SPECIAL REPAIRS TO REPLACEMENT OF BER DIESEL GENERATOR (DG SET 160KVA) AT COMNETCEN, NAVAL BASE, KOCHI.

Supply, install, testing and commissioning of approved OEM factory assembled diesel generator set of totally enclosed and sound proof (with acoustic enclosure as per CPCB 4+ norms) of capacity 160 KVA, 3 phase, 4 wire, 415 volts, 1500 RPM, AC power supply with power factor 0.8, coupled directly to alternator mounted on common base plate complete with fuel tank, battery and standard accessories and fittings, vibration pads, PCC foundation complete all as specified and directed. The genset shall conform to CPCB4 + norms for noise and emission limits and including the following : (a) ALTERNATOR :- Standard design alternator rated at 160 KVA net output at site after considering all derating factors, site conditions and at power factor 0.8, AC 3 phase, 4 wire 415 volts, 50 cycles, 1500 RPM, self excited, self regulated, screen protected, drip proof IP-23 enclosure, brushless design, insulating class H, voltage regulation +/- 1% operated voltage from no load to full load and shall be in position to generate supply with frequency regulation within +/- 3% tolerance, revolving field type. (b) DIESEL ENGINE: Adequate capacity diesel engine suitable to above alternator, radiator water cooled, to drive independently above alternator and after considering derating as per site conditions directly coupled to alternator multicylinder, multistroke, direct injection, cold starting, 1500 RPM, with an overload cap of 10% for 1 hour and in any load for 12 hours continuous running complete with standard accessories all as specified and required for safe running and operation with accessories shall be as under:- (i) Flywheel (ii) Air cleaner wet/dry type

(iii) Fuel Filter (iv) Fuel Injection system incl.injection pump, solenoid switch, nozzle as per manufacturer's specifications (v) Lubricating oil filter (vi) Lubricating oil pump (vii) Turbocharger (viii) Radiator (ix) Starting system consisting of batteries of capacity as recommended by manufacturer, battery connections with copper leads and with lugs of adequate size, initial charging of batteries, battery charger/ generator with regulator, starter motor, starter gear (x) Extension of exhaust silencer complete with exhaust pipe of suitable dia from out side canopy to out side of bldg/shed all covered with glass wool wrapped with aluminium foil of 28 SWG adequate to create draft for safe exhaust without transferring vibrations to buildings / walls, flexible exhaust pipe complete. (xi) Microprocessor control electronic metering and module for indication of battery voltage, oil pressure, engine RPM, hour meter and protection against low oil pressure and over speed of engine including electronic governing. (xii) Battery charging system with suitable capacity battery charger complete with necessary connecting leads etc all as directed (xiii) Radiator cooling system comprising of radiator, radiator fan belt.

(xiv) Fuel hoses. (xv) In Built Fuel tank of minimun 8 hours run on full load capacity of DG set (xvi) Air intake system (xvii) Common base frame of sturdy design suitable for antivibration mounting and permanent concrete foundation for mounting engine and alternator as per manufacturers instructions. (c) CONTROL PANEL :- CRCA Steel fabricated indoor type for controlling the above generating set. The control panel shall consisting of the following components:- (i) MCCB Four Pole 315 Amps, 35 KA of rated capacity (as per OEM - 1 No) (ii) Set of indicating lamps - 03 No (Load ON DG/Mains & Set Running) (iii) Set of instrument fuses - 01 Set, (iv) Set of current transformers - 01 Set (d) AMF PANEL:- Out door type made of CRCA sheet IP 65 protection 3.15mm thickness, CPRI type/approved manufacturer, Control cubical fabricated duly pretreated & powder coated finish with iron angle base frame Support floor mounted with removable gland plates, hinged front & back openable door with locking arrangement and provision for connecting incoming and outgoing cable leads and the following accessories : (i) Aluminium bus bar, 3 phase, 4 wire, 400 Amps - 01 Set

Materials and labour for earthing complete with galvanised iron earth plate electrode of size 600 mm x 600 mm x 6 mm thick, buried directly and preferably vertically in ground, earth pit not less than 2.25 Mtr deep below ground level with top edge of the plate not less than 1.5 m below ground level connected with and including galvanised earth strip of size 32 x 6mm by means of nuts, bolts, check nuts and washers made of galvanised iron or steel earthing lead to be protected by galvanised iron pipe 40 mm bore (medium grade) and other end connected to earthing test point or lightening arrestor or main controlling switch as directed including providing funnel with 20mm bore galvanised iron pipe (light grade), wire mesh, charcoal or coke and common salt in alternate layer of 15cm (compacted thickness) all round the earth electrode, concrete earth pit in PCC (1:3:6) type C-1 (with 20mm graded aggregate), 50mm thick precast RCC (1:2:4) cover slab (re-inforced with 8mm dia TMT bar @ 15 cm C/C both ways and suitable handle made of 10mm dia) including necessary earth work in excavation, returning filling and removal of surplus earth up to a distance not exceeding 50 m etc all as shown on electrical plate No. 3 of MES Schedule Part-I(2009) complete including testing on complete all as specified and directed

Supply and fix on load change over switch, in sheet steel enclosure, 320 Amp, 415 volt AC, fixed to wall/panel including suitable nuts,washers etc and connect to both in and out cable complete all as specified and directed

Supply and lay cable XLPE insulated screened PVC bedded, electric power cable, heavy duty, 1100 volt grade with stranded aluminium conductor of size 240 sq mm, 3.5 core complete all as specified and directed

Supply and lay cable XLPE insulated screened PVC bedded, electric power cable, heavy duty, 1100 volt grade with stranded aluminium conductor of size 16 sq mm, 4 core complete all as specified and directed

Excavation in trenches hard/dense soil not exceeding 1.5 mtr wide and not exceeding 1.5 mtr in depth and getting out excavated soil/sand/unserviceable LT Cable for laying of cable complete all as specified and directed

Laying of riddle sand obtained from excavation and cushioning covering of UG cable in trenches complete all as specified and directed

Returning filling in including spreading levelling watering and well ramming in layers not exceeding 25 cm in hard /loose soil complete all as specified and directed.

Removing excavated material not exceeding 50 mtr and depositing where directed at a level not exceeding 1.5 mtr above the starting point complete all as specified and directed

Material and labour for old size brick well burnt Class ‘B’ as cover to U/G cable laid dry flat over the cable with width equal to length of the cable and abutting each other with gap between adjacent slab not exceeding 10mm over under ground cable for cable protection in trenches complete all as specified and directed

Supply and lay in trenches/fixed on walls/poles GI tubing medium grade with all fittings of 80 mm bore complete all as specified and directed.

Supply and lay in trenches/fixed on walls/poles GI tubing medium grade with all fittings of 40 mm bore complete all as specified and directed.

Cutting existing concrete/metal/ bituminous road/PCC hard standing / interlock tile or tile walk way any type n.exc 45 cm width and n.exc 30 cm in depth in hard strata and making good disturbed surfaces, as per the existing with cold mix bituminous material/ PCC(1:4:8) type D2 using 40mm graded stone aggregate 150 mm thick or PCC work/refixing the inter locking/chequered tile with proper alignment to match the existing, over returning filling, watering ,ramming in layers , disposal of surplus material to a distance n.exc 50 m, complete all as specified and directed Note :-1. (GI pipe will be measured and paid separately). 2.The damaged/ broken interlocking/chequered/paver tiles/PCC hard stand shall be replaced with new one.

Excavating in post holes (or similar holes) each n exc 0.5 cum, getting out, returning, filling in and ramming earth in soft/loose soil , in layers not exceeding 25 cm and removing surplus soil to a distance n.exc 50m complete all as specified and directed

Material and labour for plain cement concrete1:3:6 Type C2 using 40 mm graded crushed stone aggregate as In foundation, filling and mass concrete in post holes complete all as specified and directed

Material and labour steel work in tubular trusses including special shaped washer etc. complete using ERW or induction butt welded tubes conforming to IS-1161-1979 grade EW-240 complete all as specified and directed

Supply and fix Pre- painted galvalume aluminium zinc coating GI based corrugated steel sheet 0.50mm thick of an colour having tensile strength of 550 Mpa as in roof covering/cladding to wall, fixed with self tapping screws including two coats of epoxy/antirust paint over steel surfaces complete all as specified and directed.

Supply and fix Pre-painted galvalume aluminium zinc coating GI based plain steel sheet 0.50mm thick of any colour having tensile strength of 550 Mpa as in roof overing/cladding to wall, fixed with self tapping screws complete all as specified and directed

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