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: tender.korba@vedanta.co.in / e.janardhan@vedanta.co.in

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.