REPLACEMENT AND RENEWAL OF CERTAIN DG SETS AGAINST BER AT INHS ASVINI, COLABA, MUMBAI

Amount

Dismantling of old unserviceable DG set of capacity 1000KVA with cooling tower with connected accessories, exhaust system and diesel distribution system including existing fuel tank and fuel supply lines etc along with other connected item from INHS ASVINI power house and depositing to the desired location all as specified and as directed by Engineer-in-charge.

Dismantling of old U/S bus trunking from DG set to existing AMF Panels along with other connected item from INHS ASVINI power house and depositing at location all as specified and as directed by Engineer-in-charge.

Supply,Installation,Testing and Commissioning of 650 KVA DG Set complete,415V,50Hz AC with acoustic enclosure,automatic starting on main failure (AMF)as per CPCB-IV Norms directly coupled to alternator brushless type, Electronic AVR and Governor,Voltage regulation±1% complete with Std control panel having all type of meters ,fuel tank of capacity 990 Ltrs(Additional Tank to Achieve this capacity is to be provided), fuel line system,suitable foundation,etc all as per the specifications given below, all as specified and as directed by Engineer-in-charge.

Supply,Installation,Testing and Commissioning of 750 KVA DG Set complete,415V,50Hz AC with acoustic enclosure,automatic starting on main failure (AMF)as per CPCB-IV Norms directly coupled to alternator brushless type, Electronic AVR and Governor,Voltage regulation±1% complete with Std control panel having all type of meters ,fuel tank of capacity 990 Ltrs(Additional Tank to Achieve this capacity is to be provided, fuel line system,suitable foundation,etc all as per the specifications given below, all as specified and as directed by Engineer-in-charge.

Technical specification and connected Items required for Item No. 03 and 04 here-in above:- DIESEL ENGINE: Diesel engine having minimum output as per capacity mentioned above with prime rated power as per ISO8528/1, speed 1500 RPM, six cylinders with turbocharged and air to air cooled,closed circuit radiator cooled cooling system, electric starting system with 24 volt DC electric starting motor,electronic governor,full automatic electronic fuel injection system with electronic governing having ECM system for perfect control of fuel and air ratio having protections LLOP ,HWT,low coolant level,high canopy temperature,engine over speed,engine overload,etc with following items like in built fuel tank of approx capacity as mentioned above,tropical radiator with cooling fan,after cooler,lub oil cooler,turbo charger,fresh water pump,electronic fuel injecting pump,24volt DC electric starting motor,dry type air filter,double bowl fuel filter, spin-on-type lube oil filter all as per the recommendations of manufacturer. ALTERNATOR:Alternator of rating as per capacity mentioned above,415voltAC,3phase,4wire system on 50Hz frequency and speed 1500 RPM at power factor 0.8(Lag) having class"H" insulation for both rotor and stator with IP23 screen protected,drip proof and conforms to BS5000,IS4722 and IEC34 standards and brush less, self excited, self regulated excitation and suitable for a permissible over load of 10% for one hour in 12hrs test run and all as per the recommendations of the manufacturer and all as specified and as directed by Engr-in-charge.

DG ENGINE CONTROL PANEL : Supply, Fabricate, install, test and commissioning PCC 3.3/PSO 602 (or any other controller having equivalent features as per OEM recommendations) Engine, AMF & synchronising controller with the below basic features Amp Sentry™ protection - for true alternator over current protection. • Genset monitoring - Monitors status of all critical engine and alternator functions. Genset battery monitoring system to sense and warn against a weak battery condition. • Configurable for single or three phase AC metering Digital Power Transfer Control (AMF) provides load transfer operation in open transition, closed transition, or soft (ramping) transfer modes. • Utility/AC Bus metering and protection Alternator data - Voltage (single or three phase line-to-line and line-to neutral) - Current (single or three phase) - kW, KVAR, power factor, KVA (three phase and total) - Frequency Utility/AC bus data Engine data - Starting battery voltage - Engine speed - Engine temperature - Engine oil pressure - Engine oil temperature complete all as specified and as directed by Engineer-in-charge.

AMF Circuit System. i) Micro Processor based generator control and monitoring unit with AMF logic suitable for either to operate automatic or manual control for starting and stopping of the engine with necessary indications. ii) AMF logic is suitable for programming different parameters at site. Iii) AMF Logic will be suitable for the following functions also: a) Switch the load to the engine supply after suitable time delay, after starting the engine on mains failure/phase failure/low voltage/high voltage etc. b) Switch the load back to the mains supply after suitable time delay when healthy mains supply is restored and stopping the engine. c) Attempt to start the engine up to three times on failure of earlier attempts with suitable time intervals.

ACOUSTIC ENCLOSURE : Acoustic enclosure shall be type tested & conforming to CPCB-IV norms as per requirements of the CPCB(Central Pollution Control Board),approved by ARAI the nodal agency of CPCB for low noise level less than 75dB (A),at a distance of 1 Meter from acoustic wall in free field conditions along with following specifications. (i)The temperature difference between ambient and air inlet at air cleaner within the enclosure shall be well within 5-7 degree centigrade,after installing Acoustic enclosure assembly. (ii)Integral fuel tank shall be provided with drain plug, air vent, inlet and outlet connections,fuel level indicator and provision for cleaning. (iii) Integrated DG Control Panel fabricated out of 16SWG CRCA sheet installed inside the Acoustic enclosure of the DG Set. (iv)Acoustic enclosure shall be weather proof,natural cooled, powder coated and fabricated out of 16 SWG CRCA MS Sheet. The canopy shall be of nut bolt type construction. The Punching of the sheet metal shall be done on CNC machines to maintain dimensional accuracy. (v)PU grade suitable Coloured Powder coating shall be done after seven tank-surface preparation process for sheet metal. Canopy shall be powder coated with polypropylene powder for longevity of colour. (vi)Canopy panel and doors shall have inside lining of FIRE RETARDANT MINERAL WOOL as acoustic material. Four hinged doors shall be provided with canopy, one door shall have glass window for control panel. (vii) LED lighting system for illumination of canopy on opening of doors of DG Set. (vii)The hot chamber of the canopy shall be properly insulated by mineral wool and Aluminum foil to prevent excess heat radiation. Specially designed supporting ribs/structure to be used to give sturdiness and reduce vibration. (viii)The Silencer shall be mounted outside the canopy. (ix)Externally accessible emergency stop button shall be provided to stop DG Sets as and when needed. (x)The exhaust gases will be taken out through suitable stainless steel flexible pipe to prevent back pressure on the engine. (xi)Removable lifting hooks shall be provided. (xii)Rope catchers shall also to be provided on the roof top,so that there will be no damage to canopy while loading/unloading and all as per the direction of the engr-in-charge.

ACCESSORIES TO BE PROVIDED WITH EACH DG SETS: The following accessories shall be provided with each DG set:- (i)Residential type Exhaust Silencer (ii)Stainless Steel Bellows (iii)24V/32Ah Integral Battery with SMPS Charger having DC Voltmeter, DC Ammeter and control fuse protection for both DC and AC circuits with copper leads for each DG set (iv)Integral Fuel Tank plus aditional tank to achieve 990L capacity. (v)03 Nos Current Transformers for Alternator Output 10/5Amp Class 1 for metering (vi) First Fill Lub Oil & Pre-Mixed Coolant for engine. (viii) Tools (ix) radiator, coolant pump, etc CIVIL WORKS :- Civil Work for the DG Sets new foundations, LT Panel foundations, structure foundations, auxiliaries foundation, angle support,including modification of existing DG foundation and cleaning,gas cutting of bolts,plates and clear the debris from the site. NOTE :- (i) All civil works not specified above, if required to be under taken for technical requirement are also deemed to be included in the quoted rate. (ii) Any other works required over and above as specified above for satisfactory completion of the entire works will be carried out without any extra cost.

Note applicable to Item NO. 3 & 4 here-in above : (i)The DG panel and AMF panel shall be complete with internal wiring with suitable size of multi stranded copper cable. The control and relays of various panels are included in the scope of these items. (ii)Tools shall be supplied as per manufacturer's instructions and cost shall deemed to be included in the cost of DG set (iii)Necessary grouting including mild steel work and anti vibration pad shall be provided by the contractor, (iv)Cost of all control cables other than mentioned in the schedule/first filling of lubricants/engine oil/radiator coolant/diesel for 12 HR testing including 10% overloading for one hour in twelve hours duration by saltwater or artificial load bank at site for load test shall deemed to be included in the rate quoted for the item (v)Necessary modification to existing RCC foundation and new foundation for one DG set including connected works for installation of DG Set shall be provided as per manufacturer's recommend ratio on existing foundation and cost deemed to be included in the rate quoted for item No.3, (vi)Necessary 10% overload test shall be carried out in the presence of the Engr-in-Charge/IEM, (vii)The contractor shall carry out all electrical incoming/outgoing connection of cables /busbar trunking including cable glands,thimbles,nut,bolt,washers,etc and with aluminum bus duct,etc. (viii)The rate of loading /unloading/transporting to the site carefully by using crane and truck /installing at INHS Asvini powerhouse/testing and commissioning shall deemed to be included in the unit rate including fuel for testing. (ix)Any damage found while loading/unloading/transporting/installing,the contractor shall replace the same without any extra cost all as specified and as directed by Engineer-in-Charge. (x) Double compression copper stain less steel/brass with chromium plated gland for fixing armoured cable in panel shall be provided at each termination point of cable.

The ACBs shall have following features: (a) Motorized with 230 V A.C. motor. (b) 230 V AC closing coil (c) 440 V Under Voltage coil (d) 24V DC Shunt trip coil (e) Draw out type with "service", "test", "isolated" position indicator with Micro switch. (f) Safety shutter of Fibre glass/polycarbonate sheet of 2mm thickness shall be provided (g) Mechanically trip free plus anti-pumping feature is to be provided. (h) Electrical trip free plus anti pumping shall be provided with relay ONLY and not by contactors. (j) Electrical/Mechanical operation counter shall be provided. (k) Door interlock with defeat features to be provided. (l) ACB shall be lockable in isolation position. Release: (a) Microprocessor release with IEC 61850 communication protocol LSIG with Digital display of Current, power & voltage parameter & shall be direct acting type, tripping ACB mechanically. (b) Short circuit, overload and earth fault protection shall be provided. (c) Vendor to suggest release type for feeders of supply range characteristic and accuracy.

Design, supply, installation, commissioning and testing of factory made, CPRI/ERDA type tested, indoor, cubical compartmental type "LT Panel for Power house DG set control panel for Auto/Manual starting of DG set with aluminium bus bar of suitable thickness and width for carrying rated current of 2500A main bus bar suitable fixed to panel with suitable insulator at suitable intervals having both sides openable with hinged double doors & locking arrangements and IP 42 protection made out of 2.00 mm thick mild steel CRCA sheet, supported and fixed on structural frame of angle iron of suitable size, including earthing stud, labeling, painting to all internal & external exposed steel surfaces with powder coating paint (7 Tank process), duly fixed in existing cable trench, with danger notice plate of 1.6 mm thick mild steel sheet, vitreous enameled (white) with letters figures and conventional skull and bones in signal red colour, suitable for 3 - phase 4 wire system, 500 V grade with single line indication of busbar on the front side necessary control wiring with PVC sheathed stranded copper conductor of appropriate length & size, including fixing lugs, bolts, screws etc. complete all as specified and directed.

The main LT panel consists of the following parts : (A) Incoming (i) ACB 1600A, 50KA, EDO Type,microprocessor based LSIG release with digital LED display of parameters such as Current, power & Voltage, Ics=Icu=Icw(1s)=50kA. -02 Nos. (Incomer from Transformers) (ii) ACB 1600A, 50KA, EDO Type,microprocessor based LSIG release with digital LED display of parameters such as Current, power & Voltage, Ics=Icu=Icw(1s)=50kA. -01 No (Incomer from DG Set of 750KVA) (ii) ACB 2000A, 50KA, EDO Type,microprocessor based LSIG release with digital LED display of parameters such as Current, power & Voltage, Ics=Icu=Icw(1s)=50kA. - 01 Nos. (Incomer from synchronizing panel of 2x650KVA DG Set) Note:- Incomer ACB of transformer & DG Sets to be provided with AMF logic & necessary interlock and Auto/manual switching system with push /button arrangement. (B) BUS COUPLER (i) ACB 2000A, 4P, 50KA, EDO Type, microprocessor based LSIG release with digital LED display of parameters such as Current, power & Voltage, Ics=Icu=Icw(1s)=50kA - 01 No. (Bus coupler to be provided with necessary mechanical and electrical interlock with the incomer ACBs.) (C )Outgoing:- (i) ACB 4P, 1600A, 50KA, EDO Type,microprocessor based LSIG release with digital LED display of parameters such as Current, power & Voltage, Ics=Icu=Icw(1s)=50kA -02 Nos. (For AC PLANT) (ii) MCCB 4P 250 Amp, 25KA, Ics=Icu=100% adjustable type – 02 Nos.

Note (i) :- (a) Enclosure shalll be made out of 14 SWG CRCA sheet and partition shall be made out of 16 SWG CRCA sheet Panel shall be front and back openable compartment type. b) Cost quoted should include for connecting existing outgoing cable with proper lugs and heavy duty terminal blocks and aluminium bus bar of suitable size. c) Cost quoted should include indication of circuit name of suitable size for every outgoing. d) Cost quoted should include maintain colour coding of all bus bars as per IE rules and insulator be fixed at regular interval of 300mm. e) Contractor should show submit layout of total panel, panel should be symmetric and getting approved from Engineer-in-Charge before installation. f) Every breaker and circuit should be indicated by on/off indication lamps. g) Microprocessor Board system to be developed for total control of DG SET side panel in Manual/ Auto mode. h) Each ACB shall have separately powered individual fault trip indication LED (For Overload short circuit, earth fault). j) Care has to be taken to provide cable chamber. Note (ii) :- a) Rate quoted should include for connecting existing outgoing cable with proper lugs and heavy duty terminal blocks and aluminium bus bar of suitable size. b) Rate quoted should include indication of circuit name of suitable size for every outgoing. c) Rate quoted should include maintain colour coding of all bus bars as per IE rules and insulator be fixed at regular interval of 300mm. (d) Double compression copper stain less steel/brass with chromium plated gland for fixing armoured cable in panel shall be provided at each termination point of cable.

Supply and fixing cable termination box with suitable busbar arrangement suitable for 650 KVA to 750 KVA DG sets with all accessories complete all as specified and directed.

Dismantling and taking down carefully part of LT panels for item No. 6 above consisting of AMF Panel, Main LT Panel and DG Set control panel and Bus Coupler panel complete with busbar, ACB's/MCCB's/Switch fuse units/ Startor's Metering system by disconnecting electric supply etc and depositing at site where directed complete all as specified and as directed by Engineer in Charge.

Fabrication,supply,installation,testing and commissioning of exhaust system with"B"Class MS exhaust pipe of following sizes,5mm thick,including providing smooth bends,flanges,gaskets,fasteners. The work includes provision of single line exhaust pipe extension for leaving exhaust gas of each DG set from silencer to atmosphere for the three DG sets from silencer outlet including necessary welding works and supporting with suitable size MC, angle iron 50mmX50mmX6mm, suitable size flange,MS flat,nut bolt and washers as required including making necessary scaffolding works for installation of the system and suitable size weather cowl/rain guard shall be provided on top of the exhaust pipe. The work includes provision of removable type vertical support of exhaust pipe from floor with 75mmX40mm"C"channel and two coat of heat resistive aluminum paint over a coat of suitable heavy duty primer on entire exhaust pipe and all as per the direction of the engr-in-charge. NOTE : (i) The angle iron, MC, MS flat, etc shall be measured and paid separately.

300mm dia

250mm dia

200mm dia

M&L for heat insulation 75mm thick to the exhaust piping and the silencers by using 100kg/m3 light resin bonded rock wool mattress (LRB mattress) up to the outer side of the wall including necessary welding works with 24SWG aluminium sheet,cladding works with wire mesh and aluminum foil, all as specified and as directed by Engr-in-charge.

Fabrication,supply,installation,testing and commissioning of radiator hot air outlet ducting from acoustic front end with 16SWGGIsheet for outer sheet and 24SWG40% perforated GI sheet for inner sheet mounted in a sturdy frame of size 50mmX50mm GI square tube 16SWGGP and 16SWGGIsheet,suitable flanges including provision of inspection door and providing suitable heat insulating materials for an approximate size2750mmX3400mmX2000mm in WXHXD for each DG set including cutting the existing floor/wall/window and making good to disturbed surface matching to the existing specifications and all as per the direction of the Engr-in-charge. NOTE only measurments will be made for the outer side dimensions b) DIMENSIONS PROVIDED ARE APPROXIMATE AND CONTRACTOR HAS TO PROVIDE AS PER ACTUAL DIMENSIONS OF THE DG SET

Supply and installation of factory-fabricated fixed blade type ,air cutting ,mild steel louvers of 230 mm depth with 45 degree inclination, bird mesh at rear, painted with red oxide primer and enamel top coat,. Louvers shall have a front surface area of 50% more than the hot air exhaust opening of the DG enclosure . Size and quantity as per site layout and airflow requirement complete all as specified and directed. Note:- 1. The louvers to be provided at hot air exhaust as well as fresh air inlet. The item to be measured as per actual surface area. 2. The cutting of wall/window/ventilators and making good the disturbed surface matching to the existing specification is inclusive of quoted rates.

Supply and installation of 18" AXIAL FLOW FAN DUCT/WALL MOUNTING WITH 0.5HP/1440RPM,3PH. MOTOR (Note: MPCB and 3Ph starter to be mounted in the LV Panel spare space above bus coupler or genset control compartment in main LT panel. The exhaust fan shall start automatically on starting of the DG set with PLC provided at Gen control panel.

Supply and fixing PVC FRLS Armoured copper multistranded control cable of following sizes single run,ISI marked including thimble,"D"clamps,etc and suitable for the connection of control panel of engine safety system and DG set complete all as specified and as directed by Engr-in-charge. Note :- Double compression copper stain less steel/brass with chromium plated gland for fixing armoured cable in panel shall be provided at each termination point of cable.

12CORE X 2.5 sqmm

4CORE X 2.5 sqmm

3CORE X 2.5 sqmm

2CORE X 2.5 sqmm

2CORE X 1 sqmm (shielded cable)

Supplying, installation, testing and commissioning of 2000A, 433V, 50Hz, 50kA for 1 Sec 3P+N-100%+PE Sandwich type Aluminium Busbar system as per IEC60439-1/2 connecting from 2X 650KVA synchronising Panel to incomer ACB in LV Panel including necessary insulation and connections at terminations. Outer casing of system consists of four C-ribbed section bars, bordered and riveted with excellent mechanical, electrical and heat loss efficiency. The sheet metal is made of hot galvenized steel 1.5mm thick having degree of protection IP55. The busbar conductor have a rectangular corss-section with rounded corner, Aluminium alloy with Tin Plating. The Insulation between the bars is ensured by a douoble sheath made of polyester film Class B. The junction contact is ensured for each phase, insulated with class F thermosetting plastic material. Enclosure is painted with RAL7035 resins with a high resistance to chemical agents with Copper Flexible Braid Connection, Horizantal Bracket, Vertical Bracket, flange ends and all mounting accessories. including flexible expansion bellows and 2000A rated copper flexible at one end of the BUSDUCT.

Supply and fixing XLPE insulated Armoured Aluminum conductor cable of sizes 400 Sqmm x 1 Core single run suitable for 1.1 KV grade with ISI mark conforming to IS:7098(Part I) with latest amendments including thimble,"D"clamps,etc and suitable for the connection complete all as specified and as directed by Engr-in-charge. Note :- Double compression copper stain less steel/brass with chromium plated gland for fixing armoured cable in panel shall be provided at each termination point of cable.

M&L for Chemical earthing complete with copper plate 90cm x 60cm x 5mm thick electrode, buried directly in ground (earth pit not less than 2.25m deep below ground level) with top edge of the plate not less than 1.5m below normal ground level, connected to 50 x 6mm copper strip as earthing lead, by means of bolts, buts, check nuts and washers of galvanized iron or steel, galvanized iron pipe of 40mm diameter, connected to earthing test point, all as shown in electrical plate No. 3 connected to earthing test point all as specified or indicated including testing on completion and including excavation, earthwork, PCC earth pit of dimensions 550 mm x 550 mm (outer) and 300 mm x 300 mm (inner) and 250 mm deep, with a 10 mm thick CI cover, hinged to CI frame on ground level, GI watering pipe, funnel etc. as all specified and directed.

Material & labour for Copper strip of size 32mm x 6mm as earth lead fixed to wall on batten or recess or chases or buried in ground or drawn in conduit/pipe or fixed to poles or any other indicated situation for loop earthing etc complete all as specified and directed.

M & L for earthing complete with galvanized steel earth plate electrode of 60cm x 60cm x 6mm size, burried directly in ground (earth pit not less than 2.25m deep below ground level) with top edge of the plate not less than 1.5m below normal ground level,connected to galvanised strip of size 32mm x 6mm as earth lead, by means of bolts, buts, check nuts and washers of galvanised iron or steel, galvanized iron pipe of 40mm diameter, connected to earthing test point all as shown in electrical plate No.3 connected to earthing test point all as specified or indicated including testing on completion and including excavation, earthwork, PCC earth pit of dimensions 550mm x 550mm (outer) and 300mm x 300mm (inner) and 250 mm deep, with a 10mm thik CI cover, hinged to CI frame on ground level, GI watering pipe, funnel etc as all specified and directed.

Material and labour for earth continuity conductor or main earthing strip fixed to wall on batten or recess or chases or buried in ground or drawn in conduit/pipe or fixed with poles or any other indicated situation for loop earthing etc as required using galvanized iron strip of size32mmX6mm including necessary drilling works,jointing,etc complete all as specified and as directed by Engr-in-charge.

Material and Labour for erection of structure steel section with H, I equal angles, cross arms, bracings, supports, clamps and back plates fabricated from structural steel sections for holding Exhaust chimney or any other structural work including nuts, bolts, washers, welding, bending cold or hot, drilling holes for bolts, in any shape or size as indicated or directed and inclusive of one primer coat, one under coat of enamel paint and one finishing coat of enamel paint complete all as specified.

Supply and fixing SS Expansion bellow for exhaust piping of following sizes :-

(a) 250mm dia

(b) 200mm dia

M & L for tubes, 'medium grade', galvanised pipe of dia 25 mm with all fitting; laid in trenches, fixed to walls or laid on floors complete all as specified and directed.

Supply and fixing 25mm bore Ball brass valves, high pressure with polythene float and flynut complete, screwed for iron pipe or brass ferrule and fixed complete all as specified.

Supply, install, testing and commissioning of flame proof ,piston type pump (Fuel Transfer Pump) 2HP, working on 230V capacity, CI body having 430 to 200 LPM discharge and 10.5 to 18 mtr head with suitable size nuts, bolts, washers including PCC foundation or Base frame structure, making electric connections of motors, earth connections with suitable size PVC copper conductor cables including suction pipe 2m with heavy grade PVC flexible connection with foot valves and flexible delivery pipes for delievery of fuel to DG Set of suitable size connections complete all as per manufacturers instructions.

Supply & Fixing modular Plug and Socket enclosure, in sheet metal enclosure with MCB, SP 20 Amps 240 Volts complete with metal clad socket including flush off in wall with cutting and making good the disturbed surface for fuel transfer pump complete all as specified and directed by the Engineer-in-charge.

M & L for tubes, 'light grade', galvanized pipe of dia 40 mm with all fitting; laid in trenches, fixed to walls or laid on floors for earth strip protection/cable passing complete all as specified and directed.

BRITE INDUSTRIES (BID ID -3466116)

AGRAWAL ASSOCIATES (BID ID -3466831)

Vijaypower Generators Limited (BID ID -3467167)

United Sales Corporation (BID ID -3464874)

rvelectricals (BID ID -3472054)