VISAKH MARKETING INSTALLATION RESITEMENT
PROJECT – WHITE OIL TERMINAL & LPG TERMINAL
Doc No: 254624-400-SP-ELE -007
Rev: C
Page 1 of 32
SPECIFICATION
FOR
415V D.G. SETS
Hindustan Petroleum Corporation Ltd
Mott MacDonald Consultants (India) Pvt. Ltd.
Visakha Dispatch Station
Kothari House, CTS No. 185
VR-ATP Area, Naval Base Post
Off Andheri - Kurla Road
Visakhapatnam - 530 014
Andheri (East)
Andhra Pradesh
Mumbai 400 059
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VISAKH MARKETING INSTALLATION RESITEMENT
PROJECT – WHITE OIL TERMINAL & LPG TERMINAL
Doc No: 254624-400-SP-ELE -007
List of Contents
Rev: C
Page 3 of 32
Pages
1
Introduction ........................................................................................................................ 4
2
Location and Environmental Conditions............................................................................ 4
2.1
Plant Location..................................................................................................................... 4
2.2
Environmental Conditions.................................................................................................. 4
2.3
Electrical System Data ....................................................................................................... 4
3
Scope of Supply.................................................................................................................. 5
4
Codes and Standards .......................................................................................................... 8
5
Technical Requirements ..................................................................................................... 8
5.1
Operational Requirements.................................................................................................. 8
5.2
DG System Operation ........................................................................................................ 9
5.3
Accessories/Equipment:.................................................................................................... 12
5.4
Starting System: ............................................................................................................... 15
5.5
Fuel System: ..................................................................................................................... 15
5.6
Lubrication System:.......................................................................................................... 16
5.7
Cooling:............................................................................................................................ 16
5.8
Air intake/Ventilation:...................................................................................................... 16
5.9
Control Panels for D.G.Sets: ............................................................................................ 16
5.10
Motors for D.G. Auxiliaries: ............................................................................................ 18
5.11
Instrumentation & control ................................................................................................ 19
5.12
Name Plates:..................................................................................................................... 19
5.13
Makes of Components...................................................................................................... 20
5.14
Painting............................................................................................................................. 20
6
Inspection and testing:...................................................................................................... 20
7
Vendor documentation: .................................................................................................... 21
8
Installation, Testing and commissioning:......................................................................... 22
9
Statutory Approval: .......................................................................................................... 24
Appendix-A: Table of Compliance .............................................................................................. 25
Appendix-B: Codes & Standards ............................................................................................... 27
Appendix-C: Recommended List of Vendors ............................................................................ 28
Appendix-D: Requisition for Engineering Documents .............................................................. 29
Appendix-E: Guaranteed Technical Particulars ......................................................................... 31
Appendix-F: Single Line Diagrams & Equipment layouts & SOQ (WOT & LPGT DG)......... 32
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VISAKH MARKETING INSTALLATION RESITEMENT
PROJECT – WHITE OIL TERMINAL & LPG TERMINAL
Doc No: 254624-400-SP-ELE -007
Rev: C
Page 4 of 32
1
Introduction
1.1
This specification covers the minimum requirements for the Design, Engineering, Supply &
Material procurement, Fabrication, Assembly, Painting, Inspection at manufacturers works,
Supply & Delivery to site, Erection, Testing and Commissioning of 415V Emergency D.G. Sets
for “White Oil Terminal project & LPG Terminal Project” of M/s. HPCL, located at
Visakhapatnam, A.P., India.
Following are the definitions:
Owner/Purchaser
Hindustan Petroleum Corporation Ltd.
Consultant
Mott MacDonald Consultants (India) Pvt. Ltd.[MMCI]
Manufacturer / Vendor
Supplier of 415V D.G.Sets
Shall
This is to be understood as mandatory in relation to the
requirements of this document.
Should
This is to be understood as a strong recommendation to
comply with the requirements of this document.
Equipment
This is to be understood as vendor supplied equipment
with all accessories.
1.2
The Vendor shall ensure that the design complies with the requirements of this specification,
and its referenced specifications and standards. The Guaranteed Technical Particulars, Appendix
E, which forms part of this specification, shall be completed by the Vendor. The Vendor shall
highlight any non-compliance at the offer stage in the Table of Compliance, Appendix A. Not
providing completed compliance table and Guaranteed Technical Particulars can cause rejection
of the offer. Failure to clearly identify specific deviations shall be assumed by the Purchaser to
be total compliance with the specification.
1.3
This specification does not relieve the Vendor from final guarantee as to materials, apparatus,
workmanship and performance of the equipment supplied.
2
Location and Environmental Conditions
2.1
Plant Location
White Oil Terminal project & LPG Terminal project of M/s. HPCL are located at
Visakhapatnam, A.P, India. The D.G.sets for White Oil Terminal & LPG Terminal shall be
located in their respective D.G.Yards within Plant Area.
2.2
Environmental Conditions
Refer Doc No.: 254624-400-SP-GEN-001 for White Oil Terminal & 256324-500-SP-GEN-001
for LPG Terminal.
2.3
Electrical System Data
Refer Doc No.: 254624-400-DS-ELE-001 for White Oil Terminal & 256324-500-DS-ELE-001
for LPG Terminal.
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VISAKH MARKETING INSTALLATION RESITEMENT
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Doc No: 254624-400-SP-ELE -007
3
Rev: C
Page 5 of 32
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.
DG-1
Unit
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.
Quantity
DG-2
Set
1
DG-3
415V, 350 kVA, 0.8 PF., Diesel
Generator Set in acoustic enclosure,
complete with all the auxiliaries, Control
panels, exhaust system, etc.
Set
1
DG-3
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.
Set
Remarks
1
415V, 1250 kVA, 0.8 PF., Diesel
Generator Set in acoustic enclosure,
complete with all the auxiliaries, ACB
with busduct, Control panels, exhaust
system, etc.
DG-1
3.1
Item Description
1
1
Scope shall include the following:
D.G. Set complete with Engine, Main Generator Control & Protection Panel, ACB with busduct,
Engine Control Panel, electronic governer, starting system, Air intake system, fuel supply
system, lubrication system, turbocharger, exhaust system with silencer, cooling system, earthing
system, etc.
3.1.1
Alternator suitable for the above mentioned Diesel generator complete with RTD’s, (Winding +
Bearing) AC brushless excitory coupling between engine and alternator.
3.1.2
Current Transformers in Alternator neutral for protections of Alternator.
3.1.3
Following Panels for each DG Set.
a)
Engine Panel and Control & Monitoring Panel
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Page 6 of 32
b)
Main Control & Protection Panel for Generator: MCP shall be supplied separately &
located in sub-station. (Refer enclosed Sub-station equipment layout attached in
Appendix-F).
c)
Excitor Panel with AVR (With provision for remote control of speed / voltage, PF
control).
d)
Engine Starting system with Batteries and Charger System, DC Distribution Boards
• Batteries mounted in a separate stands for DC supply for controls and other
requirements.
• Battery Charger (trickle as well as boost charger) with required metering and
protection for charging above batteries.
e)
AMF Panel for DG1 & DG3 only. (Not required for DG-2)
f)
Synchronising System for DG1 only. (Not required for DG-2 & DG-3)
3.1.4
ACB with busduct connection within acoustic enclosure as required by statutory agencies.
3.1.5
Cabling
Vendor to supply Cables for engine instrumentation, temperature scanner, special cables such as
screened cables within package and Cables between Engine and Engine Panels. Any Cabling
within DG Package i.e. for interconnection between Engine and Vendor supplied Panels,
between two Vendors supplied Panels shall be by DG Vendor. Scope of Cabling shall also
include supply of termination material such as glands, lugs, etc. for Cables supplied by Vendor.
Cable MTO shall be finalised by DG vendor based on approved Layout. (Refer enclosed 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
Acoustic enclosure for each D.G. Set as per the norms laid down by statutory agencies, including
internal illumination.
3.1.9
Complete exhaust system including residential type silencer, spark arrester and exhaust pipe for
each DG Set as per pollution control norms.
3.1.10 Radiator type cooling system
3.1.11 Lube Oil tank & associated System
3.1.12 Fuel oil system with day tank for each D.G. Set & additional fuel pumping system along with
filters etc. This system shall also comprise of flameproof level switches for high and low level
alarm as well as trip.
3.1.13 Base frame for D.G.Set. Stress relieving to be done for base frame.
3.1.14 Anti-vibration pads for DG Set. These pads shall be spring mounted pads of reputed make.
These shall be mounted between base frame and plain foundation slab.
3.1.15 Coupling & Guards.
3.1.16 Structural Steel for supports for piping supplied by Vendor and for supports of tanks, silencers
supplied by Vendor.
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PROJECT – WHITE OIL TERMINAL & LPG TERMINAL
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Rev: C
Page 7 of 32
3.1.17 Platforms, Ladders and Handrails as required.
3.1.18 Include all plant, machinery, material, all accessories and auxiliaries, measuring and control
equipments, all necessary interconnecting pipes and pipe fittings, wiring conduits of instrument /
sensors upto terminal box mounted on equipment, safety devices and material which are not
specially mentioned but are required to complete the equipment offered in every respect for its
satisfactory operation.
3.1.19 All the required documentation as per ‘Requisition of Engineering Documents’ -- RED form.
3.1.20 Erection / Installation and Commissioning of DG Sets.
3.1.21 First fill of lubricants & consumables including fuel oil for commissioning till performance
guarantee test.
3.1.22 DG Set running for load trial, Paralleling with APSEB grid, Operation Check.
3.1.23 Set of service tools & tackles for maintenance.
3.1.24 Commissioning spares & Spares for 2 Years operation.
3.1.25 Minor civil works like grouting chipping, drilling holes, Civil works for earthing & cable laying
etc.
3.1.26 Surface coating & final painting of complete system.
3.1.27 All the protection, monitoring and recording equipment.
3.1.28 All statutory approvals.
3.2
Engineering Services:
The Vendor shall provide engineering services, which shall include, but not necessarily be
limited to the following:
3.2.1
Designing of Ventilation system for DG acoustic enclosure.
3.2.2
Preparation of DG yard layout with all the DG set auxiliaries, housing Fuel system, lube oil
system etc.
3.2.3
Resolving engineering queries related to the equipment and components within the scope of
supply.
3.2.4
Co-ordination with L.V. Switchgear (PMCC) vendor for necessary feed back on DG control
circuitry. For further details refer Single Line Diagram and equipment Layout attached in
Appendix-F.
3.2.5
Performing and coordinating all aspects of design.
3.2.6
Providing expediting services and quality assurance with respect to ISO 9000 for all subvendors.
3.2.7
Providing Quality Assurance.
3.3
Exclusions from DG Vendor’s scope.
3.3.1
DG set foundation.
3.3.2
Civil work for DG Yard.
3.3.3
Fire fighting system of DG yard.
3.3.4
Lightning Protection for DG yard.
3.3.5
Illumination / Area Lighting of DG yard.
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VISAKH MARKETING INSTALLATION RESITEMENT
PROJECT – WHITE OIL TERMINAL & LPG TERMINAL
Doc No: 254624-400-SP-ELE -007
Rev: C
Page 8 of 32
3.3.6
415V DG Breaker panels in purchaser’s PMCC/MCC.
3.3.7
Power & Control Cables except for cables listed in Clause No. 3.1.5
3.3.8
For LPG Terminal project – Supply, Erection, Testing and Commissioning of DG-2 (500kVA)
415V Emergency D.G. Set. Existing DG will be re-sited & erected at a later date by Owner and
the same will be used as DG-2.
4
Codes and Standards
4.1
General
The 415V Emergency D.G. Sets shall meet the requirements of this specification and latest
edition of applicable standards listed in enclosed Appendix-B.
4.2
Conflicting Requirements
In case of conflict between documents relating to the enquiry or purchase order, the following
priority of documents shall apply.
First priority
:
Purchase order and variations thereto
Second priority
:
Data/requisition sheets and drawings
Third priority
:
This engineering specification.
Fourth priority
:
Indian standards/International standards.
Note: Should any conflict arise either before or after order placement the Vendor shall
immediately inform the Purchaser for technical resolution of the conflict.
5
5.1
Technical Requirements
Operational Requirements
5.1.1
The diesel generator (prime power rating) set shall be rated at site ambient temperature &
environmental conditions. Diesel generators shall be provided at the White Oil Terminal & LPG
Terminal to facilitate supply to certain essential loads during periods of non-availability of the
units and supply critical station auxiliaries during prolonged shutdowns.
5.1.2
The D.G.Set shall be capable of delivering continuously at the generator terminals, at 0.8 p.f.
lag, when operating under the site and ambient conditions.
5.1.3
D.G.Set shall be capable of satisfactorily providing an output 10 % in excess of the rated output
at the same speed for one hour in 12 hours continuous running.
5.1.4
The design parameters of the generator and excitation system shall be so chosen that the set is
stable while running at any load between no-load and full load, sudden loss of load and also
during starting of motors.
5.1.5
Self excited, self regulated excitation system along with fast response governor shall ensure that
the set comes to full speed & delivers rated output within 10 second after getting starting signal.
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5.1.6
Under transient operating condition, the time of return to within ± 3% of steady state voltage
when permitted step down load is suddenly applied shall be less than one second (assuming
speed to be constant). Further the speed droop due to such loading shall be corrected to ensure
50 Hz ±1% Hz within less than 3 seconds (momentary fluctuation in frequency shall be less than
±1 Hz). Governing system shall ensure minimum fluctuation during load changes. Inertia
constant of the rotating system shall aid the governing system. Class A1 governing system
preferably using wood ward PSG governor shall be offered. Speed droop shall be continuously
adjustable.
5.1.7
Motors re-acceleration schemes are not envisaged in case of Grid power failure & motors will be
started again after starting of D.G. set.
5.1.8
D G set shall meet the DOL starting requirement of induction motors. kW ratings of motors that
can be started DOL shall be indicated under following conditions:
a) Step load BHP prime mover engine can take (transient voltage dip for above
conditions shall be furnished).
b) Transient voltage dip limited to 20 %
5.1.9
The diesel engine set shall be provided in an acoustic enclosure as per norms laid down by
Pollution Board / statutory authorities. The enclosure shall be suitable for the environmental
conditions at site and shall be designed to prevent the ingress of dust, sand and moisture.
5.2
DG System Operation
The Diesel Generator Sets shall be suitable for manual start and auto start. In manual start the
Diesel Generator shall be started manually by an operator. In auto start the Diesel Generator
shall start on receiving an impulse from under voltage relay.
5.2.1
Manual Mode
In this mode of operation, the operator shall manually start the engine from Main Control Panel
which is located in sub-station after ensuring respective Bus-coupler and Transformer breakers are
in off condition and carrying out necessary initial steps. The operator shall give closing command
to circuit breaker after the voltage builds up to rated value.
5.2.2
Automatic Start (Automatic Main Failure scheme)
a)
Auto mode
This shall be effective in Auto position of AUTO / MANUAL Selector switch located in Main
control and protection panel. The diesel generator set will normally be at rest. Upon failure of
plant normal supply, an impulse will be extended. The impulse shall be normally from an under
voltage relay. Upon receipt of this impulse, D.G.Set shall be started automatically and brought to
rated speed and generator voltage brought to rated value. All accessories required for starting and
completion of various sequences of operation for the above purpose shall be provided. In case the
DG fails to start and run up on first attempt the engine cranking shall be repeated two more times.
When engine does not respond to three impulses, it shall be locked out and alarm given. Contacts
for repeat alarm shall be provided.
Vendor to ensure that upon failure of supply, DG-1 shall always be available within maximum
10 seconds to take care of load. Suitable scheme to achieve this shall be developed by Vendor
within Main Control and protection Panel.
Immediately after the diesel set reaches rated speed and generator reaches rated voltage, a
Voltage and frequency monitoring relay located in Main Control and protection panel shall
extend an impulse for closing generator breaker.
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b)
Rev: C
Page 10 of 32
Manual Test Mode
Facility for manually starting the diesel generator sets for routine testing shall be provided. This
shall be done by putting the AUTO / MANUAL Selector switch in Manual Position and by
pressing the Push Button on engine control panel. The scheme of operation shall be such that
the closing impulse for Generator breaker shall not be extended.
c)
Starting time:
The total time from the receipt of starting impulse for diesel generator set till the diesel
generator set reaches rated speed and rated voltage shall not be more than 10 seconds.
5.2.3
Individual DG system operational details as under:
a)
FOR PLANT LOAD (WHITE OIL TERMINAL)
Normally the Transformer – 1(distribution transformer (Grid)) shall feed entire terminal load
and all DGs shall be off and all Bus coupler of the main panel (PMCC) located in Main
substation shall be closed.
DG 1 Operation detail:
In case of grid power failure during daytime, DG-1 shall start on AMF signal from line PT.
When DG-1 is running, Bus coupler-1 and main Transformer breaker shall open. DG-1 shall
feed the entire load excluding Tank Wagon filling MCC, Bunkering/shipping MCC & Wagon
filling Gantry lighting load (LDB). Accordingly DG Vendor shall provide all interlocks and
extend the closing command to DG-1 breaker in substation.
In case DG-1 is running and grid power supply is resumed, the grid incomer ACB shall be closed
through synchronizing with DG-1 Incomer ACB and after pre set delay the DG-1 Incomer ACB
shall trip. Thus only momentary paralleling of DG-1 and Transformer incomer is envisaged.
Accordingly DG vendor shall include all interlocks and extend trip command DG-1 breaker.
Supply to Tank wagon filling MCC, Bunkering & shipping MCC & Wagon filling Gantry
lighting load (LDB) shall be restored by closing Bus-coupler (B/C-1).
During night when there is no operation in the terminal, the AMF starting scheme for DG-1 shall
have to be disabled (i.e. the Auto/Manual selector switch has to be put on Manual) in order to
enable the critical DG-3 to start on AMF.
DG-2 Operation detail:
In case of grid power failure, DG -2 shall be started manually when Wagon filling,
Bunkering/shipping/OMC operations are required. When DG-2 is working, Bus-coupler (B/C-1)
connecting these loads (on bus-2) with other loads (on bus1 & bus-3) shall be kept open.
Changeover to normal supply shall be dead manual changeover. Accordingly DG vendor shall
include all interlocks and extend the closing /Tripping Command to DG-2 Breaker in substation.
DG-2 shall not be paralleled with the grid any time or any other DGs.
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.
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In case of grid supply failure during night, the critical DG-3 shall start on AMF signal & feed the
critical load. During night when there is no operation in the terminal, the AMF starting scheme
of DG-1 shall be disabled (i.e. the auto/manual selector switch to be put on manual) in order to
enable the critical DG-3 to start on AMF. Changeover to normal supply shall be dead manual
changeover. Accordingly DG vendor shall include all interlocks and extend closing/Tripping
command to DG-3 Breaker. The critical DG-3 shall not be paralleled with the grid or any other
DGs.
b)
FOR PLANT LOAD (LPG TERMINAL)
Normally the Transformer – 1(distribution transformer (Grid)) shall feed entire terminal load
and all DGs shall be off and all Bus coupler of the main panel (PMCC) located in Main
substation shall be closed.
DG 1 Operation detail:
In case of grid power failure during daytime, DG-1 shall start on AMF signal from line PT.
When DG-1 is running, Bus coupler-1 and main Transformer breaker shall open. DG-1 shall
feed the entire load excluding Tank Truck & Tank Wagon filling LPG load (T/T and T/W MCC)
& T/T and T/W Gantry lighting load (T/T & T/W LDB). Accordingly DG Vendor shall provide
all interlocks and extend the closing command to DG-1 breaker in substation.
In case DG-1 is running and grid power supply is resumed, the grid incomer ACB shall be closed
through synchronizing with DG-1 Incomer ACB and after pre set delay the DG-1 Incomer ACB
shall trip. Thus only momentary paralleling of DG-1 and Transformer incomer is envisaged.
Accordingly DG vendor shall include all interlocks and extend trip command DG-1 breaker.
Supply to MCC for T/T & T/W filling LPG shall be restored by closing Bus-coupler (B/C-1).
During night when there is no operation in the terminal, the AMF starting scheme for DG-1 shall
have to be disabled (i.e. the Auto/Manual selector switch has to be put on Manual) in order to
enable the critical DG-3 to start on AMF.
DG-2 Operation detail (NOT IN VENDOR’S SCOPE):
In case of grid power failure, DG -2 shall be started manually when T/T & T/W Filling LPG
operations are required. When DG-2 is working, Bus-coupler (B/C-1) connecting these loads (on
bus-2) with other loads (on bus1 & bus-3) shall be kept open. Changeover to normal supply shall
be dead manual changeover. Accordingly DG vendor shall include all interlocks and extend the
closing /Tripping Command to DG-2 Breaker in substation. DG-2 shall not be paralleled with
the grid any time or any other DGs.
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.
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5.3
Rev: C
Page 12 of 32
Accessories/Equipment:
DG Sets shall comprise of following Main Equipment / Accessories. Vendor shall also include
any other Accessories / Equipments required for the satisfactory operation of DG Set as
mentioned above.
5.3.1
Diesel Engine:
The diesel engine shall be multi cylinder, four stroke, totally enclosed, prime rating, direct fuel
injection, turbo charged, compression ignitions and closed circuit water cooled.
One common base frame shall be provided for mounting the engine, with fly wheel and
alternator, complete with foundation bolts, levelling screws, anti vibration pads.
The normal speed of the engine shall preferably be 1500 RPM and the direction of rotation shall
be clearly marked on the set.
The engine shall run steadily at any load to full load within its rated load.
The engine shall have 120% overspeed withstanding capability & overspeed trip shall be set at
115% of rated speed.
The engine shall be fitted with an exhaust gas driven turbo charger, complete with its own self
contained lubricating system. The turbo charger shall be positioned at the free end of the engine.
A complete water washing system for turbocharger compressor and turbine shall be provided if
required.
The engine shall be fitted with a charge air intercooler of the air to water type. Air from the
turbocharger compressor passes to the inter cooler, and then to the engine manifold. The
intercooler shall be of tubular construction, with aluminium bronze tubes, mild sheet steel and
cast iron water headers.
Vendor shall supply all necessary equipment & accessories for satisfactory operation of diesel
engine.
5.3.2
Governing System:
Automatic speed governing system shall be provided using electronic governor. The governor
shall be driven by camshaft drive gear.
Zero percent (isochronous) to four percent droop, externally adjustable with synchronising
motor for remote speed control.
A mechanical over speed trip device along with annunciation shall be provided to automatically
shut off fuel in case the speed exceeds the prescribed limit of 115%of rated speed.
5.3.3
Flywheel:
Flywheel shall be solid disc type with guard and shall be accurately balanced.
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Doc No: 254624-400-SP-ELE -007
5.3.4
Rev: C
Page 13 of 32
Alternator:
Alternators shall be industrial type, provided with insulation Class of ‘H’ with temperature rise
limited to class ‘F’ and Degree of protection of enclosure shall be IP 23.
The alternator shall be mounted on common base frame together with the engine. No external
supply shall be required during starting & running of generator.
Alternators shall be provided with followings:
a)
Terminal Box:
All the six terminals of the generator shall be brought out three on one side and three on the
other side. Terminal box on one side shall be used for power connection, the other side similar
terminal box serving as the neutral terminal box shall be provided for forming neutral.
Current transformers shall be accommodated in neutral side terminal box of the generator for
providing protection to the generator. The number and type of CT’s to be accommodated in
neutral terminal box shall be decided by vendor. The neutral terminal box shall be spacious
enough for accommodating CT’s. In case, additional extension box is required, the same shall
also be provided.
Terminal Box shall be suitable for terminating through busduct as indicated in SLD. It shall be
well sized and easily accessible, suitably situated on the generator top part. Degree of protection
for the terminal boxes shall be IP55.
b)
Excitation:
The alternator shall have brushless self exciter mounted on the same shaft.
c)
Voltage Regulation:
± 0.5% regulation (steady state) shall be performed by a solid state type AVR (Automatic
Voltage Regulator). The response of regulator shall be such that the generator voltage is
recovered to set value on application or rejection of rated load at rated PF within a period of 0.5
sec.
Further adjusting the set voltage upto ± 5% of rated voltage shall be possible by the
potentiometer provided for the purpose.
d)
Short circuit current:
The Generator shall withstand short circuit current equivalent to its sub transient reactance for 3
sec. The Excitation System shall be designed to maintain this short circuit current.
e)
Overload Capacity:
The Generator & its excitation system shall withstand the 10% overloads for 1 hour in 12 hour
intervals. The stator winding withstands even higher overloads for short duration such as 1.5
times rating for 30secs and also withstands the stresses caused by the maximum asymmetrical
short circuit current. Generator & its excitation system shall withstand over speed of 120%
f)
Voltage Waveform:
The Generators meet the following requirements at no-load and all symmetrical loads:
• The Distortion Factor ≤ 5% for line to line voltage
• The THF Factor ≤3% at nominal voltage and frequency
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VISAKH MARKETING INSTALLATION RESITEMENT
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Doc No: 254624-400-SP-ELE -007
g)
Rev: C
Page 14 of 32
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.
j)
Winding RTD’s (6 Nos. - 2 Nos. per phase) and Bearing RTD’s (2 Nos.) to be
8 point Temperature Scanner for these RTD’s shall be provided in Generator
& metering Panel. Contact of Temperature Scanner will be used for tripping
Breaker. These RTD’S shall be suitable for early warning (alarms) and tripping
Space Heaters:
Space Heaters suitable for 240V AC shall be built-in inside the Generator. This shall be wired to
separate terminal box.
k)
Tropicalization:
The complete generator shall be provided with the universal tropicalization suitable for
operation in humid and dry tropical climate.
5.3.5
Exhaust :
Exhaust system shall consist of Expansion Bellows, insulated exhaust manifold, silencers and
other miscellaneous piping materials as required. Supply of total exhaust system inclusive of
chimney as required by Pollution Board.
The exhaust system shall be so designed to maintain back-pressure within permissible limits.
The exhaust outlet shall be outside the yard and at a height stipulated by Pollution Control
Board. Necessary information from Pollution Control Board for Exhaust outlet height shall be
obtained by vendor. Emission to air should be within permissible limits of pollution control
board.
Flexible exhaust bellows shall be supplied to compensate for the expansion of exhaust pipe & to
prevent transmission of engine vibration through the pipe system.
5.3.6
Coupling:
The Engine and the Alternator shall be coupled with a fully flexible power coupling with
suitable coupling guard. Coupling should withstand wide temperature range and should ensure
constant alignment.
5.3.7
Acoustic Enclosure:
The acoustic enclosure shall be free standing, floor mounting type, independent of DG set. The
acoustic enclosure will be modular in construction consisting of acoustically treated panels from
all the four sides and top. All the panels will be jacket filled with glass wool & covered with
perforated sheet inside. The outside fabrication will be made out of 16 SWG MS CRCA sheet
metal. A free distance of 1.5 m to be kept between DG set and the acoustic enclosure on all
sides. The doors shall be hinged lockable on either side. Ventilating louvers shall be provided at
Engine side and Alternator side for fresh air entry and for hot air exhaust. The acoustic enclosure
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Doc No: 254624-400-SP-ELE -007
Rev: C
Page 15 of 32
/ canopy can be easily assembled at the site on the leveled surface capable of withstanding the
DG weight without any civil works.
The enclosure shall be designed for installation in open air conditions and should have
aesthetic looks.
Suitable acoustic enclosure / insulation with forced ventilation shall be provided for maintaining
the sound level. Maximum level of sound at 1metre from generating source shall be 75dB(A) or
as per the norms laid down by statutory authorities.
This enclosure shall conform to the requirement of the pollution control norms of respective
locations. Lighting arrangement inside the enclosure shall be provided.
Vendor shall submit the plan showing the position of the DG set and the acoustic enclosure.
5.3.8
Miscellaneous Equipment :
Comprising of bearing (base) plates and shims for setting up the DG Set on foundation, ladders,
railing, brackets, piping holders, protection around flywheel & coupling and other required
materials. Anti-vibration pads shall be provided on base plate.
5.4
Starting System:
Electrical starting system shall be provided for the engine. Battery of adequate capacity shall be
provided with all necessary hardware and accessories. Battery charger with float and boost
charging facility shall be provided in the control panel and shall have adequate capacity of
giving 4 consecutive start up kicks with voltage monitoring and alarm devices. The battery
charging circuitry shall be such that when engine is running, the engine mounted dynamo
charges the battery and when engine is not running, the battery charger, charges the battery.
Necessary changeover scheme shall be employed in the control panels.
Necessary mechanism shall be provided for automatic starting of engine in conjunction with the
fuel oil, lube oil and cooling system. The starting solenoid valves shall be provided with manual
bypass valve for local starting.
5.5
Fuel System:
Engine shall be suitable for HSD fuel as per IS 1460: 2000. Fuel system of each D.G. Set shall
be equipped with
a) Fuel Oil Day Tank
Fuel oil day tank shall be sized to house fuel for eight hours. But the size of tank shall not
exceed the capacity laid down by statutory authorities.
The day tank shall be equipped with fuel return connection, vent, sight glass, level switch for
transfer pump control, overflow line and drain valve.
All necessary fuel line pipes, valve and other misc. piping materials from Day Tank to engine
is in vendor’s scope. Alarm shall be given for fuel low level and fuel high level in Day tank.
Day tank shall have facility for refilling fuel directly from tanker.
b) Filter:
A filter of suitable type & capacity to supply fuel oil at rated output (Duplex filter
preferred).
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Rev: C
Page 16 of 32
c) Fuel pump engine driven.
d) Fuel injection and control system for compression ignition.
In addition to above, Vendor shall supply all necessary Accessories and Equipment for the
satisfactory operation of the fuel system.
5.6
Lubrication System:
Force Feed Lubrication System by means of engine driven oil pump, replaceable, suitable type
full flow oil filter and automatic lube oil temperature control shall be included for lubrication of
engine. The oil service tank shall be provided. Hand pump shall be included to enable oil to be
supplied to all parts before starting the engine.
The lube oils used will generally comply with the additive class HD Supplement 1,
Classification API and Viscosity Class SAE 20 / 40.
The Lubricating System shall be equipped with one gear pump driven by crankshaft delivering
lube oil from service tank via relief valves, oil cooler and through system of coarse and fine
filters to the engine. Filters shall be replaceable while engine is in operation.
When engine is stopped for reasons whatsoever the hand priming pump need not be started. The
coast down tank shall take care of heat removal.
Vendor shall supply all necessary auxiliary equipment for the satisfactory operation of the
lubrication system.
5.7
Cooling:
Engine shall be Radiator cooled type. The jacket cooling water shall be circulated by engine/
electric motor driven pump. One standby pump shall also be provided in the case of electric
motor driven pump.
The cooling water system shall comprise heat exchanger, make up tank with filling vent, drain
connection, isolating valve, gauge glass and low level alarm device, pumps, flow indicator, etc.
Make up cooling water temperature shall be 35 °C.
All accessories required in the internal cooling water circuit like pipes, valves, flanges, supports,
etc. shall be provided by vendor.
5.8
Air intake/Ventilation:
Vendor to offer an arrangement so that clean and cool charge air is available near the
turbochargers. The various auxiliaries like air intake silencer, filters, dry type air cleaners and
fans which are required shall be included.
An efficient air intake silencer shall be provided for reducing in take noise to acceptable levels.
5.9
Control Panels for D.G.Sets:
Each Control Panel be extendable, freestanding & provided with followings:
•
Degree of protection IP-42
•
Earth bus complete with earthing terminals
•
Epoxy painted with paint shade Silver Grey No. 628 (IS-5)
•
Space heater & illumination lamp in each panel..
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VISAKH MARKETING INSTALLATION RESITEMENT
PROJECT – WHITE OIL TERMINAL & LPG TERMINAL
Doc No: 254624-400-SP-ELE -007
5.9.1
Rev: C
Page 17 of 32
•
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 -
Voltmeter (144 Sq.mm) with selector switch
One -
Ammeter (144 Sq.mm)with selector switch
One -
Frequency meter (45 Hz. To 55Hz.)
One -
Power Factor Meter (0.5 lead to 0.5 lead)
One -
KW Meter suitable for 3 phase, 4 wire
One -
KWH Meter suitable for 3 phase, 4 wire
One -
KVA Meter suitable for 3 phase, 4 wire
One -
KVAR Meter
One -
Hour meter
One -
Tachometer for speed measurement
Alternatively Multifunction meter can be offered.
5.9.3
Engine Panel & Engine Control & Monitoring Panel :
Engine shall be provided with two Panels. One Control Panel shall be fitted on the Engine with
hand stop control of engine, thermometers for water, oil, fuel, air temperature, necessary gauges
for measurement of water / lube oil / fuel pressure, one electrical stop indication / control, etc.
i.e. this Panel shall be with minimum controls which has to be done from Engine. Breaker Status
Indication Lamps (‘ON’, ‘OFF’ and ‘Trip’) shall be provided on this Engine Panel.
Second Panel shall be Engine Control and Monitoring Panel (ECMP) with Digital Indicators,
Analogue Gauges, Engine Status Indications, Alarm Conditions, Engine Stop / Trip Conditions,
speed indications, Engine Controls. Engine starting / stopping shall be possible from this
Control Panel in remote mode of operation.
2 Nos. Engine trouble contact shall be given from ECMP for Purchaser’s use (Annunciation,
etc.)
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VISAKH MARKETING INSTALLATION RESITEMENT
PROJECT – WHITE OIL TERMINAL & LPG TERMINAL
Doc No: 254624-400-SP-ELE -007
5.9.4
Rev: C
Page 18 of 32
Battery & Battery Charger Panel:
Individual Battery & Battery charger system shall be provided for D.G.Set start up system.
Batteries shall be of 24 V lead acid battery (SMF) / bank of adequate ampere hour capacity for
each DG set (at 10 hours discharge rate for supplying control power to control panel and starting
power to engine starting motor) complete with connecting leads first charging and routine check,
instruments including hydrometer and cell tester, teak wood stand, floor insulators, cell
supporting insulators, etc. It shall be possible to start the engine three times in immediate
succession without appreciable drop in DC Voltage. The battery shall have a sufficient capacity
to start the engine more than 4 times consecutively.
Battery charger unit shall be complete with unit transformer / rectifier with surge protection, DC
ammeter, Voltmeter, Charge rate selector etc. suitable for quick and trickle charging of batteries.
DC voltmeters, centre zero ammeters, protective fuses shall be provided. Charger shall give
constant DC output voltage irrespective of incoming voltage variation specified.
5.9.5
Exciter Panel:
AVR can be part of Exciter panel. However, Excitor Panel complete with motorised potmeter,
PF control circuit, provision for remote control of voltage (raise / lower) in case of
synchronising and required DC Metering (Field Current and Field Voltage Monitoring) shall be
provided by DG Vendor.
5.9.6
Synchronising Feature:
Synchronising feature shall be provided in Main Control Panel (MCP) for DG Set which will run
in parallel mode with any other source (Applicable for DG-1).
5.9.7
Neutral Isolation
The neutral point shall be formed in neutral side terminal box and necessary arrangement shall
be provided for connecting neutral earth pit.
5.9.8
Cables
Power cables shall be 1.1kV grade, XLPE insulated, aluminium conductor, multi core, steel
strip/wire armoured, Extruded PVC inner sheathed & Extruded FRLS PVC outer sheathed
confirming to IS 7098 (Part-1).Main power cables shall be provided by owner.
Control cables shall be 2.5Sqmm Multi stranded copper conductor, PVC insulated with extruded
PVC inner sheathed, extruded FRLS PVC outer sheathed confirming to IS 1554 (Part-1).
5.10
Motors for D.G. Auxiliaries:
1.
Make
-
Crompton Greaves / Siemens /ABB
2.
Type of Enclosure
-
TEFC with IP-55 Degree of Protection.
3.
Design Ambient Temperature for Motors shall be 45oC.
4.
Class of Insulation
5.
Terminal Box for Motors shall be amply sized to suit termination of PVC insulated
aluminium armoured cables
6.
Painting
-
-
Class ‘F’ with temperature rise restricted to class ‘B’
Smoke Grey No. 692 (IS-5)
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5.11
Rev: C
Page 19 of 32
Instrumentation & control
The measurement and controls shall be provided for efficient operation of the process as well as
for safety of equipment and operating personnel.
The equipment shall be provided with all instruments necessary for checking the performance
continuously. All meters shall be fixed on a common instrumentation panel mounted directly on
the engine frame. Instrument system shall include all standard instruments coming as a part of
engine.
Measurements and controls required for smooth and efficient operation of the DG set including
but not limited to the following:
a)
Protection devices
For the safety of each DG set following annunciation and tripping scheme shall be provided.
Audio visual alarm only, for the fault conditions in case of:
•
Fuel oil tank level low.
•
Lubricating oil pressure low.
•
Fuel oil pressure low.
•
Lube oil temperature high.
•
Exhaust gas temperature high.
•
Fuel oil day tank level high.
•
Lube oil sump tank level low.
•
Diesel engine start failure.
b)
Audio visual alarm followed by tripping in case of:
•
Lubricating oil pressure too low.
•
Crank case oil mist high.
•
Over speed.
•
Starting fault,
•
Charge air temperature too high.
•
Emergency stop (manual)
•
Alternator fault
•
Low DG voltage
•
Further fault if any shall also be included as per Mfg, Standard
Solid state annunciator shall be provided with features such as test, accept, reset push button,
lamp flashing, audible annunciation etc. Window inscription shall be arranged in a logical
manner to segregate engine faults and alternator faults etc. 20% spare windows shall be
available.
5.12
Name Plates:
Permanent non-corrosive nameplate with engraved white letters on black background indicating
the 415V D.G. Set designation shall be fixed at the top of the central panel.
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Rev: C
Page 20 of 32
Name plates shall contain the following information:
a)
Manufacturer
b)
Basic technical data such as rated voltage, rated current, RPM etc.
c)
Country of origin.
d)
Certification data such as UL certificate number etc.
Nameplates shall be provided for each Accessories with 415V D.G.Set. Warning plates shall
be provided on all removable covers or doors giving access to high voltage cables and inside
the switchgear wherever considered necessary. Danger labels shall have black letters on a
yellow background.
Internal labels and components identifications shall correspond with identities or circuit
references as shown on the schematic diagrams. All external labels shall be attached by screws
or rivets only and not by adhesive.
5.13
Makes of Components
Makes of component shall be as per ‘Recommended list of Sub-Vendors’ attached in tender
document.
5.14
Painting
All metal surfaces shall be thoroughly cleaned and degreased, pickled and phosphatised.
Thereafter, a coat of phosphate paint and a coat of zinc chromate primer shall be applied. After
removing all imperfections, all metal surfaces shall be sprayed with two coats of final paint as
per the below mentioned shades.
Engine & Alternator
:
Smoke grey No. 692 (IS-5)
Coupling Guard
:
Satin Blue No. 177 (IS-5)
Electric Panel
:
Silver grey No. 628 (IS-5)
Fuel tank & lines
:
French Blue IS No. 166 (IS-5)
Radiator
:
Jet black
Exhaust Piping
:
Aluminium
Exhaust Piping Supports
:
Smoke grey No. 692 (IS-5)
Final coat shall be of epoxy based. All unpainted parts shall be plated to prevent corrosion.
6
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 Owner’s approval, review, witnessing etc.
Inspection and testing requirements shall be in accordance with this specification, other
applicable standards as listed in this specification and the data sheets.
All Equipment shall be inspected for compliances with:
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Page 21 of 32
• Requirement of Owner’s specification & correspondence therefore.
• Applicable codes, standards and specifications, which shall also include sub-referenced
standards therein.
• Test and Inspection Plans produced by the vendor.
Inspectors have the right to request additional inspections or tests to ensure that the equipment
complies with the specification and all relevant codes & standards.
6.2
Manufacturer shall furnish valid Type Test Certificates of similar models along with the offer.
Fresh type tests for the equipment are not needed, provided the Manufacturer can submit
certificates that the equipment complies with all type tests as prescribed by IEC/IS Standard
specifying the test requirements for that equipment.
6.3
Routine tests on the equipment shall be carried out as per the relevant IEC/IS. Equipment
offered for final inspection shall be complete and ready for shipment, with the possible
exception of the final paint finish.
6.4
Routine Test certificates to be submitted for Equipment and its all auxiliaries.
6.5
Vendor to furnish required copies of test certificates, Ref Documents, Drawings, and
Instruction Manuals before equipment are dispatched.
6.6
Factory acceptance test (FAT) is required to be done at no extra cost to the purchaser. The
purchaser or his representative shall be advised of the tentative date for FAT at least 3 weeks in
advance prior to the test date. For factory acceptance test (FAT) and site acceptance test (SAT),
vendor shall consider maximum 4 hours of DG set running for these testing.
6.7
Any defects found by the TPI or the Owner’s appointed Inspector shall be rectified in his
presence. Where this is not possible or practical, check lists shall be prepared and signed by the
Third Party Inspector stating all “pending items”. Copies of these lists shall be sent to the
Owner to enable their subsequent checking. The equipment shall not leave the Vendor factory
before all defects have been rectified and without the written permission of the Owner.
6.8
All spare parts shall be subjected to the same inspection standards and full material certification
as the main order.
6.9
The equipment shall not leave the Vendor / Sub-Vendor’s factory before all discovered defects
have been rectified and without the written permission of the Owner/Purchaser.
6.10
Any acceptance or release of equipment following an inspection or test activity shall in no way
relieve the Vendor of his contractual responsibility to provide guarantees as to the suitability of
the materials, workmanship and performance of the equipment in accordance with this
specification.
6.11
Owner/Consultant reserves the right to waive the inspection at any stage. Inspection shall be
carried out only on receipt of Vendor's internal test report of the equipment offered and scrutiny
of the same. In the event, on receipt of inspection call, the Owner/Consultant’s representative
reaches the Vendor's works and finds the material not ready for inspection/incomplete/has short
supply, the inspector will return to his base station and all expenses incurred by the inspector
including to and from travelling expenses from his base station to place of inspection, boarding
and lodging etc shall be reimbursed by Vendor.
7
7.1
Vendor documentation:
All information listed here is to be furnished along with the offer as a minimum.
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Rev: C
Page 22 of 32
(a) Clause wise comments / deviations on specification in `Table of Compliance’ [enclosed
Appendix A]. If not furnished, compliance to all requirements in specifications will be
binding on the Vendor.
(b) Duly filled up Guaranteed Technical Particulars [enclosed Appendix-E].
(c) List of fittings & accessories with Makes.
(d) List of recommended spares for two years normal operation with itemised rates.
(e) Type test certificates.
(f) Technical Catalogues of Engine, Alternator, Governor, etc.
(g) List of clientele for similar equipment in last 5 years.
(h) Complete list of special tools (if required)
(i) Documents as per RED.
7.2
The Manufacturer shall furnish the drawings and documents as per enclosed Requisition for
Engineering Documents - RED Form [Appendix-D].
7.3
The Owner/Consultant will review drawings submitted by Vendor & return to the Vendor one
copy of drawings with comments to carry out necessary changes, if any, during the engineering
/ manufacturing stage. Subsequent to the approval of vendor drawings fabrication shall be
started.
7.4
The documents required by the Third Party Inspection Agency are not covered under this
specification. The Vendor shall provide all the drawings and documents required by the Third
Party Inspection agency in compliance with the applicable codes and standards.
8
Installation, Testing and Commissioning:
8.1
Scope work under this section includes site work of installation & commissioning of engine,
generator assembly, electrical panels, battery station, associated cabling, earthing, piping, fuel
pumps, fuel tanks, safety appliances (like rubber mats, first aid boxes, carbon extinguishers
etc). Necessary erection materials such as cable racks, trays, angles, chemicals etc required DG
Set & necessary statutory approvals are included in the scope of work.
8.2
The installation shall comply with relevant Indian Standards, Indian Electricity Rules and
statutory regulations that are in force in the place of installation.
8.3
Vendor shall despatch Installation and Commissioning instructions at least 2 weeks before the
arrival of the equipment.
8.4
Equipment erection, including acoustic enclosure testing and commissioning shall include
following activities:
a) Removal of packing material and clearance, removal of blocking devices provided for safe
shipment.
b) Physical inspection, preparation of defect lists.
c) Assembly of shipping sections.
d) Civil work involved in grouting the equipment base frames, concrete chipping, grouting for
wall, roof, floor supports wherever required for piping, cabling etc.
e) Tack welding of equipment, panels etc., to floor inserts wherever provided and providing floor
inserts wherever required for erection work.
f) Applying touch paints for finish painted equipment’s and finish painting of site fabricated
steel work after pre-treatment like de-rusting, degreasing, primer coating etc.
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Rev: C
Page 23 of 32
g) All pre-wired panels shall be checked for correctness as per final approved wiring diagrams.
h) Trouble free mechanical operation and site testing of relays, contactors, timers, breakers and
free rotation of all drive motors be checked.
i)
Tightness of all bolts joints in busbars, motors, generator, engine etc., shall be checked.
j)
Insulation resistance of all electrical equipment’s shall be measured and improved by cleaning
and drying. Space heaters, filament lamps (1000 watts) shall be provided and kept energized
during the entire period of erection to prevent deterioration of insulation resistance below
permitted values.
k) Duplicate earthing shall be provided for all electrical equipment’s, cable glands, tanks, and
vessels etc. as per statutory regulations.
l)
8.5
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.
a) DG set consisting of diesel engine and AC generator mounted on common base frame with
acoustic enclosure shall be erected on civil foundation with correct orientation details.
Engine control panel, battery station, charger units shall be erected within Acoustic
enclosure. Supplier shall furnish detailed layout drawing for the DG Yard.
b)
All the piping to the engine shall be done strictly as per manufacturer’s drawings. Wherever
piping involves joining by welding the same shall be as per relevant statutory regulations
(compressed air lines etc.). Unions / couplings of pipelines shall be done as per
manufacturer’s instruction /drawings, wherever welding is not preferred or permitted. All
piping shall be checked for leak proof by conducting tests as per instruction manuals of
manufacturer.
c)
Coupling of the engine and alternator shall be done after checking and correcting alignment
of shaft axes within permitted tolerances. Shaft levels shall be checked and adjusted to be
within permitted tolerances.
d)
All the auxiliary power cables between equipment supplied by DG vendor and control
cables to start and shut-off solenoids, temperature switches; level switches etc., shall be
separately installed and terminated with ferrule numbers as per manufacturer’s wiring
diagrams. Wherever control cables have to run near engine casing thermal insulations shall
be used to prevent damage due to excess temperature. Flexible conduits shall be used to
protect control cabling near the engine. All the power and control cables shall be laid
separately and in cable trenches / cable channels between generator and DG Control panel
in the yard as per approved drawing. Vacant spaces in used and unused conduits should be
plugged using M-seal monoplast filling compound. All cables shall be neatly dressed and
clamped in fabricated cable trays.
e)
DG set auxiliaries like lube oil prime pump, fuel oil pump, fuel transfer pumps, shall be run
and checked using grid supply. Similarly batteries shall be charged through charger
installed, using grid supply. First filling of lubrication oil, grease, fuel oil (into tank) etc.,
shall be done by the contractor as per manufacturer’s instructions
f)
All DG set instruments shall be tested / calibrated and set at values recommended by the
manufacturer, Inscriptions on windows shall be checked. Overload relay for alternator
protection shall be tested and set at values recommended.
g)
Installation of safety appliances like rubber mat, carbon dioxide fire extinguishers, first aid
box etc., shall be done.
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8.6
8.7
8.8
8.9
Rev: C
Page 24 of 32
When installation is completely ready for starting, following tests shall be done in addition to all
test prescribed by the manufacturer / I.S. Standards.
a)
Starting of engine manual mode / simulated DG Control condition.
b)
Shut-off of the engine-manual mode/ electrical mode simulated faults of the alternator and
engine.
c)
Over speed test.
d)
Interlock between DG breaker and grid supply.
e)
Governor speed control electrical /mechanical.
f)
Minimum time in seconds required by the set to deliver power at desired voltage and
frequency starting from standstill condition
g)
Matching the DG phase sequence with grid supply phase sequence.
h)
Checking annunciator windows for all the faults simulated during testing.
i)
Continuous full load test as specified, by starting all the motor loads direct on line
sequentially.
j)
Paralleling with Grid (Wherever applicable).
k)
Tabulation of all results in the mutually agreed format.
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.
b)
It shall be contractor’s responsibility to replace all defective / inferior materials revealed
during preliminary acceptance and final acceptance tests (P.A.T and F.A.T) at his own
expense, without affecting completion milestones.
c)
Contractor shall ensure that no tests are applied which may stress the equipment above the
limits recommended for field testing, by the manufacturer.
d)
Contractor shall be responsible for any damage that may occur to personnel / equipment
resulting from improper testing procedures.
e)
Contractor scope in testing of DG Set includes supply & filling sufficient quantities of
consumables like high speed diesel, lube oil, greases etc, necessary for carrying out all trial
runs, during preliminary acceptance tests (PAT) and final acceptance tests (FAT).
Form of completion certificate for each DG set
We certify that the installation detailed below has been installed by me / us and tested and that to
the best of my / our knowledge and belief, and it compiled with IE rules, 1956 as well as HPCL
technical specification for electrical works.
Electrical installation at
9
:
Statutory Approval:
Each DG system along with associated accessories and layout shall be acceptable to statutory
bodies like Electrical Inspector, Tariff Advisory Committee, Electricity Board, Pollution Control
Board etc. Any Changes required by them shall be carried out by Vendor without additional cost.
Getting the approvals is in Vendor’s scope. Statutory fees will be paid by Purchaser.
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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.
VENDOR REF.
Conforms
Yes/No
Alternative
Yes/No
Clarification
1
2
2.1
2.2
2.3
3
3.1
3.2
3.3
4
4.1
4.2
5
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
5.12
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CLIENT : HPCL
Spec. Clause
No.
Rev: C
Page 26 of 32
VENDOR REF.
Conforms
Yes/No
Alternative
Yes/No
Clarification
5.13
5.14
6
7
8
9
Appendix A:
Appendix B:
Appendix C:
Appendix D:
Appendix E:
Appendix F:
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Appendix-B: Codes & Standards
IS 4722
:
Rotating Electrical Machines
IS 4728
:
Terminal marking and direction of rotation for
rotating electrical machinery
IS 4889
:
Methods of determination of efficiency of rotating
electrical machines
IEC 60034
:
IEC Standard Voltages
IEC 60529
:
Degree of Protection provided by Enclosure (IP
Code)
IS 4729
:
Measurement of vibrations of rotating electrical
machines
IS 12065
Permissible limits of noise levels for rotating
electrical machine
IS 12075
Mechanical
machines
IS 12082
Temperature rise
electrical machines
BS 649
Performance of reciprocating compression ignition
Diesel Engine
BS 4999
General requirements for Rotating Electrical
Machines
BS 5000
Specification for Rotating Electrical Machines of
particular types or for particular applications
BS 6121
Mechanical cable glands
vibration
of
rotating
measurement
of
electrical
rotating
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Appendix-C: Recommended List of Vendors
Engine
:
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
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
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Appendix-D: Requisition for Engineering Documents
RED Form
Owner’s Office
Distribution Office
Hindustan Petroleum Corporation Ltd.
Visakha Terminal, Resitement Project,
VR-ATP Area, Naval Base Post,
Visakhapatnam – 530 014
Mott MacDonald Consultants(I) Pvt. Ltd
Kothari House, CTS No. 185
Off Andheri – Kurla Road
Andheri ( East), Mumbai 400059, India
SPECIAL INSTRUCTIONS
Prints
Production Schedule
Manufacturing, inspection & testing sequence plan
DRAWINGS
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 Vendor’s
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
Documents shall be sent to:
5
10
The Purchasing Office via courier service
The Purchasing Office via courier service
Required number for
OFFER
APPROVAL
Prints
Prints
TIMING FOR SUBMITTAL
FINAL
Disk
- for approval 2 weeks after order date
Prints - final issue 2 weeks after approval date
Documents shall be submitted to:
2
2
5
5
2
2
10
10
2
5
2
10
2
5
2
10
-
5
5
2
2
10
10
-
5
2
10
2
5
2
10
-
5
5
2
2
10
10
2
5
2
10
-
5
2
10
2
5
2
10
2
5
2
10
2
5
5
2
2
10
10
-
Purchasing Office via courier service
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SPARE PARTS DOCUMENTS
Rev: C
Page 30 of 32
1
10
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.
Prints
Documents shall be submitted to:
2
2
2
2
10
10
10
10
OPERATING DOCUMENTS
Installation instructions
Operating instructions
Maintenance instructions
Purchasing Office via courier service within 4
weeks
Of relevant test / inspection.
Purchasing Office via courier service not later
than time of
2
2
2
10
10
10
Dispatch of equipment.
Combine into one manual
ADDITIONAL REQUIREMENTS
1. Referenced standards / codes shall be the latest issue unless otherwise stated.
REMARKS
Invoice must certify that the drawings and engineering documents
specified above have been dispatched to all parties concerned.
Any deviation from the timing for submittal of documents shall
be notified to the Approval / Distribution Offices by fax or E
mail.
Shop fabrication shall not be started before the required approval
drawings have been released for construction by the party
concerned, unless otherwise stated on the "Approval Drawing
Specification".
Each document shall bear the item / tag and order reference
number and be dispatched by air mail, unless other instructions
are stated on the RED.
Units / dimensions to be used on Engineering documents shall be SI.
The documents shall be in English. Description on drawings and
similar documents may be in other languages provided English
translations are also given.
Drawings and documents shall be suitable for microfilming and
comply with accepted national or international standards for the
preparation of technical drawings. Only the following standard sizes
should be used: A4, A3, A2, and A1.
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Appendix-E: Guaranteed Technical Particulars
Doc No: 254624-400-DS-ELE-008
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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
ALTERNATOR
1.1
a) Make
Description
Unit
To be filled in by Vendor
b) Type
1.2
a) Manufacturer's Make No. and Frame Size
b) Conforming to Standard
1.3
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)
1.4
Power Factor
1.5
a) Rated Voltage
KVA
%
KVA
Volts, - %±
b) Number of Phases
1.6
Frequency
1.7
Number of Poles
1.8
Type of Enclosure
1.9
a) Class of Insulation
Hz., - % ±
b) Temperature Class
c) Impregnation for tropical service
1.10
% Overload for 1 hr. at Site Condition
1.11
a) 50% Overload capacity
in Sec.
b) Allowable % unbalanced load on generator
in Sec.
1.12
Percentage Efficiency at
a) P.F. - 0.8
- Full Load
- ¾ Load
- ½ Load
- ¼ Load
1.13
a) Voltage Regulation from No-Load to Full
Load at any point with 4% speed
regulation of the engine
b) Recovery Time and Voltage in response to
100% step load
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Unit
To be filled in by Vendor
c) % Voltage Adjustment on AVR
1.14
a) Type of Bearings
b) Method of Lubrication
1.15
Type of Excitation Unit
1.16
Percentage Reactances of Alternator
a) Sub Transient Reactance- xd"
%
b) Transient Reactance - xd'
%
c) Reactance - xd
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
ENGINE
2.1
Manufacturer
2.2
Engine Model
2.3
2.6
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
2.7
Maximum Overload
2.8
% Overload for 1 hour at Site Conditions
2.4
2.5
Kw
%
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Description
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Unit
2.9
Nominal Speed
2.10
Bore Dia.
mm
2.11
Length of Strokes
mm
2.12
Cylinder Arrangements
2.13
Number of Cylinders
2.14
Total Swept Volume
2.15
Compression Ratio
2.16
Time required for starting from cold condition
2.17
Heat Balance of DG Set
To be filled in by Vendor
litre
- Engine O/P
- Exhaust Gases(Heat rejection)
- Coolings(Heat rejection to coolant)
- Radiations
Total Heat Input
2.18
Machine Efficiency(Mechanical)
2.19
Thermal Efficiency
2.20
2.21
GD2 of Engine
Maintenance Schedule of Engine (First
maintenance required after commissioning)
2.22
Sound level of Engine at distance of 1 M
2.23
Exhaust Gas Flow
2.24
Temperature of Exhaust Gas
2.25
Radiator Cooled Engine only
2.26
Type of Turbocharger
2.27
Fuel Oil System
- Fuel Day Tank of size & capacity
2.28
- Specification of Fuel recommendation
Maximum Fuel Oil Consumption Rate with
0% tolerance for various loads as listed below:
litres /KWH
at 25% load
at 50% load
at 75% load
at 100% load
at 110% load
Alarm shall be given for fuel low level and
fuel high level in tank
2.29
Governing System
a) Make
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Unit
To be filled in by Vendor
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)
mm
b) Engine Panel
c) Engine Control & Monitoring Panel
d) Exciter and AVR Panel
e) Battery
f) Battery Charger + DCDB
3.0
D.G.Auxilliary Motor
3.1
Type of motor
3.2
Manufacturer
3.3
Degree of protection
3.4
Cooling classification
3.5
Frame Size
3.6
Class of Insulation
3.7
Voltage Supply
3.8
Rated Output
Kw
3.9
Speed
RPS
3.10
Efficiency
3.11
Power Factor
3.12
Line Current
4.0
Starting System (DC)
4.1
Battery operated
4.2
Battery Chargers
Volts
%
Amp
a) Manufacturer
b) Type
4.3
Batteries
a) Manufacturer
SMF, VRLA
b) Battery type
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Description
5.0
CIVIL REQUIREMENTS
5.1
a)
Weight of Engine with accessories
b)
Centre of Gravity of Engine
5.3
a) Weight of Generator
b) Total weight of DG set along with
acoustic enclosure
6.0
Recommended crane/hoist capacity
7.0
DIMENSIONS (L x B x H)
7.1
Alternator
7.2
Engine
7.3
Overall Length
7.4
Overall dimension with acoustic enclosure
7.5
D.G.Shed
Rev: C
Page 5 of 5
Unit
To be filled in by Vendor
mm
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Appendix-F: Single Line Diagrams & Equipment layouts & SOQ (WOT & LPGT DG)
Sr.
No.
Drawing Number
1
2
White Oil Terminal
254624-400-ELE-4102
254624-400-ELE-4202
3
4
LPG Terminal
256324-500-ELE-4102
256324-500-ELE-4201
5
Description
Single Line Diagram – 415V PMCC
Equipment layout for Main substation & Transformer bay
plan & section
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
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