Supply, Installation, Testing, and Commissioning of Substation Electrical works at IVC Facility at HLL Biotech Limited, Chengalpattu, Tamil Nadu

LT BUSDUCT

Supply, Manufacturing testing at workshop (FAT), delivery at site, unloading, shifting, installation, testing & commissioning of LT BUSDUCT unit for "Sandwich BUSDUCT. The scope also includes proper alignment, levelling at final location at work site, tightening of bus bars with required torque under supervision and instruction of manufacturer/client's engineer in charge.

Bus duct shall be passed between different area through wall/Ceiling and Bus duct after passing from wall/Ceiling with necessary sealing compound or wall/ceiling flange shall also part of installation material including supply and apply. Sandwich type Bus duct shall be similar to "CANALIS" type in Schneider make and "LXC" type in Siemens make.

5000 Amp SANDWICH BUSDUCT FROM TRANSFORMER TO MAIN LT PANEL (TOTAL 3 ROUTE -BOQ PROVIDED FOR 3 Nos. OF 2.5 MVA TRANSFORMERs)

5000 Amp Sandwich type Aluminium Bus duct (3L+N+E, 2 Nos. External Earth conductor) Outdoor/indoor type including accessories like Outdoor/Indoor Straight Length,90°C Outdoor/Indoor bends , Flange end ,wall flange, Copper flexible end terminations connecting at Transformer secondary and Main LT Panel side, Adaptor Box at Transformer secondary and Main LT Panel with copper shorting link, Hanger for installation , Phase cross over if required etc.complete the work in all respect ready for operation & to the entire satisfaction of Engineer-In- charge. The Scope includes supply of all hardware/Anchor fasters , supporting hanger at every meter of Bus duct and both ends of every bend etc.The Busduct should have minimum 18 months OEM warranthy.

5000A Straight Run Including Bends -Outdoor (Including Installation)-IP 66

5000A Straight Run Including Bends -Indoor (Including Installation)-IP 55

Flange End

Adaptor Box-Transformer Side & LT side

Tinned Copper Braided Flexibles -360mm (with Hardware - Nuts and Bolts)

Aluminium Interconnecting Busbar at Panel end - 500mm ( with Hardware - Nots and Bolts )

M.S Supports (Including Installation)

Horizontal Fixing Clips (2 Nos Per Horizontal Channel Supports)

Supply and fixing of Aluminium earth Strip 50 x6 mm with its all accessories-2 Runs

Phase Crossover

Horizontal Bend/Vertical Bend

Supply and fixing of Canopy 1.6mm Thickness for Outdoor Bus

Dismantling of existing 5000A sandwich type Busduct with its all accessories.

Realignment of existing 5000A aluminum Sandwich type busduct including outdoor/indoor straight lengths, 90° bends, flanges; adjusting hangers, joints, and supports for proper straightness and no stress.(Approx 14m X 2 nos) Realignment and termination of existing copper flexible ends at main LT panel and transformer secondary (both sides, 2 routes) including tightening and gap elimination-4 nos. Insulation resistance (megger) testing at 500V DC, continuity checks, and certification for entire busduct (2 routes); including isolation, cleaning insulators, and reporting. Installation of Existing adaptor box covers, end covers with copper shorting links, and busduct enclosure covers (IP-rated for outdoor/indoor)

PT Replacment with fuse

Supply, installation, testing and commissioning of 1 phase, 11 kv Epoxy Resin Cast Potential Transformer, Draw out type, 11 kV / √3 / 110 V / √3, class 0.2 , 50 HZ, 50 VA burden and 11 kV cylindrical PT fuse rated at 3.15 Amps for overcurrent protection.

Supply and Installation of ABB Make (ABB 63A A63-30-00) contactors (14 Nos), 10 sqmm cables (50 Meters), Copper Lugs (100 Nos) and connectors (50 Nos) for the 18.5 kW utility block primary pumps feeder (Suitable for 63 A)

Supply and Installation of ABB Make (ABB 63A A63-30-00) contactors (08 Nos), 10 sqmm cables (50 Meters), Copper Lugs (100 Nos) and connectors (50 Nos) for the 22 kW utility block primary pumps feeder ( Suitable for 63 A)

Transformer Service:

Transformer service includes: a) High vacuum oil filtration for 2500 kVA transformer to achieve BDV >50 kV (11/0.433 kV). b) Epoxy painting: Surface preparation, 2 coats epoxy finish on transformer exterior(spray painting) &as per OEM standard. c) Transformer oil testing per IS 1866:2000 (NABL lab) - DGA(Dissolved Gas analysis), IFT(Interfacial Tension), acidity test, Sludge Content, flashpoint, Dielectric Strength (BDV), moisture content PPM, density, resistivity, Kinematic Viscosity, appearance, furan analysis, • Dielectric dissipation factor (tan delta), • Carbon Dioxide, Carbon Monoxide, Hydrogen, Total Gas Content d) Testing and calibration of oil surge relay, Buchholz relay, PRV, OTI/WTI. e) Supply and fixing materials (epoxy paint, filtration consumables).

Repainting of 4 nos of existing 11 KV Oil type transformer 2500 kva with Epoxy painting: Surface preparation, 2 coats epoxy finish on transformer exterior (spray painting) & as per OEM standard.

Servicing and testing of ACB (Air Circuit Breaker)4000 Amps make service: Make ABB Servicing & Testing of ACB • Cleaning of insulators & contacts by CTC • Lubrication of mechanisms by CRC • Checking of electrical operation • Checking of mechanical operation • Tightness checking for terminations • Providing petroleum jelly • Insulation resistance test • Contact resistance test100A DC • Relay testing

Servicing and testing of ABB make Air Circuit Breaker 1600 Amps make service: • Cleaning of insulators & contacts by CTC • Lubrication of mechanisms by CRC • Checking of electrical operation • Checking of mechanical operation • Tightness checking for terminations • Providing petroleum jelly • Insulation resistance test • Contact resistance test100A DC • Relay testing

Servicing and testing of ACB (Air Circuit Breaker) 1200 Amps make service: ABB make • Cleaning of insulators & contacts by CTC • Lubrication of mechanisms by CRC • Checking of electrical operation • Checking of mechanical operation • Tightness checking for terminations • Providing petroleum jelly • Insulation resistance test • Contact resistance test100A DC • Relay testing

Servicing and testing of VCB Panels includes: • ABB Make 1250 Amps VCB testing and servicing • Cleaning of insulators & contacts by CTC • Lubrication of mechanisms by CRC • Checking of electrical operation • Checking of mechanical operation • Checking of auxiliary circuit • Tightness checking for terminations • Providing petroleum jelly • Insulation resistance test • Contact resistance test • Opening time & closing time test • Current Transformer testing • Potential Transformer Testing • Relay testing

Servicing and testing of ABB Make 800 amps VCB • Cleaning of insulators & contacts by CTC • Lubrication of mechanisms by CRC • Checking of electrical operation • Checking of mechanical operation • Checking of auxiliary circuit • Tightness checking for terminations • Providing petroleum jelly • Insulation resistance test • Contact resistance test • Opening time & closing time test • Current Transformer testing • Potential Transformer Testing • Relay testing

Servicing, Inspection, testing for the following items, 1. APFC panel - 850 KVAR (3 nos). 2. APFC panel - 1000 KVAR (2 nos). 3. APFC Panel -750 KVAR (3 nos). 5. APFC Panel- 600 KVAR (2 nos). 6. APFC Panel -100 KVAR (1 nos) 7. Relay setting verification of EPCOS Make BR 5016 Power Factor Controller Relays-10 nos. Work ensures power factor >0.98, proper capacitor step switching, and compliance with IS 8623/IEC 61439 for low-voltage switchgear.

Earth pit testing for HT panels (ICOG panel), measuring individual and combined earth resistance values in Ohms using fall-of-potential method, along with replacement of old bolts/nuts with stainless steel (SS) equivalents. Additional tests cover soil resistivity, touch/step potentials, and continuity verification to ensure <1 Ohm resistance per IS 3043:2018 standards

Testing of transformer neutral earth pit, measuring individual and combined earth resistance values in Ohms using fall-of-potential method, plus replacement of old bolts/nuts with new stainless steel (SS) equivalents. Additional tests include continuity from neutral CT/busbar to pit, soil resistivity, and touch/step potentials to ensure <1 Ohm per IS 3043:2018 for safe neutral grounding

Testing of LT panel chemical earth pits, measuring individual and combined earth resistance values in Ohms using fall-of-potential method , plus replacement of old bolts/nuts with new stainless steel (SS) equivalents. Additional tests include continuity from LT panel earth busbar to pits, soil resistivity and touch/step potentials to ensure <1 Ohm per IS 3043:2018, critical for chemical pits with GEM backfill

Comprehensive general servicing of 500 KVA dry type transformer (11/0.433 kV) at MRS 110 kV substation, including earthing checks, door limit switch service, insulation resistance, ratio tests, cleaning, and thermal scanning

Supply and replacement of red DMC terminal plates, (Frame ND2805-Crompton Greaves) and no of studs-6, for 45 kW & 75 kW motor cable terminals - Utility cooling tower (complete set)

High Voltage test and Insulation testing (megger test) of existing 3C x 240 sqmm AL/XLPE HT cables using 5 kV DC megger, verifying IR values >100 MΩ phase-phase/phase-earth per IS 7098 standards for reliable 11 kV operation

Supply and installation of 3-core Current Transformer (CT) 100/1A, Class 0.2 accuracy, 5VA burden for metering/protection in HT/LT panels per IS 2705 standards