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Client Name : BASF India LimitedProject Name : Project GIRProject Number: G3IR

Specification G3IR-1050-65-SP-9016Date 09-Jun-12

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Project Document No: G3IR-1050-65-SP-9016

Unit: General

Discipline: Electrical

Document Type: Specification

Document Title: SPECIFICATION FOR EMERGENCY DG SET.

1 30-Jul-12 Issued for Design RR NG VP

0 09-Jun-12 Issued for RFQ RR NG VP

Fluor BASFRevision Date Purpose Prepared By Checked By

Approved By

ISSUED FOR DESIGN

06 Aug 2012

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Record of Revisions

This specification has been revised as indicated below and described in the revision record on thefollowing page. Please destroy all previous revisions.

RevisionNo.

Date Description

0 09-Jun-12 Issued for RFQ

1 30-Jul-12 Issued for Design

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TABLE OF CONTENTS

1. GENERAL ...................................................................................................................................................... 4

1.1. SCOPE......................................................................................................................................................... 4

1.2. INTENET OF SPECIFICATION................................................................................................................... 4

1.3. GENERAL INFORMATION ......................................................................................................................... 5

1.4. CODES & STANDARDS ............................................................................................................................. 6

1.5. GENEARL REQUIREMENTS...................................................................................................................... 7

1.6. OPERATIONAL REQUIREMENTS............................................................................................................. 8

1.7.EQUIPMENT SPECIFICATION................................................................................................................... 9

1.8. SOUND PROOFING SYSTEM.................................................................................................................. 12

1.9. VENTILATION SYSTEM............................................................................................................................ 13

1.10. BATTERY AND CHARGER................................................................................................................. 13

1.11. AMF CONTROL PANEL ...................................................................................................................... 14

1.12. NEUTRAL EARTHING RESISTOR ..................................................................................................... 17

1.13. TESTS................................................................................................................................................... 17

1.14. COMMISSIONING CHECKS................................................................................................................ 19

1.15. MEASUREMENT OF VIBRATION ....................................................................................................... 20

1.16. NOISE LEVEL (SOUND PRESSURE LEVEL) CHECK ...................................................................... 20

1.17. INSTALLATION OF DG SETS............................................................................................................. 20

1.18. TRIAL OPERATION............................................................................................................................. 21

1.19. TAKING OVER..................................................................................................................................... 21

1.20. PERFORMANCE TEST OF THE SET ................................................................................................. 22

1.21. PERFORMANCE GUARANTEE.......................................................................................................... 22

1.22. DRAWINGS & DOCUMENTS .............................................................................................................. 23

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1. GENERAL

1.1. SCOPE

The scope of work covers the design, engineering, manufacture, assembly/pre-assembly,tests at manufacturers works, shop painting, packing, ocean shipment if applicable,insurance and clearance through Indian Port in case of imported plant and equipment, inlandtransportation, transit insurance, delivery to site, supervision of erection, testing andcommissioning for Emergency Diesel Generator Set complete with all accessories, auxiliariesand ancillaries as specified hereinafter and as required for safe and trouble free continuouscommercial operation, in a manner acceptable to the Owner.

The scope covers supply of all the material and services required to make the installationcomplete in all respect.

1.2. INTENET OF SPECIFICATION

1.2.1. This specification is intend to cover the following activities and services in respect ofEmergency Diesel Generator Set to be installed at the site:

Detailed design of the Emergency Diesel Generator Set along with its cooling& Exhaust system and Acoustic enclosure.

Complete manufacture including shop testing

Providing engineering data, drawings and O & M manuals as per specifiedformat etc for owners review approval and records

Packing, transportation and insurance from the manufacturers works to thesite including customs clearance/port clearance if required

Testing & commissioning and Supervision of erection at site (Erection ofEDG Set shall be done by Owners electrical contractor).

Furnishing of Mandatory Spares on FOR Site basis

1.2.2. The equipment offered by the bidder shall be of fully type tested and proven designand complete in all respect. Any material and component not specifically stated in thisspecification and which is necessary for trouble free operation of the equipment andaccessories specified in this specification shall be deemed to be included unlessspecifically excluded. All such equipment and accessories shall be supplied without

any extra cost.

1.2.3. It is not the intent to specify completely herein, all aspects of design and constructionof equipment. Nevertheless, the equipment shall conform in all respects to highstandards of engineering, design and workmanship and shall be capable ofperforming in continuous commercial operation in compliance to the requirementsmentioned in various documents.

1.2.4. Any deviation or variation from the Scope requirement and/or intent of thespecification shall be clearly defined under Deviation Schedule of the Bid ProposalSheets irrespective of the fact that such deviation/variations may be standard practiceor a possible interpretation of the specification by the Bidder. Except for these

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deviations/variations covered under Deviation Schedules which are accepted by theOwners before the award of the Contract, 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 of the specification whatsoever except for the declared deviationsubmitted by the Bidder with his proposal shall be considered. Bids not complyingwith requirement shall be treated as non-responsive and hence liable for rejection.The interpretation of the Owner in respect of the scope, details and services to beperformed by the Bidder, shall be binding, unless specifically clarified otherwise bythe Owner in writing before the Award of Contract.

1.3. GENERAL INFORMATION

1.3.1. Facilities to be provided by the Contractor

Contractor shall make his own arrangements for the following:

Bidder shall furnish a list of tools, tackles and any other equipment required

to carry out the unloading and erection of EDG at site.

Bidder shall arrange all testing and commissioning equipment required fortesting and commissioning of Emergency DG at site

Bidder shall supply all the inserts required for fixing the equipment includingthe foundation bolts before concreting and shall furnish complete datarequired to design the foundation. Contractor should ensure supply of allfoundation bolts at site within one month from the date of approval offoundation drawings and foundation bolts drawing or six months beforedispatch of Generator Sets.

Any other requirement which is necessary to put the equipment in service,shall be suppliers responsibility.

1.3.2. Facilities to be provided by the Owner

The Owner shall provide the following facilities to the bidder for successfulcommissioning and operation of the equipment being procured under thisspecification.

415V, 3 phase AC power supply.

The erection of Emergency Diesel Generator Set supplied under thispackage shall be done by Owners electrical contractor. However,supervision of erection of the same shall be in bidders scope.

1.3.3. Scope of supply

Diesel Generator set comprising the following:

Diesel Engine Complete with all accessories An alternator directly coupled to engine through flexible/rigid coupling

complete with all accessories (CT's & VT's etc.)

Control Panel

Neutral Grounding Resistor

Complete starting arrangement along with battery and its charger

Base frame and foundation bolts etc.

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Exhaust ducting meeting the statuary requirements with silencers,pipes, insulation, accessories, support structure, stack and

foundation bolts.

990 Ltr Day Oil Tank, fuel piping and accessories

Interconnection piping and accessories

Power and control cable gland and lugs at bidders equipment for allcables.

Cable & Cabling between bidders equipment

All lubricants for first filling, consumables and touch up paints etc forcommissioning

Acoustic enclosure meeting the statuary requirements. Necessaryventilation along with necessary starters & lighting shall be provided.

Any equipment/material required to make the installation complete incompliance to the RFQ requirements

1.3.4. Terminal Points

Power cable terminals at DG phase side terminal box suitable for terminationof cable, size and numbers of which shall be intimated later.

Control and signal cables at terminal blocks of EDG control panel.

1.3.5. Exclusion of Work

All Civil works pertaining to foundation, cable trench, foundation channels,anchor bolts, stubs etc. required for erection shall be excluded in the Biddersscope. However, Input data like load data, fixing details, requirements of

inserts etc for foundation design shall be furnished by bidder.

Connections to the owners station earth grid.

1.4. CODES & STANDARDS

1.4.1. All standards, specifications and codes of practice referred to herein shall be thelatest editions including all applicable official amendments and revisions as on date ofopening of bid. In case of conflict between this specification and those (IS: codes,standards, etc.) Referred to herein, the former shall prevail. All the equipment shallconform to the requirements of the following standards and codes:

Diesel Engine IS -10000, BS- 5514 and As Per StandardPractice Of Diesel Engine Manufacturers

Association Of USA.Generator IS-4722/ IEC-60034, IS-12065, IS-12075

Fuel oil for DG Set IS-15217

Diesel fuels IS-1460.

Recommended practice for hot-dipgalvanizing of iron and steel.

IS-2629

Methods for testing uniformity ofcoating of zinc coated articles

IS- 2633

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1.4.2. The installation work shall conform to Indian Electricity Act and Indian ElectricityRules as amended up to the date this specification is issued. Any approval required

from statutory authorities shall be obtained by the Contractor. Nothing in thisspecification shall be construed to relieve the Contractor of this responsibility.

1.4.3. In case of any contradiction between various referred standard/ specification/datasheet and statutory regulations, it shall be brought to the notice of Client for resolutionand no assumptions shall be made. Generally the following order of priority shallgovern:

Statutory regulations

Data Sheets

This specification

Codes and standards

1.5. GENEARL REQUIREMENTS

1.5.1. DG set including stack height, acoustics, air emission and fuel oil installation shallmeet the requirement given by gazette notification of Ministry of Environment &Forest dated 17/05/02, 01/07/03, CPCB guidelines, all statutory requirement of Govt.of India and State Pollution Board Guidelines & as updated as on date of bid opening.

1.5.2. The DG set shall be capable of generating minimum 2.4 MW (net power outputexcluding its own auxiliary power consumption) 3.0 MVA at 0.8 p.f. power atgenerator terminals under specified site condition. Contractor to provide documentaryproof to prove that the suggested model can deliver the required power.

1.5.3. The engine/prime mover shall be capable of 100% rating at specified sitetemperatures

1.5.4. The DG set shall be rated for stand by operation throughout the year. All componentsof the DG set shall be proven ones for trouble free continuous operation.

1.5.5. The owner reserves the right to reject the DG set in following conditions:

Actual consumption during performance test at site exceeds the guaranteed value by5%.

Actual output falls below 2.4MW (3000 [email protected] p.f.) at site condition.

1.5.6. However, Bidder will be given opportunity to rectify the defect in reasonable time andthe DG set may be accepted if it passes the tests successfully after rectification.

1.5.7. The DG Set shall be located inside the acoustic enclosure. The contractor shallrecommend his own layout and indicate the space requirement along with theproposal

1.5.8. The exhaust shall be discharged through a silencer and stack outside the enclosure.

1.5.9. All live parts shall be adequately protected to prevent inadvertent or accidentalcontact.

1.5.10. The painting offered on all the equipments shall be suitable for specified environmentin the complex. Bidder shall furnish a reference record of proven equipment operation

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success in a similar corrosive chemical environment. All hardware of mild steel shallbe electro-galvanized.

1.5.11. Maintenance and erection tools and tackles for all the equipment shall be provided bythe Contractor.

1.5.12. There shall be provision in neutral terminal box for mounting of differential CTs.

1.5.13. Owner shall provide One (1) number of 3 phase, 4 wire, 415V feeder and One (1)number of 110V DC supply at one point for DG auxiliary. Further distribution forbidders equipment shall be carried out by the bidder. Necessary starters forventilation fans/ exhaust fans/ priming pump motors etc. shall be in the biddersscope along with necessary AC distribution board, cables and cabling. Distributionboard shall be metal enclosed, compartmentalized, wall/structure mounted and shallbe fabricated out of cold rolled sheet steel of thickness 1.6mm with degree ofprotection of IP-54. The same shall be provided inside the acoustic enclosure.

1.6. OPERATIONAL REQUIREMENTS

1.6.1. Starting System:

Both Manual and automatic starting schemes shall be provided. The manual startingshall be local as well as from the AMF-cum-control panel while automatic startingshall be suitable for impulse from owners remote PCC.

On failure of mains supply, the D.G. set shall start automatically with the help of quickstart Auto-Mains-Failure (AMF) circuit of the control panel. The engine startingsystem shall be designed to get 3 starting signals with intermittent pauses. The

duration of starting signals and pauses shall be such that maximum time limits to startthe D.G. shall be 30 secs even after 3 starting attempts. The first step loading shallbe at 10 seconds & shall be able be able to start an estimated load. If the engine failsto start even after 3 attempts, audio & visual alarm shall indicate this condition.However, the above automatic function shall be able to be over-ridden by manualoperation in manual mode.

1.6.2. Loading Condition:

The DG Set shall be so designed that in isolated running, it shall be capable to meet thefollowing large motors starting conditions without exceeding the limits of voltage & frequencydip stipulated below and the bidder alongwith the bid shall furnish detailed calculation / curvesto prove the same.

Condition of DG Set Rating of load to be switched

i) When the set is running at no loadcondition at cold condition.

- 550 KW motor at 6.6 kV. Voltage (softstarter) with base load of 240 KW (viatrafo. of 1.6 MVA)

ii) When the set is loaded at about 50%. - 425 KW motor at 6.6 kV. Voltage (softstarter).

iii) When the set is loaded at about 70%. - load of 480 KW (via trafo. of 1.6 MVA).

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1.6.3. The DG set shall be capable of taking an overload of 10% for one hour once in every12 hours of continuous running.

1.6.4. All couplings shall be capable of withstanding the maximum generator sudden shortcircuit torque.

1.6.5. Critical speed of the machine shall not be lesser than 120% of the normal speed.

1.7. EQUIPMENT SPECIFICATION

1.7.1. DIESEL GENERATOR SET

The DG Set shall be CPCB compliant, AMF black start complete with diesel engine,alternator, air intake system, exhaust system with spark arrester silencer, completecooling system, complete lubricating oil system, fuel and air supply system withfilters, starting system, governing system, safety controls, instrument panel, fuel tank,

battery & leads, battery charger, AMF-cum-control panel, AVM pads and allauxiliaries as required for safe and proper operation of set.

DG set shall be controlled independently through separate control panel. The unitshall have integrated control with automatic starting sequence from the manuallyinitiated command from a single push button. It shall also have auto initiation throughcommand from remote from owners panel.

The DG set shall also issue automatic closing command to its supply receivingbreaker on achieving rated voltage and frequency on its terminals when controlledfrom remote. Necessary voltage and frequency relays for the purpose shall beincluded in the offer.

Electrical self starting system shall be provided, the source of energy shall bebatteries backed up by battery chargers which shall be supplied by the Contractor.

The fuel oil system and the lubricating oil shall also start operating simultaneouslyand automatically as soon as a starting impulse is received to obviate any chance ofseizure of the piston and bearing as well as air locking in fuel supply system.

Alternator vibration level shall not exceed the values as defined in IS: 12075.Alternators in case driven by Diesel engine shall be able to withstand vibration levelof 9mm/sec. as per BS 5000 Part III.

The exhaust system shall consist of insulated pipe of adequate height as per CPCB

norm.

1.7.2. DIESEL ENGINE

The engine shall be turbo charged, radiator cooled and generally in accordance withBS: 5514, IS: 10000, IS: 10002, ISO: 3046 and DIN: 6271.

Diesel engine shall be mounted on visco damper type vibration dampening systemand shall be complete with integral air intake through dry type air filters and exhaustsystems, metering facility, speed regulation system, fuel injection system, lube oil

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system, primary cooling water system along with necessary filters, silencers, ducts,exhaust, piping and fittings, valves, instruments, etc. as required.

1.7.3. GOVERNING SYSTEM

The governor shall be electronic type with class A1 type as per BS-5514.

The governor shall have necessary characteristics to maintain the speed substantiallyconstant even with sudden variation in load. However a tripping shall be providedeven if speed exceeds the maximum permissible limit.

1.7.4. LUBRICATING OIL SYSTEM

Automatic pressure lubrication shall be provided by a shaft driven gear type pumpthrough an oil cooler and fin mesh filters to the end bearing, camshaft bearings,camshaft chain and gear drives, governor, air starting, distribution, auxiliary drivegears etc.

In case manufacturers recommend lube oil pump for intermittent priming, one handdriven and one electric motor driven oil priming pump shall be provided for each DGset. In case of electric driven pump suitable rating starter shall be provided in controlpanel.

All necessary accessories like pressure gauges, temperature and oil level indicators,pressure relief valves, bypass valves, pressure switches for alarm and control shallbe furnished by the Contractor together with all inter connecting piping, fittings,supports, valves, etc.

A lubricating oil filter shall be provided for operation under normal conditions forperiod of a more than 250 hours without the necessity of its replacement or cleaning.

1.7.5. DIESEL OIL SYSTEM

The diesel oil system as provided shall be complete with simplex type filters, hoses,piping, fittings, relief valves, supports, control and instrumentation and all otheraccessories to make the installation complete.

The fuel consumption of the engine at full and three quarters of its rated power outputshall be indicated by the bidder.

A day oil tank of 990 litres fuel capacity shall be provided by the bidder, mounted onfabricated steel platform outside the acoustic enclosure. The tank shall be completewith level indicator marked in Litres, two nos. of level switches, filling inlet withremovable screen, an outlet, a drain plug, an air vent and necessary piping. The fueltank shall be painted with oil resistant paint. All pipe joints shall be brazed/ welded.

1.7.6. ALTERNATOR

The generator shall be of totally enclosed or screen protected drip proof and self aircooled type. The generator shall conform to IS 4722 or IEC-60034.

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The specified rating of the alternator shall be net output at the specified ambientconditions (i.e. rating after allowing the derating, as applicable for the stipulated site

conditions).

Excitation shall be of brushless type and shall have rating of at least 110% of what isrequired when the alternator is operating at full speed.

The alternator shall be provided with automatic voltage regulator which will maintainthe static voltage of the alternator within specified limits at all loads and the powerfactor between 0.8 and 1.0.

Space heater rated for 240V AC shall be provided to keep winding dry during idleperiods.

The alternator shall be designed for direct coupling with the engine specified aboveand shall match the same in all respects

The alternator with its exciter shall be totally enclosed air cooled and suitable for IP54protection as per IS: 4691.

Conductor, Insulation and Temperature Rise of Winding and Core

All insulated winding conductors of alternator shall be of copper. The generator statorand rotor windings core insulation and all connections including main and neutralleads shall have class-F or class-H insulation epoxy thermosetting type withtemperature rise limited to class-F or class-H insulation respectively as per in IEC-

60034 Pt.-I.

The winding shall be given power house treatment i.e. two coats of varnish andbacking followed by final coat of resin. The total insulation shall be non hygroscopic.The temperature rise of the stator core and mechanical parts in contact with oradjacent to winding shall not exceed the specified limits.

The alternator shall be provided with six numbers of embedded resistancetemperature detectors (RTDs) for measurement of winding temperature. Three ofthese shall be provided between the coils, one in each phase and the other three atthe base of the slots, placed 120 degree apart. In addition to these, two numbersRTDs shall be provided for bearing temperature measurement.

These RTDs shall be of platinum having 100 ohm resistance at 0 Deg.C andtemperature coefficient as 3.85x10^5. The RTDs shall be three lead type havingpower frequency insulation level of 7.2 KV.

1.7.7. TERMINAL BOX

Separate terminal boxes shall be provided for phase and neutral side of leads. Theterminal boxes shall be dust tight, weather proof having degree of protection of IP-42as per IS: 13947.

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The terminal box shall be of sufficient size to conveniently terminate the size andnumber of cables which shall be intimated later

Suitable tinned copper pads shall be provided for power cable termination. For singlephase cables gland plate shall be of nonmagnetic material and shall be removabletype.

Rolled aluminium or Nickel/Cadmium plated brass, heavy duty, double compressiontype cable glands, shall be mounted on removable gland plate.

As far as possible connection between exciter and alternator shall be containedwithin the machine frame and connections carrying AC and DC current shall besegregated from each other. The necessary CT's for differential protection shall beprovided on neutral side. The neutral point shall be brought to DG control panel andshall be connected to 300/100V VT, to be supplied and mounted inside the DGcontrol panel by the bidder for earth fault detection

1.7.8. EXCITATION SYSTEM

The generator shall be provided with complete excitation system capable of supplyingthe excitation current of the generator under all conditions of output from no load tofull load and capable of maintaining voltage of the generator constant within +/- 1% ofset value.

The setting range available on voltage regulator shall be at any value with +/- 10% ofthe rated voltage. It shall be possible to set the same from remote also.

The type of insulation of the armature field winding of the exciter shall be Class-B andthe temperature shall not exceed the values specified in IEC-60034 Part-I for differentparts

1.8. SOUND PROOFING SYSTEM

1.8.1. Bidder shall furnish design calculation for sound proofing/ ventilation system. Thedetailed frequency response for noise absorbing characteristic of acoustic materialshall be furnished.

1.8.2. The sound absorptive layer shall comprise of bonded type mineral wool/glass wool ofadequate thickness and density to comply the design requirements.

1.8.3. DG shall be placed in acoustic enclosure. The requirements of acoustic enclosureare as following:

The acoustic enclosure shall be fabricated from 2.0 mm thick CRCA sheet with steel

section & frame of suitable size. The construction shall be modular type to facilitatedismantling as required for maintenance. The frame shall be of sufficient stiffness andrigidity.

The enclosure shall be suitable for outdoor duty. The sheet and all sections shall bepowder coated shade of grey RAL9002.

DG set and control panel shall be located inside the enclosure. A minimum clearspace of 800mm shall be kept inside the enclosure all round the DG set.

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The exposed surface of lining shall be retained in place by minimum 1.0mm thickCRCA/ Aluminium perforated sheet. Absorptive lining shall be provided between the

perforated sheet and absorbing material. Necessary acoustic sealing shall be donein the panels/ modular unit joints.

Enclosure shall be provided with adequate lighting. Enclosure shall be provided withadequate number of door and viewing glass.

The door design shall be compatible to the enclosure design. The bonded mineralwool slab of adequate thickness shall be used. The door shall be provided with heavyduty hinges and handles. The sealing shall be done with neoprene/ silicon rubbergasket to avoid leakage of noise. The size of the door shall be as per the roomdesign/ functional requirements.

Suitable louvers with acoustic treatment shall be provided by the bidder as required.

Any other facility required to achieve the desired acoustic level shall be in the biddersscope

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1.9. VENTILATION SYSTEM

1.9.1. Ventilation system of adequate capacity shall be provided. The system shall compriseof tubular axial flow fans for air intake and air exhaust with splitter silencer.

1.9.2. The ventilation shall be design to ensure required air flow rate as per manufacturerrecommendations, after providing necessary acoustic treatment/ silencers in air flowpath. The ventilation system shall be design to prevent leakage of sound andtemperature shall not increase by more than 5 degree centigrade when DG is runningcontinuously at specified rating.

1.9.3. The construction of ventilation duct shall be from 1.6 mm thick CRCA perforatedsheet. Other constructional details shall be similar to that of the enclosure/ roomacoustic treatment

1.9.4. The exhaust air from radiator shall be discharge through modular duct of adequate

size.

1.10. BATTERY AND CHARGER

1.10.1. The battery shall be of VRLA typr, 24V and shall conform to the requirements of IS:7372. A suitable battery charger using semiconductor rectifier shall be provided torecharge the battery within ten hours. The battery for starting the engine shall becapable of performing six (6) normal starts without recharging

1.10.2. The charger shall be provided with a suitable DC Voltmeter and an Ammeter on thecontrol panel and an automatic voltage stabilizer to enable it to work satisfactorilywhen connected to a single phase 240 V, AC supply with +10% voltage variations.The charger shall have necessary filters to reduce the ripple factor less than three (3)and suitable dropping characteristics by means of choke and/ or suitable input

transformer impedance to automatically reduce the charging current as the batterygradually charges up. The minimum voltage at the end of load cycle shall not be lessthan 1.75 volts per cell. The charger shall be protected by a suitable current limitingdevice.

1.10.3. Bidder shall size the battery to meet these requirements. Bidder shall submit Detailedbattery sizing calculation in accordance with IEEE- 485 for Lead Acid type battery (asapplicable, to support the Battery AH capacity selected). The ageing factor shall betaken as 1.25, temperature factor shall be considered at minimum designtemperature of 5C and an additional design margin of 20% shall be considered whilecalculating the battery size for both type of batteries. Battery discharge characteristiccurves, temperature correction factors etc. shall be furnished by the Bidder along withthe sizing calculations for Owners approval. Battery and battery charger shall alsofeed the control supply of DG control panel and loading for the same shall be

considered while sizing the battery.

1.11. AMF CONTROL PANEL

1.11.1. Control panel with provision for local starting shall be provided which shallincorporate all controls required for starting, monitoring, regulating and stopping DGset. It shall be equipped with all necessary instrumentation to provide adequatesurveillance of DG set under all operating conditions including Standby.

1.11.2. The local control panel shall be of robust construction, floor mounting, free standingtype made of 2.0 mm thick cold rolled sheet steel. Neoprene gaskets shall be

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provided between all openings and joints. The control panels shall have IP-52 degreeof protection as per IS: 13947 Part-I. All indicating instruments shall be flush mounted

conforming to industrial grade as per IS 1248. The indicating instruments shall be96mm X 96mm size.

1.11.3. The control panel shall be of unit type construction, compact and neat, provided withhinged door with locking arrangement.

1.11.4. All cables shall have bottom entry. Enough space shall be provided in the controlpanel for easy access during maintenance and repairs.

1.11.5. A tinned copper/ aluminium bar of adequate dimension shall be provided for earthconnection complete with nuts and bolts as required for external connection toEmployers earth grid.

1.11.6. The final paint shade shall be decided during detailed engineering.

1.11.7. CT shorting links, test terminal blocks etc. shall be provided. All the equipmentmounted inside the control panel shall be identified by lamicoid labels/ stenciling bypaint.

1.11.8. Panel shall be provided with panel illumination lamp operated by the door switch andthermostat-controlled space heater. Control panel shall be furnished complete with allaccessories and wiring for safe and trouble free operation of the system.

1.11.9. Fuses

All fuses shall be of HRC cartridge link type. Screw type fuses are not acceptable.

1.11.10. Relays

Protection system shall consist of relays for IDMTL over current (voltage restrainedtype), residual earth fault, IDMTL standby earth fault, restricted earth fault, fieldfailure, over/under voltage with timer, over/under frequency with timer, reverse power,winding temperature alarm & trip and bearing temperature alarm & trip with suitabletemperature scanner. On occurrence of any type of fault, tripping command to remotecircuit breaker shall be sent through a hand reset type high speed lockout relay. Inplace of separate relays for different types of above mentioned protections, acombined generator management device can also be provided. Suitable currenttransformers (CTs) shall be provided for the protective relays. Accuracy class of theCTs shall be PS for REF relay and 5P10 for other relays

1.11.11. The control panel shall have the following provision for the control of diesel

generator set as a minimum:

i) Starting and stopping of the set.

ii) Fine adjustment of speed.

iii) Adjustment of output voltage.

iv) Local / remote selectors switch to facilitate remote starting / stopping, speed& voltage control.

v) D.C Ammeter and D.C Voltmeter for 24 V DC system for charger circuit.

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vi) DC Voltmeter for 110V DC system.

vii) Voltmeter and Ammeter for diesel generator output along with selectorswitch.

viii) Watt-hour meter & Wattmeter.

ix) Frequency meter.

x) Auto manual selector switch for priming pump motor (if required).

xi) The requirement of CT, VTs, relays, timers, auxiliary contacts shall be as perthe system requirement but not limited to the enclosed control schemes.

xii) The bidder shall supply any other controls and indications for dieselgenerator set though not specifically mentioned here but which the supplier

may recommend and are required to make system complete for satisfactoryoperation of DG sets.

1.11.12. The diesel generator sets would normally be controlled from remote for whichfollowing provisions shall be made on the control panel.

i) Starting and stopping of the DG set - Start/ Stop

ii) Speed control of DG set. - Raise/ Low

iii) Voltage control of DG set. - Raise/ Low

iv) Indication of the DG set under operation. - DG ON

v) Suitable 4-20mA transducers with dual output shall be provided in the controlpanel for KW, KVAR, Ammeter, voltmeter, Power Factor & frequency meterfor owners use at remote.

vi) The bidder is required to provide coupling relays (with diodes) having 24VDC energizing coil in the control panel for the followings for owners use

1. DG Start

2. DG Stop

3. DG Voltage Raise

4. DG Voltage Lower

5. DG Speed Raise

6. DG Speed Lower

7. DG Auto Start Enable

8. DG Auto Start Disable

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1.11.13. Provision for following status/ signal for Employer's information shall beprovided in the DG control panel:

i) DG fails to start.

ii) DG start command actuated/ reset.

iii) DG working/ stop signal.

iv) DG trouble/ normal signal.

v) DG control supply failure/ normal signal.

1.11.14. Tripping and Alarms

Any one or more of the following defects shall cause the alarm or running diesel

generator to be tripped. In case of tripping, re-start shall be prevented until the fault(s)are removed and manual resetting is done. Separate indicators shall be provided foreach of the following in control panel:

i) AC supply, 110V DC & 24V DC supply healthy (indication only).

ii) Fail to start (Alarm)

iii) Lube oil pressure low (Trip)

iv) Over Speed (Trip)

v) High cooling water temperature (Trip)

vi) Charger ON/OFF (Indication only)

vii) Fuel level low in day tank (Alarm)

viii) Fuel level very low in day tank (Trip)

ix) Alternator stator temperature high (Alarm)

x) Electrical protection operated (Trip)

xi) Incomer to emergency switchgear from DG closed.

xii) Earth fault (alarm) input from owners switchgear.

xiii) Priming pump tripped alarm

xiv) Priming pump Emergency stop (indication only)

xv) Engine start / stop (indication only)

1.11.15. Indication and Annunciation

Indicating lamps shall be of the panel mounting LED type with series resistor and oflow power consumption. Lamps shall be provided with series resistor built-up lampassembly.

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Necessary pressure switches, level switches, thermostats, flow switches, auxiliaryrelays, etc. required for the above alarm and annunciation system shall be furnished

under the scope of this specification.

1.12. NEUTRAL EARTHING RESISTOR

1.12.1. The star point of the Alternator shall be connected to earth through neutral groundingresistor (NGR) so that the maximum earth fault current through the resistor & statorwinding is limited to 400 Amps (suitable for 10 Sec with maximum temperature riselimited to 200 Deg.C).

1.12.2. Neutral grounding resistor shall be natural air cooled.

1.12.3. The resistor element shall be made of non corrodible material prefebly stainless steelAISI 304 / AISI 410.

1.12.4. The resistor shall be housed in a free standing and self supporting metal enclosuresuitable for outdoor installation having IP-34 degree of protection fabricated out of 1.5mm thick sheet steel. The top of the enclosure shall be provided with rain protectivehood. The enclosure shall be suitable for installation on a concrete foundation.

1.12.5. The front & back cover shall be removable for access to internal resistor connectionand for removal of resistor banks.

1.12.6. The enclosure shall be provided with lifting eye bolts on the top and cable connectionon side with bottom entry facility. Terminal box shall have minimum IP 55 degree ofprotection.

1.13. TESTS

1.13.1. All equipments to be supplied shall be of type tested quality. The Contractor shallsubmit for Owners approval the reports of all the type tests as listed in thisspecification and carried out within last five years from the date of bid opening. Thesereports should be for the tests conducted on the equipment similar to those proposedto be supplied under this contract and the test(s) should have been either conductedat an independent laboratory or should have been witnessed by a client.

1.13.2. In case the contractor is not able to submit report of the type test(s) conducted withinlast five years from the date of bid opening, or in the case of type test report(s) arenot found to be meeting the specification requirements, the contractor shall conductall such tests under this contract free of cost to the owner and submit the reports forapproval.

1.13.3. All acceptance and routine tests for Engine, Alternator, Battery and Battery chargeras per the specification and relevant standards shall be carried out. The oil tank shallbe tested for leakage test and enclosures to meet specified degree of protection. Theassembled DG set tested for load, noise and vibration tests. Charges for these shallbe deemed to be included in the equipment price.

1.13.4. Type Tests

Type test reports for the following type tests shall be submitted:

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Type test reports on Engine: This shall be as per BS-5514 Part-1: List A, B & C(Table 5,6 & 7).

Type test reports on Alternator

1. Measurement of resistance

2. Phase sequence test

3. Regulation test

4. Measurement of open circuit and short circuit characteristics

5. Efficiency test

6. Temperature Rise Test

7. Momentary overload test

8. Over speed test

9. High Voltage test

10. Insulation resistance test (both before and after High Voltage Test)

11. Noise level as per IS:12065

12. Vibration as per IS: 12075.

13. Determination of Deviation of voltage waveform from sinusoidal.

14. Degree of protection test on control panel for IP-52

15. Battery and battery charger as per relevant standards.

1.14. COMMISSIONING CHECKS

In addition to the checks and test recommended by the manufacturers, the contractor shall

supervise the following commissioning test to be carried out on each set at site :

1.14.1. Load Test

The engine shall be given test run for a period of at least 6 hours. The set shall be

subjected to the maximum achievable load as decided by Project Manager without

exceeding the specified DG set rating.

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During the load test half hourly records of the following be taken:

i) Ambient temperature.

ii) Exhaust temp. if exhaust thermometer is fitted.

iii) Cooling water temp. at a convenient point adjacent to the water output from

the engine jacket.

iv) Lubricating oil temp. where oil cooler fitted.

v) Lubricating oil pressure.

vi) Speed.

vii) Voltage, wattage and current output.

viii) Oil tank level.

1.14.2. Insulation Resistance Test for Alternator

Insulation resistance in mega-ohms between the coils and the frame of the alternator

when tested with a 500V megger shall not be less than IR=2x (rated voltage in

KV)+1.

1.14.3. Check of fuel consumption

A check of the fuel consumption shall be made throughout the load run test. The fuel

consumption should not exceed the design values.

1.14.4. Insulation Resistance of Wiring

Insulation resistance of control panel wiring shall be checked with 500V megger. The

IR shall not be less than one mega ohm.

1.14.5. Functional Tests

i) Functional tests on control panel.

ii) Functional tests on starting provision on the engine.

iii) Functional tests on all field devices.

iv) Functional tests on AVR and speed governor.

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1.15. MEASUREMENT OF VIBRATION

The vibration shall be measured at load as close to maximum achievable load and shall be asper manufacturer practice. Any modification/rectification required to bring down the vibration

level with in allowable limits specified by the manufacturer shall be done by the contractor.1.16. NOISE LEVEL (SOUND PRESSURE LEVEL) CHECK

Noise level measurement shall be done generally following the guidelines given in IS: 12065.

The measurement shall be carried out with a calibrated integrating sound level meter as per

IS: 9779

1.17. INSTALLATION OF DG SETS

1.17.1. The supervision of installation, testing and commissioning of Diesel-Generator setsshall be carried out by the Contractor strictly in accordance with the applicable Codesof practice, statuary requirements, local rules & regulations, the manufacturer'sinstructions, drawings etc., and/or as directed by the Employer.

1.17.2. The Contractor shall test and commission the DG set, control panels, along with otheraccessories, starting equipment (Battery & battery charger), fuel oil tank and fuel oilpiping up to the DG sets.

1.17.3. The D.G.Set shall be started and commissioned in the presence of the owner andshould run over its full load range enable the plant to be ready for performance tests.

1.17.4. The Contractor shall provide all tools, equipments and instruments required for

testing and commissioning.

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1.18. TRIAL OPERATION

1.18.1. The duration of trial operation of the D.G. Set shall be spread over for different loadsout of which it shall be continuously operated at full load for at least twenty four (24)hours or any other duration as may be agreed with owner and bidder. The trialoperation shall be considered successful, provided that each item of the emergencygeneration system can operate continuously at the specified operating condition forthe period of trial operation.

1.18.2. For the period of trial operation, the time of operation shall be counted. In case ofinterruption for any reason, the trial operation shall be repeated for full 24 hours.

1.18.3. A trial operation report comprising observations and recordings of various parametersto be measured in respect of the above trial operation shall be prepared by bidder.This report besides recording the details of various observations during trial run shallalso include the dates and times of start and finish of the trial operation and shall besigned by the representative of both owner and bidder and recording of all the detailsof interruptions occurred, adjustments made and any minor repairs done during thetrial operation shall be made by bidder. Based on the observations, necessarymodification / repairs to the system shall be carried out by the bidder to the fullsatisfaction of the owner.

1.18.4. After a successful trial operation, the bidder shall demonstrate the reliability of thecomplete emergency power system for a continuous run of 7 days.

1.18.5. The complete system shall run at an agreed load with owner during the reliability run.

1.18.6. Any part tripping during reliability run is not acceptable. In the event of the system orany part tripping on account of reasons attributable to the bidder, the reliability runshall start a fresh for 7 days period after rectification of the cause of failure by thebidder. The onus of proving that any failure is not due to faulty design, materials orworkmanship will lie with the bidder.

1.18.7. During the reliability run the bidder shall demonstrate satisfactory running of varioussystems at the specified parameters.

1.18.8. A report, comprising of observations and recordings of various parameters notedduring reliability run, shall be submitted by the bidder to the owner.

1.18.9. On successful completion of the reliability run together with having obtainedclearance from the statutory authorities, the bidder shall inform the owner in writingthat the system is ready for use.

1.19. TAKING OVER

1.19.1. The taking over certificate shall be issued by the owner to the bidder only afterevaluation of the performance guarantee test report and acceptance of the same byowner.

1.19.2. The responsibilities for prime satisfactory performance of the D.G. Set andassociated facilities at rated capacities shall be that of the bidder, irrespective of thefact that certain plant items or system might have been taken over earlier by theowner and guarantee shall commence from the date of taking over of the entiresystem by the owner or mutually agreed with owner.

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1.19.3. The bidder shall carry out all necessary repairs / modifications on erected equipmentwhich are due to the bidder's own defects / faults to the satisfaction of owner till final

completion.

1.20. PERFORMANCE TEST OF THE SET

1.20.1. The complete set shall be tested at site after installation for a period of 8 hours at theload made available by the vendor at 25%, 50, 75% &100% of the full load. Allconsumables shall be in the scope of the vendor.

1.20.2. During the above test, the temperature rise of all electrical components shall bewithin the limits prescribed by IEC for the relevant insulation classes. All control andgovernor function shall be tested through secondary actuation and fault simulation.

1.20.3. Fuel oil for the above test shall be arranged by the vendor.

1.21. PERFORMANCE GUARANTEE

Sl.No.

Parameters Guaranteed Acceptance

1 Net continuous outputexcluding own auxiliaries

2.4 MW minimum at 0.8PF at battery limit

No shortfall is acceptable

2 Engine BHP Bidders declared valueat 45 Deg.C

No shortfall is acceptable

3 Fuel Consumption at100% load

Bidders declared value Shall not exceed + 5%. Forevery 1% increase beyond5%, a penalty of 2% of theDG set cost subject tomaximum of 5% shall beimposed

4 Starting Time 10 Seconds (Max.) No deviation acceptable

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1.22. DRAWINGS & DOCUMENTS

1.22.1. Foundation plan showing location of foundation channel, floor plans etc.

1.22.2. Supporting calculations for arriving at Diesel engine/alternator ratings at the specifiedambient condition covering the following.

Rated BHP of engine at 38 Deg.C as given by manufacturer

Rated BHP of engine at 38 Deg.C considering the derating factor as given bymanufacturer

Rated BHP of engine at 45 Deg.C after deduction of mechanical auxiliaryloads connected on engine shaft.

Efficiency & Power factor of alternator at 100% load to calculate the output ofDG set at site conditions.

Alternator rating at 45 Deg.C as given by manufacturer

Derating factors to be considered for site ambient conditions as given by themanufacturers.

Alternator rating at 50 Deg.C after considering the above derating factors.

Electrical auxiliary load connected on alternator

1.22.3. Voltage drop calculation for starting the biggest motor of sizes as given under

Technical parameters.

1.22.4. GA & Foundation layout of DG sets covering dimension of various equipments i.e.alternator, engine.

1.22.5. Connection / terminal wiring diagram for DG set, DG control panel, AMF panel etc.

1.22.6. GA & foundation layout of Neutral Grounding resistor, AMF panel.

1.22.7. Data sheet of DG set, Neutral Earthing resistor.

1.22.8. Installation, Operation & Maintenance manual of DG set.

1.22.9. Illustrative and descriptive literature of DG set and AMF-cum-Control Panel.

Documents

G3IR-1050-65-SP-9016_R1