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Tender For Special Repair / Replacement Of Ber Dg Set 250 Kva And 400 Kva At Iam Iaf Under Ge (Af) Marathahalli; 1 Supply, Installation, commissioning and testing of acoustic enclosure Diesel Engine Generating set wi th AMF Panel 250 KVA/200 KW (CPCB IV+), 415 Volt, 0.8 lagging power factor 50 HZ, 1500 RPM, self excited self regulated brush less AC generator mounted on common base plate complete with fuel tank, battery and standard accessories and fittings including acoustic enclosure and all components as detailed complete all as specified and directed listed as following:- Make of DG set assembled with sound proof canopy - Greaves Cotton Ltd, Pune., Cummins, Ashok Leyland, Kirloskar. 2 (a) Diesel Engine: The capacity of Diesel engine 303 HP, water cooled, Inline, 6 cylinder, 4 stroke, 1500 RPM coupled with alternator, turbo charged after cooled, heavy duty air cleaner as per ISO 3046, w ter separate filter, fuel feed pump and other accessories as per relevant IS / BS-5514 with an overload capacity of 10% for one hour in 12 hrs, continuous running complete with standard accessories all as specified and required for safe handling and operation, salient features of accessories shall be as under:-(i) Fly wheel with housing (ii) PT fuel pump(iii) STC injectors(iv) Turbocharger, pulse tuned exhaust manifold, stainless steel exhaust flexible connections.(v) Radiator/heat exchanger with initial filled coolant (vi) Full flow filters for fuel, lube oil and by pass filter(vi) dry type replaceable paper element air cleaner with restriction indicator(vii) initial fill lube oil(viii) Starter motor 24 volts(ix) Charging alternator 24 volts 3 (b) Alternator: Standard design alternator rated at 250 KVA net output at site after considering de ratings as per site conditions at 0.8(lag) power factor AC, 3 phase four wire system 415 volts 50Hz, 1500 RPM self excited self regulated screen protected / drip proof IP23 enclosure brush less design with winding in pole faces, insulating class ‘H’ and voltage regulation of ± 0.5 to 1% at rated voltage from no load to full load, The alternator shall be confirming to BS 613/5000 and shall be in position to generate supply with frequency regulation with in± 1% tolerance the alternator will be suitable for tropical climate and shall generally confirm to BS-2613/500/IS-47221) Insulation Class-‘H’2) Excitation: self Excited3) Regulation performance: The voltage is K pt constant with ± 1 % manual voltage adjustment within adjustment within ±5%4) Frequency regulati n ± -1% 4 (c) AMF Panel :- Separate cubicle control panel Indoor type control cubical made out of 2.00 mm thick CRCA sheet dust and vermin proof totally enclosed with front opening of 415 volts 3 -phase 4 - wire AC 50 Hz, including powder coated, copper bus bar of one and half times the rated load of 250 KVA alternator out door type complete with internal wiring with PVC insulated single core copper conductor multi stranded wire of 1200 volts grade of suitable capacity, fuses, name plates consisting of 4 pole MCCBs and Contactors of capacity as recommended by the manufacturer. Detachable cable gland plates, all controls, indicators and standard standard microprocessor based LED/LCD display for indicating voltage, current, frequency, speed, kW, kWH, pf, temperature, Battery voltage, etc AMF Controller (1) Annunciationwith indication lamps for :- i. Low lub oil pressure, ii. High Water Temperature, iii. Engine over speed, iv. Battery low voltage Controls (2) Load on Indication (3) Load off indication(4) Engine start push button(5) Engine stop push button(6) Fault accept / reset push button(7) Battery Charger :-i. Transformer ii. Rectifier iii. Resistanceiv. DC Volt meter v. DC Ammeter vi. Charger rate selector switch 5 (D) Batteries: Two nos maintenance free batteries of 12 volts 180 AH capacity with multi stranded copper conductor cable of suitable size from battery to starter and from Control panel (E) Control Panel: The control system is an integrated microprocessor based generator control system providing voltage regulation, engine protection alternator protection, operator interface and isochronous governing.(F) Base frame - The Dg set engine and alternator mounted on common base frame with anti vibration pads as per manufacture recommendations.(G) Fuel tank –Fuel tank made up of 3 mm thi k HR sheet with calibrated level marking arrangements with fuel gauge stop cock, drain plug with capacity of tank approx 385Ltrs & DEF Tank Capacity (L) 60Ltrs.(H) Acoustic enclosure - Enclosure is free standing floor mounting type factory built modular in construction to facilitate easy assembly at work site and will be drop over housing type and easy access for maintenance and repairs and operation with following facilities. (1) Rugged construction maintenance free. (2) CRCA sheets for enclosure with high quality insulation materials to be used as per IS 8183 for maximum sound absorption. (3) The sheet metals treated with anti resistive solutions before painting and painted with pure polyester powder epoxy paint in outer side for better weather resistance. 6 (4) Well designed ventilation system to be provided to pump up the heat in the chamber. (5) Provide selling with special type of gaskets, frame rubbers on doors/frames for better weather protection.(6) Necessary provision for cable entry/ bus ducts and fuel line, control cables as per requirement. (7) A see through transparent glass/acrylic window in front of engine control panel to be provided for monitoring the parameters.(8) In inside the enclosure provide 12 volts LED light fitting two nos for inside illumination. (9) Necessary mounting bracket for batteries inside the enclosure.(10) The emergency stop push button provided in acoustic enclosure near Instrument panel side. (11) Work space is to be provided around the equipment for easy maintenance by the manufacturer. Notes: Unit rate quoted by the contractor shall deemed to be inclusive for the following:- (a) The contractor shall provide the artificial load, fuel, oil etc for testing the DG set at site and the cost it’s deemed to include in the quoted rate.(b) All civil works for making good the disturbed surface during installation. (c) The DG Set should comply with all the latest CPCB-IV + Norms including latest amendment issued upto the date of receipt of tender. 7 Supply, install and commissioning of Factory assembled Silent DG set with AMF panel of capacity 400KVA/320kW, 1500 RPM, Turbo Charged, water cooled comprising of suitable Engine with microprocessor based Genset controller with silencer and canopy for soundless mode (sound level not exc level specified by central pollution control board) and alternator both mounted on a common base frame conforming to ISO and IS-10002 rated for 415 volts 50 cycles, 0.8 Power factor (PF) complete residential silencer, AVM pads, battery with its leads, first fill of lub oil and all engine accessories such as self starter, alternator/dynamo with suitable coupling and base frame on foundation as recommended by the manufacturer and consisting of electrical components and maintenance free cable lead with terminal, all mounting accessories complete all as specified and directed comprising with the following. Make of DG set assembled with sound proof canopy - greaves cotton ltd,pune, Cummins, Ashok Leyland, Kirloskar 8 (a) Engine :(a) Vertical inline multi cylinder in accordance with BS-5514/IS-1002 at 1500 RPM including the following accessories :-(i) Fuel tank (Suitable for capacity for minimum 12 Hrs run).(ii) Fuel filter(iii) Lub oil filter.(iv) Lub oil cooler.(v) Dry type/ Oil bath type air cleaner.(vi) Exhaust Silencer (Industrial type).(vii) Fly wheel with starting ring.(viii) Expansion bellows.(ix) Exhaust gas turbocharger. (x) 24 Volt electric starter with 02 No maintenance free battery of suitable capacity.(xi) Battery charging alternator.Make: Greaves Cotton 9 (b) Alternator: (i) Alternator, 3 phase, 415 Volts, 50 Hzs, 0.8 PF, 1500 RPM self excited, self regulated, screen protected, drip proof alternator of capacity 400 KVA conforming to BSS 5000 (part 99) with insulation class "H", single bearing and automatic voltage regulator accessories.Make: CG / Stamford. 10 (c) Acoustic Enclosure: (i) Acoustic enclosure as per latest CPCB IV+ norms(ii) Air inlet louvers specially designed to operate at rated load even at 50 deg C air inlet temp.(iii) Powder coated for long lasting service life and superior finish.(iv) Insulation material meets exacting IS 8183.(d) Accesories: (i) Base frame fabricated from CRCA sheet of suitable thickness as per manufacturers design.(ii) Storage battery of suitable capacity as per manufacturer"s instruction mounted on angle iron frame of suitable size as directed. 11 (e) Instrument Panel: The Genset controller as per manufacturers/OEM design complete with internal wiring, bus bar etc and fitted with the accessories as per OEM recommended.(f) AMF Panel: The AMF panel shall be separate panel outside of Acoustic enclosure indoor type and made of CRCA sheet duly fabricated and powder coated and complete with internal wiring, Aluminum bus bar etc and fitted with the following accessories : (i) Power contactor of 4 Pole 700A - 02 No’s(ii) DN Base HRC Fuse HN type – 630A - 3 No’s & HRC Base HB type -800.(iii) Current Transformer of size – 700/5A – 3 No(iv) Indicating lamps (LED type) (R-Y-G) – 01 set (vi) Relay, timer and other accessories as per manufacturer.Note: Quoted rate should inclusive of testing of DGSET. 12 Taking down aluminium strip of any size and Supply & fix aluminium strip 25mm x 4mm complete with saddles and fixing screws for fitting the strip. Complete all as specified and directed. 13 Taking down old earthing and M&L for earthing complete with galvanised steel earth plate electrode 60cm X 60cm X 6mm thick, burried directly in ground (earth pit not less than 2.25 mtr deep below normal ground level) with top edge of plate not less than 1.5 mtr below normal ground level connected to galvanized strip 25 X 4mmby means of bolts, nuts, check nuts and washers of galvanized iron or steel all as shown in electrical plate No 3 of SSR Part-I connected to OH conductor on pole/ Panel/ main switch board etc all as specified or indicated and testing on completion including provision galvanized strip protected by 40 mm bore, light grade pipe and watering pipe shall be 20 mm bore medium grade GI pipe including excavation & earth work, PCC pit with RCC cover, charcoal, salt, funnel, GI strip and protection pipe upto 7.5 mtr complete all as specified and directed. 14 Supply and lay cable XLPE insulated screened PVC bedded galvanized steel strip or wire armoured electric power cables (heavy duty) 1100 volts grade with standered aluminium conductor of following sizes 240 sqmm 3.5 Corecomplete all as specified and as directed 15 Supply and lay cable XLPE insulated screened PVC bedded galvanized steel strip or wire armoured electric power cables (heavy duty) 1100 volts grade with standered aluminium conductor of following sizes 300 sqmm 3.5 Corecomplete all as specified and as directed. 16 Taking down GI pipe of any size and Supply and fixingof GI tubing, light grade, 80 mm bore with all fitting lais in trenches / pole / wall for protection of cables in repairs. Complete all as specified and directed. 17 Supply and fixingof GI tubing, light grade, 100 mm bore with all fitting lais in trenches / pole / wall for protection of cables in repairs Complete all as specified and directed. 18 Excavation in trenches in soft/loose soil not exceeding 1.5 metre wide and exceeding 1.5 metre but not excedding 3.0 metre in depth for route of cable and getting out complete all as specified and as directed 19 Returning, filling in soft/loose soil including spreading, leveling, watering and well ramming, in layers not exc 25 cm complete all as specified and as directed 20 Removingof surplus soil to a distance not exc. 50 meter and depositing where directed at a level not exc.1.5 metre above the starting point complete all as specified and as directed 21 Supply, laying riddled earth soil for cushioning to cables with a layer of riddle earth soil 15cm deep before laying the cable and 8 cm depth after laying of cable, Complete all as specified and directed. 22 M & L for sub class ‘B’ bricks, laid in trenches as cable covers / protectioncomplete all as specified and directed. 23 Disconnecting all electrical connections,earthing connection complete in all respect & dismantling the existing DG set of capacity 400 KVA/250 KVA including AMF panel, oil tanks & transporting it to the MES yard complete all as specified and directed.Note:-All tools and plants and transportation required for shifting/dismantling required is deemed to be included in the quoted rate. 24 Material and labour for boring of holes under road, pavement hard standing by trenchless technology using ultra sound technique and necessary suitable for0.4 mpa working pressure. Complete all as specified and directed.
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