Technical Specification for 1x500 KVA Diesel Generator System for MCF Bhopal
1.SCOPE OF WORK.
Supply, Installation, Testing and Commissioning of 1No. 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 / ComplianceMake/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
Place: Ayodhya Nagar Bhopal. (MP)
Latitude: 22.3 deg N
Longitude: 77.3 deg E
Altitude:572 M MSL
Max temperature:48 Deg C
Minimum temperature:5 Deg C
3. GENERAL REQUIREMENT
ComplianceThe 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
ComplianceTo 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 furnishedby the bidder
CO / :to be furnishedby 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 / Compliance1 / General
The enclosure shall meet the stringent noise levels specified by the Ministry of Environment and Forest, GOI, as per notification no. 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
2 / Dimension
Shall be suitable for housing 500 kVA model engine with 625 kVA Alternator with adopter box for Differential CT mounting and terminations of Power Cables
To be furnished
3 / Construction
Outer Body & Doors– 1.6 mm thick (16 G) CRCA
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)
4 / The acoustic is composite in construction & is a fully assembled 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.
6 / The Acoustic enclosure parts will be powder coated after pre- treatment process. The powder coating shade shall be ‘GENSET 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
5.1BASE FRAME
ComplianceThe diesel engine & alternator shall be perfectly aligned & assembled on sturdily fabricated adequately machined integral base frame made out of high quality MS channels. The base frame shall be provided with lifting facility & predrilled foundation holes for installation on anti-vibration mounting (AVM pads).
- POWER COMMAND CONTROL UNIT
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 / ComplianceMake/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
7.1Accurate digital display of engine parameters
Digital Display of engine parameters / Compliance- Battery voltage
- Coolant temperature
- Lube oil pressure
- Engine speed
- Engine running hours
- Frequency
- Exhaust temperature
- AC Volts / Line to line & Line to Neutral
- AC Amps - 3 phase
- KW / KWH, PF and frequency
- %age governing and regulation (site settable)
7.2Diagnostic and engine protections
Diagnostic and engine protections / Compliance- High coolant temperature (trip/alarm)
- Over speed (trip/alarm)
- Low oil pressure (trip)
- Battery Over/Under/Weak Volts
- Fail to start/crank,
- Sensor failure
- Low coolant level (trip/alarm)
7.3Alternator protections
Alternator protections / Compliance- Over load / Over current / Short Circuit current
- Over and Under voltage
- Over and Under Frequency
- Earth Fault
- Reverse Power
- Loss of field/Excitation
7.4 FACILITIES
Facilities / Compliance- Manual Scan
- Remote start / stop
- Data link for communication with PC through an RS 232/485 port for data logging and monitoring
- Panel lights
- Emergency Stop Push Button
- 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
8STARTING
STARTING / ComplianceMode 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) / ComplianceTank 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 / Compliance1 / Engine model / KTAA19-G10 with PCC 3100 or upgraded ver. (Cummins)
2 / Rating at 0.8 p.f. 50 Hz / 500 kVA
3 / Engine RPM at rated Power / 1500 rpm
4 / Gross Engine BHP. / Suitable to deliver required alternator output of 400 KW
5 / Type of cooling / Radiator air cooled
6 / Specific Fuel consumption (units/ liter) / >4
7 / Alternator Make & Model / Stamford/cummins latest version 625 kVA rating to meet the 70% nonlinear loads. And suitable to parallel with existing Stamford 625kVA Alternator
8 / Power drawn from the Engine. / 500 kVA
9 / Typical Alternator Efficiency @ 100 % FL / >94.8
10 / Direction Of Rotation (SAE Std) FW end / Clockwise
11 / Aspiration Of Engine / Turbo charged after cooled
12 / Max. Over speed allowed (trip set at) RPM / 1600 to 1650 rpm
13 / Mechanical Efficiency of the Engine (%) / To be furnished
14 / Thermal Efficiency of the Engine (%) / To be furnished
15 / Reference Standard For the Engine. / BS5514 /ISO3046 or latest amendments
16 / Vibration level (With & without AVM) / Max 250 microns (amplitude)
EXHAUST SYSTEM.
17 / Exhaust system Back pressure ( kPa) / To be furnished
18 / Diameter of engine exhaust outlet (inside) / To be furnished
19 / Muffler / Silencer Restriction (Residential) Ps / To be furnished
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 @ normal temp. / No de-rating
33 / De-rating of the engine – Altitude @ 50 deg C (M) / No de-rating
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
39 / Combustion air inlet flow rate (+ / - 5%) M3/min / To be furnished
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
45 / Sump capacity (Low mark level) L / To be furnished
46 / Sump capacity (High mark level) H / To be furnished
47 / Oil temperature (Max) Deg. C / To be furnished
48 / Oil temp to be maintained when set at idle condition / To be furnished
49 / Crankcase ventilation type / Breather
50 / Oil cooler type / Plate
51 / STARTING SYSTEM / Electrical. 24V DC motor with starting battery arrangements
RADIATORS DETAILS / Compliance
52 / Type & Capacity / Blower fan
53 / Radiator Cooling Fan HP rating / To be furnished
54 / Discharge of the cooling fan CM/Hr / To be furnished
55 / Cooling system efficiency / High
56 / Coolant / Red concentrate (to be mixed with DM water)
Engine mounted water pump / Yes
INSTRUMENTATION & SAFETY FEATURES. / Compliance
57 / Fuel Shut off Solenoid (Type) / 24 DC
58 / Low Lube oil Shut off (+ / - 2 %) / Required
59 / High water temp. Warning (+ / - 2%) Deg C / Required
60 / High water temperature trip (+ / - 2%) Deg C / Required
61 / Engine Over speed trip (rpm 1770) at 52 Hz / Above 1650 rpm for 10 sec
62 / Engine low speed warning (Low frequency) at 47 Hz / Required
63 / Fuel pressure gauge / Optional
64 / Air Inlet Restriction (Vacuum) Indicator / Yes
Compliance
GOVERNING SYSTEM
65 / Type of Governor / Electronic / Digital
66 / Class Of Governor (A2 / A1) / Class A1
67 / Steady State speed Band of Regulation / To be furnished
68 / Droop (+ / - 1 %) / 0 – 4% adjustable
69 / Isochronous operation / Yes, required
70 / Transient Block Load Capability / 60%
71 / Temporary & Permanent Variation (BS5514) / As per BS5514
72 / Cyclic variation (cy / sec.) / To be furnished
ENGINE NOISE LEVEL DETAILS / Compliance
74 / Mechanical noise at rated load @ 1 Meter db (A) / 75 dBA out side enclosure
75 / Mechanical noise at rated load @ 7 Meter db (A) / To be furnished
76 / Exhaust Noise @ 1.5 Meter db (A) – 100 % Load / To be furnished
77 / Exhaust Noise @ 1.5 Meter db (A) – 50 % Load / To be furnished
STARTING SYSTEM
78 / Starter / 24V,DC
79 / Battery charger with built-in regulator / Yes
TRAINING & DOCUMENTS
80 / Training at works / factory site / For one person
(Free of cost)
81 / Detail spare part catalogues & Price list / Two sets / DG set
82 / Operation, Maintenance & Trouble shooting Manual / Two sets / DG set
83 / Original factory test reports for each Gen. Set / equipment. / Two sets / DG set
12. SPECIFICATIONS FOR ALTERNATOR
Sl.No / CHARACTERISTICS / TECHNICAL DATA / Compliance1 / Make / Stamford / Cummins
2 / Model / To suit our spec
3 / Type / Self-Regulating. Brushless PMG with digital PCC AVR
4 / Accessories / i) Space Heaters for alternator
ii) Winding & Bearing Temperature sensors with scanner
5 / Frame / 625 kVA to meet 70 % non linear load
6 / Rated continuous kVA
Rated kW at 0.8 PF (Lag) / 625 kVA
500 kW
7 / Speed / 1500 RPM
8 / Frequency / 50 Hz
9 / Rated Voltage / 415 Volts
Sl.No / CHARACTERISTICS / TECHNICAL DATA / Compliance
10 / Rated continuous load current / 870 Amps
11 / Efficiency at rated voltage & 0.8 PF
100 % Full load
75 % Full load
50 % Full load / > 94.8 %
> 94.5
> 94
12 / Power Factor / 0.8 PF (lagging)
13 / Connection diagram / Series Star
14 / Resistance in Ohms
Main Stator
Main Rotor
Exciter Stator
Exciter Rotor / To be furnished
15 / Number of Phases
Neutral / Three
YES, required
16 / Type of Enclosure / IP 23
17 / Governing specification / IS 4722 (1992) or latest amendments
18 / Over load capacity / 1 Hour in every 12 hour period with 110 % over load
19 / 150 % Over load capacity / 120 seconds
20 / Class of Insulation.
Main Stator
Main Rotor / Class H
Class H
21 / Type of Alternator AVR
AVR Voltage regulation.
Sensing.
To avoid over current excitation in the Field winding, when running at low speed.
External Voltage adjustment.
Single/Parallel operation
External potentiometer
Diode protection / PCC with AVR and PMG exciter
Better than + / - 0.5 %
Three phase
Under Frequency Roll off.
(UFRO)
+ / - 5 %
YES
YES
YES
23 / Voltage regulation from No load to Full load at PF from 0.8 Lag to Unity with 4 % Speed governing of engine / < 0.5 %
24 / Damper winding / Required
25 / Direction of Rotation / Clockwise from Drive end
26 / Bearing Detail / To be furnished
27 / Bearing lubrication / Self lubricated and sealed
28 / Waveform Distortion on No Load / Less than < 1.0 %
29 / Waveform Distortion on 100% Load / Less than < 5.0 % with 70 % nonlinear load
30 / RF / Telephone interference / < 1.5 %
31 / Quadrature Droop Kit & Setting / 5 %( Factory set) for kVAr sharing only (0 To – 6 %)
32 / Unbalance load / Max. 20 %
Sl.No / CHARACTERISTICS / TECHNICAL DATA / Compliance
33 / Transient Voltage Dip on FL / <10 %
34 / Short circuit withstands capacity.
3 – Phase short circuit.
2 – Phase Short circuit
1 – Phase short circuit / To be provided by the bidders.
35 / Excitation System protection
Filter Unit
DroopCT / Required
Required
Required
36 / Space Heaters / Required
37 / Bearing Temperature sensor & Scanner / Required
TEST CERTIFICATES REQUIRED FROM FACTORY (as per IS)
38 / Measurement of winding resistance / Cold condition
39 / Measurement of insulation resistance / Cold condition
40 / High Voltage test at power frequency / Cold condition
41 / Phase sequence test / Required
42 / Voltage balance / No load
43 / AVR adjustments & Performance / Under speed protection
Terminal voltage adjustment
External potentiometer adjustment.
Droop potentiometer setting
Over speed test
Excitation protection.
44 / Voltage regulation Test / YES
45 / Efficiency at Different Loads. / To be provided
46 / High Voltage test at power frequency / Hot condition
47 / Measurement of insulation resistance / Hot condition
48 / ACCEPTANCE TESTS AT SITE / Deliverables: Factory test Certificates supporting spec. will be verified
Type test / Heat run test: Certificate will be verified
Heat run test for continuous 24 hrs will be conducted on available system loads at MCF
All consumables such as fuel, coolant and lube oil will be provided by MCF. Supplier has to arrange for sufficient manpower for round the clock operation & conducting performance tests at MCF – Bhopal.
13. Earthing system
Earthing system / Compliance1. Copper Electrode Maintenance Free Earthing system for neutral as per IS: -Providing Two number of maintenance free copper electrode earthing with Dual pipe-Flat technology of electrode made up of 50 mm dia 3Mtr. long 2mm thick copper tube as outer shell and copper tube of 40mm dia 3Mtr. long 2 mm thick as inner shell and also with terminal flat of 32x6mm 3.1Mtr. Length copper flat with 2nos. of 12 mm dia holes for strip interconnections and the entire annual space of electrode shall be filled with highly conductive crystalline compound, top & bottom sealed with copper plate and also supply and providing of all other materials, necessary tools as required also providing suitable size earth pit including excavation and refilling of earth for installing this entire electrode in ground, including supply and filling of 50Kg. of Moisture Booster around the and filling of 50Kg. of Moisture Booster around the chamber including necessary civil works complete as required.
2. GI Electrode Maintenance Free Earthing system for body: -Providing Two number of maintenance free GI electrode Earthing with Dual pipe-Flat technology of electrode made up of 2Mtr long, 50 mm dia outer GI pipe, 25 mm dia inner GI pipe, terminal flat of 30 x 10/ 12 x 12mm, the entire construction processed with Hot Dip Galvanization, outer surface upto 100 microns, and all inner surface up to 300 microns and the flat with 2nos. of 12 mm dia holes for strip interconnections and the entire annual space of electrode shall be filled with highly conductive & non corrosive crystalline compound, top & bottom sealed and also supply and providing of all other materials, necessary tools as required also providing suitable size earth pit including excavation and refilling of earth for installing this entire electrode in ground, including supply and filling of 25Kg. of Moisture Booster around the electrode in the excavated pit and providing chamber including necessary civil works complete as required.
14. DESCRIPTION OF DG SET ACCESSORIES.
Sl.No / Item Description / Compliance1 / Filters-fuel, lube oil & by pass.
2 / Flywheel housing & flywheel
3 / Spider flexible coupling.
4 / Dry type air cleaners & vacuum indicators.
5 / Hospital silencer.
6 / Stainless steel exhaust flexible bellow
7 / Flameproof diesel transfer pump with flameproof motor with FP Starter
8 / 24V DC Battery charger
15. Spares
As per BOM
BOM as per Annexure
16. Submittals.
CompliancePreliminary 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
ComplianceSystem 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