Annex A TECHNICAL SPECIFICATION FOR SUPPLY, INSTALLATION, TESTING AND COMMISSIONING OF 400V (750KVA) DIESEL 1
TECHNICAL SPECIFICATION FOR 400V, 750 kva D.G. SET 1.0 SCOPE This specification covers the requirements of design, manufacture, assembly, testing, delivery, installation and commissioning 400V, 3phase, 50 c/s, 750 kva DG Sets Generating sets with Auto Synchronization Facility required 2.0 SITE CONDITIONS 2.1 Ambient Temperature: Maximum 55ºC Minimum 0ºC 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): 400V 3.2 No. of Phases: 3 3.3 Frequency: 50 c/s 3.6 Auxiliary supply: 12 V D.C. supplies for D.G Set starting Motor. 3.0 STANDARDS The Diesel Generating set and accessories shall conform to the requirements of Iraq Standards some of are listed below: - a. BS: 649 - Diesel Engines for general purposes b. IS: 4722 - Electrical performance of rotating electrical Machinery. 4.0 SCOPE OF WORK Prime Power Rating (PRP) conforming to ISO 8528 specifications. ENGINE: Engine: direct injection, water cooled engine, 12 cylinders, and 4 strokes, rated at 1500 RPM, conforming to ISO 3046 / BS 5514 has the following specifications: - PT fuel pump, Electronic governor 2
- Heavy duty STC injectors - Hol set 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 after coolers 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 or single bearing alternator - Starting motor, battery charging alternator - Residential Silencers. ALTERNATOR: Alternator 750 KVA at 1500 RPM, 400V, 3 phase conforming to BS / IS Standards. The Alternator is brushless alternator. The alternator has the following features - Separately excited, self-regulated - Class H insulation - Salient pole revolving field - Single / double bearing - PMG standard - Voltage regulation -+ 0.5 % - IP: 23 Enclosures - Digital AVR. GENSET CONTROLS - is a microprocessor based generator set Monitoring, metering, protection and control system. It shall offer advanced levels of functions for reliability and optimum gen set 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/ digital AC output metering 3
- Battery monitoring system to sense and warn against a weak battery condition - Digital alarm and status message display - Gen set monitoring: Displays status of all critical engines and Generator set functions - Smart starting control system: Integrated fuel ramping to limit black smoke and Frequency overshoot -Advanced serviceability MOUNTING ARRANGEMENT: Engine and alternator are mounted on a common MS fabricated base frame. All on suitable base BATTERY: Set of 2 Nos.12 Volts for each DG set, uncharged maintenance free batteries with leads and terminals. 6.0 DIESEL ENGINE The Diesel Engine specifications shall be as follows: - 6.1 Type : 4 cycles, Inline, Turbo charged and after cooled. 6.2 Rating : Continuous at 55º C ambient, 95% RH & according Iraq atmosphere pressure. 6.3 No. of Cylinders : 12 6.4 No. of strokes : 4 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 : Not more than 2% Variation on a change Of load up to 20% 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 : Radiator fan cooled fan to be driven Cooling By the engine shaft. 4
6.14 Type of coupling to : Direct through flexible coupling Generator 6.15 The following accessories shall be supplied with the Engine: a. After cooler b. Air Cleaner c. Base Frame d. Crankcase breather e. Lubricating oil cooler f. Exhaust fitting flange g. Muffler Residential h. Filters i. Primary Fuel ii. flow-lubricating oil i. Governor Cat Electronic j. Lifting eyes k. Manifold exhaust, dry pumps i. Fuel Transfer ii. Lubricating oil, Gear driven iii. Jacket water, gear driven l. Radiator m. Shutoff electronic n. Battery, battery rack o. Starting electronic, 12V DC p. Mounting system q. Fuel tank base r. Any other item as may be required as recommended by Manufacturer. 7.0 ALTERNATOR The alternator shall be double bearing, revolving field type conforming to IS: 4722 as per specifications given below: - a. Rated voltage : 400V b. Rated KVA : 750 KVA under site conditions c. Rated power factor : 0.8 d No. Of phases : 3 e. Frequency : 50Hz. f. Percentage regulation : +/- 5% g. Type of excitation : Brushless, Self-regulated and separately excited, h. Insulation class : Class H for stator and rotor i. Type of enclosure : Screen protected drip proof IP23 j. Alignment : Flex plate/flywheel spigot k. Over speed capability : 150% for 30 sec l. Wave form : Less than 3% deviation m. Paralleling capability : Standard with adjustable voltage drop n. Voltage : 400V o. Voltage regulation : Less than 1% p. Voltage adjustment : ±5% 5
- 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 /res 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. - Control including: Digital indication for: - Run / Auto / Stop Control - Speed and Voltage Adjust - Engine Cycle Crank - 24-volt DC operation - Environmental sealed front face - Text alarm/event descriptions - RPM - DC volts - Operating hours - Oil pressure (psi, kpa or bar) - Coolant temperature - Volts (L-L & L-N), frequency (Hz) - Amps (per phase & average) - ekw, kva, kvar, kw-hr, %kw, PF Warning/shutdown with common LED indication of: - Low oil pressure - High coolant temperature - Over speed - Emergency stop - Failure to start (over crank) - Low coolant temperature - Low coolant level Programmable protective relaying functions: - Generator phase sequence - Over/Under voltage (27/59) - Over/Under Frequency (81 o/u) - Reverse Power (kw) (32) - Reverse reactive power (kvar) (32RV) - Overcurrent (50/51) Communications: - Six digital inputs (4.2 only) - Four relay outputs (Form A) - Two relay outputs (Form C) - Two digital outputs - Customer data link (Modbus RTU) - Accessory module data link 6
- Serial annunciator module data link - Emergency stop pushbutton Compatible with the following: - Digital I/O module - Local Annunciator - Remote CAN annunciator - Remote serial annunciator b. Engine control switch c. Ammeter voltmeter phase selector switch. d. Emergency stop push button. e. Voltage adjustable potential meter. f. Speed adjust potential meter. g. Protective relay functions. - Over voltage - Under voltage - Over frequency - Under frequency - Over current - Reverse power 8.0 ACCESSORIES: The following accessories shall be supplied: - 8.1 Fuel oil day tank capacity with outlet valve fuel level Indicator, Drain valve and hand hole for cleaning. 8.2 Industrial silencer and exhaust gas chimney. 8.3 Set of 2, 12 V suitable rated batteries with stand. 8.4 Fuel houses, pipes and exhaust piping. 8.5 Standard base frame to mount the engine and alternator. 8.6 Anti-vibration mounts - DUNLOP / GERB of required quantity. 9.0 BATTERY AND BATTERY CHARGER a. Battery charger Alternator / 12V DC output. b. DC Ammeter, flush mounting 96 sq.mm 1 c. DC voltmeter, flush mounting 96 sq.mm 1. 10.0 PAINTING The engine, alternator, base frame and control panel shall be painted with IS 631 7
11.0 SHOP TESTS Routine tests shall be conducted on the diesel engine, Alternator and control panel at Site works under Owner s representative 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. 12.0 DOCUMENTATION As a part of the equipment supply, following documents shall be supplied for Our/Owners approval/records. Records a. Instruction and maintenance Manual 13.0 PREFERRED MAKES a. Engine CUMMINS/CATERPILLAR/PERKINS /VOLVO OR Equivalent b. Alternator - STAMFORD/LEROY SOMER/ MARATHON OR Equivalent c. Battery Approving type 15.0 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 d. Determining efficiency h. Any other tests as may be required to satisfy the Owner/Electrical inspectorate of the performance. 8
14.0 SCHEDULE OF TECHNICAL PARTICULARS The following Technical data MUST be furnished with the bid: ENGINE Make Type No. of cylinders RPM BHP developed at 1500 RPM and site conditions specified Type of Governor Overload rating Type of fuel Type and grade of Lube oil Type of stating Type of cooling Governor type List of Accessories Engine coolant capacity /Lt Radiator coolant capacity/lt Guaranteed fuel and oil consumption//hour 25% 50% 75% 100% Weight of the Engine Gen set weight Shade of paint Fuel Kindly fill the data here Lube oil 16.2 ALTERNATOR Make Type Type of enclosure/frame size No. of Poles Type of excitation Stator winding connection Percentage regulation Synchronous reactance Rated voltage Voltage regulation Insulation type Rated current Guaranteed efficiency: 25% 9
Guaranteed efficiency: 50% Guaranteed efficiency: 75% Guaranteed efficiency: 100% Weight of Alternator Shade of painting (should be same as the Engine) 16.3 CONTROL PANEL Make Type Shade of Painting 16.4 BATTERY Make Type Voltage/Cell Capacity in AH 20.0 VIBRATION CONTROL The complete generator assembly shall be isolated on static deflection UN housed spring-neoprene in series isolator with non-skid neoprene pads.. All fuel line pipes shall be cushioned with a layer of harnesses and neoprene pad At attached points. All pipe work and engine silencers shall be suspended on static deflection spring-neoprene in-series hangers. NOISE LEVEL Noise level outside DG room shall not be more than 70 db at a distance of 1.5 meter. Installation and performance of the system so as to meet the end criteria. 10