Technical Part

Part-1
Design, Supply, testing, commissioning and guarantee of
‘Silent type’ 500 kVA / 400 kW (Prime rating), 3 phase,
415 volt, 50 Hz Diesel Generator sets-4 nos.(complete
with radiator, acoustic enclosure, anti-vibration
mount/pad, Electronic governing system, electronic
control panel, AMF control panel, with all necessary
piping, power & control cable etc.)

Page 1 of 32
SPECIFICATION OF 500 kVA /400 kW DIESEL ENGINE SETS WITH
ALL REQUIRED ACCESSORIES

INDEX

Sr. No. Description Page No.

01 Scope 3-4 of 31
02 General Requirements for Technical Qualification 4 of 31
03 Codes & standards 5 o 31
04 Technical Requirements for Performance of work 6-24 of 31
05 Training 25 of 31
06 Technical Specifications
07 Tests and inspection 26-27 of 31
08 Engineering, Manufacturing & Maintenance facility 28 of 31
09 Drawing & Data sheets
10 Technical Data to be filled by Tenderer 29-31 of 31

Page 2 of 32
1.0 SCOPE:
The scope of this specification is to define the requirements of supply, installation, testing,
commissioning and guarantee for intended operation of 500 kVA (Prime rating) Diesel
Generator Sets with radiator, acoustic enclosure, anti-vibration mounts, diesel tanks, AMF
control panel, all required accessories and its hook up with existing system in place of 310 kVA
DG sets at HWPK.
1.1 Dismantling, shifting and safe deposit of existing 310 kVA indoor DG sets-4 nos. with Diesel
Engine- W8V 17.5/22AMA of Kirloskar oil engine ltd. make and Alternator- 310 kVA/248 kW,
YTS6 type-3 nos. and 6AX 450/2 1000- 1 nos. of Kirloskar Electric Co. Ltd. make, one-by-one
after ensuring availability of emergency supply from existing location to our central store. Each
DG set mainly consists of Diesel engine with governor & fly wheel arrangement, Alternator, day
tank (1200 litre), fresh water tank (100 liter), existing exhaust piping (approx. 8 meters) with
silencer & turbo charger, AMF panel, jacket water & lub oil heat exchanger with their
connecting piping from DG set, Lube oil priming pump with motor, Engine jacket water
circulating pump motor & heater, self starter with 24 volt, 200 Ah battery-4 nos. etc.
1.2 Dismantling of existing RCC foundations and structures of old DG sets, day tank, heat
exchangers etc. Design & construction of new RCC (Reinforced Cement Concrete) or any other
suitable foundation for 500 kVA DG sets, day tank, radiator, AMF panel, support piping &
structure etc. as required for installation of new DG sets & its accessories. Vibrating isolators
(AVMs) / anti vibration pad to be provided to reduce generator set vibration and noise
transmission to the surrounding structure. Supply of construction materials, structural materials
and all consumables items, tools & tackle etc. for foundation shall be in supplier’s scope.
1.3 Design, supply of materials & construction of 3 hour rating fire resistant wall in between DG sets
and in between HSD tanks.
1.4 Supply, testing, installation, commissioning and guarantee of 4 nos. of ‘Silent type’ 500 kVA
Diesel Generator Sets complete with their radiator (water cooled), acoustic enclosure (as per
latest CPCB norms), anti vibration mount/pad, turbocharger, exhaust manifold with silencer,
Electronic governing system, Electronic control panel, self starting arrangement with 24 volt
battery suitable for 6 consecutive starting attempts, Flywheel arrangement, HSD day tank, AMF
control panel with Power controller, electrical analyzer unit & digital automatic voltage
regulator. Supply & installation of piping for hook up of cooling system & make up water from
existing header, lube. Oil system, fuel system from HSD tank to DG & from existing header to
HSD tank. Laying of FRLS power & control cables for connection of DGs with existing switch
gear.
1.5 Supply, installation, wiring and hook up of Protection CTs (current transformer)-8 nos and
measuring CTs-4 nos. for each 500 kVA DG sets in place of existing CTs of 310 kVA DG sets
with relays & metering devices. Dimension & other details for design of CTs is enclosed.
1.6 Supply, commissioning and hook up of Central Monitoring System consists of PLC based
centralized data logging system with redundant processor, workstation loaded with suitable
SCADA/HMI software, communication network with driver software & full licenses (original
version), PC with 250 GB HDD, LCD colour monitor 17”, Laser B/W A4 size printer and ups
(see 4.5.0 for details specifications). It needs to be communicating with individual instrument
control panels/ Power controller/ energy analyzer/ PLC of respective generators to generate
utility reports from the data logged during operation of DG sets as per HWPK requirements. The
local instrument panels / power controller / energy analyzer have to be provided with Ethernet/
Modbus/ Other suitable communication facility in order to integrate with the central monitoring
system.

Page 3 of 32
 1.7 Supervision during testing & commissioning shall be taken up under control of DG sets
manufacturer engineer. This supervision during installation, testing and commissioning shall be
considered as included in scope of all items. The supervision during installation, testing and
commissioning of DGs is in the scope of the supplier and no extra charge shall be paid for
deputation of manufacturer’s engineer. Supplier’s site engineer shall ensure that installation job
is done as per good engineering practice, tender specification and approved drawings.
1.8 The Bidder shall provide necessary supporting document for seeking clearances/approvals of
Pollution Control Board (PCB) / Central Electricity Authority (CEA) / Atomic Energy
Regulatory Body (AERB).

2.0 GENERAL REQUIREMENTS FOR TECHANICAL QUALIFICATION:

Apart from meeting technical specifications laid in subsequent pages of tender, following shall
also be necessary to qualify for technical part of tender.

2.1 The bidder shall be Original Equipment Manufacturer (OEM) or Authorized dealer of
Manufacturer. The offered equipment have to be designed, manufactured and tested as per
relevant IS / ISO /IEC / IEEE standards with latest amendments.

2.2 DG sets manufacturer should have established manufacturing facility of similar type of Diesel
Generator sets since last five (5) years and shall support for servicing and spares for minimum 20
years of operational life of DG sets.

2.3 The bidder should clearly indicate the quantity and Highest Single Value Contract executed
during last FIVE (5) years, for the offered equipment. Bidder should have executed one single
contract during last five years for the quantity equivalent to tender / bid.

2.4 They must have executed at least three orders of supply, erection & commissioning of Diesel
Generator sets of similar capacity successfully with Govt. organization, public sector or major
reputed Indian private sector organization. They should submit performance certificate for their
installation obtained from any two of above organization.

2.5 Independent assessment of performance of commissioned DG sets shall be done by HWPK also
for qualifying technical part.

2.6 The bidder shall furnish the list of earlier installation as per requirement mentioned in Para 2.2
and 2.3 with detailed address and telephone no. etc. for independent assessment.

Page 4 of 32
3.0 CODES AND STANDARDS:
The equipment shall conform to the latest issue of the relevant Indian Standard Specifications or the
ISO/IEC/IEEE specifications, wherever applicable. Some of the relevant standards are listed below:

IS-456 : Plain and Reinforced concrete-code of practice

IS-2974 : Design and construction of machine foundations-code of practice
IS-3809 : Fire resistance test of structures
ISO-3046 : Definition and Rating of Diesel engine
ISO-8528 Specification & definition of prime power rating, noise level, governor regulation of
:
Diesel engine
IS-10000 : Method of tests for Internal combustion engine
IS-10002 : Specification for constant speed compression (Diesel) engine
Environmental (Protection) Rules, 1986 latest amendment/ schedules for noise &
:
emission limit of DG sets.
IS – 3034 Code of practice for fire safety of industrial buildings – electrical generating and
:
distributing stations.
IS-12065 : Permissible limits of noise levels for rotating electrical machines
IS-12075 : Limits of vibration severity of rotating electrical machines
IS-8183 : Insulating material for better attenuation
IER-1956 : Indian electricity rule-1956
IE Act The Indian Electricity Act 1910/Indian Electricity Supply Act-1948/Electricity Act-
:
2003.
IS-4722 : Rotating Electrical Machine specification
IS-4728 : Terminal marking and direction of rotation for rotating electrical machinery
IS-7132 : Guide for testing synchronous machine
IS-4691 : Degree of protection provided by enclosures for rotating electrical machinery
IS-2165 : Guide for insulation coordination
IS-3043 : Code of practice for earthing
IS-2032 : Graphical symbols used in electric technology
IS-13947/ Specification for Low Voltage Switchgear and Control gear
:
IEC-60947
IS-10118 Code of Practice for Selection, Installation and maintenance of switchgear and
:
control gear
IS-3072 : Code of practice for installation and maintenance of switch-gear up to 1000 V.
IS-2705 : Current Transformer Specification
IS-3156 : Voltage Transformer Specification
IS-732 : Code of practice for electrical wiring installations up to 650 volts
IS-1554 PVC insulated (heavy duty) electric cables for working voltages up to and including
:
Part-1 1100 volts
IS-7098 Cross linked polyethylene insulated PVC cables for working voltages up to and
:
Part-1 including 1100 volts
IS-3842 : Application guide for Electrical relays for ac system
IS-8686 : Specification for static protection relays
IEC-60255 : Testing & specification for microprocessor relay
IS-14570/ Electrical measuring transducer for converting a.c. electrical quantities to analogue or
:
IEC 688 digital signals

Page 5 of 32
4.0 TECHNICAL REQUIREMENTS FOR PERFORMANCE OF WORK:

4.1.0 Technical requirement of Dismantling, shifting and safe deposit

of existing 4 nos. of 310 kVA DG sets with their auxiliaries:
4.1.1 The dismantling, shifting and safe deposit of the existing four nos. of diesel generator sets shall
be performed one by one.
4.1.2 One by one means complete dismantling of one no. of DG set with auxiliaries and second DG
set shall be dismantle only after commissioning & satisfactory operation of new 500 kVA DG
set with existing switchgear at this location. After installation of two DG sets remaining two
can be taken simultaneously subject to satisfactory performance of first two.
4.1.3 Each 310 kVA DG set consist of following items:
a) Diesel Engine - Kirloskar oil engine ltd. make, rating of 372 BHP (at 1000 rpm), W8V
17.5/22AMA type, overall Dimension is (in mm) 2030 x 750 x 1300 (Length x Breadth x Height) ,
eight cylinder, four-stroke inline turbo charged engine with mechanical governor & flywheel
arrangement.
b) Alternator - Kirloskar Electric Co. Ltd. make, model YTS6 type- 3 nos. , overall dimension is ( in
mm)1310 x 1400 x 930 (Length x Breadth x Height) and 6AX 450/2 1000- 1 no., 310 kVA 248
kW, 3 Phase, 4 wire, 50c/s, 1000 rpm. overall dimension is ( in mm)1240 x 1200 x 1130 (Length x
Breadth x Height)
c) Fuel Oil Tank - Approx. 1200 liter capacity MS tank.
d) Fresh Water Tank - Approx. 100 liter capacity MS tank.
e) AMF Panel - Consisting of Indicating meters, fuses, Power & control relays, Aux. contactors,
excitation system, battery charging system etc.
f) Self starting arrangement - Self Starters with Batteries (Lead Acid) - 12 volts, 200 Ah 4 Nos. with
connecting cables from starter to batteries.
g) Jacket water Heat exchanger - 1 no., Jacket water circulating pump with motor- 1 no., jacket water
heater- 1no. & their connecting piping from heat exchanger to Diesel engine, from cooling water
header to heat exchanger etc.
h) Lub. Oil heat exchanger - 1 no., Lub oil priming pump with motor-1no. & their connecting piping
from heat exchanger to diesel engine and vice versa etc.
i) Existing exhaust piping (approx.8 mtrs) with silencer, turbo charger and supporting structures.
j) All supporting structures of fuel oil tank, fresh water tank, heat exchangers, exhaust piping, lube
oil & fuel oil piping.
4.1.4 At the time of dismantling of DGs fresh HSD from tank and used HSD from diesel engine shall be
emptied in drums provided by purchaser.
4.1.5 At the time of dismantling of DGs used lube oil shall be emptied in drums provided by purchaser.
4.1.6 The Contractor shall install safety caps/end plugs/flanges to the fuel lines & water lines as
necessary before removing/dismantling the fuel/water lines from headers.
4.1.7 All types of special tools & tackles etc. required for dismantling & shifting of materials shall be
arranged by party.
4.1.8 The Contractor shall remove all equipments/materials/oil etc. associated with the existing diesel
generator equipment as mentioned above. The Contractor shall properly deposit all materials in our
store at place assigned by HWP (K).

Page 6 of 32
4.2.0 Technical requirement of civil work: Dismantling of existing RCC
foundation of 310 kVA DG sets (4nos.) and preparation of new
foundation for installation of 500 kVA DG sets – 4 nos.
4.2.1 The dismantling and preparation of new foundation of the existing four nos. of diesel generator
sets shall be performed one by one (see 4.1.2 also).
4.2.2 Each existing DG sets having RCC foundation (in cm): (a) 300x30x50 (Length x Breadth x
height) – 2 nos. (b) 50 x25 x 10- 2 nos. & (c) 110 x 110x 4- 1no.
4.2.3 The existing concrete pads / foundation of DG sets as mentioned above shall be fully
dismantle below surface level (up to depth of 300 mm) for proper bonding of new foundation.
4.2.4 The new foundation for Diesel Generator set shall be formed in accordance with the IS-2974.
Depth of foundation should be designed considering weight of 500 kVA DG set with acoustic
enclosure.
4.2.5 The length and breadth of foundation should be at least 150-300 mm (6-12’’) more than base
length and breadth of equipment. Foundation height should be about 100-150 mm above
ground level to maintain cleanliness around DG set.
4.2.6 Foundation should be designed with necessary pocket for grouting of anchoring bolt/ isolators
springs etc. as required for installation of Vibrating isolators (AVMs) / anti vibration pad for
installation of DGs. Foundation of DG sets shall qualify for seismic zone-II with post seismic
importance factor of 1.5.
4.2.7 Requirement of dimension (depth etc.), type/ design of RCC / AVMs as necessary shall be
finalized during technical discussion after opening of technical bid. In case bidder offers
altogether different foundation arrangement it shall also be accepted subject to meeting the
vibration, noise, vibration transmission and critical speed suitability criteria as per relevant
standard.
4.2.8 All areas under and adjacent to the foundation shall be well cleaned prior to pouring of
concrete. The surface except the pockets for grout shall be made rough so as to secure good
bond with fresh cement. Cement grout with non-shrinkable additive shall be used where
structurally required.
4.2.9 All surfaces other than main foundation to be chipped/ cleaned for finishing/ recoating of the
surface/floor.
4.2.10 All civil works for installation of HSD Tank, radiator, structural support for anchoring of
piping, vents, exhaust chimney etc. in the bidders’ scope.
4.2.11 Concrete of M25 or higher grade as per IS-456 shall be used for foundation of machines. The
concrete used shall be of plastic consistency without excessive water. Continuous concreting
shall be done as far as possible for entire block, leaving provisions for grouting.
4.2.12 Reinforcement may be bent and fixed in accordance with the procedure indicated in IS-2502.
Annealed steel wire (0.9mm dia or over) may be used for tying crossing bars.
4.2.13 Construction joints should be avoided. The finished surface of the foundation shall be leveled
before installing the machine.
4.2.14 The fundamental natural frequency of foundation of DG sets shall be at least 20 percent away
from the machine operating speed. Dynamic analysis, vibration analysis, static analysis, grade
of concrete, reinforcement steel etc. shall be as per IS-2974.

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4.2.15 Shuttering material shall have smooth and even surface and the joint shall not permit leakage
of cement grout. All surface of shuttering, in contact with concerts, shall be treated with a non-
staining mineral oil or other approved material to prevent adhesion with concrete and protect
reinforcement also.
4.2.16 The required routing/ lay out for cable racks, trenches shall be worked out. Main cable trench
600 mm wide is available at both side of existing DG sets. Excavation/ digging & trenches as
necessary for laying & termination of power & control cables, laying of branch piping etc.
required for installation of new DG sets in the supplier’s scope.
4.2.17 Checker plates / trench covers should be provided for newly make trenches. Brick works/
sand filling to be done for all excavation/ digging work. Backfilling the cable trench & making
up to the ground level in the supplier’s scope.
4.2.18 Supply of all construction materials (cement, concrete, reinforcement etc.), structural
materials (anchoring bolt, angle, column etc.), all consumables items (nut-bolt, clamps, shims,
cotton etc.) & shuttering materials etc. shall be in the supplier’s scope.
4.2.19 The design, drawings and specification of foundation shall be approved from Engineer-In-
Charge before execution of work.

4.3.0 Technical requirement of Design, supply & construction of 3

Hour rating fire resistant wall in between DG sets & HSD day
tanks.
4.3.1 Fire resistant reinforced concrete wall of minimum 3 hr fire rating has to be formed in
between DG sets & in between HSD tanks.
4.3.2 Concrete aggregates, thickness of reinforced concrete walls, concrete cover to the
reinforcement in wall shall be calculated considering both side exposed to fire as per
specification of IS-6142 & IS-456.
4.3.3 Height & length of fire resistant wall (non-load bearing) shall be finalized on the basis of
overall length, height and layout of DG sets & HSD tank.
4.3.4 Fire resistant wall should have ability to shown fire stability, fire integrity/ thermal insulation
or other expected duty as specified in standard fire resistance test as per IS- 3809.
4.3.5 Design and layout of the firewall shall be approved after placement of purchase order before
construction of wall.

4.4.0 Technical Specification of 500 KVA Diesel generator Set- 4 nos.

& its auxiliary.
4.4.1 Technical requirement of foundation / base rail, unloading, shifting for
installation of DG sets.
4.4.1.1 Static & dynamic load data of DG sets for foundation design shall be furnished with detail
layout drawing of DG set by manufacturer for approval.
4.4.1.2 Engine & Alternator shall be coupled through a flexible coupling and mounted on a factory
designed and tested sturdy steel channel base frame. The base shall be designed and built to
resist deflection, maintain alignment, and minimize resonant linear vibration.
4.4.1.3 The base frame shall be free from any defects such as burrs, twists, distortions etc. The
base frame shall then be painted with 2 coats each of red oxide primer and black synthetic
enamel paint to prevent rusting.

Page 8 of 32
 4.4.1.4 Provision for lifting (Eye bolts/ pockets) provided on base frame of the DG sets should be
designed considering total weight to be handled and to maintain the centre of gravity of the
DG sets while lifting. Other than this, eyebolt shall be also provided on individual major
equipment of handling (Diesel engine, alternator, radiator, acoustic enclosure, tank, AMF
panel etc.).
4.4.1.5 Anti-vibration mounting may be used to ensure the vibration & noise transmission of the
DG sets to the surrounding structure & building within the permissible limit as per IS/
manufacture’s recommendation.
4.4.1.6 Sufficient no. of suitable capacity steel spring isolators/ anti vibration mountings (AVMs)
dully approved shall be installed between the base and the mounting surface. The isolators
shall bolt to the base, and have a waffled or ribbed pad on their bottom surface. The pads
shall be resistant to heat and age, and impervious to oil, water, antifreeze, diesel fuel, and
cleaning compounds. Isolators shall have minimum of 25 mm deflection and qualify for
seismic zone as laid down in IS-1893.
4.4.1.7 The leveling and alignment of foundation shall be carried out carefully before placing the
DG sets. The final grouting of the base frame and fixing of the mounting bolts of the panels
shall be carried out only after ascertaining perfect alignment and leveling by the experienced
and skilled persons and on clearance from the engineer in charge. The base frame of DG sets
should be leveled using shims before grouting with foundation.
4.4.1.8 Before deployment of material handling equipments, chain pulley blocks, Hook, sling,
trolley etc. for erection, shifting & installation of DG sets & its auxiliaries it is necessary to
submit valid test certificates. Appropriate rating & smooth functioning of all equipment shall
be ensured before start of work. Only authorized persons should be allowed to operate
material handling equipments.

4.4.2.0 Technical requirement of Acoustic enclosure of Diesel Generator set.

4.4.2.1 The diesel generator sets are housed inside a high quality acoustic enclosure of compact,
modular & sleek design with low noise level (75 db) at a distance of 1 meter as per latest
MOEF (Ministry of Environment and forest) / CPCB (Centre pollution control board) norms.
4.4.2.2 The acoustic enclosure shall be soundproof, weatherproof, and environmental friendly
consisting of acoustically treated panels from all the four sides and top. It includes hinged
doors on either side for maintenance of DG set.
4.4.2.3 All the panels should be lined with fire proof acoustic material light resin rock wool as per
relevant IS. The material shall have more than 48 Kg/m3 density and the layer shall be 75
mm thick covered in the fiber glass sheet and perforated powder coated sheet from inside.
The outside fabrication will be made out of 2 mm GI Sheet and with ventilating louvers for
both at the engine side for fresh air entry and for hot air exhaust.
4.4.2.4 Exhaust silencer should be of domestic grade type mounted outside the enclosure,
exhausting to atmosphere. Exhaust pipe is to be extended up to height of approx. 8.8 meters
as per CPCB norms. All joints to be sealed with fireproof neoprene gaskets to withstand
temperature and pressure at site conditions. All high temperature exposed surfaces to be
insulated by glass wool with aluminum cladding up to the silencer.
4.4.2.5 Adequate ventilation should be provided to meet the air requirements for combustion and
heat removal. A ventilation fan/blower of adequate capacity to meet the total air requirement
and air changes shall be provided.
4.4.2.6 Existing Shutter modification has to be done to accommodate the inlet & outlet ducts as
necessary for air requirement for ventilation/combustion. Max allowable temp. Shall be 450
C in side the enclosure.

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 4.4.2.7 Enclosure and layout of the equipment have to design to facilitate easy access to all
serviceable parts and having sufficient space in and around the DG set for maintenance &
operation of the DG set. The fuel level gauge & engine control panel (for engine parameter)
shall be visible from outside the enclosure. Drain plugs shall be provided outside the
enclosure for draining lube oil. Handle type locking systems has to be provided for hinged
doors.
4.4.2.8 Arrangement for illumination with 40 watt tube light type fixtures has to
be make. Lights shall be arranged at both sides of DG sets inside the
enclosure. In addition to this 2 nos. of panic lighting shall also provide
inside the enclosure on 24 volt DC supply. Lights will be switched from
individual MCBs mounted on control panel cover & have back-up HRC
fuse. Two no. industrial type metallic plug socket (both side of DG).
4.4.2.9 There should be a provision of emergency shut down (by stopping solenoid)
of the diesel generating set (Prime Mover) from outside the enclosure.

4.4.3.0 Technical requirement of Exhaust system of Diesel Generator set.

4.4.3.1 The engine exhaust system shall be installed to discharge combustion gases quickly and
silently with minimum restriction. The exhaust system, including silencer, shall be designed
for minimum restriction, and in no case backpressure shall exceed 40 mm of Hg.
4.4.3.2 Engine exhaust system shall include exhaust manifold with muffler, flexible fittings,
exhaust silencer, exhaust piping, elbows, bends, heat insulating lagging/cladding, supporting
dampers, spring, rain trap, thimbles etc.
4.4.3.3 A stainless steel flexible exhaust fitting shall be provided to allow for thermal expansion
and engine vibration. The flexible fitting shall include a floating flange on one side to match
the engine exhaust outlet port(s) and bolt pattern and a fixed flange on the opposite end to
match the exhaust silencer inlet(s).
4.4.3.4 Piping shall be supported and braced to prevent weight or thermal growth being transferred
to the engine. Support dampers and springs shall be included where necessary to isolate
vibration. Roof height is approx. 7 mtrs. From ground level. First support shall be within 2.0
meter from exhaust flexible centre line.
4.4.3.5 The domestic type exhaust silencer shall be sized and supplied by the engine supplier. It
shall be mounted near the engine at suitable location to optimize silencing & backpressure to
the system. A provision for draining moisture shall be included.
4.4.3.6 The silencer shall provide extreme noise attenuation for environments with low
background noise. Silencer shall be pancake style bottom inlet, end outlet style. It should
meet stringent sound emission standards laid down by CPCB / MOEF notification.
4.4.3.7 ‘Schedule B’ MS exhaust pipe of minimum 200 mm dia (8 inch) and long end elbows shall
be used. One no. 1/ 8 inch NPT connection should be provided for measuring exhaust back
pressure during commissioning.
4.4.3.8 Exhaust piping inside the DG set room should be lagged along with aluminum sheet
cladding to avoid heat input to the room. A rain cap shall be provided to terminate the
exhaust pipe. The distance between exhaust pipe and rain cap should be higher than diameter
of pipe. Horizontal run of exhaust piping should slope downwards away from the engine to
condensate trap.
4.4.3.9 Use of thimble is necessary while passing the pipe through concrete wall. The clearance
around the pipe in walls shall be sufficient to allow free movement and expansion/
contraction of piping.

Page 10 of 32
 4.4.3.10 Emission limit (NOx level, HC, CO etc.) stack height and noise level shall comply with
the guidelines laid down by MOE&F and any other stipulation of the SPCB and CPCB in
this regard.

4.4.4.0 Technical requirement of HSD storage tank of Diesel Generator set.

4.4.4.1 The HSD storage tank of Diesel Generator set shall be installed outside of existing DG
building as nearer as possible with DG set.
4.4.4.2 The capacity of the HSD storage tank shall be of 1000 liters capacity sufficient for 8 hours
full load continuous operation. It shall be fabricated with minimum 3mm thick M.S sheet
with all standard accessories, which includes breather, drain plugs for draining diesel
complete with drain valve, trough arrangement to collect spill oil (individually or
collectively), air vent, inlet and outlet pipe connection, and manhole with cover.
4.4.4.3 HSD tank, fuel piping, valve etc. should be free from leaks. Materials of tank, valve, pipe
etc. shall be compatible with required service and shall not affect the any chemical properties
of HSD (as per IS-1460).
4.4.4.4 Installation of piping for hook up the fuel system from existing header to HSD tank &
from HSD tank to DG with necessary valve arrangements, non return valve between HSD
tank & Diesel engine & necessary flanges/blinds etc.
4.4.4.5 Wire mesh filter screen at filling point & fill neck to allow min.5%expansion space shall
be provided. Fuel water separator shall provide in between fuel tank and fuel filter, necessary
mounting arrangement/drain valve etc. to be provided.
4.4.4.6 The fuel level gauge (10-95%) to be provided visible from outside the enclosure. Electronic
fuel Level transmitter/switches to be installed and the digital/analog level indication have to
be provided in the control panel and low & high level alarm/trip at AMF panel. The full level
float arrangement has to make to avoid any spillage of oil. Each diesel engine shall be
provided with on-line fuel flow metering device (calibrated in liter) to monitor fuel
consumption.
4.4.4.7 Fuel tank should be placed on the level such that fuel outlet point (at bottom of fuel tank) is
optimally above the engine driven booster pump inlet connection. Fuel tank location should
be such that it does not obstruct free movement of service personnel.
4.4.4.8 Excavation/ digging, trenches, supports, thimbles / opening in walls as necessary for
installation of fuel system shall be in the supplier’s scope.
4.4.4.9 General arrangement & equipment layout drawings of HSD tank with DG, Isometric / P&I
diagram for complete fuel piping arrangement shall be submitted for approval before
execution of work.

4.4.5.0 Technical requirement of cooling system of Diesel Generator set.

4.4.5.1 The generator engine shall have a jacket water-cooling system with a closed circuit design
with provision for filling, expansion, and de-aeration. The cooling pump shall be gear driven
by the engine. Auxiliary coolant pumps if required for heat exchangers or separate circuit
after cooling shall be provided.
4.4.5.2 Coolant temperature shall be internally regulated to disconnect external cooling systems
until operating temperature is achieved. Cooling system should be designed considering 50
0C ambient and max temp. Rise of 5 0C is allowed inside the enclosure.

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 4.4.5.3 Heat rejected to the engine jacket water shall be discharged to the atmosphere through a
radiator. The radiator shall be sized to cool the engine continuously while operating at full
rated load. Air shall be drawn from the underside of the radiator and discharged to the
atmosphere forced by engine driven fan. The radiator shall have an expansion tank with sight
glass to allow for proper expansion and filling of the cooling system.
4.4.5.4 Cross ventilation and free flow of cool, clean and fresh air to be maintained for satisfactory
operation of DG set. Air should flow from alternator end to engine. Opening in front of
radiator should be 1.5 times radiator core and at back 2.25-3.0 times radiator core.
4.4.5.5 Installation of piping for hook up the make up water line from existing header to radiator
with necessary valve arrangements, non return valve, strainer arrangement, pressure gauge at
both side of strainer & flanges/ blinds etc.
4.4.5.6 Ducting in front of radiator may be required to take out hot air from inside of acoustic
enclosure to atmosphere. Extension duct to be designed and additional ventilation
arrangement if required shall be incorporated by supplier. It shall be finalized during
technical discussion.
4.4.5.7 Provision has to be made for low coolant level alarm, radiator water high temperature
alarm & trip, cooling water circulation failure and hook up with DG control panel and AMF
panel for annunciation.

4.4.6.0 Technical requirement of self-starting arrangement of Diesel Engine.

4.4.6.1 The engine starting system shall include 24-volt DC self-starting motor(s) (mounted on
Diesel engine), starter relay/ magnetic switch and automatic reset circuit breaker (mounted
on AMF panel) to protect against butt engagement. The engine shall be started by starter
motor engaging with the fly wheel ring gear and disengaging automatically when the engine
starts.
4.4.6.2 Batteries (2 x 12 V) automotive grade suitable for diesel engine cranking duty (conforming
to IS 7372) shall be lead acid types mounted near the starting motor. A corrosion resistant or
coated steel battery rack shall be provided with suitable rubber matting for placing batteries.
The system shall be capable of starting a properly equipped engine within 10 seconds. The
starting system shall be parallel to the engine starting batteries. The battery shall be capable
of providing at least six consecutive starting cycles with time interval of 5 second.
4.4.6.3 Double run single core TRS insulated unsheathed circular flexible cable of 70 mm2
(2228 x 0.2) size conforming to IS: 9857 shall be used for connecting Battery to starter.

4.4.7.0 Technical specification and requirement of Diesel Engine.

4.4.7.1 The Diesel Engine shall be stationary, heavy duty, compression ignition, totally enclosed,
water cooled, in line, 4 stroke, direct injection, cold battery starting, turbocharged after
cooled in accordance to BS:5514 and IS:10002 complete with all accessories.
4.4.7.2 The engine shall be capable of developing brake horsepower at 1000/1500 RPM to deliver
400 kW /500 kVA alternator output equipped with all engine-mounted parasitic and external
loads such as radiator fans, engine driven pumps etc.
4.4.7.3 The Engine Alternator set offered shall be continuous duty type of rating (Prime power)
400 kW /500 kVA. The set may be idle for a long period except for routine test periodically.
When there is no power supply the set will be required to run continuously at rated load. The
set shall be capable of taking 10% overload for one hour during a period of 12 hours.

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4.4.7.4 Diesel engine shall comply with the requirements of BS 5514 (ISO 3046). The engine shall
meet all the performance requirements of the set under the specified operating conditions.
4.4.7.5 Circulation of cooling water through the engine and radiator shall be by means of engine
driven pump. The water circuits shall be fitted with an easily accessible drain point. The
cooling fan shall be arranged to drive directly by the engine and the hot air shall ducted to
suitable openings in the generator room wall.
4.4.7.6 Lubrication of the engine shall be by means of an engine driven integral pump. The pump
shall have on the suction side a coarse strainer and on the delivery side a duplex `full flow'
fine filter complete with changeover cock to facilitate oil flow to the engine if filter becomes
blocked. The lubricating oil system capacity shall be sufficient to enable the engine to run
continuously at any load.
4.4.7.7 Lube oil priming pump with motor shall be provided when the engine is at rest. The control
circuit of the lube oil pump shall be designed to run once for six minutes after every four
hours or any other operating cycle suitable to engine design and cut off in case of engine
running.
4.4.7.8 Lubrication shall be provided by suitable capacity gear pump to develop positive pressure
for lubricating all moving parts. No moving parts shall be required lubrication by hand either
prior to the starting of engine or while it is in operation. Paper filament type lube oil filter
with lube oil cooler shall be provided for cooling and filtration of lube oil. A bypass filter
shall be provided to bypass the lube oil in case the lube. oil is not getting hot. Temperature
and pressure gauges / transmitter shall be fitted to the lubricating system. A dip stick
arrangement shall be provided to check the level of lube oil in sump.
4.4.7.9 The engine shall be efficiently silenced with suitable noise attenuators provided at
cooling/combustion air inlets and outlets. Bellow type flexible pipe shall be provided
between Engine and M.S. Exhaust Pipe.
4.4.7.10 Diesel engine assembly should have single piece Engine block, Deep hardened
crankshaft, molybdenum iron cylinder liners induction hardened, Aluminum alloy piston,
Forged steel connecting rods for piston and rod assembly, intake and exhaust valves with
hardened steel stem and hard faced to resist wear at high temperature, geared design
flywheel, fly wheel hosing with coupling guard, vibration damper etc.
4.4.7.11 To facilitate smooth starting of engine in cold weather condition Jacket water heaters shall
be provided to maintain coolant temperature of 32°C while the engine is idle. Heaters of
suitable rating (240 volt) with protection (fuse & contactor) and thermostatic controls shall
be provided. Hoses to and from the heater shall be industrial quality, which exhibit long life
in operational environments. Automatic logic shall be incorporated to isolate the heaters
during operation.
4.4.7.12 Engines shall start, achieve rated voltage and frequency, and be capable of accepting load
within 10 seconds. All four DG Sets should be identical in specifications; drooping
characteristics and transient response of shall conform to ISO 8528 and suitable for parallel
operation with grid.
4.4.7.13 the fuel system should comprise of fuel pump with Governor, fuel injectors, 24 volt DC
solenoid coil, Replaceable fuel filter. Diesel fuel rates shall be based on fuel having a low
heating value (LHV) of 42,780 kJ/kg when used at 29°C and weighing 838.9 g/l.
4.4.7.14 The governor of the engine shall be electronic type and be capable of fine governing of
speed to Class A2 of BSS 5514/1977, ISO 3046/IV.

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4.4.7.15 The governor shall be electronic besides hydraulic with manually adjustable arrangement
with a over speed trip mechanism to automatically shut-off the engine or the fuel supply if
the set reaches 110% of rated speed. In addition to this, an engine mounted emergency push
button/lever shall be provided from outside of acoustic enclosure. This shall trip the engine
when pressed. This shall be suitably protected against accidental tripping.
4.4.7.16 The engine shall run steadily and maximum change of speed because of load variation on
suddenly taking off or throwing, speed variation should be as per clause 2.3.2 of IS:10000
(Part VII).
4.4.7.17 When the engine alternator is delivering 10% and 100% of the rated power output, the
steady load speed band shall not exceed 1% of the rated speed.
4.4.7.18 The recovery time from temporary distribution to the steady load speed band at the new
load shall not exceed 3 second after taking off or throwing on the rated load.
4.4.7.19 An electronic engine control panel shall be provided on individual Diesel Generator set
visible from outside of acoustic enclosure. Following parameters/ indication shall be
available on it.
a) Engine speed (rpm)
b) lub. oil pressure (bar) and temperature ( 0c)
c) Radiator water temperature coolant temp( 0c)
d) Intake air temp ( 0c)
e) Engine runtime (hour)
f) Controller for electronic governor
g) Multi channel Temperature scanner with digital display for exhaust gas
temperature of cylinders, engine jacket water temperature, bearing & winding
temperature of alternator.
4.4.7.20 Required sensors for Engine monitoring parameters as mentioned above shall be provided
with analog/digital signal and additional potential free contacts for Central management
system.
4.4.7.21 Calibration certificates for all the measuring and controlling instruments like fuel
injection pump, thermostatic valves, tacho- generator, electronic governing system, engine
monitoring sensor / devices etc. has to be furnished before supply of materials.
4.4.7.22 Engine manufacturer shall furnished the complete data / specification sheet consisting of
No. of valves, Displacement, Compression ratio, Valve arrangement, firing order, cylinder
bore, piston stroke length, % engine loading vs specific fuel consumption curve showing
optimal engine loading with max. efficiency, max. cylinder temperature at 100% and 110 %
of prime rating, specific fuel & lub. oil consumption per KWh, Engine performance data at
different % load, power de-rating curves etc.
4.4.7.23 Maintenance and overhauling pattern/schedule, operating life of DG sets, service centre
locations and response time for maintenance shall be furnished for evaluation of post
guarantee maintenance.
4.4.7.24 Fuel consumption rate, lub oil consumption rate, Efficiency of Diesel engine shall be used
for technical evaluation and depending upon operating hours during its life cost of energy
shall be loaded for comparison of cost. fuel consumption rate at 75% of the rated load shall
be 78 litre per hour.

Page 14 of 32
4.4.8.0 Technical requirement and specification of Alternator.

4.4.8.1 The alternator shall be brushless, self excited and regulated through AVR and designed for
continuous rating of 500 KVA (at 0.8 pf lagging), 415 volts, 3 phase 4 wire, 50 Hz at
1000/1500 rpm conform to IS 4722/1970 at specified site conditions. The set shall be capable
of taking 10% overload for one hour during a period of 12 hours.
4.4.8.2 The alternator winding shall be star connected. The power supply terminals (3 phase) and
neutral terminal shall be brought out in separate terminal box. The terminals shall be
mounted in an accessible position on the alternator with necessary cable gland plates suitable
for extension of the supply to the AMF control panel.
4.4.8.3 The direction of rotation of alternator, terminal marking of 3 phase with neutral and
terminal marking of field winding shall be in accordance with IS-4728. The phase sequence
(UVW) and direction of rotation shall be clearly marked on the alternator.
4.4.8.4 The alternator shall be directly coupled to the diesel engine through flexible coupling.
The degree of protection for the generator and exciter shall be minimum IP 23.
4.4.8.5 The stator of the alternator shall be assembly of stator core, foot plates, air baffles and the
stator winding. The stator core consists of low loss electrical sheet steel. The sheets are
insulated to each other by coats of varnish at both sides. The skewed stator slots have to be
used to reduce noise level. All windings should be double layer fractional pitch chorded lap
type winding to reduce/ eliminate 5th / 7th harmonic, made of electrolytic grade copper of
high purity.
4.4.8.6 The complete rotor (cylindrical / salient type construction) shall consist of single shaft,
rotor field winding, damper winding, full bridge diode rectifier unit, brushless exciter
winding with fan. The rotor core shall be shrunk fitted on the shaft.
4.4.8.7 The shaft shall be designed sufficiently rigid to take care of transmitting torques, minimum
static deflection and natural frequency away from rated speed. The shaft should have axial
grooves in middle section to accommodate leads from exciter to field winding of alternator.
4.4.8.8 The inertia of the machine shall be adequate to meet the transient stability requirements
imposed by the interconnected electrical power system, to limit speed rise and shall have
such a value which will not cause the machine natural frequency to be in resonance with the
expected frequency of Diesel Generator sets surges. A margin of approx. 25% shall be
provided.
4.4.8.9 The alternator shall be fitted with two RTDs per phase for monitoring winding
temperature. The connecting leads of the temperature sensors shall be terminated in an
instrument terminals box. Two nos. of space heater of rating 230 volts shall be incorporated
inside the enclosures & separately wired to terminal box.
4.4.8.10 Each alternator shall be provided with its own exciter. The exciter shall have exciter
winding rotating armature type and its output fed to alternator main field through full bridge
diode rectifier mounted on single shaft. Stator winding of exciter should have main &
regulating field winding connected to the voltage regulating system. PIV of exciter diodes
must be 800v or 8 times the maximum exciter armature operating voltage, whichever is
higher.
4.4.8.11 The capacity of the excitation system shall be adequate to supply continuously 1.1 times
the excitation current and voltage required by the generator at 100% rated kVA and 100%
rated voltage & for supplying twice the excitation current required by the machine at 100 %
rated kVA and 110% rated voltage for a duration of one minute without damage.

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 4.4.8.12 The alternator characteristics shall be suitable for parallel operation with grid without any
quadrature droop compensations. The AVRs shall be suitable for voltage regulation of +/- l
% or better against all loads and prime mover drop up to 4% of the nominal speed.
4.4.8.13 The ceiling voltage shall not be less than 1.4 times the rated excitation voltage for a
minimum of 10 sec. Voltage swing (Transient response) when rated load is suddenly
switched on should be maximum 10 % with 0.2 to 0.7 sec (Recovery time). Automatic
voltage regulation ± 0.5 % to ± 1.0 % from no load to full load.

4.4.8.14 The excitation system while operating at maximum kVA, terminal voltage, power factor
& speed shall be capable of changing from rated field voltage to 90 percent of ceiling voltage
within 25 ms for a sustained drop in generator terminal voltage of 5 percent.
4.4.8.15 Neutral / star point of alternator shall be solidly earthed via neutral grounding contactor in
case of island mode and selectable incase of parallel running with grid. 2 nos. of earth points
are to be provided of alternator for body earthing.
4.4.8.16 The alternator shall be capable to deliver 150 % of FLC and having unbalanced current
carrying capacity of 20 % of FLC and Short circuit current withstand capacity is 5 times FLC
for 5 sec.( S.C. rating of existing switchgear is 36 MVA).
4.4.8.17 All the performance requirements such as automatic voltage regulation (AVR), power
system stabilizer (PSS) in accordance with the Authority’s connectivity regulations and
standards, grid standards & regulations on grid standards shall be complied.
4.4.8.18 Insulation shall be of thermal class H for the stator and the rotor windings with
temperature rises limited to that of thermal Class F. Vibration severity for the machine shall
be within the limits specified in IS 12075.The rating plate information in accordance with IS-
IS 4722/1970.
4.4.8.19 3 phase power terminal box & terminals should be suitable for terminating 3 nos. of 3
core x 300 sq. mm FRLS insulated Aluminium cable & neutral terminal box should be
suitable for 2 nos. of 150 sq.mm insulated Al. cable and glanding with double compression
cable. Separate terminal boxes shall be provided for space heater, field winding & RTDs.
4.4.8.20 Generator manufacturer’s shall furnished the complete data / specification sheet
consisting of Transient, sub transient , synchronous reactance, short circuit ratio, ceiling
voltage, excitation voltage and current at no load and full load, efficiency at diff % of load,
stator and field resistances etc. They will also furnish unity p.f. and S.C. characteristic curve,
No load loss curve, Power-load angle characteristics, power swing curve, capability curve
( V-curve) at lagging, leading & unity pf.

4.4.9.0 Technical requirement of AMF control panel of Diesel Generator Sets

4.4.9.1 Each Diesel Generator set shall be provided with independent AMF control panel. It shall
consist of components for starting, controlling and monitoring the operation of the diesel
generator set.
4.4.9.2 AMF control panel shall be floor standing, cubical pattern, fabricated with 2 mm M.S.
sheet painted with anticorrosive red oxide primer and powder coated with synthetic enamel
paint of gray shade. It shall be supported by structural steel frame with necessary
foundation / mounting arrangement and installed near the DG set.
4.4.9.3 The components of AMF control panel shall be designed, installed, wired & integrated as
per IS-10118, IS-3072, IS-732 and IS-13947. The components used in the fabrication of the
panel shall be of high quality/reliability and shall be of reputed make, the spares of which are

Page 16 of 32
 readily available in the local market. The design, drawings, layout & dimension of complete
panel shall be got approved from the Engineer-In-Charge before manufacturing.

4.4.9.4 The AMF panel shall be dust, moisture & vermin proof with IP 43 enclosure. It shall have
air circuit breaker of 800 amps rating. The breaker shall be electrically operated, horizontal
draw out type, having three poles operated through a common shaft by operating mechanism.
It shall have Service, Test and Isolate positions within the cubicle.
4.4.9.5 The circuit breaker shall be capable of rapid and smooth interruption of currents under all
conditions, completely suppressing severe and persistent short circuit conditions.

4.4.9.6 The symmetrical breaking capacity of the breaker shall be more than 50 KA / 36 MVA,
which shall remain constant within the limits of the rated voltages specified in this
specification. For voltages lower than the rated voltage, the breaking current shall remain
constant.
4.4.9.7 The circuit breaker shall be suitable for rapid closing and tripping. The breaker opening
and closing operations shall be obtained from compressed spring charging mechanism. The
mechanism for spring charging shall be motor operated with facility for manual charging
when required. Spring operated mechanism shall be complete with opening spring, closing
spring and all necessary accessories to make the mechanism a complete unit.
4.4.9.8 The auxiliary voltage of closing circuit, tripping circuit and spring charging motor shall be
110 volt dc. The closing release shall operate correctly at all values of voltage between 85%
and 110% of the rated voltage. The shunt trip shall operate correctly under all conditions of
the circuit breaker up to the rated breaking capacity of the circuit breaker and at all values of
supply voltage between 70% and 110% of the rated voltage.
4.4.9.9 The circuit breaker shall have followings inherent safety features:
i) In Test position, power contacts shall be disconnected however control contacts shall
remain undisturbed and close/trip operations of the breaker should be possible without
energising the power circuits.
ii) Operation of close/trip should not be possible unless it is fully in Service/Test or Isolate
position. Withdrawal or engagement of breaker should not be possible unless breaker is in
open or tripped condition.
iii) In service position it should not be possible to close unless auxiliary contacts provided for
it get closed.
iv) The main isolating power contacts on fixed portion should have automatically closing
shutters by movement of breaker from service to test/isolate position. They should have
door locking arrangement in closed position.
v) Operating mechanism shall have anti pumping feature for both electrically and
mechanically closing method.
vi) Mechanical trip and access to it shall be provided on the front without opening of the
compartment doors.
4.4.9.10 Mechanical and electrical indications shall be provided to show open & closed position of
the breaker and charged/discharged condition of the spring located at a place where they are
easily visible to operator, by separate indictor on the front of panel without opening
compartment door.
4.4.9.11 Auto/ manual selector switch for operation of circuit breaker & C-N-T- switch for
electrical close/ trip operation in test/ manual mode shall be provided. Breaker On/off,
Breaker in service, spring charged, Lock out (86) operated, trip ckt healthy LED indication
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 shall be provided on Breaker cubicle.

4.4.9.12 Switch fuse unit (SFU) with fuses, bimetallic relay, Power contactor, Aux. contactor etc.
required for Lub. oil priming pump (see 4.4.7.7), for ventilating fans/ blowers (see 4.4.2.5),
for illumination inside acoustic enclosure( see 4.4.2.8) & AMF panel, for jacket water heater
(see 4.4.7.11), for space heater of alternator ( see 4.4.8.9), AMF panel etc. shall be provide in
separate cubical for easy access.
4.4.9.13 A, 4 wire, 415 volt, 50 Hz Class III power supply shall be available at site for requirement
of 4.4.9.12. Necessary SFU, power contactor, on/off switch, Aux. contactor, LED indication
etc. shall be provided by manufacturer on AMF panel for incoming supply.

4.4.9.14 3Φ, 415 volt, 50 Hz alternator output shall be terminated to extended bus-bar connected to
incoming of breaker with necessary current transformers (CTs), potential transformer( PTs)
& excitation transformer etc. for measuring, protection & AVR. 415 volt R,Y,B, LED
indication for incoming supply from alternator before breaker shall be provided on Breaker
cubicle.
4.4.9.15 Neutral grounding contactor (N.G.C.) shall be provided for neutral earthing of alternator
(see 4.4.8.15). Control ckt to operate N.G.C shall be built up in PLC. Neutral CT for
Restricted Earth fault & standby earth fault shall be provided with extended bus-bar for
double earthing arrangement separately from body earthing of AMF panel. Full length
copper earth bus shall be provided at the bottom of the panel.
4.4.9.16 3Φ terminal at outgoing of circuit breaker & neutral terminal at incoming of NGC shall be
arranged horizontally with extended bus bar to terminate 3 nos. of 3 ½ core x 300 sq. mm
FRLS PVC insulated Aluminium cable.
4.4.9.17 The DG set incoming shall be provided with numerical 3 phase (microprocessor based)
multifunctional generator protection relays with self supervision feature, with LCD display
for parameters, LED indication for fault, RS-485 serial port for remote communication etc.
suitable for electrical protection of alternator which are mentioned below:
a) Voltage restrained over current protection (50/51V), two stage
b) Thermal overload protection of m/c.(49) (with alarm & trip)
c) IDMT O/C + E/F protection (51/ 51N) (selective curves)
d) Reverse power / Low forward protection (32)
e) Negative phase sequence protection (46), two stage
f) Loss of excitation (40)
g) Under / over voltage relay (27/59) two stage
h) Under / over frequency relays (81)
i) Restricted Earth fault (64 F) & standby earth fault (64 S) protection
j) Lock out feature (86)
4.4.9.18 Trip circuit supervision relay, control supply failure relay, PT fuse failure relay, lockout
relay, auxiliary relays etc. required for multiplication of alarm/ trip contact for tripping of
breaker, alarm/ trip annunciation at AMF panel, for remote indication for synchronization &
existing switchgear shall also be incorporated.
4.4.9.19 One digital Power analyzer/ energy meter/Tr-vector meter shall be provided for
monitoring electrical parameter such as KWH, KW, KVA, PF, V, I. etc. of alternator. It shall
have RS-485 serial port for remote communication of all parameters to central monitoring
Page 18 of 32
 system.

4.4.9.20 24 Volt battery for self starting of Dg sets shall be connected through Battery charging
system with suitable control & protection system and electronically controlled regulating
system for charging the batteries in float / boost mode with battery current limit. Battery shall
be charged by 415 volt supply available at same panel.
4.4.9.21 Analog voltmeter & ammeter shall be provided for monitoring of voltage & current of
battery charger & battery, for voltage & current of excitation system (field voltage &
current), for Alternator O/P voltage & currents with selector switches for 3Φ. Digital
frequency meter / Analog rpm meter & pf meter shall also be provided for DG operation.
4.4.9.22 All measuring analog / digital meter/ tri-vector meter shall be of class-0.5/1 accuracy.

4.4.9.23 Following Switch / push buttons shall be provided at AMF panel for DG operation:
a) Auto/ manual selector switch for auto / manual starting of DG sets.
b) Local/ Remote selector switch for Local & remote operation of Dg sets. Local
means from AMF panel and remote means from existing Class-III switchgear.
c) Start & stop push button for starting the DG set in local & manual mode.
d) Speed increase/ decrease push button for increasing frequency /speed in local
and manual mode.
e) Voltage raise/ lower push button in local and manual mode.
f) On/ off selector switches for 24 volt DC supply, 110 volt DC supply & 415
volt 3 phase class-III supply.
g) Float/Boost mode selector switches for battery charger.
h) Pushbutton for emergency trip to stop the Diesel generator Set, excitation etc.
4.4.9.24 PLC based control circuitry shall be designed to start, control and monitor the operation
of Diesel Generator Set. PLC shall have redundant type CPU with scan time of 10 millisec &
power supply card with LED indicating type I/O cards for monitoring & controlling the
parameters. It shall communicate to Central Monitoring System of DG system via
communicating devices and cables. 110 volt AC, UPS supply is available at site and shall be
hooked up with necessary cabling at terminals provided by you.
4.4.9.25 Lub oil pressure switch alarm & trip contacts, temp. switch alarm & trip contacts, HSD
fuel level low/high alarm & trip contacts, trip ckt supervision relay alarm contact, Electrical
fault lock out relay (86) trip contact, 24 volt dc source available contact, 415 volt class-III
supply available contact, Alternator Bearing & winding temp. alarm / trip contact from temp.
Scanner etc. shall be wired as I/Ps of PLC for logic buildup for starting & tripping of DG
sets, alarm & trip annunciation on AFM panel.
4.4.9.26 The starting philosophy shall include following points:
i) The present design envisages three operating & one standby DG sets and same shall be
maintained. All the DG sets are designed to automatically come in line in case of failure of
grid supply (Class-IV) and connect to three main Bus-Q, Bus-R, Bus-T and standby Bus-S of
Class-III (emergency) switchgear.
ii) If Auto/manual selector switch is selected in manual mode. DG can be started manually
only from AMF panel using start push button, voltage & speed can be raise/lower using
raise/lower push buttons either at AMF panel or respective Class-III switchgear panel
depending upon selection of Local/ Remote switch.

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 iii) Auto/manual selector switch is normally kept in auto mode. When the grid voltage falls
below the permissible value & after set time delay; under voltage relay of respective buses
(Bus-Q, Bus-R, Bus-T) trip the respective mains breakers (Class-IV) and initiate starting
signal to respective DGs & standby DG set.
iv) For 500 KVA DG sets: After getting starting signal from Under voltage relays PLC shall
initiate signal to start solenoid of the starter and starter motor to start the cranking of engine.
PLC shall check starting of engine & the voltage buildup of alternator (80% of rated
voltage). If engine does not get start & conform by PLC next start shall be initiated.
v) A three attempts automatic starting sequence to be designed with total lapse time of 25 sec.
After every attempts PLC shall checked the starting of the DG set and required voltage
buildup .After lapse of 25 sec engine fail to start shall appear and further starting action shall
be stoped.

vi) PLC shall initiate the starting signal to DG sets only after conforming the following:
a) If lub oil pressure is healthy.
b) If Lock out relay (86) is showing healthy.
c) If 24 volt dc supply is available.
vii) After satisfactory starting of DG set & voltage build up to 80% of rated value PLC shall
initiates the closing command to breaker of AMF panel.
4.4.9.27 PLC shall initiate the stop signal to diesel engine sets in case of following conditions:
a) If lub oil pressure becomes below the trip value.
b) Engine fails to start after three attempts.
c) If Engine temp.is high above the trip value.
d) Engine speed above 110%( set value).
e) Alternator winding temp. very high.
4.4.9.28 When class IV (grid supply) power resumes & load transfer from DG set to grid without
break (after synchronization) & DG supply incoming breaker on existing switchgear gets
trip, PLC shall initiates trip command to trip AMF panel incoming breaker. After conforming
the tripping of AMF breaker, PLC shall stop DG set after set delay in auto mode.
4.4.9.29 All DG controls, Alarm/ Trip indications, PLC aux. supply, contactor, stopping solenoid,
etc. shall be designed on 24 volt DC with sufficient redundancy derived from batteries /
charger.
4.4.9.30 Starting & tripping contacts shall be wired from PLC to start manually & stop
automatically the HSD fuel pump as per HSD level of Individual HSD tanks of DG sets.
4.4.9.31 If Lock out relay (86) operates in case of electrical fault PLC shall trips the AMF breaker.
4.4.9.32 Digital automatic voltage regulator/ controller, excitation system, excitation transformer,
metering & compounding CT, PT etc. required for voltage regulation & protection of
excitation system etc. shall be provide in separate cubical at AMF panel.
4.4.9.33 The digital automatic voltage regulator shall be microprocessor based with fully
programmable (user friendly with LCD display) in either auto/ manual mode or PF mode.
The regulator shall be capable of sensing true RMS in three phases of alternator output
voltage, or operating in single phase sensing mode. The regulator shall have over current

Page 20 of 32
 protection, with under/ over current limiter.

4.4.9.34 The regulator shall not be damaged or result in unsafe operation when subjected to open
or shorted input due to sensing loss, or sensing source shorted to ground.
4.4.9.35 A provision is made for field flashing arrangement for self excitation of the alternator,
sensing of rotating diode by monitoring excitation current, sensing of loss of excitation,
excitation voltage / current sensing for metering, for sensing of open/ short ckt/ earth fault of
excitation ckt etc., contact for alarm/ trip required for annunciation shall be incorporated.
4.4.9.36 A solid state microprocessor based alarm module shall be mounted on the AMF panel
including red (for trip / fail) and Amber (for status / alarm) flashing LEDs and silencable
alarm hooter with acknowledge, test & reset button to annunciate alarm/ trip conditions. The
hooter shall resound on subsequent alarms after silencing/acknowledgement, with the
flashing LED displaying a solid light until the condition is corrected.
4.4.9.37 Annunciation window (4 x 8) shall be provided for following function:

(i) Local mode selected (xv) Lub oil pressure low

alarm
(ii) Auto mode selected
(xvi) Lub oil pressure low trip
(iii) Manual mode selected
(xvii) Engine temp. high alarm
(iv) Remote mode selected
(xviii) Engine temp. high trip
(v) Battery low
(xix) Fuel oil level low alarm
(vi) Excitation fail
(xx) Engine over speed trip
(vii) Lock out relay 86 operated
(xxi) Lub oil priming pump
(viii) Generator winding temp.
overload
alarm
(xxii) NGC on
(ix) Generator winding temp. trip
(xxiii) PLC healthy
(x) Generator bearing temp.
alarm (xxiv) Radiator temp. high
(xi) Emergency trip operated (xxv) Low coolant level alarm
(xii) ACB trip ckt unhealthy alarm (xxvi) Automatic Governor
control fail
(xiii) Protection & metering PT
fuse failure alarm (xxvii) Stop solenoid
operated
(xiv) Engine fail to start
(xxviii) Rotating diode fail.
(xxix) spare ( 4 windows)

4.4.9.38 A Data integrator/ converter/ mixer shall be provided on the AMF panel to integrate the
data from PLC of AMF panel, from AVR, from Electronic control panel of DG set, from
window annunciator and from Power analyzer/ energy meter to communicate the monitoring,
alarm & fault data to Central Monitoring System consists for data logging and generate
utility reports.
4.4.9.39 All doors, panels, removable covers shall have neoprene gaskets around. Pressure release
diaphragms on breaker/busbar cubicle and cable termination compartments shall be provided
such that hot gases discharged during release of pressure don’t injure operating personnel.
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 Cable compartments shall be provided with removable undrilled plates of 3 mm thick for
cable entries from bottom of the panel.
4.4.9.40 All Instruments, relays and control switches requiring manual intervention shall be flush
mounted.

4.4.9.41 Panel doors shall be fitted with strong, heavy duty hinges and braced so as to prevent any
sagging, bending or distortion. The hinged parts/doors have latches at two places. The
hinges on panel doors should not deformed due to loads of relays, meters, operating switches,
knobs etc. fitted on the panel doors.
4.4.9.42 All the metallic parts, enclosures, panel doors shall be earthed to a common earth busbar
running along the entire length of the panel. The size of the earth busbar shall be selected for
carrying the max. fault current. Two earthing terminals shall be brought out for connection to
earthing grid.
4.4.9.43 Separate cable alleys shall be provided for power and control terminations. The power
connectors up to 16 amps rating can be DIN rail mounting push type. The connectors above
16 amp. shall be bolted type with protective shrouds/covers. All the power terminals shall be
provided with suitable rating terminals to terminate ring type lugs of power cables. The
power terminals shall be properly tagged / labelled and shall be mounted separately from the
control terminals. The control terminal block shall have 20 % extra terminals.
4.4.9.44 Power cable PVC FRLS (outer sheath) type- 3 nos. from alternator to existing switchgear
& control cable FRLS (outer sheath) PVC insulated from AMF panel to existing switchgear
shall be supply, laid, gland and terminated.

4.5.0 Technical requirement of Central Monitoring System

4.5.1 Central Monitoring System shall be designed with redundant processor, workstation loaded
with suitable SCADA/HMI software, communication network with driver software, PC (LCD
monitor 17”) with printer and ups to be placed centralized near DG room at average distance of
20 mtrs.
4.5.2 Individual AMF panel of DG sets shall have Data integrator / mixer (see 4.4.9.38) to
communicate on Ethernet/ Modbus / Other suitable communication facility with central
monitoring system through separate Data converter.
4.5.3 Central Monitoring System shall monitor & store all important parameter of individual DG
sets. Real time and historical data shall be shown on user friendly graphic display (mimic
diagram). CMS shall have enough memory to store data for 6 month, for periodic data logging
and to generate utility reports on excel sheet as per HWPK requirements.
4.5.4 CMS most show followings parameters:
i) Energy Parameters- Voltage, Current, frequency, KW, KWh etc.
ii) Engine parameter- Engine speed (rpm), lub. oil pressure and temperature , Intake air temp,
Engine runtime (hour), temperature of cylinders, engine jacket water temperature, bearing &
winding temperature of alternator etc. see(4.4.7.19).
iii) Important parameter alarm/ trip/ status parameter from PLC/annunciator (see 4.4.9.37) as
defined in of PLC.
4.5.5 CMC shall be supply with following components:
a) PC of reputed make shall be supply with INTEL PENTIUM (core duo) processor, 2 GB
RAM, 250 GB HDD, optical mouse, 17’’ colour LCD monitor, multimedia keyboard, Serial
(RS232) port & data converter card suitable for 4 channel I/P with 20 % spare port, DVD
combo drive complete with SCADA / driver software & all required accessories.
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 b) Latest HP Laser B/W A4 size printer complete with print technology, processor & USB
port compatible with above-mentioned PC.

c) Data converter, Shielded twisted pair serial communication cable from AMF panel to
CMC, hardware etc. required shall be in the scope of supplier.

4.6.0 Technical requirement of modification of existing system

4.6.1 Presently All four DG sets (three operating & one standby) are operating with existing 415
volt (Class-III) switchgear. They are designed to automatically come in line in case of failure
of grid supply (Class-IV) and connected to their respective buses (three main Bus-Q, Bus-R,
Bus-T and one standby Bus- S) as per existing logic and same shall be retained.
4.6.2 When class IV (grid supply) power resumes, DG sets are gets synchronized & load transfer
from DG set to grid without break. We are having common synchronization system for all DGs
with plug in arrangement to synchronize one by one DG with their respective buses (grid
supply). We have planned to use same system for synchronization by replacing the components
of synchronization panel.
4.6.3 Components Need to be supply for replacing are as follows:
a) Current Transformer of Ratio- 800/5 (20/5P10) - 4nos. 800/5(15/5P10) -4nos. 800/5(20
CL1) – 3 nos., 800/0.5- 1 no. (see sketch / dimension details).
b) Synchronizing relay, synchronoscope, frequency meters, voltmeters etc.
c) Manual freq raise lower button – 4 nos., AVR manual remote potentiometer- 4 nos.

4.7.0 List of spares to be obtained for our use after guarantee period of DG sets:

(i) Diesel Engine:

a) All Engine Bearings/Bushes- 1 set
b) Piston Assembly including piston rings, connecting rods, bolts etc. – 2 nos.
c) Piston rings(all types)- 1 set
d) Inlet valve and exhaust valve-1 set
e) Main lub oil pump assembly- 1 no.
f) Main fuel oil pump assembly-1no.
g) Fuel Injection pump-1no.
h) Gaskets and O rings-1 set.
i) Turbo Charger assembly-1 no.
j) Coupling assembly complete-1no.

(ii) Lube Oil Filters:

a) Filter Cartridge/Elements-1 set

b) Cartridge Guide- 2 no.
c) Set of filter gaskets/O rings-1 set

(iii) Fuel Oil Filters:

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 a) Filter Cartridge/Elements-1 set
b) Cartridge Guide- 2 no.
c) Set of filter gaskets/O rings-1 set

(iv) Aux Lube Oil pump:

a) Pump Assembly with motor & coupling – 1 set
b) Set of bearings/Sleeve- 1 set
c) Mechanical shaft, Seal- 1 set
d) Set of gaskets/O rings- 1 set

(v) Electrical Alternator:

a) Set of bearings – 1 set

b) Rotating Diode assembly- 1 set
c) Diode Fuse – 20 % of total qty
d) AVR cards – 1 no.
e) Governor Controller – 1no.
f) Potential transformer one of each type- 1 no.
g) Current Transformer one of each type- 1 no.
h) Control transformers one of each type- 1 no

(vi) Instrumentation:

a) 10 % of spare instruments or 1 of each type – 1 set

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5.0 TRAINING:
Successful bidder, before erection and commissioning of Diesel Generator sets at HWPK
Site will arrange for training of engineers- 2 nos. and technician-3 nos. for operation and
maintenance of DG set, PLC and associated equipments at their premises/factory.

6.0 TECHNICALSPECIFICATIONS: -
6.1. Guaranteed Technical Specifications of Diesel Generator Sets:

Engine Specifications/ make Reputed make

1.
a) Rated Prime rating 400 kW at 1500 rpm
Overload capability Min. 10 % for 1 hour in every 12 hour
b)
operation
c) Type of Engine In line, 4 stroke, compression ignition type.
d) Aspiration Turbocharged after cooled
e) Engine cooling system Radiator type
f) Governing System Electronic besides hydraulic
g) Starting Self starting
h) Noise emission control Acoustic enclosure
i) Transient/ Governor characteristics As per Class A2
j) Standard applicable IS-10002, ISO-3046 / 85280
2. Alternator specification / make Reputed make as per IS 4722
a) Rating (kW)/ Power Factor 400 kW / 0.8 p.f.
b) Rated Voltage 3 Φ, 415 volt +/- 5 %
c) Rated speed / freq. 1500 rpm / 50 Hz
Excitation / AVR Brushless excitation /Digital AVR with
d)
manual setting
e) Cooling Totally enclosed fan cooled (TEFC)
f) Rated Making Capacity 110 k Ap
g) Rated symmetrical short circuit rating 36 MVA / 50 kA at 415 voilt
h) S.C. ratio ≥ 0.5

Note- Equipment shall be of similar or higher rating.

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 7.0 TESTS AND INSPECTION:-
7.1 The DG sets shall be of proven design and should have been type tested as per IS 10000 /
10002 and IS 4722 / 7132 from reputed laboratory of the country within 5 years. Copy of
type test results shall be submitted for review. Type test should have been performed on at
least one type of item of a group of identical items to be supplied.
7.2 Routine/ performance tests of Diesel Generator sets shall be carried out at manufacturer’s
premises as per IS:10000 / IS:4722 / technical specifications of our tender in presence of
HWPK representatives.
7.3 Provisional list of test to be performed is given below:

7.3.1 Type test:

7.3.1.1 For Diesel Machine

(i) Initial performance test

a) Twelve hour rating test of engine
b) Fuel consumption test
c) Governing test
(ii) Endurance test
(iii) Determination of power
(iv) Mechanical efficiency determination
(v) Lubricating oil consumption
(vi) Test for smoke level, emission etc.

7.3.1.2 For Alternator

(i) Measurement of winding resistance

(ii) Measurement of leakage resistance & potier reactances
(iii) Measurement of open-circuit characteristics & parameter
(iv) Measurement of short-circuit characteristics & parameter
(v) Efficiency test
(vi) Temperature rise-test
(vii) Over speed test
(viii) Dielectric test
(ix) Short-circuit withstand and measurement of reactance & time const

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 7.3.2 Routine Test:

7.3.2.1 For Diesel Machine

(i) Determination of power

(ii) Fuel consumption test

(iii) Lubricating oil consumption

7.3.2.2 For Alternator

(i) Measurement of winding resistance of stator, field etc.

(ii) Insulation resistance test
(iii) Phase sequence test
(iv) Measurement of open-circuit characteristics & parameter
(v) Measurement of short-circuit characteristics & parameter

7.3 After the stand-alone test of Diesel machine and alternator is complete the bidder’s/ supplier
shall perform functional test of PLC, AMF panel etc. and show integration of PLC,
Electronic control panel, communicating devices etc. with central monitoring system.

7.4 Specification sheet & Quality Assurance plan, which shall include tests during
manufacturing, routine tests, type test etc. has to be submitted for approval before supply of
DG sets.

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 8.0 ENGINEERING, MANUFACTURING AND MAINTENANCE
FACILITY:
8.1 The DG sets with all accessories shall be engineered and supply as per technical
specifications and drawings shall be submitted for our approval.

8.2 The DG sets shall be tested and inspected at the DG sets manufacture factory. HWPK shall
reserves the right to inspect the manufacturing facility before finalization of purchase
order.

9.0 DRAWING & DATA SHEETS:

9.1 The bidder shall furnish the following drawing and data along with the offer:

9.1.1 Technical particulars/catalogues for the offered system & detailed description of the
system. The description should be self explanatory with required sketches/diagrams and
prove the technical suitability of the item offered.
9.1.2 Complete filled in data sheet for all equipment.
9.1.3 Bill of materials and recommended list of spares for two years trouble free operation (for
our future use).

9.1.4 Bidder should submit two copies of technical bid (in duplicate).

9.1.5 Bidder shall submit 4 sets of final and approved copy of all drawings, datasheet,
specification sheet, manual etc. and one set of soft copy for all documents.

9.2 DATA SHEET (DEMOGRAPHIC DATA):

HWP (K) is situated in village Anushakti (Rawatbhata) on the bank of Chambal River, 60
Kms. away from Kota by the side of Kota–Gandhi Sagar Road. Kota is a big railway
junction of western railway.

Site Condition
a) Altitude Less than 1000 M above MSL
b) Humidity 95% non condensing
c) Indoor/outdoor installation Indoor, Non-AC & may have dust particles.
d) Climate Tropical with temperature variation 3 °C to 47.5
Owner Government of India,
Department of Atomic Energy.

9.3 OTHER TECHNICAL DETAILS FOR REFERENCE:

(i) Existing Class-III switchgear arrangement single line diagram.

(ii) Layout drawing of existing DG sets enclosed.
(iii) Dimension details of existing current transformer.

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10. TECHNICAL DATA TO BE FILLED BY TENDERER:
A. Diesel Engine
1 Name of the Manufacturer
2 Type / Model No.
3 Application code / Standards
4 Rated Prime rating (kW)
5 Gross Engine power output (hp)
6 Rated speed at full load (rpm)
7 Overload capability (for 1 hr in every 12 hr)
8 Type of Engine
9 Aspiration
10 No. of cylinder
11 Bore x stroke length (mm x mm)
12 Displacement (cc / liter)
13 Firing order
14 Compression ratio
15 Air to fuel ratio
16 Piston speed
17 Engine cooling system (type)
18 Coolant capacity (liter)
19 Governing System (class)
Load variations Maximum change of speed
as a percentage of rated speed
On suddenly taking off or Transient Change
20
throwing on the rated load Permanent Change
On change of load by any step Transient Change
of 20 percent of the rated load Permanent Change
at 100 % load
Fuel consumption at 75 % load
21
rate at 50 % load
at 25 % load
Heat rejection to ambient
Heat rejection Heat rejection to coolant
22 rate Heat rejection to exhaust
Heat rejection to fuel
Heat rejection to after cooler
Cranking motor rating volt/kW
23 Starting system No. of battery
Battery voltage / amp-hr rating
Grade of oil
Lub. Oil Consumption rate / 100 hr. of running
24
system Total system capacity
Maximum Oil temperature
25 Combustion air inlet flow rate (m3/min)
Type of silencer (grade)

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 Exhaust Exhaust stack gas temperature (deg C)
system Exhaust gas flow rate (m3/min)
Exhaust flange size (internal diameter) (mm)
Exhaust system backpressure (maximum) (kPa)

Type of enclosure
Noise emission Sound level at 1 meter (db)
26
control Sound attenuation (db)
Materials used for sound attenuation
27 Dry weight ( kg)
28 Gross weight (kg)
29 Moment of inertia of rotating equipment with
flywheel & fan (kg-m2 )
30 Acceleration time of engine from cold to idle speed
31 HSD fuel tank capacity ( in liter)
B. Alternator
1. Name of the Manufacturer
2 Type / Model No. / frame size
3 Rating ( kVA / kW / p.f.)
4 Rated Voltage (volt)
5 Stator insulation class
Rated insulation level (KVp)
6 One minute power frequency withstand voltage
Lighting impulse withstand voltage
7 Rated Speed / Frequency (rpm / Hz)
8 Rated full load current (Amp)
Efficiency @ 100 % upf / 0.8 pf
9 @ 75 %
@ 50 %
Resistance Stator resistance (ohm)
10
Rotor resistance ( ohm )
Sub transient direct axis
Reactances (x) Sub transient quadrature
With time constants (τ) Transient saturated
11. Synchronous direct axis
Synchronous quadratue axis
Reactances Negative sequence (X2)
Zero sequence (X0)
12 Short circuit ratio
13 Rated short circuit current ( kA)
14 Rated fault MVA at 415 volt
15 Type of cooling
Over load capacity 10 %
16
( hr) 50 %
17 Type of excitation
Field voltage / current at rated load at u.p.f
18
at 0.8 pf lagging
19 Method of protection against shaft currents
20 Rotor insulation class
21 Exciter ceiling voltage (volt)

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 Rotor critical speed (rpm)
22
rpm
23 Temperature rise
24 Weight of rotor / moment of inertia (kg/ kg-m2 )
25 Gross weight of Alternator (kg)

C. AMF panel
1. Circuit Rating Continuous current rating
breaker Short time current rating
Peak making current
Power freq. withstand voltage
Duty cycle
Opening time
Closing time
Control voltage for closing / tripping/ spring
charging motor
2. Make & type of Automatic voltage regulator
3. Make & model of power analyzer/ tri-vector meter
4. Make & rating of indicating lamp ( rating)
5. Window annunciation type, make & size ( no. of window/ row)
6. Colour shade of AMF panel
D. General
1. Overall efficiency of at 25 %
DG sets at % of rated at 50 %
load at 75 %
at 100 %
2. Highest starting load permissible at % at 50 %
of running load at 75%
3. Control cable type
4. Power cable size & type ( PVC / FRLS )
5. History of manufacturing and earlier installation in India for
getting feed back. Enclose list
6. Delivery period.
7. Time period for installation & commissioning of one DG sets
8. List of deviations, if any, from purchaser’s requirements.
Enclose list

Note: 1. Partially filled data sheets or incomplete technical information is liable for rejection.
2. Every para of the tender should be thoroughly studied and requirement mentioned
should be addressed with back up records in the technical part of the tender.
3. Each page of this document and extra sheet submit by the bidder should be signed along
with its official seal.

Clarification regarding site conditions and system for which the Diesel Generator sets
are required can be obtained from;

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General Manager, Heavy Water Plant (Kota), PO: Anushakti, Via: Kota,
Rajasthan between 0900 hrs. and 1700 hrs. on any working day.
Following are the contact details:
Phone No. 01475# 242201, Fax No.-01475#242203

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