ANNEXURE TO TENDER NO. - · PDF file1.2 Project data and conditions 7 ... engine driven fuel oil feed pump, ... Shop inspection and test as specified. 31

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ANNEXURE TO TENDER NO.

DPS/MRPU/IGCAR/CAP/9027/PT-2161

Tender Specifications for

1000 KVA Standby Emergency Diesel Generator Set

SECTIONS

SECTION - 1: Technical Specification for Diesel Generators

SECTION - 2: Format for Submission of Technical Particulars

SECTION - 3: Price Schedule

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Section- 1

Technical Specification for Diesel Generators

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Section-1 Technical specifications

Contents

Sl No Description Page No 1.1 Scope 4 1.2 Project data and conditions 7 1.3 List of applicable documents 8 1.4 General Requirements 10 1.5 Design and Manufacturing / Construction requirements 11 1.6 Special Requirements 41 1.7 Inspection and Testing 46 1.8 General Information and Instruction to TENDERERs 53 1.9 Scope of Supply, Work and Service 54

1.10 Documentation 63 1.11 Spares 66 1.12 Special tools 68 1.13 Erection 68 1.14 Guarantee 87 1.15 Packing and shipping 89 1.16 Training 92 1.17 Datasheet 94 1.18 Preferred Make of components 111 1.19 DG load Sequence 113 1.20 Quality assurance plan 114

PreBid Meeting:

A prebid meeting has been arranged in Madras Regional Purchase Unit, Department of Atomic Energy, VI Floor, Shastri Bhavan, No.4 Haddows Road, Chennai 600006 on 6.4.2017 at 11:00 a.m. Bidders intended to participate in this tender are requested to attend the meeting. For attending the prebid meeting prior permission or gate pass is NOT required. However, bidders attending the meeting are requested to send an email to [email protected], [email protected] & [email protected] for information.

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Technical Specifications for Diesel Generators

1.1 Scope This specification covers the design, engineering, manufacture, assembly, inspections, seismic qualification and testing at TENDERER’s works, packaging, supply transportation from place of manufacture to site and unloading at site, storage, handling and transportation of equipment from storage to erection site, complete erection, site testing after erection, commissioning, performance testing of two (2) numbers of standby seismically qualified emergency Diesel Generator (DG) units with air cooled radiators, each of 1000KVA (800kW at 0.8 p.f lagging), 415 V, 3 phase, 3 wire, 50Hz along with all auxiliaries and accessories specified. It is not the intent to specify completely herein, all details of design and construction of components and their material. However, the components and their material selected shall be suitable for intensive power plant service with high efficiency and necessitates minimum surveillance and maintenance. Materials and components not specifically stated in this specification and which are necessary for meeting the requirements of this specification, shall be included in the scope of supply. Whether called for specifically or not, all accessories required for operation of DG are deemed to be considered as part of the TENDERER’s scope of supply

1.1.1 Scope of supply / Works Two(2) numbers of seismically qualified standby emergency Diesel Generator (DG) units with air cooled radiator , each of 1000KVA (800KW at 0.8 p.f) , 415 V, 3 phase, 3 wire 50Hz along with all auxiliaries and accessories necessary for easy , reliable, proper and safe operation and maintenance of DG Units. The unit shall contain the DG set, associated protection circuits, MCC panel, generator control panel and local control panel etc., for the DG. The DG unit to be supplied under this contract shall include but not limited to the following to make the system complete: 1. Fuel oil system complete with fuel oil day tank, engine driven fuel oil feed pump,

isolating valve on the fuel supply line to the day tank ,necessary piping & fittings, duplex strainers, valves, filters, instruments and control required between day tank and engine.

2. Lubricating oil system complete with lube oil sump, engine driven lube oil pump, AC motor driven standby lube oil pump, standby AC motor driven pre-lube oil pump ( if the pre lube oil pump to be operated continuously), lube oil cooler, electrical lube oil preheater if envisaged, necessary piping, fittings, valves, filters, strainers , instruments and control hardware as required.

3. DG shall be provided with air starting system arrangement having a starting air motor / direct air injection to cylinders ( air over the piston)with two AC motor driven air compressors, air driers with regenerative units, after coolers, two air receivers, necessary piping, fittings, valves, filters, instruments and control hardware as required.

4. Air intake system complete with filter, silencer (if required), pipes, fittings, supports and other necessary accessories as required.

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5. Engine exhaust gas system complete with turbocharger, exhaust manifold, silencer, exhaust piping up to discharge, insulation, expansion bellows, necessary pipes supports, adopters etc. as required

6. Design, fabrication and erection of Exhaust stack / Chimney for each DG set with steel supporting structures as per CPCB norms

7. Charge air system complete with turbocharger, charge air cooler, filter, silencer etc. as required.

8. Governing system complete with instrumentation and controls as required for safe and proper operation of DG set and as specified.

9. Complete instrumentation and control system for DG set as required and as specified. 10. Directly coupled alternator with, brushless exciter, automatic voltage regulator, CTs,

alarm initiating devices, indicating instruments and other accessories as required. Terminal arrangement shall be suitable for external cable connections.

11. Relay based control system shall be adopted. Control panels shall be hard wired with controls, relays, instruments, annunciators and other accessories in completely wired and ready to install conditions. Control cabling from instrument terminal block (TB) to DG set junction box (JB) and between DG junction box to LCP is included in the scope of TENDERER. The cabling (including cable trays) from field to control panel shall be in the scope of vendor. Field routing of the control cable shall be done through GI conduit pipes.

12. All electrical equipment shall be provided with required number of cable glands, lugs and other accessories for connection of cables.

13. The supply shall also include a standalone MCC panels to supply to the auxiliaries of the DG set.

14. Neutral grounding resistor and cubicle housing ground resistor 15. Cables between generator neutral to neutral grounding resistor with suitable gland

sealing 16. Power cable from DG MCC to all DG auxiliaries shall be of aluminum / copper

conductor, XLPE insulated and FRLS PVC sheathed. Supply of these material, installation and commissioning shall be included in scope of supplier.

17. Power cable from generator to switchgear and switchgear to plant MCC panels comes under the scope of the PURCHASER.

18. Design of civil foundation for the DG set, chimney, Radiator and other auxiliaries supplied with DG set.

19. Base frame with foundation bolts, wedges, leveling plates, etc. 20. Coupling between engine and generator with guard. 21. Piping, fittings and valves, SS braided metallic flexible joints etc., to connect the engine

to all auxiliary equipment / systems. 22. Required steel channel sections, properly drilled for mounting various equipment along

with necessary mounting hardware. 23. Platforms, walkways, stairs and handrails to provide adequate access and workplace

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24. Chimney for releasing the exhaust gas from each DG set at 30 meters from ground level / meeting the CPCB norms

25. Thermal insulation as required for complete scope of work included in the contract. 26. A stand-alone data logger (PLC based with HMI/Paperless Recorder type) to record and

monitor all critical parameters (including the digital inputs for the master trip relay, DG operating time , engine trouble alarm and trips ) for diagnosis with sufficient number of channels and having 10 spare channels for future requirement. It shall scan these inputs at an interval of typically, 20 mSec and update and store the events pertaining to any changeover of status. The storage capacity shall be such that, data logging system shall record minimum 1000 such events and shall overwrite subsequently on First In First Out (FIFO) basis.

27. Whether called for specifically or not, all accessories required for normal operation of equipment are deemed to be considered as a part of TENDERER’s scope of supply.

28. Painting of the equipment /structures 29. Supply of counter flanges and blanking plates with gaskets, nuts and bolts at all flanged

terminal points 30. Shop inspection and test as specified. 31. All start-up spares as required and all essential spares as specified. 32. One set of special erection and maintenance tools and tackle. 33. Lube oil, fuel and consumables as required for startup and commissioning first fill &

lube oil. 34. Packing, marking and forwarding. 35. Training of PURCHASER’s personnel. 36. The TENDERER shall carry out complete erection of all equipment covered under this

contract. 37. Site erection by TENDERER includes welding of equipment, supporting structures, stairs

and platforms, welding of different sections of various tanks and piping as specified in this contract.

38. Start-up, commissioning, trial operation and commissioning activities shall be performed by the TENDERER, after completion of equipment erection, to the satisfaction of the PURCHASER.

39. TENDERER shall carry out performance test of equipment at site to demonstrate guaranteed performance parameters.

1.1.2 Exclusions / Items related to scope but not included The following items are excluded from the scope of this contract. 1. Civil works for buildings. For embedment required in the RCC work, however, the

TENDERER shall furnish the required details. 2. DG room ventilation system. However, the TENDERER shall furnish ventilation

requirements such as heat load in the DG room and in the panel area to the PURCHASER.

3. Main fuel oil storage tanks and fuel oil transfer system including fuel oil piping from storage tanks up to inlet of day oil tank.

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4. All cabling from DG local control panel to remote control panel in control room. 5. EOT crane of required capacity for maintenance purpose. However, for erection of DG

and its auxiliaries, TENDERER shall make own arrangement for handling the DG sets and auxiliaries.

6. Power supply source required for commissioning 7. Earthing grid will be provided by the PURCHASER. All connections to the grid shall be in

the TENDERER scope. 8. 415V Switch gear panel

1.1.3 Terminal Points The terminal points for supply, erection and commissioning of various systems of equipment and accessories covered under this contract shall be as mentioned below-

1. Fuel oil system: The terminal point shall be the inlet isolating valve of day tanks. 2. Lubricating oil system: No terminal point. Complete lubricating oil system shall be in the

scope of Tender. 3. Air Intake and Exhaust gas system: No terminal point. Complete air intake and exhaust

system up to and including exhaust point by Tender. 4. Engine cooling water system: Complete cooling water system including air cooled radiator

shall be in the scope of the TENDERER. The terminal point will be the isolation valve on the makeup water line of Expansion tank.

5. Engine starting system: Complete air starting system along with auxiliaries is included in the TENDERER’s scope.

6. For generator, phase side terminals will be the terminal point. For the neutral side of the generator, terminal point will be the earth pit available at site. (The neutral grounding resistor and its interconnections are in the scope of the TENDERER).

7. For all auxiliary AC motors, motor terminals in the terminal box will be the terminal point. The cabling between the motor and supplied MCC panel is under the scope of the TENDERER.

8. For current transformers, terminals in the terminal box will be the terminal point. However, the cabling between CT to control panel and protection relay isunder the scope of TENDERER.

9. For control panels, terminal strip for remote connections will be the terminal points. However, cabling between local instrument to control panel is in TENDERER’s scope

10. All inter panel wiring between adjacent panels shall be done by the TENDERER. 11. The TENDERER shall be responsible for making all connections at terminal points and

supply necessary jointing, material, connectors, nuts , bolts etc.

1.1.4 Free Issue Material NIL

1.2 Project data and conditions : 1. PURCHASER : Indira Gandhi Centre for Atomic Research, Kalpakkam

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2. Project title : 13.2 MWe (40 MW Thermal ) Fast Breeder Test Reactor (FBTR), IGCAR 3. Location : Kalpakkam (approx 75km from Chennai) 4. Maximum ambient air temperature : 450C 5. Minimum dry bulb temperature : 17.60C 6. Maximum wet bulb temperature : 280C 7. Relative humidity : 15% to 100 %, Maximum likely RH at 450C is 80% 8. Air quality : Atmospheric air is sand and salt laden 9. Altitude : 7.4 metre above mean sea level 10. Power supply available at site:

a) 415V, 3 phase, 3 wire, 50Hz A/C b) 48V , 2 wire, DC ungrounded control supply

1.3 List of applicable documents 1.3.1 Codes and standards

1. The design, material, construction, manufacture, inspection, testing and performance of diesel generator set and accessories shall comply with the latest editions (including amendments thereto) of all currently applicable standards, statues, regulations and safety codes in the locality where the equipment will be installed. Nothing in this specification shall be construed to relieve the TENDERER of this responsibility

2. In the event of any conflict between the requirements of the codes/standards and this specifications, the more stringent of the two shall govern.

3. Other standards are acceptable if they are established to be equal to or superior to the listed standards. In all such cases, copies of English translation of such National standards shall be attached to the tender.

4. Bureau of Indian standards (IS) a) IS-10000 : Internal combustion engines b) IS-1460 : Diesel fuel c) IS-7132:Guide for testing synchronous machine quantities from tests d) IS-7306:Methods for determining synchronous machine quantities from tests e) IS-4722:Rotating electrical machines f) IS-4691: Degree of protection provided by enclosure for rotating electrical machinery. g) IS-6362: Designation of methods of cooling for rotating electrical machines. h) IS-4889: Method of determination of efficiency of rotating electrical machines i) IS-12065: Permissible limits of noise levels for rotating electrical machines. j) IS-12075: Mechanical vibration of rotating electrical machines with shaft heights 56mm

and higher-Measurement, evaluation and limits of vibration severity. k) IS 13364 AC generators driven by Reciprocating Internal combustion Engines Part-2 l) IS-13947: Low voltage switchgear and control (Part 1) gear: Part 1-general rules. m) IEC-60034: Rotating electrical machines n) IS-6533: Code of practice for design and construction of steel chimneys o) IS-1978- Line Pipes p) IS-2062: Steel for general structural purposes

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q) IS-1893: Criteria for earthquake resistant design of structures r) IS-6756: Electrical and electronic measuring equipment-documentation s) IS-8935: Electric solenoid operated Actuators t) IS-2848: Specification for Industrial Platinum Resistance Thermometer Sensors.

5. IEEE standards, IEC standards and USNRC regulatory guides

a) IEEE 85: Test procedure for air borne sound measurements on rotating electric machinery

b) IEEE115:IEEE Guide for test procedure for synchronous machines c) ANSI/IEEE 43:IEEE Recommended practice for testing Insulation Resistance of rotating

machines d) ANSI/IEEE 112:IEEE standard test procedure for poly phase induction motor and

generator e) IEEE 308:Standard criteria for class IE power systems for nuclear power generating

stations f) IEEE 323:IEEE standard for qualifying class IE equipment for nuclear power generating

sets g) IEEE 344: Recommended practices for seismic qualification of class –IE equipment for

nuclear power generating stations h) IEEE 387:IEEE standard criteria for diesel generator units applied as standby power

supplies for nuclear power generating stations i) ANSI/IEEE 749: IEEE standard testing of diesel generator units applied as standby

power supplies for nuclear power generating stations j) ANSI/IEEE 32: IEEE standard requirement, terminology, and test procedure for neutral

grounding devices k) IEEE 1050 : IEEE Guide for Instrumentation Control Equipment Grounding in Generating

stations l) USNRC 1.9 : Selection, design and qualification of diesel generator units used as

standby (onsite) electrical power systems at nuclear power plants m) USNRC 1.108 : Periodic testing of DG units used as on site electrical power system at

nuclear power plants

6. American National Standards Institute (ANSI) a) ANSI N195: Fuel oil system for standby diesel generator sets.

7. International standards Organization (ISO)

a) ISO- 3046 :Reciprocating internal combustion engine driven alternating current generating sets

b) ISO 1940 : Balancing quality of rigid rotors c) ISO- 10816 : Evaluation of machine vibration by measurements on non rotating parts d) ISO- 8528 : Reciprocating internal combustion engine driven AC generator sets

8. American Society of Mechanical engineers (ASME)

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a) ASME Section III : Boiler & pressure vessel code Sub section ND class III components

9. American Petroleum Institute (API) a) API-5L : Specification for line pipe b) Welded steel tank for oil storage

10. Instrument society of America (ISA) standard 11. TEMA – Tubular Heat Exchanger Manufacturers Association 12. Other codes and standards equivalent or superior to above.

1.3.2 Drawings

The following drawings are enclosed with the specifications. These drawings are supplement to the specification and should be used by the TENDERER for clarifying the intent and scope of work. The names specified in the drawings as seismicallyqualified flood safe building and Servicebuilding – 2 are same building.

1. FBTR/24000/5003/GA 2. IGC/ SB2 / 610 / AD-01 / 02 / R2 3. IGC/ SB2 / 610 / AD-01 / 03 / R1

1.4 General Requirements: 1.4.1 Qualifying requirements for TENDERER

The tenderer shall provide satisfactory evidence concerning the following in his offer. 1. That he is qualified manufacturer having plant and manufacturing facilities and who

have adequate knowledge and regularly design and manufactures DG sets of the type and ratings equal to or higher than the rating specified.

2. That he has technical expertise and / or manufacturing experience on large DG sets of the type and rating equal to or higher than the rating specified.

3. That he has adequate field service organization to provide the necessary field erection and management services required to successfully erect, test and commission the equipment as required by the specifications and documents.

4. That he has established quality assurance system and organization designed to achieve high levels of equipment reliability, both manufacturing/ supply and site installation activities.

1.4.2 In addition to the satisfactory fulfillment of the requirements stipulated above, TENDERER participating in this tender shall, on the strength of their own experience, have designed, manufactured or supplied, installed and successfully commissioned equal or higher rated equipment.

1.4.3 The system equipment shall be designed to limit the noise levels below the specified values measured at a distance of 1.0m from the source and 1.5m above the floor in any direction.

1.4.4 Overall vibration levels shall be limited as per the Zones A& B of ISO 10816. Vibration dampening devices shall be provided as required.

1.4.5 The TENDERER shall be deemed to have carefully examined the specific requirements as covered in the specification in its complete form and to have been fully informed and

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satisfied himself as to the details, nature, character and qualities of the items to be supplied including seismic requirements and other pertinent matters and details.

1.4.6 The TENDERER shall submit all supporting information, technical data, catalogue, drawings and quality assurance to enable the PURCHASER to make a detailed comparison and evaluation of Tenders without the need for further information from the TENDERER. The TENDERER shall also submit all information / price schedule as called for in the Section-2 and Section-3 of this specification.

1.4.7 In case of conflict between / within various sections of this specification or in case of any doubt, the interpretation / decision as given by the PURCHASER shall be final.

1.4.8 TENDERER shall clearly list out the proprietary items.

1.5 Design and Manufacturing / Construction requirements This section covers the supply, construction and design details of Diesel Generators and its auxiliaries.The supply scope diagram is as follows -

Scope diagram for DG set

1.5.1 General 1. The DG sets shall be highly reliable, which shall be the prime design consideration, as

the equipment is required to serve reactor safety related system. The equipment shall be capable of safe, proper and reliable operation for the specified service conditions.

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The TENDERERshall specifically explain the design features incorporated by him to achieve a high degree of reliability, availability and ease of maintenance

2. The equipment shall conform in all respects to high standards of engineering, design and workmanship and be capable of performing satisfactory operation up to TENDERER's guarantee in a manner acceptable to the PURCHASER who will interpret the meaning of drawings and specifications and may reject any work or materials which in his judgment are not in fully accordance there with.

3. It is expected that DG sets may be started about 100 times in a year and may run for about 200hours in a year. TENDERER shall confirm that DG sets offered are capable of operating under such operating conditions to the standards specified for over 25years life of the equipment. TENDERER shall list out major components which are not qualified for 25years life when operating under specified conditions. Recommended replacement schedules should be submitted. Notwithstanding the above, the rating of the DG set shall be based on continuous operation as base load set.

4. The capability and design conditions shall be as specified in Data sheet 1.17 5. Engine de-rating from the standard rating to obtain the site rating under specified site

conditions, shall be carried out in accordance with BS- 5514/ISO3046. 6. Both DG sets shall be identical in all respects. All components/parts including spares

shall be completely interchangeable. 7. The DG sets will be installed in a separate building as given in the drawing ( Ref:

FBTR/24000/5003/GA).The space available for DG set and its auxiliaries is shown in the enclosed drawing( Ref: FBTR/24000/5003/GA).The TENDERER shall select the DG set and its auxiliaries to suit the available space in the best possible manner and shall furnish the recommended layout for PURCHASER’s approval. The DG unit will be arranged to draw air from indoors. Air requirements of the engine will be supplied through a set of filters mounted on the wall towards the engine side. Exhaust will be discharged to atmosphere from the exhaust chimney.

8. The air required for the cooling requirements shall be drawn through the shutter opening by the radiator fan or any other suitable design to be approved by the PURCHASER.

9. DG sets shall be designed to operate on no load continuously for period up to two (2) hours. The no-load running capability test shall be demonstrated during the shop test.

10. Each diesel engine should be equipped with suitable flywheel to smoothen out the variations in the engine torque

11. The DG alternator and its regulation must be able to supply twice the normal current for at least 20seconds.

12. The alternator shall be capable of withstanding without damage 3 phase short circuit at its terminals for 3 seconds when operating at rated KVA and power factor at 5% over voltage.

13. The DG sets shall be capable of auto starting from warm standby condition and reaching rated voltage and frequency and ready to take load in a period of 20seconds from the initiation of start impulse without undue stress, wear and tear. The DG sets

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shall be capable of accepting therated load of the generator within a period of 60seconds from the start of initiation of start pulse as per the load sequence.

14. The DG sets will be required to operate on isolated bus only. 15. The maximum rating of the motor to be started on auto transformer will be 300 HP and

starting current will be 1500 Amps. 16. The single largest direct on line started motor load is 90 HP. 17. The DG along with auxiliaries and panels which are required for its operations shall be

qualified for specified safe shutdown earthquake as well as operating basis earthquake conditions.

1.5.2 Diesel engine 1.5.2.1 General features

1. The Diesel Engine shall be four stroke, vertical, multi cylinder single acting with mechanical fuel injection type. The engine shall be furnished with all necessary accessories in accordance with the codes and standards.

2. High speed diesel oil shall be used as the fuel for the engine 3. The diesel engine continuous rating shall be not less than 105% of Generator rating. 4. The number of cylinders shall be suitably selected by the TENDERER to obtain the rated

power output. The cylinders may have an ‘In-line” or a “Vee arrangement. However, the dimension for the engine shall be suitable for the available space.

5. The engine shall be properly balanced. The engine shall be equipped with a flywheel. The engine shall be complete with inlet air filter, silencer and an exhaust chimney.

6. The engine rating, required auxiliaries, guarantees of fuel consumption, governor performance, material and workmanship shall be in accordance with ISO-3046.

7. Diesel engine shall be designed suitably to avoid harmful vibration stresses. Harmful torsional vibration stresses shall not occur within a range from 10% above to 10% below rated idle speed and from 5% above to 5% below rated synchronous speed. Adequate measures shall be taken such that any part of flywheel, on disintegration shall not become a missile and does not impair function of other safety related equipment.

8. The noise level in the DG room at 1m distance from DG shall be less than that 100dB at 110% load.

9. Harmful vibration stresses shall not occur and RMS velocity of vibration at 100% load shall be within the limits stipulated by ISO 10816 (Zone A / Zone B).

1.5.2.2 Fuel oil system:

1. The TENDERER shall furnish a day tank not less than 4 hours full load capacity for each of diesel engines. Fuel oil pipeline from day tank to engine including piping fittings, supports etc. shall be supplied by the TENDERER

2. The day tank shall be installed outside the DG room on elevated structure to ensure gravity feed to the shaft driven fuel oil pumps. TENDERER shall confirm the suitability of the day tank elevation and size of the day tank

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3. The day tank shall be rectangular in shape. The tank shall be made from carbon steel of Grade ASTM A515 Gr.70 / equivalent. The tank shall be provided with suitable coatings / paintings for corrosion protection. The paint shall be resistance to High Speed Diesel. The tank shall conform to the requirements of IS and API standards. Slope shall be provided at one end of the bottom so that sediments and moisture collected at the bottom can be completely drained.

4. Each day tank shall be provided with the accessories and instrumentation as required. (Alarm provision for low and high level at Local Control Panel(LCP)/Main Control room)

5. An engine driven booster pump shall be provided to deliver fuel oil from the supply line to the fuel oil injectors provided on individual cylinder through duplex filters or two 100% capacity filters. Differential pressure indicating switch across the filters shall be provided to monitor the cleanliness of filter and for alarm in LCP. The excess fuel is returned to the day tank

6. TENDERER shall provide all necessary piping, fittings, supports, valves and accessories to complete the fuel oil system.

1.5.2.3 Lubricating oil system 1. Automatic pressure lubrication shall be provided by an engine driven gear pump at the free

end of the engine end driven from the crank shaft. Lubricating oil system of the engine can also supply lubricating oil to the bearings of the alternator if oil lubricated bearings is used. The pump shall take suction from a sump tank and deliver oil through an oil cooler and fine mesh filter. High pressure oil shall be supplied to the main and big end bearings, camshaft bearings, camshaft chain and gear drives, governor, air starting distributor, auxiliary drive gears, etc. Valve gear shall be lubricated at reduced pressure through a reducing valve and the cams by oil bath. The cams may be lubricated from a dip tray and the pistons by oil mist from the crank chamber or suitable pressure lubrication may be provided for them. The capacity of lubricating oil sump shall be such that it does not need frequent replenishment. In case of wet sump arrangement, it shall be adequate for 7days.The sump shall be fitted with a dipstick marked with minimum and maximum oil levels. A level switch shall be provided for low-level alarm on engine control panel. The TENDERER shall provide the necessary filters, piping, valves and fittings.

2. Suitable pressure switch shall be provided at the engine inlet for low lubeoil pressure alarm on the engine control panel and subsequently to trip the DG set when the minimum safe pressure limit has been reached.

3. 1x100% capacity duplex filters or 2x100% capacity individual filters or automatic self cleaning type filters of approved make with differential pressure indicating switch across the filter(s) shall be provided to monitor the cleanliness of filter and for alarm on LCP

4. The cooling water required for the oil cooler shall be supplied by the jacket water cooling system. The lube oil cooler design, materials, construction features etc. shall be as per relevant standards. Necessary bypass arrangement on water side of lube oil cooler shall be provided during startup until the oil temperature rises above the minimum. The bypass

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valve position shall be controlled by a temperature controller installed at the outlet of the oil cooler

5. If the engine calls for pre lubrication of the bearings before a startup after a long period of idleness, a pre lube oil pump shall be provided and operated intermittently with the help of a timer relay, when the engine stands still.

6. All necessary accessories like pressure gauges, temperature indicators, pressure relief valves, bypass valves, pressure switches for alarm and control shall be furnished by the TENDERER together with all interconnecting piping, fittings, supports valves etc. as required.

7. Engine including its turbocharger shall be designed for safe coasting down along with coasting down of engine driven lube oil pump

8. Heaters with temperature switch and safety thermostat shall be provided for heating the lube oil when engine is not in operation or hot jacket water may be used for heating lube oil.

9. The external lube oil system design, materials, construction features etc. shall be as per ASME B& PVC Section–III, ND standards

1.5.2.4 Engine Cooling water system :

1. DG set shall be equipped with engine cooling water system and air cooled radiator. DM water may be used for engine cooling by closed loop system engineered by the TENDERER. A valve with plug for draining engine cooling water at the lowest point shall be provided to facilitate quick change of engine cooling water. Make up for closed loop system shall be provided from DM water system (by PURCHASER).

2. Dissipation of the engine cooling water heat shall be done by AIR COOLED RADIATOR. The offer with engine cooling water system water cooled by service water in a heat exchanger is not acceptable and such offers will be rejected.

3. A set mounted radiator is preferred.The radiator shall be preferably fixed in line on the DG base frame or inline with the Diesel generator inside the DG room itself. The air cooling for the radiator shall be taken from the openings of the shutter. However, the supplier is free to engineer other options for the radiator orientation subject to the approval of the PURCHASER and space available in the building

4. The cylinder linings, cylinder head, valves, fuel injector, the charge air cooler and lubricating oil cooler shall be cooled by the engine cooling water.

5. The engine cooling water cooler design, materials, construction features etc. shall be as per ASME B&PVC Section–III, ND and TEMA-C standards.

6. Jacket water circulation through the engine jackets shall be established by an engine driven jacket water pump. The volume of jacket water circuit shall be suitably augmented by providing a suitable additional tank or otherwise so as to enable starting and operation of engine for a period of 3 minutes or till the time radiator fans receive power from the terminals of the diesel generator and attain full speed whichever is higher.

7. Heaters with temperature sensors with safety thermostat shall be provided to keep the engine cooling water warm to enable quick starting of the engine.

8. The TENDERER shall provide engine cooling water treatment system to prevent organic growth and corrosion

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9. Provisions shall be made for all requirements of control and instrumentation for cooling water circuit.

10. The jacket water expansion tank shall be made of mild steel plate of SA-283Grade-C or IS:2062 quality. The tank shall be suitably painted to protect the same from corrosion. Requisite mounting brackets with holding bolts, nuts and washers shall be provided by the TENDERER.

11. All necessary accessories like pressure gauges, temperature indicators, pressure relief valves, bypass valves, pressure switches for alarm and control shall be furnished by the TENDERER together with all interconnecting piping, fittings, supports, valves etc. The pipe shall be of carbon steel ASTM A106Gr.B/ IS1239 (seamless)

1.5.2.5 Engine Starting system: 1. The starting of the engine shall be by compressed air system (by TENDERER) .The compressed

air shall be made available from air compressors. The starting system of the engine shall be adequately designed to meet the requirement of diesel engine starting for six consecutive starts.

2. The starting system may comprise of a camshaft driven rotary air distributor admitting air to a series of automatic starting valves fitted on individual cylinder heads or an air cranking motor operating through a ring gear on the engine flywheel.

3. The compressed air system shall consists of: a) Two 100% capacity AC motor driven air compressors (1 working + 1 standby) per DG. This will

be powered from class III power supply source. b) Stainless steel air receivers, two per DG shall be of adequate capacity to supply air when full

for six consecutive starts of the engine. Each air compressor capacity shall be sufficient to fill the air receivers to the rated pressure within 20 minutes.

c) Heatless desiccant type air dryer with twin adsorber towers operating on cyclic mode of suitable capacity shall be provided.

d) Pressure switches for starting and stopping the compressors. e) Necessary pressure gauges, pressure switches etc. f) All protection and annunciation equipment installed in control panel suitable for local /

remote operation and indication. g) The compressed air system shall be complete with all necessary piping of stainless steel

conforming to ASTM A312 – TP 304L h) Two independent circuits shall be provided so that DG could start when one circuit fails to

supply the compressed air injection to cylinder / air starting motor. 4. The TENDERER shall provide all the necessary automation such that with one impulse

command for starting of the engine, the entire operation of starting of the diesel set and build-up of voltage takes place automatically.

5. The compressed air supply shall be kept open for a pre determined time, during which the engine should come up to adequate speed. In case the engine fails to do so, it will be stopped and the starting sequence may be repeated.

6. Provision shall be there for manual start without control supply.

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7. Safety valves shall be provided on the receivers to guard against overpressure. 8. Timer based auto moisture drain valves shall be provided on the air receivers and the

intercooler of the starting air compressor

1.5.2.6 Air Intake and Exhaust gas system 1. TENDERER shall provide an air intake pipe / duct, filter and silencer (if required) for DG sets 2. The combustion air intake may be taken from outside / inside the DG Room. DG room

ventilation system is designed for 45°C temperature. Therefore DG set surrounding temperature shall be considered as 45°C for design purpose.

3. The combustion air from air filter / cleaner shall be charged in to the cylinders by means of centrifugal compressor powered by an exhaust gas driven turbine viz. turbocharger .The turbocharger shall be mounted on the engine.

4. Charge air coolers shall be provided to cool the charge air before passing to the engine air intake manifold. The charge air cooler shall be mounted on the engine and shall be cooled by jacket water. The cooler design shall be suitable for easy accessibility without disturbing the other assembly.

5. Adequate flexible joints shall be provided on the air intake pipe/ duct to ensure isolation of engine vibrations from the air intake piping. The flexible joints shall be located as near the engine as possible.

6. The exhaust gas system shall be complete with corten/equivalent steel exhaust piping, silencer and all the accessories and shall ensure safe disposal of the exhaust gases at a suitable point outside the DG set room.

7. Stainless steel bellows shall be provided on the exhaust piping to take care of expansion/contractions due to high working temperatures. It shall also isolate the piping from engine vibrations. The flexible joint shall be provided as near the engine as possible.

8. The entire exhaust gas piping shall be provided by the TENDERER. He shall also provide necessary engineering details for support base embedded in the DG room roofing. The PURCHASER will provide embedment. The entire exhaust gas piping inside the DG room including the engine exhaust gas manifold shall be suitably lagged to prevent heating of the DG room atmosphere. Lagging shall be easily replaceable in molded form.

9. The engine exhaust shall be connected to a self-standing steel stack of 30 meter height above the ground level / as per the CPCB norms. The stack shall be designed as per IS6533 with adequate corrosion allowance. The TENDERER’s scope shall include stack, its supporting structure and base plate.

1.5.2.7 Governing system 1. The governor characteristics shall comply with the requirements of Class-A1 of ISO3046 -

1986/ AIEE No.606 of 1959 or approved equal. 2. The basic performance requirements are :

a) Steady state regulation shall be capable of adjustment between 0 and 5 %, inclusive.

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b) Steady state incremental speed regulation shall be between 1 and 8 % for power outputs greater than 10% and between 1 and 10 % for power outputs less than 10% with the steady state incremental speed regulation set at 2%. c) Steady state governing speed band shall not exceed 0.35 percent of rated speed. d) Momentary under speed shall not exceed 2 % of rated speed. e) Momentary over speed shall not exceed 8 % of rated speed f) Recovery time shall not exceed 3 seconds. g) The speed changer shall be capable of adjusting the speed of the diesel generator speed from 100 to 102 % inclusive at rated power output, from 90 to 106 percent inclusive at Zero power output and from 100 to 95 % inclusive, at power output reduced in direct proportion with speed from rated output its rated speed. h) Since, the diesel generator will normally operate isolated, ‘Isochronous operation’ (Zero droop) will be normally required for the speed governor.

3. The governing system shall be provided fast response with static electrical devices which would sense changes in generator KW load and initiate corresponding change in governor setting, even before a signal is received from normal speed governing.

4. The governing system shall has the capability for slow starting during surveillance testing of the Diesel Generator.

5. The governor shall be capable of providing speed control if a failure occurs in the electrical governing circuit.

6. A load limiting device, adjustable at engine, shall be provided. It shall be arranged so that the power output of the engine can be limited to any value between zero and the largest power output.

7. Anindependent mechanical speed trip shall be provided to automatically shut off fuel, in case the DG set speed reaches 115% of rated speed. Alarm shall be provided for over speed trip.

8. An engine mounted emergency stop push button shall be provided on each DG set.

1.5.2.8 Base frame 1. Base frame common for the engine, generator and radiator (depending on

TENDERER’s design) shall be of fabricated steel. The fabricated steel (conforming to AISI: 1025 / IS 2062 Gr- E 250- BR or equivalent) base frame welding shall be done in a continuous process and all welds shall be examined by magnetic particle examination. The entire fabrication shall be stress relived after welding.

2. Base frame shall have integral lube oil sump / separate wet sump fastened to the crankcase.

An earthing bus shall be provided on bed plate with two non-corrodible metal pads located physically opposite with respect to engine. All the AC motor driven standby pumps shall be earthed through this earthing bus.

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1.5.2.9 Cylinder Block and Crank Case 1. The cylinder block, the main structural member of the engine shall be made of

fabricated steel and steel forgings / high grade cast iron. The crank case shall be of cast iron / fabricated steel.

2. Cylinder block/crank case shall be provided with inspection cum maintenance windows for facilitating the maintenance. Additional doors shall also be provided to facilitate access for the cleaning of water jackets.

3. A breather device (for allowing the gases to escape from the crank case), and an antiexplosion device (to let off the excessive pressure in the crank case in theeventof pressurization of crank case), shall be provided.

4. The cylinder block/crank case shall be provided with suitable arrangements for mounting on to the foundation/base frame.

5. The cylinder block and crank case shall have adequate bolting provisions forassembling other engine components e.g. oil pan, crank shaft, cylinder head assembly, cylinder liner, end covers etc. Cooling water passage shall be built into the cylinder block to effect the cooling of cylinder liners, when assembled together.

1.5.2.10 Cylinder head and Valve Mechanism

1. The cylinder heads shall be cast from high strength cast iron / proven material. The cylinder head shall house the inlet and exhaust valve with their seats, guide bushes, springs and spring retainers. The fuel injector safety valve and starting valve shall also be housed in each cylinder head.

2. Suitable laminated metal compression gaskets shall be provided between cylinder block and cylinder head to ensure a durable gas tight high strength joint. Additional rubber seals for water and oil, if required may be provided.

3. Each cylinder shall be provided with adequate number of inlet and exhaust valves. The valves shall be machined from heat treated alloy steel forgings / special material. The valve stem shall be hardened at the ends for resistance against any wear.

4. The valve disc shall fit closely on valve seat. The valve seat shall be made from alloy steel. The fixture of valve seat shall be such that quick replacement of these seats shall be possible when required.

5. Incase two or more valves are provided per cylinder for the same function, then the motion of the two shall be exactly similar.

6. The valve mechanism shall be pressure lubricated with oil from the engine lubricating system.

1.5.2.11 Cylinder Liners

1. The engine shall be provided with easily replaceable cylinder liners for each cylinder. The cylinder liners shall be wet type i.e. cooling water circulates outside of the liner.

2. The cylinder liners shall be machined form heat-treated cast iron alloy / proven material. The specially treated to withstand wear and tear and shall have had scuff resistant wear surface.

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3. Suitable spaces shall be provided at the top and at the bottom of the liners for accommodating special rubber ‘O’ rings. These rings shall fit tightly into the cylinder block to ensure a watertight passage for cooling water around cylinder liner.

1.5.2.12 Piston and Piston Rings

1. The pistons shall be manufactured of forged light alloy. Each piston shall be provided with adequate spaces for accommodating the oil scrapper rings and the compression rings. Close tolerances shall be maintained between the piston diameter and cylinder liner inner diameter.

2. The oil scrapper rings and compression rings shall be of special grade cast iron alloy / proven material and shall be easily replaceable.

3. The piston shall house the gudgeon pin, which shall transmit the force from the piston to the connecting rod. The gudgeon pin shall be made of alloy steel. The surface shall be accurately ground and heat-treated. Removable type internal circlips shall be provided to prevent axial movement of gudgeon pins in the pistons.

4. The piston top shall be suitably crowned to ensure efficient combustion and proper exhaust of gases.

1.5.2.13 Crank shaft

1. The crank shaft material shall be of be forged alloy steel with hardened bearing journals and hardened or rolled fillets for maximum bending strength. The hardening shall be deep enough so that the crankshaft can be reground instead of being replaced during overhaul. Magnetic particle examination and ultrasonic test shall be conducted for the crankshaft.

2. Balance weights may be integrally forged with the crankshaft or separately bolted. If separately fixed, adequate bolt locking devices shall be provided to prevent the bolt from loosening during engine operation

3. The crankshaft shall be provided with integrally machined passages for ensuring adequate lubricating oil supply to the crank pin bearings and subsequently to the piston pin through rifle drilled passage of connecting rod.

4. The crank shaft ends shall be suitable to house the flywheel at the power take off end and timing gears at the non-driving end.

5. Helical gears shall be provided on the crank shaft for driving camshaft governor and for engine shaft driven lube oil pump. The jacket water-circulating pump may be driven off the engine by the crankshaft by means of a gear arrangement.

1.5.2.14Main and Big End Bearings Main and big end bearings shall be detachable pre-finished shells with high-gradebearing material. The big end dimensions shall be such that the connecting rods can be withdrawn through the cylinder liners.

1.5.2.15 Connecting Rod

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1. Individual pistons shall be provided with connecting rods to transmit power from the piston to the crank shaft. The connecting rod shall be drop forged alloy steel. Magnetic particle examination and ultrasonic test shall be conducted for connecting rods.

2. The lubricating oil passages shall be rifle drilled to convey the lubricating oil from the crankpin end to piston pin. Additional passages may also be provided to spray lubricating oil on the underside of the piston crown in order to ensure piston cooling.

3. The babbit lining at the piston end shall be press fitted into the connecting rod. 4. The crank pin end of the connecting rod shall be axially split to assemble it on the

crank pin. This shall also house the babbit linings in two halves. The two pieces of the connecting rod shall be held in place by forged steel alloy bolts with locking arrangement.

1.5.2.16 Cam shaft 1. The camshaft, one for each bank cylinders shall be of heat treated alloy steel. The

babbit linings for the cam shaft bearings shall be press fitted into the cylinder block subsequently machined to close tolerances.

2. The main bearings shall be lubricated from the engine lubricating oil system. The cam surfaces shall be lubricated with oil from the rocker lever.

1.5.2.17 Air inlet and exhaust gas manifold

1. The air intake and exhaust gas manifold shall be of Ni-resist casting / proven material and may be assembled in one or more pieces as required.

2. Joints between manifold pieces and between the manifold and cylinder head shall be provided with suitable gaskets.

1.5.2.18 Fuel Injection System 1. Each cylinder shall be provided with its own fuel injection pump, operated by roller

tappets from cams, which can be individually, adjusted. It shall be possible to manually adjust fuel injection to individual cylinders.

2. The fuel injection system shall be designed to inject the required amount of fuel into the cylinder for a predetermined period, as required at the correct time.

3. The injector body shall be made from forgings of high strength alloy carbon steel / proven material.

4. The fuel tubing shall be of proven material, suitably brazed to ensure permanent joints, wherever required.

5. The engine injectors and the high-pressure fuel oil pumps shall be driven off the crank shaft by well proven gear arrangement.

1.5.2.19 Engine Flywheel 1. Suitable flywheel shall be provided at the power take off end to smoothen out the

variation in engine torque. It shall be rigidly bolted to the crank shaft.

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2. The flywheel shall be made of forged alloy steel after accurate machining. It shall be statically and dynamically balanced prior to fixing on the crank shaft. Barring slots shall be provided around the flywheel rim for hand barring or suitable hand barring facility to be provided.

1.5.2.20 Engine Anchor bolts, Foundation bolts &Anti- vibration Pads:

The engine shall be provided with adequate number of anchor bolts, foundation bolts and Anti vibration pads (if required). Engine Anchor bolts, Foundation bolts & Anti vibration Pads. Alignment shims, jacking pad and lifting hooks as required, shall also be provided by the TENDERER

1.5.3 Generator This specification covers the technical requirements, which are generally applicable to a salient pole synchronous Generator and excitation system. This specification is meant for the guidance of the supplier and is not intended to cover all aspects of design and manufacture. The DG set is intended to operate in isolated mode only. It is the responsibility of the supplier to provide complete system meeting the PURCHASER’s requirement brought out in this specification.

1.5.3.1 Generator Characteristics 1. Continuous Output Rating:

The continuous output rating of the generator shall not be less than 1000 KVAat 0.8p.f lagging at 415V – 3 phase-3 wire - 50Hz without exceeding the temperature limits set out in the specific requirement. The generator shall be sized to deliver power for a generator terminal voltage between 0.9 to 1.1 times rated voltage

2. Short time overload At the time of emergency switching by one group, there is the necessity for reaccelerating or restarting of certain number of important induction motor loads. This leads to large reactive power operation and the restart up of these machines may result in low power factors, may between 0.2 and 0.3. The alternator and its regulation equipment must be able to supply twice the normal current for at least 20 seconds. The overload admissible for the alternator shall be 10% overload for two hours in 22 hours of continuous operation without over heating or showing signs of undue stress and within specified frequency variations.

3. Short-circuit Requirement a)The generator shall be capable of withstanding, without injury, a 3 seconds three

phase short circuit at its terminals when operating at rated KVA and power factor, at 5% over-voltage with fixed excitation.

b) The generator shall also be capable of withstanding any other unbalanced short circuit at its terminals provided. (I2)2. t = ≤ 20 Where I2 = Per unit negative sequence current

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t = duration of unbalanced loading in seconds. The maximum phase current for a fault of aphase-to-ground shall be limited by means of a suitable resistance to a value around 600 amps.

4. Short circuit ratio – Short circuit ratio at rated KVA and voltage shall not be less than 0.5

5. Voltage and Frequency variation The generator shall operate satisfactorily under the following conditions: a)± 5% voltage variation at rated KVA, power factor and speed. b) ± 3% frequency variation at rated KVA, power factor and voltage

6. Over speed The Generator shall withstand without mechanical injury a speed of 120% of rated speed for 2 minutes.

1.5.3.2 Generator Construction

1. All parts of the Generator and accessories shall be capable of withstanding electrical, mechanical,thermal and other stresses experienced in operation and during short circuit, faulty synchronizing and over speed condition.

2. Generator Frame and Stator a)The generator frame shall have sufficient strength and rigidity to withstandvibrations.

The stator core mounting arrangement shall be such that radial and tangential magnetic vibrations of the stator core due to electro-magnetic loading are isolated from the outer frame. The motion of the core shall be limited to safe magnitudes by means of stop collars. End shields suitably shielded from stray flux shall be provided to ensure uniform cooling of the core and the windings. All stationary parts of the generator shall be designed to avoid resonances in the operating as well as over speed range.

b) The generator when operating at rated KVA and power factor and five percent over voltage, shall be capable of withstanding, without mechanical injury, any type of short circuit at its terminal for times not exceeding the short time thermal capabilities, provided the maximum phase current is limited by external means to a value which does not exceed the maximum phase current obtained from the three-phase fault. In the case of stator windings, the criterion for no injury is that the windings shall satisfactorily withstand a normal high potential test. There shall also be no visible abnormal deformation or damage to the winding coils and connections.

c) The frame shall be stress relived

3. Stator Core Stampings The stator core shall be made of tightly clamped, adequately insulted high permeability silicon steel stampings to give minimum noise, vibration and electrical loss and proper magnetic characteristics. The laminations shall be de-burred after punching. Core clamping plates shall be of non-magnetic material. If not, adequate design features shall

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ensure that overheating due to induced currents does not occur. Slot wedges shall be of non-magnetic material.

4. Stator Windings The stator windings shall be fully insulated throughout and shall be suitable for operating with a non-effectively earthed neutral. Vacuum pressure impregnated (VPI) insulation shall be considered for winding. The coils, made of a number of parallel copper straps of adequate cross section, shall be transposed in slots to reduce eddy currents to a minimum. Individual straps shall be found in such a way as to produce a bar of solid construction and smooth surface. The complete insulation system shall meet the requirements of class-F insulation, but the temperature raise shall be limited to that of class-B insulation. All armature winding connections shall be brazed strand to strand. Provide maximum margin against local overheating.

5. Stator Winding connections The three phase windings of the generator shall be arranged for Y ( star) connection and shall be suitable for operation with neutral grounded through a resistor of high ohmic value.

6. Terminals and Terminal Arrangement a) The line and the neutral ends of stator winding of generator shall be brought into

two separate terminal boxes with bottom entry for cables. b) 6 nos. of CTs shall be mounted for differential protection. 3 nos. of

CTs for P343 shall be mounted separately. One no. of CT for earth fault protection shall be mounted on neutral side. Metering and AVR CTs shall be separately mounted. The ratio, VA burden, class of accuracy etc,. shall be approved by the purchaser

c) The CT specifications are tentative and shall be finalized after placement of order. The bidder shall supply required CTs at no extra cost

d) Separate terminal box shall be provided for space heaters and RTD’s. e) All terminal boxes shall be provided with degree of protections IP 54 confirming to

relevant IS.

7. Rotors a) Rotor

The generator rotor shall be designed and constructed to meet the speed, over speed and other duty requirements set out from a single machine. The rotor shall be machined from alloy steel bar and shall have the required physical and metallurgical properties and be capable of withstanding stresses that may be experienced throughout the operating range. The rotor shall have a large margin between the critical speed and the running speed under normal operating conditions and shall be

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subjected to a test at 20% over speedfor 2 minutes to ensure reliable operation and dynamic stability. TENDEROR shall carry out the following tests on the rotor material.

(i) Physical properties (ii) Chemical properties (iii) Non-destructive tests.

b) Retaining rings

Heavy retaining rings, machined from high strength, heat treated non-magnetic alloy steel forgings shall be provided to hold the rotor coil and end turns in place under the action of centrifugal forces when the rotor is running at 20% above its normal speed. The retaining rings shall not have undue concentration of stress and after being assembled on the rotor body shall remain unaffected by alternating deflections of the shaft ends. Die penetrations and ultrasonic test shall be conducted for forgings.

c) Rotor Winding The conductor insulation and the design and construction of rotor winding shall be such as to avoid earth faults, flow of eddy currents, local heating during normal operation, deformation, relative movement and stresses under any operating condition. Field winding shall have class-F insulation, with temperature raise limited to that of class-B insulation. The rotor shall be suitable for operation without required pre-heating of the rotor or rotor winding or pre-warming of the rotor forging.

8. Ventilation The generator shall be air cooled. Shaft mounted fans shall be provided to effect air circulation through the ventilation system. The wire mesh size shall be not greater than 3mm.

9. Bearings: All bearings shall be of the self-aligning type and shall consist of split steel shells lined with special bearing metal or anti friction type grease lubricated. If anti friction bearing with grease lubrication is used, provision shall be available for filling the grease during service and rejection pocket to drain used grease. The stray current insulation shall be provided for bearings so that all paths of stray current will be broken at two places in series at one end of the generator with provision made for determining the insulation resistance at each place of insulation. The insulation shall be non-hygroscopic and should withstand power frequency voltage of 2 KV for 1min.

1.5.3.3 Cabling

1. The TENDERER shall provide suitable clamping arrangement for connecting the PURCHASER’s cables to the terminal box. Cable glands shall be provided on the enclosure to facilitate entry of the above cables.

2. Cabling arrangement for Generator: Cable trays in trenches will be provided (by PURCHASER) in the DG room to cater for cabling generator and other accessories. Cables

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from the trenches shall be suitably supported and terminated in the generator terminal box. Required glands shall be supplied by the supplier.

3. For cables in the scope of the TENDERER, derating shall be done for 50 deg C

1.5.3.4 Temperature detectors 1. Shall be provided two temperature detectors of resistance type (Duplex RTDs at 2

different locations in each phase) in each phase stator winding. One RTDs shall be embedded in each bearing

2. The detectors shall be installed at locations where the highest temperature is expected. The leads of the temperature detectors shall be brought in a neat, untangled, and adequate manner to an easily accessible terminal box on the generator frame. The minimum size of leads shall be 1.5 mm2. The leads shall beTeflon/fibre glass/ceramic insulated to withstand temperature and shall beprotected against stray electrical fields and mechanical damage.

3. The detector coil of the RTD shall be of platinum having a DC resistance of 100 ohms at 0 deg C.

4. The temperature detectors with their leads shall be accurately calibrated. Test reports giving results of the calibrations shall be for PURCHASER scrutiny

5. A drawing indicating locations of the detectors shall be furnished 6. The RTD elements shall be subjected to the following test after installation in the stator

winding a) Insulation resistance test: The insulation resistance between the element and the

ground shall not be less than 10 megaohms at 250V DC at the ambient temperature.

b) H.V.Test : The insulation of element shall withstand 1.5KV for one minute applied between the element and ground

c) Insulation resistance test: As above after completion of H.V.Test. 7. The RTDs shall comply with the latest edition of IS:2848. Separate terminal block shall be

provided for RTDs.

1.5.3.5 Grounding Provision shall be made on generator frame at two locations for connecting PURCHASERs grounding conductors. A non –corrodible metal pad shall be welded or brazed at these locations on the frames and shall have two threaded holes for connecting the conductor lugs by means of hexagonal head bolts and spring washers

1.5.3.6 Space heaters

Space heaters of adequate capacity, rated for 240V, 50 Hz, single phase service shall be provided for the generator, to prevent condensation when equipment is not in service. Power supply from space heater shall be derived from the MCC for auxiliaries. The heaters shall be mounted in an accessible location. Terminals of the space haters shall be brought out in a separate terminal box.

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1.5.3.7 Current transformers

1. The current transformers shall comply with the relevant Indian standard, unless otherwise approved by the PURCHASER.

2. The CT shall be of cast resin type (Insulation Class E or better) and shall be cast under vacuum and cured under temperature and pressure

3. The TENDERER shall submit the ratio, VA burden and accuracy class.

1.5.3.8 Neutral Grounding resistor 1. The neutral grounding resistor is required for connecting the neutral of generator to

earth to obtain a resistance ground system. 2. The resistor shall be rated for more than 30 secs. 3. The design, manufacture and performance shall conform to IEEE-32. Calculations in line

with IEEE-32 shall be furnished by the TENDERER in order to establish the current density for short time duty with specified temperature rise limit.

4. Resistor elements : a) The resistor elements shall be stainless steel grid. b) The grid shall be securely supported at sufficient number of points so that no damage

is caused to the grids due to vibrations and no mechanical stresses are developed. The resistor elements shall be insulated from supporting bars by mica tubes. Stainless steel grid need not be painted. The insulating material used in the construction shall be heat resistant such as mica and it shall withstand temperature rise for both continuous and short time rating.

5. The resistor shall be mounted in an appropriate support structure and shall be provided with necessary approach facility.

6. Enclosure shall conform to IP 23 and terminal boxes to IP 54 standards. 7. The terminal shall be brought out through terminal bushings 8. The structure shall be grounded as per standard to the station earthing system

1.5.4 Excitation system

Brushless excitation system with permanent magnet alternator exciter, AVR, circuit breaker in exciter field circuit etc. shall be provided. Exciter shall be directly connected to the alternator shaft for brushless excitation.

1.5.4.1 Brushless excitation system

The brushless excitation system shall have the following provisions: a) A revolving armature AC exciter shall be provided. The output of the AC exciter shall be

rectified by the rotating diodes connected as a three-phase bridge. b) The complete equipment shall be installed on a bed plate of the DG set and shall be

enclosed by suitable casing. c) The rotating rectifier components shall be contained against centrifugal forces by

adequately designed retaining ring. Suitably rated heat sinks, which will also act as fan

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shall be provided for each diode. Suitable metal oxide type surge arrestor shall be provided to protect main fields against damage from voltage surge caused due to abnormal transient conditions such as faulty synchronizing, shall be connected across output of rotating rectifiers.

d) The DC outgoing leads shall preferably be segregated by locating the rectifier bridge on two separate wheels. Each arm of the bridge shall be made of more than one high powered diode arm arrangement in a suitable configuration to ensure that the diode arms withstand all fault conditions to which they may be subjected, such as high field current induced by short circuits on generator terminals or stator switchgear bus bars, high voltages caused by pole slipping or earth fault etc.

e) The total number of diode arms shall be such that the failure of 25% diodes in each arm will not cause restrictions on the unit operation at its rated condition, including field forcing. Suitably rated variatorsetc. shall be provided to give a path for the reverse polarity induced currents resulting from the generator pull out, power swing and any other abnormal conditions. Diodes and associated protective devices shall be mounted radially. It shall be ensured that the rectifying junctions are held in compression under speed.

f) The field of the AC exciter shall be supplied through the static Automatic voltage regulator.

g) Suitable means shall be provided on the generator and the rotating exciter for the measurement of generator field current and voltage for remote indication and over current / earth fault protective relaying.

h) The excitation system shall have thermal capacity equal to or better than the field of the Generator. It shall be designed to prevent harmful overvoltage at main exciter.

i) The exciter current rating shall not be less that 110 percent of actual excitation requirements of the generator, when operating at rated KVA and at any voltage between 95% and 105% of rated voltage.

j) The exciter rated voltage shall be at least 110% of rated machine excitation voltage k) The exciter ceiling voltage shall not be less than 140% of the exciter rated voltage. l) Response of excitation system shall be greater than 0.8. m) The insulation of the exciter shall be Class F Vacuum Pressure Impregnated with

temperature rise limited to class B limits. n) The excitation equipment shall be housed in a self –standing, sheet –steel cubicle with

doors. 1.5.4.2 Automatic Voltage Regulator

1. The automatic voltage regulator shall be high speed, non-dead-band type with provision for current compounding. The voltage regulating system shall be suitable for automatic and remote/local manual control of voltage. A motor driven potentiometer shall be provided for changing the voltage setting of the regulator by ± 10%. No volt protection shall be provided to initiate transfer from automatic to manual control of excitation in the event of fuse-failure in the potential signal circuit to the regulator. An equivalent / suitable scheme can also be used subjected to the PURCHASER’s approval.

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2. Necessary equipment shall be furnished for the following : a) To prevent automatic rise of field voltage in case of failure of potential supply. b) To initiate transfer from automatic to manual control of excitation on fuse failure in

the generator potential signal. c) The regulator shall regulate from generator current and potential signal.

3. The above equipment shall be housed in self standing sheet metal cubicle, completely wired and tested.

4. The band of control must be at most + 5% of the nominal value of voltage. The regulation equipment must function correctly between the frequencies 47.5 and 51.5 Hz and assure the following

a) A constant voltage of +0.5% % in steady operating condition between no load to full load. b) Return to normal voltage to +3% within a maximum of 0.5 seconds on application

suddenly of full load and the instantaneous dip in voltage limited to the value corresponding to the sub transient reactance of the alternator and not to exceed 15%.

5. The voltage regulator must be provided with compensation circuit to assure current division of reactive power. The excitation and voltage regulation shall be designed so as to cause de-excitation in case of short circuit.

6. The voltage regulator shall be capable of supplying excitation current in the event of a three phase short circuit at the Generator terminals, to facilitate operation of the protective devices.

7. Loss of voltage transformer signal due to tripping of MCB in voltage transformer circuit or any other cause shall not cause over shooting of voltage. Voltage shall be clamped to the nominal value in this condition. AVR should automatically switch over form AUTO to MANUAL under this situation. Mode selector switches shall be provided to select the mode of operation either from the Diesel Room or from the Control room.

1.5.5 Control , Protection and Instrumentation 1.5.5.1 Control system shall be hard wired and the operation of the panel is based on hard wired

relay logic. It shall be designed to provide manual or fully automatic starting and protection functions.

1.5.5.2 Starting The diesel generator shall be suitable for starting manually / automatically from the DG local control panel or from PURCHASER’sremote control panel. For this operation, necessary local –remote selector switches shall be provided at the DG local control panel. Contacts for initiating automatic start up shall be provided by the PURCHASER.

1.5.5.3 Automatic Starting When the 415V bus voltage dips to 80% or below and remains there for a period of 0.8 seconds, the diesel generator set gets an impulse for starting. The auto start commandsignal shall be wired to the terminal block and shall be available for external cable termination from

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site.The solenoid valves (duplicated) in the starting air supply line shall be opened by the starting signal. As the diesel engine gathers speed, the oil pressure at the delivery of the shaft driven oil pump shallbuildup. When it exceeds preset value, the starting air supply shall be cut off. On the other hand, if the lube oil pressure fails to build up this value after a preset time, starting failure is indicated. (the bidder can propose any of the alternative starting scheme suitable for his engine for which concurrence of the PURCHASER shall be obtained ). When frequency and voltage reach 48 Hz and 380 V respectively, an impulse shall be given for closing the alternator breaker. The diesel generator set shall be capable of building the above frequency and voltage within 20 seconds from the starting impulse given to the engine. Necessary voltage and frequency relays shall be furnished by the supplier. The starting of the engine will be blocked if any of the tripping signals are present.

1.5.5.4 DG controls, meters, indications, protections and fault indications / annunciation shall be provided from the following panels.

a) Local control panels in diesel generator building b) Control panel in control room.

1.5.5.5 DG shall be protected for all faults by the protections provided as part of the DG controls and protections.Generator protection shall be with P343. Separate Differential protection relay shall be provided. EMI/EMC qualification certificate shall be provided for the relays

1.5.5.6 Surveillance system 1. Surveillance Instrumentation

The following systems shall have sufficient mechanical electric instrumentation to survey the variables required for successful operation and to generate the abnormal, pretrip and trip signals required for alarm of such conditions: a)Fuel oil system b) Lubricating oil system c) Jacket water system d) Starting (compressed air) system e)Combustion air (air intake) system f) Exhaust system g) Governor system h) Generator i) Excitation system j) Voltage regulation system

2. Instruments for Fuel oil system a)Pressure gauge at the engine inlet. b) Pressure switch shall be provided at the engine inlet for low pressure alarm on the

engine control panel c) Relief valve shall be provided to guard against excess pressure in the pump discharge.

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d) Intrinsic safety feature shall be incorporated for all the instruments / signals in the fuel oil system.

e)Differential pressure indicating switch shall be provided across each filter for alarm on engine control panel to intimate clogging of filters.

f) Pressure transmitter shall be provided at the engine inlet for engine control panel indication.

g) Level instrumentation for HSD transfer pump should be independent of electrical power. (Preferably, Magnetic float type with potential free contacts) and stay – put status of the contacts for pump controls.

h) Separate float switch for level indication and alarms should be provided for DG day tank

i) Continuous level indication shall also be provided with non contact type instruments suitable for providing continuous level indication in local panel.

j) Level indicator shall have potential free contacts for DG day tank level very high alarm, and very low alarm.

k) A duplex strainer shall be provided at the inlet of day tank. The duplex strainer shall be located on the day tank platform. It shall be provided with differential pressure indicating switch for generating alarm on local control panel.

3. Instruments for Lube oil system a)Differential pressure indicating switch shall be provided for each lube oil filter for

alarm on engine control panel. b) Two independent pressure switches shall be provided to give low lube oil pressure

alarm and if the pressure falls below a pre-set value and subsequentlyto trip the DG set when the pressure is below the minimum safe pressure.

c) Pressure switch shall be provided for automatic operation of standby motor driven lube oil pump.

d) Relief valve shall be provided to guard against excess pressure in the pump discharge.

e)Pressure transmitter shall be provided at the engine inlet for engine control panel indication.

f) Pressure gauge at the discharge of the engine driven pump. g) One No. of temperature gauge shall be provided at the lube oil outlet from engine

bearing. A temperature switch shall also be provided for alarm on high oil temperature.

h) One temperature transmitter shall be provided at the engine inlet for engine control panel indication.

i) A temperature switch shall be provided at the engine inlet for high oil temperature alarm.

j) Engine sump level switch for low level alarm on engine control panel, level gauge and dip stick to be provided.

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k) A flow switch / pressure switch to be provided for pre-lube oil flow monitoring for alarm on engine control panel.

4. Instruments for Jacket water system a)Temperature gauges shall be provided for jacket water temperature at each cylinder

outlet, at jacket water heat exchanger outlet and the outlet of oil cooler. b) Temperature Switch shall be provided for jacket water temperature at each cylinder

outlet to give jacket water temperature high alarm and trip the DG set. c) Pressure gauge shall be provided for jacket water header inlet pressure to engine. d) A RTD controlled jacket water preheating shall be supplied, if ambient temperature

condition warrants the same. e)One No. of RTD based control system shall be provided for charge-air cooler for

controlling cooling water flow. f) One temperature transmitter at outlet header for engine control panel indication. g) Jacket water expansion tank shall be provided with low level switch for alarm on

engine control panel. Level indicator shall be provided for local indication.

5. Instruments for Cooling water system (Radiator) 1. Pressure gauge at the inlet and outlet of the cooler 2. Low flow alarm ( differential pressure type) 3. Cooling water inlet and outlet temperature gauges 4. Air inlet and outlet temperatures

6. Instruments for Starting ( Compressed Air) System

a)Pressure switches shall be provided for automatic starting and stopping of the compressor. Alarm should be provided for minimum alarm pressure (corresponding to 2 starts) and very low pressure (corresponding to zero starts)in compressed air system at a pressure below pressure switch setting.

b) Temperature gauge shall be provided at the compressor outlet. c) Pressure gauge shall be provided on each air receiver. d) Alarm for failure of changeover of drier tower. e)Timer based auto moisture drain valves shall be provided at air receivers and

compressors.

7. Instruments for Air Intake and Exhaust Gas System a)Thermocouples / RTD for cylinder head exhaust temperature and its indication in

control panel and alarm. b) Temperature transmitter shall be provided at the charge air cooler outlet

forindication on engine control panel.

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c) Temperature switch shall be provided at the charge air cooler outlet for inlet air high temp. alarm on engine control panel.

d) Pressure transmitter shall beprovided at the charge air cooler outlet for inlet air pressure indication on engine control panel.

8. Governing System a)An over speed trip mechanism shall be provided to automatically shut off fuel in case

of the DG set speed reaches about 110% of rated speed. b) Speed indicator shall be provided on the engine control panel as well as on

generator control panel. c) Two independent speed references shall be used for controlling the speed of the

engine.

9. Level instrumentation for pump should be independent of electrical power ( Preferably Magnetic float type with potential free contacts) and stay-put status of the contacts for pump controls. Separate float switch for level

10. The above instrumentation and control requirements areminimum. TENDERER shall submit in the offer complete details of instrumentation and control required for safe and reliable operation of the DG set for the approval of thePURCHASER. All transmitters and switches shall be mounted close to the tapping point. All gauges can be mounted directly on the engine or pipelines or on the rack. An isolation/route valve shall be provided for all Transmitters/Switches/Gauges. A junction box for field cables shall be provided on the engine rack.

1.5.5.7 Control Panels

1. Separate control panels (located in DG building ) shall be provided for each DG for the

following: a) Generator control panel (includes excitation) b) Engine control panel.

Composite panel housing the requirements of generator control panel and engine control panel are acceptable to the PURCHASER.They shall be supplied completely wired and ready for external connection. These panels shall be located inside the DG buildings. DG control scheme with logic diagram shall be submitted along with the offer.

2. All local and remote controls shall be designed for 48V DC 3. A selector switch with locking arrangement installed on the DG local control panel

shall select whether the set is to be on local or remote control. In the local position only, manual staring shall be possible, by means of start / stop switch on Local control panel. In the remote position, automatic or manual starting shall be possible as

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selected by Auto / Manual selector switch in the remote control room. With the switch in Auto position, the set will be started by station emergency transfer scheme. With the switch in manual position, the set will be started by Start/ Stop button switch in Main control room. An alarm shall be provided in main control room when local mode is selected.

4. Control of the generator field excitation and the speed of the set will be done by a) Raise – lower switches in the main control room b) Raise - lower switches on the DG local control panel

5. Earthing of panel shall be done with suitably rated copper conductor. 6. Equipment to be provided on each generator control panel:

a) Electrical Instruments (i) Speed indicator (ii) Three voltmeters 0-500 v / or one voltmeter with selector switch (iii) One frequency meter (iv) Wattmeter (v) KVAR meter (vi) Three ammeters / one ammeter with selector switch (vii) Power factor meter (viii) DC ammeter for field circuit of exciter (ix) DC voltmeter for field voltage of exciter (x) Elapsed time indicator (xi) Time totalizer

b) Control switches

(i) Local /Remote selector switch for DG set (Key operated) (ii) Push Buttons for start & stop of DG set (iii) Push Buttons for raising and lowering of speed (iv) Push Buttons for raising and lowering of voltage (v) One selector for Quadrature droop control (IN/OUT) stay put type. (vi) Excitation cutoff switch

The contacts shall be electrically independent and shall be suitable for 48 V DC operations.

7. Local alarms on Generator control panel The following lists of alarms are the minimum required and supplier shall indicate additional alarms, if any as per the supplier’s design / scheme. A window type annunciation panel shall be supplied on each generator panel to give visual and audible indications on occurrence of any one or more for the following troubles:

(i) Generator winding temperature high. (ii) Generator bearing /bearing lube oil temperature high. (iii) 48V fuse failure

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(iv) DG differential protection (v) DG main protection lock out relay operation (vi) over current protection (vii) DG earth fault protection (viii) Control supply fail (ix) Voltage raise limit (x) Voltage lower limit (xi) Starting failure (xii) Excitation failure (xiii) DG over voltage. (xiv) DG Under voltage (xv) Under frequency (xvi) MCB in voltage transformer circuit tripped. (xvii) Logging PLC failure (xviii) 6 Nos of spare annunciation points

8. Alarms on Engine control panel: The following lists of alarms are the minimum required and supplier shall indicate additional alarms if any as per suppliers design / scheme-

(i) High DP across fuel oil filter (ii) Low fuel oil pressure (iii) High lube oil temp at engine inlet (iv) High DP across lube oil filter (v) Low lube oil pressure (vi) High lube oil temperature at engine bearing outlet (vii) Lube oil sump level low (viii) Pre-lube oil pump not in operation (ix) High jacket water temperature (x) Jacket water level low (xi) Cooling water flow low (xii) Low fuel oil in day tank (xiii) Compressed air pressure below minimum safe pressure (corresponding to 2

Starts) (xiv) Compressed Air pressure very low (no start possible). (xv) Failure of changeover of drier (xvi) Engine fails to start (xvii) Engine tripped. (xviii) Emergency stop (xix) High exhaust gas temperature (xx) High Differential pressure high across fuel oil strainer at day tank inlet (xxi) Cylinders exhaust gas temperature high. (xxii) Spare annunciation points- 6 Numbers

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9. Alarm indications and reset For alarm indication, a common hooter and individual indication lamps shall be provided. Three numbers push buttons shall be furnished for accept, reset and test. On occurrence of a fault, the hooter shall sound and an indication lamp shall flash. On pressing acknowledge P.B, hooter shall stop but the lamp should continue to glow steady. On pressing reset P.B, the lamp shall stop glowing but if the fault persists the hooter shall sound and lamp shall flash again. Necessary auxiliary relays, Push buttons, hooter, indication lamps shall be furnished as required to achieve the above function. All alarm devices shall be suitable for operation on 48V DC.

10. Push button Heavy duty push buttons shall be furnished for the various operations. The PB shall be suitable for 48 V DC supply and shall be able to break the DC inductive currents of the different relays and contactor circuits. Stop P.B.s shall have locking provision in depressed condition. It shall be possible to add additional contacts to the PBs.

11. Selector switches Selector switches for ammeters, voltmeters and choice of control shall be furnished. The selector switches shall be of adequate rating for the duty involved. Legend plates clearly marking the operating position shall be furnished.

12. Relays Adequate number of self-reset auxiliary relays(Controlcontactors) shall be furnished for the control circuits. The relays shall have at least 4 sets of contacts, which can be provided in any combination of NO and NC. The coils shall be rated for 48V D.C. and the contacts shall be rated for making, carrying and breaking the required D.C. inductive currents for the duty involved.

13. Timers A number of timers as required shall be furnished for the control circuits. The timers shall be rated for 48 V DC and the rating of their contacts shall be suitable for the duty involved. The time settings shall be furnished to the successful tender. The timers shall be preferably being electronic.

14. Local lamp indication on DG Generator control panel Indicating lamps LED type shall be provided for the following –

a) Engine running - Red b) Engine ready to start - White c) Generator ready d) DG breaker ON e) DG breaker OFF f) Generator space heater ON

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15. Following indications shall be provided on the Engine Control panel:

a) Level indicator for DG day tank level b) Pressure indicator for fuel oil pressure at the engine inlet. c) Pressure indicator for lube oil pressure at the engine inlet. d) Temp indicator for lube. Oil tem. At the engine inlet and outlet. e) Temperature indicator for jacket water temperature at the outlet header of

circulation pump f) Temperature indicator for cylinder head / exhaust gas g) Temperature indicator for inlet air temperature at charge air cooler outlet. h) Pressure indicator for inlet air at charge air cooler outlet. i) Speed indicator for each diesel engine and turbo charger j) Runtime meter for each diesel engine ( Cumulative hours) k) No. of starts counter

16. All transmitters andswitches will be mounted on the floor mounted instrument rack

near the engine. All gauges can be mounted directly on the pipeline or on the rack. An isolation / route valve shall be provided for all transmitters / switches/ gauges. A junction box for field cables shall be provided on the same rack

17. Remote control room panel : The TENDERER should consider the following functions to be performed from Main control room for hand switches / Push buttons operation, alarms and indications from the PURCHASER’s remote control panel. The TENDERERshould develop control schemes for the DG set suitably. a) Alarm annunciations

(i) Circuit breaker trip on fault (ii) Engine trouble ( Grouped) (iii) Engine failed to start (iv) Engine trip (Grouped) (v) Low voltage / over voltage (vi) Overload (vii) Reverse power (viii) Earth fault (ix) Internal fault differential relay (x) Over speed (xi) 48V DC supply fail (xii) Under frequency

b) Measurements (i) Elapsed time indicator (four digits to read in minutes with reset) (ii) Wattmeter (iii) Frequency meter

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(iv) Speedometer (v) Ammeter (vi) Power factor meter (vii) Voltmeter

c) Controls (i) Start / Stop button for the engine (ii) Raise/ Lower voltage PBS (iii) Raise / Lower speed PBS (iv) Auto / Manual selector switch for DG set (v) Ammeter selection switch (vi) Circuit breaker switch (vii) Voltmeter selection switch (viii) Return to normal power supply.

d) Lamp indications (i) Local control (ii) Ready to start (iii) Started (iv) Voltage and frequency build up (v) Emergency run.

18. Instrument rack (i) Instrument rack, a local gauge board shall be provided for monitoring

important system pressures through pressure and temperature gauges. (ii) Engine emergency stop push button for DG set stopping. The PB shall have

locking provision in depressed condition. (iii) Self standing panel near the DG set.

19. DG auxiliary Motor control Center

(i) Should provide power supply and ON/OFF controls for DG auxiliaries ( Auto /Manual selector and ON/OFF Push buttons with status indication lamps) to DG set auxiliaries and space heaters.

(ii) Panel is fully draw out type, single front and compartmentalized design (iii) Panel feeder should consist of MCCB, MCB, OLR, contactors etc. and will be

located near the DG set. (iv) There shall be two MCCs for the duplicated auxiliaries for redundancy MCC Panel shall carry name plates carrying the following data:

i. Manufacturer. ii. Type, designation and serial number. iii. Year of Manufacture. iv. Rated continuous current, Voltage and frequency. v. Weight of complete panel. Panel designation will be displayed prominently in one or more locations. Shipping sections will be designated and identified clearly.

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Separate nameplates will be provided on each module furnishing the following with minimum letter size of 12 mm. i. Feeder rating ii. Function. iii. Feeder number. Each module will carry a name plate, inside but easily visible location, bearing the reference drawing numbers.

20. Computer based data logger system :

A stand-alone data logger (PLC based with HMI/Paperless Recorder type) to record and monitor all critical parameters (including the digital inputs for the master trip relay, DG operating time, trips and engine trouble alarm) for diagnosis with sufficient number of channels and having 10 spare channels for future requirement. It shall scan these inputs at an interval of typically, 20 m Sec and update and store the events pertaining to any changeover of status. The storage capacity shall be such that, data logging system shall record minimum 1000 such events and shall overwrite subsequently on First In First Out (FIFO) basis.

21. Panels : (i) The panels shall be fully front access, draw out type. The cubicle shall be made

of 2.5 mm thick sheet steel for load bearing frame, 2 mm for load( component) bearing doors or covers, 1.6 mm for non-load bearing doors/ covers/top, 3 mm for base frame and gland plates . A base frame made out of 75x40 mm ISMC shall be provided at the bottom with grouting holes and bolts. Preferred dimensions of the panel will be finalized during the drawing approval. The enclosure shall conform to IP 52

(ii) All equipment such as indicating instruments, recorders, selector switches, indicating lamps, annunciators etc. mounted on panels shall be semi-flush type having projection of the facia of the equipment only

(iii) A provision for internal illumination and receptacles for connection of portable equipment shall be made.The lamp shall be preferably be on the ceiling while the switch for the lamp may be fixed on the door frame such that the lamp is on when the doors open. The receptacle shall be fixed suitably on the side of the panel.. The sheet steel and the steel structure shall be chemically cleaned, rinsed, bonderized and dried. Immediately after bonderizing the steel structure shall be sprayed with a prime coat of paint. The finish of the panel shall consist of two coats of spray of aircraft grey (IS color 693) stoved enamel paint

(iv) All control wiring of the panels shall be done by single 2.5 sq.mm standard copper conductor PVC insulated cables of 1100 / 650 volts grade. All wiring shall be provided with identification ferrules at both ends. The wiring shall be neatly bunched and suitably clamped and supported

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(v) Terminal blocks shall be suitably rated for medium voltage system with adequate clearances between live parts and ground

(vi) The terminals shall be preferably of stud type provided with crimping type cable sockets. The stud shall be of sufficient length, so that at least 2 nos. sockets can be terminated. Alternatively if socket less type terminals are provided, it shall be ensured that the conductor is looped round the tightening screw and is inserted between two pressure plates. In no case tightening screw sitting on the conductor shall be accepted. All terminal blocks shall be provided with 20% spare terminals.

1.5.5.8 Permissive and Protection a) Permissive

A relay shall be provided to monitor the following conditions required to be fulfilled before the DG can be started:

(i) Diesel Generator 415 V circuit breaker is open (ii) Adequate compressed air pressure available for starting (iii) No protection trip on engine / generator (iv) No control power supply failure (v) Stop button not actuated

b) Protection

The diesel generator shall be tripped under the following conditions – 1. Control supply failure ( supervised by a relay) 2. DG failed to start shall be achieved by a timer which energizes after

starting impulse given and time out and trips the engine if lube oil pressure fails to build up in preset time.

3. Over speed of DG set as sensed by speed sensors or engine mechanical over speed trip mechanism

4. Low lube oil pressure after engine has attained 90% speed. 5. Fuel oil pressure low after 90% speed 6. Incomplete start after a preset time ( after 2 attempts ) 7. High jacket water temperature 8. Excitation failure due to tripping of field CB or failure to build up

voltage. 9. Generatoroverload 10. Generator earth fault 11. Generator overvoltage 12. Generator differential protection 13. Reverse power protection 14. Alternator stator winding temperature high 15. Emergency stop 16. Failure of both speed sensors

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2 out of 3 logic shall be employed for low lube oil pressure, overspeed,high jacket water temp and low fuel oil pressure. Triplicate sensors, contacts etc shall be provided for this purpose.

1.6 SPECIAL REQUIREMENTS 1.6.1 The DG set, its auxiliaries and other associated equipment such as control panels, neutral

grounding resistors etc. fall under the classification of clause IE equipment (IEE-308) for nuclear power station stand by duty. Hence the offered sets its auxiliaries and other associated equipment should qualify as clause IE equipment

1.6.2 The requirement for such qualification is covered in the following standards 1 IEEE 308 Standard criteria for class IE power systems for nuclear power station 2 IEEE 323 Standard for qualifying class IE power systems for nuclear power station 3 IEEE 387 Standard criteria for diesel generator units applied as standby power supplies

for Nuclear Power Generator stations 4 IEEE 344 Standard Seismic qualification of equipment for nuclear power generating

stations. The TENDERER should ensure that equipment offered meet these requirements and confirm the same in the bid. The TENDERER shall ensure all design, testing and documents required to ensure this qualifications and obtain PURCHASER’S approval

1.6.3 The DG sets shall be capable of operating throughout the entire life as class IE equipment and shall be design to provide the required power output throughout its life

1.6.4 Seismic Qualification 1) DG set and associated equipment including control panels are seismic

category-I equipment and shall be designed for both SSE (safe shut down Earth quake) and OBE (operating Basis Earthquake) as per IEEE 344.

2) Seismic requirements: The Diesel generator shall be subjected to seismic qualification tests for the following Required Response Spectra, where the horizontal acceleration at different periods is shown in Table 1. The vertical acceleration will be two-thirds of Horizontal acceleration. Damping shall be taken as 5%.

3) If a similar DG has been supplied which has the capability to with stand above seismic values, the same is acceptable with a seismic qualification certificate.

4) The control panel shall be designed and tested to withstand seismic acceleration as transmitted to them by the mounting channels at the respective mounting levels.

5) The control panels mounting channels and DG set fixing arrangement shall be designed and qualified to withstand the seismic forces specified. The TENDERER shall furnish design analysis to substantiate this

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Period VsDamping Table

Period Vs Spectral Acceleration for Different Values of Damping

6) The control panels and DG set and auxiliaries should, in addition to structural

rigidity, provide sufficient support and physical protection to the equipment mounted inside the panel and on DG set to enable them to remain operational

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and meet its essential performance requirements during and after SSE and OBE.

7) The control panels shall also be designed that at the frequencies and acceleration of floor (as per floor response spectra) resulting from the SSE, they do not amplify the forces beyond the level at which the equipment used is seismically qualified.

8) To take care of above, panels can be designed by providing sufficient rigidity so that no natural frequencies or resonance exists at a frequency less than 33 Hz. This shall be achieved by providing any or all of the following: a) Welded stiffeners b) Diagonal braces to the base. c) Continuous and stitch welding in place of spot welding.

9) Special attention of the TENDERER is drawn to this clause that the equipment cannot be accepted unless DG sets, control panels and their equipment are qualified.

1.6.5 Seismic Qualification of DG sets and panels 1) The seismic qualification of engine control panel and generator control panel

shall be carried out by actual testing, in the shake table facility at any approved testing facility. The testing shall be carried out in accordance with IEEE-344 for structural integrity and functional requirement. The TENDERER shall obtain the testing charges from testing facility and indicate the same in their offer

2) The testing charges payable to the testing agency will be reimbursed by the PURCHASER as per the tender quote. If the equipment fails to pass the seismic test at the first attempt, due to deficiencies in design or manufacture, the TENDERER shall bear the subsequent re-testing charges. The TENDERER shall be responsible for co-ordination with the testing agency for successful and timely completion of seismic testing.

3) Safe transportation of the equipment to and from the TENDERERs work to the facility, engineering and supply materials required (making base plates, base frame etc.) for mounting the equipment on shake table and required manpower to handle the equipment are to be provided by the TENDERER. He shall also arrange for the various testing instruments (such as HV testing unit, megger, DC power supply rectifiers, storage oscilloscopes etc.) required for these tests. A lump sum price for the above shall be quoted under the heading of ‘Seismic testing qualification’.

4) In consultation with PURCHASER and the testing agency, the TENDERER shall prepare a detailed testing procedure including the list of parameters to be monitored during the testing as well as tests to be carried out on the control panels before, during and after seismic test. The seismic testing procedure and

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acceptance criteria will be finalized after placement of order. As a minimum requirement, the following tests to be included: a) Monitoring of switches, TENDERERs, relay contact etc. for chattering

during the test. b) HV test and IR measurement test before and after seismic testing. c) Visual inspection.

5) If TENDERER has carried out seismic test on similar control panels with enveloped floor response spectra same or more severe than specified in this document, TENDERER may furnish a copy of type test report.

6) In view of large dimension and heavy weight of DG set, the same shall be seismically qualified by analysis. The analysis report shall be submitted for PURCHASER’S approval. a) Load combinations and allowable stresses

(i) Components, parts and component supports shall be designed as per ASME Section III, Div.1 subsection ND.

(ii) Simultaneous actions of three components of seismic forces are to be considered two horizontal and one vertical component. The two horizontal components are considered equal and vertical forces may act either upwards or downwards. The equipment shall be designed for the most severe combination.

(iii) Seismic fatigue analysis is not required when the range of primary and secondary stresses due to seismic loads alone is less than 3 Sm or equivalent.

b) The TENDERER shall state the method of analysis proposed to be carried out and indicate the facilities available or accessible to him.

c) The seismic qualification report shall comprise of the following: (i) Outline arrangement showing all pertinent dimensions and support

locations. (ii) The mechanical model employed with assumptions made and loads

imposed. (iii) Details of analytical method and the procedures followed. (iv) If a computer program is used for the details of the same, shall be

furnished to the PURCHASER. The program chosen should have been validated/ approved by recognized authorities and should have been successfully used earlier.

(v) The method to be adopted by the TENDERER for qualification is subject to prior approval of PURCHASER before commencement of analysis.

7) Seismic testing and analysis charges will be released to the TENDERER after production of successful seismic qualification certificate of the testing agency.

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8) The components like control panels, instruments etc. which are actually tested in the shake table need not be returned to the TENDERER and should not be used in the actual supply of items.

9) Acceptance by the PURCHASER of the test procedures and test reports does not relieve the TENDERER of his responsibility for guaranteed performance of the equipment in case of a seismic event of the severity levels specified by the PURCHASER

1.6.6 Seismic Qualification requirements 1.6.6.1 TENDERER shall furnish following information in his offer-

a) Whether the TENDERER has supplied similar equipment to any plant located in an area subjected to the seismic events of the same magnitude or higher (i.e. response spectra is same or higher) and have performed satisfactorily during such events

b) Whether the TENDERER has carried out seismic tests on similar equipment to prove their seismic withstand capability

c) Whether the TENDERER has carried out seismic analysis to determine seismic withstand capability

1.6.6.2 Methodology a) The seismic withstand capability is generally carried out by seismic testing at a shake-

table facility OR by analysis OR by a combination of both. Heavy and simple equipment (structure, supports, etc.) can be qualified by analysis

b) The qualification can also be done by a combination of analysis and testing. Panel frame-work can be qualified by analysis and various components like relays can be tested individually

c) For the imported items if the TENDERER wishes to carry out seismic tests abroad the same shall be clearly brought out in the offer along with all relevant details

d) The seismic test procedure will be jointly worked out by the PURCHASER, TENDERER and the test facility proposed to be used

e) After reviewing the test certificates and reports submitted, a decision would be taken whether to conduct seismic tests and this decision shall be informed to successful bidder. It shall be bidders responsibility to ensure that such timely communication regarding testing is obtained from PURCHASER and to ensure that there is no delay in delivery

f) TENDERER to quote separate price in his quotation for carrying out seismic withstand test OR analysis

g) The acceptability of seismic test institution, test procedure, method of analysis & Institution/Company performing this analysis shall rest with the purchase whose decision shall be final

1.6.7 Pollution Control and Mandatory clearances requirement 1.6.7.1 All the equipment covered under this tender shall meet the pollution control requirements

of central pollution control board and Tamilnadu State pollution control board. It is the

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responsibility of the TENDERER to provide all necessary assistance to obtain required clearances from the pollution control board to PURCHASER

1.6.7.2 Wherever required, getting approval of government bodies is the sole responsibility of TENDERER for his design, drawings, manufacturing, testing and inspection. In such cases approval by government bodies under jurisdiction will not relieve the TENDERER from his responsibility of making good of defective material, equipment, system, etc. However, TENDERER shall keep the PURCHASER or his representatives informed in writing about any approval or otherwise by such government bodies. TENDERER shall take the concurrence of PURCHASER or his representative before proceeding with rectification procedures as called by the government bodies

1.6.8 WELDING, RADIOGRAPHY AND OTHER NDT 1.6.8.1 Where applicable NDT or NDE procedures issued by PURCHASER’s Quality Assurance may be

used for inspection and testing. 1.6.8.2 Chemicals approved by the PURCHASER shall be used for the liquid penetrant / other NDT

examination 1.6.8.3 Only the Welding consumables approved by the PURCHASER shall be used 1.6.8.4 NDT or NDE shall be carried out by personnel qualified by ISNT or ASNT 1.6.8.5 Physical and chemical tests for check-test shall be carried out at laboratories approved by

the PURCHASER

1.7 INPECTION AND TESTING 1.7.1 The equipment covered by this contract shall be subjected to inspection and testing. The

TENDERER shall provide all services to establish and maintain quality of workmanship in his works and that of his SUB-TENDERERS to ensure the mechanical/electrical performance of components compliance with drawings, identification and acceptability of all materials, parts and equipment.

1.7.2 On award of the contract, the TENDERER shall prepare quality control plan identifying the various stage of manufacture, quality checks performed at each stage and the PURCHASER hold points. The document shall also furnish details of method of checking, inspection and acceptance standards/values and get the approval of PURCHASER or his representative before proceeding with manufacturing. PURCHASER or his representative shall have right to review the inspection reports, quality check and result of CONTRCTORS in-house inspection department which are not customer hold points and the TENDERER shall comply with remark made by PUCHASER or his representative on such reviews with regarding to further testing, rectification or rejection etc.

1.7.3 The TENDERER shall perform his internal inspection/testing before offering the equipment for PURCHASERS inspection. Only after ensuring that his inspection / test results are satisfactory, TENDERER shall offer the equipment for PURCHASERS inspection. HOWEVER this clause is not applicable incase of such test which are required to be done only once in the life time of the equipment.

1.7.4 The minimum inspection requirements for all components/equipment shall conform to the design and fabrication requirement as defined in the codes and standards referred to the

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specified document. The type of inspection shall be as described in quality control plan and as agreed upon by the PURCHASER, and shall include if applicable, inspection procedures prescribed by codes and regulations recognized by the governmental authority having jurisdiction over the installed goods. Static and dynamic testing of control systems in shop shall be done in the presence of PURCHASER/CONSULTANTS representative. TENDERER shall submit the test procedures, TENDER shall however take total responsibility of the integrated system at site and any shortfalls/defects shall be rectified.

1.7.5 Whenever required, getting approval of government bodies under jurisdiction is the sole responsibility of TENDERER for his design, drawings, manufacturing, testing and inspection by such bodies. In such cases approved by government bodies under jurisdiction will not relive TENDERER from his responsibility of making good of defective material/equipment/system. However, TENDERER shall keep the PURCHASER/ his representative informed in writing of any approval or otherwise any comments of such government bodies. TENDERER shall take the concurrence of PURCHASER or his representative before proceeding with rectification procedure as called by the government bodies.

1.7.6 Approval or passing of any such inspection by the PURCHASER or his authorized representative shall not, however, prejudice the right of PURCHASER to reject the equipment if it does not comply with specification when erected or give complete satisfaction in service during commissioning.

1.7.7 The TENDERER shall intimate to the PURCHASER of any material being ready for testing such test shall be to the TENDERER’S account except for the PURCHASER’S expense to witness the test. The PURCHASER or his representative, unless the inspection of the test is virtually waved, shall attend such test.

1.7.8 The TENDERER shall be notified in writing by the PURCHASER of any objection to the drawings and, all or any equipment and workmanship which in his opinion is not in accordance with the ‘Contract’. The TENDERER shall give due consideration to such objection and shall either make the modifications that may be necessary to meet the said objection or shall conform in writing to the PURCHASER giving reasons therein that no modification are necessary to comply with ‘Contract’. However, PURCHASER has the final authority to accept or reject the TENDERER’s view. The equipment/materials after rectification by the TENDERER shall be offered to the PURCHASER for his final inspection and acceptance without any additional coast to PURCHASER.

1.7.9 When the factory test have been completed to the satisfaction of the PUCHASER, the PURCHASER shall issue a certificate to this effect within fifteen (15) days after completion of test, but if the test are not witnessed by the PURCHASER’S representative, the certificate shall be issued within fifteen (15) days of the receipt of the TENDERER’S test certificate by the PURCHASER provided the results are satisfactory and conform to the specified parameters. Failure of the PURCHASER to issue such certificate shall not prevent the TENDERER from proceeding with subsequent work. The completion of these tests or the issue of the certificate shall not bind the PURCHASER to accept the equipment should it, on further test after erection, be found not to comply with the ‘contract’.

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1.7.10 In all cases where the ‘Contract’ provides for tests whether at the premises or works of the CONTRACT or of any SUBCONTRACT, the CONTRACT except where otherwise specified shall provide free of charge such items as labour, material, electricity, fuel, water, stores, operators and instruments as may be reasonable demanded by the PURCHASER or his authorized representative to carry out effectively, such test and shall be also facilities to the PURCHASER or to his authorize representative to accomplish testing.

1.7.11 The inspection by the PURCHASER and issue of inspection certificate thereon shall in no way limit the liabilities and responsibilities of the TENDERER in respect of agreed quality assurance program forming a part of the ‘Contract’.

1.7.12 Sub-Orders 1) To ensure good quality product from SUB-TENDERER, the main TENDERER shall obtain

PURCHASER’S prior approval before engaging the SUB-TENDERER. For this purpose, TENDERER shall furnish details of SUB-TENDERER such as his capability, experience, manpower, manufacture facility, quality control facilities etc. The PURCHASER may visit the SUB-TENDERER’s works to evaluate their capacity and capability to do quality job to meet specification requirements. The sub-orders should highlight the inspection and quality control requirements stipulated in the main specification and all required quality checks and tests shall be conducted as per the specification.

2) In order to facilitate the inspection of brought-out materials and equipment, the TENDERER shall submit for the approval, three (3) copies of all sub-orders placed by him as soon as they issued. Copies of any drawings referred to in the sub-order shall also be submitted, unless otherwise agreed by the PURCHASER or his representative.

3) The sub-orders and drawings referred to above shall cover all components which are subjected to electrical and mechanical pressure or stress when the plant is in operation, and also auxiliaries and spares which are to be directly dispatched to site from the SUB-TENDERER’s works.

4) All sub-orders shall clearly be marked with the main TENDERER’s name and the PUCHASER’s reference. They shall include a statement advising the SUB-TENDERER that items being ordered will also be subject to inspection and test by the PURCHASER or his representative.

5) It is important that all copies of sub-orders be clearly marked with the main TENDERER’S name and the name of the PURCHASER and ‘Contract’ reference.

1.7.13 Material Tests 1 In the event of the PURCHASER or his representative being supplied with the

particulars of tests which have been carried out for the TENDERER by the suppliers of the material, he may at his own discretion, accept the same as proper evidence of compliance with the requirements of appropriate specifications for the materials.

2 In case the correlation test certificates are not available the TENDERER, at no extra cost to the PURCHASER will get all the tests done to establish conformity of the material to its relevant code/specification.

1.7.14 Specific tests

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The manufacturer shall perform all tests necessary to ensure that equipment conforms to IEEE standard criteria for diesel generator units applied as standby power supplies for Nuclear Power Generating Stations IEEE Std. 387 -1995 (R2007) and ISO-3046. Tests shall be completely documented including records of failure, their repair and re-testing.

1.7.15 Tests On Engine (Factory production Tests)

1) The factory production tests for diesel engine, generator and excitation, control and other accessories / auxiliaries shall be conducted by the TENDERER as per IEEE Std. 387 guidelines.

2) Each engine shall be tested utilizing either a water brake dynamometer or generator to provide accurate means to control power absorption. The following tests shall be performed conforming of IEEE 387-

a) Brake in Test b) Performance test c) Data logging d) Controls- alarms and shutdown. e) Inspection

3) In addition to the performance tests covered, the following tests shall also be conducted at the manufacturer’s works. a) Capability of DG set to operate without radiator fans for the specified period. b) No load running capability test. c) Overload capability test for 2 hrs.

1.7.16 The following routine, type and special tests shall be conducted on the generator and

accessories. 1) Generator

a) Routine Tests (i) Insulation resistance test of stator & rotor (before high voltage test) (ii) High voltage test on stator & rotor windings (iii) Phase sequence test (iv) Regulation test (v) Measurement of open circuit characteristic (vi) Measurement of short circuit characteristic (vii) Measurement of DC resistance of stator, rotor and RTDs.

b) Type Tests (i) Temperature rise test (ii) high voltage test (iii) Measurement of leakage reactance and Potier reactance (iv) Efficiency test (v) Over speed test (vi) Determination of deviation of voltage wave form from sinusoidal. (vii) Short circuit test and measurement of reactance and time constants.

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(viii) Momentary overload test (ix) Telephone harmonic factor ( total harmonic distortion) (x) Measurement of vibrations (xi) Measurement of losses (xii) Evaluation of inertia constant from retardation test. (xiii) Stator leakage reactance measurement. (xiv) Measurement of capacitance and tan delta on stator winding. (xv) Measurement of noise level

The supplier shall evaluate all the parameters after the required test and review the test result with PURCHASER along with standards. If Type tests had already done on the similar machine being offered, details and documents of such Type test shall be submitted by the TENDERER.

1.7.17 Exciter 1) Routine tests

a) High voltage tests on stator and rotor windings b) Insulation resistance of stator and rotor windings c) Measurement of resistance of stator and rotor windings d) open circuit magnetization test e) Over speed test

2) Type Tests a) Temperature rise test b) Measurement of losses in excitation equipment c) Response ratio test (on one exciter) d) Voltage decay test e) Vibration measurement

3) Tests of voltage Regulator a) sensitivity test b) Response time test c) performance test on quadrature droop circuit d) Environment tests

1.7.18 Qualification requirements on D.G. set

Qualification tests shall be conducted on the completely assembled DG sets as per IEEE-387. The qualification shall be accomplished by the initial Type tests (If not done earlier) and seismic qualification requirements

(i) Initial Type tests : Type tests shall be performed following successful completion of the factory production tests. Following the successful completion of type qualification tests, the equipment shall be inspected in accordance with the manufacture practices and inspection results shall be documented. Type qualification tests shall include (a) load

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capability (b) start and load acceptance tests and (c) Margin tests in accordance with IEEE-387. If type test has already been done on the DG sets being offered , details and documents of such type tests shall be submitted by the TENDERER.

(ii) Seismic Qualification: a) Diesel generator shall be capable of operating without failure during and after

safe shutdown earthquake conditions. TENDERER shall submit detailed analysis approved by an independent organization of repute to prove the DG sets to satisfactorily withstand the seismic accelerations and continue to operate throughout the design life. Wherever feasible, equipment like control panels, excitation and regulating cubicles etc. shall be subjected to actual testing. Analysis/excitation shall follow the recommendations outline in IEEE-344 for class-1E equipment.

b) Panels/ Cabinet/cubicle totally wired and assembled shall be type tested for seismic requirements. Each type of instrument shall be type tested for seismic requirements

c) Non safety related components require analysis or test to show that they will not degrade the safety related function of the unit during a seismic event,

d) Seismic testing shall be followed by functional testing to verify the applicable capabilities in clause 4 of IEEE 387.

(iii) Ageing qualification TENDERER shall clearly list in his OFFER the components which are liable for age related failures. Those components with potential age-related failures shall be qualified as per IEEE-387.

1.7.19 Commissioning,acceptance tests and performance test shall be carried out by the TENDERER. All tests, commissioning equipment and tools required shall be brought by the TENDERER

1.7.20 Site Acceptance Tests : (i) After the final assembly and preliminary start up testing at Manufacturer place, the

diesel generator unit shall be tested at the site to demonstrate the capability of the unit to perform its intended function and to verify compliance to various performance parameters guaranteed to the bidder during tender / contract execution.

(ii) Acceptance test at site shall be conducted on the diesel generator unit shall include the following –

a. Startingtests: This test shall demonstrate the capability to attain and stabilize frequency and voltage within the limits and time defined in the equipment specifications and to demonstrate adequacy of starting system capacity as specified.

b. Load acceptance tests: This test shall demonstrate the capability to accept the individual loads in the desired sequence and time duration and to maintain the voltage and frequency within acceptable limits.

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c. Rated loadtests: Comprising of operating the DG set at 100% load for 2 hr, 110% load for 2 hr, 100% load for 24 hrs and no load for 2 hrs followed by 50% load for 0.5 hour.

d. Load rejection tests: Test to demonstrate the capability to withstand sudden load rejection of 110% of rated load.

e. Electricals tests: Tests to demonstrate that the electrical properties of generator excitation system, AVR, governing, control, protection an surveillance systems are acceptable for the intended application.

f. Subsystem tests: Tests to demonstrate the capability of the subsystems to function in accordance with the requirements of the intended application.

g. Measurement of vibration h. Tests to demonstrate operation of DG set without radiator fans for specified

duration. i. Loads to be applied, carried and rejected during site testing shall be the design

load auxiliaries located at the station. 1.7.21 The following performance parameter shall be guaranteed by the supplier to be within the

specifications in respect of the diesel generator unit and the auxiliaries, when operating under the specified site conditions:

1) Each DG set shall be capable of generating at net electrical output of ______KVA under specified site conditions at _____ Hz,_____ power factor _____ V while running at ____ RPM under.

2) Fuel oil consumption at 1/4,1/2,3/4, and full load 3) Overload capability of the Engine. 4) Maximum period for which engine can operate without water circulation.

a) During cold start of Engine. b) During hot start of Engine.

5) Starting time and ready to take load. 6) Governor response, over speed capability. 7) Lube oil consumption at 100% engine load. 8) Generator efficiency at 1/4,1/2,3/4, and full load 9) Jacket water temperature at engine inlet and outlet. 10) Lube oil temperature at Lube oil cooler inlet and outlet. 11) Overspeed trip. 12) Transient voltage and frequency dips while starting of largest size motor. 13) Transient recovery time. 14) Voltage regulator response. 15) Excitation at full load and under specified variation of voltage and speed. 16) Maximum vibration of DG set _____ mm/sec 17) The noise level at a distance of 1.0 metre from the outline of the

equipment ______dB. TENDERER shall indicate the tolerances applicable to each of the guaranteed parameters above and the reference standards.

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The documentation supplied shall be along with DG set shall be in conformance with IEEE std 387 Clause 5.1.2

1.7.22 The TENDERER shall furnish price break-up for conducting all type tests specified above in the schedule of prices. The PURCHASER reserves the right to get any or all of these tests carried out at his discretion

1.7.23 If he is not in a position to carry out any of the tests, the TENDERER shall clearly indicate the same in his offer. In case it is not possible to conduct any of these tests at manufacturer’s works, these tests may be conducted at site after erection of the complete sets. The list of such test to be conducted shall be clearly furnished in the offer. The TENDERER may in such cases submit the testing procedure for PURCHASER’s approval. Also the list of instruments required shall be submitted for PURCHASER’s information and the instruments which are not available at site shall be provided by the TENDERER on loan free of cost to the PURCHASER

1.7.24 Type test certificates are acceptable in place of type test if the type, model and rating of DG offered had already been type tested by the TENDERER. Incase PURCHASER desires to repeat the type test for the DG offered, TENDERER shall indicate in the price offer the details for performing type tests on the DG

1.8 General Information and Instruction to TENDERERS 1.8.1 It is the intent of the PURCHASER to incorporate this tender specification in the contract or

purchase order for supply, erection and commissioning of material, equipment and services. The TENDERERs are required to review these documents and clearly state in their proposals their acceptance of the same. Exceptions and deviations, if any, shall be clearly stipulated in the appropriate tendering schedule. The final contract between the PURCHASER and the TENDERER shall be subject to such changes, if any mutually agreed upon between the PURCHASER and the TENDERER and included in the main text of the contract or purchase order. All requirements as called for by this specification and any addition by the supplier as part of meeting the PURCHASER’s requirements which is specified in the tendering stage shall be included by the TENDERER and he shall quote accordingly. No extra price shall be payable on account of TENDERER not considering some requirements of thisspecification. The TENDERER shall be deemed to have carefully examined the specification in its complete form. He is also deemed to have been fully informed and satisfied himself as to the details, nature, character and qualities of the work to be carried out, site conditions, seismic requirements, other pertinent matters and details

1.8.2 TENDERER is requested to carefully examine and understand the specifications and seek clarifications, if required, to ensure that they have understood the specifications. Such clarifications should be sought in a time bound manner to ensure completion of bid evaluation within the specified time period. If the TENDERER feels that, in his opinion, certain features brought out in his offer are superior to what has been specified, these may be highlighted separately

1.8.3 Any deviation or variation from the scope requirement and/or intent of this specification shall be clearly mentioned under Schedule of Deviations irrespective of the fact that such

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deviations/variations may be standard practice or a possible interpretation of the specification by the Bidder. Except for the deviations/variations, which are accepted by the PURCHASER in writing before the award of the contract or in Purchase Order, it will be the responsibility of the Bidder to fully meet the intent and the requirements of the specification within the quoted price. No other departure from the specification except for the declared deviation indicated by the Bidder and accepted by PURCHASER in his proposal shall be considered. The interpretation of the PURCHASER in respect of the scope, details and services to be performed by the Bidder shall be binding, unless specifically clarified otherwise by the PURCHASER in writing before the award of contract

1.8.4 If there is any discrepancy with regard to the quantity indicated in the price schedules, bill of material given in the scope and tender drawings, the bidder shall quote based on the quantity indicated in the price schedule

1.8.5 As it is the intent of this tender that a complete operational and integrated DG shall be supplied erected and commissioned and handed over to PURCHASER by the successful bidder, the bidders shall satisfy themselves that all items and quantities required for complete system have been quoted for in the tender where the items and quantities are not covered in the tender the same shall be indicated as additional items required for completing the scope of work and unit and total price shall be quoted by the bidder

1.8.6 TENDERERs may please note that no claims will be entertained on account of idle work force, labour, manufacturing facility and machinery, stoppage of work, unprecedented rains, storms or any other unforeseen circumstances

1.8.7 Information to be included with the tender a) The TENDERER shall furnish all the data called for in the schedules in the standard pro-

forma to facilitate correct evaluation of his tender in a most expeditious manner. It is in the interest of the TENDERER to submit the tender in the above manner failing which it is likely that his tender may not be considered

b) The TENDERER shall submit all supporting information, technical data, catalogues, and drawings as stipulate in this tender document. This is to enable the PURCHASER to make a detailed comparison and evaluation of tenders, without the need for further information from the TENDERERs. The TENDERER shall also submit all information and price schedules as called for in the price-part of this tender document

c) TENDERER shall furnish technical information as per the pro-forma Format for submission of Technical Particulars as given in the tender document, in a separate folder along with Part-I (Technical)

d) The TENDERER shall furnish all the information called for in the tender document

1.9 SCOPE OF SUPPLY, WORK AND SERVICE The scope of this specification includes the following activities, services and works in respect of 1000KVA Diesel Generator sets. Scope of work under this package is indicated below briefly-

1.9.1 Scope of supply and work under is indicated below briefly :

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a) Complete design and engineering of all the systems, sub-systems, equipment, material and services

b) The supplier shall review and approve data, drawings, and O&M manuals etc.ofsubsuppliers before submission to PURCHASER. Providing engineering data, drawings, and O&M manuals for PURCHASER’s review, approval and records

c) Complete fabrication, manufacture including shop testing of all equipment and material

d) Packing, transportation and insurance from the manufacturer’s work to the site e) Receipt, storage, insurance, preservation and conservation of equipment at the site f) Fabrication, pre-assembly (if any), erection, testing and putting into satisfactory

operation of all the equipment/material including successful commissioning g) Supply of spares and tools h) Satisfactory conclusion of the contract and handing over of the completed and fully

functional and operational system i) The scope of work and supply covers all the necessary systems, equipment,

accessories, obtaining of statutory clearances, provision of support as required by PURCHASER for Atomic Energy Regulatory Board clearances etc. for work completion

j) The equipment shall also comply with all the requirements of technical parameters, construction, engineering and design as per this specification. The material shall conform in all respects to high standards of engineering, design and workmanship and be capable of performing in continuous commercial operation up to the TENDERER’s guarantees in a manner acceptable to the PURCHASER, who will interpret the meaning of the drawings and specifications and shall be entitled to reject any work or material which is not in full accordance therewith PURCHASER’s interpretation thus furnished shall be full and final

k) The Bidder shall be responsible for providing all material, equipment and services specified or otherwise which are required to fulfill the intent of ensuring operability, maintainability and the reliability of the complete work covered under this specification. TENDERER shall be responsible for design and engineering of overall DG system and all its elements, systems, sub-systems, auxiliary systems and services, facilities, equipment, material, etc. It shall include proper definition and execution of all interfaces with systems, equipment, material and services of PURCHASER for proper and correct design, performance and operation of the project. TENDERER shall provide complete engineering data, drawings, reports, manuals, etc. for PURCHASER’s review, approval and records

l) TENDERER shall also furnish the recommended relay settings to be adopted with respective engineering calculations

m) The TENDERER shall note that the list of standards specified elsewhere in this specification is not complete. Whenever necessary the list of standards shall be considered in conjunction with this specification, IS & IEC. In case governing standards for the equipment is different from IS or IEC, the salient points shall be clearly brought out along with English language version of the standard

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n) As detailed above the TENDERERs scope also includes the engineering and preparation of ‘As Built’ drawings

o) All drawings and documents (manuals, procedure etc.) shall also be furnished by TENDERER in soft form on compact disc media

p) The bidder to note that drawings enclosed with specifications are indicative for Tender purpose only and shall supplement the requirements specified herein. These are preliminary drawings for indicative purpose only and are subject to changes that may be necessary during detailed engineering after award of contract keeping the basic parameters as specified

q) Whether called for specifically or not all accessories required for normal operation of equipment are to be considered as a part of TENDERER’s scope of supply. Since design, engineering, supply erection and commissioning is in the scope of the vendor, details indicated in our specification are of minimum requirement. Additional requirement called for during detailed design and engineering shall have to be provided for in the offer

r) It is not the intent to specify completely herein, all details of design and construction of the equipment. However, the equipment shall conform in all respects to high standards of design, engineering and workmanship. It shall be capable of performing in continuous commercial operation upto the TENDERER’s guarantees in a manner acceptable to the PURCHASER, who will interpret the meaning of drawings and specifications. The PURCHASER shall be entitled to reject any work or material, which, in his judgment, does not meet the specifications entirely

s) The bidder shall note that the availability of work front shall be given progressively by PURCHASER and it is the intent that the successful bidder take-up and plan work accordingly following all precautions and safety requirements without waiting for completion of building

t) The TENDERER shall take necessary precautions to carry out work with utmost safety and care. The damages if any to the existing equipment shall be made good to the satisfaction of engineer in charge whose decision shall be final and binding

u) The TENDERER shall submit to the PURCHASER all drawings for review. He shall list the detailed requirements of interface between TENDERER’s work and the material and services to be supplied by PURCHASER. All existing drawings and details shall be made available to successful bidder

v) Supply of Diesel generators shall be completed within 18 months from the date of issue of Purchase order.

w) Erection, Commissioning, Training of the diesel Generator along with its auxiliaries and accessories shall be completed within 6 months from the readiness of the site.

1.9.2 Quantity Variation

a) Installation and commissioning shall be based on drawings approved and released. Before proceeding with the procurement of equipment and material the TENDERER

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shall ascertain the requirement. All wastages, consumables, surplus etc. are to TENDERER’s account and shall not be paid for by PURCHASER

b) Rates quoted for supply and installation of various equipment and spares as indicated in various modules, shall include all costs towards fabrication, welding during fabrication, inspection, NDT (if specified), painting, etc. in the supply cost. All site tests, hydro-test, welding during installation, touch-up paint, etc. shall be included in the quoted rates for installation cost

c) The PURCHASER shall have full powers to make alterations in, omissions from, addition to, or substitutions for the original specifications, drawings, designs and instructions that may appear to him to be necessary or advisable during the progress of the work

1.9.3 Quality Assurance 1.9.3.1 TheQualityAssurance Plan (QAP) for DG sets as envisaged by PURCHASER is enclosed in this

tender document. The TENDERER shall conform the acceptability of this QA plan. TENDERER shall submit their own QA plan for DG. After award of contract a final detailed QA plan, shall be prepared by the contactor considering QAP envisaged by the PURCHASER, specific tests mentioned in the technical specification and also TENDERER’S internal quality plans. This QA plan shall be submitted for PURCHASER’S approval. The approved QAP will be binding on the TENDERER

1.9.3.2 For allPURCHASERs/third party holds points, the TENDERER shall give advance intimation and shall not proceed with the inspection till the PURCHASER or the third party representative has arrived. For all hold points written clearance from the PURCHASER or the third party representative shall be obtained before proceeding with further fabrication/manufacture

1.9.3.3 After assembly of equipment, the final type, routine and seismic tests/seismic analysis shall be done. The PURCHASER shall witness all the above tests. The CONTACTOR shall give sufficient advance intimation and time for the PURCHASER to witness such tests

1.9.3.4 The TENDERER shall submit a detailed Quality Assurance Manual to ensure that the equipment and service under the scope of this contract, whether manufactured or performed within his works or at this contract, whether manufactured or performed within his works or at his SUB-TENDERER’S works or at PURCHASER’S site or at any other place of work are in accordance with the specified requirements. The Quality Assurance Manual shall cover the aspects as indicated in various standard Specification of this Tender.

TheQuality Assurance Manual shall provide the following details-

1) Organization Chart of Quality Assurance Department. 2) Qualification and experience details of the personnel of Quality Assurance

Department. 3) In-house Quality Control Plan 4) Procedures and standards adopted for designing, manufacturing, and

inspection/testing.

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5) Facilities available for inspection and testing including NDT. 6) Quality check points from raw material stage onwards indicating the

customer hold points normally adopted by him. 7) Mock-up test procedures 8) Defect rectification or deviation acceptance procedure covering approval

by Design Department, by PURCHASER, by quality Assurance Department and by collaborators. Procedure should include information flow scheme up to erection and commissioning wherever applicable.

1.9.3.5 The PURCHASER and/or his duty authorized representative shall have at all reasonable times access to the TENDERER’S premises or works and shall have the power, at all reasonable times to inspect and examine the materials and workmanship during manufacture and if part of the equipment is being manufactured or assembled on other premises or works, the TENDERER shall obtain for the PURCHASER and/or his duty authorized representative, necessary permission to inspect as if the equipment were manufactured or assembled on the TENDERER’S own premises or works

1.9.3.6 The PURCHASER or his representative shall have the right to inspect any machinery, material, structures, equipment or workmanship furnished or used by the TENDERER and may reject any which is defective or unsuitable items of the plant, or the PURCHASER may, at the expense of the TENDERER, remedy or replace such defective or unsuitable items of the plant

1.9.3.7 The PURCHASER or his representative shall at all working hours have access to all parts of the TENDERER’S and his SUB-TENDERER’S factory where items of the plant are being prepared, and shall be provided with all reasonable facilities by the TENDERER. The inspection facilities shall include all necessary tools, instruments, equipment and qualified operators to facilitate inspection. A set of latest prints of the relevant approved drawings shall be made available by the TENDERER to the PURCHASER or his representative for reference during inspection.

1.9.3.8 For the purpose of this clause. Inter-works orders are to be treated as sub-orders. It is obligatory on the TENDERER that he advices his SUB-CONTRACT of the pertinent clauses in this specification when ordering brought-out equipment or materials. In particular, the TENDERER is to advice each SUB-TENDERER that he is required to supply design calculations, drawings, inspection reports and tests certificates strictly in accordance with this specification and technical information for inclusion in the instruction manual

1.9.3.9 The TENDERER will offer test reports on incoming materials inspection, for verification by PURCHASER’S representative

1.9.3.10 TheTENDERERs to provide test pieces as required by the PURCHASER’S representative to enable him to determine the quality of material supplied under his contract. If any test fails to comply with the requirements, the PURCHASERor his representative may reject the whole material represented by the test piece. The PURCHASER or his representative shall have the right to select particular test piece of his choice from the lot in case of sample testing. In case the results are found to be not satisfactory the PURCHASER’S representative shall have the right to test more number of pieces or each piece additionally from the lot for testing or rejecting the whole lot.

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1.9.3.11 Instruments with valid calibration certificate shall be used during inspection, examination and testing

1.9.4 GUARANTEES 1.9.4.1 The TENDERER shall guarantee that material and workmanship of all components and

operation of the equipment shall meet the requirements of the specification 1.9.4.2 The items of performance as stated in "Schedule of performance guarantee" in the

specification shall be guaranteed either under penalty or under rejection. The tolerance limits applicable, if any shall be in accordance with the standards to which the equipment offered by the TENDERER conforms and the tolerance limits shall be clearly indicated in the tender

1.9.4.3 Should the performance results deviate from the guaranteed values including the specified tolerances, if any, the TENDERER shall correct his equipment at no extra cost to the PURCHASER

1.9.4.4 With respect to the goods covered in the specifications the TENDERER shall provide to the PURCHASER following guarantees-

a) Of title :- I. The TENDERER warrants that the goods are not subject to any security

interest, lien or other encumbrance II. Against patent infringements - Except when the PURCHASER furnishes design

specifications to the TENDERER, the TENDERER shall at his own expense, defend and save the PURCHASER harmless from the expenses and consequences of any suit or procedure brought against the PURCHASER, so far as said suit or procedure is based on a claim that the goods furnished constitute an infringement of any patent in existence on the date of the order. In addition, the TENDERER shall secure at his own expense a fully paid up licence or licences that will permit the PURCHASER to continue use of the goods furnished free of further claim for infringement

b) Ofperformance:- I. The TENDERER shall guarantee that the goods furnished by him are new and

of high quality in full accordance with the requirements of this tender specifications

II. Irrespective of what is specified in other sections the TENDERER guarantees that the equipment offered are guaranteed for satisfactory performance for a period of 12 months from the date of commissioning

c) Of quality:- I. If within the expiry of the above stipulated guarantee period, the subject

goods or any parts thereof are found defective because of design, workmanship or materials, the TENDERER at his own expense, repair or furnish and install replacement parts of design, workmanship and material approved by the PURCHASER

II. The guarantee period shall be extended by the length of time required to make any adjustments, changes or repairs necessary to fulfill the guarantee

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III. The TENDERER shall obtain similar guarantees from each one of his sub-TENDERERs. However, the overall responsibility shall lie with the TENDERER

1.9.5 Test at site: 1.9.5.1 The tests to be carried out on site on various systems are detailed in this tender document.

These tests are however not intended to form a comprehensive commissioning check list as it shall be the TENDERER'S responsibility to draw up and carry out such a program covering all required tests and shall be submitted to PURCHASER for his approval

1.9.5.2 The TENDERER shall be responsible to provide all necessary testing and commissioning personnel, tools and plant, test equipment, etc.at no extra cost to the PURCHASER

1.9.6 TRIAL OPERATION AND TAKING OVER 1.9.6.1 Start-up

Upon satisfactory completion of erection, in the presence of PURCHASER's representative, the TENDERER shall carry out pre-commissioning checks, inspections, tests and adjustments required to put the equipment into satisfactory, reliable and unrestricted commercial use

1.9.6.2 Commissioning stage extends from the moment of take over for commissioning after 'mechanical completion' up to the end of successful completion of 'commissioning tests, performance tests & operational tests as applicable’ and includes 'trial operation'. During this stage, the system and equipment will be in charge of the commissioning group of the PURCHASER. Commissioning of each equipment and/or system by the TENDERER will be carried out under the overall supervision of the PURCHASER's start-up and commissioning group strictly in accordance with the manufacturer's written instructions. The TENDERER's commissioning engineer shall satisfy himself regarding proper mechanical completion of equipment erection, pre-commissioning, clean up, electrical testing, instrument testing and calibration. He shall also carry out operating tests to determine appropriate settings for various devices and also direct minor repairs which may have to be carried out in the field. All data collected by him during commissioning shall be handed over to the PURCHASER's commissioning team. Routine operation during this stage will be carried out by the PURCHASER’s staff. However, any repair, modification, adjustment, etc. will have to be carried out by the TENDERER’s personnel

1.9.6.3 Startup shall Include a) Thorough inspection of all equipment and ancillaries that are erected to ensure that

they can be started, availability of power supply at the equipment, checking of lubricant for all moving equipment, etc.

b) Complete scheme checks all wiring loop checks, manual operation of systems, earth resistance measurements and all other tests and measurements called for under Indian Electricity Rules and mandatory requirements by AERB

c) Checking the direction of rotation of motor drives for moving equipment before coupling

d) Internal cavities of equipment to be free of any debris or any combustible material that might present an explosion hazard

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e) Availability of instrumentation for safe operation of equipment and auxiliaries f) Trial run and no-load run of all equipment g) Test all interlocks and instrumentation

1.9.6.4 Trial Operation

a) After the equipment is ready, it would be put on trial operation during which period all necessary adjustments shall be made while operating in the full load range

b) The duration of trial operation of the complete equipment shall be spread over a period at different load regimes out of which it shall be continuously operated at full-load for at least seven days or any other duration as may be agreed to between the PURCHASER and the TENDERER. The trial operation shall be considered successful, provided that each item of the plant can operate continuously at the specified operating condition, for the period of trial operation

c) A trial operation report comprising observations and recording of various parameters to be measured in respect of the above trial operation shall be prepared. This report, besides recording the details of various observations during trial run, shall also include the time and dates of start and finish of the trial operation and shall be signed by the representatives of both the parties. The report shall include recording of all details of interruptions that occurred, adjustments made and any minor repairs done during the trial operation. Based on the observations, necessary modifications and/or repairs to the plant shall be carried out by the TENDERER to the full satisfaction of the PURCHASER. However, minor defects which do not endanger the safe operation of the plant shall not be considered as reasons for withholding the aforesaid permission

d) When the TENDERER has notified the PURCHASER that the plant is ready for commercial service, each item of the plant shall be required to operate under the working conditions of the power station, within the limits of output specified, and either continuously or intermittently as specified, without failure of any kind for a period of thirty days before the taking-over certificate is issued. The date of taking over shall be deemed to be the date of completion of a satisfactory reliable operation. PURCHASER shall make available necessary operational staff, during this period. Should any failure occur in any item of the plant, due to or arising from faulty design, materials or workmanship sufficient to prevent commercial use of the plant, the operating period of thirty days is to commence for that item after the TENDERER has remedied the cause of failure. The onus of proving that any failure is not due to faulty design, materials or workmanship shall lie with the TENDERER. The taking over certificate will be issued on the satisfactory completion, of the reliable operation period OF 30 days.

1.9.6.5 Taking over

a) On successful completion of the trial testing, the PURCHASER will take over the plant and equipment under guarantee through formal documentation consisting of a taking over certificate jointly signed by the TENDERER and the PURCHASER. The taking over

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certificate shall include list of any defects and outstanding works to be completed by the TENDERER. TENDERER must commit a definite date by which he will rectify all such outstanding works. Any defects detected subsequent to signing of taking over certificate shall be rectified by TENDERER under guarantee. The guarantee period shall start from the date of taking over

b) The taking over certificate shall not be unreasonably withheld on account of minor omissions or defects, which do not affect the commercial service without any risk to the plant, provided always that the TENDERER undertakes to make good such omissions and defects before mutually agreed dates. Such certificates however shall be deemed to be on account and shall in no way release the TENDERER from his liabilities and responsibilities in respect of such plant

1.9.6.6 Operational guarantee The operation and maintenance of the plant and equipment during the guarantee period, as stipulated in the specification after takeover under guarantee, will be carried out by the PURCHASER's operation and ‘maintenance staff’ in accordance with the manufacturer's operation and maintenance instruction manuals and specific instructions laid down by the TENDERER's or manufacturer's commissioning engineer or specified by him from time to time. The TENDERER shall be responsible for remedying any defect in design, material, fabrication or construction. The TENDERER's commissioning engineers shall also train the PURCHASER's personnel, act as a liaison between the PURCHASER and the TENDERER, and assist the PURCHASER in ordering and obtaining spare parts, and supervising repair work during guarantee period. On successful completion of the guarantee period, the plant and equipment will be taken over completely by the PURCHASER but with such conditions as may be mutually agreed to between the PURCHASER and TENDERER depending upon the performance of the plant and equipment during the guarantee period

1.9.7 RATING AND NAME-PLATES 1.9.7.1 Each main and auxiliary item of plant shall have permanently attached to it a rating plate in

a conspicuous position. This shall be of Stainless Steel to stand the prevalent atmospheric conditions as indicated. The inscription shall be engraved in black on the plate

1.9.7.2 The size of the rating plate shall depend upon space availability but should be reasonably sized for clarity and clear inscription. The size of the plates and inscriptions shall be approved by the PURCHASER. The plates shall be attached to the body of the equipment by screws

1.9.7.3 Such nameplates shall be of corrosion-proof material anodised aluminum having engraved black lettering

1.9.7.4 In case of indoor equipment like circuit breakers, panels, starters etc., the plate shall be of multilayered laminated plastic material with black lettering engraved onto a white background. The nameplates shall be screwed to the body of the equipment

1.9.7.5 Each item of plant shall be provided with nameplate and label designating the service of that particular equipment. The shape size content of this name plates shall be submitted by the bidder for approval by PURCHASER and only such name plates as are duly approved by

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PURCHASER shall be used. The contents of this name plate shall be in line with that specified in relevant IS and shall include as a minimum the following details-

• Manufacturer’s Name • Type Designation • Voltage Current Rating • Frequency • Short Time Rating • Degree Of Protection • Country Of Manufacture • Year Of Manufacture • Applicable IS/IEC

1.9.7.6 In addition, all individual components which are discrete in the DG / auxilliaries / accessories shall be identified by their description and number, if any, as identified in the drawing duly approved by PURCHASER. Invariably ,all drawings and scheme shall have the approval of the PURCHASER

1.10 Documentation 1.10.1 To be submitted with the Bid

The following data shall be submitted with the bid. 1) Complete data as and called for in section-2 (Format for submission of

Technical Particulars) of Tender Document. 2) The following drawing /documents shall be furnished along with the

Tender. a) Detailed dimensional drawings for DG set units and accessories. b) Sectional drawings of DG sets and accessories. c) DG room layout including maintenance space. d) PIDs for DG sets with instrumentation and control for the following sub

systems, indicating clearly the scope of supply. (i) Combustion Air and Exhaust Gas system. (ii) Compressed Air system. (iii) Lubricating oil system. (iv) Fueloilsupply system. (v) Cooling water system (vi) Schematic drawing of controls, instrumentation, alarms and

protections. (vii) Schematic drawings of voltage regulator and Governor.

e) Foundation details of DG sets and accessories including loading data. f) Description write up and manufactures catalogues for diesel Engine,

Generator, Excitation system, Voltage Regulator, Governor and other accessories explaining the design features incorporated to achieve a high degree of reliability, availability and ease of maintenance.

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g) Piping layout drawing for Lube oil, fuel oil, starting air, primary and secondary cooling water, Intake and exhaust air system.

h) Detailed drawings of all auxiliary equipment such as lube oil pumps, air compressors, air receivers, day oil tank, oil cooler, jacket water cooler, expansion tank, mixing tank, cooling water pumps, fuel feed pumps, inlet air filters, exhaust silencer, inter and after coolers for air compressors, neutral grounding resistors, current transformers etc.

i) Write up on qualification tests for class 1E duty as per IEEE-387 j) Write up on seismic qualification / analysis procedure. k) Write up and details for automatic voltage regulator, Governor and

Excitation system. l) Drawings showing views of generator and exciter including

arrangement of terminals. m) Drawings showing details of excitation equipment. n) In addition to the above mentioned drawings, following documents

also should be submitted by the TENDERER. (i) Instrumentation types & makes, manufacturers name etc. (ii) Control panel details- General arrangement drawing. (iii) Simple control scheme. (iv) Functional diagrams of different logic.

o) Diesel Engine performance curves over the entire operating range speeds. p) All type test certificate

1.10.2 To be submitted after the award of contract

The following documents and drawings shall be submitted for PURCHASER’s approval after award of contract.

1.0 Detailed activity schedule covering submission of drawings, approval, QA plan and approval, procurement of material and sub orders, manufacture, type tests, routine test, submission of instruction manuals, test reports, transportation, erection, testing and commissioning.

2.0 General arrangement drawings of DG set and accessories indicating overall dimension, space required for dismantling and maintenance.

3.0 Dimensioned sectional drawings of DG sets and accessories. 4.0 DG set room layout drawing. 5.0 Foundation details, foundation design, fixing arrangement, loading data etc. 6.0 Detailed schematic drawings covering DG set start logic, protection logic,

speed control, voltage regulator and governor etc. 7.0 Detailed internal wiring diagram including terminal block numbers and ferrule

numbers, cable schedule, Bill of material. 8.0 DG set characteristic curves and characteristic curves (torque-speed) for

electric motor drives. 9.0 PIDs showing all instrumentation, control features and terminal points of

supply for the following systems:

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(a) Air Intake and exhaust gas system (b) Compressed Air system (c) Lubricating oil system (d) Fuel oil system (e) Cooling water system

10.0 Chimney drawings, air intake drawings and design computations 11.0 Quality Assurance (QA Plan) 12.0 Type / routine test report 13.0 Single line diagrams for DG auxiliaries and for the control power supplies. 14.0 Schedule for instruments, valves, pipes, etc. 15.0 Documentation in conformance with IEE-323 16.0 Instruction manual

1.10.3 Instruction Manuals

1) The TENDERER shall furnish preliminary copies of instruction manuals for PURCHASER’s review. The instruction manual shall contain detailed instructions for storage, erection, testing, operation and maintenance requirements. They shall include the following. a) Outline dimension drawing showing relevant cross sectional views,

earthing details and constructional features and schematics in miniature form.

b) Rated voltages, current, duty cycle and all other technical information which may be necessary for the safe operation of the diesel Generator.

c) Unpacking, handling at site, storage for prolonged duration, detailed instruction for the installation, operation and maintenance of the Diesel Generator.

d) Recommended list of Spares. e) Catalogue numbers of all the components which are liable to be replaced

during the life of the switchgear and busducts. f) Erection drawings with written assembly instructions that would enable to

carry out erection at site. g) Detailed instructions for installations, operation and maintenance of the

Diesel Generator. h) Pre-commissioning tests, Maintenance procedures and precautions to be

taken during operation and maintenance work. i) All detailed catalogues and literature for testing & calibration of relays,

meters and other equipment supplied.

1.10.4 The TENDERER shall follow document submission schedule as given below SI.No Item No. of copies 1.0 Drawings and documents 1.1 Initial submission (for each revision) 4 1.2 Final submission 6+1 soft copy*

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2.0 Inspection reports, Performance Test Reports 2.1 Initial submission (for each revision) 6 2.2 Final submission 6+1 soft copy* 3.0 Instruction Manual 3.1 Initial submission (for each revision) 4 3.2 Final submission 10+1 soft copy*

1.11 Spares

The TENDERER shall include in his scope of supply all the necessary (i) Start-up spares (ii) Essential spares (iii) Recommended spares as described below. The PURCHASER reserves the right to finalize the exact quantities of the spare Parts and effect price adjustments on the basis of the unit rates quoted by the TENDERER. The spares, ordered by the PURCHASER, shall be delivered at site along with the main equipment/plant.

a. The TENDERER shall also indicate the service expectancy period for the spare parts under normal operating conditions before replacement will be necessary. All spare parts shall be dispatched along with the main equipment concerned

b. The TENDERER shall indicate the prices for each and every item specified in the tender document in the respective ‘Schedule of Spare Parts’ whether or not he considers it necessary for the PURCHASER to have such spares. If the TENDERER fails to comply with the above or fails to quote the price of any spare item in the ‘Schedule of Spare Parts’ his tender may be considered incomplete and likely to be rejected. However, in case any Specified spare part is not applicable for the equipment offered by the TENDERER, the same shall be indicated as ‘Not Applicable’

c. All spares supplied shall be strictly interchangeable with the parts for which they are intended to be replacements. The spare shall be treated and packed for along storage under conditions prevailing at the site, e.g. small items shall be packed in sealed transparent plastic bags with desiccators packs as necessary.

d. Each spare shall be clearly marked or labeled on the outside of its packing with its description and purpose. When more than one spare part is packed in a single case, a general description of the contents shall be shown on the outside of such case and the detailed list enclosed. All cases containers and other packages must be suitably marked and numbered for the purposes of identification. A spare part list with identification tag Nos. for each spare part shall be furnished by TENDERER for PURCHASER’S use.

e. All cases, containers or other packages are liable to be opened for each examination as the PURCHASER may reasonably required.

f. The TENDERER shall guarantee the PURCHASER that before going out of production of spare parts for equipment furnished, he shall give at least 12 months advance notice to the PURCHASER, so that the later may order his requirement of his spare in one lot, if he so desires.

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The requirement of spares shall be for a period of Three (3) years for satisfactory operation of equipment/plant/system.

1.11.1 Startup spare 1 Start-up spares are those spares which may be required during start-up and

commissioning of the equipment/plant/system. The cost of the startup spares shall be included in the DG set itself. All spares used until the equipment/plant/system is finally handed over by the CONTRCTOR to the PURCHASER, shall come under this category.TheTENDERER shall be responsible for ready and timely availability of all the necessary and required start-up spares, during erection and commissioning activities. The

2 In spite of all care taken by the TENDERER, if a certain spare is not available with him and it is required for start-up/commissioning, the same as a special case may be taken from PURCHASER’S essential spare stock, if available. However, it shall be the responsibility of the TENDERER, to replenish the same, at the earliest, without additional cost to PURCHASER. No payment shall be made to the TENDERER for any start-up spare used by him till the handing over of the equipment/plant/system. The price of start-up spares shall not be included to load his tender during tender evaluation as cost of such spares is deemed to be included in the quoted base price.

1.11.2 Essential spare 1 Essential sparesarethosewhich are considered necessary by the PURCHASER for three

(3) years of normal plant operation. Essential spares shall be as listed 2 The TENDERER shall quote unit rates for each essential spare. The total price of all

essential spares, as enlisted in the tender document, shall be considered for tender evaluation. The PURCHASER reserves the right to alter the items and/or quantities of spares, while placing order.

3 In case any essential spare part is not considered as not applicable for the equipment offered by the TENDERER, the same shall be indicated as ‘Not applicable in the Remarks’ column. However, the TENDERER shall indicate the price for each and every essential spare item specified in the tender document in the Schedule of prices, whether or not he considers it necessary for the PURCHASER to have such spares. If the TENDERER fails to quote the price of any essential spare item, the highest price quoted by other TENDERERs for that particular item shall be considered for loading his Tender.

1.11.3 Recommended spares Recommended spares are those spare which the TENDERER are considered necessary for three (3) years of normal plant operation and which are not included in essential spares specified by the PURCHASER. The TENDERER shall indicate in the schedule of recommended spares parts, his recommended list of spares, with their unit prices. The PURCHASER shall reserves the right to buy any or all of the recommended spare parts. PURCHASER will normalize the recommended spares required and their quantities required during evaluation for all bids.

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1.12 Special Tools 1.12.1.1 For all major equipment, the TENDERER shall provide appropriate structural steel members

for mounting various handling devices which are necessary for the components erection. The cost of special tools shall be included in the DG set price itself.

1.12.1.2 The TENDERER shall indicate and include in his scope of supply all the necessary tools/tackles required for erection, maintenance and servicing of the equipment and component. Maintenance tools and tackles supplied shall be new and unused. The dispatch of tools, tackles and lifting devices shall be synchronized with the dispatch of the related system/equipment

1.12.1.3 The TENDERER shall supply all tools and tackles clearly marked with its size and /or purpose. They shall not be used for erection purpose

1.12.1.4 Each set of tools and tackles shall be suitably arranged in fitted boxes of mild steel construction. The number of boxes being determined in relation to the layout of the plant in question. The taps, stocks and dies shall be kept in approved mild steel boxes with components for individual items. If the weight of any box and its contents is such that it cannot be conveniently carried it shall be supplied on steerable rubber tyred wheels

1.12.1.5 Each tool box shall be fitted with a lock and two keys and shall be painted navy blue and clearly marked in white letters, with the name of the system/equipment for which the tools and tackles are intended

1.12.1.6 The tools and tackles with the appropriate boxes are to be handed over to the PURCHASER at the time of issue of the taking over certificate

1.13 Erection 1.13.1 Scope

a) The scope of this section covers the receipt at site, storage, erection, testing, and commissioning of various equipment covered in this DG package

b) All equipment shall be duly erected at site and all tests carried out as listed in relevant standards as well as in this specification. The costs for erection, testing and commissioning shall be included in the relevant price schedule

c) The specification and the accompanying drawings are intended to describe and provide for a finished piece of work. It is to be understood and agreed by TENDERER, that the work described shall be complete in every detail, even though every item necessarily involved is not particularly mentioned. TENDERER shall be required to provide all labour, materials, tools and equipment necessary for the entire completion of the work described and shall not avail himself of any manifesting unintentional error, omission or inconsistency that may exist

d) The TENDERER shall ensure that he has satisfied himself as to the nature and location of the work, the general and local conditions, particularly those bearing upon transportation, disposal, handling and storage of materials, availability of labour, water, electric power, roads and uncertainties of weather, or similar physical conditions of the site, the conformation and conditions of the ground character, the quality and quantities of surface and sub-surface materials to be encountered, including the sub-soil water level, the

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character of equipment / facilities needed, preliminary to and during the progress of work, and all other matters upon which information is reasonably obtainable and which can in any way affect the work or his cost there of under contract. Any failure of the TENDERER to acquaint himself with all the available information concerning these conditions will not relieve him of the responsibility of estimating properly, the difficulty or cost of success fully performing the work. Non familiarity with the site conditions will not be considered a reason either for extra claims or for not carrying out the work in strict conformity with the drawings and specifications

1.13.2 Applicable codes, standards and specifications a) The installation, testing and commissioning shall meet the requirements of all currently

applicable codes and standards including local statutory requirements b) The TENDERER shall ensure compliance with all statutes, laws, rules and regulations of the

central or state government or any other authority such as the workmen's compensation act 1923, payment of wages Act, minimum wages act 1948, employees state insurance act, employees provident fund act, etc., and any and all statutory modifications thereof in connection with employees engaged by him or his sub-TENDERERs in the work. The change in wages if any during contract pendency shall not be considered for reimbursement. The bidder is deemed to have taken this aspect in his offer for all items covered in scope of supply

c) The TENDERER shall conform to the provisions of the Indian boiler regulations, Indian factory rules, Indian electricity act and any acts of legislature relating to the work and to the regulations and bye-laws of any authority and of any water, lighting and other companies, and/or authorities with whose systems the plant or the structure is proposed to be connected and shall, before making any variations from the drawings or specifications that may be necessitated by so conforming, give to the PURCHASER written notice, specifying the variations proposed to be made and the reason for making it and apply for instructions thereon

d) All registration and statutory inspection fees, if any, in respect of his work pursuant to the ‘contract’ shall be to the account of the TENDERER. However, any registration and statutory inspection fees lawfully payable under the provisions of Indian boiler regulations, Indian electricity act and any other statutory laws and its amendments from time to time during erection in respect of the plant and equipment ultimately to be owned by the PURCHASER shall be to the account of the PURCHASER. Should any such inspection or registration need to be re-arranged due to the fault of the TENDERER or his sub-TENDERER, the additional fees for such inspection and/or registration shall be borne by the TENDERER

1.13.3 Items included in the scope The TENDERER’s scope of work at site shall include but not be limited to the following: a) Taking delivery of equipment received at site, unpacking, joint inspection by PURCHASER

and TENDERER and inventory control including checking against invoices, re-packing

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where required, submitting reports shortages and/or damages, equipment storage and erection insurance, lodging insurance claims against losses & damages, etc.

b) Transportation of materials from the stores to erection site. c) During the execution of the contract, and until completion certificate is issued, the

TENDERER will be fully liable to compensate all concerned, for any loss, damage or destruction of " Works ", structure, plant and machinery, persons, property etc., including third party risk arising due to cause attributable to the TENDERER as may be decided by the PURCHASER whose decision in this regard shall be final.. No claim shall be made against IGCAR on this account.

d) The TENDERER shall make adequate provisions for fire fighting both at the construction site and his camp.

e) The works such as disassembly, cleaning and re-assembly of equipment, where required. f) Transferring levels and co-ordinates from the master benchmarks provided by the

PURCHASER. g) Proper erection including supply of hardware, grouting of foundation bolts, base plates,

channels or frames or welding to supporting beams as required,. Preparation of foundation including breaking the lean mortar cover, chipping, etc. as required before placing base plates, channels or frames and for access to grounding conductor flats and final grouting of foundation bolts, supporting beams/EPs as required and final finishing.

h) Touch up and finish painting as required, including the supply of necessary paint of approved quality and colour as directed by PURCHASER.

i) Pre-commissioning tests on all mechanical equipment as well as electrical equipment after completion of erection. Calibration and setting of all instruments, controls and protective devices covered under this specification.

j) Tests and commissioning of all equipment and accessories covered in this specification in the presence of PURCHASER and handing over the same in fine operating condition. The TENDERER shall carryout pre-commissioning checks and tests on all electrical equipment & accessories at site.

k) Make of welding electrode has to be approved by the PURCHASER. l) Supply and initial filling of various lubricants shall be arranged by the TENDERER. The

TENDERER shall supply at no extra cost all consumable items such as electrodes, flux, gas etc. for welding/brazing, shims during erection and all other similar material including equipment foundation bolts, channels, cinch anchors, anchor fasteners, plugs, etc. which would form a part of normal erection & commissioning works and has not been specifically spelt out separately in this tender. In case the TENDERER desires to be paid for any material which in his opinion is required for work completion but not specifically called for by the PURCHASER shall so indicate the cost in a separate item failing which no payment should be made.

m) The TENDERER shall make his own arrangements for erection of any scaffolding and/or temporary platforms required for installation work, in consultation with the site engineer and remove the same after completion of work.

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n) The TENDERER shall carryout, until virtual completion, necessary repairs and/or modifications on erected equipment which are due to the TENDERER’s own defects and/or faults.

o) Drawings, instructions and recommendations shall be correctly followed in handling, setting, testing and commissioning of equipment. Extreme care shall be exercised in handling equipment to avoid distortion to stationary structures, the marring of surface finish, damage to delicate instruments and electrical parts. The TENDERER shall pay compensation or bear the expenses towards replacement and/or repair of the equipment arising out of improper handling of the equipment material by the TENDERER.

p) All materials and equipment, measuring devices, test gauges and other equipment required to carryout all necessary pre-commissioning tests prior to putting the equipment under trial run shall be arranged by the TENDERER. The TENDERER shall satisfy himself that all initial check-up to ensure safety of equipment and personnel have been carried out.

q) All erection, testing and commissioning activities shall be executed in the most expeditious manner so as to ensure successful and timely completion.

1.13.4 Items not included in scope of work:All points beyond the “terminal points” defined in this

tender document.

1.13.5 Erection, testing and commissioning procedures I. The TENDERER shall submit to the PURCHASER for his approval within a reasonable

period, a programme showing in such form as may reasonably be required by the PURCHASER, the order of procedure in which he proposes to carryout the works as to erection, testing and commissioning activities. The submission to and approval by the PURCHASER of such programme shall not relieve the TENDERER of any of his duties or responsibilities under the contract

II. After submission to and approval by the PURCHASER of such programme the TENDERER shall adhere to the order of procedure and method stated therein unless he obtains the written permission of the PURCHASER to vary such method or order

III. If at any time, it should appear to the PURCHASER that the actual progress of the works does not conform to the programme, the TENDERER shall produce, at the written request of the PURCHASER, a revised programme showing modifications to the approved programme necessary to ensure completion of the works within the time for completion

IV. The TENDERER shall submit well in advance, his scheme for movement, lifting, handling of heavy equipment, components and erection procedure also indicating the tools, tackles and equipment he proposes to employ for the same, for approval by the PURCHASER prior to actual undertaking of such work. This is essential as such activities may call for measures such as additional reinforcements to avoid overloading of structures

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V. The TENDERER shall submit a detailed write-up on commissioning test procedure for PURCHASER's approval and the same shall be finalized prior to actual commissioning and testing

1.13.6 Inspection at site I. PURCHASER or any person appointed by him shall have access and right to inspect the

work, or any part thereof, at all times and places during the progress of the work. The inspection and supervision is for the purpose of assuring PURCHASER that the plans and specifications are being properly executed and while PURCHASER and his representatives will extend to TENDERER all desired assistance in interpreting the plans and specifications, such assistance shall not relieve TENDERER of any responsibility for the work. Any work, which proves faulty, shall be corrected by TENDERER without delay. The fact that the PURCHASER or his representatives have not pointed out faulty work or work which is not in accordance with the plans and specifications shall not relieve TENDERER from correcting such work as directed by PURCHASER without additional compensation

II. When finished work is taken down for the purpose of inspection, TENDERER shall stand the entire expenses incident thereto in the event that the said work is found to be defective. If TENDERER fails to repair any defective work or does not replace any defective materials after reasonable notice, PURCHASER may decide such defective work to be repaired or defective material to be replaced and the expenses thereof shall be deducted from the amount to be paid to TENDERER

III. TENDERER shall give every facility to PURCHASER and his representatives for inspection and examination of workmanship even to the extent of discontinuing portions of the work temporarily, or of uncovering or taking down portions of the finished work at supplier premises.

1.13.7 Superintendence and labour i. TENDERER shall function as an erection organisation and furnish adequate and

competent labour (unskilled, semi-skilled and skilled), watchmen, supervisors, engineers, etc. for the duration of the work and in accordance with the requirements of the schedule of completion, and shall begin the work at such time as to ensure its completion as specified and shall complete the same, free of all dues and charges, at or before the time specified for completion. TENDERER shall make available qualified personnel for placing the system in operation and for carrying out the necessary tests and trials

ii. It is important that the TENDERER shall employ person known to be reliable and competent for the work in general and it shall be a requirement of the contract that person used on special works shall be competent, well trained and trusted employees

iii. TENDERER shall furnish details of the qualifications and experience of his qualified personnel assigned to the work

iv. TENDERER shall be personally present or employ at least one competent representative (whose name shall have previously been communicated in writing to the PURCHASER) to superintend the erection of the equipment and carrying out of the

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work under the contract. This representative shall have full technical capability and complete administrative and financial powers to expeditiously and efficiently execute the work under the contract. TENDERER or his representative(s) shall be present at site at all times when the work is in progress. Any written orders or instructions which PURCHASER may give to the said representative of TENDERER shall be deemed to have been given to the TENDERER. He shall maintain an office on the site of the work and shall at all times keep in the said office a complete set of the specifications and drawings. PURCHASER shall normally communicate directly with the said representative at site

v. TENDERER's representative at the site shall be posted and be available at site within a reasonable time after the PURCHASER informs TENDERER in writing to that effect

vi. When TENDERER or his representative is not present at the work site where it may be decided to give directions in the event of emergencies, orders may be given by PURCHASER and shall be received and obeyed by the supervisors who may have charge of the particular work in reference to which orders are given. If requested to do so, PURCHASER shall confirm such orders in writing. Any such instructions, directions or notices given by PURCHASER shall be deemed to have been given to TENDERER

vii. TENDERER's employees shall be provided with identification badges. All the employees will be required to wear these badges during the time they are at project site. All employees at work site, whenever required, shall be provided with helmets and safety shoes by TENDERER and these shall be worn by them all the time they are at work site. Employees failing to do so shall upon request of PURCHASER be summarily discharged. No employee of TENDERER shall be permitted to enter areas of construction and operation unauthorized.

viii. All employees employed by the TENDERER or his sub contractor shall be Indian Nationals only.

ix. PURCHASER shall be at liberty to object to any representative or person or skilled, semi-skilled or unskilled worker employed by TENDERER in the execution or otherwise of the work, who shall misconduct him or be incompetent, or negligent or unsuitable. TENDERER shall remove the person so objected to, upon receipt of notice in writing from PURCHASER requiring him to do so and shall provide in his place a competent representative at his own expense within reasonable time. Such persons who had been removed from the site at the request of PURCHASER shall not be again employed or allowed on the works without the permission of PURCHASER

x. Suggestions and recommendations made by the PURCHASER's personnel as well as the equipment supplier's erection supervisors relating to the work and co-ordination thereof are to be carefully and courteously considered

xi. The TENDERER shall, during the progress of the work, properly cover up and protect the DG from damage by exposure to weather, and shall take every reasonable, proper and timely and useful precaution against accident or damage to the same from any cause and shall be and remain answerable and liable for all accidents and damages. He

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shall make good such accidental and other damages in the most complete and substantial manner to the reasonable satisfaction of the PURCHASER

1.13.8 Notice on variation : If the PURCHASER makes any variation in any part of the works such reasonable notice in writing shall be given to the TENDERER as will enable him to make his arrangements accordingly. In cases where equipment is already manufactured or in the course of manufacture or any work done or drawings or patterns made required to be altered, a reasonable sum in respect thereof shall be allowed by the PURCHASER. If, in the opinion of the TENDERER, any variation is likely to prevent or prejudice the TENDERER from or in fulfilling any of his obligations under the contract he shall notify the PURCHASER thereof in writing and the PURCHASER shall decide forthwith whether or not the same shall be carried out. If the PURCHASER confirms his instructions, in writing the said modifications shall be modified to such an extent as may be justified. Until the PURCHASER so confirms his instructions, they shall be deemed not to have been given.

1.13.9 Notice on defects During the guarantee period, if any defect shall appear or damage occur due to the defective materials, workmanship or design or from any act or omission of the TENDERER, PURCHASER shall forthwith inform the TENDERER thereof stating in writing the nature of the defect or damage. The TENDERER shall remedy all defects or damages or replacements or renewals to the satisfaction of the PURCHASER

1.13.10 Notice for delivery TENDERER shall ensure that all his equipment, materials, etc. are delivered to site only upon an authorisation in writing applied for and obtained by him from the PURCHASER

1.13.11 Notices of Tests : The TENDERER shall give to the PURCHASER notice in writing of the date after which he will be ready to make the tests on completion. Unless otherwise agreed the tests shall take place within 10 days after the said date on such day or days as the PURCHASER shall notify the TENDERER in writing.

1.13.12 Notice to TENDERER All notices, written orders etc. to be given to the TENDERER by the PURCHASER under any of the provisions of the contract shall without limitation be conclusively deemed to have been received by the TENDERER if delivered or mailed to the TENDERER at the TENDERER's address mentioned in the work order or to the TENDERER's last known place of business or residence or to his resident engineer

1.13.13 Notice of change of address Either party to the contract may change its nominated address by prior written notice to the others

1.13.14 Erections SUB- TENDERER a) All specialists, merchants, tradesmen and others executing any work or supplying any

goods, materials or services appointed by the TENDERER shall be deemed to be SUB-TENDERERs

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b) TENDERER shall furnish information about the sub-TENDERERs if any to whom the TENDERER intends to sub-contract part of the work and the nature and extent of such work. Prior approval of the PURCHASER shall be obtained in all such sub-contracting case

c) TENDERER may sub-contract parts of the order, if necessary only to sub-TENDERERs approved by PURCHASER. TENDERER shall be responsible for transmitting the technical specifications, quality control and other contract terms & conditions as specified by the PURCHASER in this document to the sub-TENDERERs. TENDERER shall also furnish to PURCHASER the required copies of all sub-contracts (unpriced) showing promised delivery dates, places, etc.

d) In respect of the work, goods, materials or services etc. specified in the sub-contract, the sub-TENDERER will undertake towards the TENDERER the like obligations and liabilities as are imposed on the TENDERER towards the PURCHASER by the terms of the contract and will save harmless and indemnify the TENDERER from and against the same from all claims, proceedings, damages, costs, charges and expenses whatsoever arising out of or in connection therewith or arising out of or in connection with any failure to perform such obligations or to fulfill such liabilities

e) The sub-TENDERER will save harmless and indemnify the TENDERER from and against any negligence by the sub-TENDERER, his servants or agents, and from and against any misuse by him or them of any TENDERER's equipment provided by the TENDERER for the purposes of the contract

f) The PURCHASER shall be entitled to demand from the TENDERER reasonable proof that all payments, less retention’s have been made to sub-TENDERER in respect of the work or goods, materials or services of sub-TENDERER. Also, the TENDERER shall, if any:

i. Satisfy the PURCHASER in writing that he has reasonable cause for withholding or refusing to make such payments

ii. Produce to the PURCHASER reasonable proof that he has so informed such sub-TENDERER in writing

1.13.15 Coordination work a) Co-operation with other TENDERERs : The TENDERER shall co-operate with all other

TENDERERs or tradesmen of the PURCHASER, who may be performing other works on behalf of the PURCHASER and the workmen who may be employed by the PURCHASER and doing the work in the vicinity of the works under the contract. The TENDERER shall also so arrange to perform his work as to minimise, to the maximum extent possible, interference with the work of the other TENDERERs and his workmen. Any injury or damage that may be sustained by the employees of the other TENDERERs and of the PURCHASER due to the TENDERER's negligence shall promptly be attended at his own expense. The PURCHASER shall determine the resolution of any difference or conflict that may arise between the TENDERER and other TENDERERs or between the TENDERER and the workmen of the PURCHASER in regard to their work. If the works of the TENDERER is delayed because of any acts or omission of another TENDERER, the TENDERER shall have no claim against the PURCHASER on that account other than an extension of time for completing his works

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b) The PURCHASER shall be notified promptly by the TENDERER of any defects that could affect the TENDERER's works. The PURCHASER shall determine the corrective measures, if any, required rectifying this situation after inspection of the works and such decisions by the PURCHASER shall be binding on the TENDERER

c) The TENDERER shall co-ordinate with the other equipment or system TENDERERs, wherever it is necessary for them to work at various TENDERERs’ terminal points covered under this contract

d) Co-operation with PURCHASER: In cases where the schedule of the erection work by the TENDERER affects the operation of the system facilities of the PURCHASER, such erection work of the TENDERER shall be rescheduled to be performed only in the manner stipulated by the PURCHASER and the same shall be acceptable at all times to the TENDERER. The PURCHASER may impose such restrictions on the facilities provided to the TENDERER such as electricity, water, etc. as he may think fit in the interest of the PURCHASER and the TENDERER shall strictly adhere to such restrictions and cooperate with the PURCHASER

1.13.16 Layout and measurements a) All the works shall be performed to the lines, grades and elevations indicated on

the drawings. TENDERER shall set out the works and shall be responsible for the true and perfect setting out of the same and also for the correctness of the positions, levels, dimensions and alignment of all parts thereof.Basic horizontal and vertical control points will be established and marked by the PURCHASER at site at suitable points. These points shall be used as datum for the works under the contract

b) The TENDERER shall inform the PURCHASER well in advance of the times and places at which he wishes to do work in the area allotted to him, so that suitable datum points may be established and checked by PURCHASER to enable the TENDERER to proceed with his works

c) If at any time any error shall appear during the progress of any part of the work, TENDERER shall, at his own expense, rectify such error, if called upon to do so, to the satisfaction of PURCHASER

d) TENDERER shall maintain base lines and bench marks adjacent to various sections of work. In case of their unnecessary destruction by him or any of his employees, these shall be re-established by TENDERER at his own expense

e) The TENDERER shall level and adjust the equipment on its foundations preparatory to grouting and shall furnish all packing required for the adjustment

f) The TENDERER shall check the electrical and mechanical connections to equipment supplied under the contract before such equipment is commissioned and shall be responsible for the correctness of such connections in accordance with the contract drawings and specifications

g) The measurements so taken and certified correct by PURCHASER shall be the basis for the progress payment to the TENDERER. Where the break up of contract value on unit basis is difficult to arrive at, PURCHASER and TENDERER shall work out at

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the commencement of the contract, the weightages or the cost break-ups to arrive at a mutually agreeable basis for computation of the progress estimation

1.13.17 Clean-up a) The TENDERER shall at all times, keep the work place and storage areas free of loose

or combustible materials and waste materials. He shall provide adequate fire fighting facilities like portable fire extinguishers, sand-buckets, etc. and take necessary precautions. He shall ensure safe working practices. During the welding work portable fire extinguishers shall be kept ready near the place of work. All scaffolding, temporary structures, safety devices etc. used by him during erection shall be duly removed by him on completion of work. The removal of debris and waste to the PURCHASER's dumping yard shall be done on a daily basis to keep the site clean and safe, at all times. All waste and debris collected during work shall be removed promptly and site shall be handed over to the PURCHASER in a clean and tidy condition on completion of work. The security and safety are the sole responsibility of the TENDERER

b) All soil, filth or other matter of an offensive nature taken out of any trench, sewer, drain, cesspool or other place shall not be deposited on the surface, but shall at once be carried away by TENDERER, from the site of work for suitable and proper disposal

c) TENDERER shall not store or place the equipment, material or erection equipment on the driveways and streets and shall take care that his work in no way restricts or impedes traffic or passage of men and material. During erection, the TENDERER shall without any additional payment, at all times keep the working and storage areas used by him free from accumulation of loose or combustible material, waste materials or rubbish, to avoid fire hazard and hindrance to other works of PURCHASER. If TENDERER fails to comply with these requirements in spite of written instructions from PURCHASER, the PURCHASER will proceed to clear those areas and the expenses incurred by PURCHASER in this regard shall be payable by TENDERER. Any packing materials received with the equipment shall remain the property of PURCHASER and may be used by TENDERER for the performance of the work on payment of standard charges to PURCHASER and with prior approval of PURCHASER. At the completion of his work and before final payment, the TENDERER shall remove from site all construction equipment, temporary structures and debris and shall restore the site to a neat workman like conditions, at his cost

1.13.18 Services supplied by the supplier a) The details of the various site facilities as may be required for execution of work under

this contract, their availability and relevant terms and conditions where applicable are as given here. The following facilities can be provided by the PURCHASER in good faith at terms indicated hereunder. In case such facilities are required by the TENDERER, he shall specifically request in the offer

b) Construction water will be made available by PURCHASER at one point. Onward distribution of the same shall be the responsibility of the TENDERER

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c) Electrical power supply for construction will be supplied at two points. TENDERER should indicate extent of power in kW required at plant site onward distribution of the same including installation of necessary switchgear and distribution system in conformity with local safety rules and IE rules and regulations shall be the responsibility of TENDERER

d) The TENDERER shall indicate the extent of storage space required e) It shall be noted that no other facility, apart from those listed above shall be provided

by the PURCHASER. No claim, whatsoever, arising out of use, misuse or failure of these facilities provided will be entertained by the PURCHASER

1.13.19 Transportation of equipment and material at site a) General guidelines for the TENDERER as regards joint inspection, handing over of free

issue material to the TENDERER and transport of material from TENDERER’s warehouse to erection site of equipment are covered under this contract. At all times, the instructions of the PURCHASER shall be strictly adhered to

b) Before taking over the materials for erection from PURCHASER's stores, the TENDERER shall carry out inventory and inspection of the same in the presence of PURCHASER's representative and submit an inspection report regarding any shortages or damages to the PURCHASER

c) The equipment certified as satisfactory shall be taken for the erection and in case of equipment damaged; the directions of the PURCHASER shall be strictly adhered to

d) After taking over of the materials by the TENDERER from PURCHASER's stores the same may be transported to the location of erection at site with the help of handling equipment and/or transporting vehicles, etc.,

e) Transport of material from TENDERER’s warehouses to erection site: i. Transporting vehicles, handling equipment, manpower for lifting, loading,

unloading driving etc. shall be provided by the TENDERER for this transportation

ii. While transporting/handling the equipment, no dragging on the ground is permitted. The TENDERER shall submit his scheme for handling major pieces of equipment for approval by the PURCHASER prior to actual handling of the same

iii. It is responsibility of the TENDERER to provide adequate weather protection and security for the equipment during this transportation

iv. The TENDERER will be responsible for any damage shortage caused due to his defective or negligent handling, transporting of equipment and he shall make good such damages at no extra cost to the PURCHASER and without affecting the project schedule. Any repairs carried out shall be with prior written approval from the PURCHASER and under their supervision. A complete record of all such repair works shall be maintained by the TENDERER at all times

v. In cases where repairs or rectifications on equipment supplied under this contract or supplied under other contracts are due to reasons attributable to the TENDERER, the PURCHASER reserves the right to get such repairs or

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rectification carried out by others and recover the expenditure incurred in this connection from the TENDERER

vi. Same procedure applies to the transportation from PURCHASER’s warehouse to erection site

1.13.20 Temporary storage at site: i. This section details the general guidelines for provision of temporary storage

requirements of equipment to be provided by the TENDERER at erection site. The TENDERER will provide necessary security arrangement at temporary storage houses and offices provided by him at site

ii. Types of storage are broadly classified under the following heads- a) Outdoor storage b) Indoor storage (closed)

The TENDERER shall take all necessary care during the storage of equipment at site so that effects of high humidity and dust etc. prevailing at site do not affect the performance and life of such equipment

1.13.21 Maintenance during storage a) After receipt of the materials at site, the TENDERER is solely responsible for the same

until handing over to the PURCHASER the erected plant. The TENDERER is responsible for maintenance of all the equipment and materials in storage, at erection site during erection and until commissioning including protection of the same against theft, flood, cyclone, fire and other elements of nature and corrosion damages. In case commissioning of the equipment is delayed, the TENDERER shall be responsible for maintenance of the erected plant and equipment as directed by the PURCHASER

b) The TENDERER shall repack the equipment after inspection and store the same in an orderly manner, preserving their identification slips, tags and instruction booklets, etc., required during erection. The storage of materials shall be equipment-wise. Loose parts shall be stored in enclosed racks, preserving the identification marks and tags in good condition. The group codes shall be displayed on the racks

c) At no time shall any material be stored directly on ground. All materials shall be stored minimum 200mm above the ground by providing good wooden sleepers

d) Welded and cast units shall be stored in such manner that there is no danger of distortion

e) All special measures to prevent corrosion shall be taken by the TENDERER- i. Materials which carry a protective coating shall not be wrapped in paper, cloth

etc. as these is liable to absorb and retain moisture. The TENDERER shall inspect the materials and in case of signs of wear or damages to protective coating, that portion shall be cleaned with carbon-tetra-chloride or any other approved solution and coated with an approved protective paint. Complete

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record of all such observations and protective measures taken shall be maintained

ii. The grease recommended for protection of surfaces against rusting is refined from petroleum oil with approved additives; grease shall be only in traces. The protection offered by grease does not last more than six to twelve months

f) The TENDERER shall periodically inspect materials with specific reference to- i. Ingress of moisture and corrosion damages: regular inspection and renovation

of silicagel is essential ii. Damage to protective coating

iii. Open ends in pipes, vessels and equipment: in case any open ends are noticed, the TENDERER shall get them capped

iv. Insulation of electrical equipment: regular insulation checks are essential and these values shall be properly logged

v. Any damages to equipment or materials g) In case of any damages, these shall be promptly notified to the PURCHASER. In all

cases, the rectification shall be carried out strictly as directed by the PURCHASER h) In case such damages are attributable to the TENDERER and if, in the opinion of the

PURCHASER, the TENDERER is not competent to carry out necessary rectification, the PURCHASER shall get this done by any other agency and recover the expenditure incurred by him from the TENDERER

1.13.22 Travel and Accommodation: a) All the charges relating to the travel and accommodation of TENDERER's and sub-

TENDERER's personnel, labour, etc. shall be borne by the TENDERER. Also, the incidental charges incurred thereon shall be paid by the TENDERER

b) TENDERER shall arrange his own accommodation and mode of transport at site for all his and his sub-TENDERER's staff, personnel, labour, etc.

1.13.23 Access to site a) Suitable access to and possession of the site shall be afforded to the TENDERER by the

PURCHASER in reasonable time b) In the execution of the works, no persons other than the TENDERER or his duly

appointed representative, sub-TENDERER and workmen, shall be allowed to do work on the site, except by special permission, in writing by the PURCHASER or his representative

1.13.24 Seismic requirements: Erection is to be carried out as per approved drawing and procedure considering the seismic withstand requirements.

1.13.25 Types of storage Given below are the types of storage to be provided for various equipment listed

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Sl. No.

Item Type of Storage space Space

1 L.V. Power Cables Outdoor (on the raised plat-form). Covered with polythene sheets

2 Control Cables Outdoor (On the raised plat-form). Covered with polythene sheets

3 DG sets,Protection Panels, Control Panels

Indoor

4 Miscellaneous items Welding electrodes Rubber boards Epoxy resin Photographic material Thermosetting compound Cement bags Bolts, nuts & washers SS pipes

Air conditioned Air-conditioned Air-conditioned Air conditioned Air-conditioned Indoor Indoor Indoor

1.13.26 Specific guidelines for storage :

Given below are guidelines for certain major equipment and/or materials. These are broad guidelines only and storage shall be strictly as directed by the PURCHASER

a) Structural steel: Structural steel could safely be stored in open storage but with sufficient space in between for handling and crane movement. All steel shall be stored 300mm above ground on suitable packing to avoid damage. It should be stored according to sizes and sections preferably in the order required for erection. The area for open storage should be properly graded to avoid water logging in the storage area. Steel shall not be stored in the vicinity of areas where excavation or grading will be done. Scratched or abraded steel shall be given a coat of primer for protection after unloading and handling prior to erection. All milled and machined surfaces shall be properly protected from corrosion by suitable coating

b) Synthetic paints: These have limited life and as a safeguard against possible deterioration, the drums shall be inverted at regular intervals as specified to minimise risk of hard settling of pigments

c) Control Panels: The space heaters, where provided, shall be kept connected with power supply by the TENDERER irrespective of mode of storage. Where space heaters are not provided, use of adequate number of heating bulbs by TENDERER is recommended. The heating shall be under adequate supervision by the TENDERER. Insulation resistance shall be measured at regular intervals and megger values properly logged

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d) Motors: Besides general procedures such as regular inspection and recording of insulation resistances, in the case of L T motors, if so recommended, low voltage current flow through the windings may be maintained during storage

e) Instruments: These are stored on racks in closed storage and in air conditioned storage if so recommended. These shall be stored in their packages in dry condition and shall be handled with extreme care. Instrument flanges and nozzles, if directed, shall be coated with technical vasline. In the case of fragile instruments, the storage shall be in a separate zone away from where heavy materials are stored to minimise danger of damage

f) Documentation: TheTENDERER's store-keeping function will include maintaining various records as required by the PURCHASER. These records shall include but not be limited to the following:

i. Supplier-wise record of equipment/material received, stored and issued for erection as well as stock position

ii. Record of inspection and repairs carried out, protective measures and lubrication of equipment in storage as well as erected until the same are taken over by the PURCHASER

1.13.27 Site welding during erection : a) All site welding involved in the construction and fabrication of plant and items

covered under the contract shall be carried out in accordance with applicable codes or approved equivalents

b) All welding at site shall be carried out as specified c) Welding procedures & welder qualifications shall conform to the ASME standard d) Welding shall be identical to that used during seismic testing e) Welding procedure and weld electrode subject to PURCHASER's approval. Special

procedure may have to be adopted for welding the base channels and base-frames to the embedded EPs if the civil tolerances exceed the specified limits. The TENDERER shall prepare and submit the procedure for the PURCHASER's approval

1.13.28 Electrical safety regulation

a) In no circumstances will the TENDERER interfere with fuses and electrical equipment belonging to the PURCHASER or other TENDERERs

b) Before the TENDERER connects any electrical appliances to any plug or socket belonging to the other TENDERERs or PURCHASER, he shall:

i. Satisfy the PURCHASER that the appliance is in good working condition ii. Inform the PURCHASER of the maximum current rating, voltage and phases of

the appliances iii. Obtain the permission of the PURCHASER detailing the sockets to which the

appliances may be connected c) The PURCHASER will not grant permission to connect until he is satisfied that:

I. The appliance is in good condition and is fitted with a suitable plug

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II. The appliance is fitted with a suitable cable having two earth conductors, one of which shall be an earthed metal sheath surrounding the cover.

d) No electrical cable in use by the TENDERER and/or PURCHASER will be disturbed without prior permission. No weight of any description will be loaded on any such cable and no ladder or similar equipment will rest against or be attached to it

e) No work shall be carried out on any live equipment. The equipment must be made safe by the PURCHASER and a permit-to-work issued before any work is carried out

f) The TENDERER shall employ the necessary number of qualified, full-time electricians to maintain his temporary electrical installation

g) The TENDERER shall be liable to get his installation cleared by the electrical inspector. Payment of relevant fees at regular intervals as specified in the IE rules shall be the responsibility of the TENDERER. It should also be the responsibility of the TENDERER to satisfy the site engineers that the TENDERER's installations are in conformity with the IE rules and regulations. These installations shall be subject to periodical inspection and clearance by the engineer at site and the installation shall be open for inspection at all times and all necessary facilities for inspection shall be provided by the TENDERER to site engineer

1.13.29 Grouting a) Anchor bolts, anchor bolt holes and the bottom of equipment and column base plates

shall be cleaned of all oil, grease, dirt and loose material. The use of hot, strong, caustic solution for this purpose will be permitted

b) Prior to grouting, the hardened concrete surfaces to be grouted shall be saturated with water

c) Water in anchor bolt holes shall be removed before grouting is started d) Grouting through holes in base plates shall be by pressure grouting

1.13.30 List of drawing enclosed with the specification Drawings enclosed are for tender purposes. The TENDERER shall carry out work as per the construction drawings to be released by the PURCHASER after the placement of order

1.13.31 Coordination Procedures The procedure contained in the following paragraphs is to be followed by all contracting parties for this contract

a) Identification of key personnel: The names designations, postal addresses, telephone numbers, telex numbers, fax numbers and telegraphic addresses of the representatives of the contracting parties shall be as given during the tendering process. Any subsequent changes will be duly intimated.

b) Correspondence procedure I. All correspondence between the contracting parties shall be as given later in

this section. The TENDERER shall address all his correspondence to PURCHASER

II. All correspondence on purely commercial matters shall be sent to PURCHASER only

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III. All letters from TENDERER shall bear a reference number, which should contain a continuously running serial number. This would enable the PURCHASER to identify if any letter or document is misplaced

IV. The TENDERER shall be responsible for coordination of all activities with his sub-TENDERERs

c) Coordination meetings: I. The TENDERER shall note that he will be called upon to attend meetings with

PURCHASER and his representatives, consultant and other TENDERERs during the execution of the contract. The agenda for co-ordination meetings shall be issued by TENDERER or PURCHASER to the other party atleast three (3) weeks in advance of meeting. The TENDERER shall attend all such meetings at his own cost. The venue of the meetings would be decided in advance to suit the convenience of all parties

II. The coordination meetings are held to sort out and resolve the various technical matters and outstanding issues. In these meetings, manufacturer's progress and overall project schedule will also be discussed

1.13.32 Procedure for submission of TENDERER’s drawings and documents a) The TENDERER shall prepare a complete list of drawings and documents and shall

submit to PURCHASER for contract engineering purposes within the time limit b) This drawing schedule shall indicate title of the drawing or document, document

number, expected date of submission, actual date of submission and purpose of submission (i.e., whether for information or for approval) etc., as per engineering schedule agreed to with the PURCHASER

c) Subsequent to this, an additional list of assembly and other drawings and documents shall be submitted which are necessary to facilitate inspection, erection, testing, commissioning and maintenance of equipment and systems covered in this contract. This shall be also done within a mutually agreed period. The drawings and documents under this category may be subject to approval of PURCHASER depending upon the requirement

d) Each and every drawing or document including write-ups, data sheets, etc., shall carry project title, names of PURCHASER, document number, revision number, date of revision and brief details of revisions carried out, appropriate reference number of schedule, distribution and purpose, etc.. Wherever any revision is carried out, correspondingly revision number must be updated. The revisions carried out on any drawing or document shall be identified by encirclement and tagging the encirclement with the revision number

e) All documents shall have English version on them f) All dimensions on drawings shall be in metric units, unless otherwise specified. If any

dimension figured on a drawing differ from those obtained by scaling the drawing, the dimension as figured shall be taken as correct

g) Review of TENDERER's document and drawings by the PURCHASER will be on one-unit basis wherever documentation is identical for both units. However, for subsequent

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units, TENDERER shall certify in the documents drawings that the information contained in the document or drawings is identical with the one already reviewed by PURCHASER

h) Depending on the completeness and correctness of TENDERER's drawings and documents recommended for approval, the same will be stamped as below:

( ) Approved ( ) Approved subject to comments as noted; proceed with fabrication

consider ing comments; submit revised drawings and reproducibles for record

( ) Not approved; revise as per comments and resubmit for approval ( ) Refer covering letter no. dated ( ) Drawing of this category is not reviewed; drawing received for

information only • Approval herein neither relieves TENDERER of his contractual obligations and

responsibilities nor does it limit PURCHASER's rights under the contract • Drawing and documents are to be considered as approved only after written

approval by PURCHASER i) The TENDERER shall resubmit those drawings and documents on which clarifications

and/or modifications have been sought. This shall normally be done within two (2) weeks of receipt of comments, if not otherwise specified in engineering schedule

j) Drawings which are resubmitted by TENDERER without incorporating all the comments made by PURCHASER and without any clarifications for noncompliance with comments made, will be deemed incomplete and will neither be reviewed further nor approved

k) Any work performed or material ordered by the TENDERER prior to receipt of drawings stamped "approved subject to comments as noted" by the PURCHASER shall be at the risk of the TENDERER. After print of any drawing has been returned 'approved', the TENDERER may release all parts covered by the drawings, for production

l) One reproducible and soft copy of finally approved drawing shall be sent to the PURCHASER along with six (6) prints

m) Drawings prepared by the TENDERER and approved by the PURCHASER shall be considered as a part of the specification. However, examination and approval of the drawings by the PURCHASER shall not relieve the TENDERER of his responsibility for engineering, design, workmanship and materials, under the contract

n) Any delay in the approval of TENDERER's drawings and documents by PURCHASER due to non-compliance of the above procedural requirements by TENDERER shall be entirely to TENDERER's account

o) Secrecy : I. The technical information, drawings, specifications, and other related

documents forming part of the enquiry or 'contract' are property of the PURCHASER and shall not be used for any other purpose, except for execution

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of the 'contract'. All rights, including rights in the event of grant of a patent and registration of designs are reserved. The technical information, drawings, specifications, records and other documents shall not be copied, transcribed, traced or reproduced in any other form or otherwise in whole and/or duplicated, modified, divulged and/or disclosed to a third party nor misused in any other form whatsoever, without the PURCHASER's previous consent in writing, except to the extent required for the execution of this `contract'. These technical information, drawings, specifications and other related documents shall be returned to the PURCHASER with all approved copies and duplicates, if any, immediately after they have been used for the agreed purpose

II. In the event of any breach of this provision, the TENDERER shall indemnify the PURCHASER from any loss, cost or damage or any other claim whatsoever from any parties claiming from or through them in respect of such breach

1.13.33 Planning and Scheduling: a) After the award of contract the TENDERER shall plan the sequence of work of

manufacture and/or erection to meet the agreed plant commissioning date and shall ensure that all work, manufacture, shop testing and shipment of the equipment proceed in accordance with the required construction and erection sequence. The TENDERER shall furnish the dates of manufacture, testing, despatch, completion of erection and commissioning or stages of works as called for in the schedules

b) Within one month of LOI the TENDERER shall submit two copies (1 reproducible, 1 print) of `network schedule' to the PURCHASER showing the logic and period of the following minimum number of activities for review and approval:

I. Design and drawing submission, approval of different categories of drawings II. Quality control plan.

III. Material procurement of raw materials and bought out items. IV. Manufacturing process (indicating all major stages). V. Shop inspection/testing (indicating all inspection and tests).

VI. Shipment (indicating each planned shipment). VII. Erection (indicating all major stages for each equipment and structure).

VIII. Testing (indicating for all equipment and systems). IX. Commissioning (indicating for all equipment and systems)

c) During the execution of the contract, if it is found necessary to change the schedules, the TENDERER shall inform the PURCHASER and submit a modified network schedule with adequate reasons and evidence to the satisfaction of the PURCHASER. Such approval is not to be deemed consent to any amendment to the completion date as stated in the schedule

d) The network schedule shall be updated every month or at a frequency mutually agreed upon

e) Access to the TENDERER's and sub-TENDERER's works is to be granted to the PURCHASER at all reasonable times for the purpose of ascertaining progress

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1.13.34 Project reports for project monitoring During the execution of the contract, the TENDERER shall furnish monthly progress reports to the PURCHASER in a format as specified by the PURCHASER indicating the progress achieved during the month and total progress upto the month as against scheduled and anticipated completion dates in respect of key phases of design and engineering, manufacturing and shipment such as release of drawings for fabrication, procurement of raw material, manufacture, inspection, testing and shipment. The progress reports shall indicate all delays anticipated by TENDERER along with reasons for the delays. If called for by the PURCHASER, the TENDERER shall also furnish resource data and any other information in a specified format and frequency

1.13.35 End documentation Before the equipment is dispatched to site, the TENDERER will furnish Five (5) copies of the end documents in bound form containing following-

a. Copy of the purchase order b. Finally approved drawings c. Test reports d. Analysis reports e. Approved Design Concession Requests. f. O&M manuals containing storage, erection, commissioning, maintenance and

troubleshooting instructions, recommended spare parts. g. Detailed catalogues of various components h. Shipping releases

A soft copy of the all the above shall be submitted to the purchaser.

1.13.36 Security Rules: The TENDERER shall follow at site all security rules as may be framed by PURCHASER from time to time regarding movement of materials and equipment to and from site, issue of identity cards, control of entry of personnel and all similar matters. The TENDERER and his personnel shall abide by all security measures imposed by the Engineer or his duly authorised representative from time to time. TENDERER shall also follow all rules and regulations applicable to the area being declared / pronounced from time to time by the authorities or authority of existing Power Station in the vicinity or any other statutory orders. Nothing extra will be payable on account of stoppage / hindrance of the work. The TENDERER, his employees and agents shall not disclose any information or drawings furnished to him by the PURCHASER. Any drawings, reports and other information prepared by the TENDERER / by the PURCHASER or jointly by both for the execution of the contract shall not be disclosed without prior written approval of the Engineer. No photographs of the works or plant within site premises shall be taken, without the prior written permission

1.14 GUARANTEE 1.14.1 Performance guarantee

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The TENDERER shall ensure that the equipment and accessories supplied by him under this specification shall meet the guaranteed parameters as per the applicable codes, standards and statutes and regulations in the locality where the equipment will be installed. The TENDERER shall furnish the guaranteed parameters of each of the DG se as indicated below.

1) Each DG set shall be capable of generating at net electrical output of ______KVA under specified site conditions at _____ Hz,_____ power factor _____ V while running at ____ RPM under.

2) Fuel oil consumption at 1/4,1/2,3/4, and full load 3) Overload capability of the Engine. 4) Maximum period for which engine can operate without water circulation.

c) During cold start of Engine. d) During hot start of Engine.

5) Starting time and ready to take load. 6) Governor response, over speed capability. 7) Lube oil consumption at 100% engine load. 8) Generator efficiency at 1/4,1/2,3/4, and full load 9) Jacket water temperature at engine inlet and outlet. 10) Lube oil temperature at Lube oil cooler inlet and outlet. 11) Overspeed trip. 12) Transient voltage and frequency dips while starting of largest size motor. 13) Transient recovery time. 14) Voltage regulator response. 15) Excitation at full load and under specified variation of voltage and speed. 16) Maximum vibration of DG set _____ mm/sec 17) The noise level at a distance of 1.0 metre from the outline of the

equipment ______dB. TENDERER shall indicate the tolerances applicable to each of the guaranteed parameters above and the reference standards.

1.14.2 Performance Correction

Should the performance test results deviate from the guaranteed values, the TENDERER shall make every effort practicable, to correct the deficiencies. In case the TENDERER fails to meet the guarantees, the equipment is liable to rejected and in cases such option of rejection being exercised, the TENDERER shall replace the equipment with one that meets the guaranteed value at no extra cost to the PURCHASER

1.14.3 Delivery Completion Period The TENDERER shall guarantee delivery and erection of equipment/system specified

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1.14.4 Collaborator Guarantee 1) The TENDERER shall furnish his collaborator and/or suppliers back-up guarantee

for satisfactory performance of the equipment supplied under this contract. 2) TENDERER who is under taking the deign and/or manufacture of any part of the

equipment of specified capacity, to be supplied for the first time to the requirement of specification, should obtain a certification from his collaborators in regard to the following: a) The collaborator guarantees the design and choice of material for the part. b) The collaborator reviews and approves the fabrication details of the part. c) The collaborator guarantees the equipment performance

The collaborator monitors the Quality Assurance (QA) and quality control (QC) programme during manufacturing to enable performance requirements of the specification to be fulfilled.

1.14.5 General 1) The TENDERER warrants that the goods are of new and fresh high quality and that the

goods will be free of defects in design, material and workmanship for period of twelve (12) months from the date of commissioning of the equipment.

2) if within the expiry of the above stipulated guarantee period, the subject goods or any part thereof are found defective because of design, workmanship or material, the TENDERER shall replace the same with equipment/system meeting the requirements of specification. The guarantee period for the replaced parts or repair work of equipment/system shall be same period of 12 months from the date of replacement.

3) The TENDERER shall obtain similar guarantee from each one of his SUB-TENDERERs. However, the overall responsibility shall lie with the TENDERER

1.15 Packing and shipping 1.15.1 Packing

1) All equipment and material shall be protected for ocean shipment/inland transport, as the case may be carriage at site and outdoor storage during transit and at the site, strictly according to the instruction given in this specification.

2) The TENDERER shall pack the equipment at his own cost sufficiently and properly to ensure that are free from loss or damage while in transit to the ultimate destination.

3) The TENDERER shall be responsible for any damage to the equipment during transit and storage in all climatic conditions due to improper and inadequate packing.

4) Only packages constructed out of sound materials and of dimensions proportional to the size and weight of contents shall be used. Each package shall be limited to the size and weight that are permissible under existing sea/rail/road transport limitations as the case may be.

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5) Bundled materials shall be strapped rigidly with steel band over the protective covering.

6) Fragile materials shall be securely braced within the containers or otherwise amply fastened and packed to prevent shifting or rattling. Soft non-hygroscopic packing materials shall be placed between hard packing materials and the fragile equipment. Articles which do not completely fill the selected containers must be cushioned, braced, fastened or blocked to prevent damage to the article itself or destruction of the container. Inner bracing or blocking must be such that the content’s weight is distributed uniformly over the entire interior surfaces rather than concentrate on one or two critical points.

7) Loose materials, e.g. bolts, nuts, etc. shall be packed in gunny bags sealed in polythene bags with proper tagging.

8) Components containing glass shall be carefully covered with shock absorbing protective material such as expanded polystyrene (Thermocole).

9) All flanges and similar surfaces which are prone to scratching shall be provided with either metal or wooden caps bolted in place. Metal caps should be made from two layer of wood, each of 10 mm thickness, nailed together with the grain of each layer located at right angles to each other.

10) All openings in the equipment shall be tightly covered, plugged or capped to prevent foreign material from entering.

11) In the case of large and bulky equipment, the TENDERER shall be responsible for ascertaining transport limitations and supply the equipments in the minimum number of components or sub-assemblies, within the frame work of transport limitations.

12) Whenever necessary, proper arrangement for attaching slings for lifting shall be provided on the packages.

13) The contents of the packages shall be sealed in thick polythene sheets and all the inside walls of the packages shall be lined with water proof paper to protect the equipment from damage due to dust and moisture.

14) All Equipment shall be protected for the entire period of dispatch, long storage at site and erection, against corrosion, incidental damage due to vermin, sunlight, rain, high temperature, humid saline atmosphere, rough handling in transit, and storage in open including possible delays in transit. Material and equipment shipped across the sea shall be packed to with stand without damage, the effects of salt spray. All machined and plated parts shall be protected with anti-rust grease. Precautions shall be taken to protect shafts and journals where they rest on wooden or other supports likely to contain moisture. As such points, wrappings impregnated with antirust composition or vapour phase inhibitors shall be used. These shall have sufficient strength to resist chafing and indentation due to the protective wrappings and impregnation shall last for a minimum period of three months.

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15) Instruments conditions shall be plugged with suitable caps to avoid ingress of dust and moisture during shipment and storage. Silica gel or approved equivalent moisture absorbing material in small cotton bags shall be placed and tied at various points on the equipment, in package wherever necessary.

16) Adequate provision of skids or pallets shall be made to keep the packages above the collecting drainage. Crates and other large containers should have drain holes in the bottom to prevent collection of water within the packing. This is especially important where the cargo itself is subject to condensation (cargo’s sweat).

17) All cases, where applicable, shall be provided with suitable cutouts, closed by bolted wooden blanks to facilitate inspection by customs authorities. Water proof transparent papers shall be provided at the cutout locations to prevent water ingress into the casing through the cutout.

18) Each crate or package shall contain a packing list in a water proof envelope. Copies of the packing list, in triplicate, shall be forwarded to the PURCHASER prior to dispatch. All items of materials shall be clearly marked for easy identification against the packing list.

19) All spare parts shall be packed and treated for long storage conditions at site.

20) The PURCHASER may require to inspect and approve the packing before the items are dispatched. However, The TENDERER shall be entirely responsible for ensuring that the packing is suitable for the mode of shipment and such inspection will not exonerate the TENDERER from any loss or damage due to faulty packing.

21) Any material found short inside the intact packing cases shall be supplied by the TENDERER at no extra cost to the PURCAHSER.

22) All packing cover and packing material shall become the property of the PURCHASER.

23) All packages will be provided silica gel or equivalent approved moisture absorbing material in cotton bags.

24) For Electronic cabinets Electronic cabinets shall be packed without withdrawable modules. The modules shall be packed separately, each module being fully enclosed with polythene to prevent moisture/dust ingress. a) Silica gel or equivalent moisture absorbing material in small cotton bags

shall be placed and tied at suitable location within each cabinet. b) Any loose cables/plug connection shall be suitably tied inside the cabinet

to prevent hitting cabinet body during transportation. Plug connections shall be covered with PVC sheets.

c) Cabinet doors shall be locked and keys in plastic bags shall be attached to outer surface so as to be prominently visible.

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d) Any lamps/switches/handles etc. provided on outer surface shall be adequately protected before cabinet is packed.

e) Each cabinet shall be packed in aluminum foil/ PVC sheet bag completely sealed to prevent moisture/dust ingress. The outer packing shall be wooden.

f) Where two or more cabinets are to be joined at site, each cabinet shall be provided with a temporary sheet metal side cover plate and packed separately.

All instruments, relays, transmitters, indicating lamps, switches which are fragile nature should be removed from the DG set and panel and should be packed in the original cartons with silica gel or equivalent moisture absorbing material. Packing should be water type

1.15.2 Marking 1) All packages shall be clearly, legibly and durably marked with uniform block

letters with water proof paint on at least three sides with: a) Destination address as communicated b) Contract number. and date c) Dimensions of crate. d) Net and Gross weights. e) Sign showing ‘side up’ f) Sign showing ‘fragile’ marks incase of delicate equipment. g) Sign showing slinging and sling position h) Any handling and unpacking instructions, if considered necessary i) Identification mark relating them to the appropriate shipping documents. j) In case of spare parts, each spare part shall be clearly marked and labeled

on the outside of its packing with its description and catalogue/part number.

k) Any other necessary data to identify the equipment and relate it to contract.

2) Each package shall contain a packing note specifying the name and address of the TENDERER, the number and date of the Contract/Purchase Order, name and address of consignee, description of the material, and the quantity contained in such package.

3) The contents of the package shall be punched on a non- corrosive metal plate and nailed to the package in a prominently visible place. if number the items in the package is too many, a typed list in transparent water proof bag shall be kept inside a galvanized steel sheet packet nailed on to the outside of package in prominently visible location.

1.16 TRAINING OF PURCHASER’S PERSONNEL 1.16.1.1 The TENDERER shall train the personnel at site so as to make them proficient in operating

the equipment

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1.16.1.2 The PURCHASER'S personnel shall also be trained for routine maintenance work, lubrication, overhauling, adjustments and testing and replacement procedures to be adopted for the equipment offered

1.16.1.3 The TENDERER shall train the PURCHASER's personnel in carrying out minor repairs, if need arises, during the operation of the equipment

1.16.1.4 The TENDERER shall train two engineers for one week at the TENDERER's works so that personnel become adequately acquainted with the design and proficient in carrying out routine maintenance, overhauls repairs and operation

1.16.1.5 The TENDERER shall provide all necessary instruction material for the training, which shall include manuals, booklets, pamphlets, drawings, sketches, models, pictures, photos, colour slides, film etc. The training and instruction material shall become the property of the PURCHASER

1.16.1.6 The charges for training the PURCHASER's personnel and the cost of training material, if any, shall be indicated by the TENDERER in his offer

1.16.1.7 The TENDERER shall provide at no extra cost to the PURCHASER all necessary facilities and reasonable assistance as deemed necessary for the training. The travelling and living expenses of such personnel shall be borne by the PURCHASER

Very Important Note Price information should NOT be uploaded as a document in Part-I. Prices should be given only in the PRICE SCHEDULE of ONLINE price bid. The price breakup of different systems / accessories/spares, if any, should be given in the Optional Items – New Template. However, unpriced bid containing the list of items quoted along with taxes & levies should be uploaded as a document in Part-I. The unpriced bid should contain exactly the same item description provided in the online pricebid/ Optional Items – New of price bid. If the unpriced bid does not accompany the offer, the offer is liable for rejection.

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1.17 DATA SHEET This section covers the data sheets of major equipment and accessories covered under the system -

DIESEL GENERATOR-SET

1.0 GENERAL 1.1 Number of DG sets : Two (2) No

1.2 Type of DG Sets : Capable of starting and getting connected to 415 V Bus

1.3 Location : Indoor 1.4 Fuel specification : High Speed Diesel (HSD) conforming to IS:1460 1.5 Design site conditions for engine (a) Altitude : 7.4 m above main sea level (b) DG room ambient temperature : 45°C (c) Relative humidity : Max likely RH 80% at 450 C 1.6 Continuous output rating of DG set when

operating at above specified design site conditions after deducting consumption of all engine driven auxiliaries

: 1000 kVA

1.7 Overload capacity for 2 hr. in 24

consecutive hours of operation : 10%

1.8 Duration of no load operation : 2 hours continuously once in 3 months and

cumulative 8 hours in a year. 1.9 Duration of 30% load

operation : Continuous

1.10 Operation of DG set : Isolated bus only 1.11 Details of loads to be applied to DG set : Refer 1.19 1.12 Over speed of DG Set 1.12.1 Engine : 115% of rated speed

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1.12.2 Alternator exciter, and flywheel : 120% of rated speed 1.13 Accessories : (a) Common base frame for engine

, generator, radiator : Required (if the proposed design calls for)

(b) Foundation bolts/

anchor bolts for all equipment

: Required

(c) Anti-vibration pads for

mountings of DG set : To be provided as per design.

(d) Thermal insulation for exhaust

piping : Required

(e) Day oil tank with

necessary fittings : Required

(f) Tacho generator/speed

monitoring system : Required

(g) Shop primer and finish painting : Required

2.0 DIESEL ENGINE 2.1 Type of engine : Four(4) stroke with inline or Vee type cylinder

arrangement 2.2 Engine speed : Not more than 1500 rpm 2.3 Engine starting system : Air system 2.4 Time for starting and ready to pick up

load : Not more than20 seconds

2.5 Number of starts required : Six 2.7 Jacket water system-make-up (a) Quality : Passivated DM Water (b) pH : 7 (c) Total dissolved solids : Less than 0.1 mg/l

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(d) Turbidity : Nil (e) Calcium hardness as CaCo3 : Nil (f) Total hardness as CaCo3 : Nil 2.8 Maximum time of operation

without cooling water availability during start-up

: 3 minutes

2.9 Governor class : Class-A1 conforming to ISO-3046 Part-IV 2.10 Day tank oil storage capacity : 4hrs at full load. 2.11 Dimensions of day oil tank : As required and suitable for mounting on the

foundation provided 3.0 GENERATOR 3.1 Continuous Output Rating at specified

design ambient : 1000 kVA

3.2 Overload capability for 2 hours in 24

consecutive hours of operation : 10%

3.3 Rated Voltage : 415V (RMS) 3.4 Max. rated voltage : 433 V (RMS) 3.5 Rated stator current : As required 3.6 Rated frequency : 50 Hz 3.7 Number of phases : 3 3.8 Power Factor : 0.8 lag 3.9 Winding Connection : Star connected 3.10 Type of Enclosure : Suitable for water sprinkler system for Fire

fighting 3.11 Type of cooling : Air Cooled with shaft mounted cooling fan 3.12 Permissible voltage variation at rated

KVA, speed and PF : ± 5%

3.13 Permissible frequency variation at rated kVA and pf

: ± 3%

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3.14 Type of Insulation 3.14.1 Stator Winding : Class F } } Temperature rise 3.14.2 Field Windings : Class F } limiting to } Class-B limits. 3.14.3 Connections : Class F } 3.15 Temperature rise at maximum continuous rating over 45°C ambient 3.15.1 Stator windings (by Resistance) : 75 ° C

3.15.2 Field Windings (by resistance) : 75 ° C

3.16 Method of Neutral Grounding : Resistance earthed (To limit the fault current

to 600Amps)

3.17 Voltage drop during starting of largest

motor when D.G set is operating at rated capacity minus motor capacity

: < 15% (at generator terminals)

3.17.1 Maximum rating of motor to be started on auto transformer

: 225 kW, starting current 1500Amps

3.17.2 3.17.3

Maximum rating of motor to bestarted on DOL starter Maximum rating of motor to be stated on Star-Delta :

: 67kW 110kW

3.17.3 Starting current : 650 % at pf 0.2

3.18 Period for taking rated load after giving

starting impulse : 20 seconds – 60 seconds on load sequence

3.19 Size of earthing conductor for DG set : Cu conductor. 3.20 Excitation system : Brush less type 3.21 Excitation voltage response ratio : > 0.8

3.22 Voltage Regulator

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3.22.1 Voltage setting range of the regulator : ± 10% of the rated voltage 3.22.2 Steady state accuracy of the voltage

regulator from no load to full load : Less than ± ½ % of the rated generator voltage

3.23

Response of the voltage regulator & excitation system Maximum period to recover the generator voltage tothe set value for a step rejection of rated load at rated power factor.

:

< 2.4 sec

3.24 Time period for which Generator shall be capable of withstanding without injury a 3ø short circuit at rated kVA and power factor at 5% over voltage with fixed excitation

: 10 seconds

3.25 Voltage wave form Telephone harmonic

factor (T.H.F.) of the Line to line terminal voltage

: 3% maximum

3.27 Momentary overload : 50% current for 30 seconds after having

attained temp. equilibrium at rated load and overcurrent expected during sequential load restoration.

3.29 Short circuit ratio : >0.5

3.30 Short time I²2t value

I2 : Per unit negative sequence current t : Time in seconds.

: >20.0

3.30.1 Continuous negative sequence current

carrying capability Designed system fault level to which the DG shall be connected

: :

15% of rated current. 50 kA for 1sec

3.31 Manual starting of engine through

local/remote control

: Yes

3.32 Terminal Box

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a) : 1 No. for line side, phase segregated suitable for withstanding 50 kA for 1 sec .and suitable for receiving 12x1Cx1000 sq. mm. (Al) 415V (E) grade XLPE insulated cable (four runs per phase). The design of TB shall be such that it provides adequate space for termination of cable with adequate clearances. The terminal box shall be phase segregated..

b) : 1 No. for neutral side adequate to locate CTs

specified c) : 1 No for RTDs, BTDs, CT leads etc. d) : The degree of protection for all terminal

boxes shall be IP 54. 3.33 Current Transformers (Provided at the neutral end of the generator) 3.33.1 CT-1 (3 Nos. one/phase for differential protection) a) Ratio, class, burden : 3200/5A

Details shall be subject to review during detailed engineering and bidder shall supply required CTs at no extra cost.

3.33.2 CT-2 (Three Nos, one per phase for other protections) a) Ratio : 3200/5A b) Burden : 30 VA c) Class : 5P10 3.33.3 Current Transformers (provided in neutral grounding resistor circuit at NGR terminal box for

earth fault protection) a) Ratio : As required b) Burden : 15 VA c) Class : 5P10 3.33.4 Current Transformer for AVR : Bidder to decide. 3.34 Neutral Grounding Resistor a) Voltage rating of the neutral

grounding resistor : 415 KV/ 3

b) Ohmic value : As required

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c) Current Rating : As required for 60 seconds, d) Max. temp. rise : 375°C e) Material : Stainless steel f) Size of grounding conductor i) for NGR : AWG 4/0 Cu. ii) for NGR body : AWG 4/0 Cu 3.35 Temperature Detectors a) Type : Platinum Resistance(Pt 100) Duplex b) Resistance : 100 ohms at 0oC c) No.of detectors on stator : Minimum 2 nos./phase d) No. of detectors on bearing : One number/bearing 3.36 Space heaters a) Voltage : Single phase, 240 V b) KW rating : TENDERER to indicate 3.37 Control Panels/Junction Box a) Degree of protection for control

panels : IP42

b) Degree of protection for

Junction Box. : IP54

c) Minimum thickness of sheet

steel : 2 mm CRCA.

d) Cable entry : TOP for Control panel and BOTTOM for JB e) Type : Floor mounting, single front.

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3.38

The make, type, materials, sizes, accuracy etc., of various instruments, transducers, transmitters, control panel components etc., provided for the proposed and shall be subjected to review and approval by the PURCHASER during drawing approval. TENDERER shall supply items of approved make type and material without any extra cost to the PURCHASER.

3.38.1 Datasheet forDifferential Pressure Switch

Sl No Parameter Description

1 Type measuring element Diaphragm 2 Sensing element material SS 316 3 Case / enclosure material Pressed die cast aluminium 4 Switch accuracy + 1.5% of set value 5 Indication accuracy + 1% of FSR 6 Repeatability Less than +0.5% of span 7 Movement material SS 304 8 Dial size >100 mm 9 Window Shatter proof glass

10 Box protection IP 65 as per IS 60529 11 Set point Adjustable over span 12 Adjustment External micrometre screw for zero adj, internal

micrometre screw for range adj. 13 Over range 125% Of max operating pressure 14 Differential Adjustable Between 2% - 25% Of Span 15. Switch configuration/ rating 1 C/O, 220 V DC, 0.5 Amps 16 Insulation resistance Greater than 100 M Ohms at 500 V Dc 17 Contact resistance < 100 milli Ohms 18. Gasket material Neoprene/EPDM 19 Electrical connection cable Through double compression cable gland. 20 Tests As per IS 5439:1978 Reaffirmed 2000

Type tests As per IS 5439:1978 Reaffirmed 2000 I. Seismic test Test report to be furnished or to be tested.

Ii. Life cycle test

1 million operation (test report to be furnished)

Iii. Vibration test Test report to be furnished. Routine tests As per IS 5439:1978 Reaffirmed 2000

I. Dimensional & thread checks for end connections

On 100% Items.

Ii. Calibration test

As per IS 5439:1978 Reaffirmed 2000

Iii. Over range test At 125% of range will be done on 100% items for 10 minutes duration

Note: Calibration test shall be done before & after the seismic test

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3.38.2 Datasheet for Pressure Switch

Sl No Parameter Description 1 Type Direct sensing bellows 2 Mounting Mounting on instrumentation rack 3 Accuracy + 1% of span 4 Repeatability + 0.5% of span 5 Switch type Micro switch with auto reset 6 Contact type / rating 1 C/O, 48V DC. 2 Amps. 7 Switch differential Adjustable between 6% and 40% 8 Set pressure Adjustable over entire span with locking feature 9 Over range 125% of max. Design pressure

10 Switch setting scale To Be Calibrated Through the entire range Of Span

11 Response < 1 Sec 12 Contact resistance < 100 Milliohm 13 Insulation resistance >100 Mega ohm At 500 V DC 14 Case

IP:65 as per IS 60529 Flame proof enclosure for fuel oil PS

15. Housing material Pressure die-cast aluminium 16 Sensor material SS 316 L 17 Pressure element material SS 316 18. Wetted parts material SS 316 19 Gasket material Neoprene/EPDM 20 Socket material SS 316 21 Location / orientation Instrumentation rack mounting/vertical

22 Tests As per IS 5439:1978 Reaffirmed 2000

Type tests As per IS 5439:1978 Reaffirmed 2000 i. Life test Test Report To Be Provided Or Test Shall Be Done ii. Seismic test Test report to be submitted iii. Vibration test Test report to be submitted iv. Flame proof test Flame proof suitable for use in Group II B Application

Routine tests As per Is 5439:1978 Reaffirmed 2000 i. Dimensional check & thread

check for end connections To be done on 100% items.

ii. Calibration test As per Is 5439:1978 Reaffirmed 2000

iii Over range test At the 125% max working pressure, Duration -10 minutes, to be done on 100% items.

Note :Calibration Test To Be Done Before And After Seismic Test Wherever Specified

3.38.3 Instrument Data Sheet for Level Switches

Sl No Parameter Description 1 Type Magnetic Float Operated Level Switch

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2 Switch type / contact Micro switch / 1 C/O 3 Switch contact rating 48 V DC, 2 Amps 4 Switch differential Fixed 10 +2 mm. ( Set point shall be adjustable over

10% - 90% of the range) 5 Accuracy + 5 mm 6 Repeatability + 3 mm 7 Contact resistance <100 milli Ohms 8 Insulation resistance >100 M Ohms 9 Response < 1 Sec

10 Switch enclosure IP 65 as per IS 60529 Flame proof suitable for use in Group II B Application (For Level Switches Of Day Oil Tank)

11 Switch housing material Die cast aluminium 12 Float material SS 316 13 Gasket material Nitrile rubber 14 Float assembly material SS 304 15 Body material SS 304 16 Flanges material SS 304 17 Tests Type test To be furnished

i. Life test 1 million operation (test report to be submitted) ii. Seismic test Test report to be submitted or tested iii. Vibration test Test report to be submitted. iv. Flame proof test CMRI Dhanbadcertificate to be submitted.

Routine test To be furnished i. Dimensional & thread checks

for end connection To be done on 100% items.

ii. Calibration test To be done on 100% items.

Note : Calibration Test To Be Done Before And After Seismic Test Wherever Specified

3.38.4 Datasheetfor Displacer Type Level Transmitter


1. Type Blind Direct Acting Electronic 2 Wire Transmitter

2. Accuracy Within + 5mm Including Linearity And Hysteresis

3. Repeatability + 3mm 4. Mounting Direct on tank, top mounted 5. External zero/span adj Required 6. Over range 125% of span 7. Re Response Better than 1 second 8. Transmitter case Ip-66 as per IS 60529, flame proof enclosure for Group II B

Application.

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9. P Power Supply 48V DC 10. Ou Output Signal 4-20 mA DC Max 600 Ohm load 11. Torque Tube Material SS 316 L 12. S Suspension Material SS 304 13. D Displacer Material 304 SS 14. Co Cable Connection Through double compression type cable gland.

T Tests As per Is 13122 (Part 2):1991 Reaffirmed 2001 Type Test As per Is 13122 (Part 2):1991 Reaffirmed 2001

i. Vibration, Dry Heat, Damp Heat, Temp. Cycling & Dry Cold Test

Test report to be submitted

ii. Flame Proof Test To be furnished iii. Burn In Test CMRI Dhanbhadtest report to be submitted ( Gr.IIB

Application) Routine Test As per Is 13122 (Part 2):1991 Reaffirmed 2001

i. Dimensional & thread check for end connections

To be done on 100% Items

ii. Calibration 5 point calibration to be done on 100% items. iii. Hydrostatic test At 1.5 times rated pressure

3.38.5 Datasheetfor Temperature Switches

Sl No Parameter Description 1 Range type RTD Pt100 with suitable electronics 2 Bulb material SS 316 3 Accuracy +1% Of FSR 4 Case material Die cast Aluminium 5 Box protection IP 65 as per IS 60529 6 Over range 125% Of Span 7 Set point Adjustable at site 8 Switch type 1 C/O 9 Switch rating 48 V DC, 2 Amps

10 Electrical connection Through double compression cable gland 11 Switch characteristics Contact operation on parameter rising with

adjustable hysteresis 12 Mounting Direct on pipe or As per requirement 13 Thermowell SS 304, Drilled bar stock 14 Response time Less than 1 Sec. 15 Insulation resistance Greater than 100 M Ohms at 500 V Dc 16 Contact resistance Less than 100m Ohms 17 Repeatability +1.0% Of FSR 18 Linearity + 0.5% Of FSR 19 Extension As Per Requirement

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20 Tests As Per Is 2848: 1986 Reaffirmed 2001 Type Tests As Per Is 2848: 1986 Reaffirmed 2001

i. Seismic Test Test Report to be submitted / seismic analysis shall be done on thermowell.

ii. Life Cycle Test >1 Million Operations Test Report To Be submitted

iii. Vibration Test Test report to be submitted. Routine Tests As per Is 2848: 1986 Reaffirmed 2001

i. Dimensional & Thread Check For End Connections

To be done on 100% items.

ii. Calibration Test As per Is 5439:1978 Reaffirmed 2000 iii. Over Range Test At 125% of range, to be done on 100% items for 10

minutes duration. Note: Calibration test shall be done before & after the seismic test.

3.38.6 Datasheet for Temperature Transmitters

Sl No Parameter Description 1. Type Electronic 2 –Wire 2. Zero & span adj’mnt Required externally 3. Accuracy 0.5% of span 4. Over range 25% above max. range 5. Scale range 0-100% Linear 6. Linearity <+0.1% of span 7. Repeatability <+ 0.5% of span 8. Hysteresis <+ 0.5% of span 9. Case enclosure IP 66 as per IS 60529 10. Power supply 48V DC 11. Input signal 3-Wire RTD Pt 100 Ohm At 0o C

12. Output signal 4-20mA DC at 600 Ohm Load, Max 13. Case material Die cast aluminium 14. Cable connection Through double compression cable gland 15. Mounting brackets Required. 16. RTD specifications Simplex, to be used in thermowell drilled bar

stock, SS 316 R. Tests As per IS 13122 (Part 2) : 1991 Reaffirmed 2001 Type tests As per IS 13122 (Part 2) : 1991 Reaffirmed 2001

i. Vibration, dry heat, temps. Cycling, dry cold and damp heat test

Test report to be submitted

ii. Seismic qualification Thermowell to be qualified by analysis iii. Burn-in test Test report to be submitted

iv. Over range test At 125% Of Max. Working Pressure, Duration-10minutes.

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Routine tests As Per IS 13122 (Part 2) : 1991 Reaffirmed 2001 i. Dimensional & Thread check for

end connections To be done on 100% items.

ii. Calibration test As per IS 13122 (Part 2) : 1991 Reaffirmed 2001

3.38.7 Datasheet for Pressure Transmitters


1. Type Capacitance Type Electronic – 2 Wire Rose Mount Make preferred

2. Pressure element Diaphragm 3. Accuracy + 0.5% of calibrated span 4. Repeatability + 0.25% of span 5. Mounting Local- Pipe / Instrumentation rack mounting 6. Over range 130% of range 7. External zero / span adj Required on the transmitter body 8. Vacuum protection Required 9. Zero suppression / elevation Required. 10. Transmitter enclosure IP:66 as per IS 60529 11. Transmitter power supply 48 Volts DC 12. Transmitter output signal 4-20 mA DC @ 600 Ohms load 13. Sensing element material SS 316 L 14. Transmitter housing material Die-Cast Aluminium 15. Conduit / cable connection Through double compression cable gland. 16. Mounting brackets with fasteners Required

17. Tests As per IS 13122 (Part 2) : 1991 Reaffirmed 2001 Type tests Test report to be furnished

i. Seismic test Test report to be submitted or tested

ii. Vibration, dry heat, temp. Cycling, dry cold and damp heat test

Test certificate to be provided

iii Burn-in test Test certificate to be provided iv. Over range test

At 150% of max. Working pressure, duration-10 min. to be done on 10% items

Routine tests As per IS 13122 (Part 2) : 1991 Reaffirmed 2001 i. Calibration test As per IS 13122 (Part 2) : 1991 Reaffirmed 2001

ii. Dimensional & Thread check for end connections


iii. Hydrostatic test To be done on 100% items

Note: Calibration test shall be done before and after seismic test

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3.38.8 Datasheet for Thermocouples

Sl No Parameter Description 1. Type Duplex thermocouple 2. Temperature range As required 3. Accuracy + 0.75% of FSR as per IEC 584-2 4. Sensing element Chromel-Alumel 5. Calibration As per IEC 584-2 6. Outer sheath material SS 316 7. Inner insulation Compact Mgo Or Approved Equivalent 8. Mounting Direct on cylinders 9. Accessories Extension wire of min. 10m length , Teflon

fibre insulated with SS304 braiding. 10. Tests As per IS 12579 , 1998 Reaffirmed 2003

Routine tests As per IS 12579 , 1998 Reaffirmed 2003 i. Dimensional & Thread Check for end

connections To be done on 100% items

ii. Calibration test 5-Point calibration to be done on 100% items.

3.38.9. Datasheet for RTD

Sl No Parameter Description 1. Type Duplex Pt 100 RTD 2. Resistance 100 Ohms At 0 Deg.C 3. Accuracy As per DIN 43760, Class B 4. Sensing Element PT 100 RTD 5. Calibration As per IEC 751-1995 6. Outer Sheath Material SS 316 7. Mounting Thermowell (Suitable For Duplex RTD) 8. Accessories Thermowell And / Or Head As Required 9. General spec. Thermowell Drilled Bar Stock, SS316 10. Applicable Standards & Codes: IEC 751-1995 11. Tests As per Is 2848 : 1986 Reaffirmed 2001

Type tests As per Is 2848 : 1986 Reaffirmed 2001 i. Vibration test Test report to be submitted. Routine Tests As Per IS 2848 : 1986 Reaffirmed 2001

i. Dimensional & thread check for end connections


ii. Calibration test 5-Point calibration will be done on 100% items.

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3.38.10 Datasheet for Pressure Gauges

Sl No Parameter Description 1. Type Direct reading 2. Mounting Direct bottom entry 3. Dial size 100 Mm 4. Pointer Black coloured & micrometre zero

adjustable. 5. Accuracy + 1.0% 0f FSD 6. Repeatability + 0.5% Of FSD 7. Over pressure limit 30% above max. pressure 8. Protection IP-65 as per IS 60529 9. Joints TIG Argon Arc Welding 10. Case, movement,

Socket material AISI 304 SS AISI 316 SS

11. Bourdon material Depending on the range and the process medium, AISI 316 SS /Monel /Beryllium Copper

12. Window Shatter proof glass 13. Blow out disc, gasket Neoprene 14. Applicable standards. Is- 3624 O. Tests As per IS 3624, 1987 Reaffirmed 2004

Type tests

As per IS 3624, 1987 Reaffirmed 2004

i. Seismic test Test report to be submitted or tested Routine tests As per IS 3624, 1987 Reaffirmed 2004

i. Calibration 5-Point calibration to be done on 100% items.



iii. Over Pressure test/ Hydro test To be done on 100% items. Note: Calibration Test Shall Be Done Before And After Over Pressure & Seismic Test

3.38.11 Datasheet for Temperature Gauge

Sl No Parameter Description 1. Type Direct reading bimetal 2. Mounting Direct bottom entry (or, as per the

requirement), rigid stem 3. Dial size 100 mm 4. Repeatability + 0.5% of FSD 5. Over range limit 25% Above Full scale range 6. Protection IP-65 as per IS 60529 7. Joints TIG Argon Welding 8. Case material AISI 304 SS

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9. Stem material AISI 316 SS 10. Sensing element Bi- Metal strip coiled 11. Gasket material Neoprene 12. Thermowell material Single piece hexagonal bar stock SS 316

13. Tests As per ASME B 40.3 Type test

i. Seismic qualification of thermowell By analysis Routine tests As per ASME B 40.3

i. Calibration 5-point calibration to be done on 100% items.



iii. Over range test To be done on 100% items. iv. Tests on thermowell Bore concentricity & Hydro test

3.38.12 Datasheet for Solenoid Valves

Sl No Parameter Description 1. Type Internal Pilot Operated Diaphragm Type 2. Power supply 48V DC, free wheeling diode to be provided

across the coil. 3. Solenoid rating Continuous 4. Insulation resistance >100 MOhms at 500 V DC 5. Solenoid coil conductor material Electrolytic Copper

6 Insulation class Class ‘F’ 7 Coil enclosure IP-65 as per IS 60529 8 Operating Temperature range 15 To 65 Deg. C 9 Terminals Screwed Type

10 No of ports Two 11 Action Normally closed for air system valve &

Normally open for fuel oil system. 12 Body and internal part material SS ASTM A 351 CF 8 13 Seat material Viton 14 Tests As per IS:8935 - 1985 Reaffirmed 2004

Type tests As per IS:8935 - 1985 Reaffirmed 2004 i. Life Test up to 25000 Operations Test report to be submitted. ii. Seismic test Test report to be submitted. iii. Vibration, Dry Heat, Dry Cold, Temp.

Cycling & Damp Heat Tests, High voltage test

Test report to be submitted.

iv. Flame proof test Gr. II B Application. CIMFR , Dhanbad approval certificate

Routine tests As Per IS:8935 - 1985 Reaffirmed 2004 i. Dimensional & thread checks for end

connection 100% on all items

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ii. Hydrostatic test 100% on all items iii. Air leak test 100% on all items iv. Electrical tests

Coil pick up Coil drop out Insulation resistance

100% on all items

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1.18 Preferred List of components

The following is the List of Products and indicative Make. Bidder is free to propose any other equivalent Make meeting technical requirements, specifications along with the required details in the support of the same. The same would be analysed and accepted if found suitable after discussion between the purchaser and bidder.

Bidders are required to offer reputed equipment / component which are strictly meeting technical requirements with relevant /latest applicable standards / rules.

Sl No. ITEM MAKE 1 Alternator Kirloskar Electric /Stamford/ Crompton/BHEL 2 Auxiliary contactor L&T/Siemens 3 Selector Switches Siemens/Kaycee/Salzer 4 Over Load Relay L & T/Siemens/GE Power control 5 Fuses Fittings/Fuses L & T/GE Power Control 6 Indication LED Binay/Tecknic 7 Indicating Instruments Automatic Electric/Kappa 8 Crimping Type Lugs Do wells/Lotus/Jainson 9 Terminal Blocks Essen/Connect well

10 Siemens Type SIBG Cable Gland Prabhat/Comet/Comex 11 Protection relays SCHNEIDER 12 Safety valve Tyco Sanmar Crosby 13 Pressure gauges H Guru, Precision , General, Waree

14 Pressure switch, ΔP switches, Thermostats

Danfoss / Dag Switzer / General with adjustable hysteresis and MWP twice that of

the max. operating pressure (In case of thermostats the MWT shall be twice that of

max. operating temp.)

15 Pressure transmitters Rosemount/ABB/Yokogawa/Danfoss with adjustable zero & span

16 Level Switches/transmitters Pune Techtrol / Levcon / Swizer 17 Temperature gauges H Guru / Precision / General / Waree 18 Ball Valve Audco / KSB 19 Non return valve Leader / Audco / KSB 20 Solenoid valve Asco / Rotex

21 Auto Drain Valves JORC-NUFROUS (Timer Type with adjustable on time in seconds and off time in minutes)

22 Changeover valves, isolation valves Flowchem/Aira with actuator for inlet

23 Solenoid operated isolation valves Gemu make – Electropneumatically operated

angle seat diaphragm valves with 48 Vdc operated solenoid valves

24 Electrical components L&T / Siemens 25 Terminal Blocks Euro style – rated for 5 A / 10 A 26 Cables CCI, Finolex

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27 Dew point Meter on panel with alarm contact

Testo / GE Panametrics (At the dryer outlet or on the air receiver. Range : -60°C to +30°C)

28 Impulse tubing Annealed copper or SS316L depending on the pressure rating and strictly not nylon/PVC.

29 Thermocouples & RTDs

Tempsens, Udaipur. All the thermocouples and RTDs shall be duplex and the spare element

shall be brought out to the terminal assembly and shall be available as spare

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1.19 Load Sequence for DG set

The capacity of the New DG sets isbased on the following load requirement for one unit when normal power supply is not available-

Load

Sr.no Load description Rating Full load Current

Startingmethod Remarks

1 24V DC Charger 5.5KVA 7.6A Remain connected

2 48V DC Charger 31.3 KVA 43.5A Remain connected

3 220V DC Charger 41.3 KVA 57.3A Remain connected

4 220V AC Charger 100 KVA 138.8A Remain connected

5 Emergency Lighting 50 KVA Remain connected

6 Service water pump 30 kW DOL Remain connected

7 BSC pump 5.5 kW DOL Remain connected

8 Wardleonard Motor Primary 225 kW 368A Auto transformer with 75% voltage tapping 1500 A

Will start after 30 second from the start impulse

9 Ventilation fan motor 110 kW Star-Delta Manual 10 Wardleonard Motor

Secondary 90 kW Auto

transformer with 75% voltage tapping

Manual

11 PHEC Blower motor 11 kW 18A DOL Manual start 12 Appendix cooling blower 5.5 kW 9A DOL Manual start 13 Supply blower 11 kW DOL Manual start 14 Air-cooled compressor 67 kW 109A DOL Manual start While plotting the load profile, following can be assumed: Starting power factor 0.2 Running power factor 0.8 Starting current 720% of full load current Maximum torque of motor : 200% of full load torque DG shall be ready to take load within 20 secs from the start impulse Entire loading on D.G. Set shall be completed maximum within 60 seconds

1.20 QUALITY ASSURANCE PLAN FOR DIESEL-GENERATOR

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1.0 Scope and Purpose:

This document indicates the requirements for quality assurance of DG sets from the TENDERER. Subsequent to the placement of Purchase Order TENDERER shall submit for PURCHASER’s approval a quality assurance plan in line with this documents incorporating specific document numbers for ‘’format of records’’, “acceptance norms” and “reference documents”.

2.0 Abbreviations:

V Verified by

P Performed by

W Witness by (After lapse of due receipt notice by the PURCHASER, TENDERER may proceed with manufacture)

H Hold (Unless a written clearance is obtained from PURCHASER, CONTACTOR shall not proceed to next stage)

1 PURCHASER QS

2 CONTARCTOR QS

3 Approved External Laboratory or SUB-TENDERER QC (if TENDERER QC / facility not available)

AD PURCHASER Approved Document such as Tender Document, Purchase Order, Drawings & Test Procedures

TR Test Report

IR Inspection Report

PS Plant Standard

CHP PURCHASER / Customer hold point

IEC International Electro technical Commission standards

IEEE Institute of Electronics and Electrical Engineers standards

IS Indian Standards

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3.0 Notes:

1. Test Reports not more than five years old from date of purchase order shall be reviewed for acceptance. Otherwise test shall be carried out.

2. Minor: The characteristic of a component, process or operation whose failure neither materially reduce the usability of the product in operation, nor does it affect the aesthetic aspects.

3. Major: The characteristic of a component, process or operation whose failure may cause operation failure which cannot be readily corrected at site or cause substandard performance, increased erection and maintenance cost, reduced life or seriously affect aesthetics or ergonomics.

4. Critical: The characteristic of a component, process or operation failure of which will surely cause operating failure or intermittent troubles which is difficult to rectify at site or render the unit unfit for use or safety hazards.

5. Failure of a characteristic means failure to meet the “acceptance norms”. 6. Sampling: Generally in accordance with IS: 2500. If 100% ‘witness is carried out by

TENDERER, PURCHASER will witness on sample basis, or if 100% “witness” of tests is carried out by SUB-TENDERER, TENDERER will witness on sample basis.

7. Any deviation to this QAP shall be brought out by the TENDERER in his offer failing which this QAP shall be complied with fully.

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SECTION – 2

FORMAT FOR SUBMISSION OF TECHNICAL PARTICULARS

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2.0 TECHNICAL DATASHEETS (TO BE SUBMITTED WITH THE TENDER)

The TENDERER shall furnish the technical particulars below for the equipment quoted without which the offer shall be considered incomplete. The data provided by the supplier for the datasheet is on major parameters and the supplier has to manufacture and supply the DG sets conforming the tender specification and datasheet given in 1.16:

Sl.No. Description Response 2.1.0 DG SETS 2.1.1 Make of engine 2.1.2 Make of alternator 2.1.3 Make of control panels 2.1.4 Standard rating of DG set under ISO condition 2.1.5 Continuous rating of DG set at generator terminals under

specified site conditions

2.1.6 Duration of continuous no load operation without any adverse affect on DG set performance.

2.1.7 Overload capacity of DG set for running 2 hrs in 24hrs. 2.1.8 Qualification for Nuclear Power Station Duty: 2.1.8.1 Whether identical DG sets and auxiliaries were earlier

subjected to qualification type test as specified in the tender?

YES/NO

2.1.8.1 (a) If yes, furnish the details. 2.1.8.1 (b) If no, state how DG sets are proposed to be qualified for

application in nuclear power station standby application.

2.1.8.2 If the Purchaser desires performance qualification tests at manufacturer’s works as specified in the tender, whether tenderer performs such tests on the equipment offered?

YES/NO

2.1.9 Seismic qualification requirements: 2.1.9.1 Whether identical DG sets and auxiliaries are qualified for

seismic qualification in-accordance with IEEE-344? YES/NO

1.9.1 (a) If yes, furnish the details. 2.1.9.1(b) If no, state the qualification method proposed by the

tenderer.

2.1.9.1(c) Whether the qualification methodology will be inline with IEEE-344

YES/NO

2.1.9.1 (d) Indicate specific deviations, if any, from IEEE-344 enclosed with the tender

2.1.9.2 Proposed method of qualification for : (Analysis, Testing, Combined Analysis and testing)

2.1.9.2.1 Engine + Engine mounted components 2.1.9.2.2 Alternator 2.1.9.2.3 Coupling 2.1.9.2.4 Base frame 2.1.9.2.5 Piping, tanks, Heat exchangers, pumps, motors, valves, supports,

silencers etc. mounted out side the engine for air intake& exhaust system, cooling water system, starting air system, fuel oil system

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and lub oil system. 2.1.9.2.6 Local control panels. 2.1.9.2.7 Field instruments & instruments mounted on engine 2.1.9.2.8 Neutral Grounding Resistors 2,1.9.2.9 Solenoid valves 2.1.9.3 Whether equipment subjected to seismic testing (SSE & OBE) will

be supplied to purchaser for use in service?

2.1.9.4 If equipment subjected to seismic testing (SSE & OBE) are proposed to be supplied for purchaser in use what is the justification?

2.1.9.5 Whether the cost for not using items subjected to seismic testing indicted in the price schedule?

2.1.9.6 Details of organization which is proposed to carryout seismic qualification by:

2.1.9.6.1 Analysis 2.1.9.6.2 Testing 2.1.9.6.3 Combined analysis and testing 2.1.9.7 What are the special measures to be implemented in the design

to ensure that equipment offered qualify for the specified seismic accelerations an perform with out fail during and after being subjected to OBE’s and SSE

2.1.10 Whether documentation indicating details of components which require periodic replacement, their replacement interval, criteria for replacement etc. so that their failure in service is minimized and high level of reliability and availability of DG Set is maintained, is submitted?

2.1.11 Reliability data 2.1.11.1 Meantime between failure for DG set (total system) 2.1.11.2 Meantime to repair 2.1.11.3 Reliability to start 2.1.11.4 Maximum planned down time required for maintenance activities

/ year/Dg set.

2.1.11.5 Anticipated unplanned/breakdown maintenance time required/year/DG set.

2.1.11.6 Recommended test frequency 2.1.11.7 Designed no. of cycle of operation 2.1.11.8 Designed no. of years of operation 2.1.11.9 Calibration frequency 2.1.12 Information required for DG set Foundation design 2.1.12.1 Area of the foundation base length X Breath 2.1.12.2 Amplitude horizontal vibration parallel to axis perpendicular to

shaft axis (X-X axis)

2.1.12.3 Amplitude of horizontal vibration along the axis to shaft (Y-Y axis) 2.1.12.4 Amplitude of vertical vibration (Z-Z axis) 2.1.12.5 Amplitude of angular vibrations about XX axis 2.1.12.6 Amplitude of Angular vibrations about YY axis. 2.1.12.7 Amplitude of angular vibration about ZZ axis

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2.1.12.8 Mass moment of Inertia of DG sets about the centre of gravity of the DG set with respect to XX axis

2.1.12.9 Mass moment of Inertia of DG sets about the centre of gravity of the DG set with respect to YY axis

2.1.12.10 Mass moment of Inertia of DG sets about the centre of gravity of the DG set with respect to ZZ axis

2.1.12.11 Frequency of disturbing force 2.1.12.12 Frequency of disturbing moment 2.1.12.13 Mass of engine with auxiliaries on the engine 2.1.12.14 Mass of driven equipment 2.1.12.15 External out of balance horizontal forces in projection of axis XX 2.1.12.16 External out of balance horizontal forces in projection of axis YY 2.1.12.17 External out of balance vertical forces in projection of axis ZZ 2.1.12.18 Unbalanced moments about XX axis resulting from inertia forces

and torques, external existing torques and external out of balance forces

2.1.12.18(i) Primary 2.1.12.18(ii) Secondary 2.1.12.19 Unbalanced moment about YY axis 2.1.12.19(i) Primary 2.1.12.19(ii) Secondary 2.1.12.20 Unbalanced moment about ZZ axis 2.1.12.20(i) Primary 2.1.12.20(ii) Secondary 2.1.12.21 Distance to center of gravity of engine from the end of block 2.1.12.22 Distance to center of gravity of driven machinery from end of

block

2.1.12.23 Distance to center of gravity of engine from the base of engine. 2.1.12.24 Distance to center of gravity of driven machine from the base of

engine

2.1.12.25 Loads due to dynamic short circuit condition 2.1.12.26 Loads due to out of set running between machines 2.1.12.27 Loads due to abnormal sudden stoppage 2.1.12.28 Any further details for the design of foundation block 2.1.13 Diesel generator set is capable of operating at no load for two (2)

hrs. continuously and capable of subsequent operation at full loads without any detrimental effect.

YES/NO

2.1.14 DG Set is capable of starting and accepting load even if pre-lob oil pump and jacket water recirculation pump is not in operation for 72 hrs. prior to the start command.

YES/NO

2.1.15 Minimum load at which DG set can be operated continuously 2.1.16 Heat Balance of DG set at 100% load: 2.1.16.1 Heat input by fuel: 2.1.16.2 Electrical outputs at alternator terminals 2.1.16.3 Auxiliary consumption 2.1.16.4 Heat loss through exhaust gases

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2.1.16.5 Heat loss to engine jacket water 2.1.16.6 Heat loss to lubricating oil 2.1.16.7 Heat loss to engine room by radiation 2.1.16.8 Friction losses in engine 2.1.16.9 Other engine losses 2.1.16.10 Net engine output at the shaft under site condition 2.1.17 Whether calculations/performance curves enclosed to

demonstrate transient frequency and voltage variations during load sequencing

YES/NO

2.1.18 Reference Standards for proposed DG set 2.1.19 Reference Standards for proposed engine 2.1.20 Reference Standards for proposed alternator, controls and

electrical components

2.1.21 Standard for mechanical systems beyond DG set boundary 2.1.22 Reference Standards for instruments 2.1.23 Reference Standards for seismic qualification 2.1.24 Reference Standards for qualification testing of DG sets as per

specification

2.1.25 The noise level at 1.0 meter from DG set 2.1.26 Vibration level 2.1.26(i) Standards 2.1.26(ii) At generator base 2.1.26(iii) At generator DE & NDE main bearing houses 2.1.26(iv) Front and rear end of engine base 2.1.26(6v) Front end top edge and back end top edge of engine 2.1.27 Make, type and rating of flexible coupling between engine and

generator

2.2.0 DIESEL ENGINE AND AUXILIARIES 2.2.1 GENERAL 2.2.1.1 Engine model number 2.2.1.2 ISO output of engine 2.2.1.3 Derating factors for site conditions 2.2.1.3(a) Due to ambient temperature 2.2.1.3(b) Due to humidity 2.2.1.3(c) Due to elevation 2.2.1.3(d) Due to cooling water temperature 2.2.1.3(e) Any other factor 2.2.1.3(f) Total derating 2.2.1.4 Site output rating of engine 2.2.1.5 Specific fuel consumption at 2.2.1.5(a) 110% load 2.2.1.5(b) 100% load 2.2.1.5(c) 75% load 2.2.1.5(d) 50% load 2.2.1.6 Load of each engine driven auxiliaries 2.2.1.6(i) Engine driven fuel pump

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2.2.1.6(ii) Engine driven lube oil pump 2.2.1.6(iii) Engine driven jacket water pump 2.2.1.6(iv) Total 2.2.1.7 Consumption of all engine driven auxiliary loads considered in

arriving at rated output? YES / NO

2.2.1.8 Net output at engine shaft at site condition 2.2.1.9 Operating speed 2.2.1.10 Over speed trip set point 2.2.1.11 Brake mean effective pressure 2.2.1.11(i) At 100% load 2.2.1.11(ii) At 110% load 2.2.1.12 Mean piston speed 2.2.1.13 Type of coupling between engine and alternators and Losses in

the coupling

2.2.1.14 Engine flywheel provided? YES / NO 2.2.1.15 Common base frame for engine , generator and radiator

provided? YES / NO

2.2.1.16 Whether base frames (minimum 150mm height)provided for all floor mounted equipment including local control panels

YES / NO

2.2.1.17 Whether mechanical over speed protection provided? YES / NO 2.2.2 Construction Features of Engine 2.2.2.1 Number of strokes/cycles 2.2.2.2 Number of cylinders 2.2.2.3 Arrangement of cylinders 2.2.2.4 Cylinder bore 2.2.2.5 Piston stroke 2.2.2.6 Compressor ratio 2.2.2.7 Number of engine valve provided/cylinder 2.2.2.8 Type of valve cooling 2.2.3 Combustion Air System 2.2.3.1 Quantity of combustion air requirement at 100% load 2.2.3.2 Supercharged air pressure 2.2.3.3 Intake silencer provided YES / NO 2.2.3.4 Turbocharger 2.2.3.4(a) Make & type 2.2.3.4(b) Number 2.2.3.4(c) Speed 2.2.3.5 Charge air cooler 2.2.3.5(a) Type 2.2.3.5(b) Nos. provided 2.2.3.5(c) Charge air temperature at cooler outlet 2.2.3.6 Air intake filter 2.2.3.6(a) Provided? YES / NO 2.2.3.6(b) Type 2.2.3.6(c) Make 2.2.3.7 Air intake Duct and supports are provided

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2.2.3.8 Material of pipe and ducting 2.2.3.9 Whether the scope of intake air system offered covers completely

all items specified in the tender? YES / NO

2.2.3.10 Differential pressure indicating switch across inlet air filter provided?

YES / NO

2.2.3.11 Space required on the front wall of DG room for fixing intake air filters

2.2.3.12 Whether supply includes seismic qualification of complete intake air system

2.2.3.13 Design, equipment, manufacturing standards for complete combustion air system

2.2.4 Exhaust Gas system 2.2.4.1 Volume of gases leaving exhaust at rated engine output 2.2.4.2 Temperature of exhaust gas 2.2.4.3 Exhaust gas composition at 100% load for specified fuel 2.2.4.3(a) SO 2.2.4.3(b) NO 2.2.4.3 (c) Hydrocarbons 2.2.4.3(d) CO2 2.2.4.3(e) CO 2.2.4.3(f) Particular matter 2.2.4.3(g) Others 2.2.4.4 Exhaust pipe size 2.2.4.5 Exhaust silencer 2.2.4.5(a) Nos. provided / DG set 2.2.4.5(b) Type 2.2.4.5(c) Size 2.2.4.5(d) Location/mounting 2.2.4.5(e) Weight 2.2.4.6 Spark arrestor provided? YES / NO 2.2.4.7 Expansion joints provided as required? YES / NO 2.2.4.8 Type of thermal insulation 2.2.4.9 Material of pipe and valves 2.2.4.10 Whether passive crank case exhaust system are provided to allow

gases to escape from the crank case to a point outside the DG room?

YES / NO

2.2.4.11 Details of passive crank case exhaust system 2.2.4.11.1 Crank case pressure at 110% of load 2.2.4.11.2 Crank case pressure at 100% of load 2.2.4.11.3 Crank case pressure at 50% of load 2.2.4.11.4 Crank case pressure at 25% of load 2.2.4.11.5 Crank case pressure at 0% of load 2.2.4.11.6 Crank case pressure at which safety valve will operate 2.2.4.12 Whether exhaust gas piping, supports etc. upto discharge point

indicated in the tender drawing considered?

2.2.5 Starting Air System

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2.2.5.1 Type of starting system 2.2.5.2 Quantity of air required/start 2.2.5.3 Normal air pressure for starting engine 2.2.5.4 Starting time when the air is at rated pressure 2.2.5.5 Maximum starting time when the starting air pressure is at the

lowest permissible value

2.2.5.6 Engine is capable of starting if air is admitted to one side of vee-engine?

YES / NO

2.2.5.7 Is the starting air system is completely redundant? YES / NO 2.2.5.8 Starting time of DG set when one starting system is available 2.2.5.9 Starting time of DG set when both starting system is available 2.2.5.10 Number of compressors provided. Per DG set 2.2.5.11 Air compressor 2.2.5.11(a) Manufacturer 2.2.5.11(b) Type 2.2.5.11(c) Capacity 2.2.5.11 (d) Speed 2.2.5.11 (e) Motor rating (KW) 2.2.5.11(f) Type of intercooler 2.2.5.11(g) Type of after cooler 2.2.5.12 Air Receiver 2.2.5.12(a) Nos. provided 2.2.5.12(b) Air capacity of each air receiver 2.2.5.12(c) Normal air pressure in air receiver 2.2.5.12(d) No. of starts of engine from each receiver from a pressure

corresponding to compressor start to start to minimum pressure at which starting is blocked

2.2.5.13 Time required to replenish air in air receivers after six attempts to start.

2.2.5.14 No. of starting valves 2.2.5.15 Air dryers 2.2.5.15(a) Number provided 2.2.5.15(b) Type 2.2.5.15(c) Make 2.2.5.16 Material of pipe and valves 2.2.5.17 Material and grade of air receiver 2.2.5.18 Pressure dew point of air leaving the air dryer 2.2.5.19 Whether manual start feature (With out DC supply) considered

for starting YES/NO

2.2.5.20 Whether the scope of starting air system offered, covered completely all items specified in the tender?

YES/NO

2.2.5.21` Whether supply includes seismic qualification of starting air system as required?

2.2.5.22 Design, equipment, manufacturing standards for complete starting air system

2.2.6 Engine cooling system

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2.2.6.1 Quality of cooling water 2.2.6.2 Quantity of water required for initial filling 2.2.6.3 Make up water quantity 2.2.6.4 Maximum jacket water temperature 2.2.6.4.1 At 100% load 2.2.6.4.2 At 110% load 2.2.6.5 Minimum permissible jacket water temperature for starting the

engine

2.2.6.6 Time duration for which the engine will run at full load without external cooling water

2.2.6.6.1 During cold start of engine 2.2.6.6.2 During hot start of engine 2.2.6.7 Details of chemical additives required for jacket water 2.2.6.8 Expansion tank 2.2.6.8(a) Location 2.2.6.8(b) Working capacity 2.2.6.8(c) Dimensions 2.2.6.9 Engine driven pump 2.2.6.9(a) Provided? YES / NO 2.2.6.9(b) Number 2.2.6.9(c) Type 2.2.6.9(d) Capacity 2.2.6.9(e) Rating 2.2.6.9(f) Material for pump casing 2.2.6.9(g) Material for pump impeller 2.2.6.9(h) Type of Shaft seal 2.2.6.10 AC Motor driven jacket water recirculation pump (required

during keep warm Condition).

2.2.6.10(a) Provided? YES / NO 2.2.6.10(b) Number 2.2.6.10(c) Frequency of operation during keep warm condition 2.2.6.10(d) Rating of each pump motor 2.2.6.10(e) Material for pump casing 2.2.6.10(f) Material for pump impeller 2.2.6.10(g) Type of shaft seal 2.2.6.11 Jacket water heater 2.2.6.11(a) Provided? YES / NO 2.2.6.11(b) Number 2.2.6.11(c) Type 2.2.6.11(d) Rating of each heater 2.2.6.12 Material of pipe and fittings 2.2.6.13 Material of valves 2.2.6.14 Extra volume tank for allowing DG to start and run at full load

with out external cooling water for 2 minutes, provided?

2.2.6.14(a) If Yes, capacity of Extra volume tank 2.2.6.14(b) If Yes, Material of extra volume tank

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2.2.6.14(c) If Yes Dimension of Extra volume tank 2.2.6.15 Thermostatic valves 2.2.6.15(a) Make 2.2.6.15(b) Type 2.2.6.15(c) Temperature setting 2.2.6.16 Mixing tank 2.2.6.16(a) Capacity 2.2.6.16(b) Material 2.2.6.16(c) Dimension 2.2.6.17 AC Motor driven jacket water replenishment pump 2.2.6.17(a) Provided? 2.2.6.17(b) Pump motor rating 2.2.6.18 Air cooled radiator YES / NO 2.2.6.18.1 Type 2.2.6.18.2 Capacity 2.2.6.18.3 Air flow 2.2.6.18.4 Air ambient inlet temperature 2.2.6.18.5 Air outlet temperature 2.2.6.19 Whether the scope of cooling water system offered covers

completely all items specified in the tender? YES / NO

2.2.6.20 Whether supply includes seismic qualification of cooling water system with radiator as required?

2.2.6.21 Design, equipment, manufacturing standards for complete cooling water system

2.2.7 Lubricating Oil System 2.2.7.1 Type and grade of lube oil to be used 2.2.7.2 Quantity of lube oil required for initial filling 2.2.7.3 Lube oil consumption 2.2.7.3(i) At 100% load 2.2.7.3(ii) At 75% load 2.2.7.3(iii) At 50% load 2.2.7.3(iv) At 25% load 2.2.7.3(v) At 0%load 2.2.7.4 Type of lubricating oil sump 2.2.7.5 Capacity of lube oil sump at normal working level 2.2.7.6 Period for which DG set can operate at full load without

replenishment of oil in the lube oil sump

2.2.7.7 Minimum acceptable lube oil temperature during startup 2.2.7.8 Engine driven lube oil pump 2.2.7.8(a) Provided? YES / NO 2.2.7.8(b) Number 2.2.7.8(c) Type 2.2.7.8(d) Capacity 2.2.7.8(e) Rating 2.2.7.8(f) Material of pump casing 2.2.7.8(g) Material of pump impeller

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2.2.7.8(h) Type of shaft seal 2.2.7.9 AC motor driven pre-lube oil pump YES / NO 2.2.7.9(a) Provided? 2.2.7.9(b) Number 2.2.7.9(c) Type 2.2.7.9(d) Capacity 2.2.7.9(e) Frequency of operation during keep warm condition: 2.2.7.9(f) Motor rating 2.2.7.9(g) Material of pump casing 2.2.7.9(h) Material of pump impeller 2.2.7.9(i) Type of shaft seal 2.2.7.10 Lube oil heater 2.2.7.10(a) Provided? YES / NO 2.2.7.10(b) Number 2.2.7.10(c) Rating 2.2.7.10(d) Type 2.2.7.11 Lube oil filter 2.2.7.11(a) Make 2.2.7.11(b) Type 2.2.7.11(c) Number 2.2.7.11(d) Material of casing 2.2.7.11(e) Material of filter element 2.2.7.11(f) Rating 2.2.7.12 Portable pump for lube oil transfer from barrel to sump 2.2.7.12(a) Provided? YES / NO 2.2.7.12(b) Number 2.2.7.12(c) Type 2.2.7.12(d) Capacity 2.2.7.12(e) Motor rating 2.2.7.13 Material of pipe and fittings 2.2.7.14 Material of valves 2.2.7.15 Time for which DG set can operate after low alarm level reaches

in lube oil sump

2.2.7.16 Whether the DG set is designed to safety coast down from initial state corresponding to DG trip on low lube oil pressure to zero speed with out damaging bearings/moving parts of turbocharger, engine, alternator etc

2.2.7.17 Whether the scope of lube oil system offered covers completely all items specified in the tender?

2.2.7.18 Whether the scope includes supply of lube oil for initial filling and quantity required for site tests before handing over of DG set to IGCAR ?

YES / NO

2.2.7.19 Whether supply includes seismic qualification of lube oil system as required?

2.2.7.20 Design, Equipment, manufacturing standards for complete lube oil system.

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2.2.7.21 Thermostatic valves 2.2.7.21(a) Make 2.2.7.21(b) Type 2.2.7.21(c) Temp. setting 2.2.8 Fuel oil System 2.2.8.1 Designation of fuel oil 2.2.8.2 Engine driven fuel feed pump 2.2.8.2(a) Provided? 2.2.8.2(b) Number 2.2.8.2(c) Type 2.2.8.2(d) Capacity 2.2.8.2(e) Rating 2.2.8.2(f) Material of pump casing 2.2.8.2(g) Material of pump impeller 2.2.8.2(h) Type of shaft seal 2.2.8.3 Any fuel oil transfer pump between day oil tank and fuel feed

pump is required? YES / NO

2.2.8.4 Day tank 2.2.8.4(a) Working Capacity 2.2.8.4(b) Dimensions 2.2.8.4(c) Material 2.2.8.5 Make and type of fuel oil injectors 2.2.8.6 Fuel oil filters 2.2.8.6(a) Make 2.2.8.6(b) Type 2.2.8.6(c) Number per DG set 2.2.8.6(d) Rating 2.2.8.6(e) Material of casing 2.2.8.6(f) Material of filter element 2.2.8.7 Material of pipe and fittings 2.2.8.8 Material of valves 2.2.8.9 Electro pneumatic/solenoid valve provided at outlet of day tank? YES / NO 2.2.8.10 Double walled piping with leakage collection system provided for

high pressure fuel oil system YES / NO

2.2.8.11 Whether the scope of fuel oil system offered covers completely all items required/specified in the tender?

YES / NO

2.2.8.12 Whether supply includes seismic qualification of fuel oil system as required?

YES / NO

2.2.8.13 Design, equipment, manufacturing standards for complete fuel oil system

2.2.9 Governing system 2.2.9.1 Maximum step load that can be applied to engine at full rated

speed and no load

2.2.9.2 Transient speed change resulting from application of above maximum load.

2.2.9.3 Whether the proposed engine is capable of accepting 225KW load YES / NO

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immediately after attaining rated speed and voltage 2.2.9.4 If yes, indicate transient frequency limits and recovery time 2.2.9.5 Steady state speed regulation 2.2.9.6 Transient speed response and recovery time during following 2.2.9.6(i) Application of 225KW motor load on no load condition of DG set 2.2.9.6(ii) Application of above motor during any stage of load sequence 2.2.9.7 DG set starting time i.e ready to take load after start impulse 2.2.9.8 Type and make of governor YES / NO 2.2.9.9 Does the governor conforms to class A1 of ISO 3046 2.2.9.10 Momentary over speed after 110% of rated load rejection 2.2.9.11 DG set is provided with mechanical over speed protection YES / NO 2.2.9.12 Speed adjustment is suitable for 48V DC supply YES / NO 2.2.9.13 Speed adjustable from DG local control panel and MCR YES / NO 2.2.9.14 Speed adjustment range YES / NO 2.2.9.15 Whether governor is capable of providing speed control if

failure/power supply interruption to electronic portion of governor occurs?

YES / NO

2.2.9.16 Furnish details of mathematical model of engine and governor for simulation purpose.

2.2.10 Material of construction 2.2.10.1 Engine components 2.2.10.1(a) Cylinder block 2.2.10.1(b) Crank case 2.2.10.1(c) Cylinder head 2.2.10.1(d) Cylinder liners 2.2.10.1(e) Crank Shaft 2.2.10.1(f) Cam shaft 2.2.10.1(g) Crankshaft main bearings 2.2.10.1(h) Pistons 2.2.10.1(i) Piston rings: compression rings 2.2.10.1(j) Piston rings : Oil rings 2.2.10.1(k) Piston pin 2.2.10.1(l) Connecting rod 2.2.10.1(m) Engine valve body/seat 2.2.10.1(n) Piston ring bearings 2.2.10.1(o) Fly wheel 2.2.10.2 Day oil tank 2.2.10.3 Expansion tank 2.2.10.4 Extra volume tank 2.2.10.5 Fuel oil pipes and fittings 2.2.10.6 Lube oil pipes and fittings 2.2.10.7 Starting air pipes and fittings 2.2.10.8 Cooling water pipes and fittings 2.2.10.9 Exhaust pipe and fittings 2.2.10.10 Exhaust pipe lagging material 2.2.10.11 Exhaust silencer

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2.2.10.12 Base frame for engine/generator 2.2.10.13 Gear drives for engine driven auxiliaries 2.3.0 GENERATOR AND AUXILIARIES 2.3.1 Continuous output rating 2.3.2 Power factor 2.3.3 Rated voltage 2.3.4 Rated current per phase 2.3.5 Type of cooling 2.3.6 Type of enclosure 2.3.7 Speed 2.3.8 Frequency 2.3.9 Field current at rated output and voltage 2.3.10 Insulation class 2.3.10.1 Main stator 2.3.10.2 Main rotor 2.3.10.3 Exciter stator 2.3.10.4 Exciter rotor 2.3.11 Conductor Material 2.3.11.1 Main Stator 2.3.11.2 Main Rotor 2.3.11.3 Exciter Stator 2.3.11.4 Exciter rotor 2.3.12 Generator parameters 2.3.12.1 Synchronous Reactancesxd,xq, % 2.3.12.2 Transient Reactancesxd’ % 2.3.12.3 Subtransientreactancesxd” % 2.3.12.4 Zero sequence reactance xo % 2.3.12.5 Negative sequence reactance x2 % 2.3.12.6 Open circuit field time constant 2.3.12.7 Short circuit Ratio 2.3.12.8 WR2 of rotating mass in engine including flywheel and coupling,

WR2 generator rotor, exciter rotor, PMG & associated coupling

2.3.12.9 Resistance of main field winding at operating temperature 2.3.12.10 Maximum permissible continuous current loading of various

harmonics without derating of generator as % of full load current at 0.8 p.f

2.3.12.11 Continuous negative sequence current carrying capacity 2.3.12.12 Short time current carrying capacity 2.3.12.13 Whether short time current rating capacity of complete

generator, excitation system & AVR is adequate to cater to inrush current during sequential motor load starting over a period of 60 seconds?

YES /NO

2.3.12.14 Generator over current capability 2.3.13 Generator Performance 2.3.13.1 Full load losses 2.3.13.2 Armature copper loss

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2.3.13.3 Rotor copper loss 2.3.13.4 Core loss 2.3.13.5 Stray losses 2.3.13.6 During sequential staring of motor loads indicate following

parameters

2.3.13.6.1 Maximum generator current 2.3.13.6.2 Maximum field current 2.3.13.6.3 Maximum exciter current 2.3.13.6.4 During starting of 225 K W , indicate following parameters. 2.3.13.7 Maximum generator current 2.3.13.7.1 Maximum field current 2.3.13.7.2 Maximum exciter current 2.3.13.7.3 Maximum exciter field current 2.3.14 Efficiency 2.3.14.1 ¼ load % 2.3.14.2 ½ load % 2.3.14.3 ¾ load % 2.3.14.4 Full load % 2.3.15 Maximum temperature rise under specified operating conditions

over 50 C ambient

2.3.15.1 Stator (by resistance) 2.3.15.2 Field (by resistance) 2.3.15.3 Cores (by thermometer) 2.3.15.4 Exciter armature (resistance) 2.3.15.5 Exciter field (resistance) 2.3.16 Generator Constructional Details 2.3.16.1 Length of stator frame 2.3.16.2 Height of stator frame 2.3.16.3 Diameter of stator frame 2.3.16.4 Air gap length 2.3.16.5 Length of rotor shaft 2.3.16.6 Material of stator 2.3.16.7 Weight of rotor with exciter armature 2.3.16.8 Material of stator frame 2.3.16.9 Details of terminal boxes 2.3.16.9.1 Line side phase segregated provided YES / NO 2.3.16.9.2 Neutral side TB provided with specified current transformers YES / NO 2.3.16.9.3 Terminal Box Designed and Tested for 44 kA. Fault current (within

TB) for 0.25 secs. YES / NO

2.3.16.9.4 Terminal Box Designed and Tested for 44 kA. Fault current (external to the TB) for 0.25 secs.

YES / NO

2.3.16.9.5 Separate TBs for CT secondary, RTD’s, space heaters etc. provided YES / NO 2.3.16.10 Details of RTD’s provided 2.3.16.10.1 For stator windings (No/Phase) 2.3.16.10.2 For Bearings 2.3.16.10.3 Material of RTD

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2.3.16.10.4 Resistance at 0o C 2.3.16.10.5 Type of RTD 2.3.16.11 Details of Barings 2.3.16.11.1 Make 2.3.16.11.2 Type 2.3.16.11.3 Cooling 2.3.16.11.4 Material 2.3.17 Excitation System 2.3.17.1 Main Exciter 2.3.17.1.1 Make and type 2.3.17.1.2 Rated armature current/field current 2.3.17.1.3 Rated armature voltage /field voltage 2.3.17.1.4 No. of phases 2.3.17.1.5 Frequency / No. of poles 2.3.17.1.6. Make & rating of diodes 2.3.17.1.7 Protection provided for Diodes in case of over current 2.3.17.1.8 Protection provided for Diodes in case of over voltage 2.3.17.1.9 Insulation class of Stator 2.3.17.1.10 Insulation class of rotor 2.3.17.2 Permanent magnet generator 2.3.17.2.1 Make and type 2.3.17.2.2 Rated armature current 2.3.17.2.3 Rated armature voltage 2.3.17.2.4 Rated Frequency 2.3.17.3 Automatic voltage regulators 2.3.17.3.1 Make and type of regulators 2.3.17.3.2 Burden of AVR on purchasers PT 2.3.17.3.3 Dead band of regulators 2.3.17.3.4 Response time of AVR 2.3.17.3.5 Whether proposed AVR has provision to limit generator voltage

in case of PT signal failure? YES / NO

2.3.17.3.6 Response time of excitation system 2.3.17.3.7 Response ratio of excitation system 2.3.17.3.8 Whether the AVR & excitation system capacity is adequate to

provide required field current during (a) faults, (b) feeding large inductive loads during motor starting (Provide calculations)?

2.3.17.3.9 Whether the AVR is Digital type? YES / NO 2.3.17.3.10 Whether provision for remote voltage adjustment provided? YES / NO 2.3.17.3.11 Whether AVR is qualified for environmental conditions, EMI/RFI

conditions, if so indicate severity levels YES / NO

2.3.17.3.12 Whether AVR is suitable for the specified ambient conditions? YES / NO 2.3.17.3.13 Whether electronic components of AVR are of industrial grade? 2.3.17.3.14 Whether Diode failure detection device provided? Enclose

catalogue

2.3.17.3.15 Whether the AVR has 2-auto channel with manual back up? 2.3.17.3.16 Steady state voltage regulation:

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2.3.17.3.17 Transient voltage dip and recovery time during application of 675 K W motor load on base load of 225 K W application of above motor during any stage of load sequence

2.3.17.3.18 Furnish details of mathematical model of excitation system and AVR for simulation purpose

2.3.18 Neutral grounding Resistor 2.3.18.1 Material of resistance element 2.3.18.2 Resistance value 2.3.18.3 Maximum current that can be safely carried for 30 seconds 2.3.18.4 Maximum continuous current carrying capacity 2.3.18.5 Temperature rise corresponding to current under Sl.No. 3.18.3 &

3.18.4 above

2.3.18.6 Dimensions HxWx D 2.3.18.7 Degree of protection for enclosure 2.3.19 Details of CTs 2.3.19.1 Differential CT 2.3.19.1.1 Ratio 2.3.19.1.2 Burden 2.3.19.1.3 Construction 2.3.19.1.4 Type of insulation 2.3.19.1.5 Knee Point Voltage 2.3.19.1.6 CT Secondary resistance 2.3.19.2 Protection CT 2.3.19.2.1 Ratio 2.3.19.2.2 burden 2.3.19.2.3 Type of insulation 2.3.19.2.4 Protection class 2.3.19.2.5 Construction 2.3.19.3 Neutral CT 2.3.19.3.1 Ratio 2.3.19.3.2 burden 2.3.19.3.3 Type of insulation 2.3.19.3.4 Protection class 2.3.19.3.5 Construction 2.3.19.4 AVR CT 2.3.19.4.1 Ratio 2.3.19.4.2 burden 2.3.19.4.3 Type of insulation 2.3.19.4.4 Protection class 2.3.19.4.5 Construction 2.3.20 Control panels& MCC panels 2.3.20.1 Make 2.3.20.2 Type 2.3.20.3 Dimension 2.3.20.4 Degree of protection provided by the enclosure 2.3.20.5 Type of mounting

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2.3.20.6 Cable entry 2.3.20.7 Sheet metal details 2.3.20.7.1 Material of construction 2.3.20.7.2 Thickness of sheet metal 2.3.20.7.2.1 Frames 2.3.20.7.2.2 Covers 2.3.20.7.2.3 Load bearing member 2.3.20.7.2.4 Cable gland plate 2.3.20.7.3 Paint shade 2.3.20.7.3.1 Interior 2.3.20.7.3.2 Exterior 2.3.20.7.3.3 Proposed pre-treatment for sheet metal 2.3.20.8 Whether all instruments, alarm devices, controls, indications,

contacts, relays, auxiliary relays, timers, logics etc. as specified and required for complements have been considered and required items included in the scope of supply?

YES / NO

2.3.20.9 Detailed description of the control scheme together with the items employed to develop specified indications, alarms, controls etc. Enclosed with the tender?

YES / NO

2.3.20.10 Whether all instrumentation system and electrical /electronic components tropicalised?

YES / NO

2.3.20.11 Whether all electrical /electronic components module designed to operate at 50 deg. Ambient continuously?

YES / NO

2.3.20.12 Whether electronic transducers are provided for displaying process variables in control panels? If yes, details of transducers shall be enclosed.

YES / NO

2.3.20.13 Whether all components used are industrial grade? YES / NO 2.3.20.14 Whether environmental qualification tests have been conducted

on electrical /electronic devices, instruments, components etc? YES / NO

2.3.20.15 Whether protection circuits are independent of measurement and controls?

YES / NO

2.3.20.16 Whether the control panel/systems are qualified as per IEEE 344? YES / NO 2.3.20.17 Whether components of instruments & control are separately

qualified for seismic duty?

2.4.0 Field Instruments 2.4.1 Whether field instruments considered in the scope of supply are

generally in line with the specification? YES / NO

2.5.0 PLC 2.5.1 Whether any PLC are proposed to be used in the DG ste? YES / NO 2.5.1.1 If yes, make and type of PLC 2.5.1.2 SIL level of PLC and Standard to which PLC is qualified 2.5.1.3 Type of CPU 2.5.1.4 Whether required input, output modules and communication

busses are included in the scope of supply as per specification? YES / NO

2.5.1.5 Whether supply of required software and interface hardware is included in the scope of supply?

YES / NO

2.5.1.6 Whether the scope include carrying out all required software YES / NO

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changes till handing over of DG Set to purchaser? 2.5.1.7 Whether the scope includes submission of all required documents

for IV & V and testing of PLC at factory & site as per IV & V requirements?

YES / NO

2.6.0 WEIGHTS AND DIMENSIONS 2.6.1 Weight of fully assembled engine 2.6.2 Weight of generator 2.6.3 Weight of common base frame 2.6.4 Weight of fully assembled engine generator 2.6.5 Weight of exhaust silencer 2.6.6 GD value for DG set 2.6.7 Weight and name of heaviest part to be during maintenance for

which monorail is to be provided

2.6.8 Overall dimension of engine 2.6.9 Overall dimension of generator 2.6.10 Overall dimension of DG set 2.7.0 Whether list of proposed sub-vendors along with their credentials

is enclosed? YES / NO

2.8.0 Whether the vendor has adequate testing facility for testing DG sets? Furnish details of testing facilities.

YES / NO

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PROOF OF ABILITY The TENDERER shall furnish here a list of all similar jobs executed by him to whom a reference may be made by the PURCHASER in case the PURCHASER considers such a reference necessary – Sl no

Description of work including quantity of items

Work order or PO no and date

Value of work

Delivery date as per PO

Actual date of delivery

Contact address of Purchaser

Signature _________________________

Designation ________________________

Company _________________________

Date ___________________________

Seal of the Company

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DRAWING AND DOCUMENT SCHDULE

The following drawing / documents shall be furnished along with the tender 1.0 Detailed dimensional GA drawings for the DG set units and accessories including maintenance

space required and DG room layout drawing including control panel and MCC panel layout drawing.

2.0 Sectional drawing of DG sets and accessories 3.0 Flow diagram for DG sets with instrumentation and control for the following sub systems,

indicating clearly the scope of supply a) Combustion air system b) Compressed Air System c) Lubricating oil system d) Fuel oil supply system e) Cooling water system f) Schematic drawings for controls, instrumentation Alarms and protections g) Schematic drawings of Voltage regulator and Governor

4.0 Foundation details of DG sets units and accessories including loading data 5.0 Description write up and manufactures catalogues for diesel Engine, Generator, Excitation

system, Voltage regulator, Governor and other accessories explaining the design features incorporated to achieve a high degree of reliability, availability and ease on maintenance.

6.0 Write up on qualification tests for Class 1E duty as per IEEE-387. 7.0 Write up on seismic analysis procedure 8.0 Drawing showing views of generator and excitor including arrangement of terminals. 9.0 In addition to the above mentioned drawings, details of instrumentation types and manufactures

name etc. should be enclosed. a) Control panel details – General arrangement drawing b) Simple control scheme c) Functional diagrams of different logics. d) MCC panel

SIGNATURE ______________

DESIGNATION ______________

COMPANY ______________

DATE ______________

COMPANY SEAL

Page 159 of 171

THE FOLLOWING DOCUMENTS SHALL BE FURNISHED ALONG WITH THE TENDER

1.0 Completely filled in data sheet and schedules as per the specification 2.0 Diesel Engine performance curves over the entire operating range speeds. 3.0 All type test certificates shall be enclosed.

SIGNATURE ______________


COMPANY ______________

DATE ______________

COMPANY SEAL

Page 160 of 171

Documents schedule

2.4 Approval of drawings by Purchaser 2.5 Submission of Quality Assurance (QA) Plan 2.6 Approval of QA plan by Purchaser

1.0 Schedule

Period from Letter of Intent

1.1 The Contractor shall furnish two (2) sets of this detailed activity schedule after the issue of letter of intent (LOI) covering submission of drawings, approval, QA plan, QA approval, procurement of material and sub orders, manufactures, type tests, routine test, submission of instruction manuals, test reports, transportation, erection, testing and commissioning.

1.2 Approval of activity schedule by purchaser. 2.0 Drawing & Documents submission 2.1 General arrangement drawings of DG set and accessories indicating

overall dimension, space required for dismantling and maintenance. Dimensioned sectional drawings of DG sets and accessories. DG set room layout drawing. Foundation details, data required for foundation design, fixing arrangement, loading data, etc.

2.2 Detailed schematic drawings covering DG set start logic, protection logic, speed control, voltage regulator and governor etc.

2.3 Detailed internal wiring diagram including terminal block numbers and ferrule numbers, cable schedule, Bill of Material, DG set characteristic curves and characteristic curves (torque-speed) for electric motor drives. Flow diagram showing all instrumentation, control features and terminal points of supply for the following systems: a) Air intake and exhaust gas system. b) Compressed air system c) Lubricating oil system d ) Fuel oil system e) Cooling water system I&C documents like IS/PI diagrams I&C instrumentation book-up diagrams I&C write-up etc.

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3.0 Operation & maintenance (O&M) Manuals 3.1 The Contractor shall furnish 4 nos. of copies of the O&M manual which shall contain detailed

instruction for unpacking, handling at site, storage for prolonged duration, erection, maintenance procedure, preventive measures, list of spares, schedule of replacement of spares, operating procedure, catalogues of various components, etc. 4 copies of soft form of above O&M manual burned on CD shall be submitted to PURCHASER

3.2 A set of miniature size drawings shall be enclosed with each O&M manual covering flow diagram of various auxiliary systems, single line diagram, control schematic etc.

3.3 Two sets of O&M manuals shall be sent to Purchase as preliminary copies and on Purchaser’s approval 4 hard and 4 soft copies shall be sent incorporating Purchaser’s comments, 2months before dispatch of equipment.

4.0 History docket

Two (2) copies of history docket shall be submitted to in the bond form covering all approved documents, inspection reports, DCRs, shipping releases etc. Also 4 soft copies of history docket burned on CD shall be submitted.

SIGNATURE ______________


COMPANY ______________

DATE ______________

COMPANY SEAL

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GUARANTEED PARAMETERS

The TENDERER shall furnish the guaranteed parameters of each of the DG set as indicated below: 1.0 Each DG set shall be capable of generation at net electrical output of ________

KVA under specified site conditions at ______ Hz, _____ p.f ______ V while running ________ RPM under .

2.0 Gen. efficiency Fuel oil consumption at ¼, ½, ¾ and full load shall be as follows: Load Gen. efficiency Fuel oil consumption ¼ ½ ¾ Full 3.0 Overload capability of the engine

4.0 Maximum period for which engine can operate without raw water circulation a) During cold start of engine b) During hot start of engine

c) 5.0 Starting time and ready to take load

6.0 Governor response, over speed capability

7.0 Lube oil consumption at 100% engine load

8.0 Jacket water temperature at engine outlet

9.0 Jacket water temperature at engine outlet

10.0 Air temperature inlet at Radiator

11.0 Air temperature outlet at Radiator.

12.0 Air flow across the Radiator.

13.0 Lube oil temperature at lube oil cooler outlet

14.0 Lube oil temperature at lube oil cooler inlet

15.0 Transient voltage and frequency dips while starting of motor

16.0 Transient recovery time

17.0 Voltage regulator response

18.0 Excitation at full load and under specified variation

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19.0 Maximum peak to peak amplitude of vibration of DG set

20.0 The noise level at a distance of 1.0 meter from the equipment shall not exceed

dbA

The TENDERER shall indicate the tolerances applicable to of the guaranteed parameters above and the

SIGNATURE ______________


COMPANY ______________

DATE ______________

COMPANY SEAL

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LIST OF DEVIATION

All deviations from the tender document including the general conditions of the contract shall be set out by the TENDERER clause by clause in this schedule. Compliance with the tender document will be taken as granted in absence of mention of any departure from any of the clauses of this specification in this schedule – SECTION CLAUSE NO DEVIATION

Signature ________________________

Designation ________________________

Company _________________________

Date ___________________________

COMPANY SEAL

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MANUFACTURING SCHDULE

Schedule for manufacturing, delivery and erection from the date of purchase order placement-

I. Submission of network schedule - weeks

II. Quality control plan - weeks III. Design and drawing submission, approval of different categories of drawings - weeks IV. Material procurement of raw materials and bought out items - weeks V. Manufacturing process (indicating all major stages) - weeks

VI. Shop inspection/testing (indicating all inspection and tests) - weeks VII. Shipment (indicating each planned shipment) - weeks

VIII. Erection (indicating all major stages for each equipment and structure) - weeks IX. Testing (indicating for all equipment and systems) - weeks X. Commissioning (indicating for all equipment and systems) - weeks

Signature ________________________

Designation ________________________

Company _________________________

Date ___________________________

COMPANY SEAL

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List of Special tools (Tools and tackles) The TENDERER shall give the list of special erection and maintenance tools offered by him –

Sr no Particulars Quantity

Signature _________________________

Designation ________________________

Company _________________________

Date ___________________________

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LIST OF ADDITIONAL ENCLOSURES

The following enclosures in addition to those asked for in the Tender are given –

Sl no Document enclosed

Signature _________________________

Designation ________________________

Company _________________________

Date ___________________________

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SECTION –3

PRICE SCHDULE

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Notes for submission for Price bid

1.1 General

1.1.1 The bidders are required to quote for the entire scope of the work as contained in the Section-3 of tender document. The bids, not covering all the items as per Section-3, are liable to be rejected

1.1.2 Spares: The bidders are required to quote for all items listed under essential spares and same shall

be considered for Price Bid evaluation. In case any essential spare part is not considered as not applicable for the equipment offered by the TENDERER, the same shall be indicated as ‘Not applicable in the Remarks’ column. However, the TENDERER shall indicate the price for each and every essential spare item specified in the tender document in the Schedule of prices, whether or not he considers it necessary for the PURCHASER to have such spares. If the TENDERER fails to quote the price of any essential spare item, the highest price quoted by other TENDERERs for that particular item shall be considered for loading his Tender

1.1.3 Price bid evaluation criteria:Price bid evaluation shall be done on the basis of the sum of break up prices of the total quantity of items including specified essential spares given only in the price schedules (of the techno commercially accepted bidders). Lowest quotation (L1) shall be decided on the basis of the evaluation criteria given above.

1.1.4 The components like control panels, instruments etc. which are actually tested in the shake table

need not be returned to the TENDERER and should not be used in the actual supply of items.

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1.2 Price schedule 1.2.1 Completedesign, engineering, manufacture, assembly, inspections and testing ( inclusive of

type testing and routine testing) at TENDERER’s works , packing and forwarding and safe delivery to siteincluding unloading of two (2) numbers of standby emergency Diesel Generator (DG) unitswith air cooled radiator including MCC , control panels & Cables , each of 1000KVA (800KW at 0.8 pflagging), 415 V, 3 phase, 3 wire, 50Hz along with all auxiliaries and accessories specified as per the specifications – 2 Sets

1.2.2 Complete erection, cable connections, site testing after erection, commissioning, performance testing of two (2) numbers of standby emergencyDiesel Generator (DG) units with air cooled radiator including all panels, each of 1000KVA (800KW at 0.8 p.flagging), 415 V, 3 phase, 3 wire, 50Hz along with all auxiliaries and accessories specified – 2 Sets

1.2.3 Training for the above DG sets - Lumpsum 1.2.4 Seismic qualification of DG sets by analysis and seismic qualification of control panels and

instruments by shake table testing – 1 Lot Essential Spares

1.2.5 Governor completeincluding actuator – 1 set 1.2.6 Main engine bearing sets for one DG – 1 set 1.2.7 Cylinder Inlet and exhaust valve set for one DG set – 1 set 1.2.8 Cylinder head complete including screws - 4 set 1.2.9 Set of gaskets used in valve housing and cylinder head assembly- 6 set 1.2.10 Complete set of piston rings required for one set of piston - 6 set 1.2.11 Cylinder liner- 4 No 1.2.12 Piston – 4 no 1.2.13 Gudgeon pin set for one DG set – 1 set 1.2.14 Connecting rod – 6 no 1.2.15 Camshaft – 1 no 1.2.16 Gear set for camshaft – 1 set 1.2.17 Injection pump complete- 6 Nos 1.2.18 Fuel feed pump complete – 1 no 1.2.19 Filter elements for fuel filters of each type in fuel system - 12 No 1.2.20 Filter elements for lube oil filters of each type in lub oil system - 12 No 1.2.21 Turbocharger complete – 1 No 1.2.22 Engine driven water pump complete - 1 No 1.2.23 Electric driven pre-lub oil pump including motor -1 no 1.2.24 Air starting motor – 2 No 1.2.25 Set of control switches and push buttons consisting of one of each type- 5 No 1.2.26 Set of indicating instruments consisting of one of each type- 3 no 1.2.27 Set of temperature switches consisting of one of each type- 3 No 1.2.28 Set of pressure switches consisting of one of each type- 3 No 1.2.29 Set of temperature transducers consisting of one of each type- 3 No 1.2.30 Set of temperature sensors consisting of one of each type – 3 no

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1.2.31 Set of pressure transducers consisting of one of each type- 3 No 1.2.32 Electronic speed monitoring system, complete including speed sensors – 2 set 1.2.33 Set of auxiliary relays and indicating lamps consisting of one of each type- 5 No 1.2.34 Set of thermometers consisting of one of each type used - 5 no 1.2.35 Generator bearing shell – 2 sets 1.2.36 Automatic voltage regulator complete – 1 No 1.2.37 Set of current transformers consisting of one of each type – 2 No 1.2.38 Diode for exciter rectifier – 12 Nos 1.2.39 Stab-in contacts for the MCC – 5 sets 1.2.40 Set of fuses consisting of one of each type – 5Nos

Recommended spares

To be submitted by the Tenderer excluding the essential spare