500KV Diesel Generator and Associated Electrical works

DIESEL GENERATOR & ASSOCIATED WORKS

DG SET

415V, DG set of Prime duty, Radiator Cooled, self driven alternator, designed for operating on high speed diesel(HSD), with residential silencers, four batteries, base frame, anti vibration pads, Drip trays, Electric driven lube oil priming pump, Lube oil and Coolant complete with adapter box and other components as required. All complete as per relevant standards, technical specification of this tender, direction of engineer-in-charge.

FUEL TANK & PIPE

990ltr day fuel tank shall be fabricated out of 4mm thick MS sheets and shall include the removable cover with locking arrangement, mechanical float valve, painting, providing all the required apparatus like inlet & outlet connection, float valves, external glass/transparent tube fuel oil level indicator and low level/high level indications - Tubular Glass level Indicator with Mechanical Protection and necessary 600mm height MS support arrangement for mounting, grouting of bottom & HSD tank & structure should be earthed at both ends (cost includes GI strips), complete as per specification and direction of Engineer in charge. Scope includes first fill of fuel HSD of 990L in Day Tanks. The fuel tank shall be located away from the DG cooling fan and the entire fuel storage area shall be away from equipment location, the distance shall be as per regulations/norm. The spill kit shall be provided for collection and removal of fuel spillage. 'The day tanks are to be connected to the earth grid at two locations

Kent make analog flow meter for diesel tank, Vendor has to install this with reducer of 15mm from 25mm Dia pipe (Gravity Flow) for better Flow measurement in both the Day tank to DG set pipeline, cost includes the caliberation certificate for the Diesel Flow meter along with Bill copy to be submitted. Tank limits, Lower Limit:150L, Upper Limit:900L

Canopy for Diesel day tanks and barrels MS supports & GI/PVC canopy including welding, jointing including U clamps, supports, bolts & nuts for complete work covering both back side and sideways to prevent rain water entry. Required civil foundation work, plastering, masonry works, all associated civil works major and minor including material and labor, in connection with the above work. (In case outdoor mounted)

25 mm dia gate valves.

Hand operated fuel transfer pump with flexible hose PVC pipe of 5M length.

EXHAUST SYSTEM

Supplying, fixing & installing exhaust pipe fabricated out of 5 mm thick Class B MS and all fixing accessories and hardware for the following with 28G, aluminum sheet cladding & 100 mm thick 150 kg/cu.m density mineral wool insulation wrapped in chicken mesh including all supporting structure with arrangements like supporting frames, hooks, clamps, hardware & fasteners Etc complete as required. Necessary MS supporting accessories with anchor fastener bolts etc., to support exhaust pipe (limited to DG room), Residential silencer etc., All stacks are provided with the stack monitoring points along with the safe access arrangements. The stack shall have a porthole for monitoring the emissions

Vendor shall ensure that the Exhaust pipe vibration/heat is not transferred to the building. The exhaust pipes shall be supported in such a way that free thermal expansion of the pipes is possible, with out exerting pressure on the the structures etc. Also vendor shall provide expansion bellows and spring supports at suitable intervals for horizontal lengths to allow free expansion. The installation rate shall include necessary anti vibrating mounts/High-tech spring supports/MS angle supports at standard intervals. DG breather outlet pipe should be extended outside the DG enclosure & should be extended in the opposite direction of Radiator.

The DG stack has to be provided with conventional Lightning arrester, the down conductor 25x6mm GI strip to be connected to existing earth pit.

The day tank, steel structures are to be connected to the earth grid at two locations

Stack Height : H = h + 0.2 Sqrt(capacity of DG in KVA). h=Building Height - Varies and DG size-Varies, Hence stack height varies.

Exhaust piping with class "B" MS pipes 6mm thick complete with bends, tees, reducers flexible connections, pipe supports with cleaned with metal brush, and one coat of primer and two coat of heat resistive ALU paint, all complete as per relevant standard, technical specification and direction of Engineer in charge.

Exhaust pipe thermal insulation and cladding for the required mm dia pipe, consider Rockwool insulation of density 98kG/m3 with 50mm thick bound with GI chicken wire mesh & 24swg Al sheet

Suitable dia Flexible Bellows for 500KVA DG Exhaust System SS expansion joints (Grade SS 304). Every three floors one bellow to be considered

Suitable thermal insulation for 500KVA DG Residential type Silencer.

Fabricating, supplying and installing structural steel work starting at DG level and extending 6 Mts beyond the roof level for supporting the silencer and exhaust pipe work. The structure shall be finished with primer and 2 coats of polyurethane paint. including 3stage platform including supply of foundation bolt,template etc for Support structure

POWER CABLE

Supplying and laying of PVC insulated, heavy duty, aluminium conductor. 1.1KV grade armoured. MV cable of the following sizes as required, generally conforming to IS:1554/Part-I/1970

3.5CX400Sqmm Ar, Al

3.5CX400Sqmm Un Ar, Cu (Rate only item)

Supply & making end termination with Copper gland and aluminium lugs of PVC insulated and PVC sheatehed / XLPE aluminium conductor cable of 1.1KV grade as required:-

3.5CX400Sqmm Ar, Al

CONTROL CABLE BETWEEN PANEL TO DG

Control Cabling (Copper Multistring Armoured Cable) 650/1100V, Grade conforming to IS-7098(part-1)1988 .

6C x 2.5 sq mm (For Engine to AMF Panel)

End termination kit suitable for the above cable with copper lugs and single compression gland

2C X2.5 sq mm (From External supply of power to enclosure Lighting).

End termination kit suitable for the above cable with copper lugs and single compression gland

2C x 4 sq mm (For battery charger).

End termination kit suitable for the above cable with copper lugs and single compression gland

4C x 2.5 sq mm (Single contactor AMF Panel & Logic panel and for EB Sensing).

End termination kit suitable for the above cable with copper lugs and single compression gland

Shielded Signal cable suitable for RS485 communication

End termination kit suitable for the above cable with copper lugs and single compression gland

EARTHING SYSTEM

Supply, Installation, testing and commissioning of following sizes of Chemically treated earth electrode as per IEC. The rate shall be for complete work like vertical rod, chemical compound shall be with resistivity of 0.2ohm meter as per IEEE80, excavation, ramming, consolidation, brick work chamber, FRP cover slab etc. The earth station to be treated to obtain individual earth resistance as per requirements of local authorities. Separate drawings shall be furnished by the contractor for technical approval. (Make: Potential maintenance free electrodes, JEF Techno)

17.2 Dia, 3meters long, 100 micron, Cu bonded steel electrode with all required accessories as per norms

32 Dia, 3meters long, 100 micron, Cu bonded steel electrode with all required accessories as per norms

DESIGN & DRAWINGS

The following needs to be furnished for engineer-in-charge for drawing approval, the softcopy through email and three sets of hard copies.

The entire DG room / yard arrangement shall be properly marked with dimensions in the shop floor drawings showing plans, sections & elevations.

Complete set of equipment GA drawing with Technical Data Sheet

Temperature rise calculations inside DG room at full load with sizing calculations for fresh air and hot air louvers/attenuators shall be furnished

Back pressure calculation

ELECTRICAL:

The power cable supply, erection, testing & commissioning are part of vendors scope.

The suitable adaptor box shall be provided by the vendor to terminate the power cable/busduct at alternator terminals.

The 24 volts chargeable batteries of 180 AH including initial charging of batteries, battery leads, MS stand of Batteries, should be earthed, top acrylic transparent sheet cover should be provided covering the Battery live terminals.

DGs shall have manual operation feature, it shall also be switched on/off from Main LT panel by using lockable push buttons.

The breaker panel shall be provided by the vendor, it shall be ACB/MCCB 4P, 50kA with necessary protection settings. If the DG sync panel is part of the DG room, then the separate Breaker panel is not required, it shall be decided during shop floor drawings approval.

Supply and laying of ISI mark 1100 V grade 1 meter wide rubber mats. The furnished quantity is approximate, payment will be made based on the actual measurement.

TESTS:

All the factory test reports to be submitted

Type Test certificate shall be submitted along with the offer

To check and conduct periodic emission test, the vendor to make a provision at appropriate location and it shall be easily accessible from gound level

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