140 kVA DG SET R

Indent Number: IGC/ROMG/O&M/RMD/EMS/2014-7604
I.
Date: 29/09/2014
Description of the item:

TECHNICAL SPECIFICATION AND REQUIREMENT FOR 140 kVA DG SET
Design, manufacturing, aAssembly ,testing at manufacturers works, transportation,

safe delivery to site, guarantee, installation, testing and commissioning of 140 kVA
diesel generators at site 140kVA, 3 phase, 4 wire,415V, 50Hz, diesel generating sets
complete with 170BHP at 1500 rpm diesel engine, engine mounted manual control
panel, fuel oil tank and associated pipe line, batteries, spares and alternator with
latest CPCB approved acoustic enclosure, exhaust piping with cladding, residential
silencer, hot air ducting system and 4T pay load trailer with first fill of lub oil as per
following specifications and quantity at FBTR, IGCAR, Kalpakkam.
II.
A.
Detailed specifications and quantity :
140kVA, 3 phase & Neutral 4 wire, 415 Volts, 50Hz, Diesel
nos. 2 No
Generating sets complete with minimum170 BHP Diesel

Engine, engine mounted manual control panel, fuel oil tank
& associated pipe line, batteries and Alternator with latest
CPCB approved acoustic enclosure.
B.
C.
enclosure.
4T Pay Load Single Axle Trailer as per the drawing attched
Consumables for 5 years of trouble free operation of the
above DG setsSpares and consumables to be supplied along
with DG set
nos. 1
No
nos.
2Details
&
quantity given in
Para
Bidders shall furnish Guaranteed Technical Particulars (GTP) as per questionnaire

in annexure- IV.
Indent no. IGC/ROMG/OMG/RMD/EMS/2014-7604 dt. 29/09/2014
Specifications for 140m kVA Diesel Generator set :
1.
SCOPE:
Design,
manufacturing,
assembly,Assembly
testing
at
manufacturers
works,
transportation, safe delivery to site, guarantee, installation, testing and commissioning

at siteof 140kVA, 3 phase & Neutral, 4 wire,415V, 50Hz, diesel generating sets complete
with
Latest CPCB certified Acoustic enclosure and MCCB. The diesel engineshall be
capapble of not delivering less than 170BHP at 1500 rpm diesel engine and coupled with
140kVA , 415Volts, 50Hz alternator at 1500 rpm mounted on a common base frame
along with mounted instrument panel,, engine mounted manual control panel, fuel oil
tank and associated pipe line, batteries, spares
and alternator with latest CPCB
approved acoustic enclosure, exhaust piping with cladding, residential silencer, hot air
exhaust ducting system , residential silencer and a 4T pay load trailer with first fill of lub
oil as per following specifications at FBTR, IGCAR, Kalpakkam.
2.
2.1
PROJECT DATA:
Purchaser
:Indira Gandhi Centre for Atomic

Research, Kalpakkam.
2.2
Project
: IGCAR, Kalpakkam.
2.3
Location
: Kalpakkam, Kancheepuram District,

Tamil Nadu
2.4
Climatic conditions
: The climate is tropical with high

humidity and heavy rainfall conducive
to rust and fungus growth.
2.5
Ambient Air Temperature
: 45C
2.6
Installation
: a) 1 No to be mMounted on 4 T pay load

trailer.
b) 1 No Indoor Floor mounted.
2.7 Information to be included with the proposal:

The bidder shall submit all supporting information, technical data as requested in
Annexure IV to permit the purchaser to make a detailed comparison and evaluation of
the offers without the need for request for further information from the bidder. Tenders
submitted without these details shall be considered as incomplete and shall be laible for
rejection.
The tenderer may in addition, furnish any other supporting information, technical
data, drawings or booklets which in his view are necessary to assist the purchaser to
make detailed evaluation of his offer.
3.
APPLICABLE STANDARDS:
General requirements for rotating electrical machines
:IEC 34-1
Standard Specification for Rotating Electrical Machines
:VDE 0530, NFC 51.111
Specification for rotating electrical machines of particular

types or for particular applications. Generators to be
driven by reciprocating internal combustion engines
: BS 5000
3
Rotating Electrical Machines Specification
: IS 4722
Reciprocating compression Ignition (diesel) engines
: BS 649-1958/
ISO 3046-1: 2002
BS 5514
ISO 8528
4.
TECHNICAL SPECIFICATIONS:
4.1 Diesel Engine:
Four stroke, 6 Cylinder, water cooled with radiator and fan, turbocharged, diesel engine
developing not less than suitable for 140kVA generating set, developing 170 BHP, rated
at 1500 RPM under NTP condition of BS:649/ ISO 3046-1: 2002 and complete with the
following standard accessories
1.1.1
Flywheel with improved coupling model.
4.1.2
Coupling.
4.1.3
Dry type air cleaner
4.1.4
Corrosion inhibitant coolant
4.1.5
Radiator &, fan, ( Bblower type)
4.1.6
Fuel injection pump equivalent to PT type fuel pump
4.1.7
Hydraulic / ElelctronicGovernor
4.1.8
Lubricating Oil Filter and fuel oil filter- paper element filter
4.1.9
Lubricating Oil by Pass Filter
4.1.10
Silencer (Domestic) and Exhaust Piping with necessary bend and flanges.
(Approximately 6 mtrs long) and lagged with 19mm dia. Improved thermal
insulation completely including aluminum cladding.
4.1.11
Low Lub. Oil pressure safety cutout
4.1.12
High water temperature safety cutout
4.1.13
Over Speed Protection
4.1.14
Lubricating Oil drain: suitable piping with valve shall be provided and
extended out of engine lube oil tank to facilitate easy draining of oil.
4.1.15
Electrical Starter motor 24V DC, 20A DC or 12V dc-
4.1.16
Starting battery : The batteryElectrical starter motor shall bewith lead acid
Type and maintenance free starting batteries and leads. The battery shall
have a capacity for four nos. of consecutive start attempts on the engine.
4.1.17
Turbo charger
4.1.18
Fasteners as per load requirement. AVM pads shall be suitably placed inside
acoustic enclosure between engine, alternator and their base frame.
4.1.19
Common Base frame for mounting of Diesel Generator Set: Ssturdy,

fabricated, welded Construction, channel iron base frame for mounting the
above Engine & Alternator.
4.1.189
Exhaust Silencer (Residential) Exhaust piping with necessary bend and

flange. (Approximately 6 Mtrs. Length) Exhaust piping with flexible
connection shall be fixed with suitable flanges and supported from the roof.
The entire length shall be painted with aluminium paint and insulated with
improved thermal insulation. Exhaust pipe end shall be provided with
gravity flap to facilitate automatic opening of exhaust pipe during engine
running. Suitable rain hood shall also be provided.
4.2
Engine Mounted manual control panel

The manual control panel shall have the following features.
Starting switch with key
Lub oil temperature gauge
Lub oil pressure gauge
Water temperature gauge
Run time totaliser Total hours run Hour meter
RPM indicator
Emergency Stop Push Button
Engine Overload Protection with alarm device
4.2.1 Meters
KW and kVA meter
Frequency
Ammeter
Voltmeter
Excitation current ammeter
Battery voltage
4.2.2 Protection for the engine with indication

Low lub oil pressure
High coolant temperature
Engine overspeed
High/ low dc voltage indication
4.2.3 Protection for the alternator with indication

Under voltage
Over voltage
Under frequency
Over frequency
Over current
4.2.4 MCCB
Suitable 4 pole MCCB, rated for 140kVA, with overload and short circuit protection
is to be housed in the manual control panel with indicator. It is to be connected to
the alternator terminal by suitable cable. Suitable provision shall be available in

the acoustic panel for the outgoing cable. The manual control panel shall be
earthed properly and a common earth terminal brought out for connection to
nearest earth connection.
4.3
Fuel Tank:
Fuel tank of suitable capacity, minimum 8 hours continuous running at full load,
properly designed for safety, with fill and drain valve and level indicator. The tank
can be installed on the base frame with suitable support. The tank can be either
integrated with frame or detachable.
Calibrated Fuel level graduate gauge preferably glass, with cocks on both top &
bottom for easy replacement. Fuel inlet for filling with locking arrangement in the
top lid. Fuel outlet with globe valve arrangement.
Air vent (Breathing arrangement with De-hydrating agent actuator)
Drain plug.
Fuel supply pipe line shall be stainless steel in single length at site from fuel tank
to fuel filter with proper connections for the fuel inlet lines.
Fuel return pipe line shall be stainless steel in single length at site from fuel tank
to fuel filter with proper connections for the fuel return lines.
Necessary stand for mounting the fuel tank with proper stiffeners shall be
provided with channel sections at the bottom of the tank and tested for leak.
Outside surface of the tank shall be painted with two coats of black synthetic
enamel paint.
4.4
Alternator:
Alternator shall be , brushless type, self excited and self regulated giving an output of 112KW/140KVA , at 0.8 pf lag, 415Volts, 3 phase, 4 wire, 50Hz at
1500RPM. Band of voltage regulation 2.5 % of rated voltage from no load to full
load. The Insulation class shall be class H with temperature rise limited to class F
and suitable for operation at an aAmbient Aair tTemperature 45 C, without any
derating.
The alternator shall confirm to IS 4722.
The alternator shall have cable box suitable for 3 1/2 core 185 sq. mm Aluminium
cable. Cable, cable glands and lugs required for connecting the power cable from
the generator to the distribution panel (available at site) will be supplied by the
department as a free issue item and the same shall be installed by the contractor
as directed by the Engineer-in Charge. Grounding of the equipment shall also be
carried out by the contractor as directed by the Engineer-in-Charge.
The alternator shall have brushless excitation and a screen protected drip proof IP
23 S Enclosure.
Insulation
: Class H for stator with temp. rise limited to Class F

: Class H for Rotor
Winding
: Vacuum pressure impregmnation
stator impregnated with dip & bake method.

Rotor impregnated with Hot rolled dip method.
Excitation
Regulation
Unbalanced load
: Brushless single voltage regulation excitation

analogue type electronic AVR control.
: single Automatic voltage regulation.
: 3 phase sensing of voltage,
current and power factor to give
good operation against unbalanced

load. (30% capability)
Motor starting capacity : shall possess motor starting capacity
of the order of 1.8 to 2 times the full
load current.
Parallel Running
: Not Applicable
Ingress Protection
: IP 23 S
Short Circuit
: shall have High sustenance of short
Susceptance
circuit current of 3 to 3.5 times full

load current for 3 seconds.
Epoxy Coating
: All wound components shall be

epoxy coated after impregnation
Routine Tests
: Shall be conducted on the machine

at no extra cost.
4.5 Brushless Excitation System
Apart from the voltage regulation characteristics Tthe excitation system shall have
the following provisions- advantages.
a.
Voltage build-up from residual magnetism.
b.
Protection against low speed operation
c.
Good motor starting, the compound system giving 1.8 to 2 times full load
capability.
d.
Sustained short circuit of the order of 3 times full load current.
e.
Voltage / Hertz responsive with any abrupt reduction in speed from the
engine a corresponding reduction in voltage output relieves the engine load
allowing for faster re-establishment of correct speed.
f.
Voltage dip on acceleration of full load 0.8 power factor in the order of 15 to
20%.
g.
Recovery time at constant speed for full load application less than 0.5
seconds.
h.
Limiting of over voltage increase of regulator failure of the voltage rise shall
be limited.
i.
3 phase sensed system shall allow good operation with unbalanced load
system.
j.
Shall have good over load characteristics.
4.6
Acoustic Enclosure as per CPCB Approved:
The acoustic enclosure fro hosuing the DG set shallbe of sutable size as epr norms
prescribed CPCB. The guatnteed nosie leveles shall be of 75 decibels or less at 1 meter
distance as stipulated by CPCB. The enclosure should be fabricated using high-grade
cold rolled annealed (CRCA) sheet having 2mm thickness & steel members. High-density
sound absorption material is used to reduce the sound level to 75 DBA at a distance of 1
meter away from the set conforming to IS 8528 Part 10. The enclosure shall be surface
treated and painted with high quality polyurethane epoxy paints with prior Zinc Oxide
primer base, which makes it weather proof and suitable for out door application. The
enclosure is provided with durable industrial locking system with doors duly gasketed.
The enclosure shall have the following features.
specially designed to meet stringent MOEF/CPCB norms of 75 DBA @ 1 mtr at 75% load
under free field conditions
single point lifting for easy handling at customer site
designed to have optimum serviceability
air inlet louvers specially designed to operate at rated load made on special purpose
CNC machines for consistency in quality and workmanship
with UV resistant powder coating, can withstand extreme environments
use of special hardware for longer life
flush styling non projections
flush drains for lube oil and fuel
-
fuel filling point.

The acoustic enclosure consists of the following.
4.6.1 Acoustic Insulation:

High-density resin bonded suitable density rock Lloyd fiberglass should be
provided on all five sides including door, roof and base to absorb noise. The
10
insulation is covered with fiberglass cloth and is supported by perforated

sheet. Sound attenuators/down stream silencers are provided at all openings
for air inlet/outlet to facilitate free airflow but to absorb sound resulting in
extremely low noise level. Detachable partitions are provided inside the
enclosure to attain further noise attenuation of engine. Insulation material
shall meet IS 8183 specifications for better sound attenuation.
4.6.2 Noise Suppressor:

A suitably designed residential type noise suppressor should be provided
which minimizes the exhaust noise of the engine.
Exhaust System:
The exhaust gas should be out through a specially designed flexible pipe, which
prevents any back pressure on the engine and shall be covered with glass wool and
claded with Aluminium sheets to avoid heating of DG set chamber.
Thermal Insulation:
The exhaust system and noise suppressor should be provided with thermal
insulation by using glass wool & cladding it with aluminium sheet. Residential type of
silencer is to be provided which is to be isolated from main DG chamber to avoid excess
heat in generator set operational area.
4.6.5 Air Circulation and Ventilation System:
A suitable air circulation and ventilation system should be designed to maintain safe
operating temperatures inside the enclosure.
4.6.6 Safety & Earthing:
There should preferably be a high temperature alarm/ indication to prevent
any damage to the DG set due to rise in temperature. Suitable extended
earth terminal to be provided to suit 50 x 6 mm of Tinned Copper flats at
both sides.
11
4.6.7 Internal Lighting:

The DG set chamber shall be fitted with internal lighting system for easy maintenance,
for which cabling etc. is to be provided by the contractor.
e Suppressor:
A suitably designed residential type noise suppressor should be provided
which minimizes the exhaust noise of the engine.
4.8 Exhaust System:

The exhaust gas should be out through a specially designed flexible pipe,
which prevents any back pressure on the engine and shall be covered with
glass wool and claded with Aluminium sheets to avoid heating of DG set
chamber.
4.9 Thermal Insulation:

The exhaust system and noise suppressor should be provided with thermal
insulation by using glass wool & cladding it with aluminium sheet. Residential
type of silencer is to be provided which is to be isolated from main DG chamber
to avoid excess heat in generator set operational area.
4.10 Internal Lighting:

The DG set chamber shall be fitted with internal lighting system for easy
maintenance, for which cabling etc. is to be provided by the contractor.
5.0
TRAILER SPECIFICATIONS:
12
4T pay load Two axle single axle each at front and rear flat bed, draw bar full
trailer fitted with 7.50 X 20 -12 PR tyres ( 4 nos.), turn table, tow bar, spring
cushioned tow eye as per the drawing. The trailer shall be provided with suitable
jacks for parking. The dimensions given in the drawing are approximate and shall
be suitable to the DG to be supplied.
6.0
DEVIATIONS FROM SPECIFICATIONS:

The bidder shall note all the details of the specifications and hence shall confirm
that the offered system is as per this complete specification. In case of any
deviations from the specifications, the deviations shall be clearly listed referring to
the clause of this document in order, under the specific heading of deviations. If
bids do not list deviations specifically under this heading or do not confirm there
are no deviations from the tender document, will not be considered for evaluation.
6.0 DELIVERY:
Design,
manufacture,
assembly
of
components,
inspection,
testing
at
manufactures works, packing, supply and delivery at Indira Gandhi Centre for
Atomic Research, Kalpakkam shall be within 2 months from the date of placement
of purchase order.
Contractor shall prepare all equipment covered by this specification for transport
in such a manner as to protect it from damage in transit and ingress of water and
shall be responsible for and make good at his own expense any and all damage
due to improper packing. The contents shall be identified on the package. The
packing shall be marked with lifting and hook-up points for unloading.
The contractor shall make his own arrangements for the transportation and safe
storage at site.
Installation, testing and commissioning of the DG set shall be completed within 15
days from the date of delivery at site.
13
4 sets of operation, maintenance and troubleshooting manual complete with

drawings and test reports shall be sent with the DG set. Set of essential spares
required for next 5 years of trouble free operation of the DG sets shall also be sent
along with the DG. The quotation shall be accompanied by a list of such spares
required.
7.08.0
DRAWING INSPECTION AND TESTING:
The following test reports / drawings shall be submitted for our approval -.
Factory test reports for Diesel Engine, Alternator and other bought out items.
Foundation detail drawing.
Specification and make of component.
Operation, Maintenance and trouble shooting manual.
7.18.1
Inspection and testing
The DG set shall be assembled and offered for inspection at factory before
despatch. Lube oil & fuel oil required for initial filling and for carrying out all the
tests at site shall be provided by the contractor free of cost. The loading
arrangement for carrying out all the tests at site will be made available by the
department. The tests to be carried out at works and site are given in Annexure -1
Refer annexure I
8.0 PAINTING:
Exposed surfaces of the engine and alternator shall be given two coats of Aircraft
Grey synthetic enamel paint (shade 631 of IS 5) over the original paint provided by
the equipment manufacturer after necessary cleaning / Surface treatment. Fuel
tank outer shall be painted with 2 coats of Black synthetic enamel over a coat of
red oxide primer. Inner surface of tank shall be given a coat of oil & heat resistant
paint.
14
The fabricated panel shall be degreased, phosphated and two coats of lead primer
applied before final painting. The panel inner surface shall be painted with white
glossy paint and outer surface with light grey shade 631 of IS 5.
Surface treatment and finish:
i.
All interiors and exteriors shall be finished and painted to produce a neat,
fire resistant and durable surface which would prevent rusting and
corrosion. Sheet metal components shall be pre-treated using the 7 tank
phosphating process consisting of de-greasing, acid pickling, de-rusting,
phosphating and passivation including repeated rinsing in between. On
completion of the passivation of the components they shall be preheated.
ii.
Within 24 hours of metal treatment high lustre zinc chromate primer will be
air sprayed and then stoved. Blemishes will be covered by applying putty
and baking. Extra putty will be removed by sanding, and a second coat of
primer applied. The final coat of synthetic enamel (IS5 shade 631) will be
sprayed and stoved to achieve excellent anti-rusting and scratch resistance
properties. Thickness of painting shall be around 60 microns. Powder
Coated finish will be acceptable.
iii.
Steel components will be phosphated, stained and oiled. Fasteners will be

electro-galvanised.
9.0 INSTALLATION AND COMMISSIOING AT SITE:

Refer annexure- II
10.0 GUARANTEE:
Supplier shall provide the guarantee of minimum 12 months after successful

commissioning at site and 18 months from the date of supply, whichever is
15
earlier. Supplier shall provide all service and spares support free of cost during
the above guarantee period.
Supplier shall furnish certificate for providing service & spares support,
mentioning validity of the certificate for min10 years, along with assurance to
intimate in advance the obsolescence of the offered systems or its components.
11.0 ACCEPTANCE CRITERIA:
The following shall be the acceptance criteria. Bids with any deviation from the
table below shall not be considered for evaluation.
1
2
3
4
5
6
7
8
9
DG Set Power Rating @ 0.8 p.f. (kVA)

DG Set Power Rating (ekW)
Bulk Loading (%) (Min)
Tolerance as per ISO 3046 (Max)
Ambient Temperature (design) (C)(max)
Lube oil consumption @ full load (L/h) (Max)
Lube oil specification (Min)
Lube oil sump capacity (L) (min)
Fuel consumption in ltrs/hr @ 75% load
140
112
40
5%
45
0.05
CF4 15W40
14
10
11
12
13
14
with radiator & fan (max)

Fuel tank capacity (L)( min)
Voltage regulation (max)
Efficiency of the alternator (min)
Permissible overload(min)
Performance Guaranteed on noise level (dBA
23
200
+- 1%
90
10%
15
@ 1 m)(max)
75
Meets with Latest emission limits prescribed for new diesel engines
(up to 800 kVA for generator set (DG Sets) applications, under
notification no.GSR371 (E) Dt. 17.05.2002, no. GSR 520 (E) Dt.
01.07.2003 & No. GSR 448 (E) Dt. 12.07.2004 notified by Ministry
of environment and forests, Government of India.
12.013.0
PRICE SCHEDULE: As per annexure-III enclosed.
13.0 14.0 PREFERRED MAKE OF COMPONENTS:

16
14.1
Diesel Engine with acoustic insulation - CUMMINS/ KIRLOSKAR/Ashok
leyland
14.2
Alternator
- Kirloskar Electric /Stamford/ Crompton
III.
Detailed Justification in the case of Proprietary Items :
IV.
List of Suppliers suggested for contacting :
NA
List of suppliers to be contacted:

a)
M/s Powerica Ltd.,

6D & 6E, GEE GEE Emerald,
312, Village Road, Nungambakkam, Chennai 600 034.
b)
Generator India Corporation,

No.1/37, Bharathiyar st.,
Moovarasanpet, Madipakkam, Chennai-91.
c)
ELMECH ENGINEERS,
1402, Chiranjiv towers,
43,Nehru place, New Delhi,
DELHI-110019.
d)
M/s. Jeevan Diesels and Electricals Ltd.

No-3C, Riaz Garden, 3rd Floor,29,,
Kodambakkam High Road
Chennai - 600 034
e)
M/s. Jeevan Diesels and Electricals Ltd.

R.S.NO.55/1, Cuddalore Main Road
Kattukuppam Manapet Post
Pondicherry - 607 402
Kirloskar
17
Ahsok lelan Leypower dealer
V.
Special Instructions, if any, to Purchase Section :
Among others enquiry may also be sent to the above suppliers.
VI.
Any Other Relevant Information : -NIL
18
ANNEXURE-I
Inspection & testing at works:

Acceptance Tests:
The Diesel Generator unit and the auxiliaries shall be fully assembled with piping,
fittings as per layout at the suppliers works and the following load tests shall be
performed in the presence of departments representative.
i)
One hour at full load.
ii)
One hour at 25% load.
iii)
One hour at 50% load.
iv)
One hour at 75% load
v)
Four hours at full load followed by one hour continuous load of 110%
Tests shall include measurements, calculations functional checks as per BS 5514

part 4, ISO 3045IV.
vi)
During load test thetest ,the following parameters shall be recorded.

Voltage regulation and response time for sudden application and sudden
withdrawal of 25%, 50%, 75% and 100% load.
Speed regulation and response time for sudden application and sudden
withdrawal of 25%, 50%, 75% and 100% of load.
Fuel consumption at 25%, 50%, 75%, & 100% of load.
Engine parameters like speed, water temperature, lube oil temperature and
pressure.
Electrical parameters like frequency, voltage and current.
vii)
Logic checks.
19
viii)
Physical verification of components.
ix)
Winding resistance and insulation resistance measurement for alternator

winding.
x)
Insulation resistance measurement for power and control circuits.
xi)
High voltage test for power circuit (2.5 kV for one minute) and control circuit (2
kV)
xii)
Calibration of gauges, meters and instruments.
Note: Lube oil required for initial filling of the engine and the fuel oil required for
carrying out all the tests at the manufacturers works shall be supplied at no extra
cost.
Special Tests
Following special tests shall be conducted in presence of departments representative

on completely assembled DG set. Reference standards shall be ISO 3046/IV-1978.
i)
soundSound level (Guaranteed noise level of 75 dBA is measured at 1 metre

from DG set at any direction with acoustic enclosure). The type approval
certificate for 75dBA by the respective government nodal agency nominated by
CPCB is also acceptable.
ii)
Diesel Engine shall be run at rated load and rated speed for 4 hrs. continuously
following manufactures recommendations. There shall be no failure of
components, auxiliaries and there shall be no break in service during this
period due to failure of any of the engine components and auxiliaries.
The supplier shall furnish details of all tests that will be conducted at their
works as well as at site. In all cases, the supplier should submit detailed testing
procedure for purchasers approval well in advance.
Inspection and testing at site:

20
Physical verification of components.

Visual examination for defects, transit damages etc.
Checks for assembly, alignment, grouting, fuel, lubricating oil, water and air
circuits.
Checks for power cabling control wiring and earth connections including
terminations.
Winding resistance and insulation resistance measurement for alternator
winding.
Insulation resistance measurement for power and control circuits.
Load test for 8 hours (not less than 6 hrs at 100% load) and recording the
following. System load available at site shall be used for testing purpose.
Voltage regulation at 25%, 50%, 75% and 100% load.
Speed regulation at 25%, 50%, 75% and 100% load.
Fuel consumption at 25%, 50%, 75% and 100% load.
Engine parameters like speed, water temperature, lube oil temperature and
pressure.
Electrical parameter like frequency, voltage and current.
Note : Supply should also include first fill of Lubricating opil and Fuel oil
required for acrrying out all the test at site
21
ANNEXURE- II
INSTALLATION AND COMMISSIOING AT SITE

Scope
The scope of this specification includes receipt of material covered under the
tender at site, transportation to Diesel Generator location, installation, commissioning
and conducting tests on Diesel Generator set, auxiliaries as per ISO: 3046 part-IV to the
satisfaction of the purchaser.
22
Standards
Material/Equipment
covered
under
the
specification
shall
be
installed,
commissioned conforming to manufacturers recommendations and best engineering

practices. The layout of equipment shall be as per the approved layout drawings.
Items included in the scope of work

The scope of work includes all works required from the receipt of materials at site
up to final handling over to the purchaser of complete equipment after acceptance
testing. However a few details of scope are as below.
i) Receipt of material/equipment transported by the equipment supplier from the

railway station or at site in case of road transport, unloading, transportation to
the work.
ii) Preparation of site for installation of equipment.
iii) Supply, Installation, alignment etc., for diesel engine, alternator and all other
auxiliary systems, control cabling, necessary piping, fuel hose as per approved
drawings and manufacturers recommendations for Diesel Generator and
auxiliaries. Grounding of base frames for diesel engines, alternator, supports for
supporting piping etc., as required. Cost of all items required for installation and
commissioning the system shall be included along the main item and no separate
payment will be entertained for those items.
iv)Unloading and positioning of 1 no. DG set and accessories mounted over the
mobile 4 wheeler trailer at IGCAR.
v) Installation, alignment, & positioning of 1 no. DG set on floor.
vi)Installation of fuel tank, fuel oil lines, exhaust pipe with supports etc.
vii)Initial charging of batteries.
viii)
Initial filling of lub. oil and fuel oil.
23
ix) The entire DG and mobile truck shall be properly earthed with adequate cross
section of copper / Aluminium conductors and with a provision for connection to
the nearest earth bus/ pit as required. Earth pit and earth strip are not in
suppliers scope. Earth connection shall be provided for the alternator and frame
& also for the manual control panel. All the earth connections shall be brought
out to a common point and made available for connection to the nearest earth
available.
x) Laying, dressing, clamping and connection of cables between the DG set and the
manual control panel & the alternators terminal box to an isolation switch near
the manual control panel is in the scope of the supplier. The cables required for
connection between the distribution panel (available at site) and the isolator will
be supplied by the department free of cost during commissioning.
xi) Inspection, testing and commissioning the DG set.
xii)Test result and parameter shall be recorded in the approved format and submitted
to the Engineer-in-Charge.
xiii)
Location and size of the fuel tank shall be selected suitably and required
length of fuel hose supplied.

xiv)
At site, all works related of DG sets shall be executed by the contractor.
xv) Conducting pre-commissioning and commissioning checks and tests on all

systems of the diesel generator at site.
xvi) Conducting tests at works on the diesel engine, alternator set and auxiliaries,
setting of pressure, temperature, level transducers for alarm/trip functions,
governor adjustment etc as required, as per manufacturers recommendations. (All
instruments, recorders etc., as required shall be provided by the contractor).
xvii)
Preparation of commissioning reports and submission of the same for
purchasers approval. Reports shall contain record of all activities, data, checks,
tests, carried out during installation and commissioning. Six copies of such
reports shall be submitted in bound volumes before the completion of the job.
24
xviii)
Supply of consumables like suitable welding electrodes, packing plates,
hardware, grouting cement etc., wherever required, approved lubricants, cotton

waste etc., as required for installation and commissioning.
xix) Final finish painting of all surfaces, providing necessary thermal insulation
wherever required including painting exhaust pipes with High Temperature
resistance paint.
Items not included in the scope of work
Following items are not included in the scope of erection and commissioning
contract:-
i) DG set foundations, (however alignment, levelling etc., of base frames is included

in the scope of work), finish flooring of the Diesel Generator LOCATION.
ii) Earth pit and earth strip.
iii) Lighting and ventilation of Diesel Generator AREA.
At site, all civil works will be executed by the Department. However minor
repair/modification works if any shall be done by the supplier.
Safety
i) Successful bidder shall be responsible for safety of the equipment at all times
during the period of contract. Contractor shall replace/repair all components or
equipment which in the purchasers view are damaged by the contractor during
the contract period
ii) Contractor shall ensure safety of crew employed for erection/commissioning of the
Diesel Generator sets by providing workmen adequate protective gear as required,
25
by employing skilled and trained labour for this kind of jobs, by enforcing safety
norms to be followed by his workmen.
iii)
Purchaser reserves the right to enforce additional safety measures as

required from time to time in the interest of equipment and workforce.
Approval of erection /commissioning procedures
i) Contractor shall before the commencement of work submit detailed procedure for
erection. Commissioning of Diesel Generator set and auxiliaries. Actual erection/
commissioning
of equipment
shall start
only after
the
approval
to
inspect
of
the
procedures/methods submitted by the contractor.
ii) Purchasers
site
engineers
shall
have
the
access
erection,
commissioning procedures being followed by the contractor and contractor shall

provide all necessary instruments required for inspection.
When informed by the purchasers inspector about non-conformance erection/

commissioning procedures, standards, tolerances etc., as the case may be
contractor shall rectify the error and damage to the equipment if any, due to
contractors mistakes during erection/commissioning to the full satisfaction of
purchaser.
Superintendence and labour

The contractor shall provide supervision and work force for erection which shall
include, but limited to the following:
The employment of a competent erection superintendent who shall be constantly

at the site and shall give his whole time to the superintendence of the erection of the
26
works and whose duties shall include the supervision of the unloading, assembly and
installation, repair, replacement of any damaged components and any operating
adjustments.
The
employment
of
sufficient
number
of
assistants
to
the
erection
superintendent for supervision and work force for the number of working shifts per day
and days per week to complete the work within the time specified.
The contractor shall employ only such persons as are careful, skilled and
experienced in their several trades.
Notices
Any notice, order, direction or other communication to be given to the contractor
under any of the provision of the contract shall without limitation be conclusively
deemed to have been received by the contractor if delivered or mailed to the contractor at
the address mentioned in the contract or the contractors last known place or business
or residence or to his superintendent or foreman.
Sub-Contracts
The contractor shall not sub-let the whole/or part of erection work. The contractor
shall not sub let any part of the erection work without the written consent of the
purchaser. The contractor shall be responsible to the purchaser for all the work of the
sub-contractor. Any sub-contractor shall be bound to the contractor by the terms of
drawings and specification and shall assume towards the contractor all the obligations
and responsibilities that the contractor assumes towards the purchaser.
Co-Ordination Work
The contractor shall plan his operations so as to avoid interference with the
operation of the purchasers of others contractors or sub-contractors at the site. The
contractor shall organize his work to suit the timings shown on the construction
27
schedule or revisions thereto issued by the purchaser. The work also be co-ordinated
with running units that shut down wherever instructions are involved.
Planning
Before commencement of the job, contractor shall provide detailed schedule for the
completion of the job indicating target for the completion of major events, manpower
requirement during various stages of erection & commissioning.
Clean-Up
The contractor shall at all times keep the site free from the accumulation of waste
materials and debris and upon completion of the of the job shall clean and dispose of all
surplus materials, rubbish and temporary works of whatsoever nature and kind as
directed by the purchaser and shall leave the works and site clean and tidy.
Services to be provided by the purchaser

During the execution of the works, the purchaser shall provide for the contractor
temporary electric power at 415 volts, 3 phase, 50 Hz and 230 volt, Single phase, 50 Hz
free of charge subject to the following conditions.
The electric power will not be used for heating purposes.
The contractor shall make his own arrangements for the supply, erection and
dismantling on completion of the works of his temporary distribution system,
distribution panels and other equipment he may require for taking the power from the
purchasers supply points.
The purchaser will supply his power to the contractor at a point which will be
within 100 meters of the location of the works.
28
The contractors temporary distribution system including metering shall be subject in

every respect to the approval of the purchaser and shall be so arranged as to avoid any
interference with the operations of the other contractors on the site.
The purchaser will not hold himself responsible for the consequences of any
unintentional interruptions to the continuity of the power supply or power system
voltage and frequency fluctuations.
Transportation of erection equipment and material to the site:

The contractor shall be responsible for all transportation and erection of
equipment and material to and from the site.
Access roads and temporary buildings

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

The contractors lump sum erection prices shall include all travelling, medical,
transportation and accommodation costs of all his site forces including supervisory.
Access to site
Storage space for parts which cannot be moved directly and stored inside the plant
building will have to be placed temporarily in the site storage yards and uplifted at the
time of installation. Storage areas will be located within 1 km of the DG room.
Site welding
The contractor shall have all welding procedure, welder qualified and welding
equipment in accordance with the ASME Boiler and Pressure Vessels Code Section IX
29
prior to commencing or any welding at site. Faulty welds caused by poor workmanship
or lack of supervision on the part of contractor shall be cut-out and re-welded at the
contractors expenses. The procedure for the repair of deflecting welds shall be provided
by the purchaser prior to any repair being made.
Security rules
The contractor shall follow at site all security rules as may be framed by the
purchaser from time to time regarding removal of material from site, issue of identity
cards, control of entry of personal and all similar matters. The contractors and his
personnel shall abide by all security measures imposed by the purchaser or his duly
authorized representative from time.
ANNEXURE- III
DESCRIPTION QUANTITY AND PRICE DETAILS TO BE FURNISHED
WITH THE BID
Sl.
No
1.
Description
Supply of 140kVA 415V 3 phase &
Neutral DG set with starting batteries,
Quantity
Unit
Total cost
Price(Rs)
(Rs)
2 Nos
30
2.
3.
4.
5.
6.
standard accessories, acoustic enclosure

as per the detailed Assembly, testing,
guarantee and supply of 140KVA Diesel
Generating set
as per specifications.
4T pay load Twosingle axle trailer as per
1 nNo.
the drawing
Installation, commissioning, alignment,
& positioning of 1 no. DG set Indooron
1 No
anti vibration mounting pads.
Positioning and commissioning of 1 no.
1 Noset
DG set and accessories mounted over
the mobile 4 wheeler trailer at IGCAR.
Cost of transportation of complete Lump
equipment to IGCAR (Total)
Consumables for 5 years of trouble free
sum
Lump
operation of DG set
sum
The overall lowest cost for all the six five items together mentioned above will be
considered for arriving the lowest offer.
Rates quoted for consumables will not be considered for evaluation.
Consumables shall be quoted including mobil oil and coolant for one replacement.
ANNEXURE-IV
31
GUARANTEED TECHNICAL PARTICULARS
Sl.
No
1
TECHNICAL PARTICULARS
TO BE FILLED BY THE
BIDDER
Name of DG set manufacturer
Model Number
Rated power output and duty cycle
Rated voltage, current, power factor
and frequency
Rated voltage regulation
Maximum temperature rise of DG
set
Efficiency of the alternator
Speed of revolution (RPM) at no
load and at rated load

Direction of rotation
10
Type of excitation and excitation
11
12
voltage
Standards complied with
Ambient site conditions for which
13
the DG set is suitable.

Type of enclosure
14
Type of loads for which the genset is
15
suitable.
Maximum load that can be
switched on or off & voltage
Drop/rise permitted.
32
16.
16.1
Details of prime mover

Engine model number & its
16.2
manufacturer
Type of engine.
16.3
Fuel tank capacity (it shall be

suitable for eight hours continuous
16.4
running of DG sets at full load)

Specific fuel consumption in
16.5
(ml/kwh)
Rated engine power and ambient
condition at which rated power is
16.6
defined
Other standard fittings of the
engine to be specified by the
17
tenderers
Dry weight of the DGset
18
Maximum continuous operating
19
time at rated load

Peak power output and the
duration for which the DG set is
capable of delivering this output
20
Type of battery, battery voltage,

battery capacity and charging unit
21
details
Maximum emission level (max. limit
22
of each constituent) to be specified

Details of the trailer, type of wheel
and number of each type of wheel
23
provided.
Deviation in the generator
specification from IS specification if
33
24
24.1
any
Package performance
DG Set Power Rating with fan@ 0.8
24.2
24.3
24.4
p.f. (kVA)
DG Set Power Rating with fan(ekW)
Bulk Loading (%)
Time required to develop rated
voltage & frequency form the point
24.5
of sensing power failure

Time required to take full load from
25
the point of sensing power failure

Fuel Consumption
25.1
100 % Load with fan ((L/h)
25.2
75 % Load with fan ((L/h)
25.3
Tolerance as per ISO 3046
25.4
Ambient Temperature (design) (deg

C)
25.5
Air flow restriction (system) (Kpa)
26
Cooling System
26.1
Fan air flow across radiator (cfm)
26.2
Engine Coolant capacity (L)
27
Exhaust system
27.1
Combustion air inlet flow rate

(CFM)
27.2
Exhaust stack gas temperature (deg
34
C)
27.3
Exhaust Flange size (internal
27.4
diameter) (mm)
Exhaust system back pressure
28
(maximum available) (kPa)

Lube system
28.1
Lube oil consumption @ full load

(L/h)
28.2
Lub oil sump refill capacity with

filter (L)
29
Others
29.1
Fuel tank capacity (L)
30
Alternator
30.1
Rating (kVA)
30.2
Rating (Kw)
30.3
30.4
Pitch Preferred
Full Load current (amps)
30.5
Efficiency @ 100 %
30.6
Efficiency @ 75 %
30.7
Efficiency @ 50 %
30.8
Length (mm)
30.9
width (mm)
35
31
Acoustic enclosure
31.1
Height (mm)
31.2
Performance Guaranteed (Dba @ 1

m)
Emissions
Meets with latest emission limits prescribed for new diesel

engines (up to 800 kVA for generator set (DG Sets)
applications, notified by ministry of environment and forests,
Government of India.
36
The dimension in the drawings are approximate and can be suitably modified to
accommodate the 140 kVA diesel generator.
Signature of Indentor
Signature of Approving Authority
37

140 kVA DG SET R

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140 kVA DG SET R

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Indent Number: IGC/ROMG/O&M/RMD/EMS/2014-7604

Description of the item:

Design, manufacturing, aAssembly ,testing at manufacturers works, transportation,

Detailed specifications and quantity :

140kVA, 3 phase & Neutral 4 wire, 415 Volts, 50Hz, Diesel

Generating sets complete with minimum170 BHP Diesel

Bidders shall furnish Guaranteed Technical Particulars (GTP) as per questionnaire

Specifications for 140m kVA Diesel Generator set :

transportation, safe delivery to site, guarantee, installation, testing and commissioning

and alternator with latest CPCB

:Indira Gandhi Centre for Atomic

: Kalpakkam, Kancheepuram District,

Indent no. IGC/ROMG/OMG/RMD/EMS/2014-7604 dt. 29/09/2014

: The climate is tropical with high

Ambient Air Temperature

: a) 1 No to be mMounted on 4 T pay load

2.7 Information to be included with the proposal:

General requirements for rotating electrical machines

Standard Specification for Rotating Electrical Machines

:VDE 0530, NFC 51.111

Specification for rotating electrical machines of particular

Rotating Electrical Machines Specification

Reciprocating compression Ignition (diesel) engines

4.1 Diesel Engine:

Flywheel with improved coupling model.

Dry type air cleaner

Corrosion inhibitant coolant

Radiator &, fan, ( Bblower type)

Fuel injection pump equivalent to PT type fuel pump

Lubricating Oil by Pass Filter

Low Lub. Oil pressure safety cutout

Indent no. IGC/ROMG/OMG/RMD/EMS/2014-7604 dt. 29/09/2014

High water temperature safety cutout

Over Speed Protection

Electrical Starter motor 24V DC, 20A DC or 12V dc-

Common Base frame for mounting of Diesel Generator Set: Ssturdy,

Exhaust Silencer (Residential) Exhaust piping with necessary bend and

Engine Mounted manual control panel

Indent no. IGC/ROMG/OMG/RMD/EMS/2014-7604 dt. 29/09/2014

Run time totaliser Total hours run Hour meter

4.2.2 Protection for the engine with indication

4.2.3 Protection for the alternator with indication

the alternator terminal by suitable cable. Suitable provision shall be available in

Indent no. IGC/ROMG/OMG/RMD/EMS/2014-7604 dt. 29/09/2014

The alternator shall confirm to IS 4722.

: Class H for stator with temp. rise limited to Class F

: Vacuum pressure impregmnation

stator impregnated with dip & bake method.

: Brushless single voltage regulation excitation

Indent no. IGC/ROMG/OMG/RMD/EMS/2014-7604 dt. 29/09/2014

good operation against unbalanced

: shall have High sustenance of short

circuit current of 3 to 3.5 times full

: All wound components shall be

: Shall be conducted on the machine

4.5 Brushless Excitation System

Voltage build-up from residual magnetism.

Protection against low speed operation

Sustained short circuit of the order of 3 times full load current.

Indent no. IGC/ROMG/OMG/RMD/EMS/2014-7604 dt. 29/09/2014

Shall have good over load characteristics.

Acoustic Enclosure as per CPCB Approved:

fuel filling point.