TECHNICAL SPECIFICATION

FOR

SUPPLY, INSTALLATION, TESTING AND COMMISSIONING

OF 11KV, 3000 KVA (750KVA x 2 + 1500KVA) DIESEL
POWER GENERATING MACHINES WITH AUTO
SYNCHRONISATION FACILITY
FOR THE PROJECT
OF

BHARAT DYNAMICS LIMITED

BHANUR
MEDAK DISTRICT, A.P.

GENERAL SPECIFICATION FOR D.G SET

1.0

SCOPE OF ENQUIRY

1.1

The general character and the scope of work to be carried out under this
contract is illustrated in Drawings, Specifications and Schedule of
Quantities. The Contractor shall carry out and complete the said work
under this contract in every respect in conformity with the contract
documents and with the direction of and to the satisfaction of the Project
Manager. The contractor shall furnish all labour, materials and
equipment as listed under Schedule of Quantities and specified
otherwise, transportation and incidental necessary for supply,
installation, testing and commissioning of 1NO. OF 11KV, 1500KVA
AND 2NOS OF 11KV, 750 KVA D.G SET With Auto Synchronisation
Facility for Bharat Dynamics Limited, Bhanur, Medak district, A.P.
as described in the Specifications and as shown on the drawings. This
also includes any material, equipment, appliances and incidental work
not specifically mentioned herein or noted on the Drawings/Documents
as being furnished or installed, but which are necessary and customary
to be performed under this contract.
The scope of specification covers the design, manufacture, inspection
and testing at vendors / sub vendors works, packing, transportation
from place of manufacture to site, unloading and storing at site, complete
erection, testing and commissioning of various electrical equipment
required for operation of 1NO. OF 11KV, 1500KVA AND 2NOS OF
11KV, 750 KVA D.G SET With Auto Synchronisation Facility for
Bharat Dynamics Limited, Bhanur, Medak district, A.P.
The design, material, construction, manufacture, inspection, testing and
performance of all equipment shall comply with all currently applicable
standards, statutory regulations and safety codes in the locality where
the equipment will be installed.

1.2

The extent of scope under this contract includes all items shown in the
appropriate sketches and drawings not withstanding the fact that such
items may have been omitted from the specifications or schedules.

1.3

The scope of work is as follows but not limited to:

1. Diesel Generator complete with base plate, anti-vibration isolators
and all fixing accessories as required.
2. Acoustics for DG Room.

3. Auto Synchronising Control Panel with Auto start/stop and Auto load
sharing panel.
4. Exhaust piping, duly insulated with mineral wool and aluminium
sheet cladding.
5. Residential type Silencer, complete with GI supports, brackets
hardware etc.
6. Starting battery electrolyte in non-returnable containers complete
with stand and other accessories.
7. Day oil tanks in the case of diesel generator complete with supporting
stand, all accessories, filters, valves, fittings, level indicators, level
controllers with contacts.
8. MS pipes for fuel system, including all accessories, fittings, painting
of pipes and supports etc.
9. Hoisting and handling facilities such as cranes, tools and tackles
specially required for this kind of equipment and for lowering
equipment wherever it is to be installed.
10. Cables (HT)
11. Manual emergency hand pumps shall be provided in case of failure of
the automatic arrangements.
12. Supply and installation of Earthing System.
13. Internlocking and interconnection between DG PANEL and existing
11KV panel.
14.GENSET CONTROLS -

is a micro processor based generator set

monitoring, metering, protection and control system.

2.0

INSTRUCTIONS TO BIDDERS

2.1

Bidders shall submit all technical information and duly filled in data
sheets / schedules in soft form along with the bid.

2.2

Bidder is advised to visit the site and obtain all the data required and
other relevant details of existing facilities prior to submission of bid.
Ignorance of site conditions shall not be accepted as basis for any claim
for compensation.

2.3

All meters, instruments, gauges and other reference devices used for
testing/inspection shall have valid calibration certificate and the

accuracy shall be traced to national standards. Inspection by

PURCHASER/ENGINEER will not be carried out unless Vendor confirms
that calibrated equipment is ready for proceeding with the tests.
2.4

Bidders shall note that the design ambient temperature for all electrical
equipment is 50C.

2.5

CO-ORDINATION WITH OTHER CONTRACTORS AND AGENCIES

The contractor during the execution of the works shall co-ordinate with
other agencies associated with the project and shall work in harmony
with them without causing any hindrance or obstruction on the progress
of work in any way.
Other contractors and agencies that the contractor shall be required to
coordinate with are:
Internal / External Electrical Services Contractor
Contractors
regarding.

shall

co-ordinate

with

Electrical

services

contractor

Laying of cables on cable trays.

Lighting in the generator area

Interfacing with any works carried out by other electrical services

contractor.

Fire Alarm System Contractor

Co-ordinate with fire alarm system contractor to get the complete

information about the facility to be provided in the generator area.

Civil Works Contractor

To coordinate with civil works contractor to provide foundation,

sleeves, insert plates, supports, openings etc., necessary for the
power generating sets installation work in compliance with the
construction programme.

Plumbing & Water Supply Contractor

To collect and coordinate all the relevant information regarding

water supply and drainage pipes.

HSD TANK contractor

3.0

To collect and coordinate all the relevant information regarding

HSD supply and pipelines.

OPERATING INSTRUCTION & MAINTENANCE MANUAL

Upon completion and commissioning of DG set, the contractor shall
submit a draft copy of comprehensive operating instructions,
maintenance schedule and log sheets for all systems and equipment
included in this contract. This shall be supplementary to manufacturers
operating and maintenance manuals. Upon approval of the draft, the
contractor shall submit four (4) complete bound sets of typewritten
operating instructions and maintenance manuals; one each for retention
by Consultant and Owners site representative and two for Owners
Operating Personnel. These manuals shall also include basis of design,
detailed technical data for each piece of equipment as installed, spare
parts manual and recommended spares for 4 year period of maintenance
of each equipment. These manuals shall include:
i. Description of the work carried out / installed.
ii. Operating instructions.
iii. Maintenance instructions including procedures for preventive
maintenance.
iv. Manufacturers catalogues.
v. Spare parts list.
vi. Trouble shooting charts.
vii. Drawings
viii. Type and routine test certificates of major items.

4.0

INSPECTION AND TESTING AT MANUFACTURERS WORKS

The owner / consultant may carry out inspection and testing at
manufacturers works. No equipment shall be delivered without prior
written confirmation from Project Manager. Upon completion of work the
performance test shall demonstrate the following among other things:
i.

Equipment installed complies with specification in all respects and

is of the correct rating for the duty and site conditions.

ii.

All items operate efficiently and quietly to meet the specified

requirements.

iii.

All circuits are correctly protected and protective devices are

properly coordinated.

iv.

All non current carrying metal parts are properly and safely
grounded in accordance with the specifications and appropriate
codes of practice.

The contractor shall provide all necessary instruments and labour for
testing. He shall make adequate records of test procedures and readings
and shall repeat any tests requested by the Project Manager
/Consultant. Test certificate duly signed by a authorized person shall be
submitted for scrutiny. If it is proved that the installation or part thereof
is not satisfactorily carried out then the contractor shall be liable for the
rectification and retesting of the same as called for by the Project
Manager / Consultant. All tests shall be carried out in the presence of
representative of Project Manager / Consultant. The above general
requirements as to testing shall be read in conjunction with any
particular requirements specified elsewhere. The contractor besides
above test, shall carry out witness test for performance at full load for 6
hrs and one hour at 110% of full load.
The DG shall be tested in the presence of Owners representative at
Suppliers works in accordance with latest prevailing standards and
codes. The successful passing of any such tests will not however
prejudice the right of Purchaser to reject the DG and its accessories, if
they do not comply with specifications when erected or perform complete
satisfactory operation as intended. Supplier shall provide the test
certificate for the bought out items used, if any in the assembly of DG.
5.0

PRE-COMMISSIONING CHECKS AT SITE

All standards checks including the ones elaborated in the specifications
to ensure that the installation of the DG sets and associated systems has
been carried out satisfactorily shall be done on completion of installation.
These shall include.

5.1

DG sets

5.2

Exhaust system

- Checking of piping interconnections

Checking electrical interconnections
Checking of insulation resistance
Checking of earthing
Checking of instruments and controls.
Checking of alignment
Checking of vibration transmission to building structure.
Checking of expansion joints.

Checking of silencer operation

Checking of surface temperature of exhaust piping

5.3

Fuel system

 Checking of automatic operation of fuel transfer pumps.

5.4

General
Upon completion of work the performance test shall demonstrate the
following among other things:

6.0

i.

Equipment installed complies with specification in all respects and

is of the correct rating for the duty and site conditions.

ii.

All items operate efficiently and quietly to meet the specified

requirements.

iii.

All circuits are correctly protected and protective devices are

properly coordinated.

iv.

All non current carrying metal parts are properly and safely
grounded in accordance with the specifications and appropriate
codes of practice.

TRIAL RUN AT SITE

DG sets shall be tested at varying loads at site. The performance tests at
the works shall be carried out in presence of authorized representative
from the Clients.
The performance test on each DG sets shall be of minimum for 15 days
and 6 hours each day duration. It should also include measurement of
noise and emission as per standards and CPCB guidelines. Vibration
measurement shall also be done as per engine manufacturers
recommendation and ISO 8528 Part - 9.
All instruments, materials, consumables (fuel oil, lube oil etc.) load and
labour required for carrying out of the test shall be provided by the
Contractor.

7.0

MATERIALS AND EQUIPMENT

All materials and equipment shall conform to the relevant Indian
Standards and shall be of the approved make and design. Makes shall be
strictly in conformity with list of approved manufacturers as per
mentioned in Technical specification or BOQ.

8.0

COMPLETION CERTIFICATE
On completion of the Generator installation, certificate shall be furnished
by the contractor countersigned by the 11KV licensed electrical
supervisor under whose direct supervision the installation was carried
out. This certificate shall be in the prescribed form as required by the
local supply authority.

9.0

TRAINING OF
MAINTENANCE

OWNERS

PERSONNEL

FOR

OPERATION

AND

Upon completion of all work and all tests, the Contractor shall furnish
necessary operators, labour and helpers for operating the entire
installation for a period of fifteen (15) working days of ten (10) hours
each, to enable the Owners staff to get aquainted with the operation of
the system. During this period, the contractor shall train the Owners
personnel in the operation, adjustment and maintenance of all
equipment installed.
10.0

GUARANTEE
Upon complete of work and before issuance of certificate of virtual
completion by the Project Manager, the contractor shall furnish written
guarantee indemnifying the owner against defective materials and
workmanship for a period of one year after acceptance. The contractor
shall hold himself fully responsible for reinstallation and / or
replacement, free of cost to Owner the following:
a. Any defective work or material or equipment supplied by the
Contractor.
b. Any material or equipment supplied by the Owner which is damaged
or destroyed as result of defective workmanship by the contractor.
c. In case of failure of the supplier, to get any defect rectified within
forty eight (48) hours, the Owner reserves the right to get necessary
repairs done on his own at the supplier cost.

11.0

ENGINEER AND FOREMAN

The contractor shall employ a competent, fully 11KV licensed, qualified
full time electrical / mechanical engineer and foreman to direct the work
of installation in accordance with drawings and specifications. The
foreman shall be available at all times at site to receive instructions from
the Project Manager / Consultant for day to day activities throughout the
duration of the contract. The foreman shall correlate the progress of the
work in conjunction with all relevant requirements of the supply
authorities.

12.0

DEMONSTRATION TO OWNER
Upon completion, devices subject to manual operation shall be operated
atleast five times in presence of Project Manager Consultants to
demonstrate satisfactory operation.
The contractor shall provide performance tests upon completion of the
installation. He shall arrange all necessary instruments, tools and
tackles to check sound level, vibration and the effectiveness of acoustical
treatment and vibration isolator installed.

13.0

TOOLS AND TACKLES

The Contractor shall provide and install all necessary hoists, ladders,
scaffolding, tools, tackles, transportation of labour and materials
necessary for the proper execution and completion of the work to the
satisfaction of the Project Manager / Consultants.

14.0

APPROVAL & CLEARANCE

All associated activities required for necessary clearances / permissions
/ approvals / licenses from concerned authorities are in the scope of
Bidder.

15.0

POWER SHUTDOWN
The shall carry out the interlocking and interconnections works between
DG set auto synchronization panel and existing 11KV panel at MSDS
only duly designated 2 holidays between 10AM to 6PM with prior
intimation and permission.

16.0

SOURCE OF POWER SUPPLY

A single source of power supply shall be shown during of execution of
work from where necessary tapping arrangements shall be made by
contractor on chargeable basis for power needs of carrying out of work.

17.0

Structural Design and Structural stability certificate of Exhaust

pipes stack
The Contractor shall submit the structural design of Exhaust pipes stack
of height as per CPCB and local PCB norms to the concerned Civil
engineer for approval. After receipt of approval from Civil engineer, BDL,
the contractor shall start the erection works of stack. After completion of
stack works, the contract shall submit a structural stability certificate of
stack from GHMC approved structural engineer.

TECHNICAL SPECIFICATION
FOR
1NO. OF 11KV, 1500KVA AND 2NOS OF 11KV, 750 KVA D.G. SET
1.0

SCOPE
This specification covers the requirements of design, manufacture,
assembly, testing, delivery, installation and commissioning of ONE
(1NO.) OF 11KV, 3 phase, 50 c/s, 1500 KVA DG Set AND TWO (2Nos)
of 11KV, 3 phase, 50 c/s, 750 KVA DG Set, Diesel Generating sets
with Auto Synchronization Facility required for Bharat Dynamics
Limited, Bhanur, Medak district, A.P.

2.0

SITE CONDITIONS

2.1

Ambient Temperature

Maximum 45C
Minimum 10C

2.2

Relative Humidity

Around 60% at maximum

Temperature

2.3

Altitude

Around 1000 M above MSL.

3.0

ELECTRICAL SUPPLY PARTICULARS

3.1

System Voltage (Normal)

11KV

3.2

No. of Phases

3.3

Frequency

50 c/s

3.4

Fault level

40 KA at 11KV

3.5

Neutral Earthing

Solidly earthed

3.6

Auxiliary supply

12 V D.C. supply for D.G Set

starting Motor.

4.0

STANDARDS
The Diesel Generating set and accessories shall conform to the requirements of
latest editions of relevant India Standards some of are listed below: -

a.
b.

BS
IS

:
:

649
4722

Diesel Engines for general purposes

Electrical performance of rotating electrical
Machinery.

10

c.
d.

IS
IS
e.

5.0

:
:

2516
2147

Air Circuit Breaker

Degree of protection for LT Switchgear.

BS 5000, IS 1460, ISO 8528, BS 5514, ISO 3046

SCOPE OF WORK

Prime Power Rating (PRP) conforming to ISO 8528 specifications.

ENGINE :
Engine: direct injection, water cooled engine, 16 cylinder, 4 stroke, rated at 1500
RPM, conforming to ISO 3046 / BS 5514 has the following specifications:
- PT fuel pump, Electronic governor
- heavy duty STC injectors
- Holset turbocharger with low temperature after cooler, pulse tuned exhaust
manifold, stainless steel exhaust flexible connections
- Radiator or heat exchanger, coolant inhibitor,
- Plate type lube oil cooler
- Outboard aftercoolers
- Full flow paper element filters - fuel, lube oil and by-pass
- Dry type replaceable paper element air cleaner with restriction indicator
- Flywheel housing & flywheel to suit single / double bearing alternator
- Holset flexible coupling for double bearing alternator
- Starting motor Electric, battery charging alternator
- microprocessor based genset Controller PC 3.3.
- First fill lube oil & coolant inhibitor Full Authority Electronics,
- Residential Silencers.

ALTERNATOR:
Alternator 1500 KVA and 750KVA at 1500 RPM, 11KV, 3 phase conforming to BS /
IS Standards.
The Alternator is brushless alternator. The alternator has the following features
- Seperately excited, self-regulated
- Class H insulation
- Salient pole revolving field

11

- Single / double bearing

- PMG standard
- Voltage regulation -+ 0.5 %
- IP: 23 Enclosure
- Digital AVR is inbuilt in PCC.

GENSET CONTROLS - is a micro processor based generator set monitoring, metering,

protection and control system.

It shall offer advanced levels of functions for reliability and optimum genset
performance.

The control system shall have easy servicing capabilities that allow system parameters
to be interrogated, monitored and adjusted with a PC.
Features:
- Digital governing
- Digital voltage regulation
- protection for true alternator O/C protection
- Analog/ bargraph/ digital AC output metering
- Battery monitoring system to sense and warn against a weak battery condition
- Digital alarm and status message display
- Genset monitoring : Displays status of all critical engine and generator set functions
- Smart starting control system: Integrated fuel ramping to limit black smoke and
frequency overshoot
- Advanced serviceability
- network capability

MOUNTING ARRANGEMENT:
Engine and alternator are mounted on a common MS fabricated base frame.

12

FUEL TANK:
M.S. Fabricated stand alone with the capacity of 990 Litres external Fuel Tank
complete with level indicator, fuel inlet and outlet, air vent, drain plug, inlet
arrangement for direct filling and Man hole.

BATTERY :
Set of 4 Nos.12 Volts, uncharged maintenance free batteries with leads and
terminals.
Typical Dimension Details & Weight of D.G.Set WITH OUT Acoustic Enclosure:
L X W X Ht.
Overall Size without silencer: 60900 X 2075 X 2850 mm
Overall Size of Foundation: 6200 X 3000 X Depth as pet site conditions (150
mm above ground level)
Weight Dry 12250 kGs
The present scope of work shall include but not be limited to the following: a.

Supply and Installation of Diesel Engine, Alternator and AMF with Auto
Synchronisation control panel.

b.

Supply and Installation of all accessories and components for assembly such as
couplings, base frame, silencers, fuel day tank, 11KV power and control cables
upto MAIN panel and earthing including maintenance free earth pits as per IE
rules.

c.

Supply and Installation of battery and battery charger.

d.

Supply and Installation of fuel and exhaust piping and insulation as required
for exhaust piping.

e.

Supply of all special tools for maintenance, and safety accessories as per
standard practice and anti vibration pads.

13

f.

Supply of all drawings and documentation as called for.

g.

Checking all electrical connections.

h.

Carrying out tests and load trials on assembled unit at site in the presence of
owner to fulfill the performances guarantee.

i.

Obtaining

Electrical

Inspectorate

approval

of

layout

drawings

and

Installation.
j.

Getting safety and approval certificate from Local CEIG/ CEA Authorities for
D.G.-Sets.

k.

Local PCB Norms to be implemented for getting NOC for installation of D.G.Sets, Stack height and noise level as per PCB norms. It is the responsibility of
the D.G.-Set manufacturer/Contractor to get the necessary license from local
PCB for operating the D.G.-Sets.

l.

Liaison with concerned authorities and obtaining Explosive Licence and liason
with APTRANSCO and getting necessary approvals.

m.

The stack height shall be as per the PCB norms and the stack structure shall
be provided with Lightning Arrestor (ERICO) with aviation lamp and with
separate two earth pits for the structure.

n.

One number synchronizing panel.

o.

990 Liters Fuel Day Tank of suitable capacity.

p.

The Auto-Synchronization panel with AMF module should have BMS options for
monitoring the parameters and controlling the D.G.-Sets in Auto as well as in
manual mode.

6.0

DIESEL ENGINE
The Diesel Engine specifications shall be as follows: -

6.1

Type

4 cycle, Inline, Turbo charged and After

cooled.

6.2

Rating

Continuous at 50 C ambient, 95% RH &

720mm Hg atmospheric pressure.

6.3

No. of Cylinders

16

14

6.4

No. of strokes

6.5

BHP

1735 KVA for 1500KVA DG set

890 KVA for 750KVA DG set

6.6

RPM

1500

6.7

Overload rating

As per BS 5514

6.8

Type of governing

Electronic as per BS 649

6.9

Maximum speed
Variation on a change
Of load upto 20%

Not more than 2%

6.10

Type of fuel

High speed Diesel

6.11

Fuel consumption

To be specified by the manufacturer

6.12

Type of starter

- As per the Manufacturer recommendation.

6.13

Type of Engine
Cooling

Radiator fan cooled fan to be driven

By the engine shaft.

6.14

Type of coupling to
Generator

Direct through flexible coupling

6.15

The following accessories shall be supplied with the Engine:

a.
b.
c.
d.
e.
f.
g.
h.

i.
j.
k.

l.
m.
n.
o.

Aftercooler
Air Cleaner
Base Frame
Crankcase breather
Lubricating oil cooler
Exhaust fitting flange
Muffler Residential
Filters
i.
Primary Fuel
ii.
Full flow-lubricating oil
Governor Cat Electronic
Lifting eyes
Manifold exhaust, dry pumps
i.
Fuel Transfer
ii.
Lubricating oil, Gear driven
iii.
Jacket water, gear driven
Radiator
Shutoff electronic
Battery, battery rack
Starting electronic, 12V DC

15

7.0

p.
Mounting system
q.
Fuel tank base
r.
Any other item as may be required as recommended by manufacturer.
ALTERNATOR
The alternator shall be double bearing, revolving field type conforming to IS:
4722 as per specifications given below: -

a.

Rated voltage

11KV

b.

Rated KVA

1500 KVA under site conditions

750 KVA under site conditions

c.

Rated power factor

0.8

d.

No. Of phases

e.

Frequency

50Hz.

f.

Type of stator
Connection

Star connected

g.

Percentage regulation

+/- 5%

h.

Type of excitation

Brushless, Self regulated and Seperately

excited,

i.

Insulation class

Class H for stator and rotor

j.

Type of enclosure

Screen protected drip proof IP23

k.

Alignment

Flex plate/Flywheel spigot

l.

Overspeed capability

150% for 30 sec

m.

Wave form

Less than 3% deviation

n.

Paralleing capability

Standard with adjustable voltage drop

o.

Voltage

11KV

p.

Voltage regulation

Less than 1%

q.

Voltage adjustment

5%

r.

TIF(Tele phone Interference factor)

As per VDE 0530

s.

THF(Total Harmonic factor)

Less than 3%

16

t.
i.

ACCESSORIES
Cable Termination end box suitable to receive and terminate for 3C X 300 Sq
mm 11KV, HT cable.

ii.

Two earthing studs and lifting eyes

iii.

Name plate giving the rating particulars

8.0

AMF WITH AUTO SYNCHRONISING FACILITY AND LOAD SHARING RELAY

DEVICE.
a.

b.

Incomers
Each incomer consisting of the following:

3 Nos

1.

Three pole, 630A, Electrically operated

Spring charged drawout type Vaccum
Circuit Breaker with Over Load &
short circuit releases and with all
necessary protections NGR NIS Sync
Relay and metering MFR. 240V Ac
motors & U/V coil, 12V DC shunt trip
coil with 3NO+3NC aux contacts for
DG incoming side.
Outgoings

1 No.

Each Outgoings consisting of the following:

2 Nos.

1.

Three pole, 630A, Electrically operated

Spring charged drawout type Vaccum
Circuit Breaker with Over Load &
short circuit releases and with all
necessary protections NGR NIS Sync
Relay and metering MFR. 240V Ac
motors & U/V coil, 12V DC shunt trip
coil with 3NO+3NC aux contacts for
DG incoming side.

1 No.

2.

Meters
a. Digital Kilowatt meter, flush mounting,
96 sq.mm

1 No.

b. Digital Kilowatt hour meter, flush mounting

3Phase, 4wire 11KV system.

1 No.

17

3.

4.

5.

SWITCHES
a. 2 Pole ON/OFF DC Supply selector
switch 16A rating

1 No.

b. Mode selector switch, with Auto/

Manual/Test selection, 3pole 3way
With off 16A rating.

1 No.

TIMERS
a. Electronic type timer with 2 change
over on delay contacts with coil
voltage 240V AC.

1 No.

b. Electronic type timer with 2 change

over on delay contacts with coil
voltage 12V DC.

1 No.

AUTO SYSNCHRONISING & AUTO LOAD SHARING

a. Double voltmeter, Flush mounting
144 sq.mm

1 No.

b. Double frequency meter, flush

mounting 144 sq.mm

1 No

c. Synchronoscope, Flush mounting

1 No.

d. Synchronising lamp

2 Nos.

e. Bkr. Selector switch

1 No.

f. Auto/Manual synchronizing sel. Switch

1 No.

g. Frequency balance relay, type FN2

1 No.

h. Auto synchronizing relay, type SY1

1 No.

i. Aux contactor

1 set

j. Auto load sharing relay

1 No.

k. Motorised Potentio meter

2 Nos.

l. Push button for speed raise/lower

4 Nos.

m. Push button for voltage raise/lower

4 Nos.

18

8.1

The panel shall be further complete with ferruled internal wiring, foundation
bolts, name plates etc.

8.2

The electronic Microprocessor based AMF module shall contain the following
control and monitoring features.
-

Automatic/manual start-stop engine control with programmable safety

shutdowns and associated flashing LED indicators for low oil pressure,
high coolant temperature, over speed, over crank /rest periods

Cycle cranking adjustable 1-60 second crank/rest periods.

Cool down timer - adjustable 0-30 minutes.
Energized to run or shut shown fuel control system.
The control panel shall have metering and measuring features like,
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*

Total real power

Total reactive power
% of rated power
Power factor (average)
Total energy output
Real power each phase
Total apparent power
Power factor each phase
Total reactive energy output
Phase selector switch
Auto start / stop control
Cycle crank and cool down timer
Digital DC Voltmeter
Tachometer, Hour meter
Emergency stop push button
Engine control switch for
Auto, Start / run, Off / reset, stop
Engine speed adjust potentiometer
Voltage adjust potentiometer
Digital oil pressure and water temp gauge
Shutoffs with visual indicators for :
Low oil pressure
High water temperature
Over speed
Over crank
Low coolant level
System diagnostic codes
Programmable protective relays

a. LCD digital readout for Engine oil pressure, Coolant temperature, Engine RPM,
System DC volts, Engine running hours, Generator AC volts, AC Amps and
frequency.

19

b. Engine control switch

c. Ammeter voltmeter phase selector switch.
d.
e.
f.
g.

Emergency stop push button.

Voltage adjustable potential meter.
Speed adjust potential meter.
Protective relay functions.
Over voltage
Under voltage
Over frequency
Under frequency
Over current
Reverse power

The scope also includes all necessary components which are required for full
filament of the system for Auto start, Auto synchronisation and load sharing.
9.0

ACCESSORIES
The following accessories shall be supplied: -

9.1

Fuel oil day tank (990 Litres capacity)

drain valve and hand hole for cleaning.

with outlet valve fuel level Indicator,

9.2

Industrial silencer and exhaust gas chimney.

9.3

Set of 4, 12 V suitable rated batteries with stand.

9.4

Fuel houses, pipes and exhaust piping.

9.5

Standard base frame to mount the engine and alternator.

9.6

Anti vibration mounts - DUNLOP / GERB of required quantity.

10.0

BATTERY AND BATTERY CHARGER

a.

Battery charger unit with 240V, AC input/

12V DC out put.

3 Sets

b.

DC Ammeter, flush mounting 96 sq.mm

c.

DC voltmeter, flush monting 96 sq.mm

d.

Aux contactor 240V, Ac coil voltage with

2NO+2NC contacts.

e.

3 change over auxiliary relays

20

11.0

f.

Industrial type hooter, 12V DC

g.

HBC control fuses

13

h.

3 Phase, 4wire, 415V AC line voltage

i.

Tape wound ring type Cts

j.

Tape wound ring type CTs for EMCPII

k.

Static type reverse power relay

l.

630A TP aluminum bus bar

1 set

m.

Battery

Sealed maintenance free type

PAINTING
The engine, alternator, base frame and control panel shall be pained with IS
631 shade (Light Grey).

12.0

SHOP TESTS
Routine tests shall be conducted on the diesel engine, Alternator and control
panel at the manufacturers works and test certificates shall be furnished. The
tests on control panel shall be conducted in the presence of Owner/Owners
representative.
Witness Test by Owner / Consultant at Manufacturers work station for 2 hours
on each DG Set to be included in the DG price 0.1%, 25 %, 50%, 75%, 100%
and 110% load for 10 minutes.

13.0

DOCUMENTATION
As a part of the equipment supply, following documents shall be supplied for
our/Owners approval/records.
Records

a.

General arrangement drawing of

the diesel generating set, engine
Outline dimensions and list of
Accessories.

b.

Layout of the diesel generating

Sets along with recommended

21

Size of D.G. room

c.

General arrangement of control panel

d.

Schematic & wiring diagram

e.

Foundation plan of the set showing

Foundation bolt hole locations/mount
Locations.

f.

Routine test certificate on engine

g.

Routine test certificate on alternator

h.

Fuel piping

i.

Routine Test Certificate on VCB and Relays

j.

Routine Test Certificate of control Panel

k.

Operating instruction chart

l.

Instruction Manual

m.

Spare parts list

n.

Catalogues

o.

Consumables with specification

14.0 PACKING
The diesel engine, alternator, control panel etc. shall be suitably packed for
shipment to site by road. A complete list of parts (Packing list) shall be
furnished to the owner in duplicate.
15.0

SPARES
A recommended list of spares for two years operation of the unit shall be
submitted along with the bid.

22

16.0

PREFERRED MAKES

a.

Engine

CUMMINS/CATERPILLAR/PERKISON/

b.

Alternator

STAMFORD/TOYODENKI/LEROY SOMER

c.

VCB

GE/ABB/SCHNEDER

d.

Control Fuses

GE CONTROLS/SIEMENS/C & S

e.

KWH Meter

BHEL/SIMCO/HPL/ENERCON

f.

Battery

EXIDE/ PULSELITE / AMARON

17.0

ASSEMBLY AND INSTALLATION

The components shall be assembled at site over the foundation prepared by
other agencies.
The necessary fuel and exhaust piping shall be installed as per drawing. While
the fuel piping shall be carried out using medium guage (class B) MS Pipes, and
approved makes of fittings, the exhaust piping shall be fabricated out of
medium guage pipes of required diameter. The exhaust gas line shall be
insulated upto a height 2.5M above the floor level. The pressure loss through
exhaust system does not exceed the value recommended by the
manufacturer.
Silencers in the exhaust system to maintain the external noise level
specified by the manufacturer.

The D.G. set shall be installed over the Anti vibration mounts and the
alignment shall be carried out. The alignment shall be well within the limits
specified by the manufacturer.
The installation of cabling and earthing upto the control panel shall be carried
out and this shall comply with the statutory requirements. Any improvement
modification called for the electrical inspectorate shall be carried out at no
extra cost.
18.0

FIELD TESTING
After the assembly the unit shall be tested in the present of the client. The
following tests shall be conducted on the engine and alternator.

a.

Full load test for 8 hours

b.

Over loading test on engine as per standards

c.

Fuel & Oil consumption checks

23

d.

Determining efficiency

e.

Megger test on alternator

f.

Checking regulation

g.

Testing of control wiring.

h.

Any other tests as may be required to satisfy the Owner/Electrical inspectorate

of the performance of the Unit.

19.0

SCHEDULE OF TECHNICAL PARTICULARS

The following Technical data shall be furnished with the bid:

19.1

ENGINE
a)

Make

b)

Type

c)

No. of cylinders

d)

RPM

e)

BHP developed at 1500 RPM and site conditions specified

f)

Type of Governor

g)

Overload rating

h)

Type of fuel

i)

Type and grade of Lube oil

j)

Type of stating

k)

Type of cooling

l)

List of Accessories

m)

Protective devices fitted

n)

Derating under site conditions if any

o)

Guaranteed fuel and oil consumption/hour

Fule

24

Lube Oil

19.2

i)

Load

ii)

Load

iii)

Load

iv)

Full load

p)

Weight of the Engine

q)

Shade of paint

r)

The maximum rating of motor than be started on the DG set using DOL
starter.

ALTERNATOR
a)

Make

b)

Type

c)

Type of enclosure/frame size

d)

No. of Poles

e)

Type of excitation

f)

Stator winding connection

g)

Percentage regulation

h)

Synchronous reactance

i)

Rated voltage

j)

Rated current

k)

Guaranteed efficiency
i)

Load

ii)

Load

iii)

Load

iv)

Full Load

l)

Weight of Alternator

m)

Shade of painting (should be same as the Engine)

25

19.3

GENERAL

a)

Overall dimensions of the D.G set in fully assembled condition :

i)

Packed

ii)

Unpacked

b)

Total dead weight of the set in fully assembled condition.

c)

Dynamic weight to be considered for foundation design.

d)

Weight of heaviest part to be lifted during installation.

e)

Weight of heaviest part to be handled during routine maintenance (Excluding

Alternator)

19.4

CONTROL PANEL

a)

Make of Panel

b)

Make of VCB

c)

Interrupting capacity of VCB

d)

Whether separate sealable compartment provided for KWH Meter and CTs

e)

Weight of control panel with VCB

f)

Shade of Painting

19.5

BATTERY

a)

Make

b)

Type

c)

Voltage/Cell

d)

Capacity in AH

26

20.0 VIBRATION CONTROL

The complete generator assembly shall be isolated on static deflection
unhoused spring-neoprene in series isolator with non-skid neoprene pads.
Start-up and shut down rocking restraint snuffers shall be provided at four
corners of base frame.
All fuel line pipes shall be cushioned with a layer of harnesss and neoprene pad
at attached points. All pipe work and engine silencers shall be suspended on
static deflection spring-neoprene in-series hangers.
Detail calculation and proposal for justifying the size and provision shall be
provided for Project Manager review prior to the installation.
EMISSION LIMITS FOR DIESEL ENGINES (MORE THAN 800 KW) FOR
GENERRATOR SETS (GENSETS) APPLICATIONS

parameter

Area category

Total engine rating

of plant (includes
existing as well as
new generator)

Generator sets
commissioning
date on or after
1.7.2005

NOx (as NO) (AT

15%O2) dry basis
,in ppmv

upto 75 mw

710

upto 150 mw

NHMC(AS C) (AT
15%O2), MG NM
PM(AT
15%O2)DISEAL
FUELS HSD &
LDO
FURANCE OILS
LSHS & FO

Both A & B

100

Both A & B

75

CO (AT 15% O2)

SULPHUR
CONTENT IN
FUEL
FUEL SPECTION

Both A & B
A
B

SATCK HEIGHT
(for generator set
commissioned
afert 1.7.2003)

Stack height shall be maximum of the

following in meter
i.
14 Q0.3,Q= total so2
emission from the plant in kg
/hr
ii.
Minimum 6 m above the

100
Both A & B

150
<2%
<4%

FOR ONLY

UPTO 5 MW

27

Only diseal fuels

(HASD, LDO)
shall be used.

iii.

bulding where generator in

insutalled.
30 m.

EMISSION LIMITS FOR DIESEL ENGINES (UPTO 800 KW) FOR GENERRATOR
SETS (GENSETS) APPLICATIONS
Capacity of
diesel
engines

Date of
implementa
tion

1.2.2005

Somke
Test
limited(light cycle
absorption
co-effient,
m-1)(at full
load)
No HC CO PM
Troque Weight
X
%
ing
factors
100
0.05
9.2 1.3 3.5 0.3 0.7

1.7.2004

9.2 1.3 5.0 0.5 0.7

50

0.30

1.7.2004

9.2 1.3 3.5 0.3 0.7

25

0.30

1.7.2004

9.2 1.3 3.5 0.3 0.7

10

0.10

UPTO 19
KW
>19 KW
UPTO
176KW
>176 KW
UPTO
800KW
Satck
height (for
generator
sets
commissio
n as per
sept 2005)

Emission
limits(g/kw-hr) for

Stack height shall be maximum of the following in meter:

i h=h+0.2(kva)0.5,h=total height in meter,h=height of bulding in
meter where generator set is installed, kva =total generator
capacity of the DG IN KVA
ii. minimum 6 m above the bulding where generator in installed

Acronyms Used
MW
NOx
NO2
O2
NMHC
C
PM
CO
SO2
ppmv
FO
HSD

:
:
:
:
:
:
:
:
:
:
:
:

Mega (106) Watt

Oxides of Nitrogen
Nitrogen Dioxide
Oxygen
Non-Methane Hydrocarbon
Carbon
Particulate Matter
Carbon Monoxide
Sulphur Dioxide
Part per million (106) by volume
Furnace Oil
High speed diesel

28

LDO
LSHS
kPa
mm
kg/hr
mg / Nm3

:
:
:
:
:
:

Light Diesel Oil

Low Sulphur Heavy Stock
Kilo Pascal
Milli (103) meter
Kilo (103) gram per hour
Milli (103) gram per Normal metre cubic

Area Categories A & B are defined as follows:

Category A: Areas within the municipal limits of towns / cities having
population more than 10 lakhs and also upto 5 km beyond the
municipal limits of such towns / cities.
Category B : Areas not covered by Category A
The standards shall be regulated by the State Pollution Control Boards or
Pollution Control Committees, as the case may be.
LIMITS OF NOISE FOR POWER GENERATING MANUFACTURED ON OR AFTER
THE 1ST JANUARY, 2005
Applicability
These rules apply to Generator sets installed on or after 1st January, 2005.
Requirement of Certification Every manufacturer or importer of Power
Generating set must have valid certificates of Type Approval and also valid
certificates of conformity of production for each year, for all the product models
being manufactured or imported after 1st January, 2005 with the specified
noise limit.
All Power Generators shall have a valid Type Approval certificate and conformity
of production certificate.
All Power Generator shall have conformance label meeting the requirements.
The conformance label shall contain the following information:

Name and address of the supplier (if the address is described in

the Owners manual, it may not be included in the label).

Statement This product conforms to the Environment (Protection)

Rules, 1986

Noise limit viz. 75 dB(A) at 1 m.

25 DB insertion losses at 0.5 Mtr

Type approval certificate number.

Date of manufacturer of the product.

29

Authorized agencies for certification

The following agencies are authorized to carry out such tests as they deem
necessary for giving certificates for Type Approval and Conformity of production
testing of Generator and to give such certificates:

Automotive Research Association of India, Pune.

National Physical Laboratory, New Delhi.

Naval Science & Technology Laboratory, Palghat

National Acrospace Laboratory, Bangalore

NOISE LEVEL
Noise level outside DG room shall not be more than 70 dBA at a distance of 1.5
meter.
PERFORMANCE
The specification indicates the general layout and measures required for
meeting the end noise and vibration requirements. The contractor shall include
in his offer whatever other materials are required to be supplied for satisfactory
installation and performance of the system so as to meet the end criteria.

30