TENDER NO: RSO/ENG/LT-70/2018-19

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TITLE: – Provision of Roof-Top 10 KVA Solar Power Plant in BPI-3 at 1 of 12
Jaisalmer AFS

CONTRACTOR’S SCOPE OF WORK

Design, Supply, Installation, Testing & Commissioning of roof top Solar PV system including panels,
power conditioning units / inverter, support structures, cables etc complete at various locations of
Rajasthan State Office as per BOQ.
A) Indicative Design:

a. The system shall feed the solar energy to the load+grid.

b. In case of grid failure, the standby inverter shall create a captive grid and SPV power keeps feeding
to this captive grid. (dotted line)
c. In case of low solar irradiation or cloudy weather, the deficit power is taken from the grid or DG.
(dashed line)
d. System configuration must conform to Indian grid system (TT-N; 3-phase, neutral &
earth).

In general, the priority of usage of input energy sources should be in the following order:
a. First Priority - Solar
b. Second Priority - Solar + Grid
c. Third Priority - Grid
d. Fourth Priority - Diesel Generator

There should be no break in the supply (transfer time between supplies to be less than 10
milliseconds) while changing from one mode to another mode of operation.
The important criterion to be taken care during various stages like design, construction,
commissioning and maintenance have been enumerated below, these points may be taken care while
firming up the contract for SPV.

B) Design:
While designing, the (Engineering Procurement and Construction) EPC contractor is expected to
optimize the capacity of the plant for achieving the overall cost effectiveness i.e. minimum levelized
cost of generation in Rs/kWh.
Guidelines to be taken care by the EPC contractor during designing the SPV are elaborated as below:
a. SPV Modules:
• SPV Modules with optimum power rating to be used in appropriate combination
(series/parallel) for optimized power generation.
• Mono / Poly Crystalline PV cells to be used of ~ 250-310 watt size & with efficiency greater
than 15.5 %.
• Cell efficiency in the Solar PV should typically be 18%-20% or higher.
• Tolerance in output power shall be allowed - 0 % to +3 %.
• Modules to confirm IEC 61215, IEC 61730, IEC 62804, IEC 61853, IEC 62548 standards.
• Number of modules, Modules per string and total array capacity to be finalized to match the
requirement of inverter
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TITLE: – Provision of Roof-Top 10 KVA Solar Power Plant in BPI-3 at 2 of 12
Jaisalmer AFS

• Design to also include:

o Details of PV Array - Fixed Structure
o Tilt Angle [Latitude of the location in o] of module is generally equal to latitude angle
of the location. Variation is allowed to optimize the generation suited to roof design.
o DC Bus voltage & current
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TITLE: – Provision of Roof-Top 10 KVA Solar Power Plant in BPI-3 at 3 of 12
Jaisalmer AFS

• Details of protections to be deployed on PV array and AC output side, Over Voltage, Over
Current & Surge Protection SPV module structure to be designed according to maximum wind
load of the location and roof structure of the building. Design of SPV module structure and
distribution of load on roof top shall be prepared by civil/ structural engineer. The structural
design should preferably be vetted by engineering cell of IndianOil.
• Proposed system to be designed for synchronizing with the existing power system.

• Data networking cabling as per site requirement from PV solar system to existing plant room
and LT Panel Room (recommended for higher size solar plants only).
• PV modules to be used in a highly corrosive atmosphere (coastal areas,etc.) must qualify Salt
Mist Corrosion Testing as per IEC 61701 / IS 61701.
• Each PV module must use a RF identification tag (RFID), which must contain the following
information:
o Name of the manufacturer of PV Module
o Name of the Manufacturer of Solar cells
o Month and year of the manufacture (separately for solar cells and module)
o Country of origin (separately for solar cells and module)
o I-V curve for the module
o Peak Wattage, Imax, Vmax and FF (Fill factor) for the module
o Unique Serial No and Model No of the module
o Date and year of obtaining IEC PV module qualification certificate
o Name of the test lab issuing IEC certificate
o Other relevant information on traceability of solar cells and module as per ISO 9000
series.
• Performance of PV modules must be tested at STC (Standard Testing Conditions) and
approved by one of the IEC / NABL Accredited Testing Laboratories including Solar Energy
Centre and certification of the same shall be provided by the supplier/ vendor.
• Backsheet: Backsheet play a critical role in protecting PV modules and delivering needed
module lifetime. They protect the modules from the environment while providing electrical
insulation. The impact can be very significant. Backsheet failures can lead to module failure
modes such as catastrophic failure, unacceptable power degradation and safety failures.
Backsheet should be made up of Fluoro Polymers like PVF (Poly Vinyl Fluoride) or PVDF (Poly
Vinylidene Fluoride).
b. SPV Plant accessories and peripheral
Power conditioning units / Inverter
• Individual Inverter efficiency should be greater than 95%.
• Inverter operating temperature should be designed considering the ambient
• Temperature of the location.
• Transformer-less design of Inverters is preferred.
• String inverter should be supplied.
• Inverter size to be optimized to achieve maximum power and reliability.
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TITLE: – Provision of Roof-Top 10 KVA Solar Power Plant in BPI-3 at 4 of 12
Jaisalmer AFS

• Central inverter are used for cost optimization and ease of maintenance
• Total Harmonic distortion (THD) to be less than 3%.
• Optimum number of PCU/inverters to be considered.
• In case of centralised inverters, the inverter shall have low voltage ride through feature.
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TITLE: – Provision of Roof-Top 10 KVA Solar Power Plant in BPI-3 at 5 of 12
Jaisalmer AFS

Cables
• For PV module interconnections cable to be rated for min. 90 deg. C., UV resistant, copper
only to be used.
• Cable to be routed / laid in standard manner through cable trays & cable marker to be placed
for future identification in case of underground laying.
• For protection of unarmoured cables suitable conduit to be provided.
• UV resistant cables is to be used.
Junction boxes
• The enclosure rating shall be IP-65
Module Mounting Structure
• Module mounting structure to be constructed using durable and sturdy material like
galvanized iron.
• Bend perlins or any other component of module mounting structures to be rejected.
• Stainless steel fixtures (nut/bolt) to be used at site with hot & humid conditions.
Earthing
• Soil resistivity measurement at the site need to be undertaken prior to deciding on earthing
solutions required.
• Ensuring requisite earthing for inverters, junction box, SMU etc. as per standard procedure.
• Electrodes with proven quality as per IOC approved makes.
• Each row in the solar array need to be earthed and all earthing electrodes need to be
interconnected to form a earthing grid.
• Earthing to be provided as per IOCL approved drawing.
D) Supply of Components and Materials as detailed/ required in line with point (C) above
E) Installation of Components and Materials
Description:
a. Supply and installation of Module mounting structure/ super structure for mounting at roof
top.
b. The PV modules shall be installed with necessary tilt with the most effective orientation. Tilt
angle to be optimized to obtain maximum generation.
c. Supporting structure material shall be compatible with the PV panel mounting frame.
d. Supply and installation of power conditioning unit (PCU) consisting of Solar Charge Controller/
Inverter.
e. Supply & Installation of Battery Bank and Battery Charger System.
f. The installation shall include the electrical wiring, cabling, terminations, cable trays, micro/
string inverters, metering and hooking up the system to the including synchronization with
plant main LT Panel grid / DG set.
g. Installation of inverter should be in a ventilated area and proper inter-spacing is to be
provided.
h. Laying of power/ control copper cables from PV power to plant room, Main LT panel including
within terraces.
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TITLE: – Provision of Roof-Top 10 KVA Solar Power Plant in BPI-3 at 6 of 12
Jaisalmer AFS

i. Supply and installation of cables on prefabricated GI cable trays and / or within suspended
ceiling spaces including installation, cable trays, hangers, supports, cable terminations all
fixing accessories (terrace to plant room inclusive of PVC sleeve/ other accessories etc.
wherever required)
j. Supply and installation of earthing system with testing joint for every pit (grounding) system
including cutting of roads / paved areas / PCC floor etc and making as good as in original
shape. Prior to execution, design shall be submitted by contractor for approval by IndianOil.
k. Supply and installation of lightening arrester, required as per statutory norms/ guidelines as
approved by IndianOil.
l. Danger notice plates at some prominent locations as per IS: 2551.
m. Rubber mats of adequate thickness shall be placed in front of electrical panels.
F) Testing & Commissioning
Pre-commissioning tests of all electrical equipment. Specific points to be considered during
commissioning are:
• Continuity checking and insulation resistance measurement of cables.
• Proper crimping, lugging and glanding of cables before final terminations.
• Checking of all electrical terminations for any loose contacts.
• Proper earthing of electric equipment & solar array to be ensured.
• At junction box in solar array, voltage levels to be checked (between positive & negative
terminal, positive to earth and negative to earth) in consultation with inverter OEM.
• Inverter to be checked in testing mode and after No Fault indication is displayed on LCD it is
to be connected to grid/battery.
G) Guarantee :
Vender shall have final and total responsibility for the design and performance of all the equipments
supplied under this specification. The equipment and material shall be guaranteed for trouble free
operation for a period of 24 months from the date of commissioning. Any defect discovered during
this period shall be rectified free of charge. This includes:
• Half yearly Functional Checks of Protection circuits and Switchgear
• Checking for loose structural nuts and bolts and cable terminations between PV modules, PV
arrays, line accessories, transformers and associated switchgear on the HT side etc.
Retightening connection and replacing cables/ MC4 connectors if necessary.
• The repair/ replacement work shall be completed within 48 hours from the time of reporting
the fault.
• During the two year guarantee period, all replacements are to be done by contractor.
• A half yearly performance report of the plant inclusive of energy generation data shall be
provided as per approved format.
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TITLE: – Provision of Roof-Top 10 KVA Solar Power Plant in BPI-3 at 7 of 12
Jaisalmer AFS

MATERIAL SPECIFICATIONS
Suggested material specifications as per applicable BIS/ IEC standard/ MNRE are given as below
Item / System Applicable BIS /Equivalent IEC Standard
Or MNRE Specifications
Standard Description Standard Number
Charge Controller/MPPT Environmental Testing IEC 60068-2 (1,2,14,30)
units Efficiency Measurements / Equivalent BIS Std.
Power Conditioners/ Environmental Testing IEC 61683 / IS 61683
Inverters**including MPPT IEC 60068-2 (1, 2, 14, 30) /
and Protections Equivalent BIS Std.
Storage Batteries General Requirements & As per relevant BIS Std
Methods of Testing Tubular
Lead Acid / VRLA / GEL Capacity
Test
Charge/ Discharge Efficiency
Self-Discharge
Cables General Test and Measuring IEC 60227 / IS 694
Method PVC insulated cables IEC 60502 / IS 1554 (Pt. I & II)
for working voltage up to and
including 1100 V and UV
resistant for outdoor
installation
Switches/Circuit Breakers General Requirements IEC 60947 part I,II, III / IS 60947
/Connectors Connectors –safety A.C. /D.C. Part I,II,III
EN 50521
Junction Boxes General Requirements IP 65 (for outdoor)/ IP 54 (for
/Enclosures indoor) as per IEC 529
for Inverters/Charge
Controllers/Luminaries

**In case if the Charge controller is in-built in the inverter, no separate IEC 62093 test is required and
must additionally conform to the relevant national/international Electrical Safety Standards wherever
applicable.
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TITLE: – Provision of Roof-Top 10 KVA Solar Power Plant in BPI-3 at 8 of 12
Jaisalmer AFS

H) DOCUMENTATION

The complete documentation should be as per IEC 62446 and submitted to IOCL in triplicate.

2.1. One set of operation manuals complete with drawing, parts list (with part codes) circuit diagrams
with list ratings of components and list of do’s and don’ts for the main equipment as well as the sub-
systems should be submitted to IOCL.
2.2. One set of maintenance manuals with full information on drawings, circuit diagrams, list and suppliers
addresses for bought out parts, troubleshooting charts, programs of built in controllers etc. for the main
equipments as well as for the sub-system.
2.3. These manuals should be in the form of hard (printed) copy in English Language as well as in electronic
storage form (disc pen drive etc.).
2.4. A certificate for the adequacy of the manuals should be obtained and provided with the manuals.
Such certificate must be signed by the QA engineer of the manufacturer.

I) QUALITY ASSURANCE PLAN

The Bidder shall submit model Quality Assurance plan as applicable for equipments/Components covering
major phase of namely, design & Engineering, Procurement & ordering, Post Ordering, Site Execution in
clear terms. Quality Assurance Plan should include design control, process control, quality control, testing
of subsystem, integration and bill of material intended to be used. The same must be
submitted to IOCL with drawing approval. The basic minimum elements that must be addressed in Quality
Assurance plan are:

• Design & Engineering Phase

o Design input review.
o Checking and design verification through design review.
o On-site design modifications and its approval and incorporation mechanism.
o Submission / re-submission of drawing for approval.
o Drawing distribution and associated document control.
• Procurement & Ordering Phase
o Assessed sub-contractor base.
o Purchaser’s & Supplier’s verification of sub-contractor’s supplier / services.
o Agreement on acceptance criteria through approval of Quality Assurance Plan.
• Post Ordering Phase
o Approval, planning and monitoring of manufacturing processes.
o Handling, storage, packaging and delivery specification to avoid deterioration /
o damage of plant / equipment / components / materials supplied.
o Inspection and testing with specific reference to:
o Acceptance criteria and traceability to standard code.
o Fulfillment of pre-inspection and post inspection documents and their processing.
o Calibration requirements.
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TITLE: – Provision of Roof-Top 10 KVA Solar Power Plant in BPI-3 at 9 of 12
Jaisalmer AFS

o Positive recall system, wherever applicable.

o Distinct identification tags for acceptance / rejection.
o Control of non-conformance & correction plan.
• After supply and commissioning of Solar PV system at IOCL Chittorgarh and Jodhpur Terminals
o Operation and Maintenance Manual
o As Built drawings and system details
o Final BOM with make and rating of each component along with OEM Manuals of
Inverters.
o A Two (02) day on site classroom and hands-on training shall be given to IOCL personnel
for operating and maintaining free of cost.
o Training on O&M for 03 persons for 05 days shall be given by Vendor at vendor works free
of cost.
o Completion drawings: Contractor shall submit complete drawings set before start of the
job and after completion of the work with changes incorporated. These “As Built”
drawings shall be submitted in the form of four sets of CD’s and four portfolios (300 x 450
mm) each containing complete set of drawings on approved scale indicating the work as
- installed. These drawings shall clearly indicate following:
 Location and rating of PV arrays.
 Location and details of panels, and other particulars including approved
fabrication drawings of panel.
 Complete wiring diagram, as installed and scheduled showing all connections
in the complete electrical system.
 Routing and particulars of all cables and trays.
 Single line diagram, power schematic, control schematic with detailed bill of
materials, showing makes, types and description of all components and
accessories. The supplier shall provide easy-to-use illustrated installation and
operation manual in English for easy installation and trouble-free usage. Manual
shall contain complete system details such as array layout, schematic of the
system, working principle, clear instruction on regular maintenance, trouble-
shooting of the solar generating system, emergency shutdown procedure, etc.
J) GUARENTEE, WARRANTY AND PERFORMANCE

a. The Bidder shall study the specification and satisfy himself thoroughly regarding the workability
of the plant, equipment and systems offered and also take full responsibility for the guaranteed
operation and performance of the same as well as for their smooth safe and reliable working.
b. All equipment shall be guaranteed for workmanship, materials design and satisfactory
performance to the parameters in accordance with the specification document and relevant
clauses of the Purchase Conditions of Contract. The guarantee for performance shall cover
individual items and systems for their ratings / outputs, life and reliability. The bidder shall have
final and total responsibility for the design, electrical and mechanical performance of the entire
system under this Material Requisition.
c. PV modules used in solar power plants /systems must be warranted for their output peak watt
capacity, which should not be less than 90% at the end of 12 years and 80% at the end of 25 years.
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Jaisalmer AFS

d. The mechanical structures, electrical works including power conditioners/inverters/maximum

power point tracker units/distribution boards/digital meters, etc. and over all workmanship of the
SPV power plants/ systems must be warranted against any manufacturing/ design/ installation
defects for a minimum period of 5(Five) years.
e. Any defect found in SPV module, PCU or any other accessories during warranty period will be
replaced by the successful bidder free of cost within a period of maximum one month.
f. The system must be designed for highest possible performance ratio (PR) with minimum of 78%.
In case the guarantee is not met, the Penalty shall be imposed on bidder based upon the shortfall
in generation @ 20 Rs/KWH. on annual basis i.e.
a. The expected generation of electrical metered energy keeping 78% of PR = X
units
b. The actual generation of electrical metered energy in a year = Y units.
c. Shortfall in units = Z = X-Y units
d. Penalty imposed = Z x 20 Rs.
The amount shall be recoverd from O&M charges / PBG.
K) COMPREHENSIVE ANNUAL MAINTENANCE

The sole objective of this Operation and AMC job is to get the designed results for this 10 KWp Solar PV
power system for Jaisalmer AFS. The Comprehensive Annual Maintenance Contract (AMC) for the initial
period of 02 (Two) years [at no extra cost to IOCL] shall be started just after successful commissioning and
handing over of completely working system in all respect to IOCL. However the contract is further
extendable for next three years (Binding to the vendor). Hence vendor shall have to make arrangements
for the annual O&M contract for 5(Five) years in a row.
The Comprehensive Annual Maintenance shall start after successful completion of the
During the contract duration, the contractor shall be fully responsible for smooth functioning and
delivering designed results. Further during the contract duration, the contractor shall also be responsible
to maintain the SCADA system of this solar power plant and generating relevant data as when asked.

2.0. Scope of Annual O&M Contract:

Operation and maintenance contract for 5 years from the date of commissioning is to be taken. Scope of
the O&M contract includes the following but not limited to:

2.1. O&M of Solar Panels

2.1.1. Weekly measurement of string currents to be undertaken to identify faulty strings. In case of faulty
strings, connectors/ fuse at junction box to be checked for failure and to be replaced accordingly.
2.1.2. Fortnightly cleaning of solar panels with water and other approved cleaning agents to be done if
required. For this purpose IOCL shall supply water free of cost. Water tap terminals shall be provided by
IOCL in the proximity of selected building. Vendor shall arrange its own hose/ pipe for cleaning purposes.
2.1.3. After washing of the panels wiping shall be done. It is most critical activity as transparency of cover
glass directly influences energy generation levels.
2.1.4. Monthly checking for loose structural nuts and bolts and retightening.
2.1.5. Adjusting the tilt and clearance.
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2.1.6. Tightening of cable terminations at junction box.

2.1.7. Vendor personals shall take utmost precautions to avoid any damage to the system while cleaning
and other maintenance activity. Damaged solar modules to be replaced immediately.

2.2. O&M of Inverters

2.2.1. Monitoring of inverter wake-up in the morning.

2.2.2. Periodic measurement of voltage/current at critical locations (as per OEM instruction) for timely
identification of abnormality.
2.2.3. Cleaning of inverter regularly against dust deposition.
2.2.4. Cleaning of air filters.
2.2.5. Checking for any loose connections and retightening at the inverter terminals.

2.3. O&M of weather stations and metering units

2.3.1. Regular cleaning of quartz dome of Pyranometer and replacement of desiccant periodically as per
desiccant color indication.
2.3.2. Checking the condition and mounting of module temperature probes and ambiance temperature
probes.
2.3.3. Checking the condition of anemometer.
2.3.4. Checking the condition and working of digital energy meters.
2.3.5. Calibration and replacement of these sensors and meters as when required as suggested by the
OEM or found defective.

2.4. Spare Management

Critical spares to be identified in consultation with OEM and IOCL and need to be maintained at plant in
order to minimize the outage time in case of any fault or breakdown
• Module spares: MC4 connectors, junction box fuses.
• 4-5 modules if kept in spare will ensure timely replacement of damaged modules.
• Inverters/PCU spares: IGBTs, DC capacitor, PDC cards etc.

2.5. O&M activities related with safety

2.5.1. Earth Resistance Measurement: Earth resistance of earthing electrodes to be measured periodically
i.e. measurement in connected mode on monthly basis and in disconnected mode on quarterly basis.
Acceptable value of earth resistance for solar array is less than 2 ohms. Digital earth resistance tester of
reputed make to be used for measurement.
2.5.2. Earthing continuity in PV module structures: Quarterly visual check of GI wires and to check
electrical continuity using multimeter between module structures to be undertaken.
2.5.3. Availability of safety gadgets like hand gloves, safety helmet, proper tools and tackles etc. to be
maintained at site.
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2.6. Tools & measuring instruments

Following minimum tools & measuring instruments in addition to others required at site to be maintained
always: AC-DC clamp meter, earth resistance tester, Megger, spanner set, screw driver set, crimping tool,
Allen key set, rough file kit, cutting pliers, nose pliers etc.

2.7. Records to be maintained

For analysis purpose following records should be maintained at plant level

i) Generation On & Off time
ii) Energy generation
iii) Fault details: Type of faults, time of faults & its duration
iv) Daily report of energy generated..
v) Generation and archiving of detailed record of various parameters by the SCADA system and providing
it to IOCL. The in station operator shall also prepare other format of reports as per instruction of IOCL.

2.8. Others

2.8.1. Half yearly Functional Checks of Protection circuits and Breakers.

2.8.2. Checking for loose structural nuts and bolts and cable terminations between PV modules, PV arrays,
line accessories and associated switchgear etc. Retightening connection and replacing cables/MC4
connectors if necessary.
2.8.3. The repair/replacement work shall be completed within 48 hours from the time of reporting the
fault.
2.8.4. During O&M contract duration, Vendor’s Engineer will have to visit site every quarter and carry out
maintenance and health assessment of the complete system.
2.8.5. Vendor will have to attend any breakdown call during the O&M contract duration within 96 hours.

2.9. Payment against Operation & AMC:

2.9.1. Quarterly payment shall be done on submission of invoice. GST shall be paid extra as prevailing.