CWE/KAS-86/2024-25 SPECIAL REPAIR OF 380 KVA DG SET AGAINST BER INSTALLED AT P-2 WATER SUPPLY INSTALLATION AT KASAULI UNDER GE KASAULI

Amount

Supply, installation, commissioning and testing of Diesel Engine driven factory assembled, floor mounted, silent type diesel generating set of capacity 380 kVA output at NTP conforming to CPCB Norms-IV+ with seperate AMF control panel, 3 phase, 4 wire, 50 Hz, 415 Volts, 1500 RPM, power factor of 0.8, as per IS 10001/ 10002 complete with safety contact and metering equipment mounted on common base frame on PCC platform with anti-vibration pads as per manufacturer's recommendation including inbuilt type Manual Control Panel from DG set manufacturer’s with all fixing arrangement complete all as specified, directed and comprising the following :-

PRIME MOVER : Prime mover directly coupled with water cooled engine suitable rated matching BHP but not less than 594 BHP for driving 380 kVA (304 KW) capacity alternator, 1500 RPM, electric-start four stroke diesel engine confirming to ISO-3046/ BS-5514 and IS-10001/ 10002 for continuous running and capable for taking 10% over load for one hour for every 12 hours with the following accessories:-

(a) Cooling sytem (b) Heavy duty Radiator Cooled (c) Engine Mounted water pump (d) Thermostat (e) Coolant (f) Self contained piping (g) Fuel system

(h) High pressure common rail fuel system (i) Spin on type fuel filter (j) Self contained piping (k) Lubrication System (l) Lube Oil pump (m) spin on type Lube Oil filter

(n) Self contained piping (o) Air Intake system (p) Dry type replaceable paper element Air Filter (q) Air Intake Manifold with necessary connections (r) Turbo charger (s) Exhaust system (t) Exhaust Manifold (u) Flexible piping

(v) Silencer Hospital Grade (w) Governing System (x) Power Command (PC) Microprocessor based Controller system (y) Starting System (z) DC starter (aa) Battery Charging Alternator (bb) Inbuilt regulator

(cc) Other System (dd) Fly wheel with fly wheel housing (ee) Any other items required for functional requirement as per OEM

ALTERNATOR : Alternator 380 kVA at 0.8 Power factor, self regulated, three phase 4 wire system with neutral, 415 volts, 50 Hz, 1500 RPM conforming to BS-2613 or BS-5000/ IS-4722 complete with automatic voltage regulator to give rated output at NTP conditions. (a) The alternator shall be self excited, self regulated, self ventilated in brushless design, provided with suitable automatic voltage regulator and shall conform to BS-2613 or BS-5000. Alternator foot mounted fitted with ball or roller bearing including making cable connections. (b) The alternator shall be suitable for tropical climatic condition of Kasauli station. (c) The excitation system consists of an electronic automatic regulator having very fast response to load changes. (d) The silent features of alternator are:- (i) (+) or (-) 1% voltage regulation under static conditions. (ii) Class H insulation. (iii) Permanently lubricating bearing. (iv) 10% over load allowed for one hour for every 12 hour. (v) Copper winding with Star connection (all six leads shall be brought out of stator frame).

Control Panel with AMF Panel :- Control Panel shall be made of CRCA sheet of suitable gauge and powder coated for weather proof and long lasting finish. The control panel shall consist of the following features:- (i) Microprocessor based control panel for generator set monitoring, metering incl fuel level shown in percentage form and control system with LCD display designed to meet the demands of engine driven DG sets having digital AVR, electronic governing with temp compensation, start/ stop Engine Metering, Oil pressure, coolant temp, battery voltage, engine speed and AC alternator metering, digital Volt-Ampere (L-L Voltage, L-N voltage), current (R-Y-B Phase), frequency. (ii) Engine protection :- low lube oil pressure, High/ Low coolant temp, over speed, battery over/ under/ weak volts/ failure to crank/ start sensor. (iii) AC alternator Protector :- over/ under voltage, over/under frequency, over current, short circuit and loss of AC sensing and also having Data logging history of engine etc with protection against phase sequence, phase missing & earth fault tripping complete. (iv) Copper Bus Bar of Suitable rating with incomming/ outgoing terminals. (v) Indication Lamps for load ON and set Running. (vi) MCCBs of suitable rating with overload and short circuit protections. (vii) Contactor of suitable rating with control wiring including all metering accessories complete.

ACOUSTIC ENCLOSURE : Floor mounted Accoustic enclosure (canopy) suitable for 380 kVA DG set as per CPCB norms Norms-IV+ of the same make as that of DG set to be provided with following provisions/ specifications:- (i) The accoustic enclosure is made from CRCA sheet of suitable gauge and specially designed to meet stringent CPCB Norms- IV+ of 75 dBA @ 1Mtr at 75% load under free field condition. (ii) The sheet metal components are Hot dip not less than seven tank pre-treatment process. (iii) It is pure polyster based powder coated (inside as well as outside). All nuts / bolts / hardware are zinc coated. (iv) Baterry is accommodated in a tray inside the enclosure. (v) The doors are fitted with gasket with high quality EPON gasket to avoid leakage of sound. (vi) Sound proofing of enclosure is done with high density fire retardant PU foam conforming to IS 8183.

ACOUSTIC ENCLOSURE : Contd... (vii) Hospital Grade silencer shall be provided within enclosure to control exhaust noise. (viii) Adequate ventilation shall be provided to meet requirement for combustion and heat removal. If required a blower shall be used to meet total air requirement and air changes. (ix) Temperature of enclosure does not exceed beyond 50 degree C of ambient temperature. (x) Enclosure shall be provided with 'High enclosure temperature safety device'. (xi) There shall be provision of emergency shut down from outside the enclosure. (xii) There is arrangement of proper illumination inside the canopy. (xiii) Enclosure is provided Air inlet louvers, drains for lube oil/ fuel, fuel filling arrangement etc. (xiv) Two point for lifting for easy handling.

BATTERY : (i) Maintenance free sealed lead acid battery of appropiate AH and volts as per OEM recommendations along with all accessories along with copper battery lead, connector with in built trolley for battery. (ii) Starter motor (iii) Starter gearing (iv) Start/ Stop push button (v) Battery charger as per OEM recommendation suitable to work on 230 volts 50 Hz AC supply system for charging of DG set batteries externally when DG set is in off position. (vi) Alternator/ Dynamo of suitable capacity to charge the battteries while DG set running complete with cut out all as per manufacturer's recommendation.

Daily services fuel tank inbuilt type suitable for full load running of DG set for minimum 8 hours enclosed within the canopy including fuel level indication in main control panel all as per CPCB Norms- IV+ with level indicator inlet, outlet, drain plug, air vent and locking arrangement etc including fuel pipe connections etc complete.

Standard safety device and self starter having 12/24 volts DC as per OEM recommendation.

Heavy duty base frame of sturdy design made of MS stud with necessary reinforcement and lifting arrangements.

Sets of AVM pads between the engine alternator feet and the base frame as per OEM.

Exhaust system shall be provided with thermal insulation by using fire retardant/ non igniting foam conforming to ISO 3046/ BS-5514 to prevent excess heat radiation on the engine and safety of operator including flexible coupling with guards.

Tools:- Following set of tools shall be provided alongwith DG Set and the cost of the same shall deemed to be included in the unit rate quoted for DG set:- (i) Set of DE spanner – 6 to 32 mm - 1 set (ii) Insulated cutting plier 250 mm - 1 No (iii) Ring spanner 300 mm - 1 No (iv) Screw driver set - 1 No (v) Ring spanner set (Ratchet type) – 6mm to 32mm - 1 Set of 10. (vii) Allen key set - 1 Set (1.5mm to 10mm) (viii) Cell tester - 1 No (ix) Hydrometer - 1 No (x) Tool box-01 No (xi) Electric motor operated type fuel pump - 01 No

Note :- (i) The engine of DG set shall be suitably designed to give output of 380 kVA at NTP including 10% overload. (ii) The quoted rate for DG set is inclusive of PCC foundation. The foundation for DG set shall be made of PCC as per OEM recommedations. The size of platform shall be as per manufacturer's recommondations complete all as specified and directed. (iii) The DHPP (fuel) required for testing of DG set shall be arranged by the contractor and the cost of the same shall deemed to be included in the unit rate quoted for DG set. (iv) DG Set shall be composite type with Control panel, Prime mover, alternator and allied accesories in one enclosure.

Supply and laying, passing through pipe, testing and commissioning of 1100 Volts grade 'Heavy duty' PVC sheathed armoured cable, LT, XLPE insulated aluminium conductor, multi stranded, served with inner sheating of PVC tape armored with galvanised steel wire or tape and overall PVC sheathed of nominal cross sectional area 400 Sqmm, 3.5 core confirming to IS specification, laid in trenches/ fixed on poles, walls or under floors etc, complete including dismantling/ taking out unserviceable cable complete all as specified and as directed by Engineer-in-Charge.

Material & labour for earthing complete with galvanised steel earth electrode plate of size 600 x 600 x 6 mm thick, buried directly in ground (earth pit not less than 2.25 meter deep below normal ground level) with top edge of the plate not less than 1.50 meter below normal ground level, connected to galvanised iron earth strip 32 x 6 mm upto test point with suitable GI nuts/ bolts and brazed properly up to main board including earth pit in cement concrete 1:2:4 type B-1, precast RCC cover in 1:2:4 reinforced with expanded metal, with suitable handle, excavation and earth work in any type of soil and including medium grade GI watering pipe 20 mm bore with funnel wire mesh and GI strip protection pipe, GI, 'light grade' of 40 mm bore up to main board complete as shown in electrical plate No. 3 of MES schedule Part-I 2009, connected to earthing testing point including taking out existing unserviceable earthing including testing on completion complete all as specified and as directed by Engineer-in-charge.

Note - (i) Quoted rates shall be deemed to include for earthing strip with protection pipe up to 7.5 Meter length.

M&L for fixing of double walled corrugated HDPE duct pipe of 125 mm outer dia confirming to IS-14930 (Part-II) of approved colour with fittings for cable protection including taking down of old pipe complete all as specified and as directed by Engineer-in-Charge.

Disconnecting of existing cable terminal and taking down of unservicable DG Set of cap 380 kVA from its own location and shifting the DG Set to MES Installation/ Store for safe custody after dismantling complete all as specified and as directed by Engineer-in-Charge. Note :- Department will not provide any T&P items required for lifting of DG Set. Cost of the same shall deemed to be included in the quoted rate.

Dismantling and taking down of concrete of any description and in any position complete all as specified and as directed by Engineer-in-Charge.

Supply and fixing in replacement of earth continuity conductor or main earthing lead of 32 x 6 mm galvanized iron strip, buried in ground or fixed to wall with PVC sadddles in regular internval (60 to 75mm distance) complete all as specified and as directed by Engineer-in-Charge.

Supply and fixing in replacement of GI tubing, 'light grade' of 40 mm bore, buried in ground or fixed to wall for protection of GI strip complete all as specified and as directed by Engineer-in-Charge.

Ayushmat Contractors (BID ID -3372587)

KULBHUSHAN AGGARWAL (BID ID -3363409)

R. P. Suppliers and Construction Co. (BID ID -3372256)

Electromech Engineers (BID ID -3364905)

NARINDER KUMAR SONS (BID ID -3364565)

Natwadia Electrical Company (BID ID -3359424)