TECHNICAL SPECIFICATION

FOR

2 X 1010 KVA, 1500 RPM, 415 V DG SETS

INDEX

S. NO. SECTION SUB HEAD PAGE

NO.

1 SECTION - I GENERAL SITE CONDITION 1

2 SECTION - II SCOPE OF WORK 2

3 SECTION - III TECHNICAL SPECIFICATION - DG SETS 3

4 SECTION - IV GUARANTEED TECHNICAL PARTICULARS - DIESEL ENGINE & ALTERNATOR

12

5 SECTION - V TECHNICAL SPECIFICATION - FOR DG AUXILIARY PANEL

15

5 SECTION - VI GUARANTEED TECHNICAL PARTICULARS FOR DG AUXILIARY PANEL

22

6 SECTION - VII

TECHNICAL SPECIFICATION - FOR L.T. BUS DUCT

25

7 SECTION - VIII LIST OF APPROVED MAKES 32

7 SECTION - IX DRAWINGS 34

SECTION – I

GENERAL SITE CONDITIONS

1.0 SITE CONDITIONS

:

- Maximum Ambient temperature : 45 0C - Minimum Ambient temperature : 9 0C - Maximum Relative Humidity : 97% - Minimum Relative Humidity : 30% - Altitude above mean sea level : 1000 mtr - IMPORTANT : ALL MAJOR EQUIPMENTS LIKE ENGINE AND ALTERNATOR SHALL BE DESIGNED FOR OPERATING TEMPERATURE OF 500C FOR ALL PRACTICAL PURPOSES. BIDDERS TO FURNISH THE DERATION CALCULATION AT SITE CONDITIONS MENTIONED ABOVE IN VIEW OF THE SUPPORT FOR THE CAPACITY/SUITABILITY OF THE EQUIPMENTS OFFERED. PLEASE NOTE THAT OFFERS OF THE BIDDERS NOT SUBMITTING THE AFORESAID CALCULATIONS, SHALL NOT BE CONSIDERED.

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SECTION – II

SCOPE OF WORK GENERAL: Design, manufacturing, testing, supply, erection & commissioning of Emergency Generating

Set for prime power output of 1010 KVA at 1500 RPM, 415V + 5%, 3 Phase ,0.8 pf (lag) & 500 C ambient with complete accessories.

3.0 SCOPE OF WORK INCLUDED IN THE CONTRACT :

The scope of work in this tender shall include (but not limited to) Design, Manufacture, supply, inspection before dispatch, delivery at site, installation, testing, commissioning & handing over to CDRI the following :

a. 2 Nos. DG Sets & Accessories of rating 1010 KVA b. DG aux. Panel c. Modification and commissioning in existing DG Control panel. Note:- DG Panel & PLC synchronizing panel is already installed at site and provided with I/C breakers for these new DG’s. DG Panel consists of feeders for 6 nos. of DGs (2 nos. existing 1010KVA, 2 nos. 437.5 KVA & 2 nos. new 1010KVA). However CT’s & meter for 1010KVA feeders are provided with 800/5A rating. These CT’s are to be replaced & modification of control schematic for DG Panel / PLC Panel synchronizing is to be done by supplier of new DG’s. EXCLUSIONS : i. Foundations of DG Sets, cooling towers, pumps, water pumps and trenches, ii. Foundation of Chimney / Stack of 30 meter height. iii. Earthing of DG Sets & Panels.

(However, foundation drawing, earthing layout alongwith size of earth bus to be furnished by contractor.)

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SECTION – III

TECHNICAL SPECIFICATIONS

DIESEL GENERATOR SETS 1. GENERAL

Work covered by this contract shall include design, manufacture, supply, transportation, delivery, installation, testing and commissioning of Diesel Generator Sets and auxiliaries required for prime power generation. The generator set shall consist of a diesel engine directly coupled to an electric generator, together with the necessary control panel, battery, diesel tank etc and accessories to provide prime electric power for the duration of any failure of the normal AC source.

2. STANDARDS The equipment offered shall conform to the latest revision of relevant Indian or British Standard (BSS) as indicated below and Codes together with the requirements of the Local Supply Authority. Engine shall conform to BS 5514/IS:10000 and the alternator shall be in accordance with IS:4722/BS:2613/IEC-34(Part-1).

3. ENGINE AND ACCESSORIES :

3.1 DIESEL ENGINE : Diesel Engine of required bhp, stationary type, four stroke with V cylinder arrangement shall be complete with integral air intake through suitable air filters and exhaust system, speed regulation system, fuel injection system, lube oil system, cooling water system, silencers, self contained piping, instruments, mounted on anti vibration mounts

The engine shall have the following characteristics : Type - Suitable for generating set application, turbo charged, multi-

cylinder, 4-stroke, cold starting. Cycle - Four stroke Speed - 1,500 r.p.m. Method of Starting - Battery

Net site output - This shall be the prime power output (exclusive of the power requirements of auxiliaries deriving power with engines) at 1500 r.p.m. under site conditions.

Overload feature - The engine shall have 10% overload capacity for one hour in every 12 hours of operation.

Engine rating shall be stated in the tender in accordance with the standards above. The engine should comply to CPCB emission guidelines and should be of emission optimized type. The engine shall be installed in area where in it need be operated for long durations. Bidder need to declare the max load factor for prime power continuous duty application.

ACCESSORIES : EXHAUST SYSTEM : Turbocharger Silencers – residential type Stainless Steel Flexible Bellows. COOLING SYSTEM :

- Heat Exchanger - Cooling water centrifugal pump - Bypass Thermostat

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FUEL SYSTEM : - Fuel pump - Fuel injectors - Fuel filter - Fuel hoses - Lube oil pump - Lube oil-priming pump. - Lube oil filter - Bypass filter

INTAKE AIR SYSTEM :

- Air intake manifold - Air cleaner - Vacuum indicator - GOVERNOR : - Electronic EFC - Starting System - 24 V DC Electric starter - Battery Charging Alternator - LUBE OIL SYSTEM :

COUPLING ARRANGEMENT : - Flexible coupling - Flywheel to suit flexible coupling - Flywheel housing

PROTECTION / WARNING

- Engine: - Over Speed Shutdown - Low Lube Oil Pressure Warning /Shutdown - High Coolant Temperature Warning / Shutdown - Low Coolant Level Warning / Shutdown - Low Coolant Temperature Warning - Low And High Battery Voltage Warning - Weak Battery Warning - Dead Battery Shutdown - Over Crank Shutdown - Fail To Crank Shutdown

3.2 Fuel Consumption The engine shall be suitable for satisfactory operation on H.S.D. as locally available. - 3.3 Lubricating Oil Consumption The tenderers shall state the lubricating oil consumption in gm/bhp-hr (ltr/hr) at rated load. 3.4 Governing

The governor shall be Electronic type confirming to Class A1 and shall be a self contained unit capable of monitoring speed.

3.5 Frequency Variation :

The engine speed shall be so maintained that frequency variation at constant load including no load shall remain within band of 1% of rated frequency.

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3.6 Mounting and Foundations The engine and direct coupled alternators shall be rigidly secured to common rigid base frames fabricated from MS sections. The DG set shall be placed on concrete block with anti vibration mountings.

3.7 Exhaust Piping 3.8 Exhaust System

Each engine shall be provided with residential type silencers so as to limit the sound level from the DG set. Exhaust piping shall be fabricated from Class ‘C’ MS Black Pipe conforming to relevant IS standard size suitable to limit back pressure to within permissible limit. The exhaust shall be terminated as per pollution norms. Exhaust piping inside DG room shall be insulated with 75 mm thick mineral wool and 26 gauge Al. cladding. Exhaust piping shall be connected to the engine by means of flexible section or an expansion joint.

3.9 Turbocharger Turbocharger mounted at the side of the engine for better conversion of energy of exhaust gases resulting in more power, improved fuel economy, altitude compensation, lower exhaust temperature, lower smoke and noise level

3.10 Air Filter The engine air intake shall be fitted with dry type air cleaner with vacuum indicator facilitating change of air filter.

3.11 Fuel And Lubricating Oil Filters Filter for fuel and lubricating oil systems shall be of replaceable paper element type. 3.12 Lubricating Oil System

The engine shall be of the totally enclosed type and fitted with a positive pressure system of lubrication to all working parts. Lubricating oil shall be circulated in the engine by an engine driven pump. There shall be no moving part requiring lubrication by hand prior to the starting of the engine or while in operation. It shall be so designed that when the engine starts after a long shut down lubrication failure does not occur. Necessary priming pump for the lub oil circuit shall be installed to keep bearings primed.

3.13 Safety Controls Low Lubricating Oil Pressure

Pressure sensors shall be fitted such that in the event of a fall in the lub oil pressure and indication shall be actuated. In addition, the engine shall be automatically shut down in the event of lub oil pressure dropping to a pre-determined low value.

High Water Temperature An indication shall be given if the water temperature exceeds the safe limits and the shall be shut down when a pre-determined set water temperature is reached.

Over Speed Speed control shall be so arranged that 12-13% increase over normal rated speed shall cut off fuel supply, thus stopping the engine.

3.14 General The DG sets shall be complete with all equipments, indications and controls required for fully reliable and safe operation of the DG sets whether specifically stated in these specifications or not. It is essential that the operation of all protection equipments be completely reliable in all respects.

4.0 Engine Mounted Instruments Panel (Electronic): The flexibly mounted instrument panel on engine shall be complete with the following:

4.1 Digital Display to indicate : • Coolant Temperature • Lub Oil Pressure • Battery voltage • Engine speed • Engine Run hours

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4.2 Engine and alternator protection : The electronic panel will display the fault

codes on the screen so that the necessary action can be taken. It should also provide the engine protection features such as :

• High Coolant Temperature • Over-speed • Low lube oil pressure

4.3 The DG Set shall be supplied with micro-processor based generator

monitoring, metering & protection features like : • Analogue & Digital AC output metering • Battery monitoring system to sense and warn against a weak battery condition. • Digital alarm & status message display • Overload • Overcurrent • Over voltage • Under voltage • Over frequency • Under frequency

5.0 GENERATOR: Synchronous alternator of suitable capacity to generate 1010 KVA output at alternator terminal at 415

V, 50 Hz, 3 Phase, 4 Wire, 0.8 pf (lag) 1500 RPM and in accordance with BS:2613 / IS:4722/IEC-34(Part-I) shall be of totally enclosed or screen protected dip proof and self air-cooled type driven by the Diesel Engine. Generator shall be supplied along with its excitation system, AVR and include all necessary auxiliaries.

A Generator / Alternator shall have following characteristics: • Permissible voltage regulation (max.) in static condition + 0.5% Permissible over load of 10% for

one hour in every 12 hrs. of operation • Permissible voltage & frequency variation of + 0.5% & + 1 % respectively • Alternator shall be provided with QDCTs, RTD & BTD.

B Excitation System: The Generator shall be provided with brush less excitation system capable of supplying the excitation current of the generator under all conditions of output from no load to full load. C Enclosure : Alternator enclosure shall be Screen Protected Drip Proof (SPDP) conforming to IP-23. D Winding : Class ‘H’ Insulation shall be used for stator/rotor winding. E BATTERY : Battery of voltage and capacity compatible with the engine, complete with battery charging equipment shall be provided to energise electric starting equipment. Batteries shall be of lead-acid automotive type. The charging unit shall be part of existing DG control panel. 6 DG Set Accessories 6.1. DESCRIPTION OF WORK Scope of works includes supply, installation, testing & commissioning of following items :-

a) Cooling Tower, Pumps & associated piping. b) Exhaust Piping. c) 360 AH Battery with accessories. d) Any other item not specifically mentioned but required for satisfactory installation,

operation and maintenance of DG Set. 6.2 APPLICABLE CODES, STANARDS AND APPLICABLE PUBLICATIONS

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6.2.1 SUBMITTALS 6.2.1.1 Drawings and Data

a) DG Set layout, showing exhaust piping, typical supporting arrangement for all piping, Cooling Tower Layout.

b) P&I diagram for Cooling System & Fuel oil supply system. 6.2.1.2 Tests and Test Reports

a) Pump performance curves and power consumption with operating points duly indicated shall be submitted and verified at the time of testing and commissioning of the installation.

6.3 SPECIFICATIONS 6.3 FRP COOLING TOWER (DX- SERIES) 6.3.1 The Fibre glass Reinforced Plastic (FRP) cooling tower shall be efficient and of sturdy

design for long life. It shall be supplied in the colour shade as approved by the Engineer-in-Charge. All hardware used shall be stainless steel. The supporting frame work for the cooling tower shall be fabricated from galvanised steel with epoxy paint to protect from varying atmospheric conditions. The cooling tower shall be complete with casing, water basin, fan with suitable electric motor and supporting structure, sprinkler system and fittings and a strong supporting framework so as to make the cooling tower a complete and independent unit. The cooling tower shall be forced draft type. One cooling tower is envisaged for each D.G. set. The cooling tower shall be located on terrace .

6.3.2 FRP Casing FRP casing of the cooling tower shall be so designed that it is strong enough for the duty it

is providing. It shall be strong enough to withstand the wind pressure and vibrations. The casing shall be of such design that it can be repaired easily in case of damages. Hot water temperature and cooled water temperature shall be 43.3oC and 32.2oC respectively. Design ambient wet bulb temperature shall be 28.5oC.

6.3.3 Cooling Tower Fan The fan shall be of axial flow type, low noise and light weight. The fan shall be selected to

suit the cooling tower design. Suitable electric motor and supporting structure shall be selected for the cooling tower fan. The fans shall be fibre glass with NASA Aerofoil design Fans shall be direct driven with low RPM motors.

6.3.4 Water Basin Water basin shall be of sufficient capacity so as to provide continuous flow of water. It

shall be of FRP construction. A drain shall be provided to facilitate easy removal of accumulated dirt from the bottom of the tank.

6.3.5 Cooling Tower Supporting Structure The supporting frame work for the cooling tower shall be fabricated from galvanised steel

with epoxy paint to protect from the varying atmospheric conditions. If directed by the Engineer-in-Charge design calculations shall be furnished for approval.

6.3.6 Cooling Tower Internals The cooling tank shall have filling of PVC, MM AQUA (munters make) resistant to

corrosion and with good heat exchange efficiency. The cooling tower shall have water sprinkler system located centrally. The sprinkler head shall be fitted with suitable beam to take care of thrust and radial loads.

6.3.7 Painting The exterior and all steel (ferrous) surfaces of the tower shall be given two shop coats of

anti-corrosive paint of approved finish. 6.3.8 If these shop coats become marred during shipment or erection, the effected areas shall

be cleaned off with mineral spirits, wire brushed and spot primed, then coated with enamel paint of matching shades.

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6.3.9 RAW WATER PUMP The pumping shall be suitable to cater to the requirement of DG set, including strainer,

fittings, valves, pressure gauges, controls, Instruments, accessories, high/low temperature Audio-visual alarm etc. shall be provided. The pump shall be capable of delivery specified liter/ minute of water against specified head and complete with squirrel cage indication motor of specified H.P. with class F insulation. Water flow rates and head of the pumps shall be in accordance schedule of quantities. Pump shall be mono block end-suction design directly connected to motor. Impeller shall be hydraulically balanced and keyed to shaft. Stuffing boxes shall be integral with casing and water sealed. Shaft sleeve shall be of gun metal extending through stuffing boxes. Motor shall be drip and splash proof, designed as integral part of pump. Motor shall be suitable for 415+5% volts 3 phase, 50 cycles AC power supply. All Pumps, Motors and bases shall be supplied with approved finish. The cooling water pumps alongwith cooling tower fans shall be interlocked with DG sets, so that they start automatically alongwith the DG set, to start cooling water supply. There shall be provision for tripping the cooling water pump when the water level in cooling tower sump is low.

6.4 Exhaust Piping 6.4.1 The exhaust silencer piping system shall be MS pipes confirming to Class- B. Suitable

length of flexible piping shall be used for connecting the exhaust piping to the engine as per the recommendations of the manufacturer.

6.4.2 Exhaust pipe along with silencer inside the building shall be provided with mineral wool insulation with chicken mesh wrapping and 26 SWG aluminium cladding.

6.4.3 All terminal connections and pipes joint shall be of welded construction. The terminals of sizes 2" and above shall be butt welded, and of sizes 1.5" and below shall be socket welded, complete with flanges, jointing and fasteners.

6.4.4 This welding shall be done as per relevant ASME/ASA codes. The Contractor will have to indicate beforehand the welding procedure he proposes to use. After confirmation by the Engineer-in-Charge the procedure which is finalised shall be strictly adhered to.

6.4.5 Water Piping And Oil Piping 6.4.6 Water Piping shall be Class - B M.S. pipe. Oil piping shall be MS pipe as per A106 Gr. B

Sch. 40 or provided flexible type of SS - 304. If M.S. pipe as per IS : 1239 heavy class is used, it shall be " TATA " or any other make approved by the Engineer-in-Charge. Alternatively, the piping shall be braided flexible of SS - 304 only.

6.5 SHOCK TREATMENT CHART Shock treatment chart in English, Hindi and local language explaining the method of shock

treatment shall be provided duly framed in glass. 6.6 Testing and commissioning 7 SUPPORT SERVICES :

Throughout design, implementation, field installation the contractor shall supply consulting assistance, as required by the buyer for site preparation, field installation and other areas where technical support may be required.

8 TECHNICAL SUPPORT :

Consultation with contractor’s technical support personnel and trained field service personnel shall be readily available on a short-term/long-term basis to assist the buyer in maintaining, expanding and enhancing the installed setup.

9 INSPECTION :

Access to the contractor’s facilities during system manufacturing and testing and to any facility where systems/equipments are being produced and tested shall be available to the employer.

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DG TESTING :

TESTS AT MANUFACTURER'S WORK

The following tests shall be performed at manufacture’s works prior to packing and dispatch to site, in the presence of Project Manager/Consultant. A week’s notice shall be given. Nothing extra shall be payable. If witness is waived off the contractor shall have to submit test certificate.

On DG Set

a. Maximum power load capacity. b. Maximum motor starting capacity c. Endurance test. d. Fuel consumption at full load, 50% load, 75% load and 25% load.

On The Alternator

a. High voltage tests on stator and rotor windings. b. Insulation resistance of stator and rotor windings. c. Temperature rise test. d. Stator voltage and current tests. e. Stator phase sequence check.

On The Exciter

a. High voltage tests on stator and rotor winding. b. Insulation resistance of stator and rotor windings. c. Temperature rise test. d. Measurement of losses.

On The Automatic Voltage Regulator

a. Sensitivity test. b. Response time test. All routine test as per IS/BS codes shall be conducted on alternator, exciter and AVR.

Moreover the engine and alternator supplied shall be duly tested and supported by the test certificates of the respective manufacturer. DRAWING & DOCUMENTATION TO BE SUBMITTED WITH BID

- Filled-in Technical Particulars catalogue & literature for various equipment.

- Performance certificate of all major equipment. - Type test certificate of all major equipment. - List of Past supplier of all major equipment. - GA drawings of all major equipment. - Time frame of major activities including Bar chart. - Foundation drawings of DG sets.

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DRAWING & DOCUMENTATION TO BE SUBMITTED BY SUCCESSFUL BIDDER AFTER AWARD OF CONTRACT

- Following information and documentations in addition to what has been asked for in respective equipment specification shall be furnished by the successful bidder after award of contract for approval/reference/record of the purchaser.

- Electrical layout drawing showing location of equipment, cable routing, bus duct connections, water & fuel piping arrangement with fuel tank for DG Set, exhaust system etc. – Plan & Elevation drawing including sectional details.

- Single Line Diagram showing rating of components, metering and protection for DG Panel/PLC Panel/Distribution boards etc.

- Earthing layout showing connections to DG, panels (to be done by others).

- Modification of control schemes of existing DG panel/PLC panel with DG’s if any..

- Wiring Diagram. - Write-up on control philosophy for complete emergency electrical system

containing starting & stopping sequence, interlocks, metering, annunciation etc.

- All required drawings/documents/technical information required during various stages of works shall be submitted by the contractor as and when required by the purchaser.

- All drawings submitted by the Vendor/equipment supplier shall be in sufficient detail to indicate the type, size, general arrangement & foundation drawing, weight, the external connections, fixing arrangement required, the dimensions required for installation and interconnections with other equipment and materials, clearances and space required between various portions of equipment and any other information specifically requested.

- The above document shall be furnished in 4 sets to EPI/CDRI one set shall be returned with comments and approval. The document shall be modified incorporating the comments indicated by EPI/CDRI and 4 sets of corrected documents shall be given in 15 days time.

- The contractor shall provided within 3 weeks of award of work a complete bar chart based on the time period of the completion of the project. The bar chart shall elaborate procurement, installation, testing & commissioning of complete electrical system.

11 IMPORTANT INFORMATIONS TO BE PROVIDED BY THE BIDDER :

Duration calculation for the equipment at stated site conditions Warranty of the equipment to be provided by the manufacturer. Local Service dealer’s address to be specified. The acoustic enclosure for the DG set shall be manufactured by the DG set supplier.

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TECHNICAL SPECIFICATIONS OF ACOUSTIC ENCLOSURE ♦ Silent DG Set container is of modular construction with the provision to

assemble and dismantle easily at site. ♦ The enclosure is fabricated out of CRCA sheet of 14 SWG. ♦ The sheet metal components are hot dipped seven tank pretreated. ♦ Enclosure is polyester based powder coated (inside as well outside).

Nut, bolts & hardwares are Zinc coated. ♦ The doors are gasketed with EPDM gaskets to avoid leakage of sound. ♦ The door handles are lockable type. ♦ Sound proofing of enclosure is done with high quality rock wool/mineral

wool confirming to IS 8183, of 100 mm thickness and density at 64 Kg/M3.

♦ The rock wool is further covered with fibre glass cloth and perforated

powder coated m.s.sheet. ♦ Specially designed attenuators are provided to control sound at air entry

to the container and exit from the container. ♦ Adequate ventilation is provided to meet air requirement for combustion

and heat removal. ♦ Temperature of enclosure does not exceed beyond 5-7°C of ambient

temp. ♦ The sound insertion loss shall be as per CPCB prescribed norms

applicable presently.

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SECTION – IV

GUARANTEED TECHNICAL PARTICULARS FOR DIESEL ENGINE & ALTERNATOR

VENDOR SHALL FURNISH THE POINTWISE CONFIRMATION/INFORMATION AGAINST EACH POINT

Sl.NO. DESCRIPTION QUOTED DATA A. Diesel Engine 1. Rating : a) Continuous duty rating of the Diesel engine at site/NTP conditions in bhp/KW b) Maximum engine rating at site with 10% over load in KW. 2. Make of Engine and model no. 3. Cylinders : a) Number of Cylinders b) Cylinder length c) Cylinder diameter 4. Engine rpm 5. Aspiration 6. Cooling 7. Type of Starting 8. Type of fuel used 9. Specific fuel consumption ( Guaranteed) in At site At NTP KG/KWH condition condition a) At full load b) At 3/4th load c) At half load d) At 1/4the load 10. Lube oil consumption in Grams/Hour 11. Lube oil sump capacity in litres. variation + 12. Output at Site conditions after duration at Inlet temperature 450C. of Engine.( As per BS649 :1958 ). variation +

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Sl.NO. DESCRIPTION QUOTED DATA 13. Governing characteristics : 14. Minimum acceptable lube oil temperature at start up. 15. Maximum period for which the engine can operate without raw cooling water supply. 16. Jacket water system : a) Make up tank capacity in liters. 17. Type of Governor 18. Overall dimensions ( LxBxH ), mm 19. Weight (kg) B. Alternator 1. Continues Rated Output of the generator/alternator in - KW. 2. Continues current rating in AMP. 3. Site KW after deration 4. Generated Voltage 5. Number of phases 6. Standard 7. Class of Insulation for Alternator, Stator rotor. 8. AC Power factor 9. Rated speed (rpm) 10. Make of Alternator 11. Model No. 12. Efficiency a) At full load variation + b) At 3/4th load variation + c) At half load variation + d) At 1/4th load variation +

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Sl.NO. DESCRIPTION QUOTED DATA 13. Type of Excitation a) Rated voltage b) Rated current c) Response ratio 14. Field current at rated output and voltage 15. Temperature rise above ambient (500C ) a) Stator b) Rotor c) Cores 16. AVR - Type 17. Degree of protection 18. Full load losses variation + 19. Transient and sub-transient reactance (per unit) a) x’ d variation + b) x” d variation + 20. Short Circuit Ratio. 21. Overall dimensions (LxBxH), mm 22. Weight (kg)

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SECTION – V

TECHNICAL SPECIFICATIONS

FOR

DG AUXILIARY PANEL

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1. DESCRIPTION OF WORK This section covers the detailed requirements for design, manufacture, inspection,

transportation to site, installation testing & commissioning of L.T. Panel suitable for 415 Volts, 3 phase, 50 HZ 4 wire system, in line with schematic diagram, schedule of quantities and as specified.

2. CODES AND STANDARDS AND APPLICABLE PUBLICATION 415V Switchboard shall conform to latest applicable IS, IEC standard as listed below and

other relevant standards / code as applicable. IS : 13947 (Part – I to V) : Specification for low-voltage switchgear. IS : 1248 : Electrical measuring instruments and their

accessories. IS : 8623 : Specification for low-voltage switchgear and

Controlgear assembles. IS : 3072 : Code of practice for installation and maintenance

of switchgear. IS : 2705 (Part – I to IV) : Current Transformers IEC : 61643-12 : Surge Protection Devices for Power Lines. IEC : 60947-7-1 : Terminal Blocks 3. SPECIFICATIONS 3.1 GENERAL 3.1.1 The L.T. panel shall comprise the following type of switchgear as specified. The panel

shall be capable of fault withstand capacity of 50 KA for duration of one second. 3.1.2 The panel shall be metal enclosed, indoor type having sectionalisation of incoming, and

outgoing switchgears as specified. The design shall be cubicle type as specified. 3.1.3 The panel shall be floor mounted free standing totally enclosed and extensible type. The

panel shall be with lockable arrangement with degree of protection IP - 54 and shall be suitable for the climate conditions as specified. The design shall include all provisions for safety of operating and maintenance personnel.

3.2 CONSTRUCTION

3.2.1 The panel shall be shall be fabricated out of CRCA sheet steel 2.0 mm thick. Wherever necessary, such sheet steel member shall be stiffened by angle iron frame work. General construction shall employ the principle of compartmentalization and segregation for each circuit. Unless otherwise approved, incomer and bus section panels or sections shall be separate and independent and shall not be mixed with sections required for feeders. Each section of the rear accessible type board shall have hinged access doors at the rear. Overall height of the board shall not exceed 2.40 meters. Operating levers, handle etc. of highest unit shall not be at a height more than 1.8 m, and that of the lowest unit shall not be less than 300 mm above finished floor level. Multi-tier mounting of feeders is permissible. The general arrangement for multi-tier construction shall be such that the horizontal tiers formed present a pleasing and asthetic look. The general arrangement shall be got approved before fabrication. Cable entries for various feeders shall be either rear or from the front through cable alleys located in between two sections of minimum 300 mm width. There shall be separate gland plate for each cable entry so that there will not be dislocation of already wired circuit when new feeders are added. Cable entry plates shall therefore be sectionalized. The construction shall include necessary cable supports for clamping the cable in the cable alley or in rear cable chamber. All cable entries shall be from the top/bottom as specified. Gland plate shall be minimum 3 mm thick.

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3.2.2 Cable Termination / Bus Duct Terminations : Panel shall be design for cable entry from bottom / top as required. Sufficient space shall

be provided for each of termination and connection. All provision and accessories shall be furnish for termination and connection of power cables as per cable schedule including removal gland plates, copper / aluminums lugs, double compression brass glands with tapped washer and terminal blocks. Bus Duct connection shall be from the top. All provision for Bus Duct connection with accessories shall be provided.

3.2.3 Instruments All meters shall be Digital type flush mounted type conforming to class 1.0 for accuracy

and of size of 144 mm2 for incoming feeders and & 96 mm2 for outgoing feeders. 3.2.4 Indicator Lamps ON/OFF and phase indicator lamps shall be provided suitable for operation on AC 230

Volts supply. Necessary filter G/Y/R/A shall be provided depending upon the function. All lamps shall be protected by proper HRC fuses. All lamps shall be LED type.

3.2.5 Wiring All wiring controls, indication etc. shall be with minimum 2.5 sq. mm suitable stranded

copper conductor cables PVC insulated. Wiring shall be suitably protected within the switchboard. Runs of wires shall be neatly bunched and suitably supported and clamped. Means shall be provided for easy identification of the wires. Identification ferrules shall be used at both ends of the wires. All control wiring meant for external connection are to be brought out on terminal board. Brass/Copper thinbles, insulation tape etc. shall be provided at joints & terminations as required.

3.2.6 Terminal Blocks i. All control terminal blocks shall be unbreakable and IP 20 compliant. The metal parts of

the terminal block including the captive screw shall be of Cu. Alloy and its housing shall be Polyamide class V0/V2 as per UL94. It shall be suitable for mounting on both C&G type rail and shall be capable to withstand vibration level upto 5g.

ii. High current carrying terminal blocks suitable for 25-240 sq. mm wire shall contain individual terminal sleeve cover on each termination which is also individually separatable, to avoid accidental touch. It housing material shall be Polyamide as per UL 94 and shall be separated from each other by separating/partition plate.

3.3 Bus Bar & Bus Bar Chambers

i. Bus Bar and Connections a. The bus bar shall be of high conductivity Aluminium alloy of E 91 grade and of

adequate section. The bus bar system shall comprise a system of totally enclosed main horizontal bus bars run at the top and vertical bus bars serving all modules in vertical section on either side in cable entries. In case of rear access, horizontal bus system shall run suitably either at the top or bottom. All connections to individual circuits from the bus bar shall be with solid connections. All horizontal bus bar, vertical bus bar and connections shall be suitably sleeved with PVC sleeves or suitably insulated in an approved manner.

b. The bus bar temperature should not exceed 90o C i.e. 40oC temperature rise over

50oC ambient. The calculation for temperature rise and bus bar sizing should be furnished along with shop drawing for approval.

c. Wherever copper bus bar and Aluminium bus bar are connected to each other,

bimetallic strip shall be used.

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ii. Bus Bar Supports and Attachments

Bus bar shall be firmly fixed on supports constructed from SMC (glass fibre

reinforced thermosetting plastic). The supports shall be sufficiently robust to effectively withstand electro-mechanical stresses produced in the event of short circuit.

iii. Connection to Bus Bars

Connections to bus bars shall be made with bolts and nuts. Holes drilled into the bus

bars may be made.The bolts and nuts used for connections to bus bars shall be of Aluminium alloy, tinned forged brass or galvanised iron. Suitable precaution shall be taken against heating due to bi-metallic contact. Further for tapping off connections from bus bars, PVC insulated wire may be used for current capacities upto 100 amps and for higher current capacities solid conductors/strips suitably insulated with PVC sleeves/tape shall be used.

iv. Clearances The minimum clearances to be maintained for open and closed indoor air insulated

bus bars/electrically non-exposed and working at system voltages upto 600 volts shall be as follows :

--------------------------------------------------------------------------------------------

Between .................................................Minimum Clearances Phase to Earth ............................................. 20 mm Phase to Phase ............................................. 25 mm -------------------------------------------------------------------------------------------- v. Bus Bar Markings The colours and letters (or symbols) for bus bars : Main bus bar connections and auxilliary wiring etc. shall conform to relevant Indian

Standard. A brief from I.S. 375 (revised) is given below:

For AC bus bars and Main connections --------------------------------------------------------------------------------------------

S.No. Bus Bar & Colour Letter/Symbol Main Connection

-------------------------------------------------------------------------------------------- 1. Three Phase Red, R,Y,B.

Yellow, Blue.

2. Two Phase Red, Blue R,B 3. Single Phase Red R 4. Neutral Connection Black N 5. Connection to Green E earth 6. Phase variable (Such as connections

to reversible motors) Grey Gy.

18

vi Phase Sequence and Polarity Bus bars and main connections, when marked shall be marked in accordance with

the following table to indicate the order in which the voltages in phases reach their maximum values.

-------------------------------------------------------------------------------------------- System As indicated by Phase sequence Colours or letters as indicated Vectorially

-------------------------------------------------------------------------------------------- Three Phase Red, Yellow, Blue R, Y, B. Two Phase Red, Blue R, B.

--------------------------------------------------------------------------------------------

vii. Arrangement of Bus bars & Main Connections : Bus bars and main connections which are substantially in one plane shall be

arranged in order given as follows : a. A.C. System

i The order of phase connections shall be Red, Yellow and Blue. ii When the run of the conductors is horizontal, the red shall be on the top or

farthest away from the centre line as viewed from the front. iii When the run of the conductor is vertical, the red shall be on the extreme

left. iv When the system has a neutral connection in the same plane as the phase

connections, the neutral shall occupy an outer position. v Unless the neutral connections can be readily distinguished from the phase

connections, the order shall be red, yellow, blue and black. b. Terminations Incoming terminals shall be suitable for receiving cables.

3.4.1 PROTECTIVE DEVICES Suitable Surge Protection Devices shall be provided at the input of Panel, conforming to

IEC-61643-12 (Stage-I/Class B). The device shall be mountable on standard DIN Rail. It shall have the capability to arrest external lighting surges (of 10/350 µ waveform) up to 50 KA between Line to Neutral & 100 KA between neutral to earth. The wiring shall be as per TT configuration of wiring.

Protective devices shall be provided as specified in the schedule of quantities. There shall be not less than 4 N/O and 4 N/C auxiliary contacts rated 5 amp on each

breaker. The auxiliary contacts blocks shall be so located as to be accessible from the front. The auxiliary contacts in the trip circuits shall close before the main contacts have closed. All other contacts shall close simultaneously with the main contacts. The auxiliary contacts in the trip circuits shall open after the main contacts open.All current carrying parts shall be silver plated and suitable arcing contacts with proper arc chutes shall be provided to protect the main contacts. The heat generated in the contacts due to tripping under fault conditions shall be very nominal.

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3.4.2 MOULDED CASE CIRCUIT BREAKERS

3.4.2.1 Moulded case circuit breakers shall comply with the latest Indian Standards and IEC

standards. They shall have the voltage and current ratings, rated duty, rated short circuit service breaking capacity and rated short-time withstand current as indicated.

3.4.2.2 MCCB's shall be of the independent manual closing air-break type, rated for an uninterrupted duty, unless otherwise indicated.

3.4.2.3 Each MCCB shall have a facility for padlocking in the "OFF" position. 3.4.2.4 MCCB shall have front operating Extended door operating handle. 3.5 CURRENT TRANSFORMERS

Current Transformers shall be cast resin type.

a) All phases shall be provided with current transformers of accuracy Class I and suitable VA burden to operate associated metering.

b) Separate C.T's shall be used for protective devices.

3.6 VOLTAGE TRANSFORMER : Voltage transformers shall be cast resin type with accuracy class of 1.0. 3.7 RELAYS :

The contractor shall furnish, install and co-ordinate all relays to meet the requirement of

protection, interlock and bus transfer scheme as indicated in BOQ, Drawing, Specification and system requirement. Relays shall be Microprocessor type.

3.8 EARTHING

All components, frame etc. shall be properly earthed. Al. earth bars of 50 mm x 6 mm

shall be provided for the LT panel for the full length of the panel and connected to the frame work. Provisions shall be made for connection from this earth bar to the main earthing bar on both sides of LT Panel.

3.9 PAINTING

All steel work used in the construction of the LT panels shall have undergone a rigorous

metal treatment process as follows :-

i) Effective cleaning by hot alkaline degreasing solution followed by cold

water rinsing to remove traces of alkaline solution.

ii) Pickling in dilute sulphuric acid to remove oxide scales & rust formation, if any, followed by cold water rinsing to remove traces of acidic solution.

iii) A recognized phosphating process to facilitate durable coating of the paint on the metal surfaces and also to prevent the spread of rusting in the event of the paint film being mechanically damaged. This again, shall be followed by hot water rinsing to remove traces of phosphate solution.

iv) Passivating in de-oxalite solution to retain and augment the effects of phosphating.

v) Drying with compressed air in a dust free atmosphere.

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vi) Primer coating with two coats of a highly corrosion resistant primer,

applied wet on wet and stove dried under strictly controlled conditions of temperature and time.

vii) Finishing treatment shall be by powder coating with 60 micron minimum thickness.

3.10 LABELS Anodised Aluminium labels shall be provided on all incoming and outgoing feeder

switches. Circuit diagram showing the arrangement of the circuit inside the LT panel shall be pasted on inside of the panel door and covered with transparent laminated plastic sheet. Caution notice place shall be affixed at the back of each vertical panel.

3.11 SPACE HEATER AND PLUG SOCKET :

Each vertical panel shall be provided with thermostat controlled space heater and 5A 3 pin plug socket. Separate transformer for space heating supply has to be arranged.

4. TESTING & COMMISSIONING 4.1 TEST AT MANUFACTURERS WORK All routine tests specified in IS : 8623: shall be carried out 4.2 Test witness

Tests shall be performed in the presence of the Engineer-in-Charge. The contractor shall give at least fifteen days advance notice of the date when the tests are proposed to be carried out.

5. SUBMITTALS Following data, drawing & manual shall be submitted :- 5.1 To be submitted with bid.

a) Single Line Diagram.

b) Filled in Guaranteed Technical Particulars.

5.2 To be submitted for approval.

a) General arrangement drawing showing space required in front for withdrawls, power and control cables entry points, bus duct / cable entry details.

b) Technical particulars for each panel. c) Single Line Diagram d) Modification of control wiring diagram along with electrical interlock scheme. e) Bill of material indicating quantity, rating and make of all component. f) Foundation plan and loading. g) Type test certificate from CPRI on identical panel. h) Technical literature of each component / equipment. i) Bus bar sizing calculations along with supporting document. j) Routine test certificates carried out on the panel. k) Type test certificates for any equipment if so desired by the owner.

21

SECTION - VI

GUARANTEED TECHNICAL PARTICULARS FOR DG AUXILIARY PANEL (Separate GTP to be submitted for each size & type of panel).

Sl. No. Description Quoted Data 1.0 Assembly 1.1 Make 1.2 Type 1.3 Reference standard 1.4 Voltage (Nom./Max), Volt 1.5 Phase, frequency 1.6 Short circuit rating for 1 sec (KA) 1.7 Insulation level (KV) 1.8 Enclosure a) Degree of protection b) Minimum thickness of sheet metal (mm) 2.0 Construction 2.1 Completely compartmentalized 2.2 Working height limits from floor level (mm) 2.3 Minimum clear space required at front for

breaker (mm)

2.4 Minimum clear space required at rear (mm) 2.5 Overall dimensions (LxBxH) mm 2.6 Approximate weight (Kg) 3.0 Busbar 3.1 Make 3.2 Material & grade 3.3 Reference standard 3.4 Cross sectional area a) Main busbar b) Vertical busbar 3.5 Continuous current (at site condition, 50oC) a) Main busbar (A) b) Vertical busbar (A) 3.6 Short time current for 1sec (KA) 4.0 Circuit Breaker 4.1 Make 4.2 Type 4.3 Reference standard 4.4 Rate voltage, KV 4.5 No of poles 4.6 Rated current 4.7 Short time current for 1 second (KA) 4.8 Total closing time 4.9 No of breaks per pole 4.10 Spring charging motor a) Rating (W) b) Voltage (V)

22

4.11 Closing coil

Sl. No. Description Quoted Data a) Voltage b) Closing current (A) 4.12 Tripping coil a) Voltage b) Trip current (A) 4.13 Overall dimension (LxBxH) 5.0 MCCB 5.1 Make 5.2 Type 5.3 Reference standard 6.0 Fuse 6.1 Make 6.2 Type 6.3 Reference standard 7.0 Condactor 7.1 Make 7.2 Type 7.3 Reference standard 7.4 Duty class 7.5 Utilization category 8.0 Control & indications 8.1 Push buttons a) Make b) Type 8.2 LED a) Make b) Type 9.0 Current transformer 9.1 Make 9.2 Type 9.3 Reference standard 9.4 Ratio 9.5 VA rating 9.6 Class a) Relaying CT b) Metering CT

23

10.0 Control transformer 10.1 Make 10.2 Ratio 10.3 VA rating 11.0 Voltage transformer 11.1 Make 11.2 Type 11.3 Reference standard 11.4 Voltage ratio 11.5 Accuracy class 11.6 VA burden 12.0 Relays 12.1 Make 12.2 All relays furnished as per BOQ, specification

& drawing?

13.0 Meter 13.1 Make 13.2 Type 13.3 Reference standard 13.4 Size 14.0 Secondary wiring 14.1 Voltage grade 14.2 Conductor size & material 14.3 Type of insulation 15.0 Terminal block 15.1 Make 15.2 Type 15.3 Voltage grade 16.0 Space heater 16.1 Wattage 16.2 Voltage

24

SECTION – VII

TECHNICAL SPECIFICATIONS FOR

L.T. BUS DUCT

25

TECHNICAL SPECIFICATION FOR L.T. BUS DUCT

1. SCOPE

This section covers Design, manufacture, inspection, transportation to site, installation, testing and commissioning of Low tension bus duct for connection between DG sets and DG panel.

2. GENERAL

The layout of the bus ducts shall be in line with the drawings/site conditions and shall be got approved by Engineer-in-charge

All parts and accessories shall have appropriate match mark and part numbers for easy identification and installation at site.

3. STANDARDS

The bus duct works shall conform to up-to date amendments and relevant standards/code as applicable:

4. DESIGN

Bus duct shall be Non-segregated phase suitable for 415 volts, 3 Phase& Neutral, 50 Hz, AC supply and indoor, outdoor installation as per the requirement.

Bus duct shall be designed to withstand the fault level of 50KA for 01 second.

Bus duct shall be designed for continuous current rating as per the current rating given in the BOQ/SOQ.

5. CONSTRUCTION 5.1 ENCLOSURE

All the three phases shall be enclosed in a weather proof, dust tight enclosure, Outdoor section of the bus duct shall be completely rain proof. Weather resistant type circumferential gaskets shall be provided for making the joints with adjacent enclosures dust – proof and impervious to moisture suitable inspection opening with gaskets shall be provided for access to support insulator, lugs joints etc.

Bus duct enclosure shall be made of 14 swg. (2mm) CRCA sheet steel, for bus rating below 3000A. The degree of enclosure protection shall be IP 52 for indoor application and IPW-55 with canopy for outdoor section of the bus duct.

All ventilation openings shall be screened and drains shall be filtered to prevent entrance of dust and vermin.

The portion of bus duct at DG end may be subject to vibration. Suitable means shall be provided to isolate the transformer vibration from rest of the bus duct. For continuous operation at specified ratings, temperature rise of the bus duct and auxiliary equipment shall be limited to the site permissible values stipulated in relevant standards and/or this specification.

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Bus duct and auxiliary equipment shall be capable of withstanding the mechanical forces and thermal stresses of the short-circuit currents without any damage of deterioration of material.

The L.T. bus ducts shall be self cooled and shall not be equipped with blower or any other type of forced ventilation.

6. DETAILED SPECIFICATIONS 6.1 BUSBARS 6.1.1 Material

Bus bars shall be made up of high conductivity electrolytic quality aluminum as specified in BOQ with maximum temperature limited to 85 deg. C (i.e. 35 deg. C rise over 50 deg. C ambient).

6.1.2 Current density

The Aluminum bus bars shall be of sufficient cross section. The design current density of 1Amp/Sq. mm for aluminum bus bars shall be maintained. However, the design shall be suitable for the 50 KA fault level.

6.1.3 Neutral bar rating

The rating of the neutral bar shall be minimum 50% of the phase bar. 6.1.4 Joints

Adequate contact pressure shall be ensured by means of two bolt connection with plain & spring washers and locknuts. All bus joints shall be silver plated.

Bimetallic connectors shall be provided for connections between dissimilar metals.

The bus conductor shall be designed for bolted connections throughout the run. Joints for the bus bar shall be bolted but joints of construction with double cover fish plates and with adequate contact area.

6.1.5 Insulation & supports

Bus bars and connections shall be fully insulated for working voltage with heat shrink colour coded PVC insulating sleeves. Bus insulators shall be flame-retardant, non-hygroscopic, track resistant type with high creepage surface materials like fiber glass reinforced thermosetting plastic/ epoxy/ FRP. The supports shall be made of single piece.

They shall withstand without any damage or deformation the thermal and dynamic stresses due to short circuit currents.

6.1.6 Color coding

Bus bars shall be colour coded for easy identification (Red, Yellow, Blue for three phases and Black colour for neutral for A.C 3 phase system). Heat shrinkable, colour coded PVC insulation sleeve shall be used for this purpose.

27

6.1.7 Lay out sequence

They are so positioned that the sequence of R-Y-B-N bars shall be from left to right, top to bottom or front to rear, when viewed from the front of switchgear assembly.

6.1.8 Clearances & creepage distances

As far as possible, large phase and ground clearances and creepage distances shall be provided on the bus bar system to minimize possibilities of fault. The clearance mentioned below shall be minimum and maintained even at the connection point.

1 Phase to Phase – 35 mm 2 Phase to Neutral – 28 mm 3 Phase to Earth – 28 mm

6.2 HARD WARE

Zinc passivated or any other superior quality standard size hard ware to be used for all joints/connectioins/terminations at switchgear & control gear, bus bars, ground bus , inter-connections/ wiring etc.

6.3 Convenience of maintenance

The system shall be maintenance friendly. i.e. it should be possible to easily connect/tighten/disconnect etc.

6.4 Inspection Covers

Inspection covers shall be provided at suitable intervals as required. 6.5 Disconnect Link

Removable bolted disconnect link shall be provided in the bus for the purpose of isolation.

Disconnect link shall consist of a removable section of conductor and shall be so constructed as to permit easy removal or reinsertion without alignment difficulties.

The bus on both sides of the link shall be rigidly supported so that the disconnect link is equal in mechanical strength to any other section of the bus.

A minimum clearance of 300 mm (12”) shall be provided between the disconnected bus sections with the link removed.

6.6 Ventilation

The bus duct shall be natural cooled. 6.7 Joints, Expansion/Flexible joints

The bus bar shall be supported in such a way that the expansion/contraction does not have undue strain on the bus and at the terminals at both ends.

Circumferential neoprene gaskets shall be provided for dust tight joints with adjacent enclosure section.

The bus enclosure shall have extended bellows or equivalent means to allow for temperature changes and vibrations.

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Flexible joints shall be provided in enclosures at all points where the bus duct terminates at equipment to withstand vibration, expansion/contraction and at suitable intervals in any straight run of the bus duct where expansion and contraction would otherwise result in stresses in the supporting structures. Flexible connections shall be provided between bus sections to allow for expansion and contraction of the conductor. Flexible connection shall also be provided at all equipment terminations.

All contact surfaces shall be silver plated to ensure an efficient and trouble free connection.

6.8 Other points

Shipping length of the bus duct shall be not more than three (3) meters in length.

Filtered drains for drainage of condensate shall be provided at the lowest points and at such locations where accumulation of condensate can be expected.

6.9 GROUND BUS Two numbers of Earth bars shall run along the full length of bus duct made up of size 50 mm X 5 mm Aluminium, strip. This ground bus shall be fixed to the bus duct on the external side. It shall have provision to connect main earth/loop earth conductors with bolts, nuts, washers & spring washers. Metallic parts of the bus duct & associated structures etc. shall be bonded to the ground bus for effective earthing.

One end of the earth bus shall be joined to the LT Panel side body earth lead and the other end shall be joined to the transformer body earth.

7. INSTALLATION

All supporting structures required for hanging and/or supporting the complete bus duct shall be provided including related civil works. These include all types of supports, brackets, beams, channels, rods, clamps, hardware, etc to support with wall, roof, truss etc.

Bus ducts running along the wall should be supported at intervals not exceeding 1.5m. In case of branching, there should be a support on all branches at a distance of 30 cms from the point of branching. Support should not be less than 40mm X 40mm X6mm MS angle secured in an approved manner. Supports may also be formed as brackets fixed to walls where runs are along with walls. Supports shall be grouted on the walls.

In case of ceiling suspended bus ducts, supports made of 40mm X 40mm X6mm MS angle iron shall be provided. The horizontal interval between two such supports should not be more than 1200mm. However, additional supports to be given at the bends and termination points. These duct supports shall be suspended from the C.I/MS. boxes or suitable approved suspension device provided in the ceiling by means of 12 mm diameter MS rods. Where fish plates are available, the same can be used for busduct support works. Where there is no such provision, good quality anchor fasteners of size not less than 8mm shall be used in the ceiling.

29

Seal-off bushings complete with wall frame and support plates shall be provided where the bus duct penetrates the building wall. The seal is to prevent free exchange of air between two portions of the bus duct part of which is indoor while the other is outdoor.

Silica-gel breather shall be provided on both portions of the bus duct between the seal of bushings.

CONNECTIONS & TERMINATIONS

All matching flanges, seal-off bushings, gaskets, fittings, hardware and supports required for termination of the bus duct at the switchgears, transformers and other equipment shall be provided.

Flexible connections both for conductor and enclosure shall be provided.

a) At all equipment termination to provide for misalignment up to 25 mm (1”) in all directions.

b) Between bus duct supported from building steel to prevent transmission of vibration.

The equipment terminal connections shall be readily accessible and shall provide sufficient air gap for safe isolation of equipment during testing.

If the material of bus conductor and that of the equipment terminal connectors are different then suitable bi-metallic connectors shall be furnished.

8. PAINTING

Unless otherwise specified, the painting process shall be as follows:-

All steel surfaces shall be thoroughly cleaned by sand blasting or chemical agents, as required, to produce a smooth surface free of scales, grease and rust etc.

The steel surfaces after cleaning shall be given on all sides proper coat of anti-corrosive primer followed by two coats of powder coating painting.

The bus duct shall be finished with two coats of grey (IS 5 shade # 632) powder coated paint.

Earth strip shall be painted with green colour enamel paint.

Where the painting is damaged during transit, installation etc., and touch up painting shall be done at site.

All metallic parts involved in the installation like supports, beams, channels, brackets, clamps, poles, hardware etc. shall be enamel painted.

9. TESTS 9.1 Factory Test

The routine/acceptance tests shall be witnessed at the manufacturer’s works by CDRI representative. Test shall be carried out as per IS.

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9.2 TYPE TESTS

Bus duct shall be got manufactured by only reputed bus duct manufacturers having type tested as per IS by CPRI or other govt. testing laboratory on similar bus duct (s) with minimum 50KA short circuit current with stand capacity and the type test certificate shall be produced to the CDRI inspector at the time of factory test.

9.3 SITE TESTS In addition to the tests at manufacturer’s premises, all relevant pre-commissioning checks

and tests shall be done at site before energizing the bus duct. The following tests are to be particularly done before cable jointing or connecting the bus

duct.

1. Physical inspection for breakages/damages/orderliness. 2. Insulation resistance test with 500 V Megger. The insulation resistance shall not be

less than 100 mega ohms. 3. Earth continuity test.

All test results are to be recorded and reports should be submitted to the department.

10. COMMISSIONING

After the satisfactory installation & testing, the Bus duct shall be commissioned.

11. Drawing, Data & Manuals :- 11.1 To be submitted with the bid. 11.1.1 Technical Particulars of each rating. 11.1.2 General arrangement drawing – plan and section. 11.2 To be submitted after award of contract :- 11.2.1 Dimensional general arrangement drawings with cross sections of bus duct layout

including supporting arrangement. 11.2.2 Calculation for short circuit forces justifying the proposed arrangement and temperature

rise for bus and enclosure. 11.2.3 Detailed material list with part number. 11.2.4 Typical details of bus insulator assembly, rigid and flexible connections, grounding

provision, termination arrangement at equipment end etc. 11.2.5 Technical particulars of each rating.

Type test report.

31

SECTION – VII

The following is the list of products and indicative makes. Bidder is free to propose any other equivalent Make meeting Technical Requirements, Specifications alongwith required details in support of the same. The same would be analyzed and accepted if found suitable after discussion between EPI and bidder. The Makes shall be finalized during Technical evaluation prior to opening of Price-Bids. Bidders are required to offer reputed equipment / component which is strictly meeting technical requirements, enclosed specifications alongwith NIT and other relevant / latest applicable Standards & Rules.

S. No

Items Indicative Makes

1. Diesel Engine Cummins/Caterpillar/MTU /Mitsubishi/Perkins

2. Alternator Stamford/Cummins

3. AVM Pads Dunlop/GERB/ Resistoflex

4. MS Pipes for Exhaust/water/fuel piping Jindal/Tata

5. Valves Sant/Rama/Audco/Kirloskar

6. Batteries NICCO/Standard Furukawa/Exide

7. Acoustic Enclosure Jakson Engineers/Sudhir Engineers

8. Cooling Tower BELL / MIHIR / PAHARPUR

9. Power Control Cables CCI / Fort Gloster / Universal / Skytone

10. Butterfly Valves, Strainer, NRV C&R / Sant / Leader

11 Control wires Finolex / national / havells

12 Water circulating monobloc pumps Kirloskar / M&P / KSB

DG PANELS, DG AUXILIARY PANEL AND RELATED ITEMS :

13. MAIN DG PANELS / APFC PANEL/PLC PANEL/ C&R PANEL / RTCC / MCCB PANEL / UMDB/ DG AUXILIARY PANEL

TRICOLITE / JAKSON ENGINEERS / L&T / SCHNEIDER / GE POWER / ABB / C&S / SUDHIR GENSETS / SIEMENS / ADVANCE (SIEPAN) / RST ELECTRICALS

14. AIR CIRCUIT BREAKER L & T / GE POWER / SIEMENS / ABB / SCHNEIDER

15. MOULDED CASE CIRCUIT BREAKERS L & T / SIEMENS / SCHNEIDER/ GE POWER / ABB / LEGRAND

16. FUSE DISCONNECTOR SWITCH / SWITCH FUSE UNITS

L & T / SIEMENS / SCHNEIDER / GE POWER / ABB / C&S

17. HRC FUSES L & T / SIEMENS / GE POWER / ABB / C&S / SCHNEIDER

18. BUS DUCT ADVANCE PANEL & SWITCHGEAR PVT. LTD. / TRICOLITE / C&S / ADLEC.

32

19. AMMETER, VOLTMETER AE / MECO / UNIVERSAL / RISHAB / IMP / CONSERV

20. SELECTOR SWITCH, PUSH BUTTON SWITCH / EMERGENCY SWITCH

KAY CEE / CONTROL & SWITCH GEARS / L&T / GE POWER CONTROL / SIEMENS / BCH.

21 LED INDICATION LAMPS AE / C&S / EASUN / KAY CEE / SIEMENS / VAISHNOV / L&T

22. CT’S AE / KAPPA / UNIVERSAL / KAYCEE / IMP/ C&S / L&T / MECO.

23. STARTERS SIEMENS / L&T / CUTLER HAMMER / GE POWER / ABB / C&S / SCHNEIDER

24. SINGLE PHASING PREVENTOR / OVER LOAD PROTECTION UNIT

L&T / GE POWER / SIEMENS / MINILEC / ABB / SCHNEIDER

25. RELAYS L&T / AREVA / ABB / SIEMENS

26. CHANGE OVER SWITCH HH ELCON / C&S / INDO AISAN / HPL / C&S

27. CONTACTORS L&T / GE POWER / BCH / SIEMENS / ABB / TC / C&S / SCHNEIDER

28. KWH, PF, FREQUENCY METER JAIPUR METER / AE / HAVELLS / L&T / AREVA / SECURE / GENUS / CONSERV

29. PUSH BUTTONS L&T / SIEMENS / BCH / CON CORD / GE/ C&S

30. TIMERS L&T/ BCH / MDS / INDO ASIAN / SCHNEIDER / SIEMENS / ADVANI ORLIKON / GE POWER CONTROL

31. TIME SWITCH L&T / BCH / MDS / INDO ASIAN / SCHNEIDER / SIEMENS / ADVANI ORLIKON / GE POWER CONTROL.

32. DIGITAL METERS ENERCON / NEPTUNE / AE / L&T

33. INTELLIGENT MULTIFUNCTION DIGITAL METER

ENERCON / NEPTUNE / AE / L&T

34. PLC ROCKWELL AUTOMATION / L&T / SIEMENS

35. UPS SYSTEM FOR PLC MERLIN GERIN / EMERSON / GE DIGITAL ENERGY /

36. UPS BATTERIES EXIDE / GLOBAL-YAUSA / PANASONIC

33

SECTION - IX

DRAWINGS

SR. NO. DESCRIPTION

01

MAIN SUBSTATION (21)

34