DG Set Final Tender Raipur_1

HINDUSTAN PETROLEUM CORPORATION LTD.

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HINDUSTAN PETROLEUM CORPORATION LIMITED

ENGINEERING & PROJECTS

GRESHAM ASSURANCE HOUSE, 2ND

FLOOR,

A-1595(3) 1-A, SIR P M ROAD, FORT

MUMBAI-400 001

TENDER DOCUMENT

FOR

SUPPLY OF DG SETS

AT

RAIPUR DEPOT, CHHATTISGARH


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INDEX

Sr. No. CHAPTERS PAGES

FROM TO

1

TENDER COVER PAGE

1

1

2

INDEX

2

2

3

PROJECT DESCRIPTION & SCOPE OF

WORK

3

4

4

TIME SCHEDULE

5

6

5

SCHEDULE OF QUANTITIES

7

8

6

TECHNICAL SPECIFICATIONS

9

53

7

LIST OF APPROVED MAKES

54

55

8

QUALITY ASSURANCE PROGRAM

56

60

9

SPECIAL PAYMENT TERMS

61

61


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PROJECT

DESCRIPTION AND

SCOPE OF WORK


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Scope of Work:-

The scope of work and explanatory notes given below are added to assist the

contractor to understand the project. The detailed scope is as described in the Bill of

Quantities and Specifications. However, any item of work is required to be carried out

for proper and satisfactory completion of work with the highest standard of

workmanship. The proposed Supply, Testing, Supervision during pre-commissioning

& Commissioning of 1 No. 500 KVA & 1 No. 250 KVA Diesel Generating Set along

with Acoustic Enclosure for HINDUSTAN PETROLEUM CORPORATION

LIMITED (RAIPUR)

Site Conditions:-

The project site is located at Raipur in the state of Chhattisgarh. The vendor should

visit the site and obtain on the spot information required by him and having bearing on

this work.

Approval of Drawings & Schedules:-

All fabrication drawings for Acoustic enclosure, AMF cum Synchronizing Panel,

shall be prepared and submitted by contractor at no extra cost within the time

stipulated by the Consultants and in the manner so required by him. The vendor

shall proceed with the work only after approval of the TPI Agency/HPCL/ Consultant.

Such drawings shall be coordinated with all disciplines of work. The vendor shall also

get all the approvals from Government bodies, Pollution Control, Director of

Explosive, Electrical Inspector, Supply Authority etc. free of cost and within the

expiry of the contract.

Drawings and Specifications:- The Specifications and Schedule of rates shall be considered as part of this

contract and any work or material shown on schedule and not called for in the

specifications or vice versa, shall be executed as if specifically called for in both.

The drawings indicate the extent and general arrangements of the fixtures, controlling

switches, wiring system etc. and are essentially diagrammatic. The drawings indicate

the points of termination of conduit runs and broadly suggest the routes to be

followed.

Shop Drawings:- The Contractor shall prepare and submit the Consultants for his approval detailed

Shop drawings of AMF cum synchronizing Panel and Acoustic enclosure and any

other equipment to be fabricated by Contractor within 7 days of signing of the

Contract.

ADDRESS OF LOCATION:-

Hindustan Petroleum Corporation Limited

Mandir Hasaud IRD

District Raipur - 492101

Chhattisgarh.

Ph: (0771)2471218


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TIME SCHEDULE


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TIME SCHEDULE

DESCRIPTION OF WORK:

SUPPLY, TESTING & SUPERVISION OF COMMISSIONING OF 1 No. 500 KVA & 1 No. 250

KVA DG SETS AT RAIPUR DEPOT.

LOCATION : RAIPUR DEPOT, CHHATTISGARH

COMPLETION PERIOD: 3 (THREE) MONTHS FROM DATE OF ISSUE OF FOI/LOI/PO

WHICHEVER IS EARLIER

NOTE:

1) Time for completion shall be reckoned from the date of issue of Fax/ Letter of Intent/Purchase Order by HPCL.

2) Time for completion shall include the time required for Drawing/ QAP submission, Drawing/ QAP approval, manufacturing, Third Party Inspection, dispatch clearance, Packing & Forwarding,

Transportation and receipt of the material at the site as per requirements of Contract Document and

instructions of HPCL Engineer-in-Charge.

3) Supply of the DG Sets only comes under the LD clause while Supervision & Commissioning doesnt come under this clause.


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SCHEDULE OF

QUANTITIES


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SCHEDULE OFQUANTITIES

Sr. No.

Description Quantity Unit

1

Supply, Testing & Commissioning Of 500

KVA DG Sets

1 EACH

2

Supply, Testing & Commissioning Of 250

KVA DG Sets

1 EACH

3

Supply, Testing & Commissioning Of

Synchronizing cum AMF Control Panel

1 EACH

4

Supervision during Pre-Commissioning &

Commissioning of the DG Set &

Synchronizing cum AMF Panel

3

MAN DAY

NOTE:- All the items shall be placed on a single vendor and shall be evaluated together.


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TECHNICAL

SPECIFICATIONS


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TECHNICAL SPECIFICATIONS FOR DIESEL GENERATING SET

Scope:-

This specification covers the requirements of design, manufacture, assembly, shop

testing, delivery to project site, supervision during pre-commissioning checks &

commissioning of 1 No. 500 KVA/ 400 KW & 1 No. 250 KVA/ 200 KW Diesel

Generating Set along with Acoustic enclosure and all other related accessories with

AMF cum synchronizing Panel.

This specification covers the technical requirements of design, engineering manufacture,

assembly, testing at works and delivery in well packed condition of silent type diesel

generator set CPCB compliant complete with all required accessories and control

equipment to supply continuous electrical power. The scope shall also include third party

inspection of the DG set, provision of associated Auto synchronization/AMF panel and

supply of commissioning/mandatory spares.

This standard shall be read in conjunction with job schedule.

The scope of supply shall include the following work: -

(a) Diesel engine, complete with all the required accessories and components.

(b) Generator set for operation with the above diesel engine, complete with all the required accessories and compounds.

(c) Fuel oil system comprising of fuel oil tank, supply pump, filter, piping, valves fittings etc.

(d) Air intake system comprising of air blower, air filter, turbo charger etc.

(e) Lubrication oil system comprising of lube oil pump, filter, cooler, piping, valves fittings etc.

(f) Jacket cooling system comprising of radiator, water circulation pump, necessary piping and fittings etc.

(g) Starting system complete with battery, battery charger, starter motor, control system etc.

(h) All inter connecting piping, valves, fittings etc.

(i) Torsional vibration damper at the free end of the crank shaft.

(j) Speed regulation system.

(k) A common base frame suitable for assembly of engine, radiator and alternator


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with their accessories. Anti vibration mounting pad shall also be supplied.

(l) Exhaust manifold complete with silencers, asbestos lagging, metallic expansion bellows and piping.

(m) All necessary instruments for monitoring and safe starting, running and stopping of the D.G. set their auxiliaries complete with tubing and cabling.

(n) All safety and protective devices.

(o) Cabling material between control & protection panel and all equipment within the battery limit including cables, racks, earthing terminating materials etc.

(p) Acoustic enclosure (Central Pollution Control Board approved) made of 14 SWG CRCA sheet steel.

(q) All other items not specified here but, necessary for safe, satisfactory and uninterrupted operation of D.G. set.

(r) Set of special tools and tackles required for installation and maintenance.

(s) All other services for making DG set with its control and protection features complete in all respect.

(t) Auto Mains Failure, Auto Synchronizing and Auto Load Sharing Panel.

Following services but not limited to, will form a part of Vendors work and prices quoted will be deemed to include:

a) Supply of all equipment, materials, accessories, consumable, hardware, and

mandatory spares as well as commissioning spares.

b) Packing and forwarding of above.

c) Transporting to site.

d) Preparation of all manufacturing shop drawing / wiring drawings etc.

e) Preparation of final As Built drawings of all drawings prepared.

STANDARD SCOPE

ENGINE Direct injection, water cooled engine, 12 cylinder, 4 stroke, rated at 1500

RPM, conforming to ISO 3046 / BS 5514 has the following specifications:

Digital Electronic Governor (*)

In-line fuel pump

Optimized turbocharger

Stainless steel exhaust flexible coupling


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Silencer

Radiator

Coolant inhibitor

Plate-type lube oil cooler

Spin-on filters coolant, fuel & lube oil

Dry-type, heavy duty replaceable paper element air cleaner with restriction indicator

Flywheel housing and flywheel to suit single bearing alternator

Electrical starter motor

Battery charging alternator

First fill lube oil

Alternator: Brushless alternator

Self-excited, self regulated

Class H insulation

Salient pole revolving field

Single bearing

Digital automatic voltage regulator (part of PCC 1301)

Standard to be followed.

The design, manufacture and testing of the equipment covered by this standard shall

comply with the latest issue of the following codes and other relevant Indian standard

specifications unless otherwise specified in the specification sheet.

o BS 649 Diesel engines for general purpose.

o IS-10000 Methods of test for internal combustion engine.

o ASME codes(applicable to Diesel Generator)

o IS 4722 Rotating Electrical Machines.

o Oil coolers as per TEMA class C

o BS : 2623 Alternator

o IS: 1460 Diesel Fuels.

o IS: 4691 Degrees of protection provided by enclosures for rotating electrical machinery.

o IS 10002 Performance requirements of Diesel Engine for General purpose above 20 KW

o Indian Electricity Act & Rules.


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o Any other Standards/ Codes (BS & IS) applicable.

The design and operational features of the equipment offered shall also comply with the

provisions of latest issue of the Indian Electricity Rules and other statutory regulations.

The vendor shall, wherever necessary, make suitable modification in the equipment to

comply with the above.

DETAIL SCOPE

Design, Supply, Testing, Transportation, Supervision during Pre-commissioning checks &

Commissioning of 1No. 500 KVA & 1 No. 250 KVA Prime rated Diesel Generator set, speed

of Diesel engine not exceeding 1500 RPM, four stroke engine, designed for operating on high

speed diesel, 415 V Diesel Generator sets consisting of water-cooled engine alternator and

engine mounted radiator and suitable for AMF START, auto synchronizing and auto load

sharing along with all accessories and components such as exhaust pipes, fuel system etc.

complete erection and installation on foundation prepared by another agency, connecting to

all completed accessories and components and integrating the performance of all sub-

systems, providing assistance for the electrical vendor for testing and commissioning and

performance testing, electrical and necessary civil work for DG foundation as per the details

from the DG supplier as required for the proper and efficient functioning of DG sets as

specified in Specification / Bill of Quantities.

Design, Supply and providing assistance to the electrical contractor for testing and

commissioning of silencer Exhaust pipes with supports.

Design and Supply necessary heavy duty anti vibration spring type mounts suitable for the

DG sets and also providing assistance to the electrical contractor for installation, testing and

commissioning of the same suitable for the DG sets with necessary bolts etc. for satisfactory

installation.

Providing assistance to the electrical contractor for design, installation, testing and

commissioning of fuel pipe lines from day tank with necessary pumps, valves etc.

Providing assistance to the electrical contractor for design and preparation of the drawings for

self supported exhaust stack, provision of sampling ports for all types of stacks, submission

and obtaining approval and necessary certificate from Pollution Control Board and other

statutory authorities. Obtaining the approval from Pollution Control Board will be in the


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scope of the electrical contractor. The CPCB compliance for the DG set shall be provided by

DG manufacturer.

Providing assistance to the electrical contractor for design and Preparation of the drawing for

statutory authorities such as Pollution Control Board etc. for commissioning the system

including arranging inspection and also necessary approval / safety certificate from

authorities etc.

Providing assistance to the electrical contractor for Design and Preparation of electrical

drawings for generator and connected electrical installation work submission, obtaining

approval to drawings arranging inspection, obtaining supply certificate from Central

Electrical Inspectorate.

The DG supplier to ensure that in the guarantee period all required accessories and

components that are required for a fully functional power generating station are available at

site.

The scope shall include supply, design, supervision and commissioning of efficient

acoustic enclosure to the D.G sets in such a manner that the sound levels with all the D.G sets

operating simultaneously will be less than 75 dB within 1 mtr. at nearest boundary of the DG

set during day time. Bidder shall note that the specified acoustic performance shall be

guaranteed by him. Any measures involving civil works to be implemented at site will

separately mentioned by the vendor in their offer. Other measures involving mechanical

items (such as ducting, hoods, etc. over and above the items supplied by DG vendor for

successful commissioning) to be implemented will also be specified separately by the D.G

Contractor. The detailed specifications for acoustic enclosure is attached else where in this

tender.

Site and Building Space Restriction: In the attached site plan and building drawings,

space allocation has been shown for the D.G sets as well as all accessories. The contractor

shall ensure that all equipments are fitted within the space earmarked. No other space will be

made available.


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Standards:-

The Diesel Engine, alternator, accessories and AMF cum synchronizing panel shall comply

with the following Indian/British Standard Specification.

AMF cum synchronizing Control Panel : IS 4237 or IS 8623 (Part-I)

Diesel Generating Set:-

Voltage : 415 Volts

Phases : Three

Frequency : 50 Hz

The D. G. Sets shall be rated for 24 hours continuous duty.

The D.G. Sets shall be capable of generating a power output of 500 KVA at 0.8 PF on continuous operation under the simultaneous occurrence of the following conditions at site.

a) Maximum ambient air temperature : 45 Deg. C

b) Relative Humidity at maximum : 89

Ambient temperature.

c) All engine driven auxiliaries : required running to their full capacity

Engine deratings from the standard (N.T.P.) rating to obtain site rating shall be carried

out in accordance with latest edition of BS-5514.

The Diesel Engine and Alternator field characteristics shall be suitable for facilitating

parallel operation of similar Diesel Generating Sets with equal load distribution.

Since the Diesel Generating Sets will be utilized for emergency services, it shall be

designed without any limitation on the number and frequency of starts in any given period.

OPERATIONAL PHILOSOPHY

The specified DG Sets are required for Emergency Power Supply requirement. These DG

sets shall start automatically upon failure of the normal power supply and also stopped

automatically in case of restoration of EB supply after the mandatory checking of the supply

parameters. The DG sets shall also be able to start & stop manually through a push button.

As per Conditions mentioned in Operational Philosophy following criterias to be

fulfilled by 2Nos. of DG Sets accordingly:


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DG Set 1 250 KVA

DG Set 2 500 KVA

OPERATIONAL PHILOSOPHY:-

The load sharing shall be such that only 250 KVA DG shall be operating till the load

is less than 170 KW.

In case of any failure in the first DG set the second one shall take over the load.

Once the load increases the 170 KW 500 KVA DG shall start operating and the 250

KVA DG shall stop until the total load acting is less than 340 KW.

Once the overall load acting increases 340 KW both the DGs shall start operating and

there shall be a sharing of load between both the DG sets.

Following panel should be provided with DG sets:

DG Control panel with AMF, synchronizing and programmable features.

Battery charger panel

a. Self excited, self regulated excitation system along with fast response governor shall

ensure that the set dependably comes to full speed and delivers rated output at 415 V, 50 Hz

within 15 seconds after getting the starting signal.

b. Under steady state condition, the electronic voltage regulator shall keep the voltage

constant within 0.5 % of the rated voltage with full load at constant speed (with power

factor varying between 0.8 lag to unity). Further adjusting the set voltage up to 5% of

rated voltage shall be possible by the potentiometer provided for the purpose.

c. Under transient operating condition, the time of return to within 3% of steady state

voltage when permitted step down load is suddenly applied shall be less than one second

(assuming speed to be constant). Further the speed drop due to such loading shall be

corrected to ensure 50 Hz 1% Hz within less than 3 seconds (momentary fluctuation in

frequency shall be less than 1 Hz). Governing system shall ensure minimum fluctuation

during load changes. Inertia constant of the rotating system shall aid the governing system.

Class A11 governing system preferably using wood ward PSG governor shall be offered.

Speed drop shall be continuously adjustable.

d. D G set shall meet the DOL starting requirement of induction motors and Constant UPS

load. Machine shall develop symmetrical balanced sine wave voltage. Irregularities in


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waveform shall not cause objectionable interference to other adjacent circuits. Total

harmonic factor (THF) as found by type tests shall be less than 5% (per IS 4722).

DG location / Foundation / Anti Vibration pads

The subject two DG sets of 500KVA & 250 KVA (one each) rating shall be installed on the

foundation to be made by HPCL and shall be open on all sides. Bidder shall recommend the

minimum size of the foundation and shall submit the detailed foundation drawing along

with their proposal. Bidders shall specify and supply the number of anti vibrations pads

required for each DG set so as prevent the DG Vibrations, while running, to be transferred

to the ground.

DESIGN CRITERIA

Engine Performance

The engine shall be sized and selected as per the details given as under.

1. Rated engine power at standard operating conditions (ISO conditions)

2. Deration on account of site conditions (refer datasheet for ambient conditions) as per ISO

3046 - 1

Temperature (combustion inlet temperature) :

Altitude (dl) :

Humidity (d2) :

CW temp (d3) :

Inlet losses (d4) :

Exhaust back press (d5) :

Total Deration (Deration = dl+d2+d3+d4+d5) :

3. Site rated power (as per ISO 3046-1) of the Engine

(i.e. at stated conditions) to be obtained by deducting the total deration from the rated power.

4. Power consumed by essential dependent

and independent auxiliaries: : kW

5. Mechanical transmission losses through coupling : kW

6. The net input power available at the alternator to be obtained by decuting the

summation of power Consumed for essentials and transmission losses ( sl nos 3- sl

nos(4+5)) through coupling from the site rated power : kW


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7. Power required at the alternator input (Preq) : kW

(alternator efficiency) * Power factor |

Bidder shall ensure that net input power (sr. no. 6) shall be greater than the power required

calculated basis above (sr. no. 7) and the exact details shall be furnished along with the offer.

Performance requirements

1. The unit shall be capable of starting from cold condition.

2. The unit shall be capable of a peak of 10% in excess of the rated out put for a period of

one hour in a total of 12 consecutive hours of operation, without exceeding permissible

temperature limits and with a fairly visible exhaust.

3. The unit shall operate up to 120 % the rated speed over the entire range of out put without

undue vibrations and noise.

4. The DG Set shall be capable of taking on min 50% load equivalent to its rated capacity in

one step with no voltage dip and without affecting the frequency.

5. CDG Relay has to be provided for over current and Earth fault protection.

Diesel Engine :-

The Diesel Engine specification shall be as follows:-

TECHNICAL DATA:

Generator Set Specifications: 500 KVA

Model C 1010 D5 P or equivalent

Prime Power Rating kVA 500

Output Voltage and Frequency 415 Volts, 50 Hz

Power Factor 0.8 (lag)

No. of phases 3 phase

Engine Specifications : 500 KVA

Make Cummins/MTU/Caterpillar/

Kirloskar/Volvo/KOEL/Perkins

Model KTA 19 G9 or equivalent

No. of cylinders 6, In- Line

Aspiration Turbocharged-Air to air cooled

Bore x Stroke 159 mm x 159mm


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Displacement 18.9 ltrs

Output Prime 448 KWm

Fuel consumption @ 75% load with

Radiator & Fan

Not over 77.4 ltr/hr


Radiator & Fan


Typical lube oil consumption @ full

load


Total wet weight (engine + radiator) 2687 kg

Length x Width x Height (engine) 1970 x 1092 x 1510 mm

Compression Ratio 13.9:1

Piston speed 7.95 m/s

Governor / Class Electronic / A1

Lubricating oil system capacity 55 ltrs

Coolant capacity (engine & radiator) 175 ltrs

Combustion air intake @ 100% load

(+/- 5%)

32.7 m3/min

Fan air flow across radiator 1217 m3/min

Exhaust Temperature 538 oC

Battery capacity / Rating 180 AH, 4 x 12V

Generator Set Specifications: 250 KVA

Model

Prime Power Rating kVA 250

Output Voltage and Frequency 415 Volts, 50 Hz

Power Factor 0.8 (lag)

No. of phases 3 phase

Engine Specifications : 250 KVA

Make Cummins/MTU/Caterpillar/

Kirloskar/Volvo/KOEL/Perkins

Model 6CTAA8.3G4 or equivalent

No. of cylinders 6, In- Line

Aspiration Turbocharged-Air to air cooled

Bore x Stroke 114 mm x 135mm

Displacement 8.3 ltrs

Output Prime 448 KWm


Radiator & Fan



Radiator & Fan


Typical lube oil consumption @ full

load


Total wet weight (engine + radiator) 760 Kg


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Length x Width x Height (engine) 1129 x 711 x 1171 mm

Compression Ratio 15.35:1

Piston speed 6.75 m/s

Governor / Class Electronic / A1

Lubricating oil system capacity 39 ltrs

Coolant capacity (engine & radiator) 42 ltrs

Combustion air intake @ 100% load

(+/- 5%)

17.1 m3/min

Fan air flow across radiator 11343 lt/sec

Exhaust Temperature 523 oC

Battery capacity / Rating 65 AH, 2 x 12V

a) Silencer suitably optimized to meet stringent sound emission standards laid down by

MOEF/CPCB

b) Base rail with integral fuel tank (700 liters capacity with 500KVA & 350 lt capacity with

250KVA) is to be provided with drain plug, air vent, inlet and outlet connection, level

indicator, manhole etc.

The DG set shall be mounted inside an acoustically treated enclosure to ensure that the noise level at a distance of 1mtr does not exceed 75 dB

All the instrumentation, AMF Panel, power and control cables, as specified in the

specifications shall be provided by the contractor.

Fuel Oil System:-

Fuel Oil Day Tank :-

Fuel oil to engine shall be supplied from a "Fuel Oil Day Tank". The tank shall have a capacity of 990 litres with mounting brackets, complete with level indicator, fuel inlet and

outlet, air vent, drain plug, inlet arrangement for direct filling and set of 990 mm long fuel

hoses.

The tank shall be made from 3 mm thick mild steel and provided with suitable coatings/paintings for corrosion protection. The day tank shall be provided with a tapping at

0.6 M height, with gate valve to enable any excess fuel (greater than 500 litres) charged into

the day tank to flow back into the fuel drums. A red marking shall be provided just below

this tapping.

The day tank shall be provided with the following minimum accessories :- One (1) level gauge with isolating and drain valve. One (1) drain connection with isolating valve. One (1) manhole with cover for maintenance purposes.

The engine shall draw fuel oil from the day tank to the engine driven booster pump through 2 x 100% capacity filters or through a duplex filter. The entire piping to and from

the day tank to the engine shall be provided by the contractor. This piping shall be of

ERW/flexible hose pipes and shall be provided with necessary valves, fittings, supports, etc.


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to make the system complete. Also, the piping near the engine for about 500 mm. length

shall be flexible armoured steel hose. Additional filters may be provided by the

contractor, if required for his engine system. The engine driven booster pump shall supply

fuel oil to the injectors.

The system between the day tank and the engine shall be such as to ensure priming of the system at all times, when the engine is inoperative, for remote and quick starting of the

engine at any instant.

A fuel oil trip solenoid valve shall be provided in the fuel line to the engine for cutting off the

fuel into the engine on receipt of impulse from the DG control panel.

Lubricating Oil System:-

The lubricating oil for engine lubricating shall be collected in the oil pan located at the

bottom of the crank case/cylinder block. From the oil pan, the lubricating oil shall be led

off to a separate lube oil sump, if required.

From the oil pan or from the oil sump (if provided) the lubricating oil shall be drawn by the

engine driven lubricating oil pump through foot strainer (in the oil) and then through 2 x

100% capacity filters or a duplex filter.

The engine driven lubricating oil pump shall be of gear type with suitable pressure relieving

devices. The entire pump assembly shall be mounted on the engine cylinder block/crank case

and shall be driven off the crank shaft.

The lubricating oil from the engine driven pump shall pass through the lubricating oil cooler,

where it shall be cooled to required temperature. The lubricating oil may be cooled either by

air, jacket water or raw water. The oil cooler shall be mounted on the engine cylinder block.

Suitable bypass arrangement shall be provided for bypassing the lubricating oil cooler

during start up, until the oil temperature reaches the minimum required value.

An A.C. motor driven, intermittent operation lubricating oil priming pump shall be provided.

This pump in conjunction with a suitable clock timer shall supply lubricating oil intermittently

to the engine when the engine is inoperative.

The pressurized and cooled oil cooler shall be led through the various oil galleries in the

cylinder block/crank case to the various parts of the engine.

The lubricating oil after passing through the lubricating oil circuit of engine shall return

to the oil pan/oil pump at the bottom of the engine cylinder block/crank case.

The type and grade of lubricating oil to be used in the engine shall be indicated by the

Manufacturer.

All the interconnecting lubricating oil piping together with valves, fittings, hangars and

supports, etc. shall be provided by the contractor.

Cooling System:-

Jacket Water Cooling


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The cylinder linings, cylinder head, valves, fuel injector etc. shall be cooled by the Radiator

Cooled Engine.

The water circulation through the engine jackets shall be established by an engine driven

jacket water pump. The drive for this pump shall be taken from the engine crank shaft

either by a gear train, belt drive or a chain drive as per the manufacturer's standard

practice.

Engine Starting System:-

The engine shall be suitable for electric starting, as described below:-

Electric Starting System:-

The system shall comprise a set of starter batteries, battery charger and starter motor with requisite instruments.

The starter batteries shall be lead-acid type.

The ampere-hour capacity of the lead-acid battery shall be adequately sized for maximum six consecutive repeat start impulses to be given to the diesel engine as well as to

cater for D.C. loads on engine control panel such as enunciators and lamps, protection relays,

etc.

The starter motor shall be DC type suitable for operating on the battery voltage.

The battery charger shall be of the static type arranged to draw power either from the mains supply (240 V, 1 Phase, 50 Hz.) or from the DG supply by means of a selector

switch mounted on the AMF Control Panel.

All the cables required to make the starting system complete shall be supplied, laid and terminated by the Contractor.

The battery shall be supplied with necessary floor mounted stand made of teak wood and treated with anti-corrosive paint.

Air intake system:-

The contractor shall provide for each engine the entire air intake system to meet the

combustion air requirements of each engine.

Air shall be sucked through an air intake filter/cleaner. The air filter/cleaner may be either of the dry or wet type.

An intake air silencer at the air inlet to the air cleaner shall be provided by the Contractor to reduce the noise level, if required.

The engine shall be exhaust gas turbo charged as described below:-


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The air from the air cleaners shall be charged into the cylinders by means of a centrifugal compressor powered by an exhaust gas driven turbine. This turbocharger shall be

provided with cooling by the engine lube oil. The turbocharger shall be mounted on the

engine. One or two turbochargers, operating in parallel may be provided, depending upon

the manufacturer's standard practice.

Exhaust Gas System:-

The exhaust gas system shall be complete with all the accessories specified herein and shall ensure safe disposal of the exhaust gases at a suitable point outside the room

at a height specified by the Pollution control Board.

The exhaust gases from the engine exhaust manifold shall be led to the exhaust gas turbocharger for super charging air into the engine.

From the turbocharger the exhaust gases shall be led to residential type exhaust gas silencer and then led to a point outside the D. G. set room, at suitable height as per

statutory requirements.

Suitable flexible joints (metallic bellows) shall be provided on the exhaust piping to take care of expansion due to high working temperatures. It shall also isolate the piping from the

engine vibrations. The flexible joint shall be provided as near the engine as possible.

The exhaust gas shall be led outside the Acoustic enclosure at to be left open to sky or where ever so desired, as per Pollution Control Board's requirement. The outlet shall be

provided with a protective wire mesh net to prevent the entry of foreign particles into the

exhaust piping. Necessary supports for the exhaust gas piping shall be provided by the

Contractor.

The entire exhaust gas piping, residential type silencers, expansion bellows, etc. shall be provided by the Contractor together with necessary supports, joints, etc. Support base of

structural steel which may be required shall also be provided by the Contractor. The entire

exhaust gas piping inside the Acoustic enclosure including the engine exhaust gas manifold

Engine Cooling System

Engine shall be provided with radiator cooling. Potable water will be made available for make-up.

Engine Lubrication System

Engine lubrication shall be as per Manufacturers standard. The DG Set shall be suitable for

automatic starting on Power failure. In order to keep the DG set in ready to start condition at

all times if required by the engine manufacturer, a complete automatic pre-lubrication system

(including electric (AC) motor driven pre-lubrication pump(auxiliary LO pump) etc.) that

lubricates the Engine at regular intervals, complete with Timer logic etc. shall be included in

Bidder's scope. The frequency of starting of pre-lube pump shall be indicated by the bidder on

the datasheets.


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Engine Fuel System

The engine shall run on Diesel fuel HSD and engine standard fuel systems shall be

offered.

The diesel tank shall be provided with level switches at

25% Level one fourth fill fuel level for telemetry transmission to IBMS vendor

10% Level Low fuel level for telemetry transmission to IBMS vendor

Engine Exhaust System

The bidder scope shall be limited to the supply of residential silencer and providing

assistance to the HPCL appointed electrical vendor for the installation of complete-Exhaust

System including complete exhaust piping,' residential type silencer, expansion bellow,

fittings, insulation and stack and supports etc. The exhaust from the DG set shall meet the

prevailing pollution control board requirements besides meeting' the minimum requirements

for diesel engines.

Governing:-

The governor shall be of the Digital electronic type.

Alternator:-

The alternator shall be double bearing type as details given below:-

Alternator specifications: 500KVA DG SET Make Stamford/Kirloskar/Crompton

Frame size / Model No Suitable to tender

Voltage Regulation +/- 1.0%

Insulation Class H

Standard Enclosure IP 23

Winding Pitch 2 / 3 Pitch

Stator Winding Double layer lap

Rotor Dynamically balanced

Wave form distortion No load < 1.5% non distorting

balanced linear load < 5%

Telephone Interference

Factor

Better than 50

Total Harmonic Factor Better than 2%


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Alternator specifications: 250KVA DG SET Make Stamford/Kirloskar/Crompton

Frame size / Model No Suitable to tender

Voltage Regulation +/- 1.0%

Insulation Class H

Standard Enclosure IP 23

Winding Pitch 2 / 3 Pitch

Stator Winding Double layer lap

Rotor Dynamically balanced

Wave form distortion No load < 1.8% non distorting

balanced linear load < 5%

Telephone Interference

Factor

Better than 50

Total Harmonic Factor Better than 2%

DG AMF CUM SYNCHRONIZING CONTROL PANEL:-

The diesel generator set shall be supplied with a AMF Control panel. This AMF Panel shall

be housed inside the Acoustic enclosure. It should be floor mounting, free standing dust tight,

sheet metal enclosed, cubicle type. The AMF panel shall be fabricated out of 2.0 mm. thick cold

rolled sheet steel. The AMF panel shall be wired internally up to terminal blocks using 650

Volts grade 2.5 sq.mm. copper conductor PVC wires. The sheet metal work of the panel shall be

thoroughly cleaned, degreased, pickled, phosphatised and given two coats of primer and finished

with Powder coated paint of shade steel gray. Cable entry to the AMF control panel shall be

from the bottom for auxiliary cables such as priming pumps, Control cables etc whereas for

incoming and main power cable connections shall be through top and outgoing main power

connection from bottom.

The AMF panel shall be complete with the necessary control circuit fuses, nameplates,

internal wiring, control terminals and cable glands. The AMF panel shall have provision for

receiving starting impulses for the D.G. set from Purchaser's remote Main L.T Panel as well as to

send out tripping impulses from AMF panel to the DG incomer breaker on purchaser's Main L.T

Panel.

The AMF panel shall receive 415 Volts sensing supply from Purchaser's remote Main L.T

Panel. The necessary interlocking between ACB of Grid Power and DG set Breaker should be

done such that no two sources of Power are made parallel.


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The AMF panel shall be suitable for extension on either side. All the cable entries to the

AMF panel shall be from the bottom.

The panel shall be designed to confirm to the requirements of:

a) IS 4237 - General requirements for switchgear and control gears for voltages not exceeding

1100 volts.

b) IS 2147 - Degree of protection provided by enclosures for low voltages switchgear and control

gear.

c) IS 375 - Marking and arrangements of bus bars. Individual equipment housed in the power

control to the following IS specifications:

i) Air / Moulded case circuit breakers - IS 2516 (Part I & II/Sec.1) 1977

ii) Fuse switch and switch fuse units - IS 4064 : 1978.

iii) HRC fuse links - IS 1108 : 1962 or IS 9114 : 1979.

iv) Current Transformer - IS 2705.

v) Voltage Transformer - IS 3156.

vi) Relays - IS 3231.

vii) Indicating Instruments - IS 1248.

viii) Integrating Instruments - IS 711.

ix) Control Switches and push buttons - IS 6875.

x ) Auxiliary contractors - IS 2959.

CONSTRUCTIONS: The panels shall be:

i) Metal enclosed, indoor, floor mounted, free standing type.

ii) It shall be made up of the requisite vertical section, which when coupled together shall form

continuous dead front switch boards.

iii) Provide dust and dump protection, the degree of protection being IP 65 to IS - 13947.

iv) Be readily extensible on both sides by the addition of vertical sections after removal of the

end covers. Each vertical section shall comprise:

A front framed structure rolled / folded sheet steel channel section of minimum 3mm

thick, rigidly bolted together. This structure shall house the components contributing to the major

height of the equipment, such as circuit breaker cassettes, fuse switch units, main horizontal bus

bars, vertical risers and other front mounted accessories.

The structure shall be mounted on a rigid base frame of folded sheet steel of minimum


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3mm thick and 100mm height. The design shall ensure that the weight of the components is

adequately supported without deformation or loss of alignment during transit or during operation.

A cable chamber shall house the cable end connections of power / control cable

termination. The design shall be to ensure generous availability of space for easy installation and

maintenance of cabling, and adequate safety for making in one vertical section without coming

into accidental contact with live parts in and adjacent sections.

A cover plate at the top of the vertical section, provided with a ventilating hood where

necessary. Any aperture for ventilation shall be covered with a perforated sheet having less than

1mm diameter perforated to prevent entry of vermin.

Front and rear doors shall be fitted with nuts/bolts including neoprene gaskets with

fasteners designed to ensure proper compression of the gaskets. When covers are provided in

place of doors, generous overlap shall be assured between sheet surfaces with closely space

fasteners to preclude the entry of dust. The height of the panel should not be more than 2400mm.

The maximum height of any operating mechanism shall not be more than 2100mm. The total

depth should be adequate to cater for proper cabling space.

Panel shall be fabricated from 14 SWG CRCA sheets properly supported with angles and

channels. The cubicle shall be single front floor mounted type unless specified otherwise.

The door shall be provided with internal hinges and panel locks of superior quality. The

hinges shall be union joint type to facilitate easy removal of the doors, when necessary. Doors

shall be provided in a similar fashion, as generally provided for the outdoor cabinet where water

cannot enter into the cabinet from the door, the door shall be provided with strengthening

arrangement to avoid wobbling and distortion. Whenever the door arm opens on the horizontal

hinges, an arrangement shall be provided to latch the doors in the open condition for the

inspection of the wiring. The cabinet shall be of welded construction and not of joining

construction. The cabinet shall be compartmentalized, having the horizontal and vertical bus bars

at the back centrally located and circuit breakers shall be arranged at the bottom of the pillars and

switch fuse units at the upper portion. The panel shall be provided with a canopy on the top in

such a way, that free air circulation is available. At the same time, it shall be dust and vermin

proof. A channel frame of 300 mm height fabricated from minimum section of channels 75mm x

40mm x 6mm shall be provided at the bottom of each cabinet. This is required to make the

cabinet stable and space for bends. The foundation on holes with grouting, bolts shall be provided

in the channel frame. Cable entries shall be as shown on the panel schedules and minimum entry

depth shall be 200mm unless specified otherwise. 16 SWG MS sectionalized entry plates shall be

provided for multicore entries and 6mm hylam sheet for single core entry points. The circuit


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components shall be mounted on sectionalized 12 SWG 2.5mm thick. MS sheets, with suitable

threading in the sheets to facilitate easy maintenance, future addition, etc. push buttons, signal

lamps, and other control components shall be provided on a hinged (at the top) door with suitable

latching arrangement.

These components shall be at about 1400 mm height. The height of the panels shall not be more

than 2300 mm and the depth of the panel shall not be more than 400 mm for single front and 800

mm for double front, except for the air circuit breaker panels, where the depth could be about

900mm. Space - heaters (min. 2 nos. x 75 watts each) shall be provided with MCBs in each

panel.

The cubicle shall undergo the following process of metal treatment.

Sanding

Derusting and phosphatising with scale gun asfoclean or equivalent.

Degreasing with Asfocoat or equivalent

Two coats of red oxide primer.

Putty work.

Two coats of synthetic enamel of desired shade.

Engraved labels shall be provided indicating the feeder details, capacity and 415 Volts danger

signs. Fuses shall be HRC cartridge type conforming to IS: 3106 with a breaking capacity

corresponding to system fault level. Fuses shall be link type with visible indication. Screw type

dazed fuses are not acceptable for any rating. All disconnects shall consist of switch units quick-

make, quick-break type with silver plated contacts. The switches shall preferably have double

breaks. All switches shall be mounted in sheet steel enclosure, which in turn is mounted on

suitable angle iron framework. In wet locations switches shall be mounted on suitable angle iron

frame work. In wet locations switches shall have cost iron enclosures. Doors and covers shall be

of minimum 14 gauge CRCA sheet steel. All sheet steel work forming the exteriors or

switchboards shall be smoothly finished, leveled and free from flaws. The corners should be

rounded. The apparatus and circuits in the power control panels shall be so arranged as to

facilitate their operation and maintenance and at the same time to ensure the necessary degree of

safety.

Apparatus forming part of the power control panels shall have the following minimum

clearances:

i) Between phases - 25 mm

ii) Between phases and neutral - 25 mm

iii) Between phases and earth - 25 mm

iv) Between neutral and earth - 25 mm


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If for any reason, the above clearances are not available suitable insulation shall be provided.

Clearance shall be maintained during normal services conditions.

Creep age distances shall comply to those specified in relevant standards. All insulating materials

used in the construction of the equipment shall be arranged in multi-tier formation, except that

not more than two air circuit breakers shall be housed in a single vertical section. Metallic /

insulated barriers shall be provided within vertical sections and between adjacent sections to

ensure prevention of accidental contact with:

i) Main bus bars and vertical risers during operation, inspection or maintenance of functional

units and front mounted accessories.

ii) Cable termination of one functional units, where working of those of adjacent unit / units.

All covers providing access to live power equipments / circuits shall be provided with tool

operated fasteners to prevent unauthorized access. Provision shall be made for permanently

earthing the frames and other metal parts of the switch gear by two independent connections.

METAL TREATMENT AND FINISH :

All steel work used in the construction of the switchboards should have undergone a rigorous

metal treatment process as follows:

a) Effective cleaning by hot alkaline degreasing solution followed by cold water rinsing to

remove traces of alkaline solution.

b) Picking in dilute sulfuric acids to remove oxide scales and rust formation, if any, followed by

cold water rinsing to remove traces of acidic solution.

c) A recognized phosphating process to facilitate durable coating of the paint on the metal

surfaces and also to prevent the spread of rusting in the event of paint film being mechanically

damaged. This again, shall be followed by hot water rinsing to remove traces of phosphate

solution.

d) Passivating in de-oxalite solution to retain and augment the effects of phosphating.

e) Drying with compressed air in a dust free atmosphere.

f) Primer coating, with two coats of highly corrosion resistant primer, applied wet on stove

dried under strictly controlled conditions of temperature and time.

g) A finishing coat of stoving synthetic enamel paint to the specified shade of IS. The total

thickness of paint should not be less than 25 microns.

BUS BARS

a) The bus bars shall be air insulated and made of high conductivity, electrolytic grade

Aluminium conductor. High tensile bolts and spring washers shall be provided at all bus bar


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joints. The busbars shall be adequately insulated and protected to prevent accidental contact

during the operation and maintenance. The busbars shall have supports designed to withstand

short circuit current equivalent to 35 MVA at 415 volts. The insulation between phases and

between phases and ground of the power conductors, shall be made of synthetic resin bonded

moulding resistant to dust and dampness. All insulating material shall be non hygroscopic,

fungus proof and treated with suitable synthetic varnishes.

b) The main phase bus bars shall have continuous current rating throughout the length of each

power control panel, and the neutral bus bars shall have a continuous rating of equal size of other

phase bus bars.

c) Bus bars shall be colour coded for easy identification of individual phases and neutral

and protective earth.

d) Current Transformer: Current transformer shall comply with the requirements of IS

2705. They shall have ratios, outputs and accuracys as specified / required.

e) Indicating / Intergrating Meters: All indicating instruments shall be of flush mounting

industrial pattern, conforming to the requirements of IS 1248. The instrument shall have non-

reflecting dial, clearly divided and legibly marked scales and shall be provided with adjusting

devices in the front. Meters and voltmeters shall have moving iron spring controlled dead-beat

elements in square bezel flush type cases 144mm in size unless specified otherwise and suitable

for switch board mounting meters shall conform to BS:89 and have grade "A" accuracy. Scale

ranges shall meet with the requirement or as indicated on the drawing or in the schedule of

Quantities. Energy meters shall be two element switch board mounting type suitable for

unbalanced loads. All tripping may be through combination thermal and magnetic releases or

IDMT releases as specified. Three pole, thermal overload relay for overload protection of

Alternator through current transformer, Overload relay, Earth fault relay, Reverse power relay

etc, is to be provided for safety of the equipment.

f) Battery charger consisting of transformer / rectifier, D.C. Ammeter, charging rate selector

Off/trickle/boost is to be provided.

g) Cable Termination: Cable entries and terminals shall be provided in the switch-board to suit

the number, type and size of aluminum conductor, power cable and copper conductor control

cable specified in the detailed specifications.

h) Provision shall be made for top or bottom entry of cables as required. Generous size of cabling

chambers shall be provided, with the position of cable glands and terminals such that cables can

be easily and safely terminated. The minimum depth of the panel shall be restricted to 1600 mm

for this purpose.


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i) Barriers or shrouds shall be provided to permit safe working at the terminals of one circuit

currents without accidentally touching that of another live circuit. Cabling risers shall be

adequately supported to withstand the effects of rates short circuit currents without damage and

without causing secondary faults. Cable sockets shall be of copper and of the crimping type as

specified.

CONTROL WIRING:

All control wiring shall be carried out with 1100 / 660 V grade single core PVC cable

conforming to IS 694 / IS 8130 having standard copper conductor of minimum 2.5 Sq.mm

section for potential circuits and 2.5 mm section for current transformer circuits. Wiring shall

bear neatly bunched, adequately supported and properly routed to allow for easy access and

maintenance.

Wire shall be identified by numbered ferrules at each end. The ferrules shall be of the ring and of

non-detoriating materials. They shall be firmly located on each wire so as to prevent free

movement. All control circuit fuses shall be mounted in front of the panel and shall be easily

accessible.

INTER CONNECTION & INTERNAL WIRING

Fiber glass moulded or PVC extruded wire ways shall be provided in the control panel.

All the cables for internal wiring shall be PVC insulated of BSS or ISI approved and reputed

make. The cables shall have copper conductors only and shall be stranded and the minimum

number of stands shall be three. The rating shall conform to IEE wiring regulations. PVC flexible

conductors if required shall have minimum size of 24/36.

Cables for power circuits shall be red, yellow, and blue or otherwise. Proper colored sleeving

shall be provided at both ends of the cable.

All wires shall have at both ends a numbered ferrule or such other means of permanent

identification.

Identification making shall be read from the terminals outwards on all wires.

Terminal Blocks/ Terminations:

Terminal blocks shall be of 500 volts grade of finger touch proof type. Insulating barriers shall be

provided between adjacent terminals.


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Cables upto 150 Sq.mm alum shall be provided with clip-on type (Slide lock design) of rugged

construction. All power terminals shall be colour coded with red, yellow and blue for phases and

black for neutral.

Every cable, either for control or power duty shall be provided with crimping type copper lugs of

suitable size as specified. The lugs shall be fitted with contact grease and the crimping pressure

shall be as follows:

Copper lugs: Upto 30 Sq.mm. 1200 psi.

Above 35 Sq.mm. 2000 psi.

Bi - metallic lugs: 1000 psi.

Cable glands shall be Siemens type brass glands. These glands shall be provided for all the

outgoing connections at both ends, for power as well as control circuits and also for the incoming

cable or cables, crimping type lugs only to be used.

Earth busbars shall be of tinned copper/ alum. With holes, but the bolts and nuts and washers

shall be cadmium plated. Earth busbars all be provided all around the cubicle at the bottom and

it shall be of the same but the maximum size will be 50x 6mm with doples external earth

connection arrangement.

Bi-metallic lugs shall be used wherever copper cables are being terminated on alum. Busbars or

vice-versa.

LABELS:

Labels shall be on anodized aluminum, with white engraving on black background. They shall

be properly secured with fasteners.

TESTS:

Routine tests shall be conducted on each power control panel in accordance with CI 81,2.2

of IS 8623 and shall comprise:

i) Inspections of the power and control circuits including inspection of wiring and electrical

operational tests where necessary.

ii) Dielectric tests.

ii) Checking of protective measures and electrical continuity of the protective circuits.


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AMF LOGICS

The following AMF LOGIC shall be incorporated in the AMF control panel:

The DG Set shall start automatically when one of the following conditions is met.

(a) Mains supply failure.

(b) Mains voltage dips below 85% of nominal voltage (415V).

After the DG set starts and builds up the rates RPM & voltage, the DG breaker/ contactor shall

close & the mains breaker/contactor shall open.

Upon restoration of Mains supply & normal voltage conditions, Necessary Time Delay Shall Be

Allowed To Take Care Of Transient conditions.

ANNUNCIATOR

A solid state multi-window annunciator shall be provided on the panel board with engraved

inscriptions on acrylic sheets and with visible & audible alarms for fault.

Indications like:

1. Alternator over load

2. Reverse Power

3. Earth Fault

4. High water temperature

5. Low lube oil pressure

6. Over speed

7. Set fails to start and 2 spare annunciator windows.

STORING: The panels shall be stored in well ventilated dry places. Suitable polythelene covers shall be

provided for necessary protection against moisture.

ERECTION:

The AMF panel supplied by the DG vendor will be installed by the electrical vendor. Necessary

assistance for proper installation of the panel as follows shall be extended by the DG vendor to

the electrical vendor.

The panel shall be shall be installed on suitable foundation. Foundation shall be per the

dimensions supplied by the panel manufacturer. The foundation shall be flat and level. Suitable

grouting holes shall be provided in the foundation. Suitable MS base channel shall be embedded


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in foundation on which the panel can be directly installed. The switch boards shall be properly

aligned and bolted to the foundation by bottom plate or top plate as the case may be, by using

brass Siemens type compression glands. The individual cables shall then be led through the panel

to the required feeder compartments for necessary terminations. The cables shall be clamped to

the supporting arrangements. The switch board earth bus shall be connected to the local earth

grid.

PRE-COMMISSION TESTS:

Panels shall be commissioned only after the successful completion of the following tests.

The tests shall be carried in the presence of owner or his authorized representative.

a) All main and auxiliary bus bar connections shall be checked and tightened.

b) All wiring terminations and bus bars joints shall be checked and tightened.

c) Wiring shall be checked to ensure that it is according to the drawings.

d) All wiring shall be tested for insulation resistance by a 1000 Volts Megger.

e) Phase rotation tests shall be conducted.

f) Suitable injection tests shall be applied to all the measuring instruments to establish the

correctness and accuracy of calibration and working order.

g) Suitable injection tests shall be applied to all the measuring instruments to establish the

correctness and accuracy of calibration and working order.

h) Panel boards shall be meggered phase to phase and phase to neutral, using a 1000 V meggar

with all switchgear in closed position. The meggered value should not be less than 2.5 mega

ohms between phase and 1.5 mega ohms between phase & neutral & earth.

i) The test shall be carried out by applying 2.5 KV for one minute between Air, Three phases &

Earth. between phases and board shall with stand the same.

j) The panel boards shall be meggered phase to phase end.

All relay and protective devices shall be tested for correctness of settings and operation by

introducing a current generator and ammeter in the circuit.

Instruments Of Engine:-

The following instrumentation shall be provided by the contactor on the Instrument panel

(mounted on engine)

Dial type thermometers for the following:

a) Lube oil outlet temperature from bearings.

b) Jacket water temperature at cylinder outlet.


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Pressure gauges for the following:

a) At the lube oil header in the engine.

b) At the jacket water inlet to engine.

Hour meter-cum-RPM Indicator.

Method of Operation of Diesel Generating Set:-

Automatic Mode of Operation:

Normally the DG set control selector switch on the AMF panel shall be kept in "AUTO"

position. When normal "MAINS" supply is available, as monitored by "MAINS"

supply monitor relays mounted on AMF Panel, the DG Set shall be at rest. When the

"MAINS" supply voltage and/or frequency drops below a preset value (as set

"MAINS" supply monitor relay in AMF panel), for a preset period (as set on the 30 sec. to

5 min. timer on AMF panel), the DG set shall be given a start impulse automatically.

Once the DG set starts and the alternator voltage and frequency attain the desired values

as monitored by DG supply Monitor relay on AMF Panel, the DG In-comer circuit

breaker on the AMF panel shall be given an automatic closing impulse after preset time

(as set on the 0-60 sec. timer on AMF panel). Now the DG set shall be ready for taking

the load.

On reappearance of "MAINS" supply, transferring load on to "MAINS" bus and tripping of

the D.G. Set shall be carried out automatically.

Logic of DG sets synchronizing

There is 1 No. of 1.0 MVA 33KV/0.433 KV transformer feeding the 1 no. 500 KVA & 1

no. 250 KVA DG sets duly synchronized are being installed to provide back up power in case

of any interruption of supply.

The logic for the DG sets to start and synchronize shall be as follows.

When the total grid fails the DG sets should start one by one on master/slave basis depending

on the required load and get synchronized. The choice of master/slave selection will be done


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automatically depending on the loads that need to be fed by means of Woodgen 3200 of

Woodwards make or similar.

The DGs shall come on automatically under the above condition and shut off automatically

once the normal supply is restored.

The DGs shall have the provision of auto load sharing facilities and shall cut off one by one

the slave DGs if the shared load falls below 40%. Similarly after the master DG starts the slave

DGs shall come in when the load on the master is more than 85%.( Please note that the above

percentage may be fine tuned and might vary while placing the order.)

In case the above logic is being achieved by PLC then the requirement of UPS etc. to be

considered in the offer. A detail write up with adequate drawings must be submitted along with the

offer so that the suitability of the technically can be assessed.

Manual Mode of Operation:-

In this mode, the DG Set control selector switch on the AMF Panel shall be kept on

"Manual" position. The Diesel Generator can then be manually started by pressing the

engine "Start" push button on the AMF panel. After the DG Set comes to rated speed and the

alternator voltage and frequency attain the rated value (as monitored by the DG supply monitor

on AMF panel), it shall permit manual closing of the alternator circuit breaker. The DG set

shall be now ready to take the load.

Test Mode of Operation:-

In this mode of operation, when the DG set control selector switch on the AMF panel

is transferred to "TEST" position, control circuitry shall be so wired that it shall sense a

condition of "No Mains Supply"; (even when mains supply is healthy) and then follow a

sequence of automatic starting of DG set except without closing of the breaker.

When DG set control selector switch is kept in "OFF" position, the engine control circuit

shall be ineffective.

The DG set shall be provided with three attempt starting facility and in case the Diesel

Engine fails to start and reach its rated speed within 30 seconds, it shall be disconnected and

locked out immediately. Annunciation with alarm shall be provided on the DG control

panel when engine fails to start after three attempts to start.


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ANNUNCIATORS:-

Window type annunciator of the visual and audible type shall be provided by the vendor on

the control panel. The inscriptions on the facia plate shall be visible only when the respective

facia lamps, are lighted. Each annunciator window shall be provided with two lamps to provide

safety against lamps failure. Lamp circuit shall include series resistors, of adequate rating. The

annunciator shall be of approved make only.

One alarm hooter/buzzer common to annunciator shall be provided by the vendor. The

vendor shall also provide one set of "acknowledge", "reset" and "lamp test" push buttons

common to all the annunciator.

Sequence of operation of the annunciator shall be as follows:-

-----------------------------------------------------------------------------------------------------

Alarm Fault Audible Visual

Condition Contact Alarm Alarm

-----------------------------------------------------------------------------------------------------

NORMAL OPEN OFF OFF

ABNORMAL CLOSE ON FLASHING

ACKNOWLEDGE CLOSE OR OPEN OFF STEADY ON

BACK TO NORMAL OPEN OFF STEADY ON

RESET OPEN OFF OFF

LAMP TEST OPEN OFF STEADY ON

-----------------------------------------------------------------------------------------------------

The following conditions shall be annunciated:-

a) High water temperature and trip of the engine.

b) High lubricating oil temperature.

c) Low lubricating oil pressure and trip of the engine.

d) Engine over speed and trip.

e) Failure to start (after three start attempts).

f) Alternator Protection Relay trip..

g) Other indications considered essential for proper functioning and operation of the D.G.

Set.


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The contractor shall provide all the sensing devices at the diesel set for the above alarms

and accessory relays at the AMF panel. These shall be suitable for operation on D.C. supply

from the engine battery. The engine battery and charger shall be suitably rated for this D.C.

load. Suitable nameplates shall be provided for each window. One set of additional potential

free contacts for remote annunciation for each of the above shall also be provided.

Piping, Valves And Fittings:-

All necessary interconnecting piping with valves, fittings, specialties and support as

required shall be supplied and installed by vendor for the lube oil, fuel oil, air intake and

exhaust systems described above.

Performance Requirement:-

The diesel generator and accessories shall be so designed as to meet the following

performance requirements:-

The unit shall be capable of starting from cold conditions, reaching synchronous speed

and taking up load within the period specified from the "START" impulse, without undue

wear and stresses on equipment.

The unit shall be capable of delivering continuously at the generator terminals a net output

specified, with invisible exhaust. This net output shall be obtained after necessary de rating of

engine due to site conditions and unit auxiliary power requirements have been taken into

consideration.

The unit shall be capable of a peak output of 10% in excess of the rated output for a period of

one hour out of total of twelve consecutive hours of operation, without exceeding permissible

temperature limits and with a fairly visible exhaust.

The unit shall be continuously rated to supply power for long periods.

The unit shall be capable of meeting the specified performance when using the diesel oil

recommended by contractor.

With the unit running at no-load, rated voltage and speed, the transient voltage drop at its

terminals shall not exceed specified percentage of rated voltage, on starting a specified capacity

induction motor dire-on-line or imposition of a specified step load.

The unit shall operate up to 110% of the rated speed over the entire range of output without undue

vibrations and noise.


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Shop Tests:-

Representatives of the Third Party Agency & Purchaser shall have full access to vendor's

works to inspect and witness shop test on AMF panel. Any material or work found to be

defective or which does not meet the requirements of the specification will be rejected and shall

be replaced at supplier's cost. Purchaser reserves the right to carryout stage wise inspection of

fabrication and components.

The AMF Panel and Acoustic enclosure shall be routine tested at the manufacturer's

works as per relevant standards and routine test certificates shall be furnished. Third Party

Agency shall witness the tests. The test shall include operational tests, insulation test and HV

test.

Load test shall be carried out on the DG set for 8 hours at the site. Load bank for the testing

is to be arrange by the D.G supplier without any extra cost to the owner.

The diesel engine shall be tested at Manufacturer's works in the presence of Purchaser's

representative. All relevant tests as per IS/BS shall be carried out and test reports shall be

submitted by the contractor.

Site Tests:-

Vendor shall perform the following tests at site to the satisfaction of the Purchaser.

a) Governor response.

b) Voltage regulations and AVR Response.

c) Automatic Mains Failure cum Auto Start operation of Diesel Generating Set and load transfer

to D.G Bus.

d) Load test at site for 8 hrs continuous running with all consumables required to be arranged by

DG set Supplier free of cost to the Owner. The necessary Load Bank require to load the set with

10% Over loading for one hour is to be arranged by the Contractor at site without any extra cost.

The vendor to provide necessary assistance to the electrical vendor for executing the following

tests at site in the presence of the clients representative before energization.

Checking the alignment by engine manufacturers representative and obtaining approval.

Insulation resistance test on alternator, control panel and cabling / Bus bar trunking.

Checking the engine safeties for satisfactory operation.


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Checking vibration levels.

Testing of individual protective devices on engine and alternator and ensuring that the wiring is

carried out properly.

Full load running for 8 hours continuously. All the readings shall be logged to evaluate the fuel

consumption, lube oil pressure, water & oil temperature vis--vis the electrical load.

The noise level at 1m from the enclosure and the temperature rise inside the enclosure shall be

measured.

Any deviation from the guaranteed parameters shall be made good and these performance

parameters should be measured once again till the required results are achieved.

The DG set shall be deemed to be commissioned after satisfactory performance of all associated

equipment.

Guarantee:-

The diesel engine shall be guaranteed for satisfactory operation for a period of two years

from the date of commissioning or 5000 hour of operation whichever is earlier. The alternator,

AMF Panel and rest of the equipment supplied as part of the DG set shall be guaranteed

for a period of one year from the date of commissioning. If during this period any defects are

found in the machinery caused by faulty design or faulty materials, or workmanship, the same

shall be replaced/rectified free of cost by the contractor.

The following items of performance shall be guaranteed by the Contractor in respect of

the diesel generator unit and the auxiliaries, when operating under the specified site

conditions and when using the specified fuel oil. The same shall be demonstrated at site with all

consumables arranged and as a free issue to Owner.

a) Net electrical output at generator terminals.

b) Fuel oil consumption at 1/2, 3/4 and full load.

c) Lubricating oil consumption at full load.

d) Generator efficiency at 1/2, 3/4 and full load.


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e) 10% overload for one hour without overheating or showing signs of undue stress and within

specified frequency variation.

f) Freedom from vibration and noise.

g) Governor response, over speed trip and over speed capacity.

h) Voltage regulator response.

i) Excitation at full load and under specified variation of voltage and speed.

Contractor shall indicate the standards according to which he tolerance on the performance

figures shall be applicable.

Drawing and Data:-

Within two weeks of award of contract, 4 copies each of the following drawings shall be

submitted by contractor for approval. Subsequently 4 sets of the revised drawings together

with 1 set of reproducible incorporating Purchaser's comments shall be furnished for reference

and records as "Final Drawings".

General arrangement drawing showing overall dimensions, equipment arrangement and

details and arrangement of terminals including weight of the entire set and static and dynamic

load.

Recommended general arrangement drawing for Acoustic enclosure with all it

accessories indicating therein civil requirements of the including cable and pipe trenches etc.

Equipment foundation drawing for DG set and accessories.

Piping drawing including support details.

General arrangement drawing of the DG AMF Panel showing the various components

mounted therein, foundation details, cable terminals, overall dimensions, etc.

Wiring diagram of the AMF panel.

Before dispatch of the D.G. Set, 4 set of erection, operation and maintenance instruction

manual along with all above drawings, test certificates, spare parts list etc. shall be furnished.

Accessories:-

Following accessories shall also be supplied with the DG Set .Contractor shall indicate item

wised rate and quantities.

Standard Normal Maintenance Tool Kit:-


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Standard Normal Maintenance Kit and tackles required for maintenance of the Diesel Engine

Generator package shall be included in the Bidder's proposal. Bidder to submit a separate list for

the Package.

Set of recommended spare parts.

Common structural steel base fram

Documents

DG Set Final Tender Raipur_1