Technical Spec
Technical Spec
Technical Spec
Supply, Installation, Testing and Commissioning of 1 No. of 500 kVA DG set including
all accessories as per the detailed specifications. The System shall be inter faced with existing
Cummins make 3 x 500kVA DG sets to achieve final configuration of 4 x 500kVA DG set to
operate on Single/Parallel mode of operation
Make/Model Compliance
Make/Model of Engine: Cummins -500kVA - KTAA 19G10
Make/Model of PCC: Cummins – PCC 3100 or upgraded version
Make/Model of Alternator: -Cummins/Stamford– 625kVA
2. GEOGRAPHICAL DATA
3. GENERAL REQUIREMENT
Compliance
The Diesel Engine shall be of ‘Generator set’ application type & shall
generally confirm to ISO 3046 / BS 5514 / IS 4722/1992 with amendments
respectively.
Prime power in accordance with ISO 8528 110% overload in accordance with
ISO 3046/1, AS2789, DIN6271 and BS5514
The engine operating with diesel fuel shall correspond to Grade No: 2D
Density 85 g/ liter as per ASTM D975 / IS 1460: 1995.
The engine shall have Cold starting capability up to 0 deg. C and shall have
capability to start directly to RUN speed (1500 RPM) without any interim
warm up speed (Idle speed). Smart starting control system to be provided
4. EMISSION
Compliance
To comply in accordance with ISO 8178 D2 – 1996 Mobile of
highway standard. Typical data under ideal / test condition to
be confirmed.
Emissions: gms/bhp/hr
NOx : to be furnished by the bidder
HC : to be furnished by the bidder
CO : to be furnished by the bidder
Compliance
The Diesel – Generator set shall comprise of a Diesel Engine of
specified capacity, directly coupled to an Alternator of specified capacity
mounted over a common base frame with Anti-vibro-mounts (AVM pad as
recommended by Engine Manufacturer)
The diesel engine shall be of four stroke cycle multi-cylinder, water
cooled, turbo charged with after cooler, developing required BHP @ 1500
rpm under NTP condition of BS 5514 with an over load capacity of 110% for
one hour in any specified 12 hrs of continuous operation.
5. ACOUSTIC ENCLOSURE
SL.No DESCRIPTION Compliance
General
The enclosure shall meet the stringent noise levels specified by the
Ministry of Environment and Forest, GOI, as per notification no.
1
GSR 371 (E) dated May 17, 2002 and are to be certified for noise
levels of 75 dbA @ 1 mtr distance by the MOEF, GOI appointed
nodal agencies
Dimension
Shall be suitable for housing 500 kVA model engine with 625 kVA
2 Alternator with adopter box for Differential CT mounting and
terminations of Power Cables
To be furnished
Construction
Outer Body & Doors– 1.6 mm thick (16 G) CRCA
3 Common Base Frame – ISMC 250
Fuel Tank – 3 mm thick (10G) HR sheet Top & Bottom
Sound Insulation – 100 mm Thick Rock wool (64 kg / m3)
The acoustic is composite in construction & is a fully assembled
4
integral unit. A tough glass is to be provided for viewing the set
5 Base fuel tank to be supplied & located inside the acoustic enclosure.
The Acoustic enclosure parts will be powder coated after pre-
treatment process. The powder coating shade shall be ‘GENSET
6
GREEN’. The common base frame will be epoxy painted black
shade in colour.
7 Latest compatible Make & Model to be specified:
8 Govt. Approval details to be furnished
The general operating parameters of each generator set are to be monitored using the
state-of-the-art technology. It shall have the facility like monitoring, metering and controlling of
DG set with PC interface facility. The unit shall be environmentally sealed; solid state and
microprocessor based and shall have following minimum features.
Features Compliance
Make/Model of the PCC: PCC 3100 or Upgraded version to interface with the
existing 3 x 500 kVA Cummins DG set
Digital governing, voltage regulation, synchronizing and load sharing controls
Single/parallel mode of operation with existing Diesel generators with
PCC 3100.
Engine and Alternator protections
Amps entry protection for true alternator over current protection
Analogue and Digital AC output metering
Battery Monitoring system to sense and warn against a weak battery condition
Digital Alarm and Status message display
Gen. Set monitoring: Displays status of all critical engine and alternator and
Gen. set functions
Smart Starting control system: Integrated fuel ramping to limit black smoke,
frequency overshoot, to optimized cold weather starting
Advanced serviceability
Quality assurance to ISO
Dust, water and Oil resistant
Key type Mode switch
7.4 FACILITIES
Facilities Compliance
o Manual Scan
o Remote start / stop
o Data link for communication with PC through an RS 232/485 port
for data logging and monitoring
o Panel lights
o Emergency Stop Push Button
o Power Command Control unit with RS 232/422/485 interface
along with GCM card, SLTA – 10 gateway module, interface
cables for each units and PC (cat – 5 cable) complete with all
required hardware's & PCC Software for windows to remote
monitoring / control The system should be commissioned at site by
qualified engineers and this will be put for burn test.
Note: This PCC to be interfaced with existing 3 Nos of PCC 3100 for parallel
operation of all the four DG sets. Existing DG set Make/Model: Cummins KTA 19
G4 with PCC 3100 and Stamford 625kVA Alternator. Required Relays/contactors
and interfacing cabling to be supplied and commissioned
8 STARTING
STARTING Compliance
Mode of starting: by electrical-24V DC motor powered by Starting Batteries.
Type: 24V DC Cummins Hi pulse(latest model) makes for generator application.
Batteries have to be charged by the inbuilt charger/External charger.
9. FUEL SYSTEM
External Fuel Tank: Capacity: 900 Liters (Optional) Compliance
Tank shall have inlet & outlet pipe connections with inlet and outlet ball valves,
filling cap drain plug, level indication, level sensor & floor mounting pedestal.
One more additional inlet should be provided with suitable Filter / Strainer. The
Fuel tank shall have 1180mm W x 900 mm D x 945 mm H (approx.) to suit
existing site room dimension of 1500 mm W x 1400 mm D x 2000 H with
sufficient clearance for operating valves and maintenance. 50-mm space clearance
shall be left at top of the tank for oil expansion and contraction.
Tank shall be painted with matching color of the Engine. The fuel tank
shall be graduated and calibrated vertically to the capacity of 950 ltrs along the
transparent level indicating glass/ polythene tube. Minimum of 40 graduations
shall be done by clearly marking the level.
The inlet fuel line to be connected to the existing fuel transfer pump. The
out let line to be connected to the Engine suction line or to the Fuel tank located
inside the Acoustic enclosure through ball valve.
11. SPECIFICATIONS FOR ENGINE
Sl.No DESCRIPTION SPECIFICATION Compliance
Engine model KTAA19-G10 with PCC
1 3100 or upgraded ver.
(Cummins)
2 Rating at 0.8 p.f. 50 Hz 500 kVA
3 Engine RPM at rated Power 1500 rpm
Gross Engine BHP. Suitable to deliver required
4
alternator output of 400 KW
5 Type of cooling Radiator air cooled
6 Specific Fuel consumption (units/ liter) >4
Alternator Make & Model Stamford/cummins latest
version 625 kVA rating to
meet the 70% nonlinear
7 loads. And suitable to
parallel with existing
Stamford 625kVA
Alternator
8 Power drawn from the Engine. 500 kVA
Typical Alternator Efficiency @ 100 % >94.8
9
FL
10 Direction Of Rotation (SAE Std) FW end Clockwise
11 Aspiration Of Engine Turbo charged after cooled
Max. Over speed allowed (trip set at) 1600 to 1650 rpm
12
RPM
13 Mechanical Efficiency of the Engine (%) To be furnished
14 Thermal Efficiency of the Engine (%) To be furnished
Reference Standard For the Engine. BS5514 /ISO3046 or latest
15
amendments
Vibration level (With & without AVM) Max 250 microns
16
(amplitude)
EXHAUST SYSTEM.
17 Exhaust system Back pressure ( kPa) To be furnished
18 Diameter of engine exhaust outlet (inside) To be furnished
Muffler / Silencer Restriction To be furnished
19
(Residential) Ps
20 Noise reduction level. DB (A) To be furnished
21 Exhaust Inspection Window. As per norms
LUBE-OIL CONSUMPTION
22 Lube oil consumption @ 100 % load To be furnished
23 Lube oil consumption @ 75 % load To be furnished
24 Lube oil consumption @ 50 % load To be furnished
25 Lube oil change period (HRS) To be furnished
26 Recommended Lube oil To be furnished
HEAT REJECTION DETAILS (+ / - %)
27 Heat Rejection to Atmosphere (kW) To be furnished
28 Heat Rejection to Exhaust (kW) To be furnished
29 Heat Rejection to the Lube oil (kW) To be furnished
DE-RATING & VENTILATION DETAILS
32 De-rating of the engine – Altitude @ No de-rating
normal temp.
De-rating of the engine – Altitude @ 50 No de-rating
33
deg C (M)
34 De-rating of the engine – Humidity. No de-ration
35 Room Ventilation required (CFM) To be furnished
36 Temp. Rise inside Room (deg. C) Max. To be furnished
INTAKE SYSTEM
Compliance
37 Air intake restriction-with clean element (kPa) To be furnished
38 Air intake restriction-with dirty element (kPa) To be furnished
Combustion air inlet flow rate (+ / - 5%) To be furnished
39
M3/min
FUEL SYSTEM
40 Fuel system type To be furnished
41 Filter type To be provided
42 Filtration capacity (particle size) <40 microns
43 Fuel transfer Pump type To be furnished
LUBE OIL SYSTEM
<10 %
33 Transient Voltage Dip on FL
15. Spares
As per BOM
BOM as per Annexure
16. Submittals.
Compliance
Preliminary design review (PDR) document with Drawings for Chimney
exhaust should be submitted to MCF with in 30 days of receipt of purchase
order.
Detailed wind load / pressure withstanding capacity to be furnished for
the Stack including foundation Bolt design & details.
17. WARRANTY
Compliance
System supplied shall be covered under a warranty period of not less
than18 months from the date of receipt of the material at our sites or 12 months
from the date of commissioning of the unit at site. Engine shall carry a
warrantee period of not less than 24 months.
18. SAFETY
Compliance
In the course of the work, personnel working in the system at site should
take utmost care for their safety and work purely at individual’s/ party’s risk.
MCF will not be responsible for any untoward accidents for the party’s
working personnel.
22. DOCUMENTATION
Compliance
Apart from the original Documents provided by the Manufacturer,
agency should submit two copies of the same. Agency should prepare as-build
drawing in Autocad for both Electrical & Mechanical and submit three hard
copies in a hard bound volume and a soft copy in CD format.
Bill of Materials
A. SUPPLY OF DG SETS
Sl Rate Amount
Description Qty Unit
No. (Rs.) (Rs.)
Total-A
Total - B
C. DG SET'S ERECTION ACCESSORIES
Sl Rate Amount
Description Qty Unit
No. (Rs.) (Rs.)
Supply and installation of MS class
B for Exhaust piping and silencer
size as per the engine requirement
C1 12" and 8" dia, including bends,
collars, flange …etc as per the site
requirements
a) 12” Dia 14* Mtrs
b) 8” dia 8* Mtrs
MS supports for silencer and
C2 exhaust piping as required by 1.5* Tons
Engine
Glass wool/Mineral wool lagging
C3 with Aluminum cladding inside and
out side the powerhouse.
a) 12” Dia 14* Mtrs
b) 8” Dia 6* Mtrs
Glass wool/Mineral wool lagging
C4 with Aluminum cladding for 1 No.
Hospital Silencer
25NB MS class C for fuel piping
with flanges, bends, etc., from
C5 pump discharge header to day tank, 20 mtrs
day tank to engine and if required
engine return to day tank
Fuel line Ball valve 25NB At Main
C6 2* Nos
Tank outlet valves Delivery valve
GI duct for exhaust from the top of
C7 the enclosure to out side the 6* mtrs
building wall with louver
Total - C
Note: * indicates approx. quantity. Actual quantity to be supplied on site
requirement
D. ELECTRICAL WORKS
Sl Rate Amount
Description Qty Unit
No. (Rs.) (Rs.)
Adapter box for alternator including
interconnecting bus bars (rigid and
flexible) including copper bus bars,
isolation damper & supports, SS
D1 1 Set
bolts, Lock Nuts washers etc.
Adequate space to be provided for
terminating 4 x 300 sq. mm XLPE
cables & Differential CT's.
Differential CTs PS class suitable
for MD 32G L&T Relay
D2 6 Nos
(Panel side CT Bus dimension will
be given later)
PC interface for Power Command
Control unit with RS 232/422
interface along with GCM card /
Modlon Converter, Software / SLTA
D3 – 10 gateway module complete as 1 set
required. PCC standard Software for
windows XP to remote monitoring &
control and interfacing with existing
system.
D4 Temperature scanner for Alternator 1 No
Copper Electrode Maintenance Free
D5 Earthing system for neutral 2 Nos.
As per IS
GI Electrode Maintenance Free
Earthing system for body including
2
D6 chamber, C.I. cover Plate GI molded Nos.
Pit with marking as NE/BE As per
IS
Supply and installation of 40 x 6
D7 mm Copper strip for neutral 100 Mtrs
earthing
Supply and installation of 50 x 6
D8 mm GI strip for body earthing of 100 Mtrs
generator and panel
Supply and installation of 40 x 3
mm Copper strip for Lightning
D9 15 Mtrs
earthing with suitable insulator and
lightning spike
Total - D
E. SUPPLY OF SPARES
Sl Rate Amount
Description Qty Unit
No. (Rs.) (Rs.)
Engine Coolant concentrate additive
E1 50 Ltrs
(Red)
Total - E
Sl Rate Amount
Description Qty Unit
No. (Rs.) (Rs.)
Alternator Testing at OEM works
F1 1 No
Routine test and 8 hrs heat run test
DG. Set with enclosure Pre delivery
F2 Inspection & Testing including 8hrs 1 Nos
Heat run test
Total – F
G. OPTIONAL ITEM
Sl Rate Amount
Description Qty Unit
No. (Rs.) (Rs.)
HSD External Tank as per
G1 1 No
specification enclosed
Total - G
SUMMARY
TOTAL COST
Sl
Description Equipment Cost Rs/-
No.
Acoustic Enclosure
B I & C of DG set
C Erection materials
D Electrical works
E Spares
F Testing charges
Grand Total
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