Military Engineer Services Tender

(xiv) The details specifications appended below :- (I) ENGINE (a) General: Suitable four stroke compressed ignition, radiator water cooled,Turbocharged aspiration, continuous duty with 10% overload capacity for 1 hour in 12 hours continuous running, with 40 to 50°C intake air temperature, latest CPCB Euro emission engine ,turbocharged four stroke engine developing minimum 306 BHP @ 1500 RPM under NTP conditions, coupled to alternator mounted on Channel Iron base frame with external floor mounted fuel tank of minimum 2000 Ltrs capacity with fuel gauge and connected fuel pipeline from main fuel tank to DG fuel tank complete .The prime mover provided should be as per IS specifications. (b) Air intake system : Should comprise of dry type intake air filter mounted on engine, one in number vacuum indicator mounted on intake piping.

(c ) Exhaust System: Should comprise of one exhaust manifold, dry type, mounted on engine, one exhaust hospital type silencer which should be positioned in such a way that the exhaust gas is not sucked by the fan on the radiator/heat exchanger, thereby affecting the cooling system. The silencer should cater to the noise level tolerance prescribed in the relevant IS/BS. The silencer should be provided with flaps with a provision so that it will open only when the generator is running. The complete exhaust system shall be properly supported so that entire lot of the exhaust system shall not fall on the DG Set.

(d) Fuel System: Should comprise of disposal type element fuel filter, pressure type fuel pump mounted on engine, non return check valve in fuel supply and drain lines, wire braided hose between filter and pump, fuel system with suitable capacity electronic governor and engine mounted actuator. The fuel tank must have proper locking arrangement with level indicator and to be fixed seperately / externally. (e) Cooling System: Should comprise of radiator and connected pipeline complete, hospital type silencer and tested for 50°C ambient temperature with 7 PSI pressure cap mounted on base rail. The thermostat installed in the engine coolant outlet, fresh water pump mounted on engine, fan and fan hub mounted on engine. A reservoir of 50% of radiator capacity to replenish coolant by gravity (as and when required) is also to be provided. (f) Lubricating System: Should comprise of lubricating oil sump mounted on engine, gear driven lub oil pump mounted on engine, lubricating oil cooler-fresh water cooled integral with engine cool out circuit mounted on engine, oil filter lubricating with cap and lubricating oil dip stick for oil level check mounted on engine. The system should be capable of feeding lube oil to the main end & large end bearings, cam shaft, valve rocker gear and all moving parts.

(g) Starting System: Should comprise of suitable voltage DC electrical starter mounted on engine, with suitable maintenance free battery of capacity 12 V DC - 02 Nos with suitable AH to be mounted in trays (having rubber insulation) on the main frame. It should have the provision to charge the battery from external sources during static condition and while running of the generator.

(h) AC Generator : The generator shall be horizontal and foot mounted,250 KVA, 415 Volts, 3 phase, 4 wire, 0.8 PF, 50 HZ, self excited, self regulated, brushless AC generator, suitable for voltage regulation + 1% , an ambient temperature of 40 to 50° C as per OEM design with IP-23 enclosure class H insulation and temperature rise limited to class H as per following technical details:- (i) Type, Brush less AC Generators and space heater as per OEM design (ii) Output rating 250 KVA (iii) Output Voltage: 415 ± 1% under all loading conditions and with maximum voltage Dip at full load 0.8 PF shall be 19% as per OEM design. (iv) Output frequency 50Hz ±0.5% up to 0.8 lagging. (v) No of Phases: 3 phase with 01 Neutral (4 wire) (vi) Mounting : Horizontal foot mounted. (vii) Enclosure : Minimum IP-23 / Drip proof and screen protected. (viii) Electronic Automatic voltage regulator with response time 75 m sec and + range of voltage adjustment.

(ix) Class of insulation-'H' (x) Short circuit withstand 3 times rated current for 3 secs and overload withstand capacity for continuous duty with 10% overload capacity for 1 hour in 12 hours continuous running & 150% overload for 30 sec running (xi) Overspeed capacity 1800 RPM for 2 min. (xii) The maximum unbalanced load across phases shall be less than or equal to 25%.

NOTE : Following shall be deemed to be included in Rate quoted :- (i) Standard Control panel with AMF feature outdoor type with IP-54 for 250 KVA DG set as per OEM design. (ii) Suitable size cement concrete foundation platform of canopy base with height as required at site to mount the generator as per manufacturer's instructions/ recommendations. The cost of foundation bed incl earth work and dismantling existing CC and foundation etc is deemed to be included in the quoted rate. (iii) Connecting cables, from existing panels and connecting cables , cables glands, cable lugs to new panel complete with all necessary accessories. (iv) Install on the foundation, connecting fuel lines, cable etc. (v) Test and commissioning complete. (vi) The cost of control cables from engine Control panel to AMF panel, transportation, installation, testing & commissioning etc shall be deemed to be included in the cost quoted. (j) BASE FRAME: Shall be stand by and fabricated with CRCA sheet metal which shall be suitable to mount the engine, alternator and radiator, channel width of base frame shall be adequate to accommodate anti-vibration pads.

(k) ENGINE CONTROL PANEL: Control panel shall be powder coated , weather proof type with PCC3.3 controller or suitable equivalent controller as per OEM design, mounted inside the acoustic,consist of the following. 1.suitable rated switchgear as per OEM design 2. Engine control unit (ECU),3. Current Trasformer set 4. Indicating Lamps 5. Set running & load on set Shall be indoor type manufactured with 14/16 guage CRCA sheet and is powder coated for weather-proof and long lasting finish consisting of alarm, indication and safety ( Over speed,High coolant temperature, low oil pressure, water in fuel, engine common fault low fuel level, low coolant level, emergency stop on enclosure, under frequency, over frequency, under voltage over voltage, over current, over load kw, battery under voltage), microprocessor power command controller, Aluminium busbars with suitable capacity with incoming/outgoing terminals, indicating lamps for 'Load ON' and 'Set Running', instrument fuses duly wired and ferruled , Volt meter, ammeter with selector switches, Frequency meter, energy meter, CTs and 3 Phase indicating lamps, timers etc all as per latest engineering practices.etc. complete all as specified and directed.

(l) Standard Control panel with AMF feature for 250 KVA DG set as per OEM design to be errected inside sub-station, Standard Control panel with auto mains failure (AMF) feature complete , floor mounted type, vertical, factory made outdoor type, double door , canopy, fabricated out of CRCA sheet with angle iron base frame, floor mounted, dust and vermine proof, suitable for voltage 415 V Three Phase 4 wire, 50 HZ AC supply, weather proof, with IP-54 protection, with separate hinge door for each compartment & locking arrangement, with back door openable (Screwed), legs grouted in PCC complete including painting with two coats of epoxy powder paint over a coat of primer after under going a rigorous metal treatment process involving alkaline degreasing, descaling in dilute sulphuric acid or any other acid and phosphate and with aluminium busbar (TPN) of suitable rating, suitable double compression copper cable glands and including provn of the following :-

(i) Protection relays as per OEM design/approved make. (ii) Minimum switchgears of capacity 400 A , 4P 36 KA of qty/capacity and suitable rated neutral contractor if required as per OEM design. (iii) Suitable rated resin cast CTs. (iv) Suitable rated inbuilt AVR. (v) In built SMPS based automatic battery charger. (vii) Digital Multifunction meters suitable for RS 485 communication with LAN port hub. Make: Schneider/L&T/ABB/Legrand or OEM approved make. (xi) Suitable capacity copper control cables, necessary indications, hooters, auxilliary contactors, TNC & LVM interlocking etc. (b) BACK-UP PROTECTION :- HRC Fuse for short circuit protection. (c) MICRO PROCESSOR BASED AMF MODULE :-

(i) Functions:- (aa) Supply failure timer (ab) Restoration timer (ac) 3 in pulse automatic engine start/stop logic & engine fails to start lockout (ad) Generator voltage ,current & frequency monitoring (ae) Battery Voltage sensing & monitoring (ii) Selector switches & Push buttons (aa) Manual/auto/test selector switch (ab) Engine START/STOP (iii) Metering : Remote monitoring system with GPRS/GSM modem with SIM card and 2 year data charges complete for monitoring all DG set parameters such as Hrs run, fuel level, Engine oil pressure etc complete as per OEM design. (iv) Annuciation (LED Type): (Faults)

(aa) Engine fails to start (ab) Low lub oil pressure (ac) High water temperature (ad) Generator over load (ae) Battery Voltage (af) Low fuel level (v) Additional features:- (aa) Continuous reading digital voltmer/Ammeter/freqauency meter (ab) Multifunction meters (ac) Electronic (with counter display)KWH Meter. (vi) Relay consisting of following features. (aa) 3 Phase mains supply voltage sensing (ab) Earth fault (ac) Earth leakage (ad) LED Indications (ae) Engine ON, Load on DG (af) Mains On, Load on Mains (ag) overload (vii) Push buttons (AMF Module by pass mode):- (aa) Engine START/STOP (ab) Geneator contactor CLOSE/TRIP (ac)Mains contractor CLOSE/TRIP (ad) Fault ACCEPT/RESET (viii) Engine Meters:- (aa) Lub oil pressure (ab) Water Temparature (ix) Battery Charger:- SMPS Based automatic float cum boost battery charger with following :- (aa) DC Voltmeter & Ammeter (ab) Selector switch for auto/manual & float/Boost. (x) Bypass switch of suitable rating or bypass system as per OEM design

(m) Accessories :- (i) 01 No standard mechanical and electrical tool box. (ii) Internal covered tube lights. (n) Acoustic Enclosure :- Specially designed to meet CPCB norms 75dBA @ 1 mtr at 75% load under free field conditions. The Acoustic enclosure is made of CRCA sheets and a structural/sheet metal base with high quality noise absorbent, 11 tank pre treatment process and UV resistant powder coating of all parts to withstand extreme environment and fire-retardant grade acoustic insulation material (P.U.Foam) complying to IS 8183 with two point lifting handles. (a) Internal Lighting: Tube lights with protective mesh around it to be fitted inside the container for proper illumination

(b) Doors : The enclosure will be provided with suitable doors on the side and rear to enter the enclosure during operation and maintenance. All doors will be provided with lock and handles for opening/ closing the doors, retainers for holding the panel door. (p) Painting Scheme ISS shade 220 olive green 1994 or all as per manufacturers specifications (q) Lifting/ Transportation arrangements :- Container with suitable corners will be provided to lift the DG set along with container. This is suitable for road/ rail/ sea transportation.

(r) Trials:- Trials on site should be given as per load tests prescribed and all functional trials should be shown. Note : (i) The Engine, alternator, Control Panel, Accoustic enclosure shall be integrated unit sourced and AMF panel,to be installed inside sub-stn shall be from OEM only as per Make given in Sch 'A' Notes :- (i) Testing of DG set shall carried by rep nominated by HQ CE (A&N) Zone through Accepting Officer. The cost of POL & resistive load bank required for testing the DG Set is deemed to be included in quoted rates. The DG Set shall run for a period of 12 Hours continuosly out of which 15 minutes on No Load , 2 Hrs 15 minutes of 25% rated load, 2 hrs on 50% rated load , 2 Hrs 30 minutes on 75 % rated load, 4 Hrs on rated full load, 1 Hrs on 110% rated full load. (ii) First filling of coolant, Engine Oil, lubricants and fuel etc should be arranged by contractor for complete testing and quoted rate deemed to be inclusive for the same.

(iii) The Contractor shall submit technical specifications and General Arrangement drawings of OEM for approval before placing order. (iv)The Contractor shall make all necessary arrangements for pre-despatch inspection at manufacturer site or digital e-testing as directed by AO to be arranged and for pre-commissioning test by rep nominated by HQ CE (A&N) Zone after installation of DG set & Panel. The cost for the same is deemed to be included in quoted rate.

(v) The quoted rate inclusive earth work for foundation, Cement concrete foundation as per OEM design, necessary T&P for transportation and installation complete.(vi) The quoted rate inclusive of supply of next nearest higher capacity as per OEM design without any extra cost.(vii) The quoted rate inclusive of earth work for foundation, Cement concrete foundation as per OEM design, dismanlting of brickwall/pcc/tiles and making good the disturbed surfaces including repairs/replacement brickwall/tiles/pcc & provision of steel wire mesh/GI duct for providing proper exhaust/breathing system to DG set, necessary T&P for transportation and installation complete.Any damages to fuel line system including diversion of fuel line system from Main fuel tank/fuel pumping system to all existing and proposed DG fuel tanks as required at site shall be deemed to included in quoted rate.The contractor shall visit site before quoting the tender for ascertaining the complete work required.

Suppy and laying in trenches / ducts / fixed on walls / passing through pipes, jointing and testing of LT UG cable XLPE Insulated ,screened, PVC bedded, galvanized steel strip or wire armoured, electric power cables (heavy duty) 1100 Volts grade with stranded aluminium conductor of size 400 sq mm 3.5 core. including dismantling old unserviceable cable complete all as specified and as directed by Engineer in Charge. Note: (a) Rate inclusive of LT cable lugs and end termination kits at both ends (b) Earth work, DWC HDPE pipe shall be measured and paid seperately

Excavation in trenches any type of soil (soft/loose/hard/dense) not exc 1.5m wide and not exc 1.5m in depth for foundation, pipe, laying of cable etc not exc 10 Sqm on plan and not exc 1.5m in depth and getting out complete all as specified and as directed by Engineer-in-Charge

Returning filling in, including spreading, leveling, watering and well ramming in layers not exceeding 25 cm in soft/loose soil all as specified and as directed by Engineer-in -charge.

Removing excavated materials (soil) to a distance not exceeding 50 meters and depositing where directed at a level not exceeding 1.5 meters above the starting point all as specified and as directed by Engineer-in -charge.

Supply & Laying as in repair of Telerex DWC (Double Wall corrugated) HDPE pipe ISI marked of outer dia of 120 mm polythylene including coupler & Bend with smoooth internal and corrugated external surface for non pressue under ground cable complete all as specified and as directed by Engineer-in-Charge.

Material and labour earthing with steel earth plate electrode of size 60x60cmx6mm thick buried directly in ground to a depth not less than 2.25m deep below normal ground level with top edge of the earth plate not less than 1.5m deep below normal ground level connected to galvanized iron strip of size 32x6mm as earthing lead by means of nuts, bolts and washers of steel after welding of GI strip to earth electrode to the full length of earth plate, GI medium grade pipe 40 mm bore protection pipe upto test point, 20mm dia GI light grade watering pipe with funnel and wire mesh, RCC pit cover of size 300x300x40mm reinforced with XPM having weight not less than 4Kg/sqmm including 6mm thick MS bar handle made to shape, PCC pit with 1:3:6 type C1 with angle iron frame made of angle iron of size 40x40x4mm, adequate qty of charcoal dust and salt layers all around the earth plate, excavation , earth work in any type of soil, removal of excavated soil and returning filling in all as required at site complete all as specified in plate No 3 of SSR Part-I and all as specified and directed by Engineer-in-Charge including testing on completion.

Note:- Rate quoted is deemed to be inclusive of necessary excavation in any type of soil, earth work, PCC pit, RCC cover, funnel with watering pipe, GI earth strip upto 7.5 m long for connecting to test point etc. all as required at site for complete. ( For DG body + AMF Panel)

Material and labour earthing with copper plate 60×60cm ×3.15mm thick electrode and 20×3mm copper strip as earthing lead, buried directly in ground to a depth not less than 2.25 mtr deep below normal ground level with top edge of the earth plate not less than 1.5 mtr deep below normal ground level connected to20×3mm copper strip as earthing lead by means of nuts, bolts and washers of steel after welding of GI strip to earth electrode to the full length of earth plate, GI medium grade pipe 40 mm bore protection pipe upto test point, 20mm dia GI light grade watering pipe with funnel and wire mesh, RCC pit cover of size 300x300x40mm reinforced with XPM having weight not less than 4Kg/sqmm including 6mm thick MS bar handle made to shape, PCC pit with 1:3:6 type C1 with angle iron frame made of angle iron of size 40x40x4mm, adequate qty of charcoal dust and salt layers all around the earth plate, excavation , earth work in any type of soil, removal of excavated soil and returning filling in all as required at site complete all as specified in plate No 3 of SSR Part-I and all as specified or indicated including testing on completion. Note :-Rate quoted is deemed to be inclusive of necessary excavation in any type of soil, earth work, PCC pit, RCC cover, funnel with watering pipe,Copper earth strip upto 7.5 m long for connecting to test point etc. all as required at site for complete earthing. .(for DG neutral)

Supply & fix copper strip 20mm x 3 mm buried in ground / fixed inside duct complete all as specified and as directed by Engineer in Charge

M&L forolled mild steel work as in bands, straps, supports or stays including bolts, if required, hooks (stay) complete of grade FE-290, E-165 inlcuding necessary two coats of synthetic enamel paint with one coat of primer complete all as specified and as directed by Engineer in Charge