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FOR
SCOPE OF ENQUIRY
1.1
The general character and the scope of work to be carried out under this
contract is illustrated in Drawings, Specifications and Schedule of
Quantities. The Contractor shall carry out and complete the said work
under this contract in every respect in conformity with the contract
documents and with the direction of and to the satisfaction of the Project
Manager. The contractor shall furnish all labour, materials and
equipment as listed under Schedule of Quantities and specified
otherwise, transportation and incidental necessary for supply,
installation, testing and commissioning of 1NO. OF 11KV, 1500KVA
AND 2NOS OF 11KV, 750 KVA D.G SET With Auto Synchronisation
Facility for Bharat Dynamics Limited, Bhanur, Medak district, A.P.
as described in the Specifications and as shown on the drawings. This
also includes any material, equipment, appliances and incidental work
not specifically mentioned herein or noted on the Drawings/Documents
as being furnished or installed, but which are necessary and customary
to be performed under this contract.
The scope of specification covers the design, manufacture, inspection
and testing at vendors / sub vendors works, packing, transportation
from place of manufacture to site, unloading and storing at site, complete
erection, testing and commissioning of various electrical equipment
required for operation of 1NO. OF 11KV, 1500KVA AND 2NOS OF
11KV, 750 KVA D.G SET With Auto Synchronisation Facility for
Bharat Dynamics Limited, Bhanur, Medak district, A.P.
The design, material, construction, manufacture, inspection, testing and
performance of all equipment shall comply with all currently applicable
standards, statutory regulations and safety codes in the locality where
the equipment will be installed.
1.2
The extent of scope under this contract includes all items shown in the
appropriate sketches and drawings not withstanding the fact that such
items may have been omitted from the specifications or schedules.
1.3
3. Auto Synchronising Control Panel with Auto start/stop and Auto load
sharing panel.
4. Exhaust piping, duly insulated with mineral wool and aluminium
sheet cladding.
5. Residential type Silencer, complete with GI supports, brackets
hardware etc.
6. Starting battery electrolyte in non-returnable containers complete
with stand and other accessories.
7. Day oil tanks in the case of diesel generator complete with supporting
stand, all accessories, filters, valves, fittings, level indicators, level
controllers with contacts.
8. MS pipes for fuel system, including all accessories, fittings, painting
of pipes and supports etc.
9. Hoisting and handling facilities such as cranes, tools and tackles
specially required for this kind of equipment and for lowering
equipment wherever it is to be installed.
10. Cables (HT)
11. Manual emergency hand pumps shall be provided in case of failure of
the automatic arrangements.
12. Supply and installation of Earthing System.
13. Internlocking and interconnection between DG PANEL and existing
11KV panel.
14.GENSET CONTROLS -
2.0
INSTRUCTIONS TO BIDDERS
2.1
Bidders shall submit all technical information and duly filled in data
sheets / schedules in soft form along with the bid.
2.2
Bidder is advised to visit the site and obtain all the data required and
other relevant details of existing facilities prior to submission of bid.
Ignorance of site conditions shall not be accepted as basis for any claim
for compensation.
2.3
All meters, instruments, gauges and other reference devices used for
testing/inspection shall have valid calibration certificate and the
Bidders shall note that the design ambient temperature for all electrical
equipment is 50C.
2.5
The contractor during the execution of the works shall co-ordinate with
other agencies associated with the project and shall work in harmony
with them without causing any hindrance or obstruction on the progress
of work in any way.
Other contractors and agencies that the contractor shall be required to
coordinate with are:
Internal / External Electrical Services Contractor
Contractors
regarding.
shall
co-ordinate
with
Electrical
services
contractor
3.0
4.0
ii.
iii.
iv.
All non current carrying metal parts are properly and safely
grounded in accordance with the specifications and appropriate
codes of practice.
The contractor shall provide all necessary instruments and labour for
testing. He shall make adequate records of test procedures and readings
and shall repeat any tests requested by the Project Manager
/Consultant. Test certificate duly signed by a authorized person shall be
submitted for scrutiny. If it is proved that the installation or part thereof
is not satisfactorily carried out then the contractor shall be liable for the
rectification and retesting of the same as called for by the Project
Manager / Consultant. All tests shall be carried out in the presence of
representative of Project Manager / Consultant. The above general
requirements as to testing shall be read in conjunction with any
particular requirements specified elsewhere. The contractor besides
above test, shall carry out witness test for performance at full load for 6
hrs and one hour at 110% of full load.
The DG shall be tested in the presence of Owners representative at
Suppliers works in accordance with latest prevailing standards and
codes. The successful passing of any such tests will not however
prejudice the right of Purchaser to reject the DG and its accessories, if
they do not comply with specifications when erected or perform complete
satisfactory operation as intended. Supplier shall provide the test
certificate for the bought out items used, if any in the assembly of DG.
5.0
5.1
DG sets
5.2
Exhaust system
Fuel system
General
Upon completion of work the performance test shall demonstrate the
following among other things:
6.0
i.
ii.
iii.
iv.
All non current carrying metal parts are properly and safely
grounded in accordance with the specifications and appropriate
codes of practice.
7.0
8.0
COMPLETION CERTIFICATE
On completion of the Generator installation, certificate shall be furnished
by the contractor countersigned by the 11KV licensed electrical
supervisor under whose direct supervision the installation was carried
out. This certificate shall be in the prescribed form as required by the
local supply authority.
9.0
TRAINING OF
MAINTENANCE
OWNERS
PERSONNEL
FOR
OPERATION
AND
Upon completion of all work and all tests, the Contractor shall furnish
necessary operators, labour and helpers for operating the entire
installation for a period of fifteen (15) working days of ten (10) hours
each, to enable the Owners staff to get aquainted with the operation of
the system. During this period, the contractor shall train the Owners
personnel in the operation, adjustment and maintenance of all
equipment installed.
10.0
GUARANTEE
Upon complete of work and before issuance of certificate of virtual
completion by the Project Manager, the contractor shall furnish written
guarantee indemnifying the owner against defective materials and
workmanship for a period of one year after acceptance. The contractor
shall hold himself fully responsible for reinstallation and / or
replacement, free of cost to Owner the following:
a. Any defective work or material or equipment supplied by the
Contractor.
b. Any material or equipment supplied by the Owner which is damaged
or destroyed as result of defective workmanship by the contractor.
c. In case of failure of the supplier, to get any defect rectified within
forty eight (48) hours, the Owner reserves the right to get necessary
repairs done on his own at the supplier cost.
11.0
12.0
DEMONSTRATION TO OWNER
Upon completion, devices subject to manual operation shall be operated
atleast five times in presence of Project Manager Consultants to
demonstrate satisfactory operation.
The contractor shall provide performance tests upon completion of the
installation. He shall arrange all necessary instruments, tools and
tackles to check sound level, vibration and the effectiveness of acoustical
treatment and vibration isolator installed.
13.0
14.0
15.0
POWER SHUTDOWN
The shall carry out the interlocking and interconnections works between
DG set auto synchronization panel and existing 11KV panel at MSDS
only duly designated 2 holidays between 10AM to 6PM with prior
intimation and permission.
16.0
17.0
TECHNICAL SPECIFICATION
FOR
1NO. OF 11KV, 1500KVA AND 2NOS OF 11KV, 750 KVA D.G. SET
1.0
SCOPE
This specification covers the requirements of design, manufacture,
assembly, testing, delivery, installation and commissioning of ONE
(1NO.) OF 11KV, 3 phase, 50 c/s, 1500 KVA DG Set AND TWO (2Nos)
of 11KV, 3 phase, 50 c/s, 750 KVA DG Set, Diesel Generating sets
with Auto Synchronization Facility required for Bharat Dynamics
Limited, Bhanur, Medak district, A.P.
2.0
SITE CONDITIONS
2.1
Ambient Temperature
Maximum 45C
Minimum 10C
2.2
Relative Humidity
2.3
Altitude
3.0
3.1
11KV
3.2
No. of Phases
3.3
Frequency
50 c/s
3.4
Fault level
40 KA at 11KV
3.5
Neutral Earthing
Solidly earthed
3.6
Auxiliary supply
4.0
STANDARDS
The Diesel Generating set and accessories shall conform to the requirements of
latest editions of relevant India Standards some of are listed below: -
a.
b.
BS
IS
:
:
649
4722
10
c.
d.
IS
IS
e.
5.0
:
:
2516
2147
ALTERNATOR:
Alternator 1500 KVA and 750KVA at 1500 RPM, 11KV, 3 phase conforming to BS /
IS Standards.
The Alternator is brushless alternator. The alternator has the following features
- Seperately excited, self-regulated
- Class H insulation
- Salient pole revolving field
11
It shall offer advanced levels of functions for reliability and optimum genset
performance.
The control system shall have easy servicing capabilities that allow system parameters
to be interrogated, monitored and adjusted with a PC.
Features:
- Digital governing
- Digital voltage regulation
- protection for true alternator O/C protection
- Analog/ bargraph/ digital AC output metering
- Battery monitoring system to sense and warn against a weak battery condition
- Digital alarm and status message display
- Genset monitoring : Displays status of all critical engine and generator set functions
- Smart starting control system: Integrated fuel ramping to limit black smoke and
frequency overshoot
- Advanced serviceability
- network capability
MOUNTING ARRANGEMENT:
Engine and alternator are mounted on a common MS fabricated base frame.
12
FUEL TANK:
M.S. Fabricated stand alone with the capacity of 990 Litres external Fuel Tank
complete with level indicator, fuel inlet and outlet, air vent, drain plug, inlet
arrangement for direct filling and Man hole.
BATTERY :
Set of 4 Nos.12 Volts, uncharged maintenance free batteries with leads and
terminals.
Typical Dimension Details & Weight of D.G.Set WITH OUT Acoustic Enclosure:
L X W X Ht.
Overall Size without silencer: 60900 X 2075 X 2850 mm
Overall Size of Foundation: 6200 X 3000 X Depth as pet site conditions (150
mm above ground level)
Weight Dry 12250 kGs
The present scope of work shall include but not be limited to the following: a.
Supply and Installation of Diesel Engine, Alternator and AMF with Auto
Synchronisation control panel.
b.
Supply and Installation of all accessories and components for assembly such as
couplings, base frame, silencers, fuel day tank, 11KV power and control cables
upto MAIN panel and earthing including maintenance free earth pits as per IE
rules.
c.
d.
Supply and Installation of fuel and exhaust piping and insulation as required
for exhaust piping.
e.
Supply of all special tools for maintenance, and safety accessories as per
standard practice and anti vibration pads.
13
f.
g.
h.
Carrying out tests and load trials on assembled unit at site in the presence of
owner to fulfill the performances guarantee.
i.
Obtaining
Electrical
Inspectorate
approval
of
layout
drawings
and
Installation.
j.
Getting safety and approval certificate from Local CEIG/ CEA Authorities for
D.G.-Sets.
k.
Local PCB Norms to be implemented for getting NOC for installation of D.G.Sets, Stack height and noise level as per PCB norms. It is the responsibility of
the D.G.-Set manufacturer/Contractor to get the necessary license from local
PCB for operating the D.G.-Sets.
l.
Liaison with concerned authorities and obtaining Explosive Licence and liason
with APTRANSCO and getting necessary approvals.
m.
The stack height shall be as per the PCB norms and the stack structure shall
be provided with Lightning Arrestor (ERICO) with aviation lamp and with
separate two earth pits for the structure.
n.
o.
p.
The Auto-Synchronization panel with AMF module should have BMS options for
monitoring the parameters and controlling the D.G.-Sets in Auto as well as in
manual mode.
6.0
DIESEL ENGINE
The Diesel Engine specifications shall be as follows: -
6.1
Type
6.2
Rating
6.3
No. of Cylinders
16
14
6.4
No. of strokes
6.5
BHP
6.6
RPM
1500
6.7
Overload rating
As per BS 5514
6.8
Type of governing
6.9
Maximum speed
Variation on a change
Of load upto 20%
6.10
Type of fuel
6.11
Fuel consumption
6.12
Type of starter
6.13
Type of Engine
Cooling
6.14
Type of coupling to
Generator
6.15
i.
j.
k.
l.
m.
n.
o.
Aftercooler
Air Cleaner
Base Frame
Crankcase breather
Lubricating oil cooler
Exhaust fitting flange
Muffler Residential
Filters
i.
Primary Fuel
ii.
Full flow-lubricating oil
Governor Cat Electronic
Lifting eyes
Manifold exhaust, dry pumps
i.
Fuel Transfer
ii.
Lubricating oil, Gear driven
iii.
Jacket water, gear driven
Radiator
Shutoff electronic
Battery, battery rack
Starting electronic, 12V DC
15
7.0
p.
Mounting system
q.
Fuel tank base
r.
Any other item as may be required as recommended by manufacturer.
ALTERNATOR
The alternator shall be double bearing, revolving field type conforming to IS:
4722 as per specifications given below: -
a.
Rated voltage
11KV
b.
Rated KVA
c.
0.8
d.
No. Of phases
e.
Frequency
50Hz.
f.
Type of stator
Connection
Star connected
g.
Percentage regulation
+/- 5%
h.
Type of excitation
i.
Insulation class
j.
Type of enclosure
k.
Alignment
l.
Overspeed capability
m.
Wave form
n.
Paralleing capability
o.
Voltage
11KV
p.
Voltage regulation
Less than 1%
q.
Voltage adjustment
5%
r.
s.
Less than 3%
16
t.
i.
ACCESSORIES
Cable Termination end box suitable to receive and terminate for 3C X 300 Sq
mm 11KV, HT cable.
ii.
iii.
8.0
b.
Incomers
Each incomer consisting of the following:
3 Nos
1.
1 No.
2 Nos.
1.
1 No.
2.
Meters
a. Digital Kilowatt meter, flush mounting,
96 sq.mm
1 No.
1 No.
17
3.
4.
5.
SWITCHES
a. 2 Pole ON/OFF DC Supply selector
switch 16A rating
1 No.
1 No.
TIMERS
a. Electronic type timer with 2 change
over on delay contacts with coil
voltage 240V AC.
1 No.
1 No.
1 No.
1 No
1 No.
d. Synchronising lamp
2 Nos.
1 No.
1 No.
1 No.
1 No.
i. Aux contactor
1 set
1 No.
2 Nos.
4 Nos.
4 Nos.
18
8.1
The panel shall be further complete with ferruled internal wiring, foundation
bolts, name plates etc.
8.2
The electronic Microprocessor based AMF module shall contain the following
control and monitoring features.
-
a. LCD digital readout for Engine oil pressure, Coolant temperature, Engine RPM,
System DC volts, Engine running hours, Generator AC volts, AC Amps and
frequency.
19
The scope also includes all necessary components which are required for full
filament of the system for Auto start, Auto synchronisation and load sharing.
9.0
ACCESSORIES
The following accessories shall be supplied: -
9.1
9.2
9.3
9.4
9.5
9.6
10.0
3 Sets
b.
c.
d.
e.
20
11.0
f.
g.
13
h.
i.
j.
k.
l.
1 set
m.
Battery
PAINTING
The engine, alternator, base frame and control panel shall be pained with IS
631 shade (Light Grey).
12.0
SHOP TESTS
Routine tests shall be conducted on the diesel engine, Alternator and control
panel at the manufacturers works and test certificates shall be furnished. The
tests on control panel shall be conducted in the presence of Owner/Owners
representative.
Witness Test by Owner / Consultant at Manufacturers work station for 2 hours
on each DG Set to be included in the DG price 0.1%, 25 %, 50%, 75%, 100%
and 110% load for 10 minutes.
13.0
DOCUMENTATION
As a part of the equipment supply, following documents shall be supplied for
our/Owners approval/records.
Records
a.
b.
21
d.
e.
f.
g.
h.
Fuel piping
i.
j.
k.
l.
Instruction Manual
m.
n.
Catalogues
o.
14.0 PACKING
The diesel engine, alternator, control panel etc. shall be suitably packed for
shipment to site by road. A complete list of parts (Packing list) shall be
furnished to the owner in duplicate.
15.0
SPARES
A recommended list of spares for two years operation of the unit shall be
submitted along with the bid.
22
16.0
PREFERRED MAKES
a.
Engine
CUMMINS/CATERPILLAR/PERKISON/
b.
Alternator
STAMFORD/TOYODENKI/LEROY SOMER
c.
VCB
GE/ABB/SCHNEDER
d.
Control Fuses
GE CONTROLS/SIEMENS/C & S
e.
KWH Meter
BHEL/SIMCO/HPL/ENERCON
f.
Battery
17.0
The D.G. set shall be installed over the Anti vibration mounts and the
alignment shall be carried out. The alignment shall be well within the limits
specified by the manufacturer.
The installation of cabling and earthing upto the control panel shall be carried
out and this shall comply with the statutory requirements. Any improvement
modification called for the electrical inspectorate shall be carried out at no
extra cost.
18.0
FIELD TESTING
After the assembly the unit shall be tested in the present of the client. The
following tests shall be conducted on the engine and alternator.
a.
b.
c.
23
d.
Determining efficiency
e.
f.
Checking regulation
g.
h.
19.0
19.1
ENGINE
a)
Make
b)
Type
c)
No. of cylinders
d)
RPM
e)
f)
Type of Governor
g)
Overload rating
h)
Type of fuel
i)
j)
Type of stating
k)
Type of cooling
l)
List of Accessories
m)
n)
o)
24
Lube Oil
19.2
i)
Load
ii)
Load
iii)
Load
iv)
Full load
p)
q)
Shade of paint
r)
The maximum rating of motor than be started on the DG set using DOL
starter.
ALTERNATOR
a)
Make
b)
Type
c)
d)
No. of Poles
e)
Type of excitation
f)
g)
Percentage regulation
h)
Synchronous reactance
i)
Rated voltage
j)
Rated current
k)
Guaranteed efficiency
i)
Load
ii)
Load
iii)
Load
iv)
Full Load
l)
Weight of Alternator
m)
25
19.3
GENERAL
a)
Packed
ii)
Unpacked
b)
c)
d)
e)
19.4
CONTROL PANEL
a)
Make of Panel
b)
Make of VCB
c)
d)
Whether separate sealable compartment provided for KWH Meter and CTs
e)
f)
Shade of Painting
19.5
BATTERY
a)
Make
b)
Type
c)
Voltage/Cell
d)
Capacity in AH
26
parameter
Area category
Generator sets
commissioning
date on or after
1.7.2005
upto 75 mw
710
upto 150 mw
NHMC(AS C) (AT
15%O2), MG NM
PM(AT
15%O2)DISEAL
FUELS HSD &
LDO
FURANCE OILS
LSHS & FO
Both A & B
100
Both A & B
75
Both A & B
A
B
SATCK HEIGHT
(for generator set
commissioned
afert 1.7.2003)
100
Both A & B
150
<2%
<4%
FOR ONLY
UPTO 5 MW
27
iii.
EMISSION LIMITS FOR DIESEL ENGINES (UPTO 800 KW) FOR GENERRATOR
SETS (GENSETS) APPLICATIONS
Capacity of
diesel
engines
Date of
implementa
tion
1.2.2005
Somke
Test
limited(light cycle
absorption
co-effient,
m-1)(at full
load)
No HC CO PM
Troque Weight
X
%
ing
factors
100
0.05
9.2 1.3 3.5 0.3 0.7
1.7.2004
50
0.30
1.7.2004
25
0.30
1.7.2004
10
0.10
UPTO 19
KW
>19 KW
UPTO
176KW
>176 KW
UPTO
800KW
Satck
height (for
generator
sets
commissio
n as per
sept 2005)
Emission
limits(g/kw-hr) for
Acronyms Used
MW
NOx
NO2
O2
NMHC
C
PM
CO
SO2
ppmv
FO
HSD
:
:
:
:
:
:
:
:
:
:
:
:
28
LDO
LSHS
kPa
mm
kg/hr
mg / Nm3
:
:
:
:
:
:
29
NOISE LEVEL
Noise level outside DG room shall not be more than 70 dBA at a distance of 1.5
meter.
PERFORMANCE
The specification indicates the general layout and measures required for
meeting the end noise and vibration requirements. The contractor shall include
in his offer whatever other materials are required to be supplied for satisfactory
installation and performance of the system so as to meet the end criteria.
30