supply of centrifugal fans

Tech. specification Centrifugal Fan

Bhabha Atomic Research Centre Nuclear Recycle Board

FRWMD of 50

Government Of India Bhabha Atomic Research Centre

Nuclear Recycle Board Fast Reactor Waste Management Directorate

TENDER SPECIFICATION No.

BARC/NRB/FRWMD/FRFCF/47350/SP/06

TECHNICAL SPECIFICAIONS for

SUPPLY OF CENTRIFUGAL FANS for

WMP- FRFCF, KALAPAKKAM



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INDEX

Item Page no.

1 Scope of work 1.1 Scope of work 5 1.2 Scope of supply 5 1.3 Site operating condition 5 1.4 General 5 2 Applicable codes and standards for fan 5 3 Technical requirements 6 4 Description of equipment 7 4.1 General design features 7 4.2 Housing 7 4.3 Impellers 7 4.4 Shaft 8 4.5 Bearing 8 4.6 Shaft seals 8 4.7 Flexible connectors. 8 4.8 V- Belt drive. 8 4.9 Foundation. 9 4.10 Welding. 9 4.11 Balancing 9

4.12 Electric motors and drives 9

5 Technical data sheet 10 5.1 Design requirement for fans 10 5.2 Technical data sheet of Fans 12 6 Motor and drive system 15 6.1 Scope of specifications. 15 6.2 Content of document. 15 6.2.1 Section- A Drive motor. 16 6.2.1.1 Scope 16 6.2.1.2 Applicable standards. 16 6.2.1.3 Driven equipments 17 6.2.1.4 Performance & characteristic 17 6.2.1.5 Specific requirement of drive 18 6.2.1.6 Insulation 19 6.2.1.7 Constructional features. 19 6.2.1.8 Bearings 19 6.2.1.9 Terminal box 20 6.2.1.10 Paint and finish 20 6.2.1.11 Heating during idle period. 20



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Item Page no.

6.2.1.12 Inspection and testing of motor & VFD Drive

20

6.2.1.13 Technical data sheet of motor. 24 6.2.1.14 Specifal requirement. 29 6.2.2 Section- B - VFD Drive 30 6.2.2.1 Scope of work 30 6.2.2.2 Functional requirement 30 6.2.2.3 General 30 6.2.2.4 Requirement for manufacturer 31 6.2.2.5 Basic requirement of VFD Drive 31 6.2.2.6 VFD Drive performance 33 6.2.2.7 Protection 33 6.2.2.8 Environmental compliance 33 6.2.2.9 Enclosure and mounting. 34 6.2.2.10 User interface. 34 6.2.2.11 Communication feature 35 6.2.2.12 Man machine interface. 35 6.2.2.13 Data transfer 36 6.2.2.14 Environmental effect. 36 7 Inspection and testing 37 7.1 General 37

7.2 Stage inspection 39

7.3 Inspection of brought out items 40 7.4 Mechanical run test 40 7.5 Performance testing 40 7.6 Leak testing. 41 7.7 Shaft seal testing. 41 7.8 VFD testing. 41 7.9 Document of testing. 42 8 8.1 Drawings 42 8.2 Spares for fan 42 9 Instruction manual 42 10 Packing. 43 11 11.1 Bill of quantity of Fan 44 11.2 Bill of quantities of spares 44

12 Documents 45 12.1 To be submitted along with offer. 455 12.2 To be submitted before start of work. 45 12.3 To be submitted after completion of work. 45

13 Warning 46 14 Performance guarantee. 46 15 Delivery at site. 46 16 Delivery schedule 47



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Item Page no.

17 Price schedule 47 18 Technical data sheet to be furnished by the

bidder. 49

19 Notes to the Bidders Annex. i-xvi



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1.0 SCOPE OF WORK: 1.1 This specification establishes the technical requirements for manufacture of

supply and exhaust ventilation fans as per the technical specification and listed tender drawings. The scope of work includes design, procurement of materials, inspection of brought out items, manufacture, assembly, inspection, shop testing, packing and safe delivery at WMP- FRFCF site , IGCAR , Kalpakkam.

1.2 SCOPE OF SUPPLY:

This includes the supply of centrifugal fans along with electric motor, VFD Drive, base frame, foundation bolts, inlet/outlet flexible connections, vibration isolators, counter flanges, V belt with guard and safe delivery at site as per tender technical specifications.

1.3 SITE OPERATING CONDITION

Kalpakkam Dry bulb temperature 38 degree C Wet bulb temperature 29 degree C Elevation at G.L. Sea level

1.4 GENERAL: As the equipment covered under these specifications are required to have high degree of reliability, it is absolutely necessary to have proven design, excellent workmanship and proven industrial running record of similar equipment. The supplier shall give all exhaustive design data and literature to prove their selection of components and field data of the fans for the running experience of the equipment. The supplier shall give all to prove their capabilities to meet the quality, quantity and schedule to meet the intent of these specifications.

2.0 APPLICABLE CODES AND STANDARDS: All the materials used specified & unspecified shall be new and follow relevant BIS or equivalent International codes & standards as indicated below. In case of two standards giving different size / thickness of component, the standard giving higher strength / thickness shall be selected . In case of any conflict on sizing or code purchaser’s decision shall be binding on the contractor.

AMCA 210 - 1999 Laboratory Methods of Testing Fans for Aerodynamic Performance Rating

AMCA 300 - 2008 Reverberant Room Method for Sound Testing of Fans

IS 4894: 1968 Specifications for centrifugal fan testing



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ASME Sec IX and Sec VIII DIV I Procedure for welding & welder’s qualifications

ASME sec. V NDT requirement

IS 2062 Grade-B M.S. Plate structural steel quality

ASTM - E - 165 Liquid penetrant test

ASME section III subsection ND article 5350

Acceptance criteria for welding

BIS 210 Specification for C.I. castings

VDI 2060 Balancing of rotors

VDI 2056 Vibration criteria chart

ISO 1940 Balancing quality requirement

IS 1363 & IS 1367 For all threaded fasteners

ISO 10816-1:1995

Mechanical vibration -- Evaluation of machine vibration by measurements on non-rotating parts -- Part 1: General guidelines

AMCA 204 - 1996 Balance Quality and Vibration Levels For Fans

3.0 TECHNICAL REQUIREMENTS

All materials used must confirm with the applicable standards & codes listed in these specifications must be new in all respects. All parts shall be free from flaws & objectionable imperfections and shall be machined true in workmanship like manner. Wherever materials are not specified, they shall be properly selected by the contractor to the best standards followed in the industry for the particular applications subject to the approval of the purchaser. The units shall be built to the industries highest standards of quality to ensure maximum mechanical & electrical reliability. All the inside and external metal surface of housing, impeller etc. shall be given two coats of epoxy primer and 3 coats of epoxy painting of approved colour. The external surfaces shall be painted with 3 coats of approved paint enamel after primer. All the surface shall be thoroughly cleaned & checked, rough edges or weld spatter removed and then cleaned with non-chlorinated solvent and dried before painting.



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4.0 DESCRIPTIONS OF EQUIPMENT

4.1 GENERAL DESIGN FEATURES

The centrifugal fans shall be of Aerofoil Backward Inclined type vane design and of limit load characteristics. The design shall be such as to select fan for optimum static & mechanical efficiency and should be of stable design. If other considerations do not permit optimum selection, then selection should be right of peak efficiency curve.V2 and E2 fans shall be of SISW type. The fan selected shall be of the smallest size. At no level the operation of fans should become unstable in the operating range specified i.e. good pressure/ volume characteristics. The fan design shall be suitable for handling air at 60 0 C (Max.) . The general selection of class of construction shall be of one class higher than class for static pressure as selected for industrial purpose. The supplier shall then clearly gives the difference of construction details of the one class higher and the class of construction selected.

4.2 HOUSING The housing shall be fabricated of Mild Steel heavy gauge steel plates ( IS 2062 Grade B ) , accurately cut & formed and continuously welded through out for added strength & total air tight construction. No lock seam joints shall be allowed. Access doors bolted type shall be provided with due gaskets . For larger fans the access doors shall be big enough for person entry .The fan housing shall be of split construction and shall be with flanges and gaskets provided for leak tight bolting .The cut off shall be so designed to give smooth quite and efficient performance of air from fan outlet. The supporting structure of fan and bearing blocks shall be designed for sturdy and vibration free. Proper bracing and stiffening shall be done inside and out side.

The casing shall be of welded construction, fabricated from heavy gauge carbon steel (IS 2062 Grade B ) reinforced for rigidity and supported by structural members. Inlet Cone shall be die-formed / spun to smooth hyperbolic contoured shape.

4.3 IMPELLERS

Full rotating assembly including shaft, impeller and pulley shall be both statically and dynamically balanced for the close level of vibration & noise free operation at specified speed nearest to the fair limit but not exceeding fair limit. The balancing Grade shall be 6.3 as per VDI 2060 . In no case vibration shall exceed fair limit, it shall be nearest to good limit as defined in vibration chart against the speed. As stated, the impeller blades shall be of backward curved aerofoil design. The aerofoil section blades shall be accurately formed from single sheet of steel and welded at the trailing edge. The impeller blades shall be mild steel and securely welded to both the back plate and shroud. The critical speed of the fans shall be at



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least 1.30 time the operating speed. For class-III and heavier blades there shall be internal blades reinforcing. The shroud shall spun and of radial design. The hub shall be liberally designed with over size flanges and heavy cross section for keeping the wheel rigid to run straight & true. The aerofoil blades shall be staggered to reduce noise and smoothen out the flow leaving the blade tips. Inlet cone and fan must be centered to within +/- 0.01 inch. This is to keep blade passing frequency at low value.

4.4 SHAFT

Shaft of the fan shall be of material EN-8 and suitably designed to take up the various torque & bending moments of the total systems. It should be well designed with fillets & radii to take discontinuous stress at various section changes. The shaft shall be UT tested as per ASTM A-588 and E-317. Raw material test for checking chemical properties for shaft material shall be carried out. Shaft shall be D.P. tested after machining.

4.5 BEARINGS

The bearing of the fans shall be of spherically seated, roller, antifriction self-alighting, grease packed, pillow type of SKF / FAG or equivalent make. They will be designed to run continuously for a year between greasing. The life of the bearings shall be at least 100,000 hours.. The grease capacity shall be such that fans are suitable for continuous operation of at least 12 months before re-greasing and required minimum maintenance. An integral housing for housing two bearings will be preferred and if offered the bores for both the bearings shall be true and shall be bored in one single setting.

4.6 SHAFT SEALS Shaft seals shall be provided for all fans and shall be of labyrinth type for the exhaust fans and filled with pure Teflon braided. It shall ensure minimum leakage along the shaft and easy replaceability of packing. The purchaser shall approve the design of seals. For the supply fans shaft seals shall be of plate type for general leak tightness and shall be of approved design.

4.7 FLEXIBLE CONNECTORS:

Flexible connections shall be provided at inlet and outlet of the fans. This shall be of Two layer of leak tight cum acid & pressure resistant flexible synthetic cloth sandwiched with fibre glass thin filter padding (Fire retardant quality) of atleast 6 mm thick and 300 mm length of approved design. The design of connection shall be such that replacement is easier.

4.8 V-BELT DRIVE All the fans shall be of V-belt type drive. All the belts shall be selected to transmit the full horsepower using service factor of not less than 2.5. All V-belt drive shall be equipped with removable screen cover of heavy-duty wire mesh. At least one



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number of belt shall be spare belt in the belt drive. The belt shall be of fenner or equivalent make in matched sets. All the fans pulleys shall be statically & dynamically balanced. Pulleys shall be of approved brand of standard size as per the I.S. Fan & motor pulleys shall be mounted on shaft via Taper Lock Bushes.

4.9 FOUNDATION

The purchaser shall provide the concrete foundation. However, base frame, vibration isolators and foundation bolts will be in the scope of the supplier. The base frame design shall be such that it ensures minimum vibration to the fan. Vibration isolators shall be of Dunlop or equivalent make.

4.10 WELDING Welding of parts shall meet the high standard and all M.S. welding should be done by manual metallic arc process with coated electrodes. The welding procedure and welder qualification shall be done as per the requirement of ASME section IX of latest edition. The manufacturer shall submit the procedures for approval of purchaser. All inspection and testing shall be carried as per approved procedures. Liquid penetrant test (LPT) shall be carried out on all welds (root & final pass) and machined surfaces. The governing code shall be ASTM-E-165 type II method C. Acceptance criteria shall be as per ASME section III subsection ND article 5350. This test shall be carried out on all root pass and final pass of welding.

The following indications shall be not be accepted: a) Any linear indication will not be accepted. b) Isolated circular indications more than 1 mm or t/4 (t= Thickness) (whichever

is less) will not be accepted. c) Four or more rounded indications in a line separated by 1/16" (1.5mm) or less (edge to

edge) will not be accepted.

4.11 BALANCING (i) All rotating parts shall be statically & dynamically balanced individually and as an

assembly itself shall be put to balancing by appropriate method to ensure and guarantee vibration level of agreement. The critical speed shall be at least 30 % more than the speed selected. The balancing level shall be as per VDI 2060 Gr.6.3 . Noise and Vibration

(ii) Noise level produced by any rotating equipment individually or collectively shall not exceed 85 dB(A) measured at a distance of 1.5 meters from the source in any direction. The overall vibration level shall be as per zones A and B of ISO 10816-1. Balance quality requirement shall be G 6.3 conforming to ISO 1940/1.

4.12 ELECTRIC MOTOR AND VFD DRIVE

Electric Motor and VFD Drive shall be as per the specifications given in this document (Electric Motor and VFD Drive).



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5.0 TECHNICAL DATA SHEET

5.1 DESIGN REQUIREMENTS OF THE CENTRIFUGAL FANS DESCRIPTION TYPE A

Supply Fan V2

TYPE B Exhaust Fan

E2 1. Type &characteristic SISW ,backward inclined

,aerofoil section blade , high efficiency limit load design

SISW ,backward inclined , aerofoil section blade , high efficiency limit load design

2 Capacity at std. air density and at 760 mm Hg. Barometric press. and 300C dry bulb temp.(CMH)

65,000 CMH 75,000 CMH

3 Static pressure (mm of WG) 200 300

4 Static pressure as per AMCA Classification

Class C/III Class C/III

5 Preferred operating speed 800 RPM 1000 RPM

6 Inlet vanes requirement Yes Yes

7 Inlet condition SISW SISW

8 Fan Capacity & pressure Controls

VFD control VFD control

9 Mechanical design suitability 1000 RPM 1200 RPM

10 Outlet velocity (m/min.) Not to exceed 915 m/min.

11 Flexible connection with counter flanges

Yes, As per specifications

12 Discharge type / direction of rotation

Upblast / to suit site conditions

13 Fan-motor connection Through V belt

14 Min construction class Class-IV Class-IV

15 Vibration level at bearings Less than 4.5 mm/sec

16 Nos. of fans required 14 12



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DESCRIPTION TYPE C

Exhaust Fan E2

1. Type & Characteristic SISW ,backward inclined , aerofoil section blade , high efficiency limit load design

2 Capacity at std. air density and at 760 mm Hg. Barometric press. and 300C dry bulb temp.(CMH)

75,000 CMH

3 Static pressure (mm of WG) 400

4 Static pressure as per AMCA Classification

Class C/III

5 Preferred operating speed 1000 RPM

6 Inlet vanes requirement Yes

7 Inlet condition SISW

8 Fan Capacity & pressure Controls

VFD control

9 Mechanical design suitability 1200 RPM

10 Outlet velocity (m/min.) Not to exceed 915 m/min.

11 Flexible connection with counter flanges

Yes, As per specifications

12 Discharge type / direction of rotation

Upblast / to suit site conditions

13 Fan-motor connection Through V belt

14 Min construction class Class-IV

15 Vibration level at bearings Less than 4.5 mm/sec

16 Nos. of fans required 2



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5.2 TECHNICAL DATA FOR ALL TYPES OF THE FANS

SL no.

ITEM DESCRIPTION

A DESIGN

1 Duty Conditions Continuous

2 Limiting Pedestal Dimensions(LxWxH)

To be furnished by bidder

3 Fluid handled Air at atmospheric condition

4 Type Single Width Single Inlet (SWSI)

5 Impeller / Blade Type Backward Curved Aerofoil, high efficiency limit load design

6 Static Efficiency (Min.) 80 % (Bidder to furnish the actual)

7 Bearings Type Self Aligned Roller sized for min. L10 Life of 100000 hours

8 Greasing method External through greasing nipple

9 Drive V-Belt Drive

10 Pulleys type V-Grooved – Split Hub

11 Vibration Levels measured on bearings

Shall not exceed 4.5 mm/s as measured on the bearing in radial and axial direction.

12 Noise Levels as measured @ 1.5m surrounding in semi-reverberant field

85 dB. Bidder to furnish the actual data.

13 Lifting Lugs / Casing Inspection door

Required

14 Inlet guide Vanes Required



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SL no.

ITEM DESCRIPTION

15 Drain valve 50 NB required

B MATERIALS OF CONSTRUCTION DESCRIPTION

1 Casing (Scroll) CS Fabricated with structural angle bracings (IS-2062 Gr-B), minimum thickness 6 mm.

2 Inlet Cone CS Spun Formed to smooth hyperbolic shape (IS-2062 Gr-B), mini. thick. 6 mm.

3 Impeller CS Fabricated (IS-2062 Gr-B)

4 Back plate CS (IS-2062 Gr-B), minimum thickness 12 mm.

5 Blades Die Formed CS (IS-2062 Gr-B), minimum thickness 3 mm.

6 Shroud CS Spun / die Formed (IS-2062 Gr-B) minimum thickness 6 mm.

7 Shaft

CS – EN8 / SAE -1045 , Minimum dia. at bearing 100 mm for type A&B and 110 mm for type C

8 Common base frame for fan & motor

CS formed or structural channel sections (IS-2062 Gr-B) , minimum thickness 6 mm.

9 Pedestal IS-2062 Gr-B , minimum thickness 6 mm.

10 Bolts & nut IS-1363 Gr. C

C MISCELLENOUS ITEMS & ACCESSORIES

1 Flexible Connector at fan inlet and outlet Required



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SL no.

ITEM DESCRIPTION

2 Minimum Length 300 mm with matching CS flanges

3 Companion flanges Required

4 Common Base Frame for fan & Drive

Required

5 Motor slide rails with locks Required

6 Anchor bolts Required

D SURFACE TREATMENT & PAINTING

1 Surface treatment Sand / shot blasting before painting

2 Primer Epoxy based red oxide primer two coats as

per approved procedure

3 Finish paint Epoxy based finished paint three coats as

per approved procedure

4 Shade To be confirmed with the department



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6.0 MOTOR & DRIVE SYSTEM 6.1 SCOPE OF SPECIFICATIONS : This specification covers design , construction, assembly, testing, inspection at manufacturer’s works, delivery at site of Energy efficient Squirrel cage Induction Motors suitable for centrifugal fans , associated VFD Drives with wired panels for Supply and Exhaust Fans of of project WMP, FRFCF, Kalpakkam. The items which are excluded from this contract are:- a. Installation and commissioning of the equipments. b. PLC and associated interlocks. c. All kinds of cabling at site. 6.2 CONTENTS OF THE DOCUMENTS :

Section A : MOTOR Section B : VFD DRIVE



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6.2.1 SECTION – A DRIVE MOTOR 6.2.1.1 SCOPE : This specification covers technical requirements for the design, manufacture , inspection , testing , packing for shipment and supply of energy efficient squirrel cage induction motors required as prime movers for Supply and Exhaust fans of ACVE system for project WMP, FRFCF, IGCAR , Kalpakkam as specified in this document. 6.2.1.2 APPLICABLE STANDARDS : Latest Version of following standards:

Sr no

Indian Standard / relevant standard

Description

1 IS – 12615 Energy efficient 3 phase squirrel cage induction motor.

2 IS – 325 Specifications for 3 phase Induction Motors. 3 IS – 1271 Thermal evaluation and classification of

electrical insulation.

4 IS- 4029 Guide of testing 3 phase induction motors. 5 IS – 12075 Specifications for limits of vibration of the

motors. 6 IS – 4800 Enameled copper winding wires.

7 IS – 12075 Specifications for limits of vibration of the

motors 8 IS – 12802 Temperature Rise Measurement of rotating

Electrical machines.

9 IS – 12824 CBIP Recommendation of Motors.

10 IS 4722-2001 Rotating Electrical Machines – Specification 11

IS 2253-1974 Designation for types of construction and mounting arrangement of rotating electrical machines

12 IS 4728-1975

Terminal markings & direction of rotation for rotating electrical machinery



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13 IS 6362-1995

Designation of methods of cooling of rotating electrical machines

14 IS 4691-1985

Degrees of protection provided by enclosure for rotating electrical machinery

15 IS 12075-1987

Measurement and evaluation of vibration of rotating electrical machines

16 IS 12065-1987

Permissible Limits of Noise Level for Rotating Electrical Machines

17 IS 7816-1975

Guide for Testing Insulation Resistance of Rotating Machines

18 IS12615-1989

Induction Motors- Energy Efficient, Three Phase, Squirrel Cage- Specification

19 IS 8789-1996

Values of Performance characteristics for Three – Phase Induction Motors

20 IS 1231-1974

Dimensions of Three-phase Foot-mounted Induction Motors

21 IS 12802-1989

Temperature Rise Measurement of Rotating Electrical Machines.

22 IS 12824-1989

Type of Duty and Classes of Rating Assigned to Rotating Electrical Machines

23 ISO 1940-1 – 2003

Mechanical Vibration – Balance Quality Requirements of Rigid Motors

6.2.1.3 DRIVEN EQUIPMENT

i) When this specification forms part of the driven equipment specification, information not given in the Data Sheet will be governed by the driven equipment specification.

ii) Motors shall be capable of satisfactory operation for the application and duty as specified in the motor Data Sheet and as specified for the driven equipment.

6.2.1.4 PERFORMANCE AND CHARACTERISTICS

i) Motors shall be capable of giving rated output without reduction in the expected life span when operated continuously under the supply conditions as specified in data sheet.

ii) Motors shall be suitable for the method of starting specified in the Data Sheet.

iii) The minimum permissible voltage shall be 85% of the rated voltage during motor starting.

iv) Motors shall be capable of starting and accelerating the load with the applicable method of starting, without winding temperatures reaching injurious levels, when the



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supply voltage is in the range of 85% of the rated motor voltage to maximum permissible voltage specified in Data Sheet.

v) The locked rotor current of the motor shall not exceed 600% of full load current (subject to tolerances as per the applicable standard).

vi) Motors shall be designed to withstand 120% of rated speed for two minutes without any mechanical damage, in either direction of rotation.

vii) Motors shall be capable of developing the rated full load torque even if the supply voltage drops to 70% of the rated voltage. If such operation is envisaged for a period of one second, the pull out torque of the motor shall be at least 205% of full load torque.

viii) Motors when started with the driven equipment coupled shall be capable of withstanding at least two successive starts from cold conditions & one start from hot condition without injurious heating of windings. The motors shall also be suitable for three equally spread starts per hour under the supply conditions indicated in data sheet.

6.2.1.5 SPECIFIC REQUIREMENTS OF VFD DRIVEN MOTORS

i) The motor shall be suitable for operation with a solid-state power supply consisting of an adjustable frequency inverter for speed control.

ii) The motor shall be suitable for the current waveforms produced by the power supply including the harmonics generated by the drive.

iii) The Motor shall be designed to operate continuously at any speed over the range 40-100 % of rated speed.

iv) The permitted voltage variation should take into account the steady state voltage drop across the VFD Drive and all other system components upstream of the motor.

v) Motors required to be transferred to DOL/Star-Delta, by-pass mode shall be rated for specified variations in system line voltage and frequency. Starting current of motor in DOL/Star-Delta, bypass mode shall be limited to 600% of full load current.

vi) The motor shall be constructed to withstand torque pulsations resulting from harmonics generated by the solid-state power supply.

vii) The motor insulation shall be designed to accept the applied voltage waveform, within the Vpeak and dv/dt limits as per IEC-61800.

viii) The driven equipment manufacturer shall be solely responsible for proper selection of the motor for the given load application and the output characteristics of the driven equipment.



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6.2.1.6 INSULATION

i) Any joints in the motor insulation such as at coil connections or between slot and end winding sections shall have strength equivalent to that of the slot sections of the coil.

ii) The insulation shall be given tropical and fungicidal treatment for successful operation of the motor in hot, humid and tropical climate.

6.2.1.7 CONSTRUCTIONAL FEATURES

i) The motor construction shall be suitable for easy disassembly and reassembly. The enclosure shall be sturdy and shall permit easy removal of any part of the motor for inspection and repairs.

ii) Motors weighing more than 25 kg. shall be provided with eyebolts, lugs or other means to facilitate safe lifting.

iii) The motor bars shall not be insulated in the slot portion between the iron core laminations and the bars.

iv) Unless otherwise approved, motors shall be designed to permit convenient access for drilling vertically through motor feet or mounting flange for installation of Department’s dowel pins after motors are mounted with the driven equipment.

v) When the motor is supplied with driven equipment including a common base (bed place, channels etc.). The BIDDER shall ensure that such bed plate is adequately braced to keep vibrations and misalignment within satisfactory limits.

vi) The motor name plate shall clearly indicate the type of enclosure, protection etc..as per IS:325.

vii) The motor shall be energy efficient type (EFF-2).

6.2.1.8 BEARINGS

i) Motor bearings shall not be subjected to any external thrust load.

ii) Motor bearings shall have an estimated life of at least 40,000 hrs.

iii) The bearings shall be so constructed that the loss of lubricating fluid is kept to a minimum and greasing shall be possible without any dismantling operation.

iv) When forced oil lubrication or water cooling is required, prior approval from the Department shall be obtained.

v) When forced oil lubrication or water cooling is required, the machine shall be suitable for starting & continuous operation for at least 10 minutes, without the availability of lubrication or cooling system.



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vi) If the bearings are oil lubricated, a drain plug shall be provided for draining residual oil & an oil level sight gauge shall be provided to show the precise oil level required for standstill and running conditions.

vii) Lubricants shall be selected for prolonged storage and normal use of the motors in tropical climate and shall contain corrosion and oxidation inhibitors. Grease shall have suitable bleeding characteristics to minimise setting.

6.2.1.9 TERMINAL BOX i) Terminal boxes shall be of same construction type as that of motor body construction

designed for outdoor service, to eliminate entry of dust and water. Gaskets of neoprene or approved equivalent shall be provided at cover joints and between box and motor frame.

ii) Terminal boxes shall have a degree of protection of at least IP 55.

iii) The terminal box shall be capable of being turned through 360° in steps of 90o.

iv) The terminals shall be of the stud type with necessary plain washers, spring washers and check-nuts. They shall be substantially designed for the current carrying capacity and shall ensure ample phase to phase and phase to ground clearances.

6.2.1.10 PAINT AND FINISH

i) All motor parts shall be finished and painted to produce a neat and durable surface which would prevent rusting and corrosion. The equipment shall be thoroughly degreased, all rust, sharp edges and scale removed and treated with one coat of primer and finished with two coats of grey enamel paint.

ii) The motor fan shall also be painted to withstand corrosion. iii) The motor paint shade should be as indicated in the data sheet.

6.2.1.11 HEATING DURING IDLE PERIODS

i) Motors rated 30 kW and above shall have space heaters suitable for 110V, single phase, 50 Hz, AC supply. Space heaters shall have adequate capacity to maintain motor internal temperature above dew point to prevent moisture condensation during idle period. The space heaters shall be placed in easily accessible positions in the lowest part of the motor frame.

6.2.1.12 INSPECTION AND TESTING OF MOTOR & VFD DRIVE a. The supplier shall perform all Acceptance and Routine Tests for all motors and Type

test for one motor of each rating as per latest version of IS – 325 & IS – 4029 in the



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presence of purchaser. These Test reports shall be submitted to the Purchaser before dispatch.

b. The supplier shall notify the purchaser the date and location for the tests giving

sufficient time for the purchaser or his authorized representative to be present. The test procedure shall be approved by the purchaser.

c. Integrated testing incorporating motor, VFD drives and fans at supplier’s works to

ascertain intent specification. d. The equipment covered by this Contract shall be subjected to inspection and testing.

The BIDDER shall provide all services to establish and maintain quality of workmanship in his works and that of his SUB-BIDDERS to ensure the mechanical/electrical performance of components, compliance with drawings, identification and acceptability of all materials, parts and equipment.

e. On award of the Contract, the BIDDER shall prepare Quality Control Plan identifying

the various stages of manufacture, quality checks performed at each stage and the DEPARTMENT hold points. The document shall also furnish details of method of checking, inspection and acceptance standards/values and get the approval of DEPARTMENT or his representative before proceeding with manufacturing. DEPARTMENT or his representative shall have the right to review the inspection reports, quality checks and results of BIDDER's in house inspection department which are not DEPARTMENT hold points and the BIDDER shall comply with the remarks made by DEPARTMENT or his representative on such reviews with regards to further testing, rectification or rejection etc.

f. The BIDDER shall perform his internal inspection/testing before offering the

equipment for DEPARTMENT’s inspection. Only after ensuring that his inspection/test results are satisfactory, BIDDER shall offer the equipment for DEPARTMENT's inspection. However this clause is not applicable in case of such tests which are required to be done only once in the lifetime of the equipment.

g. The minimum inspection requirements for all components/equipment shall confirm to

the design and fabrication requirements as defined in the Codes and Standards referred to in the Specification document. The type of inspection shall be as prescribed in Quality Control plan and as agreed upon by the DEPARTMENT, and shall include, if applicable, inspection procedures prescribed by Codes and Regulations recognised by the Governmental Authority having jurisdiction over the installed goods. Static and dynamic testing of control system in shop shall be done in the presence of DEPARTMENT/CONSULTANT’s representatives. BIDDER shall submit the test procedures. BIDDER shall however take total responsibility of the integrated system at site and any short falls/defects shall be rectified.

h. Wherever required, getting approval of Government bodies under jurisdiction is the

sole responsibility of BIDDER for his design, drawings, manufacturing, testing and inspection by such bodies. In such cases approval by Government bodies under



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jurisdiction will not relieve the BIDDER from his responsibility of making good of defective material/equipment/system. However, BIDDER shall keep the DEPARTMENT/his representatives informed in writing of any approval or otherwise any comments of such Government bodies. BIDDER shall take the concurrence of DEPARTMENT or his representative before proceeding with rectification procedures as called by the Government bodies.

i. Approval or passing of any such inspection by the DEPARTMENT or his

authorised representative shall not, however, prejudice the right of the DEPARTMENT to reject the equipment if it does not comply with the specification when erected or give complete satisfaction in service.

j. The BIDDER shall intimate to the DEPARTMENT of any material being ready for

testing. Such tests shall be to the BIDDER's account except for the DEPARTMENT’s expenses to witness the tests. The DEPARTMENT or his representative, unless the inspection of the tests is virtually waived, shall attend such tests.

k. The DEPARTMENT shall give notice in writing to the BIDDER of any objection to

any drawings and, all or any equipment and workmanship which in his opinion is not in accordance with the 'Contract'. The BIDDER shall give due consideration to such objections and shall either make the modifications that may be necessary to meet the said objections or shall confirm in writing to the DEPARTMENT giving reasons therein that no modifications are necessary to comply with the 'Contract'. However, DEPARTMENT has the final authority to accept or reject the BIDDER's views. The equipment/material after rectification by the BIDDER shall be offered to the DEPARTMENT for his final inspection and acceptance without any additional cost to DEPARTMENT.

l. When the factory tests have been completed to the satisfaction of the

DEPARTMENT, the DEPARTMENT shall issue a certificate to this effect within fifteen (15) days after completion of tests, but if the tests are not witnessed by the DEPARTMENT's representative, the certificate shall be issued within fifteen (15) days of the receipt of the BIDDER's test certificate by the DEPARTMENT provided the test results are satisfactory and confirm to the specified parameters. Failure of DEPARTMENT to issue such certificate shall not prevent the BIDDER from proceeding with the subsequent work. The completion of these tests or the issue of the certificate shall not bind the DEPARTMENT to accept the equipment should it, on further tests after erection, be found not to comply with the 'Contract'.

m. In all cases where the 'Contract' provides for tests whether at the premises or Works

of the BIDDER or of any SUB-BIDDER, the BIDDER, except where otherwise specified shall provide free of charge such items as labour, materials, electricity, fuel, water, stores, apparatus and instruments as may be reasonably demanded by the DEPARTMENT or his authorised representative to carry out effectively, such tests and shall give also facilities to the DEPARTMENT or to his authorised representative to accomplish testing.



FRWMD of 50

n. The inspection by the DEPARTMENT and issue of Inspection Certificate thereon

shall in no way limit the liabilities and responsibilities of the BIDDER in respect of agreed quality assurance programme forming a part of the 'Contract'.

o. In the case of stage inspection, the BIDDER shall proceed from one stage to another

only after the component is inspected by the DEPARTMENT or his representative and permission given to proceed further. The same procedure shall be adopted for any rectifications / repairs suggested by the DEPARTMENT or his representative. At all Customer hold points the BIDDER shall compulsorily offer for inspection to DEPARTMENT and, if any waiver by DEPARTMENT, shall be obtained in writing for record purposes.

p. None of the equipment to be furnished or used in connection with the Contract shall be despatched until shop inspection, satisfactory to the DEPARTMENT or his representative has been made and specific Despatch Instructions for the equipment is issued by the DEPARTMENT. However, such shop inspection shall not relieve the BIDDER of his responsibility for furnishing the equipment confirming to the requirement of the Contract nor prejudice any claim, right or privilege which the DEPARTMENT or his representative may have because of the use of defective or unsatisfactory items of the equipment. Should the DEPARTMENT or his representative waive the right to inspect any item of the equipment, such waiver shall not relieve the BIDDER in any way from his obligation under the Contract. In the event of inspection revealing poor quality of goods, the DEPARTMENT or his representative shall be at liberty to specify additional inspection procedures, if required, to ascertain the BIDDER's compliance with the equipment Specifications.

q. All principal mill test reports, test certificates and test curves shall be supplied for all

tests carried out including other records such as stress relieving charts, radiographic charts and other non-destructive testing records. The DEPARTMENT or his representative shall reserve the right to call for certificates of origin and test certificates for all raw material and equipment at any stage of manufacture.

r. Motor shall be subjected to all the routine tests as per applicable standard in the

presence of the DEPARTMENT’S representative. Copies of test certificates of type and routine tests shall be furnished as specified in the distribution schedule, for the DEPARTMENT'S approval. The BIDDER shall ensure to use calibrated test equipment/instruments having valid calibration test certificates from standard laboratories traceable to national / international standards.

6.2.2 SUB-ORDERS

a) To ensure good quality product from SUB-BIDDER, the main BIDDER shall obtain DEPARTMENT’s prior approval before engaging the SUB-BIDDER. For this purpose, BIDDER shall furnish details of SUB-BIDDER such as his capability,



FRWMD of 50

experience, manpower, manufacturing facility, quality control facilities etc. The DEPARTMENT may visit the SUB-BIDDER's works to evaluate their capacity and capability to do quality job to meet specification requirements. The sub-orders should highlight the inspection and quality control requirements stipulated in the main Specification and all required quality checks and tests shall be conducted as per the Specification.

b) In order to facilitate the inspection of bought-out materials and equipment, the BIDDER shall submit for approval, three (3) copies of all sub-orders placed by him as soon as they are issued. Copies of any drawings referred to in the sub-order shall also be submitted, unless otherwise agreed by the DEPARTMENT or his representative.

c) The sub-orders and drawings referred to above shall cover all components which are subjected to electrical and mechanical pressure or stress when the plant is in operation, and also auxiliaries and spares which are to be directly despatched to Site from the SUB- BIDDER’s Works.

d) All sub-orders shall clearly be marked with the main BIDDER’s name and the DEPARTMENT's reference. They shall include a statement advising the SUB-BIDDER that items being ordered will also be subject to inspection and test by the DEPARTMENT or his representative

e) It is important that all copies of sub-orders be clearly marked with the main BIDDER's name and the name of the DEPARTMENT and 'Contract' reference.

f) The SUB-BIDDERS are to comply with all the applicable requirements of this Specification and in particular with this Section. Orders issued by the SUB- BIDDER are also to include the main BIDDER’s name on their sub-order in addition to the above mentioned heading.

6.2.1.13 TECHNICAL DATA SHEET

The following motor data sheet is the general data sheet for all the drive motors of the equipment covered in this appendix and elsewhere in this tender document. BIDDER shall furnish the following data sheet for all motors considered for each loads.

SR.NO DESCRIPTION UNIT SPECIFICATION REQUIREMENT

1.0 Application

ACV application - Drive motors

2.0 Motor tag no. / corresponding load Tag no. *

3.0 Number of units As required

4.0 Type of motor

Squirrel cage



FRWMD of 50


5.0 Supply system fault level kA 415V-50kA

6.0 Supply neutral

415V Solidly grounded

7.0 Rated output: KW *

8.0 Load factor *

9.0 Rated voltage V 415V

10.0 Number of phases & frequency 3PH, 50HZ

11.0 Allowable variations in supply Conditions

Voltage % + 10

Frequency % + 5

Combined % +10

12.0 Efficiency % *

13.0 Rated power factor *

14.0 Power factor during starting *

15.0 Current *

Full load

Amps

*

Starting

% FL

*

16.0 Synchronous speed RPM

*

17.0 Type of duty(clause 10.2 of IS 325 or cl 9.3 of IS 4722) CONTINUOUS

18.0 Duty designation (clause 10.3 of IS 325 or cl 9.3 of IS 4722)

S1 / as per requirement

19.0 Cyclic duration factor Not applicable

20.0 Cycles per hour Not applicable

21.0 Moment of inertia Kg-m2

*

22.0 Controlled by VFD YES/ NO

Yes

23.0 Method of starting (By pass <= 15kW DOL, >15



FRWMD of 50


starters) in case of VFD failure kW Star delta

24.0 Starting torque *

25.0 Pull out torque *

26.0 Class of insulation

Class F with temperature rise Limited to Class B

27.0 Ref ambient temperature 45 0C

28.0 Temperature rise by theromometer/wdg res

*

29.0 Location Indoor

30.0 Atmosphere Dusty

31.0 Type of cooling (IS:6362) TEFC

32.0 Designation for degree of protection (IS:4691) IP55

33.0 Terminal box

A) Location as seen from non- drive end

B) Rating short time

Current

Duration

Dynamic

KA (RMS)

SEC KA (PEAK)

Right/Left * 415V-50kA 1 415V-105kA

34.0 External cable details

A) Type

B) Number of cores

C) Size:

D) Whether flameproof cable gland by vendor

YES/ NO

XLPE insulated, Armoured, FRLS PVC sheathed, 3C Will be Furnished later No

35.0 Grounding conductors

A) Material

B) Size

Tinned stranded copper condcutor Refer Table-2



FRWMD of 50


36.0 Shaft orientation

Horizontal/Vertical/Hollow vertical *

37.0 Mounting symbol

(IS :2253 or equivalent) *

38.0 Type of coupling

Direct flexible/Gear/Belt*

39.0 Whether half coupling required Yes/No*

40.0 Rotation as seen from non-driven end

Clockwise/anticlockwise*

41.0 Bearing

Make *

Type of Bearing

Drive end *

Non drive end *

42.0 Whether bed plate required Yes

43.0 Whether rail required YES/NO*

44.0 Colour shades of plant if special

RAL 7032 Siemens Grey

45.0 Space heaters for motors required

Yes, for motors rating 30kW & above

46.0

Normal winding connection

Star /

Delta

*

47.0 Permissible no. of starts *

48.0 Hot thermal withstand time at 110% of the rated voltage.

Sec *

49.0 Starting time at 80% of the rated voltage.

Sec *



FRWMD of 50


50.0 Thermal characteristics, starting characteristics and negative sequence characteristics to be furnished

*

51.0 Motor reactance *

Sub-transient reactance pu *

Transient reactance pu *

Steady state reactance pu *

52.0 Guaranteed losses *

Iron loss kW *

Copper loss kW *

Friction, Windage & Stray losses. kW *

53.0 Weights and Dimensions *

54.0 Max. value of induced shaft voltage

mV *

NOTES: Data marked thus (*) will be decided and intimated by the bidder.



FRWMD of 50

6.2.1.14 SPECIAL REQUIREMENT :

(iii) Drive Motor

Drive motor shall be rated at least 15 % higher than the power requirement at duty point or 10 % higher than the maximum power requirement at selected speed, whichever is higher. Starting torque requirements of fan shall also be considered while selecting the motor.

(iv) Noise and Vibration

Noise level produced by any rotating equipment individually or collectively shall not exceed 85 dB(A) measured at a distance of 1.5 meters from the source in any direction. The overall vibration level shall be as per zones A and B of ISO 10816-1. Balance quality requirement shall be G 6.3 conforming to ISO 1940/1.

Rating of motors are indicative. Selection of motor and drive commensurate to fan characteristics is the responsibility of the vendor. The selection methodology and final selection are subject to approval from the department. For detailed specifications of motors attached annexure may please be referred.

Electric motor make

Kirloskar, Bharat Bijali , Crompton Greaves , ABB or equivalent

*****************************



FRWMD of 50

6.2.2 SECTION – B VFD DRIVES

6.2.2.1 SCOPE OF WORKS :

Design , Construction , assembly , testing and inspection at manufacturer’s works, delivery at centrifugal fans manufactures work site and testing with the motor and centrifugal fans for the performance of Variable Voltage and Variable Frequency VFD Drives required for speed control of 3 phase squirrel cage induction motors for Supply and Exhaust Fans in order to control the flow based on static pressure of air plenum required by the system for Project-WMF,FRFCF, Kalpakkam. (Tamilnadu)

6.2.2.2 FUNCTIONAL REQUIREMENTS :

VFD Drives selected should meet the following functional requirements.

a) Automatic Regulation of the flow , based on air plenum static pressure by controlling Fan’s speed through PID.

b) The range of static pressure variation for the fans and plenums static pressure which are to be controlled as given in technical specifications of fans of ACVE system. Air Plenum Static Pressure will be sensed by Electronic Smart , 2 wire Pressure Transmitter giving 4-20mA output to PID Controller and from PID Controller to VFD Drive. The VFD Drive shall be capable to operate the fans up to 100% of fans rated capacity by increasing the speed of the fans if need arises. It should also be able to operate as low as 60% of the rated capacity of the fans. Typical Drive & Motor connection schematic is attached for reference. It shall have in built self fault diagonstic features and based on which it shall have auto sequential start.

6.2.2.3 GENERAL

This part of the specification describes the general requirements for the Variable Speed Drives, herein referred to as VFD Drives, for use with standard IEC or [NEMA A] [NEMA B] [NEMA D] [NEMA E], [Wound Rotor] design AC motors.



FRWMD of 50

The nominal values, the standard documents and the drive’s minimum performance are defined in this part. The VFD Drive does not include motor in this specification.

The Variable Speed Drives (here in this document named by “VFD Drive “ ) are particularly dedicated for applications managing air. Most of applications as area ventilation through air supply and exhaust fans application. To avoid any mismatch between the motor and its control equipment, the VFD Drive shall be capable of auto adjustment by automatic measurement of the motor parameters without motor rotation.

6.2.2.4 REQUIREMENTS FOR THE MANUFACTURER CERTIFICATIONS

The VFD Drive Manufacturer shall have a valid ISO 9001 (2010 version) certification and an applicable quality assurance system. The VFD Drive Manufacturer shall have the Environment Certification ISO 14001 for EcoDesign. The VFD Drive Manufacturer shall design the device with more than 70% of recyclability rate. The VFD Drive Manufacturer shall design the device according to the IEC 62635 guidelines to reduce the carbon footprint.

6.2.2.5 BASIC REQUIREMENTS FOR THE VFD DRIVES

a. General requirements

The VFD Drive shall comply with National and International standards and the recommendations for electrical industrial control.

VFD Drive make Schneider, Siemens or equivalent

The VFD Drive shall be a digitally controlled drive, using, at least, the Pulse Width Modulation (PWM) with flux vector control open loop, with speed control mode, and a safety function .It shall have IGBT’s in the inverter section of the throughout the power range, and it shall have the following minimum specifications.

General specification for standard VFD Drives system low harmonics:



FRWMD of 50

Rated Input Voltage and Power range

Three-phase supply 415V +/-10%

Rated Input Frequency 50 Hz +/- 5% Protection degree IP23 ,IP42 and NEMA/UL type 1

Cooling system Heat sink Harmonics according to IEEE519

Harmonics <5% THDi

Mechanical dimensions( W X D X H in mm) .

To be furnished by the vendor.

b. Operating conditions:

Harmonics mitigation at 80 % of the load up to 100% according to IEEE519

Below 5 % of THDi for low harmonic drives or low harmonic drive systems

Displacement Factor 0.97 or better at nominal load Efficiency 96 % at nominal load for low

harmonic drives

Output Voltage 0 - UN, three-phase Acceleration/Deceleration Time Adjustable duration, linear

ramp, or customised profile. Overload capability

110% of nominal current for 1min .

Main Protections Over current, short circuit between output phases, short circuit between output phases and ground, input phase loss, output phase loss, motor overload, overvoltage, under voltage, over speed, IGBT over temperature, heat sink over temperature

Possible independent supply of control module +24 V dc Short circuit rating 50 kA on standard product

- The VFD Drive shall be able to give a 100 % output current continuously in the

above specified conditions. In order to ensure that the drive can provide the required



FRWMD of 50

output current in the specified ambient conditions, the Manufacturer shall inform the required derating, if the ambient temperature given in the project specification is higher than 50 °C or if the installation altitude is more than 1000 m above the sea level. The derating factor shall be specified so that neither the lifetime of the VFD Drive nor the unit’s performance, overload capability included, nor the reliability of the VFD Drive shall suffer.

6.2.2.6 VFD DRIVE PERFORMANCE

- The VFD Drive shall provide a speed range in the motor quadrant 1:100 in sensor

less vector control. - The VFD Drive shall provide an over torque capability better than 110% of the rated

motor torque during 60s in normal duty mode each 10 minutes. - The VFD Drive shall provide a speed accuracy 10% of the nominal slip of the

motor in sensor less vector control - The VFD Drive shall provide a torque control accuracy 15% in sensor less vector

control for AC motors

6.2.2.7 PROTECTIONS.

- The VFD Drive shall not create a hazard in the event of a short circuit at any point

within the VFD Drive when it is connected to a power source . - Upon power-up the VFD Drive shall automatically test for valid operation of

memory, option module, loss of analogue reference input, loss of communication, DC to DC power supply, control power and the pre-charge circuit.

- The Power Converter shall be protected against short circuits, between output phases

and ground and the logic and analogue outputs.

- The VFD Drive shall have solid state thermal protection. - The VFD Drive should be able to limit the motor surge ( I dv/dt ) at twice the DC bus

voltage - The VFD Drive shall display all faults in plain text and help screens shall be available

to guide the user in the troubleshooting. - The VFD Drive shall display errors with QR codes to guide the user in the

troubleshooting.

6.2.2.8 ENVIRONMENTAL COMPLIANCE



FRWMD of 50

- The materials used in the VFD Drive shall be recyclable, non-toxic and flame retardant.

6.2.2.9 ENCLOSURE AND MOUNTING

a. Enclosure design specs: - Standards : IEC 60439-1, CEI 60439, VDE 0660-500. - Cabinet access : From front - Cable entry and exit : FROM TOP/ BOTTOM b. Standard equipment of the enclosure - Switches and fuses - Graphic display terminal IP65 on front face of enclosure - Terminal mounting kit IP65. - Graphic display terminal of the VFD Drive shall be accessible for programming and

controls with the main door closed. - The whole assembly shall be implemented with a strict consideration of the EMC

Compatibility and Regulations as described further in this specification. - Total harmonics distortion shall comply with IEEE 519.

6.2.2.10 USER INTERFACE

a. General The user interface shall be identical throughout the power range to avoid confusion amongst the users and need for training in several different units. b. Inputs and outputs

At least, the following standard Inputs and Outputs shall be provided, to be used in interface with the control system:

Analogue Inputs: - 3 x Programmable current input 0(4) - 20mA or 0 – 10V - 2 of analogue inputs may be used either with PTC,PT100, PT1000 and KTY84.

Analogue Output: - 2 x Programmables analogues outputs 0 (4) - 20mA or 0–10V



FRWMD of 50

Logic inputs: - 6 x Programmable logic Inputs isolated from the mains - In accordance with IEC 61131-2 - All logic inputs may be used either in sink or source - Two logic inputs may be used as pulse inputs up to 30 kHz. Safety input: - Two input are dedicated to the STO Safe Torque Off safety function - In accordance with IEC/EN 61508-1SIL3. Relay Outputs: - 3x Programmable Digital outputs with a changeover dry contact - In accordance with IEC 61131-2. - One output is dedicated to product watch-dog. c. It shall be possible to extend the number of inputs / outputs of the VFD Drive up to : - 12 logic inputs - 5analogue inputs - 2analogue outputs - 1 logic outputs (open collector) - 6 relays 6.2.2.11 COMMUNICATIONS: a. The VFD Drive shall provide as standard one embedded Modbus port and one

embedded Ethernet Modbus TCP port. b. The VFD Drive shall have the capability to welcome additional communication card. - Profibus DP V2, 1 port, SUB-D9. - Profinet , 1 port , RJ45. - Ethernet IP / modbus TCP, 2 ports, RJ45. Dual port for daisy chain - The VFD Drive behaviour shall remain programmable even during communication

error. c. Graphic display terminal - The VFD Drive shall provide a detachable graphic display terminal 6.2.2.12 MAN MACHINE INTERFACE



FRWMD of 50

- A “Simply Start “menu for fast and easy commissioning should be provided and

parameter setting shall be easily accessible and user friendly with actual text messages and actual setting range.

- The VFD Drive shall provide a password protection to avoid unauthorized tampering with the set parameters

6.2.2.13 DATA TRANSFER

a. The VFD Drive shall provide Ethernet connectivity load the firmware of the VFD

Drives to save time for fast replacement. b. The programming terminal shall offer the possibility to display QR code for

diagnostic, maintenance and application tracking. d. The user shall be able to customize the man –machine interface:

e. The programming terminal shall be able to display a chart relative to energy

efficiency and energy management.

- Report in KW - Daily, weekly, monthly Report - Trend base on variation /time - All measurement precision must be below 5 % of deviation.

f. The VFD Drive shall have self-diagnostic capabilities to display errors and warnings

as they occur and be able to store at least 15 last errors into the error memory including.

6.2.2.14 ENVIRONMENTAL EFFECTS

a. Harmonic Distortion

Note to specifier : Guidelines for voltage and current distortion are addressed in IEEE Standard 519-1992 titled "IEEE Recommended Practices and Requirements for Harmonic Control in Electrical Power Systems", which suggests distortion limits dependent upon the electric power distribution system for industrial and commercial consumers. Collectively, all facility loads and the building electrical distribution network determines the harmonic levels at the user & electric utility interface. The VFD Drives manufacturer can provide calculations through computer modelling, specific to the installation, showing total harmonic voltage distortion.

b. Harmonic distortion analysis shall be performed. The documentation shall consist of

one-line diagrams, distribution transformer information (kVA, %Z, and X/R ratio) and emergency standby generator performance specifications. The harmonic



FRWMD of 50

distortion analysis report shall be part of the approval drawing process, submitted to the engineer for approval.

c. If the calculations determine that harmonic distortion values are higher than the

voltage and current values specified, the drive manufacturer shall provide solutions to comply with: IEEE 519-1992 guidelines

d. The supplied VFD Drive shall have built-in EMC filters and carry the CE marking

indicating that they comply with the essential requirements of the relevant EU directives. The VFD Drives shall meet the requirements set in EN 61800-3 for Industrial Low-Voltage Networks.

7 INSPECTION AND TESTING 7.1 GENERAL: (i) The equipment covered by this Contract shall be subjected to inspection and testing.

The BIDDER shall provide all services to establish and maintain quality of workmanship in his works and that of his SUB-BIDDERS to ensure the mechanical/electrical performance of components, compliance with drawings, identification and acceptability of all materials, parts and equipment.

(ii) On award of the Contract, the BIDDER shall prepare Quality Control

Plan(QAP) identifying the various stages of manufacture, quality checks performed at each stage and the DEPARTMENT hold points. The document shall also furnish details of method of checking, inspection and acceptance standards/values and get the approval of DEPARTMENT or his representative before proceeding with manufacturing. DEPARTMENT or his representative shall have the right to review the inspection reports, quality checks and results of BIDDER's in house inspection department which are not DEPARTMENT hold points and the BIDDER shall comply with the remarks made by DEPARTMENT or his representative on such reviews with regards to further testing, rectification or rejection etc.

(iii) The BIDDER shall perform his internal inspection/testing before offering the

equipment for DEPARTMENT’s inspection. Only after ensuring that his inspection/test results are satisfactory, BIDDER shall offer the equipment for DEPARTMENT's inspection. However this clause is not applicable in case of such tests which are required to be done only once in the lifetime of the equipment.

(iv) The minimum inspection requirements for all components/equipment shall confirm to

the design and fabrication requirements as defined in the Codes and Standards referred to in the Specification document. The type of inspection shall be as prescribed in Quality Control plan and as agreed upon by the DEPARTMENT, and shall include, if applicable, inspection procedures prescribed by Codes and



FRWMD of 50

Regulations recognised by the Governmental Authority having jurisdiction over the installed goods. Static and dynamic testing of control system in shop shall be done in the presence of DEPARTMENT’s representatives. BIDDER shall submit the test procedures. BIDDER shall however take total responsibility of the integrated system at site and any short falls/defects shall be rectified.

(v) The BIDDER shall intimate to the DEPARTMENT of any material being ready for testing. Such tests shall be to the BIDDER's account except for the DEPARTMENT’s expenses to witness the tests. The DEPARTMENT or his representative, unless the inspection of the tests is virtually waived, shall attend such tests.

(vi) The DEPARTMENT shall give notice in writing to the BIDDER of any objection to

any drawings and, all or any equipment and workmanship which in his opinion is not in accordance with the 'Contract'. The BIDDER shall give due consideration to such objections and shall either make the modifications that may be necessary to meet the said objections or shall confirm in writing to the DEPARTMENT giving reasons therein that no modifications are necessary to comply with the 'Contract'. However, DEPARTMENT has the final authority to accept or reject the BIDDER's views. The equipment/material after rectification by the BIDDER shall be offered to the DEPARTMENT for his final inspection and acceptance without any additional cost to DEPARTMENT.

(vii) When the factory tests have been completed to the satisfaction of the

DEPARTMENT, the DEPARTMENT shall issue a certificate to this effect within fifteen (15) days after completion of tests, but if the tests are not witnessed by the DEPARTMENT's representative, the certificate shall be issued within fifteen (15) days of the receipt of the BIDDER's test certificate by the DEPARTMENT provided the test results are satisfactory and confirm to the specified parameters. Failure of DEPARTMENT to issue such certificate shall not prevent the BIDDER from proceeding with the subsequent work. The completion of these tests or the issue of the certificate shall not bind the DEPARTMENT to accept the equipment should it, on further tests after erection, be found not to comply with the 'Contract'.

(viii) In all cases where the 'Contract' provides for tests whether at the premises or Works of

the BIDDER or of any SUB-BIDDER, the BIDDER, except where otherwise specified shall provide free of charge such items as labour, materials, electricity, fuel, water, stores, apparatus and instruments as may be reasonably demanded by the DEPARTMENT or his authorised representative to carry out effectively, such tests and shall give also facilities to the DEPARTMENT or to his authorised representative to accomplish testing.

(ix) The inspection by the DEPARTMENT and issue of Inspection Certificate thereon

shall in no way limit the liabilities and responsibilities of the BIDDER in respect of agreed quality assurance programme forming a part of the 'Contract'.



FRWMD of 50

(x) In the case of stage inspection, the BIDDER shall proceed from one stage to another only after the component is inspected by the DEPARTMENT or his representative and permission given to proceed further. The same procedure shall be adopted for any rectifications / repairs suggested by the DEPARTMENT or his representative. At all Customer hold points the BIDDER shall compulsorily offer for inspection to DEPARTMENT and, if any waiver by DEPARTMENT, shall be obtained in writing for record purposes.

(xi) None of the equipment to be furnished or used in connection with the Contract shall be despatched until shop inspection, satisfactory to the DEPARTMENT or his representative has been made and specific Despatch Instructions for the equipment is issued by the DEPARTMENT. However, such shop inspection shall not relieve the BIDDER of his responsibility for furnishing the equipment confirming to the requirement of the Contract nor prejudice any claim, right or privilege which the DEPARTMENT or his representative may have because of the use of defective or unsatisfactory items of the equipment. Should the DEPARTMENT or his representative waive the right to inspect any item of the equipment, such waiver shall not relieve the BIDDER in any way from his obligation under the Contract. In the event of inspection revealing poor quality of goods, the DEPARTMENT or his representative shall be at liberty to specify additional inspection procedures, if required, to ascertain the BIDDER's compliance with the equipment Specifications.

(xii) All principal mill test reports, material test reports, test certificates and test curves

shall be supplied for all tests carried out including other records such as stress relieving charts, radiographic charts , UT test and other non-destructive testing records. The DEPARTMENT or his representative shall reserve the right to call for certificates of origin and test certificates for all raw material and equipment at any stage of manufacture.

7.2 STAGE INSPECTION:

The fans shall be subjected to inspection to cover dimensional accuracy material used, workmanship, make and quality of bought out items. The supplier shall furnish the relevant test certificates on bought out items. The following stage inspections shall be carried out at suppliers shop.

1. Material test ( steel sheets ) 2. D.P. testing of all weldments of casing and impellers. 3. Visual testing and D.P. testing of all machined surfaces 4. UT test of shaft 5. Dimensional check 6. Dynamic balancing of the impellers with the fan shaft and pulley 7. Surface finish , painting and powder coatings of the surfaces 8. Dynamic balancing of motor pulley.



FRWMD of 50

9. Performance testing 10. Stage inspection of Motor and VFD drives

7.3 INSPECTION OF BROUGHT OUT ITEMS:

All brought items shall be inspected and test certificates shall be produced for verification to the purchaser. Items included are Pulley , V belt , vibration isolators , bearings , bearing blocks, flexible connections etc.

7.4 Mechanical Run Testing This test shall be carried out on each and every unit at manufacturer’s work to examine vibration & noise, bearing temperature rise rate and maximum bearing temperature after assembly. Each fan will be run for atleast Six hours and vibration , noise and bearing temperature rise shall be measured. Bearing temperature rise should no exceed the allowable limits. The amplitude of vibration shall be measured with strobes at various locations on the fans. The maximum severity of vibrations should not exceed fairness limit and shall lie close to good limit as per the chart. The vibration level shall be as per VDI 2056. Background level of noise (in dB) & noise level with fan in operation shall be recorded to determine the noise level of the fan. Sound ratings for the fan , based on the data obtained in accordance with AMCA 300 and reported in accordance with AMCA 301 shall be furnished . Each fan unit shall be run for an hour to check whether any rotating parts fouls with the stationary parts. The fan shall then be stopped and all fasteners shall be checked .The fan shall then be run for Six hours during which the motor bearing temperature motor current, supply voltage frequency shall also be monitored. At the end of this the various alignment shall be checked.

7.5 Performance Testing

The performance test shall be carried out on each and every fan conforming to AMCA-210 codes. This test shall be essentially to draw up the fan characteristics, which will then compared with those specified . The duration of test shall be sufficient to demonstrate that the Fans are in first class operating condition. The test results shall be submitted to purchaser for his verification and comments. Test setup drawing along with procedures shall be got approved from purchaser.



FRWMD of 50

7.6 Leak Testing (Soap Bubble test)

The fans shall be tested for leakage after complete assembly of units. This test shall consist of blanking the ends of the fans casing, pressurizing the interior to 1.5 times the maximum static pressure of the fan. All joints will be tested with an approved leak detecting soap solution.

7.7 Shaft seal Testing : Leakage through the shaft seal shall be tested as per the latest code and

standards. Leakage should be well with in the specified limits. Test procedure shall be got approved from the purchaser.

7.8 VFD TESTING :

a. All tests necessary to assure conformity with technical specifications for VFD Drives shall be carried out.

b. The supplier shall perform Acceptance and Routine Tests for all VFD Drives as per

relevant standards. These Test reports and available Type test reports shall be submitted to the Purchaser before dispatch of the Drives.

c. VFD Drives shall be subjected to following tests : - High Voltage Test without Semiconductor Devices. - Insulation Test - Electrical Control , Interlock and Sequential Operation Tests - Heat Run Test d. The supplier shall notify the purchaser the date and location for the tests giving

sufficient time for the purchaser or his authorized representative to be present. The test procedure shall be approved by the purchaser.

e. Integrated testing :

The VFD drive shall be tested along with the motor and fan operating at full range of speeds at suppliers work . The data for the pressure and flow rate shall be taken at various speed percentage of the fan and same data should be plotted on the graph to get the characteristics of the fan at different speeds . The procedure shall be repeated for at least five times for each fans in order to get correct fan characteristics curve . Each and every fan shall be tested with VFD drive for its performance and smooth operation . Supplier shall arrange necessary instrumentation and hardware for the above test at workshop before the dispatch



FRWMD of 50

of the fans to the site. Schematic of integrated VFD, motor & fan testing shall be got approved from the purchaser.

7.9 DOCUMENTATION OF TESTING

A report giving a description and results of qualification tests shall be furnished

to the purchaser . The report shall include all calculations , a description of any analytical or mathematical modeling techniques, a description of any computer code used , or other tests made in conjunction with the certification or qualification of the fan or fan assembly.

8.1 DRAWINGS :

a. All drawings submitted by the vendor including those submitted at the time of bid shall be in sufficient detail to indicate the Power circuit scheme , control block diagram, type , size, cabinet general arrangement with dimensions , bill of materials of components, self diagonostic features, weight of each unit , packing and shipment , installation plan and any other information specially requested.

b. After the award of the contract , the vendor shall submit copies of design calculations

, material specifications and detailed drawings as called for in the equipment specification for the purchaser’s review. The vendor must satisfy the purchaser as to the validity of his design with reference to the requirements as per specifications.

c. Drawings prepared by the vendor and approved by the purchaser shall be considered

as a part of the specification. However examination and approval of the drawings by the purchaser shall not relieve the vendor of his responsibility for engineering , design, workmanship and material under the contract.

d. If at any time before the completion of the work, changes are made necessitating

revision of approved drawings, the vendor shall make such revisions and proceed in the same routine as for the original approval.

e. Drawings shall include all installation and detailed mounting drawings in latest

AutoCAD version. 8.2 SPARES FOR FAN:

Supplier will also supply the spares for the different types of fans as listed in bill of quantities of spares.

9 INSTRUCTION MANUALS :

The vendor shall submit to the purchaser preliminary instruction manuals for all the Drives covered under the contract one month before the inspection of equipment.



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The final instruction manuals complete in all respect shall be submitted by the first shipment of the equipment. The instruction manual shall contain detailed circuit diagram, component rating, trouble shooting flow charts, erection procedure , testing procedure , O & M procedures of the equipment. If after the commissioning and initial operation of the equipment, the instruction manuals require any modifications / additions / changes, the same shall be incorporated and the updated final instruction manual shall be submitted by the vendor to the purchaser.

10 PACKAGING :

a. VFD Drive panels shall be protected for ocean shipment , inland transport, carriage

at the site and out door storage transit at the site.

b. Supplier shall be responsible for any damage during transit due to improper and inadequate packing.

c. Only packages constructed out of suitable material and of dimensions proportional to the size and wt. Of contents shall be used.

d. All items shall be protected for the entire period of dispatch, storage and erection, against corrosion, incidental damage, due to vermin, sun light, rain , high temperature, humid atmosphere, rough handling in transit and storage in open including delays in transit.

*********



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11.1 Bill of quantities of fan

Supply of Centrifugal fans, SISW backward inclined with aerofoil, non- over loading type , up-blast complete with motor, VVFD , base frame, belt guard, flexible connection at inlet & outlet, vibration isolators , seismic restraints, seismic qualified frame & mountings & as per the tender technical specifications and of following capacity and static pressure.

SL. NO.

TYPE CAPACITY STATIC PRESSURE

NUMBERS REQUIRED

Location

1 Type A 65,000 CMH 200 mm WG 14 Supply side

2 Type B 75,000 CMH 300 mm WG 12 Exhaust side

3 Type C 75,000 CMH 400 mm WG 2 Exhaust side(Hull

compaction)

TOTAL= 28

11.2 Bill of quantities of Spares

SL. NO.

ITEMS FAN TYPE CAPACITY NUMBERS REQUIRED

1 Impeller with shaft and bearing blocks, Motor & VFD Drive module

Type A 65,000 CMH One Set

2 Impeller with shaft and bearing blocks, Motor & VFD Drive module

Type B 75,000 CMH One Set



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12.0 DOCUMENTS TO BE SUBMITTED

Following documents are required to be submitted by the supplier.

12.1 DOCUMENTS TO BE SUBMITTED ALONG WITH OFFER

(i) Duly filled Vendor evaluation Proforma (ii) Technical data sheet (as per annexure-I) (iii) Schedule of deviation (iv) Delivery and manufacturing schedule (v) Proof of ability (vi) Catalogue/ technical literature (vii) Drawings, Foundation size along with the drawings (viii) Fan performance characteristic curves (ix) Motor & VVFD technical details/ catalogues/ manufacture/ make

& model etc.

12.2 DOCUMENTS TO BE SUBMITTED BFFORE THE START OF FABRICATION

After receipt of purchase order. The supplier shall submit to the purchaser for his approval 4 copies of the followings:

(i) Certified dimensional drawings of the fan motor assembly (ii) Characteristics curves for fans, Motors & VVFD drive. (iii) Materials of construction, make, type specification of bearings, V- belt,

pulleys, shaft, shaft seal etc. (iv) Design information to support the correctness of selection of shaft critical

speed. (v) All inspection and testing procedures and QA plan. (vi) The supplier shall furnish a detailed schedule of manufacture & delivery. (vii) Cleaning and painting procedures.

The fabrication and use of the parts shall start only on receipt of purchaser’s approval on these.

12.3 DOCUMENTS TO BE SUBMITTED AFTER COMPLETION OF THE

JOB: (i) A report giving a description and results of all the tests shall be furnished to

the purchaser .



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(ii) The report shall include all calculations, a description of any analytical or mathematical modeling techniques, a description of any computer code used , or other tests made in conjunction with the certification or qualification of the fan or fan assembly etc.

(iii) All material test reports, inspection test reports, details of all the brought out

items along with their manuals.

(iv) The supplier shall furnish 5 copies of instruction manuals to cover installation, operation, and maintenance, drawings for each type of fans. The Manual shall include instructions on alignment, lubrication details, specifications of parts etc. The purchaser shall approve the manual before fully supply is made.

(v) All the documents shall be submitted in hard copy with 5 sets. A soft copy of

the drawings of fans, motor & VVFD along with its accessories. All calculations in support of their design shall also be submitted by the supplier before the despatch of the items to the site.

13.0 WARNING The contractor shall supply full information as asked at various sections of this specification. The quotation shall be complete with detailed information technical literatures, characteristic curves etc. Quotations incomplete in this regarded shall be ignored.

14 PERFORMANCE GUARANTEE: Supplier shall give performance guarantee for a period of 18 months from date of delivery and 12 months from date of commissioning for the fans running under the specified condition and shall replace any part in the event of failure due to design and manufacturing faults.

15 DELIVERY AT SITE

15.1 All the items shall be delivered to WMP- FRFCF site , IGCAR Kalpakkam.

BIDDER shall intimate the DEPARTMENT in writing the probable date when the Equipment will be ready for despatch.

15.2 No material shall be despatched without prior consent in writing (shipping release) of the DEPARTMENT or his authorised representative



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15.3 It is the responsibility of BIDDER to insure all the equipment under this contract during transit, all risks in transit being exclusively by the BIDDER. The DEPARTMENT shall pay for only such equipment as are actually received and installed in acceptable condition.

15.4 The BIDDER shall indicate separately freight charges for transporting the

equipment to the place of delivery as specified

15.5 The packing of Equipment on arrival at Site shall be inspected on the carrier itself. Wherever feasible, the Equipment should be directly loaded on a lorry or tractor trailer. Unloading of Equipment shall be carried out by competent, experienced personnel using suitable handling equipment and approved safe procedures.

16 DELIVERY SCHEDULE:

The fabricator should clearly indicate a firm time schedule for the preparation of fabrication drawing, inspection of materials, different stages of fabrication as per inspection stages and delivery at stores. The entire scope of contract should be complete within 18 calendar months from the date of award of contract. The priorities will be given by the purchaser after the award of the contract to the supplier. The fabricator shall be govern by the following clauses. Time and date of delivery of materials to stores stipulated in the purchase order shall be deemed to be the essence of the contract and delivery must be complete not later than the specified therein.

17 PRICES SCHEDULE

The bidder should quote the rates on item basis with including supply of material and manufacturing, inspection & testing packing& forwarding and delivery to the site. The price quoted shall be firm and include for the supply of material, fabrication, inspection and testing and delivery to stores and as per the tender technical specifications.

“Supply of Centrifugal fans, SISW backward inclined with aerofoil, non over loading type , up-blast complete with motor, VVFD , base frame, belt guard, flexible connection at inlet & outlet, vibration isolators, counter flanges etc. as per the tender technical specifications and of following capacity and static pressure”.



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Item no.

Type Description

Quantity

Item Rate each (Rs.)

Total cost

(Rs.) 1 Type A 65,000 CMH &200 mm

WG 14

2 Type B 75,000 CMH & 300 mm

WG 12

3 Type C 75,000 CMH &400 mm

WG 2

4 Spares as per the BOQ for spares

5 Excise duty

6 Sales tax

7 Packing and forwarding

8 Freight charges

9 Any Other Charges

10 Validity of the offer

11 Delivery period

Total Cost(Rs.)

Payment terms:



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18.0 TECHNICAL DATA SHEET TO BE FURNISHED BY BIDDER FOR FANS ( To be submitted for all the seven types of fans separately)

Sr

No Description Type of Fan

1 Manufacturers model no./ arragement 2 Type of fan 3 Base Frame Pedestal Dimensions(LxWxH) 4 Fan rated speed (RPM)

5 Performance ( at std. density at 760 mm of Hg & 300C temp. & rated speed.)

5.1 Flow rate (CMH) 5.2 Static pressure (mm of WG.) 5.3 Total pressure (mm of WG.) 6 Fan static efficiency at rated speed (%).

7 B.H.P. required at rated speed.(at operating condition)

8 Limit load BHP of fan ( KW) 9 Power rating of selected motor (KW)/pole 10 Fan outlet velocity (m/sec.) 11 Critical speed of fan shaft assembly (RPM) 12 Fan outlet area (m2) 13 Wheel diameter. (mm.) 14 Type of Blade 15 Overall wheel width. (mm.) 16 Weight of Impeller ( in Kg. ) 17 GD2 value (in Kg. m2) 18 Shaft Dia. at Bearing (in mm) 19 Type of bearing & make 20 Bearing size, life & lubrication 21 Weight of bare fan without accessories (Kg) 22 Vibration level (in mm/sec.)

23

Fan Performance Curves, Selection Procedures and all necessary details to be furnished by the Bidder.

24 Make & model of Motor 25 Make & model of VFD Drive



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*****

MATERIALS AND THEIR THICKNESS TO BE USED

Component Description

26 Casing (material & thickness)

27 Back plate (material & thickness)

28 Shroud (material & thickness)

39 Wheel (material & thickness)

30 Shaft (material & Diameter )

31 Aerofoil blades (material & thickness)

32 Base frame (material & thickness)

33 Shaft seal type and make

34 Flexible connection material

35 Vibration isolator manufacturer.