Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9016 Date 09-Jun-12 Page 1 of 24

EMERGENCY DG SET

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

Unit: Discipline: Document Type:

General Electrical Specification

Document Title:

SPECIFICATION FOR EMERGENCY DG SET.

ISSUED FOR DESIGN

06 Aug 2012

1
0 Revision

30-Jul-12
09-Jun-12 Date

Issued for Design

Issued for RFQ Purpose

RR RR Prepared By

NG NG Checked By

VP VP Fluor BASF

Approved By

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Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

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EMERGENCY DG SET Record of Revisions

This specification has been revised as indicated below and described in the revision record on the following page. Please destroy all previous revisions. Revision No. 0 Date Description

09-Jun-12

Issued for RFQ

30-Jul-12

Issued for Design

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Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

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EMERGENCY DG SET 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. 1.11. 1.12. 1.13. 1.14. 1.15. 1.16. 1.17. 1.18. 1.19. 1.20. 1.21. 1.22. BATTERY AND CHARGER ................................................................................................................. 13 AMF CONTROL PANEL ...................................................................................................................... 14 NEUTRAL EARTHING RESISTOR ..................................................................................................... 17 TESTS................................................................................................................................................... 17 COMMISSIONING CHECKS................................................................................................................ 19 MEASUREMENT OF VIBRATION ....................................................................................................... 20 NOISE LEVEL (SOUND PRESSURE LEVEL) CHECK ...................................................................... 20 INSTALLATION OF DG SETS............................................................................................................. 20 TRIAL OPERATION ............................................................................................................................. 21 TAKING OVER ..................................................................................................................................... 21 PERFORMANCE TEST OF THE SET ................................................................................................. 22 PERFORMANCE GUARANTEE .......................................................................................................... 22 DRAWINGS & DOCUMENTS .............................................................................................................. 23

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EMERGENCY DG SET 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, inland transportation, transit insurance, delivery to site, supervision of erection, testing and commissioning for Emergency Diesel Generator Set complete with all accessories, auxiliaries and ancillaries as specified hereinafter and as required for safe and trouble free continuous commercial operation, in a manner acceptable to the Owner. The scope covers supply of all the material and services required to make the installation complete in all respect. 1.2. INTENET OF SPECIFICATION 1.2.1. This specification is intend to cover the following activities and services in respect of Emergency 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 specified format etc for owners review approval and records Packing, transportation and insurance from the manufacturers works to the site including customs clearance/port clearance if required Testing & commissioning and Supervision of erection at site (Erection of EDG 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 design and complete in all respect. Any material and component not specifically stated in this specification and which is necessary for trouble free operation of the equipment and accessories specified in this specification shall be deemed to be included unless specifically excluded. All such equipment and accessories shall be supplied without any extra cost. It is not the intent to specify completely herein, all aspects of design and construction of equipment. Nevertheless, the equipment shall conform in all respects to high standards of engineering, design and workmanship and shall be capable of performing in continuous commercial operation in compliance to the requirements mentioned in various documents. Any deviation or variation from the Scope requirement and/or intent of the specification shall be clearly defined under Deviation Schedule of the Bid Proposal Sheets irrespective of the fact that such deviation/variations may be standard practice or a possible interpretation of the specification by the Bidder. Except for these
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1.2.3.

1.2.4.

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EMERGENCY DG SET deviations/variations covered under Deviation Schedules which are accepted by the Owners 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 deviation submitted by the Bidder with his proposal shall be considered. Bids not complying with 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 be performed by the Bidder, shall be binding, unless specifically clarified otherwise by the 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 for testing and commissioning of Emergency DG at site Bidder shall supply all the inserts required for fixing the equipment including the foundation bolts before concreting and shall furnish complete data required to design the foundation. Contractor should ensure supply of all foundation bolts at site within one month from the date of approval of foundation drawings and foundation bolts drawing or six months before dispatch 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 successful commissioning and operation of the equipment being procured under this specification. 415V, 3 phase AC power supply. The erection of Emergency Diesel Generator Set supplied under this package 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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EMERGENCY DG SET 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 all cables. Cable & Cabling between bidders equipment All lubricants for first filling, consumables and touch up paints etc for commissioning Acoustic enclosure meeting the statuary requirements. Necessary ventilation along with necessary starters & lighting shall be provided. Any equipment/material required to make the installation complete in compliance to the RFQ requirements

1.3.4.

Terminal Points Power cable terminals at DG phase side terminal box suitable for termination of 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 Bidders scope. 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 the latest editions including all applicable official amendments and revisions as on date of opening 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 shall conform to the requirements of the following standards and codes: Diesel Engine IS -10000, BS- 5514 and As Per Standard Practice Of Diesel Engine Manufacturers Association Of USA. IS-4722/ IEC-60034, IS-12065, IS-12075 IS-15217 IS-1460. IS-2629 IS- 2633

Generator Fuel oil for DG Set Diesel fuels Recommended practice for hot-dip galvanizing of iron and steel. Methods for testing uniformity of coating of zinc coated articles

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EMERGENCY DG SET 1.4.2. The installation work shall conform to Indian Electricity Act and Indian Electricity Rules as amended up to the date this specification is issued. Any approval required from statutory authorities shall be obtained by the Contractor. Nothing in this specification shall be construed to relieve the Contractor of this responsibility. In case of any contradiction between various referred standard/ specification/data sheet and statutory regulations, it shall be brought to the notice of Client for resolution and no assumptions shall be made. Generally the following order of priority shall govern: 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 shall meet 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. The DG set shall be capable of generating minimum 2.4 MW (net power output excluding its own auxiliary power consumption) 3.0 MVA at 0.8 p.f. power at generator terminals under specified site condition. Contractor to provide documentary proof to prove that the suggested model can deliver the required power. The engine/prime mover shall be capable of 100% rating at specified site temperatures The DG set shall be rated for stand by operation throughout the year. All components of the DG set shall be proven ones for trouble free continuous operation. The owner reserves the right to reject the DG set in following conditions: Actual consumption during performance test at site exceeds the guaranteed value by 5%. Actual output falls below 2.4 MW (3000 KVA@0.8 p.f.) at site condition. 1.5.6. However, Bidder will be given opportunity to rectify the defect in reasonable time and the DG set may be accepted if it passes the tests successfully after rectification. The DG Set shall be located inside the acoustic enclosure. The contractor shall recommend his own layout and indicate the space requirement along with the proposal

1.4.3.

1.5.2.

1.5.3.

1.5.4.

1.5.5.

1.5.7.

1.5.8. 1.5.9.

The exhaust shall be discharged through a silencer and stack outside the enclosure. All live parts shall be adequately protected to prevent inadvertent or accidental contact.

1.5.10. The painting offered on all the equipments shall be suitable for specified environment in the complex. Bidder shall furnish a reference record of proven equipment operation
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EMERGENCY DG SET success in a similar corrosive chemical environment. All hardware of mild steel shall be electro-galvanized. 1.5.11. Maintenance and erection tools and tackles for all the equipment shall be provided by the 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 for bidders equipment shall be carried out by the bidder. Necessary starters for ventilation fans/ exhaust fans/ priming pump motors etc. shall be in the bidders scope along with necessary AC distribution board, cables and cabling. Distribution board shall be metal enclosed, compartmentalized, wall/structure mounted and shall be fabricated out of cold rolled sheet steel of thickness 1.6mm with degree of protection 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 starting shall be local as well as from the AMF-cum-control panel while automatic starting shall be suitable for impulse from owners remote PCC. On failure of mains supply, the D.G. set shall start automatically with the help of quick start Auto-Mains-Failure (AMF) circuit of the control panel. The engine starting system 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 start the D.G. shall be 30 secs even after 3 starting attempts. The first step loading shall be at 10 seconds & shall be able be able to start an estimated load. If the engine fails to 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 manual operation 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 the following large motors starting conditions without exceeding the limits of voltage & frequency dip stipulated below and the bidder alongwith the bid shall furnish detailed calculation / curves to prove the same. Condition of DG Set i) When the set is running at no load condition at cold condition. When the set is loaded at about 50%. When the set is loaded at about 70%. Rating of load to be switched 550 KW motor at 6.6 kV. Voltage (soft starter) with base load of 240 KW (via trafo. of 1.6 MVA) 425 KW motor at 6.6 kV. Voltage (soft starter). load of 480 KW (via trafo. of 1.6 MVA).

ii) iii)

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EMERGENCY DG SET 1.6.3. The DG set shall be capable of taking an overload of 10% for one hour once in every 12 hours of continuous running. All couplings shall be capable of withstanding the maximum generator sudden short circuit torque. Critical speed of the machine shall not be lesser than 120% of the normal speed.

1.6.4.

1.6.5. 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, complete cooling system, complete lubricating oil system, fuel and air supply system with filters, starting system, governing system, safety controls, instrument panel, fuel tank, battery & leads, battery charger, AMF-cum-control panel, AVM pads and all auxiliaries as required for safe and proper operation of set. DG set shall be controlled independently through separate control panel. The unit shall have integrated control with automatic starting sequence from the manually initiated command from a single push button. It shall also have auto initiation through command from remote from owners panel. The DG set shall also issue automatic closing command to its supply receiving breaker on achieving rated voltage and frequency on its terminals when controlled from remote. Necessary voltage and frequency relays for the purpose shall be included in the offer. Electrical self starting system shall be provided, the source of energy shall be batteries backed up by battery chargers which shall be supplied by the Contractor. The fuel oil system and the lubricating oil shall also start operating simultaneously and automatically as soon as a starting impulse is received to obviate any chance of seizure 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 level of 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 with BS: 5514, IS: 10000, IS: 10002, ISO: 3046 and DIN: 6271. Diesel engine shall be mounted on visco damper type vibration dampening system and shall be complete with integral air intake through dry type air filters and exhaust systems, metering facility, speed regulation system, fuel injection system, lube oil

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EMERGENCY DG SET 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 substantially constant even with sudden variation in load. However a tripping shall be provided even 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 pump through an oil cooler and fin mesh filters to the end bearing, camshaft bearings, camshaft chain and gear drives, governor, air starting, distribution, auxiliary drive gears etc. In case manufacturers recommend lube oil pump for intermittent priming, one hand driven and one electric motor driven oil priming pump shall be provided for each DG set. In case of electric driven pump suitable rating starter shall be provided in control panel. All necessary accessories like pressure gauges, temperature and oil level indicators, pressure relief valves, bypass valves, pressure switches for alarm and control shall be 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 for period 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 other accessories to make the installation complete. The fuel consumption of the engine at full and three quarters of its rated power output shall be indicated by the bidder. A day oil tank of 990 litres fuel capacity shall be provided by the bidder, mounted on fabricated steel platform outside the acoustic enclosure. The tank shall be complete with level indicator marked in Litres, two nos. of level switches, filling inlet with removable screen, an outlet, a drain plug, an air vent and necessary piping. The fuel tank 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 air cooled type. The generator shall conform to IS 4722 or IEC-60034.

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EMERGENCY DG SET The specified rating of the alternator shall be net output at the specified ambient conditions (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 is required when the alternator is operating at full speed. The alternator shall be provided with automatic voltage regulator which will maintain the static voltage of the alternator within specified limits at all loads and the power factor between 0.8 and 1.0. Space heater rated for 240V AC shall be provided to keep winding dry during idle periods. The alternator shall be designed for direct coupling with the engine specified above and shall match the same in all respects The alternator with its exciter shall be totally enclosed air cooled and suitable for IP54 protection 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 stator and rotor windings core insulation and all connections including main and neutral leads shall have class-F or class-H insulation epoxy thermosetting type with temperature rise limited to class-F or class-H insulation respectively as per in IEC60034 Pt.-I. The winding shall be given power house treatment i.e. two coats of varnish and backing 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 or adjacent to winding shall not exceed the specified limits. The alternator shall be provided with six numbers of embedded resistance temperature detectors (RTDs) for measurement of winding temperature. Three of these shall be provided between the coils, one in each phase and the other three at the base of the slots, placed 120 degree apart. In addition to these, two numbers RTDs shall be provided for bearing temperature measurement. These RTDs shall be of platinum having 100 ohm resistance at 0 Deg.C and temperature coefficient as 3.85x10^5. The RTDs shall be three lead type having power 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. The terminal boxes shall be dust tight, weather proof having degree of protection of IP-42 as per IS: 13947.

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EMERGENCY DG SET The terminal box shall be of sufficient size to conveniently terminate the size and number of cables which shall be intimated later Suitable tinned copper pads shall be provided for power cable termination. For single phase cables gland plate shall be of nonmagnetic material and shall be removable type. Rolled aluminium or Nickel/Cadmium plated brass, heavy duty, double compression type cable glands, shall be mounted on removable gland plate. As far as possible connection between exciter and alternator shall be contained within the machine frame and connections carrying AC and DC current shall be segregated from each other. The necessary CT's for differential protection shall be provided on neutral side. The neutral point shall be brought to DG control panel and shall be connected to 300/100V VT, to be supplied and mounted inside the DG control panel by the bidder for earth fault detection 1.7.8. EXCITATION SYSTEM The generator shall be provided with complete excitation system capable of supplying the excitation current of the generator under all conditions of output from no load to full load and capable of maintaining voltage of the generator constant within +/- 1% of set value. The setting range available on voltage regulator shall be at any value with +/- 10% of the 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 and the temperature shall not exceed the values specified in IEC-60034 Part-I for different parts 1.8. SOUND PROOFING SYSTEM 1.8.1. Bidder shall furnish design calculation for sound proofing/ ventilation system. The detailed frequency response for noise absorbing characteristic of acoustic material shall be furnished. The sound absorptive layer shall comprise of bonded type mineral wool/glass wool of adequate thickness and density to comply the design requirements. DG shall be placed in acoustic enclosure. The requirements of acoustic enclosure are 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 facilitate dismantling as required for maintenance. The frame shall be of sufficient stiffness and rigidity. The enclosure shall be suitable for outdoor duty. The sheet and all sections shall be powder coated shade of grey RAL9002. DG set and control panel shall be located inside the enclosure. A minimum clear space of 800mm shall be kept inside the enclosure all round the DG set.

1.8.2.

1.8.3.

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EMERGENCY DG SET The exposed surface of lining shall be retained in place by minimum 1.0mm thick CRCA/ Aluminium perforated sheet. Absorptive lining shall be provided between the perforated sheet and absorbing material. Necessary acoustic sealing shall be done in the panels/ modular unit joints. Enclosure shall be provided with adequate lighting. Enclosure shall be provided with adequate number of door and viewing glass. The door design shall be compatible to the enclosure design. The bonded mineral wool slab of adequate thickness shall be used. The door shall be provided with heavy duty hinges and handles. The sealing shall be done with neoprene/ silicon rubber gasket to avoid leakage of noise. The size of the door shall be as per the room design/ 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 bidders scope

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EMERGENCY DG SET 1.9. VENTILATION SYSTEM 1.9.1. Ventilation system of adequate capacity shall be provided. The system shall comprise of tubular axial flow fans for air intake and air exhaust with splitter silencer. The ventilation shall be design to ensure required air flow rate as per manufacturer recommendations, after providing necessary acoustic treatment/ silencers in air flow path. The ventilation system shall be design to prevent leakage of sound and temperature shall not increase by more than 5 degree centigrade when DG is running continuously at specified rating. The construction of ventilation duct shall be from 1.6 mm thick CRCA perforated sheet. Other constructional details shall be similar to that of the enclosure/ room acoustic treatment The exhaust air from radiator shall be discharge through modular duct of adequate size.

1.9.2.

1.9.3.

1.9.4.

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 to recharge the battery within ten hours. The battery for starting the engine shall be capable 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 the control panel and an automatic voltage stabilizer to enable it to work satisfactorily when 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 battery gradually charges up. The minimum voltage at the end of load cycle shall not be less than 1.75 volts per cell. The charger shall be protected by a suitable current limiting device. 1.10.3. Bidder shall size the battery to meet these requirements. Bidder shall submit Detailed battery sizing calculation in accordance with IEEE- 485 for Lead Acid type battery (as applicable, to support the Battery AH capacity selected). The ageing factor shall be taken as 1.25, temperature factor shall be considered at minimum design temperature of 5C and an additional design margin of 20% shall be considered while calculating the battery size for both type of batteries. Battery discharge characteristic curves, temperature correction factors etc. shall be furnished by the Bidder along with the sizing calculations for Owners approval. Battery and battery charger shall also feed 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 shall incorporate all controls required for starting, monitoring, regulating and stopping DG set. It shall be equipped with all necessary instrumentation to provide adequate surveillance of DG set under all operating conditions including Standby. 1.11.2. The local control panel shall be of robust construction, floor mounting, free standing type made of 2.0 mm thick cold rolled sheet steel. Neoprene gaskets shall be

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EMERGENCY DG SET provided between all openings and joints. The control panels shall have IP-52 degree of 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 be 96mm X 96mm size. 1.11.3. The control panel shall be of unit type construction, compact and neat, provided with hinged door with locking arrangement. 1.11.4. All cables shall have bottom entry. Enough space shall be provided in the control panel for easy access during maintenance and repairs. 1.11.5. A tinned copper/ aluminium bar of adequate dimension shall be provided for earth connection complete with nuts and bolts as required for external connection to Employers 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 equipment mounted inside the control panel shall be identified by lamicoid labels/ stenciling by paint. 1.11.8. Panel shall be provided with panel illumination lamp operated by the door switch and thermostat-controlled space heater. Control panel shall be furnished complete with all accessories 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 restrained type), residual earth fault, IDMTL standby earth fault, restricted earth fault, field failure, over/under voltage with timer, over/under frequency with timer, reverse power, winding temperature alarm & trip and bearing temperature alarm & trip with suitable temperature scanner. On occurrence of any type of fault, tripping command to remote circuit breaker shall be sent through a hand reset type high speed lockout relay. In place of separate relays for different types of above mentioned protections, a combined generator management device can also be provided. Suitable current transformers (CTs) shall be provided for the protective relays. Accuracy class of the CTs 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) ii) iii) iv) Starting and stopping of the set. Fine adjustment of speed. Adjustment of output voltage. Local / remote selectors switch to facilitate remote starting / stopping, speed & voltage control. D.C Ammeter and D.C Voltmeter for 24 V DC system for charger circuit.
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v)
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EMERGENCY DG SET vi) vii) DC Voltmeter for 110V DC system. Voltmeter and Ammeter for diesel generator output along with selector switch. Watt-hour meter & Wattmeter. Frequency meter. Auto manual selector switch for priming pump motor (if required). The requirement of CT, VTs, relays, timers, auxiliary contacts shall be as per the system requirement but not limited to the enclosed control schemes. The bidder shall supply any other controls and indications for diesel generator set though not specifically mentioned here but which the supplier may recommend and are required to make system complete for satisfactory operation of DG sets.

viii) ix) x) xi)

xii)

1.11.12. The diesel generator sets would normally be controlled from remote for which following provisions shall be made on the control panel. i) ii) iii) iv) v) Starting and stopping of the DG set Speed control of DG set. Voltage control of DG set. Indication of the DG set under operation. Start/ Stop Raise/ Low Raise/ Low DG ON

Suitable 4-20mA transducers with dual output shall be provided in the control panel for KW, KVAR, Ammeter, voltmeter, Power Factor & frequency meter for owners use at remote. The bidder is required to provide coupling relays (with diodes) having 24V DC 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

vi)

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Specification G3IR-1050-65-SP-9016 Date 09-Jun-12 Page 17 of 24

EMERGENCY DG SET 1.11.13. Provision for following status/ signal for Employer's information shall be provided in the DG control panel: i) ii) iii) iv) v) 1.11.14. DG fails to start. DG start command actuated/ reset. DG working/ stop signal. DG trouble/ normal signal. DG control supply failure/ normal signal. 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 for each of the following in control panel: i) ii) iii) iv) v) vi) vii) viii) ix) x) xi) xii) xiii) xiv) xv) 1.11.15. AC supply, 110V DC & 24V DC supply healthy (indication only). Fail to start (Alarm) Lube oil pressure low (Trip) Over Speed (Trip) High cooling water temperature (Trip) Charger ON/OFF (Indication only) Fuel level low in day tank (Alarm) Fuel level very low in day tank (Trip) Alternator stator temperature high (Alarm) Electrical protection operated (Trip) Incomer to emergency switchgear from DG closed. Earth fault (alarm) input from owners switchgear. Priming pump tripped alarm Priming pump Emergency stop (indication only) Engine start / stop (indication only) Indication and Annunciation

Indicating lamps shall be of the panel mounting LED type with series resistor and of low power consumption. Lamps shall be provided with series resistor built-up lamp assembly.
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EMERGENCY DG SET Necessary pressure switches, level switches, thermostats, flow switches, auxiliary relays, 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 grounding resistor (NGR) so that the maximum earth fault current through the resistor & stator winding is limited to 400 Amps (suitable for 10 Sec with maximum temperature rise limited 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 steel AISI 304 / AISI 410. 1.12.4. The resistor shall be housed in a free standing and self supporting metal enclosure suitable for outdoor installation having IP-34 degree of protection fabricated out of 1.5 mm thick sheet steel. The top of the enclosure shall be provided with rain protective hood. 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 connection and for removal of resistor banks. 1.12.6. The enclosure shall be provided with lifting eye bolts on the top and cable connection on side with bottom entry facility. Terminal box shall have minimum IP 55 degree of protection. 1.13. TESTS 1.13.1. All equipments to be supplied shall be of type tested quality. The Contractor shall submit for Owners approval the reports of all the type tests as listed in this specification and carried out within last five years from the date of bid opening. These reports should be for the tests conducted on the equipment similar to those proposed to be supplied under this contract and the test(s) should have been either conducted at 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 within last five years from the date of bid opening, or in the case of type test report(s) are not found to be meeting the specification requirements, the contractor shall conduct all such tests under this contract free of cost to the owner and submit the reports for approval.

1.13.3. All acceptance and routine tests for Engine, Alternator, Battery and Battery charger as per the specification and relevant standards shall be carried out. The oil tank shall be tested for leakage test and enclosures to meet specified degree of protection. The assembled DG set tested for load, noise and vibration tests. Charges for these shall be 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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EMERGENCY DG SET 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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EMERGENCY DG SET During the load test half hourly records of the following be taken: i) ii) iii) Ambient temperature. Exhaust temp. if exhaust thermometer is fitted. Cooling water temp. at a convenient point adjacent to the water output from the engine jacket. iv) v) vi) vii) viii) Lubricating oil temp. where oil cooler fitted. Lubricating oil pressure. Speed. Voltage, wattage and current output. 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) ii) iii) iv) Functional tests on control panel. Functional tests on starting provision on the engine. Functional tests on all field devices. Functional tests on AVR and speed governor.

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EMERGENCY DG SET 1.15. MEASUREMENT OF VIBRATION The vibration shall be measured at load as close to maximum achievable load and shall be as per 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 sets shall be carried out by the Contractor strictly in accordance with the applicable Codes of practice, statuary requirements, local rules & regulations, the manufacturer's instructions, 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 other accessories, starting equipment (Battery & battery charger), fuel oil tank and fuel oil piping up to the DG sets. 1.17.3. The D.G.Set shall be started and commissioned in the presence of the owner and should 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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EMERGENCY DG SET 1.18. TRIAL OPERATION 1.18.1. The duration of trial operation of the D.G. Set shall be spread over for different loads out 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 trial operation shall be considered successful, provided that each item of the emergency generation system can operate continuously at the specified operating condition for the period of trial operation. 1.18.2. For the period of trial operation, the time of operation shall be counted. In case of interruption 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 parameters to 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 shall also include the dates and times of start and finish of the trial operation and shall be signed by the representative of both owner and bidder and recording of all the details of interruptions occurred, adjustments made and any minor repairs done during the trial operation shall be made by bidder. Based on the observations, necessary modification / repairs to the system shall be carried out by the bidder to the full satisfaction of the owner. 1.18.4. After a successful trial operation, the bidder shall demonstrate the reliability of the complete 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 or any part tripping on account of reasons attributable to the bidder, the reliability run shall start a fresh for 7 days period after rectification of the cause of failure by the bidder. The onus of proving that any failure is not due to faulty design, materials or workmanship will lie with the bidder. 1.18.7. During the reliability run the bidder shall demonstrate satisfactory running of various systems at the specified parameters. 1.18.8. A report, comprising of observations and recordings of various parameters noted during reliability run, shall be submitted by the bidder to the owner. 1.18.9. On successful completion of the reliability run together with having obtained clearance from the statutory authorities, the bidder shall inform the owner in writing that 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 after evaluation of the performance guarantee test report and acceptance of the same by owner. 1.19.2. The responsibilities for prime satisfactory performance of the D.G. Set and associated facilities at rated capacities shall be that of the bidder, irrespective of the fact that certain plant items or system might have been taken over earlier by the owner and guarantee shall commence from the date of taking over of the entire system by the owner or mutually agreed with owner.

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EMERGENCY DG SET 1.19.3. The bidder shall carry out all necessary repairs / modifications on erected equipment which 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 the load made available by the vendor at 25%, 50, 75% &100% of the full load. All consumables shall be in the scope of the vendor. 1.20.2. During the above test, the temperature rise of all electrical components shall be within the limits prescribed by IEC for the relevant insulation classes. All control and governor 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. 1 2 3 Parameters Net continuous output excluding own auxiliaries Engine BHP Fuel Consumption 100% load at Guaranteed 2.4 MW minimum at 0.8 PF at battery limit Bidders declared value at 45 Deg.C Bidders declared value Acceptance No shortfall is acceptable No shortfall is acceptable Shall not exceed + 5%. For every 1% increase beyond 5%, a penalty of 2% of the DG set cost subject to maximum of 5% shall be imposed No deviation acceptable

Starting Time

10 Seconds (Max.)

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EMERGENCY DG SET

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 specified ambient 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 by manufacturer Rated BHP of engine at 45 Deg.C after deduction of mechanical auxiliary loads connected on engine shaft. Efficiency & Power factor of alternator at 100% load to calculate the output of DG 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 the manufacturers. 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.

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