ANNEXURE-1

Supply, Installation, testing and commissioning of 1 no of 750 KVA DG set along with all the deliverables and as per the detailed specifications given below

1.0 TECHNICAL SPECIFICATIONS FOR DIESEL GENERATING SET

1.1 SCOPEThis Specification covers the design, manufacture, test at works, supply,

installation, testing and commissioning, at site, of prime rated 750 KVA

capacity Diesel Generating (DG) set housed in an acoustic enclosure

complete with all accessories like

a. starting batteries, local control panel, control cables & accessories,

external day tank, pipes & supports, fuel, coolant, exhaust pipes with

support structure, silencer and anti vibration Mountings etc.

b. AMF / control / Power changeover panel with suitable rated &

interlocked ACB’s for Mains input, DG input and DG Output. All the

power / control cabling from DG to the panel. Power cabling between

the panel and the Power distribution panel ( Power Distribution panel is

available at site)

c. Establishment of earth grids for grounding of DG body and neutral

The scope also includes obtaining approval from State Pollution control

Board and APCPDCL and any other relevant statutory authority.

1.2 STANDARDSThe generating sets shall be designed manufactured and Tested in

Accordance with the latest revisions of British / Indian / ISO Standards.

BS 5514 - Diesel Engine

IS 4722 - AC rotating machines.

IS 10000 - Diesel Engine

ISO 8528 - 1 - Diesel Engine

1.3 GENERALThe generating set shall be prime rated, and shall be robust in

construction, factory tested and assembled to ensure perfect alignment of

Engine and Alternator on a common base frame.

The base frame shall be fabricated out of adequate thickness rolled steel

sections.

The set shall be mounted on anti vibration mountings to prevent transfer of

vibration to the foundation and structures.

The equipment shall be tropicalized and shall be suitable for operating at a

hot humid atmosphere at an ambient temperature of 50 deg. C.

The DG Set shall be capable of starting automatically on failure of mains

(AMF) and shall be capable of operating in parallel with other DG Sets.

Integration with a synchronization panel to be capable of operating with

`N` numbers of DG sets in parallel.

The DG set shall be capable of starting within 10 sec. after mains failure /

low voltage conditions and shall take up 80% of its rated power instantly

with frequency dip within 2Hz and better than 30% dip in output voltage.

The recovery time shall be less than 5 sec.

1.3.1 Daily Service Tank (Day Tank)The Supplier shall supply and Install external Daily Service tank with a

capacity for storing 990 Litres of fuel for the DG set.

The Daily Service tank shall be fitted with necessary fuel level gauge with shut off cocks.

The level switches with 2NO + 2NC contacts for the following shall be provided in the Day Tank.

a. Low Low Level

b. Low Level

c. Medium Level

d. High Level

e. High High Level

The fuel line shall be provided with flow meter with totalizer and with

necessary bypass arrangement.

The flow meter shall have necessary provisions for BMS integration (This

may be given as Optional).

The fuel line (25mm dia of Class ‘B’) shall be provided with double fuel

filters for filter change when Diesel Generator is in Running Condition.

A Tray shall be provided below the Daily Service Tank to collect the spilled

oil. The Tray shall be provided with a drain point to connect to an external

oil collection pit.

Piping for Fuel filling has to be done from the nearest point to the diesel

day tank (Approximately 25 metres length). A meter has to be provided in

the filling line for recording the periodical top up of fuel.

1.3.2 Pipe WorksAll necessary pipes and accessories for Coolant, lubricating oil, fuel oil

and exhaust shall be designed and supplied to suit the standard

arrangement for a system, mounted on anti-vibration mountings.

All pipes and accessories shall be dedicated to the DG Set.

1.3.3 Anti Vibration MountingThe generating set shall be mounted on required number of anti vibration

Mountings to prevent transfer of vibration to the Foundations and

structures.

1.4 DIESEL ENGINEThe engine shall be of 4 Stroke, Direct injection type turbo charged after

cooled & developing the rated Horsepower at a speed of 1500 rpm.

Suitable silencer shall be employed to reduce the noise to a minimum. (As

per statutory norms).

The engine must have protective devices viz. high water temperature,

low lub oil pressure, over speed cut outs etc to safe guard the engine

while running. It must also have required gauges to monitor the

performance of engine.

Suitable engine heaters shall be provided to ensure quick starting of the

engine, if needed, after prolonged shut off.

1.4.1 StartingThe engine starting shall be by means of totally enclosed axial type

electric starter suitable for 24 Volts DC. The DC supply shall be derived

from 24 volts Heavy Duty Lead Acid battery.

1.4.2 Battery Charger (Static)Apart from the engine driven battery charger for charging the starting

batteries, a static battery charger for charging the battery on mains power

i.e during engine idle time, shall also be supplied.

The battery charger shall be provided with automatic boost and trickle

charge facilities, current limit protection, automatic cut OFF on full charge

etc, to maintain the battery in fully charged / healthy condition.

The unit shall be provided with full wave rectifier with the input voltage of

230V AC supply and shall be provided with ammeter and voltmeter to

measure the input and output current and voltage (Linear power supply

and not SMPS). Suitable interlocking between the outputs from engine

driven battery charger and static charger must be provided.

The unit shall be provided with high and low DC Volts alarm.

1.4.3 CoolingAn engine driven centrifugal pump shall be employed to circulate the

coolant through a cooling radiator with an axial blower fan.

The radiator shall be designed for 50°C ambient Temperature.

A coolant temperature gauge shall be provided to indicate the coolant

temperature. The temperature gauge shall be provided with two contacts

for alarm & trip, for stopping the engine on high coolant temperature.

1.4.4 LubricationPressure lubricating oil system with an auxiliary pump with timer shall be

provided to cover the complete engine.

Full flow filters with removable elements shall be provided and these shall

be located at easily accessible location for ease of maintenance. Double

filters to be provided for filter change over during engine running condition.

The supply shall include first filling of lubricating oil after test run.

It shall be possible to add Lube Oil when the Set is in running condition.

An oil pressure and temperature gauge shall be provided to monitor the

lubrication oil pressure and temperature. The gauge shall be provided with

two contacts for alarm and trip, for stopping the engine on failure of

lubricating oil flow.

1.4.5 GovernorThe governor shall be of Electronic type, suitable for monitoring constant

engine speed, within the specified limits for auto parallel and auto load

sharing operation.

The governor shall be equipped with load sharing devices for precise load

sharing between the engines.

1.4.6 ExhaustThe exhaust piping (Class ‘B’) system shall be supplied with a residential

type silencer.

The exhaust piping and the Silencer shall be wrapped with rock wool. The

outside shall be neatly wrapped with Aluminium cladding. (24G thick) up

to 5 meter on the Stack.

The exhaust system shall be guaranteed to reduce the exhaust noise to a

level not greater than 65dB at one meter from the exhaust outlet.

The muffler and the exhaust piping shall include lagging to maintain a

surface temperature not exceeding 65 deg. C. Flexible connectors

(Expansion bellows) must be provided, wherever required.

The exhaust pipe shall be provided with Rain Caps and Bird Cowl.

1.4.7 Exhaust StackThe exhaust piping shall be taken to a suitable height of 30 meter. height

from ground Level or as per the norms specified by the Statutory

Authority. A suitable lattice type support structure shall be provided.

(Suitable to the relevant statutory norms)

The Stack shall be provided with the following.

a. Flue gas test points with suitable platform.

b. Lightning spike with down conductor and earth electrode.

c. Wind Breaker

d. Suitable ladder

The design of the lattice stack and its foundation shall be submitted for

approval.

The supplier shall provide a suitable and reliable exhaust system to

ensure the consistent compliance of all the statutory norms.

1.5 VOLTAGE REGULATOR

A rapid response voltage regulator shall be provided to regulate the

generated voltage.

The overall voltage regulations from no load to full load, including, cold to

hot variation and load power factor of 0.8 lag, shall be within 2% of the

normal value. The excitation system shall be designed to promote rapid

voltage recovery following sudden application and disconnection of loads

The Voltage regulator shall be capable of recovering within 10 sec. from

voltage dip of 6% when a load of 60% of the rated capacity of the DG set

is connected.

1.6 ALTERNATORSThe alternator shall be 3 phase, 0.8 PF, 415V AC, 4 wire 1500 RPM,

brushless type housed in screen protected drip proof enclosure. The

alternator shall be capable of delivering rated output at rated PF, with

a. The terminal voltage, differing from the rated value by not more than +/-5%.

b. The frequency differing from the rated value by not more than +/-0.5%.

THD shall be less than 5% in Phase (or) Phase - Phase voltage with

Linear symmetrical load.

The alternator shall have a minimum of 6 winding temperature detection

sensor.

The alternator shall be provided with termination box suitable for

terminating all the necessary Cables.

1.6.1 InsulationsThe insulations shall be class H and shall be fully impregnated for use in

hot, humid, tropical climatic conditions, with an ambient temperature of

50 deg.C.

The stator and Rotor windings of the alternator and the exciter shall be

provided with acid resistant varnish finish.

1.6.2 BearingsThe alternator shall be provided with single or two bearing, as per the

design, to ensure perfect alignment under all conditions. The bearing shall

be self lubricating type.

1.7 ALTERNATOR AMF CONTROL PANELA sheet steel, self supporting, cubicle type, control panel mounted inside

the Acoustic Enclosure shall be provided to house the controls and

indication of the generating set.

This Local Control Panel shall be provided with, but not limited to the

following.

a. Suitably rated protection ACB / MCCB and suitably rated CTs

b. Set of Indication Lamps

c. Restricted Earth Fault Relay with suitable CT‘s.

d. Terminal for outgoing Power & Control cables.

e. Emergency Stop Button

f. Earthing

g. Outgoing Termination Box suitable for Cable.

h. Auto Start / Stop Relay.

The various field units shall be connected to the control panel through

control cables with minimum 2.5sq.mm copper conductor.

The scope shall include suitable rated flexible copper cable between

Alternator Terminals and the Control Panel.

1.7.1 MeteringThe panel shall be provided with the combined digital meter comprising of

a. Ammeter

b. Voltmeter

c. Frequency Meter

d. KWH Meter

1.8 PARALLEL OPERATION The DG set, if required, may be operated in parallel with another DG of

750 KVA capacity. The DG Set shall be suitable for parallel operation.

Necessary Engine Control and Power Control modules for auto start, auto

synchronizing and auto load sharing facility shall be provided for the DG

Set and tested.

1.9 ACOUSTIC ENCLOSUREThe DG shall be provided with weather proof acoustic enclosure. The

enclosure shall be suitable for a noise level output of not more than 65 -

75 dB (A) at a distance of 1 metre, from any side of the DG.

The Enclosure shall be fabricated out of not less than 2.0mm thickness

sheet steel. Paint shade shall be light grey or as per standards. The

painting process shall be by using a seven tank phosphating system with

primer coating within 4 hours of phosphating and two coats of epoxy

powder coating.

All fasteners and Door Hinges shall be of stainless steel. All exposed bolts

and nuts shall be Zinc passivated.

Emergency Stop Push Button for tripping the ACB / MCCB shall be fitted

in such a way as to have access from outside the Enclosure.

The roof of the enclosure shall be suitably sloped to avoid rain water

collection / leakage inside the enclosure.

The Acoustic Enclosure shall be provided with necessary entry flanges for

following.

a. Outgoing Cables

b. Earth Bus

c. Control Cable

d. Fuel Filling Hole

e. Oil Spill Collection Pipe

And for any other standard feature

1.10 AMF / CONTROL / POWER CHANGEOVER PANELThis panel must have remote control / operation of the DG set.

The panel must sense the availability of mains power and have Auto

Mains Failure (AMF) for switching ON and OFF of the DG set in Auto /

Manual mode.

Suitably rated ACB’s and other switchgear, protective devices etc to be

provided as required.

Control cable between the DG set and this panel must be supplied, laid

and terminated at both ends by the vendor.

Continuous rated power cables to be laid between the DG set and the

panel & from this panel to the distribution panel. The cables required are

armoured 3.5 core XLPE insulated aluminium cables suitably rated for 750

KVA. The cables have to be laid through the trench / buried under ground

as per the site conditions, glanded at both ends, crimped with suitable

crimping terminal ends and terminated.

Length of the power cables required.

-Between DG set and the power changeover panel/ Control panel :

300 sq.mm aluminium cable 25 m x 4 runs = 100 m

- Between the power changeover panel / Control panel and distribution panel

300 sq.mm aluminium cable 65 m x 4 runs = 260 m

(Total length of power cable of 300 sq.mm : 100 m + 260 m= 360m)

However the vendor may calculate the actual requirement of cables on

seeing the site condition and submit the calculations to NRSC for

clearance. The cost of supply, laying and terminations of all these cables

must be taken into account while submitting quotation.

Necessary interlocking between the local panel inside the DG enclosure

and the remote power changeover panel must be made.

All the necessary tools and material including hardware required for end

terminations for completion of the cable terminations is to be arranged /

supplied by the vendor.

1.11 EARTH PITS: Two nos of earth pits for body and two nos of earth pits neutral

grounding must be made (Total – 4 nos).

Both the earth pits of body earthing must be paralleled at pit end.

Individual earth strips must be drawn from earth pit to the DG set & power

changeover panel and terminated to ensure redundancy. Similar

arrangement must be made for neutral earthing also.

The neutral earthing must be of copper plate and as per the IS standards .

A typical representation is given in the annexure- 2

The body earthing can be pipe earthing with G.I strips as per IS

standard. A typical representation is given in the annexure- 3

The vendor must supply all the required material, arrange for digging,

installation of earth pits and laying & termination of copper earth strips and

GI earth strips

Approximate length of copper strip( 2” width and 4 mm thick) required: 30

metres.

Approximate length of GI ( Galvanized Iron) strip( 2” width and 3 mm thick)

required: 40 metres.

However the vendor must verify the exact requirement as per the location

of DG and panel at the site and supply accordingly.

The earth resistance must be measured and recorded after completion.

The body and neutral resistance must be within the limits, specified as per

the relevant standards.

1.12 DRAWINGS AND MANUALSAll the following drawings, technical data sheets and calculation shall be

submitted for approval, before start of manufacture.

The Rating Plate for DG set shall cover the following details:-

1) Manufacturer’s Name

2) Model

3) Type

4) Serial No.

5) Year of Manufacture

6) Rated Power in KW

7) Over load Capacity in KW (1 Hr. for 12 Hrs)

8) Rated Voltage, Current and frequency

9) Weight

The Generator Breaker Cabinet shall cover the following details:-

a) Manufacturer’s Name

b) Model

c) Type

d) Serial No.

e) Year of Manufacture

f) Rated Voltage, Current, Frequency

g) Rated Short Circuit withstand current. (1Sec)

h) Rated Peak withstand Current

1.12.1 Drawingsa. GA Drawing of DG Set

b. Foundation Details

c. GA Drawing of Local Control Panel

d. Wiring Diagram of Local Control Panel

e. Layout showing location of all components.

f. GA of exhaust stack with lattice structure

g. Flow diagram for the machine for system like air, water, fuel,

lubrication oil, exhaust gas etc.,

h. Assembly drawings of the auxiliaries on the main engine.

i. The Circuit and GA drawing for the AMF / Control / Power change

over panel.

j. Operation and maintenance manual for the DG and all the

auxiliaries.

1.13 TOOLS AND SPARES1.13.1 Tools

The Vendor shall supply all the standard tools, normal and special,

required for operation and maintenance of the generating set, free of cost.

The vendor shall list out the tools which are being supplied along with the

generator set and this list shall be enclosed with the offer.

1.14 TEST AND INSPECTION OF THE DIESEL GENERATOR SET AT SUPPLIER'S FACTORY

1.14.1 Starting TestThe test of consecutive starts shall be carried out and the number of times

successful starts and the room temperature shall be recorded.

1.14.2 Load Test – Suppliers facilityThe engine shall be coupled with the generator and load test carried out

as per the duration given for the following percentage of the rated output.

___________________________________________________________

Load Duration

50% 30 minutes

75% 120 minutes

100% 60 minutes

110% 60 minutes

The load test will be done with a resistive load which shall be arranged by

the supplier. The following data shall be recorded at each load.

1. Engine Speed

2. Fuel oil consumption / lube oil consumption

3. Pressure and Temperature of Coolant, lubricating oil

If, for any reason, the load test could not be conducted at the works, the

same may be carried out at the site and the necessary load / fuel and any other

items, test equipment required for the test shall be arranged by the supplier.

1.14.3 Test for AlternatorThe following test and inspection for the Alternator shall be carried out at

the supplier’s factory.

1. Visual check

2. Measurement of winding resistance

3. Phase rotation check

4. No load saturation test and measurement of core loss

5. Three phase short circuit test and measurement of Copper loss

6. Measurement of mechanical loss

7. Calculation of efficiency

8. Temperature rise test9. Over speed test (120% speed for 2 minutes)10. Measurement of insulation resistance11. Dielectric strength test

12. Load acceptance13. Waveform analysis14. Any other tests as stipulated by the relevant standard.

The tests at DG set manufacturer’s works shall be done in the presence of

NRSC representative.

1.14.4 Test for Statutory ComplianceThe supplier shall test the engine on all the auxiliaries for the consistent

compliance of all the statutory norms.

1.15 TECHNICAL PARTICULARS FOR DG SET1.15.1 Diesel Engine

Type - Direct injection

Stroke - 4

Speed - 1500 rpm

Fuel - High Speed Diesel

1.15.2 AlternatorRating - Prime - 750 KVA

Voltage - 415 V

No. of Phase - 3

No. of Wires - 4

P.F. - 0.8

Speed - 1500 rpm

Short circuit withstand capacity - 300% for 10 sec.

Overload capacity - 110% for 1 Hr. for

every 12 Hrs. Operation

Load acceptance within frequency

Variation 50 ± 2Hz. and Voltage

Variation 30% of rated Voltage - 5sec.Recovery Time)

Design Ambient - 50Deg.C

Insulation - Class H

Enclosure - SPDP

Terminals - Suitable for Terminating

XLPE Al. Armoured Cable

1.16 TECHNICAL PARTICULARS (TO BE GIVEN BY THE SUPPLIER)

1.16.1 Fuel Consumption (in Liters.)

50% LOAD :

75% LOAD :

100% LOAD :

110% LOAD :

1.16.2. Lube oil consumption (in Liters.)

50% LOAD :

75% LOAD :

100% LOAD :

110% LOAD :

1.16.3. Lube oil Change frequency (in Hrs.) :

1.16.4. Minor Overhaul period (in Hrs.) :

1.16.5. Major Overhaul period :

1.16.6 Load Acceptance within frequency variation 50 ± 2 Hz. and 30% dip

in voltage with recovery time of 5 sec

Sl.No. Rated Power Voltage Dip Frequency Variation

Recovery Time to Static

a. 50%b. 60%c. 70%d. 80%

1.16.7 Load acceptance with 30% dip in voltage

with recovery time of 20Sec. : KW

1.16.8 Mean Time between Failures (MTBF) :

1.16.9 Minimum Time to Restore (MTTR) :

2.0 RECOMMENDED MAKES OF EQUIPMENT

1. Engine : CUMMINS / PERKINS / CATERPILLAR

2. Alternator : STAMFORD / NGEF / KIRLOSKAR

3. ACB / MCCB : SIEMENS (L Series) / ABB/

L & T (U POWER) / MERLIN

GERIN

4. CTs / PTs : KAPPA / SILKAANS / PRAGATHI

5. Protection Relays : ABB / AREVA / SIEMENS

6. Push Buttons / Control Switches / : TEKNIC /KAYCEE/ SIEMENS /

Indication Lamps / L & T

7. Instruments / Load Manager : CONZERV / SECURE

8. Selector Switch : SALZER / KAYCEE

9. Annunciation Windows : ENPRO / MINILEC

10. PLC : ALLEN BRADLEY

3.0. Scope of supply and break-up of estimate of quoted cost:

1. Supply of DG set along with all the associated systems: 1 Lot

2. Sound proof enclosure complete as per norms: 1 No

3. Power change over / AMF / Control panel: 1No

4. Supply, laying and termination of power / control cables between DG set

and the power change over panel as mentioned above: 1 Lot

5. Supply, laying and termination of power cable from the power change over

panel to the existing distribution panel placed at a different location: 1 Lot

6. Supply of required material and establishment of 4 nos of earth pits for

body and neutral earthing. Laying and termination of earth strips etc: 1 Lot

7. Installation, testing and commissioning of the integrated setup inclusive of

all the components: 1 Lot

8. Break-up of Sales taxes as applicable.

9. Service taxes: 1 Lot

10.Set of essential tools for routine maintenance.

11. Any other cost

4.0. General terms and conditions:

The vendors must be authorised dealers of the OEM as on the date of

submitting quote. They must submit relevant proof of the same.

The DG set and associated systems must be supplied, installed and

commissioned at NRSC campus at Balanagar, Hyderabad. The supplier

must arrange the necessary equipment / manpower needed for shifting,

positioning at the identified location etc. All the tools , required hard ware

if any needed for installation must be arranged by the supplier.

The vendor’s representative must inspect the site and get acquainted with

site conditions before submitting the proposal accordingly.

The tender is a two part bid with technical and commercial / price bid. The

vendor must give compliance of the technical specifications as mentioned

by us. The same must be submitted in the technical bid. Technical bid and

commercial bid must be submitted in separate sealed covers. Quotes with

Price included in the technical bid are liable for rejection. Price bids of the

technically qualified vendors only will be considered and opened for

further processing.

The design of all the systems must be as per the relevant standards. All

the test certificates for the tests carried out at factory must be produced.

Two sets of drawings and instruction / maintenance manuals etc to be

supplied.

Configuration of the systems must be done as per our requirement at site.

Necessary hardware required for synchronisation with other DG set &

parallel operation must be provided as mentioned in our specifications.

The necessary approvals for compliance must be obtained from CPCB,

APCPDCL etc by the vendor.

Training to be given to NRSC staff on the operations / routine

maintenance of the DG set.

Minor civil works may be required for installation of DG set.

Digging, chipping, plastering etc required for laying of cables,

establishment of exhaust structure, laying of pipes, making of earth pits

etc must be done at site. The site may be inspected and estimation done

by the vendors before submitting the quote.

The vendor must take care of their representatives working inside NRSC

campus for completion of the job. The safety and security guidelines in

force at NRSC must be adhered to. The safety of the vendor’s workforce

is not the responsibility of NRSC.

The detailed break-up of cost for all the items like DG set, AMF panel,

power change over panel, Cost of sound proof enclosure, laying and

termination of cables, providing earthing etc must be given while quoting.

The cost should also indicate all the applicable taxes, Excise duties,

Custom duty etc shown separately. Installation and commissioning

charges, service taxes etc must be given wherever applicable.

Warranty for one year must be given for the DG set.

The system with all the components , totally integrated only will be

accepted from a single sourse. Hence vendors may submit for total

solution.ddd

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Annexure-2. Typical Design of Plate Earthing