Submission On or Before
Submission On or Before
CME(ES&CH)
BUDGETARY OFFER
FOR
DESIGN, SUPPLY, INSTALLATION, TESTING AND
COMISSIONING OF 100 KVA 100 KVA SILENT DG SET WITH
AMF PANEL COMBINED WITH L.T. SWITCHGEARS FOR
CHENNAI PORT AUTHORITY AT SIGNAL STATION
TECHNICAL SPECIFICATION
SCHEDULE - ‘A’
1.0 GENERAL:
Chennai Port Authority is proposed to install 100 KVA silent D/G Set with AMF panel
combined with L.T. switch gears for Chennai Port Authority at signal station
v) Supply and Laying of G.I. Flats. All the materials and accessories shall be
supplied and executed as per relevant IS Standard and IER by the contractor.
vii) The entire work shall be executed as per direction of Engineer – in – Charge.
Note: - The 100 KVA silent D/G Set with AMF panel shall be supplied along with
similar or above rating of test Certificate issued by CPRI / ERDA in the name of
the company. The supplier/contractor shall be submitted test certificate of Engine,
Alternator, MCCB, Battery, relays and metering, etc. The contractor shall obtain
necessary approval of the drawing of silent D/G Set with AMF panel, concrete
from Ch. P. A. before fabrication.
3.0 STANDARDS
The design, manufacturer supply and testing of the various equipment’s and accessories
covered in this specification shall comply as per relevant IS standards with latest
amendments.
4.0. TECHNICAL SPECIFICATIONS: -
4.1 TECHNICAL SPECIFICATION OF 100 KVA SILENT DG SET.
Robust, Compact, Fuel efficient Diesel Generator sets designed to operate under
arduous site conditions Latest Technology & Highly Reliable. Highly Engineered for
Optimized Power Solutions. can be connected to laptop / computer using RS485 port and
monitor all the engine performance related data. Better Fuel Consumption. Low
Running cost. Compact Foot Print. Easy access for maintenance
Detailed Technical Specification
Technical Data 100 kVA @ 1500 RPM
No. of cylinders and configuration In-line 6
Method of operation 4-stroke
Bore, mm (in.) 104 (4.094)
Stroke, mm (in.) 113 (4.448)
Displacement, ltrs. 5.76
Compression ratio 16.5 ± 0.5 : 1
Fuel Tank Capacity Ltr. 230
Coolant Capacity approx. Ltr. 20
Lube Oil Capacity 17.5
Water pump type Centrifugal
Engine RPM 1500
DG weight approx. 1874 kg
Performance
with fan, kW (hp) at: KW HP
Prime Power 94 126.01
Max Standby Power 103.4 138.66
Fuel system
Fuel consumption at Prime power g / kWh Lit / Hr
75% 226 17.5
Governing Electronic - A0 Class
Oil Change Period 600 Hours or 1 year or whichever is
earlier
Starting System / Battery 12 V / 88 AH / 90 AH
Charging alternator voltage / current 12 V / 35 Amps.
Starter Motor rated voltage (DC) 12
Safety Protection
Safety Protection HWT Yes
Safety Protection for Low lube oil pressure Yes
trip
Safety Protection for Over speed Trip Yes
Safety Protection for Low Fuel Level Yes
DG Size
Length (mm) 3100 Width
Width (mm) 1300
Height including base (mm) 1700
Alternator Specification
Voltage 380-440 Volt
Frequency 50 Hz
Current @ 0.8 P.F. 139.2 Amps
Type 4 P rotating field
Voltage Regulator Solid State
Insulation class H
Temperature Raise 125 Deg. C
Exciter type Brushless
Leads Qty./Type 6 , fixed 12 re-connectable
Coupling Flex disc closed coupled
Voltage regulation No load to full load 2 P sensing + or- 1%
One step load acceptance 100% of rating
Unbalanced load- capability 25% of rated current
DIESEL ENGINE: -
100 KVA silent DG Set’s is factory assemble pre-aligned and pre-tested ready to use.
The D/G set shall be capable of working at an ambient temperature between 0 Deg C to
50 Deg C with relative humidity up to 95% condition conforming to IS10001-1981&
BS5514. Which is a 4 Cylinder, 4 stroke in-line water cooled engine with max power
output of 126.01 BHP (94 KW) with electric start and designed to run at 1500 rpm
continuous on 100% load & also capable to take 10% overload for 1 hours out of 12
hours of operation. Complies with current CPCB II emission norms (as per GSR.448 (E) -
MoEF, Govt. of India) IS O3046/BS5514 IS-10002. Electric starting by DC self-starter
shall be provided. The engine shall be fitted with electronic governor. The engine and
alternator shall be directly coupled with self-alignment flexible flange coupling. The
coupling shall be provided with a protecting guard.
ENGINE AND BLOCK: -
Optimized cast Iron Cylinder block with optimum distribution of forces Drop Forged
Steel connecting Rods. Crankshaft hardened bearing surfaces and fillets for moderate
Load on main and big-end bearing. Keystone Top Compression rings for long service
life. Replaceable valve guide and valve seats. Life yelets SAE3 Flywheel Housing
and SAE10 Flywheel. Fixed Integrated Radiator.
LUBRICATION SYSTEM
Full flow disposable spin-on oil filter for extra high filtration. Rotary displacement oil
pump driven by the crankshaft. Deep rear oil sump Short oil dip stock at rear
Integrated full flow oil cooler, side mounted Oil Change Period 600hrs or 12 months
whichever is earlier
FUEL SYSTEM
SAPL rotary FIP Plunger type fuel feed pump. Five hole fuel Injection nozzles Spin
on type fuel filter for longer duration Electronic Governor -A0 Class
INTAKE AND EXHAUST SYSTEM
supply of suitable size Residential Type Exhaust Silencer, M.S. exhaust pipe length as
per site conditions and manufacturer standard including factory made bends, flanges,
nut, bolt and necessary supports and covered with laying of Glass wool and cladding with
aluminium sheet.
COOLING SYSTEM
Poly V Belt driven, maintenance free coolant pump with high degree of efficiency.
Efficient cooling with accurate cooling control through a water distribution duct in the
cylinder block. Reliable thermostat with minimum pressure drop. Aluminium/ Copper
Radiator with pusher fan.
ELECTRICAL SYSTEM
12V DC electrical system with digital control panel. Sensors for Oil Pressure and Water
Temperature. Start on solenoid mounted on fuel injection pump.
ALTERNATOR
100 KVA single bearing alternator suitable for operation at 1500 rpm, 0.8 pf (lag) suitable
for 50 Hz, 3 phase, 4 wire system, conforming to IP-23, BS 5000 / IS 4722.
BS2613/IS4722/IEC34 The Alternators are brushless type, screen protected, drip proof,
revolving field, self-excited, self-regulated through an AVR. Class –H insulation.
GENSET CONTROLLER
Genset Control Unit with Integrated E-Governor helps in reading all Genset Inputs and
controls the Genset.
Controls the engine Speed, high temperature of engine and coolant, Low lube oil
pressure, Alternator’s differential protection, short circuit protection, under/ over voltage
protection, D/G set and Alternator all measuring instruments shall be provided. Supports
Auto Mains Failure (AMF) Functions for 3 Phase Genset. Low Fuel Level Supports
Manual Control (MCP) Functions for 3 Ph Genset. Measures Genset Voltages and
Currents Measures Mains Supply Voltages and Currents. Measures electrical
Parameters like Frequency, Power Factor, Generator Power. Monitor critical engine
safety parameters. Starts / Stops the Genset. Have Counters for Genset Start / Stop,
Run Hours, KWh, Power Factor.
FUEL TANK: -
The tank shall have fuel level indicators marked in litres, filling inlet with removable
screen, fuel out let located at minimum of 25mm above the bottom of the fuel tank. drain
plug, air vent and necessary piping, hand pump for pumping the fuel into the service tank
with necessary pipe or tube shall be provided.
ACCOUSTIC ENCLOSURE
The enclosure consists of diesel engine, alternator, Battery and battery charger. The
acoustic enclosure is made of 1.6 mm thick CRCA steel sheets and C Type sheet metal
base frame of 3 mm thick CRCA Steel Sheet, painted in semen’s gray shade. The walls
of the enclosure are insulated with fire retardant foam so as to comply with the 75 dBA at
1mtr sound levels specified by CPCB. It should be sound proof, weather proof &
environment friendly, the finished sheet metal component shall undergo seven tank
treatment process. The D/G set enclosure shall be installed on concrete pedestal 300
mm above the surface level with anti-vibration pad. High quality rock wool of required
thickness. Provision of body earth at two ends.
4.2 AMF PANEL COMBINED WITH L.T. SWITCHGEAR:
This works includes Design, Fabrication, Supply, Installation Testing and commissioning of
AMF panel combined with L. T. switchgear. This panel shall be three phase, 415 Volt, 50
Hz, dust and vermin proof, metal enclosed, indoor floor mounted, free standing and weather
proof compartmentalized, Switchboard frame load bearing members shall be fabricated
using suitable mild steel structural section or pressed and shaped CRCA sheet of thickness
not less than 2 mm. Frame shall be enclosed in CRCA of thickness not less than 2 mm. The
AMF panel combined with L. T. switchgear shall be painted with two coats of zinc rich
primer paint and two coats of colour pigmented epoxy paint.
AMF panel combined with L. T. switchgear shall be of electrolytic grade copper bus bar of
400 Amps rating for three phases and neutral including colour code and PVC sleeve.
The density of current carrying of the bus bar not less than 120 Amps /cm2. All the bus bar
shall be supported on hylem / epoxy insulators. The Bakelite sheet of 12 mm thickness
(minimum) shall be provided in side enclosures of panel and wherever it is found necessary
under relevant IS specification & IER-1956 rules. The temperature raises of the bus bar,
contacts when carrying rated current shall not exceed 55 deg. Cover the ambient
temperature. Temperature rise while carrying maximum permissible current under site
ambient condition at all cables bottom of the entry and connection shall not exceed 20 deg.
C. The degree of protection required will be IP-42/52 conforming to IS 2147/12063. All
control wiring panel shall be done with 2.5 sq. mm copper conductor PVC insulated and
1100 volts’ grade. Suitable colour coding can be adopted. All ends shall be identified with
ferrules at the ends. powder coating and 7 tanks process. automatic operation on main
failure and as well as for manual operation
Switchboard shall be comprising of a completely enclosed bus bar compartment for running
horizontal and vertical bus bars. Completely enclosed switchgear compartment, one for
each circuit for housing circuit breaker, switch fuses etc. A compartment for meter and other
control devises associated with a circuit breaker. Switch board shall be easily extensible on
both sides by adding of vertical sections after removing the end cover.
All incomer feeder and all out going feeders shall be provided multifunctional meter
three phase LED indication lamp with control switch. The multi-function meters shall be
single digital type it consists of Amps, Volts, MD, KVA, KW, KWHr, KVAR, PF and
Frequency. 2 Nos. indicating lamps with fuses for ON and OFF indication.
The AMF panel combined with L. T. switchgear shall be supplied from CPRI/ERDA
laboratories approved authorized manufacturer. The AMF panel combined with L. T.
switchgear design shall be based on similar rating of CPRI/ERDA laboratories confirmed
panel and shall produce the test report (CPRI/ERDA) along with panel. The panel is to be
provided with suitable earthing terminal as well as 2 Nos. lifting lugs on top of panel
required. The wiring of the panel is to be provided with ferules, also two danger board /
sticker of LT Voltage in three languages English / Tamil / Hindi are to be provided on the
panel.
The D/G set shall be provided with automatic start within 30 seconds facility whenever
power interruption with full load. The D/G set shall be able to start Auto/ Manual mode.
AMF panel shall be physically segregated from Generator Control Panel/ Canopy for Gen
Sets Under voltage relay Overvoltage relay Earth fault Relay DC shunt trip Mains supply
voltage sensing relay Emergency stop push button
400 AMPS AMF PANEL COMBINED WITH L.T. SWITCHGEAR
AMF PANEL
The AMF panel consists of 400 Amps four pole, 50 KA, MCCB for incomer and outgoing
supply along with required relay and contactor.
SECTION-1
Incomer : 3 Nos.
Outgoing
400A, 4P, MCCB, 50 KA : 2 Nos.
250A, 4P, MCCB, 50 KA : 2 Nos.
100A, 4P, MCCB, 50 KA : 2 Nos.
Three incomers shall be Mechanically Inter Locked. To switched ON one MCCB at a time
CURRENT TRANSFORMER
The current transformers shall withstand stresses originating from short circuits. They
shall be mounted on the switchboard.
Incoming feeder 3 Nos. 600/5 Amps,
Outgoing
2 Nos. 400 / 5 Amps
2 Nos. 250 / 5 Amps
2 Nos. 100 / 5 Amps
SECTION-2
Incomer
400A, 4P, MCCB, 50 KA : 1 No.
Outgoing
250A, 4P, MCCB, 50 KA : 3 Nos.
100A, 4P, MCCB, 50 KA : 5 Nos.
63A, 4P, MCCB, 25 KA : 2 Nos.
CURRENT TRANSFORMER
The current transformers shall withstand stresses originating from short circuits. They
shall be mounted on the switchboard.
Incoming feeder 1 No. 400/5 Amps,
Outgoing 3 Nos. 250/5Amps
5 Nos. 100 / 5 Amps
4.3 100 KVAR APFC Capacitor Panel:
100 KVAR APFC capacitor bank shall be of automatic switching type with facilities for
manual control. The capacitor bank shall be equipped with Microprocessor based
intelligence version APFC relay with 3 phase CT sensing, Switch Fuse Units with HRC
fuses (feeder Control), Heavy duty contactors and metering equipment and controlling
banks of capacitor mounted in ventilated compartments with IP:54 protections with bottom
lowers. The switch units, contactors, etc. shall be selected to suitable for Capacitor ratings.
The APFC capacitor bank shall be connected the individual capacitor. All main bus bar
connection shall be of insulated tinned copper and link cable shall be copper. The
switching of capacitor bank by a re-strike free breaker shall not cause first peak of transient
over voltage not to exceed 2Ö2 times the applied voltage (rms) for maximum duration of
1/2 cycle and shall be suitable for performing 5000 switching operation/year under these
conditions.
LT capacitor bank shall be improving the power factor from 0.8 to 0.97 and above lagging.
The rated voltage of 3 phase capacitor bank shall be 415 V (Phase to Phase) and 230 V
(Phase to Ground). The capacitor offered shall be non-self-heating type, super heavy duty
long life MPP type conforming to IS 13585. Capacitors shall be suitable for operation at
rated voltage level and frequency plus harmonics. Capacitor modules shall be provided
with in-built fuses to isolate individual faulty units from the total bank. Capacitors are also
to be provided 0.2% series Reactor to limit the fault current or inrush current during
switching operations along with ON delay timer on individual feeder.
Capacitors bank shall be provided with directly connected discharge device suitable to
reduce the residual voltage from crest value of the rated voltage to 50 volts or less within 1
min after the same is disconnected from the supply.
Relay shall be suitable for operation at low load and current sensitivity shall be equivalent
to 1%. The capacitor bank should be provided 25 KVAr x 4 Nos. The APFC capacitor
bank control switch gear consists of 1 No. 100 amps MCCB as incomer and each
individual capacitor shall be provided 4 Nos 63 Amps MCB for 25 KVAr capacitor
along with MFM meter and three phase indication LED indication lamp. Each individual
6.0. LETTER PAINTING: -All incomer cables / all outgoing cables / P.T. & C.T. details shall
be painted in front and rear sides of the CSS / LT panel specifying the full details and
furnishing the amperage, voltage, size of the cable in the red letters on white back ground.
Should be written in both L.T. & H.T. panels.
7.0 TEST REPORT AND USER MANUAL: -
Routine test, acceptance test for Engine, Alternator shall be carried out as per standard
and manufacturer guidelines in presence of TPI and also submit the test report. The
contractor is also produced data sheet for Engine, Alternator and test report and data
sheet for Battery, AMF panel, Battery charger, shall be produced.
Engine Operational and maintenance manual, Engine parts catalogue, Alternator
Operational and maintenance manual, Installation Guideline of D/G set, Data sheet for
Engine, alternator, AMF panel, Battery, Battery Charger and produce test certificates
8.0 COMPLETON PERIOD: -
The entire work will be completed 180 days from the 7th day of issue of the order.
9.0 GENERAL TERMS AND CONDITIONS:
i) The Contractor shall inspect the site before quoting the offer to acquaint themselves to
know the constraints, works involved etc.
ii) The technical specification – “Schedule-A” and Price Schedule – A1” to be read in
conjunction to make sure of the supply and installation works and other works involved.
iii) The Contractor is required to offer rates as per Authority’s format “Schedule-A1”
without fail and mention taxes and duties.
iv) The Contracting firm shall not do any damage to the existing service / live of cables/
pipe lines/ RCC slab and if any damages happened on the above the actual charges
incurred for rectification to restore as normal shall be re-covered from the firm or it shall
be rectified by their own cost.
v) Necessary precautions shall be taken by the contractor or his labors while working
near the Road, Railway Track, Power supply cables, etc.
vi) Safety and safe custody of materials tools and plants that are required by the firm
during works, testing, commissioning and till handing over to the Authority shall entirely
be the responsibility of the Contractor.
vii) The Authority shall not be responsible for any damage or loss of any of the firm’s
men and materials and for any damage / accident to the firm’s personnel. Further, it is
mandatory to inform concern authorities in case of Accident.
viii) The loading, transporting and unloading of the D/G set and panels and other items
shall be the responsibility of the contractor and own cost.
ix) The contractor if required power supply for the work. Power supply will be provided
on payment basis as per Ch. P. A. norms.
x) The clarifications, if any and site inspection the firm may contact “S.E.(ES) / Dy.
CME(ES) at II floor of Old Administrative Office, Chennai Port AUTHORITY.
Telephone Nos. 25312428 /25312542.
Note: i) The rate quoted by the firm shall be inclusive of all Taxes and duties
excluding GST.
ii) The firm shall furnish the Tax invoice for GST separately as per GST Act/ Rules.