 9980641450801 Spring with eyes 2

12 M2106 9910383805008 Ball bearing 1

13 M2112 9980640607801 Flywheel 1

14 M1213 9910383461006 Sealing ring 4

15 M1212 9910383730001 cover 4

16 M3111 9910383734001 Gasket 4

17 M3108 9910383734002 Gasket 4

18 M1201 9919000181001 cylinder 4

19 M541 9910383727001 Thrust ring 4

20 M2303 9910383748001 U-Section ring 4

21 M2313 9910383803002 Bearing Shell 8

22 M2314.5 9910383811005 Needle roller bearing 4

23 M2314.3 9910383812001 Piston 4

24 M2314.4 9910383818001 Bearing pin 4

25 M2314.1 9910383819001 Piston skirt 4

26 M558a 9980383713801 Notching Complete 1

27 M537 9980383735802 Air Line Complete 1

28 M594 9910383754002 Disc 4

29 M586 9910383757001 Nylon washer 4

30 M593 9910383757002 Washer 8

31 M570a 9910383762002 Disk 2

32 M588 9910383764001 Guide sleeve 4

33 M580 9910383778001 Spring 4

34 M601a 9910383781001 Carrier plate 2

35 M536b 9910383782001 Carrier pin 2

36 M536c 9910383783001 Upper carrier plate 4

37 M587 9980383758801 Armature compl. 4

38 M583 9980383775801 Magnetic core compl. 4

39 M579 9980383779801 Yoke plate compl. 2

40 M584 9980646750801 Coil Compl. 4

41 M712 9910383825002 Distance sleeve 39

42 M6331/M5514/ M6434 9910383855002 Cam type aux. Switch 42

43 M748 9910646225001 No. plate- I 1

44 M749 9910646226001 No. plate- II 1

45 M750 9910646227001 no. plate- III 1

46 M741 9910646292011 Ball bearing 6

47 M752 9910646699001 Keep screw 6

48 M760 9910647272001 Positioner plate 3

49 M761 9910647272002 Positioner plate 3

50 M755 9980646989801 Rail for wire 1

51 M712a 9910383831001 Spring plate 3

52 (M711.1-M711.42) Cam discs 42

53 M701 9910383822001 Shaft 3

54 M8403 9910383833001 Bearing pin 1

55 M8404 9910383834001 Bearing pin 1

AIR MOTOR (SMGR) : Replacement of following components of SMGR

Page 3 OF 4

LIST-A Annexure-2 B



1) SELECTOR (G.R)56 M8406 9910383836001 Key. 2

57 M8407 9910383836002 Key. 2

58 M8413 9910383845001 Pointer 1

59 M8416 9910383853001 Pin 1

60 M8420 9910383895001 Fixing disc 1

61 M8417 9910646215001 Control Disc for Limit Stop 1

62 M8449 9910646222001 Driving gear wheel 1

63 M8412 9910646223001 Position Indicator Disc 1

64 M8409 9980383838801 Gear Wheel Complete 1

65 M8410 9980383840802 Gearwheel with cam disc. 1

66 M8415 9980383851801 Limit stop latch 1

67 M8448 9980646296801 Gear wheel compl. 1

68 M8411 9980646297801 Mounted driving 1

69 M8414 9980646757801 Stroke Counter Complete 1

70 M536 9980383784801 Three Way Valve "B" 2

71 M535 9980383796801 Three Way Valve "A" 2

72 M8605 9910646729001 Sequence relays 2

73 M8606 9980647349801 Relays cabling 1

74 M8703 9980647355801 P.C.B. compl. 1

75 M8702.4 9910611583002 Hoder Rail 1

76 M8623 9910611583001 Holder Rail 2

77 M8622/ M8702.3 9910611589001 Lock Spring 21

78 M8620/ M8702.1 9980611582801 Series Terminal Box 21

79 M8624/ M8702.5 9980611584801 End Bail 6

80 M8604 9980647346801 Diode complete 3

81 M1916 9910383874001 Key 2

82 M1926.3 9910383881002 Bevel wheel 1

83 M1926.2 9910383889001 Rubber sleeve 6

84 M1934 9910640605001 Gasket 1

85 M8324 9910646695002 Name plate 1

86 M1911 9919000188001 Support 1

87 M1926.1 9980383878802 Coupling disk 1

88 M8317 9980646785801 Air pipe complete 1

89 M8215 9910640623002 Cover 4

90 M8205 9910640627001 Insulator cup 1

91 M8207 9910646759001 Gland 4

92 M8200.1 9980646782801Housing complete

(M8202+M8203+M8204)1

5) ACCESSORIES


1 G4415 9919000087001 Mica washer 141

2 G4416.2 9919000091001 Tube 3

3 G4406.1 9919000211003 Insulating Tube 2

4 G4406.2 9919000211001 Insulating washer big 4

5 G4406.3 9919000211002 Insulating washer small 4


1 G3933 9919000140001 Two way solenoid valve 1

2 G3939a 9989000042801 Stop Valve complete 1

3 G3902a 9980643600169 air pressure regulator 1

4 G3915 9989000145802 Terminal Complete 24

5 G3916 9919000145010 End plate 25

6 G3983a 9919000143001 Rotary Switch Complete 1

7 G3925a 9989000142801 Foot pedal switch complete 1

a) For STAINLESS STEEL GRID ELEMENT RGR

b) CONTROL PANEL ( ZSM PANEL)

Page 4 OF 4

LIST-B Annexure-2 B

1) SELECTOR (G.R)

sl.no.Part

numberDrawing number Description Qty/ TC

1 G1607 9980383548801 CARRIER PLATE ASSEMBLY 1

2 G1501 9910383543001 STEPPING WHEEL 1

3 G1601 9980383557801 BUSHING DOUBLE POLE 1

4 G2132 9980383621801 SUPPORT ASSY 1

5 G2101 9980383621801 SUPPORT ASSY 1

6 G1101 9980383452801 BASE FRAME 1

7 G1457 9910383515001 DRIVE WHEEL 1

8 G1453 9980383487801 Gearing housing 1

2) CIRCUIT BREAKER ( CGR )

sl.no.Part


1 G2506 9989000313801 CONTACT LEVER 6

2 G27 9989000066802 ARCING CHAMBER COMPLETE 3

3 G2401 9980383661802 CARRIER STRIP 6

4 G2601 9980383664801 BLOWOUT COIL COMPLETE 6

5 G 2135 9919000031001 Connecting angle 3

3) AIR MOTOR

sl.no.Part


1 M2101 9980383805801 CRANK SHAFT COMPLETE 1

2 M715 9980646294802 BEARING PLATE 1

3 M715a 9910647264003 BEARING PLATE 1

4 M2314.6 9980383813801 CONNECTING ROD COMPLETE 4

5 M557 9910383804001 Bearing plate (Left & Right) 2

6 M1101 9910383711001 Base plate 1

4) ACCESSORIES

sl.no.Part


1 G39 9989000130801 ZSM PANEL COMPLETE 1

2 M8500 9980646787803 NOTCH INDICATOR TRANSMITTER ASSY 1

3 G40 9980646210801 SELSYN RECEIVER ASSY 2

4 G42 9980385081803 MANUAL HAND DRIVE 1

5 G4407 9989000040802 Transition resistance Assy.(S.S.RGR) 1

Additional critical items (optional) of Ganz(type) NO-32 tap changer to

be replaced on condition basis by AAL

Page 1 OF 1

Annexure-Z1

Drg. No. Item No. Description Drg. No. Part No. Description 1 1 9980383557801 G1601 Condenser bushing compl. AG-207811-R1 S1601 Condenser bushing compl.

2 1 9980383508801 G1470 Lantern gear complete AG-416040-R1 S1470 Lantern gear complete

3 1 9980383547802 G1630 Contact ring compl. AG-207835-R1 S1630 Contact ring compl.

4 1 9910383458001 G1201 Contact plate SWT-135013-P1 S1201 Contact plate


Critical Component to be replaced after 12 Years of Service

Total-4


Page 1 of 1

Annexure-Z2

Drg. No. Item No. Description Drg. No. Part No. Description 1 1 9980383526801 G15.1 Contact arm without step wheel AG-210303-R1 S15.1 Contact arm without step wheel

2 1 9980383547802 G1630 Contact ring compl. AG-207835-R1 S1630 Contact ring compl.

3 1 9980383457801 G12 Contact plate compl. AG-106356-R1 S12 Contact plate compl.

4 1 9980383635804 G2180 Load switch frame complete AM-100065-R1 G1280 Load switch frame complete

5 6 9980646720801 G25 Contact system complete HAGT-225519-R1 S25 Contact system complete

6 Air motor cover complete SWT-235107-R3 A6602 Air motor cover complete

7 1 set 01 Kg Air Dryer Complete 01 Kg Air Dryer Complete

Total-7

Assemblies for unschedule arising


Annexure- U

Page 1 of 16

3.00 TECHNICAL SPECIFICATION & SCOPE OF WORK

Common scope of work for repair/rehabilitation of main transformer for Conventional Electric Loco of Indian Railway.

---------

3.1. Scope of work & Technical Specification: Transformer shall be handed over to firm

after cutting the winding of leg I,II& III. Repairs, Reconditioning, rehabilitation means Overhauling & repairs of the transformers comprising of :-

3.1.01 Dismantling, Conventional Processing, reassembling and testing of transformers. 3.1.02 Tank leakages to be checked and rectified if any. 3.1.03 Painting of Transformer Tank and fittings 3.1.04 Preliminary checks to ascertain the healthiness of transformer. 3.1.05 New Belleville Washers at all locations and Brush nuts of all Bushings etc. to be provided. 3.1.06 All drain Valves to be modified. 3.1.07 All old permallie wood cleats and supports to be replaced with SRBGF. 3.1.08 All nuts and bolts to be replaced and tightened properly. 3.1.09 Transformer washing to be carried out with hot jet of oil. 3.1.10 Complete removal of sludge from all location. 3.1.11 All leads to be anchored properly. 3.1.12 All wedges and separators provided in the windings to be ensured for their proper fittings. 3.1.13 Overhauling and checking for proper functioning of safety valve of conservator. 3.1.14 To provide additional support to the breather ( Air Dryer) container,. 3.1.15 Replacement of core fixing bolts to IS: 7271 Grade C 20 cold drawn. 3.1.16 Tap changer leads to be supported by SRBGF ring. 3.1.17 Vacuum drying of the transformer winding to be carried out, which is ideal for oil soaked coils. 3.1.18 Replacement of all cocks - Total 3 Nos. (1 for TFP tank, 1 for GR Dome & 1 for Filter Cock). 3.1.19 Replacement of Insulated Brackets below press bath & replacement of insulation below press plate to be carried out. 3.1.20 Replacement of tap changer mounting bolts, cover bolts, pedestal & securing bolts to be done. 3.1.21 New 1 Kg. Silica gel to be provided separately. 3.1.22 Flash bath on yoke bolts should be done at 1 KV for 1 Min.

Annexure- U

Page 2 of 16

3.1.23 All the transformers shall be subjected to all up to date tests as per latest standard practices for Railway Traction Transformers and test results shall

be submitted to Railways. 3.1.24 New EHV grade Transformer Oil confirming to RDSO's SMI- 127 and latest IS: 335/

SMI159 use of inhibited TFP oil to IS : 12463. Tenderers should confirm before filling the oil in each repaired transformer by them from consignee to adopt EHV grade TFP oil as per SMI- 127 or SMI-159. Having confirmed from consignee only then the contractor should fill the oil in repaired transformer. 400Ltrs. of oil for the Oil Cooler will be supplied along with repaired transformer by the contractor.

3.1.25 Transformer Bushings to be replaced and capacitance values to be recorded (5 Nos. of 1.5 KV, 4 Nos. of 3 KV, 1 No of 25 KV & 1 No of 33 KV). 3.1.26 Palm Clamps to be provided in all TFPs. 3.1.27 All 'O' rings for fixing of Tap Changer leads to be replaced. 3.1.28 Complete set of windings of all legs i.e. Leg I, Leg II and Leg III to be replaced. 3.1.29 SRBGF cleats/supports will be provided in all the legs. 3.1.30 Bus bars on top coils of 2nd & 3rd leg to be replaced. 3.1.32 Replacement of all core supporting bolts. 3.1.33 Replacement of tapping lead cleats by SRBGF. 3.1.34 Earthing coils shall be provided. 3.1.35 Insulating Sleeve between main channel & side channel, will be replaced by SRBGF

tube. 3.1.36 All grey press boards and wadman insulating sheets between main channel & core to be replaced. 3.1.37 Replacement press boards and other wooden blocks etc. 3.1.38 Replacement of all gun metal valves to be done. 3.1.39 Gauge glass on the conservator side shall be checked for proper visibility as on the

installed condition inside loco and rectified for any leakage. 3.1.40 The top cover plate and Channel will be dressed & also its flatness ensured for placing and fixing of MVRH. 3.1.41 All gaskets to be replaced. 3.1.42 All hardware to be replaced. 3.1.43 Standardization of drain and sampling valves/cocks (on different transformers different pitch threads have been provided) including checking and rectification of

leakage. 3.1.44 Replacement of Core laminations and end frame, if required as decided during joint inspection 3.1.45 The under mentioned Railways drawings & specifications shall be referred for execution of works for repairs, reconditioning, rehabilitation and testing work as

far as Railway Practices are concerned.

Annexure- U

Page 3 of 16

The other drawings and specifications required for ensuring the quality of work or raw material used by the original equipment manufactured & approved by RDSO shall be deemed inclusive as & where required even though they may not be appearing in this specification or in other specifications & drawings mentioned below.

Sr. No

Title of Drawings Drawing Nos

1 Procedure for repairing of defective welds of transformer RDSO/ELRS/SMI/102

2 Provision of Additional Insulation over tap - leads RDSO/ELRS/SMI/122

3 Tightening of core bolts with torque value 25 Kgs RDSO/ELRS/SMI/123

4 Specification for cork sheets RDSO/ELRS/SMI/124

5 Printers & Prints to be used on the loco transformer RDSO/ELRS/SMI/125

6 Flushing stagnated oil in neck portion. RDSO/ELRS/SMI/126

7 New EHV grade oil for Traction Transformers & switch gears RDSO/ELRS/SMI/127

8 Replacement of existing 'L' clamps by palm clamps for cable connection of a0, a1 bushings of transformers

Mod.NoRDSO/WAM4/80 ELW/BSL /3/WAM4/SK-135.

9 Material specification for core supporting studs of loco transformers

Mod.NoRDSO/WAM4/94 ELW/BSL/4/SK-197

10 Modification to the cleat fixture

Mod.No.RDSO/WAM4/140 ELW/BSL/MOD/SK/382

11 Modification to explosion vent of transformer to prevent oil splashing inside the loco

Mod.No.RDSO/WAM4/141 ELW/BSL/MOD/SK -377

12 Modification to neck portion of the transformer

Mod.No,RDSO/WAM4/142 ELW/BSL/WAM4/3/114.096

13 Modification to cooling pipe inside transformer

Mod.No.RDSO/WAM4/143 ELW/BSL/3/MOD/SK-375

14 Modification to improve oil circulation in the neck portion of loco transformer.

Mod.No.RDSO/WAM4/160 SKEL-4018 & SKEL -4019

15 Modification for strengthening Plates on transformer tank walls under A 33 & A34 bushings

CLW/RS/SK-9(A-D)/T- 12 (4 sheets)

16 Measures to improve the reliability Mod.No.RDSO/WAM4/176

17 Provision of crape paper of 0.2mm thick & 2.5 mm wide on bare bus bars of transformer

Mod.No.RDSO/WAM4/182

18 Improvement in welding technique RDSOL.no.3.2.1/ECdt.28.8.83 RDSO's drg.No.SKEL/3555

NOTE –

The revisions / alterations in the CLW / RDSO drawings & Specifications mentioned in

the scope of work at the time of work execution shall be also applicable.

3.2 TECHNICAL DETAILS :- 3.2.1 DIMENSIONS :- The dimensions as per the original design shall be

maintained for the components as well as repaired, reconditioned & rehabilitated transformers after finishing. Should any tenderer find any discrepancy /discrepancies in omissions from the drawing(s), if any or any of the tender forms or should he be in doubt as to their meaning, he should at once notify to the Chief Electrical Engineer Western Railway, Mumbai Churchgate.

3.2.2 MATERIALS : As mentioned in the drawings stated for respective items & drawings

followed by the original equipment Manufacturers (duly approved by the RDSO), all the material of first quality confirming to relevant specification will be used during repairs, reconditioning & rehabilitation of the transformers.

Annexure- U

Page 4 of 16

3.2.3 SPECIFICATIONS :- The repairs, reconditioning, & rehabilitation & testing

of the Transformers must be done as directed in this specification as well as standard practices followed by the Original equipment Manufacturers (duly approved by the RDSO ) during manufacturing of these transformers.

3.2.4 Special tests to be done at various stages of work at contractor's works :-

Following tests must be done in presence of Rly’s engineer.

3.2.4.1 Insulation Resistance and Capacitance value of all bushings (A0, A33, a0, a3, a4, a5, & a6).

3.2.4.2. H.V. testing at 10KV & 6 KV for one minute. 3.2.4.3. Applied voltage test at 50 Hz for one minute. 3.2.4.4. Induced H.V. test at 100 Hz. and double voltage for one minute or Induced

Voltage 60 KV for 40 Second. 3.2.4.5. Core losses and copper losses Measurement. 3.2.4.6. Winding Resistance 3.2.4.7. .Ratio Test. 3.2.4.8. Leakage test on transformer tank. 3.2.4.9. Di-Electric Strength and Acidity of transformer oil (at 60 KV 50 Hz for 1

minute and Maximum permissible acidity of oil is 0.05 mg. KOH per gm.

3.3 PROCESS FLOW CHART

The activities involved in the repair/ rehabilitation of the failed transformers have been listed out as annexure ‘A’ with the process flow chart as under:-

---------------------------------------------------------------------------------------------------------------------- Sr.No. ACTIVITIES ------ --------------------------------------------------------------------------------------------------------------

3.3.1. Un tanking of the defective transformer 3.3.2. Drain out oil from transformer completely. 3.3.3. Disconnect all pipe work and bushing on the lid. 3.3.4. Open the lid, un-tank the active part and disconnect the lid from the active part. 3.3.5. Remove the core clamping plate (End plate). 3.3.6. Remove the upper yoke laminations. 3.3.7. Remove the draw bolt, pressing plate and disc type spring washers covering the whole length of the coils. 3.3.8. Disconnect the interconnecting bus bars, cut and disconnect the connections

between the defective coil discs and healthy coil discs at the point where

they were previously soldered. Also cut and disconnect any other coil discs

necessary for the removal of the defective coil discs from the assembly.

3.3.9. Remove the coil discs one - by - one.

3.3.10. Replace the defective / damaged coil discs with equivalent new coil discs.

Replace all the distance pieces, support pieces and insulating separators.

3.3.11. Replace the draw bolts, pressing plates and disc type spring washers.

3.3.12. Press the complete assembly.

3.3.13. Replace the upper yoke laminations.

3.3.14. Replace the core clamping plate (end plate).

3.3.15. Connect the bus bars and braze the inter connections between coil

discs, soldered joints should be adequately taped, all the bare copper

Annexure- U

Page 5 of 16

bus bars should be taped.

3.3.16. Carry out the following electrical tests :- - Measurement of core losses.

- Measurement of winding resistance.

- Winding ratio.

- Measurement of copper losses.

- separate source test.

- Induced voltage test.

- Insulation resistance test.

3.3.17. Connect the lid to the active part. 3.3.18. Connect all pipe work and bushing terminations on the lid except condenser

bushing/ cable head. 3.3.19. Fill oil.

NOTE :- Ensure that, relevant Modifications & Special Maintenance Instructions Issued by RDSO are complied with during Repairs / Rehabilitation of Failed Transformer.

3.4 PROCESS OF WINDING ASSEMBLY AND COIL CONSOLIDATION.

The process of winding assembly and coil consolidation required to be adopted in the repair/ rehabilitation of the failed transformers are detailed below :-

3.4.1 WINDING STACK ON LIMB 1 Assemble the coil discs to from the winding stack for limb 1, putting in the distant pieces. Adjust the distance pieces and strengthen the coil discs and insert the guiding strips into the dove- tail holes of the distancing pieces. Press the winding stack with a total pressure of 43 t. Check the stack height and note on it on a leg attached to it. Put the assembled winding stack in the oven with forced internal air circulation and dry out at 1100C for a period of 24 Hrs. At the end of this period, retighten the springs to achieve the full pressure at 43t. again. Replace the winding stack assembly in the oven for another period of 24 Hrs. and then retighten the springs as above. Replace the stack in the oven for another period of 24 Hrs. Remove the stack and retighten the spring again. After the above THREE drying cycles, allow the winding stack to cool to room temperature. Measure the stack height at room temperature with the full pressure still applied. The winding stack height measurements are required to be taken at 3 equally spaced points and note the heights on the leg attached with the stack. The winding stack is required to be pressed using a device consisting of pressing plates, draw bolts and helical springs. The spring used for this purpose are required to have a relatively high compression for a given load such that the compression on the stack remains practically constant while the stack shrink in height during seasoning. The spring should be loaded to the permissible limit to obtain the maximum compression. EIGHT helical springs should be used each capable of a permissible load of 5t,for achieving a load of 43t. on the winding stack, the springs are required to be compressed such that compression load is 107.5% of the permissible load.

Annexure- U

Page 6 of 16

3.4.2 WINDING STACK ON LIMB 2

Coil discs forming winding stack for limb 2 should be pressed as above for two drying cycles at a pressure of 36t. The same spring assembly used in pressing winding stack of limb 1 is also used for pressing winding stack for limb 2. The compression of the springs in this case shall be 90% of the permissible limit. Measure the height of the stack after completion of the above two drying cycles and note the same on the tag attached with the stack.

3.4.3 WINDING STACK ON LIMB 3 Using the same spring assembly and with a pressure of 31t. for which the compression in the springs should be 62% of the permissible load, press the winding stack for limb 3 for 2 drying cycles. Measure the height of the stack after completion of the above two drying cycles and note the same on the tag attached with the stack.

3.5 PRESSING PROCESS OF THE COMPLETE ASSEMBLY Assemble the winding stacks of limb 1,2,& 3 on respective core legs. Place the draw bolts, coil pressing plates and discs type spring washers on the core - coil assembly. Compression as high as can be achieved by tightening the bolts so that the spring washers are completely flattened is to be applied. The whole transformer is then put in the oven at a temperature of 1100C This temperature is required to be maintained throughout the oven pressing process. The transformer should be kept in the oven for 24 Hrs. and thereafter the nuts on the draw bolts should be re-tightened until the winding stacks attain the designed height. The transformer is then allowed to cool with the pressing devices remaining tightened. After cooling, replace the upper yoke assembly laminations.

3.6 OIL FILLING The completed transformer is put back in the oven and heated up to 1100C. (Max) under maximum vacuum possible. However, the vacuum level shall not be less than 1 TORR. When the vacuum level remains unchanged for 24 Hrs. draw in the oil taking care that the vacuum does not fail while drawing the oil. In case, the dielectric strength of the oil needs to be improved. Guidelines as laid down in RDSO SMI No.159 dated 30.11.93 should be followed. Remove the transformer from the oven and allow it to cool to the room temperature. Fill up the oil until the mark on the oil level indicator is reached venting trapped air through the air released vents provided. NOTE :- THE ABOVE SEASONING PROCESS IS APPLICABLE ONLY TO WINDING ASSEMBLY WITH DISCS TYPE COILS AND IS NOT APPLICABLE TO SPIRAL OR FOIL WINDING CONSTRUCTION.

Annexure- U

Page 7 of 16

3.7 INSPECTION:- 3.7.1 INITIAL INSPECTION :-

The initial inspection of the repairable transformers due for repairs & rehabilitation will be done at LCW Workshop Dahod jointly by the Engineer’s representative and Contractor’s representative before lifting of the repairable transformers for repairs, reconditioning & rehabilitation from LCW-DHD. All the defects will be recorded and one copy of the same will be handed over to the contractor’s representative.

Before handing over of defective transformers to the contractor for repairs all the layers of winding of transformer have to be cut 100% at sheds and same will have to be certified by a gazetted officer of the respective sheds/shops not below the level of senior scale.

3.7.2 STAGE & FINAL INSPECTION:-

Stage inspection will be carried out by authorized railway representative to check the quality of workmanship & use of approved make materials during the progress of the work. Contractor shall produce all relevant proof for the raw materials being used for repairs, reconditioning & rehabilitation of the transformers. These should be as per the specification mentioned on the Railway drawings and followed by the original Equipment Manufacturer. The Inspector shall have full and free access at any time during the execution of the contract to the contractor’s works & he may require the contractor to make arrangement for inspection of the materials components at his premises or any other place specified by the Engineer/Inspector and if the contractor has been permitted to employ the services of a sub contractor, he shall in his contract with the sub contractor reserve to the Inspector a similar right. The contractor shall accept all reasonable suggestions that may be made by Railway’s representative during the progress of the work . The contractor shall provide without any extra charge all materials tools, equipments, labour & assistance of any kind which the Inspector may demand of him for any test or examination, which he require to be made on the contractor’s premises and the contractor shall bear and pay all costs of attendant thereon . If the contractor fails to comply with the conditions aforesaid, the inspector shall, in his sole judgment be entitled to remove for test and examination all or any part of the ordered works manufactured/repaired by the contractor to any premise other than his (Contractor’s) & in all such cases the contractor shall bear the cost of transport and /or carrying out such tests elsewhere. A certificate in writing of the Inspector, that, contractor has failed to provide the facilities and means for test & examination will be final & shall be binding on the contractor. The Inspector shall be associated in various tests as mentioned in CLW specification before using the component for next stage or operation. The contractor should arrange all these tests at his works free of cost.

During the FINAL INSPECTION of the transformers, the Inspector shall be associated in various tests as mentioned in CLW specification. The contractor should arrange all these tests at his works free of cost.

On acceptance of the repaired / rehabilitated transformers by the Railway’s representative, The contractor will dispatch the transformers duly packed for fitment and commissioning in the Locomotive to LCW/DHD .

The contractor shall inform the tentative dates for the Stage & Final Inspection of the Transformers at their premises minimum 15 days in advance.

Annexure- U

Page 8 of 16

3.7.3 a) INSTALLATION & COMMISSIONING: All defects noticed during fitment, commissioning & field monitoring shall be rectified by the contractor immediately (within 30 days) on receipt of advised from engineer. It may be clearly noted that final acceptance of transformers will be granted only on successful fitment, after preliminary testing, fitment along with associated equipments, commissioning, to the satisfaction of the Engineer. The contractor shall depute his representative to see the commissioning & fitment at W.Rly’s workshop for understanding the nature of defects and rectification needs on the repaired transformer. All the defects noticed during Assembly, preliminary testing fitment commissioning as well as noticed during warranty period will be rectified by the contractor at Railway’s site or at his works as directed by the Engineer For the firms who are not approved by RDSO for such works, it may be clearly noted that final acceptance of first transformers will be granted only on successful fitment, after preliminary testing, fitment along with associated equipments, commissioning, field trial & extensive field monitoring by the Railway for ONE MONTH to the satisfaction of the Engineer. Final acceptance of transformers Subsequent/remaining transformers will be granted only on successful fitment, after preliminary testing, fitment along with associated equipments, commissioning. The contractor shall depute his representative to see the commissioning & fitment at W.Rly’s shed/shop for understanding the nature of defects and rectification needs on the repaired transformer. All the defects noticed during Assembly, preliminary testing fitment commissioning & field trials as well as noticed during warranty period will be rectified by the contractor at Railway’s site or at his works as directed by the Engineer. For the firms who are approved by RDSO for such works, the receipt of transformer in Railway’s shed/shop in good condition to the satisfaction of purchaser will be considered as final acceptance.

3.7.3(b):- The testing of transformers oil during IC, AOH and IOH schedules as per SMI No.158 dated 19.1.95 (except item No.9.10,11 of annexure –I of SMI No.158) oil sample of graduator fitted with reconditioned transformers shall also be carried out along with TFP by the respective shed. The value of DGA shall remain constant as specified during the warranty period. If the DGA differs more than 10% the transformer shall be lifted by the contractor and take necessary corrective actions and the repairs be carried out by the contractor as per warranty obligation.

3.8 PACKING CONDITIONS :- On receipt of Instructions from the Engineer to dispatch the

consignment for Fitment & various commissioning tests at Railway's site i.e. LCW /DHD he contractor shall pack the transformer suitably by providing necessary supports packing and coverings etc. to avoid any damages & deterioration to the transformers during transport due to vibration or the atmospheric effect.

3.9 QUALITY ASSURANCE PLAN :- Contractor should strictly comply the QAP attached as annexure-I with this specification and material for major raw materials to be purchased from sources given in annexure-II. The inspection of raw materials by Railway authority are to be arranged at OEM’s premises. **********************

Annexure- U

Page 9 of 16

ANNEXURE-I

QUALITY ASSURANCE PLAN FOR REPAIRS OF LOCO TRANSFORMER RATING 5400 KVA.

I. RAW MATERIAL : High Conductivity electrolytic bright annealed Copper. A. Paper covered copper conductors Ref. IS 7404 Part II & IS 1666 1. Visual No burrs & sharp corners / bright smooth

surface. 2. Source of supply of copper Imported/indigenous copper / cc Rods /

strip 3. Chemical composition 99.9% pure electrolytic copper 4. Tensile strength (Min) 275 Kg/mm2 5. Elongation (Min) 30% 6. Bare conductor size To confirm to IS 6160 - 1971. 7. Size over insulation (covered

conductor) The paper covering should be tightly

wound as per clause 7 of IS 1666 8. Electrical strength of paper As per clause 8 of IS 7404 1974. 9. No. of layers of paper Two layers half over lapped IEC 76 B. LAMINATION : IS 3024 - 1965 1. Visual / surface finish No rusting, no scaling 2. Dimensions As Existing 3. Burrs Nil 4. Thickness As per Original design 5. Grade As per Original design 6. Bend The lamination should not have any

warping. 7. Surface resistivity There should be no continuity between

surface and edge. 8. Source of supply Manufacturers Original / equivalent. 9. Magnetic properties As per original stack 10. Stack height As per original 5400 KVA Transformer

design C. PORCELAIN BUSHING : IS 3347 / 5621 / 2099 1. Visual No cracks, no chipping 2. Dimensions As per IS 3347 3. Creepage As per IS 3347 4. Dry power frequency test As per IS 2099 5. Porosity test As per IS 5621 clause 3.5 6. Temperature cycle As per IS 5621 7. Mechanical strength As per IS 2099 8. Manufacturer's test report To be produced 9. Source of supply BHEL, W. S. Insulators, Jayshree

Insulators, C.J.I. Porcelains., Sampat Ceramics, Associated Porcelain (P) Ltd. Udyog Centre .

Annexure- U

Page 10 of 16

D. TRANSFORMER OIL EHV GRADE : Ref. IS 12463, 1448, 6104, 6792,6262, 6103 & RDSO SMI 158 / 159

1. Appearance Free from suspended particles 2. Dielectric strength Should be more than 60 KV 3. Density at 27 Deg. C. Should be less than 0.89 g/cm 4. Kinematics viscosity Should be less than 27 Centistokes 5. Interfacial tension (min) Should be more than 0.04 N/M 6. Flash point Should be 140 Deg. C. 7. Pour point Should be less than 6 Deg. C. 8. Neutralisation value (Max) Should be 0.03 mg/KOH/g. 9. Corrosive sulphur Should be non corrosive 10. Dielectric dissipation Should be less than 0.002. 11. Specific resistance at i) 900C Should be greater than 35 x 1012 Ohm /

cms. ii) 270C Should be greater than 1500 x 1012 Ohm /

cms 12. Oxidation stability Should be less than 0.20 mg/KOH/gm 13. Presence of oxidation inhibiter Should contain anti oxidant additives 14. S. K. Value 6 to 8 Percent 15. Ageing characteristics after

accelerated ageing test

i) Specific resistance a) At 90°C 0.2 x 1012 ohm/cm b) At 27°C 2.5 x 1012 ohm/cm ii) Dielectric dissipation factor at

90°C 0.2

iii) Total acidity (Max.) 0.05 mg/KOH/gm. iv) Total Sludge (Max.) 0.05 Percent by weight 16. Water Content (Max.) Should be less than 50 ppm 17. Manufacturers test report Should be produced 18. Quantity Suitable for 5400 KVA tank 19. Hydrogen content To be monitored specifically at works

without any interference from other gasses to form base reference point.

E. M. S. FABRICATION SHEETS : Ref. IS 226, 513 1. Surface finish No rolling defects and rusting. 2. Dimensions As per table 3, 4, & 5 of IS 513 3. Tensile strength (min) 275 N / mm2 4. Bend test Should not crack. F. RUBBER BASED CORK GASKETS : Ref. IS 4253 1. Dimensions Should be within + 10% of specified 2. Flexibility Should show no sign of cracks or

breakage.

3. Immersion test Should show no sign of disintegration in transformer oil

4. Manufacturer's test report Should be made available. 5. Source of supply Rein Talbros, Cork Industries, Gujrat Cork &

Rubber goodwill.

Annexure- U

Page 11 of 16

G. BUSBAR COPPER : Ref. IS 191 1. Chemical composition 99.9% pure electrolytic copper 2. Physical No rolling defects, no pitting 3. Burr Nil. No sharp edges. 4. Bend Test Should not crack 5. Dimensions As per requirements of 5400 KVA rating

H PAINTS : 1. Primer As per IS 2074 2. Finish As per 2932 3. Shade & Type No. As per requirement

I. SRBGF. : IS: 10192 GRADE EP I 1. Visual Should be free from damage and have a

smooth bright surface 2. Dimensions Should be as per drawing 3. Manufacturers test report To be produced 4. Source Glass Fibre, Parmali Wallace, Santi Fibre,

Atul Ind..

J CORE BOLTS (EN-20 GRADE STEEL)

:

1. Visual Should be free from burrs & sharp edges. 2. Dimensions As per original design. 3. Threading Threads should be cold rolled / M/C. Thread 4. Source of supply Open market (Raw material).

K. EPOXY FIBRE FLASS TUBES : IS 10192 GRADE EP 1 1. Visual Should be free from damage and have smooth

bright surface. 2. Dimension As per drawings. 3. Physical, Mechanical, Electrical

& Thermal Characteristics As per Table 3 column 8 of IS 10192

4. Sources of supply Glass Fibre, General Electro Mechanical Ind. Surendra Engg. Works, Uniglass Industries..

L. CREPE PAPER : IS 9335 1. Visual Should be free from damage. 2. Dimension Should be within tolerance (thickness & width) 3. Moisture absorption As per IS 9335 4. Elongation As per IS 9335 5. Dielectric Strength As per IS 9335 6. Source of supply Imported from Japan / Sweden / USA /

Germany.

M. PRESS BOARDS (PRE-COMPRESSED) : IEC 641-3-2 IEC 763 1. Visual Should be free from damage should be

homogeneous & properly consolidated. 2. Compression strength As per IEC 641. 3. Tensile strength ----- " ----- 4. Dielectric Strength ----- " ----- 5. Dimensions ----- " -----

Annexure- U

Page 12 of 16

6. Manufacturers test report To be produced 7. Source of supply Raman Boards / Senapathy / Weidmann N. COPPER SUPPORT WOOD PIECES : 1. Material TEAK WOOD. 2. Visual Should be free from knots and other

defects. 3. Dimensions As per drawing. II. ACCEPTANCE STANDARD FOR

INSPECTION :

Characteristics Acceptance standard A WINDING 1. Dimensions (ID/OD) As per drawing for 5400 KVA 2. No. of turns Within + ½ turns. 3. Insulation Should be free from damages and should

be as per data sheet for 5400 KVA 4. Resistance Specified value + 5% (by Kelvin Bridge or

Milli Ohms Meter) B CORE ASSEMBLY 1. Dimensions + 3 mm tolerance on specified value for

5400 KVA 2. No. of steps / stack thickness + 1% tolerance on specified value for

5400 KVA 3. Core bolt with epoxy glass tube Should withstand 2 KV for 1 Minute with

respect to earth 4. Lamination Should be free from damages and bends. C. ASSEMBLY BEFORE TANKING : 1. Oven drying } The core coil assembly should be Complete drying check } completely dry 2. Dimensional & visual checking of

tank Should be as per drawing for 5400 KVA.

As approved by CLW. 3. Dimensions of active part ---------- " ---------- 4. Loose connection No loose connections (random checking) 5. Connection of all components All components should be connected as

per drawing 6. Clearance between H.T. & L.T.

phase. Should be as per drawing for 5400 KVA

approved by CLW. 7. Bushing fixing As per the drawing 8. Lid fixing As per the drawing 9. Vacuum level As per the spec. (0.5mm) 10. Transformer oil BDV check after oil

filling Should be more than 50 KV.

D. TANK - TANK FABRICATION : 1. Dimension As per drawing for 5400 KVA approved by

CLW. 2. Welding joints To be continuous 3. Accessories & fittings As per drawing except cooler & blower

&MVRM.

Annexure- U

Page 13 of 16

4. Grindings & Chipping Surface to be levelled 5. Pressure test No leaks. 6. Dye penetration test No flaws. E. PAINT / TANK : 1. Surface treatment No rust no scaling surface to be levelled 2. Primer cost (outside) tank 30 mic rons (App.) 3. Inside oil resistant coat ----- " ----- 4. Final painting (outside) 70 microns (App.) A. TRANFORMER TANKING 1. Oven Drying Record to be Produced ( as per Foot note below). . Should be dry 2. Completion of drying Electrical-Should be more than 500 M.Ohms with 2.5 KV Megger. checked by IR 3. Dimensional and Visual Measurement Should be within +/- 2% of specified values. . checking of tank NOTE i) OVEN DRYING : The core coil assembly should be dried under vacuum of 0.5mm at

temperature of 105 to 110 0C until desired IR value is achieved and stabilizers ( proper record of oven drying time/ duration, vacuum level and IR values should be maintained and produced at the time of inspection.)

ii) COIL SEASONING: Firm should carry out coil seasoning under heat and pressure as per RDSO’s modification sheet 176. Firm should maintain record if time and coil shrinkage measurement. Seasoning should be continual till the coil shrinkage cycle is less than 1.00 mm.

B. FINISHING BEFORE PACKING Characteristic Type of check Acceptance standard. 1. Check for rating plate. Visual Should be as per drawing 2. Loose connections before mounting Visual Connection should be firm 3. Door fitting Visual It should flash with the firm. 4. Touch up/repainting Visual No exposed metalic surface and patches. 5. Fitment of blocking plates Visual Should be provided. 6. Oil level check. Visual Should be fitted upto the required level. 7. Cleaning Visual Should be clean. 8. BDV test of oil Oil BDV tester Minimum 50 KV. 9. Pressure yest for oil leakage Pressure test Complete unit is subjected to pressure test at 15 PSI for checking of oil leakage.

Annexure- U

Page 14 of 16

C. ELECTRICAL TEST ON COMPLETE TRANSFORMER 1. Turns ratio test. 2. Insulation resistance test at 35 Deg C IR value to be recorded after 15 seconds and again

60 seconds with motorized megger of 2.5 KV ratio of 60 seconds to 15 seconds reading (P.1) shall be above 1.6.

3. High voltage test HV 10 KV for 60 seconds. LV 10 KV for 60 seconds. AUX06 KV for 60 seconds. 4. Short circuit test for measurement of copper losses. 5. No load test for measurement of iron losses. 6. Induced over voltage test ( duration = 120 x rated freq.

-------------------- test freq. Voltage= ( 2.250 + 2000) Volts. = 2500 V ( rated voltage of windings) 7. Winding resistance measurement at 75 Deg.C specified value +/- 5%. II. INSPECTION SCHEDULE 1. Inspection shall be conducted by an authorised Officer / Railway’s representative at three

stages, Initial , Stage & Final ( firm to give min 15 days advance notice for Stage & Final Inspection )

- Inspection of tank coil ,core with ground insulation, insulating materials, hardware’s, gasket, copper items, oil, cleats etc.

- Inspecting of core-coil assembly before tanking. - Final inspection of ready transformer and oil. 2. All tank cover fasteners should be new.

SOURCE OF SUPPLY : GKW, Laxmi Precision, Sundaram Fasteners, Precision Fasteners Hindusthan Fasteners.

3. All spring in bellevile washers shall be used of original make.

NOTE –

1) The approved sources refer to the valid sources at the time of work

execution.

2) Any other sources added / deleted after the tender finalization in the scope

of work shall be applicable in the subject work.

Annexure- U

Page 15 of 16

Annexure-II Sources for major Raw materials

Sl no. Description Sources

1 Complete coil Original Equipment manufacturers

2 Transformer oil M/s APAR( Silvasa & Rebale works), M/s SAVITA(New Bombay & Silvasa works) M/s RAJ PETROSPECIALIIES( C) M/s TASHKENT M/s GANDHAR

3 LAMINATION Original Equipment manufacturers

4 PORCELAIN BUSHING BHEL, W. S. Insulators, Jayshree Insulators, C.J.I. Porcelains., Sampat Ceramics, Associated Porcelain (P) Ltd. Udyog Centre

NOTE – 1) The approved sources refer to the valid sources at the time of work execution. 2) Any other sources added / deleted after the tender finalization in the scope of work shall

be applicable in the subject work.

Annexure- U

Page 16 of 16

Annexure ‘A’ Must change items

Sr.No Description

1 Replacement of Complete winding Coil for leg I, leg II & leg III including associated insulating materials and replacing of tapping leads.

2 Replacement of all Core Supporting Bolts

3 Replacement of all gaskets

4 Replacement of all palm Clamp.

5 Modification to tank cover and replacement of hard ware, gauge glass, gun metal valve.

6 Complete replacement of transformer oil with EHV grade inhibited transformer oil as IS-12453 and RDSO SMI-159. Two drums of EHV grade inhibited transformer oil (205 ltr. In one Drum) will be supplied along with each transformer)

7 Replacement of

a 3KV LV Bushing 4Nos./TFP(a3,a4,a5a,a6)=4 Nos each transformer with A33 & A34 bushing

b 1.5 KV bushing(A0,a0,a1,a7,a8)=5 Nos in each transformer

Government of India Ministry of Railways · (a) Analyze failures of GR/CGR/RGR, SMGR & TFP and...

Documents

Transcript of Government of India Ministry of Railways · (a) Analyze failures of GR/CGR/RGR, SMGR & TFP and...