Tender For Provn Of 200 Kva Dg Set And Allied Works At Smc At Af Stn Thoise; 1 Supply, Install, Testing & Commissioning of Silent type with continuous operation Diesel Generating Set alongwith having prime power rating of 160kW/200 KVA at NTP, 415 Volt, 75 db noise level at 1 mtr distance from DG Set with suitable Engine to develop 200 KVA, AC 415 Volt at 1500RPM , 0.8 lagging power factor at 415 volts suitable for50 hz 3 phase system and ,confirming to CPCB-IV norms / latest CPCB emission norms, acoustic enclosure, anti vibration mountings, control panel and foundation. The DG set should be robust in construction factory tested and assembled to ensure perfect alignment of Engine and Alternator on a common base frame with same manufacturer.The DG set shall becomprising of following item as under: The DG set shall becomprising of following item as under: - 2 (a) Diesel Engine : The diesel engine shall be of four stroke cycle multi-cylinder, direct injection, water cooled, turbo charged, Air to air after cooling and optimised turbocharger for increased altitude capabilities, developing suitable BHP @ 1500 RPM under tropical condition of Thoise of BS 5514/ISO 3046 with an over load capacity of 110% for one hour in any specified 12 hrs of continuous operation. The engine shall confirm to IS:10000/BS:649/BS 5514.The engine shall have the following accessories: -(i) Cooling fan and radiator. (ii) DM water cooling systems with pre-mix anti-corrosive additive. (iii) Turbocharger. (iv) Fly wheel with fly wheel housing. (v) Electrical engine starter motor (disengagement after start-up) with Batteries. (vi) Battery charging systems. (vii) Stainless steel exhaust flexible elbow. (viii) Thermal sealing of exhaust pipe and aluminium cladding for complete exhaust pipe and silencer. (ix) Required filters for fuel, lube oil, air etc. (x) Sets of flexible hoses as required. (xi) Suitable rubber coupling to Alternator with guard. (xii) Suitable Engine controller for protection of the engine. (xiii) Coolant heater and crankcase heater. (xiv) Oil drain Pump. (xv) Heavy duty air cleaner etc.Make of Engine:- Kirloskar/Cummins/Greaves 3 (b) Engineprotections:(i) High coolant temperature warning & trip (ii) Low lubricating oil pressure warning & trip (iii) Low coolant level warning & trip (iv) Fail to crank trip (v) Over crank trip (vi) High and Low speed trip (vii) Low or High battery voltage alarms. (viii) Clogged filter warning (ix) Lack of fuel (x) High Canopy Temperature (xi) Set fail to start protection after failure of the set to start after successful three consecutive start attempts. 4 (c) Governor: The governor shall be of electronic type suitable for monitoringconstant engine speed within the specified limits for auto parallel and auto load sharing operation. 5 (d) Exhaust : The exhaust piping system shall be supplied with a hospital grade silencer and catalytic converter suitably optimized to meet stringent noise emission standards laid down by MoEF/CPCB-IV compliant. The exhaust piping and the silencer shall be wrapped with rock wool and/or calcium silicate. The outside shall be neatly wrapped with aluminum cladding. The exhaust line shall be extended beyond the height of the utility building roof as required by pollution control norms. Suitable supporting structure for installation shall be provided. 6 (e) Hot air exhaust (Radiator cooling):AsperOEMrecommendation ifsufficient exhaust for radiatorisnot available, the contractor hastoprovide GI duct for hot air exhaust from DG set up to designated place of duct outlet. The duct shall be made of 14 Gauge thick GI Sheet including necessary civil work. 7 (f) Fuel Tank : Inbuilt/internal bottom mounted (with-in DG set or with-in base frame) diesel tank of suitable capacity with mounting brackets, complete with fuel inlet, out let, air vent, drain plug, level indicator, inter connection pipes from tank to diesel generator as required. Suitable barrier shall be provided between Diesel tank and the Engine. Fuel tank shall befabricated as per tropical condition of Thoise with approx. capacity ordesigned capacity shall be suitable for 8 hrs continuous operation or 14 hours capacity at 75% load.In case the inbuilt base frame tank is not capable to hold POL for 8 Hrs continuous operation, contractor shall provide additional tank made up of MS sheet capacity separately as per manufacture recommendation. 8 (g) Starting system : The engine starting shall be by means of totally enclosed axial type electric starter suitable for 12/24 volts DC starting systemcomprising of starter motor, voltage regulator and arrangement for initial excitation complete with suitable number of batteries as Per OEM Specification, Sealed Maintenance Free (SMF) Lead-Acid type suitable for High Altitude Area of Thoise .The battery shall be supplied with a suitable floor mounted MS stand treated with seven tank treatment, two coats of red oxide /primer & acid resistant paint with wooden base, adaptor box etc . with copper conductor battery leads of required length and socket/clamps 9 (h) Alternator: (i) 200 KVA 3 phase 0.8 PF, 415V, 4 wire 1500 rpm self-excited and self regulatedthrough electronic AVR confirming to IS :4722/BS 2613 suitable for tropical condition with brush less exciter, housed in screen protected drip proof enclosure. The alternator shall be confirmingto IS 13364 Part-2 & IS 15999 Part-1/ IEC 60034 Part-1 capable of delivering rated output at rated power factor of 0.8, with, a terminal voltage differing from the rated value by not more than +/- 5%.(ii). Frequency differing from the rated value by not more than +/-0.5%.(iii). Short circuit capacity of 300% for 10 seconds.(iv). Over load capacity of 110% for one hour. The insulation class of the Alternator shall be class F/ H. The temperature rise shall be limited to class B andIngresses enclosure protection shall IP23 or better. The out put terminals of each Alternator shall be connected to an MCCB of suitable capacity microprocessor based, adjustable type through a cablesystem. The control panel shall be housed insidethe acoustic enclosure.Make of Alternator :-Stamford/Kirloskar electric/Jyoti/Cummins Electric/Crompton Greaves 10 (j) Alternator Protection: Alternator should have following protections: - (i) Over and Under voltage (ii) Under and Over frequency warning and trip(iii) Loss of excitation (iv) Over current and Earth Fault and Short Circuit Protection (v) Unbalanced loads (vi) Restricted Earth Fault Protection. (vii) Differential protection. (viii) Diode Failure. 11 (k)Voltage regulator: A rapid response voltage regulator shall be provided to regulate the generated voltage. The overall regulations from no load to full load, including cold to hot variation and load power factor of 0.8 lag to unity shall be within 1% of the normal voltage. The excitation system shall be designed to promote rapid voltage recovery following sudden application and 12 (l) Acoustic enclosure : The acoustic enclosure should be supplied along with DG set as per latest CPCB norm. Acoustic enclosure shall be of powder coated and fabricated out CRCA MS sheet. The canopy shall have hinged doors, one door with glass window to view proper parameters on the control panel. The canopy and doors shall have inside lining of fire retardant foam/glass wool as acoustic materials. The base frame shall be fabricated in ISMC channel or in sheet metal, with lifting hooks for convenient lifting of complete set i.e. along with canopy, engine and alternator. The sound level shall have less than 75 db (A) at a distance of 1 meter. High quality noise absorbent and fire-retardant grade acoustic. The canopy has the provision of emergency push button, external to the canopy.Note : The acoustic enclosure shall be made by the authorized certified agency of original engine manufacturer. disconnection of load. 13 (m) AMF Control panel : The control panel shall be designed for automatic ON Mains Failure Operation ofthe Generator sets, The panel will be totally enclosed, Dust tight, outdoor type, vermin proof ,floor mounted, free standing, cubical compartmentalized type with hinged doors, fabricated from 2.0 mm CRCA Steel metal having separate compartments conforming to relevant IS. The Panel will be epoxy painted powder coated with light grey shade and the panel /compartment will be fitted with the following instrument and pre-wired with colour coded flexible copper cable with failure Numbers for easy identification & maintenance. The panel shall be complete with inter connections, insulators, two nos of Earthing lugs and with suitable rating of MCCB 250A,TPN 35 KA adjustable type-04 Nos(01 No each for incoming of DG Set & Mains and 01 No outgoing for load and 01 No Spare 250A, 35 KA adjustable type) at both the end & shall incorporate the followings:-(i) Neutral contractors. (ii) AMF logic unit having protection for over frequency, under frequency, over voltage ,Low lube-oil ,and high water temperature for Engine. The AMF unit will have provision for auto start, Auto Stop of the DG Set with 3 attempts cracking relay.(iii) Main supply voltage monitor. (iv) Combined meter (MFM) for Voltage Current, Frequency, KVA ,KWH & P.F . (v) CTs of suitable rating (vi) Static Battery charger connected on mains consisting of Transformer, Rectifier D C Voltmeter C Ammeter ,charging rate selector switch (Trickle /Boost ,Indicating Lamp ,on off switch (vii) Auto /Manual mode switch (viii) Miniature Circuit Breaker for Fuses (ix) Hooter 12/24 volt (x) Annunciations ,Alarms &Trips for higher water temperature over speed set fails to startand D G overload (xi) Push Buttons for Breaker on/off DG Start/stop ,Engine Trip. Hooter Accept and For Reset (xii) Indicating Lamps for Load on mains load on DG Set Low lube oil pressure and High water temperature (xiii) Suitable size of Tinned Copper bus bar will be provided of rating 300A TPN with suitable mounting insulation.(xiv) Suitable size contactors air break type-02 Nos.(xv) Bypass arrangement in case of failure of AMF system through changeover switches, of suitable capacity on load 02 Nos, front operation type. 14 Note : (i) Cost of DG set foundation is deemed to be included in cost of item.(ii) Contractor should submit necessary drawing to GE/Engr-in-Charge before placing the order for approval.(iii) The Gen set must be affixed with label meeting the followingrequirement (The label shallbe durable and legible)(a) Name and address of the engine manufacturer.(b) Certificate that the engine conforms to the CPCB IV emission/ latest CPCB emission norms shall be provided.(c) Type and approval certificate number.(d) Date of manufacturing of Gen set.(iv) The complete DG Set including Engine/Alternator shall be factory assembled by manufacturer or its authorized OEM as approved for assembling of the DG set. A certificate in this connection shall be submitted to the GE.(v) Anything missed out above but technically required for efficient working of DG set including AMF Panel at Thoise Air Force Station is deemed to be including in quoted rates.(vi) The quoted rate shall be deemed to be inclusive of first fill of engine oil.(vii) The quoted rate shall be deemed to be inclusive of minimum12 hours test runat site as specified in PS in presence ofIEM/ rep of accepting officer, alltesting arrangements/ equipments for water load test/ suitable strip heater load shall be made available by the contractor for tests. POL shall be arranged by contractor for testing and cost deemed to be included in quoted rate.(x) The contractor shall arrange load/resistive load / water load for testing for final testing of DG set at site and the cost is deemed to be included in quoted rate. (xi) DG set should be sound proof as per latest policy/ latestCPCB Norms.(xii) Drawing for Plinth of DG Set shall be provided by OEM and approved by GE. Further the PCC foundation shall be made by the contractor and quoted rate is deemed to be included this provision.(xiii) The DG set shall be suitable for operation in high altitude and in extreme climatic conditions (Temperature dropping upto -20°C during winter) prevalent in Thoise, Ladakh.(xiv) Drg of AMF Panel shall be approved by GE. 15 M&L Earthing complete with galvanised steel earth plate electrode of size 600mm x 600mm x 6mm thick as earth electrode buried directly in ground (earth pit not less than 2.25 meter deep below ground level) with top edge of the earth plate not less than 1.5 mtr below ground level using GI strip of size 32x6mm as earthing lead continuity conductor connected to earth plate by means of GI thimbles, nuts,boltes,washer all as directed including providing earth wires protection pipe GI light grade 15mm dia form earth plate to main switch board /panel, watering pipe medium grade 20 mm dia. with wire mesh and funnel at top, earth pit and RCC pit cover in RCC1:2:4 adequate quantity of charcoal dust and salt all around the earth plate, earth work in any type of soil ,removing surplus excavated material to a distance n. exc 50mm and depositing where directed ,complete all as specified in EP No-3 of SSR -2020 PART-1 or directed ,by engineer -in- charge.(Note:- upto 7.5 mtr length of pipe of 15mm dia and GIwire shall deemed to be included in unit rate quoted by tender)Note:- Earthing wire of 4mm dia shall be deemed to be included in unit rate from earth pit to control panel of any length. 16 Supply, laying and testing cable XLPE Insulated ,screened, PVC bedded, galvanized steel strip or wire armoured, electric power cables (heavy duty) 1100 Volts grade, ISI Marked with stranded aluminium conductor of size,3.5 core 120Sqmm complete all as specified and directed. 17 Excavation in trenches n.exc. 1.5 mtr wide and n.exc 1.5 mtr deep for foundations of poles/stays/cable etc not exc 10 Sqm area on plan and getting out in Hard/Dense soil complete all as specifed and as directed by Engineer-in-Charge. 18 Returning filling in including spreading levelling, watering and well ramming in layer each not exc. 25 cm thick in a soft/loose soil complete all as specified and directed by Enginer-in-Charge. 19 Removing surplus soil to a distance not exc. 50 mtr and depositing where directed at a level n.exc. 1.5 mtr above the starting point complete all as specified and directed by Engr-in-Charge. 20 Sand cushioning to protection of underground cables, laid 8 Cm before laying and 15 Cm after laying of cable, and punned to form an overall layer of 18 Cm thick, complete all as specified and directed by Engineer-In-Charge.Note: Punned thickness shall be measured. 21 M&L for PCC cable coverClass LV, Type I,flat,size 250 mm x 150mm x 40mm laid Flat in trenches over the cable with length 250mm perpendicular to the direction of cable, adjacent/ abutting each other complete all as specified and directed.Note:-Excavation and earth work to be measured and paid for separately
