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SYARIKAT SESCO BERHAD

GENERAL SPECIFICATION

TENDER REF.: LAW01/12/PAT TITLE: TENDER FOR REPLACEMENT INCLUSIVE

OF SUPPLY, DELIVERY, DISMANTLE EXISTING BATTERIES, INSTALL, TESTING & COMMISSIONING 2 BANKS OF 110V DC BATTERY, 1 SET OF 110V BATTERY CHARGER AND 1 SET OF 110V BATTERY CHARGER AND 1 SET DC SWITCHBOARD AT MAIN DISTRIBUTION SUBSTATION, LAWAS STATION

CLOSING DATE: 18.07.2012

DISTRICT ENGINEER SYARIKAT SESCO BERHAD P.O. BOX 64 98857 LAWAS SARAWAK

LAW01/12/PAT

TENDER FOR REPLACEMENT INCLUSIVE OF SUPPLY, DELIVERY, DISMANTLE EXISTING BATTERIES, INSTALL, TESTING & COMMISSIONING 2 BANKS OF 110V DC BATTERY, 1 SET OF 110V BATTERY CHARGER AND 1 SET OF 110V

BATTERY CHARGER AND 1 SET DC SWITCHBOARD AT MAIN DISTRIBUTION SUBSTATION, LAWAS STATION

INSTRUCTIONS TO PERSON TENDERING

1. This tender must be registered with the Unit Pendaftaran Kontrator of Malaysia (UPK)

under Supplies & Service, Head II, Subhead 5(b)(iii). The tenderer should provide evidence on the registration of his Company with UPK by the attachment certified true copy of the relevant document with his tender submission.

2. The tender must be submitted using original tender document purchased from Syarikat

SESCO Berhad at the cost of RM 80.00. 3. All cells are to be supplied under wet and fully charged conditions unless stated

otherwise. 4. All inter-cell connectors, cables jumpers fitted with end lugs etc. to make up a complete

bank of battery chall be included at no additional cost. 5. One accessory box complete with one set of maintenance tools and accessories shall be

provided to the bank of battery under this contract. 6. Any deviations from specifications must be clearly stated by the tenderer in the tender

submission (i.e. in schedule 3) 7. The following are also to be submitted with the quotation, failing which their offer with

not be considered: i) Full technical particulars with catalogues, brochures and clear digrams ii) The relevant drawing showing the rack construction and dimentions of the battery

shelf/rack iii) Agency appointment and support letter, Bumiputra status certificate (if

applicable) and UPK registration certificate iv) Test report and sales record for offered product v) Model no., brand/make and country of origin of all offered items clearly stated.

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8. The Tenderer must be made on the accompanying Form of Tender with all the blanks therein and all the Schedules of Rates duly filled in ink and signed. Tender rates must include all incidental and contingent expenses.

9. No alteration is to be made in the Form of Tender or in the Schedules thereto except in

filling up the blanks as directed. If any such alterations are made or if these instructions are not fully complied with, the Tender may be rejected. Any amendments must be accompanied with the tenderer’s authorised signature and the Company’s stamp. If these instructions were not fully complied with, the tender shall be rejected.

10. Incomplete tender submission will be rejected. 11. The Tenderer, however is at liberty to add any further details that he may deem desirable

and, in the event of his so doing, must print or type such details and annex the added matter to the tender submitted by him. Such additional details shall not be binding upon the Company unless they are approved by the Company and incorporated in the contract.

12. If the Tenderer has any doubts as to the meaning of any portion of the General

Conditions or of the Specifications, he shall when submitting his tender, set out in his covering letter, the interpretation on which he relies.

13. The Tenderer is to submit with his tender in order of the relevant clauses, a statement of

any departures from the Specifications. 14. The rates offered in the tender should be without consideration of the details/departures

from the Specifications. If there is addition or deduction of the tender rates by virtue of the Company adopting those details/departures, then such additional/reduced sum should be stated in the annexed documents.

15. The Tender amount or rates will be held to include for the completion of all Works

indicated in the drawings or in the Specification and no claim will be entertained on the grounds of lack of knowledge of conditions at any time during the Contract period.

16. The Company will not be responsible for any expenses or losses, which may be incurred

by any Tenderer in the preparation of his tender.

17. For local tenders with estimated tender sum of above RM 2,000,000.00, the amount of Bid Bond/ Earnest Money, required to accompany the tender, shall be 2% of the tender sum subject to a maximum of RM 100,000.00 (Ringgit Malaysia One Hundred Thousand). Bid Bond shall be either in the form of Banker's Guarantee or Bank Draft/ Cashier Order. Bank Draft shall be issued by a bank licensed to operate in Malaysia. Banker’s Guarantee shall be issued in accordance with the Company’s standard format (Form PUR/4) by a bank licensed to operate in Malaysia or such other format as approved by the Company.

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18. All contracts exceeding RM 50,000.00 (Ringgit Malaysia Fifty Thousand) must include a

Performance Bond for 10% of the contract sum. The Performance Bond shall be either in the form of Banker's Guarantee or Bank Draft/ Cashier Order. Bank Draft shall be issued by a bank licensed to operate in Malaysia. Whereas, a Banker’s Guarantee shall be issued in an acceptable format similar to the sample format (Form PUR/5) by a bank licensed to operate in Malaysia. The Performance Bond shall be irrevocable and valid for the duration of the contract period including the defect liability/ maintenance period, if any. Within 21 days from the date of our letter of acceptance of your offer, the successful Tenderer will be required to furnish the necessary Performance Bond to the Company failing which the successful Tenderer will deem to have withdrawn from the offer and Clause 14 as stated below shall be imposed.

19. If the Tenderer withdraws or modifies his tender during the bid validity period or after having been awarded the contract, the Company shall impose the following sanctions:

• Bid Bond shall be forfeited. • Where there is no Bid Bond involved, the following penalties will be imposed:

i. 20% loading of the tender prices shall be imposed on all of the Tenderer’s future

tenders’ submission for a period of two consecutive years for the 1st offence.

ii. Barring the Tenderer from tendering for a period of three consecutive years for the 2nd offence.

iii. For any subsequent offence, the Tenderer, whether participating in his own name or

using a company as a guise or using non-participating partners of shareholders in any company whatsoever shall not be allowed to participate in any future tenders and his name and/or the offending company shall be permanently struck off from the Company’s Contractor/ Supplier Register.

20. The tender must remain valid and open for acceptance for a period of Six (6) months

from the closing date of the tender.

21. This contract is a ONE-OFF contract and shall be for duration of three (6) months and may be extended if the delay is caused by reason of any industrial dispute or any cause beyond the reasonable control of the Contractor arising after the acceptance of the tender, the Contractor shall have been delayed or impeded in the completion of the Works, whether such delay or impediment occur before or after the time (if any) or extended time

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fixed for completion, provided that the Contractor shall without delay have given to the Company notice in writing of his claim for an extension of time, the Company shall on receipt of such notice grant the Contractor from time to time in writing either prospectively or retrospectively such extension of the time fixed by the Contract for the completion of the Works as may be reasonable.

22. Bumiputra Tenderers are required to submit certified copies of Trade Registrations showing the proportion of Bumiputra participation in the companies and the names of the directors of the companies.

23. The Tenderer shall supply evidence to show the competence to undertake the works specified together with details of competent staff, which is to be provided by completing Schedule B.

24. When the Tenderer intends to employ more competent staff, this should be separately mentioned in the Schedule.

25. The tender marked "Confidential" is to be submitted in a sealed envelope which shall be clearly marked " TENDER FOR REPLACEMENT INCLUSIVE OF SUPPLY, DELIVERY, DISMANTLE EXISTING BATTERIES, INSTALL, TESTING & COMMISSIONING 2 BANKS OF 110V DC BATTERY, 1 SET OF 110V BATTERY CHARGER AND 1 SET OF 110V BATTERY CHARGER AND 1 SET DC SWITCHBOARD AT MAIN DISTRIBUTION SUBSTATION, LAWAS STATION" but shall bear no writing on the outside of the envelope which would enable the Tenderer to be identified. The sealed envelope shall be addressed to:

The Regional Manager (Northern Region) , Syarikat SESCO Berhad, Pujut 1 Road, 98000 Miri. Sarawak. Or hand on delivered to:

The Office-In-Charge, Tender Box, 2nd Floor, Syarikat SESCO Berhad, Regional Office, Miri Sarawak

On or before 3 p.m. on 18 July 2012 (Wednesday).

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26. Tenders received prior to the time of opening will be securely kept unopened. Tenders received after the time of opening will be rejected. The Company shall not be held responsible for premature opening of tenders not properly addressed or identified.

27. The Company does not bind itself to accept the lowest of any tender, nor assign any reason for the rejection of any tender.

28. The tender or any Tenderer who has not conformed with the foregoing instructions may not be considered.

29. The official currency for this Contract shall be the Ringgit Malaysia (RM) and all rates and prices shall be quoted in this currency.

30. Tenderers who require clarification of the tender document may contact the Company through:

The Regional Manager (Northern Region) ,

Syarikat SESCO Berhad, Pujut 1 Road, 98000 Miri. Sarawak.

And noted for the Attention of the District Engineer (Lawas) at Telephone No. 085-283697 during office hours.

LAW01/12/PAT

TENDER FOR REPLACEMENT INCLUSIVE OF SUPPLY, DELIVERY, DISMANTLE EXISTING BATTERIES, INSTALL, TESTING & COMMISSIONING 2 BANKS OF 110V DC BATTERY, 1 SET OF 110V BATTERY CHARGER AND 1 SET OF 110V


SPECIFICATIONS A

1. Scope of Work

The scope of work for this tender are as such, Location: Main Distribution Substation, Lawas: i. Dismantle the existing 2 banks (87 cells per bank) 110V 112 Ah batteries and 1 set of

110V battery charger, inclusive delivery of the dismantled battery and charger to SESCO’s Lawas Office.

ii. Complete supply, delivery, installation and commissioning of 2 banks battery (86 cells per bank) 110 V 184 Ah batteries at Main Distribution Substation

iii. Complete supply, delivery, installation and commissioning of 1 set of charger (dual bank), DC switchboard and cable connection to the new DC system inclusive supply and laying of new cable if required at Main Distribution Substation.

2. Extent of Contract

This contract also provides for all parts of the work to be completed in every respect for the commercial operation to the requirements of the Engineer. Notwithstanding that any details, accessories, etc required for the complete installation and satisfactory operation of the Plant are not specifically mentioned in this specification, such details shall be considered as included in the tender price.

The Tenderer are deemed to have visited the site before preparing his tender to ascertain the local condition under which the works will be carried out and also to satisfy himself regarding existing plant/equiprnent and the availability of all labour, contractor plants, materials and other items necessary for the execution of the work. He shall collect for himself any data and information that he may require, responsibility to ascertain transportation and to complete the works to meet the commissioning date as scheduled.

This Contract does not include overhead line, major civil works like building foundation, etc. however, minor repair work such as extension of Charger plinth, repair of damaged trenches, holes, covers, etc are to be deemed included in the contract sum.

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3. Tools and Appliances

All necessary tools and appliances shall be supplied under this Contract and the cost of these is deemed to be included in the Contract Price.

4. Compliance With Specification

Notwithstanding any descriptions, drawing or illustration which may have been submitted with the Tender, all details other than those shown on the Schedule of Departures will be deemed to be in accordance with the Specification and the standard specifications and codes referred to therein. Any case of doubts should be referred to the Engineer for his decision.

5. Drawing

Before the works is put in hand, dimension drawings and diagrams showing all details of the plant and materials to be used shall be submitted to the Engineer for approval. No wiring or connection diagrams shall be submitted for approval unless prior approval has been obtained for schematic diagrams. which is to include AC protection schematics, showing the facilities being provided and the working of the schemes. Wiring and connection diagrams are to be supplied for information only.

6. Programme of Work

The Contractor shall forward a copy of a chart detailing erection programme for the complete contract work to the Engineer for his comment or approval. The Contractor must take into account and make provision to anticipate of the weather conditions such as raining days. No excuse will be granted for any extension of the completion time for any or such reasons.

7. Galvanized Work

All materials to be galvanized are to be of the full dimensions shown or specified and all punching, cutting. drilling. screw tapping and the removal of burns are to be completed before the galvanizing process commences,

8. Small Wiring

Claws washers or crimped connectors shall be used to terminate all small wiring. Insulating, bushing are to be provided where necessary to prevent the chafing of wires.

All panel wiring is to conform to B.S.6231 and to be B voltage grade. The conductors are to have a minimum cross section equivalent to 50/0.25mm (2.5sq.mm), 7/0.67mm (25sq.mm) or 1/1.78mm (1.5sq.mm). Wire colours are to comply with B.S.158, viz:

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Red Red phase connections in VT. and C.T. circuits only Yellow Yellow phase connections in V.T. and C.T. circuits only. Blue Blue phase connections in V.T. and C.T. circuits only. Green Connections to earth. Black A.C. neutral connections, earthed or unearthed, connected to the

secondary circuits of V.Ts and C.Ts A.C. connections other than those above and connections in A.C./D.C. circuits.

Grey Connections in D.C. circuits.

Wiring diagrams must indicate wire colours. All diagrams are to be drawn as viewed from the back of the panel arid musts state the highest number used in any group.

All control panel wiring is to comprise conductors with a minimum cross section of 2.5 sq mm but single stranded conductors should only be employed for rigid connections, which are not subject to movement or vibration during shipment, operation or maintenance.

All wires are to be fitted with numbered ferrules of approved type at each termination. At points of interconnection between wiring, where a change of numbering cannot be avoided, double ferrules shall be provided. Such points shall be clearly indicated on the wiring diagram.

The ferrules on all wiring directly connected to circuit breaker trip coils, tripping switches, etc. shall be coloured red and marked “TRIP”. No wires may be teed or jointed between terminal points.

Electrical wiring and instruments shall be so located that leakage of oil or water cannot affect them.

Bus wiring between control panel, etc. shall be fully insulated and be completely segregated from the main panel wiring.

All metalic cases of instruments, relays, etc. mounted on control panels or cubicles, steel or otherwise, are to be connected by means of bare copper conductor of not less than 3.5 sq.mm section of the nearest earth bar.

All accessories such as cable tie, numbered ferrules, etc. shall be purchase and supply by the contractor.

9. Cable Termination Completed

Where used in this specification in relation to cables, the terms “termination complete” and “ terminating complete” refer to the work in making off the cables in glands/cable boxes/sealing ends, fitting lugs to individual cores, connection these lugs to the appropriate terminals, and insulating the terminal with approved insulating tapes or bushing. Where appropriate it also includes attaching numbered/lettered ferrules to the individual cores for identification purposes.

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10. Safety Regulations

The Contractor shall be in respect of all his employees in site conform to a standard of safety as high as, or higher than, the adopted by the Employer in respect of employees engaged in similar work.

The Contractor shall observe and comply with any Safety Regulations enforced by the Employer who is responsible for operation of the existing electrical system.

Where a shutdown of existing system is required to enable work to proceed, reasonable notice shall be given to the Engineer and the Employer and a programme agreed. Before works commence, a Permit to Work shall be issued by the Employer to a representative of the Contractor, such person to be agreed with the Engineer as being a responsible person. The recipient of a Permit to Work shall be satisfy himself that the Employer has made the equipment to be worked on dead, locked off any isolators, switches, or circuits breakers from which such equipment may he energised, posted any necessary warning notices and earthed the equipment in an approval manner. The Contractor shall also be responsible for staffs under control observing the limitations of access stated on the Permit and shall ensure that such staffs are fully informed of the areas covered by the permit. He shall also be responsible for informing all staff (including Employer’s and Engineer’s staff) employed on work covered by Permit, when the Permit has been cancelled. Any equipment or section or line not included in the Permit shall be considered to be live and be roped off and Danger Notices posted in prominent positions. Access to the work zone shall along and only along.

11. Earthing Systems

11.1Earthing Systems

The frames of all electrical apparatus and structural steelwork shall be connected by branches of the same cross sectional area to this main bar. Structure and supports forming a 3-phase set may be earthed in groups using a separate branch connection to each item of the group with a single subsidiary connection to the main earth bar. The copper strip must support on the steel structure by means of brass clamp such that no copper strip shall be become in contact with the steel members.

Isolator and earthing-switch operation mechanisms and circuit breaker control kiosks not integral with the circuit breakers shall be connected to the earth system by a branch entirely separate from that employed for earthing the isolator or earthing switch bays of the circuit-breaker structure.

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11.2Earthing Conductors

Conductors for interconnection between the electrodes in any group and between groups shall have a cross sectional area if 150 sq.mm and there shall be at least two such connections from each electrode group to a link chamber. Conductors for connection between the link chambers and stations earthing main bars shall have a cross sectional area of 150 sq.mm and there shall be at least two such connections.

There shall be two separate connections between the neutral points of the high voltage systems and the link chamber for the earthing electrodes and these shall each have a cross-sectional area of 150 sq.mm.

11.3Jointing and Bonding

Connections to plant and equipment shall be made using the earthing terminals specified. Joints in carthing strip shall have the surface cleaned and tinned and shall be riveted with copper rivets (not less than four 3mm rivets per joint) and then soldered.

12. Documentation

11.1Tender Submission

Tender submission shall be accompanied by the following documents: a. Technical leaflets/write-up for battery together with the charging and

discharging characteristics. b. Preliminary control drawings or chargers and distribution board. c. Preliminary drawings for dimension and layout of panels/cubicle including

foundation drawings. d. Experience list of battery, chargers and distribution switchboard in

manufacturer(s).

11.2Final Document The successful tenderrer shall bind all information, manuals, drawings into a booklet to form a final documents. This document shall contain the following: a. Technical leaflets/write-up for battery and charger inclusive of charging and

discharging characteristics, commissioning, instruction and maintenance manuals. etc.

b. As—built control drawings for charger s(inclusive of internal circuit diagrams) and distribution board.

c. As built drawings for dimension and layout of panels/cubicles and including foundation drawing.

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d. Parts list of all components used in the charger system. e. Trouble shooting list.

Four copies of this final document shall be provided for the battery system.

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TENDER FOR REPLACEMENT INCLUSIVE OF SUPPLY, DELIVERY, DISMANTLE

EXISTING BATTERIES, INSTALL, TESTING & COMMISSIONING 2 BANKS OF 110V DC BATTERY, 1 SET OF 110V BATTERY CHARGER AND 1 SET OF 110V


SPECIFICATIONS B

EXTENT OF CONTRACT This contract also provides for all parts of the work to be completed in every respect for the commercial operation to the requirements of the Engineer. Notwithstanding that any details, accessories, etc required for the complete installation and satisfactory operation of the Plant are not specifically mentioned in this specification, such details shall be considered as included in the tender price. The Tenderer are deemed to have visited the site before preparing his tender to ascertain the local condition under which the works will be carried out and also to satisfy himself regarding existing plant/equipment and the availability of all labour, contractor plants, materials and other items necessary for the execution of the work. He shall collect for himself any data and information that he may require, responsibility to ascertain transportation and to complete the works to meet the commissioning date as scheduled. This Contract does not include overhead line, major civil works like building foundation, etc. however, minor repair work such as extension of Charger plinth. repair of damaged trenches, holes, covers, etc arc to be deemed included in the contract sum. GENERAL REQUIREMENT OF THE BATTERY This tender requirement is for the supply and delivery of 2 banks of I IOV battery (86 cells per bank), complete with electrolyte solution, shelf/rack and accessories. The Nickel Cadmium alkaline batteries shall be of pocket plat type, constructed to withstand severe mechanical shock and vibration. The batteries are intended to meet the high rate discharge performance and the self discharge rate on open circuit shall be negligible. The batteries shall be of the high performance nickel cadmium pocket plate type complying with IEC.623:1978 and shall be designed for a life expectancy in excess of 20 years under conditions of service likely to be encountered by the equipment detailed in this Specification. The electrolyte shall be free from impurities and the Potassium Hydroxide used shall comply with BS 5634. Dilution of alkaline electrolyte and topping up of cells shall carried out using distilled water only.

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Battery cases shall be of high impact translucent plastic. The manufacturer’s company logo & name, battery, type, year & month of manufacture and max. & min. electrolyte level lines shall be permanently imprinted on the sides of containers. The rate of discharge shall be Type M with capacity not less than 184Ah for 110 V DC battery respectively. 2.1 System Specification The standard voltage shall be 1 l0V DC. The nominal voltage shall be 1.2V with rated capacity of C5 in AH (ampere-hours). The C5 discharge rate is defined as a single cell that can be deliver at the 5 hrs discharge rate to a final voltage of 1.0V at 20 C after charging , storing and discharging under specified conditions. 2.2 Electrolyte The electrolyte for the Nickel Cadmium battery shall be free from impurities. The solution shall be potassium hydroxide with small amount of lithium hydroxide at standard specific gravity of 1.20 at 20°C. 2.3 Battery Shelf/Rack A shelf/rack for the set of batteries shall be provided in this contract. The relevant drawings showing the rack construction and dimensions must be enclosed together with the tender. 2.4 Maintenance Tools and Accessories One complete set of miscellaneous equipment including the following: (a) One (1) tool box, (b) One (I) syringe hydrometers. (c) One (1) cell-testing voltmeters, (d) Two (2) cell-bridging connectors, (e) Two (2) electrolyte-pouring funnels, (f) Two (2) electrolyte thermometers, (g) Battery instruction card for wall mounting, (h) One (1) electrolyte airtight containers, (i) Tools and other items necessary for the erection and correct functioning and maintenance

of the equipment shall be provided. (j) Suitable containers shall be provided for making up electrolyte. The following criteria shall be adopted and the calculations shall observe fully the requirements of the IEC Publications:

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- the rating of each battery shall be on the basis as specified and subject to adjustment after Award of Contract such that when charged to 80% of rated capacity at the start of the duties. it shall be sufficient to supply the demands of the substation. with the charger disconnected;

- at the end of this duties the battery voltage shall not have dropped such that the voltage at

the battery terminals tills bclow 90% of the nominal system voltage when supplying the standing load;

- in addition the voltages at the terminals of all components in the system (e.g relays, trip

and closing coils) shall not be outside of the individual voltage limits applying to them. All quantities used in estimating the battery capacity shall be stated but shall not be used for ordering materials until specifically approved by the Engineer. The electrolyte capacity and general design of the batteries shall be such that inspection and maintenance, including topping up of the electrolyte, shall be at intervals of not less than twelve (12) months. 2.5 Battery Mounting Connections and Accessories Batteries shall be mounted in double tiers in framed timber stands of robust construction. The stands shall he treated with electrolyte resisting enamels or gloss paint and any metal fittings shall be located so that they will not be exposed to corrosion. The cells shall be arranged in the tiers so that each cell is readily accessible for test and inspection and electrolyte level in each cell is visible. The stands shall be mounted on insulated medium and dimension such that the bottom of the lower tier is not less than 300mm above the floor. Batteries shall be supplied and erected and complete with all necessary connections and cabling. Connections between tiers, between end cells and to the Charger shall be 35rnm2 Single Core Copper Cable, arranged on suitable racking or supports. Disconnection links shall be provided for each section of the battery at all terminals. Before jointing, joint faces shall be bright metal, free from dirt, and shall be protected by a coating or petroleum jelly. Double pole MCCB shall be provided and positioned as closed to the battery as possible and shall be rated for at least three time the maximum battery discharge current at the highest operating voltage. The MCCB shall be mounted on the opposite ends of the battery stand or rack in an approved design MCCB box. Warning labels shall be fitted to warn personnel of the danger of removing or replacing a fuse whilst the load is connected and that fuses should not be removed immediately following boost charge due to possible ignition of hydrogen gas.

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It shall not be possible to leave the battery disconnected (by means of switches or removal or operation of fuses) without some local and remote indication that such a state exists. One set of miscellaneous equipment including one syringe hydrometers, one cell- testing voltmeters, two cell-bridging connectors, two electrolyte-pouring funnels, two electrolyte thermometer, battery instruction card for wall mounting, electrolyte airtight containers, labels, tools and other items necessary for the erection and correct functioning and maintenance of the equipment shall be provided. Suitable containers shall be provided for making up electrolyte. A complete set of test and maintenance accessories suitably boxed, shall be provided for each battery. A syringe hydrometer and a durable instruction card shall be included in each set. 2.6 Condition on Delivery of Battery Cells The battery cells shall be delivered in filled and discharged conditions with 100% excess electrolyte for copping up. The battery shall be properly sealed by using suitable plugs to prevent the spilling of electrolyte during transportation. Where there is a shipping restriction for the transportation of completely filled cells, then the approval from the Engineer is required to consent to shipping the cells at its dry/empty state. 3.0 GENERAL REQUIREMENT OF BATTERY CHARGER 3.1 General 3.1 .1 Microprocessor Rectifier Type of Charger Shall Be Used. The charger input supply shall be single phase 240V, 50Hz with rated current output of 35A. The mode of control shall be ‘Thyristor-controlled’. It shall be operational under the local warm and humid environment. Each battery charging equipment shall comply with the requirements of BS.4417;1969 (lEc’1461973) shall be of the thyristor automatic constant voltage type with current limit facilities controlled, associated with a microprocessor used to pilot the system. and shall be suitable for supplying the normal constant load and at the same time maintaining the battery to which it is connected in a fully charged condition while floating across the load and charger. Arrangement shall be made such that in the event of the battery becoming discharged during AC supply failure, the rate at which recharging commences is as high as possible consistent which maintaining the automatic charging constant voltage feature and with the connections remaining undisturbed as for normal service. Each charger shall also incorporate a boost charge feature which shall, after having been started, provide an automatically controlled high charge rate sufficient to restore a fully discharged battery to the fully charged state within twelve hours without excessive gassing or any form of

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damage to the battery. The boost charge shall be initiated manually. A timer shall be provided to switch the charger to the float condition after the correct recharge time. Each charger shall operate satisfactorily within the permitted tolerances for a.c. supply voltage variations of plus or minus 10% and frequency variation from 49Hz to 51Hz. The design of the charger shall be such that it will operate satisfactorily from this supply without harm to itself, the battery or any equipment connected to D.C. auxiliary supply system. Although it is not intended that the charger be operated with the battery disconnected, the design of the charger shall, nevertheless, be such that with the battery disconnected the charger will maintain the nominal system voltage as previously specified without any damage to itself and the ripple shall not exceed 10% rms of the no load output voltage. Each charger shall also be capable of sustaining without damage to itself, a continuous permanent short circuit across its output terminals. Should the a.c. supply fail while a battery is on boost charge the switching arrangements shall automatically revert the charger float charge status and then reconnect the battery to the distribution board. 3.1.2 Batteries Chargers Alarm Devices Each battery charger shall be equipped with the following: i) Charge fail detection equipment to give local indication and remote alarm if the voltage

from the charger fails below a preset level which will be lower than the nominal float charge voltage. Suitable blocking diodes shall be provided to prevent the battery voltage being supplied to the equipment and so prevent charge fail detection. The device shall not operate on switching surges or transient loss of voltage due to faults on the a.c. system. The voltage at which the alarm operates shall be adjustable for operation over a range to be approved by the Engineer.

ii) Rectifier fuse operation detection equipment to give local indication and remote alarm of diode/thyristor and surge circuit protection fuse operation. Provision of “Local Indication” by lamps on the front of the charger cubicle and provision for “Remote Alarm” by changeover contacts rated at 5A for voltages between 30 and 250V a.c. or d.c. on the devices to energise a group alarm relay.

3.1.1 Batteries Charger Instrumentation and Controls Each charger shall also he capable of sustaining without damage to itself, a continuous permanent short-circuit across its output terminals. The use of fuses, MCB’s or other similar devices will be acceptable in meeting this requirements. In addition, each charger shall be provided with the following facilities:

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(i) a) Metering LCD Panel AC Mains Voltage Charger DC Output Voltage Charger DC Output Current Load DC Voltage Load DC Current Battery Current

b) Alarms LCD Panel Text alarm Battery High Voltage

Battery Low Voltage Charger Failed Charger a.c. voltage high Charger ac. voltage lows Charger ac. failed Charger Current High Charger rectifier fuse blown Charger capacitor fuse blown Earth fault + Earth fault - Load Voltage high Load Voltage low

c) Remote Alarm 1 set of Voltage free contact as

follows: • All alarms • Charger fail • Battery output Voltage low • Etc as per specified

d) Control Boost Charging Manual On/Off

Automatic, Time Return to Float selectable 0-99h Periodic, Selectable 1, 6, 12 months interval

Commissioning Charge Separate Current Limit Setting Float Charge Manually Selectable

Automatic Return

Current Limit Adjustable 0-100%

Charge method Constant Current/Constant Voltage I/U as per IEC 478-I

Trip Charger Fail

High DC Voltage AC mains failure

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d) Monitoring High Rate Time Remaining History Log

e) Status Indicators - Red/Green-on/off indicating lamps for AC Main - Red Light — system fault - Green Light — system healthy

f) Display Control Three menu-driven membrance keys below

LCD screen g) Protocol IEC 60870-5-103 Software shall be provided and included in the Contract Prices, Supervisory alarm and control shall be connected to I 1 kV Bus Section Bay Computer for DSCS monitoring. ii) Earth Fault Relay

A battery earth fault detecting relay which will centre tap earth the 30V systems via a high resistance shall be incorporated in the distribution panel. Each device shall have local visual indication for the station control panel alarm indication.

(iii) Current Limiting Circuit A ‘slow-start’ circuit to protect the mains circuit against high inrush current when the charger is switched on after prolonged mains failure or heavy discharge which causes the battery voltage to fall below the pre-set value. The charger shall operate at the maximum current output not exceeding 125 per cent of the rated output to restore the voltage to the pre-set value. Constant voltage charging shall recommence automatically when the battery voltage reaches the pre-set value. The current limit setting shall be adjustable down to 80 per cent rated output. The charger shall maintain the above constant voltage and current limiting characteristics whether the battery is connected or not.

(iv) Manual Control

The chargers shall be provided with an automatic/manual selector switch and the facility by O which the output voltage can be adjusted when on manual control. Boost charging shall be only be switched On/Off using manual, and automatically return to Float Charge Mode after a selectable time period.

Current limit shall be adjustable 0-100%. Charging method is as per LEC 478-1 using constant current/constant voltage (I/U).

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(v) Alarm Facilities

Fuses for capacitors, silicon diodes or silicon controlled rectifiers shall be equipped with trip indicator fuses to initiate an alarm indication on operation. The alarm equipment shall include lamps to indicate the individual alarm conditions shown below: - Charger AC volts high Charger AC volts low Charger AC failed Charger rectifier fuse blown Charger capacitor fuse blown

The Charger AC volts low’ alarm shall be prevented from operating when the AC supply fails. The Charger AC failed’ alarm shall operate in the event of the failure of any phase or when the charger is switched off

Charger Output Battery Voltmeters with Changeover Switch Charger DC Load Ammeter Centre Zero Battery Charge/Discharge Ammeter with spring return switch AC supply MCB. A link- shall be provided in the supply neutral Boost Charge indicating lamp (amber) Float/Boost Switch

4.0 GENERAL REQUIREMENT OF DC SWITCHBOARD The distribution switchboard shall be mounted adjacent to the charger control panel and shall be of the cubicle type. The exterior finish and colour of the panels shall be semi gloss deep cream to BS 382C equivalent. No equipment associated with the chargers shall be installed in the distribution board. Distribution panel shall incorporated double pole switches and fuses for the incoming DC supplying from the charger and the batteries connections. The panel shall be provided with the voltmeters and centre zero ammeter on each incoming battery section circuit. A battery earth fault detecting relay which will centre tap the 30V system via a high resistance shall be incorporate iii the distribution panel. It shall have two indicating lamps with testing facilities. The battery low voltage detecting device for the 30V system shall be incorporated in the distribution panel. No volt relays will not be accepted for these device. The voltage setting shall be adjustable over an approval range. Battery fault relay and low voltage devices shall each have three alarm contacts, one for local visual annunciation, one for station control panel alarm indication and one for audible alarm. Under voltage detection equipment to give local indication, and remote telecontrol alarms when the system voltage falls below 80% (adjustable) of’ the system voltage. A time delay shall

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incorporated to prevent initiation during temporary voltage drops caused by transient conditions including circuit-breaker closing operations The above under voltage detection equipment shall also initiate a local and supervisory alarm powered by a sealed nickel cadmium battery capable of sounding continuous alarm for 30 minutes. The local alarm shall be controlled by the substation Attended/Unattended selector switch. 240V float charge and functional check facilities shall be provided. Earth leakage detection equipment to give indication and remote alarm of the occurrence of an earth fault and to give discrimination between positive pole and negative pole earth faults. These circuit shall be incorporate to simulate positive and negative faults by operation of test push buttons. Over voltage detection equipment to give local indication and remote alarm when the d.c. voltage rises more than 5% above the normal automatic float voltage. A time delay shall be incorporated to prevent operation when a battery with high open circuit voltage is switched from the boost to float condition. Connection between the battery and the distribution cubicle shall be made in PVC insulated cable as required. Cable Laid in runs where it may be subjected to damage shall be protected by wire armoring be sheathed overall as be cleated to the wall as required. Cable boxes or gland shall be provided as appropriate for all incoming and outgoing circuits of the distribution board and the charger. Each circuit shall be fully labeled. 5.0 DC CABLING Single core cables shall be used for the connection between battery and chargers. The same applies for the bulk supply like DC board to switchgear. For low loads (individual supply) two core cables may be used. Further requirements, as specified under GTS have to be considered. PVC/PVC steel wire armoured cabling shall be supplied as required to complete the system. The cables shall be sized to suit the loads and due account must be taken of the site ambient conditions and layout with regards to current and voltage drop values. All controls, protection and LV cables will be supplied by Tenderer and shall be included in the quoted price. No straight through joints are allowed. 6.0 CABLE ERECTION

6.1.1 Scope

This Specification covers the erection of high and low voltage cables and their jointing and terminating accessories both indoors and outdoors. It also includes the bonding and earthing of multi-core and single core cables and the excavation, backfilling and temporary reinstatement where cables are laid direct in the ground.

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6.1.2 Support And Racks Cable supports and racks together with fixing clamps, bolts, nuts and screws for outdoor and indoor concrete lined trenches shall be of hot dip galvanized steel. Multi-core cables shall he clamped to the racks with smooth finish split packing pieces or cleats with bores of the correct size for the cable diameters. The cleats shall be of silicon aluminum, glass filled nylon or other tough non-hygroscope material. Single core cables erected in close trefoil 3-phase groups shall be held in position with non- magnetic clamps to the approval of the Engineer.

Cleats used to clamp single core power cables shall be of adequate strength to restain the cables axially and laterally during heat cycling and under short circuits condition.

All cable supports, racks, cleats, trays and sunshades together with all necessary steelworks and fixing materials and construction of sealing end foundations shall be provided and erected by the Contractor and the cost thereof is deemed to be included in the Tender Prices. 6.1.3 Erection of Supports

Rag bolts shall normally be used for the fixing of supports and associated steelworks to masonry.

The fixing of cable supports and associated steelworks to building structural steel works, where approved by the Engineer, shall be done with bolted clamps. Weld gun stud fixing will be allowed subject to the approval in writing of the Engineer on site but the drilling of building structural steelworks shall not be allowed, except in special circumstances and then only with prior permission in writing by the Engineer. 6.1.4 Protection Covers

Cable protective covers shall be or reinforced concrete and, unless otherwise approved shall be one metre long 300mm wide and 50mm thick. They shall be arrange for interlocking one with the other both vertically and laterally. Special covers shall be provided, if required, for short radius bends. All cable protective covers shall meet the requirements of BS 2484. The costs of providing these covers are deemed to be included in the tender cost. 6.1.5 Backfilling And Reinstatement After all cables and protective covers have been laid, the trenches shall be refilled in 150mm layers which shall be well rammed and consolidated. The surface of refilled trenched shall be temporarily reinstated and maintained by the

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Contractor in a thoroughly safe condition until complete consolidation of the soil is achieved. The cost of providing these backfilling and reinstatement are deemed to be included in the tender cost. The Contractor shall supply and back till material necessary for the replacement of unsuitable excavated material and the cost of this material together with the price rates for back filling and reinstatement shall be stated by the Contractor in the Schedules. 6.1.6 Cable Markers The cost of providing markers and identifying ferrules shall he deemed to be included in the rates for cable installation. All power control and telephone type cables shall he provided with identification markers at their termination’s and where the cables are not laid in the ground at points along the route at intervals of not more than 50 metres apart. Markers shall be made of permanent material of an approved type. Cores of solid dielectric and plastic insulated low voltage multi core control cables made off under this contract shall be identified with lettered marking ferrules which shall be made of a permanent materials and shall be of an approved type. 6.1.7 Cable Jointing And Terminating The Contractor shall be wholly responsible for the terminating into sealing ends or marshalling boxes and the jointing of all cables erected under this Contract. Cable sealing and jointing shall be in accordance with the best current practice and of first- class workmanship. The Jointers must possess JBE certificate or equivalent. Where cables sheaths, metallic layers or armour are used as earth continuity conductors, glands shall have the necessary contact surfaces and bonding clamps to provide a low resistance path under fault conditions. It is required that the anti-corrosion sheath be subjected to periodic HV dc integrity tests, the joints and sealing end boxes shall be adequately insulated and the testing facilities shall be installed with the jointing accessories in the manner approved by the Engineer. Where cables terminated into marshalling boxes supplied and installed under this Contract, glanding off and termination shall be carried out under this Contract. 6.1.8 Copper Earthing Connectors The connections between cable bonding terminals and earth shall be of high conductivity annealed copper strip which shall have a cross-sectional area of not less than 150 sq.mm.

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6.1.9 Cost of Bonding The cost of bonding and earthing at all cable terminations and joints shall be deemed to be included in the prices for jointing accessories and jointing. 7.0 INSPECTION AND TESTING 7.1 GENERAL REQUIREMENT The whole of the plant and equipment provided under the Contract shall be subjected to inspection and test by the Employer during erection and on completion. The approval of the results of any such inspection or test shall not prejudice the right of the Employer to reject the Plant if it fails to comply with the Specification when erected or to give complete satisfaction in service, The costs of all tests including the provision of the necessary test equipment whether on site shall be borne by the Contractor and shall be deemed to be included in the Contract Price and Rates. 7.2 SITE TESTS AND COMMISSIONING TEST The Contractor shall be responsible for the submission of all plant for site inspection and tests as required by the Engineer. During the course of erection, the Engineer shall have full access for inspection of the progress of the work and checking workmanship and accuracy as may be required. On completion of the work, prior to commissioning, all equipment shall be tested to the satisfaction of the Engineer to demonstrate that ii is entirely suitable for commercial operation. The Contractor shall provide all equipment necessary to carry out site tests and the cost providing this equipment shall be denied to have been included in the Contract Price. However Battery Load Test Set shall be provided by the Employer. During the course of testing, the Contractor shall be responsible for the safe keeping of the set and also to ensure that the set is in good condition. Site test and commissioning test shall be carried out by the manufacturer’s competent personnel. Before commissioning, all electrical equipment shall be subjected to site tests as deemed necessary by the Engineer. 7.3 REJECTION OF PLANT Any item of plant or component which fails to comply with the requirement of this Specification in any respect whatsoever at any stage, erection or on completion at site may be rejected by the Engineer either in whole or in part as he considers necessary. After adjustment or modification if so directed by the Engineer, the Contractor shall submit the item for further inspection and/or tests.

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Plant or components with defects of such nature that the requirements of this Specification cannot be fulfilled by adjustment or modification shall be replaced by the Contractor at his own expense and to the satisfaction of the Engineer. 7.4 GENERAL TEST REQUIREMENT A programme of tests shall be agreed between the Contractor and the Engineer, and a test programme for all Sites agreed in conjunction with the erection and commissioning programme prepared by the Engineer. Testing shall be carried out during normal working hours as far as is practicable. Tests which involve existing apparatus and outages may be carried out outside normal working hours. The contractor shall give sufficient notice to allow for the necessary outage arrangements to made in conformity with the testing programme. The contractor shall provide the requisite experienced test personnel and all relevant test equipment, unless otherwise agreed by the Engineer or stated in the Scheduled. The Contractor shall record the results of the tests clearly, in an approved form and with clear reference to the equipment and items to which they refer, so that the record can be used as the basis for maintenance tests during the working life of the equipment. The required number of site test result records shall be provided by the Contractor to the Engineer as soon as possible after completion of the tests. 7.4.1 STANDARD AND METHOD The methods of testing. unless otherwise specified in the Schedules, shall be agreed with the Engineer. Details of the test equipment and instrument used shall he noted in the test sheets in cases where the instrument or equipment characteristics can have a bearing on the test results. 7.4.2 Protection, Control, Alarms, Measurements and Indication Equipment 7.4.2.1 Wiring Insulation Resistance Test at 1000V AC for one minute are if possible to be camed out on all protection control alarm and indication circuits to ensure that writing is in satisfactory condition. Static equipment which may be damaged by the application of test voltages shall have the appropriate terminals short-circuited. Inter-relay, inter-unit and cubicle wiring carried out at site is to be checked to the appropriate circuit and/or wiring diagram. This may be done by using bells or buzzers.

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DC supplied from the station battery may also be used. Where it is found necessary during pre commissioning work to effect site modifications to the secondary wiring, site copies of the appropriate schematic and wiring diagrams shall be suitably marked as agreed with the Engineers before the circuit is commissioned. 7.4.2.2 Mechanical Inspection All relays are to be examined to ensure that they are in proper working condition and correctly adjusted, correctly labeled and that the relay case, cover, glass and gaskets are in good order and properly fitting. 7.4.2.3 Primary Injection Primary current injection tests are to be carried out by the Contractor. The primary injection methods employed for a particular installation are to be agreed with the Engineer. Tests are to be carried out as follows: a. Local primary injection to establish the ratio and polarity of current transformers as a

group, care being taken to prove the identify of current transformers of similar ratio. b. Overall primary injection to prove correct interconnection between current

transformer groups and associated relays. c. Fault setting tests to establish the value of current necessary to produce operation of

the relays. These tests are to be carried out by secondary injection applied at the wiring close to the current transformers.

7.4.2.4 DC Operations Tests are to carried out to prove the correctness of all DC polarities, the operating levels of DC relays and the correct functioning of DC relay schemes, selection and control switching, indications and at arms.

7.4.2.5 Busbars and Connectors

Flexible busbar and connections shall be tested to ensure that the correct tensions, sags and clearance will maintained over the range of environmental conditions and loads without stress to other equipment. If dynamometers are used to check the sags and tensions, they shall be checked both before and after use.

Rigid busbars and connections shall be tested to ensure that the busbars will not cause overloading to the supporting insulators under load conditions and under the range of climatic variations applicable to the site, that expansion and contraction of the equipment is fully accommodated by flexible connections.

Conductivity tests are required on all connections and joints which are made on site without exception.

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7.4.2.6 Earthing System

Tests shall be made on the effectiveness of the bonding and earthing which will include conductivity tests on selected joints, on the main earthing system and at the connections to equipment and structures.

Checks shall also be made on precautions taken to avoid corrosion attack on the earthing system. Test of the earth-resistivity shall be carried out. The earth resistance shall be measured during the installation and on completion

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