Supply, Installation, Testing and Commissioning of 2 X 700 tr central Chillers in place of existing 2 X 500 tr air Conditioning plant along with renovation/replacement of all other allied accessories at isp on Turn Key Basis


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NameSupply, Installation, Testing and Commissioning of 2 X 700 tr central Chillers in place of existing 2 X 500 tr air Conditioning plant along with renovation/replacement of all other allied accessories at isp on Turn Key Basis
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Supply, Installation, Testing and Commissioning of 2 X 700 TR Central Chillers in place of existing 2 X 500 TR Air Conditioning plant along with renovation/replacement of all other allied accessories at ISP on Turn Key Basis.



500 TR

A.C

PLANT

25M
ANNEXURE-A


2.5M








LENGTH in M

DIAMETER in M

AREA in M2

1

CHILLED WATER PIPE

500

0.25

650x2

2

CHILLED WATER PIPE

450

0.2

315x2

3

HOT WATER PIPE

350

0.2

245x2

4

HOT WATER PIPE

400

0.15

240x2




TOTAL

1700




2900



MICR






New PG





COPPER BATH

LINE 63M





Miller

Grapha






31M








14M

42M

46M

2M

11M

3M

3M

N
1.5M

A.P.M.S.


69M









CHILLED WATER SUPPLY



CHILLED WATER RETURN

HOT WATER SUPPLY


HOT WATER RETURN


ALL DIMENSIONS IN METERS





Tentative scope of mechanical work involves: ------------

  1. Supply installation testing and commissioning of 700 TR variable speed Centrifugal chillers along with suitable capacity and energy efficient Chiller pump, Condenser pump and cooling tower.

  2. Chilled water/ Condenser water/ Hot water piping (Supply & Return) along with insulation and Cladding for running 2 Chillers simultaneously including all the infrastructural requirements of Civil and mechanical support.

  3. The valves and dampers shall be of motorized type for BMS (Building Management system) compatibility.

  4. The controllers and drives shall support BMS protocols and operation friendly.

  5. Supply, installation, testing & commissioning of Double skin Air Handling Units complete with VSDs, Temp & RH controllers and Modulating valves in place of 8 old Single skin AHUs of APMS, Miller, & Grapha. The Old AHUs are to be dismantled, removed and disposed off.

  6. Supply, installation, testing & commissioning of new Double skin Air Handling Units for Rapida section including all related Civil and infrastructural works.

  7. Supply, installation, testing & commissioning of new Double skin Air Handling Units for Old PG section including all related Civil and infrastructural works.

  8. Dismantling and shifting of existing 500 TR Plant to our disposal yard.

  9. Dismantling & Removal of old Ventilation Plant No.4 to make room for A.H.U’s of Rapida.

  10. Supply/Renovation of Water softening Plant to prevent scales & algae in the water system and Cooling Towers.

  11. Isolation of sections by providing suitable motorized dampers in New PG, Letter Press, E-Passport, Adhesive A & B sections, ii) Rotatek & Satellite Envelope section.

  12. Chiller make:--Make: McQuay /Carrier/York/ Trane

  13. Pump make: Beacon Weir/ Grundfos/ Mather Platt

  14. AHU’s: Make: Blue Star/ Voltas/ Zeco/ Fedders Lloyd/ Edge Tech

  15. Cooling Tower: Paharpur, Advance

  16. Pipe: Seamless steel

  17. Speed & Valve should be controlled automatically through Digital Temp & RH controllers.

Tentative Scope of Electrical works includes: -----

  1. Validating the total load requirement of the plant and individual equipments, Tapping of 11 KV supply source form MRS to proposed location (i.e. Existing 500 Tr Blue star AC Plant) through proper VCB’s, XLPE cables, earthing etc to be laid underground.

  2. Design supply installation and testing of incomer HT panel at the proposed site with suitable interlocking for existing ring main feeder, protective relays, battery bank, power cables, transformers, VCB, ACB, bus ducts, L.T panels, other required switchgear, electrical equipments, cabling, wiring, power factor correcting equipments, earthing pits, earthing grid of suitable size and rating which will be required in addition to or after dismantling the existing available structure. Installation of remote tripping devices for the HT VCB at substation with interfacing at both ends to trip the Incomer VCB at the Main Receiving Station.

  3. Design, supply modification or/and construction of complete Civil and mechanical infrastructure like pedestals, trenches, rooms for transformers, switchgear panels, ducts, laying trays fixing supporting substructures etc. if any new additions or alterations are to be done.

  4. Design, supply and installation of electrical panels and energy efficient, harmonic free starters complete with digital energy meters, Power On LED indicators, O/L,E/F protection, reverse run protection, digital amp meter voltmeter, Incomer supply indicators, etc. for main Chiller, condenser and chiller pumps, water softener, cooling towers Hot water generators etc as the case may be.

  5. Installation of energy efficient VSDs for all the existing AHUs which include removal of the old panel, wiring, control switchgear, motors as the case may be and replacement of the same with new VSD’s as required to suit the new system.

  6. Carrying out all the necessary, cabling wiring, through cable trenches or trays with proper glands, lugs double earthlings of proper size to all the equipments.

  7. Making and /or modifying arrangement for necessary earthing pit and related earthing grid for interconnection of double earthing through copper/GI strip of suitable size throughout the installation. Installation of lightening arrestors.

  8. Design and construction of electrical system for New A.H.U’s at various locations (Sections) in the factory which shall include: - provision of power cables from the source of supply decided by ISP authorities through underground trenches or through overhead cable trays complete with required earthing. Installation of required power and lighting panels, energy efficient starters, motors ,controllers, illumination arrangement , remote switching and tripping mechanism etc. complete.

  9. Making internal lighting and ventilation arrangement to suit the new plant.




  1. The outside fittings and motors etc shall be weather proof. The VCB’S, ACB’S shall be draw out type only. All the electrical switchgear including the VCB/ACB/Circuit Breakers/SFU/FSU/Motors/ drives/ starters/Tube light fittings cables, glands, lugs, protective equipments, batteries to be used shall be clearly specified in the drawing complete with their ratings and makes offered.

  2. The proposed equipments shall be of :----

  • Makes For VCB/ACB --Crompton, ABB, L&T, GEC ,BharatBijlee , Southern switchgear

  • Makes for transformer: GEC, Crompton, Kirloskar, BharatBijlee, Indian Transformer

  • Makes For SFU's, FSU's, MCCB's:-GEC, Crompton, L&T, K&M, ABB,

  • Makes For Cables: All cables shall be of earthed type except wherever necessary and the of Finolex, Fincab, Polycab, Fixolite, FG Gloster , Torrent

  • Makes For Lugs/Glands:Chetna, Dowels or any ISI marked.

  • Makes for Meters and protective equipments : English electric,GEC, Toshnival, Rishabh,AE,

  • Makes for Batteries: Exide/Standard/Rocket/Amco .

  • Makes for Panels: From reputed manufacturers as per IS specifications and the panel Bus bar shall be of Copper with tin plated , two electrolysis method

  • MakesforMotors:Crompton,ABB,Kirloskar,GE,Baumuller,Siemens,BharatBijlee,SEW

C) Testing commissioning and fulfillment of the statutory requirements.

The firm will have to carry out the following Test along with all the Statutory as well as other Test required in such cases: -------

  1. Testing of the complete installation at No Load and Full load after completion of work.

  2. To test the entire electrical installation/substation by primary injection method and submit the reports in triplicate as required by Electrical Inspector /statute.

  3. To test and submit test reports in triplicate for Harmonic level, earth resistance, Insulation, BDV and other statutory test wherever required.

  4. Obtaining the necessary permissions/ License/Certificates from the Central Electricity Authority /MSEDCL, Pollution Control Board, Electrical Inspector etc .as and when necessary till the completion of the project.

  5. Obtaining the Structural Stability report from the competent authority.

  6. Obtaining the necessary Test Certificates from the respective manufacturers for the equipments supplied.

  7. Liaison with the outside agencies on behalf of ISP as and when necessary with the permission and sanction of ISP.

  8. Testing commissioning and fulfillment of the statutory requirements along with necessary test reports as required by competent authorities.

  9. Supplying all the drawings, circuit diagrams, SLD's, maintenance manuals, spare parts manuals, operating manual, software etc of the complete plant, AHU's, substation equipments, motors, starters, cabling, wiring in triplicate as a complete comprehensive folder for our reference and records.

D) Terms and conditions: --------

  1. The whole work is to be carried out on turn key basis and is to be completed by a single firm with maximum use of the available infrastructure but without affecting the efficiency and working life.

  2. The requirement given is a purely tentative requirement after giving consideration to our existing needs but the competent authority at ISP has authority to make any changes as warranted by situation and in the interest of ISP.

  3. After completion of the entire work the firm will have to give performance trail for 09 hrs at a stretch for 15 days at various load conditions for each plant as well as for both the plants simultaneously.

  4. The bidder will have to actually visit, ISP premises with prior permission of the competent authorities, survey the complete installation, our air conditioning requirements and all other available existing infrastructure , building structure, various locations where AC is to be provided and based on their survey, technical bid is to be submitted. The new plant is proposed to be installed in the existing building.

  5. Suitable places of A.H.U’s and other auxiliary equipments has to be finalized in consultation with ISP officials

  6. The firm will have to design the plant such that, during peak summer period both the 700 TR plants can be run in parallel and at other times only one plant will be run and another will remain as standby and the infrastructure shall be set up to cater this need. The firm has to convince ISP Officials regarding replacement of existing equipments, if any of the existing equipments which cannot be used.

  7. The firm will have to submit a comprehensive proposal which shall include following major information along with other: ------

      1. Bill of quantities/material along with per unit rates.

      2. The total electrical load requirement of each plant when run in solo and when run jointly. The electrical ratings, makes, and other major details of the various appliances proposed.

      3. The firm will have to specify the make of the Chiller; Gas used and shall attach the catalogues for all the major equipments for evaluation purpose. They will have to specify the KW/TR for full load and part load.

      4. The infrastructural requirement of the plant including :--

        • Civil infrastructure like:--area of main building, A.H.U’s, masonry works, floor slabs, foundation requirement, annex building for substation or any other equipments, water sump requirements, piping, ducting and other requirements and their lengths from the main plant, making of foundations, scaffolding for the chilled water pipe installation, breaking and making good of civil mechanical and electrical installation structures etc.

        • Electrical infrastructure i.e. total electrical load of the plant, load details of each equipment, name plate details, different motors, starters, electrical power distribution panels, cables, Power factor improvement equipments, load details of the A.H.U’s, electromechanical details of the proposed equipments., Protective equipments, metering, Hot water generator etc.

        • Single line diagrams, schematic diagrams, interconnection diagrams,

        • Layouts and locations of the A.H.U’s, Chiller and condenser pipe lines, their class, capacity makes etc.

  8. Similarly regarding our existing (electrical, mechanical, civil, plumbing/ducting) infrastructure:--

        • The firm will have to give the list of our existing infrastructure that can be used and the purpose for which it can be used and/ or can not be used with justification thereof..

        • The list of structural changes / modifications required in our existing infrastructure.

        • The new infrastructure required, its location, nature etc in detail..

  1. The firm will have to submit a list of their major client where they have completed such large projects of Rs 10 Cr and above .List of infrastructure including technical and non technical manpower available with them. Only supply will not be acceptable.

  2. The bidder will have to clearly specify the total time required to complete the entire project along with the completion stages and the tentative duration.



  1. The offer itself shall be a complete and comprehensive offer and shall not be vague in any respect. While selecting the equipments the firm shall ensure that the selected equipments are energy efficient, durable, of reputed make, CE/ISI marked, stamped certified and of standard makes only.

  2. All the electrical appliances like motors, starters and other switchgear used shall be completely harmonic free and the firm will have to check the harmonic level of our existing plant prior to installation and will have to ensure that the harmonic level after the installation of the plant shall be less than the earlier one at load conditions and is in line with the harmonic levels to be maintained as per MSEDCL guidelines in force at the time of handing over the plant.

  3. After the completion of the project the firm will have to submit original 3 sets of all the drawings like: ----Foundation drawings, General Arrangement drawing of all AC equipments, layout drawings, wiring diagrams, SLD's, equipment manuals, electrical/ electronic circuit diagrams, data sheets for the complete installation and for each and every equipment. Along with drawings for ducting, acoustic, thermal insulation, piping insulation etc.

  4. The firm shall provide minimum 01 year’s warranty for the material supplied and the workmanship and shall give performance gurantee for 18 months.

  5. The firm will have to give guarantee of providing after sales service for the next 15 years in the quotation itself and in case of Bidder being an agent, they will have give an undertaking from the OEM of the major equipments that they will provide them the required after sales support for next 15 years.

  6. The firm will have to arrange for the training of all Mechanical and electrical equipments at the OEM.'s works to ISP’s minimum 2 Engineers each (2 electrical and 2 mechanical), other than the in plant training after installation of the plant.

  7. The firm shall arrange for inspection of all the major equipments by ISP authorities prior to its dispatch.

  8. The firm will have to follow all Security and safety norms and Code of safety of ISP and will have to provide necessary coordination to CISF and Sr. safety Officer.

  9. All the HT and LT equipments shall be provided with Rubber Electrical insulated matt's as per IE rule.




  1. ISP will provide only free electricity and water supply rest all tools, tackles, forklifts, cranes lifting ,shifting equipments, skilled /unskilled manpower etc is to be brought and provided by the firm for the complete erection, testing and commissioning of the plant.

  2. The firm on whom Supply Order will be placed will have to submit the schedule of work and will have to submit the weekly report to ISP authorities.

  3. The firm will have to submit the list of spares required, and cost per unit for our future reference and records.

  4. The firm will have to arrange for the shifting of all the old electrical, mechanical equipments, civil debris and all discarded material from the plant to the place earmarked by ISP or as decided mutually.

  5. While quoting rates for items of works which may change due to site location etc the firm will have to quote the rates on per unit basis/per area/length/volume basis and billing will be done on actual.

  6. After completion of the project, the firm will have to give a detail inventory of all the major equipments, appliances in chart format complete with the details like, make, quantity, location, per unit rate, year of manufacture etc. to ISP authorities prior to handing over the installation.

  7. All the sections, equipments, cabling wiring used shall be properly labeled for easy identification and shall be shown in the SLD’s or /and other drawings.

  8. All original drawings details manuals in triplicate hard copy form and soft copy form shall be handed over to ISP prior to handing over the plant.

  9. All measurements shall be carried out as per BIS standards.

  10. In case the contract is to be executed using the services of sub contractors, the bidder will have to undertake all the liability on behalf of the subcontractor and his men , material , workmanship etc.

  11. A few details of the existing infrastructure are appended herewith separately for reference purpose.


Annexure A: Line diagram of the plant indicating distances.

Annexure B: Areas and approx. heat load of different sections

Annexure C: Available Electrical infrastructure.
Annexure B

Details of area:
1)Overall inside conditions in summer 23 +/-2 degree Celsius.

2)RH(%) 55 ±5%(Except in Old PG Process Section where the RH required is 57±1%)


Sr No

Area Name

Floor area sq ft

Ht Of Hall in ft

Equipment Load KW

Lighting load

No of people

Load TR



Nyloplate

957

13.5

13.5

2

10

37



APMS

8127

13.5

182.5

15

81

112



New PG

12610

13.5

684

11.5

98

372



Letter Press/e Passport

12610

13.5

155

11.5

127

110



Adhesive Control(A & B)

4934

13.5

nil

4.5

145

26



New pg control

4698

13.5

nil

7.5

41

22



Strong room

1698

13.5

nil

1

nil

10



Rotatek

4880

13.5

66.5

7.5

71

52



Satellite envelope

806

13.5

37

1

15

24



Miller

4052

13.5

88.5

6.5

63

61



Grapha

4235

13.5

110

5

50

73



MICR

2182

13.5

54.5

13.5

34

43



AFS

2268

13.5

29

2

38

25



Old PG Process

2193

16.5

10

6

56

21



Old PG Printing

5816

163.5

110

10

50

75



Rapida

4612

13.5

350

20

68

119

Annexure C
Details of available major Electrical installation:--

Equipment

Details

Rating

Quantity

Compressor motor

Make: Compton Greaves

385 KW

02 nos

Chiller Pump motor




45 Kw

02 nos

Condenser pump motor




45 Kw

02 nos

Hot water Generator




360 Kw

02 nos

H.W generator pump




11 Kw

02 nos

Soft water plant motor




1.5 Kw

02 nos

Cooling Tower Motors










Power Transformer

11/.440 KV,The Indian transformer Ltd.

1500 KVA

01 no

Power Transformer

11/.440 KV,The Indian transformer Ltd.

1250 KVA

02 no

Oil Immersed Switch

11 KV Southern switchgear

630 amp

02 nos

Oil Circuit Breaker

11 KV Southern switchgear

400 A

03 nos

Incomer cable from MRS to 500 TR Incomer Oil Switch

HT XLPE Cable 300 sq mm

300 sq mm

1 piece

HT Cable from Incomer OCB’s to Individual transformers

HT XLPE

120 sq mm

03 pieces.

LT Control Panel for all the auxiliary equipments like Chiller pumps, condenser pumps.

Incomer ACB ---- rating, Switch Fuse Unit and Star Delta Starter combinations




01 no

LT Control Panel for Heaters










LT Control Panel Chiller no 1

ACB

1600 amp

02 nos

LT Control Panel for all the auxiliary equipments like Ch pumps, condenser pumps,










Automatic Power factor Controller







02 nos

Terms and Conditions of PQB:--

Along with the standard techno commercial conditions the following conditions may also be added:-

  1. The whole work is to be carried out on Turn key basis. Only supply is not acceptable and firms having technical and commercial competence to carry out whole job are only eligible to participate.

  2. The tenderer shall satisfy the Purchaser that they possess Team of techno commercially competent personnel with all required ground infrastructure with latest state of the art technology, Engineering Practices and have sound base.

  3. The tenderer will have to submit a list of clients where thy have carried out similar large turn key projects of Rs10 crore and above in the recent past. They will have to attach the Supply order placed on them, The Certificate of satisfaction from the Customer where they have installed such plants.

  4. Only original manufacturers of the equipment or their valid authorized agent who are ready to take on the job on Turn key basis are eligible to participate. In case of Dealer or authorized agent, the dealer or the authorized agent will have to submit a Valid Certificate of Authorization from the OEM along with a line of mention that they will provide the required after sales service support to ISP for the next 15 years irrespective of the agency involved.

  5. The tenderer shall clearly specify the works they will outsource by subcontracting.

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