SPECIAL REPAIRS FOR REPLACEMENT OF BER 320 KVA DG SET, 62.5 KVA DG SET AND REPLACEMENT OF 11KV HT DG SYNCHRONISING PANEL FOR DG SETS AT MRSS VAJRAKOSH AT GE (SB) KARWAR

Supply, install, test and commissioning of Minimum 320 KVA/ 256 KW 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 suitable standard control panel, all mounted in acoustic enclosure and AMF panel as per manufacturers design and specification as per approved CPCB-IV norms confirming to the detailed specifications appended below :-

(I) ENGINE (a)General: Suitable four stroke compressed ignition, radiator water cooled, Turbocharged aspiration, continuous duty with 10% overload capacity for any one hour in 12 hours running, 50°C intake air temperature, CPCB-04 approved Engine developing minimum 395 BHP at 1500 RPM coupled to alternator mounted on Channel Iron base frame with in built removable fuel tank of capacity not less than 12 Hrs consumption capacity at 75% load or more as per manufactures recommendation. The prime mover provided should be as per IS specifications having engine overload protection.

(b) Air intake system : Should comprise of dry type intake air filter mounted on engine, one in number vacuum indicator mounted on intake piping.

(c ) Exhaust System: Should comprise of one exhaust manifold, dry type, mounted on engine, one exhaust silencer which should be positioned in such a way that the exhaust gas is not sucked by the fan on the radiator, thereby affecting the cooling system. The silencer should cater to the noise level tolerance prescribed in the relevant BS/IS. The silencer should be provided with flaps 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: Should 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 full authority electronic engine electronic governor and engine mounted actuator. The fuel tank must have proper locking arrangement with level indicator and to be integrated with base frame.

(e) Cooling System: Should comprise of radiator designed and tested for 50o 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) is also to be provided.

(f) Lubricating System: Should 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 should 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: Should comprise of 24 volt DC electrical starter mounted on engine, with suitable maintenance free batteries -2 Nos ( 25 Plate, 180 Amps, 12 Volts Battery )with one set of connecting leads of 70 sq mm Size Copper Cable to be mounted in trays (having rubber insulation) on the main frame or the capacity as per specification of manufacturer. It should 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, minimum 320 KVA, 415 Volts, 3 phase, 4 wire, 0.8 PF, 50 HZ, separately excited, self regulated, brushless AC generator, suitable for an ambient temperature of 50° C with IP-23 enclosure class H insulation and temperature rise limited to class H as per following technical details

(i) Type : Brush less AC Generators

(ii) Output rating minimum : 320 KVA

(iii) Output Voltage: 415 ± 1% under all loading conditions.

(iv) Output frequency : 50Hz ±0.5% 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) Automatic voltage regulator.

(ix) Class of insulation-'H'

(x) AREP excitation system

(j) BASE FRAME: Shall be stand by and fabricated from CRCA sheet or as recommended by the manufacturer metal which shall be suitable to mount the engine, alternator and radiator, channel width of base frame shall be adequate to accommodate anti-vibration pads.

(k) CONTROL PANEL: (i) Shall be indoor type manufactured with 14/16 guage CRCA sheet and is powder coated for weather-proof and long lasting finish consisting of microprocessor power command controller, Aluminium bus bars with suitable capacity with incoming/outgoing terminals, indicating lamps for 'Load ON' and 'Set Running', instrument fuses duly wired and ferruled, MCCB of suitable rating with overload and short circuit protections etc. complete all as specified and directed. (ii) Standard Auto Mains Failure panel suitable to activate the DG set automatically on power failure shall be provided with necessary accessories like switchgears, meters and other accessories. The panel shall be designed for manual operation if required. The control panel shall consist of all the controls of the alternator as required and recommended by standard codes of practice and shall be originally manufactured along with the alternator, floor mounted, cubical type with LT switch board and complete with internal wiring. Suitable arrangement shall be made for joining incoming cable and for connecting the bus duct on the outgoing side. This shall be dust/ vermin proof.

(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 at 75% load under free field conditions. The Acoustic enclosure is made of CRCA sheets and a structural/sheet metal base with high quality noise absorbent and fire-retardant grade acoustic insulation material (P.U Foam) complying to IS 8183 with two point lifting handles

(o) Internal Lighting: Tube lights with protective mesh around it to be fitted inside the container for proper illumination

(p) 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.

(q) Painting Scheme Superlative fade resistant paint can last longer in through whether conditions

(r) Lifting/ Transportation arrangements :-

Container with suitable corners will be provided to lift the DG set along with container. This is suitable for road/ rail/ sea transportation.

(s) Trials:-

Trials on site should be given as per load tests prescribed and all functional trials should be shown.

Supply, install, test and commissioning of Minimum 58.5 KVA/ 46.8 KW 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 suitable standard control panel, all mounted in acoustic enclosure and AMF panel as per manufacturers design and specification as per approved CPCB-IV norms confirming to the detailed specifications appended below :-

(I) ENGINE (a)General: Suitable four stroke compressed ignition, radiator water cooled, Turbocharged aspiration, continuous duty with 10% overload capacity for any one hour in 12 hours running, 50°C intake air temperature, CPCB-04 approved Engine developing minimum 74.4 BHP at 1500 RPM coupled to alternator mounted on Channel Iron base frame with in built removable fuel tank of capacity not less than 12 Hrs consumption capacity at 75% load or more as per manufactures recommendation. The prime mover provided should be as per IS specifications having engine overload protection.

(b) Air intake system : Should comprise of dry type intake air filter mounted on engine, one in number vacuum indicator mounted on intake piping.

(c ) Exhaust System: Should comprise of one exhaust manifold, dry type, mounted on engine, one exhaust silencer which should be positioned in such a way that the exhaust gas is not sucked by the fan on the radiator, thereby affecting the cooling system. The silencer should cater to the noise level tolerance prescribed in the relevant BS/IS. The silencer should be provided with flaps 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: Should 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 full authority electronic engine electronic governor and engine mounted actuator. The fuel tank must have proper locking arrangement with level indicator and to be integrated with base frame.

(e) Cooling System: Should comprise of radiator designed and tested for 50o 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) is also to be provided.

(f) Lubricating System: Should 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 should 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: Should comprise of 12 volt DC electrical starter mounted on engine, with suitable maintenance free battery -1 No ( 25 Plate, 150 Amps, 12 Volts Battery )with one set of connecting leads of 70 sq mm Size Copper Cable to be mounted in trays (having rubber insulation) on the main frame or the capacity as per specification of manufacturer. It should 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, minimum 58.5 KVA, 415 Volts, 3 phase, 4 wire, 0.8 PF, 50 HZ, separately excited, self regulated, brushless AC generator, suitable for an ambient temperature of 50° C with IP-23 enclosure class H insulation and temperature rise limited to class H as per following technical details

(i) Type : Brush less AC Generators

(ii) Output rating minimum : 58.5 KVA

(iii) Output Voltage: 415 ± 1% under all loading conditions.

(iv) Output frequency : 50Hz ±0.5% 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) Automatic voltage regulator.

(ix) Class of insulation-'H'

(x) AREP excitation system

(j) BASE FRAME: Shall be stand by and fabricated from CRCA sheet or as recommended by the manufacturer metal which shall be suitable to mount the engine, alternator and radiator, channel width of base frame shall be adequate to accommodate anti-vibration pads.

(k) CONTROL PANEL: (i) Shall be indoor type manufactured with 14/16 guage CRCA sheet and is powder coated for weather-proof and long lasting finish consisting of microprocessor power command controller, Aluminium bus bars with suitable capacity with incoming/outgoing terminals, indicating lamps for 'Load ON' and 'Set Running', instrument fuses duly wired and ferruled, MCCB of suitable rating with overload and short circuit protections etc. complete all as specified and directed. (ii) Standard Auto Mains Failure panel suitable to activate the DG set automatically on power failure shall be provided with necessary accessories like switchgears, meters and other accessories. The panel shall be designed for manual operation if required. The control panel shall consist of all the controls of the alternator as required and recommended by standard codes of practice and shall be originally manufactured along with the alternator, floor mounted, cubical type with LT switch board and complete with internal wiring. Suitable arrangement shall be made for joining incoming cable and for connecting the bus duct on the outgoing side. This shall be dust/ vermin proof.

(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 at 75% load under free field conditions. The Acoustic enclosure is made of CRCA sheets and a structural/sheet metal base with high quality noise absorbent and fire-retardant grade acoustic insulation material (P.U Foam) complying to IS 8183 with two point lifting handles

(o) Internal Lighting: Tube lights with protective mesh around it to be fitted inside the container for proper illumination

(p) 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.

(q) Painting Scheme

Superlative fade resistant paint can last longer in through whether conditions

(r) Lifting/ Transportation arrangements :-

Container with suitable corners will be provided to lift the DG set along with container. This is suitable for road/ rail/ sea transportation.

(s) Trials:-

Trials on site should be given as per load tests prescribed and all functional trials should be shown.

Dismantling old BER DG set of capacity 320 KVA with all connected accessories and shifting it to MES store yard.

Dismantling old BER DG set of capacity 62.5 KVA with all connected accessories and shifting it to MES store yard.

M&L for earthing complete with GI earth plate electrode of size 60cm x 60cm x 6 mm thick buried directly in ground (earth pit not less than 2.25 m deep below ground level) with top edge of the plate not less than 1.5m below the normal ground level connected with GI strip 32 x 6mm by means of bolts, nuts, check nuts & washers of galvanized iron steel including necessary excavation and earth work in any type of soil, removing surplus soil to a distance not exc 50m, with and including PCC chamber in PCC (1:2:4), type B1,using (20mm graded stone aggregate), "mild steel angle iron frame" made out of MS angle iron of size 40x 40 x 6 mm thick duly painted with two coats of synthetic enamel paint over one coat of red oxide zinc chrome primer hinged with and including 6mm thick CI cover with handle, watering arrangement with funnel internally secured with wire mesh with 20mm dia medium grade pipe for watering 40mm dia light grade, GI pipe for lead protection in & including alternate layers of charcoal dust and common salt complete all as shown in electrical "plate No '3' and connected to earthing test point all as specified and indicated including testing on completion including retrieving old GI earth plate, CI cover, GI pipes, angle iron frame from existing earthing as directed.

Dismantling of existing Synchronizing and auto load sharing R&M Panel with all connected accessories and Design, Supply, Install, commissioning and testing of HT DG AMF with auto Synchronizing and auto load sharing R&M Panel suitable for controlling 3 Nos of 11KV,1010 KVA DG sets (make Cummins) of suitable size, indoor, cubical compartmental type, front/Rear doors, with hinged doors & locking arrangement, made out of 2 mm thick mild steel CRCA sheet, supported and fixed on PCC foundation (1:2:4) type B1, including earthing stud, labeling, painting to all internal & external exposed steel surfaces with (7 tank process) powder coated paint shade epoxy powder coated shade ral-7035 thickness of paint 80 microns earth bus material aluminium earth bus bar size 1r x30x10 mm, with name plate of 1.6 mm thick mild steel sheet, vitreous enameled (white) with letters figures all as specified and directed.

The panel should detect the main supply failure, operate the DG automatically and synchronise the DGs by matching its voltage and frequency to the bus with auto load sharing & monitoring.. Auto/Manual facility to be provided. For manual operation - synchronoscopes, potentiometers, measuring meters to be provided in panel.

The panel main electrical equipment is as given below :

(a) Auto Synchronizing Auto load sharing Controller-AGC150 - 3 Nos

(b) MDM 96 sq. mm,3Ph, 3Wire, 415V, 50Hz, Aux.Supply:230V AC, CTR: ***/5A,,Cl:1.0 - 3 Nos

(c) KWH 96 sq. mm,3Ph, 3Wire, 415V, 50Hz, Aux.Supply:230V AC, CTR: ***/5A,,Cl:1.0 - 3 Nos

(d) Over current and Earth Fault Protection Relays 50/51 Relay P111 or equivalent circuit - 3 Nos

(e) Generator protection and control REG630 IEC / Equivalent - 3 Nos

(f) Master trip relay 86A - 3 Nos

(g) Master trip relay 86B - 3 Nos

(h) 22.5mm dia cluster LED type RED-230V AC ( R-Phase Live) - 3 Nos

(j) 22.5mm dia cluster LED type Yellow-230V AC ( Y-Phase Live) - 3 Nos

(k) 22.5mm dia cluster LED type Blue-230V AC ( B-Phase Live) - 3 Nos

(l) 22.5mm dia cluster LED type RED-230V AC (Breaker ON) - 3 Nos

m) 22.5mm dia cluster LED type GREEN-24 DC (Breaker OFF) - 3 Nos

n) 22.5mm dia cluster LED type AMBER-24 DC (Breaker Trip) - 3 Nos

o) 22.5mm dia cluster LED type AMBER-24 DC (Auto Trip) - 3 Nos

p) 22.5mm dia cluster LED type RED-230V AC (NIC ON ) - 3 Nos

q) 22.5mm dia cluster LED type RED-230V DC (BC ON ) - 3 Nos

r) 230V AC 50Hz 6A 4P 10kA C-Curve (Metering CKT) - 3 Nos

s) 230V AC 50Hz 10A DP 10kA C-Curve (Control CKT/UV Coil CKT) - 3 Nos

t) 230V AC 50Hz 10A DP 10kA C-Curve (Battery Charger AC i/p CKT) - 3 Nos

u) 24V DC 10A DP 10kA C-Curve (Battery Charger DC o/p CKT) - 3 Nos

v) 24V DC 6A DP 10kA C-Curve (Control CKT/Auxiliary CKT DC CKT) - 3 Nos

w) 230V AC 50Hz 6A 4P 10kA C-Curve (GCU Bus Voltage CKT) - 3 Nos

z) TNC Switch Breaker Close Open - 3 Nos

aa) DC A/V METER Combined DC Ammeter/Voltmeter 24V DC - 3 Nos

ab) Battery Charger 230V AC/24V DC, 20A - 3 Nos

ac) DG Start Push Button ,22.5sq.mm dia Spring return (1NO+1NC Elements) - 9 Nos

ad) DG Stop Push Button ,22.5sq.mm dia Spring return (1NO+1NC Element) - 9 Nos

ae) RESET Push Button ,22.5sq.mm dia Spring return (1NO+1NC Elements) - 9 Nos

af) Stop Red Mushroom Head Turn to Release Push Button (1NO+2NC Elements) - 3 Nos

ag) Hooter 24V DC - 3 Nos

ah) Auxiliary Contactor 2NO+2NC,230V AC - 6 Nos

aj) Auxiliary Contactor 2NO+2NC,24V DC - 24 Nos

ak) Auxiliary Relay 2C/O,24V DC - 12 Nos

al) Panel illumination Lamp - 4 Nos

am) Panel Space Heater - 4 Nos

an) Thermostat - 4 Nos

am)Plug and socket - 4 Nos

an) Control wiring indications

ao) Screw type 4 Sq.mm for Control CKT - 100 Nos

ap) Line Voltage Monitor 900VPR - 1 Nos

aq) 230V AC 50Hz 6A SP 10kA C-Curve (EB-SENSING Voltage CKT) - 3 Nos

ar) 22.5mm cluster LED type RED-230V AC (Mains Healthy) - 1 Nos

as) Check Synchronizing Relay - 1 Nos

at) Solid state potentiometer 0-10 volt for speed control - 3 Nos

au) Solid state potentiometer 0-3 volt for Voltage control - 3 Nos

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