Rev 0 Ps For Gg Set1

PURCHASE SPECIFICATION (TOP SHEET) Issue. Status (Fill 1 or 2 from below in this bracket [1]) 1. Entire Requisition Issued 2. Only revised pages are issued

ITEM : Gas Generator (GG) Sets

DOCUMENT NUMBER (Always quote the Document Number given below as reference)

P.S

A

ETP-RJY/E/PS/1004

0

27.01.2015

DOC.

CATEGORY

DOC NO.

REV.

DATE

M/s Automatic Electric Ltd. VENDOR CODE

VENDOR NAME

Material to be delivered at (Job site) ___ As per PO__ Within the delivery period specified in the "Purchase Order" (PO) Note: 1. This page is a record of all the Revisions of this Requisition. 2. The nature of the Revision is briefly stated in the "Details " column below,the Requisition in its entirely shall be considered for contractual purposes. 3. When a Requisition is revised, only the revised pages may be issued. 4. When revised pages only are issued, the revised pages shal from part of the original Requisition along with the revised pages shall be considered in its entirely for contractual purposes. REV.

DATE

BY

CHK

APPD

DETAILS

0

27.01.2015

VCS

LNK

AVB

Issued for Approval

A

19.11.2014

VCS

LNK

AVB

Issued for Approval

APPROVED  JV of MEIL-APLUS M/s SHIVA GENSETS PRIVATE LIMITED.

MMPL

ONGC

Date :27.01.2015

Date :

Date :

Project : CONSTRUCTION OF ETPs AND LAYING OF ASSOCIATED PIPELINES AT RAJAHMUNDRY ASSET (ETP-RJY)

SHEET 1 OF 1

CONSTRUCTION OF ETPs ALONG WITH THE LAYING OF ASSOCIATED GRE PIPE LINES AT RAJAHMUNDRY ASSET

Rev: 0A

PS FOR GAS GENERATOR (GG) SET



Doc No: ETP-RJY/E/PS/1004 



PS FOR GAS GENERATOR (GG) SETS

 

LSTK Contractor

Client

Joint Venture of MEIL-A PLUS

Oil and Natural Gas Corporation Ltd

S-2,Technocrat Indl Estate,

8th Floor,Core-3,Scope Minar ,

Balanagar,

Laxmi Nagar,

Hyderabad – 500037

Delhi-110092 (India)

Tel No: +91 40 44336700

Tel: (O) 91-11-2240 6720,

Fax: +91 40 44336800

Fax: 91-11-2240- 6690

CONSTRUCTION OF ETPs ALONG WITH THE LAYING OF ASSOCIATED GRE PIPE LINES AT RAJAHMUNDRY ASSET PS FOR GAS GENERATOR (GG) SET

Rev: 0

Doc No: ETP-RJY/E/PS/1004 

PS FOR GAS GENERATOR (GG) SETS

Issue and Revision Record: Rev

Date

Prepared

Checked

Approved

Description

0

12.01.2015 27.01.2015

VCS

LNK

AVB

Issued for Approval

A

19.11.2014

VCS

LNK

AVB

Issued for Approval

Group Disclaimer

“This document is issued for the party which commissioned it and for specific purposes connected with the above-captioned project only. It should not be relied upon by any other party or used for any other purpose. We accept no responsibility for the consequences of this document being relied upon by any other party, or being used for any other purpose, or containing any error or omission which is due to an error or omission in data supplied to us by other parties.”

 



CONSTRUCTION OF ETPs ALONG WITH THE LAYING OF ASSOCIATED GRE PIPE LINES AT RAJAHMUNDRY ASSET PS FOR GAS GENERATOR (GG) SET

Rev: 0



Doc No: ETP-RJY/E/PS/1004 

INDEX SI.No

 

Contents

Page No

1.

MTO

01

2.

Bill Of Materials

3.

Functional Specifications

4.

GA Drawings

27

5.

Engine Data Sheet

34

6.

Alternator Data Sheet

38

7.

Scope of Supply

41

8.

Make of Major Components

45

9.

QAP

47

10.

Form-B

56

11.

Form-C

58

12.

Form-D

60

13.

LOI & Acceptance

63

14.

Type Test Reports

67

15.

NOA for M/S Shiva Gensets Pvt. Ltd.

76

16.

PTR

78

17.

Catalogue

89

18.

OEM Undertaking Letter

105

03 0606

Page 1

CONSTRUCTION OF ETPs ALONG WITH THE LAYING OF ASSOCIATED GRE PIPE LINES AT RAJAHMUNDRY ASSET PS FOR GAS GENERATOR (GG) SET

Rev: 0A

Doc No: ETP-RJY/E/PS/1004 

MTO FOR GAS GENERATOR (GG) SETS

 



Page 2

CONSTRUCTION OF ETPs ALONG WITH THE LAYING OF ASSOCIATED GRE PIPE LINES AT RAJAHMUNDRY ASSET PS FOR GAS GENERATOR (GG) SET

Rev: 0A



Doc No: ETP-RJY/E/PS/1004 

MTO FOR GAS GENERATOR (GG) SETS

Sl. No

Site Location

Description

Quantity

1

Kesanapalli

500KVA

2

2

Lingala

500KVA

2

3

Gopavaram

500KVA

2

 

Page 3

CONSTRUCTION OF ETPs ALONG WITH THE LAYING OF ASSOCIATED GRE PIPE LINES AT RAJAHMUNDRY ASSET PS FOR GAS GENERATOR (GG) SET Doc No: ETP-RJY/E/PS/1004 

BILL OF MATERIALS

 

Rev: A 0



Page 4

Page 5

Page 6

CONSTRUCTION OF ETPs ALONG WITH THE LAYING OF ASSOCIATED GRE PIPE LINES AT RAJAHMUNDRY ASSET PS FOR GAS GENERATOR (GG) SET

Rev: A 0

Doc No: ETP-RJY/E/PS/1004 

Functional Specifications

 



Page 7

STANDARD SPECIFICATION FOR GENERATOR SET CONSTRUCTION OF EFFLUENT TREATMENT PLANTS AT RAJAHMUNDRY ASSETS ONSHORE ENGG SERVICES

Doc No: 269635-008-SP-4003

Rev: A

Page 1 of 20

Vol :IIIA

Section : 29



Standard Specification for Generator Set



 Oil and Natural Gas Corporation Limited

Mott MacDonald Consultants (India) Pvt. Ltd. Kothari House, CTS No. 185 Off Andheri - Kurla Road Andheri (East) Mumbai 400 059

Page 8

STANDARD SPECIFICATION FOR GENERATOR SET CONSTRUCTION OF EFFLUENT TREATMENT PLANTS AT RAJAHMUNDRY ASSETS ONSHORE ENGG SERVICES

Doc No: 269635-008-SP-4003

6HFWLRQ











Rev: A

Page 2 of 20

Vol :IIIA

Section : 29













3DJH1R

1.

Intent

3

2.

Codes & Standards

3

3.

Area Classification

5

4.

Basic Engine Design

5

4.1.

General

5

4.2.

Rated Power Output And Specific Fuel Consumption

5

4.3.

Engine Starting System

6

4.4.

Engine Fuel System – (For Diesel Engines)

7

4.5.

Engine Jacket Cooling System

7

4.6.

Combustion Air Intake & Engine Exhaust System

8

4.7.

Governing

9

4.8.

Noise And Exhaust Gas Emission

9

4.9.

Name Plate

9

4.10.

Special Requirements

9

5.

6.

Accessories

9

5.1.

Couplings And Guards

9

5.2.

Base Plate

10

5.3.

Special Tools

10

5.4.

Instrumentation

10

Electrical Requirements

10

6.1.

Alternator: Construction

10

6.2.

Excitation System

11

6.3.

Other Design Parameters

12

6.4.

System Operation

13

6.5.

Generator Control Panel

14

6.6.

Synchronizing Panel

16

7.

Painting & Name Plating

17

8.

Inspection & Testing

17

9.

Drawings & Documents

18

10.

Transport & Shipment

20

11.

Warranty

20

Page 9

STANDARD SPECIFICATION FOR GENERATOR SET CONSTRUCTION OF EFFLUENT TREATMENT PLANTS AT RAJAHMUNDRY ASSETS ONSHORE ENGG SERVICES

1.

Doc No: 269635-008-SP-4003

Rev: A

Page 3 of 20

Vol :IIIA

Section : 29

Intent This specification covers the requirements of design, manufacturing, fabrication, assembly, testing at works, packing, supply, receipt at site, installation, testing and commissioning of diesel engine or gas engine driven self excited generator set complete with all materials and accessories for efficient and trouble-free operation. The generator set shall be supplied complete with:

2.

(a)

Engine

(b)

Alternator

(c)

Brushless excitation system complete with AVR.

(d)

Local control panel including control cubicle and associated auxiliary devices, generator breaker.

(e)

AMF panel built-in the local control panel (if specified in data sheet).

(f)

Synchronizing panel located in PMCC room (if specified in data sheet).

(g)

Acoustic Enclosure

(h)

All accessories, as necessary.

Codes & Standards Equipment and their accessories covered by this specification shall be designed, manufactured and tested in compliance with the latest relevant standards published by the Bureau of Indian Standards (BIS) or International Electro−technical Commission (IEC) including their latest revisions /amendments. In the event of conflict, the following order of precedence shall prevail.   

Electrical and Mechanical Design Criteria This Specification Codes and standards

Some of the applicable standards are listed below: ISO: 3046-l

− Reciprocating Internal Combustion Engines - Performance Part 1: Standard reference conditions, declarations of power, fuel and lubricating oil consumptions and test methods.

ISO: 3046-3

− Reciprocating Internal Combustion Engines - Performance Part 3: Test measurements

ISO: 3046-4

− Reciprocating Internal Combustion Engines - Performance Part 4: Speed governing

ISO: 3046-5

− Reciprocating Internal Combustion Engines - Performance Part 5: Torsional vibrations

ISO: 3046-6

− Reciprocating Internal Combustion Engines - Performance Part 6: Overspeed protection

ISO: 8528-l

− Reciprocating Internal combustion engine driven alternating current generating sets Part 1: Application, ratings and performance

ISO: 8528-2

− Reciprocating Internal combustion engine driven alternating current generating sets Part 2: Engines



Page 10

STANDARD SPECIFICATION FOR GENERATOR SET CONSTRUCTION OF EFFLUENT TREATMENT PLANTS AT RAJAHMUNDRY ASSETS ONSHORE ENGG SERVICES

Doc No: 269635-008-SP-4003

Rev: A

Page 4 of 20

Vol :IIIA

Section : 29

ISO: 8528-5

− Reciprocating Internal combustion engine driven alternating current generating sets Part 5: Generating sets

ISO: 8528-6

− Reciprocating Internal combustion engine driven alternating current generating sets Part 6: Test methods

ASME

− The American Society of Mechanical Engineering Boiler and Pressure vessel code, Section VIII, Rules for Construction of Pressure vessels, and Section IX, Welding and Brazing Qualifications.

EEMUA

− Engineering Equipment and Material User’s Association Pub. No. 107 Recommendations for the protection of Diesel Engines for use in Zone 2 Hazardous area.

OISD 113

− Standard on classification of area for electrical installations at hydrocarbon and handling facilities.

IS – 2253

− Designations for types of construction and mounting arrangements of rotating electrical machines.

IS - 4691

− Degree of protection provided by enclosures for rotating electric m/cs

IS – 4722

− Specification – Rotating electrical machines.

IS - 4728

− Terminal markings and direction of rotation for rotating electrical machinery.

IS - 4889

− Methods of determining of efficiency of rotating electrical machines

IS - 6362

− Designation of methods of cooling for rotating electrical machines.

IS - 7132

− Guide of testing of synchronous machines

IS - 7306

− Methods of determining synchronous machine quantities form tests.

IS - 7372

− Lead acid storage battery for motor vehicle.

IS – 7816

− Guide for testing insulation resistance of rotating machines.

IS - 10118

− Code of practice for selection, installation & maintenance of switchgear and control gear

IS – 12065

− Permissible limits of noise levels for rotating electrical machines.

IS - 12075

− Measurement & evaluation of mechanical vibration of rotating electrical machinery.

IS – 12802

− Temperature rise measurements of rotating electrical machines.

IS - 12824

− Type of duty and classes of rating assigned to rotating electrical machines

IS – 13364

− AC Generators upto 20 KVA driven by reciprocating internal combustion engine.

IS – 13364, PartII

− AC Generators above 20 and upto 1250 KVA driven by reciprocating internal combustion engine.



Page 11

STANDARD SPECIFICATION FOR GENERATOR SET CONSTRUCTION OF EFFLUENT TREATMENT PLANTS AT RAJAHMUNDRY ASSETS ONSHORE ENGG SERVICES

Doc No: 269635-008-SP-4003

Rev: A

Page 5 of 20

Vol :IIIA

Section : 29

IS-13703

− Low voltage fuses.

IS - 13947

− Specification for Low-Voltage Switchgear and Control gear - Part 4 : Contractors and Motor-Starters - Section 1 : Electromechanical Contactors and Motor Starters

IEC 60947

− Low-voltage switchgear and controlgear

Note:•

All the definitions as indicated in ISO:3046 shall apply for Reciprocating Internal Combustion Engines.

•

All the definitions as indicated in ISO:8528 shall apply for Reciprocating Internal combustion engine driven alternating current generating sets.

However, all equipment shall conform to the latest Indian Electricity Rules as regards safety, earthing and other essential provisions specified therein for installation and operation of the plant. All items of equipment shall also comply with the latest regulations of statutory bodies of Government of India and the State Government, as applicable. Nothing shall be construed to relieve the Contractor of this responsibility.

3.

Area Classification Electrical and Instrumentation shall be rated for the applicable Hazardous Area classification according to OISD standard 113 and latest DGMS notifications.

4.

Basic Engine Design

4.1.

General The Engine selected shall be vendor’s standard model after taking into consideration the requirement of the driven equipment, transmission losses, site de-ration and power requirements of auxiliaries and other parasitic loads. Engine Manufacturer’s de-ration calculations for the specified site conditions shall be furnished along with the bid. As a minimum, the vendor shall consider the de-ration due to ambient temperature, altitude, relative humidity, cooling water temperature, inlet and exhaust losses etc. De-ration factor shall be worked out as per ISO: 3046. In case there is no de-ration for the specified site conditions, the Engine Manufacturer’s statement along with justification shall be furnished along with the bid. Standard reference conditions shall be as defined in ISO: 3046-1.

4.2.

Rated Power Output And Specific Fuel Consumption

4.2.1.

Engine The engine rating is the net shaft output in Kilowatts which the engine is capable of delivering continuously; between the normal maintenance intervals stated by the manufacturer, at the stated crankshaft speed and under stated ambient conditions assuming that the maintenance prescribed by the manufacturer being carried out. Engine Rating indicated by the manufacturer in the Equipment data sheet shall be with no negative tolerance.



Page 12

STANDARD SPECIFICATION FOR GENERATOR SET CONSTRUCTION OF EFFLUENT TREATMENT PLANTS AT RAJAHMUNDRY ASSETS ONSHORE ENGG SERVICES

Doc No: 269635-008-SP-4003

Rev: A

Page 6 of 20

Vol :IIIA

Section : 29

The engine shall be capable of providing an overload power of 110 % of the continuous rating at the same stated crankshaft speed for one hour with or without interruption, within a period of 12 hours of operation. Specific fuel consumption shall be indicated at 100% continuous rating as defined in clause above. The tolerances shall be as per ISO:3046- 1. 4.2.2.

Engine-Generator Set The power of the Generator Set is the power output available at the generating set terminals excluding the electrical power absorbed by the essential independent auxiliaries. Power rating of the Generator Set is the power output expressed in kilowatts at rated frequency and a power factor of 0.8 lagging unless otherwise stated. The DG set rating indicated by the manufacturer in the Equipment Data Sheet shall be with no negative tolerance. Unless otherwise specified, Generator sets whether required for continuous duty operation or intermittent / emergency service shall be capable of delivering specified power rating continuously for an unlimited number of hours per year between the stated maintenance intervals and under stated ambient conditions, assuming that the maintenance being carried out as prescribed by the manufacturers. Specific fuel consumption shall be indicated with reference to the electrical power i.e. 100% continuous rating of the Generator set, available at the terminals, taking into account the electrical power required for the auxiliaries fed from engine developed power and other power loss in the generator for a given power and power factor. The tolerances shall he as per ISO:3046-l. The vendor shall furnish with his proposal, a list of engine auxiliaries, which require electrical power. All such auxiliaries shall be further categorized on the basis of :

i.

If these are required to run continuously / intermittently.

ii.

If these are required to run before engine starting, during starting or required to run after start-up.

iii. If the above are required to be fed from engine developed power (In such a case, feeding arrangement shall be in vendor’s scope). The vendor shall clearly identify those auxiliaries, which shall be required to be fed by the Consultant/Owner.

4.3.

Engine Starting System Unless otherwise specified, the type of starting arrangement shall be battery starting. Engines shall be capable of starting without the use of cold starting aids for ambient temperatures of 4°C and above. The Vendor shall provide suitable cold starting aids with engines for quick starting at ambient temperatures below 4°C and such aids shall be clearly detailed out in the offer. Lubricating oil heaters shall not be used as a cold starting aid. Where the engine is specified/ offered with battery starting arrangement, the starter motor shall be suitable for the specified electrical area classification. Where the engine is equipped with a dual starter, the synchronising switch and the corresponding wiring/ connection with the starter motor shall be provided by the Vendor. Where the engine is specified/ offered with compressed air starting, the vendor shall specify the starting air pressure required for cranking. Unless otherwise specified the vendor shall also provide



Page 13

STANDARD SPECIFICATION FOR GENERATOR SET CONSTRUCTION OF EFFLUENT TREATMENT PLANTS AT RAJAHMUNDRY ASSETS ONSHORE ENGG SERVICES

Doc No: 269635-008-SP-4003

Rev: A

Page 7 of 20

Vol :IIIA

Section : 29

Two air compressors (one driven by a diesel engine and the other by electric motor) and air receiver(s). The system shall be provided with necessary instruments, controls and safety devices. Starting air compressors and its diesel engine driver shall be as per manufacturer’s standard and shall be proven with adequate running experience. Vendor shall however furnish with the bid full technical details of air compressor unit and its instruments/ controls. The air receiver supplied by the Vendor shall be sized for at least six consecutive starts without recharging. Air receivers shall meet ASME Section VIII & IX specifications and he equipped with a safety valve, gauge and drain valve. Where the engine is specified / required to start and/or stop automatically, the vendor shall provide the necessary controls (Automatic-curn-manual) in the engine panel, the interconnecting wiring, piping/tubing from panel to the engine and the starting/stopping equipment. A pilot lamp shall be provided in the starting equipment/control panel to indicate that the controller is in automatic position. In the event the engine does not start after three attempts the controller shall stop further cranking and operate the audio visual alarm. For engines requiring pre-lubrication immediately before startup, electric motor driven prelubrication pump connected to emergency power source with timer, suitably interlocked with the starting system shall be provided by the vendor. Unless otherwise specified the emergency power source shall be furnished by the vendor. For engines which do not require pre-lubrication immediately before start but require periodic prelubrication to keep engine lubricated for automatic start, an AC motor driven pre-lubrication pump with automatic start-stop and timers, set for specific running time to provide pre-lubrication after preset periods of intervals shall be provided by the vendor. For engines, which have only manual starting/stopping, a vendor’s standard manual prelube pump shall be provided, unless vendor does not recommend the same and proposes other means to be adopted for any pre-lubrication after prolonged shut down periods. Such means shall be explained in the bid.

4.4.

Engine Fuel System – (For Diesel Engines) A fuel float (surge) tank shall be provided along with its interconnecting piping/ hoses, in case Fuel Day tank is mounted above engine fuel connection level so as to ensure that the system does not permit gravity flow to the engine through fuel supply line during engine shutdown. The fuel day tank as a minimum shall be equipped with vent piping with flame arrester. Shielded level gauge, strainer and a hand hole of not less than 150 mm diameter, besides the required fuel connections and a drain valve. Fuel Day tanks for diesel engine driving generator shall be located outside the DG room or Fire water pump house irrespective of the capacity/ size of the fuel day tank. For all other applications, unless otherwise specified, the size of the fuel tank (day tank) shall be for six hours of engine operation at full load, limited to 990 litres.

4.5.

Engine Jacket Cooling System Engine jacket cooling system (primary Circuit) shall be closed circuit liquid cooled type including circulating pump, make up tank, heat exchanger, temperature regulating device, engine outlet cooling water temperature high alarm & trip device etc. The heat exchangers i.e. oil coolers and engine cooling water coolers, can be of any one of the following types as specified in the enquiry:



Page 14

STANDARD SPECIFICATION FOR GENERATOR SET CONSTRUCTION OF EFFLUENT TREATMENT PLANTS AT RAJAHMUNDRY ASSETS ONSHORE ENGG SERVICES

Doc No: 269635-008-SP-4003

Rev: A

Page 8 of 20

Vol :IIIA

Section : 29

a. Water cooled shell and tube type. b. Air cooled type i.e. Radiator type with engine driven fan. For radiator cooled engines, the engine shall be provided with a radiator including radiator fan, temperature control valve, expansion tank, radiator guard and other necessary piping and valves. Either Radiator shall be mounted on a common base plate or remote radiator shall be provided as specified in Scope of Work enclosed elsewhere in the bid package. The engine manufacturer depending on the service, size of engine, noise limitation and his experience may offer, subject to Consultant/Owner’s approval, remote mounted radiator system with separately driven radiator fan and additional cooling water booster pump located in the engine return line. Height of the expansion tank in the closed circuit cooling shall be at the highest level in the complete circuit. Piping connections from cooling water outlet from the top of the Engine to the top portion of the radiator shall be continuously sloping towards the engine without any pockets. Shell & tube heat exchangers shall be of single pass type with secondary cooling medium (raw water/ or any other coolant specified in the enquiry) passing through the tubes. Heat exchanger shall be of vendor’s standard design and sized for heat rejection of at least 15% greater than engine full load heat rejection.

4.6.

Combustion Air Intake & Engine Exhaust System The vendor shall prepare a layout drawing showing the layout and routing of air intake and engine exhaust piping/ducting. and include in his scope complete piping/ducting, nozzles, expansion joints and supports as required as per his layout and routing. The type and location of air intake filter shall be vendor’s standard and shall be suitable for the climatic/environmental conditions applicable to the site of installation of the engine. In case the filter is located outside the engine building/ engine enclosure, vendor shall provide the following for the filter

i.

Insect screen

ii.

Rain hood

iii. Supporting structure with approach for maintenance. The filter shall be suitably located to prevent exhaust gases getting into the intake air. Exhaust gas discharge shall be located away from ventilation air intakes to prevent re-entry of offensive fumes and also should not cause discomfort to personnel or hazards to building or equipment. Unless otherwise specified or required as per applicable statutory regulation1 the height of the engine stack from the base of the engine room shall be as under H = h + 0.2 * ¥kW where H = minimum height of the exhaust from base, m h = height of engine room eves level from the base/ height of engine acoustic enclosure from the bases, m kW = kW site rating of the engine, kW.



Page 15

STANDARD SPECIFICATION FOR GENERATOR SET CONSTRUCTION OF EFFLUENT TREATMENT PLANTS AT RAJAHMUNDRY ASSETS ONSHORE ENGG SERVICES

4.7.

Doc No: 269635-008-SP-4003

Rev: A

Page 9 of 20

Vol :IIIA

Section : 29

Governing Unless otherwise specified in the equipment data sheets, the engine shall be provided with Class A2 governing as per ISO: 3046. In case engines are required to drive generators in parallel, the governor - fuel injection pumps provided shall have identical characteristics.

4.8.

Noise And Exhaust Gas Emission Unless otherwise specified, any applicable legislation/ statutory requirements relating to the protection of environment and to the health and safety of personnel, with regard to noise and exhaust gas emission, as applicable to the place of installation shall be fully complied with by the Engine manufacturer. In case of Diesel Engine Generating sets, the DG set vendor shall also be responsible for complying to the requirements specified in any applicable official Gazette Notifications issued by Ministry of Environment and Forests, Govt. of India, for all installations intended to be located in India.

4.9.

Name Plate A name plate of l8Cr-8Ni stainless steel or Monel shall be attached by pins of a similar material to the Engine and to any other piece of major auxiliary equipment, in a location permitting easy visibility. The Consultant/Owner’s item number, the vendor’s name, serial number, rating and testing data appropriate to the unit shall appear on all name plates.

4.10. Special Requirements 4.10.1. Diesel Engine for Hazardous Area Application Engines required to be installed in Zone 2 Hazardous area shall comply with the requirement stipulated in EEMUA Pub. No.107. Flame arresters (Flame Trap), inlet air shutoff valve, exhaust spark arrester etc. shall be provided by the engine vendor in accordance with EEMUA Pub. No. 107.

5.

Accessories

5.1.

Couplings And Guards Couplings shall be sized for maximum continuous torque, which is based on the potential maximum power of the engine. Couplings for generator drive application and for horizontal pumps shall be flexible type. For vertical pumps right angle gear drive with suitable universal joint shall be used. The coupling used shall be successfully proven for the service being used. The service factor used shall be conservatively selected for the maximum horsepower rating of the engine with a factor of not less than 1.7. Non sparking guards are required over all moving parts and shall be constructed either from Aluminum alloys (other than Al-Magnesium alloy) or sheet metal lined with non sparking material. The guards shall be securely attached to the base plate on foundation by means of bolts. The guard shall be sufficiently rigid to withstand deflections as a result of bodily contact of nominally 100 kgs.



Page 16

STANDARD SPECIFICATION FOR GENERATOR SET CONSTRUCTION OF EFFLUENT TREATMENT PLANTS AT RAJAHMUNDRY ASSETS ONSHORE ENGG SERVICES

5.2.

Doc No: 269635-008-SP-4003

Rev: A

Page 10 of 20

Vol :IIIA

Section : 29

Base Plate Unless otherwise specified, a common base plate for the complete unit (engine and the driven equipment) shall be supplied by the vendor. A baseplate shall be a single fabricated steel unit, unless the Consultant/Owner and the vendor mutually agree that it may be fabricated in multiple sections. When specified, the base plate shall be suitable for column mounting i.e. of sufficient rigidity to be supported at specified points without continuous grouting under structural members. The base plate shall be provided with lifting lugs for a four point lift. Lifting the base plate complete with all equipment mounted shall not permanently distort or otherwise damage the base plate or the machinery mounted on it. The bottom of the base plate between structural members shall be open. When installed on a concrete foundation, accessibility for grouting under all load carrying structural members shall be provided.

5.3.

Special Tools When special tools and fixtures are required to disassemble, assemble or maintain the unit, they shall be included in the quotation and furnished as part of the initial supply of the machine.

5.4.

Instrumentation The vendor shall supply instrumentation and control system as specified in the enquiry. If in the opinion of the vendor, additional instruments, controls and safety devices are required, the vendor shall include the same in his scope of supply.

6.

Electrical Requirements

6.1.

Alternator: Construction

6.1.1.

The alternator shall be driven either by a diesel engine or a gas engine as specified in “Electrical Scope of Work” in bid document.

6.1.2.

The alternator with its drive unit shall be suitable for operation in indoor area having temperature maximum up to 5 Deg C above outdoor ambient temperature of 50 Deg C. Ventilation system to maintain inside temperature rise within this limit, if required shall be provided.

6.1.3.

The alternator shall be directly coupled to the prime mover and have a suitable fly wheel to ensure torque variation within acceptable limits. The alternator with its prime mover and all auxiliary items shall be mounted on a steel base-frame fitted with suitable anti-vibration isolators / pads. The generator shall be provided with necessary lifting hooks and two earth terminals on opposite sides for connection to main earth grids.

6.1.4.

Generator rating shall be the net output of the set at specified site conditions after accounting for all auxiliaries for the prime mover and the alternator.

6.1.5.

The machine shall be rotating field stationary armature type, brushless & self-excited. Alternator enclosure shall be IP-23 (minimum) with winding given suitable treatment to render it nonhygroscopic. The alternator winding shall be of class ‘F’ insulation with temperature rise limitation for class ‘B’. The windings and overhangs shall be braced to withstand the short circuit forces. Machines rated 400 kW and above shall have six nos. RTDs, unless specified otherwise in data sheet (one per phase between the coil sides to measure winding temperature and one per phase 0 at the base of slots to measure core temperature, each placed at 120 apart).

6.1.6.

The stator winding shall be star connected and all windings shall be brought out to six insulated terminals in a terminal box. Alternator rated 500 KW and above shall also be provided with neutral terminal box in addition to line terminal box. The stator neutral side connection shall be brought in



Page 17

STANDARD SPECIFICATION FOR GENERATOR SET CONSTRUCTION OF EFFLUENT TREATMENT PLANTS AT RAJAHMUNDRY ASSETS ONSHORE ENGG SERVICES

Doc No: 269635-008-SP-4003

Rev: A

Page 11 of 20

Vol :IIIA

Section : 29

neutral cubicle having protection CTs. The terminal boxes for line terminals and neutral shall have sufficient space for termination of cables of the appropriate sizes. The terminal box for control cables shall contain properly marked terminals for all internal equipment e.g. embedded temperature detectors etc. all terminals shall be stud type. The terminals boxes shall be of IP- 52 (minimum), if not stated otherwise in data sheet and complete with lugs and double compression nickel plated brass cable glands. Alternators rated 1500 KW and above shall have differential protection and shall be equipped with suitable current transformers. 6.1.7.

Field winding shall have class ‘F’ insulation with a temperature rise limited to class ‘B’. The field winding shall be capable of operating at a voltage of 125% of field voltage at rated load for at least one minute starting from stabilized temperatures at rated conditions.

6.1.8.

All parts and accessories shall be suitable to withstand stresses due to over-speed / overload / short circuit conditions specified.

6.1.9.

Bearings shall be anti-friction, shielded and pre-lubricated. Grease in the bearing enclosure shall provide additional lubrication to bearing as well as provide sealing against dust and moisture.

6.1.10. The alternator shall be air cooled unless otherwise specified. 6.1.11. The direction of rotation of the machine shall be compatible with that of the prime mover. A clear indication of the direction of rotation shall be given on either end of the machine. 6.1.12. Suitable space heater to operate on 240V, 1-phase shall be provided. Heater terminals shall be brought out to a separate terminal box. Location and maximum surface temperature of heater shall be such that no damage is caused to any insulation.

6.2.

Excitation System The alternator shall be provided with brushless type solid state self-excitation system. The excitation system shall include the automatic voltage regulator, AC exciter and rotating rectifier assembly. The field of the exciter shall be fed from the stator winding through a suitable transformer and AVR. AC voltage generated in the AC exciter shall be rectified by the rotating rectifier assembly and fed to the main field circuits. The rotor winding of the AC exciter, the rotating rectifier assembly, main field winding of the alternator and other accessories on rotor parts shall be rigidly fastened to the shaft and the connection with different items shall be anti-loosening type. All components shall be mounted considering the effects of the centrifugal forces. The exciter capacity shall be at least 20% more than the maximum requirement at any time. The exciter winding shall be insulated with class ‘F’ insulation with temperature limitation of class ‘B’ insulation. The rotating rectifier assembly shall consist of the rectifier bridge with parallel diodes, zener diode, fuses, field discharge resistors etc. Rotor circuit shall be designed to take care of rectification of AC voltage and proper field suppression through discharge resistors. The rating of Diode Bridge and armature shall be such that the full load rated current can be supplied with one branch in operation. Automatic solid state voltage regulator shall be provided with the following features as minimum: −

Short circuit protection.

−

Manual voltage control.

−

Voltage build up circuitry.

−

Over voltage protection.

Alternator shall be capable of operation over a range of + 5 % of the rated voltage unless specified otherwise. The regulator shall be supplied complete with cross current compensation (preferably static type), voltage setting device and all required accessories.



Page 18

STANDARD SPECIFICATION FOR GENERATOR SET CONSTRUCTION OF EFFLUENT TREATMENT PLANTS AT RAJAHMUNDRY ASSETS ONSHORE ENGG SERVICES

Doc No: 269635-008-SP-4003

6.3.

Other Design Parameters

6.3.1.

Transient voltage performance

Rev: A

Page 12 of 20

Vol :IIIA

Section : 29

In case of sudden application of full load at rated power factor the voltage drop shall not exceed 15% of the rated voltage. The rated voltage shall be restored within 1 second depending on the size of the machine. 6.3.2.

Voltage regulation The voltage regulation of the machine shall be within ±1% of the nominal voltage under following conditions:

6.3.3.

−

Between no load and nominal load with p.f. of 0.8 lag to unity.

−

With the machine cold or warm.

−

At a speed drop of approximately 3% of the nominal speed.

Voltage setting range The alternator terminal voltage shall be adjustable with a continuously variable potentiometer. The adjustment range shall be ±10% of the nominal voltage.

6.3.4.

Unbalanced load Unless otherwise specified, three-phase synchronous alternators of ratings up to 1250 kVA shall be capable of continuously operating on an unbalanced load of 25 percent with none of the phase currents exceeding the rated current.

6.3.5.

Waveform distortion The telephone harmonic factor (THF) of the line to line terminal voltage (alternator tested on open circuit at rated speed and voltage) shall not exceed the following values: Machine Rating Above 300 KW and up to 1000 KW Above 1000 KW and up to 5000 KW Above 5000 KW

T.H.F. 5% 3% 1.5%

The computation and measurement of THF shall be as per IS: 4722.

6.3.6.

Frequency limits The alternator shall be suitable for continuous operation at rated load for a frequency variation of ±3% of rated value. In addition the short time under frequency operating limits shall be furnished.

6.3.7.

Over current requirement The alternator shall be capable of withstanding without injury stator current of 1.5 pu for 30 seconds and 1.1 pu for one hour.

6.3.8.

Short circuit conditions The alternator shall be capable of withstanding without damage, three phase or a line to line or line to earth or two line to earth short circuit for a period of 3 seconds when operating at rated speed and rated load and with an excitation corresponding to 5% over voltage.



Page 19

STANDARD SPECIFICATION FOR GENERATOR SET CONSTRUCTION OF EFFLUENT TREATMENT PLANTS AT RAJAHMUNDRY ASSETS ONSHORE ENGG SERVICES

6.3.9.

Doc No: 269635-008-SP-4003

Rev: A

Page 13 of 20

Vol :IIIA

Section : 29

Parallel operation Generator sets shall be suitable for parallel operation amongst themselves and also with the grid at operating voltage and under load conditions up to rated value. Details of sources with which alternator is to be made parallel is available elsewhere in bid package.

6.3.10. Excitation support system Excitation system shall be provided with short circuit support equipment (series compounding) to maintain three times the rated current for three seconds in case of short circuit to ensure proper fault clearance in outgoing feeders.

6.3.11. Auxiliary systems All auxiliary motors required to start and run the prime mover shall be three phase 415 V, 50 Hz squirrel cage induction motor suitable for DOL starting. Insulation shall be class ‘F’ with a temperature rise limited to class ‘B’. All motors shall have IP – 55 enclosures as minimum and shall conform to the specification for M.V. Motors given with the bid package or relevant Indian standards (if the earlier specification is not given).

6.4.

System Operation

6.4.1.

The generator set shall normally be in an unattended area. 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:

6.4.2.

−

Auto on mains failure scheme (AMF) (if specified in Scope of work - Electrical” in Bid document)

−

Manual start in service mode.

−

Test mode.

Auto mains failure scheme This shall be effective in Auto position of Auto / Manual selector switch located in local (generator) control panel. Failure of normal power supply shall be sensed from a remotely located panel in PMCC (whenever applicable) by the auto mains failure relay which shall send signal (with a time delay) to start the standby / emergency generator (prime mover) automatically and rated speed and voltage shall be built up. All accessories required for starting and completion of various sequence of operation for the above purpose shall be provided as part of the generator set. Upon reaching the rated voltage and frequency, voltage monitoring relay located in control panel shall extend an impulse for closing sequentially first the generator breaker in the generator control panel and subsequently the incoming generator breaker in a remote panel in PMCC room (whenever applicable).

6.4.3.

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 local control panel. The scheme of operation shall be same as of auto mode as per clause 6.4.2 above except that starting impulse shall be extended manually through the start push-button in generator control panel and the generator breaker in the generator control panel and the incoming



Page 20

STANDARD SPECIFICATION FOR GENERATOR SET CONSTRUCTION OF EFFLUENT TREATMENT PLANTS AT RAJAHMUNDRY ASSETS ONSHORE ENGG SERVICES

Doc No: 269635-008-SP-4003

Rev: A

Page 14 of 20

Vol :IIIA

Section : 29

generator breaker in a remote panel in PMCC room (whenever applicable) shall also have to be closed manually.

6.4.4.

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 as per clause 6.4.3 above except that none of the generator breaker in the generator control panel or the incoming generator breaker in a remote panel in PMCC room (whenever applicable) can be closed in test mode run

6.4.5.

Shut down Unless otherwise specified, stopping the generator (prime mover) in all cases (except in AMF scheme) for a normal shut down shall only be done manually by means of a stop push button in the generator control panel. In AMF scheme, the generator (prime mover) shall stop automatically upon sensing (with a time delay) of return of normal power supply by the auto mains failure relay. The generator breaker in the generator control panel and the incoming generator breaker in a remote panel in PMCC room (whenever applicable), must trip in all cases (i.e. even if left in closed position by mistake of operator, during manual mode of operation), soon after the stop signal is sensed in any mode of operation.

6.4.6.

Starting time The total time from the receipt of the starting impulse for the alternator set till the set reaches rated speed and alternator reaches full 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 a remotely located panel at the PMCC room.

6.4.7.

Black start facility The generator set shall be provided with all necessary ‘Black start’ facility. All D.C. supplies and chargers including batteries for start up of prime mover shall be supplied

6.5.

Generator Control Panel

6.5.1.

The local generator control panel shall be floor mounted, free standing, metal enclosed fabricated with cold rolled sheet steel with thickness of 1.6 mm for doors and covers, 2 mm for load bearing parts and 3 mm for base frame, gland plate etc, dust and vermin proof type with hinged door and having a minimum degree of protection of IP- 52. If local generator control panel is placed under a shed with sides open, then degree of protection shall be IP-55.

6.5.2.

The panel should be rated for 50 KA (1 sec) short-circuit rating at 415 V, 3ĭ, 50 Hz supply.

6.5.3.

The control panel should have following basic components: (a)

1 no. 4-pole ACB (for incoming supply from the generator).

(b)

Automatic voltage regulator (AVR), AVR CT/ PTs and metering CTs.

(c)

1 set of bus bar for phases and neutral. The bus bar should be of copper having colour coded heat shrinkable PVC sleeves with suitable compartments / bakelite spacers as per requirements of the panel.

(d)

1 set of metering section having ammeter and voltmeter of suitable range with selector switches, hour-run meter, multifunction meter, PF meter, digital frequency meter and set of CT’s for metering (secondary 5A) for generator.

(e)

1 set of battery charger.

(f)

Control & protection relays required as described in section 6.4 above and 6.5.13 below.



Page 21

STANDARD SPECIFICATION FOR GENERATOR SET CONSTRUCTION OF EFFLUENT TREATMENT PLANTS AT RAJAHMUNDRY ASSETS ONSHORE ENGG SERVICES (g)

Doc No: 269635-008-SP-4003

Rev: A

Page 15 of 20

Vol :IIIA

Section : 29

Control gear for generator set auxiliaries and neutral cubicle having protection CTs.

6.5.4.

Power and control equipment shall be segregated inside the panel as far as practicable. The maximum height of the operating handle / switches shall not exceed 1800mm and the minimum height not below 300mm. All cable entry shall be from the bottom of the panel only. Necessary removable type gland plate, double compression nickel plated brass cable glands and cable lugs shall be provided with the panel.

6.5.5.

All auxiliary devices for control, indication, measurement and alarm such as push button, control / selector switches, indicating lamps, metering instruments, annunciations etc. shall be mounted on the front door of the panel. Adequate number of potential free contacts shall be provided in the control panel for any remote control, monitoring of the generator set. The generator breaker rating shall be as specified in the power distribution scheme. The breaker shall be in draw out execution. All motor starters for generator – prime mover set auxiliaries if required shall be DOL type in fixed execution with compartmentalized construction having sheet steel enclosed vertical panels along with horizontal and vertical bus bars. All bus bars shall be approachable from backside of panel. Each panel shall have a separate and approachable cable alley.

6.5.6.

Power switching shall be through MCCB of suitable rating. MCCB shall have thermo-magnetic releases.

6.5.7.

The contactors for auxiliary motor starters shall be of air-break type having AC-3 duty rating.

6.5.8.

Thermal overload relays shall be three element, positive acting, ambient temperature compensated type with adjustable setting range and built in protection feature against single phasing. All indicating instruments shall be moving iron, flush mounting type and of 72mm x 72mm square pattern. All control / selector switches rotary back connected type having a cam operated contact mechanism with knob type handle. ‘Stop’ push buttons shall be of stay push type.

6.5.9.

Wiring for power, control and signalling circuits shall be done with PVC insulated copper conductors having 660 V insulation grade. Minimum size of control wires shall be 2.5 mm2. Clamp type terminals shall be acceptable for wires up to 10 mm2 size and for conductors larger than 10 mm2 bolted type terminals with crimping lugs shall be provided. A minimum of 10% spare terminals shall be provided on each terminal block.

6.5.10. Minimum earth bus size shall be 50 x 6 mm2 electrolyte grade copper for connection to main earth grid. All non-current carrying metallic parts of the mounted equipments shall be earthed. Doors and movable parts shall be earthed using flexible copper connections. Two number terminals shall be provided in the panel for external earthing. 6.5.11. AMF (Auto Mains Failure) scheme shall be provided as part of the generator control panel and the sequence of operation of the generator for starting, running and shut down under AMF shall be as described in section 6.4 above. The DC control supply required for AMF / local control panel and for any other purpose shall be met by the DC system consisting of battery and battery charger of suitable capacity supplied along with the set of the generator and its prime-mover.

6.5.12. Tripping of Generator set for a normal shut down shall be done manually by means of a stop push button on the control panel. There shall be a mushroom type emergency stop push button on the engine also. The trip impulse should directly go to the engine’s shutdown device. 6.5.13. Control and protection system The control panel shall have all the control and protection systems to be adopted for the normal starting, running and stopping of the prime mover Additionally the control panel shall house the sensing devices and auxiliary relays for following abnormal condition: (a)

Starting battery voltage low.

(b)

DC control supply failure.

(c)

Incomplete start after a preset time



Page 22

STANDARD SPECIFICATION FOR GENERATOR SET CONSTRUCTION OF EFFLUENT TREATMENT PLANTS AT RAJAHMUNDRY ASSETS ONSHORE ENGG SERVICES

Doc No: 269635-008-SP-4003

Rev: A

Page 16 of 20

Vol :IIIA

Section : 29

(d)

Failure to start.

(e)

Excitation failure / Field failure

(f)

Voltage out of limit (over/under voltage).

(g)

Over current.

(h)

Over/under frequency.

(i)

Stator earth fault.

(j)

Rotor earth fault.

(k)

Ground fault on the system

(l)

Unbalanced loading (Negative sequence current) protection.

(m)

Differential protection (rated power • 1500 KW)

(n)

Reverse power (whenever generator is specified to run in parallel with others)

(o)

Stator winding temperature protection

Facia type annunciators shall be supplied and mounted on control panel to give visual and audible indication for the above abnormal conditions along with the specified abnormal conditions of the prime mover. The panel shall have 20% spare windows also. Tripping facility for the generator breaker (both on the generator control panel and on generator incoming breaker on remotely located PMCC panel) shall be available for conditions (e) to (o) above along with the abnormal conditions of the prime mover. Wherever specified for remote annunciation, few of these abnormal conditions of operation of the generator and the prime mover shall be simultaneously displayed through visual and audible alarms in a separate annunciation panel remotely located in the PMCC / Control room. The signals to be communicated to the remote annunciation panel are described elsewhere in the bid package.

6.6.

Synchronizing Panel

6.6.1.

Synchronizing panel shall be provided, if specified in “Scope of work - Electrical” in Bid document. Sources with which the generator needs to be run on parallel is detailed out elsewhere in bid package. The synchronizing panel shall be located remotely in the PMCC room and shall be wall mounted, metal enclosed fabricated with cold rolled sheet steel with thickness of 2 mm, dust and vermin proof type with hinged door and having a minimum degree of protection of IP- 42 and with proper double compression nickel plated brass glands.

6.6.2.

In the PMCC panel, the generator(s) incoming breaker(s) or the incoming breaker(s) from other sources of power or the bus-coupler shall be controlled through the synchronizing panel thus providing the scope of parallel operation of different sources of power in a sub-station.

6.6.3.

Synchronizing panel shall comprise of the synchro-check relay, synchroscope and frequency meter for the incoming machine and all other provisions for allowing manual synchronization of sources using the two lamp method. Provision for adjustment of both speed and voltage for the incoming generator(s) shall be available in this remotely located PMCC panel. The frequency meter shall show the bus frequency when the synchronization switch shall be in ‘OFF’ position.

6.6.4.

All the breakers referred in section 6.6.2 and controlled through the synchronizing panel shall be capable of switching “ON” only one at a time, when permitted through the synchronizing panel and the sychro-check relay and under no other condition the breaker(s) can be switched “ON”. DeadBus synchronization facility shall however be provided for all the incoming breakers.

6.6.5.

Whenever parallel operation of two or more generators is specified, there shall be suitable provision made for equal sharing of active and reactive powers between the generators and it shall be such that the ratio of sharing does not get disturbed during operation or with new loads thrown



Page 23

STANDARD SPECIFICATION FOR GENERATOR SET CONSTRUCTION OF EFFLUENT TREATMENT PLANTS AT RAJAHMUNDRY ASSETS ONSHORE ENGG SERVICES

Doc No: 269635-008-SP-4003

Rev: A

Page 17 of 20

Vol :IIIA

Section : 29

‘on’ or ‘off’ line every time. The necessary adjustments / controls for achieving the same along with the required indications shall be made available in the remotely located PMCC panel in the PMCC room where the synchronizing panel is located. 6.6.6.

Whenever synchronization panel is provided, one separate manual hand-held “Phase Sequence Meter” also needs to be provided.

6.6.7.

All meters, relays, lamps need to be properly rated and tested for their operating voltage levels; their load shall be calculated and taken into account while determining the capacity of their source of power. Provision of transformers, wherever required are to be made.

7.

Painting & Name Plating All metallic parts of the generator and the control panel and synchronizing panel (wherever specified) shall be painted / treated as per specification given under ‘painting’ in the ‘Electrical scope of work’ in bid package. All panel mounted equipments (e.g. Led, push buttons, switches, PCBs etc.) shall be provided with suitable nameplates. Labels shall be provided for every component on the cards, connecting wires as well as for the terminals in the terminal strip inside the panel. Special warning plates shall be provided on all removable covers or doors giving access to energized metallic parts above 24 volts.

8.

Inspection & Testing The generator set with all auxiliaries and control panel shall be tested to conform to the appropriate standards and the following is to be carried out as minimum:

8.1.1.

Mechanical - Engine Engines of nominal rating up to 1000 kW shall be subjected to Engine Manufacturer’s routine shop test and the test certificates shall be submitted to the Owner’s inspector(if any) for his review, provided the engine manufacturer is an ISO: 9000 certified vendor. These shall be observed tests. For all other cases, engines shall be tested in accordance with the latest edition of ISO: 3046 unless otherwise specified in the enquiry/order. The routine load and fuel consumption test shall be of the following duration: a. Part Loads (50% & 75%) - ½ hour each b. Full Load - 4 hours c. 10% Overload - 1 hour After the specified tests have been completed satisfactorily, the fuel stop on the fuel injection pump shall be set and sealed at the specified site rating including provision for 10 percent overload. Measurement of vibration level for the Set. The hydrostatic test certificates for the heat exchanger/intercooler, fuel tanks and other pressure vessels shall be furnished to the Owner’s inspector(if any) for his review at the time of load testing of the engine The engine control panel after assembly and wiring shall be functionally tested at the subvendor’s works in the presence of the Consultant/Owner’s Inspector.

8.1.2.

Electrical Copies of the type test certificates for alternator as per IS - 4722 shall be furnished for review.



Page 24

STANDARD SPECIFICATION FOR GENERATOR SET CONSTRUCTION OF EFFLUENT TREATMENT PLANTS AT RAJAHMUNDRY ASSETS ONSHORE ENGG SERVICES

Doc No: 269635-008-SP-4003

Rev: A

Page 18 of 20

Vol :IIIA

Section : 29



Inspection and testing shall include the following as minimum:

9.

(a)

Routine tests of alternator as per IS – 4722.

(b)

Functional tests, continuity tests and high voltage test on control panel to establish the performance called for in the specification.

(c)

Power frequency voltage test on switch gear and mechanical / electrical operational check.

Drawings & Documents

All drawings, calculations and data sheets shall require review and approval by Owner and shall require the issue of “as-built” documents by Contractor.

SL NO

DESCRIPTION

1

MECHANICAL

1.1

GENERAL

1

Vendor Drg/Data Schedule(this shall be the first document to be submitted after Fax/letter of intent

2

Leaflet/Catalogues

WITH OFFER

AFTER PURCHASE ORDER (REVIEW(R)/ INFORMN(I)

FINAL WITH EQUIPMENT DATA BOOK

R

YES

YES

YES

5 1.2 1

Experience record proforma and list of similar installations Deviation lists Data Sheets/Performance Curves Completed data sheets for engine

2

Deration calculations (As per ISO 3046)

1.3

Piping & Instrumentation Diagrams General Arrangement Drawings(certified dimensional outline drawings including foundation details where required)

YES

R

YES

1

Engine

YES

R

YES

2

Air intake system

YES

R

YES

3

Exhaust system

YES

R

YES

4

Radiator

YES

R

YES

5

Oil Cooler

YES

R

YES

6

Fuel Tank (Day Tank)

YES

R

YES

1.5

Layout Drawings Equipment layout showing main as well as all associated equipment/skids (engine, generator, fuel oil system, air

YES

R

3

1.4

1

YES

R

YES

R

YES

R

YES

R

YES

Page 25

STANDARD SPECIFICATION FOR GENERATOR SET CONSTRUCTION OF EFFLUENT TREATMENT PLANTS AT RAJAHMUNDRY ASSETS ONSHORE ENGG SERVICES

Doc No: 269635-008-SP-4003

Rev: A

Page 19 of 20

Vol :IIIA

Section : 29



intake system, exhaust system, local guage board, local control panel etc.) with interface piping connection, maintenance space.

2

3 1.6 1

SL NO 1.7 1.8 1.10 1.11 1 2 1

2

3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Foundation layout showing foundation details of main as well as all associated equipment/skids including local gauge board, local control panel etc. Complete details of cooling system Spares/Special Tools List of Mandatory Spares (indicating exact name of the part, part no. and material of construction)

DESCRIPTION

Inspection & Test Procedures Inspection & Test Records/Reports Installation, operation & Maintenance Manuals Mechanical Catalogue Mechanical catalogue (containing as built drawings of all the above items as listed under Mechanical) ELECTRICAL Data sheets, technical specification, construction details of generator set. Foundation & mounting details for generator control panel, space required in front for withdrawals, power & control cable entry points etc. Drawings for control Schematic, circuit diagram, alarm and protection schemes. Details of excitation system Details of cooling system General arrangement drawing Estimated capability curve Open circuit characteristics Short circuit characteristics Short time under frequency operating limits Control power requirements Bill of materials with makes.

YES

R

YES

YES

R

YES

YES

I

WITH OFFER

YES

YES

AFTER PURCHASE ORDER (REVIEW/ INFORMN) I I

YES YES

I

YES

I

YES

R

YES

R YES R

YES

YES YES YES YES YES YES YES

R R R R R R

YES YES YES YES YES YES

R

YES

YES

R

YES

YES

R

YES

Technical particulars of circuit breakers. Foundation/fixing arrangement drawing Schematic/logic diagrams Cable layout Testing procedure Copies of certificates for all type tests and routine tests for generator. Copies of certificates for all type, routine

FINAL WITH EQUIPMENT DATA BOOK

YES R R R R

YES YES YES

I

YES

I

YES

Page 26

STANDARD SPECIFICATION FOR GENERATOR SET CONSTRUCTION OF EFFLUENT TREATMENT PLANTS AT RAJAHMUNDRY ASSETS ONSHORE ENGG SERVICES

20 21

Doc No: 269635-008-SP-4003

and functional tests for panel with all individual components. Operation & maintenance manual Site storage requirements

Rev: A

Page 20 of 20

Vol :IIIA

Section : 29

I I



YES

All drawings shall have the Owner equipment number and purchase order number. Vendor shall provide a complete document package for unit components and specific for protection of the equipment if taken out of service for finite periods. Shop details shall be completed with all dimensions, thickness and details of construction including all nozzle locations and orientations. All material thickness shall be shown. All welds shall be detailed for fully described by notes or weld symbols and annotated to the relevant weld procedure specification. Review of the drawings by Owner does not relieve Contractor of his responsibility for the correctness of the design to suit the stated conditions. Manufacturer shall submit for Owner’s approval the general arrangement drawing, Generator set sizing calculations, base frame details, schematic and circuit diagrams. Owner’s approval of GA drawing, schematic, logic and circuit diagram showing every device, terminal and wire number is required before the fabrication of the panel is started. Owner’s approval of contractor drawings and certifying test results shall not relieve the manufacturer of his responsibility for supplying equipments conforming to relevant standards or for any mistake, omission or commission in manufacturer’s drawings.

10.

Transport & Shipment Transport and shipment of items shall be contractor’s responsibility. Contractor need to follow the instructions for the same detailed under clause no. 11 of ‘Electrical Scope of Work’, Document no. 269635-008-SW-4001

11.

Warranty The warranty for the items shall be as mentioned under clause no. 9 of ‘Electrical Scope of Work’, Document no. 269635-008-SW-4001.

Page 27

CONSTRUCTION OF ETPs ALONG WITH THE LAYING OF ASSOCIATED GRE PIPE LINES AT RAJAHMUNDRY ASSET PS FOR GAS GENERATOR (GG) SET Doc No: ETP-RJY/E/PS/1004 

GA DRAWINGS

 

Rev: 0A



Page 28

Page 29

PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT

6 M WIDE ROAD

REFERENCES 1.PLOT PLAN - LIN/N/PPL/2001 REV-0 2.ELECTRICAL DESIGN BASIS - 269635-008-DB-4001 REV-A

NGR -2 2472 6800 1160

1380

1821242 N 518305 E

DIMENSIONS LENGTH (mm)

WIDTH (mm)

500 KVA GG SET - 1

6800

2472

500 KVA GG SET - 2 NGR PANEL - 1

6800

2472

2900

1050

950

1000

NGR PANEL - 2

1050

950

1000

6800

REMOTE RADIATOR

1380

PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT

3321

3594

2900 (APPROX)

10500

NAME

HEIGHT (mm) 2900

PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT

PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT

KEY PLAN

6 M WIDE ROAD

2472

NGR -1

1160

3.ELECTRICAL SCOPE OF WORK - 269635-008-SW-400 REV-A 4.

1160

Page 30

PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT

REFERENCES

NGR -1

2.ELECTRICAL DESIGN BASIS - 269635-008-DB-4001 REV-A 2472

3.ELECTRICAL SCOPE OF WORK - 269635-008-SW-400 REV-A 4.

2472

NGR -2

KEY PLAN

1380

1160

6800

DIMENSIONS LENGTH (mm)

WIDTH (mm)

500 KVA GG SET - 1

6800

2472

500 KVA GG SET - 2 NGR PANEL - 1

6800

2472

2900

1050

950

1000

NGR PANEL - 2

1050

950

1000

NAME

HEIGHT (mm) 2900

PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT

PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT

6 M WIDE ROAD

PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT

1.PLOT PLAN - KES/N/PPL/2001 REV-0

Page 31

PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT PN N

6 M WIDE ROAD

REFERENCES 1.PLOT PLAN - GOP/N/PPL/2001 REV-0 2.ELECTRICAL DESIGN BASIS - 269635-008-DB-4001 REV-A

1160

3.ELECTRICAL SCOPE OF WORK - 269635-008-SW-400 REV-A 4.

NGR -1

PIPE LINE

NGR -2

CABLE ENTRY FROM PMCC

2472

PN N "

1380

1160

6800

1825910 N 614304 E DIMENSIONS LENGTH (mm)

WIDTH (mm)

500 KVA GG SET - 1

3400

1450

500 KVA GG SET - 2 NGR PANEL - 1

3400

1450

2200

1000

500

1000

NGR PANEL - 2

1000

500

1000

NAME

PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT

PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT

VACANT PLACE

HEIGHT (mm) 2200

PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT

2472

KEY PLAN

Page 32

Page 33

Page 34 29 Page

CONSTRUCTION OF ETPs ALONG WITH THE LAYING OF ASSOCIATED GRE PIPE LINES AT RAJAHMUNDRY ASSET PS FOR GAS GENERATOR (GG) SET

Rev: A 0

Doc No: ETP-RJY/E/PS/1004 

ENGINE DATA SHEET

 



Page 35

Page 36

Page 37

Page 38 33 Page

CONSTRUCTION OF ETPs ALONG WITH THE LAYING OF ASSOCIATED GRE PIPE LINES AT RAJAHMUNDRY ASSET PS FOR GAS GENERATOR (GG) SET

Rev: A 0

Doc No: ETP-RJY/E/PS/1004 

ALTERNATOR DATA SHEET

 



Page 39

Page 40

Page 41 Page 36

CONSTRUCTION OF ETPs ALONG WITH THE LAYING OF ASSOCIATED GRE PIPE LINES AT RAJAHMUNDRY ASSET PS FOR GAS GENERATOR (GG) SET Doc No: ETP-RJY/E/PS/1004 

SCOPE OF SUPPLY

 

Rev: A 0



Page 42

Page 43

Page Page44 39

Page Page45 40

CONSTRUCTION OF ETPs ALONG WITH THE LAYING OF ASSOCIATED GRE PIPE LINES AT RAJAHMUNDRY ASSET PS FOR GAS GENERATOR (GG) SET

Rev: 0

Doc No: ETP-RJY/E/PS/1004 

MAKES OF MAJOR COMPONENT

 



Page 4641 Page

Page Page 42 Page47 40

CONSTRUCTION OF ETPs ALONG WITH THE LAYING OF ASSOCIATED GRE PIPE LINES AT RAJAHMUNDRY ASSET PS FOR GAS GENERATOR (GG) SET Doc No: ETP-RJY/E/PS/1004 

QAP

 

Rev: 0A



Page Page 43 Page48 41

Page Page 44 Page49 42

Page Page50 43 Page 45

Page 514644 Page Page

Page 40

Page 52 Page 47 Page 45

Page Page 48 Page53 46

Page 54

Page Page 55 50 48

Page Page 51 Page56 49

CONSTRUCTION OF ETPs ALONG WITH THE LAYING OF ASSOCIATED GRE PIPE LINES AT RAJAHMUNDRY ASSET PS FOR GAS GENERATOR (GG) SET Doc No: ETP-RJY/E/PS/1004 

FORM B

 

Rev: 0A



Page Page 52 Page57 50

FORM-B DEVIATION LIST REQN. FOR: GAS GENERATOR (GG) SETS PROJECT: CONSTRUCTION OF ETPs AND LAYING OF ASSOCIATED PIPELINES AT RAJAHMUNDRY

ASSET (ETP-RJY) SUPPLIER: M/s SHIVA GENSETS PRIVATE LIMITED SL.No

1

DOCUMENT No/ ONGC SPEC .No. STANDARD SPEC NO:269635-008-SP4003

FOR JV MEIL-APLUS

REQUIREMENT

VENDORS DEVIATION WITH REASONs

GAS GENERATOR SET

NO DEVIATION

FOR M/s SHIVA GENSETS PRIVATE LIMITED

Page Page 53 Page58 51

CONSTRUCTION OF ETPs ALONG WITH THE LAYING OF ASSOCIATED GRE PIPE LINES AT RAJAHMUNDRY ASSET PS FOR GAS GENERATOR (GG) SET Doc No: ETP-RJY/E/PS/1004 

FORM C

 

Rev: 0A



Page 59 Page 5452 Page

Form C- LIST OF COMMISSIONING SPARES

Requisition for: GAS GENERATOR (GG) SETS Project: CONSTRUCTION OF ETPs AND LAYING OF ASSOCIATED PIPELINES AT RAJAHMUNDRY ASSET (ETP-RJY) S.No

Part Number

Description

NO SPARES REQUIRED

Contractor's Signature

Quantity

Unit Price

Total Price

-

-

-

Vendor's Signature,seal

Page 6055 53 Page Page

CONSTRUCTION OF ETPs ALONG WITH THE LAYING OF ASSOCIATED GRE PIPE LINES AT RAJAHMUNDRY ASSET PS FOR GAS GENERATOR (GG) SET Doc No: ETP-RJY/E/PS/1004 

FORM D

 

Rev: 0A



Page 56 Page 61 Page 54

Page 6255 Page Page57

Page Page 58 Page63 56

CONSTRUCTION OF ETPs ALONG WITH THE LAYING OF ASSOCIATED GRE PIPE LINES AT RAJAHMUNDRY ASSET PS FOR GAS GENERATOR (GG) SET Doc No: ETP-RJY/E/PS/1004 

LOI & ACCEPTANCE

 

Rev: 0A



Page 64 Page 5957 Page

Page Page 65 Page 6058

Page 66 Page 61 Page 59

Page 67

CONSTRUCTION OF ETPs ALONG WITH THE LAYING OF ASSOCIATED GRE PIPE LINES AT RAJAHMUNDRY ASSET PS FOR GAS GENERATOR (GG) SET Doc No: ETP-RJY/E/PS/1004 

TYPE TEST REPORTS

 

Rev: 0



Page 68

Page 69

Page 70

Page 71

Page 72

Page 73

Page 74

Page 75

Page Page76 62

CONSTRUCTION OF ETPs ALONG WITH THE LAYING OF ASSOCIATED GRE PIPE LINES AT RAJAHMUNDRY ASSET PS FOR GAS GENERATOR (GG) SET

Rev: 0

Doc No: ETP-RJY/E/PS/1004 

NOTIFICATION OF AWARD FOR M/S SHIVA GENSETS PRIVATE LIMITED (ONGC RAJAHMUNDRY)

 



Page Page 77 63

Page 78 Page Page64 60

CONSTRUCTION OF ETPs ALONG WITH THE LAYING OF ASSOCIATED GRE PIPE LINES AT RAJAHMUNDRY ASSET PS FOR GAS GENERATOR (GG) SET Doc No: ETP-RJY/E/PS/1004 

PTR

 

Rev: 0A



Gas Engine Generator Gas Engine Generator Gas Engine Generator Gas Engine Generator Gas Engine Generator

M/s Link Midd le East,Dubai

Olam Nigeria Ltd.(Through Shiva Gensets Private Limited), Lagos, Nigeria.

Paras Glass, Firozabad, Uttar Pradesh

Meera Grass, firozabad, Uttar Pradesh

Kanodia Tech {Through Shiva Gensets Private Limited) wazirabad, New Delhi

2

3

4

5

Customer Name

1

S.No

Type of Equipment

MWM GmbH

Sctimitt Enertec

Sctimitt Enertec

Sctimitt Enertec

Sctimitt Enertec

1 No x 1021 Kwe

1 No x 500KVA

1 No x 500KVA

1 No x 500KVA

1 No x 500KVA

27.08.2010

04.06.2008

28.05.2008

25.11.2013

03.08.2012

17.11.2011

14.02. 2009

06.02.2009

22.09.2014

01.01.2013

Date Of Capacity of the Purchase Commissioning Mate of Engine Genset Order Date of Gas Generator / Handing Over

Gas Engine, Alternator and related accessories

23196

8150

Gas Engine, Alternator and related accessories

100

Gas Engine, Alternator and related accessories with Acoustic Enclosure

8300

10876

Gas Engine, Alternator and related accessories

Gas Engine, Alternator and related accessories

Current Operating Hrs.

Material Details / Supplies

PAST TRACK RECORD & OTHER DETAILS OF FEW OF OUR INSTALLATIONS

Annexure-ll

PO and Handing Over certificate enclosed.

Handing Over certificate enclosed.

PO and Handing Over certificate enclosed.

PO Copy & Handing Over certificate enclosed.

Remarks

Page Page79 65

Page Page80 66 62

Page Page81 67

Page Page82 68

Page 69 Page83 65 Page

Page Page 70 Page84 66

Page Page 71 Page85 67

Page 86 Page 7268 Page

Page 87 Page 69 Page 73

Page Page 74 Page88 70

Page Page 75 Page89 72

CONSTRUCTION OF ETPs ALONG WITH THE LAYING OF ASSOCIATED GRE PIPE LINES AT RAJAHMUNDRY ASSET PS FOR GAS GENERATOR (GG) SET Doc No: ETP-RJY/E/PS/1004 

CATALOGUE

 

Rev: A 0



Page 90 Page Page 76 73

Page Page 77 Page91 74

Page Page92 78

Page 9379 Page Page 7

Page 94

Page Page95 8 Page 80

Page Page96 8 Page 81

Page Page97 82 8

Page Page98 8 Page 83

Page 99 8 Page Page 84

Page Page 85 Page100 8

Page 101 Page Page 86 8

Page 102 Page 87

Page Page103 88

Page Page 89 Page104 8

Page 105

CONSTRUCTION OF ETPs ALONG WITH THE LAYING OF ASSOCIATED GRE PIPE LINES AT RAJAHMUNDRY ASSET PS FOR GAS GENERATOR (GG) SET Doc No: ETP-RJY/E/PS/1004 

OEM Undertaking Letter

 

Rev: 0



Page 106

OEMUndertaking  NameoftheEquipment

:GASGENERATORSETS

NameoftheOEM

:M/sSHIVAGENSETSPRIVATELIMITED



AsperthetermsofETP_RJYContract(TenderNo.DLH/OES/MM/ETPRJY/X11BC11001/2011),OEM herebysubmitsthefollowingundertakings: 1.

TheOEMofequipment(s),hasinthelast10yearsmanufacturedandsuppliedatleasttwosuch similarequipment(s)elsewhereandintherangeofcapacitydesiredinthisproject.

2.

Suchequipment(s)havebeenoperatingsatisfactorilyinanyofthefollowinginstallations: a) Oil/gassurfaceprocessingfacilities, b) Hydrocarbonrefiningfacilities, c) PetrochemicalPlants; andconsistentlyachievingthelevelsofoutputfluidqualitybetterorasdesired. OEM hereby also provide process guarantee for the equipments manufactured by it for the desired performance along with manufacturing guarantee for defect free supplies (Applicable forprocessequipment).

3.

The OEM shall provide the maintenance / service / calibration facilities in India, for all the equipmentstobesuppliedunderthecontract.

4.

The OEM guarantees the 'lifetime supply' (i.e., 7 years in case of electronic equipment/items and 10 years in case of mechanical equipment/items) of spares for all the equipments to be suppliedunderthecontract.

5.

TheOEM undertakes to enterintoAnnual MaintenanceContractfor'lifetime'(i.e., 7yearsin caseofelectronicequipment/itemsand10yearsincaseofmechanicalequipment/items)forall theequipmentstobesuppliedunderthecontract.

6.

IncasetheOEMdeclines/failstohonoranyofhisabovecommitments,businessdealingswith OEMshallbeconsideredforbanningbyONGC.

 Date:27/01/2015 Place:DELHI   M/sSHIVAGENSETSPRIVATELIMITED