SPECIAL REPAIR TO CERTAIN DG SETS AT AF STN NALIYA

Amount

Supply, install, testing and commissioning of Diesel engine driven generating set 100 KVA, 3 phase 4 wire, 415 volts,1500 RPM, 50 Hz power supply with power factor 0.8 coupled directly to alternator mounted on a common base plate complete with integral acoustic enclosure having silent features such as modular bolted construction with fabrication on imported CNC torret punch machines, nine tank treatment process with pure polyster based powder coating to ensure long life in all weather conditions and for out door application/ installation, integrated design thereby facilitating /easy handling installation & shifting of the equipment at site. The design of integral acoustic enclosure should be any type approved by national Physical laboratory as per Central Pollution Control Board (CPCB-IV) latest norms/regulation with fuel tank, battery and standard accessories and PCC foundation for (acoustic enclosure also 30 CM above ground level) as recommended by manufacturer, vibration pad, sand cushioning around PCC foundation, tools and spares, as provided by manufacturer all as specified and as directed with the following specifications :-

(A) ENGINE :- Water cooled diesel engine of suitable capacity to match the 100 KVA alternator under NTP conditions with provision of 10% over load for 1 hour in every 12 hours running confirming to BS-5514/ISO-3046. The engine shall consist of following :- (i) Fly wheel (ii)Close coupling (iii) Cooling fan (iv) Radiator with guard and water pump engine mounted (iv) Radiator with guard and water pump engine mounted (v) Battery charging alternator (vi) Air cleaner heavy duty dry (vii) Fuel injection pump (FIP) (viii) Radiator fan(blower type) with guard (ix) Precision governor (mechanical type) (x) Fuel filter (xi) Lubricating oil filters (mounted) (xii) 12 V self regulating alternator belt driven by engine (xiii) Exhaust silencer heavy duty residential type (xiv) Corrosion resister /scale inhabitor (xv) Starter 12 V DC (xvi) Lubricating oil cooler (xvii) Lubricating oil pump ( gear type) (xviii) Exhaust pipeing as per manufecturer design

(B) Control Panel : The Control Panel is manufactured with 14/16 guage CRCA sheet and is powder coated for a weather - proof and long lasting finish. The Control Panel consists of the following parts: (a) S0500 Controller (b) Aluminium Bas Bars with suitable capacity with in/ outgoing terminals (c) Indicating Lamps for'Load On"and 'Set Running' (d) MCCB of suitable rating with overload and short circuit protections.

(viii) Engine protective Functions includes. (a) Configurable alarm output. (b) Emergency stop: Annunciated whenever an emergency stop signal is recieved by the control. (c) Low lube oil pressure warning and shutdown (d) High engine water tempreature warning / shutdown. (e) Low coolant temp warning. (f) Sensor failure indication. (g) Low and high battery voltage warning. (h) Weak battery warning. (j) Fail to start shut down. (k) Cranking lockout: Control will not allow the starter to engage or to crank the running engine. (l) Cyclic cranking: Configurable for the number of starting cycle (1 to 7) and duration of crank and rest periods. (ix) Alternator Protective functions includes (i) High and low AC voltage shut down (ii) Under and over frequency shutdown / warning (iii) Loss of sensing voltage input shutdown

(C) BRUSHLESS ALTERNATOR :- (i) Alternator coupled to engine through a flexible coupling to an indigenous alternator mounted on strong steel fabricated base frame suitable for mounting on a permanent foundation. Brush less alternator shall be confirming to BS- 5000 or relevant of IS-4722 (ii) Type :- self excited self regulated with automatic voltage regulator (iii) Rating:- 100 KVA at 0.8 PF lagging 4 pole horizontal at NTP condition (iv) Speed- 1500 RPM (v) System -415 V + 2.5% AC 3 phase 4 wire 50 Hz. (vi) Connection - 4 wire star connected (vii) Enclosure -Screen projected drip proof (viii) Ventilation - self ventilated (ix) Insulation -Insulation, class H , IP-23

(D) Sub base Fuel tank 14 SWG MS sheet and capacity to hold diesel sufficient for running 08 hours at full load including :- (i) Level indicator on fuel tank. (ii) Drain plug (iii) Piping for fuel tank as per manufecturer design (iv) Fuel strainer. (v) Air vent, Fuel tank shall be mounted as per manufacturers instruction (b) Battery :as provided by OEM (c) Base plate : fabricated out of MS channels ISMC of suitable size suitable for fixing DG set all as specified by the manufacturers (Necessary permission/ certificate from Central State pollution Control Board shall be accomplished with DG set) CPCB IV

(E) AMF PANEL OUTDOOR TYPE: The AMF Panel Outdoor type suitable for 100 KVA DG Set factory made out of CRCA Steel 3 mm thick Sheet floor mounted type and front operated type, totally enclosed dust, damp and vermin proof, all doors and joints will be suitable gasketed to form dust and vermin proof. The panel would be powder coated minium thickness of 50 microns, stove enameled paint finished after elaborate pretreatment to form a long lasting characteristic. The control panel will be complete in all respect with fuses, wiring and labels etc, the following will be incorporated in the AMF Panel :-

Supply, install, testing and commissioning of Diesel engine driven generating set 30 KVA, 3 phase 4 wire, 415 volts,1500 RPM, 50 Hz power supply with power factor 0.8 coupled directly to alternator mounted on a common base plate complete with integral acoustic enclosure having silent features such as modular bolted construction with fabrication on imported CNC torret punch machines, nine tank treatment process with pure polyster based powder coating to ensure long life in all weather conditions and for out door application/ installation, integrated design thereby facilitating /easy handling installation & shifting of the equipment at site. The design of integral acoustic enclosure should be any type approved by national Physical laboratory as per Central Pollution Control Board (CPCB-IV) latest norms/regulation with fuel tank, battery and standard accessories and PCC foundation for (acoustic enclosure also 30 CM above ground level) as recommended by manufacturer, vibration pad, sand cushioning around PCC foundation, tools and spares, as provided by manufacturer all as specified and as directed with the following specifications

(A) ENGINE :- Water cooled diesel engine of suitable capacity to match the 30 KVA alternator under NTP conditions with provision of 10% over load for 1 hour in every 12 hours running confirming to BS-5514/ISO-3046. The engine shall consist of following :- (i) Fly wheel (ii)Close coupling (iii) Cooling fan (iv) Radiator with guard and water pump engine mounted (iv) Radiator with guard and water pump engine mounted (v) Battery charging alternator (vi) Air cleaner heavy duty dry (vii) Fuel injection pump (FIP) (viii) Radiator fan(blower type) with guard (ix) Precision governor (mechanical type) (x) Fuel filter (xi) Lubricating oil filters (mounted) (xii) 12 V self regulating alternator belt driven by engine (xiii) Exhaust silencer heavy duty residential type (xiv) Corrosion resister /scale inhabitor (xv) Starter 12 V DC (xvi) Lubricating oil cooler (xvii) Lubricating oil pump ( gear type) (xviii) Exhaust pipeing as per manufecturer design

(B) Control Panel : The Control Panel is manufactured with 14/16 guage CRCA sheet and is powder coated for a weather - proof and long lasting finish. The Control Panel consists of the following parts: (a) S0500 Controller (b) Aluminium Bas Bars with suitable capacity with in/ outgoing terminals (c) Indicating Lamps for'Load On"and 'Set Running' (d) MCCB of suitable rating with overload and short circuit protections.

(viii) Engine protective Functions includes. (a) Configurable alarm output. (b) Emergency stop: Annunciated whenever an emergency stop signal is recieved by the control. (c) Low lube oil pressure warning and shutdown (d) High engine water tempreature warning / shutdown. (e) Low coolant temp warning. (f) Sensor failure indication. (g) Low and high battery voltage warning. (h) Weak battery warning. (j) Fail to start shut down. (k) Cranking lockout: Control will not allow the starter to engage or to crank the running engine. (l) Cyclic cranking: Configurable for the number of starting cycle (1 to 7) and duration of crank and rest periods. (ix) Alternator Protective functions includes (i) High and low AC voltage shut down (ii) Under and over frequency shutdown / warning (iii) Loss of sensing voltage input shutdown

(C) BRUSHLESS ALTERNATOR:- (i) Alternator coupled to engine through a flexible coupling to an indigenous alternator mounted on strong steel fabricated base frame suitable for mounting on a permanent foundation. Brush less alternator shall be confirming to BS- 5000 or relevant of IS-4722 (ii) Type :- self excited self regulated with automatic voltage regulator (iii) Rating:- 30 KVA at 0.8 PF lagging 4 pole horizontal at NTP condition (iv) Speed- 1500 RPM (v) System -415 V + 2.5% AC 3 phase 4 wire 50 Hz. (vi) Connection - 4 wire star connected (vii) Enclosure -Screen projected drip proof (viii) Ventilation - self ventilated (ix) Insulation -Insulation, class H , IP-23

(D) Sub base Fuel tank 14 SWG MS sheet and capacity to hold diesel sufficient for running 08 hours at full load including (i) Level indicator on fuel tank. (ii) Drain plug (iii) Piping for fuel tank as per manufecturer design (iv) Fuel strainer. (v) Air vent, Fuel tank shall be mounted as per manufacturers instruction (b) Battery :as provided by OEM (c) Base plate : fabricated out of MS channels ISMC of suitable size suitable for fixing DG set all as specified by the manufacturers (Necessary permission/ certificate from Central State pollution Control Board shall be accomplished with DG set) CPCB IV

(E) AMF PANEL OUTDOOR TYPE: The AMF Panel Outdoor type suitable for 30 KVA DG Set factory made out of CRCA Steel 3 mm thick Sheet floor mounted type and front operated type, totally enclosed dust, damp and vermin proof, all doors and joints will be suitable gasketed to form dust and vermin proof. The panel would be powder coated minium thickness of 50 microns, stove enameled paint finished after elaborate pretreatment to form a long lasting characteristic. The control panel will be complete in all respect with fuses, wiring and labels etc, the following will be incorporated in the AMF Panel :-

(1)Main Switchgear (a)4P MCCB 25KA,63A-01 No (b) 80A-100A FP (HID 1) Spreader Link 01 No. (2)Main Controlgear (a) 63A FP AC1 230VAC(MCX-12) Contactor-01 No (b)2NO+2NC (MNX-9-80-/-MCX-01-23) AUX. CONTACT BLOCK-01 No (3) MAINS METERING (a) Indicating Lamp R,Y&B 240 V AC -03 Nos. (b)4SQ.MM. BLACK DIN TYPE CONNECTOR- 01No (c)4SQ.MM. FUSE-SCREW-CLAMP-TERMINAL CONNECTOR- 03No (4) DGSWITCHGEAR (a) 63A FP 25KA TMD 415VAC (HID1) MCCB-01No. (b)80A-100A FP (HID 1) SPREADER LINK- 01No (5) DG CONTROLGEAR (a)63A FP AC1 230VAC (MCX-12) CONTACTOR- 01No (b)2NO+2NC (MNX-9-80-/-MCX-01-23) AUX. CONTACT BLOCK-01 No (6) DG METERING (a) Indicating Lamp R,Y&B 240 V AC -03 Nos. (b)4SQ.MM. BLACK DIN TYPE CONNECTOR- 01No (c)4SQ.MM. FUSE-SCREW-CLAMP-TERMINAL CONNECTOR- 03No. (7) Common Metering. (a) Indicating Lamp R,Y&B 240 V AC -03 Nos. (b)4SQ.MM. BLACK DIN TYPE CONNECTOR- 01No (c)4SQ.MM. FUSE-SCREW-CLAMP-TERMINAL CONNECTOR- 03No

NOTE FOR SERIAL ITEM NO 1.00 & 2.00 On completion the DG sets shall be tested to he entire satisfation of the Engineer-in-Charge. All testing facilities and fuel shall be provided by the contractor. The following test shall be carried out :- (A) Polarity Test - A test shall be carried out to ensure that the all equipments are connected to the correct phase or neutral or live conductor of supply. (B) Resistance to earth continuity test - Maximum continuity resistance tested with continuity tester of low Ohm meter from any point in the installation including earth continuity conductor and earth lead to earth plate shall not exceed 1.00hm., (C) Earth test - Effectiveness of earth shall be tested with an earth-tester., (D) Load test on Generator - The generating set shall be tested in presence of the representative of the Accepting officer for a period of twelve hours by various load test ass under. Fuel consumption and efficiency shall be calculated. (i) For first hour at 25% of full load, (ii) For second hour at 50% of full load, (iii) For third hour at 75% of full load, (iv) For forth to tenth hour at 100% of full load, (v) For tenth to ten and half hour at 110% of full load, (vi) For ten and half hour to twelth hour at 100% of full load.

Material and labour for earthing complete with GI earth plate electrode 600x600x6mm' buried directly in ground with top edge of the plate not less than 1.5 mts below normal ground level' and connected to earth test point by means of 32x6 mm GI strip all as specified and shown in electric plate No 3 including earthwork' PCC chamber , CI cover, protection and watering pipe, funnel, mesh etc all as required at sitecomplete all as specified and directed.

Supply, laying and testing in repair LT cable XLPE Insulated ,screened, PVC bedded, galvanized steel strip or wire armoured, electric power cables (heavy duty) 1100 Volts grade with stranded aluminium conductor of size 50 sq mm 3.5 core complete all as specified and directed.

Supply, laying and testing in repair LT cable XLPE Insulated ,screened, PVC bedded, galvanized steel strip or wire armoured, electric power cables (heavy duty) 1100 Volts grade with stranded aluminium conductor of size 150 sq mm 3.5 core complete all as specified and directed.

Excavation in trenches in soft/loose soil not exceeding 1.5 metre wide and not exceeding 1.5 metre depth including getting out for laying of cable complete all as specified and directed.

Returning filling in including spreading, leveling ,and well ramming, in layers not exceeding 25 cm each layer of any kind of soil.complete all as specified and directed.

Removing surplus excavated material from site not exceeding 50 metre from starting point and depositing where directed at level not exceeding 1.5 metre above the starting point complete all as specified and directed..

Material and labour for sand filling in-trenches with clean dry sand unwashed including gently pruning around cables complete all as specified. Note:-Punned thickness to be measured for payment.complete all as specified and directed.

Supply & Laying only un-reinforced Precast concrete cable cover of class LV type 1 flat size 250 mm x 150 mm x 40mm for protection for cable complete all as specified and as directed.complete all as specified and directed.

Dismantling of DG Set of capacity 200 KVA and make greaves(Location-3004Sqn,AF Stn Naliya) from foundation & transporting of Engine to work shop for complete servicing,repair & overhauling.Dismantling the engine complete by taking out exhaustpipes, fuel pipes, HP pipes, intake manifold, hoses, cyl heads, injectors,torbo and other related accessories, CR bearing, connecting rod, piston, piston ring, cylinder liner, lube oil pump, gears, flywheel, crankshaft. camshaft, tappetradiator,pump assembly,casing top cover,head assembly etc for complete overhauling of engine and repair/replacement of unserviceable/wornout parts i.e. piston(04nos),piston ring(04Nos),cyl liners(04Nos),turbocharger(01No), pre filter element(01 no),sec filt element(01No), lube oil filter(01No), fuel filter element(01No), micro filter(01No), cogged belt(02Nos), set of hoses(01No), oil sensor(01No), water sensor(01No), con rod brg set(04Nos), gasket cyl head(04Nos), set of gasket(01No), A V mounting(04Nos), seal valve stem(08Nos), main bearing(05Nos), connecting rod bush(04Nos), set of O ring(01No), coolent addetive(05ltrs), lube oil 15W40(20Ltrs), delivery valve(04Nos), wire harness(01No), engine oil pressure gauge(01No), fuel pipe(02Nos), leak of pipe(01No), fuel off solenoid 24V(01No), washer thrust top(02nos), washer thrust bottom(02Nos), water temp switch(01No), valve guide(08Nos), LOP switch(01No), connecting rod(02Nos), pipe FIP oil supply(01No), pipe turbo drain(01No), water pump assy(01No), valve inlet(04Nos), valve exhaust(04Nos), valve collet(16Nos), seat insert valve inl(04Nos), seat insert valve exh(04Nos), seal oil flywheel(01No), seal oil gear end(01No), element filter(FIP element)(04Nos), banjo bolt(04Nos), nozzle(04Nos), crank shaft assy(01No). etc complete including oiling,greasing and servicing of all the parts of DG Sets also incl cyl head repairing, connecting rod bush fitting & twist checking, crank shaft grinding, fuel pump calibration, radiator servicing, welding & repairing and reassembling complete and testing DG Sets for proper functioning,transportation of DG Sets to its site to its original position including connecting all incoming and outgoing cables and its on load testing complete all as per specification and satisfaction of Engineer-in-charge. Note : (i) Testing of DG set on site to be carried out by contractor for 100% load for one hour and 110% load for one hour. (ii) Contractor shall make arrangement for fuel and testing arrangement at his own cost.

Material and labour for repairing to alternator complete overhauling & servicing of the alternator 3 phase 4 wire 420 Volts AC Alternator coupled with prime mover, dismantling from prime mover and transporting to workshop for rewinding incl repair/ replacement of unserviceable parts, rewinding and assembling complete and testing for DG set of capacity 200 KVA complete all as specified and directed

Supply and fix in repair Lead Acid batteries for DG Sets(DC power supply) of 150Ah,12 volt Make :- Exide/Amaron or equivalent make as approved by GE.

Supply and fix in replacement of AVR ranging 50-110 volt DC for excitation with adjustable screws suitable for DG Set of capacity 200 KVA complete all as specified directed.

Material and labour for repair/replacement control wiring of AMF panel ofexisting specifications and size of DG Set 200 KVA complete all as specified directed.

Supply and fix in repair of battery charger of 10 Amps for 24 Volt Battery complete all as specified and directed.

Supply and fix in repair testing of new self starter of DG set of capacity 200 KVA complete all as specified directed.

Natwadia Electrical Company (BID ID -3369054)

shivam electricals and engneers (BID ID -3372574)

S R ENTERPRISES (BID ID -3372050)