Tender For Provision Of Trolley Mounted500kva Transformer And Trolley Mounted 400Kva Mobile Dg Set With Connected Items At Afs Sulur; 1 Supply installation, testing and commissioning of transformer, outdoor type step down 11/0.433 KV, HT with 3 phase and LT with 3 Phase, 4-wire system double copper wound with Off Circuit Tap Changer arrangement on HT side for a variation of secondary voltage with tapping range + 5% to -10% in steps of 2.5 % continuous rating of 500 KVA (Energy efficient not less than Level-II) conforming to IS: 1180 (Part 1):2014& other latest IS codes, Oil - IS: 335: 1993 including first fill of Oil, making incoming and outgoing connection toTransformerwith copper conductor with lugs & glands, mounting on trolley completeall as specified and directed. Make :- ESSENAR/CG/ABB/Schneideror any techno commercial equivalent make listed Ein C/HQ SC approved listNote:- (a) The quoted rates shall deemed to include the following provision (1.01 to 1.05)/ specification.(b) Trolley shall be measured and paid separately. 2 Temp. Rise in Oil [Degree C.] : as per IS, By Resistance [Degree C.] : as per IS, Ambient temperature : as per IS, Winding Material : Double wound CopperType of Cooling : ONAN, Class of Insulation : Class “A”, Vector Group : Dyn11, Frequency [Hz.] : 50, Phase : 3, Insulation Level [kV/Kvp] H.V. : 28kV,L.V. : 3kV, Primary Connection [HV] : Delta, Primary Volts : 11000V,Primary Phases : 3Primary Wires : 3,Primary rated current : Approx. 26 Amps,Secondary Connection [LV] : Star, Secondary Volts : 433V,Secondary Phases : 3, Secondary Wires : 4, Secondary rated current : Approx. 666 ,Taps on Primary /Secondary Winding for : +7.5% to –7.5% in steps of 2.5%, Primary /Secondary Voltage Variation Off Circuit Tap Changer, No. of switch positions : 7Terminal Arrangement H.V. : Bare Bushings/Cable box, L.V : Bare bushings /Cable Box, Load Losses (Level-II) At 50% Loading : As per IS in Watts (Max.)At 100% Loading : As per IS in Watts (Max.)Impedance (Z) [Percentage], HV - LV : not more than 5%No Load Current (% of Rated Current) :As per IS 3 Weights & Dimensions (Approx.)1) Core & Windings with clamps (Untanking Weight) : As per IS Specifications2) Tank & Fittings :As per IS Specifications 3) Oil :As per IS Specifications4) Total Weight : .As per IS SpecificationsOverall dimensions of the transformer (mm)Length :width :As per IS SpecificationsHeight : As per IS SpecificationsHV - LV Orientation : 180 deg.Bushing - as per latest ISPorcelainBushings HV : 3Epoxy Bushing LV : 4Painting [Finish] : PU Light GreyShade No. 631 – IS: 5 4 TESTS - Routine Tests as per IS: 1180 (Part 1):20141) Ratio test2) Polarity3) Phase angle error measurement4) I R Values5) Winding resistance6) Open circuit test7) Short circuit & Impedance test8) Separate source voltage test9) Induced over voltage test10) Vector group test11) BDV of Oillike etc.. 5 STANDARD FITTINGS AND ACCESSORIES:1) Rating & Terminal Marking Plate - One2) Earthing Terminals- Two3) Lifting Lugs -Two4) Drain Valve with blanking plate - One5) Filter Valve with blanking plate - One6) Conservator - One7) Conservator Oil filling hole with cap - One8) Oil Level indicator with min. marking - One9) Dehydrating Breatherfilled with silica gel- One10) Conservator Drain Plug - One11) Air Release Device - One12) Thermometer Pocket - One13) Pressure relief valve - One14) Roller Uni directional - Four15) Radiators As per IS16) Bare Bushings/Cable box HV -As per IS17) Bare Bushings/Cable box LV - As per IS18) Separate Neutral Terminal -One19) Off Circuit Tap Changer - One20)thermometer - One21) Buchholz relay-One 6 Note:- (i) The Studs for neutral & body shall be sufficiently long to fix 2 Nos GI strip for earthing.(ii) Cost of Cable entry boxes/Bare bushingon both sides shall be deemed to be included in quoted rates. 7 Supply, fabrications, installing, testing and commissioning of trolley suitable for 500kVA transformer with following fittings/accessories:-(i) Trolley mounting system(ii) The complete unit of Transformer should be mounted on a mobile trolley suitable for max speed of 15Km/hr(iii) Trolley should be mounted on four solid rubber tyres(with one spare wheel addition) and turning radius of trolley shall be suitable for roads(iv) TOW barshall be provided at frontand hook on rear side shall be provided.(v)m Trolley shall be minimum ground clearance of 250mm(vi)All vibrating components should be mounted on anti vibrating pads/mounts(vii) Mud guards at rear, front and side reflectors are also required in the trolley(viii) exposed surface of trolley shall be painted with two coats of synthetic enamel over a coat of red oxide primer as per colour code(ix)Aluminium ladder to be fitted on trolley, the ladder shall be sliding type and fitted below the base platform and shall be non removable.(x) Cable and connector-Trolley should be provided with separate cable drums for HT power cable and LT power cables made with 2.5mm thick MS sheet and 50mm dia soft with 2Nos bearings mounted ata suitable place trolley with suitable size of angle iron bracket(note: HT/LT cables shall be measured and paid separately).(xi) Walk around space and suitable working space around the transformerwith guards on trolley the shall be provided as per recommendations of OEM of transformer. 8 (B) OTHER ACCESSORIES(i) Tool Box- Tool box shall be made with 1mm thick mild steel sheet with suitable locking arrangement and fixed on trolley, The tool box shall have adequate size to accommodate following ISI marked:Each type of open Jaw, double end spanner, ring spanner and box spanner to tighting of all nuts and bolts of the system -01 Set, Each type of screw driver electrician pattern and star screw driver set-01No, Yellanky set-01Nos, hydraulic crimping tool bit size up to 500sqmm-01 set, Hammer -01, other tools as per recommendation of manufracturer,safety system-02Nos of 5kg fire extinguisher for electrical fire, ISI marked HT insulated rubber mat to be provided through the open surrounding of transformer.(ii) Load Carrying/Bearingcapacity not less than 5 ton for mounting of 500kVA transformer, dimensions shall be followed as per recommendation of Transformer OEM.(iii) Provision ofoutdoor type sheet metal enclosurefor fixing ACB 800Amps4 pole with as including necessary fixing arrangement with closed hinged type suitable for outdoor type sheet metal enclosure 9 Supply, install, test and commissioning ofLT, Air circuit breaker, operational voltage 415 to 660 volts, insulation voltage up to 1000 volts, AC, 50 cycles, 3 phase, 4 pole, Manual draw outtype, rated current rating 800 amps and of breaking capacity not less than 50 KA with quick make, quick break, with manual operating mechanism complete with triple mound current transformer, Microprocessor based over current stop less release and static trip release, adjustable short circuit release, earth fault release with shunt trip with indication under voltage release and wired for indicating “Trip Healthy circuit” ancillary switch etc. complete over load release rating400 to 800 Amps - 1 No. ( including cost of same) Make : - L&T/ Schneider/ Siemens/ABB 10 Supply, laying & testingAerial Bunched Cables(ABC), 11000 volts grade, of size 3 core 95 sqmm with suitable steel grip with necessary end terminations with suitable size cable lugs of lugs with crimping with tool, nuts ,bolts etc complete all as specifiedand directed. 11 S&FFlexible Earth continuity conductor 20x3 mm with insulated material to connect trolley mounted transformer for connection of Earthing /neutral terminals etc with necessary nuts and bolts etc complete all as specifiedand directed. 12 Supply and laying copper flexible cable of size 240 Sqmm single core 1100 volt including necessary end terminations with suitable with necessary end terminations crimped lugs with crimping tool,nuts,bolts etccomplete all as specifiedand directed. 13 Supply and laying copper flexible cable of size 120 Sqmm single core 1100 volt includingwith necessary end terminations crimped lugs with crimping tool,nuts, bolts etccomplete all as specifiedand directed. 14 Supply, install, testing and commissioning ofoutdoor type HT LBS Panel, IP54 degree of protection filled with /Air insulation or SF6 gas as insulation with leakage rate less as per IS, comprising of 03 Nos LBS (two incomings and one out going(Along with provision of mechanical interlocking arrangement, 11 KV, 3 phase, 50Hz, 630A, 25 KA for 1 sec factory made, out door type cubicle fabricated out of CRCA sheet 3mm thick weather, dust and vermin proof, epoxy powder coated of IP-55 protection class with self contained air insulated compartment for bus bars and cable boxes with necessary support and 630A rated aluminium bus bar including cable galleries and provision of following switch gears including earthing switch, all pre-wiring with PVC copper conductor cable of suitable sizeall as specified and as directed as per the below details :- 15 (a)Manually operated air break, load break switch along with earth switch and fuse trip mechanism of HT HRC fuse - 50A, 230 V AC, Trip Coil and Aux Contact 2 No + 2NC for all 03 Nos LBS in two incomings and one outgoing etc (b)Space heater with ON/ OFF switch 10A, 230V AC for all 03 Nos LBS in two incomings and one outgoing etc. (c)Emergency trip push bottom - 01 for all 03 Nos LBS including two in and one outgoing etc .(d)Cubicle illumination lamp with holder - 01 for all 03 Nos LBS including two in and one outgoing etc (e)Door limit switch, 230V AC for all 03 Nos LBS including two in and one outgoing etc (f)Provn of MCB, DP, 10A for control wiring for all 03 Nos LBS in two incomings and one outgoing etc (g)Provn of surge arrester 9 KV, 10 KA for all 03 Nos LBS in two incomings and one outgoing etc (h)Provn of thermostat for all 03 Nos LBS in two incomings and one outgoing etc (j)Provn of indication lamp for LBS ON/ OFF, LBS E/S ON/ OFF 230V AC.in two incomings and one outgoing etc (k) Three position disconnector/earthing switch downstream LBS in two incomings and one outgoing etc(l) Three position single spring mechanism for disconnector/earthing switch in two incomings and one outgoing etc(m) “Live Cable” LED Indicators thru Capacitor Voltage Dividers mounted on the bushings in two incomings and one outgoing etc (n)Short time breaking current - 21KA/ 3 sec(o)Making Capacity - 52.5kAp(p)Auxiliary contacts - 1NO + 1NC(q) Power frequency withstand voltage - 28KV, Impulse withstand voltage - 75KV® Nominal operating gas pressure - as per IS.(s) Green(ON)/Red(OFF) push buttons to operate VCBin two incomings and one outgoing etc 16 Supply and laying in trenches/through pipes or bare in road crossings/paths/ drains/ ducts/ floors/along poles/equipments/trenches etc. Cable Under ground, cross linked poly-ethylene (XLPE) insulated, screened, PVC bedded, galvanised steel strip armoured, electric power cables with aluminium conductor, earthed,11 KV grade,of cross sectional area 185 Sqmm x 3 core laidincluding all necessary end terminations, all cable glands, nuts bolts as required complete all as specified. 17 Boring of holes under road, pavement, hard standing by trenchless technology using ultra sounding technique and necessary machine including HDPE pipe of 150 mm dia suitable for 0.4 mpa working pressurecomplete all as specified. 18 M&L Out door cable straight through jointing kit (Heat shrinkable) suitable for XLPE under ground aluminium conductor cable, 11 KV (Earthed) grade, of cross sectional area 185 Sqmm 3 core complete all as specified and as directed. 19 Supply, install, test and commissioning stand alone HT Panel, 11 KV, 3 phase, 50Hz, 630A, 25 KA for 1 sec factory made, out door type cubicle fabricated out of CRCA sheet 3mm thick weather, dust and vermin proof, epoxy powder coated of IP-55 protection class with self contained air insulated compartment for bus bars and cable boxes with necessary support and 630A rated aluminium bus bar including cable galleries and provision of following switch gears including earthing switch, all pre-wiring with PVC copper conductor cable of suitable size including necessary PCC foundation and angle iron suitable size for mounting/ fixing all as specified and as directed as per the below details :-(a)Manually operated air break, load break switch along with earth switch and fuse trip mechanism of HT HRC fuse - 50A, 230 V AC, Trip Coil and Aux Contact 2 No + 2NC.(b)Space heater with ON/ OFF switch 10A, 230V AC.(c)Emergency trip push bottom - 01(d)Cubicle illumination lamp with holder - 01(e)Door limit switch, 230V AC.(f)Provn of MCB, DP, 10A for control wiring(g)Provn of surge arrester 9 KV, 10 KA.(h)Provn of thermostat(j)Provn of indication lamp for LBS ON/ OFF, LBS E/S ON/ OFF 230V AC.(k) Chequered rubber mat of 1100 Volts grade of size 2.0x 0.9m and thickness 12mm with ISI marked 20 Supply and installationof Earthing with Galvanised Earth Plate Electrode 600x600x 6mm thick buried directlyin Ground (Earth Pit not less than 2.25 Metre below Ground Level) with Top edge of the Plate not less than 1.50 Metre below Ground Level, connected with Galvanised Earth Strip of size 32x6 mm (upto 7.50mm length) by means of Bolts, Nuts, Check Nuts and Washers of GI or Steel and connected Earthing Testing Point/Bus-bar including GI 40mm bore light grade Protection Pipe, Earth Plate surrounded by a packed thickness of Char Coal or Coke Dust mixed with Common Salt, Magnesium Sulphate (1 : 1 : 0.5) in alternate layers of not exc 150mm thick, PCC Pit in Cement Concrete 1:3:6 (20mm graded stone aggregate) and Pre-cast RCC Cover Slab of size 350x350x50 mm in Cement Concrete 1:2:4 (20mm graded stone aggregate), reinforced with 10mm dia TMT Bars @ 100mm Centre to Centre in both ways, GI Wire Mesh, Funnel with GI Watering Pipe 20mm bore medium grade including necessary Excavation in any type of soil, Returning, Filling and Removal of surplus Spoil disposal to out side MD land and all as shown in Electrical Plate No. 3 of MES Schedule Part-I and Testing on Completion , complete all as specified and as directed. 21 Note for Item No13:-(a)All Joints should be joined by tight nut/bolts.(b)After completion of work earthing shall be tested by the contractor in presence of JE/ Engineer-in-Charge, User and proper record shall be maintained duly signed by all concerned.(c)Earth resistance tester shall be provided by the contractor. It should be calibrated from authorised company/ lab.(d)After testing if desired earth resistance of less than 5 Ohm is not obtained, the earthing will be redone at no extra cost to Govt till desired result is obtained. 22 Excavation in trenches not exceeding 1.5 mtr wide and not exceeding 1.5 mtr depthfor foundation, laying of poles, in trenches for laying cable and getting out in hard/dense soil complete all as specified 23 Returning, filling in including spreading, levelling, watering and well ramming in layers not exceeding 25 cm thick complete all as directed by Engineer-in-Charge. 24 Removal of surplus soil to a distance not exceeding 50 mtrs and depositing where directed at a level not exceeding 1.5 mtrs above the starting point complete all as directed by Engineer-in-charge. 25 Riddling Sand, obtained from excavation, for cable protection and filling 8cmthick under the cable and 15cm athick bove the cable in trench to get the thick layer of 18cm after ramming complete all as specified and as directed. 26 M&L in Un-reinforced precast concrete cable cover class HV Type 1, flat size 300mm x 180 mm x 40 mm thick complete all as specified and as directed. 27 Supply, install, testing and commisioning, factory assembled silent diesel engine driven generator set, fully wired alternator AC to give an output of 400 KVA after de-rating factor, continuously rating at apower factor 0.8 lagging,3-ph,4 wire,415 volts 50hz supply,1500rpm directly coupled with diesel engine liquid cooled mounted on common base frame on Trolley with adequate capacity of fuel tank with fuel inline and accessories, fixing and aligning on trolley with vibration pads,conrol panel and other accessories etcand comprising of following:-(i)Diesel Engine:- Liquid cooled turbo charged with after cooler to deliver suitable BHP after derating factor at 1500rpm under NTP conditions as per latest IS/SO with an overload capacity of 10% more for one hour in any 12hours continous operation with following accessories :- Diesel engine of ratedspeed at full load electric start developing system with radiator, including electronic governor with latest class as per IS, engine control panel, lub oil pumping, water pumping (by gravity or external arrangementas recommended by OEM) , fuel tank exhaust piping with silencer and suitable electric start withbatteries of adequate capacity and rating of alternator of specified capacity complete with direct /flexible coupling and coupling guard complete. 28 (a) Radiator with blower fan or heat exchanger with guard.(b) Pipe coupling for engine cooling system piping.(c) corrosion inhibitor coolant.(d) All type of filters as required and recommended by OEM (e) Fly wheel housing and fly wheel to be suit to the alternator (f) Shut off coil with safeties for LLOP/HWT/over speed.(g) Engine bearing mechanismin fly wheel housing.(h) Dry type air cleaners and vacuum indicators, silencers (k) exhaust flexible bellows, .(l) Battery charging alternator/DC dynamo.(m) First fill of oil, coolant and diesel duringcommissioning of and 12 hours testing.(n) inter connecting all cables of adequate capacity batteries control and all pipelines.(o) Self starter 24 volts DC or as recommended by OEM of DG set.(p) Electric operated electronic governor with latest class as per IS.(q)Fuel injection pump/Pressure time pump as recommended by OEM of DG set.(r) No of cylinders as recommended by OEM of DG set to achieve desired Output of 400kVA after de-rating factor. 29 (s) Providing all engine safety featureslike, water temp,engine temp,engine speed , lub oil pressure, frequency, voltage, safety control, lub oil temp,over speed stoppage(t) Adequate capacity of batteries for self starter .(ii) Fuel tank: Adequate storagecapacity fuel tank with mounting brackets factory made of 5mm thick HR/MS sheet with level indicator fuel inlet ,outlet, airvent, drain plug etc complete all as specified.(iii) Isolator panel with 630Amp MCCB,50kA with tripping mechanism(iv) Micro processor based Genset controller or Auto logical controlled Genset controller (as recommended by OEM of DG set) with monitoring features with display like voltage, currents, frequency,kVA, kW, kWH, kVarh, PF, Lub oil pressure, temparatures of engine, lub oil , water etc, RPM , run hours, No of starts, Fuel level, Auto/Manual start/stop, battery voltages and charge condtion, compatable AMF features and diagnostic features battery charging failures, over/under speeds, over/under voltages, over kW, Phase seq, phase missing, mains under/over vlotage, earth fault trip, low fuel level, low oil pressure, high engine temperature, low / high battery voltage, over crank protection, routine maintenance indicator,gen set facility, etc(v)Alternator: Suitable capacity Alternator for rated out put of 400kVA capacity after derating factor ,PF-0.8 lagging,415volts, 3-ph,4-wire,50Hz at 1500rpm,self existed and self regulated with AVR brushless, screen protected, drip proof, insulation of class-H,IP ,voltage regulation grade latest, self ventilated conforming to latest BIS standards.(vi) Acoustic enclosure: M&L for above capacity DG set i.e 400kVA DG set to reduce noise level to 75dB measured at 1.0 meter distance as per guidelines CPCB(vii) Base frame: Sturdy, fabricated welded construction, channel iron base frame(duly painted) for mounting of engine and alternator i.e complete DG setas per manufacturer design along with AVM pads, other necessary accessories complete as required.Note:- Trolley shall be measured and paid separately. 30 Supply,fabrications,installing,testing and commissioning of trolley suitable for 400kVA DG Set with following fittings/accessories:-(a) Trolley mounting system(b) The complete unit of DG set 400 KVA should be mounted on a mobile trolley suitable for max speed of 15Km/hr(iii) Trolley should be mounted on four solid rubber tyres (with one spare wheel addition) and turning radius of trolley shall be suitable for roads(iv) TOW barshall be provided at frontand hook on rear side shall be provided.(v) Trolley shall be minimum ground clearance of 250mm(vi)All vibrating components should be mounted on anti vibrating pads/mounts(viii) Mud guards at rear, front and side reflectors are also required in the trolley(viii) exposed surface of trolley shall be painted with two coats of synthetic enamel over a coat of red oxide primer as per colour code(ix)Aluminium ladder to be fitted on trolley, the ladder shall be sliding type and fitted below the base platform and shall be non removable.(x) Cable and connector-Trolley should be provided with separate cable drum LT power cables made with 2.5mm thick MS sheet and 50mm dia soft with 2Nos bearings mounted ata suitable place trolley with suitable size of angle iron bracket(note: LT cables shall be measured and paid separately).(xi) Walk around space and suitable working space around the DG set with guards on trolley the shall be provided as per recommendations of OEM of DG Set. 31 (B) OTHER ACCESSORIES(i) Tool Box- Tool box shall be made with 1mm thick mild steel sheet with suitable locking arrangement and fixed on trolley, The tool box shall have adequate size to accommodate following( ISI marked):-Each type of open Jaw, double end spanner, ring spanner and box spanner to fighting of all nuts and bolts of the system -01 Set, Each type of screw driver electrician pattern and star screw driver set-01No, Yellanky set-01Nos, hydraulic crimping tool bit size up to 500sqmm-01 set, Hammer -01, other tools as per recommendation of manufracturer,safety system-02Nos of 5kg fire extiguuinsher for electrical fire,ISI marked HT insualted rubber mat to be provided through the open sorrounding of transformer.(ii) Load Carrying/Bearingcapacity not less than 8 ton for mounting of 400kVA DG set,dimensions shall be followed as per recommendation ofDG Set OEM.(iii) Provision of sheet metal enclosurefor fixing MCCB 630Amps4 pole with as including necessary fixing arrangement with closed hinged type suitable for outdoor type sheet metal enclosure 32 S&F Earth continuity conductor drawn in conduit/pipefor loop copper earthing 20x3 mm with insulation to connect trolley mounted DG Set.
