STEEL AUTHORITY OF INDIA LTD

Transcription

1 STEEL AUTHORITY OF INDIA LTD IISCO STEEL PLANT Technical Specifications for Installation of 160KWp Roof top Off-grid solar PV system at Burnpur Hospital, IISCO Steel Plant

2 CONTENTS 1.0 Introduction 2.0 Location 3.0 Existing System 4.0 Proposed System 5.0 Scope of Work 6.0 Instruction to Tenderer 7.0 Technical specifications 7.1 Standards and codes 7.2 System specifications 7.3 Cabling 7.4 Earthing and lightning protection 7.5 Battery 7.6 Enclosure for battery bank & PCU 8.0 Guarantee 9.0 Documentation Encl : 1.Location and Roof top plan 2. Incoming Power Distribution diagram

3 1.0 INTRODUCTION: Clean and Green Solar energy, which is abundantly available in uniquely placed INDIA. is seen as a solution to India s energy security. The National Solar Mission, which is part of the National Action Plan on climate change, has been set up to promote harnessing of solar energy in the form of large grid connected solar power plants, small off grid solar power plants as well as small roof top off grid solar Power plants. SAIL-IISCO Steel Plant, Burnpur proposes to install 160 KWp (1x100 KWp+ 1 x 60) Roof top off Grid Solar Power Plant with battery bank, in Burnpur Hospital to cater the load of lighting and fan at outdoor complex including lighting system at outdoor yard. The existing source of power is proposed to serve as a backup for the Solar PV system. 2.0 LOCATION : SAIL- IISCO Steel Plant is located at Burnpur near Asansol at around 200 KM away from Kolkataconnectedby rail and road link. Burnpur Hospital of SAIL-IISCO Steel Plant is located at Central Township of Burnpur. The system will be installed at Out Patient Department of Burnpur Hospital. 3.0 EXISTING SYSTEM : Existing power supply to BurnpurHospital is arranged through two dedicated Transformers fed from two different feeders of Township Distribution Station. The rating of the transformers are750 KVA each. These two transformers 3.3 KV/ 440 V are feeding the LT PDB having sectionalizing provision. These LTPDBs have ACB in the incomer and outgoing feeders have ICTPs and OCBs as shown in the Single Line Diagram enclosed. The Technical parameters are as follows: Nominal Voltage: 415 V, 3 phase and neutral, Voltage variation: + 10 %,- 10 % Frequency: 50 Hz Frequency variation: +5%,-5% 4.0 PROPOSED SYSTEM :

4 It is proposed to install 160 KWp Off grid roof top Solar Photo Voltaic System with battery backup for essential loads on the roof top of Burnpur Hospital.Main objectives are to cater to demand side management for lighting and fan load. 4.1 Operating Philosophy :. Under normal circumstances load requirements are catered by Solar PV system. Provision for connecting the SPV system to the existing network through change over (auto). In case of insufficient generation by Solar PV system, existing system feeds the load The proposed Off-Grid roof top Solar Photo Voltaic system shall comprise of. Solar Photo Voltaic modules made of silicon solar cells connected in series. Support structures for the modules. Inter connecting cables and junction boxes. Power conditioning unit to condition the output of Solar cells in respect of voltage, phase and frequency in synchronization with existing system.. Safety/protective features like over load, over voltage and short circuit protection and protection against lightning. The interconnection of Solar PV plant with the existing system shall be submitted with the offer. The Tenderer shall submit the scheme for introducing the solar PV system in the existing network. 4.2 Power Quality Requirement:. DC injection in to the grid shall be avoided by using isolation transformer at inverter output.the limit of DC injection shall be less than 1 % as per IEC Harmonics on AC side shall be as per limits stipulated in CEA regulations on grid connectivity 1.Total Voltage harmonic distortion < 4 % 2. Individual voltage harmonic distortion < 2 % 3. Total current harmonic distortion < 8 % 4. Voltage tolerance +_ 10% of nominal voltage 5. Frequency tolerance +- 5 Hz of nominal frequency (50 Hz) 5.0 SCOPE OF WORK 5.1 The Scope of work includes design, engineering, quality surveillance, testing at manufacturer s work, packing, supply, erection, testing, commissioning and performance testing

5 of off-grid roof top Solar PV power plant of capacity 160 KWp and associated components for Burnpur Hospital. The proposed systems shall be consisting of. Solar Photo Voltaic Modules. support structures, junction boxes. inter connecting cables. Power Conditioning Unit. AC distribution board(acdb). DC distribution Board. Battery Back UP. Battery protection Panel. any other equipment necessary for safe and efficient operation of the system S.N. Description of Item Unit Rates 1 Supply, fitting, fixing of composite capacity SPV modules Set 1 with hot dip galvanized module mounting structure for the following composite capacity unit with fitting provision between 25 to 35 degree in steps of 05 degree for holding modules on structure including design & construction of RCC foundation base for holding the above structures (the work includes necessary excavation, concreting, back filling, shoring & shattering etc) lightening & over-voltage protection,earthlingprotection as per specification and direction of engineer-in-charge. 100 KW 2 Supply, fitting, fixing of composite capacity SPV modules Set 1 with hot dip galvanized module mounting structure for the following composite capacity unit with fitting provision between 25 to 35 degree in steps of 05 degree for holding modules on structure including design & construction of RCC foundation base for holding the above structures (the work includes necessary excavation, concreting, back filling, shoring & shattering etc) lightening & over-voltage protection,earthlingprotection as per specification and direction of engineer-in-charge. 60 KW 3 Supply, installation, testing & commissioning ofsolar Set 2 GradeSealed Maintenance Free VRLA battery of rating 2000AH at 240V. Each battery bank will contain suitable rack, hydrometer, thermometer, cell tester and connecting lead of adequate size, Ah meter, battery bank capacity 4 Design, supply, testing & commissioning of battery Set 2 protection panel suitable for protection of battery banks against any malfunctioning of the system along with necessary accessories for the battery banks 5 Design, manufacture, supply and installation of Power Controller Unit charge controller cum Inverter, full sine wave output suitable for both stand alone and hybrid mode Set 2

6 of operation along with all protection, controlling arrangement and required accessories suitable for (With a set of spare cards of inverters & charge controller) 160 KW SPV Power Plant with DCDB and ACDB 6 Integration of various equipment and commissioning of the power plant including all items not mentioned above but required for installation and commissioning of the power plant including PC based data monitoring system with data logging. Set The scope of work shall also include the following. Comprehensive insurance, storage and in transit transportation. Inter connection of Solar PV system with existing system.. PC based monitoring system with data logging. Civil work for installation of complete system. Commissioning spares. Auxiliary items/works. Earthling and lightning protection. Enclosure for battery and PCU complete with illumination etc.. Performance testing of the complete system. Documentation. Test report for Solar Modules from MNRE/ government approved institutions. Certificate shall not be older than 3 years. Tenderer shall arrange/ do the required formalities on behalf of SAIL-ISP to avail the subsidy from MNRE and CREDA.. Deficiencies pointed out in proposal, if any, by the committee for getting approval for subsidy shall be rectified / removed and final proposal to be prepared by the Tenderer. 5.3 The work shall be carried out as per the Technical Specifications. 5.4 The Tenderer shall be responsible for Operation and Maintenance of the system for a period of THREE years including the warranty period. Price for O & M shall be quoted separately. During the Operation and Maintenance period, the Tenderer shall train the maintenance staff of SAIL-ISP. A quarterly maintenance report shall be submitted by the Tenderer. The scope of after sales service, preventive maintenance schedule, plan of operation etc shall be defined and documents submitted with the offer. 6.0 INSTRUCTION TO TENDERER 1. The specification covers the installation of 160 KWpOff Grid roof top Solar Power Plant on roof top of Burnpur Hospital

7 2. The Tenderer shall quote for full scope of work as covered under various chapters of this specification. 3. The above work shall be executed on Turnkey basis covering scope and services as described in the respective section of this specification. 4. The offer shall be complete in all respects and any additional equipment, accessories, auxiliaries, services, work etc. which are not specifically mentioned in the specification but are required for smooth and trouble free operation and to achieve performance required to be guaranteed in terms of the Tender Document, shall be included by Tenderer in the offer. 5. Metric systems and English language shall only be used throughout the tender and in the drawings. 6 The Tenderer shall satisfy himself before submitting the offer, the nature and location of work place, kind of equipment and facilities needed during performance of the work, general and local conditions as well as other matters which can, in any way affect the work covered in this specification. 7. The successful Tenderer shall be responsible for co-ordinating the work in different areas and execute the work in agreed time schedule. 8. Provision of all labor, materials, consumables, equipment, fuel, transportation and all incidental items not shown or specified but reasonably implied or necessary for the completion of works, all in strict accordance with approved dismantling scheme/procedures/sequence general safety requirements, including revisions and amendments there to as may be required during the execution of the work. 9. Temporary staging, scaffoldings, bracings, ties, guy ropes shall be provided to prevent accidents, damage to existing structures, service lines etc. 10 Supply of all tools and tackles, temporary supports, staging / scaffoldings safety belts, guy ropes, consumables like gas etc. and all other material as deemed necessary for proper completion of work are included in the scope of work. 11. The construction work covers all civil engineering works pertaining to the construction of proposed Solar PV plant. 12 The Tenderer shall visit the site and satisfy himself, in all respects with site conditions, etc. before quoting. After acceptance of his quotation by the purchaser, claim for extra payment submitted by the Tenderer on ground of local working conditions, fouling with the existing installations etc. will not be considered.

8 13 While making the foundation for structures supporting solar panels, minimum grouting shall be resorted to on the roof top. If grouting is essential at some places, suitable treatment to prevent seepage/leakage shall be carried out by the Tenderer. As an alternative, a frame of base channels or floating foundations may be designed for the same, considering wind load etc. 14 The work as detailed above shall be commissioned within SIX months from the date of award of contract. Bar chart showing all the activities shall be submitted with the offer. 7.0 TECHNICAL SPECIFICATIONS 7.1 Standards and codes All equipments and accessories shall comply to requirement of BIS standards In case no BIS codes exist, the equipments shall meet the requirement of international standards including IEC and IEEE for design and installation of off grid PV system. The list of standards adopted shall be included in the offer The SPV module shall be provided with acceptable Test and Certified documents The quality of equipments supplied shall be generally controlled to meet the guidelines for engineering design included in the standards and codes in relevant ISI and other standards such as : i) IEEE 928 : Recommended criteria for terrestrial PV power systems ii) IEEE 928 : Recommended practice for utility interface of residential and intermediate PV systems. iii) IEEE 519 : Guide for harmonic control and reactive compensation of Static Power Controller iv) IEC : (2005) Crystalline silicon terrestrial PV modules Design and type approval(revised ) v) IEC : PV modulessafety qualification-requirement for testing vi) IEC : (2006)- PV device Measurement of PV current-voltage characteristic. vii) IS 9000 Basic environmental testing procedure for electronic and electrical items. 7.2 System Specification : The total PV solar system shall comprise of the following major components: Solar Photovoltaic modules (SPV) Support structures with foundations Junction boxes and interconnecting cables Power conditioning unit (PCU) ACDB and DCDB PC based monitoring and data logging system Solar Photovoltaic modules

9 The photovoltaic modules shall be made of monocrystalline silicon solar cells, connected in series to give required output.the interconnected cells shall be laminated in vacuum to withstand adverse environment conditions. The cells shall be encapsulated under high transmission toughened glass. Laminate edges shall be sealed with sealant tape.anodized Al. frame, resistant to shock and corrosion, conforming to JPL block V/ ISI standards, shall be used. Weather resistant RTV silicon sealant shall be used for framing. Terminal boxes shall be waterproof with provision of mounting bypass diodes Support Structures : The support structures shall be of MS with hot dip zinc galvanization.the minimum thickness of galvanization shall be 70 microns. All nuts and bolts shall be made of good quality stainless steel. The structure shall be designed to allow easy replacement of any module and shall be inline with site requirement. The basic wind pressure for design shall be 60 kg/m2 and 150kg/m2 up to a height of 30M above the mean retarding surface for winds of long and shortdurations respectively with suitable modifications for greater heights as per IS:875, after grouting and installation. Each panel frame structure shall have provision to adjust its angle of inclination as per requirement with locking facility to avoid any change in inclination due to wind. The foundation for the supporting structures on the roof top shall be so designed that minimum grouting work is resorted to. Utmost care shall be taken not to damage the roof slab and to avoid seepage. Water proofing treatment shall be given by the Tenderer where ever seepage is observed after foundation work Junction boxes and interconnecting cables The junction boxes shall be suitable for outdoor installation, dust, vermin and waterproof preferably made of FRP/ABS/Thermoplastic. Suitable cable entry points fitted with double compression cable glands of appropriate sizes for both incoming and outgoing shall be provided. Arrangements for disconnecting, testing and isolating sub groups of modules shall be provided. Metal oxide varistors shall be provided inside the array junction box. All the cables supplied shall be PVC/PVC cu. cables, 650/1100 V grade, conforming to IS The sizes shall be selected to keep the voltage drop and losses to minimum. The Tenderer shall supply installation accessories required for cable laying. Cables shall be drawn through conduits where possibility of mechanical damage exists Power Conditioning Unit :

10 . Power Conditioning Unit or PCU refers to combination of charge controller and inverter which when connected between the Solar PV array and AC mains supply performs to maximize energy drawn from array and converts the DC produced to AC with phase, frequency and voltage synchronized with existing AC mains.. It shall have Maximum Power Point Tracker to maximize energy drawn from solar array and an Inverter to convert the DC produced to AC in synch with the existing system.. The Inverter shall be a true sine wave inverter for off grid solar PV system compatible with charge controller and DCDB.. The inverter shall be complete with protections, indications and metering facilities. It shall have communication interface compatible to PC based data logging system.. The inverter shall have provision of input and output isolation.. The Tenderer shall furnish the Technical features of the inverter and max. power tracking unit offered.. Protection and indications shall be provided for. Short Circuit. Overload protection. Input Surge Voltage. Solar array reverse polarity Inverter Inverter shall have the following features. Industrial grade bi-directional inverter. Rated for continuous operation at full load. Automatic re-start after over load triggered shutdown. Protection & Safety: Specifically the inverter should be a three phase static solid state type power conditioning unit Both AC & DC lines shall have suitable fuses and Tenderers to allow safe start up and shut down of the system. Fuses used in the DC circuit should be DC rated. Inverter should have overload, surge current protection, high Temperature, over/ under voltage and over/ under frequency DCDB &ACDB : DCDB. The DCDB shall be provided in between Solar Array and Power Conditioning Unit. This can be integrated with PCU to save space.. It shall consist of MCCB of suitable ratings for connection and disconnection of array input and also Volt meters, Ammeters & charging Discharging Ampere Hour meters. It shall have LED indications for ON and OFF status as per requirement.

11 ACDB. ACDB shall be provided in between PCU and loads. It shall have MCCBs, MCB of suitable rating for connection and disconnection of PCU from load as well as protection against faults on load side load controllers and also Volt meters & Ammeters. It shall have energy meter to record energy supplied to the load PC based monitoring and data logging unit :. PC based monitoring and data logging system shall record the following parameters for study of effect of environmental and grid parameters on energy transformed by the solar system : a) Solar system temperature b) Ambient temperature c) Solar insolation d) DC Current and voltage e) DC injection in to existing system f) Efficiency of inverter g) Solar system efficiency h) Display of I-V curve of solar system i) any other parameter considered necessary. The system software shall be capable of generating bar charts, curves, tables required for analysis.. The communication interface shall be an integral part of inverter and shall be capable of communicating with the PC.. Proposed hardware shall have enough storage capacity for historic data logging. PC with TFT monitor and latest configuration shall be considered. In the offer. 7.3 Cabling. All power, control and communication cabling shall be in the scope of Tenderer.

12 . All the power cables shall be 1100V/650 V grade,pvc/pvc having copper conductor. They shall conform to IS 1554.Armoured cables shall be given as per requirement.. All the cabling including the cable interconnecting to the existing system and the PCU shall be in the scope of supply of the Tenderer.. Size selection,supply,laying,termination and testing of all cables, power and control, shall be in the scope of Tenderer. Minimum losses and voltage drop shall be the criteria for size selection.. All cable laying accessories like cable trays, clamps, conduits etc shall be in the scope of Tenderer. 7.4 Earthing and Lightning Protection : The array structure of the Solar PV system shall be grounded properly using adequate numbers of earthing pits. All metal casings/ shielding of the plant shall be thoughroly grounded. All the earths are to be bonded together. The Solar PV plant shall be provided with lightning and over voltage protection. The Varistors at input and output of inverter shall be provided to protect against lightning and over voltages. 7.5 Battery bank : The battery bank is proposed to support the essential load when solar PV is not working. The battery bank shall consist of tubular Lead Acid battery,of rating 2000AH at 240V, arranged in racks with inter connections and end connectors. The tech features and dimensions shall be submitted. The batteries shall be suitable for recharging by means of solar PV modules though solar charge controllers. Continuous battery life and state of health monitoring system shall be provided. Enclosure for battery bank and PCU: It is proposed to convert an existing covered free space of size about 6M X 4 M at ground floor, to house battery bank and PCU and Data logging system. The work involved is as follows:. Constructing an enclosure with interior suitable for installing PCU and Data logging system by changing flooring, providing false ceiling, half glazed door and Air conditioning the enclosure, if required, shall be in the scope of Tenderer.. In battery bank area acid proof tiles and wall cladding shall be provided to mount the battery racks. Exhaust fan shall be provided in this part of the room. A wash basin shall also be provided in this room.

13 . Provision of cable entry shall be planned and provided. Earthing pits and grid shall also be erected around this room. 8.0 WARRANTY: The mechanical structures, electrical works including inverters, Power Conditioning Unit, ACDB, DCDB, meters, storage battery and overall workmanship of the off Grid roof top Solar PV plant must be warranted for a minimum period of THREE years.. PV modules used shall be warranted for output wattage, which should not be less than 90% at the end of 10 years.. The Tenderer shall be responsible to replace free of cost (including transportation and insurance expenses) to the purchaser, whole or any part of supply which has become dysfunctional under normal and proper use, within one month of issue of such complaint.. In case Tenderer fails to replace/rectify the defective /damaged equipment including transit damage,shortage, within one month of intimation, the purchaser shall arrange the same at Tenderer s cost. PG Parameter: The Contractor has to demonstrate 15 days consecutive operation of the system at designed load under normal weather condition. 9.0 Documentation: The Tenderer shall furnish the following drgs/documents and obtain approvals. a) General arrangement and dimensional layout of PV array/panels with respect to roof plan of Burnpur Hospital enclosed with this TS. b) Schematic drg showing Solar PV system interacting with existing system c) Structural drg along with foundation for supporting Solar PV system on roof top. d) Overall layout of Solar PV plant. e) Room housing battery and PCU Plan f) Cable layout drgs. and termination plan g) Data sheets with tech. parameters for inverter, ACDB, DCDB h) Configuration of PC based monitoring and data logging system. The following drgs and documents shall be submitted for records 1) Two copies of installation manual/user manual with complete system details, schematics, inverter details, maintenance and troubleshooting procedures etc. 2) Two sets of copies of compiled test certificates,type and routine. 3) Soft copy of the complete system drgs. Schematics, layout drgs, structural support drgs

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