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HINDALCO INDUSTRIES LIMITED

(UNIT BIRLA COPPER)

P.O. Dahej
Dist. Bharuch
Gujarat 392130
India

1000 TPD COPPER CONTAINING SMELTER SLAG BENEFICIATION


PLANT
AT DAHEJ, GUJARAT

TECHNICAL SPECIFICATION
FOR

415 V CAPACITOR

SPECIFICATION NO. K8L06-DOC-E-330-SP-0028

October, 2008

DEVELOPMENT CONSULTANTS PRIVATE LIMITED


CONSULTING ENGINEERS
24 B PARK STREET

KOLKATA 700 016

1000 TPD COPPER CONTAINING SMELTER SLAG BENEFICIATION


PLANT AT DAHEJ, GUJARAT

SPECIFICATION NO. K8L06-DOC-E-330-SP-0028


FOR
415V CAPACITOR
INDEX

SECTION

DESCRIPTION

PART - A

PART B

I.

NOTICE INVITING TENDER

II.

INSTRUCTION IN CONNECTION WITH SUBMISSION OF TENDERS

III.

TECHNICAL SPECIFICATION

IV.

PROPOSAL EXHIBIT SHEETS

PRICE SCHEDULE

PART - A
SECTION - I
NOTICE INVITING TENDER
For and on behalf of Managing Director, Hindalco Industries Ltd, Dahej sealed tenders are invited
from approved agencies for carrying out design, engineering, manufacture, supply,
supervision(optional) during erection, testing & commissioning of 415 V Capacitor Panel for the
1000 TPD copper containing smelter slag beneficiation plant located at Dahej, Distt. Bharuch,
Gujarat.
Details
1.

Reference No. of Tender

K8L06-DOC-E-330-SP-0028

2.

Nature of Work

Design, manufacture, supply,


Supervision (optional) during installation,
testing, trial run & commissioning of 415V Capacitor
Panel.

3.

Last date of receipt of filled-up


Tender Document

__________________________.
Hindalco Industries Limited (Unit Birla Copper)
P.O. Dahej, Dist. Bharuch, Gujarat 392130

4.

Office where tender is to be


submitted.

5.

Validity of Tender

:
_____ weeks from the last date of
submission.

6.

Delivery period

:
_____ weeks from the date of placement
of order.

Managing Director
Hindalco Industries Limited (Unit Birla Copper).
Dahej

*****

SECTION II
INSTRUCTION IN CONNECTION
WITH SUBMISSION OF TENDERS
1. The tender documents are divided into two parts, namely Part-A and Part-B.
Part-A, Technical and Commercial part, comprises the followings:
a.

Notice inviting tender

b.

Instruction in connection with submission of tenders

c.

Technical specification

d.

Proposal exhibit sheets

Part-B, Price part, comprises the Price break up and the Summary of Prices.
Both to be duly filled in by the Tenderer.
2. It will be presumed that the tenderer has carefully examined the terms and conditions, as
contained in the tender documents, thoroughly and carefully, and fully acquainted himself
with all the details of the site, location, materials, weather characteristics, labour conditions
and all other information and data pertaining to and needed for the work.
3. The tendered rates should be typed or written by hand in English in the price schedules in the
tender documents in ink, both in words and figures. The amount against the respective
items of work should be calculated and totaled on each page and grand totaled on last page.
4. The rates should be written in Rupees and Paisa only.
5. The tenderer should quote his rates only for those items of work against which quantities have
been furnished in the price schedules.
6. All pages of the Tender documents including addenda/corrigenda, if any, should be initialed at
the lower left hand corner. The tender document shall be signed by the tenderer. In the
event of the tender being submitted by a firm, it must be signed by each partner thereof, and
in the absence of any partner, it shall be signed on his behalf by a person, holding the power
of attorney from the absenting partner, authorizing him to do so.
7. No alterations or modifications should be made in the contents of the tender document except
filling up the rates to be quoted in the tender document Part-B. Any tender that is not
accompanied with the complete set of tender documents, and/or which does not include
rates of all the items price schedules shall be considered incomplete and shall be rejected.
8. HIL/DCPL reserves the right to extend the date for submission of tenders. HIL/DCPL also
reserves the right to revise and/or amend the tender documents, prior to the date notified for
the receipt of price bids or the extended date for the same, as the case may be. Such
revision, amendments or extensions, if any, shall be intimated to the tenderers in the form of
addenda, letters, fax or e-mails, as may be considered suitable.
9. On receipt of tender documents, the same will be opened by HIL. HIL does not bind itself to
accept the lowest or any tender and will not assign any reason for the rejection of any or all
tenders. Also HIL reserves their right to negotiate with the lowest or any other tenderer.
10. Tenders are to be submitted in sealed envelopes, both for Part A and Part B. Any open offer
received will be rejected. Also any offer received after the due date is likely to be rejected.
11. Any further information required in connection with this tender can be obtained on any working
day, during office hours from:
The Project Manager
Hindalco Industries Limited (Unit Birla Copper),
Dahej.
SECTION III

TECHNICAL SPECIFICATION

C ONTENTS

SECTION

DESCRIPTION

1.00.00

INTENT OF SPECIFICATION

2.00.00

SCOPE OF WORK

3.00.00

GENERAL REQUIREMENTS

4.00.00

SITE CONDITIONS

5.00.00

DESIGN CRITERIA

6.00.00

SPECIFIC REQUIREMENTS

7.00.00

SURFACE PREPARATION & PAINTING

8.00.00

TESTS

9.00.00

SPECIAL TOOLS & TACKLES

10.00.00

SPARES

11.00.00

DRAWINGS, DATA & MANUALS


ATTACHMENTS

ANNEXURE - A

RATINGS AND REQUIREMENTS

ANNEXURE - B

MANDATORY SPARES

4 1 5

C AP AC I T O R

1.00.00

INTENT OF SPECIFICATION

1.01.00

This specification is intended to cover the design, manufacture, assembly,


testing at manufacturer's works, supply & delivery, properly packed for
transport to site of 415V Capacitor panel, complete with all accessories for
efficient and trouble-free operation.

1.02.00

The scope of work shall also include, at the option of the Owner/Purchaser,
the supervision of erection, testing, commissioning and putting into
successful commercial operation of all equipment furnished under this
specification.

1.03.00

The work is subject to all the terms and conditions detailed in the documents
listed below, which shall form part of this specification as if bound together.
a.

Tender Notice

b.

Instruction to Bidders

1.04.00

In the event of any discrepancy with listed documents, the stipulation of this
specification shall govern.

2.00.00

SCOPE OF WORK

2.01.00

Scope of Supply
Type, rating and connections of the equipment listed below are detailed in
the annexure. The equipment shall be offered in strict compliance with the
same.

2.01.01

One set of 415 V APFC switchboard shall be supplied:415 V, Capacitor switchboard comprising
LT capacitor banks, power & control
switching equipment, breaker and
automatic power factor correction relay etc. : One (1) Set

2.01.02

Base channel frame of the switchboard

2.01.03

One set of special tools and tackles, as required

2.01.04

Mandatory Spare parts

2.01.05

Recommended spare parts for two (2) years operation

2.01.06

All relevant drawings, data and instruction manuals.

2.02.00

Scope of Services

The services of a senior engineer, experienced in the erection and


commissioning of the equipment of similar type and rating on per diem
basis. The work includes but not limited to:2.02.01

Complete checking of materials at site and advising the Owner/Purchaser


any discrepancy thereof.

2.02.02

Advice on procedure of erection to be followed.

2.02.03

Regular supervision and following up of erection work done by others.

2.02.04

Testing, commissioning and putting the equipment into successful


commercial operation.

2.03.00

Exclusion from Scope of Work

2.03.01

All concrete foundation works.

2.03.02

Labor and equipment for unloading and installation.

2.03.03

Power & control cables for connection with equipment supplied by others.

3.00.00

GENERAL REQUIREMENTS

3.01.00

Codes and Standards

3.01.01

All equipment and materials shall be designed, manufactured and tested in


accordance with the latest applicable Indian Standards (IS) and IEC except
where modified and/or supplemented by this specification.

3.01.02

Equipment and material conforming to any other standard which ensures


equal or better quality, may be accepted. In such case, copies of the English
version of the standard adopted shall be submitted along with the bid.

3.01.03

The electrical installation shall meet the requirements of Indian Electricity


Rules as amended up to date and relevant IS Codes of Practice. In addition,
other rules and regulations applicable to the work shall be followed.

3.02.00

Drawings & Annexures

3.02.01

All drawings(if any) and annexures appended to this specification shall form
part of this specification and supplement the requirements specified herein.

3.02.02

This specification shall be read and construed in conjunction with the


drawings and annexures to determine the scope of work and terminal points.

3.02.03

The quantities shown on drawings and annexures are tentative for bidding
purpose only. Any variation arising during detailed engineering stage shall be
taken into account for adjustment of contract price based on unit rates quoted
in the bid.

3.03.00

Completeness of Supply

3.03.01

It is not the intent to specify completely herein all details of the equipment.
Nevertheless, the equipment shall be complete and operative in all aspects
and shall conform to highest standard of engineering, design and
workmanship.

3.03.02

Any material or accessory which may not have been specifically mentioned
but which is necessary or usual for satisfactory and trouble-free operation and
maintenance of the equipment shall be furnished without any extra charge.

3.03.03

The supplier shall supply all brand new equipment and accessories as
specified herein with such modification and alteration as agreed upon in
writing after mutual discussion.

3.03.04

Make of brought-out items are subject to Owner/Purchasers approval. The


contractor shall furnish relevant details to the Owner/Purchaser for his
concurrence before procurement.

3.04.00

Proposal Data
The proposal data (exihibit) sheets annexed to this document shall be filled in
without any ambiguity by typing in appropriate place on each page. These
pages must be properly signed by authorized representative of the Bidder as
verification of the data and submitted along with the bid to form part of the
bidder's formal proposal.

3.05.00

Guaranteed Performance
The performance figures quoted in Proposal Exhibit sheets shall be
guaranteed within the tolerance permitted by relevant standards. In case of
failure of the equipment to meet the guarantee, the equipment may be liable
for rejection.

3.06.00

Deviation

3.06.01

Should the Bidder wish to deviate from this specification in any way, he shall
draw specific attention to such deviation.

3.06.02

All such deviations shall be clearly mentioned on the Deviation sheet format
enclosed, with reference to the respective clause of the specification.

3.06.03

Unless such deviations are recorded in the deviation sheets and submitted
with the offer, it shall be taken for granted that the offer is made in conformity
to this specification in all respects.

3.07.00

Drawing Approval

3.07.01

Before starting manufacture of any equipment, the supplier shall have to take
approval of relevant drawings and data from purchaser in writing.

3.07.02

Any manufacture done prior to the approval of drawings/data shall be rectified


in accordance with the approved drawings/data by the supplier at his own cost
and the equipment shall be supplied within the stipulated period.

3.08.00

Experience & Qualifying Requirement

3.08.01

Necessary information about the financial and technical resources,


organization and experience to undertake the manufacturing and supply of
such equipment shall be supplied by the Bidder as an evidence of his
capability for satisfaction of the Owner/Purchaser.

3.08.02

The Bidder shall submit along with his bid a list of major contracts for supply of
similar equipment executed/being executed by him during last 5 years giving
detailed particulars such as quantity, equipment rating, contract value, name
of the Owner/Purchaser, year of commissioning etc.

3.08.03

The bidder shall submit the documentary evidence that equipment of similar
rating has been manufactured by him and are in successful operation for more
than two (2) years in two or more projects of similar nature on the date set for
opening of the bid.

3.08.04

Not withstanding anything stated above, the Owner/Purchaser reserves the


right to assess bidders financial and other capabilities to execute the contract.

3.09.00

Quality Assurance

3.09.01

The Contractor shall follow his standard procedures for quality assurance and
control. A copy of the said standard procedures shall be submitted to the
Owner/Purchaser for his reference. However, Owner/Purchaser reserves the
right to review the same and give his observations, if any, for compliance.

3.09.02

The procedures shall be in such a form as to clearly delineate the


manufacturing sequence, inspection points, tests and test procedures,
acceptable ranges / values, reference drawings etc.

3.09.03

The Owner/Purchaser shall inform the Contractor as to which of the


inspection points and tests shall be witnessed. As a minimum, inspection and
testing of the finished equipment shall be made prior to shipment, unless
specifically waived by the Owner/Purchaser. The contractor shall give at least
seven (7) days advance notice regarding readiness of the equipment.

3.09.04

Manufacturing and quality control procedures shall be available for audit to


the Owner/Purchaser and/or its representative at the place of manufacture.

3.09.05

The Owner/Purchaser reserves the right to inspect the equipment at the point
of manufacture and witness factory and other such tests as may be necessary
to ensure conformance to the specification.

3.09.06

The Owner/Purchaser may inspect the contractor's facilities prior to award of


contract.

3.09.07

The Owner/Purchaser may witness any or all of the tests stipulated in the
relevant standards and this specification.

3.09.08

The Owner/Purchaser may conduct surveillance of the Contractor's facilities


for compliance to his standard procedures of Quality Assurance and Quality
Control while work on the specified equipment is in progress.

3.10.00

Packing for Shipment

3.10.01

The equipment complete with its fittings & accessories, spares, special tools
and tackles shall be suitably protected by respective packing for shipment
considering handling during transit, distance and weather conditions
involved. The Contractor shall submit the packaging method for shipment to
be adopted by him, if so desired by the Owner/Purchaser.

3.10.02

Each consignment shall be marked with Equipment name,


Owner/Purchasers name & address, Project details, handling instruction
etc. It shall be completed with part list and identification details. The copies
of the part list of each consignment shall also be furnished to the
Owner/Purchaser after dispatch.

3.10.03

Eqpt. shall be packaged for transportation so as to meet the space and


weight limitation of transport facilities. The contractor shall obtain approval
from concerned authorities for transportation of over dimensioned
consignment/ package, if any, before starting manufacture of such
equipment.

4.00.00
4.01.00

SITE CONDITIONS
Location
The plant site is located at Dahej, Dist. Bharuch, Gujarat. Site accessibility
from nearby important places are as below:
a)
Nearest village ( Dahej )
00 Km
b)
Railway station ( Bharuch ) 45 Km
c)
Airport ( Baroda )
75Km

4.02.00

5.00.00

Site ambient conditions:


a)
Annual Rainfall
b)
Maximum temperature
c)
Minimum temperature
d)
Relative humidity
e)
Site elevation
f)
pH of the soil
g)
Wind speed
h)
Wind direction

:
:
:
:
:
:
:
:

550 to 700mm
42C during summer
8C during winter
60%(dryseason)&90%(monsoon)
10 to 11m
7.7 to 8.4
90 -150 Km./h
South West

DESIGN CRITERIA

5.01.00

415V capacitors along with its control panels shall be used for power factor
improvement in 415V switchgears. The control panel-board with integrally
housed capacitor banks shall be installed in sub-station to improve the
power factor of 415V system.

5.02.00

The capacitors shall be connected to bus-section of the panel-board and


shall be manually as well as automatically switched in and out in steps so as

to correct the power factor to the required value depending on the actual
kVAR requirement at the bus. Compensation to the lagging kVAR shall be
made having the reference power factor as 0.96. The Tenderer shall supply
the necessary L.T. capacitors and the associated control devices complete
with contactors, relays, switches, lamps etc. to achieve the above objective.
5.03.00

Capacitors shall comply with the general safety regulations for power
installation prescribed in the relevant standard.

5.04.00

Capacitors shall be designed taking care of the site conditions stated


elsewhere in the specification. All equipment, accessories and wiring shall
be provided with a tropical finish for prevention of fungus growth.

5.05.00

Capacitors units shall be suitable for operation at an r.m.s. voltage between


terminals not exceeding 1.1 times the rated voltage, excluding transients.

5.06.00

All capacitors shall be suitably protected against over current by means of


suitable over current trips (other than fuses) which are adjusted to interrupt
the circuit when the current exceeds the safe permissible limit. Capacitor
units shall also be protected against the internal faults and the affected
units / banks shall be automatically and immediately isolated in the event of
such faults.

5.07.00

Capacitors shall be provided with proper discharge device built into the unit
to reduce the residual voltage to a safe value within the specified time as
recommended in the relevant standard after the capacitor has been
disconnected from the supply. The capacitor unit under any condition should
not discharge through motor windings.

5.08.00

Capacitors shall be of insulation test class I.

6.00.00

SPECIFIC REQUIREMENT

6.01.00

Construction

6.01.01

The capacitor panel-board shall be indoor, metal-clad, floor mounted, nondraw out type. However, the incoming circuit breaker shall be draw-out type.
The board will be of double-front construction with capacitors accessible
from the back. The maximum depth of the panel allowed is 1000mm.

6.01.02

The enclosure shall conform to the degree of protection IP-4X. The minimum
thickness of CRCA sheet steel used shall be 2 mm. except for gland plate,
for which the same shall be 3 mm. The design shall be such that the
specified degree of protection is achieved even after the breaker has been
taken out of the panel. The panels shall be supplied with removable gland
plates at the top.

6.01.03

External Cable entry to the assembly shall be from top only. There will not
be any provision of cables running below the switchboards in the substation
where the capacitor panel-board will be installed.

6.01.04

The assembly shall comprise a dead-front, free standing, vertical cubicle(s).


Each cubicle shall have a front hinged door with latches and a removable
back cover. All covers and doors shall be provided with neoprene gaskets.

6.01.05

Incoming switchgear cubicle shall be so sized as to permit closing of the


front access door when the breaker is pulled out to TEST position.

6.01.06

The capacitor bank feeders shall be fully compartmentalized with metal/


insulating partitions between compartments. Working height shall be limited
between 450mm and 1800mm from floor level.

6.01.07

All relays, meters, breaker control switches, selector switches and indicating
lamps shall be flush mounted on the respective cubicle door or on control
cabinet built on the front of the cubicle. AC/DC auxiliary supply switches /
isolation switches for cubicle space heater, cubicle lamp, and spring
charging motor circuit shall be located inside metering compartment.

6.01.08

A full-height vertical cable alley with cable supports shall be provided in each
section to facilitate unit wiring. The alley shall be liberally sized to
accommodate all cables and shall have removable cover at the front for
access.

6.01.09

After isolation of power and control circuit connections, it shall be possible to


safely carry out maintenance in a compartment with the busbar and adjacent
circuit live. Necessary shrouding arrangement shall be provided for this
purpose over the cable terminations located in cable alley.

6.01.10

Provisions of two separate and distinct grounding connections shall be


provided on each capacitor control panel.

6.02.00

Configuration

6.02.01

The capacitor panel board assembly shall house three phase capacitor
banks, all the power & control switching equipment, necessary power/control
equipment and all other accessories as required to complete the assembly
to effect reliable & durable power factor improvement.

6.02.02

The whole assembly will have one incoming ACB (air circuit breaker) to feed
three phase buses. Each capacitor bank will be connected to the bus
through MCCB & power contactor, both of them having been suitably
derated as per recognized standards.

6.02.03

The power supply to the board will be three phase three wire with 415V
nominal voltage and utilisation control voltage shall be 110V AC 1
generated through a control transformer. The control trafo will supply to each
capacitor-bank feeder through curve-C MCB-s.

6.02.04

There shall be incoming voltmeter & ammeter with selector switches and
indicating lamps for all the three phases.

6.02.05

The bank feeders will be switched on & off either manually through operation
of manual/Auto selector switch, timer & On / Off push buttons, or,
automatically through operation of APFR relay, manual/Auto selector
switch & requisite auxiliary contactor-relays. The timer will have provision of
time-delay of one minute to two minutes.

6.02.06

Each bank-feeder module shall have ammeter to indicate currents of all the
three phases and ndicating lamps for bank ON status.

6.02.07

SCPD-s (short circuit protective devices) used in circuits connected to the


415V system shall adhere to wiring regulation, i.e., IS 732 latest revision.

6.03.00

Rating and Control

6.03.01

The selected basic unit size shall be 25kVAr or any lower rating as required
to achieve the specified bank sizes. The bank sizes are as mentioned in
Ratings & Requirements. The total capacitor bank shall comprise a
number of the built-up units of different ratings, connected in binary fashion
to the APFC relay through MCCB & capacitor duty contactors.

6.03.02

The automatic power factor relay shall have provisions for output signals
(potential free contacts) in twelve (12) stages to enable achieve the set
power factor at all possible loading conditions. The relay shall also have
provision for selection of maximum number of switching sequences, to
enable from equal value switching to binary value switching. It will be
possible to have both Rotational as well as Linear switching of the banks
to achieve faster response to load changes.

6.03.03

The relay shall be able to indicate if the harmonic content in the power
system crosses a preset value and switch off the capacitor banks to protect
them from premature failure.

6.03.04

The control panel shall have digital display of the set and achieved power
factors and analog display of current in all the three phases of the line.

6.03.05

The relay shall have LCD / LED display. Parameters shall be displayed in
auto mode or manual mode. Necessary membrane key pad shall be
provided for manual scrolling of display parameter. The relay shall be easily
programmable from front panel itself.

6.04.00

Bus and Bus Taps

6.04.01

The capacitor panel-board shall be provided with three phase bus bars.

6.04.02

Busbars of the capacitor panel-board shall be sized to carry continuously the


total capacitor bank current plus a 20% margin.

6.04.03

The main buses and connections shall be of high conductivity aluminum


alloy designation 63401 WP range 2 (to IS 5082), sized for specified current
ratings with maximum temperature limited to :
a.

For bolted joints (Plain or tinned)

90oC

b.

For bolted joints (Silver plated)

105oC

6.04.04

Vertical busbars shall be designed for a minimum current rating of 200 A.

6.04.05

Bus bars shall be of same size for the entire length of the switchgear.

6.04.06

All bus connections shall be silver plated. Adequate contact pressure shall
be ensured by means of two bolts connection with plain and spring washers
and locknuts. Bimetallic connectors shall be furnished for connections
between dissimilar metals.

6.04.07

Bus bars and connection shall be fully insulated for working voltage with
adequate phase/ground clearances. Insulating sleeves for bus bars and
cast-resin shrouds for joints shall be provided, suitable for maximum
temperature rise of bus bars.

6.04.08

Bus insulator shall be flame-retardant, track resistant type with creepage


distance suitable for the present application.

6.04.09

All buses and connections shall be supported and braced to withstand


stresses due to maximum short circuit current and also to take care of any
thermal expansion.

6.04.10

Bus bars shall be color coded for easy identification and so located that the
sequence R-Y-B shall be from left to right, top to bottom or front to rear, when
viewed from front of the switch-gear assembly.

6.05.00

Capacitor

6.05.01

Capacitors units shall be self-healing type to IS 13340.

6.05.02

Capacitor units shall be contained in hermetically sealed metal containers,


to protect from leaks and contamination of dielectric. All joining in the steel
casing shall be welded and tested for liquid tightness.

6.05.03

The capacitors shall be provided with properly sized discharge resistors,


which, after switching off of power, shall discharge the capacitors to less
than 50 volts within one minute.

6.05.04

Terminals of capacitor units shall be suitably brought out through bushings,


hermetically soldered to the steel case, for external cable connection.
Terminals shall be provided with studs, bolts, nuts, washers and cable shoes
of appropriate size for proper termination of flexible wires.

6.05.05

Capacitors shall be of low loss mixed dielectric design (suitable for use in
harmonic conditions & in over voltage imposed by series reactor), loss figure
being maximum 0.5watt / kVAR inclusive of that due to discharge resistor.
Impregnated paper or equivalent and polypropylene shall be used as
dielectric material.

6.05.06

Each capacitor element in a capacitor unit shall be provided with internal


fuse to remove only the faulty element from the circuit and enable the other
elements remain in service.

6.05.07

Metal container of the capacitors shall be provided with two distinct earthing
terminals with nuts, bolts, washers connected to earth continuity conductor.

6.05.08

The capacitors and their control elements like relays, contactors, timers,
protective elements shall be housed in well-ventilated panels. Capacitors
and their control elements shall be installed in different compartments of the
same panel to minimize the space requirement.

6.05.09

The terminals of all capacitors shall be made accessible.

6.06.00

Air circuit Breaker

6.06.01
6.06.02

Circuit breaker shall be triple pole, single throw and type: ACB.
Circuit breaker shall be horizontal isolation and horizontal draw out type,
having SERVICE, TEST and DISCONNECTED positions with positive
indication for each position.

6.06.03

Breaker operated incomer shall be provided with one(1) TEST-NORMALSWGR selector switch.

6.06.04

Circuit breaker shall have motor wound spring charged trip free mechanism
with anti pumping-feature and shunt trip. In addition facility for manual
charging of spring shall be provided.

6.06.05

For motor wound mechanism, spring charging shall take place automatically
after each breaker closing operation. One open-close-open operation of the
circuit breaker shall be possible after failure of power supply to the motor.

6.06.06

Mechanical safety interlock shall be provided to prevent :


a.

The circuit breaker from being racked in or out of the service position
when the breaker is closed.

b. Racking in the circuit breaker unless the control plug is fully engaged.
6.06.07

Automatic safety shutters shall be provided to fully cover the female primary
disconnects when the breaker is withdrawn.

6.06.08

The breaker shall be provided with an emergency manual trip, mechanical


ON-OFF, indication, an operation counter and mechanism charge/discharge
indicator.

6.07.00

Capacitor Bank Starter

6.07.01

Power Contactor

6.07.02

a)

Capacitor starter contractors shall be of air break, electromagnetic


type as per IS:13947 Part-4, Section-1 suitable for DOL starting of
capacitor banks and shall be of utilization category AC-6b (to IS
13947) at the rated voltage. The selection of contactor shall be done
keeping in view high in-rush current while switching capacitor bank in
parallel to already energized bank. The minimum AC-3 rating of the
contactor shall be 32A subject to capability of switching the
connected bank.

b)

Contactor starters shall comply with the requirements of IS 13947


(Part-4) in respect of co-ordination of the characteristics of MCCB,
contactor, and all downstream equipment The type of co-ordination
shall be Type-2 as per the same standard.

MCCB
a)

MCCB shall be triple pole, air break, single throw type having trip
free mechanism with quick make, quick break contacts. The MCCB
shall have current limiting feature.

b)

The compartment door shall be interlocked mechanically with the


MCCB such that the door cannot be opened unless the MCCB is in
OFF position.

c)

Short circuit protection shall be provided with the MCCB.

d)

Molded case circuit breaker shall be provided with 1 NO and 1 NC


electrically separate auxiliary contacts.

6.08.00

Control & Indication

6.08.01

One (1) TEST-NORMAL selector switch stay put type with pistol grip handle
and key interlock, in the breaker panel.

6.08.02

Three (3) indicating lights on front of breaker meter compartment :-

6.08.03

GREEN

Breaker Open and Spring Charged

RED

Breaker Closed

AMBER

Trip/Trip circuit trouble

Two (3) indicating lights on front of each capacitor bank compartment :GREEN

Off

RED

On

6.08.04

Lamps shall be clustered type LED module pilot lights in thermoplastic


enclosure with polycarbonate lens and diffuser. LED shall be protected by inbuilt fuse with surge suppressor and leakage voltage glow protection.

6.08.05

For control supply, 1x100% adequately-rated 415/110V control transformer


with necessary taps shall be provided. Auxiliary bus wires shall be used to
distribute 110V AC control supply. The control supply of different modules
shall be tapped individually from the auxiliary bus wires. Transformer rating
shall have adequate spare capacity & will be sized to IS 12021.

6.09.00

Current Transformer

6.09.01

Current transformers shall be cast resin type. All secondary connections


shall be brought out to terminal blocks where wye or delta connection shall
be made.

6.09.02

Accuracy class of the Current Transformers shall be :a.

Class 1.0 and ISF <=5 for metering.

6.09.03

Current transformer secondary shall be rated for 1 A, depending on


requirement as specified in the drawings.

6.10.00

Protection

6.10.01

The incoming circuit breaker shall be provided with integral release having
necessary features for over-current & earth-fault protection.

6.10.02

Overload and short circuit tripping of the circuit breakers shall be fully
coordinated with downstream breakers/fuses/starters to provide satisfactory
discrimination.

6.10.03

The Contractor shall furnish, install & wire relays to suit the requirements of
protection, interlock schemes.

6.11.00Meter
6.11.01Indicating instruments (96x96mm)shall be switchboard type, with 90 degree scale,
anti-glare glass and accuracy class of 2% full scale. Each meter shall have
zero adjuster on the front.
6.12.00

Switch

6.12.01

Switches shall be dust protected, heavy duty, switchboard type complete


with escutcheon plates. Contacts shall be silver surfaced, rated 10A at
operating voltage.

6.12.02

Lockable stay-put type switchgear / field / remote selector switch shall be


provided as per requirement and mounted on switchgear cubicle.

6.12.03

Meter selector switches shall be maintained contact, stay put type with knob
handle. Ammeter& voltmeter selector switches shall be four position type.
Ammeter selector switches shall have make before break feature to prevent
open circuiting of CT secondary.

6.12.04

Breaker control switch shall be multistage, spring return to normal, with lost
motion device and pistol grip handle.

6.13.00

Fuse & MCB

6.13.01

Fuses shall be HRC, link type, with minimum interrupting capacity equal to
the listed short circuit current. Fuses shall be furnished complete with fuse
bases and fittings. Visible indication shall be provided on blowing of the fuse.

6.13.02

MCB-s shall be double pole, trip free, with manual close / open mechanism.
Automatic tripping provision for over load and short circuit shall also be
provided. MCBs shall be rated for full fault level of the connected system.
MCB shall be provided with required number of auxiliary contacts as per
circuit requirement, if any.

6.14.00

Push Button
Push button shall be heavy duty, shrouded, push to actuate type with
coloured button and inscription plate. Each push button shall have 2 NO + 2
NC contacts, rated 6A min.(AC15 to IS 13947) at their respective AC
operating voltage.

6.15.00

Secondary Wiring

6.15.01

The panel-board shall be fully wired at the factory to ensure proper


functioning of control, protection and interlocking schemes.

6.15.02

Fuse, links and MCB shall be provided to permit individual circuit isolation
from bus wires without disturbing other circuits. All spare contacts of relays,
switches and other devices shall be wired up to terminal blocks.

6.15.03

Wiring shall be done with flexible, 650V grade, PVC insulated switchboard
wires with stranded copper conductors of 2.5 mm 2 for control and current
circuits and 1.5 mm2 for voltage circuits.

6.15.04

Each wire shall be identified, at both ends, with interlocking type permanent
markers bearing wire numbers as per Contractor's Wiring Diagrams. AC /
DC wiring shall have separate colour-coding.

6.15.05

Wire termination shall be made with crimping type connectors with insulating
sleeves. Wires shall not be spliced between terminals.

6.15.06

All spare contacts of relays, timers, auxiliary switches shall be wired up to


the terminal block.

6.16.00

Terminal Block

6.16.01

650V grade, multi way terminal block complete with mounting channel,
binding screws and washers for wire connections and marking strip for
circuit identification shall be provided for terminating the panel wiring.
Terminals shall be stud type, suitable for terminating 2 nos. 2.5 mm2
stranded copper conductor and provided with acrylic insulating cover.
Terminals for C.T. secondary leads shall have provision for shorting and
grounding.

6.16.02

Not more than two wires shall be connected to any terminal. Spare terminals
equal in number to 20% active terminals shall be furnished. Separate
terminal blocks shall be used for AC / DC wiring termination. Also, terminal
block for CT secondary wiring shall be separate.

6.16.03

Terminal blocks shall be located to allow easy access. Wiring shall be so


arranged that individual wires of an external cable can be connected to
consecutive terminals.

6.16.04

Terminal blocks used for interface with PLC via termination cabinet shall be
suitably sized to facilitate proper termination of interconnecting cables.

6.17.00

Cable Termination

6.17.01

The board shall be designed for cable entry from top, as specified. Sufficient
space shall be provided for ease of termination and connection.

6.17.02

All provisions and accessories shall be furnished for termination and


connection of cables, including removable gland plates, cables supports,
crimp type tinned copper/ aluminum lugs and terminal blocks.

6.17.03

Gland plates shall be minimum 3 mm thick. The gland plate and supporting
arrangement for 1/C power cables shall be of aluminum.

6.17.04

Sufficient space shall be provided between the power cable termination and
gland plate. Core balance CTs wherever specified, shall be accommodated
within this space, inside the cubicle.

6.18.00

Ground Bus

6.18.01

A ground bus, rated to carry maximum fault current, shall extend for the full
length of the board.

6.18.02

The ground bus shall be provided with two-bolt drilling with G.I. bolts and
nuts at each end to receive 75 x 10 mm G.S. flat.

6.18.03

Each stationary unit shall be connected directly to the ground bus. The
frame of each circuit breaker shall be grounded through heavy multiple
contacts at all times except when the primary disconnecting devices are
separated by a safe distance.

6.18.04

Wherever, the schematic diagrams indicate a definite ground at the


switchgear, a single wire for each circuit thus grounded shall be run
independently to the ground bus and connected thereto.

6.18.05

CT secondary neutrals shall be earthed through removable links so that


earth of one circuit may be removed without disturbing other.

6.19.00

Nameplate

6.19.01

Nameplates of approved design shall be furnished at each cubicle (one no.


each at front as well as at backside of cubicle) and at each instrument &
device mounted on or inside the cubicle.

6.19.02

The material shall be lamicoid or approved equal, 3 mm thick with white


letter on black back ground.

6.19.03

The nameplate shall be held by self-tapping screws. Nameplate size shall be


minimum 20 x 75mm for instrument/device and 40 x 150mm for panels.

6.19.04

Caution notice on suitable metal plate shall be affixed at the back of each
vertical panel.

6.20.00

Space heaters and Plug socket

6.20.01

Each cubicle shall be provided with thermostat controlled space heaters and
6A, 3 pin plug & socket.

6.20.02

Cubicle heater & plug/socket circuits shall have individual switch fuse units.

6.21.00

A.C/D.C Power Supply

6.21.01

The following power supply shall be made available to the switchgear:


A.C. supply

240V, 1, Single Feeder

D.C. supply

110V, Single Feeder

6.21.02

Bus-wires of adequate capacity shall be provided to distribute the incoming


supplies to different cubicles. Isolating switch fuse units / MCCB shall be
provided at each cubicle for A.C/D.C. supplies.

6.21.03

A.C. load shall be so distributed as to present a balance loading on threephase supply system.

6.22.00

Tropical Protection

6.22.01

All equipment, accessories and wiring shall have fungus protection, involving
special treatment of insulation and metal against fungus, insects &
corrosion.

6.22.02

Screens of corrosion resistant material shall be furnished on all ventilating


louvres to prevent the entrance of insects.

7.00.00

SURFACE PREPARATION & PAINTING

7.01.00

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.

7.02.00

After cleaning, the surfaces shall be given a phosphate coating followed by 2


coats of high quality primer and stoved after each coat.

7.03.00

The switchgear shall be finished in light gray color with two coats of powder
paint. The coating shall be done electro statically followed by stoving.

7.04.00

Sufficient quantity of touch-up paint shall be furnished for application at site.

8.00.00

TESTS

8.01.00

The board shall be completely assembled, wired, adjusted and tested at the
factory as per the relevant standards.

8.02.00

Routine Test
The tests shall include but not necessarily limited to the following :

8.03.00

a.

Operation under simulated service condition to ensure accuracy of


wiring, correctness of control scheme & proper functioning of the
equipment.

b.

All wiring and current carrying part shall be given appropriate High
Voltage test.

c.

Primary current and voltage shall be applied to all instrument


transformers.

d.

Routine test shall be carried out on all equipment such as circuit


breakers, instrument transformers, relays, meters etc. as per relevant
standard.

e.

Routine tests to IS 13340 & IS 13341.

Type Test
Following minimum tests shall be performed on the assembly, unless
otherwise mentioned in the Annexure :
a.

Impulse Test

b.

Temperature rise Test

c. Short circuit Test


The cost of such tests, if any, shall be quoted separately.
8.04.00

Test Witness
Tests shall be performed in presence of Owner/Purchaser's representative if
so desired by the Owner/Purchaser. The Contractor shall give at least seven
(7) days' advance notice of the date when the tests are to be carried out.

8.05.00

Test Certificates

8.05.01

Certified reports of all the tests carried out at the works shall be furnished in
six (6) copies for approval of the Owner/Purchaser.

8.05.02

The equipment shall be dispatched from works only after receipt of


Owner/Purchaser's written approval of the test reports.

8.05.03

Type test certificates on the equipment shall be furnished. Otherwise the


equipment shall have to be type tested, free of charge, to prove the design.

9.00.00

SPECIAL TOOLS & TACKLES

9.01.00

A set of special tools & tackle which are necessary or convenient for
erection, commissioning, maintenance and overhauling of the equipment
shall be supplied.

9.02.00

The tools shall be shipped in separate containers, clearly marked with the
name of the equipment for which they are intended.

10.00.00

SPARES

10.01.00

The Bidder shall submit a list of recommended spare parts for two (2) years
satisfactory and trouble-free operation, indicating the itemized price of each
item of the spares. The final quantity shall be decided during placement of
order.

10.02.00

The Bidder shall quote and supply mandatory spare parts as per list
annexed. The final quantity shall be decided during placement of order.

10.03.00

Each list shall be complete with specification, make, identification number, unit
rate, quantity etc.

11.00.00

DRAWINGS, DATA & MANUALS

11.01.00

Drawings, Data and Manuals shall be submitted with the bid and in
quantities and procedures as specified in General Conditions on Contract
and / or elsewhere in this specification for approval and subsequent
distribution after the issue of Letter of Intent.

11.02.00

To be submitted with the Bid

11.02.01

Typical general arrangement drawing of the equipment and foundation plan.

11.02.02

Bill of material

11.02.03

Proposal sheets duly filled in.

11.02.04

Type test certificates of the offered model of the circuit breaker, capacitors
and switchboard. The type test certificates shall not be more than 5 years
old.

11.02.05

Leaflets & brochures on equipment and other accessories explaining their


constructional details, principle of operation, special features etc.

11.03.00

To be submitted for Owner / Purchasers Approval and Distribution


(A) : Approval Category
(R) : Reference Category

11.03.01

Guaranteed Technical Particulars (A) and Quality assurance plan (R)

11.03.02

Dimensional general arrangement drawing showing disposition of various


fittings, (A)

11.03.03

Bill of material (A)

11.03.04

Foundation plan and loading (A)

11.03.05

Control schematic (A) and wiring diagrams (R)

11.03.06

Instruction manuals on circuit breaker and its accessories (R)


The manual shall clearly indicate method of installation, check ups and tests
to be carried out before commissioning of the equipment.

11.03.07

Any other relevant drawing or data necessary for satisfactory installation,


operation and maintenance.

11.04.00

The drawings and document marked with (A) above are of Approval
category and are subject to review by Owner / Purchaser. Those marked (R)
are for reference category.
The Owner / Purchaser may also review the documents marked (R) if found
necessary. The contractor shall note that the approval of drawings &
documents by the Owner / Purchaser does not relieve him of his contractual
obligation.

11.05.00

All drawings shall be prepared by using Auto CAD, approved version and
documents shall be generated using MS Office. The paper copy of the
drawings & document shall be submitted for approval & reference. All final
drawings and documents shall be submitted in CD in Auto CAD (approved
version) and MS office format as applicable for Owner / Purchasers future
reference.

11.06.00

The Bidder may note that the drawings, data and manuals listed herein are
minimum requirements only. The Bidder shall ensure that all other
necessary write-ups, curves and information required to fully describe the
equipment are submitted with his bid.

ANNEXURE-A
RATINGS AND REQUIREMENTS
1.0

SWITCHGEAR

1.1

1.2

General
Type

Service

Metal-clad, horizontal draw out &


horizontal isolation
Indoor

Enclosure

IP 4X

Standard

IS 8623.

415 10%

Phase

Three

Rated Frequency

50 Hz 3%

System grounding

Solidly grounded

Control voltage

110V AC, 1 (through trafo)

Design ambient temperature

45 oC

Bus bar

1000A

Circuit breaker

1000A

Rated short time withstand current

50 kA(min.)

Duration

1Sec.

Rated interrupting current

50 kA(min.)

AC 6b (to IS 13947)

Incomer

Through top entry cable

Outgoing

Through top entry cable.

System
Rated Voltage

1.3
1.4

1.5

1.6

V rms

Rated Current inside the cubicle


and at design ambient
temperature of 45oC

Short Circuit Rating

:-

Swithing Duty
Capacitor feeder

1.7

1.8

Termination details

Painting requirement
a)

Finish paint

Powder coating

b)

Paint base

Epoxy / poly-eurethene

c)

Paint shade

631 to IS-5

2.0

CIRCUIT BREAKER (incomer)

2.1

Type

ACB

2.2

Reference Standard

IS 13947

2.3

No. of poles

Three

2.4

Rated operational voltage (Ue)

415 V.

2.5

Rated Frequency

50 3%

2.6

Rated normal current at


site condition
Amp

1000.

2.7

Rated utilization category

2.8

Rated Insulation voltage

1000 V.

2.9

Rated impulse withstand voltage

12 kV.

2.10

Rated Making & Breaking Capacity

--

2.11

Rated Short-circuit breaking current


(Symmetrical)
kA rms
:

50 min.

2.12

Rated short-circuit making


current
kA peak

105 or more (to IEC)

2.13

Rated Operating Duty

Eight Hour.

2.14

Operating mechanism

Motor wound Spring charging

2.15

AC/DC Power Supply


Control voltage

110V DC (93V - 121V)

Service voltage

240V 10%, 1 Ph, 50 Hz 3%

Hz

3.0

Power Contactor

3.1

Type

Air-break

3.2

No. of poles

Three

3.3

Rated Frequency

50 3%

3.4

Rated normal current at


site condition
Amps

Min. 32 A.

3.5

Rated utilization category

AC 6b

Hz

3.6

Reference Standard

IEC-60947 Part 4.

4.0

Shunt Capacitor

4.1

Type

Self-healing

4.2

Rated Voltage

415V 10%

4.3

No. of phases

Three

4.4

Rated Frequency

50 3%

4.5

Dielectric

Mixed di-electric
(combination of paper &
polypropylene)

4.6

Maximum loss
(inclusive of discharge resist. loss)

0.5 watt / kVAR.

4.7

Discharge device

External resistor

4.8

Bank rating

1 x 10 kVAR
1 x 20 kVAR
1 x 40 kVAR
7 x 50 kVAR

4.9

Reference Standard

IS 13340

5.0

APFC Relay

5.1

Type

Microprocessor based.

5.2

No. of stage

12

5.3

Type of switching

Rotational / Linear

5.4

Display

Voltage, Current, pF, kVAR etc.

5.5

Harmonic annunciation

Yes.

Hz

ANNEXURE-B
MANDATORY SPARES

Bidder shall quote for the mandatory spares indicated below. In case, the bidder does not
consider any item, the Bidder shall indicate it.

Sl. no.

Item

Quantity ( nos.)

1.

Capacitor unit

One of each rating

2.

Circuit breaker closing coil

One no.

3.

Circuit breaker trip coil

One no.

4.

MCCB

One no. each type

5.

Discharge resistor

Two nos. each type

6.

Power and Control fuses of different


ratings

2 nos.

7.

Clustered type LED indicating lamp

10% of total number.

8.

MCB

One no. each type.

SECTION - IV
PROPOSAL EXHIBIT SHEETS
CONTENTS
Schedule No.

Description

I.

Key Information

II.

Equipment Data Sheet

III.

List of spares

IV.

List of special tools and tackles

V.

Deviations

VI.

Experience List

SECTION-IV
PROPOSAL EXHIBIT SHEETS

SCHEDULE - I

KEY INFORMATION ABOUT THE PROPOSAL


The Tenderer shall submit this proforma properly filled-in in a complete and unambiguous manner,
failing which the tender will be liable to rejection. No cross-reference to any other part/page of the
tender will be accepted.
1.

Name of the Tenderer

2.

Complete postal address,

3.

Telephone number
Fax number
E-mail address

:
:
:

4.

Name and Designation of the


responsible officer of the tenderer.

5.

Proposal Number and Date

6.

Validity of the offer counted from


the date of opening of the tenderer.

7.

Whether any alternative proposal


furnished in addition to the base offer

yes/no

Whether all price Schedule sheets


have been properly filled-up.

yes/no

Whether any deviation taken from


the Technical specifications. If `yes,
then whether Clause no V. of this section
has been properly filled-up covering
all such deviations.

yes/no

Whether Bidder agrees to comply with


the delivery requirement as stipulated in this
specification.

yes/no

8.
9.

10.

SCEDULE - II
DATA SHEET
(separate for each board)

(Add more sheets, if


required
1.0. 415V CAPACITOR UNIT.
1.1

Make.

1.2

Service

1.3

Type

1.4

Rated Voltage with variation

1.5

Rated Frequency with variation (Hz %)

1.6

Rated Insulation voltage

1.7

Rated KVAR

(kVAR)

1.8

Rated current

(Amps)

1.9

Rated capacitance

(F)

1.10

Guaranteed Tolerance

1.11

Number of units forming the bank

1.12

Rated KVAR of each unit

1.13

Capacitor loss

1.14

Tangent of loss angle

1.15

Maximum Permissible Current (Amp.)

1.16

Maximum Permissible Voltage Volts

1.17

Max.Permissible Temp. of the container(C) :

1.18

Value of built-in discharge resistors


of individual capacitor (ohm)

1.19

Basic impulse level

(kV)

1.20

Rating of fuses

(Amp)

1.21

Interrupting Rating of fuses (kAmp.)

1.22

Type of impregnant used

1.23

Insulation class of capacitor

(V %)

(kVAR)

1.24

Whether method connection is delta or star :

1.25

Over current prot. provided as specified(Y/N):

1.26

Protection against internal faults in capacitor


Units provided as specified (Yes/No)
:

1.27

Method of mounting

1.28

Dimensions of the capacitor bank

1.29

Weight of each bank

2.0

CAPACITOR PANEL-BOARD

2.1

Make

2.2

Type

2.3

Capacitor control panel is complete with


all equipment like contactors, relays,
switches, lamps, etc. for control of the
capacitors for automatic as well as
manual correction of power factor to
the required value.

Adjustable setting range of reference


set point provided

2.5

Range of setting

2.6

Catalogue of the automatic p.f. correction


relay furnished ?
(Yes/No)

Dimensions of the panel


(L x B x H)
(mm x mm x mm)

Weight of each panel

2.4

2.7
2.8

(kg)

(kg)

SCHEDULE - III
LIST OF RECOMMENDED SPARES

Sl.No.

Description

Identification Code

SCHEDULE - IV
LIST OF SPECIAL TOOLS AND TACKLES
Sl.No.

Description

Identification Code

SCHEDULE - V
DEVIATIONS
The Tenderer shall furnish an exhaustive list of deviations if there is any, in his

proposal as per the following format. The Price implication column shall be filled up
only with yes or no, not with any price figures.
Sl.No.

Reference from
Specification document

Description of Deviation

Price implication
(yes/no)

SCHEDULE - VI
EXPERIENCE LIST
The Tenderer shall tabulate below a list of jobs already executed by him as regards

to the supply and/or turnkey execution of similar packages/projects. The list shall
contain all relevant information on type, capacity, client, project/order values,
scheduled and actual time of execution and any other pertinent information as may
be considered worth mentioning for the purpose of assessing his capability.
Sl.
No.

Construction
Schedule

Actual time
of
Completion

Type of Work
&
Capacity

Location

Name of
Project &
Order value

Name of
Client /
Owner

Supervising
Consultant

PART - B
PRICE PART
Price Break up

PART - B
PRICE PART
Price Break up

To be filled up for all equipment


(1)

(2)

(3)

(4)

(5)

(6)

(7)

(Figures in Rs)
(8)

ExPacking & FOR Excise Sales Local


Freight & Landed price
works Forwardin works duty
tax
Govt.
transit
at site
g
Taxes
(
if
insurance
(1+2)
(3+4+5+6+7)
any)
Item number.
415V
Capacitor
panel-board
complete
with all
specified
accessories
Mandatory
Spares

Total supervision charges for erection, trial run &


commissioning including all incidental expenses
except to & fro traveling cost from location of
supplier to Purchaser site:

RECOMMENDED SPARES

Sl.No.

Description

Identification Code

Unit price

SPECIAL TOOLS AND TACKLES


Sl.No.

Description

Identification Code

Unit Price