1250kva DG Set

GAIL (India) Limited
TENDER
FOR 1250 kVA DG SET FOR
UPGRATION OF KANDLA - SAMAKHAILI LPG
PIPELINE
Bid No. 05/51/23KX/GAIL/006
MECON LIMITED

(A Govt. of India Undertaking)
A Navratna Company
NEW DELHI, INDIA
UPGRADATION OF KANDLA - SAMAKHAILI LPG

PIPELINE
BID DOCUMENT FOR PROCUREMENT
OF
1250 KVA DG SET
UNDER LIMITED DOMESTIC
COMPETITIVE BIDDING
E- Tender no. 8000000639
Bid Document No.: 05/51/23KX/GAIL/006

VOLUME II OF II
PREPARED AND ISSUED BY
MECON LIMITED
(A Govt. of India Undertaking)
Delhi, India
TENDER
PIPELINE
MECON LIMITED
MATERIAL REQUISTION
AND
TECHNICAL SPECIFICATION
TENDER FOR
1250 kVA DG SET FOR
UPGRADATION OF KANDLA SAMAKHIALI
LPG PIPELINE
MECON LIMITED
MATERIAL REQUISITION
FOR
1250 kVA DG SET
MR NO.: MEC/23KX/05/21/M/001/S006
Rev.
0
Date
20.08.2008
Prepared by
Checked by
Approved by
(Vijay Singh)
DGM
(A.K. Johri)
DGM
(K.K. De)
DGM I/C
D:\old data\Vijyant\Kandla-Samakhiali\Tender\DG Set\MR for dg set- Kandla.doc
DOC. NO.:MEC/23KX/05/21/M/001/S006
Page 2 of 4
TENDER FOR
1250 kVA DG SET FOR
LPG PIPELINE
MECON LIMITED
GENERAL:
GAIL (India) Limited intend to augment the capacity of its existing Kandla to
Samakhiali Pipeline Section from existing 0.5 MMTPA to 1.5 MMTPA to transport
LPG from Kandla Despatch Terminal (DT) to IPs, Samakhiali wherein it is being
projected in the suction line of Samakhiali Booster Pumps and fed into Jamnagar
Loni Pipeline (JLPL) to meet the demand of LPG bottling plants enroute JLPL.
Augmentation of Kandla Samakhiali section to 1.5 MMTPA will be met through
modification of existing Kandla Despatch Terminal. In case of grid power failure
electric power will be met from the proposed one no 1250 kVA DG set.
PROJECT
ITEM
BID NO.
CLIENT
:
:
:
:
UPGRADATION OF KANDLA - SAMAKHIALI LPG PIPELINE

1250 kVA DG set
05/51/23KX/GAIL/006
DESCRIPTION
UNIT
QTY
Destination
Design, engineering, manufacturing testing and

delivery at Kandla site, insurance, painting ,etc of
1250kVA DG set along with its associated
accessories, AMF control Panel, battery for
starting, battery charger, acoustic enclosure,
foundation bolts/AVM, base plates, fuel oil tank,
cabling, piping, exhaust pipe, chimney ,
insulation, supporting structure, first fill of
lubricants & consumables including fuel oil,
erection & commissioning spares, spl. tools /
tackles etc. complete as per Material Requisition
No. MEC/23KX/05/21/M/001/S006 and Technical
Attachment thereon, under Section-VII of Vol.-II
of II of Bid Document.
Mandatory Spares as listed in Technical
Attachments to Material Requisition (Item-wise
prices of Mandatory Spares to be made available
in Format-IA attached. Bidder to ensure that the
total of price break-up matches with the lump
sum prices stated herein).
Training of Purchaser's Personnel at Bidder's /
Sub-vendor's Works and / or at such Sites where
similar pumps as supplied by the Bidder are in
operation. Quoted price shall exclude all
personal / incidental expenses of the personnel
deputed by the Purchaser.
Nos.
Kandla
lot
Kandla
Nos.
Kandla
DOC. NO.:MEC/23KX/05/21/M/001/S006
Page 3 of 4
TENDER FOR
1250 kVA DG SET FOR
LPG PIPELINE
MECON LIMITED
DESCRIPTION
UNIT
QTY
Destination
Erection / Installation & Commissioning including

unloading at site, storage, watch ward , handling
and shifting at site & from storage, putting on
foundation, grouting, fabrication of structure for
supports, fabrication & erection of chimney,
laying of pipes & insulation, consumables,
arranging cranes/ tools/tackles, insurance, site
supervision as per installation & commissioning
manual
Recommended Spares for two years normal
operations & maintenance over and above as
indicated in mandatory spare parts shall be
quoted as per Format-IB attached.
Nos.
Kandla
lot
Kandla
DOC. NO.:MEC/23KX/05/21/M/001/S006
Page 4 of 4
TENDER FOR
1250 kVA DG SET FOR
LPG PIPELINE
MECON LIMITED
OF 1250 KVA DG SET
D:\old data\Vijyant\Kandla-Samakhiali\Tender\DG Set\Cover TS - DG Set.doc
TENDER - 1250 kVA DG SET

FOR
KANDLA SAMAKHIALI LPG PIPELINE
TS No. MEC/TS/05/21/006, Rev-0
MECON LIMITED
CONTENTS
Sl. No
Description
1.0
Special instructions to the Tenderer
2.0
Scope of work
3.0
Technical Specification
4.0
5.0
6.0
Quality assurance, inspection & testing, performance guarantee.
Erection, Testing and Commissioning

Mandatory spares parts for DG Set
7.0
Documents to be submitted
8.0
Data sheets
9.0
Technical check list (mechanical / engine)
10.0
Deviations to the specification
SECTION-VII Page 1 of 50
2006 MECON Limited All rights reserved
Tenderers Signature with Seal
Date:
MEC/05/51/23KX GAIL/006

FOR
MECON LIMITED
1.0
SPECIAL INSTRUCTION TO TENDERER
1.1
This specification shall be read in conjunction with the following documents.

General condition of contract & special condition of contract
1.2
Applicable codes and standards

The material used and the equipment supplied shall be new and the best of their
respective kinds and shall comply with the new latest revision of relevant Indian
Standards specification / relevant International standards. The equipment shall also
comply with the statutory requirements of Government of India, state government
and the latest revisions of Indian Electricity rules. The copies of the relevant
standards and regulations to which the equipment
1.3
Accessibility and safety
1.3.1
All equipment offered shall allow adequate access to facilitate maintenance and
repair.
1.3.2
All moving parts of the equipment shall be well guarded and protected for the
operators and maintenance personnel safety.
1.4
System of units
Metric system of units shall be followed in design and manufacture of all equipment
as well as drawing documents. Name plates of equipment as well as operating I
maintenance instruction shall be in English language.
1.5
The owner I consultant reserve right to accept or reject the tender partly or fully
without assigning any reason. The quantities of each item indicated are tentative
and are subject to change. Unit rates be quoted to take care of changes in
requirements.
1.6
The tender shall be complete in all respects including data sheets duly filled without
leaving any items.
1.7
Each equipment shall be equipped with suitable lifting facilities to facilitate erection
and maintenance.
1.8
The detailed bar chart showing various activities shall be prepared by the tenderer.
The work shall be executed as per the agreed time schedule.
1.9
Monthly I weekly construction programme can be made by the contractor and

engineer in-charge jointly based on availability of work fronts and the construction
Date:
MEC/05/51/23KX GAIL/006

FOR
MECON LIMITED
programme.
1.10
Contractor shall submit every day report on progress of work carried out on
previous day and for each category of work.
2.0
SCOPE OF WORK
Following shall be the scope of work:
2.1
Design, engineering, manufacturing, shop assembly, testing and

A) SUPPLY:
delivery at Kandla site, storage, conducting performance test at Kandla site of
GAIL-KSLP Terminal project and final painting of all the equipment of DG set along
with its associated accessories, AMF control Panel and acoustic enclosure, supply
of foundation bolts, base plates, supporting brackets etc. for the D. G. set including
first fill of lubricants & consumables including fuel oil for testing at works and site
and commissioning till performance guarantee test and Handing over.
B) ERECTION & COMMISSIONING: Grouting of equipments including cement
and supply of grouting material, transportation to the place of erection from store,
erection, testing and commissioning of DG set and associated items under scope
of supply. Construction of civil foundation shall be arranged by purchaser.
2.2.1
Inspection of the equipment by the owner / consultant at the manufacturers works

and performance testing of the equipment by the supplier in presence of owner /
consultant at manufacturers works and at site are included.
2.2.2
Unloading at site, watchward, handling and shifting , erecting on civil foundation

is in the scope of supplier. Necessary Crane required shall be arranged by
supplier. The tenderer shall include in his scope all plant, machinery, material, all
accessories and auxiliaries, measuring and control equipments, all necessary
interconnecting pipes and pipe fittings, wiring conduits of instrument / sensors
upto terminal box mounted on equipment, safety devices and material which are
not specially mentioned but are required to complete the equipment offered in
every respect for its satisfactory operation. Equipment insurance during transient, ,
erection and commissioning is in the scope of supplier.
2.3
The technological equipment involved are broadly as follows:

-
The D.G unit shall comprise of Engine, Synchronous generator complete

with brushless type excitation system, AVR, DG AMF Control Panel. The
generator set shall be complete with all controls, protection, indication,
connections, wiring, auxiliary systems for satisfactory operation. The DG set
will be started automatically in case of grid power failure. There will be
provision to start the DG set manually.
Date:
MEC/05/51/23KX GAIL/006

FOR
-
MECON LIMITED
The output rating of DG set shall be as specified in SOR/Data Sheet, at 0.8

PF, at place of installation (Kandla), referred at alternator terminals.
-
The four stroke water cooled direct coupled engine shall be capable of driving
continuously the generator to give an output of specified kVA at its alternator
terminals, its rated speed, under site condition indicated in design criteria.
Diesel engine shall be rated in accordance with BS- 5514 / ISO- 3046/1.
Engine governor shall be capable of maintaining speed within the specified limit
as per BS 5514 part 4 class A1.
Air Filter, Air Intake Manifold
Radiator type cooling system, Coolant Additive Concentrate (CAC) first fill,
Corrosion resister, Centrifugal Water Pump, Cooling water pipes from radiator
to engine
Fuel oil system with day tank (990 liters capacity) for the D.G. Set & additional
fuel piping along with filters etc.
Radiator type cooling system, Coolant Additive Concentrate (CAC) first fill,
Corrosion resister, Centrifugal Water Pump, Cooling water pipes from radiator
to engine
The engine shall be forced lubricated by shaft driven pump complete with
filters, strainers, cooler and sump of sufficient capacity for 24 hrs of
operation.
Anti-vibration pads for the set.
Engine starting system with lead acid batteries for the D.G. Set including
battery stand & battery charger.
Complete exhaust system including residential type silencer, spark arrester

, Flexible bellow for Silencer, exhaust pipe as per pollution control board
requirement, Clamps/nut/bolts for silencer, Insulation for exhaust system ,
Structural supports for silencer, Structural supports for exhaust , pipe,
Painting on exhaust pipe ( high temp paint ), Painting on structural work,
Flanges, nut, bolts and gaskets
All power & control within DG set skids including all auxiliaries shall be in
vendors scope. All power and control cabling/wiring within AMF panel shall
be in vendors scope. All power and control between alternator terminal and
AMF panel shall be in vendors scope.
Owner shall supply power and control cables from owners 415 V
switchboard to AMF panel
Date:
MEC/05/51/23KX GAIL/006
10

FOR
2.4
MECON LIMITED
Coupling & guards.
Local instrument gauge panel with Starting Key, Tachometer with hour
Meter, Water Temp. Gauge, Lub Oil Pressure Gauge, Battery charging
ammeter, Lub Oil Temperature Gauge
Complete instrumentation, controls & control panel.
All necessary interconnecting pipe works and valves.
Special tools and tackles for maintenance.
Drawing /documents /manuals /other data
Acoustic enclosure for the DG set in open execution.
Commissioning spares & supply of spares for 2 years operation.
Minor civil works like grouting chipping, making holes, Civil works for
earthing & cable laying etc. Construction of fencing, with gates, around the
DG set installation with required clearances.
Surface coating & final painting of complete system,
All the protection, monitoring and recording equipment.
All statutory approvals.
First fill of all consumables.
Fuel oil required during commissioning and PG test.
PAINTING, PACKING AND TRANSPORT
2.4.1
Equipment shall be painted with two coats of epoxy based primer followed by two
final coats of epoxy based paint. Sheet metal work shall be subjected to degreasing,
pickling, and phosphating prior to painting. Exhaust pipe shall be painted with high
temp paint.
2.4..2
The equipment shall be shipped to site suitably packed to prevent any damage.
Each package shall have labels to show purchasers name, purchase order and
equipment no. suitable lifting lugs etc. shall be provided and lifting points shall to
clearly marked on the package. Packing shall be suitable for storage at site for a
minimum period of 6 months.
Date:
MEC/05/51/23KX GAIL/006
11

FOR
2.5
MECON LIMITED
Exclusions
The following works are excluded from your scope of work
2.6
a)
Major Civil works.
b)
Illumination / Area lighting
Battery limits
a)
Inlet to combustion air intake system.
b)
Outlet of the exhaust system above acoustic enclosure above DG building

as per pollution control norms.
c)
Inlet of additional fuel filling system.
d)
All power & control within DG set skids including all auxiliaries shall be in
vendors scope. All power and control cabling/wiring within AMF panel shall
be in vendors scope. All power and control between alternator terminal and
AMF panel shall be in vendors scope.
Owner shall supply power and control cables from owners 415 V
switchboard to AMF panel
e)
Inlet of fuel filling system.
3.0
3.1
The D.G. Set shall meet the following operating conditions.

a)
Self excited, self regulated excitation system along with fast response
governor shall ensure that the set dependably comes to full speed and
delivers rated output at 415 V, 50 Hz within 15 seconds after getting the
starting signal.
b)
Under steady state condition, the electronic voltage regulator shall keep the
voltage constant within 0.5 % of the rated voltage with full load at constant
speed (with power factor varying between 0.8 lag to unity). Further adjusting
the set voltage upto 5% of rated voltage shall be possible by the
potentiometer provided for the purpose.
c)
Under transient operating condition, the time of return to within 3% of

steady state voltage when permitted step down load is suddenly applied
Date:
MEC/05/51/23KX GAIL/006
12

FOR
MECON LIMITED
shall be less than one second (assuming speed to be constant). Further the
speed drop due to such loading shall be corrected to ensure 50 Hz 1% Hz
within less than 3 seconds (momentary fluctuation in frequency shall be less
than 1 Hz). Governing system shall ensure minimum fluctuation during
load changes. Inertia constant of the rotating system shall aid the governing
system. Class A1 governing system preferably using wood ward PSG
governor shall be offered. Speed drop shall be continuously adjustable.
d)
e)
D G set shall meet the starting requirement of induction motors with VFD
drive (one no.450 kW and one no. 200KW rating) that can be started with
base loads 0%, 25%, 50%, 75% under following conditions:
i.
Current not to exceed 2 times the rated current of the Alternator for
15 seconds.
ii.
Step load BHP prime mover engine can take (transient voltage dip
for above conditions shall be furnished).
iii.
Transient voltage dip limited to 20 %
Machine shall develop symmetrical balanced sine wave voltage.

Irregularities in waveform shall not cause objectionable interference to other
adjacent circuits. Total harmonic factor (THF) as found by type tests shall
be less than 5% (per IS 4722).
3.1.2
Mode of operation (For DG set)
3.1.2.1
The control system shall be suitable for unattended operation. The control system
shall operate in fail safe mode and shall include all controls and protection
necessary for the safe operation of the package. The generator set shall function
as per the following schemes:
3.1.2.2
Auto main failure scheme (AMF)
Manual start in service mode
Manual test mode
Automatic main failure scheme

This shall be effective in Auto position of Auto/manual selection switch located in
local control panel. The generator set shall normally be at rest. Upon failure of
plant normal supply, an impulse shall be extended from purchasers equipment.
Upon receipt of this impulse, generator set shall be started automatically and
Date:
MEC/05/51/23KX GAIL/006
13

FOR
MECON LIMITED
brought to rated speed and generator voltage brought to rated value. All
accessories required for starting and completion of various sequence of operation
for the above purpose shall be provided. Provision for the synchronization with
existing/future D.G. Sets shall be provided.
Immediately after the generator sets reach rated speed and rated voltage, voltage
and frequency monitoring relays located in control panel shall extend an impulse
for closing generator breakers as per desired / selected priority / sequence.
3.1.2.3
Manual start in service mode

This shall be effective in manual position of Auto/manual switch and service
position of service/ test selector switch located in control panel. The scheme of
operation shall be same as of auto mode above except that starting impulse shall
be extended manually through the push button either in local control panel or
purchasers control panel. The synchronization between D.G. Sets shall be done
manually. The closing of Generator breakers shall also be manual.
3.1.2.4
Manual test mode

This shall be effective in test position of service/ test selector switch. The scheme
of operation shall be same as that of manual start in service mode above except
that the closing impulse for generator breaker shall not be extended automatically.
3.1.2.5
Stop
Stopping of the generator set in all cases for a normal shut down shall only be done
manually by means of push button in either local control panel or purchasers
remote panel.
3.1.2.6
Starting time
The total time from the receipt of the starting impulse for the generator set till the
set reaches rated speed and generator reaches rated voltage shall not be more
than 30 seconds. If this time is exceeded, an annunciation in the local control
panel shall be provided with a facility for repeat annunciation in purchasers panel.
3.1.2.7
Black start facility

The generating unit shall be provided with all necessary `black start facilities.
External power at 415 V TPN shall be made available by purchaser at one point
only for any equipment operation during stand-still period of generator sets. This
power shall not be available during start-up of the generator sets. All D.C. supplies
and charger including batteries for start-up of prime mover where applicable shall
be supplied along with the generator sets unless otherwise agreed. 415 V AC
Date:
MEC/05/51/23KX GAIL/006
14

FOR
MECON LIMITED
power distribution board for auxiliaries shall be supplied along with the generator
sets.
All auxiliary motors shall be three phase, 415 V, 50 Hz squirrel cage type suitable
for DOL starting or DC motor operating at 110 V or 24V. Insulation class shall be
`H. All motors shall have IP-55 enclosure.
3.2
Design Criteria
3.2.1
All equipment shall be designed to operate on the following site conditions &
system.
Kandla
Location
0
Ambient
0-50 C
RH
Climate
95% max.
Tropical normal corrosion
soil
220m
Altitude from MSL
Both maximum temperature & maximum R.H. occurs simultaneously shall be

considered for design purpose.
3.2.2
Power supply system

Mains
:
Voltage
: 415 V 10%, 3Phase & Neutral
Frequency
: 50 Hz5%
Combined variation of : 10%
voltage & frequency
System Neutral
: Solidly grounded
Insulation level
: 2.5 kV for 1 minute
System SC Level
: 50 kA for 1 second.
Control voltage
: 110 V AC single phases, 50 Hz through
Control transformer of PMCC.
DG Set
Voltage
Battery volts
: 415 V, 50 Hz (Ref. Technical specification)

: 24 V DC
For details of single line diagram of DG Set refer drawing no.

MEC/23KX/05/E9/SLD/002, R-0 (Sheet 1 of 2) AND MEC/SD/05/E9/006/001, R-0.
Date:
MEC/05/51/23KX GAIL/006
15

FOR
3.2.3
MECON LIMITED
The basic data for the engine are given below:

a)
Rating
b)
Duty
c)
d)
e)
Ref. Std.
RPM
Cooling
system
Lubrication
system
Fuel
Starting
Nature of
load
f)
g)
h)
i)
3.3
: To suit kVA specified in SOR/Data Sheet.

Generator at 0.8 P.F (Equipment selected shall be
suitable for base load application.)
: Out put specified shall be on continuous basis (24
hours) operation per day under the site conditions
specified. Further the engine shall be capable of
providing an output of 10% in excess of the rated
output at the same speed for one hour in any
period of 12 hour running.
: BS 5514 / ISO-3046/1
: 1500
: Radiator type cooling system
: Forced lubrication
: High speed diesel
: Battery starting
: For process pumps (with solid state soft starters
and VFD) loads and if necessary, illumination loads
also.
Diesel Engine And Accessories

The engine shall be suitable for industrial use and arranged for cold starting,
mechanical injection, 4 stroke, compression ignition and closed circuit water
cooled. Diesel engine prime mover to drive the alternator shall be supplied with all
standard accessories. Rating of the diesel engine shall be decided based on the
site conditions & for base application as given in this document. The engine should
be capable of delivering rated output continuously (24 hours of operation) under the
site condition specified. Further, the engine shall be capable of satisfactorily
providing an output 10 % in excess of the rated output at the same speed for one
hour in 12 hours continuous running.
The engine speed shall be maximum 1500 rpm at 50 Hz. The engine shall be
designed to reach operating speed and full load capability within 15 sec after
receiving a start signal. The engine shall run steadily at any load to full load with in
its rated load. Automatic speed governing systems shall be provided using wood
ward/PSG governor /electronic governor. Governor shall have a droop adjustable
from 0 to 4% of rated speed. Engine shall have 120% over speed withstanding
capability and over speed trip shall be set a 115% speed. The fuel for the engine
shall be High speed diesel as per IS: 1460-1974.
Date:
MEC/05/51/23KX GAIL/006
16

FOR
3.4
MECON LIMITED
Fuel System for the DG Set.

a)
Day oil tank

The capacity of day tank shall be 990 Ltrs. It shall be provided with level
gauge calibrated in Ltrs. For easy filling in & cleaning openings, drain valve
shall be provided. The oil tank be mounted on a self supported base frame.
Fuel supply & return pipes / hoses from the tank to engine and back shall
be supplied. Staging of oil tank if required shall be provided to meet engine
requirement. Alarm for low oil level shall be provided. The tank shall be
designed as per IS: 803 & shall be provided with manhole, drain, earthing,
high level & low level switches, etc. At Low-low level the engine shall trip. At
high level alarm the existing fuel transfer pump shall trip. The day oil tank
shall be filled by existing fuel oil transfer pump. A tapping from the nearby
fuel header shall be taken for filling up the day oil tank.Necessary pipes (
about 15 m) isolation valves, hoses, fitting as required shall be included in
your the scope.
b)
Filter
A filter of suitable type & capacity to supply fuel oil at rated output (Duplex
filter preferred)
3.5
c)
Fuel pump engine driven
d)
Fuel injection and control system for compression ignition.
Lubrication System
Lubrication system shall include replaceable, suitable type full flow oil filter and
automatic lube oil temperature control.
The lubrication system shall be self contained with the following equipment.
a)
Sump: To store sufficient oil for circulation, sump of sufficient capacity for
24 hours continuous operation.
b)
Pump: Shaft driven pump for forced lubrication.
c)
Filters & strainers: Filter shall be replaceable while engine is in operation.
d)
Lubricating oil cooler (if required)
e)
Interconnecting piping.
Date:
MEC/05/51/23KX GAIL/006
17

FOR
3.6
MECON LIMITED
Air Intake
The air intake shall be ensure sufficient clean air to the engine. It shall
incorporate the following.
a)
b)
Suction filter
Turbo -charger
:
:
To supply clean air to the engine.

The engine shall be provided with a
Turbocharger after cooler.
3.7
Exhaust System
3.7.1
The hot exhaust gases shall be let off with suitable exhaust system. All the hot
parts located shall be insulated. The exhaust system shall include:
a)
Exhaust
manifold
Spark
arrestor
Silencer
Shall be air cooled type
Required. To be provided by tenderer.
d)
Expansion
joint
The exhaust gases shall be let off through

residential type silencer to keep noise level to 75 dB
(A) from 1M from the enclosure
A flexible expansion joint shall be provided for
connecting the exhaust manifold to the silencer.
e)
Exhaust pipe
f)
Insulation
b)
c)
Exhaust pipe and chimney with flanges, nut, bolts,

cowl shall be provided to meet pollution control
norms.
Insulation for exhaust pipe with 0.6 mm with
aluminum cladding with leak proof lapping joints for
piping & silencer. The silencer and all indoor portion
of exhaust duct shall be insulated to maintain a
surface temperature not to exceed 700C
3.7.2
Structural work
3.7.2.1
Scope of supply and work

This Scope of work shall include but not limited to the following:
Design, Preparation of design drawings, Approval of Design & drawings, detailing,
supply, fabrication ,erection and painting of exhaust pipe including its supporting
steel structure. The design of exhaust pipe proper shall be in accordance with
technological requirement as well as structural strength stability and safety
Date:
MEC/05/51/23KX GAIL/006
18

FOR
MECON LIMITED
The steel structures shall broadly be designed to support the Exhaust pipe, The
Structure may consist of Column & Column bracing, cat ladders with caging,
landing platform and handrails
Intermediate landing shall be provided to cat ladders at an interval not more
than 5.0m
3.7.2.2
Design of structural element shall conform the following

a.
The primary load cases & load combinations on the structures as per relevant IS Code
b.
Modeling of structural 2D/3D frame & analysis using software STAAD-PRO.
c.
Design of main structural members as per STAAD-PRO/ manual calculations and

structural design of all other secondary members bracing system, base plate &
stiffeners, anchor bolts, and any other component of the structure
d.
3.7.2.3
Design of Foundation for above structure
Preparation and submission of hard & soft copies of Design calculations & drawings
for approval of the Purchaser.
f.
Preparation and submission of design calculations for typical connection details etc.
for approval of the Purchaser.
Design Basis & Considerations for Structures
Structural members shall be designed such that they are economical and safe and
meet the functional and service requirement of the technological process for which
they are designed.
a) All dead loads shall be considered in accordance with IS: 875
(Part-1) -1987.
b) All live loads shall be considered in accordance with IS: 875
(Part-2)-1987. (Also refer clause 4.04)
c) Wind loads shall be in accordance with IS: 875(Part-3)-1987
and any other consideration specific to the site.
d) Seismic loads shall be in accordance with IS: 1893 2002.
e)
In absence of any suitable provision for design loads, any
other recognized code of practice may be followed
f)
Design of steel structures shall be done in accordance with
IS: 800-1984.
g) The fabrication and erection of steel structure shall be in
accordance with IS: 800 1984
Date:
MEC/05/51/23KX GAIL/006
19

FOR
3.7.2.4
MECON LIMITED
Material specification for steel structures:

a) All rolled sections and plates shall conform to Grade A as per
IS :2062-1992 , IS:8500-1991
b) Mild Steel sheets shall conform to IS 1079:1988
c) All anchor bolts shall conform to IS : 2062-1992
d) Reinforcement Bars shall be Fe-415,GR-I Conform to IS:1786
e) RCC shall be M-25 & PCC of grade M-10
3.7.2.5
Painting system for Structural

The recommended paint systems for general service requirement of steel
structures application of primer coats, intermediate coats and final coats to develop
the required minimum dry film thickness on steel surface is as below
Surface preparation: Sa-2 according to Swedish Standard SIS055900.
Primer paint: Two coats of chlorinated rubber based zinc phosphate (DFT 35
/coat)
Intermediate paint: One coat of chlorinated rubber based MIO (DFT 75).
Finishing paint: Two coats of chlorinated rubber based paint with suitable
pigments(DFT 30/coat
3.8
Acoustic Enclosure
Suitable acoustic enclosure / insulation shall be provided for maintaining the sound
level. Outer Noise level should be below 75db (A) @ 1 Metre under Free field
condition. Clearance from Central Pollution Control Board (CPCB) should be
obtained and submitted. High quality Fire Resistant insulation material (IS 8183) for
maximum sound absorption should be used. Heat resistant Neoprene Gasket
should be provided for perfect noise and weather scaling. This enclosure shall
conform the requirement of the pollution control norms of respective locations.
Lighting arrangement inside the enclosure shall be done. The thickness of sheet
steel shall not be less than 2mm. Enclosure should be forced ventilated to maintain
acceptable temperature and must provide sufficient air for engine breathing and
cooling
3.9
Engine Cooling System

Shall consist of a closed, pressurised cooling water circuit including circulation
pump, cooling fan, radiator etc. The circulation water pump and cooling fan shall be
powered from the engine crankshaft. The cooling fan shall draw air over the engine
and discharge through the radiator.
Date:
MEC/05/51/23KX GAIL/006
20

FOR
3.10
MECON LIMITED
AC Generators and Accessories

(REF. STANDARD IS- 4722, BS-2613, VDE- 0530)
3.10.1
AC Generators shall have following constructional features:

a)
The alternator shall be revolving field, salient pole, brushless type, screen
protected drip proof sheet steel enclosure conforming to IP-23 degree of
protection as per IS 4691 (Terminal Box shall conform to IP 55). Generator
set is intended for outdoor installation & with acoustic enclosure.
b)
Laminated low loss silicon steel stator core with copper winding in class H
insulation firmly wedged in slots and braced to withstand mechanical forces,
high vibration impact stresses etc. Temperature rise limited to that for Class
F insulation.
c)
Laminated core salient poles within copper field coils (class H insulation)
firmly assembled on rotor, dynamically (balanced over the entire operating
speed range including over speed due to prime mover) to operate with
minimum vibration and provided with damping cage winding on pole shoes.
Temperature rise limited to that for Class F insulation.
d)
Exciter and pilot exciter assembled with integral with the main machine to
provide self excited, self regulated brushless excitation system, with class H
insulation. The excitation system shall comprise of excitation equipment,
automatic voltage regulator, voltage adjustor, AVR voltage failure release
(alarm). Temperature rise limited to that for Class F insulation.
e)
Fast response electronic voltage regulator mounted on the machine.
f)
Suitable terminal box with double compression type cable glands and tinned
copper lugs for terminating multiple (8-10) runs of 3.5 x 300 mm PVC
insulated armoured Cu/Al cables and shall be located on the free end or
side of the machine. Top terminal Box shall be provided.
g)
A neutral point terminal box with protection class current transformer

mounted on neutral side of the stator winding. CT shall have suitable VA and
ratio rating, with 5A / 1A secondary current rating (depending on the type of
earth-fault relay to be supplied) conforming to IS 2705. Neutral terminal box
shall be liberally dimensioned for easy accessibility to C.T and provided with
proper cable glands for power and control cabling.
h)
Embedded Thermisters in stator winding, bearing temperature detectors,

space heater shall be wired to separate terminal boxes (Thermister relay
shall be mounted in DG control panel).
Date:
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FOR
MECON LIMITED
i)
Ball and roller shall have re-greasing facility by grease gun, inherently
protected against over greasing, with seals to prevent in-grease of grease
into the machine winding. Bearing shall be anti-friction type.
j)
Pretreatment and painting to provide neat durable finish, preferably

conforming to shade 21 of IS 5.
k)
Self cooling air circulation by fans mounted on rotor.
l)
Name plate details as per clause 18.1 and 18.2.2 of IS 4722.
m)
The alternator and its excitation system shall be designed to withstand a

10% overload for 1 hour at rated voltage, speed and power factor without a
harmful temperature rise and to withstand a 200% over current for 15 sec at
rated load excitation.
n)
3.10.2
A)
The alternator and its excitation system shall be designed to

overspeed of 120%.
withstand
Data Sheet For Alternator

Alternator
Continuous rating (S1 duty :
as per IS: 4722-1922)
a)
Output
:
b)
Type of Alternator
c)
Mounting
d)
e)
Excitation
Voltage
:
:
f)
Insulation
g)
h)
Space heaters
Heater with controls
:
:
For KVA (As specified in SOR) At 0.8 PF at

specified site conditions (Base duty)
415 V, 3 phase, 4 wire 50 Hz AC.
Self contained, self excited and self regulated
along with fast response for electronic
governor.
Screen protected, drip enclosure proof, self
ventilated with removable covers to provide
easy access to excitation unit, enclosure IP23
(Terminal box in IP 55 enclosure)
Horizontal, foot mounted with end shield
bearings.
Static excitation unit mounted in alternator
Automatic self regulated regulation with 0.5%
of nominal rated voltage.
From no load to full load @ 0.8 PF for both
cold & hot conditions
Class H, tropicalised. However temp. rise to
class F
To prevent condensation, rated 415V
Required for starting / operation at 0o C as per
site conditions.
Date:
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22

FOR
3.11
DG AMF Control Panel.
3.11.1
DG control panel shall have following constructional features:
MECON LIMITED
a)
Cubicle type free standing, floor mounted, Fabricated with 2mm thick CRCA
sheet steel construction, dust and vermin proof with IP 54 degree of
protection as per IS 2147 (Intended for indoor installation). The maximum
and minimum operating height shall be 1800 mm and 300 mm respectively.
b)
Shall consist of distinct vertical Sections assembled to give single front

execution suitable for cable entry from bottom.
c)
Manufacturer, assembly and testing shall conform to Indian Standards

applicable for low Voltage switch gear and statutory regulations. Various
components like bus bars, switch fuse units, relays, timers, contactors,
lamps, various meters, static annunciator etc. shall be arranged in a logical
manner following good engineering practice and for case of maintenance,
replacement and connections.
Details of bus bar dimensions, material, insulation provided in DG control
panel shall be submitted for approval.
d)
Panels shall be completely pre-wired as per approved wiring diagrams.

Wiring for external connections shall be done upto terminal blocks (with wire
numbers and terminal numbers clearly marked).
e)
The air circuit breaker (ACB) shall be in drawout execution, provided as

main incomers in DG control panel.
f)
Switch fuse units (HP rated / heavy duty SFUs), starter units for DG
auxiliary drives shall be fixed execution with door interlocks. All live
terminals shall be properly shrouded to prevent inadvertent contact by
operating personnel. Feeder designation shall be clearly marked on each
cubicle. All meters shall be flush mounted on the cubicle doors (Max. size
96 mm x 96 mm). Separate module shall be provided for each motor starter.
g)
Anti-condensation space heater shall be provided in panels with isolator

and HRC Fuses and On/Off interlock with set.
3.11.2
Battery station
a)
Set of 24 V lead acid battery / bank of adequate ampere hour capacity for
the DG set (at 10 hours discharge rate for supplying control power to control
panel and starting power to engine starting motor) complete with connecting
Date:
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FOR
MECON LIMITED
leads first charging and routine check instruments including hydrometer and
cell tester, teak wood stand, floor insulators, cell supporting insulators, etc.
It shall be possible to start the engine three times in immediate succession
without appreciable drop in DC Voltage. The battery shall have a sufficient
capacity to start the engine more than 4 times consecutively.
b)
3.11.3
Battery charger unit can be built in as a part of DG panel. Battery charger

unit shall be complete with unit transformer / rectifier with surge protection,
DC ammeter, Voltmeter, Charge rate selector etc. suitable for quick and
trickle charging of batteries. Charger shall be suitable for 240 V, 1 Ph, 50
Hz incoming supply. DC voltmeters, centre zero ammeters, protective fuses
shall be provided. Charger shall give constant DC output voltage
irrespective of incoming voltage variation specified.
Meters and components in the DG control panel shall consist, but not limited to
following minimum items.
a) Voltmeter (144 Sq. mm) to read line to line main voltage and DC voltage with
selector switches (as per IS 1248).
b) Ammeter (144 Sq. mm) to read line current (as per IS 1248) with selector switch.
c) Frequency meter (45 Hz to 55 Hz).
d) Power factor meter (0.5 lag to 0.5 lead).
e) Kilo-watt meter.
f) Kilo-watt hour meter, with hour meter to record total hours of operation (Hour
meter shall have resent tool) shall be integrated / digital type micro processor
based similar to Enercon 3360.
g) Tachometer to measure engine speed.
h) PTs and CTs required for above meters.
i) Auto-Off-Manual selector switches (for varying engine speed wherever engine
governors are provided with motorized heads).
j) Push buttons, Engine start / stop, generator breaker close/trip, control system off,
etc. indicating lamps, lamps shall have translucent colored covered red, green,
white, amber etc., lamps with series resistors) shall indicate the following:
i)
DG set on-off.
Date:
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FOR
MECON LIMITED
ii)
Grid supply on-off.
iii)
DG supply on-off.
iv)
solid state annunciator ( 18 windows minimum) shall have following

feature. Test, accept, reset push button, two bulb for channel, lamp
flashing audible annunciation, window inscription shall be arranged
in a logical manner to segregate engine faults, and alternator faults
etc. spare window shall be available. Annunciator shall announce
following minimum faults:
i)
Set fails to start.
ii)
Low DG voltage.
iii)
Low lube oil pressure.
iv)
ACB tripped
v)
Fault in alternator
vi)
Low fuel oil level
vii)
Over speed trip.
(Further fault if any shall also be included as per Mfg, Standard or as will be
finalized during approval of drgs)
3.11.4
k)
Protective relay for tripping DG Set ACB for over current, short circuits earth
fault with flag indications. CDV62 relay with PS class CT shall be provided.
I)
Relays, timers, contactors etc for controlling and interlocking of engine fault
and for operating the engine from DG control panel.
Air circuit breaker in separate cubicle in draw out execution shall have following
features:
a) Four pole direct acting, ambient compensated, continuous adjustable thermal
release with setting range from 50% to 150% of rated current of the DG set.
b) 3 pole direct acting, current independent, continuous adjustable short circuit
release, with timer, current range 2 to 4 times the rated current of DG set (time
setting 0.1 to 0.3 seconds).
(Note: ACB with microprocessor based relays will also be considered)
Date:
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FOR
MECON LIMITED
c)
Under voltage relay with timer for giving, closing impulse to the breaker.
d)
Generator protection relays shall be as indicated in the single line drawing.
e)
Under voltage release.
f)
Shunt trip release.
g)
Draw out execution.
h)
Motorised spring charging with electrical closing in two modes:
i)
Through push button in manual mode.
i)
Additional relays shall be provided for interlocking DG breaker with grid

breaker to prevent paralleling. Breaker auxiliary switch shall have 3 NO +3
NC.
Protection Requirement
a)
Alternators shall be protected for over current, short circuits and earth fault.
b)
The thermal releases and direct acting magnetic releases of the circuit
breakers shall be accurately selected based on the rating of the alternator
and the short circuit releases shall be adjusted based on the maximum
sustained value of over current the machine can develop due to short
circuit.
c)
Thermistors connected to special thermistor relay shall trip the air circuit
breaker and stop the engine in case of excessive temperature of the
winding of Alternators.
d)
Bearing temperature detectors shall be connected to temperature indicating

instruments with adjustable alarm / trip contacts wired to annunciator in the
DG control panel.
e)
All the engine and alternator faults shall shut off the engine in addition to
tripping the breaker.
f)
All the DG auxiliary drive (if applicable) motors shall be protected by HRC
fuses and bimetal thermal over load relays (of proper ratings), with inherent
single phasing protection. Each drive motor shall have its individual isolator
and control MCB.
Date:
MEC/05/51/23KX GAIL/006
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FOR
MECON LIMITED
g)
Space heaters inside alternator shall be interlocked to switch off when

machine is running.
h)
Over speed protection shall be set at safe permissible value of speed

recommended for the set.
i)
All the field sensor elements like temperature, pressure switches etc. shall
be connected to protection circuits in a fail safe manner so that machine is
not subjected to harmful effects of temperature, pressure etc., due to
malfunctioning of the instruments.
3.11.5
Power & control cables

a)
General
All power and control cables supplied shall be as per relevant IS standards.
All LT power cables shall be 1.1 kV grade, circular / sector shaped,
stranded 3 , 4 core electrical purity Cu conductor PVC insulated, round /
flat steel strip armoured and extruded PVC inner and outer sheathed as per
relevant standards and suitable for 415V neutral solidly earthed system.
The PVC insulation used shall be suitable for continuous conductor
temperature of 85 0C.
The insulation of phase conductors shall be coloured red, yellow and blue
and the neutral black.
1.1 kV grade control cables shall be of circular stranded electrolytic grade
high conductivity annealed copper conductor with a minimum size of 2.5
sq.mm PVC insulated, round wire armoured and PVC overall sheathed.
All cores of control cables shall be continuously identified by tracer numbers
i.e. tracer numbers either embossed or printed continuously on each
individual core.
Armouring for power and control cables shall consist of galvanised steel
strips / galvanised round steel wires.
All cables shall be suitable for system particulars, site conditions and
environment conditions specified.
b)
Specification
1.1 kV heavy duty power cable multi-cores with standard sector shaped or
with compact circular stranded Cu conductors as applicable. PVC insulated
Date:
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27

FOR
MECON LIMITED
of type C PVC compound suitable for 85 0C operation core stranded

together provided with a common covering of extruded PVC inner sheath of
type ST2 PVC compound, galvanised round steel wire! flat strip armoured
and PVC outer sheathed of type ST2 PVC compound.
Type 3:1.1 kV PVC copper control and instrumentation cables (YWY)
1.1 kV solid annealed stranded copper conductor. PVC insulated of type C
PVC compound, suitable for 85 deg. C operation as per IS: 5831 1970,
cores stranded together provided with a common covering of Extruded PVC
inner sheath type ST2 PVC compound, galvanised round steel wire
armoured and overall PVC sheathed of type ST2 PVC compound and multicore.
c)
Selection
Size and type of cables for specific applications shall be selected giving due
Consideration for the following
Thermal heating effect /permissible current carrying capacity.
Allowable voltage drop as per Technical specification.

Short time current] overload requirement.
Protection system grading and short circuit current carrying capacity.
Ambient conditions.
Cable grouping factors.
Cross sectional area of the cables used in LT power circuits shall

be:
Minimum 4 sq mm per core and max. 300 sq mm Cu conductor.
Current carrying capacity of the power cables shall be calculated

considering 60% de-rating factor.
All control cables shall have stranded copper conductors.
For control circuits, PVC insulated and PVC sheathed multi-core

cables with copper conductors having a minimum cross-sectional
area of 2.5 sq mm per core shall be used. Spare cores shall be
given.
Date:
MEC/05/51/23KX GAIL/006
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FOR
MECON LIMITED
Sequential length marking shall be provided in outer sheath of all power and
control cables.
ISl marking at every metre of cable length shall be provided.
Cores of multi-core control cables shall be serially numbered.
d)
Tests
Copies of type test certificates as per relevant IS carried out on similar
cables shall be furnished.
All routine tests & acceptance tests as per relevant IS shall be carried out
on every cable size in presence of owner or his representative if specified in
QAP.
3.11.6
Instrumentation & control

The measurement and controls shall be provided for efficient operation of the
process as well as for safety of equipment and operating personnel.
The equipment shall be provided with all instruments necessary for checking the
performance continuously. All meters shall be fixed on a common instrumentation
panel mounted directly on the engine frame. Instrument system shall include all
standard instruments coming as a part of engine.
Measurements and controls required for smooth and efficient operation of the DG
set including but not limited to the following:
ii)
Protection devices
For the safety of DG set following annunciation and tripping scheme shall
be provided.
a)
Audio visual alarm only, for the fault conditions in case of:
Fuel oil tank level low.
Lubricating oil pressure low.
Fuel oil pressure low.
Lube oil temperature high.
Exhaust gas temperature high.

Date:
MEC/05/51/23KX GAIL/006
29

FOR
b)
3.11.7
Fuel oil day tank level high.
Lube oil sump tank level low.
diesel engine start failure.
MECON LIMITED
Audio visual alarm followed by tripping in case of:
Lubricating oil pressure too low.
Crank case oil mist high.
Over speed.
Starting fault,
Charge air temperature too high.
Engine Vibration too high.
Emergency stop (manual)
In addition to the common specification listed in for DG control panel in 2.2 the
following additional features shall be provided as given below for the Panel.
a)
Control panel for the DG set.

It shall comprise of one no. 3000A Air circuit breaker in draw out execution,
protection class CT, metering class CT for protection relay and measuring
instrument, power monitors, CDV-62 protection relay, PT, master trip relay,
indicating instruments, annunciation, etc.
Reverse power relays shall be provided in both the generator output
circuitry.
The neutral earthing system of the generator shall be taken to the panel and
necessary contactors shall be provided for isolation of the set.
110V control circuit for breaker closing and indications, 24V control circuit
(from battery) for engine starting / stopping, master trip relay, auxiliary
relays for multiplication of fault controls etc.
3.11.8
Foundation frame
Suitable foundation frame (common with generator with foundation bolts and nuts
shall be provided.
Date:
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FOR
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Coupling shall be suitable for type and speeds of equipment to be coupled. It shall
ensure minimum vibration in operation due to possible misalignment and
unbalances.
3.11.9
3.11.10
Preferred makes
Engine
Pipes
Alternator
:
:
Control & Relay panels

Battery
Battery charger & DC Board
LT Switch board
LT cables
:
:
:
:
:
Air circuit breaker

MCCB
:
:
Protection Relays, Aux. Relays

LT contactor & Thermal O/L
Relays
Selector
switches/
Control
switches
LT, CTS
:
:
Annunciators
Power Factor relay
Indicating Meters
:
:
:
Integrating meters
Brass / GI compression type
cable glands
Tinned copper lugs
Indicating lamps & Push
buttons
:
:
Automatic electric / Siemens / KAPPA

electricals
GEC / ALSTOM/ Yashmin
PHASITRON
Automatic electric lndustrial Meters Pvt.
Ltd., / MECO / RISHAB
IMP / BHEL / Universal Instruments / AE
Comet / Siemens
:
:
Dowells/ Electropowerke/
GE / Siemens / L & T/ BCH
Caterpillar / Cummins I Detroit/I Greaves/

KOEL.
Zenith / BSI/ Jindal/ Khandalwal.
NGEF/ Kirloskar/ Crompton Greaves /
Stamford
English Electric! Easun Reyrolle/ ABB
Exide / HBLNIFE/ AMCO/ Amara Raja
Automatic electric / HBLNIFE
Siemens / L&T/ NGEF/ GE
Cable corporation of India /Universal
cables / Indian cable company / Asian
cables.
Siemens / GE/ L & T
GE / ABB / Siemens/CROMPTON
GREAVES
GE / ABB / Siemens / Easun Reyrolle
GE / Siemens / Tele-mechanic / L & T
/Control & Switch Gear
GE / KAYCEE/ ABB / Siemens.
Applicable Codes and Standards

The design, manufacturing, testing of DG set and associated
accessories/equipment shall be in accordance with the latest revisions of the
Date:
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FOR
MECON LIMITED
following standards, wherever applicable. Where appropriate Indian Standards

are not available, the relevant IEC/BS/ISO standards shall apply.
IS
IS
: 5
: 4691
IS
IS
: 4722
: 4728
IS
: 4889
IS
: 12065
IS
IS
: 12075
: 12802
IEC
IEC
: 34 series
: 72
BS
: 649
BS
BS
: 4999
: 5000
BS
ISO
: 6121
: 3046-4
Colours for ready mixed paints and enamels.

Degree of protection provided by enclosures for rotating
electrical machinery.
Rotating Electrical machines
Terminal marking and direction of rotation for rotating
electrical machinery.
Methods of determination of efficiency of rotating electrical
machines.
Permissible limits of noise levels for rotating electrical
machine
Mechanical vibration of rotating electrical machines
Temperature rise measurement of rotating electrical
machines
Rotating Electrical Machines
Dimensions and output series for rotating electrical
machines
Performance of reciprocating compression ignition Diesel
Engine
General requirements for Rotating Electrical Machines
Specification for Rotating Electrical Machines of particular
types or for particular applications
Mechanical cable glands
Reciprocating internal combustion engines, part 4 speed
governing
The DG set and associated accessories/equipment shall also conform to the

provision of the latest revisions of the Indian Electricity Rules and other statutory
regulations currently in force.
Date:
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FOR
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4.0
QUALITY ASSURANCE, INSPECTION & TESTING , PERFORMANCE GUARANTEE.
4.1
General Requirement Of Quality Assurance

All materials, components and equipment covered under the Technical specification for
this Project shall be procured, manufactured, tested, erected and commissioned as per a
comprehensive Quality Assurance Programme. It shall be the primary responsibility of the
contractor to draw up and implement such a programme which shall be duly approved by
the Purchaser/Consultant/their authorised Inspection Agency.
The detailed Quality Assurance Plan (QAP) for manufacturing and testing of equipment
shall be prepared by the contractor and submitted for approval by the Purchaser/their
authorised Inspection Agency.
4.2
Inspection and Testing
4.2.1
The equipment shall be inspected by the Purchaser and / or their Inspection Agency at the
manufacturers works prior to despatch. The equipment will be inspected as per the tests
pre-identified in the approved QAP to ensure conformity of the same with relevant
approved drawings, data sheets, technical specification, National/International Standard.
4.2.2
The contractor shall finalise the QAP within the stipulated schedule mentioned in the
Purchase Order and the QAP shall be submitted in four sets (Blank QAP formats enclosed
shall be adopted). In case of any sub-contracting, the QAP shall be prepared by the
contractor in consultation with his sub-contractor to avoid any lapse in quality and disputes
and misunderstanding.
4.2.3
The contractor shall provide full and free access of the Inspection Agency to the
manufacturers works to carry out any stage inspection to ensure the quality of the
equipment being manufactured.
4.2.4
Only on readiness of the equipment and approval of all relevant drawings & QAP, the
contractor shall give Inspection Call to the Purchaser & the Inspection Agency with a
clear notice of 10 days for inspection. The Inspection Call shall be accompanied by the
manufacturers internal inspection report, test certificates, purchase order, sub-purchase
order, technical specification, approved QAP and approved drawings / data sheets. The
Inspection Call without above documents shall be ignored. In case of any approved subcontracting, only the main contractor shall give the Inspection Call enclosing internal
inspection/ test reports of the sub-contractor duly verified by the main contractor. In case
the equipment offered for inspection is found not ready, all the cost of the visit of the
Inspection personnels shall be borne by the contractor.
4.2.5
The contractor shall furnish all relevant documents and test certificates as required by
the Inspection Agency during inspection. Materials shall be tested only in recognised
Test House/Laboratory.
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FOR
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4.2.6
The contractor shall delegate a representative/ coordinator to coordinate with the

Inspection Agency on all inspection matters.
4.2.7
No equipment shall be offered for inspection in the painted condition unless otherwise
agreed to the purchaser.
4.2.8
The contractor shall ensure that the equipment and materials once rejected by the
Inspection Agency are not reused in the manufacture of plant and equipment. Where
parts rejected by the inspection Agency have been rectified as per pre-agreed
procedure, such parts shall be segregated for separate inspection and approval before
being used in the work.
4.2.9
The contractor shall carry out their internal inspection and obtain clearance from
Statutory bodies, like IBR, CCE, TAC, Weights & Measures, Safety, IE Rules, etc., as
required for the equipment prior to offering any such equipment for Purchasers
inspection.
4.2.10
The contractor shall provide all required instruments, tools, necessary testing and
inspection facilities free of cost to carry out the inspection. These instruments and
testing machines shall be calibrated by an agency of National/ International recognition
and the calibration shall be valid during inspection period.
4.2.11
The inspection Agency shall have the right to demand for re-testing of any material recalibration of the instrument and testing machine & the charges for the above will be
borne by the contractor.
4.2.12
No equipment shall be despatched before inspection and issue of Inspection Certificate

and despatch clearance from the Purchaser / Inspection Agency.
4.2.14
In case of waiver category items, the same shall be pre-identified in the QAP itself. For
such items, the contractor shall furnish necessary certificate, test reports, etc., as agreed
upon and indicated in the QAP. For these items also the contractor shall obtain
Inspection Waiver Certificate and despatch clearance from the purchaser Inspection
Agency before effecting despatch of equipment.
4.2.15
The issue of Inspection Certificate / Waiver Certificate for any equipment or component
thereof does not absolve the contractor from his contractual obligations towards
subsequent satisfactory performance of the equipment at site. Should any equipment
be found defective, In whole or part thereof after receipt at site or during erection/
commissioning and testing shall be made good by the contractor free of cost.
4.3
Performance Guarantee
The tenderer shall furnish the following guaranteed parameters, When operating under site
conditions at maximum continuous rating as defined in BS 5514 (ISO 3046). The
Date:
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FOR
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performance test of the DG set shall be carried out at manufacturers work. Performance
tests of any particular equipment which cannot be conducted / demonstrated either
partially or wholly at the manufacturers works, shall be conducted after erection at site in
the presence of Purchaser and their Inspection Agency. In all the cases, prior approval of
the Purchaser shall be obtained. However, arranging all testing facilities including load
shall be in the scope of supplier. Following tests shall be conducted in the presence of
purchasers representative at manufacturers work;
i)
Functional tests, continuity tests and high voltage test on control panel to
establish the performance called for in the specification.
ii)
Routine tests for alternator as per IS:4722.
iii)
Overspeed test (1.2 times the rated speed for 2 minutes).
iv)
Phase sequence test.
v)
Vibration test
vi)
Noise level test
vii)
Power and fuel consumption shall bereorded as follows;
i)
ii)
iii)
iv)
Percentage Loading
110%
Engine output
Electrical output at the generator
terminals (KVA)
Fuel consumption
Lubricating oil consumption
100%
50%
25%
vii)
Dimensional and alignment test shall be checked before PG test
viii)
Manufacturers routine test certificates for bought out items shall be

submitted. Routine and type test certificate for Switchgear shall be
submitted. Type test certificate for alternator shall be submitted.
5.0
ERECTION, TESTING & COMMISSIONING OF D.G. SET
5.1
Scope work under this section includes site work of installation & commissioning of
engine, generator assembly, electrical panels battery station, associated cabling,
including cables between DG Control panel grid breaker panel, earthing, piping,
fuel pumps, fuel tanks, safety appliances (like rubber mats, first aid boxes, carbon
extinguishers etc). Necessary erection materials such as cable racks, trays, angles,
chemicals etc required DG Set & necessary statutory approvals are included in the
scope of work.
Date:
MEC/05/51/23KX GAIL/006
35

FOR
MECON LIMITED
5.2
The installation shall comply with relevant Indian Standards, Indian Electricity Rules
and statutory regulations that are in force in the place of installation.
5.3
Equipment erection, including acoustic enclosure testing and commissioning shall

include following activities
a)
Removal of packing material and clearance, removal of blocking devices

provided for safe shipment.
b)
Physical inspection, preparation of defect lists.
c)
Assembly of shipping sections.
d)
Civil work involved in grouting the equipment base frames, concrete

chipping, grouting for wall, roof, floor supports wherever required for piping,
cabling etc.
e)
Tack welding of equipment, panels etc., to floor inserts wherever provided

and providing floor inserts wherever required for erection work.
f)
Applying touch paints for finish painted equipments and finish painting of
site fabricated steel work after pretreatment like de-rusting, degreasing,
primer coating etc.
g)
All pre-wired panels shall be checked for correctness as per final approved
wiring diagrams.
h)
Trouble free mechanical operation of relays, contactors, timers, breakers

and free rotation of all drive motors be checked.
i)
Tightness of all bolts joints in busbars, motors, generator, engine etc., shall
be checked.
j)
Insulation resistance of all electrical equipments shall be measured and

improved by cleaning and drying. Space heaters, filament lamps (1000
watts) shall be provided and kept energized during the entire period of
erection to prevent deterioration of insulation resistance below permitted
values.
k)
Duplicate earthing shall be provided for all electrical equipments, cable

glands, tanks, vessels etc. as per statutory regulations.
I)
Generator neutral shall be directly connected to pipe / plate electrode using

insulated cable. Earth ring inside DG Set shall be formed and connected to
Date:
MEC/05/51/23KX GAIL/006
36

FOR
MECON LIMITED
plant earth grid at minimum two points for DG Set to be provided by the
contractor as per IS 3043.
5.4
a)
DG set consisting of diesel engine and AC generator mounted on common

base frame with acoustic enclosure shall be erected on civil foundation with
correct orientation details. DG control panel, battery station, charger units
shall be erected inside the MCC room. Supplier shall furnish detailed layout
drawing for the DG set.
b)
All the piping to the engine shall be done strictly as per manufacturers
drawings. Wherever piping involves joining by welding the same shall be as
per relevant statutory regulations (compressed air lines etc.). Unions /
couplings of pipelines shall be done as per manufacturers instruction
/drawings, wherever welding is not preferred or permitted. All piping shall be
checked for leak proof by conducting tests as per instruction manuals of
manufacturer.
c)
Coupling of the engine and alternator shall be done after checking and
correcting alignment of shaft axes within permitted tolerances. Shaft levels
shall be checked and adjusted to be within permitted tolerances.
d)
All the power cables between DG Control panel and alternator shall be
done as per approved layout drawings. Further all control cables to start
and shut-off solenoids, temperature switches, level switches etc., shall be
separately installed and terminated with ferrule numbers as per
manufacturers wiring diagrams. Wherever control cables have to run near
engine casing thermal insulations shall be used to prevent damage due to
excess temperature. Flexible conduits shall be used to protect control
cabling near the engine. All the power and control cables shall be laid
separately and in cable trenches / cable channels between generator and
DG Control panel in the building as per approved drawing. Vacant spaces in
used and unused conduits should be plugged using M-seal monoplast filling
compound. All cables shall be neatly dressed and clamped in fabricated
cable trays.
e)
DG set auxiliaries like lube oil prime pump, fuel oil pump, fuel transfer
pumps, shall be run and checked using grid supply. Similarly batteries shall
be charged through charger installed, using grid supply. First filling of
lubrication oil, grease, fuel oil (into tank) etc., shall be done by the
contractor as per manufacturers instructions.
f)
All DG set instruments shall be tested / calibrated and set at values

recommended by the manufacturer, Inscriptions on windows shall be
checked. Overload relay for alternator protection shall be tested and set at
values recommended.
Date:
MEC/05/51/23KX GAIL/006
37

FOR
g)
5.5
MECON LIMITED
Installation of safety appliances like rubber mat, carbon dioxide fire

extinguishers, first aid box etc., shall be done.
When installation is completely ready for starting, following tests shall be done in
addition to all test prescribed by the manufacturer / I.S. Standards.
a)
b)
Starting of engine in auto and manual mode / simulated DG Control

condition.
Shut-off of the engine-manual mode/ electrical mode simulated faults of the
alternator and engine.
c)
Over speed test.
d)
Interlock between DG breaker and grid supply.
e)
Governor speed control electrical /mechanical.
f)
Minimum time in seconds required by the set to deliver power at desired

voltage and frequency starting from standstill condition.
g)
Matching the DG phase sequence with grid supply phase sequence.
h)
Checking annunciator windows for all the faults simulated during testing.
i)
Continuous full load test as specified, by starting all the motor loads
sequentially.
j)
Tabulation of all results in the mutually agreed format.
5.6
Manufacturers service personnel shall be deployed for testing commissioning,

wherever required. Contractor shall extend full co-operation and assistance to all
such personnel.
5.7
Important notes
a)
Successful commissioning of DG set is contingent upon satisfactory

working of all the units, meeting fully the requirements of the specification
and performance guarantees offered by the manufacturer.
b)
It shall be contractors responsibility to replace all defective / inferior

materials revealed during preliminary acceptance and final acceptance
tests (P.A.T and F.A.T) at his own expense, without affecting completion
milestones.
Date:
MEC/05/51/23KX GAIL/006
38

FOR
5.8
MECON LIMITED
c)
Contractor shall ensure that no tests are applied which may stress the
equipment above the limits recommended for field testing, by the
manufacturer.
d)
Contractor shall be responsible for any damage that may occur to personnel
/ equipment resulting from improper testing procedures.
e)
Contractor scope in testing of DG Set includes supply & filling sufficient

quantities of consumables like high speed diesel, lube oil, greases etc,
necessary for carrying out all trial runs, during preliminary acceptance tests
(PAT) and final acceptance tests (FAT).
Form of completion certificate for the DG set

I/we certify that the installation detailed below has been installed by me / us and
tested and that to the best of my / our knowledge and belief, and it compiled with IE
rules, 1956 as well as technical specification for electrical works.
Particulars of instruments used
1
Insulation tester
Make
:
Type
:
SI. No.
2 Earth tester
Make
:
Type
:
SI. No
3 Any other instruments
Make
:
Type
:
4 Particular works
A Cables
:
a)
Total length of underground :
cable and its size
b)
No. of joints
: End joints
Tee joints
Straight / through joints
B Earthing
a)Description of earth electrode
:
b) No. of earth electrode
: NA
c) Size of main earthing lead
:
5 Test result
a) Insulation resistance
:
Date:
MEC/05/51/23KX GAIL/006
39

FOR
i) Insulation resistance of the whole

system of conductors to earth
b) Insulation resistance
i) Insulation resistance between the
phase conductor and neutral
Between R & N
Between Y & N
Between B & N
c) Insulation resistance between the
phase conductor in case of 3 ph.
Supply
Between R & Y
Between Y & R
Between B & R
d) Earth continuity test
Maximum resistance between any
point in the earth continuity conductor
including metal conduits & main
earthing lead
e) Earth electrode resistance
No 1
No 2
No 3
No 4
Sl.
No
From size Voltage

in sq.mm
grade
Length
MECON LIMITED
: Mega-ohms
:
:
: Mega-ohms
: Mega-ohms
: Mega-ohms
:
: Mega-ohms
: Mega-ohms
: Mega-ohms
: Ohms
:
:
:
:
Ohms
Ohms
Ohms
Ohms
Insulation resistance in mega

ohms
At
the During & before
time
of covering
issue
Between
RY
RY
YB
YB
BR
BR
RN
RN
YN
YN
BN
BN
RE
RE
YE
YE
NE
NE
Date:
MEC/05/51/23KX GAIL/006
40

FOR
g)
Before commissioning
i)
Whether high voltage test
conducted
ii)
If conducted, system of
supply test voltage at
iii)
Duration
iv)
Results
v)
If not conducted,
Voltage of megger used
Earth temperature
Results of megger testing
Between R & Y
Between Y & B
Between B & R
Between R & N
Between Y & N
Between B & N
Between R & E
Between Y & E
Between B & E
MECON LIMITED
YES / NO
KV
:
:
Mins
Satisfactory / unsatisfactory
:
:
:
:
:
:
:
:
:
:
:
:
SIGNATURE OF SUPERVISOR
SIGNATURE OF CONTRACTOR
SUPERVISORS LICENCE NO.
CONTRACTORS LICENCE
NAME & ADDRESS
NAME & ADDRESS
6.0
MANDATORY SPARES PARTS
One lot of spares is the quantity of spares as mentioned below and shall be ordered and
considered for price comparison. List of Mandatory spare prices to be enclosed in Priced Bid
Envelope.
Price of mandatory spares shall be loaded for evaluation purpose
Date:
MEC/05/51/23KX GAIL/006
41

FOR
MECON LIMITED
1 set means the quantity installed in one machine (BIDDERS TO SPECIFY ITEMWISE IN THEIR
OFFER DOCUMENT)
S.No.
3
4
5
6
7
9
10
10
11
Part Description
Part
No.
ALL
ENGINE
BEARING/BUSHES
(MAIN
CONNECTING
ROD
BIG
END
CONNECTING
ROD
SMALL END ETC )
PISTON
ASSY.
INCLUDING
PISTON,
PISTON
RINGS
&
CONNECTING RODS &
CONNECTING
ROD
BOLTS ETC
PISTON RINGS (ALL
TYPES)
Liners
INLET VALVE &
EXHAUST VALVE
GASKETS & O RINGS
(SET)
5% SET OF NUTS,
WASHERS & BOLTS
(SET)
CARTRIDGE/ELEMENTS
FOR PRIMARY AND
SECONDARY FUEL OIL
FILTER
LUBE FILTERS
CARTRIDGE/ELEMENT
SET OF BEARING (LUBE
OIL PUMP)
SET OF BEARING FOR
ALTERNATOR
PREVENTIVE
MAINTENANCE KIT FOR
1000 HRS. OF
OPERATION
Qty. Reqd.
by purchaser
Price
Unit
Total
1 lot
1 lot
1 lot
1 lot
1 lot
1 lot
1 lot
1 lot
1 lot
1 lot
1 lot
1 lot
Date:
MEC/05/51/23KX GAIL/006
42

FOR
MECON LIMITED
7.0
DOCUMENTS TO BE SUPPLIED ALONGWITH OFFER/ AFTER PLACEMENT
7.1
Along with offer

a)
b)
Bar chart showing complete activities as per scope of work.

General arrangement of equipment of preliminary station layout of DG set.
c)
Layout of various service piping & cabling including earthing accessories

indicating also limit of supply.
d)
Scheme showing the starting of DG set at the line of grid power.
e)
Single line diagram of generator control panel, MCC etc., indicating make
and rating of each equipment.
f)
Descriptive and illustrative literature/ showing from manufacturer on all

equipment.
g)
A detailed experience list about supply of similar type of DG set by the

section.
h)
Write up on quality control and assurance plans to be followed during

engineering, manufacturing, testing and commissioning of plant and
equipment.
i)
De-scaling calculation in support of selection of equipment to meet site

condition.
j)
Data sheet duly filled.
k)
Tenderer shall also furnish the following:

i.
Total time required for the DG set to deliver rated power after
starting from cold conditions.
ii.
The overload capacity of the alternator.
iii.
7.2
Biggest size of motor that can be started on DG set with voltage dip
limited to 20% at alternator terminals.
After placement of order
1.
General layout drawings of DG station / Acoustic enclosure showing

locations and sizes of all systems, equipment, pipe and cable trenches etc.
Date:
MEC/05/51/23KX GAIL/006
43

FOR
7.3
MECON LIMITED
2.
The outline of the foundations of all the equipment, accessories etc. under
the scope of his supply indicating the location of anchor bolt conduits and
other inserts to be built in the foundations etc. with corresponding level.
3.
Complete load data of equipment including dynamic loading, machine

frequency etc.
Drawings for approval I comments

1.
General arrangement, cross-sectional arrangement and detailed drawings

of all equipment including diesel engine & acoustic enclosure.
2.
Scheme and piping layout drawings for fuel oil, lube oil systems.
3.
Detailed scheme of complete electrical equipment with specification & bill of

quantities.
4.
Layout drawing showing location of all electrical equipment.
5.
Cable and cable supporting structure plan and section.
6.
Earthing layout drawing with bill of materials.
7.
GA drawing of generator.
8.
Control scheme of generator.
8.0
DATA SHEETS FOR DG SET
8.1
Following technical pertaining to diesel engine / alternator shall be furnished along

with tender separately for the set.
I.
Materials of construction of the engine components
1.
2.
3.
4.
5.
6.
Base plates
:
Cylinder block
:
Cylinder head
:
Cylinder
:
Piston
:
Nos. and material of compression :
rings
Cylinder liner
Piston rod
:
Crankshaft
:
7.
8.
9.
Date:
MEC/05/51/23KX GAIL/006
44

FOR
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
II.
A)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
Crank pins
Connecting rod big end bearing
Connecting rod small end bearing
Frame
Valve seat
Valve holder
Valve guards
Valve plate
Valve spring
Main bearing
Pin shaft bearing
Tie rod
Rocker arm
Rocker valve
Cam
Roller guide
Timing rod
MECON LIMITED
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
;
:
Particulars of DG Set
Diesel engine
Name of manufacturer
:
Type and engine no.
:
Standard rating BHP
:
Rating for site conditions
:
Rated speed (RPM)
:
Direction of rotation
:
No. of strokes
:
No. of cylinders
:
Arrangement of cylinders
:
Dia. of cylinders DORE.
:
Piston stroke
:
Total piston placement
:
Mean speed of piston at rated :
speed
Compression ratio
:
Type of cylinder valves
:
a) Suction
b) Exhaust
Coolant
Firing order of cylinders
FUEL oil consumption
:
:
:
Date:
MEC/05/51/23KX GAIL/006
45

FOR
MECON LIMITED
a) at rated load
b) at 75% load
c) at 50% load
19.
20.
21.
B)
1.
2.
3.
a)
b)
c)
4
a)
b)
5
a)
b)
d)
e)
f)
6
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
Thermal efficiency based on bhp

:
Mechanical efficiency
:
Min. time required for engine from :
starting to fuel load
Fuel oil system

Make
Type
Filter
Type
No.
Location
Fuel supply pump
Type
Rating
Fuel Injection system
Make
Type
Drive
Type of fuel nozzle
type of cooling for fuel Nozzle
Fuel tank
Type & construction
Capacity
Thickness of sheet
Location
Opening data
Dia of pipe connection
- Inlet
- Outlet
Drain details
Level indicator details
Low level switch details
Fuel transfer pump details
Type & grade of fuel oil
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
Date:
MEC/05/51/23KX GAIL/006
46

FOR
C.
Lubrication oil system
1
2
a)
b)
c)
d)
e)
f)
g)
h)
3
a)
4
a)
5
a)
6
7
8
a)
b)
c)
d)
9
10
a)
b)
c)
11
12
Make & type

Lub. oil pump
Make & type
Rating
Litres
Pressure (delivery / side)
Normal operation speed
Impeller power ..
Dia. of pipe connection at suction
and discharge
Type of priming arrangement
Lub. oil filter and strainer
Make & Type
Lub. oil pressure indicator
Make & Type
Lub. oil temperature indicator
Make & Type
Low lub. oil pressure switch details
High lub. oil temperature
Lub. oil cooler
Make
Type
Tube size
Tube material
Lub. oil piping and fitting details
Lub. oil pump
Capacity (litres)
Material
Location
Qty of lub. oil required
Grade of lub. oil
Air intake system
1
a)
b)
c)
d)
Air filter
Air filter
Make
Type
Size of filtering particle
MECON LIMITED
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
Date:
MEC/05/51/23KX GAIL/006
47

FOR
E.
Exhaust gas system
1
a)
b)
c)
2
a)
b)
3
Manifold
Location
Type
Material
Silencer
Make
Type
Exhaust piping details
Exhaust gas turbo charger
1
2
3
4
5
6
Make
Type
Output
Speed
Suction pressure
Exhaust pressure
Coupling
1
2
Type
Bolting details
H
1
2
3
I
1
2
3
4
J
1
2
3
4
MECON LIMITED
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
Pyrometer equipment
Make
Location on engine
No. of points monitored
:
:
:
Dimension
Length
Width
Height
Free over head space required to
pull piston and rod assembly
Details of acoustical enclosures
Make
Size
Sound Level
Constructional details
:
:
:
:
:
:
:
:
Date:
MEC/05/51/23KX GAIL/006
48

FOR
Local gauge panel
1
2
3
4
Type of connections
Material & thickness
Size
List of instruments
Weights
1
2
Total weight of DG Set

Shipping weight of DG set
iii.
A
a)
b)
c)
d)
e)
f)
g)
h)
B
a)
b)
c)
d)
e)
C
a)
b)
c)
D)
E)
F)
a)
b)
G)
MECON LIMITED
:
:
:
:
:
:
ELECTRICS
Generator
Make
Type
Continuous Rating
Over load capacity
Speed
Over speed capacity
Critical speed
Short circuit ratio of the machine
Unsaturated direct air synchronous
Reactances.
Sub-transient
Transient
Steady stage
Zero sequence reactance
Negative sequence reactance
Short circuit time constant
Sub-transient
Transient
Inertia constant of the machine in
seconds
Zero power factor ( lagging) rating
at nominal voltage
Field current (over excitation)
Voltage regulation
50% Load thrown off
100 % Load thrown off
Sustained Short circuit current
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
Date:
MEC/05/51/23KX GAIL/006
49

FOR
a)
b)
c)
H)
a)
b)
c)
d)
e)
f)
I)
a)
b)
c)
d)
e)
J)
a)
b)
c)
d)
K)
a)
b)
c)
L)
a)
b)
c)
d)
e)
f)
g)
iv.
Excitation adjusted for rated KVA &

PF
Voltage regulator operating
With standing time (seconds) for
(a) & (b)
Current
Main field current for open circuit
voltage
Main field for rated load
Main field voltage
Main field resistance at operating
temperature
Shaft voltage
Shaft current
Generator losses at rated speed
Stator copper loss
Rotor copper loss
Iron loss
Windage & friction losses
Stray losses
Efficiency in percentage at rated
load
At 25%
At 50%
At 75%
At 100%
Bearing
Type
Make
Number
Exciter details
Rated voltage
Rated current
Ceiling voltage
Current at ceiling voltage
Details of rectifier diode bridge.
Details of voltage regulator like
make, response, time etc.
Permitted duration exciter current
at ceiling voltage
MECON LIMITED
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
DG AMF control panel data required

Rating, make, type etc of all the components in DG control panel, battery charger
Date:
MEC/05/51/23KX GAIL/006
50

FOR
MECON LIMITED
batteries, and air circuit breaker etc. shall be furnished.

M)
a)
b)
c)
d)
e)
f)
g)
h)
Air circuit breaker
Type, make rating

Current release
Current releases
Breaking time
Making capacity
Short time rating (1 sec)
Breaking time
No. of auxiliary contacts
N)
Air Breaker contactors

a)
b)
c)
d)
e)
O)
a)
b)
c)
d)
e)
P)
a)
b)
c)
d)
e)
f)
:
:
:
:
:
:
:
:
Type, make, rating, duty class (reqd. AC3)

Contact life (switch operations)
Breaking capacity (Regd 6 time operational current)
No. of auxiliary contacts:
Whether incomer contactors are mechanically interlocked (preferred)
Switch fuse units
Type, make, rating (reqd, HP rated)

Interrupting capability amps (Reqd. 6
times upto 160 amps rating 3 times at
0.3 of above 160 amps)
Fuses (Reqd, HRC link type)
Contacts (Reqd. silver plated)
Pad locking facilities in off position
:
:
Busbars
Material
Dimension R.Y.B. Neutral, Earth
Whether PVC slewing provided
Air clearance: phase to phase &
phase to earth (min. reqd, 25mm,
16mm)
Busbar
supports:
material
&
dimensions
Temperature rise (Min. 40 deg c rise
above 45 deg C ambient)
:
:
:
:
:
:
:
:
Date:
MEC/05/51/23KX GAIL/006
51

FOR
Q)
a)
b)
c)
d)
e)
Battery
Make
Type & AH rating
Discharge rate
Charging rate
Teakwood stand
insulator provided
R)
a)
b)
c)
d)
e)
f)
Battery charger
Type
Make
Whether diode or S.C.R.
Whether D.C. Output voltage constant
Type of over voltage protection
Suitability for quick & trickle charging
:
:
:
:
:
:
:
S)
a)
b)
c)
d)
e)
f)
Solid state Annunciator

Type
Make
Control voltage
No of windows
Spare windows
Features (Test, Accept, Rest required)
:
:
:
:
:
:
:
T)
a)
b)
c)
d)
e)
f)
g)
h)
i)
Power/Control/Instrument cables
Type
Voltage class
No. of course
IS
Current rating
Laying factors
Insulation details
Armour details
Technical catalogues
:
:
:
:
:
:
:
:
:
:
with
MECON LIMITED
:
:
:
:
:
porcelain :
Date:
MEC/05/51/23KX GAIL/006
52

FOR
9.0
MECON LIMITED
TECHNICAL CHECK LIST (MECHANICAL / ENGINE)
S. No. a)Description
Supply / Erection / Testing /

Commissioning
Diesel Engine
a)
Diesel Engine with lubrication system,

governing system, charging system, fuel
system, cooling system & starting system.
b)
Flywheel with barring device.
c)
Flexible coupling for engine-alternator.
d)
Guards for moving parts
e)
Heavy duty suction air filter with suction piping.
f)
Inlet and exhaust manifolds.
g)
Exhaust silence with expansion bellows
h).
7.
Common base plate for engine-alternator &

auxiliaries.
Miscellaneous
a)
Auxiliary piping
b)
Foundation Anchor bolts / AVM pads
8.
Spares
a)
Spares for 2 years normal operation as per

manual
Date:
MEC/05/51/23KX GAIL/006
53

FOR
MECON LIMITED
b)
Erection and commissioning spares as

recommended by the manufacturer (please
include the list of commissioning spares in the
proposal)
c)
Special Tools and Tackles as recommended

by the manufacturer. (Please include the list in
the proposal).
d)
Shop Inspection and testing as specified for all

items.
e)
Vendor data requirements as specified.
f)
Painting preparation of shipment and packing.
g)
ERECTION, TESTING,
AND HANDING OVER.
COMMISSIONING
TECHNICAL CHECK LIST (ELECTRICAL)

S. NO.
DESCRIPTTION
EMERGENCY GENERATORS COMPLETE WITH

STATOR,
ROTOR,
EXCITER,
ACOUSTIC
ENCLOSURE FRAME EARTHING CONNECTIONS
AND LUBRICATION SYSTEMS
SUPPLY / ERECTION /
TESTING /
COMMISSIONING
VENTILATION AIR INLET & OUTLET DUCTS
GENERATOR CONTROL PANEL, AMF PANEL,

ACBS, RELAYS, METERING PROTECTION AND
ANNUNCIATION SYSTEM..
CABLING
BETWEEN
THE
PACKAGE
EQUIPMENT AND BETWEEN PURCHASERS
Date:
MEC/05/51/23KX GAIL/006
54

FOR
MECON LIMITED
PANELS AND DG SET
EARTHING WITHIN THE BATTERY LIMITS
BATTERY AND BATTERY CHARGERS

CONTROL
POWER
REQUIREMENT
COMPLETE DG SETS.
FOR
OF
SPARES FOR ERECTION AND COMMISSIONING

AND TWO YEARS TROUBLE FREE OPERATION.
ERECTION, TESTING, COMMISSIONING AND

HANDING OVER.
9
10.
11.
AMF/ control panel

Instruments and controls mounted in local control
panel.
Two sets of batteries.
12.
13.
Battery charging equipment

Local instrument panel
Date:
MEC/05/51/23KX GAIL/006
55

FOR
10.0
S
No.
MECON LIMITED
DEVIATIONS TO THE SPECIFICATION

Clause
no.
Tender
Deviation taken
Specification
Reasons for deviations / remarks
Certified that, only the above-mentioned deviations have been taken against this tender.
Name of the bidder
Signature
Seal of the Company.
Date:
MEC/05/51/23KX GAIL/006
56
TENDER
PIPELINE
MECON LIMITED
DRAWINGS
57
TENDER FOR
1250 kVA DG SET FOR
LPG PIPELINE
MECON LIMITED
TABLE OF CONTENT
Sl.
Description of Drawings
No.
1 Main Single Line Diagram of Existing
Electrical Panels Despatch of Kandla
2 AMF Panel for DG Set.
3 AMF Panel for DG Set.
Drawings No.
MEC/23KX/05/E9/SLD/002, R-0
(Sheet 1 of 2)
MEC/SD/05/E9/006/001, R-0
MEC/23KX/E9/006/001, R-0
DOC. NO.:MEC/23KX/05/21/M/001/S006
D:\old data\Vijyant\Kandla-Samakhiali\Tender\DG Set\DRAWINGS SECTION XI.doc
Page 2 of 5
58
TENDER FOR
1250 kVA DG SET FOR
LPG PIPELINE
MECON LIMITED
DOC. NO.:MEC/23KX/05/21/M/001/S006
Page 3 of 5
59
TENDER FOR
1250 kVA DG SET FOR
LPG PIPELINE
MECON LIMITED
DOC. NO.:MEC/23KX/05/21/M/001/S006
Page 4 of 5
60
TENDER FOR
1250 kVA DG SET FOR
LPG PIPELINE
MECON LIMITED
DG SET BUILDING LAYOUT DRAWING
DOC. NO.:MEC/23KX/05/21/M/001/S006
Page 5 of 5
61

1250kva DG Set

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1250kva DG Set

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GAIL (India) Limited

GAIL (India) Limited

UPGRADATION OF KANDLA - SAMAKHAILI LPG

Bid Document No.: 05/51/23KX/GAIL/006

GAIL (India) Limited

GAIL (India) Limited

GAIL (India) Limited

UPGRADATION OF KANDLA - SAMAKHIALI LPG PIPELINE

Design, engineering, manufacturing testing and

GAIL (India) Limited

Erection / Installation & Commissioning including

GAIL (India) Limited

D:\old data\Vijyant\Kandla-Samakhiali\Tender\DG Set\Cover TS - DG Set.doc

TENDER - 1250 kVA DG SET

TS No. MEC/TS/05/21/006, Rev-0

Special instructions to the Tenderer

Quality assurance, inspection & testing, performance guarantee.

Erection, Testing and Commissioning

Technical check list (mechanical / engine)

Deviations to the specification

TENDER - 1250 kVA DG SET

TS No. MEC/TS/05/21/006, Rev-0

SPECIAL INSTRUCTION TO TENDERER

This specification shall be read in conjunction with the following documents.

Applicable codes and standards

Accessibility and safety

Monthly I weekly construction programme can be made by the contractor and

TENDER - 1250 kVA DG SET

TS No. MEC/TS/05/21/006, Rev-0

Design, engineering, manufacturing, shop assembly, testing and

Inspection of the equipment by the owner / consultant at the manufacturers works

Unloading at site, watchward, handling and shifting , erecting on civil foundation

The technological equipment involved are broadly as follows:

The D.G unit shall comprise of Engine, Synchronous generator complete

TENDER - 1250 kVA DG SET

TS No. MEC/TS/05/21/006, Rev-0

The output rating of DG set shall be as specified in SOR/Data Sheet, at 0.8

Anti-vibration pads for the set.

Complete exhaust system including residential type silencer, spark arrester

TENDER - 1250 kVA DG SET

TS No. MEC/TS/05/21/006, Rev-0

Coupling & guards.

Complete instrumentation, controls & control panel.

All necessary interconnecting pipe works and valves.

Special tools and tackles for maintenance.

Drawing /documents /manuals /other data

Acoustic enclosure for the DG set in open execution.

Commissioning spares & supply of spares for 2 years operation.

Surface coating & final painting of complete system,

All the protection, monitoring and recording equipment.

All statutory approvals.

First fill of all consumables.

Fuel oil required during commissioning and PG test.

PAINTING, PACKING AND TRANSPORT

TENDER - 1250 kVA DG SET

TS No. MEC/TS/05/21/006, Rev-0

Major Civil works.

Illumination / Area lighting

Inlet to combustion air intake system.

Outlet of the exhaust system above acoustic enclosure above DG building

Inlet of additional fuel filling system.

Inlet of fuel filling system.

The D.G. Set shall meet the following operating conditions.