4.0 Scope of Work 1 12 13 14 18 16 1 18 19 1.10 This specification covers the design, engineering, manufacturing, testing, packing, supply and retrofiting of 415 V indoor draw out type 3 Pole Air Circuit Breakers (ACB) at Panipat Naphtha Cracker as per below technical specifications for replacement of existing Contactor+SFU Module for Motor Feeders from 75KW to 160KW with modifying the existing drop-out bus bar respectively which also includes: Jumper (Top and Bottom) and bus bars dropper if required. Support insulator with channel Circuit breaker compartment door Circuit breaker mounting channel Hardware and wiring kit Review the existing control scheme, wiring diagram etc. of the existing Contactor+SFU Module for Motor Feeders from 75KW to 160KW for incorporating the schemes in the similar fashion in the retrofitted breakers, Preparation of GA drawings of the breaker panel including bus bar links arrangement and cubicle along with control wiring etc. The drawings shall be submitted for approval, The additional bus bar links, if required, of the existing bus bar size and specifications, shall be arranged by the vendor without any extra payment, ‘All materials supply (Including allcu bus-bar, droppers, wiring materials, flexible jumpers, switches, leads, ete if required) shall be in the vendor scope, All required tools & tackle shall be arranged by vendor. The vendor to provide 3 nos. of breaker lftng trolley of reputed make along withthe breakers. Spring Charging Motor - (4 Nos. for 00 A). Closing Coil - (5 Nos. for 800 A). Shunt Trip Coll - (5 Nos. for 800 A). Auxiliary limit switch - (10 Nos. for 800 A). Sliding terminal block - (2 Nos. for 00 A). Shifting of material from store to respective substation shall in the scope of the vendor. The existing Numerical Relays (details attached) are to be used in the breaker feeders. Except Numerical relays all other materials to execute the retrofiting jobs are in the vendor's scope, Material not appearing in the work order but needed to complete the job in all respect to be supplied by the vendor, No extra amount will be paid for the same. Earthing of new system as per IS/IEC standards. Sealing of PCC after work completion should be proper. All vacant holes to be sealed properlywt 112 113 20 24 22 23 24 25 Aesthetic look of switchgear shall be met by vendor. All the jobs required for completion of the retrofting work are as given below: ‘© Removal of existing Modules from chassis/eompartment, ‘© Installation of new ACB in place of existing modules compartment. ‘+ Necessary control wiring modification to match the existing scheme, ‘© Necessary busbar lik with PVC sleeves having colour code to match the existing busbar to breaker. Checking of alignment and bus bar tension, Functional checks of new ACBs. Disconnection and Connection of outgoing power and control cables for motors inthe existing modules. Application of insulation paint on the bare main busbar joints Installation of shrouds on the busbar droppers atthe back side, Documents to be submitted by vendor along the bid a) Full technical description and performance details ofthe equipment and components offered including heat losses for all components in KW. ) Overall dimensions & GA drawing ¢) Guaranteed technical particulars. a) Type test certificates from CPRI or any other Govt. approved testing laboratory €) Bill of material including makes of components. ) Main and control circuit schematic diagrams g) Vendor to submit undertaking on their letter head that Services & Spare parts support will be available for next 15 years from the date of announcement of product obsolete. The undertaking should be submitted along with the offer, The vendor shall give a notice of atleast One year to the user of equipment before phasing out the product/spares to enable the user for the placement of order and services. Codes and Standards The design, manufacture, testing and installation of Breakers being supplied shall comply with latest revisions of relevant Indian Standards or equivalent IEC standards. In case of imported equipments, standards of the country of origin shall be applicable if these standards are equivalent or stringent than the applicable Indian standards. 23 The equipment shall also conform to the provisions of Indian Electricity rules and other statutory regulations currently in force in the country. In case Indian standards are not available for any equipment, standards issued by IEC/BS) VDE! IEEE/ NEMA or equivalent agency shall be applicable. In case of any contradiction between various referred standards! specifications’ data sheet and statutory regulations the following order of priority shall govern: Statutory regulations «Datasheets26 30 34 3.2 33 34 40 44 42 43 44 45 46 + Job specifications «This specification + Codes and Standards AAI conflicts between the requirements of this specification and other relevant documents shall be referred to principal for resolution General Requirements The ACB shall be suitably designed to work as Motor feeders Each type of breaker shall be interchangeable in the other similar type retrofitted compartments of similar rating ACB shall be suitable for operation in tropical climate and under the ambient conditions as specified inthe data sheet. The draw out carriage on the switchboard shall have three positions viz, ‘service’, ‘Test’ and ‘isolated’. Automatic safety shutters shall be provided to ensure the inaccessibilty of all ive parts afer the breaker is drawn out. It shall not be possible to draw out the carriage with circuit breaker closed. The breaker feeder trolley shall remain inside the present cubical even in the ‘draw out” position. Compartment and it should be lockable. All circuit breaker trucks of the same rating shall be interchangeable. Auxiliary Wiring and Terminals Al internal wiring shall be carried out with 1.1KV grade, single core, 1.5 sq. mm. stranded copper wires having minimum of seven strands per conductor and colour coded, PVC insulation, CT circuits shall be wired with 2.5 sq. mm. wires which otherwise are similar to the above. Extra flexible wires shall be used for wiring between fixed and moving parts such as hinged doors. All wiring shall be properly supported neatly arranged, readily accessible and securely connected to equipment, terminals and terminal blocks. Internal wire terminals shall be made with solder less crimping type tinned copper lugs which shall firmly grip the conductor. When wires are being looped, either U-type or Flat pin type lugs of proper size are to be used. Insulation sleeves shall be provided over the exposed parts of lugs Printed single tube ferrules marked to correspond with panel wiring diagram shall be fitted at both ends of each wire, The wire identification marking shall be in accordance with |S: 375, Red Femules should be provided on trp circuit wiring, The wiring shall preferably be enclosed in plastic channels or neatly bunched together. 10 percent spare terminals shall be provided on each terminal block47 48 49 4.10 4a 412 4.13 444 50 5.1 52 53 54 55 56 Conductors shall be terminated with adequately sized compression type lugs for connection to equipment terminal and strips, Elemex / Tosha | Essen or equivalent terminals will also be acceptable Stranded conductors shall be soldered at the ends before connections are made to the terminals. All auxiliary equipment terminals shall be made with pressure type terminals. Sufficient terminals shall be provided on each terminal block to ensure that no more than one outgoing wire is connected per terminal Terminal strips shall preferably be separated from power circuits by metal barriers or enclosures. All spare contacts of auxiliary relays, timers etc. shall be wired up to the terminals. Each wire shall be identified at both the ends by, correctly sized PVC ferrules. Control terminal blocks shall be approved by the purchaser before being used Shorting links shall be provided for all CT terminals. Circuit breaker The circuit breakers shall be mounted on a withdraw able assembly which shall move horizontally from service position to isolated position and back. For complete withdrawal from the panel, the assembly shall bring the breaker completely out ofthe panel for futher removal using telescopic rack out trolleys. Testing of the breaker shall be possible in test position both from local control and remote. Necessary guide channels shall be provided in the breaker compartments for proper alignment of auxiliary contacts when breaker is being moved to SERVICE position. A crank or lever arrangement shall preferably be provided for smooth and positive movement of breaker between Service and Isolated positions. The rack out assembly shall have distinct SERVICE, TEST and ISOLATED positions. It shall be possible to close the breaker compartment door in isolated position also, so that the switchgear retains its specified degree of protection, The switchgear assembly shall be dust, moisture, rodent and vermin proof, with the breaker in any position SERVICE, ISOLATED or removed, and all doors and covers closed. All doors, removable covers and glass windows shall have gaskets all round with neoprene gaskets. The breaker should have a total segregation between power & control circuit thus making double Insulation & ensuring fitting of accessories while the circuit breaker is in ON position. New enclosure parts if required shall be constructed with rolled steel sections. The doors and covers shall be constructed from cold rolled steel sheets of 2.0 mm or higher thickness. The switchgear shall be cooled by natural airflow and forced cooling shall not be accepted. Hence the Retrofit connections should not cause an obstruction to natural airflow.57 58 59 5.10 5.1 5.12 5.13 5.14 5.15 5.16 Safety shutters shall be provided to cover up the fixed contacts on bus bar and cable sides when the breaker is moved to ISOLATED position. The shutters shall move automatically, through a linkage with the movement of the breaker. Preferably it shall however, be possible to open the shutters of bus bar side and cable side individually against spring pressure for testing purpose after defeating the interlock with breaker movement deliberately. A clearly visible warning label “Isolate elsewhere before earthing” shall be provided on the shutters of incoming and tie connections which could be energized from other end The breaker and the auxiliary compartments provided on the front side shall have strong hinged doors. Breaker compartment doors shall have locking facility. Suitable interlock shall be provided, which will ensure that breaker is OFF before opening the bolted covers / back doors. In the Service position, the breaker shall be so secured that its not displaced by short circuit forces. Jumpers and other components of the switchgear shall also be properly supported to withstand all possible short circuit forces corresponding to the short circuit rating specified. The current transformers for metering & protection circuits shall be mounted on the fixed portion of the compartment. All terminals except wiping/sliding type control terminals shall be shrouded with plastic covers to prevent accidental contact. For direct termination-clip on shrouded type terminals shall be provided, There shall be three positions for the draw out trolley viz: "Service" position - In this position both power and control circuits shall be connected. This shall be the normal operating position ofthe circuit breaker. "Test" position - The power contacts shall be disconnected inthis position but the control connections shall not be disturbed, it shall be possible to close and trip the breakers inthis position, "Draw out” Position - both power and control circuits shall be disconnected inthis position and breaker removed from the cubicle The circuit breaker shall be lockable in "service" and "test" positions. Safety shutters shall be provided when the breaker is in withdrawn/draw out position. No inbuilt protection in breaker is required The earth connection must remain connected in "Test" position; Earthing ofthe unt shall be done with a "pin* of with scrapping earth connections. The earth connection shall make before the main power / control contacts make and break after the power /control contacts are disconnected. Earthing connection through a plug and socket connection shall not be acceptable. Shutters shall be closed and opened automatically by the mechanical drive of the removable part of the switching device when the latter is being racked out of or into service position. To facilitate testing, a manually operated device shall be installed to permit opening and fixing in the open position of each set of shutters individually Allthe Circuit breakers shall be air break, 3 pole and draw out type.BAT 5.18 5.19 5.20 5.21 5.22 5.23 5.24 5.25 5.26 5.27 5.28 5.29 5.30 531 5.32 5.33 5.34 5.35 5.36 The circuit breakers shall be provided with mechanically operated emergency tripping device. This device shall be available on the front of the panel. Mechanically operated ‘closing’ device shall be provided forall breakers. The circuit breakers shall be provided with minimum 4 NO+ 4 NC contacts, wired and available for purchasers use, Accessories like, closing coil, shunt trip, spring charging motor, etc, are common for complete range of circuit breaker. Accessories ike closing col, shunt trip are of continuous rating to avoid failures during breaker ‘Abnormalities Allthe Accessories are pre wired so as to ease installation, no critical setting The breaker shall be tested as per IS -13947 -2, IEC -60947-2. It should be possible for the manufacturer to provide IPS4 cover for the breaker. Unless otherwise specified, all circuit breakers in the switchboard shall be provided with electrical power operating mechanism. ‘Aname plate with the switch gear designation and technical details shall be fixed in the ACB, ACB trip and closing coils shall be rated for satisfactory operation under the following conditions of supply voltage variation: a) Tripcoll 50 % to 110% of rated voltage b) Closing coil 85% to 110% of rated voltage All draw out contacts ofthe breaker whether power; control or earthing shall be silver plated. ‘Outgoing cable terminating points to be shrouded by insulating material to avoid accident. Rated Operational Voltage of the ACBs shall be 416 Volt. Rated Insulation Voltage of the ACBs shall be 1000 Volts. ACB size & terminal should be optimum designed so as to have better termination & space utlization Dimensions of new breakers with retroiting kit in such a way that it wll fix in the existing space properly. ACBs retrofit shall be done in such a way that there are minimum joints near the breaker terminal Retrofit Kit material shall be Aluminium with Electrical Grade Al. The current carrying capacity of additional bus bar should not be less than the breaker current rating, Termination shall be done with High Tensile bolts of 88 class or above along with Conical spring washers. Any type of protective release is nat acceptable in Air Circuit Breaker.60 61 62 63 64 65 66 67 68 69 6.10 Operating Mechanism Electric power operating mechanism shall be motor wound spring charged stored energy type. However, manual-operating mechanism may be of the spring charging stored energy type or the spring assisted type. For circuit breakers with electrical power operating mechanism, provision shall also be made for manual spring charging. Closing time of circuit breakers with manual operating mechanism shall be independent ofthe speed of the operating handle. All stored energy operating mechanism shall be equipped with following features: Failure of springs, vibrations or shocks shall nt cause unintended operation of breaker or prevent intended tripping operation. Closing of circuit breakers shall be prevented unless the spring is fully charged, All electrical power operating mechanisms shall be suitable for remote operation and shall be equipped with following features. ‘© Provided with universal motor operable on AC or DC control supplies. Provided with emergency manual charging faciliy. The motor shall be automaticaly, decoupled (mechanically) once the manua-charging handle is inserted ‘© Closing operation of circuit breaker shall automaticaly initiate charging ofthe spring for the next closing operation without waiting for tripping of circuit breaker. ‘© Closing operation shall be completed once the closing impulse is given and the first device in the control scheme has responded even though the control switch | Push Button is released provided no counter trip impulse is present Circuit breaker trip and closing coils in case of electrically operated breakers and trip colin case of mechanically operated breakers and circuit breaker indication shall be suitable for satisfactory operation on a control supply system indicated in data sheets/job specification. Circuit breakers shall be provided with anti-pumping and trp free feature, Circuit breakers shall be provided with operation counters. The operating mechanism shall be such that failure of any auxiliary spring shall not prevent tripping and shall not lead to closing or tripping of circuit breaker. Failure of any auxiliary spring shall also not cause damage to the circuit breaker or endanger the operator. The time taken for charging of closing spring shall not exceed 20 seconds. The spring charging shall take place automatically after a closing operation. Breaker operation shall be independent ofthe spring charging motor which shall only charge the closing spring, Opening spring shall get charged automatically during closing operation. As long as power supply is available to the charging motor a continuous sequence of closing and opening operations shall be possible, One open-close- open operation of the circuit breaker shall be possible after failure of power supply to the motor. Spring charging motors shall be capable of starting and charging the closing spring twice in quick succession without exceeding acceptable winding temperature when the control supply voltage is anywhere6.11 6.12 6.13 6.14 615 6.16 617 6.18 70 7 72 73 between 85% and 110% of the rated voltage. The initial temperature shall be as prevalent in the switchgear panel during full load operation with 50 deg. C ambient air temperature, The motor shall be provided with short circuit protection. The manual spring charging lever should be availabe in breaker, by that breaker's spring can be charged, if supply of breaker fails. Motor windings shall be provided with class E insulation or better. The insulation shall be given tropical and fungicidal treatment for successful operation ofthe motor in a hot, humid and tropical ciate, Circuit breaker shall be provided with inter pole barriers of flame proof insulating materials. The use of inflammable materials ike Hylam shall not be acceptable, Breaker should be provided with a provision of LOTO Lock. Facilities shall be provided for mechanical tipping ofthe breaker! contactor and for manual charging of the stored energy mechanism for a complete duty cycle, in an emergency Each panel shall have two separate limit switches, one for the Service position and the other for TEST position. Each of these limit switches shall have at least two (2) contacts which shall close in the respective positions, Movement of breaker between SERVICE and ISOLATED positions shall be mechanically prevented when the breaker is closed Closing of the breaker shall be possible only when breaker is either in ISOLATED or in SERVICE position and shall not be possible when breaker is in between It shall be possible to easily insert breaker of one typical rating into any one ofthe panels meant for same rating but at the same time shall be prevented from inserting it into panels meant for a different type or rating, Control and Indication Control supply of breaker shall be 220 V DC. The power supply for breaker opening, closing and spring charging mechanism shall be designed accordingly. Circuit breakers Open and closed positions; Service and test locations and spring charged condition shall also be indicated mechanically in addition to electrical indications. Following LED indication shall be provided on breaker panel indication Colour of LED ‘ACB Close” Red ‘ACB ‘Open! Green ACB Trip" ‘Amber ‘ACB Spring charged Blue ‘ACB Trip circuit healthy White ‘ACB Test Position” Yellow8.0 81 82 83 84 9.0 10.0 10.1 10.2 103 104 Interlocks There shall be a safe interlocking mechanism provided between the air circuit breaker and the existing cubicle to ensure safe operation, protection to personnel and correct sequence of operations, Compartment doors shall be interlocked against opening when the breaker is in ON position. However, itis possible to defeat interlock for inspection. It shall not be possible to push “in” a drawn out circuit breaker in a closed condition or withdraw circuit breaker in closed condition. It shall be possible to operate a circuit breaker only in the defined “Full in” or “service” and “test” position inside the panel. It shall not be possible to operate a circuit breaker in an intermediate position while inserting or withdrawing circuit breaker. Pal ing All sheet steel work shall be pre-treated, in tanks, in accordance with IS: 6005. Degreasing shall be done by alkaline cleaning. Rust and scales shall be removed by pickling with acid, After picking, the parts shall be washed in running water. Then these shall be rinsed in slightly alkaline hot water and dried. The phosphate coating shall be “Class-C’ as specified in IS: 6005. The phosphate surfaces shall be rinsed and passivated. After passivation, Electrostatic Powder Coating shall be used. Powder should meet requirements of IS 13871 (Powder costing specification). Finishing paint shade for complete panels excluding end covers shall be RAL9002 & RALS012 for extreme end covers of all boards, unless required otherwise by the Employer. The paint thickness shall not be less than 50 microns. Finished parts shall be suitably packed and wrapped with protective covering to protect the finished surfaces from scratches, grease, dit and oll spots during testing, transportation, handling and erection. Tests and Inspection Testing ofthe breakers shall be done as per standard tests mentioned in the IS for 0.415KV air circuit breakers. However parties shall provide thelist of tests (Routine & Type) to be performed along with the offer. All equipment to be supplied shall be of type tested design, The Party shall submit for Owner's approval the reports of al the type tests as listed in this specification and carried out within last ten years from the date of bid opening. These reports should be for the tests conducted on the equipment similar to those proposed to be supplied under this contract and the test(s) should have been either conducted at an independent laboratory or should have been witnessed by a client In case the Party is not able to submit report of the type test(s) conducted within last ten years from the date of bid opening, or in case the type test report(s) are not found to be meeting the specication requirements, the Party shall conduct all such tests under this contract at no addtional cost either at third party lab or in presence of client/owner's representative and submit the reports for approval All routine tests as per the specification and relevant standards shall be carried out,105 106 107 108 109 10.10 10.11 10.12 Charges for these shall be deemed to be included in the equipment price. The following type tests reports on circuit breaker / circuit breaker panels, of each voltage class and current rating shall be submitted. The ACB shall comply with the requirement of latest revision of the standards issued by BIS (annexure-6) ‘© Short circuit duty test on circuit breaker, mounted inside the panel offered Short time withstand test on circuit breaker ‘© Power frequency withstand test on breaker mounted in side panel. ‘© Lightning impulse withstand test on breaker mounted in side panel ‘© Measurement of resistance of main circuit ‘© Mechanical operation test Type tests if asked shall be performed. Short circuit test shall be performed at CPRI and heat run test may be performed at manufacturer's works, All acceptance and routine tests as per the specification and relevant standards IEC 62271-200 & IEC 6271-100 shall be carried out. Charges for these shall be deemed to be included in the equipment price 1OCL Engineer/TPI, at manufacturer works, shall witness the routine & quality tests. The testing location should be properly equipped with all testing facilities. Vendor has to provide the complete testing & inspection plan in advance with complete schedule & list of tests to be witnessed. The tests shall be carried out as per agreed criteria based on standard procedures The breakers shall be dispatched only ater the Factory acceptance Test (FAT). The SAT (Site Acceptance test) shall be carried out for individual breaker at site after the final commissioning of each breaker. The breaker shall be tested in all respect and thereafter it wil be handed over to IOCL and shall be taken into service as per requirement. The testing at site will be done party as mentioned. + Manual operation of breakers completely assembled Power closing / opening operation, manually and electrically at extreme condition of control supply voltage, Closing and tripping time. Trip free and ant-pumping operation IR values, resistance and minimum pick up voltage of coils. Simultaneous closing of all the three phases. Check electrical and mechanical interlocks provided. Checks on spring charging motor, correct operation of limit switches and time of charging All functional checks. At site vendor has to necessarily breaker opening time, closing time, conduct IR value and Contact resistance (at minimum 100 Amps) of the retrofited ACB along with all necessary Electrical control circuit checks, Vendor to bring calibrated testing equipment for the same,10.13, 1100 WA U2 13 14 N56 6 WT 120 124 122 123 13.0 The vendor must provide Test certificates as per Indian standard, Warranty certificates, three hard copies of approved modified drawings as well as soft-copies in .PDF format as well as dwg format stored in CD. Drawings and documents by Vendor Following drawings and documents shall be submitted to the Purchaser for approval before completion of fabrication and assembly of the equipment:- Complete assembly drawing showing details of bus, connections, terminals and other equipment. Bill of material Complete wiring and interconnection diagrams showing connection of all devices, such as relays, meters, switches, metering transformers, and terminal strips, ete. Termination schedule for each switchgear cubicle for inter phasing and inter panel wiring Minimum six sets of final as built drawing, six sets of O&M manual, engineering data, factory test reports, site test & commissioning reports shall be submitted by the vendor in hard copy. Agency shall also submit three sets of as built drawings and manuals in soft copy on CD media, Final drawing / As built drawings shall be furnished after the equipment is commissioned incorporating all changes along with reproducible for Purchaser's records. Packing and Transport The breakers shall be divided into several shipping sections for protection and ease of handling during transportation and also it should be moisture proof the equipment package shall be suitable for transportation by ship / ral or road, Al breakers shall be packed as separate shipping sections. The panel shall be covered in polythene sheets before being placed in crates to prevent damage to finish, Crates shall have skid bottom for handling. Special notations such as This side up’, ‘Fragile’, ‘Centre of gravity’, ‘Weight etc. shall be clearly marked on the package together with Tag nos., P.O. nos. etc The equipment may be stored outdoors for long periods before installation. The packing should also be suitable for outdoor storage areas with heavy rains! high ambient temperature unless otherwise agreed Performance Guarantee The Air Circuit Breakers along with all supplied equipments shall be guaranteed for trouble free operation fora period of 12 months from the date of commissioning or 18 months from date of receipt at site, whichever is earlier. Any defects discovered during this period shall be replaced / rected free140 144 14.2 143 144 145 146 147 148 149 14.10 14.11 of charge. During the guarantee period vendor shall attend all the defects within very short notice (within 4-5 working days after complaint registered). Important Notes For Vendors The scope of work mentioned in the technical specifications is indicative only and vendors shall make their own assessment of the complete retrofiting job, Vendors are advised to make a site visit for thorough assessment of the job. The new retrofted ACBs shall be designed suitably so that the Electrical system parameters, existing facilities and control functions remain unaltered The offered equipment shall be brand new with state of art technology and proven field track record, No prototype equipment shall be offered. Vendor shall vist site along with design expert, to study the existing scheme for execution, feasibility before submission of quotation, Without visiting the site the offer of the party shall be liable for rejection. Vendor shall have to quote for all items & quantity as the job is of comprehensive nature. The evaluation of this project shall be done on the basis of total cost inclusive of breaker retro cost, and material supply for breaker Portion Testing & inspection of all hardware, equipment’, and schemes covered in the scope of supply Party to provide the ITP (Inspection & Test plan) of Air Circuit breaker for the approval of IOCL. after the placement of order. TPI of the Air Circuit breaker being supplied to IOCL to be done & report of TPI shall be submitted along with supply of material The total cost of TPI including all requirement of testing facilities etc, shall be in vendors scope. Party to quote the rates of Ar Circuit breaker accordingly. All the dismantled material / part of the old panel / breaker shall be the property of IOCL. Suitable intimation to be given to IOCL before carrying out TP! of supplied Air Circuit breaker. TPI may be witnessed by IOCL representative. Enclosed technical specification sheets to be duly fled up, signed/stamped & to be submitted along with the offer by the vendors.1.0: EXISTING FEEDER AND DRAWING DETAILS NAME OF WORK: Supply & Retrofitting of 800Amps ACBs (in existing 415V PCCs at $S-01, SS-02, 5-09, $S-10, SS-11, $5-13 & SS-16 at PNC. ‘These 129 No's retrofitting of ACBs are to be done in the M/s C&S Electric Ltd & M/s L&T Limited Make Switchboard at respective PCCs at Substation # 01, 02, 09, 10, 11, 13 & 16 which has been supplied to us (IOCL PANIPAT) by M/s C&S Electric Ltd. & M/s L&T Limited in 2008 and 2009, FEEDER LIST:~ Following Feeder list is attached as annexure-1 a) Feeder List SS-01 & 02 for NCU & BDU. b) Feeder List SS-09 for CPP. ©) Feeder List SS-10 for DMRO. d) Feeder List SS-11, 13 & 16 for OFFSITE & Non-Plant Building. DRAWINGS:- Following GA Drawing, SLD & Schematic Drawing for Existing Panels is attached as annexure-2:- a) SS-01: PCC-0131 & PCC-0132. b) $5-02: PCC-0231, PCC-0232 & PCC-0233, )_SS-09: PCC-EMG, PCC-0931, PCC-0933 & PCC-0935. d) SS-10: PCC-1031 & PCC-1032. e) 95-11: PCC-1131. f)$S-13: PCC-1331, PCC-1332 & PCC-1333. 8) SS-16: PCC-1631 Following Electrical Layout is attached as annexure-3:- a) 8-01 b) $S-02 ©) 5-09 d) $5-10 e) SS-11 f) $5-13 8) S5-16: JOCL Technical Specification for ACB Retrofitting Job is also attached as Annexure-4 for implementation. 2.0: Scope of Work Item No. 10. Design, Manufacturing & Supply of Air Circuit Breakers:-Design, Manufacturing & Supply of Air Circuit Breakers (ACBs), suitable for retrofitting in Power Contactor + SFU Modules of different rating from 75KW to 160 KW in PCCs at different Substations at PNC along with supply of required protection & measuring CTs, MCBs, Fuses, Control Contactors, Links, LEDs, Aluminium Bus bars etc. as per the specifications mentioned in Technical Specifications section, site condition and tender terms and conditions. Item No. 20. installation & Commissioning of Air Circuit Breaker:- Installation & Commissioning of 800A Air Circuit Breaker, Dismantling of existing Power Contactor + SFU Module and removing the same & retrofitting the New Breakers (ACBs), Testing and Commissioning along with supply of all Sundry Materials, AL bus-bars, Protection & Measuring CT's, Shrouds, Supports, MCBs, Fuses, Control Contactors, LEDs for Indications, hardware materials required for retrofitting in existing panel with complete wiring including supply of technicians, supervisor, skilled & unskilled labours, necessary Tools-Tackles etc. as per instruction of engineer in charge and tender terms and conditions. Retrofitting job for the following existing Modules:- 1) In respective PCC switchgear of $S-01, 02, 09, 10, 11, 13 & 16 at PNC: 129 No's Existing Power Contactor + SFU Modules with new 800Amps, 415Volts ACBs. 2) CT Requirements: Suitable for the motor load mentioned in the feeder list as annexure-1. 3) Aux supply of Closing/ Tripping / LED Circuit: 220DC Control supply for the closing/ tripping & indication circuit shall be DC. Installation work includes Dismantling of the existing modules, Removal of existing incoming and outgoing links, Installation of new cradles, Tracing of old wires, Fabrication jobs for installation of incoming and outgoing bus bars, Installation and mounting of CTs, Fuses, MCBs, Control Contactors, Switches, Links, Shrouds, Hylam Sheets, Disconnection & Connection of the outgoing power & control cables, Retrofitting job by installing the new ACBs, Testing, Pre- Commissioning, Commissioning of all retrofitted modules/ handing over to client, functional check, any other activity as per instruction of site engineer-in-charge, as per enclosed specifications, data sheets and other codes and standard attached or referred. Also Includes Testing & Commissioning of the Outgoing Motor Feeders that are to be shifted from the existing SFU+Contactor feeders to the ACB feeders in the extended panel including provision of additional TBs at the marshalling panel compartment in the existing PCC/PMCC for the termination of DCS cables with interpanel wiring. The new retrofitted ACBs shall be designed suitably so that the Electrical System parameters, existing facilities and control functions remain unchanged. 3.0 ADDITIONAL CONDITIONS OF CONTRACT:1. Review of aux supply requirement: Vendor to review the existing control supply availability in the panel and shall suggest the changes required for any augmentation of AC/DC control supply requirements for incorporating the additional breaker modules. Installation of additional TBs & MCBs for DC supply and any other component required for the retrofitting are in the vendor scope. 2. Vendor to submit the design documents and QAP of the proposed breaker, auxiliary power supply requirements to IOCL for approval before carrying out manufacturing/fabrication. 3, The existing feeders are interfaced with the DCS through connection at the marshalling panel. Vendor to provide all interface wiring with terminations up to the marshalling panel for all retrofitted breakers in respective PCCs. 4, Vendor should get all drawings & specifications (General Arrangement Drawings, Schematic Diagram of feeders, Bill of Materials, QAP and General Notes) approved from IOCL, Panipat before proceeding for retrofitting job. 5. Vendor should provide six (6) sets of as-built drawings and Master Bill of materials of the retrofitted modules along with softcopy in CD with the delivery of the item. 6. All materials supply (Including AL bus-bar, droppers, wiring materials, flexible jumpers, switches, leads, MCBs, Control Contactors, Indication Lamps, Hylam Sheets, CTs and Shrouds etc. shall be in the vendor scope. All required tools & tackle shall be arranged by vendor. 7. Shifting of material from store to respective substation shall in the scope of the contractor. 8. Vendor has to supply the CTs (3 Nos. of CTs for protection-Class 5P20, 1 Nos. of CT for metering-Class 1.0) compatible with the breakers. No extra amount will be paid for the same. 9. Vendor shall visit the site with his technical team within 7 days of issue of work order. 10 Vendor should submit the drawings and schematics for approval within 15 days of site visit. M/s 1OCL will provide approval within 7 days of receiving of drawing and schematics. 11. Vendor will provide the standard checklist for installation of panels and job should be carried as per direction of Engineer In charge. 12. Test report for installation, testing, commissioning of panels to be submitted by vendor. 13. Transportation and stacking of salvaged unusable material to owner's store or as advised by and as per the directions of the Engineer-in-Charge, anywhere within Panipat Naphtha Cracker premises shall be in the scope of vendor.14. The Party has to dispatch or bring all the breakers & other materials for execution of job. The owner will provide sufficient space for storage of the materials. 15. Equipment’s like welding machine / drill machine / grinder/ bus bar bending machine, busbar sleeving machine etc. required for the mechanical related jobs shall be arranged by the contractor without any extra payment. 16. Any requirement of structural item e.g. plate, channel, strip of any material for retrofitting, the same is to be arranged by the contractor without any extra payment. 17. All the testing equipment’s e.g. multi-meter, micro-ohm meter, Insulation tester, etc. & material e.g. wire, ferrule, lug, auxiliary relay etc. required for executing the job, shall be arranged by the contractor without any extra payment. All special tools like bus bar bending machine, drilling machine and sleeving machine to be brought by the vendor to site for executing the job. 18. The work shall be done as per procedures / clearance system prevailing in the Panipat Naphtha Cracker related to safety. The necessary clearances required during the execution of job, shall be obtained by the party, from the various agencies of the Panipat Refinery (Fire & safety, shift personnel, RSM etc.), depending upon the job requirement as per Panipat Naphtha Cracker norms. 19. The work shall be done as per relevant IS / IEC specifications / as per manufacturer's recommendations or as per direction of E-I-C. 20. The contractor shall deploy sufficient man-power to execute and complete the job with-in time as per the instruction of EIC. 21. The price is inclusive of boarding, lodging, to & fro. No extra charges will be paid for the same. 22. The Existing schematic drawing for PCCs will be provided by M/s IOCL. 23. The existing Numerical Relays are to be used in the breaker panels. 24. The jobs & items not appearing in the Purchase Order but required to complete retrofitting {job in all respect shall be in the scope of the vendor, No extra payment shall be made. 27. Party will strictly adhere to the safety rules formulated by Panipat Refinery & Petrochemical Complex. 28. Party should arrange their own labour, tool and tackles to complete the job in all respect.29. The party shall have to obtain C&A/ Police verification while reporting for the work from the concerned area of residence of the workman. Contractor engaging any person for the work in the Refinery shall be required to come with C&A/ Police verification from the concerned area before reporting for work or they should engage personnel whose C&A/ Police verification is already available. 30. M/s ICL will inform about the shutdown schedule (15) Fifteen days in advance by mail and according to that vendor will mobilize his service team for installation and commissioning of breaker modules. 31. Contractor shall make his own assessment of the shutdown jobs and accordingly arrange the necessary Infrastructure / manpower In order to complete the total job in the shutdown period. 32. Vendor has to make micro level planning to carry out the job in the stipulated shutdown period .Vendor to provide the Bar Chart showing man power deployment to Engineer-in-charge before start of the job. 33. Vendor has to provide the daily job progress reports to the Engineer-in-charge. 34. Contractor to furnish their site organogram of technical staff for the execution of job. 35. All the electrical accessories to be used in the breaker e.g. plug, contactor, switches etc. shall be of standard make (like Siemens, L&T, Schneider, Technic, Switron or equivalent make). 36. The contractor shall be fully responsible for the conduct of his employee and ensure their behaviour with the dealing persons is always good & cordial 37. Contractor will arrange his own transport & accommodation during the stay at Panipat for execution of job. 38. The working duration shall be as per the normal working hrs. (General shift -0830 Hrs. to 1715 Hrs.) However contractor may have to work for extended hours after 5 PM and also on Sundays & Holidays or during night hour, if required depending upon the availability of the feeder / bus shutdown. No extra payment shall be given for the working period beyond 5 PM. 39. All labour laws and other statutory obligations providing in the state of Indian Union, which may come in force from time to time during the contract period has to be strictly adhered. 40. No modification in the panel wiring shall be permitted for executing the retrofitting job without approval of EIC. 41. Gap between phase to phase and phase to earth for all bus bars to be maintained as per relevant IS/ IEC standard.42. Bus bars to be PVC sleeved with shrouds in bus bar joints and Bakelite sheets to isolate all /e parts for ease of maintenance in future. 4.0. Time line of execution: (i) Site visit for scheme finalisation: 7 days from placement of WO. (ii) Submission of GA drawings, QAP, design documents including aux power requirements: within 7 Days of site visit. (iii) Site Handing Over: January 2022. 5.0 Inspection: All breakers and extension panels are to be inspected by IOCL approved TPI/IOCL engineer at factory works before dispatch. 6.0 Information required by purchaser from the bidder during offer submission 6.1 Full technical description and performance details of the equipment and components offered including heat losses for all components in KW, 6.2 Overall dimensions, GA drawing, shipping dimensions & weight of the switchgear. 6.3 Deviation taken by the vendor from the requirements of this specification. 6.4 Guaranteed technical particulars. 6.5 Type test certificates from CPRI or any other Govt. approved testing laboratory 6.6 Bill of material including makes of components. 6.7 Vendor to submit undertaking on their letter head that Services & Spare parts support will be available for next 15 years from the date of announcement of product obsolete. The undertaking should be submitted along with the offer. The vendor shall give a notice of at least One year to the user of equipment before phasing out the product/spares to enable the user for the placement of order and services. 6.8 Filled data sheet of ACB. 6.9 Vendor to mobilise a site vehicle (Pick-Up Type) for the movement of their manpower and shifting of material inside PNC.