REPORT TO ACCOMPANY THE ESTIMATE FOR THE WORK OF “Provision of 30KVA Diesel Generator set with control panel arrangement to the Additional building of District Industries centre at Tirunelveli” EST Rs.4,10,000/-

The Government in G. O. (D) 7 Micro small and Medium Enterprises Department/dated 17.01.2013. have accorded Administrative sanction of Rs.125 lakhs for the work of construction of Additional office building and Repair and renovation for existing building in District Industries centre at Tirunelveli in Tirunelveli District.

Based on the above, the detailed estimate for the work of construction of Additional office building and repairs and renovation of existing building in District Industries centre at Tirunelveli is technically sanctioned for Rs.125 lakhs and registered in CER No.63/CE/MDU/2012-2013.

In the main estimate, lumpsum provisions are provided for electrical works as detailed below:

1. Internal and External electrification - Rs.5,00,000/-2. Provision of AC units in conference hall

and Data processing centre - Rs.2,50,000/-3. Provision for 30KVA Generator set - Rs.3,50,000/-

Utilizing the LS provision for internal and external electrification, estimate was prepared and sanctioned for Rs.5 lakhs and registered in DR No. and for AC units in Conference hall and Data Processing centre was prepared and technically sanctioned for Rs. 2.50 Lakhs and registered in DR No.

While preparing the estimate for the work of “Provision of 30KVA Diesel Generator set with control panel arrangement to the Additional building of District Industries centre at Tirunelveli” the funds allotted is inadequate. The cost of the estimate works out to Rs.4,10,000/-. The Additional cost of Rs.60,000/- should be needed for the execution of this work.

The cost of the estimate works out to Rs.4,10,000/- (Rupees Four lakhs and Ten Thousand only) . The estimate is prepared based on the schedule of rates for the year 2013-14 and the market rates. The rate adopted for generator set is adopted by the quotation from M/s. Genlite Engineering Pvt. Ltd., Dindigul.

The expenditure is debitable to the head of account “8443 Civil Deposit” (Payment by the Executive Engineer, PWD, Buildings Maintenance Division, Tirunelveli)”

Assistant Engineer, PWD Assistant Executive Engineer, Electrical section. Electrical Sub-Division, PWDThoothukudi. Tirunelveli.

ESTIMATE ABSTRACT

Name of work: Provision of 30KVA Diesel Generator set with control panel arrangement to the Additional building of District Industries centre at Thoothukudi.

EST Rs.4,10,000/-

Sl.No

Qty Description of work Rate/Per Amount

1. 1 Set

Supply, testing commissioning & Handling over of 1No 30KVA diesel generator set 0.8P.F, 3 ph, 415 Volts, 50c/s, 1500 RPM as detailed below. Kirloskar Green/ Ashok Leyland/ Greaves/ Mahindra & Mahindra/ Equivalent) A. EngineGenset model No.KG30WS DG set with Kiroloskar make engine model 3R1040 (Meeeting emission & Noise compliant) developing 43 Bhp, Water cooled diesel engine, cylinder-3 suitable for generating application with shaft out put suitable capacity at 1500 RPM under NTP condition as per bss 5414-ISO 8528. The engine shall comprise the following standard scope of supply.1) Oil type air cleaner 2) Expansion bellow3) Radiator, radiator fan and mounting4) Exhaust gas turbo charger 5) Lube oil cooler6) Fuel filter (pre and micro)7) In-line mono-block fuel injection pump with governor and fuel feed pump8) 12V electric starting motor9) 12V battery charging alternator10) Engine test certificateEngine instrument panel mountedEngine control panel consisting of On/OFF/START/KEY, lube oil pressure gauge, oil temperature gauge, high water temperature gauge and electronic hour meter. Safety system of Engineer: The engines shall trip for the following conditions with Visual alarm device.1) Low lubricating oil pressure2) High water temperature3) V. belt failure

373200/Ea 373200.00

B. ALTERNATORKirloskar Green/ Crompton Greaves/ Equivalent Alternator capacity of 30KVA/24KW AC 3phase, 50HZ, 415Volts, 0.8pf, 4 wire self exited, self regulated design to run at 1500 RPM under NTP conditions conforming IS KG184C to be coupled directly to the diesel engine and test certificate. The alternator shall be screen protected trip proof with IP 23 protection (Kirloskat/ Crompton/ Standard) 3)STANDARD CONTROL PANEL:The standard control panel (cubical) should be vermin proof and dust proof best quality sheet steel of 16 SWG CRCA MS sheet and floor mounted with suitable hinged glass doors, enamel painted and incorporating the following with suitable provision for connection incoming and outgoing leads have to be made on the control panel comprising.

a) MCBb) Voltmeter with voltmeter selector switchc) Ammeter with ammeter selector switchd) Indicating danger for “Set run” and “Load

on”e) Set of control fusesf) Set of current transformers.g) KW hour meterh) Frequency meteri) HRC fusesj) Battery changing ammeter.

1. UNDER/OVER LIMITi. High coolant Temperatureii. Low lube oil pressureiii. Over speediv. Start failv. Emergency stopvi. Over load2. FAULT INDICATIONS:i. Lop-Low Lub oil pressureii. HWT-High water temperatureiii. OL-Over loadiv. E.STOP-Emergency stop

3. STATUS LED INDICATIONS.i. START FAIL – start failii. AUTO- Auto modeiii. MAN-Manual mode

iv. MAINS-Mains Availablev. DG-Genset ON4. OPERATING KEYS ON AMF CONTROLLERi. START- Starts the gen set in Manual Modeii. E-STOP- Stops the Gen set in manual mode5. PARAMETER SETTING KEYSi. DIP switches The panel should be completed with bus bars internal connections and with necessary fuses, cables and other accessories and with tappings for the incoming supply from the alternator and for the outgoing supply to the load.4) ACOUSTIC ENCLOSURE:Kirloskar Green/Equivalent/Acoustic enclosure shall be powder coated and fabricated out of 16SWG CRCA MS sheet. The silent canopy shall be nut bolt type construction. Critical processes of punching are done on CNC machines to maintain dimensional accuracy of holes within 0.1mm power coating is done after seven-tank surface preparation process of sheet metal. Canopy panel and door shall have inside lining of FIRE-RETARDANT from 80-100kg/M3 density mineral wool of 25mm thickness as acoustic material. Four hinged doors shall be rocided to canopy.SURFACE TREATMENT – PAINTINGThe enclosure shall be suitably treated for degreasing, degusting and phosphating. The canopies are assed through seven-tank treatment thoroughly. ADDITIONAL FEATURES:Canopy fabricated on CNC machines with dimensional accuracy of 0.1mm so as to increase its durability. Special designed supporting ribs/structures to give sturdiness and to reduce the vibrations of the DG sets if any. WORLD CLASS COOLING PACKAGE:Class cooling package for which it can also perform at 45 deg c ambient temperature. No grounding required on the ground, only a level surface capable of with standing the DG weight. Lifting hooks should be provided for the acoustic enclosure, which should unloaded independent of the DG set. The gen set base frame should be provided with hooks for unloading.

Temperature rise inside the canopy:Designed as to maintain the temperature difference between ambient and air inlet at air cleaner within the enclosure well with in 5-7 deg centigrade. 5) Base FrameBase frame fabricated in sheet metal. The base frame should be rugged in construction and designed for mounting engine and brush less alternator close coupled, with cross members mounted on AVM. The base frame shall have provision for mounting of acoustic enclosure on it. 6) Fuel Tank66Lts. Removable fuel tank shall be fabricated out of 14 SWG CRCA MS sheet and its part of base frame. Its is duly painted and fitted with inlet and outlet connections and mechanical fuel gauge. Fuel tank can be easily removed for cleaning or any maintenance.7) Battery1 No 12V 150 AH battery 15plates 8) Exhaust PipingDG set should be offered complete with exhaust piping i.e. silencer is mounted and connected by means of MS pipe through flexible pipe to the engine manifold. Entire exhaust piping inside the canopy (cold Zone) is insulated by means of ceramic wool and aluminum gladded. 9) Supply of maintenance and operating manual:

1. Operation & Maintenance manual for Engine

2. Maintenance Manual for Alternator3. Engine test certificate 4. Alternator test certificate5. Circuit diagram for control panel6. DG set test certificate7. CPCB compliance label fixed on canopy

Erection, Testing and commissioning:The Erection shall comprising of:Erection of generator set with proper. Providing ISI earthling with earth electrode of 2.1meter length, 1:1/2” diameter class ‘B’ GI pipe for alternator and control panel including masonry work with cover slabs for earth bits – 5Nos.

First charging of lubrication oil, first charging of battery and providing 80ltrs. Fuel oil to run the set for eight hours on full load test and commissioning. Supply of tools required for the maintenance and operations of the generator set.Supply maintenance manual books with engine and alternator parts list.Supply and installing of exhaust piping of sufficient length with suitable MS pipes extended to outside.First charging of fuel oil for the full tank level while handing over to the user department. (Data-A)

2. 70 Mts

Supply and run of No.8 SWG copper conductor in suitable PVC rigid pipe on wall with painting of suitable colour for earth connection. (DATA-B)

89.70/Mt 6279.00

3. 25 Mts

Supply and laying of 3 ½ x 25 sq.mm PVC armored LTUG cable in a trench to be excavated at a depth of 0.75 meter putting 0.15mt. Layer of sand and covering the cable completely with bricks and sand and refilling the earth to make good. (SD-204)

385.20/Mt 9630.00

4. 20 Mtr

Supply and clamping of 3 ½ x 25 sq.mm PVC LTUG armored LTUG cable on post or on wall with MS Clamps. (SD-222)

340.20/Mt 6804.00

5. 2 Nos

Supply and fixing of brass cable gland for 3 1/2 x 25sqmm PVC armored LTUG cable with earth connection. (SD-186)

194.55/Ea 389.10

6. 1 no

Supply and fixing of 63A changeover switch (L&T/Havells) on suitable angle iron frame work with MS cable entry boxes and earth connection only. (Data-C)

6295.10 6295.10

402597.207. Unforeseen items 7402.80

Total 410000.00(Rupees Four lakhs and Ten Thousand only)

Assistant Engineer, PWD Assistant Executive Engineer, Electrical section. Electrical Sub Division, PWD Tirunelveli. Tirunelveli.

DATA SHEETDATA-A

Qty Description Rate Amount1 No

1Job

80Ltr

1Job

5Nos

Supply of 30KVA water cooled DG set including freight charges (loading and unloading) all Taxes etc., (as per MR)Towards the charges for erection, testing and handing over of Genset Supply of diesel to run the Genset for minimum 8hours (Initial testing)Towards the charges construction of RCC foundation bed (as per PWD Civil department rate enclosed)ISI earthing (as per SD-233)

340000/Ea

LS

60/Ltr

LS

1693.30/Mt

340000.00

10000.00

4800.00

9906.00

8466.50373172.50

Sundries etc., 27.50 Total 373200.00

Say Rs.373200/EaDATA-B

Qty Description Rate Amount90mtr90mtr/10.38kg300Nos1 Gross2 Gross1/3 bag

PVC rigid pipe 16mm No.8 copper conductorT.W plugM.S. saddle 16mmBrass screw 25mm Cement and

14.20/Mt519/kg

0.34//Ea44/Gr

82.50/Gr531/Bag

1278.005386.18102.0044.00

165.00132.68

7107.86Add 1% sundries etc., 35.53Labour charges (SD-54X1/3) (2784/3) 928.00

Total 8071.39Rate/Mt=8071.39/90

Say Rs.89.68 (or) 89.70/Mtr

Data-C

Qty Description Rate Amount

Less: 1 no

Add: 1 no

As per SD-16563A TPN MC switch 63A Change over switch

3270.00/ea

3710.00/ea

5855.083270.002585.083710.00

Total 6295.08

Say Rs. 6295.10/-

Assistant Engineer, PWD Assistant Executive Engineer, Electrical section. Electrical Sub Division, PWDTirunelveli. Tirunelveli.

LOAD DETAILS ADDITIONAL BUILDING OF DISTRICT INDUSTRIES CENTRE,

TIRUNELVELI

1. 4’36W SBT fitting 20 Nos x 36W 720 W2. B.H. with 14W CFL 12 Nos x 14W 168 W3. Twin mirror optic 41Nos x 72W 2952 W4. 48” AC ceiling fan 21 Nos x 60W 1260 W5. 12” AC exhaust fan 7 Nos x 60W 420 W6. 65W street light fitting 8 Nos x 45W 360 W7. 5Amp plug 20 Nos x 100W 2000W8. Computer plug 20 Nos x 300W 6000W9. 15A plug (essential plug) 5 Nos x 500W 2500W10. 20A AC plug 5 nos X 2000W 10000W11. 5 KVA UPS unit 5000 W

Total 31380 W

Approximate 31 KW

Let the diversity factor be 0.7 essential

Load is 31 KW x 0.7 = 21.70 KW

Apply P.F as 0.8 the capacity of

Generator = 21.70 KW =27.12 KVA 0.8

Hence 1No 30KVA Diesel Generator set is proposed

Assistant Engineer, PWD Assistant Executive Engineer, Electrical section, Electrical Sub Division, PWD Tirunelveli. Tirunelveli.