TENDER DOCUMENT FOR SUPPLY, INSTALLATION, TESTING AND COMMISSIONING

OF 9.6KWP SOLAR PV PLANT AT SV & IP STATIONS OF MMBPL

TENDER DOCUMENT FOR

SUPPLY, INSTALLATION, TESTING
AND COMMISSIONING OF
9.6KWP SOLAR PV PLANT
AT SV & IP STATIONS OF MMBPL
TENDER DOCUMENT FOR SUPPLY, INSTALLATION, TESTING AND COMMISSIONING
OF 9.6KWP SOLAR PV PLANT AT SV & IP STATIONS OF MMBPL

Section Description

A Scope of Tender

B Technical Specifications for Solar PV power plant

C Vendor data required

D Inspection and Test Plan

TENDER DOCUMENT FOR SUPPLY, INSTALLATION, TESTING AND COMMISSIONING
OF 9.6KWP SOLAR PV PLANT AT SV & IP STATIONS OF MMBPL

A. SCOPE OF TENDER
 TENDER DOCUMENT FOR SUPPLY, INSTALLATION, TESTING AND COMMISSIONING
OF 9.6KWP SOLAR PV PLANT AT SV & IP STATIONS OF MMBPL

1.0 INTRODUCTION:

Bharat Petroleum Corporation limited (BPCL), a Maharatna PSU of Govt of India, operate
a cross country Pipeline from Mumbai to Bijawasan (MMBPL). This pipeline is having
intermediate sectionalising valve stations. BPCL intends to ensure uninterrupted
availability of power at Sectional Valve (SV) station where grid power supply interruption
is high thereby necessitating need for consistent power supply during the periods of
interruptions. BPCL is proposing to set up environment friendly Solar Power plant at these
SV station. Autonomy for the system shall be two days including one day of zero sunshine.

Details of Load proposed on solar plant (Maximum demand):

DC LOAD:

48 V, 3 kW which includes SCADA, Telecom and instrumentation systems, cathodic

protection etc.

SINGLE PHASE AC LOAD:

Daily Load lighting - 1.0 kW,

Fan / Exhaust Fans: 1.5 kW
Periodic load: Motor operated valve - 1.5 kW

2.0 DESIGN BASIS:

Solar PV Power plants shall be designed considering the following:

1. Loads: Above AC and DC load that shall be supplied by 9.6 kWP Solar PV Power plant
having three numbers of 48V 60A Solar charge controller and one 5 KVA 230V, 1-ph,
50Hz industrial grade inverter with by-pass facility. Vendor to ensure the load indicated
above shall be met by solar. Inverter is out of scope of bidder.

2. System Voltage: 48V DC (nominal), DC supply has to cater the requirement of both
charging of the battery and the 48 V DC load of the system.

3. Existing two sets 48 V, 500 AH of VRLA GEL / OPZS Battery bank shall be connected
with solar system for power back up. These battery banks are also connected to charger
which will provide DC power from SEB fed power supply in case of inadequacy of solar
power.

4. In addition to DC load, AC load shall be fed at 230 V, 1-ph, 50 Hz standalone inverters

along with provision of invertor bypass to SEB power in case of battery power failure.
 TENDER DOCUMENT FOR SUPPLY, INSTALLATION, TESTING AND COMMISSIONING
OF 9.6KWP SOLAR PV PLANT AT SV & IP STATIONS OF MMBPL

Scheme shall be implemented as given Single line Diagram as attached in Annexure-1.

3.0 SCOPE OF WORK:

3.1 Site survey, design, detail engineering, manufacturing, supply, transportation, loading,
unloading, installation, testing & commissioning of fixed tilt type Solar Power Plant of 48
V DC, 9.6 kWp, capacity to meet AC & DC power requirements of SV Stations (SV-16,
23, IP-JULVANIA of MMBPL) with one year warrantee period followed by 2 year
comprehensive annual maintenance contract (CMC) .

3.2 The scope of work includes :

Sr.
Item Description Unit Remarks
No.

Study, site survey, preparation of drawings and reports in all

respect including assessment of building stability study for SV-
16, 23, IP-Julvania report submission.

The following shall be supplied, in accordance with this

specification; standards stated herein & enclosed appendices:

a) 48VDC, 9.6kWp fixed tilt type off grid solar power plant
to charger existing 48V/500AH VRLA / OPzS battery bank &
supply station load with solar panels, supporting structure
1 b) AJB panel LS
c) 48V/ 60A MPPT solar charge controller panel (3 Nos)
d) Interconnecting cables (FRLS Type)
e) AC / DC cables to meet the functional requirement as per
SLD.
f) 1 number of ACDB consisting of 3X 20A MCB
g) 1 No of relay driver for charge controller ON/ OFF status
with 2 Nos potential free contact
h) Any other material required for proper functioning &
performance of the solar power plant.
One year performance guarantee of complete system
including preventive / breakdown maintenance during one
year as specified in tender.

2 years CMC of solar power plant after completion of 1 st year

2 LS
PBG period
 TENDER DOCUMENT FOR SUPPLY, INSTALLATION, TESTING AND COMMISSIONING
OF 9.6KWP SOLAR PV PLANT AT SV & IP STATIONS OF MMBPL

4.0 Bill of Materials

A complete Bill of Materials inclusive of Solar PV Modules, array Junction box, main
junction box, cables, SCC, Array mounting structures etc shall be provided along with the
offer. The numbers of each component proposed for supply shall be clearly specified. The
items not listed in BOM but required for successful installation/commissioning of power
plants shall also be added, as required at no extra cost to BPCL.

5.0 Spare parts

Bidder shall keep stock of essential spares at their nearest service center and/or at each site
at their cost for 2 years of CMC after 1 year of warranty. However bidder shall list out
spare parts required for power plant.

6.0 Installation and commissioning

i The bidder shall quote for Installation and commissioning of power plant.
ii The bidder is responsible for arranging all the accessories and measuring instruments
required to smoothly commission the power plants.
iii The plant shall be commissioned in the presence of BPCL authorized personnel or its
nominated representative.
iv An acceptance report shall be prepared and signed by all participating parties.

7.0 Packing, shipping and marking

The bidder shall be responsible for assuring that all commodities shipped are properly
packed and protected to prevent damage or deterioration during shipment. Packaging and
shipping costs shall be borne by the supplier. Customs clearance and all costs and actions
associated with import duties, taxes and processing of documents within India are borne by
the bidder. Transportation, loading, unloading at site is in the scope of bidder.

8.0 After sales & service

The bidder shall give the details of their service centers in the states where it is intended to
install Solar PV systems and ensure that all the essential men and materials are placed to
ensure quick and efficient after sales service. Training and after sales service is an
important component of supply. The terms and conditions for training and after sales
supply and service are to be presented clearly in the proposal and the extent and duration of
after sales support clearly defined. An explanation of preventative maintenance schedule,
plan of operation, scope and implementation of the after sales service is to be defined.

9.0 COMPREHENSSIVE ANNUAL MAINTENANCE

9.1 The Two years comprehensive AMC for solar plant including all equipments will start after
One year warranty period. If there is any failure in the plant or parts against the equipment,
then the supplier shall either repair or exchange the failed part within CAMC period at no
 TENDER DOCUMENT FOR SUPPLY, INSTALLATION, TESTING AND COMMISSIONING
OF 9.6KWP SOLAR PV PLANT AT SV & IP STATIONS OF MMBPL

extra cost to BPCL. The CAMC will be on-site service & time, travel and expenses related
to such services will be to vendor’s expense.

BPCL would like to enter into CAMC contract for a period of total Two Years subsequent
to expiry of Warranty period.

9.1.1 Threshold limit for CAMC Charges:

Yearly comprehensive AMC cost of Solar PV power plant will be minimum 5% per annum
of quoted Basic Price of supply portion only (Excluding installation & commissioning
cost). Vendor is free to quote 5% per annum or any higher rate.

Offer of any vendor quoting CAMC charges below the above mentioned threshold limit
will be commercially evaluated considering CAMC charges at rate of 5 % of quoted price
for supply portion by the respective bidder. However, order shall be placed based on quoted
price by bidder.

9.1.2 Hence, vendors are requested to check up the above mentioned Threshold limits in % while
quoting the CAMC charges.

9.1.3 The vendor shall ensure trouble free plant operation and shall carry out preventive/ routine
maintenance at least once in Six months by OEM’s qualified and trained engineers.

9.1.4 On notification of break down, service engineer will be deputed at site for troubleshooting
and to restore the solar system in minimum time. Vendor shall respond within 48 hours of
notification.

9.1.5 Bidder shall note that Agreements for CAMC tenders will be prepared separately from
main tender and BPCL reserves the right to award or not award CAMC Tenders
immediately or later date, depending upon conditions prevailing at that time.

9.1.6 As part of CAMC, the solar vendor shall maintain the critical/ recommended spares
inventory at BPCL or vendor site, to reduce MTTR. Consumed spare parts will be
replenished within 15 days. If needed, BPCL will provide proper storage for spares and
provide the security, inventory accuracy, packaging and environmental conditions. The
supplier shall provide list of critical/ recommended spares along with offer. These spares
will be exclusively stocked for BPCL and will not be used for any other customer in any
case.

9.1.7 Successful Bidder will carry out CAMC through OEM/OEM Authorized representative
only.

9.1.8 In the event of supplier showing lack of attendance to the work or negligence or
unfair performance in the opinion of Engineer-In-Charge, then BPCL may terminate
the CAMC contract at any stage without prejudice to the right by action under any other
relevant clause of the contract by giving suitable notice to the vendor and at his risk and
cost by forfeiting security deposit / encashing PBG.

9.1.9 Particular care shall be taken for outdoor equipment to prevent corrosion during CAMC
 TENDER DOCUMENT FOR SUPPLY, INSTALLATION, TESTING AND COMMISSIONING
OF 9.6KWP SOLAR PV PLANT AT SV & IP STATIONS OF MMBPL

period.

9.1.10 Cleaning of the panels, junction boxes etc shall also be carried out regularly during CAMC
period.

9.1.11 The pending performance warrantee liability if any, occurred during PG period will be
carried over in CAMC Period and the same will be adjusted for in CAMC period directly
between BPCL and Successful Bidder.

9.1.12 Under CAMC, procedure for maintenance of solar system shall be as follows:
 TENDER DOCUMENT FOR SUPPLY, INSTALLATION, TESTING AND COMMISSIONING
OF 9.6KWP SOLAR PV PLANT AT SV & IP STATIONS OF MMBPL

10.0 DELIVERY

Drawing /design to be submitted for approval within two weeks of receipt of confirm
order/ LOA. The material is to be delivered to the site within eight weeks from date of
drawing approval and installation is to be done within two weeks from the date of supply
of material.
Total delivery period of the job will be 14 weeks from the date of PO.

For CMC, separate PO will be issued post warranty period completion.

11.0 DOCUMENTATION:

Vendor has to submit for each site one soft & hard copies as per vendor’s data requirement
at various stages which includes drawings, Installation manual / user manual of the solar
PV power plant. The manual shall include complete system details such as array lay out,
schematic of the system, working principle etc. Step by step maintenance and
troubleshooting procedures shall be given in the manuals.
B. Technical Specifications for Solar
PV power plant
1.0 OPERATING PHILOSOPHY

1.1 Presently station has three phase SEB power connection and emergency backup DG set.

1.2 Lighting load and single phase AC load is fed from SEB power and DC load is fed at 48V
through existing 500Ah battery banks & dual float cum boost battery chargers.

1.3 On installation of Proposed solar PV power plant. Priority will be given on feed load through
solar and back up battery bank. On inadequacy of solar /battery power SEB power shall be used
for feeding AC & DC load. In case of invertor malfunction SEB output shall be connected to
ACDB via bypass provision.

BATTERY
CHARGER

1.4 The overview schematic requirement of solar PV power plant is shown above and detailed
scheme is shown in single line diagram attached as annexure-1. The solar PV array will produce
DC electricity directly from sun light shall be conditioned to 48V DC by Solar Charge Controller
& 230V AC by inverter and their output feeds:
- Battery
- DC load
- AC load

1.5 Scenario 1:When solar PV main power is available:

The solar plant will cater station DC & AC load directly in addition to charging 48V/500Ah battery
banks.
Scenario 2: When power from solar array is not available:
Charged battery banks will cater DC & AC load till the battery is discharged to 43.2 V.
Scenario 3: When battery discharged voltage reaches to 1.8 Volt/ cell i.e. battery bank voltage to
43.2 Volt:
Loads shall be fed through grid supply.

1.6 Necessary arrangement to be provided such as existing battery bank shall be connected with solar
as well as with existing charger as shown in single line diagram.
1.7 The supplied system shall be compatible to operate in integrated manner without any manual
intervention.

1.8 There shall be no break in load power during changeover from solar to Grid or Vice-versa.

2.0 GENERAL REQUIREMENT

Offers would be evaluated on lowest net landed price basis (lowest cost to BPCL) and order shall
be awarded to lowest quote bidder.

2.1 Net Landed price means total cost of the work i.e. Basic price of all works & material inclusive of
all taxes, levies, transportation, Installing & Commissioning cost including all material & labour
charges and Two years CMC cost.

2.2 The offered equipment shall be brand new with state of art technology and proven field track
record. No prototype equipment shall be offered.

2.3 Vendor shall ensure availability of spare parts and maintenance support services for the offered
equipment for at least 10 years from the date of supply.

2.4 Preferably, all equipment like Solar Charge controller, ACDB, Metering arrangement etc shall be
incorporated in one panel, a proposed design of same is given in Annexure 2, the panel shall have
good aesthetic appearance. Sizing of panel shall be such that forced cooling requirement shall be
avoided.

2.5 The panels used for integrated panel, Solar Charge Controller shall be made up of minimum 1.6mm
thick CRCA sheet, powder coated with dust, vermin and waterproof (IP31) nature. Single or double
doors as per availability with locking arrangement. The panel size shall be big enough to house
equipment, its accessories, meters, all cable terminations maintaining clearances from all around
panel for easy maintenance & troubleshoting.

2.6 The panel shall be designed for indoor condition & shall be floor mounted, minimum 500mm or as
per site requirement clearence from ground shall be provided for easy cable terminations & to
avoid dust accumulation from running fan.

2.7 All external cables such as cable from AJB to Integrated panel, Lighting panel to Integrated panel,
Battery Charger to Integrated panel etc. shall be FRLS armoured type. All internal cable shall be
FRLS type and properly dressed & laid through proper cable route and ducts. Double/ Single
compression Nickle Plated Brass cable glands to be provided for termination of cable at AJB,
Integrated panel, ACDB etc.

2.8 The panel shall have all cable entries from bottom with detachable gland plate.
2.9 Sleeved DC Cu bus bar shall be provided at output of SCC to tap off supply for Battery bank,
DCDC converter and Inverter.

2.10 Suitable rated MCB / MCCB shall be provided at input & output of each component such as solar
charge controller, DCDC converter, AJB etc.

2.11 Suitable size and rating terminal block shall be installed inside panel to terminate both incoming &
outgoing cables. All cable termination / wires shall be lugged, ferruled and terminals shall be
numbered.

2.12 Over-voltage protection scheme to be provided in SCC to avoid any malfunction due to boost
charging (at 66V) by existing battery charger. Kindly refer Annexure-1 for scheme.

3.0 Detailed Design & Stability Reports & Documents:

The Detailed Design & assessment of Stability shall contain but not limited the following details:

3.1 Site survey and Layout Planning to be carried out by the party after tender award.

3.2 Based on the building Stability assessment vendor has to design of all components of the SPV
Power system.

3.3 Plan indicating the suitable area for installation of solar plant, dimension, north-south direction &
any other relevant information for each site.

3.4 All technical particulars along with Single Line Diagram (SLD).

3.5 Module Mounting Structure Details with Design, Drawings.

3.6 This Detailed Design & reports along with all necessary documents has to be certified by
competent agency. The final report shall be submitted within 15 days from date of PO and before
purchase of solar material. Purchase of material shall be done only after approval of drawings
from BPCL.

4.0 Charger room

The bidder shall give the details of array layout and control room layout along with the offer. The
room shall be provided by BPCL to meet the space requirement to house Integrated panel,
Distribution Boards etc.
 5.0 FACTORY ACCEPTANCE TEST & THIRD PARTY INSPECTION:

Contractor will submit and get approved detailed comprehensive Quality Assurance Plan
(QAP) within 10 days from date of issue of the order for bought out items and items
manufactured by them. The Quality Plan shall be submitted broadly under following sub-
heads:-

a) Raw material/Bought Out items and Components

b) In process inspection and test/checks to establish successful
completion/Accomplishment of the process
c) Final tests/checks in accordance with relevant national/ international
Standards/specification.

5.1 The shop test shall be carried out to prove the performance parameters of the offered model.
The testing shall be done in the presence of BPCL / the representatives of BPCL/ Third party
inspection.

5.2 Manufacturer has to submit procedure for Test carried out at their Factory. All test reports to be
submitted for review.

6. RECOMMENDED LIST OF VENDORS FOR COMPONENTS OF ALL UNITS:

MCB/ MCCB/ SPDs: L&T / Areva / ABB / Siemens

Relays: Areva / ABB / Siemens / SEL/ Schnieder
LT contactor & O/L Relays: Siemens / Tele-mechanic / L & T
Switches: GEC ALSTHOM / KAYCEE/ ABB / Siemens / Rishab
CTs: Automatic electric / ECS / KAPPA electricals / Pragati
Indicating Meters: Automatic electric industrial Meters Pvt. Ltd., / IMP / MECO
/ RISHAB / Enercon / L&T.
Indicating lamps (LED type only): GECALSTHOM/ Siemens / L & T /
Telemecanique / Teknic.
Charge Controller: MORNINGSTAR/SCHNEIDER/ BLUE SKY/ GENASUN/
MIDNITE SOLAR/ OUTBACK POWER/ MAGNUM ENERGY
 DETAILED SPECIFICATIONS

1.0 APPLICABLE BIS /EQUIVALENT IEC STANDARDS / APPLICABLE MNRE

SPECIFICATIONS

1.0.1. The PV modules must conform to the latest edition of the following IEC / equivalent BIS standards
for PV module design qualification and type approval:

a) Crystalline Silicon Terrestrial PV Modules: IEC 61215 / IS14286.

b) Thin Film Terrestrial PV Modules : IEC 61646 / Equivalent IS (Under Dev)

c) Concentrator PV Modules & Assemblies : IEC 62108

d) In addition, the modules must conform to IEC 61730 Part 1-requirements for construction & Part
2 - requirements for testing, for safety qualification or Equivalent IS (Under Dev.)

e) 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.

2.0. SOLAR PV MODULE & ARRAYS

2.0.1 Crystalline high power cells shall be used in the Solar Photovoltaic module. Each Solar module
shall consist of 72(minimum) Photovoltaic cells redundantly interconnected to generate
=>280Wp.

2.0.2 Photo / electrical conversion efficiency of SPV modules & cell shall be greater than 15%
& 17% respectively at STC. Module shall be made of high transmissivity low iron tempered
glass front surface giving high encapsulation gain and hot butyl rubber edge sealant or tough
multi layered polymer back sheet for module protection and mechanical support & to provide
high voltage electrical insulation.

2.0.3 The panels shall be manufactured with fill factor of 72%.

2.0.4 Each solar module shall have RF ID & must be able to withstand environmental conditions and
last the life of the solar module and shall be kept inside the module laminate.

2.0.5 Each RF ID tag shall have following data:

a) Name of the manufacturer of PV Module

b) Name of the Manufacturer of Solar cells
c) Month and year of the manufacture (separately for solar cells and module)
d) I-V curve for the module
e) Wp, Im, Vm and FF for the module
f) Unique Serial No and Model No of the module
g) Date and year of obtaining IEC PV module qualification certificate
h) Name of the test lab issuing IEC certificate.
i) Other relevant information on traceability of solar cells and module as per ISO 9000 standard.

2.0.6 To connect the solar module interconnection 4 SQMM double insulated copper cable with MC-4
terminal shall be provided. The interconnecting cables shall be encapsulated by heat shrinkable
sleeves to withstand high temperature up to 100 degC. The terminal box on the module should
have a provision for opening for replacing the cable, if required.

2.0.7 Module junction box (weather proof) shall be designed for long life outdoor operation in harsh
and corrosive environment.

2.0.8 All materials used shall have a proven history of reliable and stable operation in external
applications at site conditions as mentioned elsewhere.

2.0.9 Temperature coefficient of the panel at 25degC of following shall be submitted:

Power
Voltage
Current

2.0.10 The rated output power of any supplied module shall not vary more than + 3-5% (only +
tolerance is acceptable) from the average power rating of all modules.

2.0.11 The bird spike shall be provided to avoid bird sitting on the solar modules at the highest point of
the array/module structure.

2.0.12 The module frame is made of corrosion resistant materials, which is electrolytically
compatible with the structural material used for mounting the module. The encapsulation
arrangement shall ensure complete moisture proofing for the entire life of the solar modules.

2.0.13 The module termination box shall be of reputed make confirming to IP65, UV resistant & made
up of thermoplastic material.

2.0.14 Protective devices against surges at the PV module shall be provided, if required. Low voltage
drop bypass and / or blocking diode(s) may also be provided, if required.

2.0.15 Array capacity & Charge Controller Capacity shall not be less than 9.6kWp after de-rating due
to temperature co-efficient at site ambient temperature. Supplier has to take necessary additional
capacity while designing the number of panels.

2.0.16 Whenever more than one module is required, identical modules shall be used.
2.0.17 Modules alignment and tilt angle shall be calculated to provide the maximum annual energy
output. This shall be decided based on the location of array installation.

2.0.18 Recommended Make: Trina Solar/ Canadian Solar/ Jinko Solar/ Risen Energy/ Vikram Solar/
Waaree Solar/ Goldi Green Technologies Pvt. Ltd./ Tata Power Solar Systems Ltd./ Moser Baer
Solar Limited/ BEL/ BHEL/ CEL Or equivalent on prior approval from BPCL

3.0 MODULE MOUNTING STRUCTURE

3.0.1. The PV modules will be installed on rooftop of building or on ground level based on detail
engineering.

3.0.2 Bidder can visit the sites before submitting any bid. Any claims made afterwards will not be
entertained.

3.0.3 In case of building rooftop installation, bidder has to submit detailed calculation of loading,
stability of building.

3.0.4 After installation of PV modules on rooftop, bidder has to submit building stability certificate
from competent agency.

3.0.5 Bidder shall take all necessary precautions to have proper bonding between existing rooftop & PV
module foundations to withstand wind speed of 150km/h.

3.0.6 The array structure shall be made of hot dip galvanized MS angles of size not less than 50 mm x
50 mm x 6 mm size. The minimum thickness of galvanization shall be at least 100 microns. All
nuts & bolts (double nut bolts with spring and normal washer to be considered) shall be made of
very good quality stainless steel confirming to SS 304 minimum. The minimum clearance of the
lowest part of the module structure and the developed ground level shall not be less than 300 mm.

3.0.7 The mounting structural steel shall be as per latest IS 2062-1992 & galvazation of mounting
structure shall be in compliance with latest IS 4759.

3.0.8 The work should be completed with supply, fitting fixing of clamps, saddles, nut & bolts etc.
While quoting the rate, the bidder may mention the design & type of structure offered.

3.0.9 The structure shall be designed to allow easy replacement of any module and shall be in line with
site requirements.

3.0.10 The structure shall be designed for simple mechanical and electrical installation. It shall support
SPV modules at a given orientation, absorb and transfer the mechanical loads to the ground
 properly. There shall be no requirement of welding or complex machinery at site.

3.0.11 The array structure shall be so designed that it will occupy minimum space without sacrificing the
output from SPV panels at the same time it will withstand wind speed as per IS 875.

3.0.12 The structure shall have provision to adjust panel angle throughout year to maintain maximum
generation.

3.0.13 The supplier/manufacturer shall specify installation details of the PV modules and the support
structures with appropriate diagrams and drawings. The drawings along with detailed design and
calculations for wattage requirements shall be submitted to BPCL for approval before starting the
execution work.

4.0 PCC: ARRAY FOUNDATION BASE

4.0.1 The legs of the structures made with GI angles will be fixed and grouted in the PCC foundation
columns made with 1:2:4 cement concrete. While making foundation design, due consideration
shall be given to weight of module assembly, maximum wind speed 150km/h and seismic
factors for the site as per IS 875.

4.0.2 Bidder shall design foundation (RCC and PCC) and structure considering the wind loads and
structural load bearing capacity of the building.
4.0.3 The bidder shall specify installation details of the solar PV modules and the support
structures with lay-out drawings and array connection diagrams. The work shall be
carried out as per the designs approved by BPCL Engineer In-charge .

4.0.4 After installation, bidder has to carry out waterproofing of the building roof irrespective of the
foundation technique.

5 ARRAY JUNCTION BOX

5.0.1 Bidder has to supply, install, test & commission array junction box panels as per site requirement
& shall be used for combining all the incoming lines from the solar strings/arrays and deriving
one common bi-polar array output.

5.0.2 The panel shall be made up of minimum 1.6mm thick CRCA sheet, powder coated with dust,
vermin and waterproof (IP65) nature. Preferrably double doors as per availability with locking
arrangement.

5.0.3 The panel shall be designed for outdoor condition & shall be wall or pole mounted.

5.0.4 The panel shall have all cable entries from bottom with detachable gland plate.
5.0.5 Surge Protection Devices are to protect the PV modules as well as the other electrical / electronic
systems from transient over voltages created due to lightning and to reduce insulation breakdowns
due to lightning. The SPDs shall be of 2 nos of pluggable type installed in a star connected
common base. The SPD’s should be tested and approved according to IEC 61643-11 and EN
50539-11: 2013-03 for the following parameters to be used.
Type of connection: Between Positive, Negative and Earth in star connection
Voltage: up to 1000 volts DC, Maximum Discharge current: 40 KA (8/20mS)
Nominal Discharge Current: 20 KA (8/20mS), Voltage Protection Level: 2.6 KV (for 600 volt
system), 4.0 KV (for 1000 volt system);
Response Time: 25 nS

5.0.6 Isolator suitable for 1000 volts DC solar application at the outgoing side. It should comply with
IEC 60947–3, IEC 61364–4-410 and IEC 60364-7-712.

5.0.7 One Earthing bus bar of suitable size & of copper shall be installed in AJB & protruding outside
from panel at two distinct locations to receive earthing connection.

5.0.8 Separate isolation MCB to be provided at AJB output terminal at AJB end and AJB input terminal
at Integrated panel end.
The Array junction box shall meet following specifications:

Parameters Array configuration

Maximum DC Input Range 1000V
No of DC Inputs As per array arrangement
No of DC Outputs As per array arrangement
Number of Terminal Blocks As per array arrangement
Reverse Blocking Diode, No’s As per array arrangement
Maximum Input Fuse Rating in both polarity As per array arrangement
Maximum string current per fuse holder with all string fuse** As per array arrangement
DC Current of bus bar, A 100
Maximum Continuous Current of bus bar, A 160
Isolator/MCB/MCCB As per array arrangement
+Ve & -Ve Input Wire Size,1C x sqmm As per array arrangement

MOV minimum two 110/680V

Surge Protection Device (SPD) minimum two 600/1000V, Class II
Connectors @ Output Ring type connection
Cable gland clamping range, mm 12 – 32
Type of Protections Short-Circuit, Surge
International standards followed IEC 60364
Disconnection switch 100A DC DP MCCB

6 SOLAR INTEGARTED PANEL

As SPV array produce uncontrolled direct current electricity, it is necessary to convert this
uncontrolled direct current into controlled or constant direct current and alternating current and
adjust the voltage levels before powering equipment designed for nominal DC and nominal mains
AC supply. Conversion shall be achieved using a solar charge controller and an Inverter having
input transformer and the associated control and protection devices (Inverter is free issue material
by BPCL). MPPT (Maximum Power Point Tracker) Solar Charge Controller shall be housed as an
interface between Solar PV array & the Inverter, to maximize Solar PV array energy input into
the System and to supply the DC load and for charging of battery.

6.0.1 Maximum Power Point Tracker (MPPT)

Maximum power point tracker (electronic) shall be integrated to maximize energy drawn from the
 Solar PV array. The MPPT shall be microprocessor / micro-controller based to minimize power
losses. The efficiency of the MPPT shall not be less than 98% and shall be suitably designed to
meet array capacity. The system shall be microprocessor / micro controller based suitable for OFF
GRID solar power plant.

6.0.2 Main features of System

a) The system shall be capable of complete automatic operation, power ON, wakeup and
shutdown.

b) The system shall be self-commutated and shall utilize a circuit topology and Components
suitably for meeting the specifications listed below at low cost, high conversion efficiency and
with high reliability.

c) The system (solar charge controller and inverter) shall be designed to withstand starting in-rush
current when Motor is started and provide trip free operation.

d) In system there shall be a direct current isolation provided at the output by means of a suitable
isolating transformer.

e) The system shall be able to withstand an overload to the extent of 10%. The system shall include
appropriate self-protective and self-diagnostic features to protect itself and the PV array from
damage in the event of system component failure or from parameters - beyond the system’s safe
operating range due to internal or external causes. The self-protective features shall not allow
any operation from the front panel to cause the system to be operated in a manner which may be
unsafe or damaging.

f) The high voltage and power circuits of the system shall be separated from the low voltage and
control circuits. All conductors shall be made of stranded copper and suitable insulation shall be
used for the power and control cables.

g) The solar charge controller shall withstand a high voltage test of 2 kV rms, between either the
input or the output terminals and the cabinet (chassis).

h) Full protection against accidental open circuit, short circuit and reverse polarity at the input
shall be provided.

i) The system shall include ground lugs for equipment and PV array grounding. The DC circuit ground
shall be a solid, two point ground connection in accordance with prevailing national standards.
Positive DC bus is grounded in existing system to provide power to Telecom panel.

j) All exposed surfaces of ferrous parts shall be thoroughly cleaned, primed and painted or
otherwise suitably protected to survive a nominal 15 year design life of the unit. The integrated
panel enclosure shall be weatherproof and capable of surviving intact under all ambient
conditions. Moisture condensation and entry of rodents and insects shall be prevented in the
system enclosure.
k) Components and circuit boards mounted inside the enclosures shall be clearly identified with
appropriate permanent designations, which shall – also serve to identity the items on the
supplied drawings.

l) All doors, covers, panels and cable exits shall have gasket or otherwise designed to limit the entry of
dust and moisture. All doors shall be equipped with locks. All openings shall be provided with
grills or screens with openings not larger than 0.95 cm (about 3/8 inch).

m) In the design and fabrication of system, the site temperature (0 to 50 degree C), incident sunlight
and the effect of ambient temperature on component life shall be considered carefully. Similar
consideration shall be given to the heat sinking of MOSFET’s, blocking diodes and similar
components.

n) All indication LEDs and meters shall be placed on front face of integrated panel to ease the
monitoring.

o) Normally inverter will invert charge controller or battery power to run AC load. Incase of solar
& battery voltage unavailabilty the inverter will feed AC load through SEB bypass feeder
automatically.

p) Suitable DANGER tags shall be provided wherever there is a possibility of getting shock or
there can be a possibility of manual interference. Such as at the back of each panel, Junction
Box etc. The DANGER tags shall be made as per apropriate CEA guidelines.

7 EARTHING

7.0.1 Bidder has to make earthing connections of the panels and all equipments to the existing earthing
grid and bus bars. These connections should be confirming to recent edition of IS: 3043.
7.0.2 For rooftop PV Panel array structure lightning protection, bidder has to make arrangements for
earth strip connections to existing grid.

8 DC & AC CABLES
All cables shall meet:

a) IS1554, IS 5831 standards

b) Temp. Range: -10 Deg C to +80 Deg C.
c) Voltage rating 650/1100V
d) Recommended make: KEI/KEC/UNIVERSAL/NICCO/Equivalent on prior
e) Approval from BPCL
f) All Cables shall be FRLS type with minimum oxygen Index 29 %.
g) All cable laid outside panel shall be armored FRLS type, In case of unavailability of armored
cable for PV application i.e. from AJB to Solar Charge Controller then alternative arrangement
through GI Pipe/ GI conduit to be made after approval from EIC.

8.0.1 For the DC cabling used in PV panels, XLPE insulated and PVC sheathed, UV stabilized single
core flexible copper cables shall be used from individual solar modules to AJB.
8.0.2 From AJB to charge controller which will be installed inside building, XLPE & PVC sheathed,
UV stabilized three cores, and armoured copper cable shall be used.

8.0.3 All cable lying outside building & on walls or terrace shall be laid on GI perforated inverted or
closed cable tray of size D=1.5”xW=6” secured firmly with wall or terrace. The trays shall be
secured at interval of 10” throughout tray length using anchor & fasteners of minimum 3/8”
diameter. Cables shall be tied to the tray at an interval of 10” using aluminium strips. The cable
ends shall be provided with aluminium cable tags & on route cable markers will be provided at
each turning points.

8.0.4 For ground mounting panels, all cables from modules to AJB shall be through UV stabilized
PVC rigid pipe of minimum wall thickness 0.133”. The PVC pipe shall be buried underground
at a depth of minimum one meter. All pipe connectors like T, bend, elbow shall be secured
properly for its long life.

8.0.5 Armoured cables shall be used for ground installation, they shall be properly buried
underground as per IS 1255 using sand & bricks at a depth of minimum 700mm in all kind of
soil including hard rock.

8.0.6 All cable laying inside building shall be underground. Bidder has to break existing PCC, remove
sand, side-line existing cables & lay new solar & other cables at a depth of minimum 700mm.

8.0.7 Bidder has to make necessary holes in walls to enter cables coming from AJB.

8.0.8 Bidder has to make industry grade soft PCC of 1:2:4 proportions which was broken for cable
laying.

8.0.9 Bidder has to close all holes made in wall for cable laying.

8.0.10 The total voltage drop on the cable segments from the solar PV modules to the AJB shall not
exceed 1.0%.

8.0.11 The total voltage drop on the cable segments from the AJB to charge controller shall not exceed
1.0%

8.0.12 Cables and wires used for the interconnection of solar PV modules shall be provided with solar
PV connectors and couplers.

8.0.13 All cables and conduit pipes shall be clamped to the rooftop/ walls/parapet with thermo-plastic
clamps at intervals not exceeding 30 cm.

8.0.14 The minimum DC cable size shall be 4.0 mm2 copper for PV panel interconnection. The
minimum AC cable size shall be 4.0 mm2 copper. This is indicated as minimum however cable
size may increase based on current rating. All external cables shall be armoured cable.

8.0.15 Cables and conduits that have to pass through walls or ceilings shall be taken through a PVC
pipe sleeve.

8.0.16 Cable conductors shall be terminated with DC cable glands & tinned copper lugs to prevent
 fraying and breaking of individual wire strands. The termination of the DC and AC cables at the
Inverter shall be done as per instructions of the manufacturer, which in most cases will include
the use of special connectors & cross ferrules.

8.0.17 Only copper cables of appropriate size and of reputed-make shall have to be used.

8.0.18 All connections should be properly terminated, soldered and/or sealed from outdoor and indoor
elements. Relevant codes and operating manuals must be followed. Extensive wiring and
terminations (connection points) for all PV components is needed along with electrical
connection to lighting loads.

8.0.19 All the Cu PVC or XLPE insulated armoured, sheathed cables required for the plant will be
provided by the bidder.

8.0.20 Only terminal cable joints shall be accepted. No cable joint to join two cable ends shall be
accepted. All cable/wires shall be marked with good quality letter and number ferrules of proper
sizes so that the cables can be identified easily.

8.0.21 All cables shall be supplied in the single largest length to restricting the straight through joints to
the minimum number.

8.0.22 Minimum two (02) number loop must be provided at the start and end each span of cable laying.
Loop length shall be as per relevant Indian Standard.

8.0.23 Following is the provisional cable schedule to be followed by bidder which may change during
detailed engineering:

a) Cables from solar module to AJB

b) Cable from AJB to Solar Charge controller
c) Solar Charge controller to Inverter input.
d) Cables from Solar Charge Controller DC output to DCDC converter
e) Cable from Solar Charge Controller DC output to Battery charger for battery bank
f) Cable from DCDC converter to battery charger for load DCDB
g) Cable for existing ACDB to inverter Grid input (bypass)
h) Cable from inverter AC output to lighting DB.

Distance between ACDB/DCDB/Charger from Solar Integrated Panel shall be maximum 25

meter.
C. VENDOR DATA REQUIRED
 List of data to be submitted at each stage of tender with the number of copies is given below:

NUMBER OF COPIES TO BE SUBMITTED AT:

S.NO. DESCRIPTION
APPROVAL STAGE
TIME OF AS BUILT
BIDDING DOCUMENT
REVIEW RECORD

1 List of Vendor’s Documents 4

1 2
& drawings

2 Detail Design Drawing & 4

2
Stability Report

3 Technical Questionnaire 1 4

4 Bill of Material 1 2 4

5 Data Sheets 1 2 4

6 Single Line Diagram 1 2 4

7 Block and Logic Diagram 2 4

8 Control Schematics 2 4

9 GA Drawing including 4
foundation & mounting 2
details

10 Sectional View Drawing 2 4

11 Name plate & Label drawing 2 4

12 Terminal box detail drawing 4

with termination 2
details

13 Wiring Diagram and 4

2
Terminal Details

14 Catalogues 1 2 4
15 Calculations for: Panel 4
Sizing, Solar Charge
Controller/ Component Sizing 1 2
(power & electronic

devices), System Cable

16 Solar Panel Arrangement 4

2
Drawing

17 Installation, Operational and 4

maintenance 2
Manual

18 Quality Assurance Plan 2 4

19 Inspection plan & Test 4

2
Procedure

20 Site acceptance tests 2 4

procedure
21 Sub-vendor List & Supplier’s 4
1 2
List

22 List of commissioning spares 1 2 4

23 Packing List 4

24 Cubical Arrangement 4
2
Drawing

25 Technical Deviations List (if 4

1
any)

26 Performance Test certificate

1
& reports / PTR

27 Reference List of previous 4

1
Projects

28 Inspection & Type Test 4

Certificate for all Equipment 1 2
provided, as applicable
i. Review of the vendor drawings by BPCL would be only to check compatibility with the basic designs
and concepts and would in no way absolve the manufacturer/fabricator of his responsibility to meet the
applicable codes, specifications and statutory rules/regulations.
ii. Each drawing shall show (possibly grouped in the right lowest corner, near the title) the following data
as a minimum for identification purpose:

PROJECT: 9.6KWP SOLAR POWER PLANT

CLIENT: M/s BPCL

PURCHASE ORDER NO.:

EQPT. ITEM NO.:

DRAWING NO. (With proper revision marks):

iii. All Final drawings/documents, as listed above, shall also be submitted as electronics files (drawings in a
utocad/scanned images). Electronic files for all drawings and documents shall be submitted together with
the Manufacturing Record Book. The standard document format shall be Portable Document Format
(PDF), but Vendor shall provide with native source files upon the Purchaser’s request for his
convenience.
iv. All drawings shall be generated in DWG format of Auto Cad, of which native files (DWG) shall be
submitted to Purchaser.
v. All units and dimensions shall be in metric system.
vi. All documentation shall be in English.
vii. The Vendor shall complete the “Vendor Proposed Date” column indicating his proposed submission
date. At the same time the Vendor shall advise those documents he will not be submitting because the
information required is provided for within another document. He shall also advise how many
documents he will be supplying within each category.
viii. The Vendor will be required to submit all documentation in accordance with the agreed dates.
ix. Purchaser will review the documents and return them to the Vendor within 2 weeks of submission.
x. The Vendor shall incorporate the comments and return the document within 2 weeks of receipt from
Purchaser.
xi. As built drawings to be provided within 15 days of equipment release.
xii. All details asked in Datasheet section of the tender is to be submitted while bidding for the tender.

NOTE: ALL THIS DATA HAS TO BE SUBMITTED FOR EACH ITEM QUOTED VIZ: SOLAR PANELS,
ACDB, SCC, BASE FOUNDATION DETAILS ETC.
DATA TO BE SUBMITTED BY VENDOR WITH TECHNICAL BID:

Solar panels
Sr
technical specifications vendor remarks
no
1 Make
2 Model
3 Type
4 Number of Cells
5 Pmp (WP)
6 Voc (V)
7 Isc (I)
8 Vmp (V)
9 Imp (I)
10 Module Efficiency
11 Dimensions (mm)
12 Weight (Kgs)
13 X-Pitch
14 Y-Pitch
15 Cell construction
16 Panel Frame
17 Front Glass
18 Cables & Connectors
19 Normal Operating cell temperature
20 Temperature co-efficient (Pmax)
21 Temperature co-efficient (Voc)
22 Temperature co-efficient (Isc)
23 Operating module temperature
24 Maximum Voltage DC
25 Maximum load
26 Certifications
 AJB
Sr
Technical specifications Vendor remarks
no
1 Make
2 Model
3 Type
4 Number of cable entries
5 Rated DC Voltage
6 Number of MCB
7 Size & number of input cable entry
8 Size & number of output cable entry
9 MOV details
10 SPD details
11 MCCB details
12 Certification
SOLAR CHARGE CONTROLLER

S.No
Technical specifications Vendor remarks
1 Make
2 Model
3 Type
4 Number of cable entries
5 Rated DC Voltage
6 Rated DC current
7 Cooling (Natural / Forced)
8 Ambient temperature
9 Efficiency
10 Switching Device
11 Protection
12 Communication Protocol
13 Heat Sinks
TECHINCAL QUESTIONNAIRE TO BE SUBMITTED ALONG WITH TECHICAL OFFER

Sr. Description Specified byVendor’s Remark

No. Purchaser response
(Yes/No) (Yes/ No)
1.0 Scope of Supply:
1.1. Confirm scope of supply as per clauses of tender for Yes
solar power plant is understood & price quoted in price
bid accordingly.
1.2. Confirm Operational Philosophy of integrated system is Yes
understood as per given clauses & system offered meets
the requirement
2.0 PV Modules:
2.1. Confirm Array capacity & Charge Controller Capacity is Yes
not be less than 9.6kWp after de-rating due to temperature
co-efficient at site ambient temperature.
2.2. Confirm 4 SQMM double insulated copper cable with Yes
MC-4 terminal is provided to interconnect the solar
module.
2.3. Confirm Temperature coefficient of the panel at 25degC Yes
of following is submitted:
Power, Voltage, Current.
2.4. Confirm the rated output power of any supplied module Yes
will not vary more than + 3-5% (only + tolerance is
acceptable) from the average power rating of all modules.
2.5. Confirm whenever more than one module is required, Yes
identical modules shall be used.
2.6. Confirm the modules quoted for the plant is of Yes
recommended make.
2.7. Confirm if Recommended Make of Solar modules is Yes
considered: Trina Solar/ Canadian Solar/ Jinko Solar/
Risen Energy/ Vikram Solar/ Waaree Solar/ Goldi Green
Technologies Pvt. Ltd./ Tata Power Solar Systems Ltd./
Moser Baer Solar Limited/ BEL/ BHEL/ CEL / Renewsys
Or equivalent on prior approval from BPCL
3.0. MODULE MOUNTING STRUCTURE
3.1. Confirm after installation of PV modules on rooftop, Yes
bidder has to submit building stability certificate from
competent agency.
3.2. Confirm bidder shall take all necessary precautions to have Yes
proper bonding between existing rooftop & PV module
foundations to withstand wind speed of 150km/h.
3.3. Confirm the array structure shall be made of hot dip Yes
galvanized MS angles of size not less than 50 mm x 50
mm x 6 mm size. The minimum thickness of
galvanization shall be at least 100 microns. All nuts &
bolts shall be made of very good quality stainless steel
confirming to SS 304 minimum. The minimum clearance
of the lowest part of the module structure and the
developed ground level shall not be less than 300 mm.
4.0. PCC: ARRAY FOUNDATION BASE

4.1. Confirm the array foundation base will be constructed as Yes

per clauses 4.0 of Section C: Technical Specifications for
Solar PV power plant

5.0. ARRAY JUNCTION BOX

5.1. Confirm the array junction box shall be as per c clause 5.0 Yes
of Section C: Technical Specifications for Solar PV power
plant .
5.2. Confirm the components used in the unit is of Yes
recommended make.

6.0. SYSTEM
6.1. Confirm supply, installation, testing & commissioning of Yes
Three Nos of MPPT charge controllers each of rating 60A,
48V.

6.2 Confirm supply, installation, testing & commissioning of Yes

solar power plant having three nos of SCC with 48VDC
output as per site requirement fulfilling clauses 1.0 to 12.0
of Section C: Technical Specifications for Solar PV power
plant
7.0 SOLAR CHARGE CONTROLLER

7.1 Confirm if the proposed Converter are of following make

and confirms to Clause 8 of Part C: Technical Specification
of Solar PV Power Plant: Make:
MORNINGSTAR/SCHNEIDER/ BLUE SKY/
GENASUN/ MIDNITE SOLAR/ OUTBACK POWER/
MAGNUM ENERGY or equivalent based on prior
approval from BPCL
8.0 GENERAL REQUIREMENTS
8.1 Please confirm Potential free contact for each equipment is Yes
considered as per specification
8.2 Confirm the components used in the unit is of Yes
recommended make.

8.3 Confirm the cable provided are FRLS type with minimum
oxygen Index 29 %. and it is of recommended make. Yes
8.4 All external cables used are suitable sized FRLS type
armoured cable Yes

9.0 COMPREHENSIVE ANNUAL MAINTENANCE

9.1 Confirm CAMC offer as per specifications is submited. Yes

D. INSPECTION & TEST PLAN
INSPECTION & TEST PLAN FOR SOLAR POWER PLANT

STAGE CHARACTERISTICS QUANTUM RECORD SCOPE OF

OF CHECK INSPECTION

Vendor
vendor
SL.NO.

BPCL
Sub
1 Module Mounting Structure
1.1 MS Steel section  Mechanical & Chemical "1 sample/ Vendor’s W R R
As per IS 4923 test 50 T" Test
 Yield Stress Records /
 Ultimate Stress External
Lab
 % Elongation
 Chemical Analysis
1.2 For finish Zinc Coating  Thickness of Zinc  10 Technical W R R
Coating sample spec
 Weight of Zinc / lot
 Uniformity of Zinc  3
Coating sample
 Adhesion Test ( / lot
Hammer Checking)  3
sample
/ lot
 3
sample
/ lot
2 Solar Photovoltaic module
2.1 Solar Cell  Visual 100% Incoming W R R
 Visual Cell Quality
 Dimensions Check
Register
 Electrical

2.2 Junction Box (Protection  Visual 100% Incoming W R R

Degree-IP65)  Visual & Electrical Good
 Dimensions Inspection
Report
W- Witness, R-Review

*- Vendor to submit these reports before offering items for inspection to BPCL.
ANNEXURE 1

9.6KWP SOLAR PV POWER PLANT