TENDER DOCUMENT FOR SUPPLY OF DG SETS BATHINDA DEPOT, PUNJAB

Transcription

1 HINDUSTAN PETROLEUM CORPORATION LIMITED ENGINEERING & PROJECTS GRESHAM ASSURANCE HOUSE, 2 ND FLOOR, A-1595(3) 1-A, SIR P M ROAD, FORT MUMBAI TENDER DOCUMENT FOR SUPPLY OF DG SETS AT BATHINDA DEPOT, PUNJAB 1 of 60

2 INDEX Sr. No. CHAPTERS PAGES FROM TO 1 TENDER COVER PAGE INDEX PROJECT DESCRIPTION & SCOPE OF WORK TIME SCHEDULE SCHEDULE OF QUANTITIES TECHNICAL SPECIFICATIONS LIST OF APPROVED MAKES QUALITY ASSURANCE PROGRAM SPECIAL PAYMENT TERMS of 60

3 PROJECT DESCRIPTION AND SCOPE OF WORK 3 of 60

4 Scope of Work:- The scope of work and explanatory notes given below are added to assist the contractor to understand the project. The detailed scope is as described in the Bill of Quantities and Specifications. However, any item of work is required to be carried out for proper and satisfactory completion of work with the highest standard of workmanship. The proposed Supply, Testing, Supervision during pre-commissioning & Commissioning of 2 Nos., 500 KVA Diesel Generating Set along with Acoustic Enclosure for HINDUSTAN PETROLEUM CORPORATION LIMITED (BATHINDA) Site Conditions:- The project site is located at Bathinda in the state of Punjab. The vendor should visit the site and obtain on the spot information required by him and having bearing on this work. Approval of Drawings & Schedules:- All fabrication drawings for Acoustic enclosure, AMF cum Synchronizing Panel, shall be prepared and submitted by contractor at no extra cost within the time stipulated by the Consultants and in the manner so required by him. The vendor shall proceed with the work only after approval of the TPI Agency/HPCL/ Consultant. Such drawings shall be coordinated with all disciplines of work. The vendor shall also get all the approvals from Government bodies, Pollution Control, Director of Explosive, Electrical Inspector PSEB, Supply Authority etc. free of cost and within the expiry of the contract. Drawings and Specifications:- The Specifications and Schedule of rates shall be considered as part of this contract and any work or material shown on schedule and not called for in the specifications or vice versa, shall be executed as if specifically called for in both. The drawings indicate the extent and general arrangements of the fixtures, controlling switches, wiring system etc. and are essentially diagrammatic. The drawings indicate the points of termination of conduit runs and broadly suggest the routes to be followed. Shop Drawings:- The Contractor shall prepare and submit the Consultants for his approval detailed Shop drawings of AMF cum synchronizing Panel and Acoustic enclosure and any other equipment to be fabricated by Contractor within 7 days of signing of the Contract. ADDRESS OF LOCATION:- Hindustan Petroleum Corporation Limited Bulk Supplies Depot, Phoos Mandi, Mansa Road Bathinda, Punjab of 60

5 TIME SCHEDULE 5 of 60

6 TIME SCHEDULE DESCRIPTION OF WORK: SUPPLY, TESTING & SUPERVISION OF COMMISSIONING OF 2 No. 500 KVA DG SETS AT BATHINDA DEPOT. LOCATION : BATHINDA COMPLETION PERIOD: 3 (THREE) MONTHS FROM DATE OF ISSUE OF FOI/LOI/PO WHICHEVER IS EARLIER NOTE: 1) Time for completion shall be reckoned from the date of issue of Fax/ Letter of Intent/Purchase Order by HPCL. 2) Time for completion shall include the time required for Drawing/ QAP submission, Drawing/ QAP approval, manufacturing, Third Party Inspection, dispatch clearance, Packing & Forwarding, Transportation and receipt of the material at the site as per requirements of Contract Document and instructions of HPCL Engineer-in-Charge. 3) Supply of the DG Sets only comes under the LD clause while Supervision & Commissioning doesn t come under this clause. 6 of 60

7 SCHEDULE OF QUANTITIES 7 of 60

8 SCHEDULE OFQUANTITIES Sr. No. Description Quantity Unit 1 Supply, Testing & Commissioning Of 500 KVA DG Set s 2 EACH 2 Supply, Testing & Commissioning Of Synchronizing cum AMF Control Panel 1 EACH 3 Supervision during Pre-Commissioning & Commissioning of the DG Set & Synchronizing cum AMF Panel 3 MAN DAY NOTE:- All the items shall be placed on a single vendor and shall be evaluated together. 8 of 60

9 TECHNICAL SPECIFICATIONS 9 of 60

10 TECHNICAL SPECIFICATIONS FOR DIESEL GENERATING SET Scope:- This specification covers the requirements of design, manufacture, assembly, shop testing, delivery to project site, supervision during pre-commissioning checks & commissioning of 2 Nos. 500 KVA/ 400 KW Diesel Generating Set along with Acoustic enclosure and all other related accessories with AMF cum synchronizing Panel. This specification covers the technical requirements of design, engineering manufacture, assembly, testing at works and delivery in well packed condition of silent type diesel generator set CPCB compliant complete with all required accessories and control equipment to supply continuous electrical power. The scope shall also include third party inspection of the DG set, provision of associated Auto synchronization/amf panel and supply of commissioning/mandatory spares. This standard shall be read in conjunction with job schedule. The scope of supply shall include the following work: - (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (k) Diesel engine, complete with all the required accessories and components. Generator set for operation with the above diesel engine, complete with all the required accessories and compounds. Fuel oil system comprising of fuel oil tank, supply pump, filter, piping, valves fittings etc. Air intake system comprising of air blower, air filter, turbo charger etc. Lubrication oil system comprising of lube oil pump, filter, cooler, piping, valves fittings etc. Jacket cooling system comprising of radiator, water circulation pump, necessary piping and fittings etc. Starting system complete with battery, battery charger, starter motor, control system etc. All inter connecting piping, valves, fittings etc. Torsional vibration damper at the free end of the crank shaft. Speed regulation system. A common base frame suitable for assembly of engine, radiator and alternator 10 of 60

11 with their accessories. Anti vibration mounting pad shall also be supplied. (l) (m) (n) (o) (p) (q) (r) (s) (t) Exhaust manifold complete with silencers, asbestos lagging, metallic expansion bellows and piping. All necessary instruments for monitoring and safe starting, running and stopping of the D.G. set their auxiliaries complete with tubing and cabling. All safety and protective devices. Cabling material between control & protection panel and all equipment within the battery limit including cables, racks, earthing terminating materials etc. Acoustic enclosure (Central Pollution Control Board approved) made of 14 SWG CRCA sheet steel. All other items not specified here but, necessary for safe, satisfactory and uninterrupted operation of D.G. set. Set of special tools and tackles required for installation and maintenance. All other services for making DG set with its control and protection features complete in all respect. Auto Mains Failure, Auto Synchronizing and Auto Load Sharing Panel. Following services but not limited to, will form a part of Vendor s work and prices quoted will be deemed to include: a) Supply of all equipment, materials, accessories, consumable, hardware, and mandatory spares as well as commissioning spares. b) Packing and forwarding of above. c) Transporting to site. d) Preparation of all manufacturing shop drawing / wiring drawings etc. e) Preparation of final As Built drawings of all drawings prepared. STANDARD SCOPE ENGINE Direct injection, water cooled engine, 12 cylinder, 4 stroke, rated at 1500 RPM, conforming to ISO 3046 / BS 5514 has the following specifications: Digital Electronic Governor (*) In-line fuel pump Optimized turbocharger Stainless steel exhaust flexible coupling 11 of 60

12 Silencer Radiator Coolant inhibitor Plate-type lube oil cooler Spin-on filters coolant, fuel & lube oil Dry-type, heavy duty replaceable paper element air cleaner with restriction indicator Flywheel housing and flywheel to suit single bearing alternator Electrical starter motor Battery charging alternator First fill lube oil Alternator: Brushless alternator Self-excited, self regulated Class H insulation Salient pole revolving field Single bearing Digital automatic voltage regulator (part of PCC 1301) Standard to be followed. The design, manufacture and testing of the equipment covered by this standard shall comply with the latest issue of the following codes and other relevant Indian standard specifications unless otherwise specified in the specification sheet. o BS 649 Diesel engines for general purpose. o IS Methods of test for internal combustion engine. o ASME codes(applicable to Diesel Generator) o IS 4722 Rotating Electrical Machines. o Oil coolers as per TEMA class C o BS : 2623 Alternator o IS: 1460 Diesel Fuels. o IS: 4691 Degrees of protection provided by enclosures for rotating electrical machinery. o IS Performance requirements of Diesel Engine for General purpose above 20 KW o Indian Electricity Act & Rules. 12 of 60

13 o Any other Standards/ Codes (BS & IS) applicable. The design and operational features of the equipment offered shall also comply with the provisions of latest issue of the Indian Electricity Rules and other statutory regulations. The vendor shall, wherever necessary, make suitable modification in the equipment to comply with the above. DETAIL SCOPE Design, Supply, Testing, Transportation, Supervision during Pre-commissioning checks & Commissioning of 2 Nos. 500 KVA Prime rated Diesel Generator set, speed of Diesel engine not exceeding 1500 RPM, four stroke engine, designed for operating on high speed diesel, 415 V Diesel Generator sets consisting of water-cooled engine alternator and engine mounted radiator and suitable for AMF START, auto synchronizing and auto load sharing along with all accessories and components such as exhaust pipes, fuel system etc. complete erection and installation on foundation prepared by another agency, connecting to all completed accessories and components and integrating the performance of all sub-systems, providing assistance for the electrical vendor for testing and commissioning and performance testing, electrical and necessary civil work for DG foundation as per the details from the DG supplier as required for the proper and efficient functioning of DG sets as specified in Specification / Bill of Quantities. Design, Supply and providing assistance to the electrical contractor for testing and commissioning of silencer Exhaust pipes with supports. Design and Supply necessary heavy duty anti vibration spring type mounts suitable for the DG sets and also providing assistance to the electrical contractor for installation, testing and commissioning of the same suitable for the DG sets with necessary bolts etc. for satisfactory installation. Providing assistance to the electrical contractor for design, installation, testing and commissioning of fuel pipe lines from day tank with necessary pumps, valves etc. Providing assistance to the electrical contractor for design and preparation of the drawings for self supported exhaust stack, provision of sampling ports for all types of stacks, submission and obtaining approval and necessary certificate from Pollution Control Board and other statutory authorities. Obtaining the approval from Pollution Control Board will be in the 13 of 60

14 scope of the electrical contractor. The CPCB compliance for the DG set shall be provided by DG manufacturer. Providing assistance to the electrical contractor for design and Preparation of the drawing for statutory authorities such as Pollution Control Board etc. for commissioning the system including arranging inspection and also necessary approval / safety certificate from authorities etc. Providing assistance to the electrical contractor for Design and Preparation of electrical drawings for generator and connected electrical installation work submission, obtaining approval to drawings arranging inspection, obtaining supply certificate from Central Electrical Inspectorate. The DG supplier to ensure that in the guarantee period all required accessories and components that are required for a fully functional power generating station are available at site. The scope shall include supply, design, supervision and commissioning of efficient acoustic enclosure to the D.G sets in such a manner that the sound levels with all the D.G sets operating simultaneously will be less than 75 db within 1 mtr. at nearest boundary of the DG set during day time. Bidder shall note that the specified acoustic performance shall be guaranteed by him. Any measures involving civil works to be implemented at site will separately mentioned by the vendor in their offer. Other measures involving mechanical items (such as ducting, hoods, etc. over and above the items supplied by DG vendor for successful commissioning) to be implemented will also be specified separately by the D.G Contractor. The detailed specifications for acoustic enclosure is attached else where in this tender. Site and Building Space Restriction: In the attached site plan and building drawings, space allocation has been shown for the D.G sets as well as all accessories. The contractor shall ensure that all equipments are fitted within the space earmarked. No other space will be made available. 14 of 60

15 Standards:- The Diesel Engine, alternator, accessories and AMF cum synchronizing panel shall comply with the following Indian/British Standard Specification. AMF cum synchronizing Control Panel : IS 4237 or IS 8623 (Part-I) Diesel Generating Set:- Voltage Phases Frequency : 415 Volts : Three : 50 Hz The D. G. Sets shall be rated for 24 hours continuous duty. The D.G. Sets shall be capable of generating a power output of 500 KVA at 0.8 PF on continuous operation under the simultaneous occurrence of the following conditions at site. a) Maximum ambient air temperature : 45 Deg. C b) Relative Humidity at maximum : 89 Ambient temperature. c) All engine driven auxiliaries : required running to their full capacity Engine deratings from the standard (N.T.P.) rating to obtain site rating shall be carried out in accordance with latest edition of BS The Diesel Engine and Alternator field characteristics shall be suitable for facilitating parallel operation of similar Diesel Generating Sets with equal load distribution. Since the Diesel Generating Sets will be utilized for emergency services, it shall be designed without any limitation on the number and frequency of starts in any given period. OPERATIONAL PHILOSOPHY The specified DG Sets are required for Emergency Power Supply requirement. These DG sets shall start automatically upon failure of the normal power supply and also stopped automatically in case of restoration of EB supply after the mandatory checking of the supply parameters. The DG sets shall also be able to start & stop manually through a push button. As per Conditions mentioned in Operational Philosophy following criteria s to be fulfilled by 2Nos. of DG Sets accordingly: 15 of 60

16 DG Set KVA DG Set KVA OPERATIONAL PHILOSOPHY:- The load sharing shall be such that only 1 DG shall be operating till the load is less than 325 KW. In case of any failure in the first DG set the second one shall take over the load. Once the load increases the 325 KW both the DG s shall start operating and the load shall be equally distributed on both the DG s. Following panel should be provided with DG sets: DG Control panel with AMF, synchronizing and programmable features. Battery charger panel a. Self excited, self regulated excitation system along with fast response governor shall ensure that the set dependably comes to full speed and delivers rated output at 415 V, 50 Hz within 15 seconds after getting the starting signal. b. Under steady state condition, the electronic voltage regulator shall keep the voltage constant within ± 0.5 % of the rated voltage with full load at constant speed (with power factor varying between 0.8 lag to unity). Further adjusting the set voltage up to ± 5% of rated voltage shall be possible by the potentiometer provided for the purpose. c. Under transient operating condition, the time of return to within ±3% of steady state voltage when permitted step down load is suddenly applied shall be less than one second (assuming speed to be constant). Further the speed drop due to such loading shall be corrected to ensure 50 Hz 1% Hz within less than 3 seconds (momentary fluctuation in frequency shall be less than ± 1 Hz). Governing system shall ensure minimum fluctuation during load changes. Inertia constant of the rotating system shall aid the governing system. Class A11 governing system preferably using wood ward PSG governor shall be offered. Speed drop shall be continuously adjustable. d. D G set shall meet the DOL starting requirement of induction motors and Constant UPS load. Machine shall develop symmetrical balanced sine wave voltage. Irregularities in waveform shall not cause objectionable interference to other adjacent circuits. Total harmonic factor (THF) as found by type tests shall be less than 5% (per IS 4722). 16 of 60

17 DG location / Foundation / Anti Vibration pads The subject two DG sets of 500KVA rating shall be installed on the foundation to be made by HPCL and shall be open on all sides. Bidder shall recommend the minimum size of the foundation and shall submit the detailed foundation drawing along with their proposal. Bidders shall specify and supply the number of anti vibrations pads required for each DG set so as prevent the DG Vibrations, while running, to be transferred to the ground. DESIGN CRITERIA Engine Performance The engine shall be sized and selected as per the details given as under. 1. Rated engine power at standard operating conditions (ISO conditions) 2. Deration on account of site conditions (refer datasheet for ambient conditions) as per ISO Temperature (combustion inlet temperature) : Altitude (dl) : Humidity (d2) : CW temp (d3) : Inlet losses (d4) : Exhaust back press (d5) : Total Deration (Deration = dl+d2+d3+d4+d5) : 3. Site rated power (as per ISO ) of the Engine (i.e. at stated conditions) to be obtained by deducting the total deration from the rated power. 4. Power consumed by essential dependent and independent auxiliaries: : kw 5. Mechanical transmission losses through coupling : kw 6. The net input power available at the alternator to be obtained by decuting the summation of power Consumed for essentials and transmission losses ( sl nos 3- sl nos(4+5)) through coupling from the site rated power : kw 7. Power required at the alternator input (Preq) : kw (alternator efficiency) * Power factor 17 of 60

18 Bidder shall ensure that net input power (sr. no. 6) shall be greater than the power required calculated basis above (sr. no. 7) and the exact details shall be furnished along with the offer. Performance requirements 1. The unit shall be capable of starting from cold condition. 2. The unit shall be capable of a peak of 10% in excess of the rated out put for a period of one hour in a total of 12 consecutive hours of operation, without exceeding permissible temperature limits and with a fairly visible exhaust. 3. The unit shall operate up to 120 % the rated speed over the entire range of out put without undue vibrations and noise. 4. The DG Set shall be capable of taking on min 50% load equivalent to its rated capacity in one step with no voltage dip and without affecting the frequency. 5. CDG Relay has to be provided for over current and Earth fault protection. Diesel Engine :- The Diesel Engine specification shall be as follows:- TECHNICAL DATA: Generator Set Specifications: 500 KVA Model C 1010 D5 P or equivalent Prime Power Rating kva 500 Output Voltage and Frequency 415 Volts, 50 Hz Power Factor 0.8 (lag) No. of phases 3 phase Engine Specifications : 500 KVA Make Model No. of cylinders Aspiration Bore x Stroke Displacement Output Prime Fuel 75% load with Radiator & Fan Cummins/MTU/Caterpillar/ Kirloskar/Volvo/KOEL/Perkins KTA 19 G9 or equivalent 6, In- Line Turbocharged-Air to air cooled 159 mm x 159mm 18.9 ltrs 448 KWm Not over 77.4 ltr/hr 18 of 60

19 Fuel 100% load with Not over ltr/hr Radiator & Fan Typical lube oil full Not over 0.12 ltr/hr load Total wet weight (engine + radiator) 2687 kg Length x Width x Height (engine) 1970 x 1092 x 1510 mm Compression Ratio 13.9:1 Piston speed 7.95 m/s Governor / Class Electronic / A1 Lubricating oil system capacity 55 ltrs Coolant capacity (engine & radiator) 175 ltrs Combustion air 100% load 32.7 m 3 /min (+/- 5%) Fan air flow across radiator 1217 m 3 /min Exhaust Temperature 538 o C Battery capacity / Rating 180 AH, 4 x 12V a) Silencer suitably optimized to meet stringent sound emission standards laid down by MOEF/CPCB b) Base rail with integral fuel tank (990 liters capacity) is to be provided with drain plug, air vent, inlet and outlet connection, level indicator, manhole etc. c) 4 x 12V dry, uncharged batteries with connecting leads and terminals The DG set shall be mounted inside an acoustically treated enclosure to ensure that the noise level at a distance of 1mtr does not exceed 75 db All the instrumentation, AMF Panel, power and control cables, as specified in the specifications shall be provided by the contractor. Fuel Oil System:- Fuel Oil Day Tank :- Fuel oil to engine shall be supplied from a "Fuel Oil Day Tank". The tank shall have a capacity of 990 litres with mounting brackets, complete with level indicator, fuel inlet and outlet, air vent, drain plug, inlet arrangement for direct filling and set of 990 mm long fuel hoses. The tank shall be made from 6 mm thick mild steel and provided with suitable coatings/paintings for corrosion protection. The day tank shall be provided with a tapping at 0.6 M height, with gate valve to enable any excess fuel (greater than 500 litres) charged into the day tank to flow back into the fuel drums. A red marking shall be provided just below this tapping. The day tank shall be provided with the following minimum accessories :- One (1) level gauge with isolating and drain valve. One (1) drain connection with isolating valve. One (1) manhole with cover for maintenance purposes. 19 of 60

20 The engine shall draw fuel oil from the day tank to the engine driven booster pump through 2 x 100% capacity filters or through a duplex filter. The entire piping to and from the day tank to the engine shall be provided by the contractor. This piping shall be of ERW/flexible hose pipes and shall be provided with necessary valves, fittings, supports, etc. to make the system complete. Also, the piping near the engine for about 500 mm. length shall be flexible armoured steel hose. Additional filters may be provided by the contractor, if required for his engine system. The engine driven booster pump shall supply fuel oil to the injectors. The system between the day tank and the engine shall be such as to ensure priming of the system at all times, when the engine is inoperative, for remote and quick starting of the engine at any instant. A fuel oil trip solenoid valve shall be provided in the fuel line to the engine for cutting off the fuel into the engine on receipt of impulse from the DG control panel. Lubricating Oil System:- The lubricating oil for engine lubricating shall be collected in the oil pan located at the bottom of the crank case/cylinder block. From the oil pan, the lubricating oil shall be led off to a separate lube oil sump, if required. From the oil pan or from the oil sump (if provided) the lubricating oil shall be drawn by the engine driven lubricating oil pump through foot strainer (in the oil) and then through 2 x 100% capacity filters or a duplex filter. The engine driven lubricating oil pump shall be of gear type with suitable pressure relieving devices. The entire pump assembly shall be mounted on the engine cylinder block/crank case and shall be driven off the crank shaft. The lubricating oil from the engine driven pump shall pass through the lubricating oil cooler, where it shall be cooled to required temperature. The lubricating oil may be cooled either by air, jacket water or raw water. The oil cooler shall be mounted on the engine cylinder block. Suitable bypass arrangement shall be provided for bypassing the lubricating oil cooler during start up, until the oil temperature reaches the minimum required value. An A.C. motor driven, intermittent operation lubricating oil priming pump shall be provided. This pump in conjunction with a suitable clock timer shall supply lubricating oil intermittently to the engine when the engine is inoperative. The pressurized and cooled oil cooler shall be led through the various oil galleries in the cylinder block/crank case to the various parts of the engine. The lubricating oil after passing through the lubricating oil circuit of engine shall return to the oil pan/oil pump at the bottom of the engine cylinder block/crank case. The type and grade of lubricating oil to be used in the engine shall be indicated by the Manufacturer. All the interconnecting lubricating oil piping together with valves, fittings, hangars and supports, etc. shall be provided by the contractor. 20 of 60

21 Cooling System:- Jacket Water Cooling The cylinder linings, cylinder head, valves, fuel injector etc. shall be cooled by the Radiator Cooled Engine. The water circulation through the engine jackets shall be established by an engine driven jacket water pump. The drive for this pump shall be taken from the engine crank shaft either by a gear train, belt drive or a chain drive as per the manufacturer's standard practice. Engine Starting System:- The engine shall be suitable for electric starting, as described below:- Electric Starting System:- The system shall comprise a set of starter batteries, battery charger and starter motor with requisite instruments. The starter batteries shall be lead-acid type. The ampere-hour capacity of the lead-acid battery shall be adequately sized for maximum six consecutive repeat start impulses to be given to the diesel engine as well as to cater for D.C. loads on engine control panel such as enunciators and lamps, protection relays, etc. The starter motor shall be DC type suitable for operating on the battery voltage. The battery charger shall be of the static type arranged to draw power either from the mains supply (240 V, 1 Phase, 50 Hz.) or from the DG supply by means of a selector switch mounted on the AMF Control Panel. All the cables required to make the starting system complete shall be supplied, laid and terminated by the Contractor. The battery shall be supplied with necessary floor mounted stand made of teak wood and treated with anti-corrosive paint. Air intake system:- The contractor shall provide for each engine the entire air intake system to combustion air requirements of each engine. meet the Air shall be sucked through an air intake filter/cleaner. The air filter/cleaner may be either of the dry or wet type. An intake air silencer at the air inlet to the air cleaner shall be provided by the Contractor to reduce the noise level, if required. 21 of 60

22 The engine shall be exhaust gas turbo charged as described below:- The air from the air cleaners shall be charged into the cylinders by means of a centrifugal compressor powered by an exhaust gas driven turbine. This turbocharger shall be provided with cooling by the engine lube oil. The turbocharger shall be mounted on the engine. One or two turbochargers, operating in parallel may be provided, depending upon the manufacturer's standard practice. Exhaust Gas System:- The exhaust gas system shall be complete with all the accessories specified herein and shall ensure safe disposal of the exhaust gases at a suitable point outside the room at a height specified by the Pollution control Board. The exhaust gases from the engine exhaust manifold shall be led to the exhaust gas turbocharger for super charging air into the engine. From the turbocharger the exhaust gases shall be led to residential type exhaust gas silencer and then led to a point outside the D. G. set room, at suitable height as per statutory requirements. Suitable flexible joints (metallic bellows) shall be provided on the exhaust piping to take care of expansion due to high working temperatures. It shall also isolate the piping from the engine vibrations. The flexible joint shall be provided as near the engine as possible. The exhaust gas shall be led outside the Acoustic enclosure at to be left open to sky or where ever so desired, as per Pollution Control Board's requirement. The outlet shall be provided with a protective wire mesh net to prevent the entry of foreign particles into the exhaust piping. Necessary supports for the exhaust gas piping shall be provided by the Contractor. The entire exhaust gas piping, residential type silencers, expansion bellows, etc. shall be provided by the Contractor together with necessary supports, joints, etc. Support base of structural steel which may be required shall also be provided by the Contractor. The entire exhaust gas piping inside the Acoustic enclosure including the engine exhaust gas manifold Engine Cooling System Engine shall be provided with radiator cooling. Potable water will be made available for make-up. Engine Lubrication System Engine lubrication shall be as per Manufacturer s standard. The DG Set shall be suitable for automatic starting on Power failure. In order to keep the DG set in ready to start condition at all times if required by the engine manufacturer, a complete automatic pre-lubrication system (including electric (AC) motor driven pre-lubrication pump(auxiliary LO pump) etc.) that lubricates the Engine at regular intervals, complete with Timer logic etc. shall be included in 22 of 60

23 Bidder's scope. The frequency of starting of pre-lube pump shall be indicated by the bidder on the datasheets. Engine Fuel System The engine shall run on Diesel fuel HSD and engine standard fuel systems shall be offered. The diesel tank shall be provided with level switches at 25% Level one fourth fill fuel level for telemetry transmission to IBMS vendor 10% Level Low fuel level for telemetry transmission to IBMS vendor Engine Exhaust System The bidder scope shall be limited to the supply of residential silencer and providing assistance to the HPCL appointed electrical vendor for the installation of complete-exhaust System including complete exhaust piping,' residential type silencer, expansion bellow, fittings, insulation and stack and supports etc. The exhaust from the DG set shall meet the prevailing pollution control board requirements besides meeting' the minimum requirements for diesel engines. Governing:- The governor shall be of the Digital electronic type. Alternator:- The alternator shall be double bearing type as details given below:- Alternator specifications: 500KVA DG SET Make Stamford/Kirloskar/Crompton Frame size / Model No Suitable to tender Voltage Regulation +/- 1.0% Insulation Class H Standard Enclosure IP 23 Winding Pitch Stator Winding Rotor 2 / 3 Pitch Double layer lap Dynamically balanced Wave form distortion No load < 1.5% non distorting balanced linear load < 5% Telephone Interference Better than 50 Factor Total Harmonic Factor Better than 2% 23 of 60

24 DG AMF CUM SYNCHRONIZING CONTROL PANEL:- The diesel generator set shall be supplied with a AMF Control panel. This AMF Panel shall be housed inside the Acoustic enclosure. It should be floor mounting, free standing dust tight, sheet metal enclosed, cubicle type. The AMF panel shall be fabricated out of 2.0 mm. thick cold rolled sheet steel. The AMF panel shall be wired internally up to terminal blocks using 650 Volts grade 2.5 sq.mm. copper conductor PVC wires. The sheet metal work of the panel shall be thoroughly cleaned, degreased, pickled, phosphatised and given two coats of primer and finished with Powder coated paint of shade steel gray. Cable entry to the AMF control panel shall be from the bottom for auxiliary cables such as priming pumps, Control cables etc whereas for incoming and main power cable connections shall be through top and outgoing main power connection from bottom. The AMF panel shall be complete with the necessary control circuit fuses, nameplates, internal wiring, control terminals and cable glands. The AMF panel shall have provision for receiving starting impulses for the D.G. set from Purchaser's remote Main L.T Panel as well as to send out tripping impulses from AMF panel to the DG incomer breaker on purchaser's Main L.T Panel. The AMF panel shall receive 415 Volts sensing supply from Purchaser's remote Main L.T Panel. The necessary interlocking between ACB of Grid Power and DG set Breaker should be done such that no two sources of Power are made parallel. The AMF panel shall be suitable for extension on either side. All the cable entries to the AMF panel shall be from the bottom. The panel shall be designed to confirm to the requirements of: a) IS General requirements for switchgear and control gears for voltages not exceeding 1100 volts. b) IS Degree of protection provided by enclosures for low voltages switchgear and control gear. c) IS Marking and arrangements of bus bars. Individual equipment housed in the power control to the following IS specifications: i) Air / Moulded case circuit breakers - IS 2516 (Part I & II/Sec.1) 1977 ii) Fuse switch and switch fuse units - IS 4064 : iii) HRC fuse links - IS 1108 : 1962 or IS 9114 : of 60

25 iv) Current Transformer - IS v) Voltage Transformer - IS vi) Relays - IS vii) Indicating Instruments - IS viii) Integrating Instruments - IS 711. ix) Control Switches and push buttons - IS x ) Auxiliary contractors - IS CONSTRUCTIONS: The panels shall be: i) Metal enclosed, indoor, floor mounted, free standing type. ii) It shall be made up of the requisite vertical section, which when coupled together shall form continuous dead front switch boards. iii) Provide dust and dump protection, the degree of protection being IP 65 to IS iv) Be readily extensible on both sides by the addition of vertical sections after removal of the end covers. Each vertical section shall comprise: A front framed structure rolled / folded sheet steel channel section of minimum 3mm thick, rigidly bolted together. This structure shall house the components contributing to the major height of the equipment, such as circuit breaker cassettes, fuse switch units, main horizontal bus bars, vertical risers and other front mounted accessories. The structure shall be mounted on a rigid base frame of folded sheet steel of minimum 3mm thick and 100mm height. The design shall ensure that the weight of the components is adequately supported without deformation or loss of alignment during transit or during operation. A cable chamber shall house the cable end connections of power / control cable termination. The design shall be to ensure generous availability of space for easy installation and maintenance of cabling, and adequate safety for making in one vertical section without coming into accidental contact with live parts in and adjacent sections. A cover plate at the top of the vertical section, provided with a ventilating hood where necessary. Any aperture for ventilation shall be covered with a perforated sheet having less than 1mm diameter perforated to prevent entry of vermin. Front and rear doors shall be fitted with nuts/bolts including neoprene gaskets with fasteners designed to ensure proper compression of the gaskets. When covers are provided in place of doors, generous overlap shall be assured between sheet surfaces with closely space fasteners to preclude the entry of dust. The height of the panel should not be more than 2400mm. 25 of 60

26 The maximum height of any operating mechanism shall not be more than 2100mm. The total depth should be adequate to cater for proper cabling space. Panel shall be fabricated from 14 SWG CRCA sheets properly supported with angles and channels. The cubicle shall be single front floor mounted type unless specified otherwise. The door shall be provided with internal hinges and panel locks of superior quality. The hinges shall be union joint type to facilitate easy removal of the doors, when necessary. Doors shall be provided in a similar fashion, as generally provided for the outdoor cabinet where water cannot enter into the cabinet from the door, the door shall be provided with strengthening arrangement to avoid wobbling and distortion. Whenever the door arm opens on the horizontal hinges, an arrangement shall be provided to latch the doors in the open condition for the inspection of the wiring. The cabinet shall be of welded construction and not of joining construction. The cabinet shall be compartmentalized, having the horizontal and vertical bus bars at the back centrally located and circuit breakers shall be arranged at the bottom of the pillars and switch fuse units at the upper portion. The panel shall be provided with a canopy on the top in such a way, that free air circulation is available. At the same time, it shall be dust and vermin proof. A channel frame of 300 mm height fabricated from minimum section of channels 75mm x 40mm x 6mm shall be provided at the bottom of each cabinet. This is required to make the cabinet stable and space for bends. The foundation on holes with grouting, bolts shall be provided in the channel frame. Cable entries shall be as shown on the panel schedules and minimum entry depth shall be 200mm unless specified otherwise. 16 SWG MS sectionalized entry plates shall be provided for multicore entries and 6mm hylam sheet for single core entry points. The circuit components shall be mounted on sectionalized 12 SWG 2.5mm thick. MS sheets, with suitable threading in the sheets to facilitate easy maintenance, future addition, etc. push buttons, signal lamps, and other control components shall be provided on a hinged (at the top) door with suitable latching arrangement. These components shall be at about 1400 mm height. The height of the panels shall not be more than 2300 mm and the depth of the panel shall not be more than 400 mm for single front and 800 mm for double front, except for the air circuit breaker panels, where the depth could be about 900mm. Space - heaters (min. 2 nos. x 75 watts each) shall be provided with MCBs in each panel. The cubicle shall undergo the following process of metal treatment. Sanding Derusting and phosphatising with scale gun asfoclean or equivalent. Degreasing with Asfocoat or equivalent 26 of 60

27 Two coats of red oxide primer. Putty work. Two coats of synthetic enamel of desired shade. Engraved labels shall be provided indicating the feeder details, capacity and 415 Volts danger signs. Fuses shall be HRC cartridge type conforming to IS: 3106 with a breaking capacity corresponding to system fault level. Fuses shall be link type with visible indication. Screw type dazed fuses are not acceptable for any rating. All disconnects shall consist of switch units quickmake, quick-break type with silver plated contacts. The switches shall preferably have double breaks. All switches shall be mounted in sheet steel enclosure, which in turn is mounted on suitable angle iron framework. In wet locations switches shall be mounted on suitable angle iron frame work. In wet locations switches shall have cost iron enclosures. Doors and covers shall be of minimum 14 gauge CRCA sheet steel. All sheet steel work forming the exteriors or switchboards shall be smoothly finished, leveled and free from flaws. The corners should be rounded. The apparatus and circuits in the power control panels shall be so arranged as to facilitate their operation and maintenance and at the same time to ensure the necessary degree of safety. Apparatus forming part of the power control panels shall have the following minimum clearances: i) Between phases - 25 mm ii) Between phases and neutral - 25 mm iii) Between phases and earth - 25 mm iv) Between neutral and earth - 25 mm If for any reason, the above clearances are not available suitable insulation shall be provided. Clearance shall be maintained during normal services conditions. Creep age distances shall comply to those specified in relevant standards. All insulating materials used in the construction of the equipment shall be arranged in multi-tier formation, except that not more than two air circuit breakers shall be housed in a single vertical section. Metallic / insulated barriers shall be provided within vertical sections and between adjacent sections to ensure prevention of accidental contact with: i) Main bus bars and vertical risers during operation, inspection or maintenance of functional units and front mounted accessories. ii) Cable termination of one functional units, where working of those of adjacent unit / units. All covers providing access to live power equipments / circuits shall be provided with tool operated fasteners to prevent unauthorized access. Provision shall be made for permanently earthing the frames and other metal parts of the switch gear by two independent connections. 27 of 60

28 METAL TREATMENT AND FINISH : All steel work used in the construction of the switchboards should have undergone a rigorous metal treatment process as follows: a) Effective cleaning by hot alkaline degreasing solution followed by cold water rinsing to remove traces of alkaline solution. b) Picking in dilute sulfuric acids to remove oxide scales and rust formation, if any, followed by cold water rinsing to remove traces of acidic solution. c) A recognized phosphating process to facilitate durable coating of the paint on the metal surfaces and also to prevent the spread of rusting in the event of paint film being mechanically damaged. This again, shall be followed by hot water rinsing to remove traces of phosphate solution. d) Passivating in de-oxalite solution to retain and augment the effects of phosphating. e) Drying with compressed air in a dust free atmosphere. f) Primer coating, with two coats of highly corrosion resistant primer, applied wet on stove dried under strictly controlled conditions of temperature and time. g) A finishing coat of stoving synthetic enamel paint to the specified shade of IS. The total thickness of paint should not be less than 25 microns. BUS BARS a) The bus bars shall be air insulated and made of high conductivity, electrolytic grade Aluminium conductor. High tensile bolts and spring washers shall be provided at all bus bar joints. The busbar s shall be adequately insulated and protected to prevent accidental contact during the operation and maintenance. The busbar s shall have supports designed to withstand short circuit current equivalent to 35 MVA at 415 volts. The insulation between phases and between phases and ground of the power conductors, shall be made of synthetic resin bonded moulding resistant to dust and dampness. All insulating material shall be non hygroscopic, fungus proof and treated with suitable synthetic varnishes. b) The main phase bus bars shall have continuous current rating throughout the length of each power control panel, and the neutral bus bars shall have a continuous rating of equal size of other phase bus bars. c) Bus bars shall be colour coded for easy identification of individual phases and neutral and protective earth. d) Current Transformer: Current transformer shall comply with the requirements of IS They shall have ratios, outputs and accuracy s as specified / required. 28 of 60

29 e) Indicating / Intergrating Meters: All indicating instruments shall be of flush mounting industrial pattern, conforming to the requirements of IS The instrument shall have nonreflecting dial, clearly divided and legibly marked scales and shall be provided with adjusting devices in the front. Meters and voltmeters shall have moving iron spring controlled dead-beat elements in square bezel flush type cases 144mm in size unless specified otherwise and suitable for switch board mounting meters shall conform to BS:89 and have grade "A" accuracy. Scale ranges shall meet with the requirement or as indicated on the drawing or in the schedule of Quantities. Energy meters shall be two element switch board mounting type suitable for unbalanced loads. All tripping may be through combination thermal and magnetic releases or IDMT releases as specified. Three pole, thermal overload relay for overload protection of Alternator through current transformer, Overload relay, Earth fault relay, Reverse power relay etc, is to be provided for safety of the equipment. f) Battery charger consisting of transformer / rectifier, D.C. Ammeter, charging rate selector Off/trickle/boost is to be provided. g) Cable Termination: Cable entries and terminals shall be provided in the switch-board to suit the number, type and size of aluminum conductor, power cable and copper conductor control cable specified in the detailed specifications. h) Provision shall be made for top or bottom entry of cables as required. Generous size of cabling chambers shall be provided, with the position of cable glands and terminals such that cables can be easily and safely terminated. The minimum depth of the panel shall be restricted to 1600 mm for this purpose. i) Barriers or shrouds shall be provided to permit safe working at the terminals of one circuit currents without accidentally touching that of another live circuit. Cabling risers shall be adequately supported to withstand the effects of rates short circuit currents without damage and without causing secondary faults. Cable sockets shall be of copper and of the crimping type as specified. CONTROL WIRING: All control wiring shall be carried out with 1100 / 660 V grade single core PVC cable conforming to IS 694 / IS 8130 having standard copper conductor of minimum 2.5 Sq.mm section for potential circuits and 2.5 mm section for current transformer circuits. Wiring shall bear neatly bunched, adequately supported and properly routed to allow for easy access and maintenance. 29 of 60

30 Wire shall be identified by numbered ferrules at each end. The ferrules shall be of the ring and of non-detoriating materials. They shall be firmly located on each wire so as to prevent free movement. All control circuit fuses shall be mounted in front of the panel and shall be easily accessible. INTER CONNECTION & INTERNAL WIRING Fiber glass moulded or PVC extruded wire ways shall be provided in the control panel. All the cables for internal wiring shall be PVC insulated of BSS or ISI approved and reputed make. The cables shall have copper conductors only and shall be stranded and the minimum number of stands shall be three. The rating shall conform to IEE wiring regulations. PVC flexible conductors if required shall have minimum size of 24/36. Cables for power circuits shall be red, yellow, and blue or otherwise. Proper colored sleeving shall be provided at both ends of the cable. All wires shall have at both ends a numbered ferrule or such other means of permanent identification. Identification making shall be read from the terminals outwards on all wires. Terminal Blocks/ Terminations: Terminal blocks shall be of 500 volts grade of finger touch proof type. Insulating barriers shall be provided between adjacent terminals. Cables upto 150 Sq.mm alum shall be provided with clip-on type (Slide lock design) of rugged construction. All power terminals shall be colour coded with red, yellow and blue for phases and black for neutral. Every cable, either for control or power duty shall be provided with crimping type copper lugs of suitable size as specified. The lugs shall be fitted with contact grease and the crimping pressure shall be as follows: Copper lugs: Upto 30 Sq.mm psi. Above 35 Sq.mm psi. Bi - metallic lugs: 1000 psi. Cable glands shall be Siemens type brass glands. These glands shall be provided for all the outgoing connections at both ends, for power as well as control circuits and also for the incoming cable or cables, crimping type lugs only to be used. 30 of 60

31 Earth busbar s shall be of tinned copper/ alum. With holes, but the bolts and nuts and washers shall be cadmium plated. Earth busbar s all be provided all around the cubicle at the bottom and it shall be of the same but the maximum size will be 50x 6mm with doples external earth connection arrangement. Bi-metallic lugs shall be used wherever copper cables are being terminated on alum. Busbar s or vice-versa. LABELS: Labels shall be on anodized aluminum, with white engraving on black background. They shall be properly secured with fasteners. TESTS: Routine tests shall be conducted on each power control panel in accordance with CI 81,2.2 of IS 8623 and shall comprise: i) Inspections of the power and control circuits including inspection of wiring and electrical operational tests where necessary. ii) Dielectric tests. ii) Checking of protective measures and electrical continuity of the protective circuits. AMF LOGICS The following AMF LOGIC shall be incorporated in the AMF control panel: The DG Set shall start automatically when one of the following conditions is met. (a) Mains supply failure. (b) Mains voltage dips below 85% of nominal voltage (415V). After the DG set starts and builds up the rates RPM & voltage, the DG breaker/ contactor shall close & the mains breaker/contactor shall open. Upon restoration of Mains supply & normal voltage conditions, Necessary Time Delay Shall Be Allowed To Take Care Of Transient conditions. ANNUNCIATOR A solid state multi-window annunciator shall be provided on the panel board with engraved inscriptions on acrylic sheets and with visible & audible alarms for fault. 31 of 60

32 Indications like: 1. Alternator over load 2. Reverse Power 3. Earth Fault 4. High water temperature 5. Low lube oil pressure 6. Over speed 7. Set fails to start and 2 spare annunciator windows. STORING: The panels shall be stored in well ventilated dry places. Suitable polythelene covers shall be provided for necessary protection against moisture. ERECTION: The AMF panel supplied by the DG vendor will be installed by the electrical vendor. Necessary assistance for proper installation of the panel as follows shall be extended by the DG vendor to the electrical vendor. The panel shall be shall be installed on suitable foundation. Foundation shall be per the dimensions supplied by the panel manufacturer. The foundation shall be flat and level. Suitable grouting holes shall be provided in the foundation. Suitable MS base channel shall be embedded in foundation on which the panel can be directly installed. The switch boards shall be properly aligned and bolted to the foundation by bottom plate or top plate as the case may be, by using brass Siemens type compression glands. The individual cables shall then be led through the panel to the required feeder compartments for necessary terminations. The cables shall be clamped to the supporting arrangements. The switch board earth bus shall be connected to the local earth grid. PRE-COMMISSION TESTS: Panels shall be commissioned only after the successful completion of the following tests. The tests shall be carried in the presence of owner or his authorized representative. a) All main and auxiliary bus bar connections shall be checked and tightened. b) All wiring terminations and bus bars joints shall be checked and tightened. c) Wiring shall be checked to ensure that it is according to the drawings. d) All wiring shall be tested for insulation resistance by a 1000 Volts Megger. e) Phase rotation tests shall be conducted. 32 of 60