solarpvsystem

8/3/2019 solarpvsystem

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1

ANNEXURE-A

Important points for Capacity Selection of Solar PV System1. The power generating capacity of Photovoltaic System is denoted by

Kilo watt Peak (measured at standard test conditions of solar

radiation of 1000 watt per Sq.metre) .As per the report of Central

Electricity Authority ,the average power delivered by Solar PVSystem is not more than the 20% Peak Power, so that each KW of

Solar Array of Output power corresponds to 4.8 KWh per day ( 24hrs

x 1 KW x 20% = 4.8 KWH).

2. The SPV system of 3.75 KWp,5 KWp,7.5KWp ,10 KWp may be

selected for installation at site depending upon the actual load and

Solar Insolation available at that particular site and availability of

Electricity Board Power Supply as per the following criteria:

(i)The 3.75 KWp systems may be chosen for smallerconfigurations of outdoor BTS sites and where the

availability of power is more than 12 to 14 hrs per

day.

(ii)The 5 KWp system may be installed for outdoor BTS

sites where availability of power 6-12 hrs a day.

(iii) The 7.5 KWp system may be used for outdoor

BTS sites where power availability is less than 6 hrs

per day.

(iv) The 10 KWp system may be used for outdoor

sites having more than one BTS.

3.0 The key parameters for various capacities of SPV system shall be as under:

4.0 The Specifications attached are for 5 KWp Solar PV System and the aboveparameters may be accordingly substituted .

SPV Capacity Battery Capacity Minimum No. ofunits generationguaranteed

Incentive to begiven for Ist yr forthe generationexceeding no. of

units.3.75 KWp 2X 200AH 5900KWH 6200KWH

5 KWp 2X600AH 7900 KWH 8300KWH

7.5 KWp 2X800 AH 11900KWH 12500 KWH

10KWp 2X1250AH 15800 KWH 16600 KWH


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SPECIFICATIO

5KWp Solar Photo Voltaic (SPV) power supply

[Hybrid: Solar- Grid-DG] for BSL BTS sites.

(EW-02/2010)

TEDER ELIGIBILITY CRITERIA:-

(a) Financial Norms:

The Work execution turnover of the firm shall not be less thanRs. 50 LAKHS in the past three years from the date of NIT

(b) Physical Norms:

Manufacturers of SPV Module having accreditation with ISO 9001-2000(or Latest ISO) and ISO 14001(Latest issue) and IEC 61215 certified.

(OR)Authorized suppliers / vendor approved by the above original

manufacturers. The authorization letter specific to the concerned tenderon printed letter head of the manufacturer in this regard will have to beproduced by the supplier/ vendor.

Note: The tender will not be opened at all, if the firm fails to submit thedocumentary proof for eligibility as said above.


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ScheduleofQuantity

SITCof5KWpSolarPho

toVoltaic(SPV)powers

upply[Hybrid:Solar-Gr

id-DG]forvariousBTSinBSL

Sl

o

DescriptionofItem

Qty

Unitcost/job

TotaletCost

toBSL(3x12)

Basicprice

exclusiveofall

levies&charges

Exciseduty+Cess

/Customduty

SalesTax/VAT(see

imp.ote3below)

Freight,Insurance,

Packingand

Forwarding

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paid/payableby

agency

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ofalllevies&Taxes

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DutiesandTaxes

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unitprice

Discountoffered

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etCosttoBSL

perset(9-10-11)

Rs.

Rs.

Rs.

Rs.

Rs.

Rs.

Rs.

Rs.

Rs.

Rs.

1

2

3

4

5

6

7

8

9

10

11

12

13

1 1

PARTA

SupplyofSolarPVSystem

01Job

1

Supplyof

follow

ingra

ting

Solar

PVSystem

capa

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4

Sl.

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DescriptionofItem

Qty

U

nitcost/job

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Service

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column5)

etcost

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(

6-7)

1

2

3

4

5

6

7

8

9

1

PARTB:InstallationTestingandcom

missioningofSolar-

HybridPowerGenerationSy

stem

01Job

Installation,

TestingandCommissioningo

ffollowingratingSolar

PV

System

capableofgenerating48VD

C

Powerconsistingof

SPVpanel,arraymountingstructure,Chargecontrolunit,Battery

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TECHNICAL SPECIFICATIONS

Sl.No Sub Head Page No

1 Scope 7

2 SPV Module/Array 8

3 Charge Control Unit 11

4 Battery 15

5 Interconnecting Cable 15

6 General Requirement 157 DC termination 16

8 Cabling and Wiring 16

9 Meters 16

10 Earthing 17

11 Marking and Labeling 17

12 Circuit and cabling diagram 17

13 Finishing and Painting 17

14 Name plate 17

15 Guarantee and Defects Liability 18

16 Packing 18

17 Quality and Workmanship 1818 Documentation 18

19 Test Certificates 19

20 Date of Completion 19

21 Testing at Site 19

22 Accessories 19

23 Other conditions 20

24 Completion Plan 20

25 Terms of Payment 21

26 Maintenance & Guidelines 21

27 Technical Particulars

(Actual To be filled by Vendor)

23

28 Approved Makes 24

29 Block Diagram of SPV Module 25

30 Typical Test Format for Battery set 26

31 Test Schedule for MF-VRLA Battery Set 27


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TECHNICAL SPECIFICATIONS 5KWp SOLAR PHOTO VOLTAIC (SPV) POWER SUPPLY[HYBRID: SOLAR-GRID-DG] FOR TELECOM EQUIPMENTS for 5KWp Capacity

1. Scope:

This document contains the generic requirements of 5KWp Solar Photo Voltaic(SPV) power supply for various Telecom equipment, working on - 48V DC.These power supplies shall be capable of generating minimum of7900KWH peryear. The mean Insolation on any panel kept at optimum tilt at places where thesolar panel is installed is assumed to be 4.5 KW hour/m/day. The minimumunits generated shall be calculated on prorate basis w.r.t actual insolation at theparticular location as per the published data of insolation for that location.

48V/5KWp Hybrid SPV Power Supply consisting of :48V/5KWp SPV Power Generating Source with 48V/5KWp Charge controller.ExistingSMPS (FR + FC)Individual Solar module rating shall not be less than 200 Wp at STC (Higherratings can be used) and shall meet following minimum requirement:Efficiency of cell c 14%Efficiency of module m 13%Fill factor shall be better than 70%.

Test certificates for the above performance from ETDC/any other GovtTest Centers have to be produced on sample basis.

The BSNL reserves the right to get any sample tested in the presence oftheir officer to witness this test in ETDC/ any other NABL accreditedGovt Test Labs.

This type of power supply shall have provision, so that, when both the output ofSMPS and SPV power source are available, they shall take the load collectively.

SPV power source shall deliver the load as per its available power and rest of theload shall be taken care of by SMPS. For proper load sharing of the two powersources, it shall be ensured that voltage of the SPV power source, even in worstworking conditions (high SPV cell temperature) is higher than that of the SMPS.

TheSPV system should be suitable for:

1. The Solar supply should be available both for the battery charging andfor the BTS Load as a float.

2. Solar controller and charge controller should be assembled in one unit box

3. The Solar panel output should be terminated with supervisory controlthrough two-way switch.

4. The control panel should not show indication of battery charging whenit is not being actually charged.

The SPV Hybrid Power Supply System shall be supplied as complete unitincluding charge controller, maintenance free battery bank, Solar panel, modulemounting structure, interconnecting cable etc. required for its satisfactoryoperation.

Site Layout Design:

The contractor will submit his layout design for SPV module including itsstructural details to Engineer in Charge for approval prior to start of work. It isexpected the contractor will visit the site before quoting the tender. The available


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space over the existing DG canopy/BTS Shelter may also be utilized forinstallation of SPV Module in consultation with Engineer in Charge.

2. SPV MODULE/ARRAYSolar Photo Voltaic Generating Source: SPV generating sources constitutedof the following building blocks:

SPV Module: SPV Module is the basic building block of the SPV power supply,which consists of a number of Solar Cells (a Semi Conductor Device which whenexposed to sun light produces DC electricity) connected in series andhermetically sealed with a toughened and highly transparent front glass cover.These modules are connected in series and parallel to get the desired power andvoltage. The Rated DC current of One module shall be 200Wp or higher.

SPV Panel: SPV Modules of same rating are connected in series to form a SPVpanel to get the desired voltage.

SPV Array: A number of panels are connected in parallel to get the desiredpower. This whole combination is called an array. The SPV array is so designedthat, it provides the necessary battery charging current and simultaneouslymeets the load demand, when sufficient sunshine is available.

Design Features: The mechanical design and construction of SPVmodules, panels and mounting structure shall be inherently robust and rigidunder all conditions of operation, adjustment, storage and transport. Sharpedges shall be avoided.

SPV Modules : The cells shall be fully encapsulated and mounted behind atoughened low iron high transmission glass surface of thickness not less than3mm to protect the cells from moisture, dust and external environment. Thecontacts should be corrosion resistant. The leads must be weather protected.

SPV modules shall be constructed of materials and component, which are knownto be resistant to damage or deleterious change when exposed outdoors for aperiod of 25 years in any of the climatic conditions prevailing in India and providemechanical and environmental protection to the encapsulated components. Thepossibility of attack by birds and animals shall be taken into account whenselecting materials for the exterior of modules.

The modules shall have proven laminate construction. The laminates shall besealed in a frame of light weight anodized aluminum to provide shock resistanceand a further moisture barrier. The back surface shall be of white refractive

plastic material such as TEDLAR.

The sealing of edges of glass on the frames shall be hermetically tight so thatrain water and dew do not enter into the cell compartment.

A terminal box shall be attached to the SPV module frame to be IP 65 rated.The terminal box should be resistant to moisture ingress and shall includeintegral by-pass diode to protect cell overheating due to localized shading. Themodule shall preferably be self draining and self cleaning.

The design of the solar module shall be multi-cell and modular in construction to

provide the required output.


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The SPV module is for use in terrestrial application and is to comprise of mono-crystalline/ poly-crystalline silicon solar cells to be connected in series parallelarrangement. Each module shall be completely encapsulated and sealed toprovide reliable operation under adverse climatic conditions.

The SPV modules shall comply with the requirement of IEC 61215 and IEC61730. The relevant certificates shall be submitted by the firm.

Electrical requirements: The module must deliver full current to the loadcorresponding to the terminal voltage of 54V, plus the diode drop and cable dropat a maximum expected cell temperature (55 deg C).

Minimum stipulated life: The minimum stipulated life of the SPVModule shall be 25 Years. The de-rating factor of 1.0% per year of the SPVGenerating Source/module rated power is permissible for the period of first 10years and thereafter the further derating shall be restricted to 10% of thecapacity at the end of 25th Year, thus module/SPV power generating source shalldeliver at least 80% of its rated power in 25th year.

Cells: Cells can be either mono-crystalline or Polycrystalline encapsulated SiliconCells. Permissible cell area per watt is between 60cm square and 100cm square.All the cells used in a module shall be identical, of regular shape and shall havethe same rating with tolerance +/-5%. The actual rating of the modules in apanel shall be within 5% of the average rating of the four modules. While in anarray, the rating of the panels shall also be within 5% of the average rating ofthe panels in the SPV power generating source.

Open Circuit Voltage: Maximum, minimum and nominal Voltages to bespecified, by the manufacturer, at 25 deg C. but in no case it shall be less thanthe value specified in Electrical requirements as above.

Voltage de-rating: shall not be more than -0.5% per degree C above 25degree C cell temperature.

Mounting Structure for SPV Array: SPV Modules/panels/arrays are mountedon a specially designed galvanized angle iron/ powder coated angle iron supportstructure. It shall also provide for angle of tilt with horizontal in accordance withlatitude of place of installation.

It shall be provided for mounting the SPV module on any of the followinglocations:-

a) Roof top

b) On the ground at an angle of tilt with horizontal, inaccordance with the latitude of the place of installation.

The steel for the mounting structure shall be as per IS 2062: 1992 andmounting structure galvanization shall be in compliance of IS 4759 (latest issue).

The mounting arrangement shall be suitable for column mounting or flat surfaceas per site requirement.

The Mounting structure shall be easily transportable and designed towithstand the wind speed of 200KM/hour. Design calculation shall be furnished

to show that the proposed structure will withstand the wind speed of 200 Km/hr.The design for the mounting structure shall have the certification from arecognized Lab/Institution for the purpose.


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Provision for directional and angular adjustment shall be made to ensure theoptimum utilization of incident sunlight.

The design/drawings of the mounting structure shall be supplied along with themodule.

The mounting structure shall be suitably designed to withstand the weight of thepanel/array.

The exact mounting mechanism shall be decided as per the actual requirementat the site of installation.

Lightning and Surge Protection: The power supply shall be adequatelyprotected against lightning at SPV input side by a protection device, in aseparate casing, attached on outside the charge controller in the followingconfiguration:

Protection of Charge Controller from SPV array side:On the SPV power source side of charge controller, the charge controller shall beadequately protected against lightning and surges in a manner as given below:

a) First stage protection to DC path, from the SPV array shall be provided withGD tube protection between +ve and earth and ve and earth. The GD tubesshall be provided with a proper rated fuse to avoid short circuit due to failureof the protection component. The failure of fuse or protective device shallcreate an alarm (Visual as well as Audio) to draw the immediate attention ofthe maintenance staff.

b) Second Stage protection for DC shall consist of MOV between +ve to earthand ve to earth.

Proper de-coupling using suitably rated inductance shall be provided between thetwo stages for proper co-ordination.

The ratings of MOVs and GD Tubes shall be as follows:

GD Tube: not less than 10KA, having the following current >= 100Amps. Therating of fuse used for protection of GD Tube shall be as per GD tubespecification.

MOV: 5 KA at 8/20S wave shape. The voltage rating of the MOVs shall be at

least V higher than specified value of the SPV array.

Dimensions: SPV Module/panel/Array: To be specified by the manufacturer.

Environmental Requirements: SPV module/panel/array, ChargeController unit, Mounting Structure and Batteries shall be capable of working in asaline atmosphere in coastal areas and shall be free from any corrosion at anyperiod of time. The SPV module/panel/array, charge controller and battery shallalso work with the guaranteed performance at an altitude in excess of 3000meters above MSL. These units shall also be capable of withstanding the rigorsof transportation and storage.


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Environmental requirements for SPV Module/Panels: SPV Modulesshall satisfy the IEC 61215 and IEC 61730 for the module and environmental testconditions:

Test certificates for the above performance from ETDC/any other GovtTest Centers

Product identification SPV Module:

Each module should have a name plate/ label on its rear side detailing producttype, rated power, rated voltage, open circuit voltage, short circuit current, all asmeasured under standard test condition( STC) , weight, maximum fuse ratingetc.

Each individual module should have a unique identification alpha numeric codewhich is bar coded and the label to be permanently affixed on the interior of themodule before lamination indicating the date, month and year of manufacturing.

3. Charge Controller Unit :

The charge controller shall provide for all the functions, as detailed below.It shall provide for the necessary DC power supply to the load and battery andalso protect battery bank from over charge, deep discharge, reverse polarity andshort circuit, thereby ensuring that the electrical characteristics are met foroptimum performance and reliability. It monitors all the functions of SPV powersource and SMPS (some on charge controller along with SMPS and all other onthe SMPS). It provides for termination for output of the SPV array, output of theSMPS (through a switch, if required), load and battery. It shall have facility forpositive ground. It shall house all the necessary alarms, monitoring and controlcircuits. It shall also provide for the mounting of the lightning and surgeprotection devices (SPV side on the charge controller itself). The charge

controller shall also select the most optimum power source available at anyparticular instance for catering the load at that instance. The priorities forselecting the various sources shall be site settable. The factory default settingshould have solar PV source as first priority followed by EB supply and the lastoption shall be DG source.

The Charge controller shall have one MCB, Multi function meter to measureKWH, Voltage and Current of SPV Output. The CCU shall also have the capabilityfor Data logging, with the help of RS 232/RS 485/USB Port along with necessaryconnection cable of minimum length of 1 metre, for last 4 months as per thedefined periodicity (Site Settable) of not less than One Minute for the following

parameters.a) Array Voltageb) Array Currentc) Array Energy output (Cumulative)d) Battery Currente) Battery voltagef) Battery power

The CCU should also have facility for remote monitoring with help of GSMmodem for connection to BSNL TOC.

CCU design will ensure optimal energy transfer from the SPV systemusing MPPT (Maximum Power Point Tracking) technique whichmaximizes the amount of current going into the battery/load from the


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solar array. It should have micro-controller based controls to adapt tothe changing conditions of the sun light but not just a fixed SPV voltagefor maximum energy transfer.

The Supplier shall provide one standby charge controller module of CCU as spare.CCU should be modular in construction with power modules and Distribution,Switching, Control and Alarm module. Should be able to increase the capacity ofthe total system just by adding the SPV modules and CCU modules withoutreplacing the whole CCU just like SMPS system. The module controls need to bemicro-controller based. Float and Charge modes need to be like the SMPS.

Burn-in Test : The Charge Controller shall be capable of withstanding aburn-in test for 72 hours at an ambient temperature of 50 C, when theequipment is working at full rated load. This test may be performed in atemperature controlled room with free air flow. Necessary test set-up for thepurpose shall be provided by the manufacturer. The temperature rise of heatdissipating components above the ambient, measured directly or at the heat sinkin the first 8 hours of the above test shall not be more than:Transformers and Chokes : 70 C for B grade of Insulation. For higher gradeof insulation, higher temperature rise is permissible subject to the followingconditions:

i) It is at least 20C below the permissible limit for the grade of insulation.ii) The temperature rise shall be at least 30C below the curie temperature of

the magnetic material.iii) This temperature shall neither affect other components nor lead to fire

hazard.

Semiconductor devices: 60C or as per component specification.

The Supplier has to get SPV charge controller approved by TSEC, CGM

(QA) Bangalore within 45 days from the date of award of work,including integration for one pro-type unit as per actual siterequirement.

Insulation Resistance Test: The insulation resistance of a fully wired (bydisconnecting all external Power connections) Charge Controller and SMPS, whentested with a 500V DC megger, shall not be less than 5 meg ohms for thefollowing conditions:

a) Shorted DC Output terminals and Earth (charge Controller).b) Shorted DC input Terminals and Earth (Charge Controller Unit).

c) Shorted DC input terminals and Shorted DC output Terminals (Chargecontroller).

The manufacturer shall ensure that :

All the above components shall be of reputed make and easily replaceabletype.

All the protective elements shall be cartridge type.


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Charge controller Unit: Electrical Requirements:

Voltage to Load and battery: The SPV voltage at the output of the chargecontroller shall be limited to 55.2V for 48V power supplies.

Efficiency: Efficiency of the charge controller at full load and rated outputvoltage of 54V for 48V power supply respectively shall be in excess of 90% whileworking on SPV power source.

Psophometric Noise ( e.m.f.weighted at 800 Hz) : While working on SPVPower as well as SMPS, Psophometeric Noise with a battery of appropriatecapacity floated and Radio Telephone equipment connected across the outputshall be within 2mV.Test certificate for meeting above requirement is to be submitted.

Protections : The charge controller shall provide for the control circuitryusing solid state switching techniques to incorporate suitable protections (with atolerance of +/- 1% for DC voltage and current) to safeguard circuit against thefollowing conditions:

a) DC over voltage :Charge controller: The output voltage of the charge controller shallbe limited to 55.2 V for 48 V power supply. In case the charge controlleroutput voltage exceeds 56V for 48V power supply due to failure of thevoltage control device provided to control the SPV Power Source voltage,the SPV power source shall be isolated automatically, creating alarm. SPVpower source shall get reconnected when the load voltage falls below thespecified level, which corresponds to output voltage of 55.2V for 48Vpower supplies.

b) Reverse Polarity : There shall not be any damage to thecomponents of the power supply in case the polarity is reversed. The unitshall start its normal function when the correct polarity is restored.

d) Reverse flow of current from the battery to the module: To avoidthe discharge of the battery through the modules during non-sunlightperiod or SMPS (when not delivering the output), the blocking diodes orany other suitable arrangement shall be provided in the charge controllerbetween :

SPV power source and battery terminals

e) Over Load/Short Circuit : The unit shall be protected for overload/short circuit. It shall be ensured that short circuit does not lead toany fire hazard.

f) Fuse / circuit Breakers with current limiting devices : Suitablyfault rated fuses or circuit breakers with current limiting devices shall beprovided for the following:

1. Negative DC output.

2. Against failure of control sensing circuit.


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Note : 1. Use of mechanical switching devices such as relays etc. is notpermitted in the control circuit. MCBs are, however, permitted forshort circuit protection only. But these can be used in the powercircuit to limit the inrush current and isolation purposes.

2. Two fuses (minimum) of each type shall be provided with each unit.These fuses shall be kept inside the unit in an enclosure.For logicpower, re-settable fuses must be used.

Monitoring Alarms and Indicating Lamps: Audio & Visual indications/alpha numeric display shall be provided by means of bright LCDs. Differentcolour display for different modes shall also be provided.Functional Indications: The following indications shall be provided toindicate mode in which the unit is functioning.

Alarm Indications (for Charge Controller) :1. SPV Output Voltage Low2. SPV Output Voltage High3. Battery Low4. Battery reverse polarity5. Over load6. Equipment Circuit Breaker Trip (if used)

All the alarm circuits shall be provided with solid state technology. Use ofelectromechanical relays is precluded.

All the alarms shall be DC only. All alarm circuits shall be provided with suitabledelay to ensure that they do not operate to transients.

Every Alarm condition shall be accompanied with an audio alarm with a non-locking type audio cut-off facility.

All the protections/alarms shall be within tolerance of 0.25V in case of DCvoltage and 1% in case of current.

Two Potential Free Contacts (one for alarm and one redundant) shall be providedfor extension of alarm to centralized display.

All indications shall be suitably designated and there shall be provision for theireasy identification from a distance of at least 3 meters.

A manual reset switch (non-locking/push button type) for disabling audio alarmshall be provided. In such case, the visual indication shall continue for the

receive attention, till the fault is attended and rectified.

The unit shall only be based on menu driven Micro Processor ControlledTechniques for Modules, for control, monitoring and alarms. Setting of all theparameters shall be through menu-driven microprocessor control only. Use ofpotentiometer for setting of parameters is not permitted. The powersupply shall be RS 485 compatible.

Dimensions: The dimensions of the charge controller unit shall be minimum butsufficient to house all the components, including battery and lightning protectionsection. It shall take care of the thermal engineering requirements of the unit.

Note 1: Only approved MCBs which do not produce spark, while manually,isolating or connecting the battery.


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Note 2: Battery shall be protected against the short circuit from any sourceincluding control and sensing circuitry.

4. Battery Bank : The Battery shall be mounted in the stand and shall beaccommodated in the weather proof MS shelter/ MS box suitable for IP-55Protection supplied along with the battery bank. The battery stand and box

/shelter shall be made M.S and shall have sufficient mechanical strength.

For 48V Power supply, a 24 cell battery formed by 2V cells is used. Mono-blockare not permissible for the purpose.

The battery shall be 48V (24 cells) VRLA type.

The vendor will supply VRLA batteries having TSEC approval by CGM(QA), Bangalore.The vendor should get his prototype battery tested for incremental testfor solar application as per the GR from BSNL QA, before supply.

5. Interconnecting Cables : Interconnecting copper conductor cables areused for providing interconnection between:SPV modules, panelsSPV Generating Source (array) and Charge ControllerCharge controller and SMPS (Hybrid power supplies)Charge controller and batteryCharge controller and load.

The Length of the interconnecting cables shall be as per the requirement of thesite. The gauge of the cable shall be so chosen that the total voltage drop acrossthe whole length of cable shall be less than 340mV (2% of voltage at peakpower) for 48V SPV power generating source. It shall also be capable of takingload without overheating. The termination of the cables shall be through lugs of

suitable gauge. The cables used shall be fire retardant and suitable for outdoorapplication.6. General Requirements

Constructional features: All the components as given above shall be mountedin the charge controller made of a metallic box with the captive screws withwashers.

The structure of the unit/rack shall be made up of rigid frame work of MS steelprofiles with proper ventilating arrangements. The structural strength of theframework shall be able to withstand the ultimate mechanical load of the

unit/rack without any deformity. Unit/rack shall be free of sharp edges or sharpcorners. The unit/rack shall have suitable ventilating arrangements (forcedcooling from the sides is not permitted). The front door (if provided) and reardoor may be of hinged or removable type. The gauge of metal sheet for panelsshall not be less than 2mm.

Proper thermal engineering of hardware design shall be done by themanufacturer so as to ensure the uninterrupted use of the equipment. Unit/rack,complete, with all panels fitted, shall be designed to allow cooling by naturalconvection.

The battery is mounted inside the shelter; the battery mounting fixture shall besuch as to hold the battery firmly in position in any orientation. Proper signshowing the orientation of the unit shall be marked.


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Provision for mounting the charge controller unit on the wall as well as Floor tobe provided.

All the components mounted on the PCB shall be permanently fixed To PCB. Useof mounting sockets for components is not allowed.

The unit or rack shall ensure uniform floor loading below 320 kg/Sq metre.

7. DC Terminations:

Proper termination shall be provided in the charge controller to terminate theleads from the battery, load and cable from the SPV power source.

At the input and output, proper rated fuses and circuit breakers shall beprovided on the ve lead from the unit. All DC +ve and ve leads shall beclearly marked.

The terminals shall be capable to withstand the peak load.

The fuse or circuit breakers with current limiting devices used, shall beaccessible and properly rated.The DC output to Battery and Load shall be through cable/bus-bars as perrequirement. However, for inter-rack connections, cables of proper ratingpermitted.

The isolation of any of the battery from the load shall create an alarm.

All the AC, DC Control & alarm cabling shall be supplied with the rack.

Mounting of Component and Layout: Component mounting and fixing

methods shall be secured.

8.Cabling and Wiring : All insulated conductors except those within confines ofa printed circuit board assembly shall be of the rating enough to withstand themaximum current and voltage during fault and overload. The wires and cablesused shall be fire retardant as per IS 1554 with amendment 1 (June 94). It shallbe neatly secured in position and adequately supported. Where wires passthrough any of metal panel or cover, the hole through which they pass shall besuitably bushed.

9. Meters: There shall be provision to monitor the voltage and current and

KWH generated by solar PV system as given below:

In Charge Controller, there shall be a provision to monitor DC current as well asvoltage and KWH generated from solar PV System, and monitor DC current aswell as voltage of any of the Battery bank, SPV array and that of the load withthe help of Digital meters. Digital meters display/resolution should be such thatit is clearly and unambiguously readable from a distance of 1 metre. The metersnormally shall indicate the System voltage and current.The firm can provide a common multi function meter having facility to showvoltage & current for battery bank, SPV Array, load.

Current : +/- 1.0 % of the range or better, shall be able to read up to full digitfor meter range 100A and 1 place decimal for lower meter range.


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Voltage : +/- 1.0% of the range or better with a resolution of one decimal pointin case of DC voltmeter.

10. Earthing: Proper earthing shall be provided for SPVmodules/panels/array, mounting structure, lightning surge protection componentand body of charge controller. Charge controller cabinet shall be provided withtwo earth terminals in effective electrical contact with the body of thecabinet/rack. All metal parts of the components, which do not carry current,shall be bonded thereto. Nominal cross sectional area of earth continuityconductor, not contained within the cable, shall be half (minimum) of eachcurrent carrying conductor to be protected but in no case it shall be less than 3mm diameter. Continuity conductor used for the purpose shall only be ofcopper. Suitable terminals shall be provided for terminating earth conductor tothe existing earth bus.(Provision of new earth is not included in this scope).

11. Marking and Labeling: The terminals of the module/panel, battery,Charge Controller, components of the charge controller and terminals shall beproperly sign written to enable identification of each of them with reference tothe suppliers installation manual. Designation of keys, switches and othercomponents mounted on the front/inside panel and other operating positionsshall clearly screen printed or sign-written. Wiring shall be clearly &permanently identified with designation or a colour code which corresponds tocircuit diagram. Where non-standard colours are used cable functions shall beclearly & permanently labeled at both ends.

Fuse holder identification shall include details of fuse rating & type.

12. Circuit & Cabling Diagram: A screen printed/laminated circuit andcabling diagram, of Charge Controller shall be provided in the charge controller.The same should also be provided in the manual. Interconnection diagram of the

modules of the panels on SPV module/panels shall also be provided for readyreference of the maintenance staff.

13. Finish & Painting :

Corrosion Resistance: All surfaces of the equipment including frame modules,covers, chassis, brackets, etc., shall be treated to prevent corrosion.

The structure and panels shall be Galvanised iron / powdered coated/Weatherproof paint.Colour scheme shall be as follows: Siemens Gray

14. Name Plate: A name plate, anodized shall be suitably fixed to the modulesof the glass), iron structure and charge controller with the following:

Name Plate for SPV Panel and Mounting Structure:Name of the UserManufacturers name and identification markName of the ItemModel No.Serial No. of the unitYear of manufacture

Name Plate for Charge Controller:Name of the userManufacturers name and identification mark


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Name of the ItemModel No.Type of unitSerial No.of the unitYear of manufactureRating and voltage of the charge controllerBattery Capacity and voltageBattery impedance of the fully charged, 80% discharged and fully dischargecondition.Date on which the freshening charge was given to the battery before discharge.Due date for the freshening charge.Voltage at 80% DOD.Input voltage (Hybrid systems only)Output Voltage and CurrentOn the front top of the Charge controller cabinet, an anodized, screen printed orany other arrangement ensuring better life expectancy designation plate in

Bold letters showing 48V/.KWp SPV POWER SUPPLY FOR TELECOMEQUIPMENT.

15. GUARANTEE & DEFECTS LIABILITY PERIODThe complete system shall be guaranteed for Three years, the manufacture shallguarantee all the equipments supplied by him for any kind of defect . The firmshall also undertake the comprehensive maintenance of the entire solar PVinstallations for the period of three years including the batteries supplied by thevendor.

The vendor has to perform the weekly check at site including cleaning of thepanel etc.

16. Packing: Packing and transportation of solar panels, Charge Controller,Battery and Mounting Structure shall be made such that the equipment is not

damaged, while transporting, loading and unloading.

17. Quality and Workmanship:All the units of the system shall be manufactured in accordance withinternational quality management systems ISO 9001-2000(or latest ISO), forwhich the manufacturer shall be duly accredited. A quality plan describing thequality assurance system followed by the manufacturer would be required to besubmitted. The manufacturer shall also be accredited for the compliance ofISO14001 (latest issue) pertaining to environmental requirements.

All wiring shall be neatly secured in position and adequately supported Metal

panel or cover holes through which the wires or cables pass shall be bushed.

All materials and workmanship shall be of professional quality to ensure therequirements.

18. Documentation: Technical literature in English with complete anddetailed block schematic and circuit diagrams of its assemblies with test voltageat different test points of the units shall be provided. A soft copy as well as ahard copy of the above shall also be provided. All aspects of installation,

operation, maintenance trouble shooting and repair shall be covered in thismanual. The manual shall include the following:


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Installation, Operation and Maintenance manual part shall include:

Safety measures to be observed in handling of the equipment.Precautions at the time of installation, operation and maintenance.Detailed structural drawing of mounting structure, charge connector modules,panels.Detailed interconnecting diagram between the various units of the system.Procedures for routine maintenance, preventive maintenance, trouble shootingand replacement.Illustration of internal and external mechanical parts.Complete layout, detailed block schematic and circuit diagrams and assemblieswith test voltages at different test points.Typical I V curves at 25 deg C with the formula of interpolation.

Hard copy of the documentation shall be prepared using good quality paper withclear and crisp printing. All the drawings in clear printing shall be attached tothe hand book binding. The binding of the manual shall be long lasting andpresentable. One set of flow chart drawings necessary for trouble shooting shallbe provided with lamination, with each manual.

19. TEST CERTIFICATEThe firm shall submit following test certificate on supply of the materials

at site. Manufacturer test certificate for Battery bank, SPV cells & SPV Moduleetc. and test Certificate from ETDC/any other NABL Accredited Govt Test Labsfor SPV Cell/Module.(i) For the BSNL QA TSEC approved items,(not applicable for prototype approveditems) Bulk testing has to be Performed i.e. all the quantity supplied for theseshould be QA tested.(ii) Department may test each set at factory without any extra payment.(iii) All test certificate as per the environmental requirements shall be produced.iv) The design for the mounting structure shall have the certification from a

recognized Lab/Institution for the purpose.

20. DATE OF COMPLETIONDate of successful performance testing of seven days as mentioned below shallbe taken as date of completion .

21. TESTING AT SITE

(a) Performance testing as per specifications of agreement shall be carried outfor a period of seven days to calculate the energy output generated by the solarPV system. All equipment required for testing shall be provided by the firm

without any extra cost. All certifications required as per the agreement shall bearranged by the firm without any extra cost.

(b)The firm without any extra cost will supply variable resistive load for testing of battery.In case of failure of the SPV module, Battery & system during testing, all equipmentsnecessary for testing shall be provided again free of cost. In case of failure of the SPVmodule, battery & system during testing, the department reserves the right to rejectthe complete set. Decision of Engineer-in-Charge in this regard shall be final

22. ACCESSORIESAll standard accessories required for SPV power generation, battery bank, shall

be got from the manufactures as a part of equipment.


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23. OTHER CONDITIONS(i) The firm should note that offers with condition and/ or conditional rebates other

than technical offer will be summarily rejected.(ii) The rates for all items of work, shall, unless clearly specified otherwise, include

cost of all labour, materials and other inputs involved in the execution of theitem.

(iii) The layout of the work will be given by the Engineer-in charge or his dulyauthorized representative at site of works.

(iv) The work will be done as per current CPWD/ BSNL /TEC Specification.(v) The contractor has to test the panel and bus bar for the insulation for which

nothing extra is payable.(vi) Inter connection between bus bar and switch of capacity 100 Amps. & above will

be done with solid copper conductor with PVC Insulation.(vii) The route for the cable laying should be got approved by the Engineer-in Charge.(viii) Under ground cables should be subjected to pressure Insulation test before and

after laying the same in the ducts. In case of unsatisfactory result the cost of allrepairs and replacement and all extra work of removal and relaying will have tobe borne by the contractor.

(ix) The contractor has to arrange the following testa) Earthing test. b) Insulation test. c) Continuity test.

xi) Any damage done to the building during the execution will have to be made goodto the entire satisfaction of Engineer-in-charge.

xii) Only ISI marked material shall be used. In case ISI marked is not available inparticular item, material conforming to BS, shall be provided.

24. COMPLETION PLANThe firm shall supply three sets of drawings/documents immediately oncompletion of the work as detailed below:

i) Plan lay out of the SPV system indicating various equipments.ii) Foundation details of SPV system.iii) Schematic diagram of control wiring.

iv) Operation & maintenance manual.v) Cable route showing the followings;

a) Layout of the cable.b) Length, Size, Type and grade of cables.c) Method of laying i.e. direct in ground or in pipes etc.d) Location of each joint with jointing methods.e) Route markers and joint markers with reference to permanent Road mark

available at site. Failing which necessary amount will be recovered fromhis final bill as per relevant clause.

f) Any parts found defective during the guarantee period shall be replacedfree of cost by the contractor. The services of the contractors personnel, if

required during this period shall be made available free of cost to thedepartment.

g) The contractor shall depute his representative to the site within 48 (fortyeight) hours of notification of defects by the department.

h) The representative of department and firm shall prepare a joint reportregarding the nature of defect and remedial action required. Timeschedule for such action shall be also finalized.

i) In case the contractor fails to depute his representative within 48 (fortyeight) hours of notification of defects or fails to cause remedial measurewithin a reasonable time as decided during joint inspection, thedepartment may proceed to do so at the contractors risk and expenses

without prejudice to any other right.The contractor shall visit and inspect the work as per the maintenance

schedule during the Guarantee period to check the health of the installation. The


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Battery shall be boost charged once in a month for 18hrs to 24 hrs @ 2.3V. TheEngineer-in-charge or his representative shall certify this fact. In case thecontractor does not comply with this provision in respective quarter period, theDepartment will forfeit 10% of security deposit amount for each quarter.

25.Terms of Payment :Payment to the contractors, during progress of work, will be regulated as below:-Supply agreement:

a) 70% of prorata of the approved price breakup of contract value onreceipt of equipment at site and after satisfactory physical installation andseven days testing at site

b) 10% of the approved value of supply portion at the end of I year (to be paidon quarterly basis @2.5% at the end of each quarter for the comprehensivemaintenance including weekly checks, the firm is required to submit thesatisfactory working certificate for each weekly visit) .

c) 10% of the approved value of supply portion at the end of II year (to be paidon quarterly basis @2.5% at the end of each quarter for the comprehensivemaintenance including weekly checks, the firm is required to submit thesatisfactory working certificate for each weekly visit).

d) 10% of the approved value of supply portion at the end of III year (to bepaid on quarterly basis @2.5% at the end of each quarter for thecomprehensive maintenance including weekly checks, the firm is required tosubmit the satisfactory working certificate for each weekly visit)

ITC agreement:a) 100% of pro-rata of the approved price breakup of ITC part (i.e part

B) after installation and commissioning and seven days of testing at site.

NOTE:1) These SPV power supplies shall be capable of generating minimum of7900

KWH per year. Final Reading of the same shall be taken at the end of 12

months from date of commissioning.2) If the SPV Energy Generated falls short of expected 7900 KWH in first year,a recovery on prorate basis of awarded amount shall be made from theperformance Guarantee/balance amount due to the firm.

3) If the SPV Energy Generated is in excess of8400 KWH in first year, a bonuson excess units exceeding 8400 KWH @ Rs 5/KWH (for the first year only)shall be paid to the firm along with the release of Security Deposit.

4) The Supplier has to get SPV charge controller approved by TSEC,CGM (QA) Bangalore within 45 days from the date of award, failingwhich the Performance Guarantee of 5% will be forfeited and theagreement will be terminated.

26. Maintenance Schedule & Guidelines:

WEEKLY CHECK:1The vendor has to perform the weekly check at site including cleaning of the panel

etc

MONTHLY CHECK:

2Check the charge controller for proper alarms indications & proper functioning byoperating Alarm Check Key.

3 For VRLA batteries check the voltages :Between 13.00 and 14 hours on a bright sunny day for any mark deviation in cell

voltages (the indication of cell deterioration).


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27. Technical Particulars [To be filled by Vendor]

Particulars of SPV system Actual offered by Firm

DC output of PV Array (KWp)

Area required (square feet)

No. of cells in one PV module

DC rating of one module (WP)

Connection configuration

Rated DC current of one module

Rated DC voltage of one module(Vmpp)

No. of PV module in one array (all inseries)

Max. DC output voltage of Array(Volt)

No. of Arrays

Make of SPV module

Model of SPV module

Make of Charge controller

Model of Charge controller

Make of Battery

Model of Battery


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28.APPROVED MAKES

ABattery :Valve Regulated Lead Acid(VRLA) Batteries 2V - 600 AH

The vendor will supply VRLA batterieshaving TSEC approval by CGM (QA), BSNLBangalore.

B Charge Controller

The Supplier has to supply only TESC CGM(QA), BSNL BANGALORE approved charge

controller (OR) The Supplier has to get SPVcharge controller approved by TSEC, CGM(QA) Bangalore within 45 days from thedate of award

C SPV Module

Manufactured by units accredited with ISO -9001-2000 (or Latest ISO) and ISO14001(Latest issue) & conforming to IEC61215 and IEC 61730. The Manufacturedshould get one prototype TESC approval forSPV module as per tender specification

before supply at site from CGM (QA), BSNLBANGALORE.

D DC MCB BSNL QA CACT Approved

Note: Any other items which do not have specific approvals, shall be provided after obtainingapproval of Engineer in charge.


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LIGHTNING &SURGE

PROTECTIVE

DEVICES ON THE

OUTSIDE OF THE

CHARGE

CONTROLLER

UNIT

SPV

POWER

CONTROL

PROTECTI

ON

ALARM

AMF/Change

Over Panel

Existing

FR FC

UNIT

(SMPS

POWER

PLANT)

D

G


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30. TYPICAL TEST FORMAT FOR BATTERY BANK (600Ah):

CELL N.L F.L 1ST HR 2ND HR 3RD HR 4TH HR 5TH HR 6TH HR 7TH HR 8TH HR

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

BTRY

VOLT

Note: 1) Discharge Test to be conducted for 10 Hours for a fully charged Battery Bank, dischargerate @ 10% of Total Capacity.

2) Individual Cell Voltage should not fall below 1.74V at any time.3) Battery Bank Voltage should not fall below 44V at any time.4) Two Battery Banks to be tested at separate intervals.5) Interconnecting wires, Control Switch gear, Resistive Load, Suitable Shunt for measuring

discharge current ( 60A) etc to be provided byFirm for the Test.


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(31) TEST SCHEDULE FOR MF-VRLA BATTERY SET

S.No. TEST REMARKS

1. Check the installation in a clean proper ventilatedand dry location

2. CAPACITY TEST :-

Check the capacity of battery set (Test Discharge)[Taken after freshening charge at C-10 rate i.e. 1/10thof rated capacity applying temperature correction to27C.]

2.1 Measure and record the voltage of each cell hourlyupto 8 hours then at every 15 minutes.

2.2 Record the room temperature hourly

2.3 Record the discharge current/load current hourly.

3. End of discharge : Stop the test discharge at 1.85 xN (N=No. of cell) terminal volts or any cell voltagereaches to 1.74 volt.

4. Visual examination check

4.1 Check alignment and levelling of battery set.

4.2 Check cracks of battery container and finish paint ofstand.

4.3 Polarity sign writings.

4.4 Check of fuse rating and link on positive lead.

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