STATEMENT OF TECHNICAL REQUIREMENTS
MV LABORATORYFOR
INS VALSURA
EED50XX
Oct 2013
ISSUING AUTHORITY
DIRECTORATE OF ELECTRICAL ENGINEERING
I N T E G R A T E D H E A D Q U A R T E R S
M O D ( N A V Y )
N E W D E L H I 1 1 0 0 1 1
RECORD OF AMENDMENTS
Sno. Amendment Authority Date Signature
Revision Note: Nil
Historical Record: Nil
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INDEX
SL NO DESCRIPTION PAGE NO
1. Introduction 62. Scope 63. Purpose 64. Type 75. System Configuration 76. MV Captive Power Plant 77. MV SWBD 88. LV SWBD & Power Transformer 99. Creepage & Clearance 1110. MV Motor & Four Quadrant Load (4 QL) Machine 1111. MV Motor & Four Quadrant Load (4 QL) Drive 1112. Load Bank 1213. LV Motors & Starter Driver 1214. Cooling Arrangement 1215. Control & Monitoring 1216. Control Supply for SWBDs 1217. SCADA System 131518. MV Power Electronics Lab 1519. Misc. Requirements 1520. Operational & Fire Safety 1621. Civil Works 1722. Cabling 171823. Equipment & Materials 1924. Equipment Stowage 1925. Equipment Spares 1926. Life Cycle Support 2027. Comprehensive Maintenance Contract 2028. Installation Support 2029. STW & Commissioning 2030. System Performance Responsibility 2131. Delivery 2132. Training 2133. Warranty 2134. Applicable Documents 21
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LIST OF APPENDICES
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1. Introduction . The SOTRs contained herein represent the technical, functional and design requirements for Medium Voltage (MV) Lab to be set up at INS Valsura.
2. Scope . The scope covers the functional, technical, design, documentation and support requirements of MV Lab. The Vendor would also be required to provide necessary technical support for carrying out installation. The vendor, post installation, would be required to undertake commissioning and offer the equipment for acceptance trials.
3. Purpose . The purpose of setting up the MV Lab at INS Valsura is as follows:
(a) To facilitate practical handson training to officers and sailors of the Indian Navy in the concepts, safety, operation and maintenance of MV power systems and power electronics.
(b) To equip officers and sailors of the Indian Navy with the capability to effectively maintain such systems on board ships.
(c) Operational Role and Necessity . At present all IN Ships generate power in the Low Voltage (LV) range, typically 440V / 415V / 380 V. However, with introduction of the allelectric ship concept in military and merchant ships worldwide, Medium Voltage (MV) in the ranges of 115 kV have become the operating voltages in such ships. The adoption of the allelectric ship concept by the Indian Navy is imminent in light of the technical and economical advantages it offers, and the proposed induction of four LPDs with electric propulsion. Successful induction will require focussed training in the basic concepts, safety, operation and maintenance of switchgear, machinery accessories / auxiliaries operating at MV and the power electronic control systems that will drive and control such machinery / systems. The MV laboratory is essentially required at INS Valsura for practical handson training to officers and sailors of the Indian Navy in the concepts, safety, operation and maintenance of all MV equipment, to equip them with the necessary skills to ensure optimum maintenance/ performance of these systems post induction on board ships.
(d) To impart training to carry out routine maintenance and trouble shooting of the MV equipment.
(e) To provide suitable facilities for simulation of malfunctions with consequent failures and provide trainees the opportunity of practically carrying out the instructions for maintenance and service.
(f) Additionally the Lab will also provide facility to:
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(f.i) Conduct theoretical and practical classes in close conjunction with each other in the following specified fields of MV technology, MV equipment operation / maintenance and power system controls:
(af.i.a) Concepts and use of MVspecific power system test eqpt(af.i.b) Online insulation and Earth fault indication monitoring in MV(af.i.c) 4quadrant operation of highpower MV induction motor(af.i.d) MV Active Front End (AFE) PWM drives(af.i.e) Advanced controls of MV power system through SCADA(af.i.f) Application of PLC on Gigabit Ethernet (GBe) bus
(f.ii) Conduct equipmentspecific training for ship crews in MV systems.
(f.iii) Conduct experiments in motor control and associated power control systems and power management for trainees.
4. Type . The laboratory shall be a selfcontained facility primarily for the purpose of training and familiarising of Officers and Sailors of the Indian Navy with operation, maintenance and safety aspects of MV power generation, distribution and highpower motors. MV equipments should comply with requirements of latest IEC standards to avert the effect of harmonics on the diesel generators and other loads. The laboratory should also have a dedicated facility to undertake defect diagnosis, repairs, maintenance and testing of various components of the MV Lab.
5. System Configuration . A single line diagram schematic of the MV lab facility is placed at Appendix A. The MV lab will consist of one 6.6 KV, 50 Hz, 3 Ph MV switchboard; two 1.5 MWe captive power plants; two 5 MW 3phase MV induction motors; two 5MW AFE IGBT/ IGCT based PWM drive converters with common front end and DC bus; one 2 MW resistive load bank; SCADA system including Power Management System (PMS); one each 15 KW LV induction, synchronous & DC motor along with soft starter, synchronous drive & DC drive respectively; one suitably rated 6.6 KV / 415V, 3 Ph, 50 Hz, stepdown transformer for feeding to the LV switchboard through a HCOS; one HP air compressor along with suitable air bottles, cooling arrangements for 5 MW machines and drives, and chiller plants as required. The facility should be equipped with all the requisite workbenches, tools, safety gear, calibration / test facilities, etc.
Functional Requirements
6. MV Captive Power Plant . 02 Nos. DG sets consisting of diesel prime movers and alternators, to be provided by the vendor. It should be feasible to synchronise/ parallel these DG sets through a synchronisation panel to be fitted in the MV Switchboard and be capable of continuous parallel operation in auto, semiautomatic
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and manual modes. The specifications for each MV diesel generator should conform to IEC publication 60034, and be as follows:
(a) Diesel generator power output 1.5 MWe, with generator neutral earthing resistor panel. Generators to be provided with ventilated acoustic enclosures.
(b) Output voltage 6.6 KV, 50 Hz, 3 Ph.
(c) Star connected winding, with neutral point brought out for connection to Earthing resistor.
(d) Overload capacity 110%.
(e) Local control panel for control and monitoring of prime movers.
(f) To be sized for continuous duty (S1)
(g) Protection IP 53 or higher
(h) Insulation Class F of Higher
(j) Heating Class H
(k) Power factor > 0.8
(l) Efficiency > 96%
(m) Prime movers to be provided with requisite auxiliaries, including (but not to) complete cooling system, fuel system & storage, and HP air starting system including compressor, storage bottles, air lines and valves.
(n) Capability of minimum 03 (three) restarts with stored HP air.
7. MV Switchboard . A 6.6 KV switchboard with arcproof design (IEC 602983) to be provided to prevent personal injury and to limit equipment damage during short circuits in a worstcase scenario. BusCouplers to be provided for interconnecting sections of the bus bars.
(a) The switchboard should be fitted with suitably rated Vacuum Circuit Breakers (VCBs), controls and indications. The VCBs should be drawout type, microcontrollerbased with status display panel, and should have overcurrent trip, instantaneous short circuit trip, over/undervoltage trip, earth fault, over/underfrequency trip and reverse power trip features. Provision should exist for automatic, semiautomatic and manual synchronisation.
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(b) 01 customised trolley shall be provided for breaker removal.
(c) 01 set of tools / test eqpt shall be provided for maintenance.
(d) Each of the two sections of MV switchboard shall be of steel construction, and will be of selfstanding type equipped with all necessary controls and instruments for single or parallel operation of generators, and earth fault indication system.
(e) Each panel of the switchboard enclosure should be provided with an earthing stud.
(f) An online insulation monitoring system to be provided, for monitoring insulation of buses and also outgoing feeders.
(g) Remote control panel for captive power plant prime movers.
(h) Rated Short Circuit withstand capability . OEM to forward designed short circuit current calculations wrt the load, duly certified by a third party such as DNV, BV, etc.
8. LV Switchboard and Power Transformer . 415V, 50 Hz, 3 Ph shall be derived from the main MV supply by means of a 6.6 KV / 415 V stepdown power transformer through a HCOS of suitable rating (both to be supplied by vendor) supplied from the MV switchboard, to cater to all LV loads and auxiliaries including 20% growth margin. The vendor shall provide necessary cabling for other input to the HCOS from a 11 KV / 415 V transformer being provided through civil works. This transformer will be fed by Paschim Gujrat Vij Corporation Ltd (PGVCL). Transformers will also provide galvanic isolation between LV and MV systems. This LV switchboard shall be divided into two sections (one each for auxiliaries and LV motors). The salient features are as follows:
(a) Each section of LV switchboard will be of steel construction, and will be of selfstanding type equipped with all necessary controls and instruments, and Earth fault indication facility.
(b) An online insulation monitoring system to be provided with provision of monitoring insulation of buses and also feeder outgoings.
(c) Provision of LV supply (single / three phase as required) to support auxiliary systems such as ventilation / cooling systems, pumping systems, blowers, etc for selfsustaining operation of the entire facility, excluding general lighting and ventilation.
(d) Each panel of the switchboard enclosure should be provided with an earthing stud.
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(e) Rated Short Circuit withstand capability . OEM to forward designed short circuit current calculations wrt the load, duly certified by a third party such as DNV, BV, etc.
(f) The preliminary configuration of switchboards is as follows (to be provided separately for both MV and LV switchboard except where specified):
SNo
Description
(a) One generator protection panels on MV swbd for each of the generators, consisting of the following:(a.i) Overload (overcurrent) trip indication(a.ii) Reverse power trip indication(a.iii) Under/overfrequency trip indications(a.iv) Under/overvoltage trip indications(a.v) Short circuit trip indications(a.vi) Singlephasing protection
(b) Motorised breakers for the switchboards, all with OPEN / CLOSE / TRIP indicating lamps, as follows:(a.i) 06 VCBs in MV swbd (02 incomers, 02 outgoing, 01 bus coupler & 01 spare)(a.ii) 03 ACBs (01 feeder in MV swbd, 01 incomer & 01 bus coupler in LV swbd)(a.iii) 03 outgoing feeder MCCBs in LV swbd for LV motors(a.iv) Outgoing feeder MCCBs in LV swbd as required for auxiliaries(a.v) 04 spare MCCBs in LV swbd as growth margin.
(c) Kilowatt meters:(a.i) 01 each for 02 alternators(a.ii) 01 for MV drives(a.iii) 01 for LV incomer
(d) AC Ammeters with phase selector switch:(a.i) 01 each for 02 alternators(a.ii) 01 for MV drives(a.iii) 01 for LV incomer
(e) AC Voltmeters:(a.i) 01 each for 02 alternators(a.ii) 01 for MV drives(a.iii) 01 for LV incomer
(f) Frequency meters:(a.i) 01 each for 02 alternators(a.ii) 01 for MV drives(a.iii) 01 for LV incomer
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(g) Synchroscope with generator synchronising panel on MV swbd(h) Space heaters (with thermostat) for swbd enclosure(j) Generator Panel, including following for each generator:
(a.i) Voltage regulators (Auto / Manual) for AVRs(a.ii) Governor control switches(a.iii) White lamps (Generator ‘ON’)
(k) Earth fault monitoring system including testing lamp with switch and Kiloohm meter
(l) One each power factor meter in MV & LV swbds
(m) Online insulation monitoring system
(n) Singlephase protection device for LV swbd incomer (for protection from singlephasing in PGVCL supply)
(g) Each switchboard should also be provided with a generator protection unit, clock and mimic diagram. Oilproof, shockgrade rubber matting conforming to BS921 shall be provided in front and rear of both switchboards. Both the switchboard enclosures should be of rating IP 53 or higher. The generator protection unit will consist of reverse power and overload trip. All maintenance work including removal and replacement of components from the switchboard should be possible from the front. Hand rails will have insulated sleeving. Each section of the switch board will be provided with anodised wiring diagram plate at a suitable location to facilitate fault diagnosis / rectification.
(h) Bus bars will be made of high conducting copper supported on rigid insulators. The bus bars will be covered by an insulating material as an additional safeguard.
(j) All cables entering the switchboard will be fitted with approved glands in accordance with latest IEC standards. All fixing lugs will have closed eyes and not slots. All small wiring will be well supported and neatly run without excessive bunching and will be secured at suitable intervals by insulating cleats. The ends of all wires will be provided with suitable insulating identification ferrules or sleeves. Laying of cables to be as per IEC 60092352. Cables should be laid to ensure segregation of power and control cables.
(k) Instruments will be flush mounted, of suitable size, scale and of Grade 1 accuracy. A red line will be marked in the scale at appropriate places in the voltmeters, ammeters and frequency meters. Instrument transformers are to comply with IS 2706 and IS 3156, and all meters shall be compatible with the SCADA system. Flame retardant screwedon metallic label plates for each switch, instrument, control indicator and fuse, indicating their functions, shall be provided.
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9. Creepage and Clearance . The minimum creepage and clearance distances provided for all connections, terminals and similar bare ‘live’ parts are to be determined in accordance with the requirements of BS EN 600711 and BS EN 600712.
10. MV Motor and Four Quadrant Load (4QL) Machine . Two in number 3 phase, 50 Hz AC MV Induction Motor, of rating 5 MW, cooled by fresh water / deionised water, shall be installed. One shall be designated as “MV Motor” and the other as “4Quadrant Load machine”. These induction motors should operate at a suitable voltage between 3 KV and 6.6 KV, with RPMs in the range of 0200 rpm in both directions. The motor enclosures should have ingress protection of IP 54 or higher, and insulation / temperature class of Grade H. The motors shall be equipped with winding and bearing temperature sensors (PT100), anticondensation heaters and vibration sensors for motor bearings at both drive and nondrive ends. The motors are to be sized for continuous duty (S1) as per IEC publication 60034. The motors shall be capable of providing upto fullload torque at all speeds in both directions, and be capable of operating in all four torque/speed quadrants, as in a ship when driving the propeller..
11. MV Motor Drive and Four Quadrant Load (4QL) Drive . The “MV motor” shall be supplied from a drive converter which is to be IGBT / IGCT based, minimum 12pulse PWM type. The converter will have an Active Front End (AFE) configuration for driving the MV Motor. The converter drive shall be fresh water / deionised water cooled. The AFE of the drive shall be fed with 6.6 KV input from the MV bus bar. The converter shall have temperature supervision / alarm and the output voltage shall be according to MV motor voltage. The minimum ingress protection rating to be IP 54 for the drive. The Converter supplied shall conform to IEC Publication 60146. The motor drive systems shall be designed and arranged to preclude generation of and susceptibility to electromagnetic interference (EMI). Further all the components of the converter drive should be rated for MV operation. The drive system shall be able to handle internally, the power generated from the MV motor, when the rotation of the MV motor is set to the opposite direction due to operation in braking quadrant. The 4QL drive will convert the power generated from the MV generator back to the MV switch board by undertaking necessary conversions.
12. Load Bank . One resistive load bank of 2 MW capacity is to be provided by the vendor. The load bank shall have all control / indication / safety features and integral forceddraught air cooling system fed by the LV switchboard. The load bank shall be connected to the MV bus bar through a suitable feeder VCB to load the DGs for load trials or as otherwise required. The load bank shall have facility to achieve smooth increment of load from zero to maximum value.
13. LV Motors and Starters / Drives . The following LV motors, along with drives and loads shall be provided. All motors shall be rated to 15 KW. The minimum ingress protection rating to be IP 54 for LV motors and starters / drives. LV Motors
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should have Class F insulation, continuously rated and efficiency must be ≥ 95%. The starters of these motors shall provide protections for overcurrent, singlephasing/phase failure (except for DC motor), earth fault, thermal (thermistor) protection and undervoltage.
(a) One AC squirrel cage induction motor along with suitable load and associated soft starter, conforming to latest IEC standards.
(b) One DC Motor along with associated DC drive and suitable load.
(c) One AC synchronous motor along with suitable drive and load.
(d) The loads for all LV motors shall be pumps. Water supply and discharge lines for the pumps would be in the scope of civil works.
14. Cooling Arrangement . The MV motor, 4QL machine and both drives shall be fresh water / deionised water cooled for an ambient temperature of 45°C. A chiller plant shall be provided by the vendor for cooling of drives and rotating machinery. Further a water reservoir would be provided in the scope of civil works; however, all requirements of cooling tower and piping for circulating water from the reservoir for equipment cooling would be in vendor’s scope of supply.
15. Control and Monitoring . Local and remote control panels incorporating complete functionality for all possible operating conditions and monitoring parameters of prime mover and alternator of each DG set are to be provided by the OEM. Further, Local Control Panel (LCP) for MV Motor and 4QL machine shall also be provided by the vendor.
16. Control Supply for Switchboards . 230V, 50 Hz, 1 ph domestic supply will be provided through civil works, and any requirements of “control supply / rectified supply” may be derived from this supply by the vendor. Further, a centralised UPS system of suitable rating to be provided by the vendor for providing minimum 30 minutes back up for control supplies of diesel engines, drives, both switchboards, SCADA and control system.
17. SCADA System . The main task of the SCADA system shall be to capture testing & operating data and to exert operational control over the system. All system components required to be monitored / controlled must be capable of interfacing with the SCADA system for this purpose. The SCADA system shall have the following features:
(a) The SCADA system shall be PLCbased. Source code of the PLC program, along with a suitable mechanism for reloading of PLC software, shall be provided by the vendor. All the system components being monitored shall be integrated using highspeed Gigabit Ethernet (GbE) networks configured in clientserver architecture.
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(b) It shall have two work stations with full administrative / control privileges, one each located at the equipment site and in the SCADA control station / MV Power Systems Lab.
(c) It should provide all the normal functions including power management, machinery control & surveillance, and a comprehensive centralised alarm and monitoring system. It should be capable of realtime control and monitoring of power management system, MV motor & 4QL, MV drives, and electrical distribution equipment.
(d) It should provide comprehensive realtime data facilities including userconfigurable alarm parameters; alarm messages containing comprehensive descriptions; alarm banner visible at all times; alarm acknowledgement; time & date tags; reporting, sorting, trending and filtering of data and operator events; graphical capabilities; and facility for viewing reports at remotely located monitoring stations, including networked classroom monitors.
(e) All logged data should be viewable in graphical and tabular form, and be exportable to MATLAB & Microsoft Excel, and also be archived on DVDR.
(f) It should be able to support 256 I/O devices, subsystems, servers, etc for trending, alarm & reporting, and other data handling. The average refresh time on the HMI should be less than 01 sec, and recall time for historical trend values should be less than 05 sec per day of data.
(g) Provision should exist for interfacing the SCADA system with a fire alarm system.
(h) Security shall be fully integrated into the SCADA software to allow access to any part of the system only to users with appropriate access rights via encrypted passwords. The software shall support unlimited number of users, with facility to define a unique password and access privileges for each user. Passwords shall be hidden in both configuration and runtime environment to ensure that personnel cannot access other accounts. Provision of administrative control through administrative password to be provided for reloading of the software, changing user access rights, etc.
(j) The SCADA software shall be configurable as a single global database and it should be possible to make configuration changes to the database from any station of the system in a manner that is completely transparent to the user.
(k) The SCADA system software should be upgradeable with minimum modification.
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(l) HMI should be provided with exhaustive mimic pages for comprehensive monitoring and control of the entire facility. A 52” LED display shall be provided for display of HMI mimic pages.
(m) The graphic display pages shall be capable of a minimum of 2000 tags, with realtime updates within less than 01 sec. The graphic system shall support a screen resolution equivalent to full HD (1080p) and shall support multiple monitors on a single computer. This support shall include separate windows on each monitor.
(n) It should be possible to display other graphic pages by selecting screen targets and to automatically display any screen based on the condition of the tag.
(p) Monitoring of parameters of DG sets, MV switchboard, drives, MV motor, 4QL machine, load bank; LV switchboard, LV motors and drives, online insulation monitoring, earth fault monitoring, cooling systems, health monitoring, including the following:
(p.i) DG remote START / STOP.(p.ii) Monitoring of voltage, current, frequency, power and power factor.(p.iii) Remote control of MV and LV breakers, and monitoring of ON / OFF / TRIP status of all breakers.(p.iv) Control & monitoring of 5MW PWM drives, and monitoring of 5 MW induction motor & 4QL machine parameters.(p.v) Functioning of safety interlocks during operation of the entire facility.(p.vi) Monitoring of 4Q operation of 5 MW induction motor and graphical display of all functional parameters. Also visual representation of operation in each quadrant to be available on SCADA display.
(q) Adequate memory capacity is to be provided to store data of at least one month.
(r) Fault injection facility through simulation mode for following to be available. The extent of physical actuation required will be discussed during the prebid meeting.
(a.i) Tripping of 01 DG when running in parallel with another DG(a.ii) VCB safety trip(a.iii) MV feeder short circuit(a.iv) MV motor trip(a.v) LV AC short circuit(a.vi) Low insulation trip
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(s) An exhaustive BuiltIn Test Equipment (BITE) facility for self check of the SCADA system.
(t) The SCADA System must be modelled on the physical power system for compliance with Def Stan 6122 (Definition of Modelling Standards – Marine Electrical Power Systems)
18. MV Power Electronics Lab . The MV Power Electronics Lab shall have the following general features:
(a) One SCADA monitoring workstation for the facility.(b) One 4’ x 6’ datawall for graphical display of 4quadrant operation and for other training / display purposes, for a class of approx 45 trainees. (c) 30 client training workstations linked to SCADA system PC through clientserver LAN.(d) CBT package for training on functioning of induction motor PWM drive.(e) Tools, test benches, test jigs, test equipment for routine inspection, maintenance and calibration of drives.(f) Any other test equipment / accessories applicable for MV power electronics.(g) 10 in no. HV insulation testers (5 KV) with battery backup facility.(h) 10 in no. 3Phase trueRMS clampon meters, with KWh, harmonics & inrush current measurement, with PC interface.(j) 05 in no. power quality analysers with PC interface.(k) 05 in no. earth fault testers.(l) 02 in no. IR temperature guns.
19. Miscellaneous Requirements . The following miscellaneous requirements are also to be met:
(a) Training . Training aids including visual and static models to be provided by the vendor, including the following:
(i) One disassembled VCB.(ii) One Power Stack showing switching devices, driver and cooling arrangement / heat sink.(iii) ComputerBased Training (CBT) package include animation, video clips, photographs and text, for training on operating principles, functioning and basic maintenance of entire facility.(iv) PowerPoint presentations on the following:
(aa) Description and functional aspects of the entire setup.(ab) 4quadrant operation concepts and its realisation by the MV motor and 4QL.(ac) Theory and functional aspects of MV PWM drive.
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(ad) Safety in MV systems
(b) FATs . FATs to be subsystemwise at OEM factory premises and integration trials to be offered on site by vendor. The procedure for the FATs / commissioning are to be decided mutually, clearly stipulating the acceptable parameters (with limiting values) and the procedure for conduct of various trials and measurements. The draft Acceptance Trial Procedure (ATP) documents are to be prepared by the Vendor and submitted to the Customer, at least 03 months before FATs/ commissioning so as to undertake vetting and finalising the ATP, at least 01 months prior to conduct of FATs and commissioning.
(c) All associated infrastructure requirements viz., piping, cabling, etc., as well as installation/ STW/ Commissioning activities are to be undertaken by vendor.
20. Operational and Fire Safety . The MV Lab should be designed to minimize human error in operation. The vendor should ensure warning statements are provided in operation, maintenance and repair instructions and distinctive markings are made on hazardous components or equipment to be provided to ensure personnel protection. The entire setup shall conform to extant safety standards and norms. The Vendor shall provide a comprehensive Automatic Fire Detection System (AFDS) for sensing of fire / smoke / temperature rise / electric arc and CCTV system at relevant locations in the facility. The following shall be provided / catered to for safety of men and material during operation / maintenance of the facility:
(a) Protective Devices . All conductors will be protected in accordance with their current carrying capacities. Installations will be protected against accidental over currents including short circuits. The protective devices will provide complete protection to ensure continuity of service under fault conditions through action of the protective devices.
(b) CCTV cameras with a central control and monitoring unit which should be interfaced with the SCADA system for remote operation.
(c) Fire/Smoke/Arc sensors with a central control and monitoring unit which should be interfaced with the SCADA system for remote operation.
(d) Arcdetection / temperature sensors inside MV swbd enclosure.
(e) CO2 injection ports in MV swbd for fighting internal fires.
(f) Suitable measures to dissipate static charge buildup in MV swbd prior to opening the enclosure.
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(g) Proper grounding / earthing and earth fault protection for all major components of the facility.
(h) Appropriate routing of all water pipelines to preclude possibility of water spray onto electrical components.
(i) Test equipment / MVrated rubber mats / gloves / tools for handling and maintenance of MV equipment.
(j) Appropriate safety tallies and warning signs.
21. Civil Works . The requirement of Civil Works are to be jointly finalised with the Vendor by IN, so that all requirements of installation of equipment, associated cooling, cabling, and lifting/ transportation requirements, along with associated maintenance envelopes are catered to in the design stage. Necessary civil works will be provided by IN.
22. Cabling .
(a) MV Cables . All MV cables are to be in accordance with BS 68831991 with the following exceptions and additions:
(a.i) Selection of a suitable cable for MV applications is to be in accordance with requirements of latest IEC standards. (a.ii) Braided copper wire screen is to be used on the cores. This is to be ensured even voltage stress on the insulation and avoid touch potential problems at the cable surface. (a.iii) The cables must have conductors conforming to BS 6360 Class 5. This is to assist provide additional flexibility to assist during installation and to improve shock resistance of equipment.(a.iv) The cable sheath is to comply with Def Stan 6112 Part 31. This is to provide superior tear and oil resistance; and Limited Fire Hazard (LFH) and Zero Halogen (ZH) characteristics.(a.v) Cables used in systems above 3.3 KV must be provided with a continuous metallic sheath, regardless of whether or not the cable is armoured.(a.vi) Below 3.3 KV the metallic sheath may be omitted provided that the cable is armoured.(a.vii) It is not necessary to provide armoured cables or a galvanized steel wire braid throughout the MV distribution system. However, local protection of cables may be needed in hazardous areas.
(b) LV Cables . All LV cables are to be in accordance with the following specifications :
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(b.i) LV cables as per latest IEC standards should be used for power cabling application. LFH cables to be used for all requirements of internal and control cabling.(b.ii) Cable groups shall be supported on galvanized steel hanger/ trays without damaging their outer coverings. (b.iii) Shielded screen cables will be used for active or sensitive circuits to avoid electromagnetic interference.(b.iv) Cable lug terminals will be installed on each connected conductor. Solder less type lug terminals / Wago terminals will be used for all application except for equipment having solder type terminals / pin type connectors provided by the manufacturer.
(c) Wiring . Complete electrical installation and wiring should be undertaken by the vendor and also all relevant drawings need to be approved by IHQ, MoD(N). Further, plans of all wiring, complete feeder lists giving details for each feeder and branch circuit of the load, wire size, type of cables rating or setting of breakers, rating of fuses / MCBs and switches are to be submitted to IHQ MoD (N).
(d) Earthing . Earthing pit (maintenancefree) and Earthing strips, as required, to be provided by the vendor.
(e) Main Cable Route . Cables are to be routed so that:
(e.i) MV cables are run separately from LV and signal cables on separate cable trays. Separation between MV and other cables is to be at least 300 mm.(e.ii) MV Cable running on cable trays are provided with individual overall metallic screens, regardless of any requirements for armoured cables.(e.iii) MV cables are run in trunkings if further physical protection is required.(e.iv) Adequate slack is provided at both ends of cables.
(f) Grouping of Cables . The MV cables, LV supply, control cables are to be grouped separately and compactly, to reduce vulnerability.
(g) Avoidance of Open Spaces . Cable runs in the open spaces are to be kept to an absolute minimum and to be suitably protected against environmental conditions.
(h) Flexible Cables .
(h.i) All main flexible cables are to be long enough for the ends to join possible connections points furthest apart in their respective locations whilst allowing most of the cable length to remain as spare.
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(h.ii) Single core cables are to be coloured red, yellow or blue for (0.15 m) at each end to indicate phases by means of heatshrink sleeving.
(j) Cable Identification . Brass cable identification tallies are to be affixed at each end, indicating circuit reference number as per drawings.
23. Equipment and Materials .
(a) Eyebolts are required to be provided for equipment over 40 Kilograms in weight.(b) Adequate service and maintenance envelopes are to be provided for all equipment / machinery.(c) Equipment working from system voltages of 50 V and over are to be earthed.(d) All equipment are to be fitted with Brass rating plates.(e) Standard warning tallies, red in colour with white lettering, indicating “DANGER: 6.6 KV AC”, “DANGER: 415 VOLTS AC” and “DANGER: DC SUPPLY” shall be fitted on the equipment, wherever applicable.
24. Equipment Stowage . The vendor shall provide suitable stowage containers for all electrical equipment to guard against deterioration by heat, moisture and dust, before installation.
25. Equipment spares . Following details in the form of DBF file is to be provided for the spare parts used in the MV Lab:
First Table – Firm’s Details
S.NO.
NAME (CHAR) FIRMS NAME & ADDRESS DETAILS
1 ADDRESS (CHAR 30)2 ADDRESS LINE 1 (CHAR 30)3 ADDRESS LINE 2 (CHAR 30)4 CITY (CHAR 30)5 STATE (CHAR 20)6 PIN CODE (CHAR 8)7 CONNECTING CODE (CHAR 3)8 TELEPHONE NO (CHAR 15)9 FAX NO (CHAR 15)10 ALTERNATE FAX NO (CHAR 15)11 E MAIL (CHAR 20)12 DEALER VENDOR NAME (CHAR 60)
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Second Table Spare Part Details
SL NO
DESCRIPTION (CHAR) TYPE
1 ITEM CODE (CHAR 24) PART NO2 ITEM DESC (CHAR 50) DESCRIPTION OF ITEM3 ITEM DENOM (CHAR 3) DENOMINATION (No. OR SET)4 MONTH SHELF LIFE (SMALL INT) 0 (ZERO) FOR NONSHELF
LIFE ITEM5 VALUE (CHAR 20) DRAWING NUMBER WITH SL
NO OF THE PART IN THE DRAWING
6 EQPT ITEM CODE (CHAR 32) MAX EQUIPMENT7 YEAR OF
OBSOLESCENCE(CHAR 4) NIL
8 EASK ITEM CODE (CHAR 32) IDENTIFIED FOR E/A/S/K (EQPT/ ASSEMBLY/ SUBASSEMBLY/ KIT)
9 EASK TYPE (CHAR 1) MAJ (MAJOR)MED (MEDIUM)MIN (MINOR)
10 QTY CONSTITUENT (SMALL INT) QTY OF SPARE PART IN THAT E/A/S/K
11 QTY BD MANUFACTURER
(SMALL INT) RECOMMENDED BY OEM
12 QTY OB MANUFACTURER
(SMALL INT) RECOMMENDED BY OEM
13 ROUTINE TYPE (CHAR 1) Y: YEARLYQ: QUARTERLYM: MONTHLYH: HOURLYB: B1ANNUALLY
14 PERIODICITY (SMALL INT) NIL15 UNIT PRICE CC (INT) PRICE OF UNIT ITEM16 CURRENCY CODE (CHAR 3) INR17 UNIT PRICE REF (CHAR 50) PRICE REFERENCE18 PRICE DATE (DATE) DATE OF PRICE19 VED CATEGORY (CHAR 1) VITAL / ESSENTIAL /
DESIRABLE
26. Life Cycle Support . The vendor shall provide support for the Lab for a period of up to 20 years after commissioning. Such support shall be provided at INS
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Valsura, Jamnagar, India. The vendor shall also provide lifetime supply of spares / accessories that attain obsolescence during this 20year period.
27. Comprehensive Maintenance Contract . The vendor shall propose pricing and conditions for a Comprehensive Maintenance Contract (CMC) for five years beyond the initial warranty period of eighteen (18) months after system user acceptance, in their proposal. This option may be exercised by Indian Navy. This will include periodic visits for maintenance and oncall visit for repairs. 28. Installation Support . Vendor’s pricing shall include the provision of technical support for the installation and commissioning of the MV Lab at INS Valsura, Jamnagar. Vendor shall also provide installation data, guidelines, and prerequisites to the user. The Vendor should clearly indicate the services and assistance required from the user at INS Valsura, Jamnagar for installation of the MV lab.
29. STW and Commissioning . The Vendor is responsible for setting to work, and commissioning of the system.
30. System Performance Responsibility . Vendor has to undertake full responsibility for ensuring satisfactory performance of the system.
31. Delivery . The vendor should deliver the equipment for installation to INS Valsura, Jamnagar, India in accordance with the schedule provided in the purchase order. Exact dates of delivery must be intimated to INS Valsura at least 02 weeks in advance to enable proper arrangements at the site. Primary acceptance will be after successful completion of all required factory tests. Final acceptance will be in accordance with the inspection acceptance clauses as set forth in the purchase order. All preservation, packaging, packing and marking containers for items delivered should be in accordance with best commercial practice for tropical climate.
32. Training . The vendor shall be required to forward a training programme and undertake training on the MV Lab for Naval Personnel at INS Valsura premises for a duration in two sessions of approx 01 week each, with an interval of 0612 months. The training should include safety, operation, maintenance & repair aspects relating to the entire facility.
33. Warranty . The equipment with associated controls / instrumentation is to be guaranteed for stipulated performance for 24 months after commissioning. The equipment supplied shall be warranted from manufacturing defects, and for performance for the said period and cover all the defects arising from malfunction through design faults, inappropriate material, bad production and noncompliance with specifications. Any expense because of repairs / supply of spares against guarantee defects is to be borne by the vendor.
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34. Applicable Documents . The documents to be referred for this SOTR are specified in Appendix ‘A’. While every effort has been made to ensure the completeness of the list, document users are cautioned that they must meet all specified requirements of the documents cited in this SOTR, whether or not they are listed. The aspects of Standards and Specifications, Quality Assurance, Installation/ Training and Maintenance have been detailed at Appendices ‘B’, ‘C’, ‘D’, ‘E’, ‘F’, ‘G’, ‘H’, ‘J’ ‘K’ ‘L’ and ‘M’. These do not include documents cited in other sections of this SOTR or recommended for additional information or as examples
Appendix A(Refers to Para 32 )
SUMMARY OF STANDARDS / SPECIFICATIONS APPLICABLE
1. The standards pertaining to various electrical equipment / system are as follows. The latest version of these Specs, at the time of ordering, would be valid for the system:
(a) IEEE 12207 Software Documentation
(b) IEC publication 60034 MV diesel generator
(a) IEC Publication 60034 (All Parts) Generators, MV Motors(b) IEC Publication 60076 (All Parts) MV Distribution transformers(j) IEC Publication 60146 (All Parts) MV Converters(k) NES 607/ 1/IEC Design of MV Distribution System(l) NES 532/ IEC Design of LV Distribution System onboard ships(m) IEEE Std 519 Recommended practices and requirements for Harmonic Control in electrical power systems (n) IEC Publication 146 Voltage THD in switchboards
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(o) Def Stan 615 Part 4, Issue 4 and STANAQ 1008 Quality of Electrical Power Systems(p) IEC Publication 60092352 Cable Laying arrangement(q) IEC Standards for LV Motors, Starters and Control Panel(r) NES530 /IEC LV SwitchboardNES536/NES537/NES538/IEC LV Transformer
Appendix B(Refers to Para 32 )
GENERAL STANDARDS AND SPECIFICATIONS RELIABILITY AND MAINTAINABILITY
1. System Performance .
(a) Design Review . The OEM is required to schedule formal design reviews during the development of the system to ensure that the user requirements and envisaged functionalities are captured correctly at the design stage. The frequency of the design reviews will be finalized during the contract conclusion
(b) Reliability . The system design should be based on standard engineering principles to provide a reliable product. The reliability figures in terms of MTBF / MTTR shall be estimated by the OEM and submitted as part of the technical proposal. The system performance will degrade gracefully in the event of a failure. The system will contain no 'single point' control, whose malfunctioning would result in a catastrophic failure. The functional redundancy will be available in the shortest possible time through hardware/software reconfiguration without loss of data and time. The design will cater for adequate fail safe features.
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(c) Maintainability . The system shall be able to run online and offline maintenance diagnostics centrally. The builtin test equipment (BITE) will be capable of detecting and localising faults down to a single replaceable PCB/Module within 5 minutes of the fault occurrence. The monitoring system will also be designed to indicate corrective action either by a display or through a fault detection code, with amplifying notes used in conjunction with the maintenance manual. The hardware maintenance system will be designed as an offline one and isolation of faulty units in the maintenance mode will be on a nottointerfere basis with the healthy system. The manufacturer will prepare and submit the following data on maintainability:
(i) Maintainability programme(ii) Maintainability prediction
2. MTBF/MTTR . System shall be designed for high MTBF of greater than 8000 hours and low MTTR of not exceeding 15 minutes.
3. Commonality . The manufacturer to mention the level of commonality achieved within the system at the following levels.
(a) Module/sub module level(b) PCB level(c) Component level.
4. Configuration Management . To keep track of the platform specific modifications undertaken on the systems and to ensure suitable documentation of the upgrades incorporated throughout the life cycle of the equipment, there is a requirement for maintaining configuration control. The policy guidelines for configuration management has been promulgated by IHQ vide letter WM/2807/01 dated 26 Sep 07. The supplier is to submit the Configuration Management (CM) document in accordance with these guidelines prior to issue of Inote.
Appendix C(Refers to Para 32 )
GENERAL STANDARDS AND SPECIFICATIONS QUALITY ASSURANCE / CONTROL
1. Quality Assurance . The manufacturer should submit draft QAP (Quality Assurance Programme) to the nominated QA agency before the Technical Negotiation Committee (TNC) meeting. The supplier is required to submit ATP/FAT document to IHQ MoD(N) at least 03 months prior to FATs. The approving authority (IHQ MoD(N)) reserves the right to amend / modify the QAP/ATP/FATs document. The approved QAP/ATP will form basis for inspection/quality checks/acceptance of items/equipment. The equipment supplied by the vendor would be accepted subject to evaluation and clearance by team comprising reps from IHQ MoD(N). The item should be of latest version conforming to current production standard having 100% defined life at the time of delivery. In case of imported items, the inspection of equipment would involve audit of CoCs/test reports by QA authority.
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2. Dedicated software audit including code walkthrough / IV&V will be carried out jointly by Indian Navy. Details of test equipment, test methods, preliminary qualification tests, etc are to be indicated.
3. The QAP checks would be carried out by the Authorized Inspection Agency, as appointed by the Indian Navy. The software audit will be carried out jointly by Indian Navy, STQC/third party.
4. Components . The components used in MV laboratory shall withstand the environment prevalent at Jamnagar, Gujarat in, India. Standard specification and grade of material of each component used shall be indicated in the binding drawings. Make and type of components are to be listed in the binding drawings.
5. Internal Wiring . The internal cabling and wiring is required to conform to IEC standards and ensuring use of Low Fire Hazard (LFH) cables/wires.
6. Test Points . All test points, indicators and controls shall be suitably labeled and the same to be elaborated in the concerned document. All connectors required for the testing needs to be supplied with the equipment.
7. Inspection & Testing .
(a) Inspection .(i) Inspection Authority : IHQ/MoD Navy(ii) Inspecting Officer : Nominated by IHQ MoD Navy(iii) Receipt Inspection : INS Valsura, Jamnagar(iv) Installation : INS Valsura, Jamnagar(v) Base trials : IHQ/MoD Navy /INS Valsura, Jamnagar
(b) The product offered by the manufacturers should conform to standard engineering practices. The system will be subjected to stage inspection and final test and trials by the Naval Inspection Agencies as mutually agreed with the manufacturer. Any deviation from the mentioned specifications will be brought to the notice of IHQMoD (Navy).
13. System Design Reviews & Acceptance. The supplier is to propose methods & procedures for the testing and integration of the system with machinery/equipment and other subsystem during the development. These proposals are to include the description of the level at which individual components of software design are to be tested prior to integration. Description of the approach to testing is to differentiate between implementation, verification and validation of the software. Testing approach is to also include dynamic high fidelity simulation and stimulation. Periodic design reviews of the system will be held as follows:
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(a) Preliminary Design Review(s) (PDRs) . Preliminary Design Review(s) (PDRs would be held at IHQ MoD (N) with participation of the OEM. During the PDR(s), the OEM would be required to present the software design, data protocols, integration details and other system specific design details for approval by the IHQ MoD (N).
(b) Critical Design Review (CDR) . CDR of the system would be held at the OEM premises. During the CDR, final software and hardware designs would be reviewed by the IHQ MoD(N) team. After CDR, the software would be ported on the hardware.
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Appendix D(Refers to Para 32 )
GENERAL STANDARDS AND SPECIFICATIONS EMI / EMC CONSIDERATIONS
1. EMI/EMC Specifications. The entire system should have total electromagnetic compatibility. EMI/EMC checks are to be undertaken as per the IEC specifications. The OEM/Vendor to submit the details of EMI/EMC tests conducted and test reports to IHQMoD (N) for vetting and acceptance.
2. ESD Protection . The system design will take into account adequate measures for Electro Static Discharge (ESD) control and protection at PCB/module/assembly and unit level. Each Electro Static Discharge sensitive part/assembly will be duly marked with a symbol/warning. The manufacturer will use ESD protective materials for handling, packaging storage and transport.
3. Digital Ground . A provision of Digital Ground System is a mandatory requirement. The OEM should adhere to using zero volt as the standard signal reference voltage level. If any system supplier intends to deviate and use any other signal reference voltage than it must be informed to IHQMoD(N). Also this must be clearly indicated by the system supplier in his technical proposal.
4. The cabinets are to be designed for EMI/EMC compatibility by providing suitable EM gaskets and CuBe strips at openings and are to be properly grounded. AC lines are to be filtered for RFI in each cabinet. Shielded twisted pair cables are to be used where signals are susceptible to interferences. Multicore twisted pair cables with overall shield are to be used for signal and control data interconnection and they are to be properly terminated. The DC supplies are to be adequately filtered and each PCB is to be provided with transient suppressors.
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Appendix E(Refers to Para 32 )
GENERAL STANDARDS AND SPECIFICATIONS SUPPLIER’S SCOPE OF SYSTEM SUPPLY
1. The supplier's scope of system supply shall cover the supply of equipment, Installation Material, Spares, Drawings and Documentation, installation supervision, setting to work, testing, on board commissioning, base trials. The supplier is to list down in detail, the deliverables to be provided to the customer at various stages of supply as mutually agreed upon. The complete scope of supply of the system by supplier (depending on whether the subsystems to be interfaced are BFE or to be delivered by the Ivendor) shall include material as given in succeeding paragraphs.
2. Installation Material . One set of installation material that includes intercabinet cables, connectors, shock mounts, special fasteners, special tools, special fittings etc. which shall be supplied by the supplier.
3. Testing and Tuning Spares . The supplier shall recommend one set of Testing and Tuning Spares for each subsystem, as required for STW, and commissioning of the system.
4. Special Tools and Test Equipment . The OEM is to provide details of following test equipment that would be required taking into account IN's maintenance philosophy.
(a) Test Equipment . This should be adequate to meet the requirement of all repairs/ maintenance expected to be carried out by the user.
(b) Special test equipment. Specialtotype test equipment shall be made available in the shore base for specific tests/checks on the equipment.
5. Spares The supplier shall prepare the list of spares (including onboard maintenance tools) based on the Reliability and Maintainability data and taking into account IN’s maintenance philosophy, and shall forward to IHQ MOD (Navy) for vetting during the prebid meeting. The manufacturer should clearly indicate the basis for ranging and scaling of spares. This should include the list of spare parts, tools and accessories, which must be carried on the ship, for preventive maintenance, trouble shooting and quick repairs to ensure no more than 15 minutes of ‘Down Time’ for the system at any given instance. One set of spares is to be supplied with the system. PCBs offered as OBS should also undergo Endurance Test either on a reference system or on main system. However, in case the qty of PCBs is large, Endurance Test to be conducted on a sampling plan, approved by Insp. Authority. List of all spares/items used in the system with the following classification and details is to be provided to the IN during the prebid meeting:
(a) COTS / Non COTS items.(b) PCB or module functionality Processor Function/ Input Output Function
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(c) Memory Devices(d) Digital / Analogue.(e) With /without embedded software.(f) Hydraulic components /Electrical drives(j) Pneumatic control components.(k) Produced by vendor quoting/ sourced.(l) Repairable by vendor quoting/ repaired by third party.(m) Checked by BITE/Not Checked by BITE.(p) Estimated MTBF in hours.(q) Circuit diagrams available/not available.(r) Fittings like Cooling Fans, Filters, Track Ball, Joystick etc.(s) Consumables like fuses, indication lamps etc.(t) Numbers/quantity fitted the system.(u) Shelf life of spare.(v) Itemised cost of all items.
6. Drawings and Documentation.
(a) Firm is required to submit one hard copy and one soft copy of the draft system documents including software documents to IHQ MOD (Navy) for vetting at least 3 months prior to conduct of FATs of the system.
(b) One set of finalised / approved documents should be supplied with the equipment. Additional 6 sets (hard copy) and one soft copy on CD ROM of documents should also be supplied.
(c) Supply of documents will be part of the order and should be costed for in the order.
(d) Documents in CDROM are to be as per Level 4 Interactive Electronic Technical Manual (IETM).
(e) . The vetting and approval of the documents would be done by IHQ, MoD(N)
(f) Software documents (if any dedicated OS, Application software or Embedded software has been utilized in the equipment) should be as per IEEE 12207 standard.
(g) The documentation and drawings shall contain complete information for installation, operation, inspection, maintenance, repair / overhaul, testing and trials and should include the following:
Sl No. DESCRIPTION REMARKS(i) Design Specifications The design specification for
the System and its role needs to be mentioned.
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(ii) User hand book Covering composition and brief description of equipment with block diagram; Technical parameters; Brief technical description with Photographic or graphical representation of each unit; Detailed functional and Operating instructions giving
(iii) Technical manual Covering detailed technical description of each unit with associated drawings and diagrams. It should also include data on Integrated (iv) Installation manual Covering composition of equipment, Cabling diagram and cable specifications, Cable connection schedule, Complete binding data, Installation drawings, List of (v) Maintenance and
Repair manualCovering Instructions on servicing; Planned Preventive Maintenance; on dismantling and assembling of each unit; Faults, their causes and remedial action; Repair, overhaul
(vi) Maintenance Schedule Comprehensive Maintenance Schedules are to be provided along with system. These schedules should cover all the relevant aspects and
(vii) Part catalogue, List ofspare parts, Test equipment
The manual should include(a) Catalogue of parts listing out all the replaceable parts(b) List of spares(c) List of test equipment(d) Service Log Books
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(viii) Test and Trial schedules(a) Inproduction Test Procedures(b) Engineering, Environmentaland Quality Inspection Procedures(c) Factory Acceptance Trials Schedule(d) Installation Check Schedule(e) Integrated Trials Schedule(f) Final Trials Schedule at INS Valsura Jamnagar
(ix) Instructions on Testing & Tuning and Setting To Work
Containing instructions on Testing and Tuning, alignment, Checking and adjustment to individual parts and of the equipment as a whole.
(x) Software Manual
Software logic for the System.
(xi) System Integration Plan
Containing technical details of all the hardware and software interfaces with the external systems.
(xii) 'As Made' drawings
As applicable
(xiii) Test data/certificates
As applicable
(xiv) Firmware Support Manual
This will contain the procedure to reprogram all the programmable devices
(h) Configuration control Documents indicating changes in version to be provided.
7. Binding Data . Three hard copies and two sets on CD ROM of the following binding drawings/ documents are to be supplied by the OEM within 3 weeks of placement of order:
(a) Block diagram of the system
(b) Installation documents covering detailed procedure for installation with sequence of activities.
(c) Installation drawings indicating overall dimensions, C.G., weight, maintenance envelope etc of each unit.
(d) Recommended arrangement of devices in nominated compartments.
(e) Inter unitcabling diagram with cables specifications.
(f) Cable connection Schedule.(g) Power supply scheme for the system.
(h) Heat Dissipation of individual units in compartment & in close loop ventilation system, as required for the system.(j) Parts identification list, indicating part no, qty., maker's name, Specification etc.(k) Requirements for support systems such as firefighting, communication, lighting etc.
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(l) Cable length limitation etc, if any.(m) Detailed foundation drawing including bolting plan.
8. Shipping . All equipment shall be adequately packed and protected with supports to ensure adequate protection during all modes of transportation. Each unit within a package/container shall be clearly marked for identification. The container shall clearly indicate the item description with caution marks, quantity, weight, size etc. A separate document giving details and instructions for storage, preservations, handling and transportation after delivery is to be supplied. The supplier should indicate the delivery schedule, transport, packing, preservation, insurance etc.
9. Preservation, Packaging and Shipping . The stores shall be supplied in longterm preserved condition that is suitable for storage under tropical high humidity conditions for a period of 24 months.
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Appendix G(Refers to Para 32 )
GENERAL STANDARDS AND SPECIFICATIONS INSTALLATION AND COMMISSIONING
1. Installation. Installation of the system will be carried out by the OEM. The responsibilities of the OEM include the following:
(a) Coordination with the IHQ MoD Navy/INS Valsura for the installation work.
(b) Providing instructions to the IHQ MoD Navy/INS Valsura for installation of the system. Cable laying will be done by the shipbuilder before start of the installation activities.
2. SettingtoWork . The supplier shall carry out:
(a) Settingtowork.
(b) Testing and Tuning of the system.
3. FATs and HATs/SATs . The supplier is to offer the system for FATs and Base Trials at INS Valsura as per IHQ, MoD(N) approved schedule.
4. Factory Acceptance Trials (FATs) . The supplier shall prepare a Factory Acceptance Trials (FATs) schedule. Personnel from Indian Navy will be present during such trials. The schedule should state how the supplier would demonstrate that the delivered system will meet the functional and performance requirements indicated as per Indian Navy's SOTR. The factory acceptance trials procedure shall comprise of
(a) Functional Tests
(b) Verification of design, especially firmware and software
(c) Test equipment used, calibration requirements
(d) Pass/Fail criteria
(e) Expected duration and time schedule
5. The FATs schedule formulated by the supplier should be forwarded to IHQ, MoD(N) for vetting and approval at least 03 months prior to the trials.
6. All EMI/EMC and Environmental Qualification tests required need to be completed prior to FATs.
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7. Base Acceptance Trials (HATs) & Sea Acceptance Trials (SATs) . The supplier is required to provide necessary representative(s) to conduct the trials.
8. System Performance Responsibility . In case of any irregularities in the operation / performance of the system or nonconformance to specified parameters observed on integration with ships system, the supplier is bound to rectify the defect. The supplier shall ensure complete responsibility of satisfactory operation of the system on board.
Appendix H(Refers to Para 32 )
GENERAL STANDARDS AND SPECIFICATIONS PRODUCT SUPPORT
IN Maintenance Philosophy
1. Onboard Repair/ Maintenance . Base repair at INS Valsura shall be to replacement at PCB/ Modules (LRU) level. Routine maintenance and serviceability check/terminal performance checks would also be undertaken by user as part of 1st line maintenance.
2. CMC for Repair/ Maintenance . The Isystem being COTS system, all repairs beyond 1st line maintenance will be through CMC contracts with the OEM. The CMC should include (but not limited to) following repair works:
(a) PCB/module repairs down to component level.
(b) Repairs/overhaul/refurbishing and testing of major assemblies/ complete system.
(c) Setting to work, testing and tuning onboard ships after major repairs/overhauls.
(d) Repair and 'calibration of BITE and other test equipment.
Product Support from Vendor
3. The supplier should undertake to ensure guaranteed and continuous product support for a period of 15 years from the date of supply of the first system and associated equipment, by way of the following:
(a) Supply of spare parts and materials.
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(b) Offering of alternative solutions in the event of obsolescence of the components/technologies, including those bought out or subcontracted.
(c) Continuous upgradation program.
(d) Modifications and repairs.
(e) Provide at least two years notice, in the event of any likely production shut down (only after 10 years of support) to enable procurement of LTE spares.
(f) Undertake repairs through Annual Maintenance Contract/Rate Contracts as and when directed by the user / IHQ MoD(N).
(g) Continuous supply of amendments to the documentation.
4. Software Backup . Backup of software used in the system (both on Hard Disks and EPROMs), software reloading jigs and detailed procedure to reload the software is to be provided.
5. Hardware Warranty . The warranty period of MV lab should be for a duration of 24 months from the date of completion of Base Trials at INS Valsura.
6. Training . The Training program objective is to enable the End User Personnel to operate, maintain the MV Lab. The Training package is to include the following:
(a) Basic Training . The manufacturer should undertake the responsibility of training naval personnel (including civilian personnel of the yard), as nominated by IHQ/MoD (N), on the exploitation and maintenance of the MV Lab. The duration of training and number of personnel should be worked out by the manufacturer in consultation with IHQ/MoD (N). Interactive multimedia training modules and suitable software for training on the system be used.
(c) CBTS. CBTs should cover the system as well as the subsystems and must cater for dual level of complexity, i.e. for operator level and maintainer levels. The CBTs must cover exploitation/operator training, elucidated functionalities of the system (working principle of the system, electrical diagrams, mechanical interaction and functional charts) and include trouble shooting modules. Complete check off list for repair and maintenance to be included.
(d) Simulator Software . Suitable software must be provided for carrying out training at locations designated by IN.
(e) Testing and Calibration . The firm shall provide training to IN and Dockyard personnel on testing and calibration of the system.
7. The Training package for the MV lab is recommended as follows (duration in working days):
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SI No.
Course Description No of DurationParticipants (Days)
(a) Operators 7 5
(b) Training staff of IN 3 5(c) Base Maintenance personnel for 1st
and 2ndlevel maintenance 10 5
8. Maintenance . The manufacturer should forward recommended maintenance schedules for preventive and corrective maintenance of the system within three months of placement of order for necessary approval at IHQ.
Appendix J(Refers to Para 1.2)
Appendix K (Refers to Para 32 )
SCOPE OF DELIVERABLES BY VENDORS FOR MV LAB
35. Deliverables . The preliminary scope of supply for the MV Lab constitutes the following, with technical details and specifications as elaborated in the foregoing Paras:
(a) 1.5 MW Diesel Generators (DG) Sets including all auxiliaries, Qty. 02 sets.
(b) Suitable HP Air starting system for both prime movers, including compressor, air storage bottles, air lines, valves and indicators, Qty. 01 set, capable of 03 (three) restarts from storage bottles.
(c) All fuel, cooling water and specialised ventilation / chilling / cooling systems including appropriate storage tanks and cooling tower.
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(d) 6.6 KV MV Switchboard, Qty. 01 No.
(e) 415 V LV Switchboard, Qty. 01 No.
(f) Transformer of suitable Rating 6.6 KV/ 415V, 3 Ph, 50 Hz and HCOS of suitable rating, Qty. 01 each.
(g) 5 MW MV induction motor operating at a suitable voltage between 3 KV and 6.6 KV, Qty 02 No.
(h) Active Front End (AFE) IGBT / IGCT based PWM converter, Qty. 02 Nos with common active front end and common DC Bus.
(j) 2 MW resistive load bank, Qty. 01 No.
15 KW, 50 Hz, 3Phase LV squirrelcage induction motor with pump as load, Qty. 01 No.
(k) Soft starter for LV induction motor, Qty. 01 No.
(l) 15 KW LV DC Motor with pump as load, Qty. 01 No
(m) LV DC Drive to run the LV DC motor at full load, Qty. 01 No.
(n) 15 KW, 50 Hz, 3Phase LV synchronous motor with drive and pump as load, Qty. 01 No.
(p) A suitable Synchronous motor drive, Qty. 01 No.
(q) Local and remote control panels for DG prime movers alternators, MV motor, 4QL machine and drives.
(r) UPS for all control supplies, to provide backup for minimum 30 minutes.
(s) SCADA system including fault injection facility, power management system and BITE.
(t) MV Power Electronics Lab. (as per Para 23)
(u) MV Power Systems Lab. (as per Para 24)
(v) Essential Documentation, Tools / Accessories, including requisite workbenches, safety gears, calibration / test facilities, etc. In addition, the following to be also provided:
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(p.i) Spares as per MRLS.(p.ii) Jigs / fixtures for maintenance / repairs, including lifting brackets(p.iii) Test equipment, rubber mats, operator safety & protection equipment including PPE (Personnel Protection Equipment).(p.iv) Soft discharge rod for discharging static charge buildup upto 11 KV / 6 microfarad.(p.v) Training aids.(p.vi) Equipment operation and maintenance documents.(p.vii) Preliminary & Detailed Project Reports.(p.viii) Draft of 5year Comprehensive Maintenance Contract, to be finalised on expiry of Warrantee period.
(w) The vendor shall provide all system piping and interconnecting cables upto the water connection(s) and power supplies being provided through civil works.
(x) Earthing pit (maintenancefree) and earthing strips, as required.
(y) Suitable stowage containers for all electrical equipment.
(z) Training aids, including computerbased documents / packages and visual & static models.
Appendix L(Refers to Para 32 )
SYSTEM MAINTENANCE REQUIREMENTS
1. In accordance with IHQ MoD(N) policy guidelines in vogue, the MV lab will be maintained through AMC with the respective system OEM. The suppliers are required to furnish following details along with the main system bids:
(a) Indicative cost for AMC as % of main system cost.
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(b)The indicative cost should be separate for comprehensive and non comprehensive AMC along with detailed terms and conditions.
(c) Itemised cost of all spares.
(d)Turn around time for repairs.
(e)The spares should be categorized as per VED rating (Vital, Essential, and Desirable).
(f)Recommended stock level based on system MTBF, VED, MTTR etc. The system MTBF, MTTR and maintainability data should be calculated based on the requirements mentioned in MIL HDBK 217F and MIL HDBK 472 procedure5.
(g) Test equipment for level 1 and level 2 maintenance.
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