138WE/L-204/2025-26

Supply, install, testing and commissioning of 500KVA/400 KW DG set diesel engine driven Generating set with alternator, out put Voltage 415 Volts +/- 1% at set value of 415 V at a frequency 50HZ +/- 0.5%, with cold starting capability to work under -30 degree celcius to +30 degree celcius, suitable for prime duty with STD control panel outdoor type IP-54 consisting of AMF feature to be erected, (NTP suitable for installing at Base Camp), all mounted in acoustic enclosure and Control panel as per manufacturer's design and specifications confirming to latest norms of CPCB IV+ complete with the following and connected accessories including taking out existing DG Set from the sub station without damaging the existing structure and placing the old DG Set at a place as directed by the Engr-in-Charge :- i) DG Fuel tank of minimum capacity 770 Ltrs with fuel gauge etc complete fixed on suitable PCC foundation frame, grouted on floor with connecting fuel pipelines from main fuel tank to DG fuel tank all as per OEM recommendations. ii) Battery & Leads. iii) Silencer-Hospital type with pipe line & radiator as per OEM design & recommendations complete as per latest CPCB IV+ norms. iv) AVM Pads. v) First Fill of Lube. vii) Acoustic Enclosure. viii) Standard Control Panel (AMF) outdoor type with connected switchgear/relays/meters complete IP-54. (ix) Engine model QSM15-G-1, 6 cylinder 4 stroke.

(ix) Suitable size cement concrete foundation platform of canopy base with height as required at site to mount the generator as per manufacturer's instructions/ recommendations. The cost of foundation bed including earth work etc shall deemed to be included in the unit rates quoted against this item.(x) Connecting cables, from existing panels and connecting cables , cables glands, cable lugs to new panel complete with all necessary accessories. (xi) Install on the foundation, provn & install connecting fuel pipe lines, cables etc.(xii) Testing and commissioning complete including POL and resistive load bank required for testing.

(xiv) The detailed specifications are appended below :- (I) ENGINE (a) General: Suitable four stroke compressed ignition,suitable to start at - 30 digree celcius, radiator water cooled,Turbocharged aspiration, continuous duty with 10% overload capacity for 1 hour in 12 hours continuous running, with 40 to 50°C intake air temperature, latest CPCB IV+ norms engine, turbocharged four stroke engine developing minimum 888 BHP @ 1500 RPM under NTP conditions, coupled to alternator mounted on Channel Iron base frame with external floor mounted fuel tank of minimum 770 Ltrs capacity with fuel gauge and connected fuel pipeline from main fuel tank to DG fuel tank complete .The prime mover provided shall be as per IS specifications. (b) Air intake system : Shall comprise of dry type intake air filter mounted on engine, one in number vacuum indicator mounted on intake piping.

(c) Exhaust System: Shall comprise of one exhaust manifold, dry type, mounted on engine, one exhaust hospital type silencer which shall be positioned in such a way that the exhaust gas is not sucked by the fan on the radiator/heat exchanger, thereby affecting the cooling system. The silencer shall cater to the noise level tolerance prescribed in the relevant IS/BS. The silencer shall be provided with flaps with a provision so that it will open only when the generator is running. The complete exhaust system shall be properly supported so that entire lot of the exhaust system shall not fall on the DG Set.

(d) Fuel System: shall comprise of disposal type element fuel filter, pressure type fuel pump mounted on engine, non return check valve in fuel supply and drain lines, wire braided hose between filter and pump, fuel system with suitable capacity electronic governor and engine mounted actuator. The fuel tank shall have proper locking arrangement with level indicator and to be fixed seperately / externally. (e) Cooling System: shall comprise of radiator and connected pipeline complete, silencer and tested for 50°C ambient temperature with 7 PSI pressure cap mounted on base rail. The thermostat installed in the engine coolant outlet, fresh water pump mounted on engine, fan and fan hub mounted on engine. A reservoir of 50% of radiator capacity to replenish coolant by gravity (as and when required) shall also be provided. (f) Lubricating System: shall comprise of lubricating oil sump mounted on engine, gear driven lub oil pump mounted on engine, lubricating oil cooler-fresh water cooled integral with engine cool out circuit mounted on engine, oil filter lubricating with cap and lubricating oil dip stick for oil level check mounted on engine. The system shall be capable of feeding lube oil to the main end & large end bearings, cam shaft, valve rocker gear and all moving parts.

(g) Starting System: Shall comprise of suitable voltage DC electrical starter mounted on engine, with suitable maintenance free battery of capacity 12 V DC - 02 Nos with suitable AH to be mounted in trays (having rubber insulation) on the main frame. It shall have the provision to charge the battery from external sources during static condition and while running of the generator.

(h) AC Generator : The generator shall be horizontal and foot mounted, 500 KVA, 415 Volts, 3 phase, 4 wire, 0.8 PF, 50 HZ, self excited, self regulated, brushless AC generator, suitable for voltage regulation + 1% , an ambient temperature of 40 to 50° C as per OEM design with IP-23 enclosure class H insulation and temperature rise limited to class H as per following technical details:- (i) Type, Brush less AC Generator and space heater as per OEM design.(ii) Output rating 500 KVA.(iii) Output Voltage: 415 ± 1% under all loading conditions and with maximum voltage Dip at full load 0.8 PF shall be < 19% as per OEM design.(iv) Output frequency 50Hz up to 0.8 lagging.(v) No of Phases: 3 phase with 01 Neutral (4 wire).(vi) Mounting : Horizontal foot mounted.(vii) Enclosure : Minimum IP-23 / Drip proof and screen protected.(viii) Electronic Automatic voltage regulator with response time < 75 m sec and + range of voltage adjustment.(ix) Class of insulation-'H'.(x) Short circuit withstand 3 times rated current for 3 secs and overload withstand capacity for continuous duty with 10% overload capacity for 1 hour in 12 hours continuous running & 150% overload for 30 sec running.(xi) Noise Level is 75 dB (A) at distance of 1mtr in open free field environment as per ISO 8528 part 20.(xii) The maximum unbalanced load across phases shall be less than or equal to 25%. xiii) Battery charger- EMI/EMC compliant static battery (82.5 KVA & above ). Battery isolator switch. (xiv) Telematics for DG Monitoring -std for 82.5 KVA & above

(l) Standard Control panel with AMF feature for 500 KVA DG set as per OEM design to be errected inside sub-station, Standard Control panel with auto mains failure (AMF) feature complete , floor mounted type, vertical, factory made outdoor type, double door, canopy, fabricated out of CRCA sheet with angle iron base frame, floor mounted, dust and vermin proof, suitable for voltage 415 V, Three Phase, 4 wire, 50 HZ AC supply, weather proof, with IP-54 protection, with separate hinge door for each compartment & locking arrangement, with back door openable (Screwed), legs grouted in PCC complete including painting with two coats of epoxy powder paint over a coat of primer after under going a rigorous metal treatment process involving alkaline degreasing, descaling in dilute sulphuric acid or any other acid and phosphate and with aluminium busbar (TPN) of suitable rating, suitable double compression copper cable glands including provn of the following :-

(i) Protection relays as per OEM design/approved make.(ii) Minimum switchgears of capacity 800 A , 4P, 50 KA of qty/capacity and suitable rated neutral contactor if required as per OEM design.(iii) Suitable rated resin cast CTs.(iv) Suitable rated in-built AVR.(v) In-built SMPS based automatic battery charger.(vii) Digital Multifunction meters suitable for RS 485 communication with LAN port hub. Make: Schneider/L&T/ABB/Legrand or OEM approved make. (xi) Suitable capacity copper control cables, necessary indications, hooters, auxilliary contactors, TNC & LVM interlocking etc.INCOMER- .(a) 3 pole 750 Amp MCCB (b) BACK-UP PROTECTION :- HRC Fuse for short circuit protection.(c) MICRO PROCESSOR BASED AMF MODULE :-

(m) Accessories :- (i) 01 No standard mechanical and electrical tool box. (ii) Internal covered tube lights. (n) Acoustic Enclosure :- Specially designed to meet CPCB norms 75dBA @ 1 mtr distance in open free field environment as per ISO 8528 part 10. The Acoustic enclosure is made of CRCA sheets and a structural/sheet metal base with high quality noise absorbent, 11 tank pre treatment process and UV resistant powder coating of all parts to withstand extreme environment and fire-retardant grade acoustic insulation material (P.U.Foam) complying to IS 8183 with two point lifting handles. (a) Internal Lighting: Tube lights with protective mesh around it to be fitted inside the container for proper illumination

(b) Doors : The enclosure will be provided with suitable doors on the side and rear to enter the enclosure during operation and maintenance. All doors will be provided with lock and handles for opening/ closing the doors, retainers for holding the panel door.(p) Painting Scheme ISS shade 220 olive green 1994 or all as per manufacturer's specifications.(q) Lifting/ Transportation arrangements :- Container with suitable corners will be provided to lift the DG set along with container. This shall be suitable for road/ rail/ sea transportation.

Supply, installation , testing and commissioning of compatible Synchronization Panel designed for auto load sharing and seamless DG-DG synchronization Includes advanced protection, AMF logic, and user-friendly controls for reliable multi-DG operations. Suitable for continuous and standby power applications . The panel shall be designed with two incomers and two outgoing breakers of 800 A, 50 KA, ACB capacity . Outdoor Panel of Free standing, Floor Mounting Cubicle with IP54 Protection, Approval shall be obtained for the panel design before placing order.

Material and labour for making of opening, resurfacing, making of cable duct including MS (Mild steel sheet 5mm thick with suitable duct size) duct cover including hard standing of DG Set and synchronization panel complete all as specified and directed.

Material & labour for earthing using galvanized steel earth plate electrode 600mm x 600mm x 6 mm thick buried directly in ground (earth pit not less than 2.25 mtr depth below normal ground level) with top edge of earth plate not less than 1.5 mtr below normal ground level connected to and including galvanized steel strip 32 mm x 6 mm size as earth lead upto equipment by means of steel bolts, nuts, check nuts and washers, test point made of GI strip 10cm thick PCC 1:2:4, type B-1 in pit with precast RCC 1:2:4 type B-1 in cover reinforced with XPM not less than 4 Kg per Sqm with 40mm bore GI light grade protection pipe, 20mm bore GI medium grade watering pipe with funnel including charcoal, dust, salt, all as shown in electric plate No 3 of SSR Part-I (2009) Specifications, complete with necessary earth work in any type of soil, removal to a distance not exceeding 50 mtr including testing on completion & dismantling of existing earthing, complete all as specified & directed.(4 -for each DG SET and 2-Synchronization Panel)

Supply, laying and testing cable XLPE Insulated ,screened, PVC bedded, galvanized steel strip or wire armoured, electric power cables (heavy duty) 1100 Volts grade with stranded aluminium conductor of size 300 sqmm 3.5 core complete all as specified & directed.

Excavation in trenches not exceeding 1.5 metre wide and not exc 1.5 metre in depth for foundation of pole / stay, or cable in trenches and getting out in hard/dense soil complete all as specified and as directed.

Returning, filing in including spreading, leveling, watering and well ramming in layers n.exc 25 cm width, complete all as specified and directed.

Removing excavated material to a distance n.exc.50m and depositing where directed at level n.exc. 1.5m above the starting point complete all as specified and directed.

Supply and fixing double wall corrugated (DWC) pipe outer dia 400mm and inner dia 392 mm, laid in trenches etc with suitable clamp for protection of cable complete all as directed .

Supply and fixing cable jointing kit for 1100V (Earthed) grade cable for outdoor termination Heat shrink type joint complete with jointing material and accessories suitable for 3.5 core XLPE armoured aluminium conductor cable of size 300 sqmm complete all as specified & directed.

Supply and fixing GI Strip 32 x 6 mm for making connection of DG Set earthing to connect DG Set to Earth test point complete all as specified and directed.

Supply only Goti Set tool kit for making, opening connection of DG Sets complete all as specified & directed.

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