254624-400-SP-ELE-007-Rev C-FINAL

VISAKH MARKETING INSTALLATION RESITEMENT

PROJECT – WHITE OIL TERMINAL & LPG TERMINAL

Doc No: 254624-400-SP-ELE -007 Rev: C Page 1 of 32

P:\Andheri\IndiaProject\254624 HPCL- White Oil Terminal\04 Electrical\Documents\13 Specifications\DG set\Rev.C\254624-400-SP-ELE-

007-Rev C.doc

Hindustan Petroleum Corporation Ltd

Visakha Dispatch Station

VR-ATP Area, Naval Base Post

Visakhapatnam - 530 014

Andhra Pradesh

Mott MacDonald Consultants (India) Pvt. Ltd.

Kothari House, CTS No. 185

Off Andheri - Kurla Road

Andheri (East)

Mumbai 400 059

SPECIFICATION

FOR

415V D.G. SETS





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List of Contents Pages

1 Introduction ........................................................................................................................ 4

2 Location and Environmental Conditions............................................................................ 4

2.1 Plant Location..................................................................................................................... 4

2.2 Environmental Conditions.................................................................................................. 4

2.3 Electrical System Data ....................................................................................................... 4

3 Scope of Supply.................................................................................................................. 5

4 Codes and Standards .......................................................................................................... 8

5 Technical Requirements ..................................................................................................... 8

5.1 Operational Requirements.................................................................................................. 8

5.2 DG System Operation ........................................................................................................ 9

5.3 Accessories/Equipment: .................................................................................................... 12

5.4 Starting System: ............................................................................................................... 15

5.5 Fuel System: ..................................................................................................................... 15

5.6 Lubrication System:.......................................................................................................... 16

5.7 Cooling:............................................................................................................................ 16

5.8 Air intake/Ventilation:...................................................................................................... 16

5.9 Control Panels for D.G.Sets: ............................................................................................ 16

5.10 Motors for D.G. Auxiliaries: ............................................................................................ 18

5.11 Instrumentation & control ................................................................................................ 19

5.12 Name Plates:..................................................................................................................... 19

5.13 Makes of Components...................................................................................................... 20

5.14 Painting............................................................................................................................. 20

6 Inspection and testing:...................................................................................................... 20

7 Vendor documentation: .................................................................................................... 21

8 Installation, Testing and commissioning:......................................................................... 22

9 Statutory Approval: .......................................................................................................... 24

Appendix-A: Table of Compliance .............................................................................................. 25

Appendix-B: Codes & Standards ............................................................................................... 27

Appendix-C: Recommended List of Vendors ............................................................................ 28

Appendix-D: Requisition for Engineering Documents .............................................................. 29

Appendix-E: Guaranteed Technical Particulars ......................................................................... 31

Appendix-F: Single Line Diagrams & Equipment layouts & SOQ (WOT & LPGT DG)......... 32





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1 Introduction

1.1 This specification covers the minimum requirements for the Design, Engineering, Supply &

Material procurement, Fabrication, Assembly, Painting, Inspection at manufacturers works,

Supply & Delivery to site, Erection, Testing and Commissioning of 415V Emergency D.G. Sets

for “White Oil Terminal project & LPG Terminal Project” of M/s. HPCL, located at

Visakhapatnam, A.P., India.

Following are the definitions:

Owner/Purchaser Hindustan Petroleum Corporation Ltd.

Consultant Mott MacDonald Consultants (India) Pvt. Ltd.[MMCI]

Manufacturer / Vendor Supplier of 415V D.G.Sets

Shall This is to be understood as mandatory in relation to the

requirements of this document.

Should This is to be understood as a strong recommendation to

comply with the requirements of this document.

Equipment This is to be understood as vendor supplied equipment

with all accessories.

1.2 The Vendor shall ensure that the design complies with the requirements of this specification,

and its referenced specifications and standards. The Guaranteed Technical Particulars, Appendix

E, which forms part of this specification, shall be completed by the Vendor. The Vendor shall

highlight any non-compliance at the offer stage in the Table of Compliance, Appendix A. Not

providing completed compliance table and Guaranteed Technical Particulars can cause rejection

of the offer. Failure to clearly identify specific deviations shall be assumed by the Purchaser to

be total compliance with the specification.

1.3 This specification does not relieve the Vendor from final guarantee as to materials, apparatus,

workmanship and performance of the equipment supplied.

2 Location and Environmental Conditions

2.1 Plant Location

White Oil Terminal project & LPG Terminal project of M/s. HPCL are located at

Visakhapatnam, A.P, India. The D.G.sets for White Oil Terminal & LPG Terminal shall be

located in their respective D.G.Yards within Plant Area.

2.2 Environmental Conditions

Refer Doc No.: 254624-400-SP-GEN-001 for White Oil Terminal & 256324-500-SP-GEN-001

for LPG Terminal.

2.3 Electrical System Data

Refer Doc No.: 254624-400-DS-ELE-001 for White Oil Terminal & 256324-500-DS-ELE-001

for LPG Terminal.





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3 Scope of Supply

The following 415V D.G. Sets of prime power rating (As per ISO 8528-1) shall be supplied, in

accordance with this specification, standards stated herein & enclosed appendices.

Sr.

No. Item Description Unit Quantity Remarks

FOR PLANT LOADS (WHITE OIL TERMINAL)

DG-1

415V, 1250 kVA, 0.8 PF., Diesel

Generator Set in acoustic enclosure,

complete with all the auxiliaries, ACB

with busduct, Control panels, exhaust

system, etc.

Set 1

DG-2

415V, 1250 kVA, 0.8 PF., Diesel




system, etc.

Set 1

DG-3

415V, 350 kVA, 0.8 PF., Diesel


complete with all the auxiliaries, Control

panels, exhaust system, etc.

Set 1

FOR PLANT LOADS (LPG TERMINAL)

DG-1

415V, 1000 kVA, 0.8 PF., Diesel




system, etc.

Set 1

DG-3

415V, 350 kVA, 0.8 PF., Diesel


complete with all the auxiliaries, Control

panels, exhaust system, etc.

Set 1

3.1 Scope shall include the following:

D.G. Set complete with Engine, Main Generator Control & Protection Panel, ACB with busduct,

Engine Control Panel, electronic governer, starting system, Air intake system, fuel supply

system, lubrication system, turbocharger, exhaust system with silencer, cooling system, earthing

system, etc.

3.1.1 Alternator suitable for the above mentioned Diesel generator complete with RTD’s, (Winding +

Bearing) AC brushless excitory coupling between engine and alternator.

3.1.2 Current Transformers in Alternator neutral for protections of Alternator.

3.1.3 Following Panels for each DG Set.

a) Engine Panel and Control & Monitoring Panel





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b) Main Control & Protection Panel for Generator: MCP shall be supplied separately &

located in sub-station. (Refer enclosed Sub-station equipment layout attached in

Appendix-F).

c) Excitor Panel with AVR (With provision for remote control of speed / voltage, PF

control).

d) Engine Starting system with Batteries and Charger System, DC Distribution Boards

• Batteries mounted in a separate stands for DC supply for controls and other

requirements.

• Battery Charger (trickle as well as boost charger) with required metering and

protection for charging above batteries.

e) AMF Panel for DG1 & DG3 only. (Not required for DG-2)

f) Synchronising System for DG1 only. (Not required for DG-2 & DG-3)

3.1.4 ACB with busduct connection within acoustic enclosure as required by statutory agencies.

3.1.5 Cabling

Vendor to supply Cables for engine instrumentation, temperature scanner, special cables such as

screened cables within package and Cables between Engine and Engine Panels. Any Cabling

within DG Package i.e. for interconnection between Engine and Vendor supplied Panels,

between two Vendors supplied Panels shall be by DG Vendor. Scope of Cabling shall also

include supply of termination material such as glands, lugs, etc. for Cables supplied by Vendor.

Cable MTO shall be finalised by DG vendor based on approved Layout. (Refer enclosed Sub-

station equipment layout attached in Appendix-F).

3.1.6 Earthing System

Complete earthing system including earth pits for body & neutral earthing.

3.1.7 Piping.

All Piping and accessories within the DG Package required for connection of inlet air, fuel, Lube

oil, exhaust & cooling systems.

3.1.8 Acoustic enclosure for each D.G. Set as per the norms laid down by statutory agencies, including

internal illumination.

3.1.9 Complete exhaust system including residential type silencer, spark arrester and exhaust pipe for

each DG Set as per pollution control norms.

3.1.10 Radiator type cooling system

3.1.11 Lube Oil tank & associated System

3.1.12 Fuel oil system with day tank for each D.G. Set & additional fuel pumping system along with

filters etc. This system shall also comprise of flameproof level switches for high and low level

alarm as well as trip.

3.1.13 Base frame for D.G.Set. Stress relieving to be done for base frame.

3.1.14 Anti-vibration pads for DG Set. These pads shall be spring mounted pads of reputed make.

These shall be mounted between base frame and plain foundation slab.

3.1.15 Coupling & Guards.

3.1.16 Structural Steel for supports for piping supplied by Vendor and for supports of tanks, silencers

supplied by Vendor.





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3.1.17 Platforms, Ladders and Handrails as required.

3.1.18 Include all plant, machinery, material, all accessories and auxiliaries, measuring and control

equipments, all necessary interconnecting pipes and pipe fittings, wiring conduits of instrument /

sensors upto terminal box mounted on equipment, safety devices and material which are not

specially mentioned but are required to complete the equipment offered in every respect for its

satisfactory operation.

3.1.19 All the required documentation as per ‘Requisition of Engineering Documents’ -- RED form.

3.1.20 Erection / Installation and Commissioning of DG Sets.

3.1.21 First fill of lubricants & consumables including fuel oil for commissioning till performance

guarantee test.

3.1.22 DG Set running for load trial, Paralleling with APSEB grid, Operation Check.

3.1.23 Set of service tools & tackles for maintenance.

3.1.24 Commissioning spares & Spares for 2 Years operation.

3.1.25 Minor civil works like grouting chipping, drilling holes, Civil works for earthing & cable laying

etc.

3.1.26 Surface coating & final painting of complete system.

3.1.27 All the protection, monitoring and recording equipment.

3.1.28 All statutory approvals.

3.2 Engineering Services:

The Vendor shall provide engineering services, which shall include, but not necessarily be

limited to the following:

3.2.1 Designing of Ventilation system for DG acoustic enclosure.

3.2.2 Preparation of DG yard layout with all the DG set auxiliaries, housing Fuel system, lube oil

system etc.

3.2.3 Resolving engineering queries related to the equipment and components within the scope of

supply.

3.2.4 Co-ordination with L.V. Switchgear (PMCC) vendor for necessary feed back on DG control

circuitry. For further details refer Single Line Diagram and equipment Layout attached in

Appendix-F.

3.2.5 Performing and coordinating all aspects of design.

3.2.6 Providing expediting services and quality assurance with respect to ISO 9000 for all sub-

vendors.

3.2.7 Providing Quality Assurance.

3.3 Exclusions from DG Vendor’s scope.

3.3.1 DG set foundation.

3.3.2 Civil work for DG Yard.

3.3.3 Fire fighting system of DG yard.

3.3.4 Lightning Protection for DG yard.

3.3.5 Illumination / Area Lighting of DG yard.





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3.3.6 415V DG Breaker panels in purchaser’s PMCC/MCC.

3.3.7 Power & Control Cables except for cables listed in Clause No. 3.1.5

3.3.8 For LPG Terminal project – Supply, Erection, Testing and Commissioning of DG-2 (500kVA)

415V Emergency D.G. Set. Existing DG will be re-sited & erected at a later date by Owner and

the same will be used as DG-2.

4 Codes and Standards

4.1 General

The 415V Emergency D.G. Sets shall meet the requirements of this specification and latest

edition of applicable standards listed in enclosed Appendix-B.

4.2 Conflicting Requirements

In case of conflict between documents relating to the enquiry or purchase order, the following

priority of documents shall apply.

First priority : Purchase order and variations thereto

Second priority : Data/requisition sheets and drawings

Third priority : This engineering specification.

Fourth priority : Indian standards/International standards.

Note: Should any conflict arise either before or after order placement the Vendor shall

immediately inform the Purchaser for technical resolution of the conflict.

5 Technical Requirements

5.1 Operational Requirements

5.1.1 The diesel generator (prime power rating) set shall be rated at site ambient temperature &

environmental conditions. Diesel generators shall be provided at the White Oil Terminal & LPG

Terminal to facilitate supply to certain essential loads during periods of non-availability of the

units and supply critical station auxiliaries during prolonged shutdowns.

5.1.2 The D.G.Set shall be capable of delivering continuously at the generator terminals, at 0.8 p.f.

lag, when operating under the site and ambient conditions.

5.1.3 D.G.Set shall be capable of satisfactorily providing an output 10 % in excess of the rated output

at the same speed for one hour in 12 hours continuous running.

5.1.4 The design parameters of the generator and excitation system shall be so chosen that the set is

stable while running at any load between no-load and full load, sudden loss of load and also

during starting of motors.

5.1.5 Self excited, self regulated excitation system along with fast response governor shall ensure that

the set comes to full speed & delivers rated output within 10 second after getting starting signal.





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5.1.6 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 droop 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 A1 governing system

preferably using wood ward PSG governor shall be offered. Speed droop shall be continuously

adjustable.

5.1.7 Motors re-acceleration schemes are not envisaged in case of Grid power failure & motors will be

started again after starting of D.G. set.

5.1.8 D G set shall meet the DOL starting requirement of induction motors. kW ratings of motors that

can be started DOL shall be indicated under following conditions:

a) Step load BHP prime mover engine can take (transient voltage dip for above

conditions shall be furnished).

b) Transient voltage dip limited to 20 %

5.1.9 The diesel engine set shall be provided in an acoustic enclosure as per norms laid down by

Pollution Board / statutory authorities. The enclosure shall be suitable for the environmental

conditions at site and shall be designed to prevent the ingress of dust, sand and moisture.

5.2 DG System Operation

The Diesel Generator Sets shall be suitable for manual start and auto start. In manual start the

Diesel Generator shall be started manually by an operator. In auto start the Diesel Generator

shall start on receiving an impulse from under voltage relay.

5.2.1 Manual Mode

In this mode of operation, the operator shall manually start the engine from Main Control Panel

which is located in sub-station after ensuring respective Bus-coupler and Transformer breakers are

in off condition and carrying out necessary initial steps. The operator shall give closing command

to circuit breaker after the voltage builds up to rated value.

5.2.2 Automatic Start (Automatic Main Failure scheme)

a) Auto mode

This shall be effective in Auto position of AUTO / MANUAL Selector switch located in Main

control and protection panel. The diesel generator set will normally be at rest. Upon failure of

plant normal supply, an impulse will be extended. The impulse shall be normally from an under

voltage relay. Upon receipt of this impulse, D.G.Set shall be started automatically and brought to

rated speed and generator voltage brought to rated value. All accessories required for starting and

completion of various sequences of operation for the above purpose shall be provided. In case the

DG fails to start and run up on first attempt the engine cranking shall be repeated two more times.

When engine does not respond to three impulses, it shall be locked out and alarm given. Contacts

for repeat alarm shall be provided.

Vendor to ensure that upon failure of supply, DG-1 shall always be available within maximum

10 seconds to take care of load. Suitable scheme to achieve this shall be developed by Vendor

within Main Control and protection Panel.

Immediately after the diesel set reaches rated speed and generator reaches rated voltage, a

Voltage and frequency monitoring relay located in Main Control and protection panel shall

extend an impulse for closing generator breaker.





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b) Manual Test Mode

Facility for manually starting the diesel generator sets for routine testing shall be provided. This

shall be done by putting the AUTO / MANUAL Selector switch in Manual Position and by

pressing the Push Button on engine control panel. The scheme of operation shall be such that

the closing impulse for Generator breaker shall not be extended.

c) Starting time:

The total time from the receipt of starting impulse for diesel generator set till the diesel

generator set reaches rated speed and rated voltage shall not be more than 10 seconds.

5.2.3 Individual DG system operational details as under:

a) FOR PLANT LOAD (WHITE OIL TERMINAL)

Normally the Transformer – 1(distribution transformer (Grid)) shall feed entire terminal load

and all DGs shall be off and all Bus coupler of the main panel (PMCC) located in Main

substation shall be closed.

DG 1 Operation detail:

In case of grid power failure during daytime, DG-1 shall start on AMF signal from line PT.

When DG-1 is running, Bus coupler-1 and main Transformer breaker shall open. DG-1 shall

feed the entire load excluding Tank Wagon filling MCC, Bunkering/shipping MCC & Wagon

filling Gantry lighting load (LDB). Accordingly DG Vendor shall provide all interlocks and

extend the closing command to DG-1 breaker in substation.

In case DG-1 is running and grid power supply is resumed, the grid incomer ACB shall be closed

through synchronizing with DG-1 Incomer ACB and after pre set delay the DG-1 Incomer ACB

shall trip. Thus only momentary paralleling of DG-1 and Transformer incomer is envisaged.

Accordingly DG vendor shall include all interlocks and extend trip command DG-1 breaker.

Supply to Tank wagon filling MCC, Bunkering & shipping MCC & Wagon filling Gantry

lighting load (LDB) shall be restored by closing Bus-coupler (B/C-1).

During night when there is no operation in the terminal, the AMF starting scheme for DG-1 shall

have to be disabled (i.e. the Auto/Manual selector switch has to be put on Manual) in order to

enable the critical DG-3 to start on AMF.

DG-2 Operation detail:

In case of grid power failure, DG -2 shall be started manually when Wagon filling,

Bunkering/shipping/OMC operations are required. When DG-2 is working, Bus-coupler (B/C-1)

connecting these loads (on bus-2) with other loads (on bus1 & bus-3) shall be kept open.

Changeover to normal supply shall be dead manual changeover. Accordingly DG vendor shall

include all interlocks and extend the closing /Tripping Command to DG-2 Breaker in substation.

DG-2 shall not be paralleled with the grid any time or any other DGs.


In case of grid power failure during day time & DG-1 fails to start, DG-3 shall start on AMF

signal from Bus PT on critical bus after some time delay. Suitable timer shall be provided by DG

Vendor for this purpose. When critical DG-3 is working, Bus coupler (B/C-2) connecting critical

Bus-3 with Bus-1 shall be kept open.





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In case of grid supply failure during night, the critical DG-3 shall start on AMF signal & feed the

critical load. During night when there is no operation in the terminal, the AMF starting scheme

of DG-1 shall be disabled (i.e. the auto/manual selector switch to be put on manual) in order to

enable the critical DG-3 to start on AMF. Changeover to normal supply shall be dead manual

changeover. Accordingly DG vendor shall include all interlocks and extend closing/Tripping

command to DG-3 Breaker. The critical DG-3 shall not be paralleled with the grid or any other

DGs.

b) FOR PLANT LOAD (LPG TERMINAL)

Normally the Transformer – 1(distribution transformer (Grid)) shall feed entire terminal load

and all DGs shall be off and all Bus coupler of the main panel (PMCC) located in Main

substation shall be closed.

DG 1 Operation detail:

In case of grid power failure during daytime, DG-1 shall start on AMF signal from line PT.

When DG-1 is running, Bus coupler-1 and main Transformer breaker shall open. DG-1 shall

feed the entire load excluding Tank Truck & Tank Wagon filling LPG load (T/T and T/W MCC)

& T/T and T/W Gantry lighting load (T/T & T/W LDB). Accordingly DG Vendor shall provide

all interlocks and extend the closing command to DG-1 breaker in substation.

In case DG-1 is running and grid power supply is resumed, the grid incomer ACB shall be closed

through synchronizing with DG-1 Incomer ACB and after pre set delay the DG-1 Incomer ACB

shall trip. Thus only momentary paralleling of DG-1 and Transformer incomer is envisaged.

Accordingly DG vendor shall include all interlocks and extend trip command DG-1 breaker.

Supply to MCC for T/T & T/W filling LPG shall be restored by closing Bus-coupler (B/C-1).

During night when there is no operation in the terminal, the AMF starting scheme for DG-1 shall

have to be disabled (i.e. the Auto/Manual selector switch has to be put on Manual) in order to

enable the critical DG-3 to start on AMF.

DG-2 Operation detail (NOT IN VENDOR’S SCOPE):

In case of grid power failure, DG -2 shall be started manually when T/T & T/W Filling LPG

operations are required. When DG-2 is working, Bus-coupler (B/C-1) connecting these loads (on

bus-2) with other loads (on bus1 & bus-3) shall be kept open. Changeover to normal supply shall

be dead manual changeover. Accordingly DG vendor shall include all interlocks and extend the

closing /Tripping Command to DG-2 Breaker in substation. DG-2 shall not be paralleled with

the grid any time or any other DGs.


In case of grid power failure during day time & DG-1 fails to start, DG-3 shall start on AMF

signal from Bus PT on critical bus after some time delay. Suitable timer shall be provided by DG

Vendor for this purpose. When critical DG-3 is working, Bus coupler (B/C-2) connecting critical

Bus-3 with Bus-1 shall be kept open.

In case of grid supply failure during night, the critical DG-3 shall start on AMF signal & feed the

critical load. During night when there is no operation in the terminal, the AMF starting scheme

of DG-1 shall be disabled (i.e. the auto/manual selector switch to be put on manual) in order to

enable the critical DG-3 to start on AMF. Changeover to normal supply shall be dead manual

changeover. Accordingly DG vendor shall include all interlocks and extend closing/Tripping

command to DG-3 Breaker. The critical DG-3 shall not be paralleled with the grid or any other

DGs.





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5.3 Accessories/Equipment:

DG Sets shall comprise of following Main Equipment / Accessories. Vendor shall also include

any other Accessories / Equipments required for the satisfactory operation of DG Set as

mentioned above.

5.3.1 Diesel Engine:

The diesel engine shall be multi cylinder, four stroke, totally enclosed, prime rating, direct fuel

injection, turbo charged, compression ignitions and closed circuit water cooled.

One common base frame shall be provided for mounting the engine, with fly wheel and

alternator, complete with foundation bolts, levelling screws, anti vibration pads.

The normal speed of the engine shall preferably be 1500 RPM and the direction of rotation shall

be clearly marked on the set.

The engine shall run steadily at any load to full load within its rated load.

The engine shall have 120% overspeed withstanding capability & overspeed trip shall be set at

115% of rated speed.

The engine shall be fitted with an exhaust gas driven turbo charger, complete with its own self

contained lubricating system. The turbo charger shall be positioned at the free end of the engine.

A complete water washing system for turbocharger compressor and turbine shall be provided if

required.

The engine shall be fitted with a charge air intercooler of the air to water type. Air from the

turbocharger compressor passes to the inter cooler, and then to the engine manifold. The

intercooler shall be of tubular construction, with aluminium bronze tubes, mild sheet steel and

cast iron water headers.

Vendor shall supply all necessary equipment & accessories for satisfactory operation of diesel

engine.

5.3.2 Governing System:

Automatic speed governing system shall be provided using electronic governor. The governor

shall be driven by camshaft drive gear.

Zero percent (isochronous) to four percent droop, externally adjustable with synchronising

motor for remote speed control.

A mechanical over speed trip device along with annunciation shall be provided to automatically

shut off fuel in case the speed exceeds the prescribed limit of 115%of rated speed.

5.3.3 Flywheel:

Flywheel shall be solid disc type with guard and shall be accurately balanced.





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5.3.4 Alternator:

Alternators shall be industrial type, provided with insulation Class of ‘H’ with temperature rise

limited to class ‘F’ and Degree of protection of enclosure shall be IP 23.

The alternator shall be mounted on common base frame together with the engine. No external

supply shall be required during starting & running of generator.

Alternators shall be provided with followings:

a) Terminal Box:

All the six terminals of the generator shall be brought out three on one side and three on the

other side. Terminal box on one side shall be used for power connection, the other side similar

terminal box serving as the neutral terminal box shall be provided for forming neutral.

Current transformers shall be accommodated in neutral side terminal box of the generator for

providing protection to the generator. The number and type of CT’s to be accommodated in

neutral terminal box shall be decided by vendor. The neutral terminal box shall be spacious

enough for accommodating CT’s. In case, additional extension box is required, the same shall

also be provided.

Terminal Box shall be suitable for terminating through busduct as indicated in SLD. It shall be

well sized and easily accessible, suitably situated on the generator top part. Degree of protection

for the terminal boxes shall be IP55.

b) Excitation:

The alternator shall have brushless self exciter mounted on the same shaft.

c) Voltage Regulation:

± 0.5% regulation (steady state) shall be performed by a solid state type AVR (Automatic

Voltage Regulator). The response of regulator shall be such that the generator voltage is

recovered to set value on application or rejection of rated load at rated PF within a period of 0.5

sec.

Further adjusting the set voltage upto ± 5% of rated voltage shall be possible by the

potentiometer provided for the purpose.

d) Short circuit current:

The Generator shall withstand short circuit current equivalent to its sub transient reactance for 3

sec. The Excitation System shall be designed to maintain this short circuit current.

e) Overload Capacity:

The Generator & its excitation system shall withstand the 10% overloads for 1 hour in 12 hour

intervals. The stator winding withstands even higher overloads for short duration such as 1.5

times rating for 30secs and also withstands the stresses caused by the maximum asymmetrical

short circuit current. Generator & its excitation system shall withstand over speed of 120%

f) Voltage Waveform:

The Generators meet the following requirements at no-load and all symmetrical loads:

• The Distortion Factor ≤ 5% for line to line voltage

• The THF Factor ≤3% at nominal voltage and frequency





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g) Radio Interference:

This shall be within the limits defined by applicable standards.

h) Unbalance load:

The generator shall operate with the asymmetric loads of the phase current not exceeding the

nominal current.

i) Thermal Detection:

Generator Winding RTD’s (6 Nos. - 2 Nos. per phase) and Bearing RTD’s (2 Nos.) to be

provided. 8 point Temperature Scanner for these RTD’s shall be provided in Generator

protection & metering Panel. Contact of Temperature Scanner will be used for tripping

Generator Breaker. These RTD’S shall be suitable for early warning (alarms) and tripping

stages.

j) Space Heaters:

Space Heaters suitable for 240V AC shall be built-in inside the Generator. This shall be wired to

separate terminal box.

k) Tropicalization:

The complete generator shall be provided with the universal tropicalization suitable for

operation in humid and dry tropical climate.

5.3.5 Exhaust :

Exhaust system shall consist of Expansion Bellows, insulated exhaust manifold, silencers and

other miscellaneous piping materials as required. Supply of total exhaust system inclusive of

chimney as required by Pollution Board.

The exhaust system shall be so designed to maintain back-pressure within permissible limits.

The exhaust outlet shall be outside the yard and at a height stipulated by Pollution Control

Board. Necessary information from Pollution Control Board for Exhaust outlet height shall be

obtained by vendor. Emission to air should be within permissible limits of pollution control

board.

Flexible exhaust bellows shall be supplied to compensate for the expansion of exhaust pipe & to

prevent transmission of engine vibration through the pipe system.

5.3.6 Coupling:

The Engine and the Alternator shall be coupled with a fully flexible power coupling with

suitable coupling guard. Coupling should withstand wide temperature range and should ensure

constant alignment.

5.3.7 Acoustic Enclosure:

The acoustic enclosure shall be free standing, floor mounting type, independent of DG set. The

acoustic enclosure will be modular in construction consisting of acoustically treated panels from

all the four sides and top. All the panels will be jacket filled with glass wool & covered with

perforated sheet inside. The outside fabrication will be made out of 16 SWG MS CRCA sheet

metal. A free distance of 1.5 m to be kept between DG set and the acoustic enclosure on all

sides. The doors shall be hinged lockable on either side. Ventilating louvers shall be provided at

Engine side and Alternator side for fresh air entry and for hot air exhaust. The acoustic enclosure





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/ canopy can be easily assembled at the site on the leveled surface capable of withstanding the

DG weight without any civil works.

The enclosure shall be designed for installation in open air conditions and should have

aesthetic looks.

Suitable acoustic enclosure / insulation with forced ventilation shall be provided for maintaining

the sound level. Maximum level of sound at 1metre from generating source shall be 75dB(A) or

as per the norms laid down by statutory authorities.

This enclosure shall conform to the requirement of the pollution control norms of respective

locations. Lighting arrangement inside the enclosure shall be provided.

Vendor shall submit the plan showing the position of the DG set and the acoustic enclosure.

5.3.8 Miscellaneous Equipment :

Comprising of bearing (base) plates and shims for setting up the DG Set on foundation, ladders,

railing, brackets, piping holders, protection around flywheel & coupling and other required

materials. Anti-vibration pads shall be provided on base plate.

5.4 Starting System:

Electrical starting system shall be provided for the engine. Battery of adequate capacity shall be

provided with all necessary hardware and accessories. Battery charger with float and boost

charging facility shall be provided in the control panel and shall have adequate capacity of

giving 4 consecutive start up kicks with voltage monitoring and alarm devices. The battery

charging circuitry shall be such that when engine is running, the engine mounted dynamo

charges the battery and when engine is not running, the battery charger, charges the battery.

Necessary changeover scheme shall be employed in the control panels.

Necessary mechanism shall be provided for automatic starting of engine in conjunction with the

fuel oil, lube oil and cooling system. The starting solenoid valves shall be provided with manual

bypass valve for local starting.

5.5 Fuel System:

Engine shall be suitable for HSD fuel as per IS 1460: 2000. Fuel system of each D.G. Set shall

be equipped with

a) Fuel Oil Day Tank

Fuel oil day tank shall be sized to house fuel for eight hours. But the size of tank shall not

exceed the capacity laid down by statutory authorities.

The day tank shall be equipped with fuel return connection, vent, sight glass, level switch for

transfer pump control, overflow line and drain valve.

All necessary fuel line pipes, valve and other misc. piping materials from Day Tank to engine

is in vendor’s scope. Alarm shall be given for fuel low level and fuel high level in Day tank.

Day tank shall have facility for refilling fuel directly from tanker.

b) Filter:

A filter of suitable type & capacity to supply fuel oil at rated output (Duplex filter

preferred).





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c) Fuel pump engine driven.

d) Fuel injection and control system for compression ignition.

In addition to above, Vendor shall supply all necessary Accessories and Equipment for the

satisfactory operation of the fuel system.

5.6 Lubrication System:

Force Feed Lubrication System by means of engine driven oil pump, replaceable, suitable type

full flow oil filter and automatic lube oil temperature control shall be included for lubrication of

engine. The oil service tank shall be provided. Hand pump shall be included to enable oil to be

supplied to all parts before starting the engine.

The lube oils used will generally comply with the additive class HD Supplement 1,

Classification API and Viscosity Class SAE 20 / 40.

The Lubricating System shall be equipped with one gear pump driven by crankshaft delivering

lube oil from service tank via relief valves, oil cooler and through system of coarse and fine

filters to the engine. Filters shall be replaceable while engine is in operation.

When engine is stopped for reasons whatsoever the hand priming pump need not be started. The

coast down tank shall take care of heat removal.

Vendor shall supply all necessary auxiliary equipment for the satisfactory operation of the

lubrication system.

5.7 Cooling:

Engine shall be Radiator cooled type. The jacket cooling water shall be circulated by engine/

electric motor driven pump. One standby pump shall also be provided in the case of electric

motor driven pump.

The cooling water system shall comprise heat exchanger, make up tank with filling vent, drain

connection, isolating valve, gauge glass and low level alarm device, pumps, flow indicator, etc.

Make up cooling water temperature shall be 35 °C.

All accessories required in the internal cooling water circuit like pipes, valves, flanges, supports,

etc. shall be provided by vendor.

5.8 Air intake/Ventilation:

Vendor to offer an arrangement so that clean and cool charge air is available near the

turbochargers. The various auxiliaries like air intake silencer, filters, dry type air cleaners and

fans which are required shall be included.

An efficient air intake silencer shall be provided for reducing in take noise to acceptable levels.

5.9 Control Panels for D.G.Sets:

Each Control Panel be extendable, freestanding & provided with followings:

• Degree of protection IP-42

• Earth bus complete with earthing terminals

• Epoxy painted with paint shade Silver Grey No. 628 (IS-5)

• Space heater & illumination lamp in each panel..





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• Cable Entry from Bottom

• Potential transformers & Current transformers as required. (CT internal wiring shall

be connected to terminal block for external connection )

• Indicating (LED) lamps, Pushbuttons, TNC Switches, Selector switches Relays,

Timers, contactors, etc. as required.

5.9.1 AMF Panel:

Circuitry for AMF shall be integral part of Main Control and protection Panel (MCP) for auto

start of DG-1 when grid supply fails & for DG-3 in case of DG-1 fails to start & during night. No

separate AMF Panel for DG Sets shall be provided.

5.9.2 Main Control and protection Panel (MCP):

a) Protections

Relays shall be numerical type. Minimum relays shall be provided as per enclosed

single line diagram.

b) Metering

One - Voltmeter (144 Sq.mm) with selector switch

One - Ammeter (144 Sq.mm)with selector switch

One - Frequency meter (45 Hz. To 55Hz.)

One - Power Factor Meter (0.5 lead to 0.5 lead)

One - KW Meter suitable for 3 phase, 4 wire

One - KWH Meter suitable for 3 phase, 4 wire

One - KVA Meter suitable for 3 phase, 4 wire

One - KVAR Meter

One - Hour meter

One - Tachometer for speed measurement

Alternatively Multifunction meter can be offered.

5.9.3 Engine Panel & Engine Control & Monitoring Panel :

Engine shall be provided with two Panels. One Control Panel shall be fitted on the Engine with

hand stop control of engine, thermometers for water, oil, fuel, air temperature, necessary gauges

for measurement of water / lube oil / fuel pressure, one electrical stop indication / control, etc.

i.e. this Panel shall be with minimum controls which has to be done from Engine. Breaker Status

Indication Lamps (‘ON’, ‘OFF’ and ‘Trip’) shall be provided on this Engine Panel.

Second Panel shall be Engine Control and Monitoring Panel (ECMP) with Digital Indicators,

Analogue Gauges, Engine Status Indications, Alarm Conditions, Engine Stop / Trip Conditions,

speed indications, Engine Controls. Engine starting / stopping shall be possible from this

Control Panel in remote mode of operation.

2 Nos. Engine trouble contact shall be given from ECMP for Purchaser’s use (Annunciation,

etc.)





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5.9.4 Battery & Battery Charger Panel:

Individual Battery & Battery charger system shall be provided for D.G.Set start up system.

Batteries shall be of 24 V lead acid battery (SMF) / bank of adequate ampere hour capacity for

each DG set (at 10 hours discharge rate for supplying control power to control panel and starting

power to engine starting motor) complete with connecting leads first charging and routine check,

instruments including hydrometer and cell tester, teak wood stand, floor insulators, cell

supporting insulators, etc. It shall be possible to start the engine three times in immediate

succession without appreciable drop in DC Voltage. The battery shall have a sufficient capacity

to start the engine more than 4 times consecutively.

Battery charger unit shall be complete with unit transformer / rectifier with surge protection, DC

ammeter, Voltmeter, Charge rate selector etc. suitable for quick and trickle charging of batteries.

DC voltmeters, centre zero ammeters, protective fuses shall be provided. Charger shall give

constant DC output voltage irrespective of incoming voltage variation specified.

5.9.5 Exciter Panel:

AVR can be part of Exciter panel. However, Excitor Panel complete with motorised potmeter,

PF control circuit, provision for remote control of voltage (raise / lower) in case of

synchronising and required DC Metering (Field Current and Field Voltage Monitoring) shall be

provided by DG Vendor.

5.9.6 Synchronising Feature:

Synchronising feature shall be provided in Main Control Panel (MCP) for DG Set which will run

in parallel mode with any other source (Applicable for DG-1).

5.9.7 Neutral Isolation

The neutral point shall be formed in neutral side terminal box and necessary arrangement shall

be provided for connecting neutral earth pit.

5.9.8 Cables

Power cables shall be 1.1kV grade, XLPE insulated, aluminium conductor, multi core, steel

strip/wire armoured, Extruded PVC inner sheathed & Extruded FRLS PVC outer sheathed

confirming to IS 7098 (Part-1).Main power cables shall be provided by owner.

Control cables shall be 2.5Sqmm Multi stranded copper conductor, PVC insulated with extruded

PVC inner sheathed, extruded FRLS PVC outer sheathed confirming to IS 1554 (Part-1).

5.10 Motors for D.G. Auxiliaries:

1. Make - Crompton Greaves / Siemens /ABB

2. Type of Enclosure - TEFC with IP-55 Degree of Protection.

3. Design Ambient Temperature for Motors shall be 45oC.

4. Class of Insulation - Class ‘F’ with temperature rise restricted to class ‘B’

5. Terminal Box for Motors shall be amply sized to suit termination of PVC insulated

aluminium armoured cables

6. Painting - Smoke Grey No. 692 (IS-5)





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5.11 Instrumentation & control

The measurement and controls shall be provided for efficient operation of the process as well as

for safety of equipment and operating personnel.

The equipment shall be provided with all instruments necessary for checking the performance

continuously. All meters shall be fixed on a common instrumentation panel mounted directly on

the engine frame. Instrument system shall include all standard instruments coming as a part of

engine.

Measurements and controls required for smooth and efficient operation of the DG set including

but not limited to the following:

a) Protection devices

For the safety of each DG set following annunciation and tripping scheme shall be provided.

Audio visual alarm only, for the fault conditions in case of:

• Fuel oil tank level low.

• Lubricating oil pressure low.

• Fuel oil pressure low.

• Lube oil temperature high.

• Exhaust gas temperature high.

• Fuel oil day tank level high.

• Lube oil sump tank level low.

• Diesel engine start failure.

b) Audio visual alarm followed by tripping in case of:

• Lubricating oil pressure too low.

• Crank case oil mist high.

• Over speed.

• Starting fault,

• Charge air temperature too high.

• Emergency stop (manual)

• Alternator fault

• Low DG voltage

• Further fault if any shall also be included as per Mfg, Standard

Solid state annunciator shall be provided with features such as test, accept, reset push button,

lamp flashing, audible annunciation etc. Window inscription shall be arranged in a logical

manner to segregate engine faults and alternator faults etc. 20% spare windows shall be

available.

5.12 Name Plates:

Permanent non-corrosive nameplate with engraved white letters on black background indicating

the 415V D.G. Set designation shall be fixed at the top of the central panel.





007-Rev C.doc

Name plates shall contain the following information:

a) Manufacturer

b) Basic technical data such as rated voltage, rated current, RPM etc.

c) Country of origin.

d) Certification data such as UL certificate number etc.

Nameplates shall be provided for each Accessories with 415V D.G.Set. Warning plates shall

be provided on all removable covers or doors giving access to high voltage cables and inside

the switchgear wherever considered necessary. Danger labels shall have black letters on a

yellow background.

Internal labels and components identifications shall correspond with identities or circuit

references as shown on the schematic diagrams. All external labels shall be attached by screws

or rivets only and not by adhesive.

5.13 Makes of Components

Makes of component shall be as per ‘Recommended list of Sub-Vendors’ attached in tender

document.

5.14 Painting

All metal surfaces shall be thoroughly cleaned and degreased, pickled and phosphatised.

Thereafter, a coat of phosphate paint and a coat of zinc chromate primer shall be applied. After

removing all imperfections, all metal surfaces shall be sprayed with two coats of final paint as

per the below mentioned shades.

Engine & Alternator : Smoke grey No. 692 (IS-5)

Coupling Guard : Satin Blue No. 177 (IS-5)

Electric Panel : Silver grey No. 628 (IS-5)

Fuel tank & lines : French Blue IS No. 166 (IS-5)

Radiator : Jet black

Exhaust Piping : Aluminium

Exhaust Piping Supports : Smoke grey No. 692 (IS-5)

Final coat shall be of epoxy based. All unpainted parts shall be plated to prevent corrosion.

6 INSPECTION AND TESTING:

6.1 The responsibility for inspection, certification, etc. of all materials, parts lies with the Vendor.

The Vendor shall specify all of the inspection and testing requirements in the quality plan

which shall identify the activities requiring the Owner’s approval, review, witnessing etc.

Inspection and testing requirements shall be in accordance with this specification, other

applicable standards as listed in this specification and the data sheets.

All Equipment shall be inspected for compliances with:





007-Rev C.doc

• Requirement of Owner’s specification & correspondence therefore.

• Applicable codes, standards and specifications, which shall also include sub-referenced

standards therein.

• Test and Inspection Plans produced by the vendor.

Inspectors have the right to request additional inspections or tests to ensure that the equipment

complies with the specification and all relevant codes & standards.

6.2 Manufacturer shall furnish valid Type Test Certificates of similar models along with the offer.

Fresh type tests for the equipment are not needed, provided the Manufacturer can submit

certificates that the equipment complies with all type tests as prescribed by IEC/IS Standard

specifying the test requirements for that equipment.

6.3 Routine tests on the equipment shall be carried out as per the relevant IEC/IS. Equipment

offered for final inspection shall be complete and ready for shipment, with the possible

exception of the final paint finish.

6.4 Routine Test certificates to be submitted for Equipment and its all auxiliaries.

6.5 Vendor to furnish required copies of test certificates, Ref Documents, Drawings, and

Instruction Manuals before equipment are dispatched.

6.6 Factory acceptance test (FAT) is required to be done at no extra cost to the purchaser. The

purchaser or his representative shall be advised of the tentative date for FAT at least 3 weeks in

advance prior to the test date. For factory acceptance test (FAT) and site acceptance test (SAT),

vendor shall consider maximum 4 hours of DG set running for these testing.

6.7 Any defects found by the TPI or the Owner’s appointed Inspector shall be rectified in his

presence. Where this is not possible or practical, check lists shall be prepared and signed by the

Third Party Inspector stating all “pending items”. Copies of these lists shall be sent to the

Owner to enable their subsequent checking. The equipment shall not leave the Vendor factory

before all defects have been rectified and without the written permission of the Owner.

6.8 All spare parts shall be subjected to the same inspection standards and full material certification

as the main order.

6.9 The equipment shall not leave the Vendor / Sub-Vendor’s factory before all discovered defects

have been rectified and without the written permission of the Owner/Purchaser.

6.10 Any acceptance or release of equipment following an inspection or test activity shall in no way

relieve the Vendor of his contractual responsibility to provide guarantees as to the suitability of

the materials, workmanship and performance of the equipment in accordance with this

specification.

6.11 Owner/Consultant reserves the right to waive the inspection at any stage. Inspection shall be

carried out only on receipt of Vendor's internal test report of the equipment offered and scrutiny

of the same. In the event, on receipt of inspection call, the Owner/Consultant’s representative

reaches the Vendor's works and finds the material not ready for inspection/incomplete/has short

supply, the inspector will return to his base station and all expenses incurred by the inspector

including to and from travelling expenses from his base station to place of inspection, boarding

and lodging etc shall be reimbursed by Vendor.

7 Vendor documentation:

7.1 All information listed here is to be furnished along with the offer as a minimum.





007-Rev C.doc

(a) Clause wise comments / deviations on specification in `Table of Compliance’ [enclosed

Appendix A]. If not furnished, compliance to all requirements in specifications will be

binding on the Vendor.

(b) Duly filled up Guaranteed Technical Particulars [enclosed Appendix-E].

(c) List of fittings & accessories with Makes.

(d) List of recommended spares for two years normal operation with itemised rates.

(e) Type test certificates.

(f) Technical Catalogues of Engine, Alternator, Governor, etc.

(g) List of clientele for similar equipment in last 5 years.

(h) Complete list of special tools (if required)

(i) Documents as per RED.

7.2 The Manufacturer shall furnish the drawings and documents as per enclosed Requisition for

Engineering Documents - RED Form [Appendix-D].

7.3 The Owner/Consultant will review drawings submitted by Vendor & return to the Vendor one

copy of drawings with comments to carry out necessary changes, if any, during the engineering

/ manufacturing stage. Subsequent to the approval of vendor drawings fabrication shall be

started.

7.4 The documents required by the Third Party Inspection Agency are not covered under this

specification. The Vendor shall provide all the drawings and documents required by the Third

Party Inspection agency in compliance with the applicable codes and standards.

8 Installation, Testing and Commissioning:

8.1 Scope work under this section includes site work of installation & commissioning of engine,

generator assembly, electrical panels, battery station, associated cabling, earthing, piping, fuel

pumps, fuel tanks, safety appliances (like rubber mats, first aid boxes, carbon extinguishers

etc). Necessary erection materials such as cable racks, trays, angles, chemicals etc required DG

Set & necessary statutory approvals are included in the scope of work.

8.2 The installation shall comply with relevant Indian Standards, Indian Electricity Rules and

statutory regulations that are in force in the place of installation.

8.3 Vendor shall despatch Installation and Commissioning instructions at least 2 weeks before the

arrival of the equipment.

8.4 Equipment erection, including acoustic enclosure testing and commissioning shall include

following activities:

a) Removal of packing material and clearance, removal of blocking devices provided for safe

shipment.

b) Physical inspection, preparation of defect lists.

c) Assembly of shipping sections.

d) Civil work involved in grouting the equipment base frames, concrete chipping, grouting for

wall, roof, floor supports wherever required for piping, cabling etc.

e) Tack welding of equipment, panels etc., to floor inserts wherever provided and providing floor

inserts wherever required for erection work.

f) Applying touch paints for finish painted equipment’s and finish painting of site fabricated

steel work after pre-treatment like de-rusting, degreasing, primer coating etc.





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g) All pre-wired panels shall be checked for correctness as per final approved wiring diagrams.

h) Trouble free mechanical operation and site testing of relays, contactors, timers, breakers and

free rotation of all drive motors be checked.

i) Tightness of all bolts joints in busbars, motors, generator, engine etc., shall be checked.

j) Insulation resistance of all electrical equipment’s shall be measured and improved by cleaning

and drying. Space heaters, filament lamps (1000 watts) shall be provided and kept energized

during the entire period of erection to prevent deterioration of insulation resistance below

permitted values.

k) Duplicate earthing shall be provided for all electrical equipment’s, cable glands, tanks, and

vessels etc. as per statutory regulations.

l) Generator neutral shall be directly connected to pipe / plate electrode using insulated cable.

Earth ring inside DG Set shall be formed and connected to plant earth grid at minimum two

points for DG Set to be provided by the contractor as per IS 3043.

8.5 a) DG set consisting of diesel engine and AC generator mounted on common base frame with

acoustic enclosure shall be erected on civil foundation with correct orientation details.

Engine control panel, battery station, charger units shall be erected within Acoustic

enclosure. Supplier shall furnish detailed layout drawing for the DG Yard.

b) All the piping to the engine shall be done strictly as per manufacturer’s drawings. Wherever

piping involves joining by welding the same shall be as per relevant statutory regulations

(compressed air lines etc.). Unions / couplings of pipelines shall be done as per

manufacturer’s instruction /drawings, wherever welding is not preferred or permitted. All

piping shall be checked for leak proof by conducting tests as per instruction manuals of

manufacturer.

c) Coupling of the engine and alternator shall be done after checking and correcting alignment

of shaft axes within permitted tolerances. Shaft levels shall be checked and adjusted to be

within permitted tolerances.

d) All the auxiliary power cables between equipment supplied by DG vendor and control

cables to start and shut-off solenoids, temperature switches; level switches etc., shall be

separately installed and terminated with ferrule numbers as per manufacturer’s wiring

diagrams. Wherever control cables have to run near engine casing thermal insulations shall

be used to prevent damage due to excess temperature. Flexible conduits shall be used to

protect control cabling near the engine. All the power and control cables shall be laid

separately and in cable trenches / cable channels between generator and DG Control panel

in the yard as per approved drawing. Vacant spaces in used and unused conduits should be

plugged using M-seal monoplast filling compound. All cables shall be neatly dressed and

clamped in fabricated cable trays.

e) DG set auxiliaries like lube oil prime pump, fuel oil pump, fuel transfer pumps, shall be run

and checked using grid supply. Similarly batteries shall be charged through charger

installed, using grid supply. First filling of lubrication oil, grease, fuel oil (into tank) etc.,

shall be done by the contractor as per manufacturer’s instructions

f) All DG set instruments shall be tested / calibrated and set at values recommended by the

manufacturer, Inscriptions on windows shall be checked. Overload relay for alternator

protection shall be tested and set at values recommended.

g) Installation of safety appliances like rubber mat, carbon dioxide fire extinguishers, first aid

box etc., shall be done.





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8.6 When installation is completely ready for starting, following tests shall be done in addition to all

test prescribed by the manufacturer / I.S. Standards.

a) Starting of engine manual mode / simulated DG Control condition.

b) Shut-off of the engine-manual mode/ electrical mode simulated faults of the alternator and

engine.

c) Over speed test.

d) Interlock between DG breaker and grid supply.

e) Governor speed control electrical /mechanical.

f) Minimum time in seconds required by the set to deliver power at desired voltage and

frequency starting from standstill condition

g) Matching the DG phase sequence with grid supply phase sequence.

h) Checking annunciator windows for all the faults simulated during testing.

i) Continuous full load test as specified, by starting all the motor loads direct on line

sequentially.

j) Paralleling with Grid (Wherever applicable).

k) Tabulation of all results in the mutually agreed format.

8.7 Vendor shall provide qualified personnel for installation and carryout site testing and

commissioning of all equipment supplied under this contract.

8.8 Important notes

a) Successful commissioning of DG set is contingent upon satisfactory working of all the units,

meeting fully the requirements of the specification and performance guarantees offered by the

manufacturer.

b) It shall be contractor’s responsibility to replace all defective / inferior materials revealed

during preliminary acceptance and final acceptance tests (P.A.T and F.A.T) at his own

expense, without affecting completion milestones.

c) Contractor shall ensure that no tests are applied which may stress the equipment above the

limits recommended for field testing, by the manufacturer.

d) Contractor shall be responsible for any damage that may occur to personnel / equipment

resulting from improper testing procedures.

e) Contractor scope in testing of DG Set includes supply & filling sufficient quantities of

consumables like high speed diesel, lube oil, greases etc, necessary for carrying out all trial

runs, during preliminary acceptance tests (PAT) and final acceptance tests (FAT).

8.9 Form of completion certificate for each DG set

We certify that the installation detailed below has been installed by me / us and tested and that to

the best of my / our knowledge and belief, and it compiled with IE rules, 1956 as well as HPCL

technical specification for electrical works.

Electrical installation at :

9 Statutory Approval:

Each DG system along with associated accessories and layout shall be acceptable to statutory

bodies like Electrical Inspector, Tariff Advisory Committee, Electricity Board, Pollution Control

Board etc. Any Changes required by them shall be carried out by Vendor without additional cost.

Getting the approvals is in Vendor’s scope. Statutory fees will be paid by Purchaser.





007-Rev C.doc

Appendix-A: Table of Compliance

The Vendor shall confirm that clauses of the specification have been complied with/accepted or further

clarifications are desired, or Vendor has taken a deviation with reason thereto.

CLIENT : HPCL

VENDOR REF.

Spec. Clause

No.

Conforms

Yes/No

Alternative

Yes/No Clarification

1

2

2.1

2.2

2.3

3

3.1

3.2

3.3

4

4.1

4.2

5

5.1

5.2

5.3

5.4

5.5

5.6

5.7

5.8

5.9

5.10

5.11

5.12





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CLIENT : HPCL

VENDOR REF.

Spec. Clause

No.

Conforms

Yes/No

Alternative

Yes/No Clarification

5.13

5.14

6

7

8

9

Appendix A:

Appendix B:

Appendix C:

Appendix D:

Appendix E:

Appendix F:





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Appendix-B: Codes & Standards

IS 4722 : Rotating Electrical Machines

IS 4728 : Terminal marking and direction of rotation for

rotating electrical machinery

IS 4889 : Methods of determination of efficiency of rotating

electrical machines

IEC 60034 : IEC Standard Voltages

IEC 60529 : Degree of Protection provided by Enclosure (IP

Code)

IS 4729 : Measurement of vibrations of rotating electrical

machines

IS 12065 Permissible limits of noise levels for rotating

electrical machine

IS 12075 Mechanical vibration of rotating electrical

machines

IS 12082 Temperature rise measurement of rotating

electrical machines

BS 649 Performance of reciprocating compression ignition

Diesel Engine

BS 4999 General requirements for Rotating Electrical

Machines

BS 5000 Specification for Rotating Electrical Machines of

particular types or for particular applications

BS 6121 Mechanical cable glands





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Appendix-C: Recommended List of Vendors

Engine : Caterpillar / Cummins / Detroit /

Greaves / KOEL / PERKINS / MTU /

Volvo.

Pipes : Zenith / BSI/ Jindal/ Khandalwal.

Alternator : NGEF/ Kirloskar/ Crompton Greaves /

Stanford

Control & Relay panels : English Electric/Easun Reyrolle / ABB

/ Siemens / AREVA

Battery : Chloride / Standard / UB-MEC/

AMCO / HBL

Battery charger & DC Board : Automatic electric / Afcoset / Caldyne

LT Switch board : Siemens / L&T / Schneider/

GECALSTHOM

LT cables : Cable corporation of India /Universal

cables / Indian cable company / Asian

cables /Polycab.

MCCB / ACB : L&T / Areva / ABB / Siemens /

Merlin Gerin

Protection Relays, Aux. Relays : Areva / ABB / Siemens

LT contactor & Thermal O/L

Relays

: Siemens / Tele-mechanic / L & T

/Control & Switch Gear

Selector switches/ Control

switches

: GECALSTHOM / KAYCEE/ ABB /

Siemens.

LT, CTS : Automatic electric / Siemens / KAPPA

electricals /Pragati

Annunciators : GEC / ALSTOM/ Yashmin / Bharani

Electronics / MECO / Minilec

Indicating Meters : Automatic electric industrial Meters

Pvt. Ltd., / MECO / RISHAB /

Enercon / L & T

Integrating meters : IMP / BHEL / Universal Instruments /

AE

Brass / GI compression type cable

glands

: Comet / HAWKE / HUMMEL

Tinned copper lugs : Dowells/ Electropowerke / HAWKE

Indicating lamps (LED type only)

& Push buttons

: GECALSTHOM/ Siemens / L & T /

Telemecanique / RAAS Control /

Teknic





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Appendix-D: Requisition for Engineering Documents

RED Form

Owner’s Office Distribution Office

Hindustan Petroleum Corporation Ltd.

Visakha Terminal, Resitement Project,

VR-ATP Area, Naval Base Post,

Visakhapatnam – 530 014

Mott MacDonald Consultants(I) Pvt. Ltd

Kothari House, CTS No. 185

Off Andheri – Kurla Road

Andheri ( East), Mumbai 400059, India

SPECIAL INSTRUCTIONS Prints Documents shall be sent to:

Production Schedule 5 The Purchasing Office via courier service

Manufacturing, inspection & testing sequence plan 10 The Purchasing Office via courier service

DRAWINGS Required number for TIMING FOR SUBMITTAL

OFFER APPROVAL FINAL - for approval 2 weeks after order date

Approval drawings / Final drawings to be

submitted under cover of an ADS form / FDS

form respectively

Prints Prints Disk Prints - final issue 2 weeks after approval date

Documents shall be submitted to:

Submission of Following not limited to:

Guaranteed Technical Particulars 2 5 2 10

General Arrangement Drawing showing

weights, front view of all panels supplied by

DG vendor. The plan showing the position of

the DG set and the acoustic enclosure.

2 5 2 10

Dimensional and cross sectional drawings &

Foundation Plan for D.G.Set

2 5 2 10

Suggested layout of D.G.Yard with all

accessories and maintenance space

2 5 2 10

Name Plate Drawing. - 5 2 10

Foundation Plan & Loading details like static

dynamic, centre of gravity of loads & Location

of loads, etc.

Also Foundation requirements of all externally

mounted DG auxiliaries and fuel/lube oil tanks.

- 5 2 10

Connection and wiring diagrams of all panels

supplied by DG package vendor.

- 5 2 10

Detailed Cable and interconnection schedule

for auxiliary Power & Control Cables for D.G.

Package.(Including cables not in Vendor’s

scope)

2 5 2 10

Derating Curves - 5 2 10

Performance Curves torque, fuel consumption,

engine speed and power output.

- 5 2 10

P & I Diagrams for fuel oil system, lube oil

system, Air starting system, Cooling water

System, Exhaust System

2 5 2 10

Vendor's design calculation, necessary

documents and/or data for the calculation of the

power output of the engine in respect to the site

and climatic condition detailed in data sheet.

- 5 2 10

Bill of Materials for D.G.Set, Fuel & lube oil

system, Cooling water system, electrical system

engine and alternator control system.

2 5 2 10

Test Certificates and technical catalogues for

bought out items and D.G.Set.

2 5 2 10

Spares List for two Years Operation 2 5 2 10

As Built Drawing - 5 2 10 Purchasing Office via courier service





007-Rev C.doc

SPARE PARTS DOCUMENTS 1 10 ESPIR forms including 1 transparency

TEST AND INSPECTION DOCUMENTS Prints

Documents to be submitted under transmittal Documents shall be submitted to:

Manufacturing report 2 10

Test Report / Data Curves 2 10

Calibration Certificates for testing Instruments. 2 10

Bought out Equipment Certificates. 2 10 Purchasing Office via courier service within 4

weeks

Of relevant test / inspection.

OPERATING DOCUMENTS Purchasing Office via courier service not later

than time of

Installation instructions 2 10 Dispatch of equipment.

Operating instructions 2 10 Combine into one manual

Maintenance instructions 2 10

ADDITIONAL REQUIREMENTS

1. Referenced standards / codes shall be the latest issue unless otherwise stated.

REMARKS

Invoice must certify that the drawings and engineering documents

specified above have been dispatched to all parties concerned.

Any deviation from the timing for submittal of documents shall

be notified to the Approval / Distribution Offices by fax or E

mail.

Shop fabrication shall not be started before the required approval

drawings have been released for construction by the party

concerned, unless otherwise stated on the "Approval Drawing

Specification".

Each document shall bear the item / tag and order reference

number and be dispatched by air mail, unless other instructions

are stated on the RED.

Units / dimensions to be used on Engineering documents shall be SI.

The documents shall be in English. Description on drawings and

similar documents may be in other languages provided English

translations are also given.

Drawings and documents shall be suitable for microfilming and

comply with accepted national or international standards for the

preparation of technical drawings. Only the following standard sizes

should be used: A4, A3, A2, and A1.





007-Rev C.doc

Appendix-E: Guaranteed Technical Particulars

Doc No: 254624-400-DS-ELE-008

VISAKH MARKETING INSTALLATION REISTEMENT

PROJECT WHITE OIL TERMINAL & LPG TERMINAL

Doc No:254624-400-DS-ELE-008 Rev: C Page 1 of 5

P:\Andheri\IndiaProject\254624 HPCL- White Oil Terminal\04 Electrical\Documents\13 Specifications\DG set\Rev.C\Appendix-E

Guaranteed Technical Particulars-latest.doc

GUARANTEED TECHNICAL PARTICULARS

(To be filled in by the Vendor)

Note: Vendor to furnish separate guaranteed technical particulars for each D.G. Set.

Sr.

No Description Unit To be filled in by Vendor

1.0 ALTERNATOR

1.1 a) Make

b) Type

1.2 a) Manufacturer's Make No. and Frame Size

b) Conforming to Standard

1.3 a) Rated KVA KVA

b) % Average power output for 24 hours of

operation available to user

%

c) KVA Output for continuous operation at

site conditions available to user (excluding DG

set auxiliaries)

KVA

1.4 Power Factor

1.5 a) Rated Voltage Volts, - %±

b) Number of Phases

1.6 Frequency Hz., - % ±

1.7 Number of Poles

1.8 Type of Enclosure

1.9 a) Class of Insulation

b) Temperature Class

c) Impregnation for tropical service

1.10 % Overload for 1 hr. at Site Condition

1.11 a) 50% Overload capacity in Sec.

b) Allowable % unbalanced load on generator in Sec.

1.12 Percentage Efficiency at

a) P.F. - 0.8

- Full Load

- ¾ Load

- ½ Load

- ¼ Load

1.13

a) Voltage Regulation from No-Load to Full

Load at any point with 4% speed

regulation of the engine

b) Recovery Time and Voltage in response to

100% step load






Sr.


c) % Voltage Adjustment on AVR

1.14 a) Type of Bearings

b) Method of Lubrication

1.15 Type of Excitation Unit

1.16 Percentage Reactances of Alternator

a) Sub Transient Reactance- xd" %

b) Transient Reactance - xd' %

c) Reactance - xd %

1.17

Respective DG set allowable Base Load with

maximum rating motor (with soft starter) can

be started with 10% voltage dip. Details as

follows

For White Oil Terminal

a) DG-1

–Base load-1037kVA

-Maximum motor rating-55kW

b) DG-2

–Base load-978kVA


c) DG-3

–Base load-309kVA


For LPG Terminal

a) DG-1

–Base load-865kVA


b) DG-3

–Base load-250kVA


2.0

ENGINE

2.1 Manufacturer

2.2 Engine Model

2.3 Anti-Vibration Pad (vendor to Provide)

2.4

Nominal Output Engine only / without Engine

Driven Pumps

2.5

Output of the Engine equipped with Auxiliary

Drives required to be fed from DG Set Kw

2.6

% Average power output for 24 hours of

operation available to user

%

2.7 Maximum Overload

2.8 % Overload for 1 hour at Site Conditions






Sr.


2.9 Nominal Speed

2.10 Bore Dia. mm

2.11 Length of Strokes mm

2.12 Cylinder Arrangements

2.13 Number of Cylinders

2.14 Total Swept Volume litre

2.15 Compression Ratio

2.16 Time required for starting from cold condition

2.17 Heat Balance of DG Set

- Engine O/P

- Exhaust Gases(Heat rejection)

- Coolings(Heat rejection to coolant)

- Radiations

Total Heat Input

2.18 Machine Efficiency(Mechanical)

2.19 Thermal Efficiency

2.20 GD2 of Engine

2.21

Maintenance Schedule of Engine (First

maintenance required after commissioning)

2.22 Sound level of Engine at distance of 1 M

2.23 Exhaust Gas Flow

2.24 Temperature of Exhaust Gas

2.25 Radiator Cooled Engine only

2.26 Type of Turbocharger

2.27 Fuel Oil System

- Fuel Day Tank of size & capacity

- Specification of Fuel recommendation

2.28

Maximum Fuel Oil Consumption Rate with

0% tolerance for various loads as listed below: litres /KWH

at 25% load

at 50% load

at 75% load

at 100% load

at 110% load

Alarm shall be given for fuel low level and

fuel high level in tank

2.29 Governing System

a) Make






Sr.


b) Type of Governor (enclose detailed

catalogue)

c) Standard to which it conforms

d) Response time of Governor

2.30 Panels

Vendor to furnish dimensions of Panels

supplied by him (L x W x H) mm

a) Main Control Panel (Control & Protection

Panel)

b) Engine Panel

c) Engine Control & Monitoring Panel

d) Exciter and AVR Panel

e) Battery

f) Battery Charger + DCDB

3.0 D.G.Auxilliary Motor

3.1 Type of motor

3.2 Manufacturer

3.3 Degree of protection

3.4 Cooling classification

3.5 Frame Size

3.6 Class of Insulation

3.7 Voltage Supply Volts

3.8 Rated Output Kw

3.9 Speed RPS

3.10 Efficiency %

3.11 Power Factor

3.12 Line Current Amp

4.0 Starting System (DC)

4.1 Battery operated

4.2 Battery Chargers

a) Manufacturer

b) Type

4.3 Batteries

a) Manufacturer SMF, VRLA

b) Battery type






Sr.


5.0 CIVIL REQUIREMENTS

5.1 a) Weight of Engine with accessories

b) Centre of Gravity of Engine

5.3 a) Weight of Generator

b) Total weight of DG set along with

acoustic enclosure

6.0 Recommended crane/hoist capacity

7.0 DIMENSIONS (L x B x H) mm

7.1 Alternator

7.2 Engine

7.3 Overall Length

7.4 Overall dimension with acoustic enclosure

7.5 D.G.Shed





007-Rev C.doc

Appendix-F: Single Line Diagrams & Equipment layouts & SOQ (WOT & LPGT DG)

Sr.

No.

Drawing Number Description

White Oil Terminal

1 254624-400-ELE-4102 Single Line Diagram – 415V PMCC

2 254624-400-ELE-4202 Equipment layout for Main substation & Transformer bay

plan & section

LPG Terminal

3 256324-500-ELE-4102 Single Line Diagram – 415V PMCC

4 256324-500-ELE-4201 Equipment layout for Main substation & Transformer bay

plan & section

White Oil Terminal & LPG Terminal

5 254624-400-SC-ELE-007 WOT & LPGT – DG SOQ

254624-400-SP-ELE-007-Rev C-FINAL

Documents

mott macdonald

automanual

andheriindiaproject254624

guaranteed

maximum motor

closing tripping

white oil

audio visual