Comprehensive Maint of 01 MV Solar PV Power Plant at AFS Kanpur

Amount

Supply, Fixing, Testing and commissioning of Solar PV Modules of 325 Wp rating of latest specification Solor Photo Voltic Module ,in replacement of damaged/non-functional modules at 1 MW solar power plant all as directed by Engineer-in-Charge. Note : Solar PV module shall comprises of the following as under:-

The modules must be of similar electrical characteristics as the existing modules and compatible with the existing plant’s inverter string configuration, protection, and mounting systems.

The modules shall be either Polycrystalline or Monocrystalline PERC with matching wattage capacity of existing modules.

Modules should match the existing string configuration to avoid mismatch losses and optimize plant performance.

The voltage and current ratings of the replacement modules shall not vary by more than ±5% from the originally installed modules to maintain string performance.

All PV modules supplied shall conform to the following international and national certifications: (i) IEC 61215 (Design Qualification and Type Approval) (ii) IEC 61730 (Photovoltaic Safety Qualification) (iii) IEC 61701 (Salt Mist Corrosion Test – if the plant is near coastal zone) (iv) IEC 62804 (PID Resistance) (v) MNRE Approved Manufacturer List (ALMM inclusion mandatory as per current MNRE guidelines)

Module Construction details: (i). Glass: Tempered, low-iron, anti-reflective coated glass with at least 3.2 mm thickness and >91% transmittance. (ii). Encapsulant: High-transparency EVA (Ethylene Vinyl Acetate) with UV stabilization. (iii). Backsheet: Multilayer polymer sheet with high dielectric strength and weather resistance (white preferred). (iv). Frame: Anodized aluminum frame with minimum 1.5 mm thickness and provision for grounding. (v). Junction Box: IP67 rated, with bypass diodes, heat-resistant and suitable for rooftop or open-air mounting. (vi). Connectors: MC4 compatible connectors, pre-attached, IP67 rated with locking system.

Electrical Characteristics: (i). Maximum Power Voltage (Vmp): 30V–50V (depending on module wattage) (ii). Maximum Power Current (Imp): 7.5A–15A (iii). Operating Voltage Range: 0–1000V DC (with 1500V options allowed if plant is designed so) (iv). Power Tolerance: 0 to +5% (only positive tolerance) (v). Module Efficiency: ≥18% for mono-PERC, ≥16.5% for polycrystalline (vi). Temperature Coefficient of Power: ~ -0.35%/°C or better

Mounting: (i). Modules shall be mounted on the existing module mounting structures using compatible mid clamps, end clamps, and fasteners. (ii). Care must be taken to avoid stress or micro-cracks during installation. (iii). Damaged or loose clamps or fasteners shall be replaced with stainless steel Grade SS304/SS316.

Electrical Integration: (i). Electrical connections shall be done using existing or new MC4 connectors with proper polarity markings. (ii). Strings must be tested for correct voltage before energizing. (iii). Cable routing shall follow original layout and be protected with UV-resistant conduits if exposed.

Workmanship: (i). Only trained personnel certified under Suryamitra or equivalent MNRE schemes shall be allowed for module handling. (ii). Work must be performed in daylight hours under clear sky conditions to facilitate insulation and voltage checks. (iii). Any damaged modules during installation shall be replaced at contractor’s cost.

Testing and Commissioning: After installation, the following tests shall be carried out: (i). Open Circuit Voltage (Voc) and Short Circuit Current (Isc) test of each new module before string integration. (ii). Insulation Resistance Test using 1000V megger, results to be >100 MΩ. (iii). String IV Curve post-integration to ensure proper alignment with expected parameters. (iv). Visual inspection for cracks, delamination, discoloration, frame corrosion, or water ingress. (v). Thermographic imaging to detect hotspots or faulty bypass diodes.

Material Warranty: Replacement modules shall have: (i). Product Warranty: Minimum 2 years against manufacturing defects (ii). Performance Warranty: 5 years with ≥90% output at 5 years and ≥80% at 10 years

Payment Terms: (i). Quantity shall be measured as the number of PV modules successfully replaced, tested, and commissioned. (ii). Payment shall be made per module basis including supply, transport, installation, testing, and documentation. (iii). No payment shall be made for modules found defective during testing or damaged during installation.

General Notes: (i). Contractor must submit datasheets, origin certificates, ALMM proof, and test certificates with supply. (ii). All packaging materials and damaged modules must be safely removed from site. (iii). Supply must be from Tier-1 module manufacturers (as per Bloomberg NEF list, if applicable). (iv). Any mismatch losses caused due to non-identical modules shall be rectified at contractor’s expense.

Supply, Laying, Termination, and Testing of UV-resistant, falme-retardent, weatherproof Electron Beam Cross-linked Copper DC Solar Cables suitable for outdoor DC applications of size 4 sqmm in the existing 1 MW Solar PV Power Plant for interconnection of solar PV modules, string connections to String Combiner Boxes (SCBs), and SCB-to-inverter runs and removal of removing physically damaged, exposed, under-sized, or degraded cables from the plant. Make: As per existing. Notes as under :-

Cable Specification: (i). Type: Electron Beam Cross-linked Solar DC Cable, single-core, flexible, copper conductor (ii). Voltage Rating: 1000V / 1500V DC (iii). Temperature Range: -40°C to +120°C continuous operation (iv). Insulation: XLPO (Cross-linked Polyolefin) (v). Sheath: UV-resistant XLPO / TPE sheath, weather-resistant (vi). Flame Retardancy: FRLSZH (Flame Retardant Low Smoke Zero Halogen) (vii). Colour: Red (positive), Black (negative), with clear polarity marking

Conductor Specification: (i). Material: Annealed Tinned Copper, electrolytic grade (ii). Construction: Fine stranded, Class-5 per IS 8130 (iii). Cross-sections:4 sqmm: For module-to-module and module-to-string wiring 6 sqmm / 10 sqmm: For SCB-to-inverter runs, depending on current rating (iv). Minimum conductor purity: ≥99.97% copper content

Standards and Certifications: (i). IS/IEC 60228 – Conductor Class (ii). EN 50618 / TUV 2 PFG 1169 – Solar Cable Performance (iii). IS 694 / IS 7098 (Part 1) – General Cable Standards (iv). IEC 60332-1 – Flame Retardant Test (v). IEC 60754 – Halogen-Free Properties (vi). RoHS Compliant

Insulation & Jacket Characteristics: (i). Ozone-resistant (ii). UV-resistant for 25+ years outdoor life (iii). Halogen-free and self-extinguishing (iv). Compatible with wide ambient temperature range (v). Mechanical Strength: Withstand at least 20N/mm² tensile strength

Installation Guidelines (i). Removal of Existing Faulty Cabling: (a) Contractor shall identify and dismantle all brittle, exposed, shorted, or mouse-bitten DC cables. (b) Redundant or tangled cabling must be removed and disposed of properly. (ii). Routing and Protection (a) Cables shall be routed using existing cable trays, UV-stabilized HDPE conduits, or GI cable ducts. (b) Underground DC cabling shall be avoided unless existing routes require it; if laid underground, cables must be inside HDPE pipe of minimum 2mm wall thickness and buried at 600mm depth with warning tape. (c) Cable bending radius shall not exceed 4x outer diameter. (d) Adequate spacing between DC and AC cable routes shall be maintained to avoid induction and EMI.

(iii). Cable Laying: (a) Cable must be laid without mechanical tension or twisting. (b) Pulling must be done using a cable stocking or grip to avoid conductor damage. (c) Use of rollers, cable ladders, and pulling socks recommended (iv). Termination: (a) Terminations shall be done with properly sized crimping lugs, ring/fork type as required, using hydraulic crimping tools. (b) Lug crimping shall be tested by pull test (manual). (c) Heat shrink sleeves of color-coded insulation (red/black) to be applied at terminations. (d) All terminations to SCBs shall be tightened using torque-controlled tools as per torque charts. (e) MC4 connectors or equivalent IP67-rated connectors to be used between modules and strings

Testing and Commissioning: (i). Continuity Test: Check each cable for open circuit using a multi meter or cable tracer. (ii). Polarity Check: Confirm correct positive/negative polarity from modules to SCB and SCB to inverter. (iii). Insulation Resistance (IR Test):Conduct IR test using 1000V DC megger and Acceptable result: ≥100 MΩ between conductor and earth (iv). Voltage Drop Check: Ensure voltage drop between modules and inverter input is within 2% under full-load conditions. (v). Visual Quality Check: Verify no exposed copper, kinks, abrasions, or improper bends and Ensure all cables are securely clamped and labelled. (vi). Labelling: All cables shall be labelled at both ends using UV-rated ferrules or tags. Labelling to include string number, polarity, and destination.

Payment Terms: (i). Payment shall be made per metre of cable laid, terminated, and tested, including supply of lugs, sleeves, markers, and associated installation materials. (ii). Separate line item for 4, 6, and 10 sqmm as defined in BOQ as applicable. (iii). No payment shall be made for damaged or non-tested cable.

General Conditions (i). Cables shall be procured only from MNRE empanelled manufacturers or BIS/ISO certified cable suppliers (e.g., Polycab, Havells, KEI, Finolex, RR Kabel). (ii). Contractor must submit factory test certificates (Type Test and Routine Test) with cable supplies. (iii). Unused cable reels must be stored under shade and away from moisture or chemicals. (iv). All works to be executed in compliance with IS 3043, IS 732, CEA (Measures relating to Safety and Electric Supply) Regulations, and MNRE guidelines for solar installations. (v) Cable Ties and Supports of UV-resistant nylon cable ties at shades and Stainless steel cable ties for outdoor exposure (vi)Cable markers at every 5 meters and at both ends (vii)Separate routes for AC and DC cables (viii)Minimum 300 mm separation between AC/DC paths to avoid interference (ix) Loose laying prohibited — all cables must be clamped at every 50 cm (x) Cable entry into panels with proper glands, no sharp bends

All as above item No 2 but for cable size of 6 sqmm

All as above item No 2 but for cable size of 10 sqmm

supplying, installing, wiring, testing, and commissioning of new String Combiner Boxes (SCBs) to replace faulty units in a 1 MW grid-connected solar photovoltaic (PV) power plant so as to ensure the electrical integrity, safety, and operational restoration of all strings from the field arrays to the string inverters .The SCBs must be suitable for outdoor use, compatible with the existing inverter system (typically 1000 VDC / 1100 VDC rated), and must integrate safely into the plant’s monitoring and protection system.Make: As per existing

Rating and Configuration: (a) System Voltage: 1000V DC (minimum), 1100V DC preferred (b) String Input Capacity: 8-in / 1-out (or to match the plant’s original design) (c) Output: 1 combined positive and 1 negative terminal (d) Nominal Operating Current: Per string 10 A–15 A (e) Total Output Current: ≥100 A depending on number of input strings

Enclosure: (a) Type: UV-stabilized, weatherproof, dustproof, flame-retardant IP65 or higher (IP67 preferred) thermoplastic or powder-coated mild steel (minimum 2 mm thickness) (b) Ingress Protection: Minimum IP65 as per IEC 60529 (c) Protection Class: Class II insulation (double insulated) (d) Enclosure Type: Wall-mount or pedestal mount (as required), with gland plates for cable entry

Internal Components: (i) DC Fuse Holders & Fuses: (a) Rated for 1000V DC / 1100V DC (b) Individual string protection with gPV fuses (c) Current rating of fuses: 15 A – 20 A (d) Fuses must be certified to IEC 60269-6 or equivalent (e) Fuses shall be removable and clearly labelled (ii) Surge Protection Devices (SPDs): (a) Type 2 DC SPD as per IEC 61643-31 (b) Nominal discharge current: ≥20 kA (c) Voltage Protection Level (Up): <2.5 kV (d) Replaceable cartridges preferred (e) Thermal disconnection and visual fault indicator required

(iii) DC Disconnect (Isolator): (a) Rated for ≥150% of output current (b) Rotary-type switch with external lockable handle (c) Certified to IEC 60947-3 or equivalent (d) Arc suppression chamber and quick break design preferred (iv) Busbars and Terminals: (a) Electrolytic grade tinned copper (b) PVC sleeved or heat shrink insulated (c) All terminals clearly labelled with string numbers (v) Optional Monitoring Equipment (If applicable): (a) String current sensors (Hall-effect) with RS-485/Modbus output (b) Local LED indicator for string health (optional) (c) Provision for future SCADA integration

Cable Terminations and Accessories: (a) Suitable MC4-compatible input terminals (b) Output cable lugs (tinned copper) provided by contractor (c) Cable entry through weatherproof cable glands (PG21 or equivalent) (d) Internal cable routing shall be neat and tied using UV-resistant ties

Standards and Certifications: All SCB components and assembly shall comply with the following: (a) IEC 60269-6 – fuses for photovoltaic applications (b) IEC 61439-1/2 – low voltage switchgear and controlgear assemblies (c) IEC 60947-3 – switch-disconnectors (d) IEC 61643-31 – SPDs for PV (e) IEC 60529 – Ingress protection (f) IS 8623 (Part 1) for compliance with Indian standards (g) CEA Safety Regulations and MNRE Guidelines (latest)

Installation Requirements: (a) SCBs shall be installed in the exact existing layout locations. (b) Earth connection to SCB body must be established with minimum 16 sqmm green-yellow copper conductor, connected to existing plant earth grid.

Testing and Commissioning: Each installed SCB shall be tested for: (a) Continuity of Strings: Test all strings connected via SCB for continuity and correct polarity. (b) Insulation Resistance Test: IR between each string and ground (>100 MΩ with 1000V DC megger). (c) Voltage Measurement: Measure open-circuit voltage from each string at SCB output. (d) SPD Operation Test: If surge has occurred, the fault indicator must be visible; test with simulated voltage (if applicable). (e) Fuse Functionality: Each fuse shall be tested for continuity after energizing to ensure operation under load.

Material Warranty Requirements: Minimum 5 years comprehensive warranty on SCB from manufacturer

General Notes: (a) All SCBs must be procured from MNRE-empanelled vendors or OEMs with ISO 9001, 14001 certifications (b) All electrical work to be done by certified electricians with solar O&M experience

Material & Labour for repair, retrofitting, and replacement of damaged or corroded module mounting structures (MMS), fasteners, purlins, brackets, and other mechanical support elements so as to ensure restoration to original structural stability complete all as directed by Engineer in Charge. Note: 1. The rate quoted is deemed inclusive of dismantling of severely rusted or bent members, Fabrication and installation of replacement vertical supports, purlins, module rails, Realignment and levelling to restore tilt angle and application of anti-rust primer, coat paint and cold galvanizing spray. 2. The Material shall be Pre-galvanized mild steel with minimum 80 microns zinc coating and to be fitted as per original drawing and minimum thickness of 2.5 mm for vertical supports and 2.0 mm for purlins and rails. 3. The rate quoted shall be deemed inclusive of accessories i.e. Bolts & Fasteners of SS 304 of reed sizes with locking washers and anti-seize compound and torue wrench tightning to prescribed torque. make : As per existing

M&L for Earthing complete with galvanized steel plate electrode 60cm X 60cm X 6 mm thick buried directly in ground (Earth pit not less than 2.25 Mtrs deep below ground level) with top edge of the plate not less than 1.5 Mtr below normal ground level connected to galvanized strip 32 X 6mm size by means of bolts, nuts, check nuts and washer of galvanized iron or of steel, earth lead protected by 40mm dia GI pipe light grade watering pipe 20mm dia GI light grade GI wire messed funnel, alternative layer of charcoal and salt, PCC chamber, recessed for and including RCC cover including all necessary excavation and earth work, earth strips connected to HT/LT equipment testing the earthing after completion all as specified and shown in electrical plate No 3 of MES SSR Pt- I 2009 print, complete all as specified & directed. Note:- GI earth strip and GI protection pipe beyond 7.5 Mtr long measured and paid separately

M&L for dismantling, taking out all earth connection of strip from any type panel board/transformer to earth test point any size and replace the worn out earth strip proper clamp, shadle,nut/bolts and washers connect all joint with new nuts/bolts and washers to in original position all as specified and directed. Note :- Earth Gi/Copper strip measured and paid separetely.

Supply only copper strip of size 32 x 6 mm all as specified and as directed .

Supply only GI earth strip of size 32 x 6 mm all as specified and as directed .

M&L for open earthing pit cover and filled with salt water in earthing pit and next day testing of earthing resistance, using suitable earth megger and marked on earthing test point with white/black paint and record in register submit to Engr-In-Charge all as specified and directed . Note :- required salt rate shall be included in the quoted rate. (ii) Earth resistance Testing kit shall be provided by the contractor.

M&L for aggregate 20 mm and 40 mm thick, the first layer of lower size aggregate shall be spread uniformly and compacted to a thckness of approximately 40 mm, the second layer consist of 50 mm and 25 mm size aggregate mixed in proportion of 2:1 by volume, which shall be spread uniformly and compacted to the thickness of approximately 60 mm thick all as specified and directed.

Supply and installation of bimetallic transition strips (Copper–Aluminium) of thickness 4mm, width 25 mm and length 100 mm, for interconnecting copper earthing conductors to aluminium busbars or terminals, including drilling, cleaning of surfaces, application of anti-oxidant compound, bolting, and ensuring galvanic isolation complete all as directed by Engineer in Charge. Note: 1.The strip shall be hot roll bonded, manufactured from high-purity electrolytic copper and electrical-grade aluminium, designed to prevent galvanic corrosion while maintaining long-term mechanical strength and electrical conductivity. 2.The item includes necessary fasteners, jointing materials, and minor civil works (if required) for secure mounting. All works shall be executed as per relevant IS/IEC standards and as directed by the Engineer-in-Charge.

S&F XLPE insulated armoured heavy duty LT electric cable for connection Inverter to ACDB/MDB with aluminium conductor 1100 volts grade cross- sectional area 70 Sqmm size cable of 3.5 core including taking down existing cable complete all as specified and as directed.

(i). Cables shall be procured only from MNRE empanelled manufacturers or BIS/ISO certified cable suppliers (e.g., Polycab, Havells, KEI, Finolex, RR Kabel). (ii). Contractor must submit factory test certificates (Type Test and Routine Test) with cable supplies. (iii). Unused cable reels must be stored under shade and away from moisture or chemicals. (iv). All works to be executed in compliance with IS 3043, IS 732, CEA (Measures relating to Safety and Electric Supply) Regulations, and MNRE guidelines for solar installations. (v) Cable Ties and Supports of UV-resistant nylon cable ties at shades and Stainless steel cable ties for outdoor exposure (vi)Cable markers at every 5 meters and at both ends (vii)Separate routes for AC and DC cables (viii)Minimum 300 mm separation between AC/DC paths to avoid interference (ix) Loose laying prohibited — all cables must be clamped at every 50 cm (x) Cable entry into panels with proper glands, no sharp bends

Supply, replacement, installation, and testing of male and female MC4 connectors, cable glands, and cable lugs at various points in the 1 MW solar PV plant where deterioration, corrosion, or physical damage has been observed complete all as directed by Engineer in Charge.

Note: 1. The works shall include removal of defective components, supply of new components, crimping, tightening, continuity testing, insulation resistance measurement, and final commissioning to ensure safe and reliable electrical connections across the entire plant. 2. MC4 Connectors: (i). Type: UV resistant, IP68 rated, weatherproof MC4-type solar connectors. (ii). Current Rating: Minimum 30 A continuous. (iii). Voltage Rating: 1000 V DC minimum (preferably 1500 V DC certified). (iv). Material: High-quality PPO (Polyphenylene Oxide) insulation, with tinned copper contacts. (v). Connection Method: Crimp connection (not solder type). (vi). Operating Temperature: -40°C to +90°C. (vii). Flame Class: UL94-V0 or better. (viii). Certifications: TÜV/UL certified for photovoltaic applications. (ix). Compatibility: Shall be compatible with 4 mm², 6 mm², and 10 mm² solar DC cables. 3. MC4 connectors must be from reputed manufacturers Staubli, Renhe, Multi-Contact, or equivalent, complying with IEC 62852 standards.

Supply and Fix Cable Glands of Weatherproof, UV resistant, dustproof, and waterproof type, Material: Nylon (Polyamide PA6) or SS-304 for outdoor use, Protection Class: Minimum IP66, Size: Suitable for 4 mm² to 10 mm² solar cables, Color: Black for UV resistance, Locknuts deemed inclusive along with glands. The Glands must have anti-twist protection and strain relief as per IEC 62444 standards.

Supply and Compression type cable lugs for crimping of Material: Electrolytic grade copper, tinned finish, Conforming to : IS: 8309 and IS: 8337 standards, Hole Size: Compatible with inverter SCB/MDB terminals as reqd, Cross-sectional area: 6 mm², 10 mm², 16 mm², as per site cable sizes, Surface Finish: Anti-corrosion treated. Note: Crimping: Shall be done using hydraulic crimping tools only.

Supply, installation, testing, and commissioning of String Monitoring Units (SMUs) for the 1 MW Solar PV Plant. The SMUs shall be installed in existing/newly designated combiner locations to facilitate real-time monitoring of each string’s performance (current, voltage, temperature) and detect faults like open strings, diode failures, or shading effects. of system preventive maintenance and monitoring, reducing downtime and improving plant yield all as directed by Engineer in Charge. Make: Phonienix Contact/ ABB/ Schneider/Sungrow/Bentek or as approved by GE

General Requirements: (i). Technology: Microcontroller/PLC-based system with analog and digital inputs. (ii). Location: Outdoor installation – must be IP65 or higher rated. (iii). Type: Wall-mounted / Pedestal-mounted as per site conditions. (iv). Compatibility: Must be fully compatible with existing SCADA or data acquisition system (DAS). (v). Input Source: Each SMU must be capable of monitoring minimum 12–16 strings.

Electrical Characteristics: (i). Maximum Input Current per String: ≥ 15 A DC. (ii). Maximum System Voltage: ≥ 1000 V DC. (iii). Measurement Range: String Voltage: 0–1000 V DC String Current: 0–20 A DC (iv). Accuracy: Voltage Measurement: ±1% or better. Current Measurement: ±1% or better.

Protection Features: (i). Surge Protection: Type II SPD installed on DC side. (ii). String Fuse Protection: Each string must have appropriately rated DC fuses (10 A / 15 A as per string capacity). (iii). Reverse Polarity Protection: In-built. (iv). Ground Fault Detection: Preferred.

Communication and Data Interface: (i). Protocols Supported: Modbus RTU (RS-485 port) mandatory; Modbus TCP/IP desirable. (ii). Communication Distance: Up to 1200 meters without signal booster (for RS-485). (iii). Provision for Plug-and-Play to SCADA/RTU without needing extra converters. (iv). Data Logging: Minimum internal memory backup for 1 day in case of communication loss. (v). Status Indications: LED indicators for Power ON, String Fault, Fuse Blown, SPD Fault

Enclosure and Build: (i). Enclosure Type: Polycarbonate / FRP / powder-coated aluminium. (ii). Protection Rating: Minimum IP65 for outdoor, UV-resistant. (iii). Mounting: Strong anti-corrosive brackets or poles, vibration-resistant.

Installation Directions: (i). Verify site location suitability for SMU mounting (avoid shading, water pooling areas). (ii). Use UV-resistant conduits for cabling between PV strings and SMU. (iii). Fuse holders shall be mounted neatly with labelled identification per string. (iv). Earthing of SMU body and surge protection device separately as per IS 3043. (v). Communication cabling (twisted pair, shielded cable) from SMU to SCADA system. (vi). Final calibration and functional testing after installation.

Testing and Commissioning: (i). Verification of all string voltages and currents under live conditions. (ii). Fuse continuity checks. (iii). Surge protection operation testing.

Warranty: (i). SMUs must come with a minimum 2-year comprehensive warranty from OEM, covering parts and labor.

Safety Measures: (i). All work on DC side shall only be done after isolating strings. (ii). Rubber mats, insulated gloves, and PPE must be used.

Standards and References: (i). IEC 60364 (Electrical installations for buildings) (ii). IEC 62548 (PV Array Installation) (iii). EC 61010 (Safety requirements for electrical

Design, fabrication, supply, installation, and commissioning of signage boards across the 1 MW solar PV plant for safety, operational instructions, hazard warnings, identification of plant areas, and compliance with statutory norms under applicable electrical safety and industrial regulations all as directed by Engineer in Charge.

Note: Material Specifications: (i). Material: Reflective Steel Sheet suitable for outdoor use (ii). Thickness: 1.5 mm (SS304) thickness. (iii). Size: 600 mm × 450 mm (iv). Background Colour Danger signs: Red and White. Mandatory signs: Blue and White. Informative signs: Green and White. (v). Print Quality: High-quality UV-resistant, fade-proof, outdoor-grade vinyl printing laminated over the surface. (vi). Font: Typeface: Helvetica or Arial Bold (simple, sans-serif).Font Size: Minimum 50 mm for easy visibility from 5–7 meters distance.

Mounting and Installation: Fixing: Mounted on GI/MS poles (2” diameter) with anchor bolts into concrete foundations OR wall-mounted as required. Height: Minimum 1.5 m above ground level (edge of sign). Supports: Galvanized Mild Steel (MS) support frames to be used with primer and two coats of outdoor-grade enamel paint. Foundations: Concrete pedestal of size 300 mm × 300 mm × 600 mm (depth) where free-standing signs are installed.

Types of Signage Boards Required: Warning Signs: High Voltage Danger, DC Caution, Live Terminals, Risk of Electric Shock, etc. Mandatory Signs: Use of PPE, No Unauthorized Access, Fire Assembly Points. Informative Signs: Layout maps, Array Identifications, Inverter Room Names Emergency Signs: Emergency Shutdown Procedures, Fire Extinguisher Locations, Exit Signs.

Locations: Array areas:1 per block (~10 signs). Inverter Rooms / SCB Panels: (~12 signs). Entry / Exit Points: 2 signs (Entry/Exit). Fire Extinguisher Points and Emergency Procedures:~6 signs. Danger Plates (at LA, SCBs, Inverters, etc.):~25 plates.

Compliance and Regulations: IS: 2551 (Danger Notice Plates) OSHA Standards for Safety Signage National Building Code (NBC) Part 4 (Fire and Life Safety) All signage must meet Indian Electrical Rules, Factories Act norms, and latest CEA Safety regulations.

Quality : Materials must be from reputed manufacturers. Reflective boards to comply with ASTM D4956 Type 1 or better for retro reflectivity. Fabrication drawings must be submitted for approval before execution.

Testing and Acceptance: Engineer-in-Charge to approve location and height before final fixing.

All as above item no 18 but for Larger Layout Map of size 1200 mm × 900 mm for Plant Layout Map Board at Main Gate/Entrance

Comprehensive manual and mechanical cleaning of the 1 MW solar plant area, removal of unwanted vegetation, grasses, shrubs, minor trees to ensure unobstructed operation and maintenance access throughout the plant area to create a clean, safe, and operational environment around all equipment, cable trenches, access roads, inverters, SCBs, and module arrays all as directed by Engineer in Charge

Note: Cleaning: (i). Complete removal of all grasses, creepers, bushes, and small plants growing around modules, cables, and structures. (ii). Cutting/removal of minor trees with girth up to 100 mm (using hand tools or chainsaws). (iii). Collection and shifting of debris to designated disposal areas outside solar field. (iv). Removal of broken plastic, garbage, stones from the array areas. (v). Mechanical Cleaning (where feasible): Use of brush cutters or grass mowers in large open stretches.

Chemical Treatment: (i). Application of non-toxic herbicides (glyphosate-based) after cleaning to prevent regrowth for 3–4 months. (ii). Only environmentally safe herbicides approved under Indian environmental standards to be used.

Waste Disposal: (i). All uprooted vegetation, debris, and waste to be transported using tractor trolleys or manual carriers. (ii). Disposal to be done outside the premises at a legally permitted waste disposal site. (iii). No burning of vegetation inside the plant allowed to prevent fire risk.

Safety and Quality Assurance: (i). Mandatory use of gloves, boots, and eye protection during cleaning operations. (ii). Controlled herbicide application avoiding contact with solar panels or structures. (iii). Earth leakage protection for electrically powered equipment used on-site. (iv). First Aid kits available at site during clearing activities.

Preventive Maintenance:( part of Preventive / Comprehensive maintenance BOQ item) (i). Monthly Cleaning: (a) Rechecking and cutting new vegetation regrowth around equipment areas. (b) Immediate desilting if water stagnation noticed near any inverter/SCB. (ii). Regular Rounds: (a) Every 15 days visual inspection (b) Herbicide reapplication after 4 months if regrowth significant (iii). Documenting: (a) Photo documentation of cleaned areas before and after each major cleaning round. (b) Maintenance logbook entry after every activity.

Design, Supply, Installation, and Commissioning 500 LPH (Liters per Hour) capacity Demineralized Water Plant to ensure that array cleaning is performed using low Total Dissolved Solids (TDS) water to prevent permanent deposits on glass surfaces complete all as specified.

Note: System Components: (i). Pre-filtration Unit: Sand and Activated Carbon Filters (ii). RO Membrane Stage: Multi-membrane setup to bring TDS < 30 ppm (iii). UV Sterilization: Post RO stage to ensure biological safety (iv). Final Output: TDS ≤ 30 ppm; pH between 6.5–7.5 (v). Motor Pump: 1 HP, energy efficient (vi). Storage Tank: 1000 Litre HDPE tank with level indicators (vii). Skid Mount: Plant mounted on GI frame with wheels for easy relocation

Automation: (i). Automatic flushing of RO membranes (ii). Low Pressure and High Pressure Cut-off Switches (iii). Manual control panel with emergency stop

Water Quality Monitoring: (i). Online TDS meter with digital display (ii). Periodic manual sampling provision

Installation and Commissioning: (i). Civil base works for DM Plant foundation (if required) (ii). Electrification of DM Plant (LT cabling included) (iii). Pipeline routing, tap installation (iv). Complete flushing, pressure testing of pipelines

Misc: (i). Operational training to Staff on DM plant handling (ii). Display of basic troubleshooting chart near DM Plant

Supply and Fix HDPE (High-Density Polyethylene) PE-100 pipes of Size: 40 mm OD for main branch,Pressure Rating: PN 6 / PN 10 suitable for open field application, UV Resistance: Pipes to have minimum 10 years UV resistance certification, Jointing Method: Electro-fusion couplers or butt-welded joints, Supports: HDPE pipe saddles on MS/GI fabricated clamps every 3 meters, Burial Depth: 300 mm underground ), Distance Between Water Outlets: Every 25 meters horizontally across arrays complete all as specified.

All as above item 23 but for pipe size 20 mm OD for distribution taps

Supply and Fix Plastic bib taps 15 mm with GI mounting stands and Lockable covers for taps to prevent misuse all as specified.

Supply and Fix Non Return Valve of dia 40 mm for preventing backflow at branches

Supply and fix in replacement of fuse model No UK 10, 3-HESI 1000V 10,3X38 32 A 1000 V DC all as specified and directed

Supply and fix in replacement of fuse contact (plugtrap) model No PT 5-HF 12 DC-ST Uc-14V DC In- 450 mA K-264 all as specified and directed

Supply and fix in replacement of contact model VAL-MS 1000 V DC-PV-ST15 kA, F3K-054 all as specified and as directed .

Supply and fix in replacement of switch disconnector 1000 V DC 315 Amps AC as per existig make all as specified and as directed .

Supply and fix in replacement of cooling fan as per requirement, suitable for solar system as per existing make all as specified and as directed .

Supply and fix in replacement of air filter of capacity 400 m3/Hr , itable for solar system as per existing make all as specified and as directed .

Systematic testing, pre-commissioning checks, energization, fine-tuning, trial runs, and formal re-commissioning of the entire 1 MW solar PV plant after completion of maintenance, repairs, supply, and installation jobs and before preventive maintenance item to ensure that the plant is safe, fully functional, performing at expected output, and compliant with all technical, safety, and statutory standards. The rate quoted shall be deemed inclusive of all labour, testing equipment, temporary arrangements, tools, instruments, manpower, documentation, coordination with KESCO and consumables. Note:-

C:omponents Covered : (i). Solar PV Modules and Arrays (ii). Array Structures and Supports (iii). Cables and Cable Termination Kits (iv). String Combiner Boxes (SCBs) (v). String Monitoring Units (SMUs) (vi). Protection Devices (SPDs, Fuses, MCCBs) (vii). String Inverters (viii). Earth Pits and Earthing Network (ix). LT Panels (AC side) (x). Array Cleaning System

Visual and Physical Checks: String labelling visual checks, polarity marking verification.

Electrical Testing and Commissioning: (i) Electrical Testing: (a) Module Testing: I-V Curve Tracing (for 5% of total modules randomly). Insulation Resistance Testing at 1000 V DC between positive/negative to earth. (b) String Testing: Open Circuit Voltage (Voc) and Short Circuit Current (Isc) verification. String continuity check. String current balancing between similar orientation arrays. (c) Inverter Testing: Functional test with dummy load or live generation. MPPT operation verification. Grid synchronization check (frequency, voltage windows). (d) Earthing and Lightning Protection: Earth Resistance Testing using clamp-on or three-point method (earth pit value ≤ 5 ohms mandatory). Continuity test of earthing connections.

(e) Protection Devices: MCCB/MCB tripping at fault conditions. SPD operation test. (ii) Performance Verification: (a) Plant shall be monitored continuously for minimum 7 days after commissioning. (b) Daily energy yield to be compared with expected generation (PR: 75–80% minimum during clear days). (c) Specific yield and CUF to be calculated and documented. (iii) Trial Run: The system shall undergo a minimum 7 days trial operation. All alarms, tripping, shutdowns to be recorded and analyzed. (iv) Documentation and Reports: (a) Module string performance sheets.Inverter performance data logs. (b) Electrical Test Reports (IR, continuity, earth resistance, etc.). (c) Commissioning Certificates duly signed by Engineer-in-Charge

(iii) Trial Run: The system shall undergo a minimum 7 days trial operation. All alarms, tripping, shutdowns to be recorded and analyzed. (iv) Documentation and Reports: (a) Module string performance sheets. (b) Inverter performance data logs. (c) Electrical Test Reports (IR, continuity, earth resistance, etc.). (d) Commissioning Certificates duly signed by Engineer-in-Charge

Tools and Equipment Required: (i) Earth Resistance Tester (ii) Megger (1kV DC) (iii) I-V Curve Tracer (iv) Clamp meters (AC/DC) (v) Multimeters (True RMS) (vi) Portable SCADA/communication analyzer (if needed) (vii) Thermal Imaging Camera (optional but desirable)

Safety Measures: (i) Work shall be done only in presence of Engineer-in-Charge or his authorized representative. (ii) All DC circuits shall be tested with appropriate PPE. (iii) Live AC side testing shall be carried out by licensed electricians only. (iv) Lock-out/Tag-out procedures shall be followed for any energized equipment.

Acceptance Criteria: (i) Visual: No damages, loose connections, proper signage. (ii) Electrical: All testing values within permissible limits. (iii) Functional: All major systems (DC, AC, SCADA, Protection) must function without alarms. (iv) Output: Minimum guaranteed PR > 75% post-commissioning.

Coordination: The contractor shall assist Engineer-in-Charge for any coordination needed with DISCOM / CEIG (if statutory clearance for energization is separately required).

Payment Terms: Payment shall be made after successful completion of testing, commissioning, handing over of full commissioning report, and acceptance by Engineer-in-Charge.

Warranty: performance guarantee for testing services: If system fails to operate properly within 7 days of commissioning without any external faults (like storm, vandalism, etc.), the contractor must rectify at their own cost.

Standards and References: (i). IEC 62446: Grid Connected PV Systems – Testing, Commissioning (ii). IS 16221: Installation and Safety Testing of Solar PV Systems (iii). CEA (Measures relating to Safety and Electric Supply) Regulations 2020

Preventive Maintenance of 1 MW Solar PV Plant after re-commissioning. This preventive maintenance (PM) plan covers all systems of the 1 MW solar plant over six months; to restore and sustain peak performance, extend equipment life, and minimize downtime by detecting issues early all as directed by Engineer in Charge. All work must comply with OEM/O&M manuals, national electrical codes (e.g. IEC 60364, IS 16221), IEC 62446-1 testing standards, MNRE guidelines, and industry best practices. All activities must be performed by Trained, authorized personnel with proper tools and PPE.

General Guidelines (i) Training & Personnel: Qualified electrical engineers/technicians and helpers should be on-site. (Minimum one site in-charge with relevant engineering degree/diploma, plus one electrician and helper). All staff must follow lock-out/tag-out (LOTO) procedures for live equipment, use insulated tools on DC circuits, and wear PPE (helmets, gloves, safety harnesses for work at height, etc.). (ii) Safety & Environment: Ensure zero unauthorized modifications during maintenance; avoid water waste (use recirculation and efficient spraying during cleaning); prevent chemical contamination. First-aid and firefighting equipment must be available. (iii) Documentation: To maintain detailed PM records. To maintain logbooks and checklists for each component (modules, inverters, SCBs, etc.), capturing inspection results and corrective actions. Submit a monthly PM report (with photos, test results, and a health summary of systems) to the Engineer-in-Charge. Consistently report all PM activities to the asset owner as required.

(iv) Standards Compliance: To follow national /international standards. In particular, to perform electrical tests as per IEC 62446-1 (e.g. PV string I–V curve tracing, insulation resistance testing, continuity checks, and thermography). Periodic inspection of disconnects, fuses, and protective devices must meet local safety regulations (IEC 60364, IS 16221, etc.). To use manufacturer-approved methods for cleaning and servicing to preserve warranties.

Maintenance Tasks by Component (i) PV Modules (a) Visual Inspection (Monthly): Check modules and mounting clamps for cracks, delamination, discoloration, hotspots, snail trails, or glass damage . Remove any debris or shading (e.g. vegetation or bird droppings). (b) Cleaning (Biweekly/Monthly): Wash panels with low-mineral (deionized) water and soft brushes or microfiber cloths; avoid detergents or high-pressure sprays . Only clean when module temperature is below ~50 °C and sunlight is low to prevent thermal shock. (c) Electrical Testing (Quarterly): Trace I–V curves on a sample (~5% of modules per month or per inverter) and compare with design specs. Perform infrared thermography (hand-held or drone) to spot hot cells or bypass diode issues. Check module connectors and junction boxes for tightness and corrosion . (d) Mounting Hardware Torque (quarterly): Verify and retorque all module clamps, mid-clamps, end-clamps, and structural bolts as per manufacturer’s torque settings . Replace any worn or damaged bolts/nuts with hot-dip galvanized hardware. Frequency: Monthly inspections and cleaning (at least twice per month, more if dusty); I–V testing and thermal imaging quarterly.

(e) Protection Devices: MCCB/MCB tripping at fault conditions. SPD operation test. (ii) Performance Verification: (a) Plant shall be monitored continuously for minimum 7 days after commissioning. (b) Daily energy yield to be compared with expected generation (PR: 75–80% minimum during clear days). (c) Specific yield and CUF to be calculated and documented. (iii) Trial Run: The system shall undergo a minimum 7 days trial operation. All alarms, tripping, shutdowns to be recorded and analyzed. (iv) Documentation and Reports: (a) Module string performance sheets.Inverter performance data logs. (b) Electrical Test Reports (IR, continuity, earth resistance, etc.). (c) Commissioning Certificates duly signed by Engineer-in-Charge

(ii) Module Mounting Structures (a) Visual Inspection (Monthly): Look for rust, corrosion, paint peeling, deformation, loose joints, or foundation cracks . Check alignment and tilt of arrays, and ensure there is no accumulated debris in drains. (b) Preventive Repairs & Painting (Quarterly/As Needed): Remove rust and repaint exposed steel with anti-corrosive primer and finish coat . Touch-up paint every 3–6 months as required. Replace any damaged structural members or brackets. (c) Bolt Tightening (Quarterly): Retorque all rack bolts, anchor bolts, and support brackets quarterly. Frequency: Monthly visual checks; repaint/repair quarterly or as needed; tighten/torque bolts quarterly.

(iii) String Inverters (a) Visual & Operational Checks (Monthly): Review inverter displays and SCADA logs for alarms, error codes or unusual readings. Ensure ventilators and heat sinks are dust-free and unobstructed . (b) Cleaning (Quarterly): Open the inverter cabinet to clean dust from interior (fans, filters, power modules) using dry air blowers. Replace or clean air filters (if fitted) . Wipe down exterior panels. (c) Electrical & Software Checks (Monthly/Quarterly): Tighten all DC and AC terminal connections to spec; verify torque of lugs. Update firmware/software when updates are available. Run inverter self-tests and monitor efficiency against design values. Test protective devices (ground-fault/arc-fault detectors) for proper operation. (d) Environmental Protection: Ensure inverter enclosures remain sealed and shaded from direct sun/rain. Check that roof drains do not flood inverter pads . (e) Frequency: Monthly inspection and log review; quarterly deep clean and filter service; firmware updates as needed.

(iv) Combiner Boxes (SCBs) and Protection Devices (a) Inspection (Monthly): Open SCBs to inspect string terminals, fuses, SPDs, and busbars for dust, corrosion, burn marks or moisture ingress. Verify that string labels/diagrams are legible. (b) Cleaning: Dust or blow clean interior of SCBs monthly to prevent heat buildup. Ensure enclosure gaskets are intact to keep out water. (c) Electrical Checks: Retorque all MC4 connectors and terminal lugs quarterly. Test each string fuse and SPD (surge protector) functionality; replace any blown fuses or degraded SPDs. Perform insulation resistance tests on strings (megger) at least once during the 6 month period. Conduct a thermal imaging scan of SCBs and connectors once during the contract to catch hot spots . Frequency: Monthly visual and cleaning; quarterly torque and tests; semiannual IR testing of insulation; thermal imaging once.

(v) DC/AC Cabling (a) Visual Inspection (Monthly): Inspect all DC and AC cables, conduit, and trays for insulation damage, rodent bites, UV degradation, or mechanical wear. Check for loose clamps or sagging trays. (b) Electrical Testing: Perform insulation resistance (IR) testing on DC strings (1000 V megger) every 6 months. Test AC feeder cable insulation and continuity during scheduled outages if possible. (c) Tightening & Repairs: Tighten any loose cable terminations at inverters, SCBs and AC junctions during inspections. Replace damaged cable segments with UV-resistant, TUV-certified PV cables . Secure cables with UV-rated ties and proper supports. Frequency: Monthly visual & mechanical checks; IR insulation tests semi-annually; immediate repairs as needed.

(vi) Earthing and Lightning Protection (a) Earth Resistance: Measure resistance of all earth pits (100% of grid) quarterly using a 3-point method . Record values and compare to baseline; if any pit exceeds specifications, clear or reterminate. (b) Continuity & Bonds: Inspect bonding conductors and lightning downpipes monthly for tight connections and corrosion. Tighten any loose earthing clamps. (c) Covers and Chambers: Clean earth pit chamber covers bimonthly to prevent water ingress. After major storms or flooding, inspect all earthing enclosures and repair any damage. Frequency: Quarterly earth pit resistance tests; monthly continuity checks; chamber cleaning every 2 months.

(vii) LT Panels and Distribution (a) Visual & Functional Checks (Bi-Monthly): Inspect LT (power) panels and AC distribution boards for dust, vermin nests, or moisture. Tighten all incoming/outgoing cable terminations. Operate and trip-test breakers under load to ensure proper function. (b) Thermal/IR Testing: Perform infrared scans on loaded busbars and breakers annually (or during a shutdown) to detect loose connections. (c) Housekeeping: Clean panel interiors and dust off components every 2 months. Lubricate any moving parts (doors, handles). Frequency: Bi-monthly inspections and cleaning; annual thermal check; immediate action on anomalies.

(viii) Water Supply & Cleaning System (a) Pipe lines: Inspect water pipelines and joints monthly for leaks or cracks . Check pump operation and pressure; lubricate pump bearings as recommended. Flush storage tanks and strainers bi-monthly. (b) DM Water Plant: Operate demineralization (DI) plant or RO system per OEM schedule. Backwash or regenerate filter media and membranes monthly; replace cartridge filters every 3 months . Measure output water TDS after each service; if >30 ppm, perform membrane cleaning . Ensure sufficient DI water is available for cleaning. Frequency: Monthly inspections; filter/membrane maintenance quarterly or per manufacturer; TDS testing bi-weekly.

(ix) Vegetation & Site Housekeeping (a) Groundskeeping (Monthly): Trim weeds and grass around arrays, inverters, and fencing to prevent shading, fire hazard and equipment infestation . Clean drainage ditches and remove sediment near equipment. Immediately remove any sand/mud or debris that accumulates after heavy rains. (b) Periodic Treatment: Re-apply herbicide every 3 months to control regrowth. Suppress dust around panels with gravel or water spraying if ambient dust is high. Frequency: Monthly cleaning; herbicide or chemical control every 3 months.

Documentation & Reporting: To Maintain detailed records of every PM activity. For each month, prepare a report including:, test readings (insulation resistance, earth resistance, etc.), completed task checklists, and identification of any defects or corrective actions. Submit reports to the Engineer-in-Charge for review. Keep daily logs of module cleaning and minor chores for transparency. All spare parts installed must have relevant certificates (OEM warranty ≥1 year) and, if required, third-party inspection certification .

Manpower, Safety & Compliance: • Staffing: Maintain the following team on-site throughout the contract: a solar maintenance engineer (degree/diploma), ≥1 electricians with solar experience, and 1 helpers for cleaning/vegetation tasks. Ensure staff availability 5 days per week. • Safety Measures: Implement Lockout-Tagout procedures on any energized equipment. Use fall protection (safety harnesses) for work on elevated structures. Handle all tools and equipment in accordance with safety standards (e.g. insulated tools for DC work). No live work on DC circuits without proper isolation and PPE. • Quality: Perform all work in accordance with manufacturers’ O&M manuals. Any deviation must be approved by the Engineer-in-Charge. Maintain a culture of quality by using calibrated test equipment and following standard test procedures (e.g. manufacturer-recommended IR test voltage ).

santosh electronics (BID ID -3476182)

Bharat Sales Corporation (BID ID -3473981)