PROVN OF SPL ITEMS AT WATER SUPPLY PUMPING STN UNDER GE (WEST) MATHURA

Amount

Supply, installation, testing and commissioning of trolley mounted mobile diesel driven silent generating set to give an out put of 100 KVA /80 KW at 415 Volts, AC supply, 50 HZ, 3 phase, 4 wire directly coupled to diesel engine, liquid cooled, mounted on 4 wheel trolley with common base plate complete with fuel tank of adequate capacity, vibration damper, other accessories, acoustic enclosure, alternator etc complete all as specified and as directed . The DG set shall offer best fuel economy, best comprehensive warranty terms on entire package including rubber components and lowest maintenance cost to give most economical power solution. The DG set shall offer lowest noise levels in its range and shall be CPCB certified for emissions and noise compliance to give environment friendly power solution. The generator set shall meet the stringent exhaust emission tests as per latest MoEF norms without sacrificing fuel efficiency at normal operating loads of following make and technical specifications :- Engine Make - Cummins, Ruston, Greaves Cotton, Cater Pillar, Ashok Leyland, Mahindra or as approved by GE Alternator Make - Stamford, Jyoti, Alstom, Areva, Crompton Greaves, Leroy Somer or as approved by GE

A. Engine Specifications:- Developing a net minimum power as per MoEF certified - 159 HP ( ± 5 % ), suitably matched with alternator to give a net directed output as specified. The engine shall be capable of delivering the required out put at 1500 RPM, as per BIS under NTP condition with provision of 10% overloading for one hours in every 12 hours of operation. The diesel engine shall also conform to IS : 10000/IS 1460/IS 13018/ISO : 3046/BS : 649 / BS : 5514 as amended upto date. The scope of supply includes :- (i) Electrical starter motor 12V DC (ii) Battery charging alternator (iii) MICO fuel system (iv) Dual spin-on fuel filter (v) Turbocharger (vi) Residential silencer (vii) Dry type air cleaner (viii) Shut-off coil with safeties for LLOP/HWT (ix) Dynamically balanced fly-wheel and flywheel housing (x) First fill of lube oil and coolant

The technical data shall be all as specified below comprising of the following:- (i) BHP – suitable for giving a min power of 159 HP as per ISO 8528-Part-1/certified MoEF at the load terminals of alternator at 1500 rpm. (ii) All moving parts of the engine shall be mechanically guarded in such a manner that a human finger cannot touch any moving Part. (iii) Cooling – Liquid Cooled. (iv) Aspiration – Turbo Charged air cooled. (v) No. of Cylinders – 06. (vi) No. of cycles – 4 stroke. (vii) RPM – 1500. (viii) Fuel - HSD (ix) Fuel injection : Engine should have suitable fuel injection system in order to achieve low fuel consumption. (x) Starting System - 12V Electrical (xi) Lube oil specification – CI4 15W40. (xii) Governing specification – Electronic governor of class A1, as per ISO 3046/BS 5514 to maintain engine speed at all conditions of load. (xiii) Type of driven – Direct SAE flange coupling. (xiv) Battery capacity/rating – 12V DC, 88/90 AH. (xv) Any other item not included/specified, but is a standard design of the manufacturer.

ALTERNATOR :- The diesel engine mentioned herein before shall be coupled through flexible coupling to an indigenous synchronous alternator mounted on a strong mild steel fabricated common base frame, with AVM pads suitable for continuous operation at 1500 RPM, 415VAC, 0.8 pf (lag) suitable for 50 HZ, 3 phase, 4 wire system, brushless type, screen protected revolving field, self excited self regulated through an AVR all as conforming to IS 4722, BS 5000 & IEC:60034 as amended upto date. The alternator has the following features :- (i) Voltage Regulation - ± 1.0% (max) in static conditions. (ii) Voltage variation - ± 5.0 % (iii) Class of Insulation - H Class (iv) Degree of protection - IP 23 (v) Overload duration/capacity - 10% for one hour in every 12 hours of continuous use (vi) Frequency variation - As defined by the Engine Governor (± 1.0 %) (vii) Type of AVR( Automatic Voltage Regulator) - Electronic (viii) Stator Winding - Double layer lap (viii) Rotor - Dynamically balanced

Contrl Panel with microprocessor based monitoring and control system :- The control panel should be manufactured with 14/16 gauge CRCA sheet with powder coated for weather proof and long lasting finish The control panel consisting Multifunction digital meter displaying the following parameters :- (i) Voltage (Phase to Neutral & Phase to Phase). (ii) Current. (iii) Frequency. (iv) Coolant temperature. (v) Engine Oil pressure. (vi) Power Factor. (vii) KWHR. (viii) DG Set running Hrs. (ix) Engine RPM. (x) Battery voltage. (xi) MCCB of suitable rating with overload and short circuit protections. (xii) Push button-switch or ON/OFF Switch for ON and OFF operation. (xiii) Aluminium bus bar with suitable capacity with in and outgoing terminals. (xiv) LED Indicating Lamps set for 'Load On' and 'Set Running'. (xv)Insrument fuses duly wired and ferruled.

System operation : Manual Mode. (i) In a manual mode, it shall be feasible to start-up the generator set by the operator on pressing the start push button (ii) Three attempts starting facility shall be operative for the start-up function (ii) Alternator circuit breakers closing and trip operations shall also be through operator only by pressing the appropriate button on the panel and closure shall be feasible only after alternator has built up full voltage. If the load is already on ‘mains’, pressure on ‘close’ button shall be ineffective.

Engine shut down and alternator protection equipments : Following shut down and protection system with audio visual annunciation shall be integrated in the controller panel.1. For Engine :- (i) Low lubricating oil pressure. (ii) High/low coolant temperature. (iii) Engine over/under speed (iv) Low Fuel level. (v) High canopy temperature For Alternator :- (i) Over load) Short circuit) Earth fault) Over voltage) Over/Under frequency.

Battery/Electrical System - (i) Batteries of 12 VDC, 88/90 AH with copper cable of suitable sizes should be supplied with Genset are generally dry and uncharged. First charging of uncharged batteries is very important and should be done from authorized battery charging centre. Initial charging should be done for 72 - 80 hours. (ii) Batteries should be placed on stands and relatively at cool place.

FUEL TANK :- One No of sheet metal steel tank fabricated from 2mm thick MS sheet of suitable capacity to contain diesel for 8.0 Hrs running at full load including the following :- (i) Level indicator duly calibrated for indicating the quantity of diesel in the tank. (ii) Drain plug with 2 meter pipe for drain out. (iii) Fuel strainer. (iv) Pipe for fuel supply to engine. (v) Fuel pump manually operated for filling tank rotary type.

Acoustic enclosure: The acoustic enclosure shall be fabricated out of the CRCA sheet of thickness not less than 1.6 mm on the outside cover with inside cover having not less than 0.6 mm thick perforated powder coated CRCA sheet conforming to MoEF/CPCB norms suitable for out door installation in exposed to weather condition and to limit over all noise level to 75 dBA at a distance of 1 Mtr at 75 % load or as specified by MoEF(Ministry of Environment & Forest). The enclosure has the following features:- (a) The construction should be such that it prevents entry of rain water splashing into the enclosure and allows free & quick flow of rain water to the ground in the event of heavy rain. (b) The hinged doors shall be made form not less than 16 SWG (1.6 mm) thick CRCA sheet and will be made air tight with neoprene rubber gasket and heavy duty locks (c) Designed to have optimum serviceability (d) Air inlet louvers specially designed to operate at rated load made on special purpose CNC machines for consistency in quality and workmanship (e) Powder coated for long lasting service life and superior finish (f) Acoustic enclosures are supplied with built in Anti Vibration Mountings (AVM). As such Genset can be installed directly on the leveled surface (g) USE of special hardware for longer life (h) Insulation material meets exacting IS 8183 specifications for better sound attenuation.

(j) Flush styling - no projection (k) Fluid drains for lube oil & fuel. (l) The canopy should be as compact as possible with good aesthetic look. (m) Fuel tank suitable for 8 hours of operation (n) The enclosure is of modular construction with the provision to assemble and dismantle easily at site. (o) The sheet metal components are hot dip seven tank pretreated before powder coating. (p) The enclosure is powder coated (inside as well outside) with a special pure polyester based powder. All nut and bolts/external hardware is made from stainless steel. (q) There is provision for filling fuel from outside the enclosure with locking arrangement. (r) External drain plugs are provided for draining Lub. Oil and diesel. (s) The doors are gasketed with high quality EPDN gaskets to prevent leakage of sound. (t) The door handles are locking type. (u) Sound proofing of the enclosure is done with high quality rock wool/mineral wool confirming to IS 8183. The rock wool is further covered with fiber glass tissue and perforated sheet. (v) A special residential silencer is provided within the enclosure to reduce exhaust noise.

(w) Specially designed attenuators are provided to control sound at air entry and exit points. (x) Adequate ventilation is provided to meet total air requirement. If required, a blower is provided to meet total air requirement. (y) Temperature of enclosure does not exceed beyond 5 degree centigrade of ambient temperature. (z) The enclosure is provided with high enclosure temperature safety trip. (aa) Provision of emergency shut down from outside the enclosure. (ab) An arrangement for illuminating the enclosure from inside. (ac) The acoustic lining should be made up of high quality insulation material i.e. glass/mineral wool of minimum 50mm thickness and 75 Kg/cubic metre to 100 Kg/ cubic meter for sound absorption as per standard design of manufacturer’s to reduce the sound level as per CPCB norms. The insulation material shall be covered with fine glass fiber cloth and should be supported by perforated M.S. Sheet duly powder coated.

COUPLING & MOUNTING ARRANGEMENT : The engine and alternator are directly coupled by a SAE flange and mounted through AVM pads on a heavy duty steel base frame. The arrangement ensures that there is no chance of misalignment of the DG Set and vibrations of the DG Set are not transmitted to the base frame & to the enclosure. The fuel tank is mounted in the base of the enclosure. The batteries are kept in a separate tray inside the enclosure. COMMISSIONING: The DG Set shall be successfully commissioned by the contractor at the site as directed. TROLLEY SPECIFICATION : Fabrication of 04 wheel ( double axle ) trolley for mounting arrangement of DG sets with Fe 410 grade steel to hold the complete DG set of minimum platform size 4100 mm x 1250 mm and designed to carry minimum 4000Kgs weight with the following Specification complete in all respect and as directed:- (i) MS Chassis - MC 200X75mm. (ii) MS Axle two Nos - 65X65mm. (iii) MS Chequered plate top - 8mm thick supported with suitable size angle and beams welded to Chassis and base plate. (iv) Rims and wheels - 4 Nos, tyer 7.5/16 inches (16 Ply) of make MRF/CEAT/Apollo. (v) Hydraulic Parking break - (vi) Towing hook of suitable size. (vii) Leaf springs suspension sets with U clamps - 04 Sets. (viii) Trolley shall be painted with two coats of synthetic enamel paint over a coat of red oxide/ Zinc chrome primer of approved colour.

Exhaust System : DG Set sahll be fitted with retrofit Emission Control Device (RECD) to control exhaust emission limits as per latest guideline issued by CPCB And meet requirements of environmental (protection) Rule 1986.

Supply, installation, testing, alignment and commissioning of centrifugal pump set, electrical driven of discharge capacity of pump 30 to 35 Ltr/Sec at 60 Mtr head coupled with three phase 415 VAC, 50 Hz induction motor of capacity 50 HP suitable for existing size of suction pipe of 125 mm & discharge/delivery size of 100 mm duly mounted on MS base frame including suitable Nos of AVM pads coupling guard with following make and technical specifications :- Centrifugal Pump Make - Kirloskar( Model - DSM 100/36 ), Beacon, Crompton Greaves, KSB, Mather & Platt, CRI Coimbatore, WASP or as approved by GE Induction Motor Make - Kirloskar( Frame - KI 225S), ABB, Mather & Platt, Areva T&D, NGEF or as approved by GE.

Centrifugal Pump Specifications:- The technical data shall be all as specified below comprising of the following :- (i) Casing : Horizontal axially split volute type, suction and discharge nozzles and supporting feet cast integral with lower half casing. (ii) Impellers : Enclosed type accurately balanced impellers are placed back to back to balance axial thrust load. (iii) Shaft : The high tensile steel shaft accurately machined and ground is supported by antifriction bearings. The shaft is protected by shaft sleeves from wear in stuffing box area. (iv) Stuffing Box : The stuffing box can be sealed by gland packing or by mechanical seal and is suitable for liquids having temperature up to 90 degree centigrade. (v) Bearings : Deep groove ball/roller bearings are provided. Standard lubrication is grease. (vi) Direction of Rotation : Clockwise viewed from driving end. (vii) Drive : Suitable for coupling with electric induction motor (viii) Flanges : Standard drilling as per BS 4504 Table 16/11. (ix) Impellers : Enclosed type accurately balanced impellers are placed back to back to balance axial thrust load.

Induction Motor Specifications:- The technical data shall be all as specified below comprising of the following :- (i) Type of Motor - 3 Phase squirrel cage induction moto suitable for 415 Volt ( ± 10 %) , 50 Hz (±5%), combined variation 10 %, insulation class F with temperature rise limited to class B, degree of protection IP -55, Duty - S 1, Efficiency class conforms to IS 12615 , IEC 60034-1 & testing according to IEC 60034 -2-1. (ii) Power - 50 HP/37 KW (iii) No of Pole - 4 (iv) Speed - 1480 RPM (v) Efficiency - 95.2 % as per IE 4 (vi) Power factor - 0.86 (vii) Rated Current - 63.5 Amp (viii) Enclosure type - TEFC (Totally Enclosed Fan Cooled).

Supply, lowering, lifting, alignment, testing and commissioning of vertical turbine pump 227 CuM/Hr or 50,000 Gallon/Hr at 60 Mtr head, electrical driven coupled with vertical hollow shaft (VHS) three phase induction motor of capacity 75 HP, 415 VAC, 50 Hz with following technical specifications:- Vertical turbine pump Make – WPIL (Worthington Pump India Ltd, Model – 5GM 12 TC), KIRLOSKAR, XYLEM, FLOWSERVE, SHERA, JYOTI as approved by GE. Induction Motor Make – Kirloskar (Frame-SVH 250), ABB, Mather & Platt, Areva T&D, NGEF as approved by GE.

Vertical Turbine Pump Specifications:- The technical data shall be all as specified below comprising of the following:- (i) Blow Assembly:- The intermediate bowls, discharge cases and suction bowls shall be flanged type constructed from close grain cast iron, and shall conform to ASTM A48, class 30, internally porcelain coated, externally coated with backed epoxy. (ii) Impellers:- Zinc free bronze, diffuser and casing are designed to deliver the required head and capacity as efficiently as possible. The impellers shall be produced by investment cast method and shall be of the enclosed type. They shall be free from defects, machined and accurately balanced and placed back to back to balance axial thrust load for optimum efficiency and performance. (iii) Shaft:- The shaft material shall be constructed from stainless steel ASTM A582 type 416. It shall be precision machined and straightened with tolerance limit. (iv) Stuffing box:- The stuffing box shall be ductile iron, ASTM A536 class 65, rated at 250 psi or an optional balanced mechanical seal. It shall have an available fitting for pressure relief. The packing follower gland shall be 201 stainless steel and secured in place by stainless steel studs and nuts. The packing box bearing shall be bronze B-505-836. A rubber water slinger shall be provided to operate on the top shaft, above the packing gland. (v) Bearing retainers: Investment cast 201 stainless steel bearing retainers, also known as spiders, shall be furnished for shaft stabilization at each column pipe coupling. A rubber fluted line shaft bearing, retained with a shoulder at each end, shall be installed in each bearing retainer. (vi) Suction Strainer:- A stainless steel basket strainer of a suitable size shall be provided and attached to the pump suction with stainless steel fasteners. Galvanized strainers are not acceptable. (vii) Drive:- Suitable for coupling with electric induction motor. (viii) Length of MS column Pipe assembly flanged type (8.0 inch dia, thickness not less than 7.0mm) should not be less than 100 feet for lifting of water upto the depth of 40 mtr (approx).

Induction Motor Specifications:- The technical data shall be all as specified below comprising of the following:- (i) Type of Motor – Vertical hollow shaft (VHS) three phase induction motor suitable for 415 volt (¬+10%), 50 Hz (¬+ 5 %), combined variation 10 %, insulation class F with temperature rise limited to class B, Duty – S1, conforming to IS 325, Efficiency class conforms to IS 12615, IEC 60034-1 & testing according to IEC 600324-2-1. (ii) Power – 75 HP/55KW (iii) No of Pole – 4 (iv) Speed – 1480 RPM (v) Efficiency – 95.7% as per IE 4 (vi) Power factor – 0.86 (vii) Rated Current – 93.5 Amp (viii) Enclosure type – IP 23 (ix) Bearing suitable to bear thrust load of 2860 Kgs: (a) Top side – Oil Lubricated, bearing No 2932E. (b) Bottom Side – Grease Lubricated, bearing No – 6316 (x) Direction of Rotation – Anti clock wise viewed from top of Motor.

shyam construction

M/s Singh Engineering Corporation