PROVISION OF 01 X 200 KVA DG SET WITH CABLE AND OVERHEAD PROTECTION FOR FEME AND SPECIAL REPAIR/REPLACEMENT OF 125 KVA DG SET AGAINST BER IN CDM SECUNDERABAD UNDER GE (U) SECUNDERABAD

Amount

GENERATING SET DIESEL ENGINE DRIVEN :- Supply, transportation and safe delivery to Site, unloading, safe storage, installation, testing and commissioning of 1 No. 200 KVA, 3 Phase & Neutral, 415 Volts, 50 Hz, Silent Diesel Generating Set, complete with CPCB-II Acoustic Enclosure and Retrofitting pollution control emmission system. The Diesel Engine shall be capable of delivering required BHP at 1500 RPM and coupled with 200 kVA, 415 Volts, 50 Hz Alternator at 1500 RPM mounted on a common base frame along with Genset Controller complete all as specified and directed. Make : Engine : CUMMINS/CATERPILLAR/ KIRLOSKAR GREEN Alternator : STAMFORD / CATERPILLAR / LEROY SOMER / KIRLOSKAR GREEN / CROMPTON GREAVES Battery : EXIDE / AMAR RAJA / AMCO General (a) Diesel engine and alternator shall be closely coupled and mounted on a base plate of robust in construction. (b) DG Set shall meet the requirements of environmental protection rules, 1986 as laid down by Ministry of Environmental & Forest read with GSR 371(E) dated 17.05.2002,GSR 520(E) dated 01.07.2003, GSR 448(E) dated 12.07.2004, GSR 771 (E) dated 11.12.2013 & GSR 232(E) dated 31.03.2014, Gazette Notification No. 167 dated.31.03.2014 and Gazette Notification No. 578 dated. 11.11.2014 amended up to date, in respect of "emission norms" for the engine and in respect of noise norms for DG sets. (c) DG Set should have protection against under voltage, over voltage, under frequency, over frequency, low battery voltage, over current, short circuit, phase sequence change etc.

Turbocharged Diesel Engine:- The turbocharged Diesel Engine shall be water cooled, developing required BHP at 1500 RPM with class A-1 electronic governing to deliver specified continuous KVA output at 0.8 Power Factor Lag at NTP conditions. The Diesel engine should be capable of providing 10% overload for one hour in every 12 hours continuous running at full load. The turbocharged Diesel engine shall conform to IS:13018/1990(reaffirmed 2005) and IS:10000 series (with latest Amendments / Equivalent ISO. Specific fuel consumption (SFC) shall be as per IS specification.

The Turbocharged Diesel engine shall be complete with the following accessories: (a) Integral Fuel tank with air breather, drain plug with capacity for 8 hours of continuous running at full load or 400 liters capacity, whichever is lesser as per clause 8.0. (b) Engine instrument panel as per clause 7.0 consisting of starting switch with key/Password protection, lube oil temperature and pressure indications, High coolant temperature, RPM indicator and hour meter with additional feature of auto start/remote start and auto stop. (c) Safety control to shut down the engine in the event of over speed, low lube oil pressure and high engine water temperature. (d) Exhaust silencer residential type. (e) 24 V starting system complete charging alternator or dynamo and cut-out. (f) Lead Acid - maintenance free batteries of suitable ratings with connecting cables. The batteries shall be supplied dry and in uncharged condition and shall conform to relevant IS only. (g) Anti-Vibration mountings for complete DG set in case of flexible coupling and for turbocharged engine in case of direct coupling. (h) The fuel level should be indicated with the help of suitable sensor. (j) There should be provision for filling the fuel from outside (as in case of automobiles) with locking arrangement. (k) Flywheel to suit flexible coupling as per manufacturer design. (l) Coupling with guard. (m) Air cleaner. (n) Radiator & Fan. (Blower Type) as per manufacturer design. (o) Fuel Injection Pump (p) Electronic Governor. (q) Lubricating Oil Filter. (r) Common Base frame for mounting of Diesel Generator Set: Sturdy, fabricated, welded Construction, channel iron base frame for mounting the above Engine & Alternator.

Engine Mounted Instrument Panel (a) Starting provisions (b) Battery voltage indications (c) Lub oil pressure gauge (d) Water temperature gauge (e) Run time Totaliser – Digital (f) RPM indicator – Digital (g) Emergency Stop Push Button (With provision to extend Remote STOP)

Fuel Tank (a) Integral Fuel tank with air breather, drain plug with capacity for 8 hours of continuous running at full load or 990 liters capacity, whichever is lesser. (b) Calibrated Fuel level Indications in percentage. (a) Fuel Inlet for filling with locking arrangement in the top lid. (b) Fuel outlet. (c) Air vent. (d) Drain plug. (e) Provision for Cleaning of Fuel tank.

Alternator :- (a) The alternator shall be self excited and self regulated of 200KVA rating in three phase at 415 Volts, 50 Hz, 1500 RPM & 0.8 PF and shall conform to IEC 60034 / IS:13364 (Part 2) / 1992(reaffirmed 2008). The alternator shall be of brushless type only with VG-3 Grade of voltage regulation. The alternators shall be screen protected, drip proof with IP-23 or better degree of protection as per IS: 4691/85(reaffirmed 2004). The alternator should be suitable to take unbalanced load as per IEC 60034 / IS: 13364 (Part-2)/1992(reaffirmed 2008). The Insulation class shall be H and suitable for operation at an design Ambient Air Temperature of 40o C, without any shall be H and suitable for operation at an design Ambient Air Temperature of 40o C, without any de-rating. (b) The Alternator shall have cable box suitable for terminating the 2 Runs of 3.5core, 185 sqmm XLPE cable. (c) The Alternator shall have Brushless excitation. (d) Insulation : Class "H" for Stator & Rotor (e) Winding : Vacuum pressure impregnation (f) Excitation : Brushless Compound Excitation System. (g) Regulation : AVR (h) Unbalanced Load : 3 Phase sensing of voltage and current and power factor to give good operation against unbalanced load. (30% capability) (j) Motor Starting Capacity : Shall possess Motor starting capacity of the order of 3 to 3.5 times the full load current. (k) Manufacturing : Shall conform to the following Standards :-

Specifications :- IEC 60034 NFC 51.111 VDE 0530 BS 5000 IEC 2-3 IS 13364 Protection : IP 23 or better Short Circuit Sustenance : Shall have High sustenance of Short Circuit current of 3 times full load current for 3 Seconds. Epoxy Coating : All wound components shall be epoxy coated after impregnation Routine Tests : Shall be conducted on the machine at no extra cost.

Excitation System :- (i) The excitation shall be self exiced type. The self excitation shall be a three phase high frequency AC Generator mounted on the main rotor shaft. The stator of the PMG shall be high frequency AC Generator mounted on the main rotor shaft. The stator of the PMG shall be three phase wound and the rotor shall be provided with permanent magnet. The output of the stator shall feed the power supply to the Automatic Voltage Regulator (AVR). AVR range of voltage adjustment be + 5%. (ii) The excitation produced by this winding shall be set slightly above the required value, giving a regulation of + 1%.

(iii) Apart from the voltage regulation characteristics the excitation system shall have the following features. (a) Voltage build-up from residual magnetism. (b) Protection against low speed operation (c) Voltages dip on acceleration of full load 0.8 Power Factor in the order of 15 to 20%. (d) Recovery time at constant speed for rated load application shall be 1.0 seconds (max). (e) Recovery time at constant speed for rated load rejection shall be 1.5 seconds (max). (f) 3 Phase sensed system shall allow good operation with unbalanced load system. (g) Shall have good overload characteristics. The DG set shall be capable of taking 10 % overload for 1 hr in every 12 hrs of continuous operation. (h) Harmonic distortion factor of output of alternator shall be less than 3% at open circuit voltage (IS 13364 Part 2).

Control Panel : - (a) Control panel shall be fabricated with 14 gauge CRCA sheet and powder coated for weather - proof and long lasting finish. (b) The control panel shall be consisting of the following parts/ features. (i) Power Command 1.2 controller or equivalent. (ii) Indicating lamps for ‘Load ON’ and ‘Set Running’. (iii) Instrument fuses duly wired and ferruled. (iv) Control system is a microprocessor based generator set monitoring, metering and control system with LCD display. (v) Intuitive operator interface which includes LED backlit LCD display with tactile feel soft-switches and generator set status LED lamps. (vi) Digital AVR with torque matching. (vii) Digital Electronic Governing with temperature compensation and smart starting. (viii) SAE J1939 interface to Full Authority Electronic (FAE) engines. (ix). Remote start-stop from AMF. (x) Engine metering: Oil pressure, Coolant temperature, Battery Voltage, Engine Speed, AC (xi) Alternator metering: L-L Voltage and L-N Voltage, Current (1 and 3 phase), Volt-Amperes (phase and total) and Frequency. (xii) Engine protection: Low lube oil pressure, High/Low coolant temperature, over speed, Battery (xiii) Over/Under/Weak Volts, Fail to crank/start, Sensor failure. (xiv) AC Alternator protection: Over/Under voltage, Over/Under frequency, Over current, Short circuit and Loss of AC sensing. (xv) Data logging: Engine hours, Control hours, Engine starts and upto 10 recent fault codes. (xvi) Configurable glow plug control. (xvii) Configurable cycle cranking. (xviii) 12 and 24 Volt DC operation. (xix) Sleep mode. (xx) Programmable I/Os (4 inputs and 2 outputs). (xxi) Modbus interface (RS485 RTU) compatible. (xxii) In Power compatible (PC based service tool). (xxiii) Certifications - meets the requirement of relevant UL, NFPA, ISO, IEC, Mil Std., CE and CSA standards.

Acoustic Enclosure :- The acoustic enclosure shall conform to the drawings approved by a Govt./NABL lab., for conformity to noise norms. The Acoustic enclosure should consist of following:- (a) The enclosure should be fabricated out of CRCA sheet of minimum 1.6 mm thick. (b) The sheet metal components should be suitably pre-treated with 7 tank process and should be powder coated to have long life of enclosure. (c) The battery should be accommodated in a separate tray in the enclosure. (d) There should be provision of drain plugs for draining lube oil and diesel. (e) The doors should be gasketed with quality gaskets to avoid leakage of sound. (f) The door handle should be lockable type. (g) Sound proofing of enclosures should be done with high quality rock wool/ mineral wool/foam/fibre glass wool. (h) The rock, mineral, fibre glass wool is further covered with fibre glass cloth and perforated powder coated sheet. (j) Special silencer should be provided along with the enclosure and proper angle inor support to control exhaust noise. (k) Specially designed louvers should be provided to control sound at air entry to the container and exit from the container. (l) It should have Type approval certificate and also COP certificate (if applicable) from certification agencies mentioning MOEF notification No.371 (E) dated 17.05.2002 or as amended and applicable at the time of supply. (m) Ambient temperature limit inside the canopy should be specified. (n) There shall be provision for emergency STOP from outside the enclosure. (o) Acoustic Enclosure shall conform to pollution noise norms stipulated in notification GSR 371(E) dated 17.05.2002, amended up to date.

Notes:- Quoted rates are deemed to be inclusive of the following :- (i) Inbuilt control panel along with MCCB of suitable ratings for overload / short circuit protection :- (ii) Cost of first filling of lubricants, fuel required for testing and accessories required for proper functioning of DG set shall be deemed to be included in quoted unit rate. (iii) Testing of DG set set on artificial load shall be carried out for 12 hour with 10 % over load for one hour. (iv) Necessary arrangement of Pre-commissioning inspection of Inspecting officer to be arranged by the Contractor. (v) Contractor should submit the technical specifications of the DG set and take necessary approval of accepting officer before placing order to the company.

AMF CONTROL PANEL SUITABLE FOR OUTDOOR INSTALLATION WITH BY PASS ARRANGEMENT : Supply, Installation, Testing and commissioning of AMF (Automatic Mains Failure) panel suitable for generating set of capacity 200 KVA factory made, fabricated out of CRCA sheet (3.00 mm thick) of min size 1.675 M X 1.500 M X0.50 M, totally enclosed, dust , damp and vermin proof free standing floor mounted type and front operated, degree of protection required will be IP-55 conforming to IS 2147 with and including necessary foundation ( Minimum height of the base of the panel board should not be less than 0.45 Meter) having the following features / facilities:-

Supply, install, test and commissioning of Silent Diesel Engine Generating set 415 volts, 3 phase, 4 wire engine as per IS : 10001/10002 conforming to CPCB Norms II, and alternator as per IS : 13364 of capacity 125 KVA/ 100 KW at site complete with control panel having meters, sound proof canopy etc including all accessories as per manufactures standard and as per the details given below and independent relay panel for automatic on mains failure :- Note : (i) AC Generator should be suitable for ambient conditions at Secunderabad and confirming to IS. (ii) The capacity of generator set shall be net after all de-rating factor as per relevant IS design) Make : Engine : CUMMINS/CATERPILLAR/KIRLOSKAR GREEN Alternator : STAMFORD / CATERPILLAR / LEROY SOMER / KIRLOSKAR GREEN / CROMPTON GREAVES Battery : EXIDE / AMAR RAJA / AMCO or as per manufacturer specification.

Alternator :- Standard design alternator rated at (100 KW) net output at site after considering all de-rating factors, site conditions and at power factor 0.8, AC, 3 phase 4 wire, 415 V, 50 Cycles/Second, 1500 RPM self excited, self regulated, screen protected, drip proof IP 23 enclosure, brush less design, voltage regulation ± 2.5 %.

Diesel Engine :- Diesel engine of suitable capacity, water cooled, closed circuit as per BS-649 or IS-1002 direct injuction type . Electric starting system having rated speed 1500 RPM. The DG set Shall be capable for running 24 hrs continuously with 10% over loading for 01 hour in every 12 hours as per BS-5514/BS-649. Engine shall be multi cylinder, multi stroke, direct injection and equipped with all standard fitting as per manufacture's recommendations and mounted on common base frame with following Specifications :- (i) Fly wheel with housing :- Common base frame of sturdy design suitable for anti vibration mounting and permanent concrete foundation for mounting engine and alternator as per manufacturer's instructions (ii) Cooling system :- (a) Mounted radiator with fan & belts & guard, rubber hoses and thermostat. (b) Cooling water pump centrifugal type . " (iii) Governer :- Electronic Governer. (iv) Electric Starting System :- Electric Self starter, 12 volts DC (12 volt, 180 AH battery 1 No's) charging alternator as per manufacturer's design, copper leads with lugs of adequate size complete with initial charging of maintenance free battery 1x12 volt 180 AH capacity. Make :- Exide or as per manufacturer's specification.

(v) Generator Monitoring Panel :- Comprising of following :- (a) Microprocessor based genset controller for metering, monitoring, governing and protection (b) Engine protection for low lub oil pressure, high coolant temperature (Alarm & Shutdown) (c) Alternator protection parameters like under voltage, over current, under frequency, over frequency (Alarm & Shut down) (vi) Accessories :- AVM Pads built or separately mounted to manufacturer base frames. (vii) Coupling Arrangements :- Fixed coupling, flywheel to suit fixed coupling and fly wheel housing. (viii) Exhaust System :- Silencer complete with exhaust pipe of suitable size upto and outside the building all covered with asbestos rope of suitable size all as directed. (ix) Fuel Tank :- Daily service fuel tank of capacity suitable for 12 hours continuous operation made out of 3 mm thick (heat retardant) sheet with indicating gauge, built inside the acoustic enclosures or as per manufacturer's design.

Civil Works:- All civil works related to foundation, installation of panel and equipment and depth of foundation shall be minimum 300mm with ant vibration pads, or as recommended by the manufacturers. Cables from DG set to AMF panel, AMF panel to main panel will be measured under relevant schedule. Note:- (i) The fuel for final testing of 12 hours shall be supplied by the contractor and cost deemed to be included in the above offer. All other necessary equipments like resistance load strip heater of suitable capacity/rating and any other items required for final testing shall be provided by the contractor without any extra cost to department. (ii) The testing of Genset for continuous 12 Hours shall be done by an officer detailed by accepting officer after installation at site No load - 1/2 Hour 25% load - 1/2 Hour 50% load - 1 Hour 75% load - 1 Hour 100% load - 8 Hours 110% load - 1 Hour (iii) Provision of all control cable and their termination are deemed to be included in quoted rate.

S & F Retrofitting Pollution control emission system suitable for Capacity 125 KVA DG Sets as mention above with following specifications as given below:- (i) Capturing Chamber- Stainless steel (ii) Mechanical Pressure Relief Valve (iii) Online Monitoring (iv) Sensor (Temp & Pressure) (v) Manual Bypass system (vi) Back Pressure Limit for DG Set - 10.15 kpa (vii) Stack Back Pressure <1 kpa (viii) Piping- Included up to 10 meter length

Advance Maintenance Free G.I. SAFE EARTHING Electrode with PIPE of not less than 50 mm outer dia) and two meter length, The electrode should be of galvinised (80 -100 micron) along with earth lead as Galvanised steel strip of size 32 X6 mm 7.5 m . The GI Electrode shall be pre-filled with Crystalline Conductive Material (CCM) . The GI electrode shall be surrounded with 25 kg Backfill compound to provide maximum contact between the electrode and Back Fill Compound. The earthing pit cover should be factory built ( size TOP- 10 Inch, Bottom -13 Inch, Height 10.25 Inch ) made of heavy duty Polypropylene complete all as specified and directed

Supply and lay in trenches/fixed to walls/poles etc connecting buy using lugs, testing and commissioning XLPE insulated and PVC sheathed heavy duty LT 1100 Volts grade armoured underground cable with stranded aluminium conductor 3.5 Core 150 Sqmm complete all, as specified and directed. Note : Cable to be terminated in four places.

All as per item No:6 here-in-before but 3.5 Core 185 Sqmm

Supplying and laying unreinforced precast concrete cable cover class LV , Type 1 flat with size 250mm x150 mm x 40mm all as specified and directed by Engr-in-Charge.

Spreading riddled earth ( after preparation of excavated earth) in Cable duct for cushioning of cable laid in trenches complete all as directed by Engineer-in-Charge Note:- Punned thickness 18 CM (6.25 Cm below cale and 11.75 cm above cale) will be measured for payment purpose. The earth removed during excavation to be used as rddled earth after crushing and sieving. Quoted rate inclusive of all arrangement as mentioned.

Excavation in trenches n.exc 1.5 m wide and n.exc 1.5 m in depth for laying pipes/cables in trenches/for foundation of PCC/steel pole/ manhole saft etc n exc 10 sqm on plan and n exc 1.5m in depth and getting out in hard/ dense soil

Excavation in post holes (or similar holes ) each nexc 0.5 cum getting out returning filling in hard/ dense soil.

Returning, filling in , including spreading, levelling,watering and well ramming in layers not exceeding 25 cms in hard/ dense soil

Removing surplus soil to a distance n.exc 50 m and depositing where directed at a level n exc. 1.5 m above the starting point

M&L PCC 1:4:8, type D-2 (using 40 mm graded crushed stone aggregate) as in foundations filling and mass concrete complete all as specified and directed.

Material and labour for PCC 1:3:6 type C2 using 40mm graded stone aggregate as in foundation / bed concrete.

M&L Pre-cast cement concrete block masonry Type C1 1:3:6 (20mm graded aggregate) with solid blocks, exc. 10cm in width and setting in cement mortar 1:6 complete

M&L for 100 mm thick cement concrete 1:2:4 type B-2 (using 40mm graded crushed stone aggregate) as in sub base or sub floors finishing the surfaces even and rough to receive the topping layer complete all as specified and directed.

M&L for 40 mm thick Cement concrete type B-1, 1:2:4 (20mm graded stone aggregate) finishing the surfaces even complete all as specified and directed.

M&L Rendering 10mm thick in CM 1:6 on fair faces of brick work or concrete surfaces

M&L Three coats of white wash including preparing new surfaces plastered or unplastered

S&F steel work in tubular trusses / poles (unframed) including purlins, rafters and special shaped washer etc complete using ERW or induction butt welded tubes confirming to IS-1161-1979 grade St-240 complete all as specified and directed.

Providing and fixing 0.56 mm thick aluminium alloy colour coated roofing sheets of alloy IS designation 31500, temper H*8 conforming to IS 737 and dimension as per IS Code 2676 with characteristics of good formability and corrosion resistance and troughed profile with center to center pitch of 200 mm, depth of 32 mm, overall profile width 1092 mm, cover width 1000mm at all heights, levels and locations. The profile sheets shall be fixed to truss members in slope or required pitch or curvature with Hex cap headed self drilling/ tapping stainless steel screws M6, 60 mm long with 3 mm EPDM seal washer etc, all inclusive of labour, scaffolding, T&P and sundries etc. complete all as specified and directed. Make : TATA / JINDAL / HINDALCO

M&L Two coats of synthetic enamel paint on steel surfaces of any description, over 10cm in width or girth, over a coat of primer including preparation of new surfaces all as specified

Dismantling of all electrical connection and taking Down Old Unsv BER 30 KVA Existing DG Set from CDM Area and Shifting to AGE E/M No l store yard (approx 2 KM distance) all including dismantling and transportation charges

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MONA GENERATOR SEVICES PVT. LTD.