PROVN OF NEW DG SET FOR P-67 BUILDING (6 LU OFFICE) AT AFS KANPUR.

Supply, installation, testing and commissioning of 'Silent type' diesel generating set having prime power rating of 82.5 kVA at 0.8 power factor lagging, 415 V, 1500 rpm, 50 Hz, 3 phase 4 wire system, for 0.85 load factor, CPCB IV+ compliant (Central Pollution Control Board), with acoustic enclosure, anti vibration mountings, control panel and foundation. The engine is designed to meet the stringent exhaust emission tests as per the revised Ministry of Environment, Forest and Climate Change (MoEFCC) norms. The DG set shall be robust in construction, factory tested and assembled to ensure perfect alignment of engine and alternator on a common base frame. The DG set power rating indicated above is inclusive of altitude correction factor; however the DG set shall be designed and suitable to operate under the tropical conditions of Chakeri, Kanpur, and for more details on service conditions refer to the particular specification. The DG set shall be an eco-friendly product complying with CPCB noise and emission norms (noise and emission values lower than CPCB limits) and complying with CPCB IV+ emission standards as per the latest MoEFCC notification. The DG set shall comprise the following items as under :-

Diesel Engine : The diesel engine shall be of four stroke cycle, multi-cylinder, direct injection, radiator water cooled, turbocharged with after cooler, air to air after cooling and optimised turbocharger for increased altitude capability, developing not less than 100 BHP (brake horse power) at 1500 rpm (MoEFCC certified power) under NTP condition of BS 5514/ISO 3046, with an overload capacity of 110% for one hour in any specified 12 hours of continuous operation, suitable for generating set application in automatic mains failure (AMF) mode. The engine shall conform to IS 10000/BS 5514/ISO 3046. The engine shall have the following accessories : (i) Cooling fan and radiator. (ii) Demineralised (DM) water cooling system with pre-mix anti-corrosive additive. (iii) Turbocharger. (iv) Fly wheel with fly wheel housing. (v) Electric engine starter motor with disengagement after start-up, with battery. (vi) Battery charging system. (vii) Industrial/Residential silencer and exhaust pipes having suitable height with supporting structure. (viii) Stainless steel exhaust flexible elbow. (ix) Thermal sealing of exhaust pipe and aluminium cladding for complete exhaust pipe and silencer. (x) Required filters for fuel, lube oil, air etc. (xi) Sets of flexible hoses as required. (xii) Suitable rubber coupling to alternator with guard. (xiii) Suitable engine controller for protection of the engine. (xiv) Coolant heater. (xv) Oil drain pump. (xvi) Heavy duty air cleaner. (xvii) Electronic starter motor with soft start engagement feature. (xviii) Plate type lube oil cooler with first fill of lube oil and coolant. (xix) Selective catalytic reduction (SCR) system complete with diesel exhaust fluid (DEF) tank.

Engine protections : (i) High coolant temperature warning and trip (ii) Low lubricating oil pressure warning and trip (iii) Low coolant level warning and trip (iv) Fail to crank trip (v) Over crank trip (vi) High and low speed trip (vii) Low or high battery voltage alarms (viii) Clogged filter warning (ix) Lack of fuel (x) High canopy temperature (xi) Set fail to start protection after three consecutive unsuccessful start attempts.

Starting system : The engine starting shall be by means of totally enclosed axial type electric starter suitable for 12 V DC starting system comprising starter motor, voltage regulator and arrangement for initial excitation, complete with 12 V batteries or with suitable number of batteries (25 plates, 150 Ah, sealed maintenance free (SMF) lead-acid type) as required as per specifications. The battery shall be supplied with a suitable floor mounted mild steel (MS) stand treated with seven tank treatment, two coats of red oxide primer and acid resistant paint, with wooden base, adaptor box etc., with copper conductor battery leads of required length and socket/clamps.

Engine mounted instrumentation panel fitted with and having digital display for the following : (i) Start stop switch with key (ii) Water temperature indication (iii) Lubrication oil pressure indication (iv) Lubrication oil temperature indication (v) Battery charging indication and rpm indication (vi) Over speed indication and engine hours indication (vii) Low lube oil temperature indication.

Alternator : Brushless type, screen protected, revolving field, permanent magnet generator (PMG) excited alternator conforming to IS/IEC 60034-1 rated at 82.5 kVA, 3 phase, 0.8 PF, 415 V, 4 wire, 1500 rpm, class H insulation, voltage regulated through automatic voltage regulator (AVR) conforming to IS/IEC 60034-1, suitable for tropical conditions with brushless exciter, dynamically balanced rotor, alternator efficiency not less than 90%, housed in screen with the following :- (i) Terminal voltage differing from the rated value by not more than +/- 5% (ii) Frequency differing from the rated value by not more than +/- 0.5% (iii) Short circuit capacity of 300% for 10 seconds. (iv) Overload capacity of 110% for one hour. The insulation class of the alternator shall be class H. The temperature rise shall be limited to class B and ingress enclosure protection shall be IP 23 or better. The alternator shall be fitted with suitable number of resistance temperature detectors (RTD) and bearing temperature detectors (BTD) along with space heaters.

Alternator protection : Alternator shall have the following protections (i) Over and under voltage (ii) Under and over frequency warning and trip (iii) Loss of excitation (iv) Over current, earth fault and short circuit protection (v) Unbalanced loads (vi) Diode failure.

Voltage regulator : A rapid response voltage regulator shall be provided to regulate the generated voltage. The overall regulation from no load to full load, including cold to hot variation and load power factor of 0.8 lag to unity, shall be within 2% of the nominal voltage. The excitation system shall be designed to promote rapid voltage recovery following sudden application and disconnection of load.

Acoustic enclosure : The acoustic enclosure shall be supplied along with the DG set from the manufacturer's outlet itself as per the latest CPCB norms. The acoustic enclosure shall be powder coated and fabricated out of 2 mm thick cold rolled cold annealed (CRCA) MS sheet. The canopy shall have four hinged doors, one with flush window to view the parameters on the control panel properly. The canopy and doors shall have inside lining of fire retardant foam/glass wool as acoustic material. The base frame shall be fabricated in Indian Standard Medium Channel (ISMC) or in sheet metal with lifting hooks for convenient lifting of the complete set, i.e. along with canopy, engine and alternator. The sound level shall be less than 75 dB(A) at a distance of 1 metre. High quality noise absorbent and fire-retardant grade acoustic insulation material (PU foam) of density not less than 30 kg/cum and self-extinguishing grade. The allowable temperature rise inside the canopy is 5 to 7 deg. Centigrade. The measurement of noise shall be as per ISO 3744/ISO 8528 (Part 10) standard. The canopy shall have provision for an emergency push button, external to the canopy.

Governor : The governor shall be of electronic type, integral with fuel injection pump (FIP) and with isochronous capability, suitable for maintaining constant engine speed within the specified limits.