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DESIGN, SUPPLY, INSTALLATION, TESTING AND COMMISSIONING INCLUDING COMPREHENSIVE ANNUAL

MAINTENANCE OF 50kWp ON-GRID SOLAR POWER PLANT (Interconnected to local LT grid without batteries) AT

MCF,HASSAN, KARNATAKA.

____________________________________________________________________________________________________________________________

PART-A: -Techno-commercial details

Annexure-I

TYPE OF SOLAR POWER PLANTS:-

Roof mounted solar power plant – 20KWp

Ground mounted solar power plant – 30 KWp

I. GENERAL a. Geographical details where solar power plant to be installed: -

Place: Master Control facility, Department of space, Govt of India (ISRO), Hassan, Karnataka state, 573201and it is 185 Kmtr from Bangalore.

Latitude of the place:13 Deg “N” Longitude is 76 Deg “E”

b. Type of Bid: -

Two part bid with part –A (Annexure-I,II,III &IV) is techno-commercial bid and part –(B) is the price bid. Tenderer shall go through all the technical specifications of annexure-I,II & III and roof plan of the building before submitting the bid. Also if required, tenderer can visit the site before submitting the quote.

c. Technical requirements mentioned in the annexure-I, II & III are to be met by the tenderer.

d. Price bid shall be submitted separately in a sealed cover. e. Supply, installation and commissioning of solar power plant is turnkey

work. Tenderer shall submit the technical and price bids as per the technical requirement, site plan and system requirements as per standard practice and manufacturer recommendation. Also item sl no. 2,3 & 4 (supply of UG cable from ACDB to LT distribution panel and screened twisted pair communication cable) will be paid as per actual requirement at site.

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f. Annexure-II is having technical specifications. Tenderer shall submit the technical bid along with duly filled guaranteed technical particulars enclosed in annexure-III.

g. The requirement may not be restricted only to the tender specifications, if any item required additionally to meet the design requirement may be considered suitably.

h. ELIGIBILITY:-

1. Tenderer should have successfully designed, installed and commissioned the similar roof top ground mount type solar power plant system of not less than 50 kWp plant at single location/with single purchase order.

2. Also the work completion and satisfactory working certificate from more than one year issued by the user/customer to be enclosed with the technical bid.

3. Tenderer shall enclose the list of customers and purchase order/completion report etc since Jan-2015 along with the tender. Also they shall be in the similar business for not less than three years.

4. Solar PV modules offered by the tenderer shall have valid approval from the MNRE of Indian government . Also all the acceptance tests as per relevant IS/IEC shall be conducted in India only (Availability of required test set up to be confirmed). II. Tenderer shall submit the following details along with the technical

bid.

a. Tentative GA/ dimensional drawing showing the layout of the SPV system with all its subsystems to match with existing roof plan (Roof plan/Drawing enclosed) for roof mount system and existing ground area for ground based system. All dimensions considering the clearances are to be mentioned.

b. Tentative dimensional drawings for PV module supporting structure (made of GI) and RCC pedestals.

c. Bill of materials with required quantity, specifications, make, model proposed

by the tenderer (Make and model shall be one among the Department approved list enclosed in annexure-II). If for some of the devices, Department approved makes are not available, reputed make and brand to be selected and model no. to be mentioned in BOQ.

d. MNRE approval for the solar PV modules and String Inverters offered by the

tenderer.

e. Certificate from the cable manufacturer regarding suitability of cables offered for solar power applications and it serve for 25 years without any damage. Also it shall have good temperature resistance property.

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f. Technical data sheet / catalogs from the manufacturer for the major items like Solar PV cell/ module, String Inverter, AC/DC DB’s, Junction boxes, All Cables, Connectors etc.

III. Pre-design review (PDR) :

Successful tenderer shall attend the pre-design review meeting at MCF, Hassan to discuss the design and layout plan as per the tender specifications and site conditions before starting the actual design for total system. Based on the PDR, successful tenderer shall submit the following design details & drawings for the Department approval within fifteen days from the date of PDR meeting. Work shall be started after approval from the Department.

a. Shadow Analysis at the site to be done and accordingly design, strings & arrays layout considering optimal usage of space, the bidder should submit the Shadow Analysis Report to MCF for approval.

b. General arrangement and dimensional layout for the whole SPV plant. It shall be ensured that the layout / arrangement shall suit to the available space.

c. Schematic drawing showing the details of SPV panels, power conditioning units/ string inverters, Array junction boxes, AC and DC DB’s, meters etc.

d. Item wise bill of materials for complete SPV plant covering all the components and associated accessories.

e. Structural drawings/ mounting arrangement for the roof top / Ground mount installation along with foundation drawings.

f. Design details for the electrical scheme consisting of PV modules, AC and DC distribution boards, String inverters etc with all formulae and calculations.

g. Design details of PV module mounting structure, RCC Foundation / pedestal for fixing the GI mounting structure to withstand 120Km/hour wind speed with all formulae and calculations.

h. Any modification as per standards suggested in the design document / drawing by Department (MCF) are to be considered and implemented.

i. The bidder shall submit preliminary drawing for approval & based on any modification or recommendation, if any. The bidder shall submit three sets of hard copy and soft copy in CD of final drawing for formal approval to proceed with construction work.

j. Formats for reports and charts for analysis of various parameters.

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k. Acceptance test shall be carried out at manufacturer works as per relevant IS/IEC and as per approved acceptance test plan (ATP) Any modifications/deviations pointed out by our Engineer’s during Inspection have to be carried out without any additional cost implication.

l. All the works are to be carried out as per the detailed specifications mentioned in the annexure-II, approved design & drawings and as per relevant standards.

IV. Validity of offer: Not less than 120 days from the date of submission of tender.

V. Delivery period/Completion of work including installation & commissioning: - 24 weeks from the date of approval of design documents and drawings

VI. Payment Terms: - a. 60% against supply of major items like PCU/Inverters, PV modules, GI

supporting structures, AC and DC distribution boards.

b. 20% against supply of remaining installation accessories and its installation.

c. 20% against testing, commissioning and acceptance of total work. VII. Warranty: - Total solar power plant with all the sub systems are to be

provided with warranty of five years from the date of commissioning and handing over. Any defects during this period to be attended free of cost with supply of required spares / equipments.

VIII. Security deposit and performance Bank guaranty during warranty

period shall be provided as per Department terms. Security deposited 10 % of PO value to be deposited up to completion of the work. Performance Bank guaranty (PBG) of 10% of the total value of the work to be deposited for the whole warranty period and also for the period of comprehensive annual maintenance period i. e up to 15 years from the date of commissioning and handing over to MCF. PBG amount deposited will be released only after satisfactory completion of the 15 years.

IX. Comprehensive Annual maintenance contract: - Tenderer shall

submit the quote for comprehensive annual maintenance contract from 6th year to 15 th year. During the AMC period, successful tenderer shall attend to the regular preventive maintenance of the whole system including PV module cleaning. Attending to any break downs with supply of all the spares, inverters, PV modules, tools etc within 36 hours from the time of registration of the complaint. Detailed maintenance required is enclosed at annexure-II

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a. During AMC period, performance bank guaranty of 10% of total PO value to be submitted as per Department terms.

X. Details of make /model no offered by the tenderer are to be mentioned in the annexure III (Guaranteed technical particulars) and submitted with technical bid. Also data sheet / technical literatures for all the items like Solar PV cells & modules, String Inverter, All Cables, Junction boxes, AC & DC DB’S, CPVC pipe and connectors etc from the manufacturer are to be submitted along with the technical bid.

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DESIGN, SUPPLY, INSTALLATION, TESTING AND COMMISSIONING INCLUDING COMPREHENSIVE ANNUAL

MAINTENANCE OF 50kWp ON-GRID SOLAR POWER PLANT (Interconnected to local LT grid without batteries) AT

MCF,HASSAN, KARNATAKA.

____________________________________________________________________________

Annexue-II- TECHNICAL SPECIFICATIONS

1. INTRODUCTION:

Master control facility (MCF) is planning to utilize renewable energy by setting up solar power plant of 50KWp. The proposed solar power plants (SPP) are On grid type which will be integrated with the existing low tension (LT) power system for internal use. The LT distribution operates at 415V, 50Hz, 3 phase, 4 wire, AC system.

Solar power plant of 20 KWp is proposed on the roof of power station #3 building and 30 KWp plant is proposed to mount on the ground.

Exporting power to the external utility grid is not envisaged and not in the scope of work. Whereas interconnecting and supplying of solar power to local LT distribution panel is in the scope of work.

2. DEFINITION

On grid Solar Roof Top and Ground mount type Photo Voltaic (SPV) power plant consists of SPV array, Module Mounting Structure, Power Conditioning Unit (PCU) consisting of Maximum Power Point Tracker (MPPT), Inverter, and Controls & Protections, interconnect cables and switches. PV Array is mounted on a suitable fixed GI structure. This system is without battery and should be designed with necessary features to feed the AC power to the local LT power panel/system during day time. Component sand parts used in the SPV power plants including the PV modules, metallic structures, cables, junction box, switches, PCU setc., should conform to the BIS or IEC or international specifications, wherever such specifications are available and applicable.

3. SCOPE OF WORK:-

Design, engineering, manufacturing quality surveillance, testing at manufacturer’s work, packing, supply, integration and installation at site, commissioning and performance testing of solar power plant (SPP) at MCF, Hassan, Karnataka-573201.

Solar power plants shall consist of following equipment’s/components.

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a. Solar PV modules consisting of required number of Crystalline PV cells.

b. LT power system interactive type Power Conditioning Unit (PCU) with Remote Monitoring System having string inverter, Maximum power point tracker (MPPT) etc.

c. Metering.

d. Mounting structures made of GI fixed with RCC pedestal.

e. Junction Boxes.

f. AC and DC distribution boards

g. Maintenance free Earthing and lightening protections.

h. IR/UV protected PVC Cables for PV module interconnections, Interconnecting power cable from PV module to array JB, array JB to DCDB, DCDB to inverter and inverter to ACDB , power cables for solar power plant application are to be used. All the cables are to be laid in CPVC pipe. All cables exposed to the sun light are to be laid in the suitable dia, class 1, SDR-11 grade CPVC pipe with required bends/elbows and to be clamped properly for roof top plant. In addition to the above for the ground based system all the interconnecting cables are to be laid in CPVC pipe fixed properly on the elevated GI stand minimum 600mm above the ground level. (Note:- In the ground mounting plant, none of the interconnecting cables are to be laid underground. All the interconnecting cables are to be routed in the CPVC pipe fixed on suitable GI supporting stand fixed on a concrete pedestal. Minimum thickness of GI angle/ channels used for stand should be 5 to 6 mm)

i. UG cable from ACDB to LT panel /distribution system is also in the scope of the work. These cables are to be laid in suitable GI perforated cable tray with cover and having minimum 3mm wall thick ness (Cables are to be laid on the roof/ wall on the cable tray and also to be laid in ground with earth excavation and protection bricks & sand as per standards (750mm below ground level with top and side bricks and filled with sand up to the bricks top level as per drawing enclosed.

j. Different sensors with data logging facility like, solar insolation/irradiation or insolation, module and ambient temperature, wind speed etc.k

k. Data logging system with existing desktop computer to store different parameters / data and display etc. Also the connectivity from the solar power plant to the existing (LAN) network & desktop computer through screened twisted pair cable. (Desktop computer is not in the scope of work)

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l. Civil works like foundation/ pedestals for fixing GI structure for fixing PV modules, inverter and AC/DC distribution boards etc. are also in the scope of the work. Also any minor Civil works required like opening in the existing wall / ceiling, plastering and finishing with painting etc. shall be carried out by the successful tenderer.

m. The total solar PV array capacity should not be less than allocated capacity (kWp) and should comprise of solar crystalline modules of minimum 250Wp and above wattage. Module capacity less than minimum 250Wp will not be accepted.

n. If Any other equipment’s/ancillaries necessary for reliable, safe and efficient operation of the solar power plants as per standards and statutory provisions are applicable.

o. Tenderer is liable to comply with the provisions of all safety regulations and all prevailing laws. Instructions of the Department safety manual are also to be followed.

Note: Solar power is planned to utilize during day time only, but no storage batteries are planned and not in the scope of the work. Also it is not planned to export the power to the external grid. Solar power plant output will be interconnected with the local LT panel/grid only at two different LT power panels.

4. WARRANTIES:

a. Material Warranty:-

The total solar power plant including hardware components shall carry comprehensive onsite warranty for a period of five years (5 year) from the date of commissioning and handing over of the solar power plant.

Any problems/ defects found during the above period (5 years from date of commissioning and handing over the Department) are to be attended with free supply of all the spares by the tenderer free of cost. No additional cost will be paid by the Department.

b. Performance Warranty:

Also solar PV modules shall carry performance guarantee for a period of 25 years from the date of commissioning.

NOTE: - Tenderer shall also indicate the cost of comprehensive annual maintenance cost (AMC ) from 6th year to 15th year for the smooth functioning of the solar power plant. Also the list of tools/tackles and spares required to be maintained at site is to be enclosed with the tender along with Technical bid.

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5. GUARANTEED GENERATION: -

The solar power plants supplied and installed by the successful tenderer shall be guaranteed to generate solar power on an average annual basis during the period of warranty and thereafter up to 25 years. However, degradation as per MNRE guidelines is allowed.

Minimum annual generation of 1500 KWH per KWp of solar power plant to be guaranteed.

Daily system generated records shall be maintained for the actual solar power produced with effect from the date of commissioning and handing over to MCF. Calibration certificate for the tri-vector meter from the manufacturer shall be submitted to the Department.

On completion of one year period and every year the total power generated will be reviewed by the Department. In case. the solar power plant fails to generate the minimum guaranteed annual solar power energy/KWH/units, the supplier /contractor shall immediately arrange to pay to the Department through a crossed Demand draft issued by scheduled bank @ Rs. 15/- per unit (KWH) of such shortage of generated power with respect to the minimum units guaranteed. If supplier fails to remit the amount within 15 days , the amount shall be recovered by the Department by en-cashing the performance bank guaranty held by the Department without any further notice.

In case, the actual solar power units generated are in excess of the guaranteed generation, no extra payment or bonus will be paid to the supplier/ contractor. Generated energy will be recorded every month and calculated every year. Energy generated will not be adjusted for the subsequent years. No consideration of any sort will be made on account of shutting down of the solar power plant for repair or maintenance or any other reasons except under force majeure conditions.

6. COMPLETION PERIOD: -

The entire work comprising of Design, Engineering, manufacture, inspection and testing of performance at manufacturer’s works, delivery at site, erection, testing and commissioning at MCF, Hassan shall be carried out within the period of six months from the date of approving of the design & drawings.

7. CODES AND STANDARDS:-

All the equipment’s and accessories shall comply with requirements of standards published by Bureau of Indian standards. In case no BIS code exists, they shall meet the requirements of International standards including IEEE for design and installation of solar PV modules. Also IEC standards specification has to be met if BIS is not available.

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The PV modules must confirm to the latest edition of any of the following IEC / equivalent BIS standards for PV modules design qualification and type approval.

Specifications of solar power plant with all its equipments /accessories , and testing etc shall confirm to following BIS/IEC/IEEE standards.

a. Crystalline silicon terrestrial PV modules- IEC61215/IS14286

b. Also PV modules shall confirm to IEC 61730 part1 - Requirement for construction and part-2 -Requirements for testing for safety qualification. If IS available , it shall meet the specifications of IS.

c. PV modules must qualify salt mist corrosion testing as per IEC 61701 /IS 61701.

d. IEEE 928: - Recommended criteria for terrestrial PV power system.

e. IEEE 519: - Guide for harmonic control and reactive compensation of static power controller.

f. IEC 60904 -1 Photovoltaic Devices part-1: - Measurement of photovoltaic Current-Voltage characteristics.

g. IEC-61724: - Photovoltaic system performance monitoring and measurements.

h. IEC 61683/IS 61683: - Efficiency measurements of power conditioning units (PCU) /String Inverter.

i. IEC 60068-2-6: 2007: - Environmental testing for electronic equipment’s: vibration test for Inverter

j. IEC 60068-2-21: 2006: - Robustness of terminals and integral mounting device of the inverter

k. IEC 60068-2-27: 2008: - Environmental testing for inverter: Shock

l. IEC 60068-2-75: 1197: - Environmental testing: Hammer test for inverter

m. IEC 60068-2-78: 2012: - Environmental testing: Damp heat, steady state tests for inverter

If Equivalent BIS standard for environmental testing is available, BIS to be followed. Also any other specifications need to be satisfied as per relevant IS/IEC standards are to be met.

n. IEC 61727:-DC Injection into the grid.

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o. National Electric safety code-NFPA 70 with latest amendments or equivalent National standard.

p. National Electrical safety code- ANCI C2 or equivalent national standard.

q. AC & DC Distribution board: Relevant IS /IEC standards.

r. Urmoured and unarmoured UG cables: IS 7098 part-1,1988, IS 8130, /IS 694, /IS1554 with latest amendments. Also IS/IEC code satisfying the required specifications for power cables used for solar power applications are to be mentioned.

s. Chlorinated polyvinyl chloride (CPVC) pipes: - IS 15778. With latest amendments

t. IS 9000 Basic environmental testing procedure for electronic and electrical items.

u. Any other IS/IEC latest standards specifications required are to be met /confirmed.

8. SITE DETAILS PROPOSED FOR INSTALLATION OF SOLAR POWER PLANT: -

Roof plan of the building above which the solar power plant is planned and area /location of the ground based solar power plant where solar power plants are intended to install are enclosed for the reference of the tenderer. If required tenderer can visit the proposed site.

Contractor shall consider the environmental conditions; solar insolation/irradiation & wind speed for the locations specified and design the system accordingly.

9. SUBMISSION OF ACCEPTANCE TEST PLAN & PRE-DESPATCH INSPECTION:

Successful tenderer shall submit the acceptance test plan / inspection plan 10 days before the date of acceptance test to the MCF for approval of the acceptance test plan. If there is any modification in the test plan based on relevant IS/IEC standards, these modifications are to be incorporated in the test plan and same to be followed during the inspection.

Successful tenderer shall arrange for witnessing the acceptance test / Inspection by the Department (MCF) Engineers / Third party inspection. Also prior information to be sent to MCF regarding the date of inspection. All the test certificates for all the equipments / sub systems are to be provided during inspection.

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10. TECHNICAL SPECIFICATION OF INDIVIDUAL SYSTEMS:

10.1. SOLAR PHOTOVOLTAIC MODULES:

a. The PV modules used should be type tested by any one of the accredited test laboratories under ministry of new and renewable energy (MNRE) , Government of India. The solar PV modules shall be made of crystalline silicon solar cells connected in series / parallel. Poly / Mono crystalline solar cells shall be used.

b. The cells used in the modules shall be of reputed make.

c. SPV modules of similar output with +/- 2 % tolerance in single string shall be employed to avoid array mismatch losses.

d. SPV module shall contain crystalline high power silicon solar cells. The solar cell shall have surface anti-reflective coating to help for absorbing more light in all weather conditions.

e. Photo/ electrical conversion efficiency of SPV module shall be minimum 15.3%.

f. Fill factor of the module shall not be less than 70%.

g. Each module shall have low iron tempered glass front for strength and superior light transmission. It shall also have tough multi-layered polymer back sheet for environmental protection against moisture & provide high voltage insulation. Transmittance of glass shall not be less than 91 %. The PV module shall be provided with lead wire with water proof (IP 65 class of protection) connector for output terminals.

h. Module junction box (weather resistant) and UV, IR protected shall be designed for long life outdoor operation in harsh environment.

i. Bird spikes shall be provided to avoid bird sitting on the solar modules at the highest point of the array/ module structure.

j. SPV modules shall be highly reliable, light weight and shall have a performance efficiency up to the end of their life as per MNRE specifications.

k. Wherever more than one module is required, identical modules shall be used.

l. Protective devices against surges at the PV module shall be provided. Low voltage drop by-pass diode to minimize power drop caused due to shading are to be provided.

m. The PV modules shall be resistant to abrasion, hail impact, rain, water and

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environmental pollution. The PV modules shall be provided with anti-reflection coating and back surface field (BSF) structure to increase conversion efficiency.

n. It shall withstand relative humidity up to 95% and temperature conditions varying from 0 Deg centigrade to +50 Deg centigrade.

o. The solar modules shall have suitable encapsulation & sealing arrangements to protect the silicon cells from environment. The encapsulation arrangement shall ensure complete moisture proofing (IP65 class of protection) for the entire life of each module. The terminal block shall be Nylon material.

p. The PV modules and PV array structures shall be properly grounded using maintenance free earthing kit and shall suit the respective site conditions to achieve the desired earth resistance as per standards (less than 5.0 Ohm for both lightning protection and equipment/ body earthing) _.

q. I-V Curves at STC should be provided by the successful bidder for all the PV modules.

r. The peak-power point voltage and the peak-power point current of any supplied module and/or any module string (series connected modules) shall not vary by more than 2(two) percent from the respective arithmetic means for all modules and/or for all module strings, as the case may be.

s. The module shall be provided with a junction box with either provision of external screw terminal connection or sealed type and with by-pass diode. The box shall have hinged, weatherproof lid with screws and cable gland entry points or may be of sealed type and IP-65rated.

10.2. Identification and Traceability:-

Modules deployed must use a RF identification tag (RFID). Following information must be mentioned in the RFID used on each modules (This can be inside or outside the laminate, but must be able to withstand harsh environmental conditions.

a. Name of the manufacturer of the PV module

b. Name of the manufacturer of Solar Cells.

c. Month & year of the manufacture (separate for solar cells and modules)

d. Country of origin (separately for solar cells and module)

e. I-Vcurve for the module’s Maximum power (Pm)Wattage,Im,Vm, FF for all

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the modules.

f. photo/electrical conversion efficiency of the modules and fill factor.

g. Measured temperature, Corrected temperature.

h. Open circuit voltage, operating voltage & short circuit current

i. Polarity of terminals or leads.

j. Unique Serial No and Model No of the module

k. Date and year of obtaining IEC for PV module qualification certificate.

l. Name of the test lab issuing IEC certificate.

m. Other relevant information on traceability of solar cells and module as per MNRE or other standards.

10.3 PV MODULE MOUNTING (ARRAY)STRUCTURE: -

One of the 20 KWp plant is proposed to be installed on the roof of the existing building. Another 30KWp plant is proposed to install on the ground

a. Modules are proposed to be installed on the roof of existing RCC building and ground. The array structures shall be designed such that it will occupy minimum space without sacrificing the output from SPV panels. Array layout indicating suitable clearance within the array and other components shall be submitted along with the tender for both 20 kWp & 30 kWp plants.

b. Hot dip galvanized MS mounting structures shall be used for mounting the PV modules/panels/arrays. Mounting structure should have angle of inclination as per the site conditions to take maximum insolation/irradiation throughout the year. Hot dip galvanized MS angles/channels shall be with minimum 5mm thick and base plate shall be minimum 10mm thick and galvanization thickness of minimum 120 micron to be done. Also minimum dimension of GI angles and channels shall be 50 x50 mm x 5mm thick (angles) and 50x100 x5mm thick (channels).GI mounting structure shall be designed to withstand the wind speed of 120KM/Hour (minimum). Drawings of the GI structure and RCC pedestal are to be submitted along with the tender. All the works shall be carried out as per IS 875-part-3. Also following data to be considering for calculation of wind load as per the IS 875-part-3 . Basic wind speed – 33 m/sec or 120 km/hour Terrain category -2 Topography factor k3 -1.00

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Importance factor for cyclonic region k4 – 1.00 Height of influence for roof mount system -10 to15 mtr Roof Mounting Plant:- Roof mount plant shall comply with the following specifications

c. Suitable mounting structure shall be designed and installation shall be carefully executed such that the existing water proof treatment is not disturbed / punctured. In case of any disturbance to the existing water proofing, same is to be made good and also it shall be ensured that there will not be any leakages. Foundation of the mounting structure also shall be included. Leak proof treatment shall be done for the RCC pedestals also.

d. The foundation for the GI module mounting structure shall be with RCC and minimum 1:2:4 concrete mix constructions or any better combination based on local site condition requirement for which design details shall be submitted for department approval before starting the work. The dimension of the RCC pedestals are to be designed based on the load data of the members at base plate level. The RCC pedestals are to be designed as per latest edition of IS 456.Suitable adhesive materials of reputed company like FOSROC or equivalent is to be used to join the pedestal with existing roofing system (for proper bonding). OPC 45 grade cement, M-sand and Fe 500D grade reinforcing steel is to be used for RCC pedestals. Also the detailed specifications in Annexure-III and drawing no.MCF:2 to be considered for constructing pedestals for roof top plant. Roof plan of the building is enclosed –Drg- No.MCF:1 Ground mount Plant:- All the requirement mentioned under sl no. 10.3 are to be followed for designing the foundation and pedestal and submitted for department approval during PDR (Pre design review). All other specifications mentioned under sl no.10.3 of the tender are common for both ground and roof mount plants.

e. The Mounting structure and foundation shall be so designed to withstand the speed of the wind zone of the location where PV system is proposed to be installed (Minimum wind speed of120kM/hour to be considered). It may been ensured that the design has been certified by a recognized Lab/Institution in this regard. Successful tenderer shall submit wind loading calculation sheet of GI support structure and RCC foundation for department approval before starting the work. Suitable fastening arrangement such as grouting and calming should be provided to secure the installation against the specific wind speed.

f. All the fasteners used for PV module mounting structure shall be of stainless steel of grade SS304.

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g. The clearance of the lowest part of the module structure and the roof top or ground shall not be less than 1000mm to have easy maintenance.

h. The module alignment and tilt angle shall be calculated to provide the maximum annual energy output. This shall be decided based on the location of the installation.

i. The mounting structure steel shall be as per latest IS2062:1992 and galvanization of the mounting structure shall be in compliance with latest IS4759.

j. Structural material shall be corrosion resistant and electrolytically compatible with the materials used in the module frame, its fasteners, nuts and bolts etc.

k. Regarding Civil structures the successful bidder need to take care of the load baring capacity of the roof and need to arrange suitable structures based on the quality of roof for roof mount system.

l. Successful bidder shall submit the design details of the mounting structure with RCC pedestal etc to department for the approval of the design before starting the work. If any changes made by department based on the requirement, those changes to be incorporated.

10.4. JNCTION BOXES (JBs)

a. Module Junction box/ Connector box: -

Junction boxes on each PV modules shall be UV/IR protected and suitable for outdoor application with IP 65 class of protection. It shall be durable for operation in harsh environment and serve for 25 years. It shall have by pass diodes also.

b. Array Junction box with IP 65 class of protection :-

The array junction boxes are to be provided in the array for termination of connecting cables. The Junction Boxes (JBs) shall be made of GRP/FRP/ABS plastic and UV/RI protected with dust, water & vermin roof arrangement. All wires/cables must be terminated through cable lugs. The JBs shall be such that input & output termination can be made through suitable cable glands. JB’s shall be with IP 65 class of protection for outdoor application. It shall have suitable rating Copper bus bars/cage clamp type terminal blocks housed in the junction box. It shall be Conforming to IP65 class of protection standard. Hinged door with EPDM rubber gasket to prevent waterentry. Single/double compression cable glands. Provision of earthings etc.

c. Each Junction Box shall have High quality, Suitable capacity Metal Oxide

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Varistors (MOVs)/SPDs for external over voltage protection along with suitable Reverse Blocking Diodes. The Junction Boxes shall have suitable arrangement for monitoring and disconnection for each of the groups.

d. Suitable markings shall be provided on the cables & terminal blocks for easy identification and the cable ferrules must be fitted at the cable termination points for identification.

10.5. DCDISTRIBUTION BOARD with IP 65 class of protection :

DC Distribution panel to receive the DC output from the PV array field. It shall be placed in between array junction box and inverter input

DC distribution boards shall be made of MS sheet steel enclosure confirm to IP 65 protection (For outdoor applications). Suitable capacity MCBs/MCCB shall be provided for controlling the DC power output to the PCU/Inverter. DB enclosure shall be fabricated from MS sheet steel of minimum 2 mm thickness and MS sheets are to be seven tank processed to remove dust, oil, grease etc. Painting shall be done by powder coating / enamel paint of siemens grey color. Also it shall have rain protection shade. DCDB to be fixed at the height of minimum 600mm on MS stand and legs of the stand to be grouted and concreted to fix on the roof or ground. For Ground based system, DB is to be elevated above the ground level with a concrete pedestal of height 600mm

Surge protectors of appropriate rating shall be provided.

10.6. AC DISTRIBUTION PANEL BOARD with IP 65 class of protection

a. AC Distribution Panel Board (ACDB)shall control the AC power from PCU/inverter. Also it shall have inter connection from ACDB to mains at LT Busbar in LT panel/ LT distribution system.

b. All switches and the circuit breakers, connectors shall confirm to relevant IS /IEC standards.

c. All the Panels shall be metal clad, totally enclosed, rigid, floor / wall mounted ,air-insulated, cubical type suitable for operation on three phase 415volts,50Hz supply. DB enclosure shall be fabricated from MS sheet steel of minimum 2 mm thickness. MS sheets are to be seven tank processed to remove dust, oil, grease etc. Painting shall be done by powder coating / enamel paint of siemens grey color. Also it shall have rain protection shade. ACDB shall be fixed on the MS frame with minimum 600mm height and supporting legs of the frame shall be grouted and concreted to fix properly on the RCC roof.

d. ACDB shall have circuit breakers /MCB/MCCB of suitable rating for

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connection and disconnection. It shall also have output indication lamps and multi function meter to read current, voltage, power and energy utilized from solar power plant. Also it shall have suitable rating copper busbars.

e. The panels shall be designed for minimum expected ambient temperature of 50 degree Celsius, 80 percent humidity.

f. ACDB shall be outdoor mounting type with IP 65 or better class of protection.

g. Shall conform to Indian Electricity Act and rules and relevant IS/IEC standards.

h. All the protection, indication, metering devices are to be considered as per standards. Any of the items required for the ACDB not mentioned in the tender also to be considered and supplied.

i. Surge protectors of appropriate rating shall be provided.

j. ACDB to be fixed at the height of minimum 600mm on MS stand and legs of the stand to be grouted and concreted to fix on the roof or ground. For Ground based system, DB is to be elevated above the ground level with a concrete pedestal of height 600mm

k. ACDB’s shall be tested as per the relevant IS code.

10.7. PCU/ARRAYSIZERATIO:

The combined wattage of all inverters should not be less than rated capacity of power plant under STC.

Maximum power point tracker shall be integrated in the PCU/inverter to maximize energy drawn from the array.

10.8. PCU/Inverter:

As SPV array produce direct current electricity, it is necessary to convert this direct current in to alternating current and adjust the voltage levels to match the LT distribution panel voltage. Conversion shall be achieved using an electronic Inverter and the associated control and protection devices. All these components of the system are termed as “Power Conditioning Unit(PCU)”. In addition, the PCU shall also house MPPT (Maximum Power Point Tracker), an interface between Solar PV array & the Inverter. Power conditioning unit/inverter should also be DG set interactive. Inverter output should be compatible with the LT power system frequency. Typical technical features of the inverter shall be as follows:

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Switching devices IGBT/MOSFET

Control Microprocessor/DSP

INPUT:

o Max input voltage:

o DC voltage range:

o Start up voltage:

o Nominal DC voltage:

1000V

200 to 1000V 

>250V 

635V 

OUTPUT

Nominal AC output voltage and frequency

Accuracy of output control

Output frequency :

Accuracy of frequency control -

Grid Frequency Synchronization range

Ambient temperature considered :

Humidity:

Protection of Enclosure:

LT Grid Frequency Tolerance range:

LT Grid Voltage tolerance:

No-load losses:

Inverter efficiency(minimum):

Total harmonic distortion (THD):

Power factor :

415V,3Phase,50Hz

+/- 1% 

50Hz 

+/- 0.1 % 

+/- 3Hz or more

-0oC to 50oC

95%Non-condensing

IP-65(Minimum) for outdoor application 

+/- 3Hz  

(-20%&+15%)

Less than1% of rated power

>95% 

<3% and shall comply with IEEE512 

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Three phase PCU/inverter shall be used 0.8 lag to 0.8 lead

‐‐ 

PROTECTION: Inverter shall have following minimum protections

Over current at output

Over voltage at both input and output

Over/ under grid frequency

Inverter fan failure

Over temperature

Short circuit

Earth fault

Protection against lightning

Surge voltage induced at output due to external sources

Reverse power flow protection.

DC/AC side surge protection-inbuilt with MOV etc

Any other protection required as per relevant standard are to be considered

a. PCU/ inverter shall be capable of complete automatic operation including wake-up, synchronization & shut down.

b. Built-in meter and data logger to monitor plant performance through external computer shall be provided. Also it shall have continuous monitor to read the electrical parameters and status of the solar power system, LT distribution system etc.

c. The system shall be suitable to adapt, synchronize and satisfactorily deliver power to the grid during all normal functioning of the system.

d. Liquid crystal display shall be provided on the inverter front panel or on

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separate data logging / display device to display the following minimum parameters.

DC input voltage

DC input current

AC power output (KW) delivered to internal LT grid.

kWH / units generated.

Current date and time

Time active, Time disabled,

Temperature (Deg. Centigrade)

Inverter status.

AC over & under voltage

OVER and under frequency.

Ground fault.

PV starting and stopping voltage.

Over and under voltage delay.

Over frequency.

Ground fault delay

PV starting and stopping delay.

Also any other display setting parameters required as per standard are to be considered.

e. The power conditioning units/inverters should comply with applicable IEC/equivalent BIS standard for efficiency measurements and environmental tests as per standard codes IEC61683/IS61683 and IEC60068-2/Equivalent BIS .

f. The PCU/inverter should be tested from the MNRE approved test centres /NABL/BIS/IEC accredited testing-calibration laboratories.

10.9. GRID ISLANDING AND CONTROL:

a. In the event of power failure on the electric grid, it is required that any

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independent power-producing inverters attached to the grid turn off in a short period of time. This prevents the inverters from continuing to feed power into small sections of the grid, known as “islands. ”Powered islands present a risk to workers who may expect the area to be unpowered, and they may also damage grid-tied equipment. The Roof top PV system shall be equipped with islanding protection. In addition to disconnection from the grid(due to islanding protection) disconnection due to under and overvoltage conditions shall also be provided.

b. System shall be provided with adequate rating MCB’s /MCCB’s, on inverter input side (DC) as well as output side (AC) for overload and short circuit protection to isolate the DC and AC system for maintenance. DC MCB’s of adequate rating shall also be provided in DCDB to protect them from short circuit.

c. Manual disconnection, four pole isolation MCCB for manual disconnection to LT grid shall be provided in the ACDB to isolate from LT panel to carry out the maintenance.

10.10. SYNCHRONISATION FEATURE: -

The output power from SPV would be fed to the inverters which converts DC produced by SPV array to AC and feeds it in to the main electricity grid after synchronization. In case of grid failure, or low or high voltage, solar PV system shall be out of synchronization and shall be disconnected from the grid. Once the DG set comes into service PV system shall again be synchronized with DG supply and load requirement would be met to the extent of availability of power. 4pole isolation of inverter output with respect to the LT grid/DG power connection need to be provided.

Output power from the inverter shall be fed to building side LT panel. Supply and laying of UG cable (Aluminium conductor, XLPE insulated, armoured UG cable from ACDB to LT panel is also in the scope of this work.

Solar PV system shall be provided with synchronization feature having three inputs for comparison

Grid / DG power supply v/s solar PV module output so as to connect the SPV system in synchronism with the internal LT utility or DG distribution panel.

In case of LT grid failure, solar PV system shall be disconnected from the grid and out of synchronization for a period till DG supply is restored.

Once DG supply is restored PV system shall be synchronized with the DG supply.

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NOTE: - Both utility and DG power will be extended on the same LT panel. AC power interfacing from ACDC to LT grid is at one place only

Inverters are to be fixed at the height of minimum 600mm on MS stand and legs of the stand to be grouted and concreted to fix on the roof or ground. For Ground based system inverter is to be elevated above the ground level with a concrete pedestal of height 600mm (Minimum)

10.11. METERING SCHEME: -

Digital Multi-function meter shall be provided in the ACDB. Multi-function meter and CT’s of appropriate rating and suitable class as per standard IS shall be provided for measuring the solar gross generation on continuous basis and register the cumulative energy generated. The energy meter shall have default display of cumulative kWh displayed continuously and following parameters also shall be displayed.

LCD test

Date and time

Instantaneous current

Instantaneous voltage

Current maximum demand in KW

Cumulative kWH / units generated by solar power plant

Frequency

Power factor

Also any other important parameters required are to be displayed.--------

10.12. DATA ACQUISITION SYSTEM / PLANT MONITORING/SCADA

a. Data Acquisition System shall be provided for both the solar power plant separately.

b. To record and display the different parameters like wind speed, Solar insolation / irradiation, Module temperature and ambient temperature, required sensors are to be supplied and fixed at appropriate locations. All the parameters are to be read through the data logger and any other required arrangements (All sensors shall be supplied with calibration certificate from authorized testing agency).

c. Solar string inverter and Multi-function meter shall have data

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communication facility. All the inverters parameters are to be read through communication network and display and store in the existing computer.

d. Data logging system shall log the data / parameters of all inverters and AC Multi function meter and different sensors as mentioned above are to be displayed on the computer screen properly.

e. Data communication shall be done through the screened twisted pair cable and connected to the existing LAN/internal network (local area network of MCF) at the identified location.

f. Screened Twisted pair cables from the Solar power plant to the internal LAN network are to be supplied and laid properly by the tenderer. Twisted pair cables are to be laid in 14 SWG MS conduit of 20/25mm dia with 14 SWG copper earth wire. Copper earth wire to be earthed. Also Surge suppressor suitable for communication lines/ RS 485 lines with proper specifications are to be supplied and connected at both ends (i.e. at Solar power plant and LAN connectivity ends). For the ground mount solar power plant screened twisted pair cables along with copper wire are to be laid in suitable size HDPE pipe and pipe to be laid in the ground at below 750mm along with power cable or in the concrete trench as per site conditions. Surge suppressors are to be provided for both roof and ground mounted plants.

g. Required web based licensed software’s are to be supplied and loaded in the existing computer for visualization and data storage.

h. Licensed Software for centralized monitoring system shall be provided for down load and analysis of cumulative data of all the plants and the data of the solar radiation and temperature and wind speed monitoring system.

i. PC based monitoring system to record, parameters from inverters, Multi function meter and weather station parameters and various analysis shall be required through bar charts, graphs and tables.

j. Communication interface shall be an integral part of inverter and other devices like Multi function meter and weather station. It shall be suitable to be connected to local computer and also remotely via web using either standard modem or GSM or WiFi modem. Demonstration to be done in remote PC through web view. Web view software’s also to be supplied and loaded.

k. Visualization screens are to be prepared in the existing computer system (Supply of Computer system is not in the scope of the work). Screens shall have following parameter and graphs to display continuously on the screen.

1. Current power

2. Today Energy

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3. Inverters: - Total energy from commissioning and today energy.

4. Last update date and time.

5. Weather station: - Current Wind speed, Ambient temperature, PV module temperature and Solar irradiation.

6. Graphs: - Today’s Plant power v/s Hour and Today’s energy v/s Hour

7. Any other parameter considered by the supplier of the solar PV system based on prudent practice.

8. Since solar power plants are to be installed at two different places, separate weather sensors are to be provided for both the plants. Interconnection with the existing network and preparation of visualization screens and report generation to be done for both the solar power plants in the single desk top computer.

Reports generation for different parameters: -

a. Day/ date wise reports for AC and DC parameters of inverter

b. Day/ date wise reports for AC parameters, Energy for Multi-function meter.

c. Day/ date wise parameters for weather station parameters as mentioned above.

d. Customized reports for all the parameters mentioned in the day wise reports. Previous history to be stored in the data base. It shall display the reports for required period only (from and to date).

e. Date and time are to be recorded in the reports. Parameters are to be logged for every minute.

e. Any other parameter considered by the supplier of the solar PV system based on prudent practice

11. PROTECTIONS

The system should be provided with all necessary protections like earthing, , Lightning protection, and grid islanding as follows:

11.1. EARTHING AND LIGHTNING PROTECTION

Earthing shall be maintenance free chemical earthing to achieve the earth resistance less than 5 Ohm. Each array structure of the PV yard should be grounded/earthed properly as per standards.

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The SPV power plants shall be provided with lightning & overvoltage protection. The main aim in this protection shall be to reduce the over voltage to a tolerable value before it reaches the PV modules or other sub system components. The source of over voltage can be lightning, atmosphere disturbances etc The entire space occupying the SPV array shall be suitably protected against Lightning by deploying required number of Lightning Arrestors. Lightning protection should be provided as per relevant IS/IEC standard. The protection against induced high-voltages shall be provided by the use of metal oxide varistors (MOVs)or Surge suppressors for the SPV plant and suitable earthing shall be provided such that induced transients find an alternate route to earth. Separate eathing stations are to be provided for lightning protection and body/equipment earthing of the system.

Lightning protection and body /equipment earthing strip/wires are to be brought to the ground level earth station for connectivity. Approximate height of the building is 15 mtr (Two floors). Providing earthing systems are also in the scope of work.

In addition the lighting arrester/masts should also be earthed properly. Earth Resistance shall be tested in presence of the representative of Department as and when required after earthing by calibrated earth tester. PCU,ACDB and DCDB should also be earthed properly.

12. CABLES AND ACCESSORIES

Cables of appropriate size to be used in the system and it shall have the following characteristics:

a. Special purpose, solar power application cables only to be used. All the cables used from PV module to array JB, JB’s to DCBD, DCDB to inverter, Inverter to input of ACDB shall be UV and weather resistant. Cable shall have double insulation to protect against short circuit, ground fault etc. internal core insulation shall be XLPE and external insulation shall be resistant to salt water, alkaline, acid, UV radiation and abrasion etc.

b. Certificate from the manufacturer regarding suitability of cable for solar power application and ensuring the expected life of 25 years are to be enclosed with the technical bid.

c. For interconnecting PV modules and PV modules to arrays junction boxes, 1.1 KV grade single core, multi strand, copper conductor, double insulation cable suitable for solar power application shall be used.

d. Cables from array JB to DCDB , From DCDB to inverter, 1.1 KV grade, single core/multi core, multi strand copper conductor, double insulation cable suitable for solar power application shall be used.

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e. Cable from inverters to ACDB, four core, XLPE insulated, copper conductor, 1.1 KV grade, multi stand and multi core unarmoured, double insulation cable suitable for solar power application shall be used. Also cable specifications shall meet to the relevant IS /IEC standards.

f. From AC DB to LT distribution panel:- Four core, XLPE insulated, Aluminium conductor, armoured 1.1KV class cables to be used. Approximate length of the solar power plant -ACDB to LT panel is 150 Mtr in case of roof mount plat and 180 mtr in case of ground based solar power plant.

g. Specifications and testing for all the cables shall be as per relevant IS/ IEC codes. Also following minimum specifications shall be met

h. Temp. Range of the cables: 0 o C to +90oC.

i. Voltagerating-1100V

j. Resistance to heat, cold, water, oil, abrasion, UV radiation

k. Sizes of cables between PV modules, array interconnections, array to junction boxes, junction boxes to DCDB & ACDB’s to Inverter etc. shall be so selected to keep the voltage drop (power loss) of the entire solar power system to the minimum. The cables (as per IS) should be insulated with a special grade PVC compound formulated for outdoor use.

l. The size of each type of DC cable selected shall be based on minimum voltage drop however; the maximum drop shall be limited to 1%.

m. The size of each type of AC cables selected shall be based on minimum voltage drop however; the maximum drop shall be limited to2% (2% of peak power voltage).

n. Cable Routing and Marking: All cable/wires exposed to sun light are to be routed in a CPVC (Chlorinated polyvinyl chloride) pipes with class-1, SDR-11 specifications having suitable diameter and with good strength to withstand the external weather conditions for minimum 25 years. Also cables/ wires are to be suitably tagged and marked with proper manner by good quality ferule or by other means so that the cables are easily identified. CPVC pipe specification shall meet to IS 15778 standards. Bends/ couplers if required for the pipe are to be used and proper fixing arrangement to be made for the pipe without damaging the roof. Also leak proof treatment to be provided for the places where screws are used to fix the pipes. Pipes shall be provided with bends/elbows etc if required. For the ground based system all the CPVC pipes used for cable protection are to be routed on the MS stands / frames concreted at the bottom. No cables are to be laid in the ground.

o. Pipes for protection are to be used for laying the cables from PV module to array junction box, Array JB to DCDB, DCDB to Inverter and Inverter to ACDB input. Also if the PV module interconnecting cables are exposed to sunlight, those cables are to be laid in the pipes.

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p. The Cable and pipes shall be so selected that it should withstand the extreme weather conditions for minimum 25 years ( expected life of the solar power plant).

q. Bidder to indicate size and length as per system design requirement. All the cables required for the plant shall be supplied by the bidder.

r. Supply and laying of UG cable from ACDB to LT power grid is also in the scope of the work. It shall be of 4core, XLPE insulated, aluminium conductor, armoured UG cable. Approximate length from the roof top of the building to LT panel is 150 Mtr and from ground based plat to power panel is 180 mtr. Routing of this cable shall be done on the roof/wall/column with perforated GI cable tray with top cover and all bends, Tees and suitable fixing supports and brackets (Cable tray shall have minimum wall thickness of cable tray shall be 3mm and width shall be suitable to the size of the UG cable). Cables are to be laid party in ground for roof based plant and fully in case of ground based systems. Also the cable to be laid in the ground with earth excavation and providing protection bricks & sand as per standards and refilling of the earth with cable route markers. Proper identification tags are also to be provided.

13. TOOLS & TACKLES AND SPARES:

a. After completion of installation & commissioning of the power plant, necessary tools & tackles are to be provided free of cost by the bidder for maintenance purpose. Tenderer shall submit the list of tools and tackles along with the technical bid.

b. Successful tenderer shall supply and keep the required minimum emergency spares at the site (MCF) to avoid the down time during break downs.

14. DANGER BOARDS:

Danger board should be provided as and where necessary as per IE Act./IE rules as amended up to date.

15. Identification boards:

Identification boards are to be provided for all the components of the solar power plant for easy identification

16. DESIGN & DRAWINGS TO BE FURNISHAED BY THE SUCESSFUL TENDERER BEFORE STARTING THE WORK.

Successful tenderer shall attend the PDR meeting (Pre-design review) at MCF,Hassan. Based on the discussion and as per the technical specifications,

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submit the following design details & drawings for the Department approval. Work shall be started after approval from the Department.

a. Carryout Shadow Analysis at the site and accordingly design strings &arrays layout considering optimal usage of space,The bidder should submit the Shadow Analysis Report to MCF for approval.

b. General arrangement and dimensional layout for the whole SPV plant. It shall be ensured that the layout / arrangement shall suit to the available space (Roof or ground area).

c. Schematic drawing showing the details of SPV panels, power conditioning units’/ string inverters, Array junction boxes, AC and DC DB’s, meters etc.

d. Item wise bill of materials for complete SPV plant covering all the components and associated accessories with specifications, make model nos. and catalogs etc.

e. Structural drawings/ mounting arrangement for the roof top and ground based installation along with foundation drawings.

f. Design details for the electrical scheme consisting of PV modules, AC and DC distribution boards, String inverters etc with all formulae and calculations.

g. Design details of PV module mounting structure, RCC Foundation / pedestal for fixing the GI mounting structure to withstand 120Km/hour wind speed with all formulae and calculations. Certification / approval of the authorized lab is to be submitted for design data.

h. MCF reserves the right to modify the design as per standards, Layout and specification of sub-systems and components at any stage as per local site conditions/requirements.

i. The bidder shall submit preliminary drawing for approval & based on any modification or recommendation, if any. The bidder shall submit three sets of hard copy and soft copy in CD of final drawing for formal approval to proceed with construction work.

j. Formats for reports and charts for analysis of various parameters.

17. SAFETY MEASURES:

The bidder shall take entire responsibility for electrical safety and safe installation procedures of the installation(s) including connectivity with the LT grid and follow all the safety rules & regulations applicable time to time. MCF is not responsible for any accidents occurred at site. Safety of the workers/

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Engineer’s are to be ensured at all the levels of work. Also all the instructions mentioned in the Dept. “contractor safety manual” to be followed.

18. ACCEPTANCE TEST AND PROCEDURE (ATP):

a. Successful bidder shall submit the Acceptance test procedure (ATP) for all the devices like PV modules, PV module mounting structure, PCU / String inverters, AC & DC distribution boards, Array junction boxes, DC & AC Cables, CPVC pipes, Screened twisted pair cables for data communication. ATP shall be as per relevant IS/ IEC standards. Acceptance test shall be arranged only after approval of ATP.

b. Acceptance test date/s shall be intimated to the Department ten days before the test date.

c. Check out procedure for all the installations and site testing shall be carried out to ensure the proper working and efficiency of the complete installation. Also all the devices shall be tested for minimum ten working days after commissioning of the plant.

d. If required Department may appoint a third party inspection agency during factory and site acceptance tests of all the devices of the solar power plants. Necessary details / assistance required shall be provided during the inspection. Any changes / rectification suggested by the Department and third party shall be carried out without any additional cost.

e. All the components of the system are to be dispatched only after dispatch clearance from the Department.

19. TEST REPORTS:

a. Type test certificates for the entire test specified in relevant IS for the solar PV modules, inverters, DB/JB’s and other component shall be submitted by the contractor for verification during acceptance test and same to be sent along with the items.

b. The supplier shall carryout all routine test as specified in the relevant standards (IS/IEC) on all the components in the presence of the Department representatives at works before dispatch and furnish copies of test reports for Department approval. If required stage inspection will be carried out by the Department.

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c. If Departments desires, stage inspection of the different devices of solar power plant are to be arranged at manufacturer’s works.

d. Equipment’s shall not be dispatched unless the test certificates are duly approved and dispatch clearance given by the Department.

e. Four sets of approved test certificates are to be submitted to Department.

f. Supplier shall carry out all routine and functional tests as specified in the relevant standards on the assembled SPV power plant with all accessories in the presence of the Department ‘s representatives at the proposed sites and site commissioning test reports are to be submitted. 20. PACKING, SHIPPING AND DELIVERY:

a. It is the responsibility of the supplier that all the parts are properly packed and protected to prevent damage during shipment. Packaging and shipping cost shall be borne by the supplier. All packages shall be delivered / unloaded at site by the successful tenderer.

b. All the materials are to be unloaded at site “MCF, Hassan, Karnatake-573201” with prior intimation to Department.

21. INSTALLATION:

a. Installation shall be carried out by qualified engineers who have adequate experience in the installation of solar power plants. Necessary experienced technicians and labours are to be deployed to carry out the work.

b. Supplier is responsible for arranging all the materials, tools, tackles, measuring instruments required for smooth commissioning of the solar power plant.

22. MAINTENANCE OF SPV PLANT

a. The bidder shall be responsible for Maintenance of the Solar power plant in the warranty period (Minimum 5 years warranty to be given) , during which MCF will monitor the activities for effective performance in line with conditions specified elsewhere in the bid document. During this period, the bidder shall be

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responsible for supply of all spare parts as required from time to time for scheduled and preventive maintenance, major overhauling of the plant, replacement of defective modules, inverters/ PCU’s etc and maintaining log sheets for operation detail, deployment of staff for /engineer for maintenance supervision. b. Maintenance Scheduled to be submitted by the bidder and same to be followed.

c. After completion of five years’ warranty period, Mandatorily the Successful bidder should enter in to the Annual comprehensive maintenance contract (CAMC) for further period of 10 years (6th year to 15 th year). All the spares, tools, man power etc required to rectify the problem are to be arranged by the bidder. Quote shall be submitted for comprehensive annual maintenance from 6th to 15 year separately as per price bid form enclosed with the tender.

23. MAINTENANCE REQUIREMENT DURING WARRANTY AND CAMC PERIOD FROM 6th to 15 year:

a. Easy access shall be provided for all components in the SPV power plant and connecting equipment’s. Maintenance platforms if required for inverters, AC & DC distribution boards are to be provided for easy inspection of the equipments b. Successful bidder shall provide comprehensive maintenance during warranty period and also comprehensive maintenance for the period from 6th to 15th year (10 years). The quoted prices shall be including cost of labour, materials, spares, tools and instruments etc. c. Personnel deputed for maintenance shall be qualified and well trained and shall be capable of handling any type of maintenance quickly, safely and timely. d. Deputed personnel shall continuously monitor the performance of the solar power plants and carry out regular maintenance of the plants to keep the solar power plant clean to ensure peak performance. However, all materials consumables required for proper cleaning shall be supplied by the successful bidder. e. Normal and preventive maintenance of solar power plant such as cleaning of PV module surface, tightening of electrical connections and any other maintenance in the inverters and AC/DCDB’s as suggested by the manufacturer are to be carried out at least once in a month. Plant performance details are to be submitted on monthly basis. f. During the maintenance, monthly energy generated and down time etc are to

33  

be recorded and submitted to Department. g. Resistance of the earthing system shall be measured and recorded every month. If earth resistance is more, action to be taken to reduce the same. h. Any break down calls shall be attended within 36 hours of registering the complaints.

i. Maintenance record shall be maintained by the successful bidder to record the regular maintenance, reasons for break downs, steps taken to attend the breakdowns, duration of breakdowns etc.

24. SYSTEM DOCUMENTATION:

Following information’s are to be documented and four sets of hard copies and one set of soft copy are to be handed over to Department during handing over of the system.

Detailed information and principle of operation of all the systems/ subsystems, Detailed technical specifications, Operation & functions and features, Design data with all the calculations, Layout and fabrication drawings, O&M manual, Safety precautions during maintenance, Completion /as built drawings of the whole system. Bill of materials with data sheets. Details of SCADA and software’s and any other information required are to be documented.

25. FINAL/ AS BUILT DRAWINGSTO BE SUBMITTED BY THE SUCESSFUL TENDERER.

Successful tenderer shall submit four sets of hard copy and one in soft format of following drawings after completion of work.

a. Shadow Analysis Report

b. General arrangement and dimensional layout for the whole SPV plant. It shall be ensured that the layout / arrangement shall suit to the available space.

c. Schematic drawing showing the details of SPV panels, power conditioning units/ string inverters, Array junction boxes, AC and DC DB’s, meters etc.

d. Item wise bill of materials for complete SPV plant covering all the components and associated accessories with specifications, make model nos. and catalogs etc.

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e. Structural drawings/ mounting arrangement for the solar power plant installation along with foundation drawings.

f. Design details for the electrical scheme consisting of PV modules, AC and DC distribution boards, String inverters etc with all formulae and calculations.

g. Design details of PV module mounting structure, RCC Foundation / pedestal for fixing the GI mounting structure to withstand 120Km/hour wind speed with all formulae and calculations. Certification / approval of the authorized lab is to be submitted for design data.

26. INSTRUCTION AND O & M MANUAL

Four sets of Instruction and Operation & maintenance manual shall be submitted by the successful bidder. The manual shall be submitted at the time of dispatch of the equipment and shall include the following.

Precaution during unpacking. Instruction for handling at site Erection or construction drawing approved by the MCF. Detailed instructions and procedures for the installation, operation and

maintenance. Pre-commissioning tests. Clear instructions about monitoring of PV modules Do’s and Don’ts Specimen log book. Principle of operation of various equipment’s. Safety and reliability aspects. Metering scheme. Power conditioning units/ inverts, its software and controls.

Clear instruction on regular maintenance and trouble shooting of solar power plants Name and address of the person or service center to be contacted in case of

failure or complaint. Bill of material with make, model no etc. Trouble shooting /diagnostic procedure.

27. TRAINING:

Successful bidder shall arrange for the training on String Inverter, Solar PV modules etc at factory /site for mutually agreed duration and number of persons to enable the Department to maintain the solar power system.

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28. Department approved make and models.

For all the devices/components, only the Department approved make and models mentioned below shall be used. No other makes are acceptable. If it is not in the approved list mentioned below, reputed brands shall be used and all the items, make/model proposed are to be mentioned in the technical bid.

Solar PV cells & modules:

MNRE approved make only. MNRE approval to be attached in technical bid

Solar string Inverter:

REFUSOL / KACO / SMA / DELTA / OPTIMAL POWER SYNERGY (OPS).

DC & AC control MCB:

LEGRAND / SCHNEIDER / ABB / GE / INDO ASIAN / SAFELINE / L&T / HAVELLS / HPL / STANDARD / SIEMENS / C&S ELECTRIC / NORTH-WEST / HAGER

MCCB : LEGRAND / SCHNEIDER / ABB / L&T / HAVELLS / STANDARD /

SIEMENS / C&S ELECTRIC

ARMOURED AND UNARMOURED CABLES FOR SOLAR POWER APPLICATION:

Havells, Glostar, Unistar, RPG, POLYCAB, CCI , Finolex, Torrent, KEI industries, INSUCON, RAVIN, BONLON, INDOCAB, VICCO, RALLISON, CORDS CABLE, SINCO, AVOCAB, TERA, CRYSTAL CABLES, RHINO, THERMO ,CABLES, ELKAY, UNICAB, GEMSCAB, V-GUARD

MAINTENANCE FREE CHEMICAL EARTHING: OBO BETTERMANN / TEREC (SGI) / ERICO (GEM) / LORESS/ASHLOK / JMV LPS SMC JB’s (ARRAY JB’s):

Hensel, Spelesberg, BCH Electric, ABB, Pyrotech Electronics, Devi polymers, Pustron, Safybox, Sintex.

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Multi function Meter:- L&T, Schneider, Meco, Neutranics, Nippen, CG, Elmeasure, Rishab, Krykard, SATEC, CIRCUTOR, RIKEN, CG SCHLUMBERGER, AUTOMATIC ELECTRIC (AE), RIKEN, SECURE

Current Transformer :- NIPPEN, PARAS, INTRANS, KAPPA ELECTRICALS, AUTOMATIC ELECTRIC (AE), NEWTRONICS MANUFACTURING COMPANY

Other components like connectors, hardware’s etc: Only reputed brands will be accepted. Make of the components not listed shall be considered with reputed make and same to be mentioned in the tender/ BOQ

NOTE:- Details of make /model no offered by the tenderer are to be mentioned in the annexure III and submitted with technical bid. Also data sheet / technical literatures for all the items like Solar PV cells & modules, String Inverter, All Cables, Junction boxes, AC & DC DB’S, HDPE / CPVC pipe and connectors etc from the manufacturer are to be submitted along with the technical bid.

 

 

 

 

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DESIGN, SUPPLY, INSTALLATION, TESTING AND COMMISSIONING INCLUDING COMPREHENSIVE ANNUAL

MAINTENANCE OF 50kWp ON-GRID SOLAR POWER PLANT (Interconnected to local LT grid without batteries) AT

MCF,HASSAN, KARNATAKA.

PART‐B:PRICEBID

Sl no Description of the item Qty Unit

1 Design supply, installation , testing and commissioning including comprehensive annual maintenance of 20 kWp on grid , roof top type solar power plant at MCF,Hassan, Karnataka. All the detailed technical specifications enclosed as Part A, annexure-I , II III &IV are applicable for the work and these technical specifications are to be satisfied.

1 set

2 Design supply, installation , testing and commissioning including comprehensive annual maintenance of 30 kWp on grid , ground mounted type solar power plant at MCF,Hassan, Karnataka. All the detailed technical specifications enclosed as Part A, annexure-I , II, III& IV are applicable for the work and these technical specifications are to be satisfied.

1 set

3 Supply of 4 core X 70 sqmm, (Cable code :- A2XFY) aluminium conductor, XLPE insulated steel strip armoured, 1100 V grade UG cable as per the relevant IS standards and as per the detailed specifications enclosed in annexure-II. (For interfacing 30 kWp plant ground based solar power plant to Power station#1LT panel). Laying shall be as per part-A, annexure-II. Note :- cable is to be laid party in ground below 750mm with protection bricks and sand as per IE rule and relevant standards. Also cable to be laid party in the existing concrete trench. (Drawing for laying of cable in ground is enclosed as DrG-no.MCF:3)

180 Mtr

4 Supply of 4 core X50 sqmm, (Cable code :- A2XFY) aluminium conductor, XLPE insulated steel strip armoured, 1100 V grade UG cable as per the relevant IS standards and as per the detailed specifications enclosed in annexure-II.( For interfacing 20 kWp plant to LT panel available at power station#3 building) Laying shall be as per part-A, annexure-II. Note :- cable is to be laid on the roof top / wall with cable tray and party in ground below

150 Mtr

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750mm with protection bricks and sand as per IE rule and relevant standards

5 Supply and laying of screened twisted pair data communication cable for data communication from inverter, weather sensors, TVM in the AC DB etc to local network and desktop computer. Cable to be laid in suitable size (20/25mm) 16 SWG HGMS conduit pipe with bends, elbows, junction boxes etc for roof mount plant and laid in the suitable size 2mm thick HDPE pipe for ground based plant. Also data cable to be laid along with 14 SWG copper wire for protection against external over voltages / surges. Also MS conduit to be painted properly with black paint. Laying shall be as per part-A, annexure-II.

300 Mtr

6 Data acquisition / plant monitoring system:- Supply , Providing and testing data monitoring system along with required data logger for weather sensor (wind, PV module and ambient temperature and solar insolation sensors), inverters, Multifunction meter . Work including supply and loading the necessary software’s, configuration in the existing desk top computer, interconnecting with existing local area network, generating visualization screen for monitoring and report generation etc complete as per the details mentioned in annexure-II. Since solar power plants are to be installed at two different places, separate weather sensors are to be provided for both the plants. Interconnection with the existing network and preparation of visualization screens and report generation to be done for both the solar power plants.

1 Job

7 Charges towards comprehensive annual maintenance (CAMC). Any defects/failures are to be attended with supply of required spares/ equipment’s and tools etc as per details mentioned in part-A, annexure-I &II

7.1 Charges towards CAMC for sixth year (12 months after completion of five years warranty period)

1 job

7.2 Charges towards CAMC for seventh year 1 job

7.3 Charges towards CAMC for eighth year 1 job

7.4 Charges towards CAMC for ninth year 1 job

7.5 Charges towards CAMC for tenth year 1 job

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7.6 Charges towards CAMC for eleventh year 1 job

7.7 Charges towards CAMC for twelvth year 1 job

7.8 Charges towards CAMC for thirteenth year 1 job

7.9 Charges towards CAMC for fourteenth year 1 job

7.10 Charges towards CAMC for fifteenth year 1 job

NOTE TO TENDERER:-

a. All the works are to be carried out as per the detailed specifications enclosed at annexure-I, II and III. Also the relevant IS, IEC and MNRE standards are to be satisfied for all the devices

b. Solar power plants of 20 kWp is to be commissioned on roof top and 30KWp plant to be installed on the ground and both are to be interfaced with the local LT distribution panels. c. Inverters supplied shall be of 10 and 20 KW capacity only d. Sl no. 1 , 2 and 6 are turnkey basis and supply, installation, commissioning and handing over etc as per part-A annexures-I, II, III and IV are responsibility of the successful tenderer. e. Payment for the items under sl no. 3 to 5 will be paid as per the actual requirement at site. Also payment for sl no.7 will be paid after successful completion of every one year after five years’ warranty period. f. Price/ rates for the comprehensive annual maintenance from 6th to 15 year is to be submitted along with the price bid. Also taking up of the CAMC from 6th to 15th year is mandatory. g. Only CPVC pipes of specifications mentioned in the Part-A are to be used for laying cables for connecting PV modules, array JB and DC/AC DB’s etc. h. Except the modification work on the roof for roof mount plant the material used for concrete foundation, pedestal and GI supporting structure are same for the ground and roof mount solar power plants as mentioned in the tender annexure I,II,III and IV.

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Annexure-IV :-

Specifications for concrete pedestal for roof mount solar power plant

1. The Roof of the building is laid with 3 Course weather proof treatment, which needs to be cut in to pockets of required size. (Care shall be taken to ensure prevention of rainwater entry to the WPC during cutting). RCC reinforcement cage may be placed directly over the RCC slab in the pockets to the required height. The shuttering needs to be provided for the portion of the pedestal above the WPC.

2. The Grade of concrete may be M-25 mixed with Integral water proofing compound. Required no of bolts are to be placed before pouring the concrete for the pedestals. 3. After 7 Days of curing; the external surface of the Pedestal and the portion of the WPC to the extent of 45cm all-round the pedestal including the top of the pedestal needs to be plastered with CM 1:3 for 20mm thick mixed with integral water proofing compound. 4. Curing shall be continued for further 7 Days and after 21Days of Concreting the Legs of the Solar panels and be mounted over the pedestals. 5. Care shall be taken while cutting the pockets over the slab to ensure that the vibration should be minimum. 6. All plastic materials/packing materials are to be disposed properly. If it is left on the rooftop; there is always a chance being blocked in the Rainwater down take pipe. 7. A minimum of 1.0m clearance may be maintained between the solar panel and roof slab for maintenance.

Specification for Materials to be used :

1. Dismantling carefully the weather proof course to the required regular size & shape by cutting the edges using mechanical cutters, chipping and removing the WPC to expose the RCC slab beneath, disposal of debris up to a lead of 500mts etc complete. 2. Steel reinforcement for all RCC items including decoiling, cutting, hooking, bending, cranking, fabricating to required shape, placing in position and tying the system with soft drawn annealed GI binding wire of diameter not less than 1.00mm with 2 strands etc; complete all as per specifications at all heights (binding wire will not be measured for payment). 2.1 Using Thermo-Mechanically Treated (TMT) bars - Fe500 3. Providing rigid and water tight CENTERING AND SHUTTERING using best quality wood/ plywood/ steel forms and centering with steel props, acro tubes etc., including strutting, propping, bracing, staging etc., complete for all RCC

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items fixed in position as required including labour for careful removal of form work etc., complete all as per specifications at all heights. In horizontal / vertical/ slanting surfaces. 3.1 Foundations, footings, bases of columns including pedestalsetc. 4. Providing and laying in position REINFORCED CEMENT CONCRETE Mixed with approved Integral water proofing compound at the prescribed dosage by the manufacturer, using graded hard granite stone aggregate of 20mm nominal size obtained from approved quarry including mechanical mixing, vibrating, compaction, finishing, curing, etc; complete all as per specifications but excluding the cost of form works and steel reinforcement. (Rate to include labour for keeping embedment if any, wherever required while casting). Mix ratio is specified is for cement : M sand : graded stone aggregate, UPTO FLOOR FIVE LEVEL. In Pedestals, walls, columns, pillars, posts, etc., with 4.1 RCC 1:1.5:3 5. Providing and fixing GI hexagonal chicken wire mesh of size 12mm x22g to the RCC column pedestals and the WPC layer including necessary nails for fixing etc, complete all as per specification and direction of engineer-in-charge for all floor at all heights. 6. Water proof cement plastering of thickness as specified below in cement mortar 1:3 (cement : M sand) mixed with approved water proofing compound such as CICO or ACCOPROOF or equivalent as per manufacturers specifications including scaffolding, curing, etc; complete for EXTERNAL SURFACES all as per specifications for heights up to 10m above GL. 6.1 20mm thick