DG Spec Final Approval

EQUIPMENT DESIGN

ENGINEERS

CLIENT : RELIANCE INDUSTRIES LTD.DOCUMENT NUMBER

MH-IDMHMUMB001-E-SP-002

PROJECT : IDC & UTILTIY BLCOK SHEET NO. 1 OF 46

TECHNICAL SPECIFICATIONS

FOR

DIESEL GENERATING SETS

FOR BID ENQUIRY

REVISION NO. A R0 R1

ISSUED FOR REVIEW/

APPROVAL

ISSEUED FOR

ENQUIRY

REVISED AS PER

RIL COMMENTS

PREPD.BY/DATE ET : 30/08/07 ET: 11/09/07 ET: 18/09/07

CHKD. BY/DATE PSL : 30/08/07 PSL : 12/09/07 PSL : 19/09/07

APPD. BY/ DATE

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CLIENT : RELIANCE INDUSTRIES LTD. SHEET NO. 2 OF 46

I. DIESEL GENERATING SETS: SCOPE.......................................................................................................... 3

II. APPROVAL FROM STATUTORY AUTHORITIES......................................................................................4

III. EXCLUSIONS.................................................................................................................................................... 4

IV. DESIGN.............................................................................................................................................................. 4

V. CODES & STANDARDS................................................................................................................................... 5

VI. GENERAL......................................................................................................................................................... 6

VII. OPERATING CONDITIONS............................................................................................................................ 6

VIII. TECHNICAL PARTICULARS AND DATA SHEETS....................................................................................7

IX. PERFORMANCE REQUIREMENT................................................................................................................ 8

X. ALTERNATOR................................................................................................................................................. 9

XI. GENERATOR CONTROL PANEL................................................................................................................ 14

XII. 11KV SWITCHGEAR FOR DG OUTPUT CONTROL................................................................................19

XIII. DIESEL ENGINE............................................................................................................................................ 23

XIV. INDUCTION MOTORS FOR AUXILIARY DRIVES...................................................................................28

XV. PLC SYSTEM FOR DG.................................................................................................................................. 29

XVI. TESTS............................................................................................................................................................... 34

XVII. MAINTENANCE TOOL AND TACKLES.....................................................................................................36

XVIII. SPARES............................................................................................................................................................ 36

XIX. DRAWINGS AND DOCUMENTS SCHEDULE...............................................................................................37

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EQUIPMENT DESIGN

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I. DIESEL GENERATING SETS: SCOPE

This specification covers the technical requirements of design, manufacture, inspection and testing at

manufacturer's works, delivery to site, supervision of erection, testing and commissioning of Four (4) nos.

diesel generator sets having generation voltage of 11kV, rated output of 3750KVA (continuous), 1500 rpm

comprising the following:

1. DG set complete with all ancillary equipment, accessories, instruments and associated controls.

2. Fuel oil system complete with 990 L. day tank, feed pump, priming pump, necessary piping,

valves, filters and strainers, instruments, accessories, etc.

3. Lubricating oil (L.O.) system complete with L.O. sump, L.O. Pump, necessary piping, valves and

fittings, filters and strainers, L.O. heat exchanger, instruments, accessories etc.

4. Compressed air assisted starting system with all accessories like compressor, compressed air

bottle, necessary piping, valves etc., electrical starter for the compressor, interconnecting LV

power and control cables to make the system self-sufficient. In case the Supplier’s standard

design provides for battery starting, he may offer complete system related to battery starting.

5. Air intake and exhaust system, complete with filters, silencers, ducts, pipe fittings & accessories

and supporting arrangement for exhaust system. The silencer shall be “residential” type.

6. Directly coupled A.C. machine (generator) with terminal box, rotating diode type brush-less exciter,

automatic voltage regulator, alarm initiating devices and other accessories.

7. Independent control panel with controls and instruments for each engine & alternator complete

with AMF facility for starting of the engine and with necessary controls, interlocks, protections,

metering and indications as per functional requirement of AMF feature. 11 KV VCB panel to be

installed local to the gensets, complete with all controls shall also be included under this facility.

8. Motors for auxiliary drives.

9. Automatic and Manual synchronizing equipment for 4 DG sets.

10. Anti-vibration pads for mounting of the DG set.

11. PLC control system with SCADA function for remote operation of the DG system with facilities for

event logging, trending, mimics alarm etc.

12. LT power cables and control & signaling cables for DG installation along with the cable schedule

for the same.

13. Supply of consumables/spares for testing and commissioning of the DG sets at site.

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II. APPROVAL FROM STATUTORY AUTHORITIES.

The Bidder shall be responsible to obtain the approval of the Electrical Inspectorate or any other required

statutory authorities including approval from the Maharashtra Pollution Board and No Objection Certificate

from M.S.E.B. for the design, supply, installation, testing and commissioning of the equipment under his scope.

Necessary official fees and charges will be reimbursed by the Purchaser on production of the receipt. All the

required drawings, documents for the above purpose shall be prepared and supplied by the Supplier.

III. EXCLUSIONS

Equipments & services excluded from scope of this specification.

All Civil works

11kV Cables

Main Bulk storage tank for diesel

Chimney and supporting structure

Cooling Tower with associated cooling water circulation pumps

However design inputs for chimney, supporting structure and cooling tower to be provided by the vendor.

IV. DESIGN

The design and workmanship shall be in accordance with the best engineering practices, to ensure satisfactory

performance and service life. The equipment offered by the Supplier shall be complete in all respects. Any

materials or accessories, which may not have been specifically mentioned, but which are usual and necessary

for the satisfactory and trouble free operation and maintenance of the equipment, shall be provided without any

extra cost to the purchaser.

V. SPARES

Sufficient spares for the DG Sets , shall be provided by the Bidder for maintenance of the DG Set for at least

2Years after successful commissioning , separate Quotation shall be provided for the same.

Annual maintenance contract of the DG Set from the successful Bidder shall be negotiated separately.

All Commissioning SPARES are tobe listed for FREE supply by the Bidder.

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V. CODES & STANDARDS

The design, construction, manufacture, inspection, testing and performance shall comply with all the currently

applicable statutes, safety codes, latest editions of relevant Indian Standards (IS), British Standards (BS),

International Electro Technical Commission (IEC) publication, NEMA and VDE Standards.

Some of the applicable Standards are given below:

IS 1601 - Performance & testing of IC engines for general purposeBS-5514 - Performance & testing of diesel Part 3-5 engines for general purposesIS-1600 - Type testing of constant speed internal combustion engines for general purposesIS-1460 - Specification for diesel fuelsIS-4729 - Measurement and evaluation of vibration of rotating electrical machinesIS-78 - Guide for testing insulation resistance of rotating machinesIS-2516 - A.C. Circuit breakersIS-3427 - Metal enclosed switchgear IS-2705 - Current transformers IS-3156 - Voltage transformersIS-375 - Marking and arrangement for switchgear bus barsIS-5422 - Turbine type generatorsIS-4722 - Rotating electrical machinesIS-1885 - Electro technical vocabulary Part XXXVIS-4729 - Measurement and evaluation of rotating electrical machinesIS-4728 - Terminal markings for rotating electrical machineryIS-2208 - HRC cartridge fuse links up to 650VIS-1248 - Electrical indicating instrumentsIS-3231 - Electrical relays for power system protectionIS-5082 - Aluminium busbarsIS-3072 - Installation and maintenance of switchgearIS-6875 - Control SwitchesIS-2551 - Danger notice platesIS-2253 - Designations for types of construction & mounting arrangement of rotating

electrical machines IS-6362 - Designation of methods of cooling for rotating electrical IS-4889 - Method of determination of efficiency of rotating electrical machineryIS-4691 - Degrees of protection provided by enclosures for rotating electrical machinery AIEE-60 - Recommended specification for speed governing of internal combustion engine

generator units IEC-34 - Rotating Machines

The DG set shall also conform to the provisions of latest Indian Electricity Act, Indian Electricity Rules and

Regulations of Statutory Authorities (Chief Electrical Inspector to the Government) and the norms set by the

Pollution Control Board.

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The equipment conforming to any other national standards, which ensure equivalent quality, are acceptable.

In such cases, the Bidder shall clearly indicate the standard adopted, and furnish a copy of the English

translation of the standard along with the tender. Should there be any dispute on design standard; the most

stringent one shall be adopted.

VI. GENERAL

The diesel generating set shall be indoor type AMF operated and shall comprise of diesel engine,

coupled to a suitable alternator, having brush-less excitation system complete with all accessories.

All equipment shall be of the class most suitable for working under the specified conditions and shall

withstand the atmospheric conditions without deterioration and without affecting the performance

requirements.

Material of construction for interconnecting pipes, pipe fittings, exhaust duct, bolts and nuts shall be as

per relevant standards and suitable to withstand the temperature of the gas/liquid within the pipe. All

externally mounted hardware can be of cast iron.

Nameplates and labels provided for engine, alternator, control panel and Switchgear, accessories, etc.

shall be of stainless steel only.

VII. OPERATING CONDITIONS

D.G. sets are intended for supplying stand-by power as the most reliable source of supply, in the event

of failure of utility grid.

The electrical load for diesel generating system shall comprise HT (6.6 KV)/LT motors, lighting and

other miscellaneous loads fed through suitable step-down transformers.

The starting time of the set shall be kept to a minimum which has been specified in Annexure-I.

The DG sets shall be suitable for parallel operation among themselves. Parallel operation with utility

grid is not envisaged.

Momentary paralleling with grid at the time of restoration of power supply should be possible.

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VIII. TECHNICAL PARTICULARS AND DATA SHEETS

Sr. Description Requirement Bidder’s Confirmation

1 Quantity 4 Nos.(as per delivery

schedule indicated

elsewhere)

2 Type of installation INDOOR

3 Rating (MVA) 3.75 (continuous)

4 Rated Output voltage (KV) 11

5 Site conditions

5.1Altitude Less than 1000 M. above

Mean Sea Level

Ambient Temperature

Maximum 40o C

Minimum 10o C

Design 45o C inside DG House

5.2Relative Humidity

5.3Maximum 95%

5.4Site Environment Polluted

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IX. PERFORMANCE REQUIREMENT

1 Type of output voltage Sinusoidal *

2 Nature of load 3 Nos. 6.6kV, 900KW chillers

fed through 11/6.6 KV

transformers and other LT load

with maximum motor rating of

110kW fed through 11/0.433 KV

transformers.

3 Time for Diesel engine to start and take up load

from Grid failure

Maximum 15 Seconds. *

4 Mode of operation Synchronized *

4.1In case of grid power failure Out of 4 sets, Engines of 3 pre

selected “duty” DG shall start on

AMF and take up the loads

within stipulated time.

4.2Isolated/ parallel mode

4.2.1 With grid supply The DG sets shall never be

operated in parallel with grid

supply except for momentary

paralleling for power restoration.

*

4.2.2 Isolated mode During initial stage of project

implementation, 1 no. DG set

may be required to run in

isolation to cater to the initial

load.

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4.2.3 Parallel mode When the complete project is

implemented, the DG sets shall

be required to synchronize

among themselves and take up

the entire load proposed to be

connected to them.

4.2.4 Shut down of DG sets after restoration of grid

supply.

This shall not be automatic and

manual intervention for DG shut

down and re-transfer the bus to

grid supply will be required.

X. ALTERNATOR

Sr. Description Requirement Bidder’s

Confirmation

1 Rated voltage and frequency 3 phase, 11KV, 50Hz

2 Output rating 3750 KVA

3 Rated Power factor 0.8

4 Type of enclosure Industrial SPDP

5 Degree of protection IP23

6 Class of insulation / temperature rise Min. Class `F' with temp. rise

limited to class B

7 Type of cooling Air cooled

8 Generator neutral system earthing

recommendation

Solidly earthed. Bidder to clarify

whether neutral of all DG sets

can be directly earthed or

through an isolator for earthing

of individual DG set, one at a

time.

*

8.1Neutral isolation facility In case the bidder recommends

the earthing of neutral of one of

the four DG sets only, then the

bidder shall include isolator /

*

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Confirmation

contactor, adequately rated for

each of the DG set in his scope

of supply.

9 Minimum protections required Refer clause no: 11 of part XI

10 Excitation system

10.1Type rotating diode type brush-less

excitation system

*

10.2Type of exciter fast response type designed to

have a low time constant to

minimize voltage transients

under severe load changes.

*

10.3Insulation class F

10.4Exciter system Shaft driven A.C. exciter with

rotating rectifiers.

10.5In built protections for over-voltage and rate of

rise of voltage

Required

10.5.1 Field forcing capability capable of forcing the field for

more than 3 sec in the event of

dead fault at the terminals.

11 Contribution by DG to faults downstream in

MVA

11.1Initial during 1st 7 cycles corresponding to xd” *

11.2Up to 0.5 sec corresponding to xd’ *

11.3Continuous corresponding to xd *

12 Maximum over voltage surge that DG set can

withstand without deterioration and subsequent

damage. (Note DG sets are controlled by

VCBs)

*

13 AUTOMATIC VOLTAGE REGULATOR

13.1Type High speed, adjustable dead

band, Electronic type

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Confirmation

13.2Control AUTO/MANUAL

13.3CTs and VTs for AVR operation To be included by the bidder as

required.

*

13.4Accuracy + 0.5% from no load to full load

13.5Response time for step load (from no load to full

load) &recovery of voltage to within 95%-in sec.

*

13.6Range of voltage adjustment *

14 Performance Figures

14.1Efficiency at 100% loads *



15 Temperature rise

15.1Cooling medium temperature (measured by

detector or thermometer), °C

*

15.2Temperature rise of armature winding above

cooling medium (measured by embedded

detectors), °C

*

15.3Temperature rise of field winding above cooling

medium temperature (resistance), °C

*

15.4Temperature of cooling air from the windings

(detector or thermocouple), °C

*

16 Losses

16.1Total no-load losses *

16.1.1 Total load losses at 50% load



17 Short circuit current withstand and duration

17.1Asymmetrical short circuit current withstand and

duration for 3 sec.

*

17.2Symmetrical short circuit current withstand and

duration for 3 sec.

*

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Confirmation

18 Electrical characteristics (calculated on

maximum capacity) at 100% cooling for direct

axis and quadrature axis

18.1Unsaturated synchronous reactance % *

18.2Unsaturated transient reactance % *

18.3Unsaturated sub-transient reactance % *

18.4Saturated synchronous reactance % *

18.5Saturated transient reactance % *

18.6Saturated sub-transient reactance % *


Confirmation

18.7Negative sequence reactance % *

18.8Zero sequence reactance % *

18.9D.C. resistance *

18.9.1 stator winding *

18.9.2 rotor winding *

19 Machine Time Constant

19.1Open circuit transient time constant *

19.2Short circuit transient time constant *

19.3Short circuit sub-transient time constant *

19.4Short circuit armature time constant *

20 Unbalanced Stator Current Capability

20.1Ratio of negative sequence component of the

system currents to rated current

8% or more *

21 Momentary Excess current for Generator capable of withstanding fifteen

(15) sec. a current of fifty (50)

percent in excess of its rated

current

*

22 Stator

22.1Material of construction high quality silicon steel

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Confirmation

lamination to achieve high

permeability with low hysterisis

and eddy current losses.

22.2Windings securely braced and wedged to

withstand damage from

mechanical & electrical forces

imposed on the windings during

full voltage short circuit

conditions & for the same

reason, they have to be heavily

insulated

23 Rotor

23.1Construction machined from a solid steel

forging


Confirmation

23.2Rotor winding MOC Silver bearing copper

23.3Joints between coils or half coils to be brazed

24 Damper winding for satisfactory parallel running to be provided *

25 Insulation level

25.1Basic insulation level, KV peak As per BS/IEC *

25.2Power frequency withstand, KV r.m.s. As per BS/IEC *

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26 Vibration limits Within limits of BS/IEC *

27 Noise level Within limits of BS/IEC *

28 Painting finish Epoxy. Paint Shade as per

manufacturer’s standard.

*

29 Termination details Cable Box suitable for 1 no. 11

KV, Al/XLPE, 3Cx300 sq. mm.

cable with heat shrink

termination – Raychem type

30 Special precautions taken in the insulation

system of the generator for protections against

switching surges generated by VCB.

Extra bracing for insulation *

31 Accessories

31.1Thermostat controlled anti-condensation space

heater

Required. Supply voltage 240V

AC, 50 Hz

*

31.2RTDS wired up to the terminal block in

a separate terminal box

*

31.2.1 2 nos. bearing RTDs Required *

31.2.2 6 nos. winding RTDS (2nos./phase) Required *

31.312-point Temperature Scanner for generator

winding RTDs and engine & generator bearing

RTDs

Required *

31.4Earhing

31.4.1 Earthing pads for alternator Required *

31.4.2 Two independent earth terminals on the frame,

complete with nuts, spring washer, and plain

washer for earthing of engine..

Required

31.5Vibration monitoring system including sensors

and compatible monitoring unit to provide alarm.

Required *

32 Make of Alternator *

33 Protection CTs

33.1Construction Cast Resin

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33.2Location Neutral side of phase winding &

neutral circuit

33.3Ratio & class Refer Attached S.L.D. for

Metering & Protections

34 Normal time the genset can run continuously

without requiring maintenance. (in hours)

*

XI. GENERATOR CONTROL PANEL


Confirmation

1 Execution floor mounting

2 Installation Indoor

3 Degree of protection IP52

4 Sheet steel CRCA

5 Sheet steel thickness

5.1 Base frame / channel 3mm

5.2 Load bearing members 2mm

5.3 Internal partitions, doors etc 1.6mm

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Confirmation

6 Type of assembly Bolted

7 Surface treatment 7 tank for removal of rust,

scale, oil, grease & dirt by

pickling followed by phospating

followed by 2 coats of zinc rich

primer

8 Surface finish Powder Coated Epoxy with

paint shade RAL-7032

9 Cable entry Bottom

10 Panel accessories Thermostat controlled space

heater and cubicle lamp

11 Protective Relays

11.1 Type Numerical, programmable at

site

11.2Supply Voltage 110V DC

11.3Rated Current 1A

11.4No. of output contacts As required for control scheme

11.5Operation indicator Required

11.6Minimum protective functions required

11.6.1 Voltage restraint IDMT Over

current

*

11.6.2 Under frequency *

11.6.3 Over frequency *

11.6.4 Under voltage *

11.6.5 Over voltage *

11.6.6 Reverse power/ loss of prime

mover

*

11.6.7 Restricted earth fault

instantaneous (high impedance

circulating current)

*

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11.6.8 IDMT earth fault – residual

current based

*

11.6.9 Standby ground over current

fault IDMT, neutral current

based

*

11.6.10 Negative phase sequence over

current, voltage unbalance,

inter-turn fault

11.6.11 Loss of excitation

11.6.12 Differential over current

11.6.13 Master trip relay, hand reset,

lock out type

*

11.6.14 Trip ckt supervision relay *

11.6.15 Redundancy in BUS PT voltage

(through BUS PT Relay ) for

110V AC Bus Wiring control

Bus with for both sections of

11KV Switchgear Board.

11.6.16 Field Protection Relays for the

Exciter (single E/F (alarm) ,

Double E/F (trip )

NOTE:The above functions can be discrete numerical relays based or software based built into PLC.

12 Meters

12.1Type Digital, 7 segment LED

12.2Metering Required For Line Currents, Line voltages,

frequency, PF, KVA, KW, kVAR

(Multi-function Load Managers

are preferred)

13 Control and selector switches

13.1Auto/Manual to select Auto or manual mode of

operation

13.2Local / Remote to select Local or Remote mode

13.3Breaker Control switch Trip - Neutral - Close, Spring

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return to Neutral.

14 Indicating Lamps

14.1Type Cluster LED

14.2Lens colours

14.3Red : C.B. “ON”

14.4Green : C.B. “OFF”

14.5White : “Trip Supply Supervision”

14.6Amber : Auto trip

14.7White : “Spring Charged”

14.8RYB : Phase Indication

15 Window type facia annunciators

15.1Voltage 110V DC

15.2Equipped with ‘Sound Cancel’, ‘Acknowledge’

and ‘Reset’ push buttons

15.3Provided with Two lamps connected in

parallel on each facia window

15.4Suitable for Open to Alarm & Close to

Alarm –site selectable

15.5Designed for an operating sequence indicated below *

Alarm Condition Fault Contact Audible

Alarm

Visual Alarm

Normal Open Off Off

Abnormal Closed On Flashing

Sound cancel Closed or Open Off Flashing

Acknowledge Closed or Open Off Steady on

Back to Normal Open Off Steady on

Reset Open Off Off

Lamp Test Open Off Steady on

15.6Minimum alarm/annunciation required for

alternator

Generator electrical faults

Downstream system fault

Bearing temperature high

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Winding temperature high

AVR trouble

Excitation trouble

16 Minimum alarm/annunciation required for

engine

Lube. oil pressure low & low-

low

Jacket water temperature high

and high-high

Engine fails to start

Engine/ Generator Bearing

temperature high and high-high

Engine shutdown

Compressed air system trouble

Engine over speed

Fuel oil tank level low and low-

low

17 Push buttons

17.1Type Spring return or stay put type

as required

17.2Contacts 2 NO + 2 NC minimum

18 Labels & Name Plates

18.1Material PVC or Anodised Aluminimum

18.2Engraving Black engraving on white

background

18.3Size of the label To suit application / importance.

18.4Fixing With self-tapping screws.

19 Wiring

19.1Control wiring

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19.1.1 Type 660V grade, PVC insulated

super-flexible copper wire

19.1.2 Size 2.5 sq. mm. for CT circuit

1.5 sq. mm. for control circuit

19.1.3 Colour Black for AC circuits and Grey

for DC circuit

19.1.4 Termination on equipment terminals / terminal

blocks

With crimped type, tinned

copper lugs , preferably WAGO

Type

19.1.5 Ferruling Required with non – detachable

type printed ferrules

20 Terminal Blocks Preferably WAGO type

20.1Control terminal size 2.5 sq. mm. minimum

20.2No. of spare control terminals 10% minimum

21 Synchronizing Facility

Auto Synchronizing with each other Required *

Manual synchronizing facility Required *

Check synchro. facility to prevent wrong

synchronizing

Required *

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XII. 11KV SWITCHGEAR FOR DG OUTPUT CONTROL

1 Execution Indoor, metal enclosed,

floor mounting, free-

standing, dust and

vermin-proof

2 Degree of protection IP4X

3 Sheet steel CRCA

4 Sheet steel thickness

4.1 Base frame / channel 3mm

4.2 Load bearing members 2mm

4.3 Internal partitions, doors etc 1.6mm

5 Type of assembly Bolted

6 Surface treatment 7 tank for removal of

rust, scale, oil, grease,

dirt by pickling followed

by phosphating

followed by 2 coats of

zinc rich primer

7 Surface Finish Powder Coated Epoxy

with paint shade RAL

7032

8 Cable entry Bottom

9 Version of circuit breakers – fixed or draw-out Drawout

10 Panel accessories Space heater with MCB

and thermostat + cubicle

lamp

11 Bus bars

11.1Material Electrolytic Aluminium

11.2Continuous current rating 400A *

11.3Insulation for bus bars Heat shrinkable

providing full insulation

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11.4 Bus bar temperature rise while carrying

rated current

Final temperature of

850C for bus bars and

900C for joints with an

ambient of 400C

11.5 Bus bar Supports SMC, DMC or cast resin

12 Circuit breaker

12.1 Type of circuit breakers Vacuum

12.2 No. of poles 3

12.3 Make *

12.4 Rating 630A

12.5 Derated current rating at site condition 630A *

12.6 Breaking capacity 26.24kA at 11kV = 500

MVA

12.7 Short time rating 26.24kA for 1 second

12.8 Execution Draw – out

12.9 Mechanism Motorised

12.10 Control Supply Voltage

12.10.1 Spring charging Motor 240V AC

12.10.2 Closing and tripping coil 110V DC

12.11 CB mechanical indications (flags) `ON’, `OFF’, “Service”,

“Test”, “Isolated”,

“Spring charged”

12.12 CB operation facility AUTO/MANUAL

12.13 Spare Auxiliary contacts 4 NO + 4 NC wired to

terminal block

13 Requirement of surge suppressor

13.1 For machines switched with VCB Required

13.2 Type Gapless, Zinc Oxide

13.3 Class Rotating Machine class

14 Meters

14.1 Type Digital, 7 segment LED

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14.2 Metering required for Line Currents, Line

voltages

15 Control and selector switches

15.1 Function

15.2 Auto/manual to select Auto or manual mode of

operation

15.3 Local / remote to select Local or Remote mode

15.4 Breaker control switch Trip - Neutral - Close,

Spring return to Neutral.

16 Indicating lamps

16.1 Type Cluster LED

16.2 Lens colours

16.3 Red : C.B. “ON”

16.4 Green : C.B. “OFF”

16.5 White : “Trip Supply Supervision”

16.6 Amber : Auto trip

16.7 White : “Spring Charged”

16.8 RYB : Phase Indication

17 Push Buttons

17.1 Type Spring return or stay put

type as required

17.2 Contacts 2 NO + 2 NC minimum

18 Labels & Nameplates

18.1 Material PVC or Anodised

Aluminimum

18.2 Engraving Black engraving on

white background

18.3 Size of the label To suit application /

importance.

18.4 Fixing With self-tapping

screws.

18.5 Use Main Panel, feeders

and individual devices

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19 Wiring

19.1 Control wiring

19.1.1 Type 660V grade, PVC

insulated super-flexible

copper wire

19.1.2 Size 2.5 sq. mm. for CT

circuit

1.5 sq. mm. for control

circuit

19.1.3 Colour Black for AC circuits and

Grey for DC circuit

19.1.4 Termination on equipment terminals /

terminal blocks

With crimped type,

tinned copper lugs

preferably WAGO Type

19.1.5 Ferruling Required with non –

detachable type printed

ferrules

20 Terminal blocks Preferably WAGO type

20.1 Control terminal size 2.5 sq. mm. minimum

20.2 No. Of spare control terminals 10% minimum

21 Testing

All routine tests as per applicable standards Required.

22 Quality Assurance Plan *

EQUIPMENT DESIGN

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SPECIFICATIONS FOR


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XIII. DIESEL ENGINE


1 Make *

2 Engine capacity (KW) Compatible with

alternator of 3750KVA

0.8 PF

*

3 Type of fuel for engine commercial High speed

diesel (HSD)

*

4 Engine Speed 1500 RPM *

5 Short time overload capacity of engine *

6 Cooling Water Cooled *

6.1 Cooling water requirement Mcu/Hr *

6.2 Inlet water temperature 32 Deg C

6.3 Outlet water temperature 37 Deg C maximum *

6.4 Quality of cooling water Raw / DM/ treated *

6.5 Cooling water system monitoring instrumentation Flow meters, inlet &

outlet water temp.

indicator

*

6.6 Maximum duration the DG can run at rated load

without cooling water

*

7 No of cylinders *

8 Time interval between successive starts *

9 Fuel oil system

9.1 Day tank Capacity 990 liters

9.2 Accessory Filling, draining and

vent connection with

valves and level

switches for low oil

level & high oil level

alarm and automatic

operation scheme for

day-tank filling.

EQUIPMENT DESIGN

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Rev-R0



9.3 Type of filter Duplex


9.4 Pre-Combustion Chamber Designed so as to

achieve safe knock-free

performance with

smokeless exhaust

10 Type of engine multi-cylinder, totally

enclosed, continuous

duty, direct fuel

injection, turbo-

charged, compression

ignition, inter-cooled oil

engine

10.1 Specific fuel consumption under site conditions

10.1.1 Full Load

10.1.2 3/4 Full Load

10.1.3 1/2 Full Load

11 Lubricating Oil System Pressure fed type *

11.1 Lube. Oil required at rated Load *

11.2 Type of filter in lube oil system to take load due to

clogging of Lube filter

Duplex type

11.3 Arrangement to bypass the oil cooler during

starting until oil temperature rises above

minimum.

Required

11.4 Bypass valve to prevent engine being starved of

oil in case filter is choked

Required

11.5 Accessories such as pressure gauges,

temperature indicators, pressure relief valves,

bypass valves, pressure switches

Required

EQUIPMENT DESIGN

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11.6 Engine shaft driven lube oil pump 1

11.7 Electrical motor driven lube oil pump 1 working+ 1 standby

12 Lube Oil Coolers As Required

13 Engine starting system

13.1 Type of starting Compressed air starting


13.2 No. of starts to be permitted by compressed air

system

Minimum 3 consecutive

starting attempts

13.3 Compressed air system 1 no. compressor

having adequate

capacity to be installed

local to the diesel

engine. Individual

compressor for

individual DG.

13.4 Completeness of compressed air system Storage receiver

adequate to hold

compressed air for 3

successive starts of the

engine, necessary

interconnecting piping,

pressure gauges,

pressure switches for

automatic cycling of the

compressor, electric

starter, LV power &

control cabling.

*

13.5 Starting solenoid valves with manual bypass

valve for local starting ( UPS / DC Supply )

Required

EQUIPMENT DESIGN

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SPECIFICATIONS FOR


DOCUMENT NUMBER


Rev-R0



14 Governing system

14.1 Make *

14.2 Type Electronic type

14.2.1 Load sharing features Required *

14.2.2 Adjustable droop Required *

14.3 Steady state speed regulation *

14.4 Steady state governing speed plus or minus % of

rated speed

*

14.5 Momentary over speed after full load rejection %

of rated speed

*


14.6 Momentary under speed of rated speed after

sudden increase of 25% rated load

*

14.7 Prescribed speed band ± rated speed *

14.8 Safety over - speed trip device

to automatically shut off

fuel in case the speed

exceeds the prescribed

limit.

*

15 Exhaust system

15.1 Engine exhaust system, complete with exhaust

gas driven turbo charger, residential silencer,

ducting, bends , silicate lagging, supporting

accessories etc

Required

15.2 G.I. cladding for Exhaust pipes within enclosure 22 gauge with thermal

insulation

16 Local Indicator Panel

16.1 Flexibly mounted local indicator panel with speed

indicator and gauges for lubricating oil pressure

before and after filter

Required

EQUIPMENT DESIGN

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SPECIFICATIONS FOR


DOCUMENT NUMBER


Rev-R0



17 Bearings Self-aligning journal

bearings

17.1 Type Self lubricated type

17.2 No. *

17.3 Life *

17.4 Lubrication *

17.5 Type of lubricant *

17.6 Lubricating interval *

17.7 Well with a suitable thermometer in the oil drain

and a suitable sight flow opening to observe

bearing oil flow. They shall also be provided with

Pt-100 type RTDs for monitoring their

temperature.

Required

17.8 Maximum generator shaft voltage 100 mV


17.9 In case, shaft voltage exceeds 100mV Non-driving end bearing

housing and lead-in &

lead out pipes to be

fully insulated (Non

conductive insulation)

17.10Separate terminal box for space heater and

R.T.D./Thermistors

Required

18 Forced Lubrication System In case forced

lubrication is required,

bidder shall provide 1

W+ 1 SB forced lube oil

pumps, electrical motor

driven.

19 Engine exercising facility to be built into engine

and generator control panel

Normal service,

Auto, Manual

*

19.1 “Service” (Duty)- Engine shall remain as “Ready-

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SPECIFICATIONS FOR


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to-start” and shall start automatically when called

upon (AMF)

19.2 Automatic exercising Engine should be able

to start and run at a

preset time (e.g. once

a week) and shall run

for preset time (e.g.

30min) this shall be

programmable at site

without load

19.3 Manual Exercising Operator shall be in a

position to start and run

the engine as desired

20 Overall dimensions of fully assembled DG unit

20.1 Without acoustic enclosure *

21 Weight schedule

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21.1 Overall weight of complete system for foundation

design

*

21.2 Heaviest single unit to be handled during normal

maintenance KGs

*

XIV. INDUCTION MOTORS FOR AUXILIARY DRIVES


1 Rated Voltage 415V ±10%, 50 Hz, ±5%

2 Type of installation Industrial, 3 phase,

squirrel cage

3 Degree of protection IP54 for indoor and IP 55

for outdoor

4 Reference standard IS 325.

5 Surface treatment painted with chemical

works type epoxy paint

6 Winding treatment windings shall be treated

for chemically corrosive

atmosphere. Overhang

shall be applied with gel

coat epoxy paint.

7 Minimum Motor rating 15% higher than the

driven equipment input

power requirement

8 Insulation class Class B or better

9 Minimum starting voltage 80% of rated voltage

EQUIPMENT DESIGN

ENGINEERS

SPECIFICATIONS FOR


DOCUMENT NUMBER


Rev-R0


XV. PLC SYSTEM FOR DG

A PLC (Programmable Logic Controller) system shall be provided for centralized control of 4nos. 3750 KVA DG

sets. Only the functional requirement expected from the system are specified here. The Bidder has to make

his own estimate about hardware requirement.

9.1 SCOPE: Supply of hardware to support the software and for operator interface.

Develop software based on the functional requirements stipulated in this specification.

Loading of the software into PLC system at the Bidder’s Works and testing by simulation.

Deliver the equipment at site.

Supervision of installation, testing and on load commissioning of the system.

Training of the Owner’s operating personnel for 5 working days for operating, maintenance trouble-

shooting, editing / modifications to the software etc.

Supply of essential spares.

9.2 PERFORMANCE REQUIREMENTS OF THE PLC SYSTEM –

The following performance activities are expected from the PLC:

Starting and stopping of 04 nos. DG sets along with their auxiliaries in a sequenced manner.

The DG sets are to run in synchronism with each other.

The PLC shall allow selection of any three out of four DG duty sets as “Service” sets and fourth as

“standby”.

Automatic Mains Failure starting of 3 nos. duty DG sets. In case one of the DG set fails to start or trip

during operation, the standby DG set shall be brought into operation automatically.

ON – OFF control of DG sets VCBs.

Generation of static and dynamic mimic for each DG set along with important parameters of generator

and engine.

Fault report generation indicating type of fault and date & time of occurrence of the fault. The system

shall be capable of loading the faults in its memory for 48 hours.

Generation print-outs periodically or on-demand as desired by the operator in a format to be approved

by the Purchaser.

EQUIPMENT DESIGN

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SPECIFICATIONS FOR


DOCUMENT NUMBER


Rev-R0


Basic System

The basic system shall comprise the following:

Central Processing Unit.

Adequate Memory for storing and running of the software.

Interfacing device viz.

Key board

Mouse

17” flat screen Colour Monitor

Laser Printer for taking hard copy output.

Programming unit (as described below)

Adequate number of digital I / O racks.

Adequate number of Analogue / Analogue or Analogue / digital converters.

Sheet steel cabinet to house the CPU, I / O racks and converters etc.

Interconnecting cabling between various devices of the system

Self – diagnostics.

Back – up storage of the software.

Any other hardware / software that is required to make the system complete and fully operational. The

Bidder shall clearly spell out all such features is his Bid for better understanding / evaluation of his Bid.

System hardware requirement

CPU

The Bidder shall select the CPU with appropriate speed so that the software can be run with reasonable speed

and the data can be updated reasonably fast. The Bidder shall furnish technical particulars of the CPU offered.

MEMORY

Memory offered shall be adequate:

To store the entire software with at least 100% spare memory for future alternations additions / losses in

corrupt memory segments. (ROM / Hard Disk)

To run the entire software with at least 100% spare memory for the same purpose as above (RAM). The

Bidder shall furnish technical particulars of the Memory offered.

INTERFACING DEVICE

The keyboard, Mouse and 17” flat screen colour monitor shall be standard commercially available

device available in the market, to the extent possible.

PRINTER

This shall be standard commercially available laser type.

Programming Unit

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SPECIFICATIONS FOR


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Rev-R0


This has been described in more details in the following paragraph under “Software”

EQUIPMENT DESIGN

ENGINEERS

SPECIFICATIONS FOR


DOCUMENT NUMBER


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Digital I / O racks -

Digital input cards are required to accept inputs such as VCB auxiliary contacts, temperature switch,

pressure switch contacts etc. These shall be potential – free. The interrogating voltage shall preferably

be low voltage DC (such as 12 or 24 V. DC) which has to be generated by the Bidder. Digital output

cards, complete with heavy duty auxiliary interposing relays if required, shall be suitable for onerous

switching duty such as operation of VCB closing and tripping coil at 110 V. DC.

Analogue / Analogue or Analogue / Digital converters –

Analogue input signals such as DG set current and voltages shall be the inputs to the PLC system. Currents

shall be 0-1 A and voltages 0-110V corresponding to 0-11 kV, 50 Hz AC signals. The converters shall convert

them for use in PLC software.

Construction

The sheet steel cabinet shall be floor mounting, free – standing, CRCA sheet cabinet made out of 2 mm thick

sheet.

The sheet shall under go 7 – tank chemical pre-treatment which shall be followed by epoxy based powder

coating in shade RAL 7032 or the one approved by the Purchaser. The cubicle shall provide degree of

protection not less than IP 52. Neoprene gasketting shall be provided at the doors and all metal-to-metal

contacts. Louvres, if required, shall be covered by fine wire mesh.

The cable entry shall be from bottom. Panel earthing and system earthing shall be provided as detailed under

“Earthing“ below. If glass is used in the panel door for viewing of the PLC system, the same shall be heat

resistant toughened type.

The cubicle, in general, shall be aesthetically built and compatible with the system & its installation

Interconnecting Cabling –

All interconnecting cabling between the CPU, Digital I / O Racks, Analogue input racks, keyboard, mouse,

VDU, printer, programming unit etc. shall be included by the Bidder in his scope of supply.

Field cabling for digital inputs / outputs, analogue inputs etc. shall also be provided by the bidder.

Self Diagnostic

The PLC system shall be complete with hardware and software for providing self-diagnostic feature for the

system. Failure of power supplies, components, PCBs shall be indicated by RED LEDs. The LEDs shall be

tagged to indicate the type of failure that has taken place.

The Bidder shall furnish an operations and Maintenance Manual highlighting the steps that are to be taken by

the operator in the event of occurrence of such an event.

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Back – up storage of the software

In the event of the software getting non-operative / corrupt due to some reason the operator should be capable

of re-loading the same into the PLC system.

The Bidder shall, therefore, included in his scope suitable back-up system such as a CD (with a drive)

Completeness of the System

If the Bidder feels that based on his experience certain additional hardware / software is required to be included

by him to make the system fully operation, he shall offer the same, highlighting the particulars.

Software

The sequencing logic shall be either ladder diagram based or execution statement based. It is preferable that

the operator is in a position to edit the logic or add the ladders / execution statement from his PC with the help

of keyboard or mouse.

Power supply

The Purchaser shall make available power at 240V, Single phase, 50 Hz or 415 V, 3 ph., 4 wire, 50 Hz,

depending on the KVA requirement of the PLC system.

The industrial (plant power distribution) power supply is prone to frequent failures, is subject to over voltages /

under voltages and is likely to be contaminated by spurious noise signals, spike etc.

The Bidder shall clearly state in his Bid whether the above mentioned power supply is acceptable to his system,

in which case he has to elaborate the arrangements made by him in his PLC input power supply system.

If the Bidder requires conditioned and UPS power supply for his system,

He shall include adequately rated UPS system operating on the abovementioned Industrial type power supply,

with adequately rated (AH capacity) sealed Maintenance – Free batteries.

Other power supplies such as 12 / 24 V DC or as required, for the electronics system of the PLC, in any case

will have to be derived by the Bidder himself. Necessary power packs and other hardware required for this

purpose will have to be included by the bidder in his scope.

Earthing

The Bidder shall clearly spell out the requirement of earthing, both panel frame earthing and signal earthing in

his bid. He shall highlight the requirement of “Clean Earth” if required. He shall also furnish specifications i.e.

size and shielded / unshielded cable for interconnection between PLC system and earth pits.

Training

The Bidder shall include in his scope training of Purchaser’s operating staff for a period of 5 working days. The

training shall cover a minimum of

EQUIPMENT DESIGN

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SPECIFICATIONS FOR


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Rev-R0


Familiarization of configuration of the PLC system.

Familiarization and working of the software including the procedure for loading of the software from

back-up storage system, editing of / modifications to the preloaded software.

Actual operation of the DG system including the VCBs from the PLC.

Fault diagnostics and trouble-shooting

Repair of the faulty PCB / replacement by spare PCBs etc.

10 BIDDER’S EXPERIENCEThe Bidder shall furnish a reference list to establish his credentials by way of submitting a list of at least 5 nos.

industrial type projects executed in last 3 years of similar ratings.

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XVI. TESTS

Tests shall be carried out during and after completion of manufacture of different component parts and

the assembly, as applicable, in accordance with the requirement of relevant codes and standards.

Bidder shall indicate other tests, which are required to be carried out at site after installation.

Tests shall be performed in presence of Purchaser's representative if so desired by Purchaser, at

Supplier's works on completed assembly of the DG set. The Bidder shall give at least two (2) weeks

advance notice for inspection.

Following tests shall be carried out on the engine-generator completed assembly at manufacturer's works:

a) Power run of auxiliary equipment.

b) Functional checks and adjustments of speed governor and control devices.

25.1 The generator shall be subjected to following tests (for which only Test Certificates are required):

a) High voltage tests on stator and rotor windings.

b) Insulation resistance of stator and rotor windings.

c) Temperature rise test

d) Open circuit and short circuit tests.

e) Stator phase sequence check.

f) Overload capability test.

g) Measurement of air gap.

h) Stator winding resistance measurement

25.2 Excitation System

The excitation system shall be subjected to the following tests at manufacturer's works (for which only Test

Certificates are required):

a) High voltage tests on windings.

b) Insulation resistance of windings.

c) Temperature rise test.

d) Measurement of resistance of stator and rotor windings.

e) Open circuit magnetization test.

f) Functional check and operation of relays, protection, metering and signalling schemes.

25.3 Voltage regulator

The voltage regulator shall be subjected to the following tests at manufacturer's works (for which only Test

Certificates are required):

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a) Sensitivity test.

b) Response time test.

25.4 Control Panels

The control panels shall be subjected to the following tests at manufacturer's works, which shall be witnessed

by the Purchaser/ his representative.

a) Continuity Checks

b) High voltage withstand test as per relevant standard.

c) Insulation resistance test.

d) Functional and operation test.

25.5 D.G. set and the auxiliaries

D.G. set and the auxiliaries shall be assembled at the manufacturer's works and the following tests shall be

performed, which shall be witnessed by the Purchaser/ his representative.

a) One (1) hour running at full load.

b) One (1) hour running at 3/4 load.

c) One (1) hour running at 110% full load.

d) Engine starting time.

e) Fuel consumption test.

Before each test, the engine shall be brought to a steady state under the conditions of the test.

25.6 Tests at Site

The tests shall be performed after proper installation of the diesel generating unit at site to prove the proper

operation of interlock circuits and the capability of the engine to start and pick-up load in the specified time,

under supervision of the purchaser's representative responsible for supervision of testing and commissioning.

Guarantee tests to prove guaranteed performance of the D.G. set shall also be carried out at site after proper

installation.

25.7 Test Certificates

a. Test certificates shall be submitted in six (6) copies.

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SPECIFICATIONS FOR


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b. The test certificates shall be furnished to the purchaser for prior approval before despatch of any

equipment from works and the approval in writing from purchaser shall be essential to effect dispatch of the

equipment.

c. The test reports shall indicate complete identification of the data, including serial number of each

equipment.

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SPECIFICATIONS FOR


DOCUMENT NUMBER


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XVII. MAINTENANCE TOOL AND TACKLES

The Bidder shall furnish to the purchaser a complete and unused set of all special tools and tackles,

which are necessary or convenient for erection, testing and commissioning, maintenance and

overhauling of any of the equipment provided under this specification.

The tools shall be shipped in separate containers clearly marked with the name of equipment for which

they are intended.

The Bidder shall submit a list of tools proposed to be furnished under the scope of supply with his

proposal.

XVIII. SPARES

Adequate quantity of spares for DG sets, shall be provided by the bidder for maintenance of the Dg sets at

least for 2 years after successful commissioning.

The bidder shall submit a list of recommended spare parts, with suggested quantities and catalogue numbers,

for ten(10) years smooth and trouble free operation.

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SPECIFICATIONS FOR


DOCUMENT NUMBER


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XIX. DRAWINGS AND DOCUMENTS SCHEDULE

A. FOR GENERATOR CONTROL & BREAKER PANEL

Documents shall comprise but not limited to the following:

Required after Purchase Order

Engineering Data Require

d

With

Bid-Qty

For

approval

Qty

No. of

weeks

As

built

Qty

No. of weeks

1 Outline dimension drawing 2 4 2 6 6

2 Cross sections with part description

3 Foundation drawings with static & dynamic

loading data

2 4 2 6 6

4 Completed Data Sheets 2

5 Bill of Materials for scope of Supply 2 4 2 6 6

6 Performance Data /Curves:/Discharge

curves

2

7 Installation / Operation / Maintenance

Manual

3 With dispatch

8 Priced Spare List for 10 years service 2

9 Terminal point schedule / drawing 4 2 6 6

10 Control Schematic Diagram 4 2 6 6

11 Description of Control Sequences

12 Type test certificate for short circuit

withstand for panel

2

13 Type test certificate for short circuit

breaking current of circuit breaker

2

14 At the time of inspection 6 At the time of

inspection15 Test Certificates for bought out items 6

EQUIPMENT DESIGN

ENGINEERS

SPECIFICATIONS FOR


DOCUMENT NUMBER


Rev-R0


(Breaker, CT, PT, Meter, Relay)

EQUIPMENT DESIGN

ENGINEERS

SPECIFICATIONS FOR


DOCUMENT NUMBER


Rev-R0


B. DRAWING AND DOCUMENTS SCHEDULE FOR DG SYSTEM

Documents shall comprise but not limited to the following:

Required after Purchase Order

Engineering Data Reqd

With

Bid

For

approval

Qty

No.of

weeks

As

built

Qty

No.of weeks

1 General arrangement drawing showing all

major dimensions, including clearances

required and crane requirement for

assembly & dis- mantling, nett & shipping

weights of all items of equipment.

2 4 2 6 6

2 Recommended layout showing room

dimensions, ventilation requirement civil

foundations, loading data, trench, wall

opening, etc.

2 4 2 6 6

3 Schematic P & I diagrams for lube oil, fuel

oil, jacket cooling, etc.

2 4 2 6 6

4 Schematic diagrams for control panel,

synchronising panel, voltage regulator,

governor

2 4 2 6 6

5 Literature, write ups, description of DG set

excitation system, voltage regulator,

governor & other auxiliaries

2 4 2 6 6

6 Voltage dip calculations - 4 2 6 6

7 Test reports - - - 6 Before

despatch

8 Generator characteristic curves yes 3 2 6 6

9 Bill of material 2 4 2 6 6

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