gail (india) limited · gail (india) limited intend to augment the capacity of its existing kandla...

GAIL (India) Limited

TENDER

FOR 1250 kVA DG SET FOR UPGRATION OF KANDLA - SAMAKHAILI LPG

PIPELINE Bid No. 05/51/23KX/GAIL/006

MECON LIMITED

GAIL (India) Limited (A Govt. of India Undertaking)

A Navratna Company NEW DELHI, INDIA

UPGRADATION OF KANDLA - SAMAKHAILI LPG PIPELINE

BID DOCUMENT FOR PROCUREMENT

OF

1250 KVA DG SET

UNDER LIMITED DOMESTIC COMPETITIVE BIDDING

E- Tender no. 8000000639

Bid Document No.: 05/51/23KX/GAIL/006

VOLUME – II OF II

PREPARED AND ISSUED BY

MECON LIMITED (A Govt. of India Undertaking)

Delhi, India

1


TENDER



MECON LIMITED

MATERIAL REQUISTION

AND

TECHNICAL SPECIFICATION

2


TENDER FOR 1250 kVA DG SET FOR

UPGRADATION OF KANDLA – SAMAKHIALI LPG PIPELINE

Bid No. 05/51/23KX/GAIL/006 MECON LIMITED

MATERIAL REQUISITION DOC. NO.:MEC/23KX/05/21/M/001/S006 D:\old data\Vijyant\Kandla-Samakhiali\Tender\DG Set\MR for dg set- Kandla.doc Page 2 of 4

MATERIAL REQUISITION FOR

1250 kVA DG SET MR NO.: MEC/23KX/05/21/M/001/S006

Rev. Date Prepared by Checked by Approved by

0 20.08.2008

(Vijay Singh) DGM

(A.K. Johri) DGM

(K.K. De) DGM I/C

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MATERIAL REQUISITION

GENERAL: GAIL (India) Limited intend to augment the capacity of its existing Kandla to Samakhiali Pipeline Section from existing 0.5 MMTPA to 1.5 MMTPA to transport LPG from Kandla Despatch Terminal (DT) to IPs, Samakhiali wherein it is being projected in the suction line of Samakhiali Booster Pumps and fed into Jamnagar Loni Pipeline (JLPL) to meet the demand of LPG bottling plants enroute JLPL.

Augmentation of Kandla – Samakhiali section to 1.5 MMTPA will be met through modification of existing Kandla Despatch Terminal. In case of grid power failure electric power will be met from the proposed one no 1250 kVA DG set.

PROJECT : UPGRADATION OF KANDLA - SAMAKHIALI LPG PIPELINE ITEM : 1250 kVA DG set BID NO. : 05/51/23KX/GAIL/006 CLIENT : GAIL (India) Limited

DESCRIPTION UNIT QTY Destination

1 Design, engineering, manufacturing testing and delivery at Kandla site, insurance, painting ,etc of 1250kVA DG set along with its associated accessories, AMF control Panel, battery for starting, battery charger, acoustic enclosure, foundation bolts/AVM, base plates, fuel oil tank, cabling, piping, exhaust pipe, chimney , insulation, supporting structure, first fill of lubricants & consumables including fuel oil, erection & commissioning spares, spl. tools / tackles etc. complete as per Material Requisition No. MEC/23KX/05/21/M/001/S006 and Technical Attachment thereon, under Section-VII of Vol.-II of II of Bid Document.

Nos. 1 Kandla

2 Mandatory Spares as listed in Technical Attachments to Material Requisition (Item-wise prices of Mandatory Spares to be made available in Format-IA attached. Bidder to ensure that the total of price break-up matches with the lump sum prices stated herein).

lot 1 Kandla

3 Training of Purchaser's Personnel at Bidder's / Sub-vendor's Works and / or at such Sites where similar pumps as supplied by the Bidder are in operation. Quoted price shall exclude all personal / incidental expenses of the personnel deputed by the Purchaser.

Nos. 1 Kandla

4






DESCRIPTION UNIT QTY Destination

4 Erection / Installation & Commissioning including unloading at site, storage, watch ward , handling and shifting at site & from storage, putting on foundation, grouting, fabrication of structure for supports, fabrication & erection of chimney, laying of pipes & insulation, consumables, arranging cranes/ tools/tackles, insurance, site supervision as per installation & commissioning manual

Nos. 1 Kandla

5 Recommended Spares for two years normal operations & maintenance over and above as indicated in mandatory spare parts shall be quoted as per Format-IB attached.

lot 1 Kandla

5





D:\old data\Vijyant\Kandla-Samakhiali\Tender\DG Set\Cover TS - DG Set.doc

TECHNICAL SPECIFICATION OF 1250 KVA DG SET

6


TENDER - 1250 kVA DG SET FOR KANDLA – SAMAKHIALI LPG PIPELINE

TS No. MEC/TS/05/21/006, Rev-0 MECON LIMITED

SECTION-VII Page 1 of 50

© 2006 MECON Limited All rights reserved Tenderer’s Signature with Seal Date: MEC/05/51/23KX GAIL/006

CONTENTS

Sl. No Description

1.0 Special instructions to the Tenderer

2.0 Scope of work

3.0 Technical Specification

4.0 Quality assurance, inspection & testing, performance guarantee.

5.0 Erection, Testing and Commissioning

6.0 Mandatory spares parts for DG Set

7.0 Documents to be submitted

8.0 Data sheets

9.0 Technical check list (mechanical / engine)

10.0 Deviations to the specification

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1.0 SPECIAL INSTRUCTION TO TENDERER 1.1 This specification shall be read in conjunction with the following documents.

General condition of contract & special condition of contract

1.2 Applicable codes and standards The material used and the equipment supplied shall be new and the best of their

respective kinds and shall comply with the new latest revision of relevant Indian Standards specification / relevant International standards. The equipment shall also comply with the statutory requirements of Government of India, state government and the latest revisions of Indian Electricity rules. The copies of the relevant standards and regulations to which the equipment

1.3 Accessibility and safety 1.3.1 All equipment offered shall allow adequate access to facilitate maintenance and

repair. 1.3.2 All moving parts of the equipment shall be well guarded and protected for the

operators and maintenance personnel safety. 1.4 System of units Metric system of units shall be followed in design and manufacture of all equipment

as well as drawing documents. Name plates of equipment as well as operating I maintenance instruction shall be in English language.

1.5 The owner I consultant reserve right to accept or reject the tender partly or fully

without assigning any reason. The quantities of each item indicated are tentative and are subject to change. Unit rates be quoted to take care of changes in requirements.

1.6 The tender shall be complete in all respects including data sheets duly filled without

leaving any items. 1.7 Each equipment shall be equipped with suitable lifting facilities to facilitate erection

and maintenance. 1.8 The detailed bar chart showing various activities shall be prepared by the tenderer.

The work shall be executed as per the agreed time schedule. 1.9 Monthly I weekly construction programme can be made by the contractor and

engineer in-charge jointly based on availability of work fronts and the construction

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programme. 1.10 Contractor shall submit every day report on progress of work carried out on

previous day and for each category of work. 2.0 SCOPE OF WORK

Following shall be the scope of work:

2.1 A) SUPPLY: Design, engineering, manufacturing, shop assembly, testing and delivery at Kandla site, storage, conducting performance test at Kandla site of GAIL-KSLP Terminal project and final painting of all the equipment of DG set along with its associated accessories, AMF control Panel and acoustic enclosure, supply of foundation bolts, base plates, supporting brackets etc. for the D. G. set including first fill of lubricants & consumables including fuel oil for testing at works and site and commissioning till performance guarantee test and Handing over.

B) ERECTION & COMMISSIONING: Grouting of equipments including cement and supply of grouting material, transportation to the place of erection from store, erection, testing and commissioning of DG set and associated items under scope of supply. Construction of civil foundation shall be arranged by purchaser.

2.2.1 Inspection of the equipment by the owner / consultant at the manufacturer’s works

and performance testing of the equipment by the supplier in presence of owner / consultant at manufacturer’s works and at site are included.

2.2.2 Unloading at site, watchward, handling and shifting , erecting on civil foundation

is in the scope of supplier. Necessary Crane required shall be arranged by supplier. The tenderer shall include in his scope all plant, machinery, material, all accessories and auxiliaries, measuring and control equipments, all necessary interconnecting pipes and pipe fittings, wiring conduits of instrument / sensors upto terminal box mounted on equipment, safety devices and material which are not specially mentioned but are required to complete the equipment offered in every respect for its satisfactory operation. Equipment insurance during transient, , erection and commissioning is in the scope of supplier.

2.3 The technological equipment involved are broadly as follows:

- The D.G unit shall comprise of Engine, Synchronous generator complete with brushless type excitation system, AVR, DG AMF Control Panel. The generator set shall be complete with all controls, protection, indication, connections, wiring, auxiliary systems for satisfactory operation. The DG set will be started automatically in case of grid power failure. There will be provision to start the DG set manually.

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- The output rating of DG set shall be as specified in SOR/Data Sheet, at 0.8 PF, at place of installation (Kandla), referred at alternator terminals.

- The four stroke water cooled direct coupled engine shall be capable of driving

continuously the generator to give an output of specified kVA at its alternator terminals, its rated speed, under site condition indicated in design criteria. Diesel engine shall be rated in accordance with BS- 5514 / ISO- 3046/1. Engine governor shall be capable of maintaining speed within the specified limit as per BS 5514 part 4 class A1.

- Air Filter, Air Intake Manifold - Radiator type cooling system, Coolant Additive Concentrate (CAC) first fill,

Corrosion resister, Centrifugal Water Pump, Cooling water pipes from radiator to engine

- Fuel oil system with day tank (990 liters capacity) for the D.G. Set & additional

fuel piping along with filters etc. - Radiator type cooling system, Coolant Additive Concentrate (CAC) first fill,

Corrosion resister, Centrifugal Water Pump, Cooling water pipes from radiator to engine

- The engine shall be forced lubricated by shaft driven pump complete with

filters, strainers, cooler and sump of sufficient capacity for 24 hrs of operation.

- Anti-vibration pads for the set. - Engine starting system with lead acid batteries for the D.G. Set including

battery stand & battery charger. - Complete exhaust system including residential type silencer, spark arrester

, Flexible bellow for Silencer, exhaust pipe as per pollution control board requirement, Clamps/nut/bolts for silencer, Insulation for exhaust system , Structural supports for silencer, Structural supports for exhaust , pipe, Painting on exhaust pipe ( high temp paint ), Painting on structural work, Flanges, nut, bolts and gaskets

- All power & control within DG set skids including all auxiliaries shall be in

vendor’s scope. All power and control cabling/wiring within AMF panel shall be in vendor’s scope. All power and control between alternator terminal and AMF panel shall be in vendor’s scope. Owner shall supply power and control cables from owner’s 415 V switchboard to AMF panel

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- Coupling & guards. - Local instrument gauge panel with Starting Key, Tachometer with hour

Meter, Water Temp. Gauge, Lub Oil Pressure Gauge, Battery charging ammeter, Lub Oil Temperature Gauge

- Complete instrumentation, controls & control panel. - All necessary interconnecting pipe works and valves. - Special tools and tackles for maintenance. - Drawing /documents /manuals /other data - Acoustic enclosure for the DG set in open execution. - Commissioning spares & supply of spares for 2 years operation. - Minor civil works like grouting chipping, making holes, Civil works for

earthing & cable laying etc. Construction of fencing, with gates, around the DG set installation with required clearances.

- Surface coating & final painting of complete system, - All the protection, monitoring and recording equipment. - All statutory approvals. - First fill of all consumables.

- Fuel oil required during commissioning and PG test.

2.4 PAINTING, PACKING AND TRANSPORT

2.4.1 Equipment shall be painted with two coats of epoxy based primer followed by two final coats of epoxy based paint. Sheet metal work shall be subjected to degreasing, pickling, and phosphating prior to painting. Exhaust pipe shall be painted with high temp paint.

2.4..2 The equipment shall be shipped to site suitably packed to prevent any damage.

Each package shall have labels to show purchaser’s name, purchase order and equipment no. suitable lifting lugs etc. shall be provided and lifting points shall to clearly marked on the package. Packing shall be suitable for storage at site for a minimum period of 6 months.

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2.5 Exclusions

The following works are excluded from your scope of work

a) Major Civil works.

b) Illumination / Area lighting

2.6 Battery limits

a) Inlet to combustion air intake system.

b) Outlet of the exhaust system above acoustic enclosure above DG building as per pollution control norms.

c) Inlet of additional fuel filling system. d) All power & control within DG set skids including all auxiliaries shall be in

vendor’s scope. All power and control cabling/wiring within AMF panel shall be in vendor’s scope. All power and control between alternator terminal and AMF panel shall be in vendor’s scope. Owner shall supply power and control cables from owner’s 415 V switchboard to AMF panel

e) Inlet of fuel filling system.

3.0 TECHNICAL SPECIFICATION 3.1 The D.G. Set shall meet the following operating conditions.

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 upto ± 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

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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 A1 governing system preferably using wood ward PSG governor shall be offered. Speed drop shall be continuously adjustable.

d) D G set shall meet the starting requirement of induction motors with VFD

drive (one no.450 kW and one no. 200KW rating) that can be started with base loads 0%, 25%, 50%, 75% under following conditions:

i. Current not to exceed 2 times the rated current of the Alternator for

15 seconds. ii. Step load BHP prime mover engine can take (transient voltage dip

for above conditions shall be furnished). iii. Transient voltage dip limited to 20 %

e) Machine shall develop symmetrical balanced sine wave voltage.

Irregularities in 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).

3.1.2 Mode of operation (For DG set) 3.1.2.1 The control system shall be suitable for unattended operation. The control system

shall operate in fail safe mode and shall include all controls and protection necessary for the safe operation of the package. The generator set shall function as per the following schemes:

- Auto main failure scheme (AMF) - Manual start in service mode

- Manual test mode

3.1.2.2 Automatic main failure scheme

This shall be effective in Auto position of Auto/manual selection switch located in local control panel. The generator set shall normally be at rest. Upon failure of plant normal supply, an impulse shall be extended from purchaser’s equipment. Upon receipt of this impulse, generator set shall be started automatically and

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brought to rated speed and generator voltage brought to rated value. All accessories required for starting and completion of various sequence of operation for the above purpose shall be provided. Provision for the synchronization with existing/future D.G. Sets shall be provided. Immediately after the generator sets reach rated speed and rated voltage, voltage and frequency monitoring relays located in control panel shall extend an impulse for closing generator breakers as per desired / selected priority / sequence.

3.1.2.3 Manual start in service mode

This shall be effective in manual position of Auto/manual switch and service position of service/ test selector switch located in control panel. The scheme of operation shall be same as of auto mode above except that starting impulse shall be extended manually through the push button either in local control panel or purchaser’s control panel. The synchronization between D.G. Sets shall be done manually. The closing of Generator breakers shall also be manual.

3.1.2.4 Manual test mode

This shall be effective in test position of service/ test selector switch. The scheme of operation shall be same as that of manual start in service mode above except that the closing impulse for generator breaker shall not be extended automatically.

3.1.2.5 Stop

Stopping of the generator set in all cases for a normal shut down shall only be done manually by means of push button in either local control panel or purchaser’s remote panel.

3.1.2.6 Starting time

The total time from the receipt of the starting impulse for the generator set till the set reaches rated speed and generator reaches rated voltage shall not be more than 30 seconds. If this time is exceeded, an annunciation in the local control panel shall be provided with a facility for repeat annunciation in purchaser’s panel.

3.1.2.7 Black start facility

The generating unit shall be provided with all necessary `black start’ facilities. External power at 415 V TPN shall be made available by purchaser at one point only for any equipment operation during stand-still period of generator sets. This power shall not be available during start-up of the generator sets. All D.C. supplies and charger including batteries for start-up of prime mover where applicable shall be supplied along with the generator sets unless otherwise agreed. 415 V AC

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power distribution board for auxiliaries shall be supplied along with the generator sets. All auxiliary motors shall be three phase, 415 V, 50 Hz squirrel cage type suitable for DOL starting or DC motor operating at 110 V or 24V. Insulation class shall be `H’. All motors shall have IP-55 enclosure.

3.2 Design Criteria 3.2.1 All equipment shall be designed to operate on the following site conditions &

system.

Location Kandla Ambient 0-500C

RH 95% max. Climate Tropical normal corrosion

soil Altitude from MSL 220m

Both maximum temperature & maximum R.H. occurs simultaneously shall be considered for design purpose.

3.2.2 Power supply system

Mains : Voltage : 415 V± 10%, 3Phase & Neutral Frequency : 50 Hz±5% Combined variation of voltage & frequency

: ± 10%

System Neutral : Solidly grounded Insulation level : 2.5 kV for 1 minute System SC Level : 50 kA for 1 second. Control voltage : 110 V AC single phases, 50 Hz through

Control transformer of PMCC. DG Set

Voltage : 415 V, 50 Hz (Ref. Technical specification) Battery volts : 24 V DC

For details of single line diagram of DG Set refer drawing no. MEC/23KX/05/E9/SLD/002, R-0 (Sheet 1 of 2) AND MEC/SD/05/E9/006/001, R-0.

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3.2.3 The basic data for the engine are given below:

a) Rating : To suit kVA specified in SOR/Data Sheet. Generator at 0.8 P.F (Equipment selected shall be suitable for base load application.)

b) Duty : Out put specified shall be on continuous basis (24 hours) operation per day under the site conditions specified. Further the engine shall be capable of providing an output of 10% in excess of the rated output at the same speed for one hour in any period of 12 hour running.

c) Ref. Std. : BS 5514 / ISO-3046/1 d) RPM : 1500 e) Cooling

system : Radiator type cooling system

f) Lubrication system

: Forced lubrication

g) Fuel : High speed diesel h) Starting : Battery starting i) Nature of

load : For process pumps (with solid state soft starters

and VFD) loads and if necessary, illumination loads also.

3.3 Diesel Engine And Accessories

The engine shall be suitable for industrial use and arranged for cold starting, mechanical injection, 4 stroke, compression ignition and closed circuit water cooled. Diesel engine prime mover to drive the alternator shall be supplied with all standard accessories. Rating of the diesel engine shall be decided based on the site conditions & for base application as given in this document. The engine should be capable of delivering rated output continuously (24 hours of operation) under the site condition specified. Further, the engine shall be capable of satisfactorily providing an output 10 % in excess of the rated output at the same speed for one hour in 12 hours continuous running.

The engine speed shall be maximum 1500 rpm at 50 Hz. The engine shall be designed to reach operating speed and full load capability within 15 sec after receiving a start signal. The engine shall run steadily at any load to full load with in its rated load. Automatic speed governing systems shall be provided using wood ward/PSG governor /electronic governor. Governor shall have a droop adjustable from 0 to 4% of rated speed. Engine shall have 120% over speed withstanding capability and over speed trip shall be set a 115% speed. The fuel for the engine shall be High speed diesel as per IS: 1460-1974.

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3.4 Fuel System for the DG Set.

a) Day oil tank

The capacity of day tank shall be 990 Ltrs. It shall be provided with level gauge calibrated in Ltrs. For easy filling in & cleaning openings, drain valve shall be provided. The oil tank be mounted on a self supported base frame. Fuel supply & return pipes / hoses from the tank to engine and back shall be supplied. Staging of oil tank if required shall be provided to meet engine requirement. Alarm for low oil level shall be provided. The tank shall be designed as per IS: 803 & shall be provided with manhole, drain, earthing, high level & low level switches, etc. At Low-low level the engine shall trip. At high level alarm the existing fuel transfer pump shall trip. The day oil tank shall be filled by existing fuel oil transfer pump. A tapping from the nearby fuel header shall be taken for filling up the day oil tank.Necessary pipes ( about 15 m) isolation valves, hoses, fitting as required shall be included in your the scope.

b) Filter

A filter of suitable type & capacity to supply fuel oil at rated output (Duplex filter preferred)

c) Fuel pump engine driven

d) Fuel injection and control system for compression ignition.

3.5 Lubrication System

Lubrication system shall include replaceable, suitable type full flow oil filter and automatic lube oil temperature control. The lubrication system shall be self contained with the following equipment.

a) Sump: To store sufficient oil for circulation, sump of sufficient capacity for

24 hours continuous operation.

b) Pump: Shaft driven pump for forced lubrication.

c) Filters & strainers: Filter shall be replaceable while engine is in operation. d) Lubricating oil cooler (if required) e) Interconnecting piping.

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3.6 Air Intake The air intake shall be ensure sufficient clean air to the engine. It shall incorporate the following.

a) Suction filter : To supply clean air to the engine. b) Turbo -charger : The engine shall be provided with a

Turbocharger after cooler. 3.7 Exhaust System 3.7.1 The hot exhaust gases shall be let off with suitable exhaust system. All the hot

parts located shall be insulated. The exhaust system shall include: a) Exhaust

manifold : Shall be air cooled type

b) Spark arrestor

: Required. To be provided by tenderer.

c) Silencer : The exhaust gases shall be let off through residential type silencer to keep noise level to 75 dB (A) from 1M from the enclosure

d) Expansion joint

: A flexible expansion joint shall be provided for connecting the exhaust manifold to the silencer.

e) Exhaust pipe : Exhaust pipe and chimney with flanges, nut, bolts, cowl shall be provided to meet pollution control norms.

f) Insulation Insulation for exhaust pipe with 0.6 mm with aluminum cladding with leak proof lapping joints for piping & silencer. The silencer and all indoor portion of exhaust duct shall be insulated to maintain a surface temperature not to exceed 700C

3.7.2 Structural work 3.7.2.1 Scope of supply and work

This Scope of work shall include but not limited to the following: Design, Preparation of design drawings, Approval of Design & drawings, detailing,

supply, fabrication ,erection and painting of exhaust pipe including its supporting steel structure. The design of exhaust pipe proper shall be in accordance with technological requirement as well as structural strength stability and safety

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The steel structures shall broadly be designed to support the Exhaust pipe, The Structure may consist of Column & Column bracing, cat ladders with caging, landing platform and handrails Intermediate landing shall be provided to cat ladders at an interval not more than 5.0m

3.7.2.2 Design of structural element shall conform the following

a. The primary load cases & load combinations on the structures as per relevant IS Code

b. Modeling of structural 2D/3D frame & analysis using software STAAD-PRO.

c. Design of main structural members as per STAAD-PRO/ manual calculations and structural design of all other secondary members bracing system, base plate & stiffeners, anchor bolts, and any other component of the structure

d. Design of Foundation for above structure

e Preparation and submission of hard & soft copies of Design calculations & drawings

for approval of the Purchaser.

f. Preparation and submission of design calculations for typical connection details etc. for approval of the Purchaser.

3.7.2.3 Design Basis & Considerations for Structures

Structural members shall be designed such that they are economical and safe and meet the functional and service requirement of the technological process for which they are designed. a) All dead loads shall be considered in accordance with IS: 875 (Part-1) -1987. b) All live loads shall be considered in accordance with IS: 875 (Part-2)-1987. (Also refer clause 4.04) c) Wind loads shall be in accordance with IS: 875(Part-3)-1987 and any other consideration specific to the site. d) Seismic loads shall be in accordance with IS: 1893 – 2002. e) In absence of any suitable provision for design loads, any other recognized code of practice may be followed f) Design of steel structures shall be done in accordance with IS: 800-1984. g) The fabrication and erection of steel structure shall be in accordance with IS: 800 – 1984

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3.7.2.4 Material specification for steel structures: a) All rolled sections and plates shall conform to Grade –A as per IS :2062-1992 , IS:8500-1991 b) Mild Steel sheets shall conform to IS 1079:1988 c) All anchor bolts shall conform to IS : 2062-1992 d) Reinforcement Bars shall be Fe-415,GR-I Conform to IS:1786 e) RCC shall be M-25 & PCC of grade M-10

3.7.2.5 Painting system for Structural

The recommended paint systems for general service requirement of steel structures application of primer coats, intermediate coats and final coats to develop the required minimum dry film thickness on steel surface is as below Surface preparation: Sa-2 according to Swedish Standard SIS055900. Primer paint: Two coats of chlorinated rubber based zinc phosphate (DFT 35 µ/coat) Intermediate paint: One coat of chlorinated rubber based MIO (DFT 75µ). Finishing paint: Two coats of chlorinated rubber based paint with suitable pigments(DFT 30µ/coat

3.8 Acoustic Enclosure

Suitable acoustic enclosure / insulation shall be provided for maintaining the sound level. Outer Noise level should be below 75db (A) @ 1 Metre under Free field condition. Clearance from Central Pollution Control Board (CPCB) should be obtained and submitted. High quality Fire Resistant insulation material (IS 8183) for maximum sound absorption should be used. Heat resistant Neoprene Gasket should be provided for perfect noise and weather scaling. This enclosure shall conform the requirement of the pollution control norms of respective locations. Lighting arrangement inside the enclosure shall be done. The thickness of sheet steel shall not be less than 2mm. Enclosure should be forced ventilated to maintain acceptable temperature and must provide sufficient air for engine breathing and cooling

3.9 Engine Cooling System

Shall consist of a closed, pressurised cooling water circuit including circulation pump, cooling fan, radiator etc. The circulation water pump and cooling fan shall be powered from the engine crankshaft. The cooling fan shall draw air over the engine and discharge through the radiator.

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3.10 AC Generators and Accessories

(REF. STANDARD IS- 4722, BS-2613, VDE- 0530)

3.10.1 AC Generators shall have following constructional features:

a) The alternator shall be revolving field, salient pole, brushless type, screen protected drip proof sheet steel enclosure conforming to IP-23 degree of protection as per IS 4691 (Terminal Box shall conform to IP 55). Generator set is intended for outdoor installation & with acoustic enclosure.

b) Laminated low loss silicon steel stator core with copper winding in class H

insulation firmly wedged in slots and braced to withstand mechanical forces, high vibration impact stresses etc. Temperature rise limited to that for Class F insulation.

c) Laminated core salient poles within copper field coils (class H insulation)

firmly assembled on rotor, dynamically (balanced over the entire operating speed range including over speed due to prime mover) to operate with minimum vibration and provided with damping cage winding on pole shoes. Temperature rise limited to that for Class F insulation.

d) Exciter and pilot exciter assembled with integral with the main machine to

provide self excited, self regulated brushless excitation system, with class H insulation. The excitation system shall comprise of excitation equipment, automatic voltage regulator, voltage adjustor, AVR voltage failure release (alarm). Temperature rise limited to that for Class F insulation.

e) Fast response electronic voltage regulator mounted on the machine.

f) Suitable terminal box with double compression type cable glands and tinned

copper lugs for terminating multiple (8-10) runs of 3.5 x 300 mm PVC insulated armoured Cu/Al cables and shall be located on the free end or side of the machine. Top terminal Box shall be provided.

g) A neutral point terminal box with protection class current transformer

mounted on neutral side of the stator winding. CT shall have suitable VA and ratio rating, with 5A / 1A secondary current rating (depending on the type of earth-fault relay to be supplied) conforming to IS 2705. Neutral terminal box shall be liberally dimensioned for easy accessibility to C.T and provided with proper cable glands for power and control cabling.

h) Embedded Thermisters in stator winding, bearing temperature detectors,

space heater shall be wired to separate terminal boxes (Thermister relay shall be mounted in DG control panel).

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i) Ball and roller shall have re-greasing facility by grease gun, inherently protected against over greasing, with seals to prevent in-grease of grease into the machine winding. Bearing shall be anti-friction type.

j) Pretreatment and painting to provide neat durable finish, preferably

conforming to shade 21 of IS 5. k) Self cooling air circulation by fans mounted on rotor. l) Name plate details as per clause 18.1 and 18.2.2 of IS 4722. m) The alternator and its excitation system shall be designed to withstand a

10% overload for 1 hour at rated voltage, speed and power factor without a harmful temperature rise and to withstand a 200% over current for 15 sec at rated load excitation.

n) The alternator and its excitation system shall be designed to withstand

overspeed of 120%.

3.10.2 Data Sheet For Alternator A) Alternator

Continuous rating (S1 duty as per IS: 4722-1922)

: For KVA (As specified in SOR) At 0.8 PF at specified site conditions (Base duty)

a) Output : 415 V, 3 phase, 4 wire 50 Hz AC. b) Type of Alternator Self contained, self excited and self regulated

along with fast response for electronic governor. Screen protected, drip enclosure proof, self ventilated with removable covers to provide easy access to excitation unit, enclosure IP23 (Terminal box in IP 55 enclosure)

c) Mounting : Horizontal, foot mounted with end shield bearings.

d) Excitation : Static excitation unit mounted in alternator e) Voltage : Automatic self regulated regulation with ±0.5%

of nominal rated voltage. From no load to full load @ 0.8 PF for both cold & hot conditions

f) Insulation : Class – H, tropicalised. However temp. rise to class – F

g) Space heaters : To prevent condensation, rated 415V h) Heater with controls : Required for starting / operation at 0o C as per

site conditions.

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3.11 DG AMF Control Panel. 3.11.1 DG control panel shall have following constructional features:

a) Cubicle type free standing, floor mounted, Fabricated with 2mm thick CRCA

sheet steel construction, dust and vermin proof with IP 54 degree of protection as per IS 2147 (Intended for indoor installation). The maximum and minimum operating height shall be 1800 mm and 300 mm respectively.

b) Shall consist of distinct vertical Sections assembled to give single front

execution suitable for cable entry from bottom.

c) Manufacturer, assembly and testing shall conform to Indian Standards applicable for low Voltage switch gear and statutory regulations. Various components like bus bars, switch fuse units, relays, timers, contactors, lamps, various meters, static annunciator etc. shall be arranged in a logical manner following good engineering practice and for case of maintenance, replacement and connections.

Details of bus bar dimensions, material, insulation provided in DG control panel shall be submitted for approval.

d) Panels shall be completely pre-wired as per approved wiring diagrams.

Wiring for external connections shall be done upto terminal blocks (with wire numbers and terminal numbers clearly marked).

e) The air circuit breaker (ACB) shall be in drawout execution, provided as

main incomers in DG control panel.

f) Switch fuse units (HP rated / heavy duty SFUs), starter units for DG auxiliary drives shall be fixed execution with door interlocks. All live terminals shall be properly shrouded to prevent inadvertent contact by operating personnel. Feeder designation shall be clearly marked on each cubicle. All meters shall be flush mounted on the cubicle doors (Max. size 96 mm x 96 mm). Separate module shall be provided for each motor starter.

g) Anti-condensation space heater shall be provided in panels with isolator

and HRC Fuses and On/Off interlock with set. 3.11.2 Battery station

a) Set of 24 V lead acid battery / bank of adequate ampere hour capacity for the DG set (at 10 hours discharge rate for supplying control power to control panel and starting power to engine starting motor) complete with connecting

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leads first charging and routine check instruments including hydrometer and cell tester, teak wood stand, floor insulators, cell supporting insulators, etc. It shall be possible to start the engine three times in immediate succession without appreciable drop in DC Voltage. The battery shall have a sufficient capacity to start the engine more than 4 times consecutively.

b) Battery charger unit can be built in as a part of DG panel. Battery charger

unit shall be complete with unit transformer / rectifier with surge protection, DC ammeter, Voltmeter, Charge rate selector etc. suitable for quick and trickle charging of batteries. Charger shall be suitable for 240 V, 1 Ph, 50 Hz incoming supply. DC voltmeters, centre zero ammeters, protective fuses shall be provided. Charger shall give constant DC output voltage irrespective of incoming voltage variation specified.

3.11.3 Meters and components in the DG control panel shall consist, but not limited to

following minimum items.

a) Voltmeter (144 Sq. mm) to read line to line main voltage and DC voltage with selector switches (as per IS 1248).

b) Ammeter (144 Sq. mm) to read line current (as per IS 1248) with selector switch. c) Frequency meter (45 Hz to 55 Hz). d) Power factor meter (0.5 lag to 0.5 lead). e) Kilo-watt meter. f) Kilo-watt hour meter, with hour meter to record total hours of operation (Hour

meter shall have resent tool) shall be integrated / digital type micro processor based similar to Enercon 3360.

g) Tachometer to measure engine speed. h) PTs and CTs required for above meters. i) Auto-Off-Manual selector switches (for varying engine speed wherever engine

governors are provided with motorized heads). j) Push buttons, Engine start / stop, generator breaker close/trip, control system off,

etc. indicating lamps, lamps shall have translucent colored covered red, green, white, amber etc., lamps with series resistors) shall indicate the following:

i) DG set on-off.

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ii) Grid supply on-off. iii) DG supply on-off. iv) solid state annunciator ( 18 windows minimum) shall have following

feature. Test, accept, reset push button, two bulb for channel, lamp flashing audible annunciation, window inscription shall be arranged in a logical manner to segregate engine faults, and alternator faults etc. spare window shall be available. Annunciator shall announce following minimum faults:

i) Set fails to start. ii) Low DG voltage.

iii) Low lube oil pressure. iv) ACB tripped

v) Fault in alternator

vi) Low fuel oil level vii) Over speed trip.

(Further fault if any shall also be included as per Mfg, Standard or as will be finalized during approval of drgs)

k) Protective relay for tripping DG Set ACB for over current, short circuits earth

fault with flag indications. CDV62 relay with PS class CT shall be provided. I) Relays, timers, contactors etc for controlling and interlocking of engine fault

and for operating the engine from DG control panel.

3.11.4 Air circuit breaker in separate cubicle in draw out execution shall have following features:

a) Four pole direct acting, ambient compensated, continuous adjustable thermal

release with setting range from 50% to 150% of rated current of the DG set.

b) 3 pole direct acting, current independent, continuous adjustable short circuit release, with timer, current range 2 to 4 times the rated current of DG set (time setting 0.1 to 0.3 seconds).

(Note: ACB with microprocessor based relays will also be considered)

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c) Under voltage relay with timer for giving, closing impulse to the breaker. d) Generator protection relays shall be as indicated in the single line drawing. e) Under voltage release. f) Shunt trip release. g) Draw out execution. h) Motorised spring charging with electrical closing in two modes: i) Through push button in manual mode.

i) Additional relays shall be provided for interlocking DG breaker with grid

breaker to prevent paralleling. Breaker auxiliary switch shall have 3 NO +3 NC.

Protection Requirement

a) Alternators shall be protected for over current, short circuits and earth fault. b) The thermal releases and direct acting magnetic releases of the circuit

breakers shall be accurately selected based on the rating of the alternator and the short circuit releases shall be adjusted based on the maximum sustained value of over current the machine can develop due to short circuit.

c) Thermistors connected to special thermistor relay shall trip the air circuit

breaker and stop the engine in case of excessive temperature of the winding of Alternators.

d) Bearing temperature detectors shall be connected to temperature indicating

instruments with adjustable alarm / trip contacts wired to annunciator in the DG control panel.

e) All the engine and alternator faults shall shut off the engine in addition to

tripping the breaker. f) All the DG auxiliary drive (if applicable) motors shall be protected by HRC

fuses and bimetal thermal over load relays (of proper ratings), with inherent single phasing protection. Each drive motor shall have its individual isolator and control MCB.

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g) Space heaters inside alternator shall be interlocked to switch off when machine is running.

h) Over speed protection shall be set at safe permissible value of speed

recommended for the set. i) All the field sensor elements like temperature, pressure switches etc. shall

be connected to protection circuits in a fail safe manner so that machine is not subjected to harmful effects of temperature, pressure etc., due to malfunctioning of the instruments.

3.11.5 Power & control cables

a) General

All power and control cables supplied shall be as per relevant IS standards.

All LT power cables shall be 1.1 kV grade, circular / sector shaped, stranded 3 ½, 4 core electrical purity Cu conductor PVC insulated, round / flat steel strip armoured and extruded PVC inner and outer sheathed as per relevant standards and suitable for 415V neutral solidly earthed system. The PVC insulation used shall be suitable for continuous conductor temperature of 85 0C.

The insulation of phase conductors shall be coloured red, yellow and blue and the neutral black.

1.1 kV grade control cables shall be of circular stranded electrolytic grade high conductivity annealed copper conductor with a minimum size of 2.5 sq.mm PVC insulated, round wire armoured and PVC overall sheathed.

All cores of control cables shall be continuously identified by tracer numbers i.e. tracer numbers either embossed or printed continuously on each individual core.

Armouring for power and control cables shall consist of galvanised steel strips / galvanised round steel wires.

All cables shall be suitable for system particulars, site conditions and environment conditions specified.

b) Specification

1.1 kV heavy duty power cable multi-cores with standard sector shaped or with compact circular stranded Cu conductors as applicable. PVC insulated

27






of type C PVC compound suitable for 85 0C operation core stranded together provided with a common covering of extruded PVC inner sheath of type ST2 PVC compound, galvanised round steel wire! flat strip armoured and PVC outer sheathed of type ST2 PVC compound.

Type 3:1.1 kV PVC copper control and instrumentation cables (YWY)

1.1 kV solid annealed stranded copper conductor. PVC insulated of type C PVC compound, suitable for 85 deg. C operation as per IS: 5831 — 1970, cores stranded together provided with a common covering of Extruded PVC inner sheath type ST2 PVC compound, galvanised round steel wire armoured and overall PVC sheathed of type ST2 PVC compound and multi-core.

c) Selection

Size and type of cables for specific applications shall be selected giving due Consideration for the following

— Thermal heating effect /permissible current carrying capacity.

— Allowable voltage drop as per Technical specification. — Short time current] overload requirement. — Protection system grading and short circuit current carrying capacity. — Ambient conditions. — Cable grouping factors. — Cross sectional area of the cables used in LT power circuits shall

be: — Minimum 4 sq mm per core and max. 300 sq mm Cu conductor. — Current carrying capacity of the power cables shall be calculated

considering 60% de-rating factor.

All control cables shall have stranded copper conductors. — For control circuits, PVC insulated and PVC sheathed multi-core

cables with copper conductors having a minimum cross-sectional area of 2.5 sq mm per core shall be used. Spare cores shall be given.

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Sequential length marking shall be provided in outer sheath of all power and control cables.

ISl marking at every metre of cable length shall be provided.

Cores of multi-core control cables shall be serially numbered.

d) Tests

Copies of type test certificates as per relevant IS carried out on similar cables shall be furnished.

All routine tests & acceptance tests as per relevant IS shall be carried out on every cable size in presence of owner or his representative if specified in QAP.

3.11.6 Instrumentation & control

The measurement and controls shall be provided for efficient operation of the process as well as for safety of equipment and operating personnel.

The equipment shall be provided with all instruments necessary for checking the performance continuously. All meters shall be fixed on a common instrumentation panel mounted directly on the engine frame. Instrument system shall include all standard instruments coming as a part of engine.

Measurements and controls required for smooth and efficient operation of the DG set including but not limited to the following:

ii) Protection devices

For the safety of DG set following annunciation and tripping scheme shall be provided.

a) Audio visual alarm only, for the fault conditions in case of:

— Fuel oil tank level low. — Lubricating oil pressure low. — Fuel oil pressure low. — Lube oil temperature high. — Exhaust gas temperature high.

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— Fuel oil day tank level high. — Lube oil sump tank level low. — diesel engine start failure.

b) Audio visual alarm followed by tripping in case of:

— Lubricating oil pressure too low. — Crank case oil mist high. — Over speed. — Starting fault, — Charge air temperature too high. — Engine Vibration too high. — Emergency stop (manual)

3.11.7 In addition to the common specification listed in for DG control panel in 2.2 the

following additional features shall be provided as given below for the Panel.

a) Control panel for the DG set. It shall comprise of one no. 3000A Air circuit breaker in draw out execution,

protection class CT, metering class CT for protection relay and measuring instrument, power monitors, CDV-62 protection relay, PT, master trip relay, indicating instruments, annunciation, etc.

Reverse power relays shall be provided in both the generator output

circuitry. The neutral earthing system of the generator shall be taken to the panel and

necessary contactors shall be provided for isolation of the set. 110V control circuit for breaker closing and indications, 24V control circuit

(from battery) for engine starting / stopping, master trip relay, auxiliary relays for multiplication of fault controls etc.

3.11.8 Foundation frame

Suitable foundation frame (common with generator with foundation bolts and nuts shall be provided.

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Coupling shall be suitable for type and speeds of equipment to be coupled. It shall ensure minimum vibration in operation due to possible misalignment and unbalances.

3.11.9 Preferred makes

Engine : Caterpillar / Cummins I Detroit/I Greaves/ KOEL.

Pipes : Zenith / BSI/ Jindal/ Khandalwal. Alternator : NGEF/ Kirloskar/ Crompton Greaves /

Stamford Control & Relay panels : English Electric! Easun Reyrolle/ ABB Battery : Exide / HBLNIFE/ AMCO/ Amara Raja Battery charger & DC Board : Automatic electric / HBLNIFE LT Switch board : Siemens / L&T/ NGEF/ GE LT cables : Cable corporation of India /Universal

cables / Indian cable company / Asian cables.

Air circuit breaker : Siemens / GE/ L & T MCCB : GE / ABB / Siemens/CROMPTON

GREAVES Protection Relays, Aux. Relays : GE / ABB / Siemens / Easun Reyrolle LT contactor & Thermal O/L Relays

: GE / Siemens / Tele-mechanic / L & T /Control & Switch Gear

Selector switches/ Control switches

: GE / KAYCEE/ ABB / Siemens.

LT, CTS : Automatic electric / Siemens / KAPPA electricals

Annunciators : GEC / ALSTOM/ Yashmin Power Factor relay : PHASITRON Indicating Meters : Automatic electric lndustrial Meters Pvt.

Ltd., / MECO / RISHAB Integrating meters : IMP / BHEL / Universal Instruments / AE Brass / GI compression type cable glands

: Comet / Siemens

Tinned copper lugs : Dowells/ Electropowerke/ Indicating lamps & Push buttons

: GE / Siemens / L & T/ BCH

3.11.10 Applicable Codes and Standards

The design, manufacturing, testing of DG set and associated accessories/equipment shall be in accordance with the latest revisions of the

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following standards, wherever applicable. Where appropriate Indian Standards are not available, the relevant IEC/BS/ISO standards shall apply.

IS : 5 Colours for ready mixed paints and enamels. IS : 4691 Degree of protection provided by enclosures for rotating

electrical machinery. IS : 4722 Rotating Electrical machines IS : 4728 Terminal marking and direction of rotation for rotating

electrical machinery. IS : 4889 Methods of determination of efficiency of rotating electrical

machines. IS : 12065 Permissible limits of noise levels for rotating electrical

machine IS : 12075 Mechanical vibration of rotating electrical machines IS : 12802 Temperature rise measurement of rotating electrical

machines IEC : 34 series Rotating Electrical Machines IEC : 72 Dimensions and output series for rotating electrical

machines BS : 649 Performance of reciprocating compression ignition Diesel

Engine BS : 4999 General requirements for Rotating Electrical Machines BS : 5000 Specification for Rotating Electrical Machines of particular

types or for particular applications BS : 6121 Mechanical cable glands ISO : 3046-4 Reciprocating internal combustion engines, part 4 speed

governing

The DG set and associated accessories/equipment shall also conform to the provision of the latest revisions of the Indian Electricity Rules and other statutory regulations currently in force.

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4.0 QUALITY ASSURANCE, INSPECTION & TESTING , PERFORMANCE GUARANTEE. 4.1 General Requirement Of Quality Assurance

All materials, components and equipment covered under the Technical specification for this Project shall be procured, manufactured, tested, erected and commissioned as per a comprehensive Quality Assurance Programme. It shall be the primary responsibility of the contractor to draw up and implement such a programme which shall be duly approved by the Purchaser/Consultant/their authorised Inspection Agency. The detailed Quality Assurance Plan (QAP) for manufacturing and testing of equipment shall be prepared by the contractor and submitted for approval by the Purchaser/their authorised Inspection Agency.

4.2 Inspection and Testing

4.2.1 The equipment shall be inspected by the Purchaser and / or their Inspection Agency at the

manufacturer’s works prior to despatch. The equipment will be inspected as per the tests pre-identified in the approved QAP to ensure conformity of the same with relevant approved drawings, data sheets, technical specification, National/International Standard.

4.2.2 The contractor shall finalise the QAP within the stipulated schedule mentioned in the

Purchase Order and the QAP shall be submitted in four sets (Blank QAP formats enclosed shall be adopted). In case of any sub-contracting, the QAP shall be prepared by the contractor in consultation with his sub-contractor to avoid any lapse in quality and disputes and misunderstanding.

4.2.3 The contractor shall provide full and free access of the Inspection Agency to the

manufacturer’s works to carry out any stage inspection to ensure the quality of the equipment being manufactured.

4.2.4 Only on readiness of the equipment and approval of all relevant drawings & QAP, the

contractor shall give “Inspection Call” to the Purchaser & the Inspection Agency with a clear notice of 10 days for inspection. The Inspection Call shall be accompanied by the manufacturer’s internal inspection report, test certificates, purchase order, sub-purchase order, technical specification, approved QAP and approved drawings / data sheets. The Inspection Call without above documents shall be ignored. In case of any approved sub-contracting, only the main contractor shall give the Inspection Call enclosing internal inspection/ test reports of the sub-contractor duly verified by the main contractor. In case the equipment offered for inspection is found not ready, all the cost of the visit of the Inspection personnels shall be borne by the contractor.

4.2.5 The contractor shall furnish all relevant documents and test certificates as required by

the Inspection Agency during inspection. Materials shall be tested only in recognised Test House/Laboratory.

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4.2.6 The contractor shall delegate a representative/ coordinator to coordinate with the Inspection Agency on all inspection matters.

4.2.7 No equipment shall be offered for inspection in the painted condition unless otherwise

agreed to the purchaser.

4.2.8 The contractor shall ensure that the equipment and materials once rejected by the Inspection Agency are not reused in the manufacture of plant and equipment. Where parts rejected by the inspection Agency have been rectified as per pre-agreed procedure, such parts shall be segregated for separate inspection and approval before being used in the work.

4.2.9 The contractor shall carry out their internal inspection and obtain clearance from

Statutory bodies, like IBR, CCE, TAC, Weights & Measures, Safety, IE Rules, etc., as required for the equipment prior to offering any such equipment for Purchaser’s inspection.

4.2.10 The contractor shall provide all required instruments, tools, necessary testing and

inspection facilities free of cost to carry out the inspection. These instruments and testing machines shall be calibrated by an agency of National/ International recognition and the calibration shall be valid during inspection period.

4.2.11 The inspection Agency shall have the right to demand for re-testing of any material re-

calibration of the instrument and testing machine & the charges for the above will be borne by the contractor.

4.2.12 No equipment shall be despatched before inspection and issue of Inspection Certificate

and despatch clearance from the Purchaser / Inspection Agency. 4.2.14 In case of waiver category items, the same shall be pre-identified in the QAP itself. For

such items, the contractor shall furnish necessary certificate, test reports, etc., as agreed upon and indicated in the QAP. For these items also the contractor shall obtain “Inspection Waiver Certificate” and despatch clearance from the purchaser Inspection Agency before effecting despatch of equipment.

4.2.15 The issue of Inspection Certificate / Waiver Certificate for any equipment or component

thereof does not absolve the contractor from his contractual obligations towards subsequent satisfactory performance of the equipment at site. Should any equipment be found defective, In whole or part thereof after receipt at site or during erection/ commissioning and testing shall be made good by the contractor free of cost.

4.3 Performance Guarantee

The tenderer shall furnish the following guaranteed parameters, When operating under site conditions at maximum continuous rating as defined in BS 5514 (ISO 3046). The

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performance test of the DG set shall be carried out at manufacturer’s work. Performance tests of any particular equipment which cannot be conducted / demonstrated either partially or wholly at the manufacturer’s works, shall be conducted after erection at site in the presence of Purchaser and their Inspection Agency. In all the cases, prior approval of the Purchaser shall be obtained. However, arranging all testing facilities including load shall be in the scope of supplier. Following tests shall be conducted in the presence of purchaser’s representative at manufacturer’s work;

i) Functional tests, continuity tests and high voltage test on control panel to

establish the performance called for in the specification. ii) Routine tests for alternator as per IS:4722.

iii) Overspeed test (1.2 times the rated speed for 2 minutes).

iv) Phase sequence test.

v) Vibration test

vi) Noise level test

vii) Power and fuel consumption shall bereorded as follows;

Percentage Loading 110% 100% 50% 25% i) Engine output ii) Electrical output at the generator

terminals (KVA)

iii) Fuel consumption iv) Lubricating oil consumption

vii) Dimensional and alignment test shall be checked before PG test

viii) Manufacturer’s routine test certificates for bought out items shall be

submitted. Routine and type test certificate for Switchgear shall be submitted. Type test certificate for alternator shall be submitted.

5.0 ERECTION, TESTING & COMMISSIONING OF D.G. SET 5.1 Scope work under this section includes site work of installation & commissioning of

engine, generator assembly, electrical panels battery station, associated cabling, including cables between DG Control panel grid breaker panel, earthing, piping, fuel pumps, fuel tanks, safety appliances (like rubber mats, first aid boxes, carbon extinguishers etc). Necessary erection materials such as cable racks, trays, angles, chemicals etc required DG Set & necessary statutory approvals are included in the scope of work.

35






5.2 The installation shall comply with relevant Indian Standards, Indian Electricity Rules

and statutory regulations that are in force in the place of installation. 5.3 Equipment erection, including acoustic enclosure testing and commissioning shall

include following activities

a) Removal of packing material and clearance, removal of blocking devices provided for safe shipment.

b) Physical inspection, preparation of defect lists. c) Assembly of shipping sections. d) Civil work involved in grouting the equipment base frames, concrete

chipping, grouting for wall, roof, floor supports wherever required for piping, cabling etc.

e) Tack welding of equipment, panels etc., to floor inserts wherever provided

and providing floor inserts wherever required for erection work. f) Applying touch paints for finish painted equipment’s and finish painting of

site fabricated steel work after pretreatment like de-rusting, degreasing, primer coating etc.

g) All pre-wired panels shall be checked for correctness as per final approved

wiring diagrams. h) Trouble free mechanical operation of relays, contactors, timers, breakers

and free rotation of all drive motors be checked. i) Tightness of all bolts joints in busbars, motors, generator, engine etc., shall

be checked.

j) Insulation resistance of all electrical equipment’s shall be measured and improved by cleaning and drying. Space heaters, filament lamps (1000 watts) shall be provided and kept energized during the entire period of erection to prevent deterioration of insulation resistance below permitted values.

k) Duplicate earthing shall be provided for all electrical equipment’s, cable

glands, tanks, vessels etc. as per statutory regulations.

I) Generator neutral shall be directly connected to pipe / plate electrode using insulated cable. Earth ring inside DG Set shall be formed and connected to

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plant earth grid at minimum two points for DG Set to be provided by the contractor as per IS 3043.

5.4 a) DG set consisting of diesel engine and AC generator mounted on common

base frame with acoustic enclosure shall be erected on civil foundation with correct orientation details. DG control panel, battery station, charger units shall be erected inside the MCC room. Supplier shall furnish detailed layout drawing for the DG set.

b) All the piping to the engine shall be done strictly as per manufacturer’s

drawings. Wherever piping involves joining by welding the same shall be as per relevant statutory regulations (compressed air lines etc.). Unions / couplings of pipelines shall be done as per manufacturer’s instruction /drawings, wherever welding is not preferred or permitted. All piping shall be checked for leak proof by conducting tests as per instruction manuals of manufacturer.

c) Coupling of the engine and alternator shall be done after checking and

correcting alignment of shaft axes within permitted tolerances. Shaft levels shall be checked and adjusted to be within permitted tolerances.

d) All the power cables between DG Control panel and alternator shall be

done as per approved layout drawings. Further all control cables to start and shut-off solenoids, temperature switches, level switches etc., shall be separately installed and terminated with ferrule numbers as per manufacturer’s wiring diagrams. Wherever control cables have to run near engine casing thermal insulations shall be used to prevent damage due to excess temperature. Flexible conduits shall be used to protect control cabling near the engine. All the power and control cables shall be laid separately and in cable trenches / cable channels between generator and DG Control panel in the building as per approved drawing. Vacant spaces in used and unused conduits should be plugged using M-seal monoplast filling compound. All cables shall be neatly dressed and clamped in fabricated cable trays.

e) DG set auxiliaries like lube oil prime pump, fuel oil pump, fuel transfer

pumps, shall be run and checked using grid supply. Similarly batteries shall be charged through charger installed, using grid supply. First filling of lubrication oil, grease, fuel oil (into tank) etc., shall be done by the contractor as per manufacturer’s instructions.

f) All DG set instruments shall be tested / calibrated and set at values

recommended by the manufacturer, Inscriptions on windows shall be checked. Overload relay for alternator protection shall be tested and set at values recommended.

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g) Installation of safety appliances like rubber mat, carbon dioxide fire

extinguishers, first aid box etc., shall be done. 5.5 When installation is completely ready for starting, following tests shall be done in

addition to all test prescribed by the manufacturer / I.S. Standards.

a) Starting of engine in auto and manual mode / simulated DG Control condition.

b) Shut-off of the engine-manual mode/ electrical mode simulated faults of the

alternator and engine. c) Over speed test. d) Interlock between DG breaker and grid supply. e) Governor speed control electrical /mechanical. f) Minimum time in seconds required by the set to deliver power at desired

voltage and frequency starting from standstill condition. g) Matching the DG phase sequence with grid supply phase sequence. h) Checking annunciator windows for all the faults simulated during testing. i) Continuous full load test as specified, by starting all the motor loads

sequentially. j) Tabulation of all results in the mutually agreed format.

5.6 Manufacturer’s service personnel shall be deployed for testing commissioning,

wherever required. Contractor shall extend full co-operation and assistance to all such personnel.

5.7 Important notes

a) Successful commissioning of DG set is contingent upon satisfactory

working of all the units, meeting fully the requirements of the specification and performance guarantees offered by the manufacturer.

b) It shall be contractor’s responsibility to replace all defective / inferior

materials revealed during preliminary acceptance and final acceptance tests (P.A.T and F.A.T) at his own expense, without affecting completion milestones.

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c) Contractor shall ensure that no tests are applied which may stress the equipment above the limits recommended for field testing, by the manufacturer.

d) Contractor shall be responsible for any damage that may occur to personnel

/ equipment resulting from improper testing procedures. e) Contractor scope in testing of DG Set includes supply & filling sufficient

quantities of consumables like high speed diesel, lube oil, greases etc, necessary for carrying out all trial runs, during preliminary acceptance tests (PAT) and final acceptance tests (FAT).

5.8 Form of completion certificate for the DG set

I/we certify that the installation detailed below has been installed by me / us and tested and that to the best of my / our knowledge and belief, and it compiled with IE rules, 1956 as well as technical specification for electrical works.

Particulars of instruments used 1 Insulation tester Make : Type : SI. No. 2 Earth tester Make : Type : SI. No 3 Any other instruments Make : Type : 4 Particular works A Cables : a) Total length of underground

cable and its size :

b) No. of joints : End joints Tee joints Straight / through joints B Earthing a)Description of earth electrode : b) No. of earth electrode : N A c) Size of main earthing lead : 5 Test result a) Insulation resistance :

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i) Insulation resistance of the whole system of conductors to earth

: Mega-ohms

b) Insulation resistance : i) Insulation resistance between the

phase conductor and neutral :

Between R & N : Mega-ohms Between Y & N : Mega-ohms Between B & N : Mega-ohms c) Insulation resistance between the

phase conductor in case of 3 ph. Supply

:

Between R & Y : Mega-ohms Between Y & R : Mega-ohms Between B & R : Mega-ohms d) Earth continuity test Maximum resistance between any

point in the earth continuity conductor including metal conduits & main earthing lead

: Ohms

e) Earth — electrode resistance No 1 : Ohms No 2 : Ohms No 3 : Ohms No 4 : Ohms

Sl. No

From size … in sq.mm

Voltage grade

Length Insulation resistance in mega ohms

At the time of issue

During & before covering

Between RY RY YB YB BR BR RN RN YN YN BN BN RE RE YE YE NE NE

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g) Before commissioning i) Whether high voltage test

conducted : YES / NO

ii) If conducted, system of supply test voltage at

: KV

iii) Duration : Mins iv) Results : Satisfactory / unsatisfactory v) If not conducted, Voltage of megger used : Earth temperature : Results of megger testing : Between R & Y : Between Y & B : Between B & R : Between R & N : Between Y & N : Between B & N : Between R & E : Between Y & E : Between B & E :

SIGNATURE OF SUPERVISOR

SIGNATURE OF CONTRACTOR

SUPERVISOR’S LICENCE NO.

CONTRACTOR’S LICENCE

NAME & ADDRESS NAME & ADDRESS 6.0 MANDATORY SPARES PARTS

One lot of spares is the quantity of spares as mentioned below and shall be ordered and considered for price comparison. List of Mandatory spare prices to be enclosed in Priced Bid Envelope.

Price of mandatory spares shall be loaded for evaluation purpose

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1 set means the quantity installed in one machine (BIDDERS TO SPECIFY ITEMWISE IN THEIR OFFER DOCUMENT)

Price S.No. Part Description Part No.

Qty. Reqd. by purchaser Unit Total

1 ALL ENGINE BEARING/BUSHES (MAIN CONNECTING ROD BIG END CONNECTING ROD SMALL END ETC )

1 lot

2 PISTON ASSY. INCLUDING PISTON, PISTON RINGS & CONNECTING RODS & CONNECTING ROD BOLTS ETC

1 lot

3 PISTON RINGS (ALL TYPES)

1 lot

4 Liners 1 lot 5 INLET VALVE &

EXHAUST VALVE 1 lot

6 GASKETS & O RINGS (SET)

1 lot

7 5% SET OF NUTS, WASHERS & BOLTS (SET)

1 lot

8 CARTRIDGE/ELEMENTS FOR PRIMARY AND SECONDARY FUEL OIL FILTER

1 lot

9 LUBE FILTERS CARTRIDGE/ELEMENT

1 lot

10 SET OF BEARING (LUBE OIL PUMP)

1 lot

10 SET OF BEARING FOR ALTERNATOR

1 lot

11 PREVENTIVE MAINTENANCE KIT FOR 1000 HRS. OF OPERATION

1 lot

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7.0 DOCUMENTS TO BE SUPPLIED ALONGWITH OFFER/ AFTER PLACEMENT 7.1 Along with offer

a) Bar chart showing complete activities as per scope of work.

b) General arrangement of equipment of preliminary station layout of DG set. c) Layout of various service piping & cabling including earthing accessories

indicating also limit of supply. d) Scheme showing the starting of DG set at the line of grid power. e) Single line diagram of generator control panel, MCC etc., indicating make

and rating of each equipment. f) Descriptive and illustrative literature/ showing from manufacturer on all

equipment. g) A detailed experience list about supply of similar type of DG set by the

section. h) Write up on quality control and assurance plans to be followed during

engineering, manufacturing, testing and commissioning of plant and equipment.

i) De-scaling calculation in support of selection of equipment to meet site

condition. j) Data sheet duly filled. k) Tenderer shall also furnish the following:

i. Total time required for the DG set to deliver rated power after

starting from cold conditions.

ii. The overload capacity of the alternator.

iii. Biggest size of motor that can be started on DG set with voltage dip limited to 20% at alternator terminals.

7.2 After placement of order

1. General layout drawings of DG station / Acoustic enclosure showing locations and sizes of all systems, equipment, pipe and cable trenches etc.

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2. The outline of the foundations of all the equipment, accessories etc. under

the scope of his supply indicating the location of anchor bolt conduits and other inserts to be built in the foundations etc. with corresponding level.

3. Complete load data of equipment including dynamic loading, machine

frequency etc. 7.3 Drawings for approval I comments

1. General arrangement, cross-sectional arrangement and detailed drawings of all equipment including diesel engine & acoustic enclosure.

2. Scheme and piping layout drawings for fuel oil, lube oil systems. 3. Detailed scheme of complete electrical equipment with specification & bill of

quantities. 4. Layout drawing showing location of all electrical equipment. 5. Cable and cable supporting structure plan and section. 6. Earthing layout drawing with bill of materials. 7. GA drawing of generator. 8. Control scheme of generator.

8.0 DATA SHEETS FOR DG SET

8.1 Following technical pertaining to diesel engine / alternator shall be furnished along

with tender separately for the set. I. Materials of construction of the engine components

1. Base plates : 2. Cylinder block : 3. Cylinder head : 4. Cylinder : 5. Piston : 6. Nos. and material of compression

rings :

7. Cylinder liner 8. Piston rod : 9. Crankshaft :

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10. Crank pins : 11. Connecting rod big end bearing : 12. Connecting rod small end bearing : 13. Frame : 14. Valve seat : 15. Valve holder : 16. Valve guards : 17. Valve plate : 18. Valve spring : 19. Main bearing : 20. Pin shaft bearing : 21. Tie rod : 22. Rocker arm : 23. Rocker valve : 24. Cam : 25. Roller guide ; 26. Timing rod :

II. Particulars of DG Set A) Diesel engine 1. Name of manufacturer : 2. Type and engine no. : 3. Standard rating BHP : 4. Rating for site conditions : 5. Rated speed (RPM) : 6. Direction of rotation : 7. No. of strokes : 8. No. of cylinders : 9. Arrangement of cylinders : 10. Dia. of cylinders DORE. : 11. Piston stroke : 12. Total piston placement : 13. Mean speed of piston at rated

speed :

14. Compression ratio : 15. Type of cylinder valves

a) Suction b) Exhaust

:

16. Coolant : 17. Firing order of cylinders : 18. FUEL oil consumption :

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a) at rated load b) at 75% load c) at 50% load

19. Thermal efficiency based on bhp : 20. Mechanical efficiency : 21. Min. time required for engine from

starting to fuel load

:

B) Fuel oil system 1. Make : 2. Type : 3. Filter : a) Type : b) No. : c) Location : 4 Fuel supply pump : a) Type : b) Rating : 5 Fuel Injection system : a) Make b) Type d) Drive e) Type of fuel nozzle : f) type of cooling for fuel Nozzle : 6 Fuel tank : a) Type & construction : b) Capacity : c) Thickness of sheet : d) Location : e) Opening data : f) Dia• of pipe connection

- Inlet - Outlet

:

g) Drain details : h) Level indicator details : i) Low level switch details : j) Fuel transfer pump details : k) Type & grade of fuel oil :

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C. Lubrication oil system 1 Make & type : 2 Lub. oil pump : a) Make & type : b) Rating : c) Litres : d) Pressure (delivery / side) : e) Normal operation speed : f) Impeller power .. : g) Dia. of pipe connection at suction

and discharge :

h) Type of priming arrangement : 3 Lub. oil filter and strainer : a) Make & Type : 4 Lub. oil pressure indicator : a) Make & Type : 5 Lub. oil temperature indicator : a) Make & Type : 6 Low lub. oil pressure switch details : 7 High lub. oil temperature : 8 Lub. oil cooler : a) Make : b) Type : c) Tube size : d) Tube material : 9 Lub. oil piping and fitting details : 10 Lub. oil pump : a) Capacity (litres) : b) Material : c) Location : 11 Qty of lub. oil required : 12 Grade of lub. oil : D Air intake system 1 Air filter : a) Air filter : b) Make : c) Type : d) Size of filtering particle :

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E. Exhaust gas system 1 Manifold : a) Location : b) Type : c) Material : 2 Silencer : a) Make : b) Type : 3 Exhaust piping details : F Exhaust gas turbo charger 1 Make : 2 Type : 3 Output : 4 Speed : 5 Suction pressure : 6 Exhaust pressure : G Coupling 1 Type : 2 Bolting details : H Pyrometer equipment 1 Make : 2 Location on engine : 3 No. of points monitored : I Dimension 1 Length : 2 Width : 3 Height : 4 Free over head space required to

pull piston and rod assembly :

J Details of acoustical enclosures 1 Make : 2 Size : 3 Sound Level : 4 Constructional details :

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K Local gauge panel 1 Type of connections : 2 Material & thickness : 3 Size : 4 List of instruments : L Weights 1 Total weight of DG Set : 2 Shipping weight of DG set :

iii. ELECTRICS A Generator : a) Make : b) Type : c) Continuous Rating : d) Over load capacity : e) Speed : f) Over speed capacity : g) Critical speed : h) Short circuit ratio of the machine : B Unsaturated direct air synchronous

Reactances. :

a) Sub-transient : b) Transient : c) Steady stage : d) Zero sequence reactance : e) Negative sequence reactance : C Short circuit time constant : a) Sub-transient : b) Transient : c) Inertia constant of the machine in

seconds :

D) Zero power factor ( lagging) rating at nominal voltage

:

E) Field current (over excitation) : F) Voltage regulation : a) 50% Load thrown off : b) 100 % Load thrown off : G) Sustained Short circuit current :

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a) Excitation adjusted for rated KVA & PF

:

b) Voltage regulator operating : c) With standing time (seconds) for

(a) & (b) :

H) Current : a) Main field current for open circuit

voltage :

b) Main field for rated load : c) Main field voltage : d) Main field resistance at operating

temperature :

e) Shaft voltage : f) Shaft current : I) Generator losses at rated speed : a) Stator copper loss : b) Rotor copper loss : c) Iron loss : d) Windage & friction losses : e) Stray losses : J) Efficiency in percentage at rated

load :

a) At 25% : b) At 50% : c) At 75% : d) At 100% : K) Bearing : a) Type : b) Make : c) Number : L) Exciter details : a) Rated voltage : b) Rated current : c) Ceiling voltage : d) Current at ceiling voltage : e) Details of rectifier diode bridge. : f) Details of voltage regulator like

make, response, time etc. :

g) Permitted duration exciter current at ceiling voltage

:

iv. DG AMF control panel data required

Rating, make, type etc of all the components in DG control panel, battery charger

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batteries, and air circuit breaker etc. shall be furnished. M) Air circuit breaker

a) Type, make rating : b) Current release : c) Current releases : d) Breaking time : e) Making capacity : f) Short time rating (1 sec) : g) Breaking time : h) No. of auxiliary contacts :

N) Air Breaker contactors

a) Type, make, rating, duty class (reqd. AC3) b) Contact life (switch operations) c) Breaking capacity (Regd 6 time operational current) d) No. of auxiliary contacts: e) Whether incomer contactors are mechanically interlocked (preferred)

O) Switch fuse units

a) Type, make, rating (reqd, HP rated) : b) Interrupting capability amps (Reqd. 6

times upto 160 amps rating 3 times at 0.3 of above 160 amps)

:

c) Fuses (Reqd, HRC link type) : d) Contacts (Reqd. silver plated) : e) Pad locking facilities in off position : P) Busbars : a) Material : b) Dimension R.Y.B. Neutral, Earth : c) Whether PVC slewing provided d) Air clearance: phase to phase &

phase to earth (min. reqd, 25mm, 16mm)

:

e) Busbar supports: material & dimensions

:

f) Temperature rise (Min. 40 deg c rise above 45 deg C ambient)

:

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Q) Battery : a) Make : b) Type & AH rating : c) Discharge rate : d) Charging rate : e) Teakwood stand with porcelain

insulator provided :

R) Battery charger : a) Type : b) Make : c) Whether diode or S.C.R. : d) Whether D.C. Output voltage constant : e) Type of over voltage protection : f) Suitability for quick & trickle charging : S) Solid state Annunciator : a) Type : b) Make : c) Control voltage : d) No of windows : e) Spare windows : f) Features (Test, Accept, Rest required) : T) Power/Control/Instrument cables : a) Type : b) Voltage class : c) No. of course : d) IS : e) Current rating : f) Laying factors : g) Insulation details : h) Armour details : i) Technical catalogues :

52






9.0 TECHNICAL CHECK LIST (MECHANICAL / ENGINE) S. No. a)Description Supply / Erection / Testing /

Commissioning

1 Diesel Engine

a) Diesel Engine with lubrication system, governing system, charging system, fuel system, cooling system & starting system.

√

b) Flywheel with barring device. √

c) Flexible coupling for engine-alternator. √

d) Guards for moving parts √

e) Heavy duty suction air filter with suction piping. √

f) Inlet and exhaust manifolds. √

g) Exhaust silence with expansion bellows √

h). Common base plate for engine-alternator & auxiliaries.

√

7. Miscellaneous

a) Auxiliary piping √

b) Foundation Anchor bolts / AVM pads √

8. Spares √

a) Spares for 2 years normal operation as per manual

√

53






b) Erection and commissioning spares as recommended by the manufacturer (please include the list of commissioning spares in the proposal)

√

c) Special Tools and Tackles as recommended by the manufacturer. (Please include the list in the proposal).

√

d) Shop Inspection and testing as specified for all items.

√

e) Vendor data requirements as specified. √

f) Painting preparation of shipment and packing. √

g) ERECTION, TESTING, COMMISSIONING AND HANDING OVER.

√

TECHNICAL CHECK LIST (ELECTRICAL) S. NO. DESCRIPTTION SUPPLY / ERECTION /

TESTING / COMMISSIONING

1 EMERGENCY GENERATORS COMPLETE WITH STATOR, ROTOR, EXCITER, ACOUSTIC ENCLOSURE FRAME EARTHING CONNECTIONS AND LUBRICATION SYSTEMS

√

2 VENTILATION AIR INLET & OUTLET DUCTS

√

3 GENERATOR CONTROL PANEL, AMF PANEL, ACBS, RELAYS, METERING PROTECTION AND ANNUNCIATION SYSTEM..

√

4 CABLING BETWEEN THE PACKAGE EQUIPMENT AND BETWEEN PURCHASERS

√

54






PANELS AND DG SET

5 EARTHING WITHIN THE BATTERY LIMITS

√

6 BATTERY AND BATTERY CHARGERS FOR CONTROL POWER REQUIREMENT OF COMPLETE DG SETS.

√

7 SPARES FOR ERECTION AND COMMISSIONING AND TWO YEARS TROUBLE FREE OPERATION.

√

8 ERECTION, TESTING, COMMISSIONING AND HANDING OVER.

√

9 AMF/ control panel √ 10. Instruments and controls mounted in local control

panel. √

11. Two sets of batteries.

√

12. Battery charging equipment √ 13. Local instrument panel

√

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10.0 DEVIATIONS TO THE SPECIFICATION

S No.

Clause no.

Tender Specification

Deviation taken Reasons for deviations / remarks

Certified that, only the above-mentioned deviations have been taken against this tender. Name of the bidder Signature Seal of the Company.

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TENDER



MECON LIMITED

DRAWINGS

57





MATERIAL REQUISITION DOC. NO.:MEC/23KX/05/21/M/001/S006 D:\old data\Vijyant\Kandla-Samakhiali\Tender\DG Set\DRAWINGS SECTION XI.doc Page 2 of 5

TABLE OF CONTENT

Sl. No.

Description of Drawings Drawings No.

1 Main Single Line Diagram of Existing Electrical Panels Despatch of Kandla

MEC/23KX/05/E9/SLD/002, R-0 (Sheet 1 of 2)

2 AMF Panel for DG Set. MEC/SD/05/E9/006/001, R-0 3 AMF Panel for DG Set. MEC/23KX/E9/006/001, R-0

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59






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DG SET BUILDING LAYOUT DRAWING

61