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DOCUMENT NUMBER

CLIENT : RELIANCE INDUSTRIES LTD. MH-IDMHMUMB001-E-SP-002


EQUIPMENT DESIGN
PROJECT : IDC & UTILTIY BLCOK SHEET NO. 1 OF 41
ENGINEERS

TECHNICAL SPECIFICATIONS
FOR
DIESEL GENERATING SETS

FOR BID ENQUIRY

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

I.DIESEL GENERATING SETS: SCOPE...........................................................................................................................3

II.APPROVAL FROM STATUTORY AUTHORITIES......................................................................................................4

III.EXCLUSIONS ..................................................................................................................................................................4

IV.DESIGN ..............................................................................................................................................................................4

V. SPARES .....................................................................................................................................................................4

V.CODES & STANDARDS....................................................................................................................................................5

VI.GENERAL..........................................................................................................................................................................6

VII.OPERATING CONDITIONS.........................................................................................................................................6

VIII.TECHNICAL PARTICULARS AND DATA SHEETS...............................................................................................7

IX.PERFORMANCE REQUIREMENT..............................................................................................................................8

X.ALTERNATOR ...................................................................................................................................................................9

XI.GENERATOR CONTROL PANEL...............................................................................................................................14

XII.11KV SWITCHGEAR FOR DG OUTPUT CONTROL ...........................................................................................21

XIII.DIESEL ENGINE .......................................................................................................................................................26

XIV.INDUCTION MOTORS FOR AUXILIARY DRIVES..............................................................................................31

XV.PLC SYSTEM FOR DG.................................................................................................................................................32

XVI.TESTS............................................................................................................................................................................37

XVII.MAINTENANCE TOOL AND TACKLES...............................................................................................................39

XVIII.SPARES.......................................................................................................................................................................39

XIX.DRAWINGS AND DOCUMENTS SCHEDULE ......................................................................................................40


SPECIFICATIONS FOR DOCUMENT NUMBER
MH-IDMHMUMB001-E-SP-002
EQUIPMENT DESIGN DIESEL GENERATING SETS
Rev-R0
ENGINEERS
CLIENT : RELIANCE INDUSTRIES LTD. SHEET NO. 3 OF 41

I. DIESEL GENERATING SETS: SCOPE

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

II. APPROVAL FROM STATUTORY AUTHORITIES.

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

Equipments & services excluded from scope of this specification.


 All Civil works
 11kV Cables
 Main Bulk storage tank for diesel
 Chimney and supporting structure
 Cooling Tower with associated cooling water circulation pumps

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

V. CODES & STANDARDS

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.

VII. OPERATING CONDITIONS

 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

VIII. TECHNICAL PARTICULARS AND DATA SHEETS

Sr. Description Requirement Bidder’s Confirmation


1 Quantity 4 Nos.(as per delivery
schedule indicated
elsewhere)
2 Type of installation INDOOR
3 Rating (MVA) 3.75 (continuous)
4 Rated Output voltage (KV) 11
5 Site conditions
Altitude Less than 1000 M. above
Mean Sea Level
Ambient Temperature
Maximum 40o C
Minimum 10o C
Design 45o C inside DG House
Relative Humidity
Maximum 95%
Site Environment Polluted
SPECIFICATIONS FOR DOCUMENT NUMBER
MH-IDMHMUMB001-E-SP-002
EQUIPMENT DESIGN DIESEL GENERATING SETS
Rev-R0
ENGINEERS
CLIENT : RELIANCE INDUSTRIES LTD. SHEET NO. 8 OF 41

IX. PERFORMANCE REQUIREMENT

1 Type of output voltage Sinusoidal *


2 Nature of load 3 Nos. 6.6kV, 900KW chillers
fed through 11/6.6 KV
transformers and other LT load
with maximum motor rating of
110kW fed through 11/0.433 KV
transformers.
3 Time for Diesel engine to start and take up load Maximum 15 Seconds. *
from Grid failure
4 Mode of operation Synchronized *
In case of grid power failure Out of 4 sets, Engines of 3 pre
selected “duty” DG shall start on
AMF and take up the loads
within stipulated time.

Isolated/ parallel mode


4.1.1 With grid supply The DG sets shall never be *
operated in parallel with grid
supply except for momentary
paralleling for power restoration.
4.1.2 Isolated mode During initial stage of project
implementation, 1 no. DG set
may be required to run in
isolation to cater to the initial
load.

4.1.3 Parallel mode When the complete project is


implemented, the DG sets shall
be required to synchronize
among themselves and take up
the entire load proposed to be
connected to them.
4.1.4 Shut down of DG sets after restoration of grid This shall not be automatic and
supply. manual intervention for DG shut
down and re-transfer the bus to
grid supply will be required.
SPECIFICATIONS FOR DOCUMENT NUMBER
MH-IDMHMUMB001-E-SP-002
EQUIPMENT DESIGN DIESEL GENERATING SETS
Rev-R0
ENGINEERS
CLIENT : RELIANCE INDUSTRIES LTD. SHEET NO. 9 OF 41

X. ALTERNATOR

Sr. Description Requirement Bidder’s


Confirmation
1 Rated voltage and frequency 3 phase, 11KV, 50Hz
2 Output rating 3750 KVA
3 Rated Power factor 0.8
4 Type of enclosure Industrial SPDP
5 Degree of protection IP23
6 Class of insulation / temperature rise Min. Class `F' with temp. rise
limited to class B
7 Type of cooling Air cooled
8 Generator neutral system earthing Solidly earthed. Bidder to *
recommendation clarify whether neutral of all DG
sets can be directly earthed or
through an isolator for earthing
of individual DG set, one at a
time.
Neutral isolation facility In case the bidder recommends *
the earthing of neutral of one of
the four DG sets only, then the
bidder shall include isolator /
contactor, adequately rated for
each of the DG set in his scope
of supply.
9 Minimum protections required Refer clause no: 11 of part 34
10 Excitation system
Type rotating diode type brush-less *
excitation system
Type of exciter fast response type designed to *
have a low time constant to
minimize voltage transients
under severe load changes.
Insulation class F
Exciter system Shaft driven A.C. exciter with
rotating rectifiers.
In built protections for over-voltage and rate of Required
rise of voltage
SPECIFICATIONS FOR DOCUMENT NUMBER
MH-IDMHMUMB001-E-SP-002
EQUIPMENT DESIGN DIESEL GENERATING SETS
Rev-R0
ENGINEERS
CLIENT : RELIANCE INDUSTRIES LTD. SHEET NO. 10 OF 41

Sr. Description Requirement Bidder’s


Confirmation
10.1. Field forcing capability capable of forcing the field for
1
more than 3 sec in the event of
dead fault at the terminals.
11 Contribution by DG to faults downstream in
MVA
Initial during 1st 7 cycles corresponding to xd” *
Up to 0.5 sec corresponding to xd’ *
Continuous corresponding to xd *
12 Maximum over voltage surge that DG set can *
withstand without deterioration and subsequent
damage. (Note DG sets are controlled by
VCBs)
13 AUTOMATIC VOLTAGE REGULATOR
Type High speed, adjustable dead
band, Electronic type
Control AUTO/MANUAL
CTs and VTs for AVR operation To be included by the bidder as *
required.
Accuracy + 0.5% from no load to full load
Response time for step load (from no load to *
full load) &recovery of voltage to within 95%-in
sec.
Range of voltage adjustment *
14 Performance Figures
Efficiency at 100% loads *
Efficiency at 75% loads *
Efficiency at 50% loads *
15 Temperature rise
Cooling medium temperature (measured by *
detector or thermometer), °C
Temperature rise of armature winding above *
cooling medium (measured by embedded
detectors), °C
Temperature rise of field winding above cooling *
medium temperature (resistance), °C
Temperature of cooling air from the windings *
(detector or thermocouple), °C
16 Losses
Total no-load losses *
SPECIFICATIONS FOR DOCUMENT NUMBER
MH-IDMHMUMB001-E-SP-002
EQUIPMENT DESIGN DIESEL GENERATING SETS
Rev-R0
ENGINEERS
CLIENT : RELIANCE INDUSTRIES LTD. SHEET NO. 11 OF 41

Sr. Description Requirement Bidder’s


Confirmation
16.1. Total load losses at 50% load
1
16.1. Total load losses at 75% load
2
16.1. Total load losses at 100% load
3
17 Short circuit current withstand and duration
Asymmetrical short circuit current withstand and *
duration for 3 sec.
Symmetrical short circuit current withstand and *
duration for 3 sec.
18 Electrical characteristics (calculated on
maximum capacity) at 100% cooling for direct
axis and quadrature axis
Unsaturated synchronous reactance % *
Unsaturated transient reactance % *
Unsaturated sub-transient reactance % *
Saturated synchronous reactance % *
Saturated transient reactance % *
Saturated sub-transient reactance % *

Sr. Description Requirement Bidder’s


Confirmation
Negative sequence reactance % *
Zero sequence reactance % *
D.C. resistance *
18.1. stator winding *
1
18.1. rotor winding *
2
19 Machine Time Constant
Open circuit transient time constant *
Short circuit transient time constant *
Short circuit sub-transient time constant *
Short circuit armature time constant *
20 Unbalanced Stator Current Capability
Ratio of negative sequence component of the 8% or more *
system currents to rated current
21 Momentary Excess current for Generator capable of withstanding fifteen *
(15) sec. a current of fifty (50)
percent in excess of its rated
current
22 Stator
Material of construction high quality silicon steel
lamination to achieve high
permeability with low hysterisis
SPECIFICATIONS FOR DOCUMENT NUMBER
MH-IDMHMUMB001-E-SP-002
EQUIPMENT DESIGN DIESEL GENERATING SETS
Rev-R0
ENGINEERS
CLIENT : RELIANCE INDUSTRIES LTD. SHEET NO. 12 OF 41

Sr. Description Requirement Bidder’s


Confirmation
and eddy current losses.
Windings securely braced and wedged to
withstand damage from
mechanical & electrical forces
imposed on the windings during
full voltage short circuit
conditions & for the same
reason, they have to be heavily
insulated
23 Rotor
Construction machined from a solid steel
forging

Sr. Description Requirement Bidder’s


Confirmation
Rotor winding MOC Silver bearing copper

Joints between coils or half coils to be brazed

24 Damper winding for satisfactory parallel running to be provided *


25 Insulation level
Basic insulation level, KV peak As per BS/IEC *
Power frequency withstand, KV r.m.s. As per BS/IEC *
26 Vibration limits Within limits of BS/IEC *
27 Noise level Within limits of BS/IEC *
28 Painting finish Epoxy. Paint Shade as per *
manufacturer’s standard.
29 Termination details Cable Box suitable for 1 no. 11
KV, Al/XLPE, 3Cx300 sq. mm.
cable with heat shrink
termination – Raychem type
30 Special precautions taken in the insulation Extra bracing for insulation *
system of the generator for protections against
switching surges generated by VCB.
31 Accessories
Thermostat controlled anti-condensation space Required. Supply voltage 240V *
heater AC, 50 Hz
RTDS wired up to the terminal block in *
a separate terminal box
SPECIFICATIONS FOR DOCUMENT NUMBER
MH-IDMHMUMB001-E-SP-002
EQUIPMENT DESIGN DIESEL GENERATING SETS
Rev-R0
ENGINEERS
CLIENT : RELIANCE INDUSTRIES LTD. SHEET NO. 13 OF 41

Sr. Description Requirement Bidder’s


Confirmation
Rotor winding MOC Silver bearing copper

Joints between coils or half coils to be brazed

24 Damper winding for satisfactory parallel running to be provided *


25 Insulation level
Basic insulation level, KV peak As per BS/IEC *
Power frequency withstand, KV r.m.s. As per BS/IEC *
26 Vibration limits Within limits of BS/IEC *
27 Noise level Within limits of BS/IEC *
28 Painting finish Epoxy. Paint Shade as per *
manufacturer’s standard.
29 Termination details Cable Box suitable for 1 no. 11
KV, Al/XLPE, 3Cx300 sq. mm.
cable with heat shrink
termination – Raychem type
30 Special precautions taken in the insulation Extra bracing for insulation *
system of the generator for protections against
switching surges generated by VCB.
31 Accessories
Thermostat controlled anti-condensation space Required. Supply voltage 240V *
heater AC, 50 Hz
31.1. 2 nos. bearing RTDs Required *
1
31.1. 6 nos. winding RTDS (2nos./phase) Required *
2
12-point Temperature Scanner for generator Required *
winding RTDs and engine & generator bearing
RTDs
Earhing
31.1. Earthing pads for alternator Required *
3
31.1. Two independent earth terminals on the frame, Required
4
complete with nuts, spring washer, and plain
washer for earthing of engine..
Vibration monitoring system including sensors Required *
and compatible monitoring unit to provide
alarm.
32 Make of Alternator *
33 Protection CTs
Construction Cast Resin
Location Neutral side of phase winding &
neutral circuit
Ratio & class Refer Attached S.L.D. for
SPECIFICATIONS FOR DOCUMENT NUMBER
MH-IDMHMUMB001-E-SP-002
EQUIPMENT DESIGN DIESEL GENERATING SETS
Rev-R0
ENGINEERS
CLIENT : RELIANCE INDUSTRIES LTD. SHEET NO. 14 OF 41

Sr. Description Requirement Bidder’s


Confirmation
Rotor winding MOC Silver bearing copper

Joints between coils or half coils to be brazed

24 Damper winding for satisfactory parallel running to be provided *


25 Insulation level
Basic insulation level, KV peak As per BS/IEC *
Power frequency withstand, KV r.m.s. As per BS/IEC *
26 Vibration limits Within limits of BS/IEC *
27 Noise level Within limits of BS/IEC *
28 Painting finish Epoxy. Paint Shade as per *
manufacturer’s standard.
29 Termination details Cable Box suitable for 1 no. 11
KV, Al/XLPE, 3Cx300 sq. mm.
cable with heat shrink
termination – Raychem type
30 Special precautions taken in the insulation Extra bracing for insulation *
system of the generator for protections against
switching surges generated by VCB.
31 Accessories
Thermostat controlled anti-condensation space Required. Supply voltage 240V *
heater AC, 50 Hz
Metering & Protections
34 Normal time the genset can run continuously *
without requiring maintenance. (in hours)

XI. GENERATOR CONTROL PANEL

Sr. Description Requirement Bidder’s


Confirmation
1 Execution floor mounting
2 Installation Indoor
3 Degree of protection IP52
4 Sheet steel CRCA
5 Sheet steel thickness
5.1 Base frame / channel 3mm
5.2 Load bearing members 2mm
5.3 Internal partitions, doors etc 1.6mm
SPECIFICATIONS FOR DOCUMENT NUMBER
MH-IDMHMUMB001-E-SP-002
EQUIPMENT DESIGN DIESEL GENERATING SETS
Rev-R0
ENGINEERS
CLIENT : RELIANCE INDUSTRIES LTD. SHEET NO. 15 OF 41

Sr. Description Requirement Bidder’s


Confirmation
6 Type of assembly Bolted
7 Surface treatment 7 tank for removal of rust,
scale, oil, grease & dirt by
pickling followed by phospating
followed by 2 coats of zinc rich
primer
8 Surface finish Powder Coated Epoxy with
paint shade RAL-7032
9 Cable entry Bottom
10 Panel accessories Thermostat controlled space
heater and cubicle lamp
11 Protective Relays
Type Numerical, programmable at
site
Supply Voltage 110V DC
Rated Current 1A
No. of output contacts As required for control scheme
Operation indicator Required
Minimum protective functions required
11.1. Voltage restraint IDMT Over *
1
current
11.1. Under frequency *
2
11.1. Over frequency *
3
11.1. Under voltage *
4
11.1. Over voltage *
5
11.1. Reverse power/ loss of prime *
6
mover
11.1. Restricted earth fault *
7
instantaneous (high impedance
circulating current)
SPECIFICATIONS FOR DOCUMENT NUMBER
MH-IDMHMUMB001-E-SP-002
EQUIPMENT DESIGN DIESEL GENERATING SETS
Rev-R0
ENGINEERS
CLIENT : RELIANCE INDUSTRIES LTD. SHEET NO. 16 OF 41

11.1. IDMT earth fault – residual *


8
current based
11.1. Standby ground over current *
9
fault IDMT, neutral current
based
11.1. Negative phase sequence over
10
current, voltage unbalance,
inter-turn fault
11.1.1 Loss of excitation
1
11.1. Differential over current
12
11.1. Master trip relay, hand reset, *
13
lock out type
11.1. Trip ckt supervision relay *
14
11.1. Redundancy in BUS PT voltage
15
(through BUS PT Relay ) for
110V AC Bus Wiring control
Bus with for both sections of
11KV Switchgear Board.
11.1. Field Protection Relays for the
16
Exciter (single E/F (alarm) ,
Double E/F (trip )
NOTE:The above functions can be discrete numerical relays based or software based built into PLC.
12 Meters
Type Digital, 7 segment LED
Metering Required For Line Currents, Line voltages,
frequency, PF, KVA, KW, kVAR
(Multi-function Load Managers
are preferred)
13 Control and selector switches
Auto/Manual to select Auto or manual mode of
operation
Local / Remote to select Local or Remote mode
Breaker Control switch Trip - Neutral - Close, Spring
return to Neutral.
14 Indicating Lamps
Type Cluster LED
Lens colours
Red : C.B. “ON”
Green : C.B. “OFF”
White : “Trip Supply Supervision”
Amber : Auto trip
White : “Spring Charged”
RYB : Phase Indication
SPECIFICATIONS FOR DOCUMENT NUMBER
MH-IDMHMUMB001-E-SP-002
EQUIPMENT DESIGN DIESEL GENERATING SETS
Rev-R0
ENGINEERS
CLIENT : RELIANCE INDUSTRIES LTD. SHEET NO. 17 OF 41

11.1. IDMT earth fault – residual *


8
current based
11.1. Standby ground over current *
9
fault IDMT, neutral current
based
11.1. Negative phase sequence over
10
current, voltage unbalance,
inter-turn fault
11.1.1 Loss of excitation
1
11.1. Differential over current
12
11.1. Master trip relay, hand reset, *
13
lock out type
11.1. Trip ckt supervision relay *
14
11.1. Redundancy in BUS PT voltage
15
(through BUS PT Relay ) for
110V AC Bus Wiring control
Bus with for both sections of
11KV Switchgear Board.
11.1. Field Protection Relays for the
16
Exciter (single E/F (alarm) ,
Double E/F (trip )
NOTE:The above functions can be discrete numerical relays based or software based built into PLC.
12 Meters
Type Digital, 7 segment LED
Metering Required For Line Currents, Line voltages,
frequency, PF, KVA, KW, kVAR
(Multi-function Load Managers
are preferred)
13 Control and selector switches
15 Window type facia annunciators
Voltage 110V DC
Equipped with ‘Sound Cancel’, ‘Acknowledge’
and ‘Reset’ push buttons
Provided with Two lamps connected in
parallel on each facia window
Suitable for Open to Alarm & Close to
Alarm –site selectable
Designed for an operating sequence indicated below *
Alarm Condition Fault Contact Audible Visual Alarm
Alarm
Normal Open Off Off
Abnormal Closed On Flashing
SPECIFICATIONS FOR DOCUMENT NUMBER
MH-IDMHMUMB001-E-SP-002
EQUIPMENT DESIGN DIESEL GENERATING SETS
Rev-R0
ENGINEERS
CLIENT : RELIANCE INDUSTRIES LTD. SHEET NO. 18 OF 41

11.1. IDMT earth fault – residual *


8
current based
11.1. Standby ground over current *
9
fault IDMT, neutral current
based
11.1. Negative phase sequence over
10
current, voltage unbalance,
inter-turn fault
11.1.1 Loss of excitation
1
11.1. Differential over current
12
11.1. Master trip relay, hand reset, *
13
lock out type
11.1. Trip ckt supervision relay *
14
11.1. Redundancy in BUS PT voltage
15
(through BUS PT Relay ) for
110V AC Bus Wiring control
Bus with for both sections of
11KV Switchgear Board.
11.1. Field Protection Relays for the
16
Exciter (single E/F (alarm) ,
Double E/F (trip )
NOTE:The above functions can be discrete numerical relays based or software based built into PLC.
12 Meters
Type Digital, 7 segment LED
Metering Required For Line Currents, Line voltages,
frequency, PF, KVA, KW, kVAR
(Multi-function Load Managers
are preferred)
13 Control and selector switches
Sound cancel Closed or Open Off Flashing
Acknowledge Closed or Open Off Steady on
Back to Normal Open Off Steady on
Reset Open Off Off
Lamp Test Open Off Steady on
Minimum alarm/annunciation required for Generator electrical faults
alternator
Downstream system fault
Bearing temperature high
Winding temperature high
AVR trouble
Excitation trouble
SPECIFICATIONS FOR DOCUMENT NUMBER
MH-IDMHMUMB001-E-SP-002
EQUIPMENT DESIGN DIESEL GENERATING SETS
Rev-R0
ENGINEERS
CLIENT : RELIANCE INDUSTRIES LTD. SHEET NO. 19 OF 41

11.1. IDMT earth fault – residual *


8
current based
11.1. Standby ground over current *
9
fault IDMT, neutral current
based
11.1. Negative phase sequence over
10
current, voltage unbalance,
inter-turn fault
11.1.1 Loss of excitation
1
11.1. Differential over current
12
11.1. Master trip relay, hand reset, *
13
lock out type
11.1. Trip ckt supervision relay *
14
11.1. Redundancy in BUS PT voltage
15
(through BUS PT Relay ) for
110V AC Bus Wiring control
Bus with for both sections of
11KV Switchgear Board.
11.1. Field Protection Relays for the
16
Exciter (single E/F (alarm) ,
Double E/F (trip )
NOTE:The above functions can be discrete numerical relays based or software based built into PLC.
12 Meters
Type Digital, 7 segment LED
Metering Required For Line Currents, Line voltages,
frequency, PF, KVA, KW, kVAR
(Multi-function Load Managers
are preferred)
13 Control and selector switches
16 Minimum alarm/annunciation required for Lube. oil pressure low & low-
engine low
Jacket water temperature high
and high-high
Engine fails to start
Engine/ Generator Bearing
temperature high and high-high
Engine shutdown
Compressed air system trouble
Engine over speed
SPECIFICATIONS FOR DOCUMENT NUMBER
MH-IDMHMUMB001-E-SP-002
EQUIPMENT DESIGN DIESEL GENERATING SETS
Rev-R0
ENGINEERS
CLIENT : RELIANCE INDUSTRIES LTD. SHEET NO. 20 OF 41

Fuel oil tank level low and low-


low
17 Push buttons
Type Spring return or stay put type
as required
Contacts 2 NO + 2 NC minimum
18 Labels & Name Plates
Material PVC or Anodised Aluminimum
Engraving Black engraving on white
background
Size of the label To suit application / importance.
Fixing With self-tapping screws.
19 Wiring
Control wiring
19.1. Type 660V grade, PVC insulated
1
super-flexible copper wire
19.1. Size 2.5 sq. mm. for CT circuit
2
1.5 sq. mm. for control circuit
19.1. Colour Black for AC circuits and Grey
3
for DC circuit
19.1. Termination on equipment terminals / terminal With crimped type, tinned
4
blocks copper lugs , preferably WAGO
Type
19.1. Ferruling Required with non – detachable
5
type printed ferrules
20 Terminal Blocks Preferably WAGO type
Control terminal size 2.5 sq. mm. minimum
No. of spare control terminals 10% minimum
21 Synchronizing Facility
Auto Synchronizing with each other Required *
Manual synchronizing facility Required *
Check synchro. facility to prevent wrong Required *
synchronizing
SPECIFICATIONS FOR DOCUMENT NUMBER
MH-IDMHMUMB001-E-SP-002
EQUIPMENT DESIGN DIESEL GENERATING SETS
Rev-R0
ENGINEERS
CLIENT : RELIANCE INDUSTRIES LTD. SHEET NO. 21 OF 41

XII. 11KV SWITCHGEAR FOR DG OUTPUT CONTROL

1 Execution Indoor, metal enclosed,


floor mounting, free-
standing, dust and
vermin-proof
2 Degree of protection IP4X
3 Sheet steel CRCA
4 Sheet steel thickness
Base frame / channel 3mm
Load bearing members 2mm
Internal partitions, doors etc 1.6mm
5 Type of assembly Bolted
6 Surface treatment 7 tank for removal of
rust, scale, oil, grease,
dirt by pickling followed
by phosphating
followed by 2 coats of
zinc rich primer
7 Surface Finish Powder Coated Epoxy
with paint shade RAL
7032
8 Cable entry Bottom
9 Version of circuit breakers – fixed or draw-out Drawout
10 Panel accessories Space heater with MCB
and thermostat + cubicle
lamp
11 Bus bars
Material Electrolytic Aluminium
Continuous current rating 400A *
Insulation for bus bars Heat shrinkable
providing full insulation
SPECIFICATIONS FOR DOCUMENT NUMBER
MH-IDMHMUMB001-E-SP-002
EQUIPMENT DESIGN DIESEL GENERATING SETS
Rev-R0
ENGINEERS
CLIENT : RELIANCE INDUSTRIES LTD. SHEET NO. 22 OF 41

Bus bar temperature rise while carrying Final temperature of


rated current 85 C for bus bars and
0

900C for joints with an


ambient of 400C
Bus bar Supports SMC, DMC or cast resin
12 Circuit breaker
Type of circuit breakers Vacuum
No. of poles 3
Make *
Rating 630A
Derated current rating at site condition 630A *
Breaking capacity 26.24kA at 11kV = 500
MVA
Short time rating 26.24kA for 1 second
Execution Draw – out
Mechanism Motorised
Control Supply Voltage
12.1.1 Spring charging Motor 240V AC
12.1.2 Closing and tripping coil 110V DC
CB mechanical indications (flags) `ON’, `OFF’, “Service”,
“Test”, “Isolated”, “Spring
charged”
CB operation facility AUTO/MANUAL

Spare Auxiliary contacts 4 NO + 4 NC wired to


terminal block
13 Requirement of surge suppressor
For machines switched with VCB Required
Type Gapless, Zinc Oxide
Class Rotating Machine class
14 Meters
Type Digital, 7 segment LED
Metering required for Line Currents, Line
voltages
15 Control and selector switches
Function
Auto/manual to select Auto or manual mode of
operation
Local / remote to select Local or Remote mode
Breaker control switch Trip - Neutral - Close,
Spring return to Neutral.
16 Indicating lamps
Type Cluster LED
Lens colours
Red : C.B. “ON”
Green : C.B. “OFF”
SPECIFICATIONS FOR DOCUMENT NUMBER
MH-IDMHMUMB001-E-SP-002
EQUIPMENT DESIGN DIESEL GENERATING SETS
Rev-R0
ENGINEERS
CLIENT : RELIANCE INDUSTRIES LTD. SHEET NO. 23 OF 41

Bus bar temperature rise while carrying Final temperature of


rated current 85 C for bus bars and
0

900C for joints with an


ambient of 400C
Bus bar Supports SMC, DMC or cast resin
12 Circuit breaker
Type of circuit breakers Vacuum
No. of poles 3
Make *
Rating 630A
Derated current rating at site condition 630A *
Breaking capacity 26.24kA at 11kV = 500
MVA
Short time rating 26.24kA for 1 second
Execution Draw – out
Mechanism Motorised
Control Supply Voltage
12.1.1 Spring charging Motor 240V AC
12.1.2 Closing and tripping coil 110V DC
CB mechanical indications (flags) `ON’, `OFF’, “Service”,
“Test”, “Isolated”, “Spring
charged”
CB operation facility AUTO/MANUAL

Spare Auxiliary contacts 4 NO + 4 NC wired to


terminal block
White : “Trip Supply Supervision”
Amber : Auto trip
White : “Spring Charged”
RYB : Phase Indication
17 Push Buttons
Type Spring return or stay put
type as required
Contacts 2 NO + 2 NC minimum
18 Labels & Nameplates
Material PVC or Anodised
Aluminimum
Engraving Black engraving on
white background
Size of the label To suit application /
importance.
Fixing With self-tapping
screws.
Use Main Panel, feeders
and individual devices
SPECIFICATIONS FOR DOCUMENT NUMBER
MH-IDMHMUMB001-E-SP-002
EQUIPMENT DESIGN DIESEL GENERATING SETS
Rev-R0
ENGINEERS
CLIENT : RELIANCE INDUSTRIES LTD. SHEET NO. 24 OF 41

Bus bar temperature rise while carrying Final temperature of


rated current 85 C for bus bars and
0

900C for joints with an


ambient of 400C
Bus bar Supports SMC, DMC or cast resin
12 Circuit breaker
Type of circuit breakers Vacuum
No. of poles 3
Make *
Rating 630A
Derated current rating at site condition 630A *
Breaking capacity 26.24kA at 11kV = 500
MVA
Short time rating 26.24kA for 1 second
Execution Draw – out
Mechanism Motorised
Control Supply Voltage
12.1.1 Spring charging Motor 240V AC
12.1.2 Closing and tripping coil 110V DC
CB mechanical indications (flags) `ON’, `OFF’, “Service”,
“Test”, “Isolated”, “Spring
charged”
CB operation facility AUTO/MANUAL

Spare Auxiliary contacts 4 NO + 4 NC wired to


terminal block
19 Wiring
Control wiring
19.1.1 Type 660V grade, PVC
insulated super-flexible
copper wire
19.1.2 Size 2.5 sq. mm. for CT
circuit
1.5 sq. mm. for control
circuit
19.1.3 Colour Black for AC circuits and
Grey for DC circuit
19.1.4 Termination on equipment terminals / With crimped type,
terminal blocks tinned copper lugs
preferably WAGO Type
19.1.5 Ferruling Required with non –
detachable type printed
ferrules
20 Terminal blocks Preferably WAGO type
Control terminal size 2.5 sq. mm. minimum
SPECIFICATIONS FOR DOCUMENT NUMBER
MH-IDMHMUMB001-E-SP-002
EQUIPMENT DESIGN DIESEL GENERATING SETS
Rev-R0
ENGINEERS
CLIENT : RELIANCE INDUSTRIES LTD. SHEET NO. 25 OF 41

Bus bar temperature rise while carrying Final temperature of


rated current 85 C for bus bars and
0

900C for joints with an


ambient of 400C
Bus bar Supports SMC, DMC or cast resin
12 Circuit breaker
Type of circuit breakers Vacuum
No. of poles 3
Make *
Rating 630A
Derated current rating at site condition 630A *
Breaking capacity 26.24kA at 11kV = 500
MVA
Short time rating 26.24kA for 1 second
Execution Draw – out
Mechanism Motorised
Control Supply Voltage
12.1.1 Spring charging Motor 240V AC
12.1.2 Closing and tripping coil 110V DC
CB mechanical indications (flags) `ON’, `OFF’, “Service”,
“Test”, “Isolated”, “Spring
charged”
CB operation facility AUTO/MANUAL

Spare Auxiliary contacts 4 NO + 4 NC wired to


terminal block
No. Of spare control terminals 10% minimum
21 Testing
All routine tests as per applicable standards Required.
22 Quality Assurance Plan *
SPECIFICATIONS FOR DOCUMENT NUMBER
MH-IDMHMUMB001-E-SP-002
EQUIPMENT DESIGN DIESEL GENERATING SETS
Rev-R0
ENGINEERS
CLIENT : RELIANCE INDUSTRIES LTD. SHEET NO. 26 OF 41

XIII. DIESEL ENGINE

Sr. Description Requirement Bidder’s Confirmation


1 Make *
2 Engine capacity (KW) Compatible with *
alternator of 3750KVA
0.8 PF
3 Type of fuel for engine commercial High speed *
diesel (HSD)
4 Engine Speed 1500 RPM *
5 Short time overload capacity of engine *
6 Cooling Water Cooled *
Cooling water requirement Mcu/Hr *
Inlet water temperature 32 Deg C
Outlet water temperature 37 Deg C maximum *
Quality of cooling water Raw / DM/ treated *
Cooling water system monitoring instrumentation Flow meters, inlet & *
outlet water temp.
indicator
Maximum duration the DG can run at rated load *
without cooling water
7 No of cylinders *
8 Time interval between successive starts *
9 Fuel oil system
Day tank Capacity 990 liters
Accessory Filling, draining and
vent connection with
valves and level
switches for low oil
level & high oil level
alarm and automatic
operation scheme for
day-tank filling.
Type of filter Duplex

Sr. Description Requirement Bidder’s Confirmation


Pre-Combustion Chamber Designed so as to
achieve safe knock-
free performance with
smokeless exhaust
SPECIFICATIONS FOR DOCUMENT NUMBER
MH-IDMHMUMB001-E-SP-002
EQUIPMENT DESIGN DIESEL GENERATING SETS
Rev-R0
ENGINEERS
CLIENT : RELIANCE INDUSTRIES LTD. SHEET NO. 27 OF 41

Sr. Description Requirement Bidder’s Confirmation


10 Type of engine multi-cylinder, totally
enclosed, continuous
duty, direct fuel
injection, turbo-
charged, compression
ignition, inter-cooled oil
engine
Specific fuel consumption under site conditions
10.1.1 Full Load
10.1.2 3/4 Full Load
10.1.3 1/2 Full Load
11 Lubricating Oil System Pressure fed type *
Lube. Oil required at rated Load *

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

Sr. Description Requirement Bidder’s Confirmation


No. of starts to be permitted by compressed air Minimum 3 consecutive
system starting attempts
Compressed air system 1 no. compressor
having adequate
capacity to be installed
local to the diesel
engine. Individual
compressor for
individual DG.
SPECIFICATIONS FOR DOCUMENT NUMBER
MH-IDMHMUMB001-E-SP-002
EQUIPMENT DESIGN DIESEL GENERATING SETS
Rev-R0
ENGINEERS
CLIENT : RELIANCE INDUSTRIES LTD. SHEET NO. 28 OF 41

Sr. Description Requirement Bidder’s Confirmation


Completeness of compressed air system Storage receiver *
adequate to hold
compressed air for 3
successive starts of the
engine, necessary
interconnecting piping,
pressure gauges,
pressure switches for
automatic cycling of the
compressor, electric
starter, LV power &
control cabling.
Starting solenoid valves with manual bypass Required
valve for local starting ( UPS / DC Supply )
14 Governing system
Make *
Type Electronic type
14.1.1 Load sharing features Required *
14.1.2 Adjustable droop Required *
Steady state speed regulation *
Steady state governing speed plus or minus % of *
rated speed
Momentary over speed after full load rejection % *
of rated speed

Sr. Description Requirement Bidder’s Confirmation


Momentary under speed of rated speed after *
sudden increase of 25% rated load
Prescribed speed band ± rated speed *
Safety over - speed trip device *
to automatically shut
off fuel in case the
speed exceeds the
prescribed limit.
15 Exhaust system
Engine exhaust system, complete with exhaust Required
gas driven turbo charger, residential silencer,
ducting, bends , silicate lagging, supporting
accessories etc
G.I. cladding for Exhaust pipes within enclosure 22 gauge with thermal
insulation
SPECIFICATIONS FOR DOCUMENT NUMBER
MH-IDMHMUMB001-E-SP-002
EQUIPMENT DESIGN DIESEL GENERATING SETS
Rev-R0
ENGINEERS
CLIENT : RELIANCE INDUSTRIES LTD. SHEET NO. 29 OF 41

Sr. Description Requirement Bidder’s Confirmation


16 Local Indicator Panel
Flexibly mounted local indicator panel with speed Required
indicator and gauges for lubricating oil pressure
before and after filter
17 Bearings Self-aligning journal
bearings
Type Self lubricated type
No. *
Life *
Lubrication *
Type of lubricant *
Lubricating interval *
Well with a suitable thermometer in the oil drain Required
and a suitable sight flow opening to observe
bearing oil flow. They shall also be provided with
Pt-100 type RTDs for monitoring their
temperature.
Maximum generator shaft voltage 100 mV

Sr. Description Requirement Bidder’s Confirmation


In case, shaft voltage exceeds 100mV Non-driving end
bearing housing and
lead-in & lead out pipes
to be fully insulated
(Non conductive
insulation)
Separate terminal box for space heater and Required
R.T.D./Thermistors
18 Forced Lubrication System In case forced
lubrication is required,
bidder shall provide 1
W+ 1 SB forced lube
oil pumps, electrical
motor driven.
19 Engine exercising facility to be built into engine Normal service, *
and generator control panel Auto, Manual
“Service” (Duty)- Engine shall remain as “Ready-
to-start” and shall start automatically when called
upon (AMF)
Automatic exercising Engine should be able
to start and run at a
SPECIFICATIONS FOR DOCUMENT NUMBER
MH-IDMHMUMB001-E-SP-002
EQUIPMENT DESIGN DIESEL GENERATING SETS
Rev-R0
ENGINEERS
CLIENT : RELIANCE INDUSTRIES LTD. SHEET NO. 30 OF 41

Sr. Description Requirement Bidder’s Confirmation


preset time (e.g. once
a week) and shall run
for preset time (e.g.
30min) this shall be
programmable at site
without load
Manual Exercising Operator shall be in a
position to start and run
the engine as desired
20 Overall dimensions of fully assembled DG unit
Without acoustic enclosure *
21 Weight schedule
SPECIFICATIONS FOR DOCUMENT NUMBER
MH-IDMHMUMB001-E-SP-002
EQUIPMENT DESIGN DIESEL GENERATING SETS
Rev-R0
ENGINEERS
CLIENT : RELIANCE INDUSTRIES LTD. SHEET NO. 31 OF 41

Sr. Description Requirement Bidder’s Confirmation


Overall weight of complete system for foundation *
design
Heaviest single unit to be handled during normal *
maintenance KGs

XIV. INDUCTION MOTORS FOR AUXILIARY DRIVES

Sr. Description Requirement Bidder’s Confirmation


1 Rated Voltage 415V ±10%, 50 Hz, ±5%
2 Type of installation Industrial, 3 phase,
squirrel cage
3 Degree of protection IP54 for indoor and IP 55
for outdoor
4 Reference standard IS 325.
5 Surface treatment painted with chemical
works type epoxy paint
6 Winding treatment windings shall be treated
for chemically corrosive
atmosphere. Overhang
shall be applied with gel
coat epoxy paint.
7 Minimum Motor rating 15% higher than the
driven equipment input
power requirement
8 Insulation class Class B or better
9 Minimum starting voltage 80% of rated voltage
SPECIFICATIONS FOR DOCUMENT NUMBER
MH-IDMHMUMB001-E-SP-002
EQUIPMENT DESIGN DIESEL GENERATING SETS
Rev-R0
ENGINEERS
CLIENT : RELIANCE INDUSTRIES LTD. SHEET NO. 32 OF 41

XV. PLC SYSTEM FOR DG

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.

9.2 PERFORMANCE REQUIREMENTS OF THE PLC SYSTEM –

The following performance activities are expected from the PLC:


 Starting and stopping of 04 nos. DG sets along with their auxiliaries in a sequenced manner.
 The DG sets are to run in synchronism with each other.
 The PLC shall allow selection of any three out of four DG duty sets as “Service” sets and fourth as
“standby”.
 Automatic Mains Failure starting of 3 nos. duty DG sets. In case one of the DG set fails to start or trip
during operation, the standby DG set shall be brought into operation automatically.
 ON – OFF control of DG sets VCBs.
 Generation of static and dynamic mimic for each DG set along with important parameters of generator
and engine.
 Fault report generation indicating type of fault and date & time of occurrence of the fault. The system
shall be capable of loading the faults in its memory for 48 hours.
 Generation print-outs periodically or on-demand as desired by the operator in a format to be approved
by the Purchaser.
SPECIFICATIONS FOR DOCUMENT NUMBER
MH-IDMHMUMB001-E-SP-002
EQUIPMENT DESIGN DIESEL GENERATING SETS
Rev-R0
ENGINEERS
CLIENT : RELIANCE INDUSTRIES LTD. SHEET NO. 33 OF 41

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

Back – up storage of the software


In the event of the software getting non-operative / corrupt due to some reason the operator should be capable
of re-loading the same into the PLC system.
The Bidder shall, therefore, included in his scope suitable back-up system such as a CD (with a drive)
Completeness of the System
If the Bidder feels that based on his experience certain additional hardware / software is required to be
included by him to make the system fully operation, he shall offer the same, highlighting the particulars.
Software
The sequencing logic shall be either ladder diagram based or execution statement based. It is preferable that
the operator is in a position to edit the logic or add the ladders / execution statement from his PC with the help
of keyboard or mouse.
Power supply
The Purchaser shall make available power at 240V, Single phase, 50 Hz or 415 V, 3 ph., 4 wire, 50 Hz,
depending on the KVA requirement of the PLC system.
The industrial (plant power distribution) power supply is prone to frequent failures, is subject to over voltages /
under voltages and is likely to be contaminated by spurious noise signals, spike etc.
The Bidder shall clearly state in his Bid whether the above mentioned power supply is acceptable to his
system, in which case he has to elaborate the arrangements made by him in his PLC input power supply
system.
If the Bidder requires conditioned and UPS power supply for his system,
He shall include adequately rated UPS system operating on the abovementioned Industrial type power supply,
with adequately rated (AH capacity) sealed Maintenance – Free batteries.
Other power supplies such as 12 / 24 V DC or as required, for the electronics system of the PLC, in any case
will have to be derived by the Bidder himself. Necessary power packs and other hardware required for this
purpose will have to be included by the bidder in his scope.

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

Familiarization of configuration of the PLC system.


 Familiarization and working of the software including the procedure for loading of the software from
back-up storage system, editing of / modifications to the preloaded software.
 Actual operation of the DG system including the VCBs from the PLC.
 Fault diagnostics and trouble-shooting
 Repair of the faulty PCB / replacement by spare PCBs etc.

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

25.4 Control Panels


The control panels shall be subjected to the following tests at manufacturer's works, which shall be witnessed
by the Purchaser/ his representative.
a) Continuity Checks
b) High voltage withstand test as per relevant standard.
c) Insulation resistance test.
d) Functional and operation test.

25.5 D.G. set and the auxiliaries


D.G. set and the auxiliaries shall be assembled at the manufacturer's works and the following tests shall be
performed, which shall be witnessed by the Purchaser/ his representative.
a) One (1) hour running at full load.
b) One (1) hour running at 3/4 load.
c) One (1) hour running at 110% full load.
d) Engine starting time.
e) Fuel consumption test.
Before each test, the engine shall be brought to a steady state under the conditions of the test.

25.6 Tests at Site

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.

25.7 Test Certificates


a. Test certificates shall be submitted in six (6) copies.

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

XVII. MAINTENANCE TOOL AND TACKLES

 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

XIX. DRAWINGS AND DOCUMENTS SCHEDULE

A. FOR GENERATOR CONTROL & BREAKER PANEL


Documents shall comprise but not limited to the following:

Required after Purchase Order

Engineering Data Require For No. of As No. of weeks


d approva weeks built
With l Qty Qty
Bid-Qty

1 Outline dimension drawing 2 4 2 6 6


2 Cross sections with part description
3 Foundation drawings with static & dynamic 2 4 2 6 6
loading data
4 Completed Data Sheets 2
5 Bill of Materials for scope of Supply 2 4 2 6 6
6 Performance Data /Curves:/Discharge 2
curves
7 Installation / Operation / Maintenance 3 With dispatch
Manual
8 Priced Spare List for 10 years service 2
9 Terminal point schedule / drawing 4 2 6 6
10 Control Schematic Diagram 4 2 6 6
11 Description of Control Sequences
12 Type test certificate for short circuit 2
withstand for panel
13 Type test certificate for short circuit 2
breaking current of circuit breaker
14 At the time of inspection 6 At the time of
15 Test Certificates for bought out items 6
inspection
(Breaker, CT, PT, Meter, Relay)
SPECIFICATIONS FOR DOCUMENT NUMBER
MH-IDMHMUMB001-E-SP-002
EQUIPMENT DESIGN DIESEL GENERATING SETS
Rev-R0
ENGINEERS
CLIENT : RELIANCE INDUSTRIES LTD. SHEET NO. 41 OF 41

B. DRAWING AND DOCUMENTS SCHEDULE FOR DG SYSTEM


Documents shall comprise but not limited to the following:

Required after Purchase Order

Engineering Data Reqd For No.of As No.of weeks


With approval weeks built
Bid Qty Qty

1 General arrangement drawing showing all 2 4 2 6 6


major dimensions, including clearances
required and crane requirement for
assembly & dis- mantling, nett & shipping
weights of all items of equipment.
2 Recommended layout showing room 2 4 2 6 6
dimensions, ventilation requirement civil
foundations, loading data, trench, wall
opening, etc.
3 Schematic P & I diagrams for lube oil, fuel 2 4 2 6 6
oil, jacket cooling, etc.
4 Schematic diagrams for control panel, 2 4 2 6 6
synchronising panel, voltage regulator,
governor
5 Literature, write ups, description of DG set 2 4 2 6 6
excitation system, voltage regulator,
governor & other auxiliaries
6 Voltage dip calculations - 4 2 6 6
7 Test reports - - - 6 Before
despatch
8 Generator characteristic curves yes 3 2 6 6
9 Bill of material 2 4 2 6 6