TECHNICAL SPECIFICATION FOR DIESEL GENERATOR SETS

1. Scope

The scope of work includes Design, manufacturing, assembly, testing at manufacturer's works,
Supply, transportation and safe delivery to IGCAR site, unloading, safe storage, installation,
testing and commissioning of Diesel Generator sets as per schedule of quantities and as per
the following specifications.

2. Project Data

2.1. Purchaser : Department of Atomic Energy, Kalpakkam.

2.2. Locations : Kalpakkam, Tamil Nadu.

2.3. Climatic conditions : The climate is tropical with high humidity and heavy rainfall conducive
to rust and fungus growth.

2.4. Ambient Temperature : 40o C.

2.5. Installations : Indoor

2.6. Sites for installation : PDC-XII substation and DWR-WP at IGCAR, Kalpakkam.

3. Delivery

The DG sets shall be directly delivered to the Stores Officer, Central Stores- IGCAR, Kalpakkam.
Supply, Installation, testing and commissioning of DG sets shall be completed within Six months from
the date of release of Purchase order. The supplier shall make his own arrangements for the
transportation, safe delivery and unloading the DG sets at site using Crane.

4. PQ criteria for accepting the bids :

4.1. The TENDERER shall provide satisfactory evidence concerning the following in their offer failing
which the offer will be rejected.

a) That bidder shall be a qualified GOEM (Generator Original Equipment Manufacturer

of DG sets, System integrator of DG sets), who regularly manufactures / assembles
the DG sets and has adequate technical knowledge, expertise, manpower and
practical experience. The offered Diesel Generators shall meet the requirements of
Environmental (Protection) Rules 1986 as laid down by Min. of Environment &
Forests read with GSR 371 (E) dated 17.5.2002,GSR 520(E)dated 1.7.2003 ,
No.448 (E)dated 12.07.2004 , GSR 771(E) dated 11.12.2013 GSR 232(E)dated
31.03.2014,Gazette Notification No.167 dated. 31.03.2014 and Gazette Notification
No. 578 dated. 11.11.2014 in respect of noise and emission norms. The latest
amendments to above GSRs shall be applicable as and when amended by Ministry
of Environment and Forest, Government of India.

4.2. In addition to the satisfactory fulfilment of the requirements stipulated above, TENDERERS
participating in this tender shall, on the strength of their own experience, have designed,
assembled, installed and successfully commissioned equal or higher rated DG sets in at least
FIVE (5) nos. in power plant units/industries, each of which has been in satisfactory commercial
operation for at least two (2) years. Proof for the same shall be submitted.
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5. Tender Evaluation

5.1. Overall quoted cost in price schedule with GST will be considered for the evaluation,
corresponding to each DG capacity separately.

5.2. Item wise L1 will be considered for placement of Purchase Order.

6. Deviation

Deviation from this specification shall be clearly brought out during the pre bid meeting. Wherever
the deviations are not clearly brought out/mentioned it will be deemed that the offered DG sets will
fully comply with this technical specification, irrespective of whether the literature enclosed with the
offer agrees or not.

7. Acceptance of material received at site

On receipt of DG set at site, if any transit damage is observed, the damages shall be rectified free of
cost by the bidder. However major damages, affecting the performance of the DG set for long run
will lead to rejection of DG set and replacement with new DG set. No payment will be made for
rejected DG sets. DG sets will be accepted on successful completion of installation, testing and
commissioning at site, as per relevant Indian Standards and attached technical specification.

8. Standards

Material/Equipment covered under the specification shall be installed, commissioned conforming to

manufacturer’s recommendations and best engineering practices. The DG sets covered by this
Specification unless otherwise stated, shall be designed in accordance with the latest editions of the
following STANDARDS.

CODE DESCRIPTION

Reciprocating Internal Combustion Engine Driven Alternating Current

IS/ISO 8528
Generating Sets
IS:13364 (Part- Specification for AC generators driven by Reciprocating Internal
2) combustion engine: Part 2 Rated above 20 kVA and upto 1250 kVA
IS:1460 Automotive diesel fuel-specification

IS/IEC 60034-1 Rotating electrical machines, Part 1: Rating and performance

ISO 3046 Reciprocating Internal Combustion Engine – Performance

ISO 9001 Quality Management Systems

IS 13018 Internal combustion engines – Method of test for pressure charged

engines
IS 14257 Lead-Acid Storage Batteries for Motor Vehicles with Light Weight and
High Cranking Performance- Specification

Page 2 of 21
9. Technical Particulars of Diesel Generator sets

9.1. The DG set shall comprise of the following systems to make it complete in all respects.

a. Diesel Engine

b. Fuel oil system

c. Starting system

d. Lubrication system

e. Cooling water system

f. Exhaust system

g. Alternator

h. Engine controller

i. CPCB norms II compliance Acoustic enclosure

9.2. Common Base frame for mounting of Diesel Generator Set: Sturdy, fabricated, welded
Construction, channel iron base frame for mounting the Engine & Alternator.

9.3. Supply & exhaust air louvers provided in the acoustic enclosure shall be provided with additional
SS wire mesh as directed by the EIC to avoid entry of reptiles.

9.3.1. The DG set shall be capable of taking 10 % overload for 1hr in every 12 hrs of operation.

9.4. The 625 kVA DG set shall be capable of 50% block loading capacity & 250 kVA DG set shall be
capable of 40% block loading capacity.

9.5. The DG set shall be designed to be continuously connected to the grid and to feed rated full load
for 1 hour.

10. Diesel Engine

10.1. The Features of the engine shall be Four Stroke, Direct Injection, Liquid Cooled, Turbocharged,
After Cooled, Six Cylinder, Diesel Engine developing not less than the required BHP, rated at
1500 RPM under NTP condition as per ISO 3046, suitable for generating set application on AMF
mode. The DG set shall be capable of block loading capacity (50% for 625 kVA, 40% for 250
kVA) and complete with the following standard accessories:

a. Flywheel to suit flexible coupling.

b. Coupling with guard.

c. Air cleaner.

d. Radiator & Fan. (Blower Type)

e. Fuel Injection Pump.

f. Electronic Governor with CT for operating in droop mode.

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 g. Lubricating Oil Filter.

h. Lubrication Oil - Low Pressure - Safety cut-out

i. Water Temperature High - Safety cut-out

j. 24 V DC cranking motor cum charging alternator

k. Tubular Lead Acid batteries of suitable ratings with connecting cables.

l. Turbo Charger

m. Anti Vibration Mounting Pads and required fasteners.

10.2. Engine shall be suitable for HSD fuel as per IS 1460: 2000.

10.3. Supplier shall provide data regarding the minimum load the engine is capable of sustaining
indefinitely without deterioration.

11. Fuel oil System:

11.1. Dedicated Fuel tank suitable for external mounting, made out of 3 mm thick M.S. sheet square/
rectangle cross section of capacity 990 Litres approx. shall be provided with the following
arrangements.

a. Calibrated Fuel level Gauge with cocks on both top & bottom for easy replacement.

b. Fuel Inlet connection with locking arrangement at the top lid.

c. Fuel outlet with valve arrangement.

d. Air vent.

e. Drain plug.

11.2. Fuel Supply and Return Hose (wire braided) near the Engine with suitable isolating valves for
connecting rigid MS Fuel Inlet/Outlet Lines from/to external Fuel Oil tank with complete
accessories for connection.

11.3. Necessary stand for mounting the fuel tank. Proper stiffeners shall be provided with channel
sections at the bottom of the tank and tested for leak. Outside surface of the tank shall be
painted with two coats each of red oxide primer and Black synthetic enamel paint.

11.4. Alarm shall be given for fuel low level and fuel high level in fuel tank. Fuel level indication shall
be provided on the tank and shall have facility for refilling directly from tanker.

11.5. All necessary fuel line pipes (1 inch dia, Medium duty), valve and other misc. piping materials
from tank to engine, fuel return connection, vent, sight glass, level switch for transfer pump
control, overflow line, drain valve and required fuel for site testing shall be provided.

11.6. A filter of suitable type & capacity to supply fuel oil at rated output (Spin-on type paper filter is
preferred).

11.7. Engine driven Fuel pump.

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11.8. Fuel injection and control system for compression ignition.

11.9. In addition to above, Bidder shall supply all necessary Accessories and Equipment for the
satisfactory operation of the fuel system.

11.10. Fuel tank drawing with all accessories shall be submitted to department for approval.

12. Starting System:

12.1.1. Electrical starting system shall be provided for the engine. High discharge rate, Tubular lead acid
type batteries shall be provided with all necessary hardware and accessories.

12.1.2. Batteries shall be of 24V DC, rated capacity as per OEM recommendation.

12.1.3. Battery shall have adequate capacity of giving minimum 3 consecutive start up kicks with
voltage monitoring and alarm devices.

12.1.4. The battery charging circuitry shall be such that when engine is running, the engine mounted
dynamo charges the battery.

12.1.5. FRPVC insulated multi strand copper conductor shall be used for battery connections and
shorting links. The cable size shall be suitable for the current rating. Suitable coated brass
connecting clamps shall be used for connection at battery end.

13. Lube oil System:

13.1.1. Force Feed Lubrication System by means of engine driven oil pump, replaceable, suitable type
full flow oil filter, oil service tank shall be provided.

13.1.2. The lube oils used will generally comply with the additive class HD Supplement 1, Classification
API and Viscosity Class SAE 20 / 40.

13.1.3. The Lubricating System shall be equipped with one gear pump driven by crankshaft delivering
lube oil from service tank via relief valves, oil cooler and through system of coarse and fine filters
to the engine.

13.1.4. Bidder shall supply all necessary auxiliary equipment for the satisfactory operation of the
lubrication system.

13.1.5. Tripping of DG set for high lube oil temperature, Low lube oil pressure shall be provided.

14. Cooling system:

14.1.1. Engine shall be Radiator cooled type. The jacket cooling water shall be circulated by engine/
electric motor driven pump.

14.1.2. All accessories required in the internal cooling water circuit like pipes, valves, flanges, supports,
etc. shall be provided by Bidder.

15. Fume gas exhaust:

15.1. Hospital grade silencer shall be provided for fume gas exhaust.

15.2. Class ‘B” Fume exhaust piping with necessary bends, flanges, etc. from Engine to outdoor
(length required as per the attached site layout) insulated with mineral wool and covered with 24

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 Gauge (0.5 mm) aluminium cladding shall be provided. The pipe shall be of medium duty type.
The height of exhaust chimney shall be as per the statutory requirements.

15.3. Exhaust pipe end shall be provided with gravity flap to facilitate automatic opening of exhaust
pipe during engine running. Suitable rain hood and SS wire mesh shall also be provided at the
mouth of exhaust pipe.

15.4. Fume exhaust pipe shall be suitably supported with 2 nos. GI angles (50x 6 mm) from ceiling
and one cross connecting piece, for every 1 m length. Rivets, Nut, Bolt, anchor fasteners
required for the fume exhaust support, coupling, etc., are also included in the scope of bidder.

16. Hot air exhaust (Radiator cooling):

16.1. GI duct shall be provided for hot air exhaust from DG set up to designated place of duct outlet
marked in the site layout drawing. The duct shall be made of 14 Gauge thick GI sheet.

16.2. DG set with acoustic enclosure will be installed indoor inside the DG room. DG room layout is
attached for reference.

16.3. Galvanised Iron (GI) duct shall be provided for venting hot exhaust air out of the DG room, from
radiator hot air outlet point of the DG Acoustic enclosure through nearest brick wall.

16.4. The bidder shall submit Hot air duct layout drawing to department for approval, before taken up
the duct work.

16.5. The duct shall be made of 14 SWG thick, Class-8, Galvanized Iron (GI) Sheet.

16.6. Duct shall be closed with GI/SS weld mesh of suitable size outside the DG room to avoid entry of
birds.

16.7. Duct opening at the outdoor shall be provided with suitable bend / rain shielding arrangement.

16.8. Ducting shall be done in such a way that, during DG operation hot air passing through radiator
vented out to atmosphere without leakage through coupling. Duct shall be coupled with MS
flanges and Neoprene gasket suitable for the hot environment.

16.9. Duct shall be suitably supported with the 2 nos. GI angles (50x 6 mm) from ceiling and one cross
connecting piece, for every 1 m length. All GI items required for the duct support is included in
the scope of bidder. Rivets, Nut, Bolt, anchor fasteners (Hilti make) required for the duct support,
coupling, etc., are also included in the scope of bidder.

16.10. Scaffolding if required shall be arranged by the bidder at site.

17. Alternator

17.1. Brushless type, PMG excited and self regulated giving the specified outputs continuously, at 0.8
pf lag, 415 Volts, 3 Phase, 4 Wire, 50 Hz at 1500 RPM.

17.2. The Alternator shall confirm to IS 13364 Part-2 & IS 15999 Part-1/ IEC 60034 Part-1.

17.3. Alternator armature winding shall be star connected. Neutral point of the winding shall be
brought up to the alternator terminal box with same size conductor of the Phase.

17.4. Band of voltage regulation + 1 % of rated voltage (VG-3 grade) with FET type Automatic Voltage
Regulator (AVR).
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17.5. The alternator winding Insulation shall be class H for stator and rotor. Winding insulation shall be
treated with Vacuum pressure impregnation method.

17.6. Alternator shall be suitable for operation at an Ambient Air Temperature 40 0C, without any de-
rating.

17.7. Alternators shall be protected with IP 23 enclosure.

17.8. Bearing temperature & Winding temperature detector shall be provided.

17.9. Space heaters shall be provided.

17.10. Alternator shall be suitable for parallel operation with other sources of supply / alternator. Other
supply source available at site can have +/- 5% voltage variation.

17.11. Alternators shall be capable of continuously operating on a 25 % unbalanced load with none of
the phase currents exceeding the rated current.

17.12. Wave form Deviation, Telephonic harmonic factor, Harmonic Distortion factor value shall meet IS
13364 Part 2.

17.13. For 625 kVA DG set: Alternator shall have dedicated terminal box with extended Tinned
copper bus bars suitable for connecting Conventional TPN Aluminium Bus duct
(truncking). Supply of Bus duct is not in the scope of bidder.

17.14. For 250 kVA DG set : The Alternator shall have dedicated cable terminal box with extended
tinned copper bus bars suitable for terminating the 2 Runs of 3.5 core 240 sq. mm XLPE
insulated Aluminium cable.

17.15. Application : 625 kVA DG sets – Majorly Non linear loads (Computer servers,
UPS, etc.,)

250 kVA DG set – Majorly Non linear loads (UPS, etc.,)

17.16. Motor Starting Capacity : Shall possess Motor starting capacity of 30kW motor with 50%
based load.

17.17. Short Circuit Sustenance : Shall have High sustenance of Short Circuit current for 3
Seconds.

17.18. Epoxy Coating : All wound components shall be epoxy coated after
impregnation.

17.19. Routine Tests : Shall be conducted as per relevant IS on the machine at no

extra cost.

18. Alternator Excitation System

18.1. The excitation of alternator shall be Brushless, PMG excitation type.

18.2. The alternator shall have VG-3 grade voltage characteristics as per IS 13364 Part-2.

a. The inherent voltage regulation shall be +/- 1%.

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 b. Recovery time (at rated voltage) for sudden application of rated load shall be 1.0 seconds
(max) and transient voltage drop is 15%.

c. Recovery time (at rated power factor and constant speed) for sudden rejection of rated
load shall be 1.5 seconds (max) and transient voltage rise is 20%.

18.3. Apart from the voltage regulation characteristics the excitation system shall have the following
features.

a. Voltage build-up from residual magnetism.

b. Protection against low speed operation.

c. 3 Phase sensing system shall allow good operation with unbalanced load system.

d. Shall have good overload characteristics.

19. Engine Controller

19.1. The controller shall be consisting of the following features.

a. Real time clock for fault and event time stamping

b. 12 V or 24 V DC battery operation

c. Compatible with shunt and PMG excitation

d. Configurable for any frequency, voltage, power.

e. Compatible for PC based software service tool

f. Fully encapsulated control board

g. Configurable four discrete inputs & four dry contact relay outputs

h. Exerciser clock

19.2. Controller HMI display parameters

• Alternator data

o Voltage, Current, kW, KVAR, power factor, kVA, frequency

• Utility/AC bus data

o Voltage, Current, kW, KVAR, power factor, kVA, frequency

• Engine data

o Starting battery Voltage, Engine speed, Engine temperature, Engine oil pressure,
Engine oil temperature, Intake manifold temperature

19.3. Protection functions

• Alternator over current protection

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 • Generator set monitoring and protection

• Utility/AC bus metering and protection

19.4. Control functions

• Load transfer operation in open transition, closed transition or soft transfer modes

• Regulation of genset real and reactive power output while paralleling

• Digital frequency synchronisation and voltage matching

• Isochronous load share

• Droop kW and kVAR control

• Digital voltage regulation with three phase sensing

• Sync check function with adjustments for phase angle window, voltage window, frequency
window and time delay

• Breaker control

19.5. Monitoring functions

• Status of all critical engine and alternator functions

• Genset battery monitoring to sense and warn weak battery condition

a. Metering functions : Digital genset metering (AC & DC)

b. Indicating lamps for ‘Load ON’ and ‘Set Running’

c. Fault status indication LED

d. Instrument fuses duly wired and ferruled

e. Control system shall comprise of a microprocessor based generator set monitoring,

metering and control system with LCD display

f. Intuitive operator interface which includes LED backlit LCD display with tactile feel soft-
switches and generator set status LED lamps

g. Digital AVR PMG excitation with torque matching.

h. Digital Electronic Governing with temperature compensation and smart starting.

i. Engine metering: Oil pressure, Coolant temperature, Battery Voltage, Engine Speed
(RPM), AC Alternator metering: L-L Voltage and L-N Voltage, Current (1 and 3 phase),
Volt-Amperes (phase and total), Energy, active power, reactive power, Power factor and
Frequency, Run time totaliser and Run time indicator.

j. Engine protection: Low lube oil pressure, High/Low coolant temperature, over speed,
Battery Over/Under/Weak Volts, Fail to crank/start, Sensor failure, Cranking lockout, fault
simulation with PC based software tool.
Page 9 of 21
 k. Starting switch with key

l. AC Alternator protection: Over/Under voltage, Over/Under frequency, Over current

warning/ shutdown, Short circuit and Loss of AC sensing, Field overload, Over load
warning, Reverse power.

m. Data logging: Engine hours, Control hours, Engine starts and upto 10 recent fault codes

n. Configurable glow plug control

o. Programmable I/Os, with expandable modules

p. PC tool interface

q. Modbus interface (RS485 RTU)

r. Genset output power derate option in response to fault condition

s. Certifications - meets the requirement of relevant UL, NFPA, ISO, IEC, Mil Std., CE and
CSA standards

19.6. Engine control functions

a. SAE J1939 interface to Full Authority Electronic (FAE) engines.

b. Temperature dependent governing dynamics

c. Isochronous governing

d. Droop electronic speed governing

e. Remote start-stop facility.

f. Emergency Stop Push Button (With provision to extend Remote STOP)

g. Sleep mode

h. Configurable cranking cycle

i. Time delay start and stop

19.7. Alternator control functions

a. Digital output voltage regulation

b. Droop voltage regulation

c. Torque-matched V/Hz overload control

d. Fault current regulation

19.8. Paralleling functions

• First start sensor system

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 • Synchronising

• Extended paralleling with power regulation at Genset / utility metering point

• Load sharing control

• Load govern control

• Load demand control

• Sync check function with external sync check output

• Power transfer control

19.9. Controller shall be fabricated with 14 gauge CRCA sheet and powder coated for weather-proof
and long lasting finish.

19.10. In the event of failure of Automatic Controller in the AMF Panel, the main protections such as
Low Lube Oil Pressure Trip, High Water Temperature Trip, Low Fuel Oil Pressure Trip, Over
speed Trip shall be achieved through required contactors and the Engine shall be protected from
such faults.

20. Acoustic Enclosure

20.1.1. DG set should have Type approval certificate and also COP certificate (if applicable) from
certification agencies mentioning MOEF notification No.371(E) dated 17.05.2002 or as amended
and applicable at the time of supply.

20.2. The acoustic enclosure shall meet stringent MoEF/ CPCB-II norms of 75 dBA @ 1mtr at 75%
load under free field conditions.

20.3. The acoustic enclosure shall conform to the drawings TYPE approved by a Govt./NABL lab., for
conformity to noise norms.

20.4. The acoustic enclosure shall consist of following.

a. The enclosure should be fabricated out of CRCA sheet of minimum 2 mm thick. The
sheet metal components should be suitably pretreated and should be powder coated with
weather proof paint to have long life of enclosure.

b. The enclosure shall vermin proof.

c. Structural/ sheet metal base frame and Anti Vibration Pad shall be provided for mounting
Engine and alternator.

d. High quality noise absorbent and fire-retardant grade acoustic insulation material of 100
mm thick shall be provided. Density of insulation shall be min 96 kg/cubm.

e. A special Hospital silencer should be provided along with the enclosure to control
exhaust noise.

f. Specially designed louvers should be provided to control sound at air entry to the
container and exit from the container.

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 g. The fresh air intake and radiator exhaust shall be provided with wired mesh arrangement
to avoid rodent entry.

h. There should be provision of drain plugs for draining lube oil and diesel.

i. The battery should be accommodated in a separate tray in the enclosure.

j. There shall be emergency STOP push button from outside the enclosure.

k. Ambient temperature limit inside the canopy shall not cause derating of the alternator.

l. Lifting hook arrangement shall be provided for handling DG set at site.

m. Glass inspection window shall be provided on acoustic enclosure in front of engine

control panel.

21. Earthing

The DG sets shall have identified earthing terminals/provision (2 Nos. for body and 2 Nos. for
Neutral) for connecting to the external earthing grid.

22. Painting

Exposed surfaces of the engine and alternator shall be given TWO coats of shade as approved
by the Department Engineer. External Fuel Oil Tank outer shall be painted with 2 coats of Black
synthetic enamel over a coat of red oxide primer. Inner surface of tank shall be given a coat of
Oil & heat resistant paint.

23. Drawing, Inspection & Testing

23.1. Test reports & Drawing Approval:

The following Test Reports/Drawings shall be submitted for our approval.

a. GA Drawing

b. Scheme drawing for engine control panel input/output interfacing with external system

c. Type test reports for Diesel Engine, Alternator and factory test reports for other bought
out items.

d. Operation, Maintenance and troubleshooting manual.

e. Manufacturing Quality plan and Field Quality plan

23.2. Inspection & Testing at Manufacturer’s Works:

The DG set shall be assembled and offered for inspection only at Bidder’s premises before
despatch. The following tests shall be conducted at factory in the presence of the Department
Engineer or his authorised representative. Lube Oil required for initial filling of the Engine and the
Fuel Oil required for carrying out all the tests at the manufacturer's works shall be supplied by
bidder at no extra cost.

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 a. Physical Verification of components.

b. Winding resistance and Insulation resistance measurement for Alternator winding.

c. Phase sequence test

d. High voltage test (Before and after load test)

e. Insulation Resistance measurement.

f. Voltage regulation and response time for sudden application and sudden withdrawal of
25%, 50%, 75% and 100% load.

g. Speed regulation and response time for sudden application and sudden withdrawal of
25%, 50%, 75% and 100% load.

h. Load test for 4 hours (not less than 3hrs at 100% load) and recording the following.

• Fuel consumption at 25%, 50%, 75%, & 100% of load.

• Engine parameters like speed, water temperature, lube oil pressure.

• Electrical parameters like frequency, voltage, current.

i. Checking for trouble free starting and oil leakage.

j. Leak test for fuel tank.

k. Vibration test : Vibration below AVM’s shall not exceed 100 microns.

23.3. Inspection & Testing at Site:

a. The following checks and tests shall be carried out for all the DG sets at site after
installation. Physical Verification of components. Visual examination for defects, transit
damages etc.

b. Checks for assembly, alignment, fuel, lubricating oil, water and air circuits.

c. Checks for power cabling control wiring and earth connections including terminations.

d. Winding resistance and Insulation resistance measurement for Alternator winding.

e. Insulation Resistance measurement.

f. High voltage test.

g. Checking AMF logic functions and operation including simulation of protective devices
which shall be carried out in the presence of the DG Set manufacturer’s representative.

h. Synchronisation with Grid and transfer of load from grid to DG and checking of DG
parameters on load with the load available at site.

i. All functional tests including normalisation of power after return of grid power by auto-
synchronisation

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 Supply also shall include first fill of Lube Oil & Fuel Oil required for carrying out all the above
tests at Site.

24. Packing, Unloading and Storing

24.1. The Contractor shall prepare all equipment covered by this specification for transport in such a
manner as to protect it from damage in transit and ingress of water and shall be responsible for
and make good at his own expense any and all damage due to improper packing and transit
damages. The contests shall be identified on the package. The packing shall be marked with
lifting and hook-up points for unloading.

24.2. The Contractor shall also make his own arrangements for transportation, unloading and
safe storage of the supplied items at site as directed by the departmental site engineer.

24.3. 4 sets of Operation, Maintenance, and troubleshooting manual complete with drawings and test
reports shall be sent with the DG set.

25. Guarantee

The DG set shall be guaranteed against any type of manufacturing defects and trouble free operation
conforming to this specification for a period of at least 24 Months and warranty for 5 years towards
Critical parts of the engine (Cylinder head, Cam shaft, Crank shaft, Cylinder block, Connecting rod) from
the date of acceptance.

26. Installation, testing & commissioning of DG set

26.1. Scope

The scope includes receipt of all the material covered under this tender at site, transportation to
Diesel Generator room, installation, Testing at site, commissioning and conducting acceptance
tests on Diesel Generator set, auxiliaries as per ISO: 3046 part-IV, batteries, exhaust pipes with
accessories, thermal insulation with mineral wool, aluminium cladding for exhaust, hot air
exhaust ducting from engine top, MS support materials, Class B fuel pipe from DG set to day
tank, 990L fuel tank with level indicator for DG’s to the satisfaction of the Department Engineer.

26.2. The responsibility for installing and commissioning of DG sets shall be that of the bidder.

26.3. The work covers from receipt of all materials at site up to final handing over to the Department
Engineer of complete equipment after acceptance testing.

26.4. Receipt of material/equipment transported from manufacturer’s works, unloading at site using
cranes.

26.5. Preparation of site for installation of equipment.

26.6. Unloading and placement of DG sets on foundation.

26.7. Installation, alignment etc., for diesel engine, alternator, exciter, excitation cubicles and all other
auxiliary systems, necessary piping, fuel hose as per approved drawings and manufacturer’s
recommendations for Diesel Generator and auxiliaries.

26.8. First fill of lube oil and all filters shall be provided by the bidder.

26.9. Initial charging & capacity test of batteries.

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26.10. Installation and commissioning of diesel oil storage “Day tank”, silencers, associated fume gas
exhaust piping with thermal insulation and Al cladding, hot air exhaust duct, MS support and
other accessories.

26.11. Supply and fixing of required tinned copper bus bars for connection to aluminium bus duct also
included in this scope.

26.12. Conducting pre-commissioning and commissioning checks and tests on all systems of the diesel
generator at site.

26.13. Conducting acceptance tests at site on the diesel engine, alternator set and auxiliaries, proving
the performance figures quoted in the offer, setting of pressure, temperature, level transducers
for alarm/trip functions, governor adjustment etc as required, as per manufacturers
recommendations. (All instruments, recorders etc., as required shall be provided by the
contractor).

26.14. The bidder shall conduct trial run of all the DG sets with available electrical loads.

26.15. Preparation of commissioning reports and submission of the same for Departments approval.
Reports shall contain record of all activities, data, checks, tests, carried out during installation
and commissioning. Six copies of such reports shall be submitted in bound volumes before the
completion of the job.

26.16. Supply of consumables like suitable welding electrodes, packing plates, hardware, grouting
cement etc., wherever required, approved lubricants, cotton waste etc., as required for
installation and commissioning.

26.17. Final finish painting, providing necessary thermal insulation wherever required including painting
exhaust pipes with High Temperature resistance paint.

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27. Schedule of quantities :

The bidders are advised to visit the site before quoting, to ascertain installation requirements.
Bidders can take reference of the attached site layout for arriving the requirement of fume gas
exhaust piping system, hot air ducting system and associated GI supports, etc.,

All the supply related items shall be quoted in the supply Cost and Installation, testing &
commissioning item to be quoted in installation cost in the price format.

Sl. No. Description Quantity

1 Supply, Installation, testing & Commissioning of Three 2 Nos.
phase, 415 V, 50 Hz, 1500 rpm, 0.8 p.f lag, 625 kVA/500
kW Diesel Generator set, complete with Diesel Engine,
Alternator mounted on a common base frame, CPCB-II
Acoustic Enclosure, Engine mounted Instrument
Panel/Controller suitable for AMF & auto synchronization
with utility grid, External Fuel Oil Tank of 990 Litres
capacity & associated pipe lines, Fume gas Exhaust
Piping with thermal insulation and covered with 24
Gauge aluminium cladding, Hospital Silencer, Hot Air
Exhaust Ducting made of 14 Gauge thick GI sheet
System and Tubular Lead acid starting Batteries as per
the technical specifications, at PDC-XII substation,
IGCAR, Kalpakkam.
2 Supply, Installation, testing & Commissioning of Three 1 No.
phase, 415 V, 50 Hz, 1500 rpm, 0.8 p.f lag, 250 kVA/200
kW Diesel Generator set, complete with Diesel Engine,
Alternator mounted on a common base frame, CPCB-II
Acoustic Enclosure, Engine mounted Instrument
Panel/Controller suitable for AMF & auto synchronization
with utility grid, External Fuel Oil Tank of 990 Litres
capacity & associated pipe lines, Fume gas Exhaust
Piping with thermal insulation and covered with 24
Gauge aluminium cladding, Hospital Silencer, Hot Air
Exhaust Ducting made of 14 Gauge thick GI sheet
System and Tubular Lead acid starting Batteries as per
the technical specifications, at DWR-WP, IGCAR,
Kalpakkam.

28. Items not included in the scope of work

28.1.1. Following items are not included in the scope of erection and commissioning contract:-

a. Construction of Diesel Generator room, DG set foundations, (however alignment,

levelling etc., of base frames is included in the scope of work), finish flooring of the Diesel
Generator room.

b. Lighting and ventilation of Diesel Generator room.

c. Statutory approvals for the DG sets

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 d. Supply & installation of Power cables, grounding conductors.

28.1.2. At site, all civil works shall be executed by the Department. However minor repair/modification
works if required shall be done by the contractor.

29. Safety

29.1.1. Successful bidder shall be responsible for safety of the equipment at all times during the period
of contract. Contractor shall replace/repair all components or equipment which in the
Departments view are damaged by the contractor or failed during the contract period.

29.1.2. Contractor shall ensure safety of crew employed for erection/commissioning of the Diesel
Generator sets by providing workmen adequate protective gear as required, by employing skilled
and trained labour for this kind of jobs, by enforcing safety norms to be followed by his workmen.

29.1.3. In addition to the above the contractor shall follow the AERB safety guide lines.

29.1.4. Department Engineer reserves the right to enforce additional safety measures as required from
time to time in the interest of equipment and workforce.

30. Approval of erection /commissioning procedures

30.1.1. Contractor shall before the commencement of work submit detailed procedure for erection and
commissioning of Diesel Generator set and auxiliaries. Actual erection/commissioning of
equipment shall start only after the approval of the procedures/methods submitted by the
contractor.

30.1.2. Department site engineers shall have the access to inspect erection, commissioning procedures
being followed by the contractor and contractor shall provide all necessary instruments required
for inspection.

30.1.3. When informed by the Department inspector about non-conformance erection/commissioning

procedures, standards, tolerances etc., as the case may be contractor shall rectify the error and
damage to the equipment if any, due to contractor’s poor workmanship/handling during
erection/commissioning to the full satisfaction of Department Engineer.

31. Superintendence and labour

31.1.1. The contractor shall provide supervision and work force for erection which shall include, but
limited to the following:

31.1.2. The employment of a competent erection superintendent who shall be constantly at the site and
shall give his whole time to the superintendence of the erection of the works and whose duties
shall include the supervision of the unloading, assembly and installation, repair, replacement of
any damaged components and any operating adjustments.

31.1.3. The employment of a sufficient number of assistants to the erection superintendent for
supervision and work force for the number of working shifts per day and days per week to
complete the work within the time specified.

31.1.4. The contractor shall employ only such persons as are careful, skilled and experienced in their
several trades.

32. Notices

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32.1.1. Any notice, order, direction or other communication to be given to the contractor under any of the
provision of the work order shall without limitation be conclusively deemed to have been received
by the contractor if delivered or mailed to the contractor at the address mentioned in the work
order or the contractor’s last known place or business or residence or to his superintendent or
foreman.

33. Sub-contracts

33.1.1. The contractor shall not sub-let any part of the erection work without the written consent of the
Department Engineer. The contractor shall be responsible to the Department Engineer for all the
work of the sub-contractor. Any sub-contractor shall be bound to the contractor by the terms of
drawings and specification and shall assume towards the contractor all the obligations and
responsibilities that the contractor assumes towards the Department Engineer.

34. Co-ordination work

34.1.1. The contractor shall plan his operations so as to avoid interference with the operation of the
Departments of others contractors or sub-contractors at the site. The contractor shall organize
his work to suit the timings shown on the construction schedule or revisions thereto issued by the
Department Engineer. The work also be co-ordinated with running units that shut down wherever
instructions are involved.

35. Planning

35.1.1. Before commencement of the job, contractor shall provide detailed schedule for the completion
of the job indicating target for the completion of major events, manpower requirement during
various stages of erection & commissioning.

36. Clean-up

36.1.1. The contractor shall at all times keep the site free from the accumulation of waste materials and
debris and upon completion of the of the job shall clean and dispose of all surplus materials,
rubbish and temporary works of whatsoever nature and kind as directed by the Department
Engineer and shall leave the works and site clean and tidy.

37. Services to be provided by the department

37.1.1. During the execution of the works, the department shall provide for the contractor “temporary
electric power’ at 415 volts, 3 phase, 50 Hz and 230 volt, Single phase, 50 Hz at free of cost
subject to the following conditions.

37.1.2. The electric power shall not be used for heating purposes.

37.1.3. The contractor shall make his own arrangements for the supply, erection and dismantling on
completion of the works of his temporary distribution system, distribution panels and other
equipment he may require for taking the power from the Department supply points.

37.1.4. The Department Engineer shall provide the power supply to the contractor at a point which shall
be within 100 meters of the location of the works.

37.1.5. The contractor’s temporary distribution system including metering shall be subject in every
respect to the approval of the Department Engineer and shall be so arranged as to avoid any
interference with the operations of the other contractors on the site. The distribution board shall
have ELCB of 30mA sensitivity.

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37.1.6. The Department Engineer shall not hold himself responsible for the consequences of any
unintentional interruptions to the continuity of the power supply or power system voltage and
frequency fluctuations.

38. Transportation of erection equipment and material to the site:

38.1.1. The contractor shall be responsible for all transportation of erection equipment and material to
and from the site.

39. Access roads and temporary buildings

39.1.1. The contractor shall have the reasonable use of existing roads at the site. The contractor may
use the main roads into the plant for vehicle provided that it does not interfere with access by
other contractors to the plant. The contractor shall regulate the entry of vehicles into the plant.

40. Access to site

40.1.1. Storage space for parts which cannot be moved directly and stored inside the plant building shall
have to be placed temporarily in the site storage yards and uplifted at the time of installation.
Storage areas shall be located within 1 km of the DG room.

41. Site welding

41.1.1. The contractor shall have all welding procedure, qualified welder and welding equipment in
accordance with the ASME Boiler and Pressure Vessels Code Section IX prior to commencing or
any welding at site.

41.1.2. Faulty welds caused by poor workmanship or lack of supervision on the part of contractor shall
be cut-out and re-welded at the contractor’s expenses. The procedure for the repair of deflective
welds shall be provided by the Department Engineer prior to any repair being made.

42. Security rules

42.1.1. The contractor shall follow at site all security rules as may be framed by the department from
time to time regarding removal of material from site, issue of identity cards, control of entry of
personal and all similar matters. The contractors and his personnel shall abide by all security
measures imposed by the department or their duly authorized representative from time.

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43. Guaranteed Technical Particulars

Model
Duty
No. of Phases
Output voltage
General
Frequency
Power factor
Current
Speed
Emission norms compliance
Make
Model
MoEF certified power
Required power for rated kVA
Cooling
Aspiration
No. of cylinders
Bore x Stroke
Compression ratio
Displacement
Engine
Fuel
Performance class of genset
Starting system
Lube oil specification
Lube oil sump capacity, High-low level
Total coolant capacity
Exhaust pipe size
Total wet weight (Engine + radiator)
L X W X H (engine)
Exhaust temperature
100% Load with radiator and fan (L/Hr)
Fuel Consumption 75% load with radiator and fan (L/Hr)
Tolerance as per ISO 3046
Make
Frame
Enclosure IP
Voltage regulation
Class of insulation
Maximum unbalanced load across phases
Alternator Rating (KVA)
Rating (kW)
Pitch
Full Load current (Amps)
Efficiency @ 100%
Efficiency @ 75%
Efficiency @ 50%
THD
Wave form distortion
DG Set Power Rating with fan @ 0.8 p.f.
Package
(KVA)
performance
DG Set Power Rating with fan (ekW)

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 Block Loading of Engine (%)
Time required to develop rated voltage &
frequency from the point of sensing power
failure
Time required to take full load from the point
of sensing power failure
Others Fuel tank capacity (L)
Length (mm)
Width (mm)
Acoustic enclosure
Height (mm)
Performance Guaranteed (dBA @ 1 mtr.)at 75
% Load
Sheet thickness
Insulation thickness
Density of insulation
Model
Make
AMF function
Digital synchronization & voltage matching
Digital AVR
AVR construction (SCR or FET)
List of engine protection features
Engine controller
List of alternator protection features
Modbus communication
Load sharing control
Load govern control
No. of programmable I/O’s
Sync check, with external output
Breaker control
Engine : 24 Months from the date of
Guarantee acceptance
Alternator: 24 Months from the date of
acceptance
Critical Parts such as Cylinder Head,
Camshaft, Crankshaft, Cylinder Block,
Connecting rod: 60 Months from the date of
acceptance

***********

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