REPLACEMENT OF EXISTING OLD VINTAGE DG SET WITH NEW CAPACITY OF 250 KVA DG SET AT RATNUCHAK UNDER GE KALUCHAK

Amount

Design, Supply, Erection, Interconnection to existing panel, testing, commissioning, loading, transportation from manufacturers factory site and unloading at Kaluchak of Silent Type Diesel Generator Set having prime power rating of 250 KVA, 415 Volts at 1500 rpm, 0.8 lagging power factor with diesel engine alternator, acoustic enclosure with AMF panel alongwith dedicated DG Set control panel and necessary instrumentation having arrangement for termination of 2 Nos. 3.5 Core, 150 Sqmm armoured aluminium XLPE cables at incoming and outgoing sides of panel for interconnection to existing panel alongwith pipe / cable tray for laying cables alongwith necessary civil breaking and repair work as required at site, control cables, batteries, battery charger, fuel tank, fuel piping, silencer, exhaust piping thermal logging, asbestos rope insulation, cladding etc for exhaust piping complete as required, consisting of the following :-

(A) Diesel Engine : Diesel engine shall be the standard design of the OEM. It should be 4 stroke, water cooled naturally aspired / turbocharged as per OEM standard, electric start 6 cylinder inline assembly of minimum 310 BHP for giving a power rating in KVA at the load terminals of alternator at 1500 rpm at actual site conditions (Jammu City, J&K) and confirming to BS 5514, BS 649, IS 10000 capable of taking 10% overloading for one hour after 12 hours of continuous operation. The average load factor of the engine over a period of 24 Hrs shall be 0.85 (85%) for prime power output. The engine shall be fitted with all the required accessories.

(i) Dynamically balanced flywheel (ii) Necessary flexible coupling and guard for Alternator and Engi (iii) Air cleaner (dry / oil bath type) as per manufacturer standard (iv) Governor of Class G2 and shall be self contained unit capable of monitoring speed (v) Daily fuel service tank with minimum capacity of 8 hours of continuous operation fabricated from 14/16 SWG sheet metal complete witth inlet, outlet connections, air venty tap, drain plug and level indicator gauge, stainless steel fuel piping from tank to engine with valves, unions, reducers, flexible hose connection and floor mounting pedestal, twin fuel filters and fuel injectors. The fuel tank shall be located inside the acoustic enclosure itself. (vi) Dry exhaust manifold with suitable exhaust residential grade silencer to reduce noise level (vii) Suitable self starter for 12 V /24 V DC (viii) Battery charging Alternator unit and voltage regulator suitable for starting batteries, battery racks, interconnecting leads and terminals

(ix) Battery Charge (x) Necessary gear driven oil pump for lubricating oil, priming of engine bearing as well as fuel system as per OEM recommendations (xi) Lubrication oil cooler (xii) Lubrication oil filters with replaceable elements (xiii) Crank case heater as per standard (xiv) Fuel injection system to minimize the fuel consumption (xv) Fuel control solenoid (xvi) Fuel pump with engine speed adjustme

(xvii) Electronic engine management control panel fitted and having digital display of followings :- (a) Start / Stop key switch (b) Lube oil pressure indication (c) Water temperature indication (d) RPM indication (e) Engine hours indication (f) Battery charging indication (g) Low lube oil trip indication (h) High water temperature indication (j) Overspeed indication (k) Overload trip indication (xviii) All moving parts of the engine shall be mechanically guarded with MS mesh guard in such a manner that a human finger connot touch any moving part (xix) Radiator (xx) Any other item not mentioned / specified but is a standard design of the OEM

(B) Derating of the Set : The output of the DG Set shall be under the following climate conditions and in conformity wit CPCB approved type test (a) Outside maximum temperature : 45 degree C. (b) Height above MSL - Kaluchak, Jammu (c) RH - 59% (d) DG Set should be type tested for noise and emission norms / standard as per latest CPCB norms

(C) Alternator : Self excited screen protected self regulated brushes alternator horizontal foot mounted in single bearing construction with following specifications. Rated PF 0.8 Lagging. Rated voltage 415 Volts. Rated frequent 50 Hz, no of phases - 3. Enclosure SPDP, Degree of protection IP-23, Ventilation - Self ventilated air cooled. Ambient temperature 50 degree C. Insulation Class H, Temperature rise within limits of Class H insulation, Voltage regulation =+/ -1% Voltage Variation =+/-5%. Overload duration / capacity - 10% for one hour in every 12 hours of continuous use. Frequency =+/- 1% as defined by governor. Variation excitation - Self excited, Type of AVR - Electronic (Soft) Type of bearing and lubrication arrangement. Anti friction bearing with grease lubrication. Standard IS 4722 & IEC:34 as amended upto date. In the event of any fault due to over voltage / high bearing Temperature / high winding temperature or an external fault, the AVR shall remove the excitation voltage to the Alternator. An emergency trip push button shall also be provided which is located outside the acoustic enclosure.

Voltage dip shall not exceed 20% of the rated voltage for any step load or tansuient load. The winding shall not develop hot spots exceeding safe limits due to imbalance of 20% between any two phases from no load to full load. The generator shall preferably be capable of withstanding a current equal to 1.5 times the rated current for a period of not more than 15 seconds. The performance characteristics of the alternator shall be as below. Efficiency at full load 0.8 PF not less than 90%. Total distortion factor less than 3%, 10% overload - 1 hour in every 12 hours of continuous use. 50% overload - 15 seconds.

(D) Terminal Box suitable for terminating two cables of 3.5 core x 150 Sqmm size. Aluminium / Copper armoured XLPE cables. (E) Two Nos of Earth Terminals on opposite sides with vibration proof connections non ferrous hardware etc with galvanise plate and passivated washer of minimum size 12 mm dia hole shall be provided. (F) Space Heater shall be provided with MCB control and thermostat such that during idle period it does not absorb moisture.

(G) Engine mounted Instrument Panel filled with having digital display for 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 (vi) RPM indication (vii) Overspeed indication (viii) Low lube oil trip indication (ix) Engine Hours indication (H) Base Frame & Foundation : Both the engine and the alternator shall be mounted on suitable base frame made of MS channel with necessary reinforcement which shall be installed on suitable cement concrete foundation as per foundation diagram of the manufacturers and vibration isolation arrangement as per recommendation of manufacturers. (J) Fuel Tank : Fuel tank of minimum cpacity of 450 litres shall be located at the bottom of the unit with provision for filling and fitted with gauge. The same shall be fabricated out of 3 mm thick MS Sheet.

(K) Starting System : The electric starting equipment will comprise of following :- (i) 02 Nos. of 180 AH maintenance free battery duly initial charged and battery lead of adequate capacity. Make of battery - Koel Green / Exide / Luminous / Sukam (ii) Starter motor (iii) Starter gearing (iv) Start / Stop push button (v) Inverter cum battery charger 500 VA capacity suitable to work on 220 volts 50 Hz AC Supply system for charging of DG Set batteries externally when DG Set is in off position. (vi) Alternator / Dynamic of suitable capacity to charge the batteries while DG Set is running complete with autocut all as per OEM recommendations shall be required at 24 / 12 V DC and cable size of 70 Sqmm . Batteries supplied with DG Set shall be dry and uncharged. Initial charging shall be done for 72 - 80 Hrs. The batteries shall be placed inside the acoustic enclosure.

(N) Platform for mounting of DG Set : A PCC fountation platform (1:2:4, M-20 grade) of approximate depth 150mm above the finished Gen Set room floor level is required so as to provide levelled surface for placement of the acoustic enclosure. The length and breadth of foundations should be atleast 250mm more on all sides than the size of the enclosure. The Gen Set should be mounted on AVM inside the enclosure. Location of platform / foundation as directed by Engineer-in-Charge. The quoted rate shall be inclusive of platform and foundation work.

(O) Acoustic Enclosure : The acoustic enclosure shall be designed and manufactured confirming to relevant BIS suitable for outdoor installation exposed to weather condition and to limit overall noise level to 75 DB (A) at a distance of 1 metre from the enclosure as per CPCB norms under free field conditions 75% load. The enclosure shall be fabricated out of 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. The hinge door shall be made from not less than 16 SWG thick CRCA sheet and will be made airtight with neoprene gasket and heavy duty locks. All metal parts should be processed through 7 tank process. The enclosure should be powder coated green colour. The enclosure should accommodate the daily service fuel tank as per OEM recommendations capacity. There should be a fuel gauge which should show the level of fuel even when the DG Set is not running. The gauge should be calibrated. The fuel tank should be fitted from outside provided with a lockable cap.

The batteries should be accomodated in the enclosure in the rack. The enclosure should be provided with high enclosure temperature safety device. The acoustic lining shall be made of high quality insulation material like glass wool / mineral wool / rock wool / with minimum of 50 mm thick and 75 Kg / cubic metre sound absorption as per standard design of OEM to reduce the sound level as per CPCB norms. The insulation material shall be covered with fine glass fibre cloth and would be supported by perforated MS sheet duly powder coated. The enclosure shall be provided with suitable size and no of hinged type doors along the length of the enclosure on each side for easy access inside the acoustic enclosure. Sufficient space will be provided inside the enclosure on all sides of the DG Set for inspection easy maintenance and repairs. The MS base frame shall be provided having lifting facilities and predrilled foundation holes for installations on anti vibration mounting (AVM pads).

(P) Testing : All major equipments / items i.e. engine & alternator in assembled condition electrical control panel etc shall be offered initial inspection at factory / manufacturers work before dispatch at site of work Kaluchak (Jammu). After inspection of these items shall be cleared for dispatch at site. After completion of the installation work at site of work in all respects the contractor shall offer the DG Set for testing. Testing shall be carried out as under in the presence of SEI / IEM of department. The contractor shall arrange OEM Testing Engineer on testing day without any extra charge to department and he himself be present or his authorise rep on testing day. All testing arrangements i.e resistive load, necessary cabling, T&P fuel (diesel) etc required for testing shall be arranged by contractor without any extra charged to department. The DG Set shall be tested on resistive load of unity powder factor for the rated KW rating. During testing DG Set shall be operated for 12 hours. During the test all control and safety operations shall be checked and proper record will be maintained.

(Q) Safety measures : All equipments shall incorporate suitable safety provisions to ensure safety of the operating personnel as per manufacturers standard practice.

Earthing complete with galvanized steel earth plate electrode 600mm x 600mm x 6mm thick buried directly in ground (earth pit not less than 2.25 meter deep below ground level) with top edge of plate not less than 1.5 meter below normal ground level, connected to galvanized steel strip 32 x 6 mm by means of bolts, nuts, check nuts and washers of galvanized iron or steel all as shown in electrical plate No. 3 of SSR Pt-I including necessary excavation and earth work PCC (1:3:6) type C-1 with 50 mm thick pre cast RCC (1:2:4) type B-1 cover slab (reinforced with 8 mm dia deformed bar @ 15 cm C/C both ways and suitable handle of 10 mm dia round bar) including providing charcoal or coke and common salt in alternate layers of 15 cm compacted thickness all around the earth electrode, with funnel and 20 mm bore galvanized iron watering pipe (medium grade) wire mesh, GI lugs, complete in all respect. Contd to 2.01

GI earth wire protected by 15 mm bore (light grade) galvanized iron pipe and other end connected with main switch board of earthing test point as directed including proper lugs including disposal of soil to a distance not exceeding 50 mtr and necessary testing on completion complete all as specified and as directed by the Engr-in-Charge. Note : 1. Earthing Installation shall be done in the presence of Engr-in-Charge. 2. Earth resistance shall not exceed 1 Ohm.

Earthing complete with copper earth plate electrode 600mm x 600mm x 3.15 mm thick buried directly in ground (earth pit not less than 2.25 meter deep below ground level) with top edge of plate not less than 1.5 meter below normal ground level, connected to copper strip 32 x 6 mm by means of bolts, nuts, check nuts and washers of galvanized iron or steel all as shown in electrical plate No. 3 of SSR Pt-I including necessary excavation and earth work PCC (1:3:6) type C-1 with 50 mm thick pre cast RCC (1:2:4) type B-1 cover slab (reinforced with 8 mm dia deformed bar @ 15 cm C/C both ways and suitable handle of 10 mm dia round bar) including providing charcoal or coke and common salt in alternate layers of 15 cm compacted thickness all around the earth electrode, with funnel and 20 mm bore galvanized iron watering pipe (medium grade) wire mesh, GI lugs, complete in all respect. Contd to 3.01

GI earth wire/strip protected by 40 mm bore (light grade) galvanized iron pipe and other end connected with main switch board of earthing test point as directed including proper lugs including disposal of soil to a distance not exceeding 50 mtr and necessary testing on completion complete all as specified and as directed by the Engr-in-Charge. Note : 1. Earthing Installation shall be done in the presence of Engr-in-Charge. 2. Earth resistance shall not exceed 1 Ohm.

Supply, laying and testing underground LT Cable XLPE insulated, armoured heavy duty electric cable with aluminium conductor. 1100 volts grade, cross sectional area 150 sq mm 3.5 core size all as specified & directed by Engr in Charge.

Excavation in trenches not exc. 1.5 m wide and not exc. 1.5 m depth for foundation laying of cable etc or for shaft wells cesspits manholes per holes etc 10sqmm on plan and n.exe 1.5m in depth and getting out in any type of soil, complete all as sepecified & dirceted by EIC.

Sand cushioning to underground cables provided with a layer of sand 8cm thick before laying the cable in trenches and 15cm thick after laying the cable in trenches complete all as specified. Note:- 1. Dry fine sand of best available quality shall be used. 2. Punned thickness shall be made and paid.

Supply and laying well burnt old size sub class 'B' bricks laid flat with width equal to length of brick perpendicular to the direction of cable, adjacent/abutting each other complete all as specified and as sirected by Engineer-in-charge in trenches over the cable for protection.

Returning filling in, including spreading, leveling, watering and well ramming in layers not exc 25m thick all as specified and directed.

Removing excavated material from site to a distance not exc 50 metre away and depositing where directed not exc 1.5mtr from the starting point all as directed.

On load changeover switch in sheet metal enclosure 400 Amp four pole, modular type, positive isolation, door interlock and padlock facility confirming to IS / IEC 60947-3 complete all as directed. Make :- C&S Cat No. ECSCS400DM4CO (DM SERIES) or equivalent in SCHNEIDER / SIEMENS / ABB

Galvanized iron tubing 80mm bore medium grade with all fitting laid in trenches / wall / floor / pole for protection of cable including providing fixing clamps, bolts and nuts of suitable size all as specified and as directed by the Engineer-in-Charge. Note : Excavation, earth work shall be measured and paid separately.

Earth continuity conductor or main earthing lead fixed to wall on batten or recess or chases or buried in ground or drawn in conduit / pipe or fixed to poles or any other indicated situation for loop earthing etc as required 32 x 6 mm galvanized strip.

Earth continuity conductor or main earthing lead fixed to wall on batten or recess or chases or buried in ground or drawn in conduit / pipe or fixed to poles or any other indicated situation for loop earthing etc as required 20 x 3 mm Copper strip.

Earth continuity conductor or main earthing lead fixed to wall on batten or recess or chases or buried in ground or drawn in conduit / pipe or fixed to poles or any other indicated situation for loop earthing etc as required 20 x 3 mm Copper strip.

Ashoka Engineers

MONA GENERATOR SEVICES PVT. LTD.