PROVN OF MOBILE DG SET ALONGWITH ASSOCIATED WORKS UNDER GE AF NAL

Supply, installation, testing and commissioning of 400 KVA/320 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%, suitable for prime duty operation, with AMF Control Panel, outdoor type IP-54 to be errected at location indicated, (NTP for suitable for installing at Bikaner) all mounted in acoustic enclosure and Control panel as per manufacturers design and specification conforming to norms of CPCB IV+ and latest amendments if any complete with the following including dismantling of old DG sets and connected accessories and depositing to MES store yard. The details are as below: i) DG Fuel tank of minimum capacity 850 Ltr inside the canopy with fuel gauge etc. complete fixed. ii) Battery & Leads iii) Silencer to be of hospital grade, radiator as per OEM design & recommendations complete as per latest CPCB norms, iv) AVM Pads, v) First fill of engine lubricating oil and coolant as recommended by the engine OEM, including all commissioning consumables vi) Acoustic Enclosure, vii)AMF Control panel outdoor type with connected switchgears/ relays/ meters complete IP-54 to be errected at location indicated. viii) The acoustic enclosure shall be designed, manufactured, assembled and tested in accordance with the applicable CPCB requirements and shall meet the specified noise level and acoustic performance. The bidder shall submit manufacturer/OEM test certificates and relevant type-test/ performance-test reports.

(ix) The Contractor shall construct PCC foundation of mix ratio 4:2:1. The foundation dimensions shall be 300 mm larger than the overall length and breadth of the DG Set, with a total height of 400 mm (200 mm below ground level and 200 mm above ground level). (x) Supply, laying and termination of 3 Runs of 3.5 core 240 Sq.mm Aluminium XLPE power cable for a route length up to 180 metres, complete with glands, lugs and accessories. (xi) Supply and installation of GI Pipe Earthing for DG Set body complete with 25 x 5 mm GI Strip up to 10 metres per earth pit, and Copper Pipe Earthing for DG Set neutral complete with 25 x 3 mm Copper Strip up to 10 metres per earth pit." (xii) Testing and Commissioning complete including resistive load bank required for testing. (xiii) The cost of control cables from engine Control panel to AMF panel, transportation, installation, testing & commissioning etc shall be deemed to be included in the cost quoted. (xiv) The details specifications appended below :-

(A) ENGINE (a) General: Suitable four stroke compressed ignition, radiator water cooled,Turbocharged aspiration, continuous duty with 10% overload capacity for 1 hour in 12 hours continuous running, with 40°C intake air temperature, latest CPCB IV+ emission engine, turbocharged four stroke engine developing minimum 490 BHP @ 1500 RPM under NTP conditions, coupled to alternator mounted on Channel Iron base frame with internal floor mounted fuel tank of minimum 850 Ltrs capacity with fuel gauge and connected fuel pipeline from main fuel tank to DG fuel tank complete .The prime mover provided should be as per IS specifications. (b) Air intake system: Should comprise of dry type intake air filter mounted on engine. (c ) Exhaust System: The exhaust system shall comprise industrial-grade exhaust silencers, designed to achieve the prescribed noise attenuation and suitable for continuous operation of the DG Set. The exhaust system shall be complete with necessary bends, flanges, supports, flexible connections and other required accessories. 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 electronic governor and engine mounted actuator. The fuel tank must have proper locking arrangement with level indicator and to be provided externally/separately. (e) Cooling System: The DG Set shall be provided with a radiator-type cooling system suitable for operation at 50°C ambient temperature, complete with radiator, pressure cap, engine-mounted fresh-water pump, thermostat, fan and fan hub. A suitable coolant expansion/recovery reservoir shall also be provided for replenishment of coolant as required. The complete cooling system shall be suitable for continuous operation of the DG Set under the specified ambient conditions.

(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 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 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 400 KVA, 415 Volts, 3 phase, 4 wire, 0.8 PF, 50 HZ, AREP type self excited &self regulated, brushless AC generator, suitable for voltage regulation + 0.5% , an ambient temperature of 40° 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 with AREP based Excitor as per OEM design (ii) Output rating 400 KVA (iii) Output Voltage: 415 ± 1% under all loading conditions and with maximum voltage Dip at full load 0.8 PF. (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) 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) Overspeed capacity 1800 RPM for 2 min. (xii)Suitable for Maximum Unbalanced Load across phases shall be less than or equal to 25%. NOTE : Following shall be deemed to be included in cost quoted :-

(i) ENGINE CONTROL PANEL: The DG Set shall be provided with an OEM-designed, weatherproof, powder-coated Engine Control Panel, suitable for mounting inside the acoustic enclosure. The panel shall be complete with KG740 Controller and necessary engine monitoring, control, indication, metering and protection functions. The controller shall provide protections including over-speed, high coolant temperature, low oil pressure, water in fuel, engine common fault, low fuel level, low coolant level, emergency stop, under/over frequency, under/over voltage, over current, overload and other applicable engine safety protections.

(j) AMF CONTROL PANEL: Standard AMF Control Panel, outdoor, floor-mounted, double-door, sloping-canopy type with IP-54 protection, suitable for 400 kVA DG Set, as per OEM design. The panel shall be suitable for 415 V, 3 Phase, 4 Wire, 50 Hz AC supply and shall be dust and vermin proof. (i) Mains Incomer Power Contactor: 700 A, 4-Pole, suitable for 415 V AC, AC-3 duty, with adequate short-circuit withstand capacity and necessary auxiliary contacts. (ii) DG Incomer Power Contactor: 700 A, 4-Pole, suitable for 415 V AC, AC-3 duty, with adequate short-circuit withstand capacity and necessary auxiliary contacts. (iii) Both contactors shall be provided with electrical interlocking to prevent simultaneous closing of Mains and DG supplies. (iv) Suitable protection relays, as per OEM design and approved make, shall be provided for necessary protection of the DG Set and supply. (v) Suitable resin-cast CTs of required ratio and accuracy class shall be provided for metering and protection. (vi) Digital multifunction meter with voltage, current, frequency, power, power factor and energy measurement, with RS-485 communication interface. (vii) SMPS-based automatic battery charger, 24 V DC, 20 A capacity, complete with necessary DC voltmeter, DC ammeter and protections. (viii) Suitable TPN aluminium busbars of adequate current-carrying capacity with necessary supports, shrouding and termination arrangements. (ix) Suitable double-compression cable glands, terminals, control cables, auxiliary contactors, control fuses, indicating lamps, hooter, selector switches, TNC switch and other necessary control accessories shall be provided. (x) AMF Functions: Mains failure sensing, adjustable mains failure timer, restoration timer, automatic DG start/stop sequence, engine fail-to-start lockout, generator voltage/current/frequency monitoring and battery voltage monitoring.

(xi) Suitable HRC fuses shall be provided for back-up short-circuit protection wherever required. (xii) Remote Monitoring System: The DG Set shall be provided with a suitable remote monitoring system for remote monitoring of DG Set operating parameters, alarms, faults, running status, voltage, current, frequency, load and other essential parameters through suitable communication interface. (xiii) The panel shall be complete with necessary electrical/control interlocking, wiring, ferruling, terminal blocks, identification labels and accessories for satisfactory automatic operation of the DG Set. (xiv) Provision shall be kept for future expansion/addition of one DG Set, wherever required. (xv) The complete AMF Panel shall be factory-fabricated, tested and supplied with all necessary accessories as per OEM design and latest engineering practices.

M&L for trolley totally enclosed suitable for carry the DG set of capacity 400 KVA outdoor type the trolley having following technical specifications:- (a) Dimention of platform : 6300 x 2500mm (+ 10mm). (b) Height : 2000mm (+10mm). (c) Platform (Floor) : MS Plate 6mm thick. (d) Chasesis (base frame) : MS Channel 100 x 75mm. (e) Trolley side (cage frame) : MS Sq pipe 50mm x 50mmx2mm thick . (f) Front & Rear & Side Door : (3 doors) Fabricated with MS angle iron 50x50x5mm. (g) Jack sys (h) Axel : 2 Axel size 75mm sq and length 1800mm front. (j) Rims : Rim 4 in numbers. jack system,hook with connected items (k) Tyres and tubes : 5 in Nos inflatable of size 600 x 16. (l) Suspension : Leaf spring suspension provided on all four wheels. (m) Turn table : MS Channel 100 x 38mm MS plate suitable for turn table. (n) Draw Bar : MS Channel 100 x 38mm (+2mm). (o) Toeing Hook : MS round 75mm. (p) Loading capacity : Suitable to carry 400KVA DG set. (q) Paint : Grey Enamel Painted of approved shades. Note : The quoted rate inclusive of preparation of trolley for 400 KVA DG with wheels drawing by Contractor and approved by GE.