technical specification for 500kva & 125kva diesel

M/s PRISTINE MEGA FOOD PARK PVT. LTD.

TECHNICAL SPECIFICATION FOR

500KVA & 125KVA DIESEL GENERATOR SETS


INDEX

SR.

NO.

CHAPTERS PAGES

FROM TO

1

TENDER COVER PAGE

1

1

2

INDEX

2

2

3

TECHNICAL SPECIFICATIONS

3

38

4

LIST OF APPROVED MAKES

39

40

5

QUALITY ASSURANCE PROGRAMME

41

45

6

DRAWINGS - -


TECHNICAL

SPECIFICATIONS


TECHNICAL SPECIFICATIONS FOR DIESEL GENERATING SET Scope:-

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

delivery to project site, supervision during pre-commissioning checks & commissioning of 1

No. 500 KVA A+1 No. 125 KVADiesel Generating Set along with Acoustic enclosure and

all other related accessories with DG synchronizing Panel.

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

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

generator set, CPCB compliant, complete with all required accessories and control equipment

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

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

commissioning/mandatory spares.

This standard shall be read in conjunction with job schedule.

The scope of supply shall include the following work: -

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

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

accessories and compounds.

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

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

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

etc.

(f) Jacket cooling system comprising of radiator, water circulation pump, necessary piping

and fittings etc.

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

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

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

(j) Speed regulation system.

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

accessories. Anti vibration mounting pad shall also be supplied.


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

and piping. Upto a Height and supporting structures to conform to pollution control norms.

(m) All necessary instruments for monitoring and safe starting, running and stopping of the

D.G. set their auxiliaries complete with tubing and cabling.

(n) All safety and protective devices.

(o) Cabling material between control & protection panel and all equipment within the battery

limit including cables, racks, earthing terminating materials etc.

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

sheet steel.

(q) All other items not specified here but, necessary for safe, satisfactory and uninterrupted

operation of D.G. set.

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

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

all respect.

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

Following services but not limited to, will form a part of Vendor‟s work and prices quoted

will be deemed to include:

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

spares as well as commissioning spares.

b) Packing and forwarding of above.

c) Transporting to site.

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

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

STANDARD SCOPE

ENGINE Direct injection, water cooled engine, 4 stroke, rated at 1500 RPM, conforming to

ISO 3046 / BS 5514 has the following specifications:

Digital Electronic Governor (*)

In-line fuel pump

Optimized turbocharger

Stainless steel exhaust flexible coupling

Silencer


Radiator

Coolant inhibitor

Plate-type lube oil cooler

Spin-on filters – coolant, fuel & lube oil

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

Flywheel housing and flywheel to suit single bearing alternator

Electrical starter motor

Battery charging alternator

First fill lube oil

Alternator: Brushless alternator

Self-excited, self regulated

Class „H insulation

Salient pole revolving field

Single bearing

Digital automatic voltage regulator (part of PCC 1301)

Standard to be followed.

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

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

unless otherwise specified in the specification sheet.

oBS 649 – Diesel engines for general purpose. (In absence of equivalent Indian Code)

oIS-10000 – Methods of test for internal combustion engine.

oASME codes(applicable to Diesel Generator) (In absence of equivalent Indian Code)

oIS 4722 – Rotating Electrical Machines.

oOil coolers as per TEMA class “C”

oBS : 2623 Alternator (In absence of equivalent Indian Code)

oIS: 1460 Diesel Fuels.

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


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

oIndian Electricity Act & Rules.

oAny other Standards/ Codes (BS & IS) applicable.

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

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

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

with the above.

DETAIL SCOPE

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

Commissioning of 1No.500 KVA+1 No. 125 KVAPrime rated Diesel Generator set, speed of

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

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

engine mounted radiator and suitable for AMF START along with all accessories and

components such asexhaust pipes, fuel system etc. complete erection and installation on

foundation prepared by another agency, connecting toall completed accessories and

components and integrating the performance of all sub-systems, providing assistance for the

electrical vendor for testing and commissioning and performance testing, electrical and

necessary civil work for DG foundation as per the details from the DG supplier as required

for the proper and efficient functioning of DG sets as specified in Specification / Bill of

Quantities.

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

commissioning of silencer Exhaust pipes with supports.

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

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

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

installation.

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

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

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

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

submission and obtaining approval and necessary certificate from Pollution Control Board

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

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

provided by DG manufacturer.

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

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


including arranging inspection and also necessary approval / safety certificate from

authorities etc.

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

drawings for generator and connected electrical installation work submission, obtaining

approval to drawings arranging inspection, obtaining supply certificate from Central

Electrical Inspectorate.

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

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

site.

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

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

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

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

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

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

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

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

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

tender.

Site and Building Space Restriction: The Contractor will provide the size & height of the

room along with the attached site plan and building drawings,space allocation shown for the

D.G sets as well as all accessories with drawing showing the placement of each DG set, cable

electrical panel & cable trench. The contractor shall ensure that all equipments are fitted

within the space earmarked.No other space will be made available.

Standards:- The Diesel Engine, alternator, accessories and AMF cum synchronizing panel shall

comply with the following Indian/British Standard Specification.

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

Diesel Generating Set:-

Voltage : 415 Volts

Phases : Three

Frequency : 50 Hz

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


The D.G. Sets shall be capable of generating a power output of rated KVA at 0.8 PF

on continuous operation under the simultaneous occurrence of the following conditions at

site.

a) Maximum ambient air temperature : 45 Deg. C

b) Relative Humidity at maximum :54%

Ambient temperature.

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

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

accordance with latest edition of BS-5514. (In absence of Indian equivalent code)

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

operation of similar Diesel Generating Sets with equal load distribution.

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

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

OPERATIONAL PHILOSOPHY

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

start automatically upon failure of the normal power supply and also stopped automatically in case

of restoration of EB supply after the mandatory checking of the supply parameters. The DG sets

shall also be able to start & stop manually through a push button.

As per condition mentioned in Operation Philosophy, following criteria to be fulfilled by 4 nos of sets accordingly 1D G Set -------------- 500 KVA (~400 kw) 1D G Set -------------- 125 KVA (~100 kw)

SEQUENCE OF OPERATIONS: -

Provide by vender

Following panel should be provided with DG sets:

DG Control panel with AMF, synchronizing and programmable features.

Battery charger panel

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

the set dependably comes to full speed and delivers rated output at 415 V, 50 Hz within 15 seconds

after getting the starting signal.

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

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


between 0.8 lag to unity). Further adjusting the set voltage up to ± 5% of rated voltage shall be

possible by the potentiometer provided for the purpose.

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

permitted step down load is suddenly applied shall be less than one second (assuming speed to be

constant). Further the speed drop due to such loading shall be corrected to ensure 50 Hz 1% Hz

within less than 3 seconds (momentary fluctuation in frequency shall be less than ± 1 Hz). Governing

system shall ensure minimum fluctuation during load changes. Inertia constant of the rotating system

shall aid the governing system. Class A11 governing system preferably using wood ward PSG

governor shall be offered. Speed drop shall be continuously adjustable.

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

Machine shall develop symmetrical balanced sine wave voltage. Irregularities in

Waveform shall not cause objectionable interference to other adjacent circuits. Total harmonic factor

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

DG location / Foundation / Anti Vibration pads

The subject 1 DG sets of (1no 500 KVA +1no 125 KVA) rating shall be installed on the foundation

to be made by PMFPPL and shall be open on all sides. Bidder shall recommend the minimum sizes

of the foundations and shall submit the detailed Anchorage Plan with load date along with their

proposal. Bidders shall specify and supply the number of anti vibrations pads required for each DG

set so as prevent the DG Vibrations, while running, to be transferred to the ground.

DESIGN CRITERIA

Engine Performance

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

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

2. Deration on account of site conditions (refer datasheet for ambient conditions) as per ISO 3046 - 1

Temperature (combustion inlet temperature):

Altitude (dl) :

Humidity (d2) :

CW temp (d3) :

Inlet losses (d4) :

Exhaust back press (d5) :

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


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

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

4. Power consumed by essential dependent

and independent auxiliaries: : kW

5. Mechanical transmission losses through coupling : kW

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

Consumed for essentials and transmission losses ( slnos 3- slnos(4+5)) through coupling from the site

rated power : kW

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

(alternator efficiency) * Power factor |

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

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

Performance requirements

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

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

a total of 12 consecutive hours of operation, without exceeding permissible temperature limits and

with a fairly visible exhaust.

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

vibrations and noise.

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

with no voltage dip and without affecting the frequency.

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

Diesel Engine :-

The Diesel Engine specification shall be as follows:-


TECHNICAL DATA:

Generator Set Specifications: 500 KVA Model To be filled by bidder

Prime Power Rating kVA To be filled by bidder

Output Voltage and Frequency To be filled by bidder

Power Factor To be filled by bidder

No. of phases To be filled by bidder

Engine Specifications :500KVA Make To be filled by bidder

Model To be filled by bidder

No. of cylinders To be filled by bidder

Aspiration To be filled by bidder

Bore x Stroke To be filled by Bidder

Displacement To be filled by bidder

Output – Prime To be filled by bidder

Fuel consumption @ 75% load with

Radiator & Fan

To be filled by bidder


Radiator & Fan


Typical lube oil consumption @ full

load


Total wet weight (engine + radiator) To be filled by bidder

Length x Width x Height (engine) To be filled by bidder

Compression Ratio To be filled by bidder

Piston speed To be filled by bidder

Governor / Class To be filled by bidder

Lubricating oil system capacity To be filled by bidder

Coolant capacity (engine & radiator) To be filled by bidder

Combustion air intake @ 100% load

(+/- 5%)


Fan air flow across radiator To be filled by bidder

Exhaust Temperature To be filled by bidder

Battery capacity / Rating To be filled by bidder

TECHNICAL DATA:

Generator Set Specifications: 125 KVA Model To be filled by bidder

Prime Power Rating kVA To be filled by bidder

Output Voltage and Frequency To be filled by bidder

Power Factor To be filled by bidder

No. of phases To be filled by bidder


Engine Specifications :125KVA Make To be filled by bidder

Model To be filled by bidder

No. of cylinders To be filled by bidder

Aspiration To be filled by bidder

Bore x Stroke To be filled by Bidder

Displacement To be filled by bidder

Output – Prime To be filled by bidder


Radiator & Fan



Radiator & Fan


Typical lube oil consumption @ full

load


Total wet weight (engine + radiator) To be filled by bidder

Length x Width x Height (engine) To be filled by bidder

Compression Ratio To be filled by bidder

Piston speed To be filled by bidder

Governor / Class To be filled by bidder

Lubricating oil system capacity To be filled by bidder

Coolant capacity (engine & radiator) To be filled by bidder

Combustion air intake @ 100% load

(+/- 5%)


Fan air flow across radiator To be filled by bidder

Exhaust Temperature To be filled by bidder

Battery capacity / Rating To be filled by bidder

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

MOEF/CPCB

The DG set shall be mounted inside an acoustically treated enclosure to ensure that the noise

level at a distance of 1mtr does not exceed 75 dB

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

Specifications shall be provided by the contractor.

Lubricating Oil System:-

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

the crank case/cylinder block. From the oil pan, the lubricating oil shall be led off to a separate

lube oil sump, if required.


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

engine driven lubricating oil pump through foot strainer (in the oil) and then through 2 x 100%

capacity filters or a duplex filter.

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

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

shall be driven off the crank shaft.

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

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

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

bypass arrangement shall be provided for bypassing the lubricating oil cooler during start up,

until the oil temperature reaches the minimum required value.

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

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

the engine when the engine is inoperative.

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

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

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

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

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

Manufacturer.

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

etc. shall be provided by the contractor.

Cooling System:-

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

Engine.

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

pump. The drive for this pump shall be taken from the engine crank shaft either by a gear train, belt

drive or a chain drive as per the manufacturer's standard practice.

Engine Starting System:-

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

Electric Starting System:-


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

requisite instruments.

The starter batteries shall be lead-acid type.

The ampere-hour capacity of the lead-acid battery shall be adequately sized for maximum six

consecutive repeat start impulses to be given to the diesel engine as well as to cater for D.C. loads on

engine control panel such as enunciators and lamps, protection relays, etc.

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

The battery charger shall be of the static type arranged to draw power either from the mains

supply (240 V, 1 Phase, 50 Hz.) or from the DG supply by means of a selector switch mounted on the

AMF Control Panel.

All the cables required to make the starting system complete shall be supplied, laid and

terminated by the Contractor.

The battery shall be supplied with necessary floor mounted stand made of teak wood and treated

with anti-corrosive paint.

Air intake system:-

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

requirements of each engine.

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

dry or wet type.

An intake air silencer at the air inlet to the air cleaner shall be provided by the Contractor to

reduce the noise level, if required.

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

The air from the air cleaners shall be charged into the cylinders by means of a centrifugal

compressor powered by an exhaust gas driven turbine. This turbocharger shall be provided with

cooling by the engine lube oil. The turbocharger shall be mounted on the engine. One or two

turbochargers, operating in parallel may be provided, depending upon the manufacturer's standard

practice.

Exhaust Gas System:-

The exhaust gas system shall be complete with all the accessories specified herein and shall ensure

safe disposal of the exhaust gases at a suitable point outside the room at a height specified approved

by the Pollution control Board.


The exhaust gases from the engine exhaust manifold shall be led to the exhaust gas turbocharger for

super charging air into the engine.

From the turbocharger the exhaust gases shall be led to residential type exhaust gas silencer and then

led to a point outside the D. G. set room, at suitable height as per statutory requirements.

Suitable flexible joints (metallic bellows) shall be provided on the exhaust piping to take care of

expansion due to high working temperatures. It shall also isolate the piping from the engine

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

The exhaust gas shall be led outside the Acoustic enclosure at to be left open to sky or where ever so

desired, as per Pollution Control Board's requirement. The outlet shall be provided with a protective

wire mesh net to prevent the entry of foreign particles into the exhaust piping. Necessary supports for

the exhaust gas piping shall be provided by the Contractor.

The entire exhaust gas piping, residential type silencers, expansion bellows, etc. shall be provided by

the Contractor together with necessary supports, joints, etc. Support base of structural steel which

may be required shall also be provided by the Contractoralongwithrespective foundation

requirements to be indicated in drawings. The entire exhaust gas piping inside the Acoustic enclosure

including the engine exhaust gas manifold

Engine Cooling System

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

Engine Lubrication System

Engine lubrication shall be as per Manufacturer’s standard. The DG Set shall be suitable for

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

if required by the engine manufacturer, a complete automatic pre-lubrication system (including

electric (AC) motor driven pre-lubrication pump(auxiliary LO pump) etc.) that lubricates the Engine

at regular intervals, complete with Timer logic etc. shall be included in Bidder's scope. The

frequency of starting of pre-lube pump shall be indicated by the bidder on the datasheets.

Engine Fuel System

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

The diesel tank shall be provided with level switches at

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

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

Engine Exhaust System

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

PMFPPL appointed electrical vendor for the installation of complete-Exhaust System including


complete exhaust piping,' residential type silencer, expansion bellow, fittings, insulation and stack

and supports etc. The exhaust from the DG set shall meet the prevailing pollution control board

requirements besides meeting' the minimum requirements for diesel engines.

Governing:-

The governor shall be of the Digital electronic type.

Alternator:-

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

Alternator specifications: 500KVA DG SET

Make

Stamford/Kirloskar/Crompton

Frame Size / Model No. Suitable to tender

Voltage Regulation +/-1.0%

Insulation Class H

Standard Enclosure IP 23

Winding Pitch 2/3 Pitch

Stator Winding Double layer Lap

Rotor Dynamically balanced

Wave form Distortion

No load < 1.5% non distorting balanced linear

load < 5%

Telephone Interference Factor Better than 50

Total Harmonic Factor Better than 2%

Alternator specifications: 125KVA DG SET

Make


Frame Size / Model No. Suitable to tender

Voltage Regulation +/-1.0%

Insulation Class H

Standard Enclosure IP 23

Winding Pitch 2/3 Pitch

Stator Winding Double layer Lap

Rotor Dynamically balanced

Wave form Distortion

No load < 1.5% non distorting balanced linear

load < 5%

Telephone Interference Factor Better than 50

Total Harmonic Factor Better than 2%


DG AMF CONTROL PANEL:-

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

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

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

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

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

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

and finished with Powder coated paint of shade steel gray. Cable entry to the AMF control

panel shall be from the bottom for auxiliary cables such as priming pumps, Control cables etc

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

main power connection from bottom.

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

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

receiving starting impulses for the D.G. set from Purchaser's remote PCC Panel as well

as to send out tripping impulses from AMF panel to the DG incomer breaker on purchaser's

PCC Panel.

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

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

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

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

AMF panel shall be from the bottom.

CONTROL WIRING:

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

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

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

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

maintenance.

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

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

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

easily accessible.

INTER CONNECTION & INTERNAL WIRING

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

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

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


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

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

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

shall be provided at both ends of the cable.

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

identification.

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

Terminal Blocks/ Terminations:

Terminal blocks shall be of 500 volts grade of finger touch proof type. Insulating barriers shall be provided between adjacent terminals. Cables upto 150 Sq.mm alum shall be provided with clip-on type (Slide lock design) of

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

phases and black for neutral.

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

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

pressure shall be as follows:

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

Above 35 Sq.mm. 2000 psi.

Bi - metallic lugs: 1000 psi.

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

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

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

Earth busbar‟s shall be of tinned copper/ alum. With holes, but the bolts and nuts and

washers shall be cadmium plated. Earth busbar‟s all be provided all around the cubicle at the

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

external earth connection arrangement.

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

Busbar‟s or vice-versa.

LABELS:

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

shall be properly secured with fasteners.


TESTS:

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

IS 8623 and shall comprise:

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

operational tests where necessary.

ii) Dielectric tests.

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

AMF LOGICS

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

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

(a) Mains supply failure.

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

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

shall close & the mains breaker/contactor shall open.

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

Be Allowed To Take Care Of Transient conditions.

ANNUNCIATOR

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

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

Indications like:

1. Alternator over load

2. Reverse Power

3. Earth Fault

4. High water temperature

5. Low lube oil pressure

6. Over speed

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

STORING:

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

provided for necessary protection against moisture.

ERECTION:

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

Necessary assistance for proper installation of the panel as follows shall be extended by the

DG vendor to the electrical vendor.


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

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

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

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

shall be properly aligned and bolted to the foundation by bottom plate or top plate as the case

may be, by using brass Siemens type compression glands. The individual cables shall then be

led through the panel to the required feeder compartments for necessary terminations. The

cables shall be clamped to the supporting arrangements. The switch board earth bus shall be

connected to the local earth grid.

PRE-COMMISSION TESTS:

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

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

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

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

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

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

e) Phase rotation tests shall be conducted.

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

correctness and accuracy of calibration and working order.

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

correctness and accuracy of calibration and working order.

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

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

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

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

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

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

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

introducing a current generator and ammeter in the circuit.

Instruments Of Engine:-

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

on engine)


Dial type thermometers for the following:

a) Lube oil outlet temperature from bearings.

b) Jacket water temperature at cylinder outlet.

Pressure gauges for the following:

a) At the lube oil header in the engine.

b) At the jacket water inlet to engine.

Hour meter-cum-RPM Indicator.

Method of Operation of Diesel Generating Set:-

Automatic Mode of Operation:

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

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

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

and/or frequency drops below a preset value (as set "MAINS" supply monitor relay in AMF

panel), for a preset period (as set on the 30 sec. to 5 min. timer on AMF panel), the DG set shall

be given a start impulse automatically.

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

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

AMF panel shall be given an automatic closing impulse after preset time (as set on the 0-60 sec.

timer on AMF panel). Now the DG set shall be ready for taking the load.

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

D.G. Set shall be carried out automatically.

Manual Mode of Operation:-

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

position. The Diesel Generator can then be manually started by pressing the engine "Start" push

button on the AMF panel. After the DG Set comes to rated speed and the alternator voltage and

frequency attain the rated value (as monitored by the DG supply monitor on AMF panel), it shall

permit manual closing of the alternator circuit breaker. The DG set shall be now ready to take the

load.

Test Mode of Operation:-

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

"TEST" position, control circuitry shall be so wired that it shall sense a condition of "No Mains


Supply"; (even when mains supply is healthy) and then follow a sequence of automatic starting of

DG set except without closing of the breaker.

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

ineffective.

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

start and reach its rated speed within 30 seconds, it shall be disconnected and locked out

immediately. Annunciation with alarm shall be provided on the DG control panel when engine fails

to start after three attempts to start.

ANNUNCIATORS:-

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

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

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

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

annunciator shall be of approved make only.

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

shall also provide one set of "acknowledge", "reset" and "lamp test" push buttons common to all

the annunciator.

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

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

Alarm Fault Audible Visual

Condition Contact Alarm Alarm

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

NORMAL OPEN OFF OFF

ABNORMAL CLOSE ON FLASHING

ACKNOWLEDGE CLOSE OR OPEN OFF STEADY ON

BACK TO NORMAL OPEN OFF STEADY ON

RESET OPEN OFF OFF

LAMP TEST OPEN OFF STEADY ON

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

The following conditions shall be annunciated:-

a) High water temperature and trip of the engine.

b) High lubricating oil temperature.

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

d) Engine over speed and trip.

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

f) Alternator Protection Relay trip..


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

Set.

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

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

engine battery. The engine battery and charger shall be suitably rated for this D.C. load. Suitable

nameplates shall be provided for each window. One set of additional potential free contacts for

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

Piping, Valves And Fittings:-

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

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

systems described above.

Performance Requirement:-

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

performance requirements:-

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

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

and stresses on equipment.

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

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

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

consideration.

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

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

temperature limits and with a fairly visible exhaust.

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

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

recommended by contractor.

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

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

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

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

undue vibrations and noise.


Shop Tests:-

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

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

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

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

inspection of fabrication and components.

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

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

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

test and HV test.

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

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

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

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

submitted by the contractor.

Site Tests:-

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

a) Governor response.

b) Voltage regulations and AVR Response.

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

load transfer to D.G Bus.

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

arranged by DG set Supplier free of cost to the Owner. The necessary Load Bank

require to load the set with 10% Over loading for one hour is to be arranged by the

Contractor at site without any extra cost.

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

following tests at site in the presence of the client’s representative before energization.

Checking the alignment by engine manufacturer’s representative and obtaining approval.

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

Checking the engine safeties for satisfactory operation.

Checking vibration levels.


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

is carried out properly.

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

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

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

be measured.

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

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

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

associated equipment.

Guarantee:-

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

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

Panel and rest of the equipment supplied as part of the DG set shall be guaranteed for a period of

one year from the date of commissioning. If during this period any defects are found in the

machinery caused by faulty design or faulty materials, or workmanship, the same shall be

replaced/rectified free of cost by the contractor.

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

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

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

arranged and as a free issue to Owner.

a) Net electrical output at generator terminals.

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

c) Lubricating oil consumption at full load.

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

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

specified frequency variation.

f) Freedom from vibration and noise.

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

h) Voltage regulator response.

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

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

shall be applicable.

Drawing and Data:-

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

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


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

for reference and records as "Final Drawings".

General arrangement drawing showing overall dimensions, equipment arrangement and

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

dynamic load.

Recommended general arrangement drawing for Acoustic enclosure with all it

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

etc.

Equipment foundation drawing for DG set and accessories.

Piping drawing including support details.

General arrangement drawing of the DG Synchronizing Panel showing the various

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

Wiring diagram of the AMF panel.

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

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

furnished.

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

wised rate and quantities.

Standard Normal Maintenance Tool Kit:-

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

Engine Generator package shall be included in the Bidder's proposal. Bidder to submit a

separate list for the Package.

Set of recommended spare parts.

Common structural steel base frame for engine and alternator suitable for installation on a

permanent foundation with foundation bolts.

Testing and Commissioning:- The Vendor shall carryout testing and commissioning of the DG set. All the tests as listed

above. Necessary testing instruments, leads, etc. shall be provided by the Contractor.

All consumables required for 8 hours continuous load testing commissioning of the DG Sets

at site such as lube oil, lubricating grease, fuel oil, first fill of high speed diesel and other

consumables shall be arranged by the Contractor without any extra cost to owners.

Civil Works:- All civil works such as building, foundations for DG set, cable trenches, pipe trenches shall

be provided by the purchaser. However, contractor shall furnish necessaryfoundation details,

weights of equipment, etc. equipment layout and inserts to be provided to the Purchaser.

Also, grouting of all foundation bolts/frames shall be carried out by the Contractor.

Training and Operator:-


Contractor shall arrange to provide at their works necessary training of purchaser's operators

and mechanics on proper operations and maintenance of the DG set, without any extra cost.

The duration of the training shall be as mutually agreed upon.

Technical Particulars:-

The technical particulars of the DG sets offered shall be furnished in the format indicated in

the enclosed Annexure-

The Contractor has to note that in case the DG set cluster does not get cleared by Statutory

Authorities due to any of the technical issues (other than the installation work) it shall the

complete responsibility to satisfy these authorities and to provide whatever necessary to get

the relevant sanction. If any additional material or any other changes are desired the same

required to be brought out at the tender stage. If the same is not brought out, then it will be

deemed that the vendor has already accounted for these statutory changes.

DATASHEET OF DG SET

ENGINE

Sr. No. Description Requirements

Vendors

Confirmation

1. Make and model no.

Cummins/MTU/Caterpillar/

PerkinsNolvo/Kirloskar/KOEL

2. Rating 1Nos. 5000 KVA/1NO 125KVA

1500 rpm

3. Operating method.

Four stroke/Direct injection

4. Standards BS:5514/ISO 3046

5. Starting Electrical

6. Engine Cooling

a. 1.Radiator cooled

b. 2.Engine mounted

Water P/p

c. 3.Thermostat

d. 4.Corrosion Inhibitor

e. 5.Self contained

piping

7. Fuel System

f. PT Fuel Pump

g. Injectors

h. Fuel Filters

i. Self contained piping 8.

Lubricating System

a. Oil Pump


b. Strainer c. Lube oil Cooler d. Oil Filter

e. Bypass Filter

f. Self contained piping g. Outboard h. Paper element filter i. First fill of oil and

coolant

9. Air Intake System

Dry Type replaceable Filter

with restriction indicator

Air Intake Manifold with

necessary connections

Turbo Charged after cooled

10. Exhaust System

a. Exhaust Manifold

b. Flexible piping of

stainless steel c. Residential Silencer

with catalytic converter

11. Governor Electronic type

12

Starting System

a. Starter 24V DC

b. Battery Charging by

Alternator

c. With in-built

Regulator d. Integrated fuel ramping

to limit smoke and

frequency overshoot

13. Instrument System

Lube oil pressure

High water Temp. Starting Key

14.

Safety System

a. Digital display of LO

Pressure.

b. Digital display of

Water

Temperature

15.

Other Accessories

Flywheel

Flywheel Housing

Fuel tank


AVM Pads


ALTERNATOR

1 Make


2 Output 500 KVA/125kva

3 Power Factor 0.8

4 Rated Generating

415 V with voltage regulation

+/- Voltage 0.5 %

5 Frequency 50 Hz

6 Speed 1500 RPM

7 Class of Insulation H

8 Winding Connection Star Connection

9 Overload Capacity

10% for one hour in any 12 hours of

operation without exceeding

temperature rise limits specified i n BS:2613

or BS:5000/IS 4722 when corrected to

ambient temperature at site.

10 Bearings Long life Double Bearing

11 Enclosure Drip Proof & Screen Protected I P23

12 Parallel Operation Required with provision of auto

synchronizing and auto load sharing

13 Excitation

Self excited, self regulated, self

ventilated brushless design

provided with suitable automatic

regulator for rated output at NIP

conditions

Meters

Digital All critical Engine and

Alternator status to be displayed.

14 Batteries

2No's of 12 Volts (500 KVA) with

warning and monitoring system

15 Display Digital Alarm and status


SPECIFICATION FOR ACOUSTIC ENCLOSURE FOR

1X500 KVA+1NO 125KVADIESEL GENERATING SET

Scope:-

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

to project site, site testing, supervision and commissioning of 1 No., Acoustic Enclosure for housing

1 no. 500 KVA/ 400 KW+1 no. 125 KVA/ 100 KWDiesel Generating Set along with Acoustic

Enclosure and all other related accessories and AMF Panel.

Standards:-

The Acoustic enclosure shall comply and meet the requirements of Diesel Engine, alternator,

accessories and AMF panel shall comply with the Pollution control Norms both from Noise and Flue

Gas pollutant requirements.

Technical Specifications:

The acoustic enclosure to house Diesel Generating Set of 1NO500 KVA + 1 NO 125KVA

continuous output suitable to develop 415 volts and 50 Hz. A.C supply at 1500 R.P.M Radiator

Cooled and of Cummins or approved make.

The vendor to guarantee noise level of the treated enclosure as 75 DB at 1 meter or 65 DB at 3

meter distance.

The Enclosure shall have two heavy duty steel hinged door with acoustic air inlet and outlet. The

size of the inlet and out let shall be adequate enough to suit the engine performance.

The acoustic treatment to the Enclosure shall be done using glass/mineral wool of density at level

64 is to be provided on the walls and ceiling of the diesel generating Enclosure.

All the acoustic panels will be mounted on a suitable sized frame works fabricated using

minimum 75 x 75 x 6 mm angles which will be fixed to the walls with necessary anchor bolts/

hardware.

The thickness of the insulation required should be adequate to meet the sound level of 75 DB at 1

meter or 65 DB at 3.0 meter distance but should not be less than 50 mm thickness.

The vendor shall also provide acoustic louvers/dampers at the air inlet and exit from the D.G

Enclosure and radiators to ensure that sound level is within 65-75 DB at a distance of 3.0 meter on all

sides of the D.G Enclosure.

The Vendor to complete the acoustic calculations as required to be carried out by the vendor and

If it is established that blowers/axial flow fans of adequate capacity are required to be put then the

same shall be provided by the vendor at no extra cost to the owners.

The vendor has to further ensure that the inside temperature of the Enclosure does not rise by

more than the permitted level by the engine and alternator manufacture.


The Acoustic panels shall be fabricated in such a manner that it should be possible to remove any

of the Generating set component including engine and the alternator from the acoustic Enclosure by

dismantling the relevant acoustic panels without disturbing the other set.

All the panels should under go seven tank painting process and all the panels shall be powder

coated of approved color by the Architects. The acoustic Enclosure shall be totally weather, vermin

and dust proof to enable the generator to operate on ambient temperature of 40 C.

The doors shall be preferably of 2.4 Meter height and 1.2 Met width or any other suitable

dimensions as approved by consultants.

The doors shall have automatic lock, pad looking, at the top to prevent rain water entry etc.

The interior (sides and top) of the shell shall have stiffeners at regular interval made out of 20

SWG M.S. sheet steel of folded type and welded rigidly with the outer shell. Blanket form glass wool

(crown 150 x 100) to be laid in the interval surface and covered with 22 SWG aluminum perforated

sheet. The aluminum perforated sheet shall be screwed to the stiffeners. The stiffeners shall be placed

closely to each other to avoid buckling of perforated sheet.

Tube light fixtures of approved make shall be provided inside the acoustic Enclosure as per the

layout prepared by the consultants and these fittings shall be wired up using 2.5 sq. mm

approved make wires in GI Conduit of minimum 16 Gauge and all these fixtures shall be operated by

MCB DB of approved make which shall be provided by the vendor.

The acoustic Enclosure shall have dust tight opening to take out the residential type silencer with

proper support and brought out of the enclosure on the top. The Exhaust gas shall be let out in the

atmosphere in the manner specified by the CPCB Norms.

The total acoustic Enclosure panels shall be made up of min 16 SWG MS sheets and properly

treated with seven tank process using pickling, passivation, rinsing, de-rusting etc processes and

finally coated with Zinc coated primer and finished with approved shade of enamel paint.

The acoustic Enclosure shall also have to mount exhaust fans of appropriate sizes. The size and

the quantity of the exhaust fans for removing the heat from the acoustic Enclosure shall be decided

by the vendor.

The rate shall also include supply of Exhaust fans or axial fans if required all complete as

required.

The rate shall include testing, supervision and commissioning 1 No. 500 KVA set inside the

acoustic Enclosure all complete as required and as per final direction and approval of Consultant.

Any other requirement as per Engine/Alternator manufacturer’s requirements and / or meeting the

standards as laid down by Central pollution Board with latest amendments to suit the site conditions

etc. to be complied with.


The ventilation fan shall be of the axial flow type designed to handle the static pressure estimated

based on the inlet air duct size and length.

The relevant tests should be carried out for Acoustic Enclosure.

1 ACCOUSTIC ENCLOSURE

1.1 Dimensions

1.2

Sound level at 1 mtr. from the

enclosure

Drawing by vendor

For bidding

The bidder shall submit offer with the following documents in two sets.

- Schedule of deviations from technical specifications.

- List of proposed makes, for the items listed in the tender.

- Technical datasheets & Catalogues major items, highlighting the offered models.

- Other documents and comments, if any.

For approval before construction/erection

The Vendor shall submit the following documents.

- For all the supplies, the contractor shall submit the following documents in 4 sets for approval.

- General arrangement drawings, with all dimensions, showing: space-requirements, weights (for

transport and service conditions), requirements of civil works (compatible with the tendered

specifications), fixing and mounting facilities, connection devices, etc.

-Electrical drawings, showing: power single line and functional/control multi line diagrams, terminal

blocks, components‟ list with make, type, quantity, etc.

- Quality assurance plan and bar-chart showing manufacturing schedule.

The vendor shall incorporate all comments and submit revised drawings in stipulated time till all

drawings are finally approved for manufacturing.

Final

- The vendor shall submit the following documents, reflecting the true final as built situation, in 6

sets, and one soft copy in CD.


- The drawings including wiring diagrams as revised and “as built”.

- Inspection and preliminary testing certificates and reports and shipping release.

- Test certificates of kWh meters from Government approved Lab or Electric Supply Co. of

concerned area.

- Guarantee certificates.

- Operation, Instruction & maintenance manuals, Catalogues etc.

- Any other certificate / report as called for by the Engineer.

THIRD PARTY INSPECTION

SCOPE

The third party inspection shall be conducted for the following major components

The Diesel Engine shall be Load tested and fuel consumption tested at the engine manufacturer’s

works. Refer standard specification clause no: 4.1.3 of standard specification for diesel Engines.

The Alternator shall be subjected to all tests at Alternator manufacturer’s shop as defined in the data

sheet and technical specification.

The control panels shall be tested at Panel manufacturer’s works.

The QAP & ITP shall be submitted by the vendor for approval of PMFPPL before carrying out TPI

The approved agencies for inspection are as follows.

Lloyds EIL

Rites

DNV

Bureau Veritas

SGS The item rate quoted for the DGSETS shall include the charges for carrying out third party

inspection.

The power required to carryout requisite inspection, coordination with third party agency etc,,

necessary charges for third party agency shall have to be borne by the vendor. QAP shall have to be


submitted by the vendor well in advance for PMFPPL approval. Inspection shall be carried out only

after the QAP is approved.

Brief Description Of The Scope

The following scope lays down minimum requirements but not limited to the same and shall be read

in conjunction with Data sheets/Technical specification and all other requirements as laid out in the

tender documents. The vendor shall arrange to carryout all other tests not spelt out in the below scope

but necessary for successful performance of the DG set’s.

Scope Of Inspection:

Routine tests as per IS: 1600 & 1601, BS 5514 & IS 4722 shall be carried out by vendor on bare

engine and alternator in presence of Third Party inspection Agency (TPIA).

Third party Inspection agency shall give a certificate to the effect that entire DG set along with

accessories conform to the specifications given in the purchase order.

Following test shall be carried out on Diesel Engine & Alternative & certificate to be

submitted to Third Party for review and endorsement.

Routine test for Engine as per BS - 5514 / IS- 1600 and 1601, like fuel consumption test etc. Maximum duration of test is 8 hours. Routine test for alternator as per IS: 4722 or other applicable I.S. Like insulation resistance test, high

voltage test, etc.

The relevant visual Inspection for Acoustic Enclosure to be done as follows:

a) The acoustic enclosure shall be designed for easy access to serviceable parts.

b) Modular construction for easy assembling and dismantling.

c) Fabricated out of CRCA sheet steel of 14 gauge. Base Frame shall be made out of ISMC of

suitable sections or made out of sheet steel of 5mm minimum thickness. Base frame & main body

sheet steel thickness as per CPCB approved design shall also be acceptable. CPCB approved drawing

in this regards is to be submitted to the owner during the drawing approval stage.

d) The hardware shall be of high tensile grade i.e. bolts of 10.9/8.8 grade. Hardware shall be

passivated.

e) Sound proofing of enclosure shall be done with quality rock wool/mineral wool, conforming to IS-

8183, of suitable density.

f) The rock wool /Glass wool shall further be covered with fibre glass cloth/fibre tissue paper fire

resistive and perforated powder coated sheet of 0.6 mm thickness.

g) Residential silencer is to be provided with the DG to control the exhaust noise.

h) Interconnection between silencer and engine shall be through stainless steel flexible hose/pipe.

i) Attenuators shall be provided to control sound at air entry & exit in the enclosure.


j) Battery shall be accommodated in a separate tray in the Enclosure.

k) The doors shall be gasketed with high quality EPDN gaskets to avoid leakage of sound.

l) The door handles shall be lockable type.

m) The sheet metal components shall be hot dip seven tanks pre-treated.

n) The enclosure shall be P.P. based powder coated (inside as well as outside) in colour RAL

7032/7035.

o) Base frame shall be epoxy coated when fabricated.

p) Emergency Stop Push Button shall be provided outside the enclosure

q) The Enclosure shall have on its body a 63A TPN five pin metal clad socket & plug for termination

of three phase supply at a single point, for the AC load of lube priming pump, battery chargers for

Control panel & DG starting battery banks, internal illumination of the Enclosure, etc. The power

supply inside the Enclosure shall be distributed by providing a Distribution board & interconnecting

cables by the Vendor

r) The maximum noise level shall not exceed 75 db (A) at 1 mtr from the enclosure surface

s) There shall be provision for drain plugs for draining lube oil / diesel.

Vendor shall perform the following tests on DG set at work shop and Third party inspection agency

will witness the tests.

1. Starting

2. Governor operation

3. Voltage Regulator response

4. Loan Run

5. No load - 5 min.

25% load - 15 min.

50 % load - 30 min.

75 % load - 30 min

100% load - 60 min

110% load - 60 min.

TESTING & INSPECTION AMF PANEL:

The panel boards shall be factory tested/inspected before finishing and dispatch.

The following tests shall be carried out:


INSULATION RESISTANCE TEST

Panel boards shall be meggered phase to phase and phase to neutral, using a 1000 V meggar with all

switchgear in closed position. The meggered value should not be less than 2.5 mega ohms between

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

HIGH VOLTAGE TEST

The test shall be carried out by applying 2.5 KV for one minute between Air, three phase & earth.

Between phase and the board shall withstand the same.

Panel boards shall be meggered phase to phase end.

Test reports shall be submitted to Third party inspection agency for endorsement.


LIST OF APPROVED BRANDS/MAKES OF EQUIPMENTS

REQUIRED UNDER THIS TENDER

The following are the list of approved brands/makes of equipments required under this tender. Please

note that wherever there is a multiple choice of brands/makes approved, any one make as nominated

by the Owners/Consultants will have to be supplied by the Vendor without any extra cost to the

owners. No deviation in this will be accepted by the owners.

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

Sr. Approved Makes/Brands being

No. Description Makes offered by the

Contractor ----------------------------------------------------------------------------------------------------------------

1. Low Tension, 415 Volts AC SCHNEIDER-MASTERPACT.

Air Circuit Breaker, 3/4 SIEMENS-3WL

Pole 50 Hz. 50 KA-STR. ABB-E-MAX-SACE,

L & T-U-POWER-SR71

2. Low Tension, Molded SCHNIDER-COMPACT

Case Circuit Breaker, SIEMENS-SENTRON-3VL

415 Volts AC, 3 Phase ABB-T-MAX-SACE

50 Hz., 50 KA/35 KA-STR. L & T – D SINE

Ics=Icu& Microprocessor

3. LED Type Indicating Lamps SCHNIDER/L & T/

with Color LED. SIEMENS

4. Selector Switches for SCHNIDER/L & T

Ammeter/Voltmeter. SIEMENS

5. Meters, Analog type. IMP/

for Ammeters, Voltmeters, RISHABH

PF meters, Frequency Meters.

6. Energy Meters. SECURE/

L & T/CONZERV

7. Relays. SCHNIDER

ABB/SIEMENS

8. FRLS Panel wires, in LAPP/

color in 660/1100 Volts R.R. KABEL

grade. (Unilay Construction) POLYCAB

9. Lugs, Crimping type, JENSON

tinned copper heavy LAPP

duty only.


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

Sr. Approved Makes/Brands being

No. Description Makes offered by the

Contractor --------------------------------------------------------------------------------------------------------------------

10. Push Button Stations SCHNIDER/

type, in different L & T /SIEMENS/

colour codes.

11. Terminal Blocks, WAGO/

Clip on type. LAPP

12. MS fabricated Panels APPROVED BY

CONSULTANTS.

13. Starters/Contactor/ TELEMECANIQUE / L & T

Timers. SIEMENS / ABB

14. Miniature Circuit Breaker SCHNIDER/

of 10 KA Breaking Capacity LEGRAND

and Boards. L & T/ABB

15. CTs - 660 Volts grade RECO/KAPPA

ABS CASINGS INDCOIL

16. Load Managers. CONZERV / L & T / ENERCON

17. HRC Control fuses with ABB/BUSSMAN

bakelite/typeMoulded SIEMENS/L & T

fuse holders.

18. Push Button Stations TECHNIK/MOELLER/

type, in different SIEMENS/

colour codes. VAISHNAV

19. Terminal Blocks, ELMEX/WAGO

Clipon type. CONNECTWELL

20. DG SET- ENGINE CUMMINS/VOLVO/KOEL

CATERPILLAR/PERKINS/MTU

21. ALTERNATOR STAMFORD/ CROMPTON/

KIRLOSKAR

22. BATTERIES EXIDE / CUMMINS

23. PLC SYNCHRONIZING PANEL SPE ELECTROTECH PVT. LTD/

SUDHIR/STERLING AND WILSON

24. PLC ROCKWELL AUTOMATION / L&T /SIEMENS

24. Any other Item. SAMPLE FOR APPROVAL

OF THE CONSULTANTS


QUALITY

ASSURANCE PLAN


1.1] QA PLAN

1.2] ITP

1.3] DRAWING SCHEDULE

1.4] PROGRESS REPORT AND SCHEDULE

1.5] WAIVER AND DEVIATION

1.6] PROCUREMENT OF BOUGHT OUT MATERIALS

1.7] CALIBRATION RECORDS

1.8] INSPECTION TEST STATUS

1.9] QUALITY RECORDS

1.10] IDENTIFICATION AND TRACEABILITY

1.11] VENDOR DOCUMENT FOR REVIEW AND RECORDS

1.12] DOCUMENTS UNDER REVIEW CATEGORY.

1.13] FINAL DOCUMENTS


QUALITY ASSURANCE PLAN AND INSPECTION & TESTING PLAN REQUIREMENTS

1.1] QA PLAN

Vendor during bidding stage shall submit his quality assurance plans (QAP) consisting of relevant

procedures covering various activities like design and engineering, material procurement ,

manufacture inspection and testing, documentation, dispatch to site , erection and commissioning

wherever applicable and maintenance of quality records in the post order stage. The vendor shall

submit the QAP to the site engineer for approval within 2 weeks from the date of receipt of LOI/ PO

whichever is earlier. The QAP shall be approved by the authorized representative of tpi agency and

then to PMFPPL after the approval of TPI agency.

1.2] ITP

Vendor shall submit inspection and test plan for approval within 2 weeks of loi/po and before

commencement of manufacture to the site engineer as well as to the third party inspection agency

(tpia) that the vendor wishes to appoint for carrying out inspection and testing. This document should

clearly specify the name, designation of the person concerned (with telephone/mobile no and email)

and communication address of the tpi.

1.3] DRAWING SCHEDULE

Vendor shall submit a total index of drawings and documents required for approval/review/records

along with the scheduled date of submission of each drawing/document within 2 weeks from date of

issue of LOI/ PO whichever is earlier.

1.4] Progress report and schedule

Vendor shall submit monthly progress report and update procurement engineering and manufacturing

schedule every month starting from 2 weeks from date of issue of foi/po whichever is earlier.

1.5] Waiver and deviation

Vendor shall strictly comply with the PO stipulations and no deviations shall be permitted. 1.6] Procurement of bought out materials

All critical materials such as casting, forging, fitting, pressure holding parts electrical and instrument

accessories etc. Shall be purchased by the vendor from sub- vendors having BVQI, IRS, LLOYD‟s,

CEIL or DNV approval. Vendor shall submit a list of bought out materials for PMFPPL approval

within 2 weeks from the date of issue of FOI/PO whichever is earlier.

1.7] Calibration records

Vendor shall use only calibrated measuring and test instruments and maintain calibration records.

Vendor shall furnish records of calibration of measuring and test instruments including recalibration

records to third party inspection agency on demand.


1.8] Inspection test status Inspection and test status of products shall be identified by using markings. Authorized stamps, tags,

route cards, inspection cards etc. During the course of manufacture to clearly indicate acceptance/

rejection of tests/stages of inspection performed during its manufacturing cycle. The identification of

test status shall be maintained and records submitted as and when demanded by PMFPPL/TPI

Agency.

1.9] Quality Records

Vendor shall maintain quality records as per his procedures. Inspection reports & test records copies

shall be furnished to PMFPPL/ TPI Agency.

1.10] Identification And Traceability

Vendor shall establish and maintain a standard written procedure for identifying the products from

applicable drawing specifications or other documents during all stages of production delivery. A

copy of this standard procedure shall be made available to PMFPPL/TPI Agency. The vendor shall

ensure that each product which is going in the process of fabrication / manufacture / construction /

erection has proper identification throughout the process including the final output.

1.11] Vendor Document For Review And Records

General

1] All documents shall be in English language and SI system of units. 2] Review of the vendor drawing by third party inspection agency / PMFPPL would be only to

review the compatibility with basic design and concepts and in no way absolve the vendor of his

responsibility to comply with PO requirements, applicable codes, specifications and statutory

rules/regulations.

3] Submission of documents for review/records shall commence within 2 weeks from the date of

issue of FOI/PO.

4] The vendor shall submit all drawings and documents in three copies as stipulated in the vendor

data requirement along with documents index. The documents shall also be submitted in soft copies

to expedite the process of approval/review.

Vendor shall ensure that each drawing shall contain the following information:

Po no name of equipment, tag no., name of project, client, drawing/ document title, drawing no.,

revision and date.

The drawing document shall be checked approved and duly signed stamped by the vendor revisions

and date.

1.12] Documents under review category.


Following review codes shall be used for review of vendor documents / drawings.

AFI :Approved for inspection

AFM : Approved for manufacturing / fabrication as per comments

Vendor shall resubmit the same after incorporating the comments before carrying out final inspection

by TPI Agency and dispatch.

Not approved: Resubmission required in cases of major non- conformities with respect to PO

specifications.

1.13 Final documents

Final drawings/documents consisting of technical data manual as a compilation of as-built certified

drawing and manufacturing data and test records duly certified by PMFPPL/ TPI Agency should be

submitted in three sets along with soft copy of the same.

Maintenance instructions of the material/equipment’s (wherever applicable) shall also be submitted in three sets and in soft format.