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TENDER DOCUMENT FOR SUPPLY OF
SYNCHRONOUS GENERATOR
FOR BALCO
TENDER NO: BALCO/PLANT/SUPPLY/17-18
Head Commercial
Bharat Aluminum Company Ltd.
Commercial Office
Admin Building
BALCO NAGAR
Korba – 495684
Tel: +91 7759 252463 E-mail: [email protected] / [email protected]
INSTRUCTION OF BIDDERS
Vedanta Resources plc (“Vedanta”) is a LSE listed FTSE 100 Company with a market cap
including that of its listed subsidiaries of about $ 50 billion. We operate across the following core
business sectors: Zinc-Lead-Silver, Copper, Aluminum, Iron Ore and Energy, with operation
located in geographies spanning India, Australia, UAE, Zambia, South Africa, Namibia and
Ireland. Over the past 5 years the group has displayed exemplary appetite for organic and
inorganic growth-with an industry leading organic growth program of $ 20 billion nearing
completion.
Bharat Aluminum Company Limited (BALCO) is a group company of Vedanta in Aluminum
business, having its integrated Aluminum complex at Korba, Chattisgarh, comprising an
Aluminum Smelter of 245000 TPA with two captive power plants of 270 MW and 540 MW.
BALCO is also in process of putting up an additional power plant of 1200 MW and 650000 TPA
Aluminum smelter.
What BALCO is looking forward with this Vendor:-
High Level of Service quality.
100% adherence to all the deliverables.
Zero accidents environment.
100% reporting of all the near miss incidents and corrective measures for all to ensure no
accident due to the unsafe conditions.
Increased availability of all the equipments and the total system to ensure better efficiency and
higher levels of productivity.
Ensuring higher productivity per man hour by introducing better Operating Procedures.
Introduction of innovative ideas which can save in terms of time or money.
Information / Credential of Suppliers…..
The following information is Compulsory and should be furnished completed in all aspects along with
your offer.
1. Brief history of organization, along with organization chart, mentioning the Name,
Designation & Tel.Nos of the contact persons in your company holding all key
positions.
2. Client list, with copies Contracts of your Top 5 clients.
3. Banker’s name and your Company’s annual audited report / Balance Sheet for last 2 years.
4. The details of Machinery and Equipment available with you which are in working condition
are to be furnished.
5. If the space provided in the registration form is not sufficient, please attach separate
Sheets and give Annexure reference number on the attached sheet.
6. Registration Details
a. Registration No. and date
(Kindly attach a photocopy of registration certificate)
b. Membership to any body
c. Any other Statutory Registration.
d. Registration details with taxation authorities:
i) Permanent Income Tax A/c No.
ii) Service tax Registration
iii) Tin Number
iv) Excise registration no.
v) LST & CST no.
ANNEXTURE I
BALCO’S GENRAL TERMS AND CONDITIONS TERMS:
1. Price:
Price quoted should be inclusive of Freight & Transit Insurance i.e. F.O.R. Balco Door Delivery
basis.
2. Taxes & Duties:
As applicable
3. Delivery Period :
Delivery period should be offered on the basis of actual manufacturing time and transit time
required to deliver the material at our stores.
4. Payment Terms:
Payment will be released within 30 days after receipt & acceptance of material at our store site.
5. Acceptance of Offers:
BALCO is not bound to accept the lowest offer or to give any reasons for rejection of any offer
and it shall be the sole discretion of the company to consider or reject any bid. A formal Purchase
Order shall be issued by BALCO towards the successful bidder in the event of acceptance of the
offer. Unless a formal Vendor has been concluded no offer shall be deemed as accepted. Balco
reserves the right to award Order to more than one agency or split the order at its own discretion.
6. Modification & Agreement:
BALCO shall have the right to modify the ordered quantity in view of variation of requirement,
price increase / decrease. Modification of Agreement may also take place in Vendor period as it
may be shortened or extended in proposition to our supply pattern as we full depend on our
Vendor’s commitments.
7. Damage To Balco’s Property:
Any loss / damage to Balco due to negligence or willful attitude of the supplier or his employees
while execution of the supplier shall be recovered from the Vendor are pending bills.
8 Occupational Health & Safety:
The vender shall be responsible to take all precautions to ensure safety of the labors / workers at
work. The vender will supply his labors / workers safety equipment as per rules. If you’re
bringing your own equipment to carryout of job inside the plant such equipment should be
subject hazard identifications and risk assessment prior to commencing of work.
The persons engaged by you shall be given appropriate awareness on OH&S; those personal who
will carry out jobs affecting OH&S shall be properly trained and made competent for the job
performed by them. During emergency situation which may be faced in the plant your personal
should move to the emergency shelters. They should not lighter around nor spread any rumor.
12 Indemnity:
The Vendor shall keep Balco indemnified from and against all actions, suits, proceedings, losses,
costs, damage, claim and demands of every nature and descriptions due to any acts of the
Vendor.
13 Insurance:
The will take workmen compensation insurance policy from the Insurance Company so as to
enable him to discharge various liabilities under workmen compensation act and submit
documents within seven days of its start of work. The Vendor shall be required to obtain Group
Insurance Policy for the labors to be engaged in the work.
14 Illegal Gratification:
This Vendor can be terminated if any bribe, commission, gift or advantage given, promised or
offered by the Vendor to any employee of Balco.
15 Liquidated Damage:
Delivery time is the essence of contract, delivery beyond the contractual delivery terms shall
entall Liquidated Damage (LD) @ 0.5% per week of the Total Order value and maximum to an
extent of 5% of the Total Order Value.
17 Force Majeure:
For failure of delivery of material due to war, restraint, imposed by government, earthquake, fire,
explosion, riot, lockout, etc, beyond human control directly interfering with the work, Balco shall
only allow such additional time as may be considered justified by the circumstances of the case.
No claim whatsoever of compensation from the Vendor for loss etc. on this account shall be
entertained. Direct or indirect loss, if any, to Balco due to negligence of the Vendor during this
period, on this account can however be recovered from the Vendor.
18. Arbitration:
In case of any dispute or difference between the Parties the matter shall be decided by mutual
negotiation & agreement. If any difference persists on a matter of law or interpretation of this
document the decision of mutually appointed arbitrator would be final & binding. All disputes
arising out of or in connection with the present Vendor shall be finally settled under the Rules of
Arbitration of the International Chamber of Commerce by one Arbitrator appointed in
accordance with the said Rules. The Contract shall be governed by, construed and interpreted in
accordance with the laws in India. The venue of Arbitration shall be at Korba India only. The
Arbitration shall be held in English language and the award of the Arbitration shall be final and
binding to both the parties.
27. Jurisdiction:
This Vendor will be subject to Korba, Chhattisgarh Jurisdiction only for all legal matters.
1.00.00 GENERAL
1.01.00 Make :
Jinan Power
Equipment Factory
1.02.00 Type :
WX21Z-073LLT
1.03.00 Reference Standard :
GB/T7064-2002
1.04.00 Enclosure :
IP54
1.05.00 Type of Cooling
a) Stator Winding :
Air-cooled
b) Stator Core :
Air-cooled
c) Rotor :
Air-cooled
d) Main Exciter :
ÎÞ£¬¾²Ö¹Àø´Å
1.06.00 Rated Speed r.p.m. :
3000
2.00.00 MAIN RATINGS
2.01.00 Guaranteed Ratings at designed closed
cycle auxiliary cooling water inlet
temperature and 0.8 Lagging Power
Factor
a) Rated output MW :
135
b) Maximum continuous rating (M.C.R.) MW :
135
c) Rated Power Factor :
0.8
d) Rated Terminal Voltage KV :
13.8
e) Rated Stator Current Amps. :
7060
f) Phase Nos. :
3
g) Rated Frequency Hz :
50
h) Excitation at rated output
i) Voltage Volts :
252.8
ii) Current Amps. :
1526.7
i) Short Circuit Ratio at rated output :
0.475
j) Permissible ± Tolerance in S.C.R. :
±15%
2.02.00 Ratings at designed closed cycle auxiliary cooling
water inlet temperature and 0.85 lagging Power
Factor
a) Continuous output MW :
143
b) Maximum continuous rating (MCR) MW :
143
c) Excitation at Continuous Output
i) Voltage Volts :
245.0
ii) Current Amps :
1478.8
2.03.00 Ratings at designed closed cycle auxiliary
cooling water inlet temperature and 0.9
Lagging Power Factor
a) Continuous output MW :
151
b) Maximum continuous rating (MCR) MW :
151
c) Excitation at Continuous Output
i) Voltage Volts :
235.8
ii) Current Amps :
1422.8
3.00.00 PERFORMANCE
3.01.00 Efficiency at rated p.f.
a) 100% load
% : 98.72
b) 75% load
% : 98.57
c) 50% load
% : 98.15
d) 40% load
% : 97.5
e) 25% load
% : 96.73
3.02.00 At Generator Rated Output, Rated Speed
& Power Factor, the Permissible Variation
Range in
a) Terminal Voltage
% : ±5
b) Frequency
% : -5 % to +3 %
c) Absolute sum of combined voltage and
frequency variation
%
: ±5
3.05.00 Generator Reactive Capability
a) Maximum Inductive Loading (Zero Lag) MVAR : 110
b) Maximum Capacitive Loading (Zero Lead)
MVAR : 110
c) Capacitive Loading at Rated Load (MW) and
Voltage
MVAR : 101.25
3.06.00 Permissible Unbalanced Loading subject
to current not being exceeded the rated
current in any phase
a) Maximum continuous negative sequence
current - I2
% : 8
b) Maximum value of I22t for transient
operation under system fault (I2 in p.u. and
t in secs)
: 10
3.07.00 Generator Asynchronous Operation
a) Permissible Load
% f.l. : 67.5
b) Duration
min. : 15
3.09.00 Overload Performance
a) Stator Current
% f.l. : 150
b) Time
Sec. : 30
3.11.00 Maximum Continuous Generator Capability
under One cooler section out of operation
MVA : 80%
4.00.00 TEMPERATURES
4.01.00 Ambient Temperature
a) Cooling Water at Inlet to Heat Exchanger
°C : 33
b) Ambient Air
°C :
4.02.00 Guaranteed Temperature Rise over
specified Ambient Temperature
a) Stator Winding
°C : 60 Deg C
b) Stator Core -
i) In contact with Insulated Winding
°C : 55 Deg C
ii) Not in contact with Insulated Winding
°C : 55 Deg C
c) Rotor Winding
°C : 50 Deg C
5.07.00 Maximum Allowable Overspeed
r.p.m. : 3600
6.00.00 REACTANCES ETC. (In % at Rated MVA &
KV)
6.01.00 Direct Axis Reactances (Saturated/
Unsaturated)
a) Synchronous - xd
% : 235/210.6
b) Transient - xd'
% : 25.5/23.9
c) Sub-transient - xd"
% : 19.3/15.1
6.02.00 Quadrature Axis Reactances (Saturated/
Unsaturated)
a) Synchronous - xq
% : 220.2/220.2
b) Transient - xq'
% : 41.5/37.3
c) Sub-transient - xq"
% : 20.7/15.9
6.03.00 Negative Sequence Reactance - x2
% : 19.7/15.7
6.04.00 Zero Sequence Reactance - x0
% : 8.3/6.5
6.05.00 Potier Reactance - Xp
% : 25.3
6.06.00 Permissible Tolerance in all Guaranteed Reactance
Values
% : ±15
6.07.00 Effective Winding Capacitance to Earth
a) Per Phase
mfd : 0.437
b) All phases connected to earth
mfd : 1.311
6.08.00 Effective Surge Impedance to Neutral per phase
ohm :
6.09.00 Armature Resistance per Phase at
a) 25°C
ohm : 0.001028
b) 75°C
ohm : 0.001226
6.10.00 Field Resistance at
a) 25°C
ohm : 0.1256
b) 75°C
ohm : 0.1491
7.00.00 TIME CONSTANTS
7.01.00 Direct Axis Transient
a) Open Circuit Time Constant Td'o
Sec. : 9.455
b) Short Circuit Time Constant Td'
Sec. : 1.028
7.02.00 Direct Axis Sub-transient
a) Open Circuit Time Constant Td"o
Sec : 0.023
b) Short Circuit Time Constant Td"
Sec : 0.017
7.03.00 Quadrature Axis Transient
a) Open Circuit Time Constant Tq'o
Sec : 0.905
b) Short Circuit Time Constant Tq'
Sec : 0.170
7.04.00 Quadrature Axis Sub-transient
a) Open Circuit Time Constant Tq"o
Sec : 0.034
b) Short Circuit Time Constant Tq"
Sec : 0.017
7.05.00 Armature Short Circuit Time Constant Ta
Sec : 0.578
8.00.00 SHORT CIRCUIT CURRENT (In p.u.)
8.01.00 Sub-transient Current
a) 3-Phase Short Circuit
% : 663.6
b) 2-Phase Short Circuit
% : 497.6
c) 1-Phase to Neutral Short Circuit
% : 695.1
8.02.00 Transient Current
a) 3-Phase Short Circuit
% : 418.8
b) 2-Phase Short Circuit
% : 397.1
c) 1-Phase to Neutral Short Circuit
% : 577.3
8.03.00 Steady State Current
a) 3-Phase Short Circuit
% : 146
b) 2-Phase Short Circuit
% : 236
c) 1-Phase to Neutral Short Circuit
% : 397
9.00.00 DESIGN AND CONSTRUCTION
9.01.00 Stator Core
a) Type of Mounting : laminated
b) Grade of Steel
i) Thickness mm : 0.5
ii) Loss figure Watt / Kg : 0.0031
c) Generator air gap mm : 55
9.02.00 Stator Winding
a) Winding transposed Yes/No : Yes
b) Phase connection : Y
c) Insulation
i) Class : F
ii) Type : Micadur-Compact
iii) Corona protection : outer
d) Dielectric test voltage kV : 28.6
e) Impulse voltage strength kVp :
f) Insulation Class
i) Slot : F
ii) End coil : F
g) Arrangement of partial discharge
measurement within stator windings during
running condition of generator
Yes/No : yes
9.03.00 Terminals
a) No. of Terminals brought out
i) Phase : 3
ii) Neutral : 3
b) Type of terminal bushings : No
c) Net space available for mounting bushing
current transformers
: no
d) Bushing CT furnished Yes/No : No
e) If yes state No. and specification of Bushing
CT
: No
f) Dielectric test voltage KV :
9.04.00 Rotor
a) Material for
i) Rotor forging : 26NiCrMoV145
ii) Retaining ring : X8CrMn1818
iii) Rotor wedge : CuNi2Si
9.05.00 Rotor Winding
a) Insulation
i) Class : F
ii) Type : Nomex
b) Turns per pole : 12
c) Dielectric test voltage KV : 2.528
9.06.00 Bearing
a) Type : Bracket
b) Oil quantity per bearing lit/sec : 164
c) Oil pressure Kg/ cm²(g) : 1.2
10.00.00 EXCITATION SYSTEM
10.01.00 Nominal Exciter response ratio
a) With generator at no load Sec-1 :
b) With generator at rated load Sec-1 : ¡Ý2
10.02.00 Excitation System voltage response time Sec. : ¡Ü0.1
10.03.00 Ceiling Current Amps : 3053.4
10.04.00 Ceiling Voltage Volts : 505.6
10.05.00 Ceiling Duty duration Sec. :
10.06.00 "Rapid De-fluxing" time and the technique used
Sec. : 1.8
10.07.00 Type pf de-excitation system : ¿ª¹ØÃð´Å
10.08.00 Field reversal capability :
10.09.00 Excitation system time constant Sec. :
10.10.00 Auxiliary power requirement KW :
10.11.00 Forced Cooling System requirement :
10.12.00 Base field voltage Volts :
10.13.00 Natural frequency of T.G. torsional oscillations
Hz :
10.14.00 Space requirement including clearance mm :
10.15.00 Shelf life of the solid state spares :
10.16.00 Time for which spare parts (including solid state)
will be kept available
:
11.00.00 AUTOMATIC VOLTAGE REGULATOR
11.01.00 Make : Guangzhou Electric
Apparatus Research
Institute
11.02.00 Type : Exc2000
11.03.00 Power supply to regulator Volts : 252.8
11.04.00 Range of Voltage adjustments
a) Auto : 10-130
b) Manual : 5-130
11.05.00 Range of Operation
a) Frequency Hz :
b) Temperature °C : 0-50
11.06.00 Accuracy : £¼0.5%
11.07.00 Dead Band :
11.08.00 Response time to apply field forcing voltage with a
5% drop
milli sec. :
19.00.00 GENERATOR LOSSES
19.01.00 Iron Loss
a) At no load KW :
b) At full load KW : 292.8
19.02.00 Stator Copper loss KW : 183.4
19.03.00 Rotor Copper Loss
a) At no load KW :
b) At full load KW : 298.6
18.04.00 Stray Load Loss KW : 203.0
18.05.00 Friction and windage loss KW : 752.5
18.06.00 Excitation Losses
a) Exciter loss KW : ÎÞ
b) Rotary rectifier loss KW : ÎÞ
c) Collector-brush contact loss KW : 17.1
20.00.00 MAIN WEIGHTS
20.01.00 Weight of the Generator Stator Tonnes : 131.6
20.02.00 Weight of the Generator Rotor Tonnes : 33.7
20.03.00 Weight of the Complete Generator (Stator plus
Rotor)
Tonnes : 172.1
SCOPE FOR VENDOR
In CPP-2 of BALCO, we are having four units of 135MW each. The generator of units was supplied by M/s
Shandong Jinan Power Equipment Factory, China. The Specifications and other details of generator are given in
separate document. The design of generator is based on GVPI technology.
We are in the process of going for complete replacement of “Generator Stator Shell” in one of our units with
stator shell made by GVPI technology. We are looking for any renowned machine manufacturer / service
provider, who can supply complete stator shell with 100% compatible to installed stator of generator in term of
both mechanical and Electrical design and dimensions.
The scope for the vendor will be as follows:
1. Vendor will supply complete stator shell, processed with GVPI technology, which can replace
installed generator stator without disturbing alignment of the machine with turbine, bearing
pedestal and other connected systems.
2. Pre-measurement of Generator in coupled condition to be done by vendor for dimensions and
alignment
3. De-coupling and Rotor thread – out to be done by vendor
4. Dismantling of installed stator shell to be done without damaging any other structure / equipment
to be done by vendor. In case of any damage, Vendor will rectify/replace for free of cost.
5. Positioning and proper installation of newly manufactured stator shell will be done by vendor with
proper care and safety.
6. Disconnection and connection of all electrical and mechanical interfaces/connections has to be
done by vendor
7. Rotor Thread-in to be done by vendor after proper installation, commissioning tests on generator
stator.
8. Alignment and coupling of generator rotor with turbine and giving clearance for unit startup.
9. Performing any dynamic testing if required after starting of turbine rolling.
Other conditions:
BALCO will provide OEM design drawings / other developed drawings to the vendor
Vendor will design, get approval from EIC of BALCO for designs of stator bars, core laminations, and
end rings Etc., before starting their manufacturing process.
Vendor will intimate BALCO regarding process of manufacturing process and same will be
supervised by BALCO as per requirements.
All factory tests for generator core, stator bars, complete shell has to be done as per Standards, will
be witnessed by BALCO.
Transportation of manufactured stator shell will be arranged by vendor, up to BALCO site, in well
packed condition, which will be free from any moisture and dust ingress.
All the tools and tackles required for dismantling and installation of generator will be arranged by
vendor.
All the consumables and other materials will be arranged by Vendor.
Only Power source and EOT crane will be arranged by BALCO to the execution of all jobs related to
stator replacement. EOT crane operator has to be arranged by vendor.
All kind of transportations, for materials, consumables, testing kit, manpower and any other
resources will be with vendor’s scope.
Boarding and lodging for the team coming for stator replacement work will be arranged by vendor.
BALCO only will provide local transportation of the vendor’s team from the point of local lodging to
the plant.
Performance deliverables:
1. Vendor will supply the complete stator shell within 6 months from the date of Order
2. Complete replacement of stator shell to be completed at site within 12 days ( from the day of stopping
of turbine barring to clearance for barring gear start after replacement)
3. Warranty for the supplied generator stator and workmanship will be for 10 Years from the day of
machine taken in service after stator replacement.