Specifications of Requisition No. Q120206H
Appendix 'A'
Tender No. N0293
Sr.
No
PART II SCHDULE OF REQUIRMENT
NATURE OF SUPPLIES
1
MOBILE PORTABLE ELECTRONICALLY CONTROLLED LOAD BANK CAPACITY 25KW, WITH
CONTROLLER AS PER SPECIFICATIONS AT APPENDIX B
2
TROLLEY MOUNTED UNREGULATED DC POWER UNIT FOR TESTING CAPACITY 5 KW,
12V-24V-36V-48V DC SELECTABLE,
TECHNICAL SPECIFICATIONS
It consists a battery bank of rating 5kW and shall have
terminals for 12V, 24V, 36V & 48V. The 12V and 24V terminals
are necessary for tapping the voltages for starting TATRA
vehicles/ DGF sets cranking etc at trial site, as such battery
of 120AH or higher rating is necessary. 36V and 48V terminals
are for special applications. Battery charger for 48V systems
shall also be mounted on the trolley for charging the battery.
The input of battery charger is 230V, AC, 50Hz supply. The
battery charger also shall have necessary protections.
Input
- 440VAC/415AC +/-10%, 3PHASE, 50Hz
Output - 12V-24V-36V-48V SELECTABLE, DC
Output power- 5KW max, DC
Instruments - Monitoring and measuring instruments shall
indicate all necessary electrical parameters. suitable digital
LED display with scrolling/ individual instruments shall be
provided
Protection - system shall be protected suitably on input side
as well as on output side from short circuit and any other
faults.
Mounting- System shall be mounted on a suitable towable swing
type trolley. Trolley shall have solid tyre/Teflon wheel
suitable for movement on road.
ACCEPTANCE TEST - i)The system shall be tested on rated load
and at different selectable voltage for its functionality
ii) Battery charger is tested for its functionality and
measured the charging current.
3
REGULATED DC POWER SOURCE, 12V-24V-36V-48V DC, 30AMP MAXIMUM AS PER
TECHNICAL SPECIFICATIONS
INPUT
- 440VAC/415AC +/-10%, 3PHASE, 50Hz
OUTPUT
- 12V-24V-36V-48V SELECTABLE
OUTPUT CURRENT - 30Amp. MAX.
LINE % LAOD REGULATION - BETTER THAN 0.5%
RIPPLE
- LESS THAN 10Mv rms
PROTECTION - INPUT SIDE SINGLE PHASING AND OVER VOLTAGE
PROTECTION SHALL BE PROVIDED. OUTPUT SHORT CIRCUIT/OVER LOAD
PROTECTION SHALL BE PROVIDED WITH SUITABLE ARRANGEMENTS.
MONITORING INSTRUMENTS -THREE & HALF DIGIT DPM PROVIDED FOR
O/P VOLTAGE & CURRENT AND OTHER PARAMETERS.
ACCEPTANCE TESTS - SYSTEM SHALL BE TESTED AT FULL LOAD FOR 8
HOUR CONTINUOUSLY WITHOUT ANY FAILURE.
1
Specifications of Requisition No. Q120206H
APPENDIX ‘B
TECHNICAL SPECIFICATIONS
OF
PORTABLE ELECTRONICALLY CONTROLLED LOAD BANK- 25kW
1. INTRODUCTION
1.1
The Portable Electronically controlled Load Bank (Automatic and programmable
type) shall consist of stainless steel coil, inductive unit, air blowers, outlet flap and
switch gear fitted on a mobile trolley structure. It shall have proper electronic controller
for its operation. This Load bank will be used as a portable test facility. The system
mounted on trolley shall be transportable by prime mover / tractor at any desired location.
Height shall be less than 2.25m from ground level and shall have suitable solid tyre
/Teflon wheel. The load bank shall be easily detachable from the trolley for any
requirements.
1.2
Details of configuration and other technical parameters of the Load Bank are
enumerated in succeeding paragraphs of this specification.
2. SCOPE OF WORK
i)
Electronic load bank 25 kW with control panel as per technical specifications
ii)
Load cable 4 core, 50 sq.mm, EPDM flexible copper conductor cable 100mtr
length
iii)
Towable swing type Trolley with solid tyre/ teflon
iv)
Sound level meter of latest version to measure the sound level
v)
Tools
vi)
Approval of drawings and circuit / load diagrams
vii)
Integration, assembly and mounting of components on Trolley
viii) Testing & Trials as per Acceptance Test Plan (ATP) at Firm’s premises
ix)
Delivery at R&DE(E)
x)
Final trials with DG set/ UPS for acceptance of equipment
xi)
Training.
3. TECHNICAL DESCRIPTION
3.1
It shall be designed to test the equipment of various capacity from 3kVA to 25
kVA. The construction shall be simple, easy to understand and operate. The facility of
testing operation by local / remote shall exist in the system. It should be possible to
carryout local operation on load bank and remote operation by Supervisory Control Data
Acquisition System (SCADA) based through computer.
3.2
The Load Bank shall have facility to select the rating of Generator, Power Factor
(PF), (i.e. 0.8 or 1) and gradual as well as direct loading.
3.3
The direct loading shall consist of increment in load 25%, 50%, 75% at 0.8 PF
and 100% & 110% load at 1 PF.
3.4
The Programmable Logic Controller (PLC) will be provided in Load Bank shall
give commands to respective contactors to get the required load to test equipment like
Genset as per selected Load steps.
2
Specifications of Requisition No. Q120206H
3.5
The Load Bank shall have testing provision for gradual as well as direct step
loading. Resistive or inductive load increment facility shall also be provided to test the
generator at required power factors.
3.6
The system shall be transportable by prime mover / tractor at any desired location
and height shall be less than 2.25m from ground level and shall have suitable solid tyre
/Teflon wheel. The load bank shall be easily detachable from the trolley for any
requirements.
4. TECHNICAL SPECIFICATION
i)
Capacity
25kW
ii)
Power factor Range
i) 0.8 to unity
iii)
Test equipment Input supply
-3 Ph, 415 V 10%, 50 Hz, 4 wire , AC or
230V, 50Hz
iv)
Auxiliary supply for
3 Ph, 415 V  10% 50 Hz supply or single
cooling fans
phase
v)
Control Supply
110V DC
vi)
Load fluctuations
Not greater than 3% of applied load.
vii)
Humidity
95% R. H.
viii) Ambient Temp
(-)20C to 550C
ix)
Cooling
Forced Air Cooled
x)
Operation
Outdoor
xi)
Insulation Class
‘H’
xii)
Duty
Continuous
xiii) SCADA Facility
ASTRA Software based SCADA System to
monitor and log of Load Parameters within
50 mtr of distance.
xiv) Altitude
1500 mtr above Mean sea level (MSL)
xv)
Terrain
Desert / hilly
xvi) Size of system
Overall height shall be less than 2000mm
and shall be transportable in a truck
xvii) Mobile Trolley
The system shall be mounted on mobile
towable trolley platform
xviii) Current for loading – Resistive load of 10KW for each phase and Inductive
load of 3.5KW for each phase. Total load 25kW Max.
xix)
Protections
–
Safety protection by MCB. Over temperature indication
& alarm.
xix) Local display
– provided for Voltage, Current & power factor .
xx)
Controls
– through Computer in step of 2Amp.for resistive &
4A for inductive load.
5. ESSENTIAL FUNCTIONS
i) System to be designed in such a way that acceptability criteria for functioning of
Genset / UPS shall automatically declared, such as it is acceptable or rejected.
3
Specifications of Requisition No. Q120206H
ii) Software should have provision to note fuel Tank capacity and consumption of
fuel per hour for given engine provision should be met to set alarm to indicate
refueling of Genset with power advance notice.
iii) Transient Voltage dip (TVD) /Transient Voltage Recovery time (TVR) to be
mentioned in the system. Resolution should be 50 Millisecond. Sampling rate
should be compatible for resolution of 50 Millisecond
iv) System shall have provision for selection of Analog to Digital Converter (ADC)
& Digital to Analog converter (DAC).
v) Sampling time should be suitable for resolution of 50 Millisecond during
TVD/TVR
vi) It shall have outlet air flap at top.
vii) Load in each section will be arranged in 1kVA, 2 kVA,5 kVA,10 kVA,20 kVA &
25 kVA as per requirement. The Load can also be selected automatically through
SCADA.
viii)
Broadly system shall consist of load panel with manual controls, local
displays, personal computer to interface with the panel, software & hardware
required and one suitable printer.
6. TECHNICAL SPECFICATION FOR BROUGHTOUT ITEMS
6.1
COMPUTERISED CONTROL PANEL : - The computer is required for
Installation of SCADA Software with printer Attachment, the technical particulars are as
follows.
6.1.1 PROCESSOR
i)
Intel Pentium – IV
2.4
ii)
Chip Set
Intel 850 G suitable for DDRRAM
iii)
Cache Memory
256 kb
iv)
Clock Speed
533 MHz FSB
v)
Memory
1GB DD RAM
vi)
Hard Disk
500 GB Hard Disk Drive
vii)
Floppy Drive
1.44 MB
viii) Zip Drive
1 GB equivalent
ix)
DVD ROM Drive
16  DVD ROM Drive / CD Compatible
x)
CD Writer
Internal CD Writer (Compaq)
xi)
Key Board
107 keys key Board (Compaq)
xii)
Mouse
Scroll Mouse
xiii) Monitor
Compaq 17” SVGA Colour Monitor
xiv) Graphics
4  APG 64 MB RAM
xv)
NIC
10 /100 MB RAM
xvi) Modem
In – built / External (56 kbps)
xvii) Multi Media Kit with Speakers & Microphone
xviii) Disk Controller
Integrated ultra ATA / 100
xix) Audio
Integrated AC 97 Audio code
xx)
Windows latest supporting version
4
Specifications of Requisition No. Q120206H
xxi)
6.1.2
Dust Cover for the Systems
Latest version colour printer for taking the prints in A4 size, H P make
7 DRAWING / SKETCHES
The contractor has to make final drawings / sketches / circuit and load diagram
and same to be get approved from R&DE(E). The procurement of components /
manufacturing of load bank will commence only after approval of respective drawings /
diagrams
8 TOOLS
The following tools shall be supplied by the vendor along with the system
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
Star screwdriver set complete
- 1 No
Allen key set
- 1 No
Soldering gun 25kW
- 1No
Soldering gun 60W
- 1No
Soldering Gun 100W
- 1No
Cutting Plier 12 inch
- 1No
Nose Plier 6 inch
- 1 No
Hacksaw 18 inch
- 1No
Hacksaw 6 inch
- 1No
Hammer 1 kg
- 1 No
Double ended Spanner set (5mm- 24mm) – 1 set
9. INSTALLATION / COMMISSIONING / TRIALS
The contractor has to arrange manpower with necessary facilities required for
Installation of system at R&DE(E) and trials with Power sources.
10. TRAINING
Training is to be imparted to minimum 3 persons on total system including
testing. The training material has to be arranged by the contractor.
11. WARRANTY
The contractor has to provided warranty for the period of one year from the date
of acceptance of the system. If any deficiencies are found in the system, the same has to
be rectified by the contractor during the warranty period.
5
Specifications of Requisition No. Q120206H
12. ACCEPTANCE TEST PLAN FOR LOAD BANK 25kVA
The Acceptance Test Plan is enclosed, contractor has to prepare his own QA plan and submit the same for approval
Sr.
No.
Types of
Test
1.
Material Ref. /
standard
Critical Parameters to be
tested
Locatio
n/
Sample
size
100%
Acceptan
ce Level
Instrumentatio
n/ Test Method
Remarks
As per
standard
Authorised Test
Laboratory
Checking Copper BUS Bar
sizes as per diagram for
auxiliary and generator
supply
It shall be transportable in
truck after removing the
trolley. Toad bank shall be
easily removable from
trolley.
Ht – less tha 2250mm
From ground level.
Necessary clearance to be
given for transportation.
100%
As per
standard
Calibrated Tape
or Vernier
Test Certificate of bought out
components shall be supplied
by vendor before installation
of same in the system
It will be verified for RYB
and Neutral Bus
100%
 5mm
Calibrated Tape
b) Minimum line & Line to
& Line to Earth clearance –
20 mm
100%
 2mm
Calibrated Tape
Brought out
components
2.
Visual
inspection
3.
Dimensional
inspection
As per drawing
6
Measured for resistive grid
and contactor terminals qt,
RE, YE,BE and RY,YB,BR
respectively
Specifications of Requisition No. Q120206H
4.
Insulation
Testing
Total installed
Load Units
’’
5.
Megger
Testing
’’
6.
Resistance of
resistive
check
’’
7.
Inductive
Testing
’’
Aux supply Bus Bars /
Generator supply Bus bars
a) Megger Test: It will be
carried out prior to High
voltage test for RE, YE,
BE, RY,YB &BR phases
b) High voltage test: It will
be carried out for RYB-E,
RY, YB & BR phases. Test
voltage will be 2.5 kV
Megger Test – After high
voltage test : It will be
carried out for all six phases
like RE, YE, BE, RY,YB
,BR
Resistance of resistive load
will be measured with 50 Hz
supply and variable voltage
dimmer stat check. It will
measure voltage. Current
and necessary resistance
will be calculated.
100%
10M
Megger
Shall be carried out with 1000
V Megger before HV test
100%
Shall
sustain
2.5kv at 1
minute
10M
Through High
Voltage Testing
It shall be carried out at 50
cycles for one minute
Megameter
It shall be carried out with
1000 V Megger for Auxiliary
as well as Generator supply
Bus Bars
Voltmeter &
Ammeter
It shall be carried out from
Taps 1 – 2 to 13 – 14
100%
Party
checking
as per
Load
diagram
The impendance of
inductive load shall be
measured with 50 Hz supply
and variable voltage dimmer
stat check. The inductive
load shall be measured in
voltage, current and
impendance.
It shall be carried for section
1,2,3 and 4 respectively.
’’
7
--
’’
Specifications of Requisition No. Q120206H
8.
Load Testing
Endurance Test
as per IS
Rated Load, Voltage,
Current and Power Factor
100%
As per
standard
Actual load
bank will be
utilised of
carrying out
necessary
testing
The load bank will be
connected to generator. Test
procedure will be carried out
for the period of 14 hours.
i) Start
ii) 0.5 hour – Warm up at 25%
rated load
iii) 3.5 hour – 100% rated
load
iv) 3 hour – 50% rated load
v) 1 hour – 110% rated load
vi) 0.5 hour – No load
vii) 3.5 hour – 100% rated
load
viii) 2 hour – 50% rated load
9.
Load Testing
Endurance Test
as per IS
(Through
SCADA)
Rated Load, Voltage,
Current and Power Factor
100%
As per
standard
Actual load
bank will be
utilised of
carrying out
necessary
testing
The procedure as per Sr. No. 8
will be carried through
SCADA based Software
8