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Rajiv Gandhi National Institute of Youth Development (Institute of National Importance by the Act of Parliament)

Ministry of Youth Affairs & Sports, Government of India

Chennai - Bangalore Highway, Pennalur,

Sriperumbudur – 602 105, Tamil Nadu. India

Phone : (091)044 - 27162741, 27162705 Fax : (091)044 – 27163227

Website : www.rgniyd.gov.in

TENDER DOCUMENT

FOR SUPPLY ERECTION, COMMISSIONING AND TESTING

OF

380 KVA DG SET

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Rajiv Gandhi National Institute of Youth Development

INDEX

1. INTRODUCTION

2. INSTRUCTIONS TO BIDDERS

3. SPECIAL TERMS AND CONDITIONS

4. GENERAL TERMS AND CONDITION

5. SPECIFICATIONS FOR DIESEL GENERATING SETS

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Rajiv Gandhi National Institute of Youth Development

INTRODUCTION

1. LOCATION OF SITE:

Address of site location is as given below. The intending vendor should inspect the site at his

own expense and make himself familiar with the site conditions. Non-familiarity of the site

conditions will not be a reason either for extra or for not carrying out the work in conformity

with the drawings and specifications.

New Auditorium Building in RGNIYD @ Sriperumbudur.

ADDRESS OF THE LOCATION

Rajiv Gandhi National Institute of Youth Development (Institute of National Importance by the Act of Parliament)

Ministry of Youth Affairs & Sports, Government of India

Chennai - Bangalore Highway, Pennalur,

Sriperumbudur – 602 105, Tamil Nadu. India

FOLLOWING DOCUMENTS TO BE ENCLOSED WITH THE UNPRICED BID (The documents to be

uploaded in RGNIYD e-procurement module)

1. VENDOR TO SUBMIT THEIR DETAILED SCHEDULE COMPRISING OF SUPPLY,

INSTALLATION AND COMMISSIONING OF DG SET.

INCASE VENDOR FAILS TO ENCLOSE THE ABOVE DOCUMENTS ALONG WITH THEIR

UNPRICED BAID, THEIR BID SHALL BE REJECTED.

INSTRUCTIONS TO BIDDERS

If there are no deviations, the tenderer shall advise the same as Nil Deviation.

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Rajiv Gandhi National Institute of Youth Development

If there is any contradiction between various sections of the tender booklet, the specifications of DG Set

shall hold over the Special Terms of the Contract, which shall hold over the General Terms & Conditions.

1. Name or person at tenderer’s office to be

Contacted for any clarification regarding this job :

2. Designation :

3. Phone No. or Nos :

4. Fax No. or contact Fax No. :

5. Address for correspondence :

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Rajiv Gandhi National Institute of Youth Development

SPECIAL TERMS AND CONDITIONS

1. COMPLETION PERIOD : 3 (THREE) Months

(a) SUPPLY

Supply within 3 months from the date of issue of LOI/PO or the date of advice to supply the

equipment by Director, RGNIYD.

(b) ERECTION & COMMISSIONING

Vendor shall depute his Engineer within 7 days of intimation by RGNIYD for supervision of erection

& Commissioning of DG Set.

Vendor shall make separate visits for installation & commissioning at the cost of the Vendor.

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Rajiv Gandhi National Institute of Youth Development

GENERAL TERMS AND CONDITIONS

1. All materials required for the job will have to be arranged by the contractor meeting the standard

quality.

2. The contractor will have to make his own arrangement to transport the required materials outside

and inside the working place and leaving the premises in a neat and tidy condition after the

completion of the job to the satisfaction of the Director, RGNIYD.

3. The contractor will have to arrange for safe keeping of his materials and should provide necessary

arrangements for safe guarding the materials. RGNIYD will not be responsible for any claims

with regard to this.

4. The tenderers are advised to visit the site and get acquainted with the site conditions RGNIYD

will not provide any infrastructure such as power, water, lighting etc., at site. Vendor has to make

their own arrangements for transportation of material, movement of heavy equipment at site.

5. The tenderers should note the site conditions before quoting. The site will be offered on AS IS

WHERE IS for the execution of this job and it will be sole responsibility of the vendor to ensure

that they abide by the various rules, regulations, bye-laws and other requirements, etc. for

execution of this job.

6. When the person signing the tender is not sole proprietor, the necessary Power of Attorney

authoring the person to act on behalf of the proprietor or Organisation should be produced /

attached with the tender in the Unpriced Bid.

7. The tenderers should study the various tender conditions /documents etc. carefully before

submitting their offers. If there are any doubts, they should get clarifications from RGNIYD in

writing but this shall not be a justification for submission of late tenders or extension of due date

of the tender.

8. All entries and rates in the tender form must be written in permanent ink or typewritten, Erasures,

overwriting or corrections, if any, should be attested under the full signatures of the tenderer. All

rates should be both in figures and words. The total amount should be given both in figures and

words in the tender form. In case of any difference, the rate expressed in words will be taken as

authentic.

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9. As far as possible, the tenderers should endeavor not to stipulate any counter terms / conditions or

modifications of tender clauses and should quote strictly as per tender conditions. This will assist

in proper evaluation of each offer. However, should there be any specific comments in respect of

any clause, the same may be highlighted in a separate deviation schedule in the Unpriced Bid

10. RGNIYD reserves its right to split the order to more than one Party.

11. RGNIYD reserves the right to reject offers not meeting its standard requirements and commercial

conditions.

12. RGNIYD shall not be bound to accept the lowest tender and reserves right to accept any or more

tenders in part.

13. RGNIYD reserves the right to accept any tender in whole or in part or reject any or all tenders

without assigning any reason.

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DIESEL GENERATOR SET & AUXILIARIES

SCOPE: The scope covers the design, manufacture, inspection, supply to site, testing & commissioning of the Diesel Generator set & Auxiliaries as specified.

STANDARDS: The following standards / codes shall be applicable. BS : 649 Diesel Engine IS : 4722 BS : 2623 Alternator IS : 1460 Diesel Fuels. IS 4691 Degrees of protection provided by enclosures for rotating electrical machinery. IS : 1600 Type testing of constant speed internal combustion engines for general purposes. Tamil Nadu Electricity Act & Rules. Any other Standards / Codes (BS & IS) applicable. All standard/codes shall be the latest with revisions up to date.

GENERAL The Diesel Generator set shall be outdoor type, designed for 24 hours operation engine coupled to suitable alternator having self, brushless / static excitation system and include all necessary accessories. The engine and alternator shall be on mounts. Required set of foundations bolts, nuts, washers, etc., and set of spanner and tools shall be supplied.

DIESEL ENGINES The Engine shall be multi-cylinder, naturally aspirated air cooled suitable over an ambient of 45 deg. Centigrade. The engine shall be constructed out of cast iron with forced feed fuel injection & lubrication system. The suction and exhaust valves of the cylinder shall be well designed to offer minimum flow resistance to achieve high air charging and scavenging efficiencies. The valve

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drives shall be force lubricated. The piston shall be die cast aluminum. And the head surface shall be force cooled with lubricant. The crank shaft journal shall be induction hardened and a bored. The connecting rod, crank shaft, cam shaft shall be induction hardened and all the alignments shall improve the efficiency. The governor shall regulate the speed to achieve stable performance. The engine shall be flexibly coupled to the alternator and shall be provided with a coupling guard.

FUEL OIL SYSTEM

A fuel tank of not less than 8 hours rated capacity with mechanical oil level indicator to indicate

low and high levels shall be supplied. Hand pump shall be supplied for pumping oil from barrels

to the overhead fuel Tank.

ENGINE STARTING SYSTEM Starting of diesel engine shall be through electrical starting system. The Electrical Starting System shall comprise of starter, motor, batteries and battery charger and all the necessary instruments and accessories. Air Intake and Exhaust system. Air intake filter and silencer (if necessary) be provided. The exhaust system shall consist of an exhaust gas driven turbocharger, exhaust gas silencer, necessary piping, adaptors etc. The exhaust piping shall be insulated using asbestos roping and the silencer shall be flange coupled.

GOVERNING SYSTEM : Governor shall be provided for keeping constant speed within certain limits with variable load. The governor shall have following features: The governor speed drop shall be adjustable between 3.5 to 4% of the nominal speed at any load upto full load. The nominal speed shall be adjustable by +/- 5%. The rate of frequency variation shall not exceed 0.5 Hz. in every second. An over speed trip mechanism shall be provided to shut-off fuel automatically in case the set reaches the over speed between 11% and 130% of rated speed. An engine mounted emergency STOP push button shall be provided for tripping the engine manually. A flexible coupling with guard shall be provided.

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ENGINE INSTRUMENTS PANEL

The following instruments shall be provided:

Starting switch with key.

Dial type thermometers for water & lube oil with alarm and trip contacts.

Pressure Gauge with alarm & trip contacts.

RPM indicator, Tachometer, Hour meter and Tachogenerator Mechanical

switch to trip DG Set during over speed conditions. ALTERNATOR The alternator shall be designed for rating, voltage etc. as indicated in the data sheet with class F insulation. The alternator shall be capable of carrying and unbalanced load of 25% without injurious heating of any part, provided rated current is not exceeded. The voltage unbalance consequent to 25% unbalanced load between phases shall not exceed +/-2% of average terminal voltage, provided the power factor in any phase does not fall below 0.8. The alternator shall withstand a short circuit at its terminal for three seconds with excitation adjusted to develop rated voltage at no load without any damage. The sub transient fault current shall not exceed 15 times the full load current. The field winding shall be fully insulated from the core. The field system shall have low inductance to allow good voltage regulation. The alternator shall be self-excited through a suitable transformer – rectifier combination with adjustable compounding to provide a flat or rising characteristic with load. The excitation unit shall have necessary protection for field discharge and an easy arrangement to re magnetize in case of loss of residual magnetism. The alternator shall be of drip proof construction and shall be self- ventilated. The temperature rise shall be within the prescribed limits of class F insulation. When feeding a 10% overload for one hour during every 12 hour run of full rated load with the cooling air at ambient temp. The line of neutral ends of each phase winding of the Generator shall be brought out on six suitably located terminals. The size of the cables, to be provided by owner is indicated in the Data sheet. Vendor shall provide suitable clamping arrangement for connecting the cables to the terminals. The terminals shall be suitably enclosed to prevent short circuits by rodents etc. Shunt field regulator and automatic voltage regulator if specified in the data sheet.

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240 V Single phase space heater shall be provided in the lower part of the station frame. The arrangement shall be made such that space heater shall be cut out automatically, when the alternator starts running. The alternator shall be provided with two nos. earthing terminals which shall be separated from the neutral terminals. The Alternator shall be externally regulated type with a voltage variation of +/-5% of the rated voltage with +/-3% frequency variation.

PERFORMANCE REQUIREMENT

The unit shall be capable of starting from cold condition. The unit shall be capable of a peak of 10% in excess of the rated output for a period of one hour in a total of 12 consecutive hours of operation, without exceeding permissible temperature limits and with a fairly visible exhaust. The unit shall operate upto 120 % the rated speed over the entire range of out put without undue vibrations and noise. The DG Set shall be capable of taking on min 50% load equivalent to its rated capacity in one step with no voltage dip and without affecting the frequency.

PACKING AND DESPATCH This unit shall be packed suitably to facilitate installation and transportation. During transport care shall be taken to avoid damage to paint or accessories of the equipment. If any damage is caused during transport, the vendor shall repair the same free of cost.

TEST Following test shall be carried out on Diesel Engine & Alternative & certificate to be submitted to Third Party for review. Routine test for Engine as per BS - 5514 / IS- 1600 and 1601, like fuel consumption test etc. Maximum duration of test is 3-4 hours. Routine test for alternator as per IS: 4722 or other applicable I.S. Like insulation resistance test, high voltage test, etc. Vendor shall perform the following tests at site to the satisfaction of Owner /Consultant:

1. Starting 2. Governor operation

3. Voltage Regulator response

4. Loan Run

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No load - 5 min. 25% load - 15 min. 50 % load - 30 min. 75 % load - 30 min 100% load - 60 min

110% load - 60 min

5. CONTROLS OPERATION Vendor shall submit five copies of routine tests and type test certificate for approval before dispatch.

BUSBAR

The busbar shall be tinned electrolytic copper/alum. As shown on drawings. The busbars shall be covered with PVC sleeves and properly supported. The busbars shall be adequately insulated and protected to prevent accidental contact during the operation and maintenance. The busbars shall have supports designed to withstand short circuit current equivalent to 35MVA at 415 volts. The insulation between the phases and ground of the power conductors shall be made of synthetic resin bonded moulding, resistant to dust and dampness. All insulating material shall be non-hygroscopic, Fungus proof and treated with suitable synthetic varnishes.

INTER CONNECTION & INTER WIRING Fiber glass moulded or PVC extruded wire ways shall be provided in the control panel. All the cables for internal wiring shall be PVC insulated of BSS or ISI approved and reputed make. The cables shall have copper conductors only and shall be stranded and the minimum number of stands shall be three. The rating shall conform to IEE wiring regulations. PVC flexible conductors if required shall have minimum size of 24/36. Cables for power circuits shall be red, yellow, and blue or otherwise. Proper coloured sleeving hall be provided at both ends of the cable. All wires shall have at both ends a numbered ferrule or such other means of permanent identification. Identification making shall be read from the terminals outwards on all wires.

TERMINAL / TERMINATIONS

Cables up to 150 Sqmm aluminium, shall be provided with clip-on type (slide lock design) of rugged construction. All power terminals shall be colour coded with red, yellow and blue for phases and black for neutral. Every cable, either for control or power duty shall be provided with crimping type copper lugs of suitable size as specified. The lugs shall be fitted with contact grease and the crimping pressure

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shall be as follows: Copper lugs : Upto 30 Sq.mm 1200 psi. Above 35 Sq.mm 2000 psi. Bi - metallic lugs : 1000 psi. Cable glands shall be Siemens type brass glands. These glands shall be provided for all the outgoing connections at both ends, for power as well as control circuits and also for the incoming cable or cables. Crimping type lugs only to be used. Earth busbars shall be of tinned copper / aluminium with holes, but the bolts and nuts and washers shall be cadmium plated. Earth busbars shall be provided all around the cubicle at the bottom and it shall be of the same but the maximum size will be 50 x 6mm with doples external earth connection arrangement. Bi-metallic lugs shall be used wherever copper cables are being terminated on aluminium Busbars or vice-versa.

Annunciator A solid state multi-window annunciator shall be provided on the panel board with engraved inscriptions on acrylic sheets and with visible & audible alarms.

CDG RELAY has to be provided for Over Current and Earth Fault protection. TESTING & INSPECTION : The panel boards shall be factory tested / inspected before finishing and dispatch. The following tests shall be carried out : a) Insulation resistance test b) Panel boards shall be meggered phase to phase end. The following tests shall be carried out:

INSULATION RESISTANCE TEST Panel boards shall be meggered phase to phase and phase to neutral, using a 1000 V meggar with all switchgear in closed position. The meggered value should not be less than 2.5 mega ohms between phase and 1.5 mega ohms between phase & neutral & earth.

HIGH VOLTAGE TEST The test shall be carried out by applying 2.5 KV for one minute between Air three phase & earth Between phase and the board shall withstand the same.

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MODE OF MEASUREMENT The panel complete with various components as specified in the schedule of quantity shall be treated as one unit for the purpose of measurement & payment.

THIRD PARTY INSPECTION The vendor should arrange for Third Party inspection and the cost for this shall be indicated separately in the offer. Inspection may be carried out by any of the following parties:

Lloyds EIL Rites Bureau Veritas

SCOPE OF INSPECTION : Routine tests as per IS: 1600 & 1601, BS 5514 & IS 4722 shall be carried out on bare engine and alternator in presence of Third Party inspection Agency (TPIA).

GUARANTEES Vendor shall guarantee design, materials, workmanship and performance for a period of 24 months from the date of initial operation or 24 months after delivery at job site of all goods supplied under order, which ever date shall first occur.

DRAWINGS: Soft copy to be uploaded in e procurement module and hard copy of same to be

send by courier .

Vendor shall submit four prints of following:

General arrangement drawings Foundations details Electrical wiring and schematic diagrams. Fuel oil system with instrumentation and control details. Lube oil system with instrumentation and controls details. Governor system and voltage regulator details. D.G. Set instrumentation and control system details. The vendor shall also provide four sets of installation operating maintenance and major overhauling instructions manual before

One print of each drawing will be returned to vendor after making all necessary corrections, changes and required clarifications. Vendor shall incorporate these and send within fifteen (15) days six prints of each drawing.

DELIVERY PERIOD

The DG sets complete with diesel tanks, panel, acoustic enclosure and other accessories shall be supplied to sites as given in the SPECIAL TERMS & CONDITIONS.

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SPECIFICATIONS FOR ACCOUSTIC ENCLOSURE / CANOPY

The DG set shall be provided with acoustic enclosure / canopy to reduce the sound level and to house the entire DG set (Engine & Alternator set) assembly in open condition

ACOUSTIC ENCLOSURE

CONSTRUCTION : The acoustic enclosure shall be free standing, floor mounting type, independent of DG set. The acoustic enclosure will be modular in construction consisting of acoustically treated panels from all the four sides and top. All the panels will be jacket filled with glass wool & covered with perforated sheet inside. The outside fabrication will be made of 16 SWG MS CRCA sheet metal. A free distance of 1.5m to be kept between DG set and the acoustic enclosure on all sides. The acoustic enclosure / canopy can be easily assembled at the site on the leveled surface capable of withstanding the DG weight without any civil works.

The enclosure shall be designed for installation in open air conditions and should have aesthetic

looks. Vendor shall submit the plan showing the position of the DG set and the acoustic enclosure.

DOORS : Hinged lockable doors on either side

VENTILATING LOUVERS : Both at the Engine side and Alternator side for fresh air entry and for hot air exhaust

PERFORMANCE : The sound level shall be less than 75 dbA at

a distance of 1 (one) meter from the acoustic enclosure/ canopy under free-field conditions

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SECTION III

GAURANTEED TECHNICAL PARTICULARS

380 KVA DG SET :Party should scan the below mentioned technical specification details and

upload the same in e portal site after filling the data which is required to be provided by tenderer.

Site Conditions :

PROJECT

Ambient Temp. ( Deg. Celsius)

Altitude ( Mtr. above MSL) Less than 37 Mtrs.

Relative Humidity 82%

TECHNICAL SPECIFICATIONS DG SET

GENERATOR RATING 380 KVA QTY : 1 Nos.

A) DIESEL ENGINE

MAKE :

ENGINE MODEL :

BHP AT 1500 RPM

NO. OF CYLINDER & ARRANGEMENT

ACCESSORIES l ( TO BE PROVIDED BY THE VENDOR

VENDOR'S CONFIRMATION WITH DETAILS

FLYWHEEL & FLYWHEEL HOUSING

FLEXIBLE COUPLING

AIR CLEANER

CORROSION RESISTOR

RADIATOR

FUEL PUMP

GOVERNOR

LUBE OIL FILTER

LUBE OIL BY PASS FILTER

LUBE OIL CIRCULATING PUM"

COOLING WATER PUMP

EXHAUST SILENCER

EXHAUST GAS TURBO CHARGER

CHARGE AFTER COOLER

STATER & BATTERY CHARGING

ALTERNATOR

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( 24V DC)

FUEL FILTER

EXHAUST PIPE FLEXIBLE :

SAFETY CONTROLS :

A) HIGH WATER TEMP.

B) LOW LUB. OIL PRESSURE

TACHO- HOUR METER (with rpm indicator) MECHANICAL TYPE

B) ENGINE INSTRUMENTAL PANEL :

STARTING SWITCH ( WITH KEY)

WATER TEMP GAUGE

LUB OIL PR. GAUGE

LUB OIL TEMP. GAUGE

BATTERY CHARGING AMMETER

C) ALTERNATOR :

MAKE : KEC / NGEF / AVK / STAMFORD

CAPACITY : 380 KVA

MOUNTING :

INSULATION : CLASS H

ENCLOSURE : IP 21

RATIGNG :

VENDOR TO PROVIDE :

1. AUTOMATIC VOLTAGE REGULATOR

(With manual voltage adjustment)

2. SPACE HEATER

(With auto cut-off)

3. WINDING TEMP. & BEARING TEMP DETECTOR

4. TERMINAL BOX

D) BASE FRAME

MATERIAL :

ANTI VIBRATION MOUNTING PADS :

E) FDUEL TANK

CAPACITY :

VENDOR TO PROVIDE

AIR VENT :

DRAIN PLUG :

INLET & OUTLET CONNECTIONS :

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LEVEL INDICATOR :

F) BATTERY SET

TYPE NICKEL - CADMIUM BATTERY

NO OF BATTERIES/VOLTAGE OF EACH :

MAKE: SAB NIFE ( CELL TYPE - KPH)

G) CONTROL PANEL :

AIR CIRCUIT BREAKER (with Under voltage release, safety shutter & shunt trip)

MCCB FOR 380 KVA

NEUTRAL CONTACTOR

VOLTMETER (with selector switch) RANGE :

AMMETER (with selector switch) RANGE :

FREQUENCY METER :

KW/HP METER :

PF METER :

KWH METER :

WINDOW ANNUNCIATION WITH VISIUAL INDICATION FOR FOLLOWING:

LOW LUBE POIL PRESSURE

HIGH WATER TEMPERATURE

SET START/STOP

LOW FUEL LEVEL

OVER VOLTAGE RELAY

EARTH FAULT RELAY

SPARE

PUSH BOTTON - hooter accept / fault clear

INSTRUMENT FUSES :

ON/OFF SWITCH (for manual DG control)

AUTO CONTROL CIRCUIT(for lube oil

priming

control)

SELECTOR SWITCH- (AUTO / MANUAL /

OFF)

INDICATING LAMP (for load on set/ load on

mains)

ELECTRONIC HOOTER

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NOTE : VENDOR TO GIVE LIST OF SPARES TO BE SUPPLIED WITH DG SET FOR 3000 HOURS OF NORMAL OPERATION. VENDOR TO GIVE LIST OF TOOLS TO BE SUPPLIED WITH ENGINE FOR MINOR MAINTAINCE OF ENGINE:

SCHEDULE OF QUANTITIES

FOR SUPPLY OF DG SET

TO

RGNIYD

Party should quote for one job ie Supply, installation, testing, commissioning as 1 quantity each which is inclusive of all below mentioned tasks.

ITEM NO.

DESCRIPTION

Qty.

UNIT

380 KVA DG SET:

1 Supply of 380 KVA Diesel Generating set

with Engine, alternator and Control panel

as well as local Engine controls, acoustic

enclosure meeting the local Pollution

control board (PCB) norms fuel tank,

exhaust piping as per TNPCB, TNEB

requirement, anti-vibration pads, along with

all the necessary accessories etc. complete

as required for operation of DG set and

meeting the technical requirements as

specified in the tender document.

1 Nos.

2 Supply of spares required for operation of

380 KVA DG set for 3000 hours of

operation, List of spares to be specified in

the Unpriced bid

1 Set

3 Supervision of installation of 380 KVA DG

set at RGNIYD at Sriperumbudur

1 LS

4 Supervision of Commissioning of 380

KVA DG set at RGNIYD at Sriperumbudur

1 LS