20748111(Standby DG Set& AMF Panel)(Jun-12)

8/17/2019 20748111(Standby DG Set& AMF Panel)(Jun-12)

1/23

SECTION 8111

CONTINUOUS RATING LOW VOLTAGE DG SET & AUTO MAINS FAILURE/

STARTUP (AMF/ATS) PANEL EMERGENCY SUPPLY

8111.1 DESCRIPTION

The work under this section consists of supplying, installation, testing &

commissioning of all material and accessories of the complete DieselGenerator (continuous rating at 50oC) set including utomatic !ains Transfer

"witch, fuel tank, control panel, all accessories as specified here#in, and gi$en

in the "chedule of %rices

The Diesel Generator (continuous rating at 50oC) set shall 'e a standard design

of a reputed manufacturer, who shall ha$e similar units in operations for

similar applications and field conditions The ngine must 'e of origin *,urope or " The lternator must 'e of origin *, urope, " or

%akistan The manufacturer shall also ha$e ade+uate maintenance facilities in

the $icinity of %roect with mechanically +ualified and e-perienced personneltrained for operation and on#site maintenance of the e+uipments & materials

offered 'y the !anufacturer in his 'id

The DG set shall 'e rated for continuous duty and suita'le for indoor. outdoor (as applica'le) installation /t shall 'e capa'le for un'alanced loads upto 01

of actual load and for continuous part load operation The set shall 'e capa'le

of starting and operating at the rated output as per the climatic conditions(typical range gi$en in the following ta'le) and at an altitude of the site of

installation (gi$en le$el of the site of installation in meters a'o$e mean sea

le$el) The power rating shown in the rele$ant section of "chedule of prices('ill of +uantities) is the power rating re+uired to 'e deli$ered to load 'y the

diesel generator set after applying all derating factors rele$ant to the site

The ta'le 'elow shows the am'ient temperatures (see definition (2) and therelati$e humidity rates to which the e+uipment can 'e su'mitted according to

the category they 'elong3 the later may 'e stated 'y the particular

specifications

Climai! C"#$ii"#%

"%#2

Ca'" I II III

4ated operating range

()

T26

725oC

T6

70oC

T26

#5oC

T6

785oC

T26

#5oC

T6

755oC

!a-imum operating

limits ()

T6

75oC

T86

780oC

T6

#20oC

T86

790oC

T26

#25oC

T6

790oC

!a-imum relati$e

humidity

:51

at 7oC

;01

at 7oC

2001

at 785oC


2/23

2 m'ient temperature (/C 90882#0#09)

Temperature determined within specified conditions of the air which

surrounds the whole e+uipment

4ated operating range6

4ange of $alues at which e+uipment performs within specifications

!a-imum operating limits6

4ange of $alues at which e+uipment can still work without deterioration or degradation of its operating +ualities

The ratings must 'e su'stantiated with manufacturer>s standard pu'lished data

The Diesel Generator set after reducing the power a'sor'ed 'y the au-iliaries,shall deli$er rated power output under the site conditions ll au-iliaries,

accessories and connections 'etween systems alongwith all necessary ca'les,

fittings, hardware, etc, for complete installation of Diesel engine, Generator,control panel, including fuel & oil storage, e-haust system, etc, shall 'efurnished 'y the manufacturer

The engine shall 'e directly coupled to the generator, and shall ha$e a ratedspeed of 2500 rpm The set shall 'e capa'le of sustaining without damage,

51 o$er speed under any a'normal operating condition

The engine#generator set shall 'e mounted on suita'le rigid steel 'ase frame

with $i'ration isolators ?ea$y duty lifting eyes and.or acking screws shall 'e

pro$ided on the skid The foundation 'olts and all other material.hardware for

complete installation of the set, as re+uired, shall 'e furnished with the setny e-cessi$e torsional $i'ration shall 'e a$oided for 'oth engine and

alternator The set shall 'e suita'le for full load starting @hen the generator is

operating at no#load, the application of full load current, taking into accountthe surge due to starting of e+uipment, should 'e possi'le with ma-imum

transient $oltage drop of 251 of the rated $oltage The time taken to restore

the generator $oltage to A:1 of rated $alue should not e-ceed 25 seconds Theset shall 'e capa'le for starting and accepting full load within 25 seconds after

receipt of starting signal The !anufacturer shall su'mit the e+uipment layout

and other installation details along with the 'id

The details and technical data concerning Diesel Generator set shall 'esu'mitted with tender 'id @here re+uired the documents from the

manufacturer shall 'e furnished in support of the information furnished

"%#


3/23

8111.* APPLICA+LE STANDARDS/CODES

The Diesel ngine and Generator set shall conform to the following standards

as applica'le

B" 5528 # 4eciprocating /nternal Com'ustion ngine

B" 8AAA # General 4e+uirements for 4otating lectrical !achines

B" 5000#AA # 4otating lectrical machines of particular types or for

particular application

D/= 9929 # ?oriontal "teel Tanks for the "torage a'o$e Ground of

%etroleum %roducts in i+uid Eorm

Eor other e+uipment and materials related to the Diesel Generator set, the

!anufacturer shall follow rele$ant international standards

8111., MATERIAL RE-UIREMENTS

;2222 Di%l E#'i#

;22222 G#al

The Diesel ngine shall 'e four strokes, compression ignition,

suita'le for emrgency supply duty "tarting shall 'e through

motor operated electric starter The engine shall 'e e+uippedwith an alternator type automatic charging system to charge the

'atteries during running of engine The engine shall 'e pro$ided

with re+uired au-iliaries, guarantees of fuel consumption,

acceptance tests, torsional $i'ration characteristics

;2222 Ai I#a

ir intake shall 'e through tur'o charger and e+uipped with dry

type filter "uita'le attenuators shall 'e installed to reduce noise

at the air inlet The filter assem'ly shall 'e constructed of non#corrosi$e materials

;2222 E#'i# C""li#'

ngine shall ha$e a forced air draft, water cooled radiator

supplied with a core guard Cooling system shall ha$e an enginedri$en centrifugal pump for cooling water circulation Cooling

"%#


4/23

shall 'e thermostatically controlled n engine shut down timer

shall 'e pro$ided to keep the engine running on no#load after

any operation of set, so that the engine is sufficiently cooled tostart again instantly, if re+uired, without rise in temperature

a'o$e safe limits The radiator shall 'e designed to cool the

engine at specified output in am'ient temperature uptoma-imum $alue 4adiator fle-i'le ducting, flange and all

necessary ductwork, fle-i'le connections, fittings and supports

shall 'e supplied to e-tend from the radiator to the e-haustslou$ers so that hot air from the radiator escapes freely to the

outside of the 'uilding

;22228 E#'i# L0i!ai"#

gear type positi$e pressure lu'rication pump shall 'e

pro$ided with efficient filtration arrangement for the lu'ricationsystem 0Folt C mains#operated heater with thermostat

shall 'e pro$ided in the crankcase The heater shall 'e designed

for automatic switching to ensure that temperature of oil ismaintained for proper operation of the engine

;22225 S$ G"2#"

The speed go$ernor shall 'e mechanical complying with the

re+uirements of B" 5528 class 2Go$ernor shall regulate

engine speed so as to maintain the generator fre+uency within

±1 of the rated fre+uency "ta'le engine speed shall 'e

attained within 25 seconds after the engine has 'een started

"ta'le engine speed shall 'e restored within 20 seconds of anysudden change in load, from no load to full load During this

change of load or surge, the speed shall not $ary 'y more than

±51 of the rated speed !eans shall 'e pro$ided on the engine

to shut down the engine automatically in the e$ent that theengine speed e-ceeds the shutdown speed

;22229 Fl S%m

ngine shall operate on Commercial ?igh#"peed Diesel oil

fuel oil strainer.filter shall 'e pro$ided in the fuel line Euel

system for Diesel engine shall not re+uire any priming The fuelsystem shall comprise3

• Euel storage tank

• Euel transfer pumps

• %iping

"%#8


5/23

The fuel storage tank shall ha$e capacity to store fuel oil for twel$e

(2) hours continuous operation of the set at the rated output The tank shall ha$e le$el switch for monitoring low fuel le$el in the tank The

low#le$el switch shall pro$ide an annunciation and pre$ent starting of

set and to stop the set when the fuel in storage tank is at this le$el Thetank shall 'e pro$ided with o$erflow, $ent, supply and discharge

$al$es, inspection co$er, drain $al$e and glass sight gauge

The fuel storage tank shall 'e designed, fa'ricated and finished inaccordance with the re+uirements of D/= 9929 # ?oriontal "teel Tanks

for the 'o$e Ground "torage of %etroleum %roducts in i+uid Eorm

The small fuel day tank shall 'e incorporated in the steel 'ase frame of the DG set The structural steelwork shall 'e protected from corrosion

The fuel piping to 'e furnished shall include fuel supply pipe from tank to the set, o$er flow pipe from the set to the tank, le$el indicator, fuel

cap with 'reather, drain pipe from the tank

;2222: Ra$ia" E34a% D!

The radiator e-haust duct shall pro$ided for e-haust of hot air

through DG set radiator The radiator e-haust shall 'e designedand routed in such a way so as to gi$e minimum resistance to

airflow

;2222; E34a% S%m

-haust system shall 'e e+uipped with a 5EAVY DUTYRESIDENTIAL type silencer complete with muffler, e-haustmanifold, fle-i'le connector, e-haust el'ow, e-haust pipe,

raincap, and associated fittings This e-haust line shall 'e

ade+uately co$ered with insulation material o$er its entirelength ie from the engine to the termination point at rain cap

ll supports for e-haust system shall 'e furnished

;2222A +a

?ea$y#duty maintenance free lead acid 'atteries shall 'e

pro$ided with the set and mounted on the skid The fully

charged 'atteries shall 'e furnished with the set and connectedwith the help of hea$y duty interconnecting ca'les

The 'atteries shall 'e of ade+uate ampere#hour rating.capacityto satisfy the following re+uirements6#

a Crank the engine at firing speed for at least 25 seconds

"%#5


6/23

' /f the engine does not start on the first attempt, crank the engine

two more times for the a'o$e duration at an inter$al of 0seconds 'etween each cranking operation

;222 Al#a"

;2222 G#al

The alternator shall 'e synchronous The alternator shall 'e

capa'le of carrying, continuously 201 o$er load of rated output

with the field set for normal rated load e-citation for 2 hour in

e$ery 2 hours operation

The alternator shall 'e rated as follows6

Capacity 6 s stated in BoH

Foltage 6 800.0 F

%hases 6 %hase, 8 wire, grounded neutralEre+uency 6 50 ?

%ower Eactor 6 0; lagging

;222 E3!iai"#

-citation shall 'e from 'rushless rotating diodes mounted on

the main shaft for #phase full wa$e rectification

;222 Wi#$i#'%

lternator windings shall ha$e Class ? insulation and shall 'eimpregnated for tropical use The temperature rise of winding

under normal operating conditions and at rated load shall not

e-ceed the limits specified for Class#B insulation nti#

condensate heaters shall 'e pro$ided for windings The heatersshall 'e thermostatically controlled for switching ON after the

set has stopped The thermostat range shall 'e adusta'le and set

to pre$ent o$erheating of windings Eor protection of windingsfrom damage due to o$erheating, thermistors shall 'e em'edded

to stop the set in case the temperature of winding rises a'o$e

the safe $alue

;2228 D2iai"# Fa!"

The de$iation factor of the open#circuit line to line terminal

$oltage shall not e-ceed 020

"%#9


7/23

;2225 V"la' R'lai"#

Foltage regulator shall 'e solid state with pro$ision for manual

setting 4egulator shall 'e so designed to protect the e-citer when the set is running at reduced speed during starting or

idling of the prime mo$er Foltage regulation shall 'e 7 51

from no#load to full load Transient $oltage drop shall 'e lessthan 251 at full load and 0; power factor Time re+uired to

restore to steady state conditions after transient $oltage

fluctuation shall not e-ceed 20sec

;2229 S4" Ci!i Caa0ili

Generator shall 'e capa'le of withstanding without inury, a 0

seconds three phase short circuit at its terminals when operatingat rated output and power factor with fi-ed e-citation

;222: Tma Ri%

lternator temperature rises at continuous rating in an am'ientof 5 degree C shall not e-ceed :0 degree C 'y resistance

measurement on the field The e-citer temperature rise shall not

e-ceed 5 degree C 'y resistance measurement on field or

armature when the main generator is on continuous rating

;222; Vi0ai"# a#$ +ala#!

The $i'ration le$el of the alternator when coupled to the engine

shall not e-ceed the /"< "pecifications or e+ui$alent

;222A +ai#'%

The 'earings shall prefera'ly 'e grease lu'ricated and anti#

friction type and shall 'e selected to pro$ide for long trou'lefree ser$ice

;222 I#$i!ai"#/Mi#' Pa#l%

;2222 G#al

The indication.metering panel shall 'e designed for front

access, completely assem'led, wired and tested The control

panels shall conform to the constructional re+uirements as per

international standards and norms

"%#:


8/23

The panel shall incorporate protection and control e+uipment,

measuring instruments, control and instrument transformers,$oltage regulator, go$ernor controls, 'attery charger, indicating

lamps, etc ngra$ed nameplates of stainless steel shall 'e

pro$ided on all panels for clearly identifying panels and de$icesmounted inside of panels "tandard nameplate with 'lack

lettering shall 'e pro$ided

Ca'les and capillary tu'ing shall 'e tagged with a neoprene disc

or appro$ed e+ui$alent, stamped with the ca'le num'er or tu'e

function for easy identification

;222 Ci!i +a

The Triple pole moulded circuit 'reaker shall 'e pro$ided with

the set The circuit 'reaker shall ha$e the Thermal o$er currentand short circuit releases as 'elow6

/th I 90 to 2001 of Current rating

/sc I 5k

The circuit 'reaker shall 'e mounted in a $i'ration isolated

sheet steel 'o- with ade+uate access for incoming and out going

ca'les

;222 +a C4a'

Battery charger shall 'e static type and shall pro$ide for 'oth

trickle and 'oost charging of the 'atteries when the engine is

not in operation The charger shall 'e of suita'le capacity to

fully recharge the completely discharged 'atteries within four hours at 'oost charge static 'attery charger installed in the

control panel shall 'e pro$ided to charge the 'atteries when the

engine is not running "uita'le interlocks shall 'e pro$ided to pre$ent simultaneous operation of 'oth charging systems

;2228 I#%m#% a#$ C"#"l%

i mmeter (measuring as re+uired)

ii mmeter %hase selector switch

iii Foltmeter (0#500 $olt C)

i$ Foltmeter phase selector switch

"%#;


9/23

$ Ere+uency meter

$i "tart . stop key switch

$ii Battery condition $oltmeter

$iii DC Foltmeter for 'atteries

$iii Tachometer for ngine speed in 4e$olutions

%er !inute (4%!)

i- u'e oil pressure in %"/

- u'e oil temperature in Degrees Celsius

-i ngine water temperature in Degrees Celsius

-ii ngine operation. running time in hours

;2228 Sa6 D2i!%

Eollowing safety de$ices shall 'e pro$ided The audi'le alarm shall

operate on any fault condition and shall 'e reseta'le manually and

automatically through a timer after 25 minutes whiche$er is earlier6

A I larm SD I "hutdown TD I dusta'le Time Delay

i) ngine


10/23

i-)


11/23

f) The system shall 'e self resetting after each cycle of operation

To start the set immediately when the main supply fails

g) Two normally open potentially free contacts shall 'e pro$ided

which shall close when the set is started with the operation

mode selector switch in auto or manual position The contactsshall 'e wired upto the terminals 'lock in control panel

h) four position selector switch shall 'e pro$ided for selectingthe operation mode ie utomatic#!anual#Test#stop.

!aintenance mode to facilitate the following operation6#

i) A"mai!

s descri'ed in a to d

ii) Ma#al

!anual starting of the set and load transfer from normalto stand'y and $ice $ersa

iii) T%

Testing the changeo$er operation when so desired and

also for starting and running the set without interrupting

the normal operation /n case of failure of main supply,the set shall automatically re$ert to automatic mode of

operation

i$) S"/Mai##a#!

%ro$ision shall 'e made to isolate the system for trou'leshooting and maintenance without interruption of mains

power supply The set shall not 'e capa'le of starting in

this condition

;2229 Tmi#al +l"!% a#$ Tmi#al%

Terminal 'locks for control wiring shall 'e General lectric Type 'stud terminal 'locks or appro$ed e+ui$alent Terminal studs and wires

shall 'e num'ered or otherwise marked in accordance with the

applica'le schematic and wiring diagrams

Terminal 'locks shall 'e arranged with sufficient room for each

connection of incoming ca'les %arallel rows of terminal 'locks shall

'e spaced at least 250mm (9) apart

"%#22


12/23

Blocks shall 'e mounted in $ertical columns along the sides of cu'icles

or on $ertical panels specially pro$ided for terminal 'locks 01 spare 'locks distri'uted o$er the columns of terminal 'locks shall 'e

pro$ided

Terminals shall 'e suita'le for screw terminals and shall 'e sied

according to the wire 'eing terminated

%ro$isions shall 'e made to terminate and ground the o$erall copper

shields of all incoming ca'les 'y a suita'le method appro$ed 'y the

ngineer

;222: C"m"## Wii#'

ll internal wiring shall 'e in accordance with /C or FD "tandards

with annealed copper conductor, thermo#plastic insulated with ano$erall flame# retardant 'raid @ire sies for control wiring in no case

shall 'e smaller than 5 mm The wire ends shall 'e permanentlyfitted with compression type connectors 'efore attaching to terminal

studs

@iring 'etween terminals of $arious de$ices shall 'e point to point

ll internal wiring shall 'e neatly trunked in wiring troughs 'ound and

anchored

ll groups of 'undled conductors to hinged doors and panels shall use

e-tra#fle-i'le wire arranged so that a twisting rather than a 'ending

motion is imparted to the mo$ing conductor 'undle ach 'undle shall 'e anchored to the fi-ed mem'er at the opposite end of the hinge a-is

to the anchoring point on the mo$ing mem'er so that the mo$ing

'undle length is the ma-imum a$aila'le without loops

ll wires shall 'e identified at 'oth ends according to the schematic

diagram

8111. TESTS9

;22282 G#al

The set furnished 'y the Contractor under this Contract shall 'e su'ect

to tests in the shop and at site in the presence of the ngineer for conformity to re+uirements of the "pecifications

"%#2


13/23

;2228 Di%l E#'i#

ll mechanical parts shall 'e run under simulated operating conditionsat the !anufacturer>s works

ll tests shall 'e conducted in accordance with the appropriate codesfor testing The tests to 'e carried out shall include, 'ut not 'e limited

to, the following6

i) Dynamic 'alancing together with o$er speed tests of the

generator e-citer and rectifiers

ii) Bench testing of all accessories

iii) Jero load operation of the diesel engine assem'lies to test the

following6

# Fi'ration

# u'ricating system

# Euel system

# Go$ernor system

# Temperature control system

#


14/23

;2228 R"i# T%%

4outine tests on the generator shall 'e performed 4outine testsshall include6

a) 4esistance of armature and field windings

') %olarity of field coils

c) Check of mechanical 'alance

d) Check of no#load field current or e-citer field current

e) Foltage 'alance

f) %hase se+uence

g) =o#load saturation cur$e

h) /nsulation and high potential tests

i)


15/23

;22288 C4aa!i%i!% T% C2%

Eollowing completion of type tests, !anufacturer shall pro$idecharacteristics cur$es of the 'rushless e-citation system These

cur$es shall show6

a) -citer field amps and $olts $ersus generator line

current at 0;0 %f and ma-imum and minimum

temperature rises

') -citer field amps and $olts $ersus generator line

current at 20 %f and ma-imum and minimum

temperature rises

c) s for (a) a'o$e, 'ut with one diode failed

The a'o$e si- cur$es shall 'e plotted from no#load to ma-imumrated load at rated generator $oltage Eollowing appro$al of

cur$es 'y the ngineer, they shall 'e incorporated 'y the!anufacturer into the mergency Diesel Generating "et

!aintenance !anual

;22285 P6"ma#! T%%

t the conclusion of installation of the mergency Diesel

Generating "et at site, commissioning tests shall 'e carried out 'y the Contractor.!anufacturer to demonstrate the satisfactory

operation of the e+uipment and to $erify the guaranteed

performance figures of the diesel unit The tests shall comprises6

2 %reliminary tests on indi$idual components

Continuous one#hour heat run at 50 percent load ratingin parallel with the system

Continuous one#hour heat run at :5 percent load ratingin parallel with the system

8 Continuous four#hour heat run at 200 percent load

rating in parallel with the system

5 %art load heat runs to demonstrate satisfactory operation

and esta'lish fuel consumption at the respecti$e loads9 The tests shall also include6

a) %erformance of Go$erning characteristics and protecti$e systems

"%#25


16/23


17/23


18/23

SPECIFIC WOR;S DATA FOR GEN SET

TEC5NICAL DATA FOR DG SET & AMF PANEL

S. N" Daa R


19/23

S. N" Daa R


20/23

S. N" Daa R


21/23

S. N" Daa R


22/23

S. N" Daa R


23/23

S. N" Daa R

Documents

20748111(Standby DG Set& AMF Panel)(Jun-12)