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
7 Rev: C Page 1 of 32
SPECIFICATION FOR 415V D.G. SETS
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
P:\Andheri\IndiaProject\254624 HPCL- White Oil Terminal\04 Electrical\Documents\13 Specifications\DG set\Rev.C\254624-400-SP-ELE007-Rev C.doc
VISAKH MARKETING INSTALLATION RESITEMENT PROJECT WHITE OIL TERMINAL & LPG TERMINAL Doc No: 254624-400-SP-ELE -007 Rev: C Page 3 of 32
List of Contents
Pages
1 2 2.1 2.2 2.3 3 4 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 5.13 5.14 6 7 8 9
Introduction ........................................................................................................................ 4 Location and Environmental Conditions............................................................................ 4 Plant Location..................................................................................................................... 4 Environmental Conditions.................................................................................................. 4 Electrical System Data ....................................................................................................... 4 Scope of Supply.................................................................................................................. 5 Codes and Standards .......................................................................................................... 8 Technical Requirements ..................................................................................................... 8 Operational Requirements.................................................................................................. 8 DG System Operation ........................................................................................................ 9 Accessories/Equipment:.................................................................................................... 12 Starting System: ............................................................................................................... 15 Fuel System: ..................................................................................................................... 15 Lubrication System:.......................................................................................................... 16 Cooling:............................................................................................................................ 16 Air intake/Ventilation:...................................................................................................... 16 Control Panels for D.G.Sets: ............................................................................................ 16 Motors for D.G. Auxiliaries: ............................................................................................ 18 Instrumentation & control ................................................................................................ 19 Name Plates:..................................................................................................................... 19 Makes of Components...................................................................................................... 20 Painting............................................................................................................................. 20 Inspection and testing:...................................................................................................... 20 Vendor documentation: .................................................................................................... 21 Installation, Testing and commissioning:......................................................................... 22 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
1
1.1
Introduction
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 Consultant Manufacturer / Vendor Shall Should Equipment Hindustan Petroleum Corporation Ltd. Mott MacDonald Consultants (India) Pvt. Ltd.[MMCI] Supplier of 415V D.G.Sets This is to be understood as mandatory in relation to the requirements of this document. This is to be understood as a strong recommendation to comply with the requirements of this document. 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. This specification does not relieve the Vendor from final guarantee as to materials, apparatus, workmanship and performance of the equipment supplied.
1.3
2
2.1
Location and Environmental Conditions

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.
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
DG-1
FOR PLANT LOADS (WHITE OIL TERMINAL) 415V, 1250 kVA, 0.8 PF., Diesel Generator Set in acoustic enclosure, complete with all the auxiliaries, ACB Set with busduct, Control panels, exhaust system, etc. 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. 415V, 350 kVA, 0.8 PF., Diesel Generator Set in acoustic enclosure, complete with all the auxiliaries, Control panels, exhaust system, etc.
DG-2
Set
DG-3
Set
DG-1
FOR PLANT LOADS (LPG TERMINAL) 415V, 1000 kVA, 0.8 PF., Diesel Generator Set in acoustic enclosure, complete with all the auxiliaries, ACB Set with busduct, Control panels, exhaust system, etc. 415V, 350 kVA, 0.8 PF., Diesel Generator Set in acoustic enclosure, complete with all the auxiliaries, Control panels, exhaust system, etc.
DG-3
Set
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 3.1.2 3.1.3
Alternator suitable for the above mentioned Diesel generator complete with RTDs, (Winding + Bearing) AC brushless excitory coupling between engine and alternator. Current Transformers in Alternator neutral for protections of Alternator. Following Panels for each DG Set. a) Engine Panel and Control & Monitoring Panel
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). Excitor Panel with AVR (With provision for remote control of speed / voltage, PF control). 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.
c) d)
e) f) 3.1.4 3.1.5
AMF Panel for DG1 & DG3 only. (Not required for DG-2) Synchronising System for DG1 only. (Not required for DG-2 & DG-3)
ACB with busduct connection within acoustic enclosure as required by statutory agencies. 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 Substation 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 3.1.9
Acoustic enclosure for each D.G. Set as per the norms laid down by statutory agencies, including internal illumination. 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.
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 3.2.2 3.2.3 3.2.4 Designing of Ventilation system for DG acoustic enclosure. Preparation of DG yard layout with all the DG set auxiliaries, housing Fuel system, lube oil system etc. Resolving engineering queries related to the equipment and components within the scope of supply. 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. Performing and coordinating all aspects of design. Providing expediting services and quality assurance with respect to ISO 9000 for all subvendors. Providing Quality Assurance. Exclusions from DG Vendors scope. DG set foundation. Civil work for DG Yard. Fire fighting system of DG yard. Lightning Protection for DG yard. Illumination / Area Lighting of DG yard.
3.2.5 3.2.6 3.2.7 3.3 3.3.1 3.3.2 3.3.3 3.3.4 3.3.5
3.3.6 3.3.7 3.3.8
415V DG Breaker panels in purchasers PMCC/MCC. Power & Control Cables except for cables listed in Clause No. 3.1.5 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
4.1
Codes and Standards

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 Second priority Third priority Fourth priority : : : : Purchase order and variations thereto Data/requisition sheets and drawings This engineering specification. 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
5.1 5.1.1
Technical Requirements Operational Requirements 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. 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. 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. 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. 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.
5.1.2 5.1.3 5.1.4
5.1.5
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. Motors re-acceleration schemes are not envisaged in case of Grid power failure & motors will be started again after starting of D.G. set. 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).
5.1.7 5.1.8
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. 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 a) Automatic Start (Automatic Main Failure scheme) 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.
5.2
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 a)
Individual DG system operational details as under: 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. DG-3 Operation detail: 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. 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 VENDORS 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. DG-3 Operation detail: 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.
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.
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 CTs to be accommodated in neutral terminal box shall be decided by vendor. The neutral terminal box shall be spacious enough for accommodating CTs. 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
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 provided. protection Generator stages. Winding RTDs (6 Nos. - 2 Nos. per phase) and Bearing RTDs (2 Nos.) to be 8 point Temperature Scanner for these RTDs shall be provided in Generator & metering Panel. Contact of Temperature Scanner will be used for tripping Breaker. These RTDS shall be suitable for early warning (alarms) and tripping
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
/ 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 vendors 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).
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..
5.9.1
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.
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 One One One One One One One One One Voltmeter (144 Sq.mm) with selector switch Ammeter (144 Sq.mm)with selector switch Frequency meter (45 Hz. To 55Hz.) Power Factor Meter (0.5 lead to 0.5 lead) KW Meter suitable for 3 phase, 4 wire KWH Meter suitable for 3 phase, 4 wire KVA Meter suitable for 3 phase, 4 wire KVAR Meter Hour meter 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 Purchasers use (Annunciation, etc.)
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. 2. 3. 4. 5. 6. Make Type of Enclosure Crompton Greaves / Siemens /ABB TEFC with IP-55 Degree of Protection.
Design Ambient Temperature for Motors shall be 45oC. Class of Insulation Class F with temperature rise restricted to class B
Terminal Box for Motors shall be amply sized to suit termination of PVC insulated aluminium armoured cables Painting Smoke Grey No. 692 (IS-5)
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: b) 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. 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.
Name plates shall contain the following information: a) b) c) d) Manufacturer Basic technical data such as rated voltage, rated current, RPM etc. Country of origin. 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 Coupling Guard Electric Panel Fuel tank & lines Radiator Exhaust Piping Exhaust Piping Supports : : : : : : : Smoke grey No. 692 (IS-5) Satin Blue No. 177 (IS-5) Silver grey No. 628 (IS-5) French Blue IS No. 166 (IS-5) Jet black Aluminium Smoke grey No. 692 (IS-5)
Final coat shall be of epoxy based. All unpainted parts shall be plated to prevent corrosion.
6
6.1
INSPECTION AND TESTING: 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 Owners 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:
Requirement of Owners 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. 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. Routine Test certificates to be submitted for Equipment and its all auxiliaries. Vendor to furnish required copies of test certificates, Ref Documents, Drawings, and Instruction Manuals before equipment are dispatched. 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. Any defects found by the TPI or the Owners 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. All spare parts shall be subjected to the same inspection standards and full material certification as the main order. The equipment shall not leave the Vendor / Sub-Vendors factory before all discovered defects have been rectified and without the written permission of the Owner/Purchaser. 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. 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/Consultants 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.
6.3
6.4 6.5 6.6
6.7
6.8 6.9 6.10
6.11
7
7.1
Vendor documentation:
All information listed here is to be furnished along with the offer as a minimum.
(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 7.3 The Manufacturer shall furnish the drawings and documents as per enclosed Requisition for Engineering Documents - RED Form [Appendix-D]. 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. 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.
7.4
8
8.1
Installation, Testing and Commissioning:

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. The installation shall comply with relevant Indian Standards, Indian Electricity Rules and statutory regulations that are in force in the place of installation. Vendor shall despatch Installation and Commissioning instructions at least 2 weeks before the arrival of the equipment. 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 equipments and finish painting of site fabricated steel work after pre-treatment like de-rusting, degreasing, primer coating etc.
8.2 8.3 8.4
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) j) Tightness of all bolts joints in busbars, motors, generator, engine etc., shall be checked. Insulation resistance of all electrical equipments 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 equipments, 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 manufacturers 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 manufacturers 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. 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. 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 manufacturers 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. 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 manufacturers instructions 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. Installation of safety appliances like rubber mat, carbon dioxide fire extinguishers, first aid box etc., shall be done.
c)
d)
e)
f)
g)
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) b) c) d) e) f) g) h) i) j) k) Starting of engine manual mode / simulated DG Control condition. Shut-off of the engine-manual mode/ electrical mode simulated faults of the alternator and engine. Over speed test. Interlock between DG breaker and grid supply. Governor speed control electrical /mechanical. Minimum time in seconds required by the set to deliver power at desired voltage and frequency starting from standstill condition Matching the DG phase sequence with grid supply phase sequence. Checking annunciator windows for all the faults simulated during testing. Continuous full load test as specified, by starting all the motor loads direct on line sequentially. Paralleling with Grid (Wherever applicable). Tabulation of all results in the mutually agreed format.
8.7 8.8
Vendor shall provide qualified personnel for installation and carryout site testing and commissioning of all equipment supplied under this contract. 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. It shall be contractors 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. Contractor shall ensure that no tests are applied which may stress the equipment above the limits recommended for field testing, by the manufacturer. Contractor shall be responsible for any damage that may occur to personnel / equipment resulting from improper testing procedures. 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).
b)
c) d) e)
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 :
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 Vendors scope. Statutory fees will be paid by Purchaser.
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 Spec. Clause No. 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
VENDOR REF. Conforms Yes/No Alternative Yes/No
Clarification
CLIENT : HPCL Spec. Clause No. 5.13 5.14 6 7 8 9 Appendix A: Appendix B: Appendix C: Appendix D: Appendix E: Appendix F: Conforms Yes/No Alternative Yes/No
VENDOR REF.
Clarification
Appendix-B: Codes & Standards IS 4722 IS 4728 IS 4889 IEC 60034 IEC 60529 IS 4729 IS 12065 IS 12075 IS 12082 BS 649 BS 4999 BS 5000 BS 6121 : : : : : : Rotating Electrical Machines Terminal marking and direction of rotation for rotating electrical machinery Methods of determination of efficiency of rotating electrical machines IEC Standard Voltages Degree of Protection provided by Enclosure (IP Code) Measurement of vibrations of rotating electrical machines Permissible limits of noise levels for rotating electrical machine Mechanical machines vibration of rotating of electrical rotating
Temperature rise electrical machines
measurement
Performance of reciprocating compression ignition Diesel Engine General requirements for Rotating Electrical Machines Specification for Rotating Electrical Machines of particular types or for particular applications Mechanical cable glands
Appendix-C: Recommended List of Vendors Engine : Caterpillar / Cummins / Detroit / Greaves / KOEL / PERKINS / MTU / Volvo. Zenith / BSI/ Jindal/ Khandalwal. NGEF/ Kirloskar/ Crompton Greaves / Stanford English Electric/Easun Reyrolle / ABB / Siemens / AREVA Chloride / Standard / UB-MEC/ AMCO / HBL Automatic electric / Afcoset / Caldyne Siemens / L&T / Schneider/ GECALSTHOM Cable corporation of India /Universal cables / Indian cable company / Asian cables /Polycab. L&T / Areva / ABB / Siemens / Merlin Gerin Areva / ABB / Siemens Siemens / Tele-mechanic / L & T /Control & Switch Gear GECALSTHOM / KAYCEE/ ABB / Siemens. Automatic electric / Siemens / KAPPA electricals /Pragati GEC / ALSTOM/ Yashmin / Bharani Electronics / MECO / Minilec Automatic electric industrial Meters Pvt. Ltd., / MECO / RISHAB / Enercon / L & T IMP / BHEL / Universal Instruments / AE Comet / HAWKE / HUMMEL Dowells/ Electropowerke / HAWKE GECALSTHOM/ Siemens / L & T / Telemecanique / RAAS Control / Teknic
Pipes Alternator Control & Relay panels Battery Battery charger & DC Board LT Switch board LT cables
: : : : : : :
MCCB / ACB Protection Relays, Aux. Relays LT contactor & Thermal O/L Relays Selector switches/ Control switches LT, CTS Annunciators Indicating Meters
: : : : : : :
Integrating meters
Brass / GI compression type cable : glands Tinned copper lugs : Indicating lamps (LED type only) : & Push buttons
Appendix-D: Requisition for Engineering Documents RED Form

Owners Office Hindustan Petroleum Corporation Ltd. Visakha Terminal, Resitement Project, VR-ATP Area, Naval Base Post, Visakhapatnam 530 014 SPECIAL INSTRUCTIONS Production Schedule Manufacturing, inspection & testing sequence plan DRAWINGS
OFFER
Distribution Office Mott MacDonald Consultants(I) Pvt. Ltd Kothari House, CTS No. 185 Off Andheri Kurla Road Andheri ( East), Mumbai 400059, India Prints 5 10 Required number for
APPROVAL FINAL
Documents shall be sent to: The Purchasing Office via courier service The Purchasing Office via courier service TIMING FOR SUBMITTAL - for approval 2 weeks after order date Documents shall be submitted to:
Approval drawings / Final drawings to be submitted under cover of an ADS form / FDS form respectively Submission of Following not limited to: Guaranteed Technical Particulars 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. Dimensional and cross sectional drawings & Foundation Plan for D.G.Set Suggested layout of D.G.Yard with all accessories and maintenance space Name Plate Drawing. 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. Connection and wiring diagrams of all panels supplied by DG package vendor. Detailed Cable and interconnection schedule for auxiliary Power & Control Cables for D.G. Package.(Including cables not in Vendors scope) Derating Curves Performance Curves torque, fuel consumption, engine speed and power output. P & I Diagrams for fuel oil system, lube oil system, Air starting system, Cooling water System, Exhaust System 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. Bill of Materials for D.G.Set, Fuel & lube oil system, Cooling water system, electrical system engine and alternator control system. Test Certificates and technical catalogues for bought out items and D.G.Set. Spares List for two Years Operation As Built Drawing
Prints
Prints
Disk
Prints - final issue 2 weeks after approval date
2 2
5 5
2 2
10 10
2 2 -
5 5 5 5
2 2 2 2
10 10 10 10
5 5
2 2
10 10
5 5 5
2 2 2
10 10 10
10
10
2 2 -
5 5 5
2 2 2
10 10 10
Purchasing Office via courier service
SPARE PARTS DOCUMENTS ESPIR forms including 1 transparency TEST AND INSPECTION DOCUMENTS Documents to be submitted under transmittal Manufacturing report Test Report / Data Curves Calibration Certificates for testing Instruments. Bought out Equipment Certificates.
10
Prints Documents shall be submitted to: 2 2 2 2 10 10 10 10
Purchasing Office via courier service within 4 weeks Of relevant test / inspection. Purchasing Office via courier service not later than time of
OPERATING DOCUMENTS Installation instructions Operating instructions Maintenance instructions ADDITIONAL REQUIREMENTS 1. Referenced standards / codes shall be the latest issue unless otherwise stated. 2 2 2 10 10 10
Dispatch of equipment. Combine into one manual
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.
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
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 1.0 1.1 1.2 1.3 Description ALTERNATOR a) Make b) Type a) Manufacturer's Make No. and Frame Size b) Conforming to Standard a) Rated 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) Power Factor a) Rated Voltage b) Number of Phases 1.6 1.7 1.8 1.9 Frequency Number of Poles Type of Enclosure a) Class of Insulation b) Temperature Class c) Impregnation for tropical service 1.10 1.11 1.12 % Overload for 1 hr. at Site Condition a) 50% Overload capacity b) Allowable % unbalanced load on generator Percentage Efficiency at a) P.F. - 0.8 - Full Load - Load - Load - Load 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 in Sec. in Sec. Hz., - % Volts, - % KVA % Unit To be filled in by Vendor
KVA
1.4 1.5
1.13
P:\Andheri\IndiaProject\254624 HPCL- White Oil Terminal\04 Electrical\Documents\13 Specifications\DG set\Rev.C\Appendix-E Guaranteed Technical Particulars-latest.doc
Doc No:254624-400-DS-ELE-008
Rev: C Unit
Page 2 of 5 To be filled in by Vendor
Sr. No 1.14 1.15 1.16
Description c) % Voltage Adjustment on AVR a) Type of Bearings b) Method of Lubrication Type of Excitation Unit Percentage Reactances of Alternator a) Sub Transient Reactance- xd" b) Transient Reactance - xd' c) Reactance - xd 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 -Maximum motor rating-180kW c) DG-3 Base load-309kVA -Maximum motor rating-30kW For LPG Terminal a) DG-1 Base load-865kVA -Maximum motor rating-55kW b) DG-3 Base load-250kVA -Maximum motor rating-22kW
% % %
1.17
2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8
ENGINE Manufacturer Engine Model Anti-Vibration Pad (vendor to Provide) Nominal Output Engine only / without Engine Driven Pumps Output of the Engine equipped with Auxiliary Drives required to be fed from DG Set % Average power output for 24 hours of operation available to user Maximum Overload % Overload for 1 hour at Site Conditions
Kw %
Doc No:254624-400-DS-ELE-008
Rev: C Unit
Sr. No 2.9 2.10 2.11 2.12 2.13 2.14 2.15 2.16 2.17 Nominal Speed Bore Dia.
Description
mm mm
Length of Strokes Cylinder Arrangements Number of Cylinders Total Swept Volume Compression Ratio Time required for starting from cold condition Heat Balance of DG Set - Engine O/P - Exhaust Gases(Heat rejection) - Coolings(Heat rejection to coolant) - Radiations Total Heat Input
litre
2.18 2.19 2.20 2.21 2.22 2.23 2.24 2.25 2.26 2.27
Machine Efficiency(Mechanical) Thermal Efficiency GD2 of Engine Maintenance Schedule of Engine (First maintenance required after commissioning) Sound level of Engine at distance of 1 M Exhaust Gas Flow Temperature of Exhaust Gas Radiator Cooled Engine only Type of Turbocharger Fuel Oil System - Fuel Day Tank of size & capacity - Specification of Fuel recommendation Maximum Fuel Oil Consumption Rate with 0% tolerance for various loads as listed below: 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
2.28
litres /KWH
2.29
Governing System a) Make
Doc No:254624-400-DS-ELE-008
Rev: C Unit
Sr. No
Description 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) 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
mm
3.0 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 4.0 4.1 4.2
D.G.Auxilliary Motor Type of motor Manufacturer Degree of protection Cooling classification Frame Size Class of Insulation Voltage Supply Rated Output Speed Efficiency Power Factor Line Current Starting System (DC) Battery operated Battery Chargers a) Manufacturer b) Type Amp Volts Kw RPS %
4.3
Batteries a) Manufacturer b) Battery type SMF, VRLA
Doc No:254624-400-DS-ELE-008
Rev: C Unit
Sr. No 5.0 5.1 5.3 a) b)
Description CIVIL REQUIREMENTS Weight of Engine with accessories Centre of Gravity of Engine
a) Weight of Generator b) Total weight of DG set along with acoustic enclosure Recommended crane/hoist capacity DIMENSIONS (L x B x H) Alternator Engine Overall Length Overall dimension with acoustic enclosure D.G.Shed mm
6.0 7.0 7.1 7.2 7.3 7.4 7.5
Appendix-F: Single Line Diagrams & Equipment layouts & SOQ (WOT & LPGT DG)
Sr. No. 1 2
Drawing Number White Oil Terminal 254624-400-ELE-4102 254624-400-ELE-4202 LPG Terminal 256324-500-ELE-4102 256324-500-ELE-4201
Description
Single Line Diagram 415V PMCC Equipment layout for Main substation & Transformer bay plan & section
3 4
Single Line Diagram 415V PMCC Equipment layout for Main substation & Transformer bay plan & section White Oil Terminal & LPG Terminal 254624-400-SC-ELE-007 WOT & LPGT DG SOQ

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

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VISAKH MARKETING INSTALLATION RESITEMENT PROJECT WHITE OIL TERMINAL & LPG TERMINAL Doc No: 254624-400-SP-ELE -007

SPECIFICATION FOR 415V D.G. SETS

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Location and Environmental Conditions

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3.1.1 3.1.2 3.1.3

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3.2.5 3.2.6 3.2.7 3.3 3.3.1 3.3.2 3.3.3 3.3.4 3.3.5

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3.3.6 3.3.7 3.3.8

Codes and Standards

5.1.2 5.1.3 5.1.4

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b) Transient voltage dip limited to 20 %

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a) Fuel Oil Day Tank

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6.4 6.5 6.6

6.8 6.9 6.10

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Installation, Testing and Commissioning:

8.2 8.3 8.4

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Appendix-A: Table of Compliance

VENDOR REF. Conforms Yes/No Alternative Yes/No

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Temperature rise electrical machines

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Appendix-D: Requisition for Engineering Documents RED Form

Prints - final issue 2 weeks after approval date

Purchasing Office via courier service

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Prints Documents shall be submitted to: 2 2 2 2 10 10 10 10

Dispatch of equipment. Combine into one manual

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Appendix-E: Guaranteed Technical Particulars Doc No: 254624-400-DS-ELE-008

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Page 2 of 5 To be filled in by Vendor

Sr. No 1.14 1.15 1.16

2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8

Page 3 of 5 To be filled in by Vendor

Governing System a) Make

Page 4 of 5 To be filled in by Vendor

Batteries a) Manufacturer b) Battery type SMF, VRLA

Page 5 of 5 To be filled in by Vendor

Sr. No 5.0 5.1 5.3 a) b)

6.0 7.0 7.1 7.2 7.3 7.4 7.5

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