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TECHNICAL SPECIFICATIONS
FOR
DIESEL GENERATING SETS
REVISION NO. A R0 R1
ISSUED FOR REVIEW/ ISSEUED FOR REVISED AS PER
APPROVAL ENQUIRY RIL COMMENTS
PREPD.BY/DATE ET : 30/08/07 ET: 11/09/07 ET: 18/09/07
CHKD. BY/DATE PSL : 30/08/07 PSL : 12/09/07 PSL : 19/09/07
APPD. BY/ DATE
SPECIFICATIONS FOR DOCUMENT NUMBER
MH-IDMHMUMB001-E-SP-002
EQUIPMENT DESIGN DIESEL GENERATING SETS
Rev-R0
ENGINEERS
CLIENT : RELIANCE INDUSTRIES LTD. SHEET NO. 2 OF 41
III.EXCLUSIONS ..................................................................................................................................................................4
IV.DESIGN ..............................................................................................................................................................................4
V. SPARES .....................................................................................................................................................................4
VI.GENERAL..........................................................................................................................................................................6
VII.OPERATING CONDITIONS.........................................................................................................................................6
IX.PERFORMANCE REQUIREMENT..............................................................................................................................8
X.ALTERNATOR ...................................................................................................................................................................9
XVI.TESTS............................................................................................................................................................................37
XVIII.SPARES.......................................................................................................................................................................39
This specification covers the technical requirements of design, manufacture, inspection and testing at
manufacturer's works, delivery to site, supervision of erection, testing and commissioning of Four (4) nos.
diesel generator sets having generation voltage of 11kV, rated output of 3750KVA (continuous), 1500 rpm
comprising the following:
1. DG set complete with all ancillary equipment, accessories, instruments and associated controls.
2. Fuel oil system complete with 990 L. day tank, feed pump, priming pump, necessary piping,
valves, filters and strainers, instruments, accessories, etc.
3. Lubricating oil (L.O.) system complete with L.O. sump, L.O. Pump, necessary piping, valves and
fittings, filters and strainers, L.O. heat exchanger, instruments, accessories etc.
4. Compressed air assisted starting system with all accessories like compressor, compressed air
bottle, necessary piping, valves etc., electrical starter for the compressor, interconnecting LV
power and control cables to make the system self-sufficient. In case the Supplier’s standard
design provides for battery starting, he may offer complete system related to battery starting.
5. Air intake and exhaust system, complete with filters, silencers, ducts, pipe fittings & accessories
and supporting arrangement for exhaust system. The silencer shall be “residential” type.
6. Directly coupled A.C. machine (generator) with terminal box, rotating diode type brush-less
exciter, automatic voltage regulator, alarm initiating devices and other accessories.
7. Independent control panel with controls and instruments for each engine & alternator complete
with AMF facility for starting of the engine and with necessary controls, interlocks, protections,
metering and indications as per functional requirement of AMF feature. 11 KV VCB panel to be
installed local to the gensets, complete with all controls shall also be included under this facility.
8. Motors for auxiliary drives.
9. Automatic and Manual synchronizing equipment for 4 DG sets.
10. Anti-vibration pads for mounting of the DG set.
11. PLC control system with SCADA function for remote operation of the DG system with facilities for
event logging, trending, mimics alarm etc.
12. LT power cables and control & signaling cables for DG installation along with the cable schedule
for the same.
13. Supply of consumables/spares for testing and commissioning of the DG sets at site.
SPECIFICATIONS FOR DOCUMENT NUMBER
MH-IDMHMUMB001-E-SP-002
EQUIPMENT DESIGN DIESEL GENERATING SETS
Rev-R0
ENGINEERS
CLIENT : RELIANCE INDUSTRIES LTD. SHEET NO. 4 OF 41
The Bidder shall be responsible to obtain the approval of the Electrical Inspectorate or any other required
statutory authorities including approval from the Maharashtra Pollution Board and No Objection Certificate
from M.S.E.B. for the design, supply, installation, testing and commissioning of the equipment under his scope.
Necessary official fees and charges will be reimbursed by the Purchaser on production of the receipt. All the
required drawings, documents for the above purpose shall be prepared and supplied by the Supplier.
III. EXCLUSIONS
However design inputs for chimney, supporting structure and cooling tower to be provided by the vendor.
IV. DESIGN
The design and workmanship shall be in accordance with the best engineering practices, to ensure satisfactory
performance and service life. The equipment offered by the Supplier shall be complete in all respects. Any
materials or accessories, which may not have been specifically mentioned, but which are usual and necessary
for the satisfactory and trouble free operation and maintenance of the equipment, shall be provided without any
extra cost to the purchaser.
V. SPARES
Sufficient spares for the DG Sets , shall be provided by the Bidder for maintenance of the DG Set for at least
2Years after successful commissioning , separate Quotation shall be provided for the same.
Annual maintenance contract of the DG Set from the successful Bidder shall be negotiated separately.
All Commissioning SPARES are tobe listed for FREE supply by the Bidder.
SPECIFICATIONS FOR DOCUMENT NUMBER
MH-IDMHMUMB001-E-SP-002
EQUIPMENT DESIGN DIESEL GENERATING SETS
Rev-R0
ENGINEERS
CLIENT : RELIANCE INDUSTRIES LTD. SHEET NO. 5 OF 41
The design, construction, manufacture, inspection, testing and performance shall comply with all the currently
applicable statutes, safety codes, latest editions of relevant Indian Standards (IS), British Standards (BS),
International Electro Technical Commission (IEC) publication, NEMA and VDE Standards.
Some of the applicable Standards are given below:
IS 1601 - Performance & testing of IC engines for general purpose
BS-5514 - Performance & testing of diesel Part 3-5 engines for general purposes
IS-1600 - Type testing of constant speed internal combustion engines for general purposes
IS-1460 - Specification for diesel fuels
IS-4729 - Measurement and evaluation of vibration of rotating electrical machines
IS-78 - Guide for testing insulation resistance of rotating machines
IS-2516 - A.C. Circuit breakers
IS-3427 - Metal enclosed switchgear
IS-2705 - Current transformers
IS-3156 - Voltage transformers
IS-375 - Marking and arrangement for switchgear bus bars
IS-5422 - Turbine type generators
IS-4722 - Rotating electrical machines
IS-1885 - Electro technical vocabulary Part XXXV
IS-4729 - Measurement and evaluation of rotating electrical machines
IS-4728 - Terminal markings for rotating electrical machinery
IS-2208 - HRC cartridge fuse links up to 650V
IS-1248 - Electrical indicating instruments
IS-3231 - Electrical relays for power system protection
IS-5082 - Aluminium busbars
IS-3072 - Installation and maintenance of switchgear
IS-6875 - Control Switches
IS-2551 - Danger notice plates
IS-2253 - Designations for types of construction & mounting arrangement of rotating
electrical machines
IS-6362 - Designation of methods of cooling for rotating electrical
IS-4889 - Method of determination of efficiency of rotating electrical machinery
IS-4691 - Degrees of protection provided by enclosures for rotating electrical machinery
AIEE-60 - Recommended specification for speed governing of internal combustion engine
generator units
IEC-34 - Rotating Machines
The DG set shall also conform to the provisions of latest Indian Electricity Act, Indian Electricity Rules and
Regulations of Statutory Authorities (Chief Electrical Inspector to the Government) and the norms set by the
Pollution Control Board.
The equipment conforming to any other national standards, which ensure equivalent quality, are acceptable.
In such cases, the Bidder shall clearly indicate the standard adopted, and furnish a copy of the English
translation of the standard along with the tender. Should there be any dispute on design standard; the most
stringent one shall be adopted.
SPECIFICATIONS FOR DOCUMENT NUMBER
MH-IDMHMUMB001-E-SP-002
EQUIPMENT DESIGN DIESEL GENERATING SETS
Rev-R0
ENGINEERS
CLIENT : RELIANCE INDUSTRIES LTD. SHEET NO. 6 OF 41
VI. GENERAL
The diesel generating set shall be indoor type AMF operated and shall comprise of diesel engine,
coupled to a suitable alternator, having brush-less excitation system complete with all accessories.
All equipment shall be of the class most suitable for working under the specified conditions and shall
withstand the atmospheric conditions without deterioration and without affecting the performance
requirements.
Material of construction for interconnecting pipes, pipe fittings, exhaust duct, bolts and nuts shall be as
per relevant standards and suitable to withstand the temperature of the gas/liquid within the pipe. All
externally mounted hardware can be of cast iron.
Nameplates and labels provided for engine, alternator, control panel and Switchgear, accessories, etc.
shall be of stainless steel only.
D.G. sets are intended for supplying stand-by power as the most reliable source of supply, in the event
of failure of utility grid.
The electrical load for diesel generating system shall comprise HT (6.6 KV)/LT motors, lighting and
other miscellaneous loads fed through suitable step-down transformers.
The starting time of the set shall be kept to a minimum which has been specified in Annexure-I.
The DG sets shall be suitable for parallel operation among themselves. Parallel operation with utility
grid is not envisaged.
Momentary paralleling with grid at the time of restoration of power supply should be possible.
SPECIFICATIONS FOR DOCUMENT NUMBER
MH-IDMHMUMB001-E-SP-002
EQUIPMENT DESIGN DIESEL GENERATING SETS
Rev-R0
ENGINEERS
CLIENT : RELIANCE INDUSTRIES LTD. SHEET NO. 7 OF 41
X. ALTERNATOR
Type of filter in lube oil system to take load due Duplex type
to clogging of Lube filter
Arrangement to bypass the oil cooler during Required
starting until oil temperature rises above
minimum.
Bypass valve to prevent engine being starved of Required
oil in case filter is choked
Accessories such as pressure gauges, Required
temperature indicators, pressure relief valves,
bypass valves, pressure switches
Engine shaft driven lube oil pump 1
Electrical motor driven lube oil pump 1 working+ 1 standby
12 Lube Oil Coolers As Required
13 Engine starting system
Type of starting Compressed air starting
A PLC (Programmable Logic Controller) system shall be provided for centralized control of 4nos. 3750 KVA
DG sets. Only the functional requirement expected from the system are specified here. The Bidder has to
make his own estimate about hardware requirement.
9.1 SCOPE:
Supply of hardware to support the software and for operator interface.
Develop software based on the functional requirements stipulated in this specification.
Loading of the software into PLC system at the Bidder’s Works and testing by simulation.
Deliver the equipment at site.
Supervision of installation, testing and on load commissioning of the system.
Training of the Owner’s operating personnel for 5 working days for operating, maintenance trouble-
shooting, editing / modifications to the software etc.
Supply of essential spares.
Basic System
The basic system shall comprise the following:
Central Processing Unit.
Adequate Memory for storing and running of the software.
Interfacing device viz.
Key board
Mouse
17” flat screen Colour Monitor
Laser Printer for taking hard copy output.
Programming unit (as described below)
Adequate number of digital I / O racks.
Adequate number of Analogue / Analogue or Analogue / digital converters.
Sheet steel cabinet to house the CPU, I / O racks and converters etc.
Interconnecting cabling between various devices of the system
Self – diagnostics.
Back – up storage of the software.
Any other hardware / software that is required to make the system complete and fully operational. The
Bidder shall clearly spell out all such features is his Bid for better understanding / evaluation of his Bid.
System hardware requirement
CPU
The Bidder shall select the CPU with appropriate speed so that the software can be run with reasonable speed
and the data can be updated reasonably fast. The Bidder shall furnish technical particulars of the CPU offered.
MEMORY
Memory offered shall be adequate:
To store the entire software with at least 100% spare memory for future alternations additions / losses in
corrupt memory segments. (ROM / Hard Disk)
To run the entire software with at least 100% spare memory for the same purpose as above (RAM). The
Bidder shall furnish technical particulars of the Memory offered.
INTERFACING DEVICE
The keyboard, Mouse and 17” flat screen colour monitor shall be standard commercially available
device available in the market, to the extent possible.
PRINTER
This shall be standard commercially available laser type.
Programming Unit
This has been described in more details in the following paragraph under “Software”
SPECIFICATIONS FOR DOCUMENT NUMBER
MH-IDMHMUMB001-E-SP-002
EQUIPMENT DESIGN DIESEL GENERATING SETS
Rev-R0
ENGINEERS
CLIENT : RELIANCE INDUSTRIES LTD. SHEET NO. 34 OF 41
Digital I / O racks -
Digital input cards are required to accept inputs such as VCB auxiliary contacts, temperature switch,
pressure switch contacts etc. These shall be potential – free. The interrogating voltage shall preferably
be low voltage DC (such as 12 or 24 V. DC) which has to be generated by the Bidder. Digital output
cards, complete with heavy duty auxiliary interposing relays if required, shall be suitable for onerous
switching duty such as operation of VCB closing and tripping coil at 110 V. DC.
Analogue / Analogue or Analogue / Digital converters –
Analogue input signals such as DG set current and voltages shall be the inputs to the PLC system. Currents
shall be 0-1 A and voltages 0-110V corresponding to 0-11 kV, 50 Hz AC signals. The converters shall convert
them for use in PLC software.
Construction
The sheet steel cabinet shall be floor mounting, free – standing, CRCA sheet cabinet made out of 2 mm thick
sheet.
The sheet shall under go 7 – tank chemical pre-treatment which shall be followed by epoxy based powder
coating in shade RAL 7032 or the one approved by the Purchaser. The cubicle shall provide degree of
protection not less than IP 52. Neoprene gasketting shall be provided at the doors and all metal-to-metal
contacts. Louvres, if required, shall be covered by fine wire mesh.
The cable entry shall be from bottom. Panel earthing and system earthing shall be provided as detailed under
“Earthing“ below. If glass is used in the panel door for viewing of the PLC system, the same shall be heat
resistant toughened type.
The cubicle, in general, shall be aesthetically built and compatible with the system & its installation
Interconnecting Cabling –
All interconnecting cabling between the CPU, Digital I / O Racks, Analogue input racks, keyboard, mouse,
VDU, printer, programming unit etc. shall be included by the Bidder in his scope of supply.
Field cabling for digital inputs / outputs, analogue inputs etc. shall also be provided by the bidder.
Self Diagnostic
The PLC system shall be complete with hardware and software for providing self-diagnostic feature for the
system. Failure of power supplies, components, PCBs shall be indicated by RED LEDs. The LEDs shall be
tagged to indicate the type of failure that has taken place.
The Bidder shall furnish an operations and Maintenance Manual highlighting the steps that are to be taken by
the operator in the event of occurrence of such an event.
SPECIFICATIONS FOR DOCUMENT NUMBER
MH-IDMHMUMB001-E-SP-002
EQUIPMENT DESIGN DIESEL GENERATING SETS
Rev-R0
ENGINEERS
CLIENT : RELIANCE INDUSTRIES LTD. SHEET NO. 35 OF 41
Earthing
The Bidder shall clearly spell out the requirement of earthing, both panel frame earthing and signal earthing in
his bid. He shall highlight the requirement of “Clean Earth” if required. He shall also furnish specifications i.e.
size and shielded / unshielded cable for interconnection between PLC system and earth pits.
Training
The Bidder shall include in his scope training of Purchaser’s operating staff for a period of 5 working days. The
training shall cover a minimum of
SPECIFICATIONS FOR DOCUMENT NUMBER
MH-IDMHMUMB001-E-SP-002
EQUIPMENT DESIGN DIESEL GENERATING SETS
Rev-R0
ENGINEERS
CLIENT : RELIANCE INDUSTRIES LTD. SHEET NO. 36 OF 41
10 BIDDER’S EXPERIENCE
The Bidder shall furnish a reference list to establish his credentials by way of submitting a list of at least 5 nos.
industrial type projects executed in last 3 years of similar ratings.
SPECIFICATIONS FOR DOCUMENT NUMBER
MH-IDMHMUMB001-E-SP-002
EQUIPMENT DESIGN DIESEL GENERATING SETS
Rev-R0
ENGINEERS
CLIENT : RELIANCE INDUSTRIES LTD. SHEET NO. 37 OF 41
XVI. TESTS
Tests shall be carried out during and after completion of manufacture of different component parts and
the assembly, as applicable, in accordance with the requirement of relevant codes and standards.
Bidder shall indicate other tests, which are required to be carried out at site after installation.
Tests shall be performed in presence of Purchaser's representative if so desired by Purchaser, at
Supplier's works on completed assembly of the DG set. The Bidder shall give at least two (2) weeks
advance notice for inspection.
Following tests shall be carried out on the engine-generator completed assembly at manufacturer's works:
a) Power run of auxiliary equipment.
b) Functional checks and adjustments of speed governor and control devices.
25.1 The generator shall be subjected to following tests (for which only Test Certificates are required):
a) High voltage tests on stator and rotor windings.
b) Insulation resistance of stator and rotor windings.
c) Temperature rise test
d) Open circuit and short circuit tests.
e) Stator phase sequence check.
f) Overload capability test.
g) Measurement of air gap.
h) Stator winding resistance measurement
25.2 Excitation System
The excitation system shall be subjected to the following tests at manufacturer's works (for which only Test
Certificates are required):
a) High voltage tests on windings.
b) Insulation resistance of windings.
c) Temperature rise test.
d) Measurement of resistance of stator and rotor windings.
e) Open circuit magnetization test.
f) Functional check and operation of relays, protection, metering and signalling schemes.
25.3 Voltage regulator
The voltage regulator shall be subjected to the following tests at manufacturer's works (for which only Test
Certificates are required):
a) Sensitivity test.
b) Response time test.
SPECIFICATIONS FOR DOCUMENT NUMBER
MH-IDMHMUMB001-E-SP-002
EQUIPMENT DESIGN DIESEL GENERATING SETS
Rev-R0
ENGINEERS
CLIENT : RELIANCE INDUSTRIES LTD. SHEET NO. 38 OF 41
The tests shall be performed after proper installation of the diesel generating unit at site to prove the proper
operation of interlock circuits and the capability of the engine to start and pick-up load in the specified time,
under supervision of the purchaser's representative responsible for supervision of testing and commissioning.
Guarantee tests to prove guaranteed performance of the D.G. set shall also be carried out at site after proper
installation.
b. The test certificates shall be furnished to the purchaser for prior approval before despatch of any
equipment from works and the approval in writing from purchaser shall be essential to effect dispatch of the
equipment.
c. The test reports shall indicate complete identification of the data, including serial number of each
equipment.
SPECIFICATIONS FOR DOCUMENT NUMBER
MH-IDMHMUMB001-E-SP-002
EQUIPMENT DESIGN DIESEL GENERATING SETS
Rev-R0
ENGINEERS
CLIENT : RELIANCE INDUSTRIES LTD. SHEET NO. 39 OF 41
The Bidder shall furnish to the purchaser a complete and unused set of all special tools and tackles,
which are necessary or convenient for erection, testing and commissioning, maintenance and
overhauling of any of the equipment provided under this specification.
The tools shall be shipped in separate containers clearly marked with the name of equipment for which
they are intended.
The Bidder shall submit a list of tools proposed to be furnished under the scope of supply with his
proposal.
XVIII. SPARES
Adequate quantity of spares for DG sets, shall be provided by the bidder for maintenance of the Dg sets
at
least for 2 years after successful commissioning.
The bidder shall submit a list of recommended spare parts, with suggested quantities and catalogue numbers,
for ten(10) years smooth and trouble free operation.
SPECIFICATIONS FOR DOCUMENT NUMBER
MH-IDMHMUMB001-E-SP-002
EQUIPMENT DESIGN DIESEL GENERATING SETS
Rev-R0
ENGINEERS
CLIENT : RELIANCE INDUSTRIES LTD. SHEET NO. 40 OF 41