Upgradation by P/F Installation, Testing and Commissioning of Star Delta FASD including protection relay for 3 Nos. 100 HP motor along with recapitalization of electromechanical equipments at LIS Talwara

Design, Fabrication, Installation, testing and commissioning of auto starter cum fault analyzer cum protection and control panel suitable for 100 HP unit no I , II & III installed at LIS Talwara involving fabrication of power handling unit/Fully Automatic Star Delta Starter comprising of 250 amp 3- pole MCCB of suitable breaking capacity, 1No. Main contactor of 185 Amp capacity, 1No. Delta Contactor of 185 Amp capacity and 1 No. Star Contactor of 140 Amp. capacity of reputed/standard make with an arrangement of incoming and outgoing supply lines. The system should be provided with solid state fault analyzer cum controller. The complete system should be enclosed in a floor mounted MS sheet enclosure/box of suitable gauge and dimensions which should follow IS standards and should have proper entry and exit holes for incoming and outgoing cables. The enclosure should be finished with powder coated painting from inside as well as the outer surface with approved colour. Job also includes mounting of the panel to the floor of the pump room by using MS angles. Further the enclosure should be front shutter mounted with key locking system having glass/fibre window digital electronic voltmeter and digital ampere meter which are to be provided along with required current transformers and selector switches. The internal control wiring should be done with flexible PVC LT cable with proper thimbling at each end. FEATURES AND SPECIFICATIONS: The system should trip the motor on power failure and on appearance of any electrical fault mentioned below which may otherwise damage the motor field coils and should not restart automatically until unless the system is reset manually, thus providing automation to the system and protection to the motor. The System/Star Delta auto starter should not fall into delta if it does not fall into star mode first and should remain de-energised to avoid damage to the motor/machinery and also to the power source/transformer. The system/star delta auto starter should trip off if does not fall into delta and remains in star mode for more than 10-20 seconds. The system should provide protection against: Low voltage (below 350V), High voltage (above 450V), Single phasing, Reverse phasing, Un balanced phasing, Dry running, Overloading. In addition the system shall have: Separate LED fault indicators, LED phase indicators, an isolation by pass system with a blinking indicator, a siren/audio warning system which activates on starter failure only to trip the motor on appearance of any electrical fault mentioned above to warn the operator to switch off the motor manually, 03 LED contactor ‘COIL OK’ indicators one for each of the contactors/coils. LED star and delta indicators to access the star to delta timing and tamper proof starting system to avoid manipulations by the motor operator to keep the system in a permanently ON position. Bimetal overload relay: A bimetal over load relay of suitable range should be fitted with in the starter as an extra protection to protect the motor in case of failure of fault analyzer with an isolation/bye pass switch to bye pass the fault analyzer. Dismantling 100 HP motor of unit no I from base frame and disconnecting all the electrical connections, decoupling of motor from pump at LIS Talwara. Taking the motor out of the pump house, carriage to roadside with the help of tools, tackles & manual labour through hilly terrain. Loading in mechanical transport, for shifting to workshop and carriage back after conducting necessary repairs. Dismantling of the motor by way of unscrewing of nuts/bolts and then extraction of rotor from the stator extracting out old damaged/burnt copper winding from the stator. Initial cleaning, washing of rotor and stator with clean fresh water and then drying up. Cleaning the slots of stator with appropriate chemical cleanser. Complete rewinding of the stator with providing/winding and fitting of new copper wires of requisite gauge and specifications. Providing and fitting of new F class insulation, packing material. Varnishing the stator winding with superior quality varnish and drying the stator winding completely. Providing/Fitting of bearings nos.6318/C3 to driving as well as to the non driving end of the motor as per sample. Reassembling the motor with the help of nuts/bolts/screws after inserting rotor inside the stator of the motor and checking the continuity of each phase. Refitting/installation of 100 HP motor of unit no. I on the base frame and coupling it with pump and making all the electrical connections by way of providing, fitting & crimping of new aluminium thimbles. Dismantling of 3.5 cusec, 48m head split casing pump of pumping unit no. I from the base frame at LIS Talwara after decoupling it from motor, taking out impeller shaft assembly after dismantling of pump body. The job involves complete dismantling of bearings from the bearing housing. Cleaning all components like impeller shaft assembly bearing housings, gland bushes, rings, pump body, top cover etc. thoroughly with abundant fresh water and thereafter appropriate solvents to remove silt, mud and rust etc. Providing/fitting of 2 no. new bearings at both NDE and DE as per the given sample. Reassembling/refitting of the pump components and closing the top cover by P/F of new nuts, bolts, studs, washers, rubber/paper sheet and gland packing along with greasing. Reinstalling on the base frame by providing / fitting of new nuts, washers etc. Coupling with motor after providing and fitting of coupling tyre, coupling bolts-06 nos. along with rubber bush as per sample and checking for alignment. Repair to 200mm dia foot valve of Unit-I, Unit-II and Unit-III at LIS Talwara. Dismantling of the foot valves from the flange joints by way of opening/cutting of rusted nuts and bolts and fishing out the foot valves from the river Chenab. Similarly dismantling of the suction pipe pieces from the flange joints and extracting them out. Shifting of the dismantled foot valves and suction pipe pieces near the pump room by deploying manual labour and using tools / tackles. Dismantling of foot valves and replacing the leather sheets (cut to size), flap mechanism with hinge pin, rubber sheet for flanges with required nuts and bolts. Job also includes cleaning/servicing of the suction pipes to remove silt, mud etc from inside and outside using appropriate tools and tackles like crow bars, MS rods etc. Washing the pipes thoroughly with abundant water and thereafter with appropriate chemicals. Drying up the pipes. Job also includes carrying out repairs by way of welding works near the dislodged flange rims and damaged portions of the suction pipes with good quality electrodes. Re-assembling and fitting the suction pipe pieces to foot valves and refitting them back respectively to their pumping units by providing/fitting of required nuts, bolts, rubber flange joints etc. Providing, Installation, testing and commissioning of 2HP three phase mono block priming pump unit to replace the existing damaged priming pump set installed at the LIS Talwara. The Pumping unit shall be of standard/reputed make. The Monoblock priming pump shall be mounted on suitable M.S angle frame and properly anchored. Job includes providing and fitting of suitable insulated copper cable with MCCB of appropriate rating required as per site condition for running of the priming pump. The Job also includes fitting of Monoblock priming pump with existing 40mm and 50mm dia pipes / valves by providing/fitting of suitable reducers etc. Repair / Recapitalization, servicing of Main Reflux valve 400mm dia installed on rising main at LIS Talwara by way of unfastening of rusted/damaged studs/nuts and bolts, opening of bonnet cover, extraction of damaged disc assembly. Checking for any cracks removing of any foreign material deposited inside the body by scrubbing, washing etc. then cleaning with appropriate solvent. Providing, fabrication and fitting of complete disc assembly and then refitting on the bonnet cover by providing/fitting of new rubber joint, studs, nuts and bolts as per site requirement. Job further includes repair/service to sluice valve 150mm Dia of unit no. I by way of extraction of stem rod with nut, opening of body seat ring, ring for flap, gland bracket with gland stud/nut and proper cleaning of parts with clean water/appropriate solvent. Replacement of bolts, nuts & rubber gaskets. Reassembling and refitting of the sluice valve. Providing/Fitting of gland packing and proper lubrication. Job further involves repairs/servicing/cleaning to 150mmdia Reflux Valve / NRV of Unit no. I by way of extraction of hinged flapped disc, nuts, bolts, washers, gasket and cleaning with clean water/appropriate solvent and then replacing of gaskets and rubber seals followed by reassembling back to original assembly. The job also involves carrying out repairs to all these valves by way of welding works near the dislodged flange rims and damaged portions (if any) of the valve body with good quality welding electrodes. The entire work includes cost of material, skilled and unskilled labour charges, transportation charges, design, testing and commissioning charges on full load (if any / as applicable), headload charges up to the site of work keeping in view the difficult hilly terrain between the road side and the pump room, hire charges of tools and tackles required for the job inclusive of all taxes as applicable and rebate on old parts. Complete Job