Military Engineer Services Tender

(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 380 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 Make :-Deep Sea/ Woodward / C&S)

Removing surplus excavated material to a distance not exceeding 50 meter above the starting point complete all as specified and directed.

(a) Annunciation with indication lamps for :- (i) Low lub oil pressure. (ii) High Water Temperature. (iii) Engine over speed. (iv) Battery low voltage controls (b) Load on Indication (c) Load off indication (d) Engine start push button (e) Engine stop push button (f) Fault accept / reset push button (g) Battery Charger :- (i) Transformer (ii) Rectifier (iii) Resistance (iv) DC Volt meter (v) DC Ammeter (vi) Charger rate selector switch

NOTE - The quoted rate shall also deemed to be included the following :- (i) Prior to installation of maintenance free chemical earthing, soil resistivity test to be carried out at the location where earthing work to be done in presence of Engr-in- Charge/JE (E/M),user and the report has to submit to Garrison Engineer with recommendation of manufacturer, if required additional interconnection of earthing (not more than 08 number of earthing) to achive earth result less then 1 Ohms. The arrangement done for soil resistivity testing and submission of report with recommendation deemed to be included in the quoted rate.

Dismantling of exsting DG set of any capacity and type incuding disconnecting carefully all electrical connection duly taking down proper shut down form concerned sub station under intimation to JE E/M and earth strips, keeping them at safe custody for depositing in MES store complete all as specified and directed. Note - Rate are includes for required Lifting and shifting (tolls /crane) of DG sets to MES store yard.

Returning and filling of trenches in two parts (i) using riddled soil obtained from excavated soil upto depth of 30 cm (8 cm below cable and remaining above cable) for cushioning of cable and (ii) refilling the trench of remaining depth with normal excavated soil all as specified and directed. Note :- Excavated soil shall shall be riddle by using sieve to separate composite particles etc as per IS 1255-1983 and refilling in trenches all as in cable cushioning.

(iv) Exhaust System :- Exhaust System complete with exhaust piping of 150mm dia with MS pipe light grade up to & outside and 1meter away from the enclosure, covered with asbestos rope and aluminium foil of 28 SWG complete with in the enclosure for safe exhaust without transforming vibration to the wall of the enclosure. Exhaust gas turbo charger type. Exhaust manifold Silencer : Residual type Bellows (v) Fuel System :- Fuel injection system with fuel injectors, fuel injection solenoid switch controlled by electronic governor for 1% speed /frequency regulation, Fuel filters, Fuel hoses. (vi) Lub oil System :Lubricating oil filter,Lubricating oil pump

Supply, installation, testing & commissioning of maintenance free chemical earthing system comprising of 17mm dia copper bonded rod 3 mtr long horizontally pre welded T-terminal rod with provision for connection size of 50 x 150mm long, 6mm thickness with equal space either side, with 12mm dia hole of 02 numbers each on either side of the terminal clamp with 250 microns (average) coating thickness, tested and certified by CPRI India alongwith 50 Kg earth energizer compound and 10 litres earth resistance reducing liquid. The earthing energizer compound and resistance reducing earthing liquid shall be tested as per IEC-62561-7 read with ASTM G57-06, CI 3.4 A by any NABL accredited lab. The above mentioned rod shall be installed in 4-6 inch bore, 12 feet depth with a distance of minimum 3 meters between each installation complete all as specified and directed. (Make - Model HTSP 317 of safeTrode or equivalent in OBO Betterman/ FURSE/ERICO)

(v) Earth enhancing material should not leach into the adjacent soil or underground water channels and its PH value should be in neutral range complete all as specified and as directed. It should solidify when mixed with water and set like concrete. (vi) Copper strip of size 20 x 3 mm (99.99% molecularly copper) should be fixed on proper post insulator at the instrument end ( copper strip upto 7.5 RM will be considered in unit quoted rate and extra will be measured and paid separately). vii) Testing of earth shall be carried out in presence of departmental and user representative and report shall be submitted to Garrison Engineer duly signed by all concerned. (viii) Earth resistance tester will be provided by the contractor. Tester should be calibrated from authorised company/ lab.

(xii) During the guarantee period, if earth resistance is not maintained less than 1 ohm the contractor has to redo or rectify at no extra cost to Govt till desired result is maintained. (xiii) A security deposit of value equal to 2.5 % of the rate quoted for each chemical earthing each earthing shall be retained from payment due to the contractor from final bill for the guarantee period. (xiv) The electrode shall carry manufacturer's name . (xv) The connection clamp shall be permanentlly welded to the copper bounded rod to avoid any kind of connectivity loss,.The pre-welded copper bounded rod shall not need any additional clamp for termination.

Supply and laying of cable XLPE insulated screened PVC bedded galvanised steel strip or wire armoued, electric power cable (heavy duty) 1100 volts grade with stranded aluminimum conductor of size 185 sqmm 3.5 core, all as specified and directed..

Taking down any type and size of Earthing complete all as specified and directed.

(B) Diesel Engine - Naturally aspirated/turbo charged/turbo charged after cooled , water cooled continuous rated CPCB IV + approved engine with 10% over load capacity capable at 1500 RPM suitable for direct coupling with single bearing alternator multi cylinder multi stroke direct injection, cold starting 1500 RPM, as per relevant ISI/BS - 5514 complete with standard accessories all as specified and required for safe handling and operation salient features of accessories shall be as under:- (Make: Cummins / KOEL (Kirloskar) / Greaves Cotton / Mahendra/ Cater pillar Ashok Leyland) (i) Fly wheel with housing (ii) Cooling system :- Moulded radiator with fan & belts (iii) Cooling Water pump - Centrifugal type belt driven

S&F Copper strip 20 x 3mm thick (99.99% molecularly copper) as earthing lead fixed to wall/roofs etc including taking down existing one all as directed. (NOTE - All Joints should be joined by Exothermic Welding or Brazing)

Material and labour for Earth pit cover made of heavy duty poly plastic of high grade polypropylene tested and certified by any NABL accredited lab for load bearing capacity not less than 7.2 tonnes with top dia not less than 250mm, bottom dia not less than 330 mm and height not less than 260 mm for each electrode pit complete all as specified and directed. (Make : Model SEPC 250 of SAFE TRODE/ Electrogrip Model/ EGTEK3LC of ISG Global or equivalent) Note :- The contractor shall submit load bearing capacity certificate from the manufacturer.

Taking down any type and size of LT cable from wall/pole/below GL including excavation after taking proper shut down from concerned sub station complete all as specified and directed.

NOTE: The quoted rate deem to be included the following :- (a) excavation, removing of soft soil and PCC, Cement Concrete foundation, filling and mass concrete type B2 (1:2:4) using 40 mm graded aggregate of size as specified by the manufacturer for placing of DG Set complete all as specified and directed. (b) Anti vibration mounting pads as per manufacturers guidelines. (c) Testing of DG set to be carried out by Rep of accepting officer/IEM. (d) Artificial load i.e. strip heaters of suitable capacity to be made available during test. (e) Extended terminals with tinned copper has to be provided for terminating the incoming & out going cable with suitable lugs for MCCB’s if required. (f) U/G cable to be laid/connected DG set cubicle panel to AMF control panel (change over panel) all as specified.

(D) Acoustic Enclosure - Prefabricated factory built, free standing, floor mounting type acoustic enclosure of modular construction suitable for accommodating the 380 KVA Engine Alternator set, AMF type control panel, fuel tank etc as per specifications and conditions attached. The engine and enclosure shall conform to the latest Environment (Protection) Act 1986 (29 of 1986) of Ministry of Environment and Forest Notification dated 17th May 2002 and 12th July 2004 and as amended up-to-date. Valid CPCB IV+ certificate of authorized agency such as ARAI of Pune, NPL New Delhi, NSTL Vishakhapatnam, FCRI Palghat and NAL Bangalore shall be submitted. Manufactured by OEM suitable for 380 KVA DG Set as following:- (i) NAL approved as per CPCB IV+ (ii) It Should be as per latest rules and regulations of Ministry of Environment and Forest and Pollution control board

Material and labour as in repair for Earth pit indicator for existing earthing pit made out of 16 mm dia and 60 cm long MS Squre Bar embeded in PCC (1:3:6) type C-1 using 20 mm graded stone agreegate in PCC block of size 300 x 300 X 300mm including CI/MS plate of size 250X300X 3 mm thick fixed on side of earth pit cover complete painting and writing over the plate ie. Type , Result, Date of measurement and pit number with Black beground with white and complete all as specified and as directed.

(xvi) The acceptable earth resistance at earth busbar/ test point shall not be more than 0.1 ohm. (xvii) Earth work such as auguring and making good the surrounding area shall carried out in any type of soil. (xviii) The contractor shall submit CPRI India certified document for copper bonded rod to ensure genuity of material along with sample approval. (xix) Sign board of mild steel 2 mm thick duly painted with two coats of synthetic enamel paint over a coat of red oxide Zinc chrome primer showing result of earthing should be fixed near the earth pit after completion as directed .

M & L for Bricks covering with width equal to length of brick as mechanical protection to cable with well burnt sub class ‘B’ bricks having crushing strength not less than 75 Kg/Sqcm, laid dry flat complete all as specified and directed..

(i) The capacity of Generator set shall be net after considering all due de-rating factors as per relevant ISI design . (ii) Rate quoted shall be deemed to be inclusive of cable and terminations from Generator to the AMF Panel, with necessary holes to wall including making good to disturbed surfaces so as to match with the existing finishes all as specified and directed. (iii) The quoted rate shall be deemed to be inclusive of first fill of oil and final successful acceptance test .

(ii) The description/ size/ qty of items mentioned in above are for indicating only however qty/ size may vary at site condition to maintain the earth resistance 1 ohm. The contractor shall quote rate by considering all factors. (iii) Rate of earth energizer compound of 25 Kg of 02 bags and earth resistance reducing liquid 10 litre per cane for each pit deemed to be included in the quoted rate. (iv) Resistivity of earth energizer compound and resistance reducing earthing liquid shall be certified by any NABL accredited lab carried out as per IEC-62561-7 read with ASTMG57-06, CI-3.4A and the certificate of same shall be submitted by the contractor along with sample approval.

(ix) Earthing shall be tested after completion of work by the contractor in presence of Engr-in-charge, user and proper record shall be maintained duly signed by all concerned. After testing if the desired earth resistance of less than 1 Ohm is not obtained, the earthing will be redone at no extra cost to Govt. till desired result is obtained. (x) The contractor shall give a written guarantee of minimum three years for maintaining the earth resistance less than 1 Ohm after certified date of completion. (xi) No further maintenance or periodic watering or recharge shall be required in earthing during its guarantee period of over 03 years in all type of soil including soft/ disintegrated or hard rock.

(A) Alternator - (i) Standard design alternator rated at 380 kVA net output at site after considering de-rating as per site conditions at 0.8 (lag) power factor AC, 3 - phase 4 - wire 415 volts 50 Hz, 1500 RPM, self excited self regulated screen protected drip proof IP 23 enclosure brushless design with winding in pole faces, insulating class 'H' and voltage regulation of +/- 1% at rated voltage from no load to full load. (ii) The alternator shall be conforming to BS 2613/5000 and shall be imposition to generate supply with frequency regulation with in +/- 1% tolerance. The alternator will be suitable for tropical climate and shall generally conform to BS - 2613/5000/ IS – 4722 i) Insulation class - 'H' Make: Stamford / Kirloskar (KOEL green) / Crompton Greaves. (iii) Temperature rise Class - 'H‘ (iv) Excitation : Self Excited (v) Regulation performance: The voltage is kept constant with +/- 1%, manual voltage adjustment within +/- 5%, v) Frequency regulation +/- 1%

(iii) The generating set batteries and control panel should be inside the enclosure. (v) Construction Details/specification are as follows: (a) Outer body :- CRCA Sheet of 1.6mm thick (b) Doors :- CRCA sheet of 1.6 mm thick (c) Sound Insulation :- As per OEM Norms (vi) The accoustic should be composite in construction and fully assembled integral unit (vii) The batteries should be placed inside the enclosure beside the DG Set on a suitable insulated plat form (ix) The DG Set should be provided with external Emergency stop push button (x) The enclosure should be suitably illuminated by LED Lamp fittings. (xi) The noise level should be 75 dba at 1m under free field conditions. (xii) The acoustic enclosure parts shall be of powder coated after pre treatment process. The powder coating shade should be Gen set Green. The base frame should be painted with epoxy based black shade