SPECIAL REPAIRS FOR REPLACEMENT OF 500 KVA DG SET AT AF STATION CARNICOBAR

Amount

Supply, Installation, commissioning and testing of acoustic enclosure Diesel Engine Generating set 500 KVA/400 KW (CPCB IV+), 415 Volt, 0.8 lagging power factor 50 HZ, 1500 RPM, self excited self regulated brush less AC generator mounted on common base plate complete with fuel tank, battery and standard accessories and fittings including acoustic enclosure suitable for ambient condition at Carnicobar and confirming to condition under IS/IEC 60034-1, ISO 1460, ISO 8528, ISO 3046, ISO 9001, ISO 13018 and all components as detailed complete all as listed as following:- i) The capacity of Generator set shall be net after all due de rating factors as per relevant ISI design. ii) The quoted rate shall be deemed to be inclusive of first fill of oil and final successful acceptance test. iii) The quoted rate shall be deemed to be inclusive load test of DG set at site, fuel Oil and load etc shall be arrange by the contractor without any extra cost.

a) Diesel Engine: The capacity of Diesel engine 594 HP, water cooled multi cylinder 4 stroke, 1500 RPM coupled with alternator, turbo charged after cooled, heavy duty air cleaner as per ISO 3046, water separate filter, fuel feed pump and other accessories as per relevant IS / BS-5514 with an overload capacity of 10% for one hour in 12 hrs, continuous running complete with standard accessories all as specified and required for safe handling and operation, salient features of accessories shall be as under:- (i) Fly wheel with housing (ii) PT fuel pump (iii) STC injectors (iv) turbocharger, pulse tuned exhaust manifold, stainless steel exhaust flexible connections (v) Radiator/heat exchanger with initial filled coolant (vi) Plate type lub oil coolers (vii) out board after coolers (viii) Full flow filters for fuel, lube oil and by pass filter (ix) dry type replaceable paper element air cleaner with restriction indicator (x) electric control panel (xi) Microprocessor based genset controller (xii) initial fill lub oil (xiii) Starter motor 24 volts (xiv) Charging alternator 24 volts

b) Alternator: Standard design alternator rated at 500 KVA net output at site after considering de ratings as per site conditions at 0.8(lag) power factor AC, 3 phase four wire system 415 volts 50Hz, 1500 RPM self excited self regulated screen protected / drip proof IP23 enclosure brush less design with winding in pole faces, insulating class ‘H’ and voltage regulation of ± 0.5 to 1% at rated voltage from no load to full load, The alternator shall be confirming to BS 2613/5000 and shall be in position to generate supply with frequency regulation with in± 1% tolerance the alternator will be suitable for tropical climate and shall generally confirm to BS-2613/500/IS-4722. i) Insulation Class-‘H’ ii) Excitation: self Excited iv) Regulation performance: The voltage is Kept constant with ± 1 % manual voltage adjustment within ±5% v) Frequency regulation ± -1%

c) Exhaust System: Supplying and fixing exhaust gas piping of required length and suitable dia. Welded black MS 'B' Class pipe conforming to IS:3589 cut to required lengths and installed with necessary bends, supports and clamps, anti-vibration mountings, insulation of exhaust system with mineral wool / Rockwool, 50 mm thick wiremesh & aluminum cladding etc., as specified and required as per site condition and as per manufacturer's instructions. d) Batteries: Two nos maintenance free batteries of 12 volts 180 AH capacity with multi stranded copper conductor cable of suitable size from battery to starter and from control panel e) Control Panel PC: The control system is an integrated microprocessor based generator control system providing voltage regulation, engine protection alternator protection, operator interface and isochronous governing (i) Amp Sentry - Integral amp sentry protection which provides a full range of alternator protection function suitable to alternator provided (ii) Power management - control function provides battery monitoring, testing and smart starting control system (iii) Advanced control methodology- Three phase sensing FET based full wave rectified voltage regulation and a PWM output for stable operation with all type of loads (iv) Communication interface - control comes standard with PCCnet and module interface. (v) Regulation compliant - Prototype tested UL CSA and CE compliant. (vi) Service - Inpower PC based service tool for detailed diagnostics setup, data logging and fault simulation and reliable operations in harsh environment with independent of PC/Laptop for setting up.

f) Operator panel features: display the utility data/ AC bus data having 320 x 240 pixels graphic LED back light LCD with bar graph for displaying electrical parameters, auto manual start stop, fault reset and lamp test/ panel lamp switches, alpha numeric display with push buttons, LED Lamps including genset running remote start, not in auto, common shutdown, common warning, manual run mode, auto mode and stop . g) Paralleling control functions : Digital frequency synchronization and voltage matching, Isochronous KW and KVAR, load sharing controls, drop KW and KVAR, Sync check, extended paralleling, Digital power transfer control(AMF) provide load transfer, operation in open or closed transition or soft(ramping) transfer mode h) Alternator data - Line to neutral and line to line AC volts , three phase AC current, Frequency, KW,Kvar, power factor KVA (3 phase and total) (i) Engine data DC voltage, Engine speed, lub oil pressure, coolant temperature/ low level, (j) Other data Genset model, Start attempts, starts, running hors, KW hours, Load profile, Fault history, data logging and fault simulation (k) Digital governing - Integrated digital electronic isochronous governor, temperature dynamic governing (l) Digital voltage regulation - Integrated digital electronic voltage regulator, three phase four wire line to line sensing, configurable torque matching (m) AC protection - Over current and short circuit shutdown, Over current warning, single/three phase fault regulation, Over and under voltage shutdown, Over and under frequency Shutdown, Overload warning with alarm, Reverse power shutdown, Field over load

(n) Engine protection:- Battery voltage monitoring, protection, Over speed shutdown, low oil pressure warning and shutdown, high coolant temperature warning/shutdown, low coolant level warning/shutdown, low coolant temperature warning, Fail to start, Cranking lock out, Sensor failure indication, Low fuel warning or shut down (o) Control functions- Time delay start and cool down, Real time clock for fault, event time stamping, Exerciser clock and time delay start/stop, Data logging, load shed/dump as per configure priority, remote emergency stop (p) Base frame - The Dg set engine and alternator mounted on common base frame with anti vibration pads as per manufacture recommendations (q) Fuel tank - Fuel tank made up of 3 mm thick HR sheet with calibrated level marking arrangements with fuel gauge stop cock, drain plug with capacity of tank approx. 12 hrs running capacity as per manufacturer recommendation.

u) Acoustic enclosure - Enclosure is free standing floor mounting type factory built modular in construction to facilitate essy assembly at work site and will be drop over housing type and easy access for maintenance and repairs and operation with following facilities (i) rugged construction maintenance free and easily assembly at site (ii) made out of 16 swg/1.6 mm thick CRCA sheets for enclosure with high quality insulation materials to be used as per IS 8183 for maximum sound absorption and the layers supported by perforated sheets (iii) The sheet metals treated with anti resistive solutions before painting and painted with pure polyester powder epoxy paint in outer side for better weather resistance (iv) Well designed ventilation system to be provided to pump up the heat in the chamber (v) provide selling with special type of gaskets, frame rubbers on doors/frames for better weather protection (vi) Necessary provision for cable entry/ bus ducts and fuel line, control cables as per requirement (vii) A see through transparent glass/acrylic window in front of engine control panel to be provide for monitoring the parameters (viii) In inside the enclosure provide 12/24 volts LED light fitting two nos for inside illumination

(ix) The temp inside the enclosure will with in 7 degree centigrade above the ambient temperature (x) necessary mounting bracket for batteries in side the enclosure (xi) The emergency stop push button provided in acoustic enclosure near control panel side (xii) Work space is to be provided around the equipment for easy maintenance by the manufacturer Notes: Unit rate quoted by the tenderer shall deemed to be inclusive for the following:- (i) The contractor shall provide the artificial load, fuel, oil etc for testing the DG set at site and the cost its deemed to include in the quoted rate. (ii) All civil works for making good the disturbed surface during installation. (iii) The DG Set should comply with all the latest CPCB-IV + Norms. (iv) 04 numbers of GI strip earthing complete with 25x4 mm GI strip. (v) Contractor shall ensure that this 500 KVA DG set is synchronized with other existing DG sets in the CAPTIVE POWER HOUSE and ensure that it works perfectly. The quoted rate is deemed to include for this provision also and nothing extra is payable on a later date on this account. (vi) Taking down old DG set of any capacity from captive power house and unload & handover the same to MES store yard as directed by Engineer In Charge. (vii) The capacity of DG set shall be net after all derating factors as per relevant IS design.

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