PCPL 0630 3 401

ITC LIMITED,
PUNE
PROJECT WEST SIDE
DIESEL GENERATOR SET

ENQUIRY SPECIFICATION
PCPL-0626-3-406
SEP - 2007
Rev.R0
POET CONSULTANTS PVT. LTD

P OWER E NGINEERING & T ECHNOLOGY C ONSULTANTS
Anugraha, #460, I Block, III Stage, Basaveswaranagar, Bangalore 560 079.
Tel. / Fax: 091-80-2322 5333
E-mail: info@poetconsultants.in, URL: www.poetconsultants.in
R0, 20-09-2007
REV NO. & DATE
ALN
VR
PREPARED BY
RV
CHECKED BY
APPROVED BY
DOCUMENT No
PCPL-0626-3-406
DG SET
PAGE: 1 of 1
CONTENTS
SECTION
Sl.
No.
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DOCUMENT NO.
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PCPL-0626-3-406-01
PCPL-0626-3-406-02-1
PCPL-0626-3-406-02-2
3
4
4
4
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PCPL-0626-3-406-03
PCPL-0626-3-406-04-01
PCPL-0626-3-406-04-01-1
PCPL-0626-3-406-04-02
PCPL-0626-3-406-04-02-1
PCPL-0626-3-406-04-03
PCPL-0626-3-406-04-03-1
PCPL-0626-3-406-04-04
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PCPL-0626-3-406-04-05
PCPL-0626-3-406-04-05-1
PCPL-0626-3-406-04-06
PCPL-0626-3-406-04-06-1
PCPL-0626-3-406-04-07
PCPL-0626-3-406-04-07-1
PCPL-0626-3-406-05
PCPL-0626-3-406-06
DRAWING NO.
PCPL-0626-3-SK-001
PCPL-0626-3-SK-002
PCPL-0626-3-SK-003
PCPL-0626-3-SK-004
PCPL-0626-3-SK-005
PCPL-0626-4-SLD-003
PCPL-0626-4-SK-001
PCPL-0626-4-SK-004
TITLE
Scope of Enquiry
Project Information
ITC EHS Constructional Safety
Requirements
Specific Technical Requirements
DG Set
DG Set- Data sheet
Acoustic Enclosure
Acoustic Enclosure-Data sheet
Rotary screw pump
Rotary screw pump-Data sheet.
Erection, Testing and Commissioning
of Mechanical Equipment and
Systems.
Control and Relay Panel
Control and Relay Panel-Data sheet
Battery
Battery-Data sheet
Battery Charger
Battery Charger-Data sheet
Price Schedule
Deviation Schedule
No. of
pages
1
1
9
6
11
7
1
2
1
2
4
6
11
7
4
7
5
1
1
DRAWINGS
REV No. of
TITLE
sheets
P0
1
DG House Layout
P0
1
DG House Cross Section
P0
1
HSD Day Tank Data Sheet
P0
1
Flow Diagram-Lube Oil System
P0
1
Flow Diagram-Fuel Oil System
P0
1
Single Line Diagram-DG Sets
P0
1
Legend
P8
1
Energy Centre Electrical Panel Room Layout.
ISSUE No: R0
DATE: 20-09-2007
DOCUMENT No
PCPL-0626-3-406-01
SECTION - 1
PAGE: 1 of 1
SCOPE OF ENQUIRY
1.0
This specification covers the design, engineering, procurement, manufacture, inspection

and testing at the works of manufacturer and/or sub-vendor, packing for shipment,
forwarding, including transit insurance, receipt at site, storage and handling at site,
erection, testing, cleaning, start-up & commissioning and performance testing - all to the
satisfaction of Owner or Owners authorized representatives and in accordance with
these specifications and as per good engineering practices of Five Diesel Generator sets
each capable of delivering a power output of 1000kVA at generator terminal under
specified site conditions complete with auxiliaries and integral systems as part of .
Project West Side Cigarette factory of M/S. ITC LTD., ITD at PUNE
2.0
It is not the intent to specify completely herein, all the details of design and construction
of the equipment. However, the equipment shall conform in all respects to high standards
of engineering, design and workmanship and be capable of performing in continuous
commercial operation up to vendors guarantee period in a manner acceptable to the
purchaser, who will interpret the meaning of the drawings and specifications and shall
have the right to reject any work or material which in his judgement are not in full
accordance therewith.
3.0
Bidder shall quote for all the systems covered in this specification.
ISSUE No: R0
DATE: 20-09-2007
DOCUMENT No
PCPL-0626-3-406-02-1
PROJECT INFORMATION
1.0
2.0
3.0
4.0
OWNER
CONSULTANT
PROJECT TITLE
LOCATION
5.0
ELEVATION ABOVE MEAN SEA

LEVEL
NEAREST RAILWAY STATION
NEAREST NATIONAL HIGHWAY
NEAREST AIRPORT
ANNUAL AVE. AMBIENT TEMP.
a. Maximum
b. Minimum
c. Amb. Temp. for Equipment Design
ANNUAL RAIN FALL
HUMIDITY
SEISMIC ZONE
TROPICALIZATION
6.0
7.0
8.0
9.0
10.0
11.0
12.0
13.0
14.0
15.0
PLANT MAIN EARTH GRID

AUXILIARY POWER SUPPLY
a. MV AC Power Supply
b. Lighting Fixtures, spring charging

motors and Space Heaters
c. Control supply for HV Swgr and MV
PCC
d. Control supply for others
16.0
AUXILIARY SUPPLY VOLTAGE

VARIATION
a. AC Supply
b. DC Supply
SECTION - 2
PAGE: 1 of 1
ITC Limited, ITD Pune

Poet Consultants Pvt. Ltd., Bangalore
Project West Side
Ranjangaon MIDC Ind.Area ,Ranjangaon (60 km
North east of the city of Pune)
603 m
Pune Railway Station
Pune-Ahmednagar highway(SH-60)
Pune
38O C
11O C
45O C
Approx. 400 700 mm
17-80%
Zone 4 as per IS 1893
All equipment supplied against this specification shall
be given tropical and fungicidal treatment in view of
the climatic conditions prevailing at site. Tropical
protection shall conform to BS CP -1014-1963,
Protection of Electrical Power Equipment against
climatic conditions.
75 X 12 mm GS
415V, 3-phase, 4-wire, 50 Hz effectively earthed
system with voltage variation of +/-10%, frequency
variation of +/- 5%, or combined variation of voltage
and frequency up to +/- 10%.
240V, 1-phase, 2-wire, 50Hz.
48V DC
110V AC from 415/55-0-55 centre tapped control
transformer to be provided by the vendor.
Voltage Variation: +/- 10%
Frequency Variation: +/- 5%
Combined Voltage and Frequency Variation: + or 10%
Voltage Variation : +10% to -15%
All devices and equipment shall be suitable for
continuous operation over the entire range of voltage
and frequency indicated above, without any change in
their performance.
ISSUE No: R0
DATE: 20-09-2007
DOCUMENT No
PCPL-0626-3-406-02-2
ITC EHS CONSTRUCTIONAL

SAFETY REQUIREMENTS
SECTION - 2
PAGE: 1 of 9
Part - I
Introduction
1.1
This document defines the operations undertaken by contractors and sub-contractors on

the clients premises, which can give rise to fire hazards to those engaged in the work
and others who may be working, standing or passing the vicinity.
1.2
It is the companys endeavor to secure a high standard of safety on our sites therefore,
contractors and sub-contractors must know their duties under common law, both for
establishments and their own employees and to conduct their business and methods of
work to confirm to the best practices.
1.3
Before the client / company allows any contracting or sub-contracting firm to carryout
work on its premises, the company insists that contractors and sub-contractors
understand their duties regarding safe practices for themselves, others and regulations
covering the type of work they will be carrying out.
1.4
In furtherance to this policy, rules herein have been devised to bring to the notice of
Contractors, and sub-contractors some of the more common hazards, and appropriate
preventive measures in connection with the erection, construction, cleaning, painting,
alteration or demolition of plant, machinery and building.
1.5
The client is confident that the observance of these rules will be no hindrance to the
progress of the work, but will assist in the avoidance of accidents.
1.6
IT IS IN A TERM OF ALL CONTRACTS BETWEEN THE CLIENT AND

CONTRACTORS THAT THEY AND ANY SUB-CONTRACTORS APPOINTED BY
THEM COMPLY WITH THESE RULES AND THEIR COOPERATION IS
THEREFORE OBLIGATORY IN CARRYING OUT THE PRECAUTIONS LAID
DOWN.
1.7
Section 2 details general rules, which are applicable to most contractors and subcontractors.
1.8
Section 3 details specific rules, which must be followed where applicable, where a
particular type of work is to be undertaken.
1.9
All contractor Supervisors will make sure that the engineering services / Safety Manager
on company sites are notified as and when he and others (sub-contractors) are reporting
for work on that site.
ISSUE No: R0
DATE: 20-09-2007
DOCUMENT No
PCPL-0626-3-406-02-2

SAFETY REQUIREMENTS
SECTION - 2
PAGE: 2 of 9
PART 2
Rules for General Operations
2.1
Access
Nothing shall be done or omitted to be done by Contractors or sub-contractors or their
employees to render unsafe or obstruct:
2.2
Any means of access to the places at which people are required to work.
The passage of people and / or vehicles whether on a defined gangway or

not, unless permission is obtained from the designated Safety Officer /
Engineer.
Access for emergency apparatus such as fire fighting equipment.
Contractors and sub-contractors shall nevertheless provide adequate

fencing, lighting and warning signs to ensure safety at all times.
Accident and Incident Reporting:

All noticeable accidents, dangerous occurrences and potentially hazardous situations
shall be reported to the Safety officer / Engineer on site.
2.3
Contractors and Sub-contractors Tools and Equipment

All contractors and sub-contractors tools and equipment must comply with statutory
regulations and approved codes of practices.
2.4
Hazardous material
The contractor must inform the Safety Officer / Engineer, prior to commencement of
work of processes or materials connected with the contract work of a hazardous nature.
The contractor will have to secure storage for any such material.
2.5
Dust and Fume Control

Contractors and sub-contractors must inform Safety officer / Engineer on company site
of all processes producing dust or fumes, and under the conditions as laid down in the
Factories Act 1948, Sections 14 and 37 the Safety precautions are to be fulfilled.
2.6
Fire Hazards and Precautions

When on site, the Companys fire regulations as well as the regulations under section 38
of the factories act, 1948 must be observed at all times.
2.7
Contractors and sub-contractors working on Company sites must not remove or displace
may guard, fencing or other safety equipment which is designed to protect personnel or
machine or any place where safety equipment has been provided, without the written
permission of the Safety Officer or his designated representatives.
2.8
Housekeeping
2.8.1
Housekeeping and hygiene go hand in hand with safe working practices.

Contractors and sub-contractors must leave work areas in a clean, tidy and safe
conditions at the end of each working period.
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DATE: 20-09-2007
DOCUMENT No
PCPL-0626-3-406-02-2

SAFETY REQUIREMENTS
SECTION - 2
PAGE: 3 of 9
2.8.2
Special attention must be paid to potential fire hazards, trip points and equipment
left in a working period.
2.8.3
Contamination of the tobacco / food product (by drill surf, saw dust, oil, sealant,
paints and materials etc.)
2.9
Noise
Contractors and sub-contractors working on company premises or sites must obtain
permission from the safety officer / engineer if the processes being employed to carry out
that work significantly increase the ambient noise level in that area being worked.
2.10
Overhead Working
No work may be carried out above the heads of people or over gangway or roads, until
all usual precautions have been taken to ensure the safety of the person below, and until
the Safety Officer / Engineer grants permission. Each specific site of overhead working
will require consent from the Safety Officer / Engineer. This will be given after
satisfactory inspection.
Work may be carried out in the vicinity of power cables only when permission is
obtained from the Safety Officer and / or Site Engineer.
Work connected with overhead safety includes the movement of long metal objects,
machinery, jibs, masts, arms or other elevated parts.
2.11
Working at a height
All temporary structures erected by contractors or sub-contractors for the purpose of
allowing their staff to work at heights of more than 2 m. above floor level must be
constructed in accordance with the safety regulations laid down.
Metal ladders must not be used where there is any possibility of the ladder coming into
contact with electrical lines. In these places the ladders to be made of wood in good
condition.
Roof working must be properly supervised.
2.12
Safety Clothes and Equipment

This shall be supplied by contractors and sub-contractors who are working on company
sites and must be adequate for the well being of their staff engaged in the type of work
contracted for.
The equipment and its use must comply with the regulations and codes of practices as
laid down that apply to the conditions of work being undertaken.
Contractors and sub-contractors will be responsible for the use of any tools and
equipment that is supplied by them or their staff to the exclusion of all responsibility of
the client. Tools will be maintained to the highest standard of safety. Whilst in the
possession of such tools, the person so using said tools is responsible for the continued
maintenance of safety standards.
It is the individuals responsibility to ensure that the tools he works with are suitable for
the job and in a safe condition prior to work commencement. All necessary tools and
ISSUE No: R0
DATE: 20-09-2007
DOCUMENT No
PCPL-0626-3-406-02-2

SAFETY REQUIREMENTS
SECTION - 2
PAGE: 4 of 9
equipment to complete a contract shall be supplied by the contractor. Due provision must
be made during contract.
2.13
Plant Services
Before using plant services such as electricity, permission to do so must be obtained
from the appropriate authority, site engineer or safety officer.
2.14
Supervision
Contractors working on company premises must ensure that their staff are adequately
supervised.
2.15
Warning Signs and Notices

Suitable warning signs are to be displayed warning potential hazards. A proper written
permission to be taken by Project Manager / Safety Manager to work in confined areas
and all the necessary safety precautions to be adopted.
2.16
As the works and services become energised a Permit to Work system will be brought
into operations and shall be adhered to strictly.
2.17
All flammable items shall be clearly marked and stored safely securely in properly
ventilated areas. Fire-fighting equipment shall be readily available adjacent to those
areas, for use in case of emergency.
2.18
All operators will be equipped and attend a Safety induction course on joining site and
shall sign to acknowledge that they have attended the course. Copies of the signed
acknowledgments will be passed to the Project safety officer.
2.19
The contractor will nominate a senior staff member who will be responsible for all
aspects of health and safety in relation to the contractors workforce on site. The person
so nominated shall hold weekly safety talks with his operators, the minutes of which
shall be passed on to the project safety officer.
2.20
A project safety committee will be formed under the direction of the project safety
officer. The nominated member of the contractors staff will be required to attend the
weekly meetings of the project safety committee.
ISSUE No: R0
DATE: 20-09-2007
DOCUMENT No
PCPL-0626-3-406-02-2

SAFETY REQUIREMENTS
SECTION - 2
PAGE: 5 of 9
PART - 3
Tools
3.1
Electricity driven portable tools

Permission is to be obtained from the nominated person before any contractor or subcontractors electrical hand tools can be connected to the electricity supply.
Connection must be given by 3-core cable and 3-pin plugs and sockets, except when
tools are double insulated on a 2-wire supply. Where the supply is 3 phase 4-core cable
and 4-pin plugs and sockets with earth connections must be used.
Makeshift connections are prohibited.
The use of extension cables is discouraged but sometimes necessary.
Portable electric lamps must be gripper type with caged wire protection for the bulk
and precautions as laid down under Section 36-37 of the Factories Act, 1948 must be
observed.
In damp conditions, voltage must not exceed 25 V, supplied from a double wound
transformer.
Hand tool voltages are to be 110 V and contractors and sub-contactors must supply their
own double wound transformer 110 / 250 V-50 Hz with the centre tap effectively
earthed.
In all cases, with the exception of double insulated tools, the metal work of the tool part
is effectively earthed, also any flexible metallic cable coverings must be earthed.
Distribution feeder used for construction power supply / hand tools shall be provided
with 30mA rating ELCB
3.2
Compressed Air Tools

Contractors and sub-contractors must obtain permission to use any air supply tool on
company site.
Contractors and sub-contractors must also provide suitable noise suppression for
pneumatic hammers, drills etc.
3.3
Percussion Cartridge Tools

(Operators to be trained and issued certificates from supplier)
Permission to use percussion tools must be obtained from the designated safety
representative prior to use of these tools. Also, when using percussion tools, it is the
individuals duty to ensure that the charges used in the said tools are correct. These tools
are to be handled as dangerous weapons, never leave tools unattended, never leave tools
charged or stores charged, and never point tools at personnel, always lock-up when they
are not in use.
3.4
Abrasive cutting and Grinding tools

Only operators who are fully trained in the use of such tools shall be allowed to operate
them on site.
ISSUE No: R0
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DOCUMENT No
PCPL-0626-3-406-02-2

SAFETY REQUIREMENTS
SECTION - 2
PAGE: 6 of 9
Such tools shall be used for their designed purpose only.

Such tools shall be fitted with discs / stones matched to the tool speed required and of the
appropriate type for the particular operation.
When grinding metal, surrounding areas shall be cleared and / or protected to prevent
damage and fire.
Protective eye - goggles shall be given for work at all times.
3.5
Hoisting and Lifting

(All access gates at landing levels to be inter logged with hoist)
Permission must be obtained prior to the use of company plant and equipment or any
other hoisting and lifting equipment from the factory engineer or other nominated
responsible person.
Operators must be experienced in slinging loads and use of equipment.
Equipment must be adequate for the purpose required and anchorage approved by the
site safety officer.
Loads, whenever possible, should not be overseeing work areas,
All equipment so used, must have examined by a competent person and where necessary
a certificate obtained in accordance with section 28 and 29 of the Factories Act 1948.
When cranes are used, an experienced banksman shall be provided with close
communications to crane operator.
No object is to be left unattended whilst using lifting equipment.
3.6
Movement of Plant and Machinery

Permission must be obtained prior to the movement of construction materials, plant or
equipment about or on a company site.
3.7
Powered Industrial Trucks

Permission must be obtained prior to the use of lift trucks by contractors or subcontractors on company sites.
Trucks must only be driven by competent licensed personnel and must comply with
statutory regulations.
ISSUE No: R0
DATE: 20-09-2007
DOCUMENT No
PCPL-0626-3-406-02-2

SAFETY REQUIREMENTS
SECTION - 2
PAGE: 7 of 9
PART - 4
Contractors and Sub-contractors Guidelines
4.1
Safe working practices must be observed at all times.
4.2
It is the responsibility of the Contractor and sub-contractors staffs to use appropriate

personal protection. It is the contractors and sub-contractors obligation to supply
necessary protective equipment and clothing.
4.3
Certain areas are designated hazardous (e.g. Noisy areas) - and warning signs must be
obeyed.
4.4
Where the contractors and sub-contractors work presents a potential hazard, appropriate
notices must be supplied and displayed and the area made secure as far as is reasonably
possible.
4.5
The client will not provide tools, materials, lifting or access equipment, fixing or raw
materials, unless by previous arrangements.
4.6
Any equipment brought to the site by Contractors and sub-contractors must not be used
by untrained persons, and attention is drawn to the indemnity clause of ITC orders,
which states that the contractor is liable for any consequent damage or loss to people,
equipment or buildings.
4.7
All welding, burning and grinding operations, which potentially cause fire, must be
reported to Security.
4.8
No alcohol is permitted on site and anyone deemed to be under the influence of alcohol
will be required to leave the site.
4.9
Vehicle parking will be in designated areas only.
4.10
Smoking is NOT allowed in work areas.
4.11
No food is to be consumed or left in work areas.
4.12
Warning signs and speed restrictions must be strictly observed.
4.13
Place of work to be left in a tidy and safe condition at the end of each work period.
4.14
All injuries must be reported to the Ambulance Room or to Security beyond normal
hours. Security staffs are all trained in first-aid.
4.15
All workmen shall have valid identification cards issued by the Project Engineer.
4.16
All work men shall wear helmets approved boots.
4.17.
Only licensed wire men shall be allowed to carry out electrical work.
4.18.
Rubber gloves and rubber boots of correct voltage grade shall be used while working On
Line panels.
4.19.
Temporary supply shall be tapped from a source panel, which is properly fabricated and
permanently fixed and effectively earthed.
4.20.
Each tapping shall have ELCB of 30mA rating and shall be taken through armored
sheathed multi core cable or for distance up to 10mtr through un-armoured multi core
ISSUE No: R0
DATE: 20-09-2007
DOCUMENT No
PCPL-0626-3-406-02-2

SAFETY REQUIREMENTS
SECTION - 2
PAGE: 8 of 9
sheathed cable with inbuilt earth wire or earth wire clamped to the cable. All three phase
connection shall have double earth wire.
4.21.
All hand tools shall be of 110 Volts A/C double insulated.
4.22.
Welding set shall be properly earthed through an insulated cable to the nearest earth pit.
Welder shall use welding shield.
4.23.
Wooden ladders/godi shall not be used for working at height. Properly designated
platforms of steel with nylon wheels shall be used for working at heights as per safety
guide lines.
4.24.
Live line testers and test lamps shall not be used. Usages of multi meters with long
probes are to be followed. All lamps for temporary use shall be protective guards.
4.25.
Safety belts and retro guards shall be used to prevent works man from tripping /falling
from a height.
4.26.
Work men using drilling / grinding/cutting tools shall be used eye protection(specs)..
4.27.
Only authorised approved equipment /tools shall be used in execution of work.
4.28.
Wire cutting tools and knives etc., shall be provided with safety handles
4.29.
Cable laying shall be carried out using roller. etc.
4.30.
Danger board to caution the passersby shall be provided wherever hazard work being
done.
4.31.
Every activity at site shall be cleared and authorized by the safety manager / project
engineer before commencement of such activity.
4.32.
All debris shall be cleared at once on hour to hour basis. Violation of norms will be
considered as breach of contract and will be liable for heavy damages.
WATER AND POWER REQUIRED FOR ERECTION.
4.33.
Water and power required for erection will be supplied by the owners at one point.
ISSUE No: R0
DATE: 20-09-2007
DOCUMENT No
PCPL-0626-3-406-02-2

SAFETY REQUIREMENTS
SECTION - 2
PAGE: 9 of 9
PART - 5
General
It is a term of our contract with you that you and your employees and sub-contractors
you appoint shall:
A. Whilst on company premises comply with all health and safety legislation and company
health and safety regulations in force from time to time.
B. Ensure that all equipment and tools brought on to the premises will be in a safe condition,
have recently been checked and that all personnel using the equipment and tools have
been trained in their safe operations and
C. Ensure that training has been given in the safe operation of the work to be carried out on the
premises.
STORAGE
The owner will identify space for storing of contractors materials at site.
The contractor shall make temporary partition, lockable arrangements watch and ward at
his own cost and clear the store as and when required by the owners. The contractor shall
clear all debris on daily basis.
ISSUE No: R0
DATE: 20-09-2007
DOCUMENT No
PCPL-0626-3-406-03
1.0
SPECIFIC TECHNICAL REQUIREMENTS
SECTION - 3
PAGE: 1 of 6
GENERAL
1.1
This Section describes the scope of work under this contract and must be read in
conjunction with complementary Sections, Exclusions, Terminal Points and attached
drawings to obtain a proper interpretation of the scope. It shall be clearly understood by
Bidders that all supplies and services as required to install and commission of
Emergency D.G Sets.
1.2
In keeping with the concept of turnkey contract, Bidder shall be responsible for the
design, engineering, procurement, manufacture, inspection and testing at the works of
manufacturer and/or sub-vendor, packing for shipment, forwarding, including transit
insurance, receipt at site, storage and handling at site, erection, testing, start-up &
commissioning and performance testing - all to the satisfaction of Owner or Owners
authorized representatives and in accordance with these specifications and as per good
engineering practices.
1.3
The above responsibilities of the Bidder would include but not limited to Five (5)
numbers 1000kVA Emergency Diesel Generator Sets and its all associated auxiliaries as
detailed below under clause 2.0.
1.4
In the event of conflict between various sections, data sheets & drawings, then the
explanation given in Section-3 to be considered for interpretation/ implementation.
2.0
EQUIPMENT/ SYSTEMS TO BE PROVIDED BY THE BIDDER:
2.1
Five (5) Nos 1000kVA at 0.8 lagging power factor, 415 volts, 3 phase, 4 W, 50Hz, 1500RPM Diesel Engine driven generating set complete with cabling, earthing and one set of
tools and tackles. The DG Sets shall be suitable for continuous parallel operation with
each other.
2.2
All the sketches enclosed as part of the specification are for bidding purposes only and are
suggestive. Successful Bidders shall furnish detailed design drawings for approval before
manufacture.
2.3
Diesel engine, 4 stroke cycle, water cooled, turbo charged, after cooled developing
required BHP at 1500 rpm under NTP conditions of BS 649-1958 complete with
following accessories for each set:
2.3.1
Fly wheel and suitable flexible couplings.
2.3.2
Intake air system with air cleaner (dry type).
2.3.3
Water pump-centrifugal type-engine mounted.
2.3.4
Fuel oil system including Fuel pumps etc.,(Tentative fuel oil flow diagram is
detailed at PCPL-0626-3-SK-005)
2.3.5
Fuel filters and lube oil filter.
2.3.6
Radiator.
2.3.7
Fan (Blower type) with safety guard if required.
2.3.8
Electronic Governor having facility for remote control of speed (RPM).

ISSUE No: R0
DATE: 20-09-2007
DOCUMENT No
PCPL-0626-3-406-03
2.3.9
SECTION - 3
PAGE: 2 of 6
Battery and Battery charger systems.

One No. 24V battery and battery charger systems complete with DC starter, Dynamo,
built in voltage regulator, battery stand, etc, for each DG Set. The Battery offered shall
be suitable for a minimum of 3 consecutive starts (when fully charged) of DG Set on
cold condition.
2.3.10
Throttle control lever with remote stopping (shut-off) facility.
2.3.11
Instrumentation system including engine and generator protection system.
2.3.12
Safety control against low lube oil pressure and high cooling water temperature.
2.3.13
Lube oil Temperature gauge.
2.3.14
Lube oil Pressure gauge.
2.3.15
Water temperature gauge.
2.3.16
Battery charging ampere metering.
2.3.17
Hour run meter cum RPM meter.
2.3.18
Exhaust system covering ducts, expansion joints, silencer insulation and necessary
supports etc. The insulation shall be of mineral wool, with wire mesh binding and GS
sheet cladding. Independent galvanised steel exhaust stack for each DG shall be
supplied, as per PCB guidelines. The Bidder shall provide necessary common structural
supports for the exhaust piping system.
2.3.19
A common lattice support structure shall be provided for the exhaust stacks. The
support structure shall be suitable for supporting exhaust stacks of Five DGs of
1000Kva.
2.3.20
Support structure shall be hot dip galvanised finish self supporting complete with
ladder for maintenance, landing space, etc.
2.3.21
Civil foundation for the lattice structure support shall be part of the package.
2.3.22
Sensors for oil pressure, high water temperature and over speed.
2.3.23
Complete piping, valves, fitting and specialties for fuel oil, lube oil, cooling water,
and intake air and exhaust system.
2.3.24
All foundation channels, bolts, anchors, shims, resilient mounting pads, Antivibration pads and other accessories as per manufacturers recommendations.
2.3.25
Four sets of operating and instruction manuals and Spare parts book
2.3.26
Complete lube oil system including initial charge of lubricating oil. The proposed
lube oil system is indicated in the enclosed Flow diagram.
2.3.27
Necessary safety equipment (fire extinguisher, rubber mat, etc.) as stipulated by

statutory authorities.
2.3.28
Acoustic enclosures
ISSUE No: R0
DATE: 20-09-2007
DOCUMENT No
PCPL-0626-3-406-03
SECTION - 3
PAGE: 3 of 6
2.3.29
Complete fuel oil system covering HSD Booster pumps day tanks, pipings, valves
and fittings, etc. as per drawing no. PCPL-0626-3-SK-005.The Bidder shall size the
piping and booster pumps accordingly.
2.3.30
Fuel oil system comprising one 900 Litre capacity day tank and piping from day
tank to DG set. Typical scheme is detailed at the enclosed drawing PCPL-0626-3-SK003.
2.4
Set of Alternator and other electrical accessories comprising of :
2.4.1
Five(5) - 1000KVA alternator with all accessories as described in Section 4 of this

specification.
2.4.2
One (1) lot 1100 volt grade, XLPE insulated, armoured, control cables required for
DG set, Day tank & AMF panels.
2.4.3
One (1) lot cable terminations, comprising gland plates, cable glands, cable lugs
etc.
2.4.4
One (1) lot earthing materials required for DG set neutral and body earthing.
2.4.5
Two (2) Neutral switching panels complete with Motorised MCCB and neutral
CTs.
2.5
Successful bidder shall be responsible for getting all statutory clearances/ approvals (like
PCB, CEIG etc.). The applicable statutory fees shall be paid by ITCL.
2.6
Typical layout of the DG Sets is shown on Dwg Nos. PCPL-0626-3-SK-001 and sectional
views are indicated on Dwg No.PCPL-0626-3-SK-002.
2.7
All control wiring shall be carried out using multistranded copper conductor, FRLS PVC
insulated wires of sizes as indicated at various sections.
2.8
The entire electrical control system shall be designed with fuse less system logic. For SC
protection, MCBs of suitable rating and characteristics shall be used.
2.9
Potential transformers shall be provided with primary MPCB and secondary MCB+RCCB
(30mA) protections.
2.10 Space heaters provided either in alternator or in panels, shall be controlled by 50-90%
setting range humidistat and MCB protection.
2.11 All instrumentation, meters, relays, switches, etc., used shall be totally shrouded design
with finger touch proof terminations for human safety.
3.0
3.1
APPROVED MAKES.
The following makes of component are acceptable. Any other make if offered shall be
subject to PURCHASERS approval:
1. Diesel Engines
Cummins/ MTU/ Caterpillar
2. Generator
Stamford/ Leroy Somers
3. Cooling Tower
Paharpur Cooling Towers Ltd, GEA Energy
ISSUE No: R0
DATE: 20-09-2007
DOCUMENT No
PCPL-0626-3-406-03
SECTION - 3
PAGE: 4 of 6
Systems, Wetbulb cooling towers Pvt Ltd.
4.0
4.1
4. Electronic Governor
Woodwards
5. MCCB
Schneider Elec / ABB /Siemens
6. Air Circuit Breakers
Schneider Elec / ABB /Siemens
7. MCB/ ELCB
Schneider Elec / Siemens / MDS Legrand

(Lexic range)
8. Power & Aux Contactors
Schneider Elec / Siemens /ABB / ABIL
9. Battery Bank
Amco/ Amara Raja/ Exide/ Sabnife
10. Battery Charger
Amara Raja/ Sabnife/ Caldyne
11. Instrument Transformers
ABB/ Siemens/ Automatic Elec/ Kappa
12. Control Cables
CCI/ NICCO/ Universal/ Torrent/ Finolex/

LAPP
13. MV Switchboards
Siemens/ L&T/ ABB/ GEPC/ C&S Delhi/

Venus Controls & Switchgear, Kolkatta/ Sen
& Singh, Kolkatta/ Advanced Electro Control
Sys, Delhi/ Tricolite, Delhi
14. Pre-fabricated panels for LV

Switchboards and control panels
Rittal
15. Wall mounted DBs
MDS Legrand/ Siemens/ Schneider/ ABB
16. Switches/ Sockets/ Boxes
Legrand/ Clipsal
19. Steel
SAIL/ TISCO/ ESSAR
20. Terminal connectors/ Glands
Wago/ Phoenix
21. Bushings/ Insulators
Modern/ BHEL/ WSI/ Jayashree/ IEC
22. Protective relays
ABB/ Siemens/ GE Multilin/ Easun Reyrolle/

Alstom/ Woodward
23. Analog & Digital meters
Enercon/ AE/ IMP/ ABB
24. MS Conduits & Accessories,

Cable lugs
Dowells
DOCUMENTATION:
Whether explicitly mentioned or not in the various sections of this specification, Vendor
documentation shall include hard copies of as built drawings, operating and instruction
manuals, training manuals, etc., in Six sets after delivery of DG Sets to site. Vendor shall
submit DG Set overall general arrangement drawings giving plan, elevation and side
view with bill of material and makes; drawings for external terminations like bus duct
flanges and cable box chambers, major component drawings, schematic & wiring
ISSUE No: R0
DATE: 20-09-2007
DOCUMENT No
PCPL-0626-3-406-03
SECTION - 3
PAGE: 5 of 6
diagrams with ferrule and terminal numbers etc., in FOUR sets for approval before start
of manufacture.
4.2
4.3
5.0
The following minimum documentation shall be furnished along with the completed bid:
Description of the DG set with basic technical details
Data sheets for DG set including generator and accessories as called for in Data
Sheet-B.
G.A. drawings & Catalogues.
Reference list of supplier make till date.
Essential spares list along with unit rate
On award of contract the successful Bidder shall furnish the following documentation/
drawings in FOUR for approval:
Data sheets for DG set including generator and accessories as called for in Data
Sheet-B.
DG Set & AMF panel GA drawings
Block interlock diagrams
Schematic and control wiring diagrams.
Cable schedule and ICS
Earthing layout
Foundation layout
Exhaust Stack drawings
Exhaust Stack and structural support Calculations/ design details
Copies of valid type test reports.
Schedule of maintenance with O&M manuals
EXCLUSIONS:
5.1
Supply and installation of power cables and bus ducts from DG to DG PCC.
5.2
External Control terminations beyond AMF, Neutral switching and DG sets.
5.3
Supply and installation of cable trays and tray supports.
5.4
Supply and installation of DG room lighting.
5.5
Bulk Diesel storage tank and its piping up to the Day tanks.
5.6
Supply and installation of earthing material other than for the DG & AMF panel.
ISSUE No: R0
DATE: 20-09-2007
DOCUMENT No
PCPL-0626-3-406-03
5.7
6.0
6.1
7.0
7.1
SECTION - 3
PAGE: 6 of 6
All civil works required for the DG room, except the minor civil works like Exhaust stack
foundation, grouting, etc.,
DELIVERY:
The DG sets to be procured under this specification shall be supplied to site within the
period as stipulated in the forwarding letter. Bidder shall submit a bar chart for various
activities of manufacturing, testing, inspection and delivery.
PERFORMANCE GUARANTEE:
The equipment shall have a warranty of 18 months from the date of supply or 12 months
from the date of commissioning, whichever is later.
ISSUE No: R0
DATE: 20-09-2007
DOCUMENT No
PCPL-0626-3-406-04-01
1.0
DG SET
SECTION - 4
PAGE: 1 of 11
GENERAL
1.1
The diesel engine shall drive the generator either directly or through a gear-box
(if required). The diesel generator shall be designed to deliver maximum power output
possible at site conditions specified in project information.
1.2
All necessary auxiliaries with adequate capacities to make the plant complete
such as fuel forwarding and injection system, lubricating oil system, governing system,
cooling water system, start-up system, intake and exhaust gas systems, fuel oil treatment
plant, if required etc., shall be provided and these shall be complete in all respects.
2.0
DIESEL ENGINE
2.1
The diesel engine shall be of medium speed type.
2.2
The engine shall be of four-stroke type with either in line or V-type cylinder
arrangement.
2.3
The major moving parts such as crankshaft and connecting rods shall be of drop
forged design and shall have high degree of mechanical reliability.
2.4
The pistons shall be manufactured with heat treated steels or other equivalent
proven materials. The cylinder liners shall be of proven wear resistant materials designed
for fuel under consideration.
2.5
The cylinder head shall be of proven material. The cylinder head shall house inlet
and exhaust valves, starting air valve and fuel injector. A forced cooling arrangement
shall be provided around the exhaust valve seats and the fuel injectors.
2.6
The fuel injectors shall have easy accessibility and it should be possible to
remove them using simple methods.
2.7
The inlet and exhaust valves shall be precisely controlled via roller tappets, short
push rods and forked rocker arms.
2.8
The exhaust valves shall be made of high temperature hot corrosion resistant
material. The inlet and exhaust valves shall have hard chromium plated or equivalent
proven material stems.
2.9
Governing system
a.
The diesel engine shall be provided with an electronic type of speed governor. The
governor and the speed governing system shall be capable of controlling and
regulating the diesel engine speed in accordance with the requirements of class A1
governing as stipulated in ISO 3046 part IV.
b.
An over speed trip mechanism shall be provided to automatically shut off fuel in
case the engine speed reaches 110% of the rated speed. The speed at which the
mechanism trips the engine shall be adjustable. An engine mounted emergency stop
push button shall be provided, which when operated will trip the engine.
ISSUE No: R0
DATE: 20-09-2007
DOCUMENT No
PCPL-0626-3-406-04-01
2.10
DG SET
SECTION - 4
PAGE: 2 of 11
Layout
a.The engine and generator shall be provided on a common base frame. The supply of
supporting springs, foundation bolts etc., shall be in Bidders scope.
b.
The engine shall be provided with adequate number of anchor bolts, foundation
bolts and anti vibration pads, alignment shims, as stipulated by the Bidder.
c.Necessary platforms with access ladders shall be provided by Bidder around the diesel
engine for easy operation and maintenance purpose.
d.
2.11
Necessary acoustic enclosure for the complete Diesel engine generator set shall also
be provided to minimize the noise level.
Fuel System
a.High Speed Diesel Oil is proposed to be used as load carrying fuel in the diesel engine.
Actual fuel oil samples shall be collected from the purchaser and analyzed by the
Bidder prior to commencement of actual design of the equipment.
2.12
Intake air system

a.The air intake system shall be provided with a residential silencer to reduce the noise
produced by the intake system.
b.
A flexible connection shall be provided in the intake system to minimize the

vibration.
c.The intake system shall be complete with interconnection ducting between air filter and
turbocharger, nuts, bolts, flange joints and supports required for installation.
d.
The air from the air filter shall be charged into the engine cylinders by means of a
turbocharger powered by an exhaust gas driven turbine. The turbo charger bearings
shall be cooled by the engine lube oil system. Suitable acoustic insulation shall be
provided for the turbo-charger for minimizing the noise level.
e.A turbo charger-washing skid (common for both the units) with pressurising pump,
detergent tank, flexible hose pipes, etc. shall be provided by the Bidder, Bidder shall
furnish with his bid a write-up on the operational procedure of the washing skid.
2.13
Exhaust Gas System.

a.The exhaust system shall be complete with all the accessories specified herein and
shall ensure safe disposal of the exhaust gases through the common stack located
outside the DG house.
b.
The stack height shall be calculated based on the fuel and the height shall meet the
requirements of currently applicable pollution standards and regulations.
c.Suitable expansion joint shall be provided on the exhaust ducting to take care of the
expansion due to the high working fluid temperature.
d.
The complete duct including silencer shall be insulated to maintain the surface
temperature of the external cladding to within 200 C above the ambient temperature.
ISSUE No: R0
DATE: 20-09-2007
DOCUMENT No
PCPL-0626-3-406-04-01
2.14
SECTION - 4
PAGE: 3 of 11
DG SET
Chimney/ Exhaust Stack:

a. One common Chimney / or Independent Stacks (Refer Section-3 and /or Data SheetA catering to DG Sets shall be supplied. The exhaust from the DG Sets shall be
suitably connected to the chimney/Stack.
b. Chimney/ stack design shall conform to IS6533 Part I & II
c. Necessary access ladder with platforms shall be provided (with minimum width of
800mm).
d. All plates & sections shall conform to IS2062 of fusion welding quality or IS 8500.
necessary corrosion allowance shall be provided in the stack design.
e. Wind load as per IS8500 and earthquake as per IS1893 shall be considered for
structural design.
f. Stack lightning protection shall be provided.
g. Stack shall be provided with aviation warning lights.
h. Stack surface finish shall be hot dip galvanised.
i. Necessary hopper and drain point at the bottom of the stack shall be provided.
j. Necessary sampling points as per the emission regulations shall be provided.
2.15
Lubrication system:
a.The lubrication system complete with all the accessories shall ensure good distribution
of lubricating oil to all moving parts of the engine.
b.
2.16
Bidder shall specifically indicate in his bid whether it is necessary to establish

adequate lube oil system pressure before starting and during coasting down of the
diesel engine. An oil purifier of adequate capacity for each engine to continuously
clean and purify the lubricating oil shall be provided.
Cooling System
a. The DG sets shall be designed for radiator type cooling. The bidder shall furnish the
radiator cooling scheme and the quality of water required .All accessories required
for the cooling scheme shall be supplied.
b. If the radiator requires special coolant mix for the cooling circuit, the same shall be
indicated by the Bidder.
c. Supply of the DG set shall include the first fill of coolant.
2.17
Piping
a.The design of pipe lines, pipe assemblies, pipe fittings, flanges and components, valves
and specialties and any other pressure retaining part in a piping system shall be
carried out in accordance with the applicable power codes and standard.
b.
Pipelines shall be designed adequately to meet the system requirement of flow,

pressure drop, etc., under all operating modes of the plant.
c.While routing piping, the following requirements shall be taken into account:
ISSUE No: R0
DATE: 20-09-2007
DOCUMENT No
PCPL-0626-3-406-04-01
SECTION - 4
PAGE: 4 of 11
DG SET
i.
The piping shall be arranged to provide clearance for the removal of equipment
requiring maintenance and for easy access to valves and other piping accessories
required for operation.
ii.
Overhead piping shall have a minimum vertical clearance of 2.3metres above

walkways and working areas and 6metres above roadways.
iii.
Sufficient upstream and down stream lengths shall be provided for flow
measuring devices, control valves, etc.
iv.
At all the screwed valves and screwed connections on equipment, unions shall be
provided to facilitate disassembly.
v.
The hangers and supports shall be spaced in accordance with the standard
engineering practice as outlined in applicable codes and standards.
d.
Instrument Connections complete with:

i. All thermo well stubs shall have an internal threading to M33x2.
3.0
3.1
ii.
Pressure measurement stubs on fuel oil lines shall be of NB 25mm size.
iii.
Drain connections on pipelines shall be at least of NB 25 size.
GENERATOR AND ACCESSORIES

Performances:
a. The generator system shall be as shown in enclosed Single Line Diagram / Data
Sheets.
b. Each generator shall be rated as detailed at Section-3 and Data sheet.
c. The generator shall have overload capacity as per applicable standards.
d. The generator shall be capable of withstanding a three phase short circuit at the
generator terminals for 3 seconds when operating under rated condition.
e. The generator shall be suitable for continuous parallel operation with each other and
the station supply.
3.2
Excitation System:
a. The excitation shall be of the brushless type complete with permanent magnet
generator, automatic voltage regulator field discharge system and all other
accessories.
b. The AVR shall have auto-manual mode and shall have output limiters for stator limit,
rotor limit and field current limit. The manual mode shall be completely
independent of auto mode. Automatic change over from auto to manual mode shall
be provided in case of auto mode faults.
c. The AVR and other excitation system devices shall be mounted on the AMF panel or
in a separate panel.
3.3
Enclosure:
ISSUE No: R0
DATE: 20-09-2007
DOCUMENT No
PCPL-0626-3-406-04-01
SECTION - 4
PAGE: 5 of 11
DG SET
The generator shall have enclosure type IP23 to IEC 34.5

3.4
Insulation:
a. The stator, rotor and exciter winding insulation shall be class F with temperature rise
limited to class B.
3.5
Terminal Boxes:
a. The phase side and neutral side of the generator winding shall be brought out into
two physically separate terminal boxes.
3.6
Neutral Current Transformers:

a. A multi core current transformer shall be provided on each neutral side lead inside
the neutral terminal box, before formation of the neutral.The multi core neutral CT
shall have the following cores
i) Core -1, protection CT .The parameters shall be as shown in the SLD.
ii) Core-2- metering CT. The parameters shall be as shown in the SLD.
b. One CT shall be provided in the Y phase for AVR.The parameters shall be as shown
in SLD
3.7
Neutral end connection

a. The star point of neutral end winding shall be brought out for solidly earthed through
a neutral disconnecting switch.
b. Only one neutral switch of the generators running in parallel shall remain closed at a
time to avoid multiple earthing.The neutral switch of the first generator connected
to the bus shall be closed and closing of neutral switches of the subsequent
generation shall be blocked.
c. Annunciation shall be provided on AMF panel for the following conditions:i) None of the neutral switches is closed
ii) More than one neutral is closed when running in parallel.
d. MCCBs shall be provided with auxiliary contacts as well as auxiliary relays for the
above control and interlock requirements.
e. Single core CTs for:
i) Core 1, Class PS core for REF protection.
ii) Core 2, 5P20 Class protection core.
3.8
Space Heater
a. The generator shall be provided with space heater suitable for 240volts, single phase,
and 50Hz supply. Space heater shall have adequate capacity to maintain internal
temperature of machine above dew point to prevent moisture condensation during
shutdown periods.
b. The space heaters shall be humidistat controlled duly protected by 30mA ELCB.
ISSUE No: R0
DATE: 20-09-2007
DOCUMENT No
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SECTION - 4
PAGE: 6 of 11
DG SET
c. The space heater supply shall be obtained from the DG-MCC.

3.9
Other Equipment
a.
4.0
4.1
5.0
5.1
6.0
The following equipment shall be supplied as part of the contract.

i)
One (1) set Maintenance free Battery and Battery Charger of adequate capacity
for starting duty, one set for each DG set.
ii)
One (1) set Maintenance free Battery and Battery charger of adequate capacity
for the control supply for AMF and control panel, if called for that is Datasheet /
Section-3.
iii)
All 1.1kV grade, XLPE insulated, armoured power and control cables required
for the installation.
iv)
All power and control cable terminations as required consisting of removable

gland plates. Double compression type cable glands and crimp type heavy duty
Dowells tinned copper cable legs.
v)
All earthing conductors, earth pits etc.
COOLING SYSTEM
The Diesel engine shall have radiator cooling system. All accessories required for
the cooling system shall be furnished.
LUBE OIL SYSTEM
The Owner will supply the lube oil at one terminal point as indicated in the above
flow diagram. All pipe work as required for the above system shall be provided complete
with pipes, fittings, flanges, gaskets, fasteners, valves, strainers, expansion joints,
flexible hoses, hangers, supports and all other accessories as applicable / as may be
required.
FUEL OIL SYSTEM
6.1
Two Nos. HSD Booster pumps- (one working and one standby) will supply the
diesel oil to the individual HSD day tanks located at an elevation of 0.5m near each
engine.
6.2
All pipe work as required for the above system shall be provided complete with
pipes, fittings, flanges, gaskets, fasteners, valves, strainers expansion joints, flexible
hoses, hangers, supports and all other accessories as applicable / as may be required.
7.0
7.1
HSD DAY TANKS

Scope
ISSUE No: R0
DATE: 20-09-2007
DOCUMENT No
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SECTION - 4
PAGE: 7 of 11
DG SET
The Scope covers the design, materials, fabrication, testing and erection of One (1) No.
of HSD Day tank for each DG Set.
7.2
Codes and Design

The design and fabrication of storage tanks shall comply with all currently applicable
statutes, regulations and safety codes in the locality where the equipment will be
installed. The equipment shall also conform to the latest applicable
Indian/British/USA/IEC standards.
7.3
Design requirement
Storage tanks shall be designed based on the applicable codes in respect of corrosion
allowance, minimum thickness, connection and appurtenances, roof and structures,
Earthing cleats, fabrication tolerances etc. The main parameters and requirement is
indicated in the data sheet.
8.0
8.1
9.0
THERMAL INSULATION
Thermal insulation using mineral wool, shall be provided for exhaust piping and for all
other hot surfaces for personnel protection.
PAINTING
9.1
All equipment supplied under the contract shall be suitable for operation under the
climatic and operating conditions prevailing at the site. All parts and surfaces which are
subject to corrosion shall be made of such materials, and shall be provided with such
protective finishes, as are appropriate to protect the installed equipment from
deterioration or injury due to the climatic conditions or operating environment. All
electrical and auxiliary equipment shall be specially treated for tropical conditions.
9.2
Bidder shall specify the details of the painting, and special treatment for tropical
conditions, in his offer.
10.0
PERFORMANCE REQUIREMENT
The DG sets shall be capable for start up from cold condition reaching synchronous
speed and rated voltage in less than10 seconds from the start impulse. The DG set
10.1
Thereafter shall also be capable of taking the full rated load, within 30 secs. Without
undue vibration and overheating of the engine.
10.2
The maximum permissible voltage and frequency spreads of output supply for the DG
set shall be limited 10 percent and 5 percent respectively and combined voltage and
frequency fluctuation of 10 percent.
10.3
Manual facilities shall be provided to start the DG set for test purposes.
10.4
The generator shall be capable of carrying an unbalanced load of 25% without injurious
heating of any part, provided the rated current is not exceeded.
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DOCUMENT No
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SECTION - 4
PAGE: 8 of 11
DG SET
10.5
The diesel engine shall be capable of operating continuously with High speed diesel oil
as available commercially.
10.6
The diesel generator shall be capable of giving a net output at specified nominal voltage
at the generator terminals after de-rating, if any.
10.7
Performance tests shall be carried out at shop floor and at site to prove the performance
for the offered equipment.
11.0
MAINTENANCE
11.1
As Built drawing and operation and maintenance manual:
11.2
Vendor shall provide as built drawings and operation and maintenance manuals for
complete facilities.
11.3
The Vendor shall prepare, and keep up-to-date, a complete set of As Built records of
the execution of the Works, showing the exact as built location, sizes and details of the
work as executed, with cross-references to relevant specifications and data sheets. . Two
copies shall be submitted to the Purchaser prior to the commencement of the tests.
11.4
Prior to the issue of any Taking-over certificate, the Vendor shall submit one soft copy,
one full-size original copy and six printed copies of the relevant As Built Drawings
and any further Construction Documents that may be specified by Purchaser.
11.5
The Vendor before commencement of trial run of the equipment shall submit 6 (six)
copies of the operation and maintenance manuals, in English language, containing
descriptions, illustrations, sketches, drawings, sectional drawings, sectional arrangement
view and manufacturers part numbers to enable the connections, functions, operation
and maintenance of all components of the complete plant to be easily followed and for
all parts to be easily identified to facilitate ordering of the replacement parts. Exploded
views where appropriate shall be used for clarity.
11.6
The operation manual shall also include the following:
Technical data of each instrument and their performance.
Instructions for servicing and overhauling.
Particulars of lubricating oil and grease to be used, also alternative indigenous

commercial lubricating oils suitable for use.
Performance curves
List of tools mounted on wall panels.
List of spares provided in the spare box.
Spare parts list, with manufacturers part numbers.
11.7
These manuals shall be submitted before commencement of Trial run.
11.8
Supervision of operation and maintenance during defect liability period:
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DOCUMENT No
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11.9
SECTION - 4
PAGE: 9 of 11
DG SET
The Vendor shall be responsible to provide suitably qualified and experienced personnel
for the 12 month Defect Liability Period following successful completion of the trial run
period and issuance of the Taking-Over Certificate by the Purchaser. The personnel
provided by the Vendor shall be fully experienced in managing, operating and
maintaining all aspects of the plant and facilities, shall be responsible to monitor and
ensure the successful performance of the system throughout the Defect Liability Period,
and shall be responsible to ensure that the Purchasers personnel are provided with onthe-job training as may be necessary to ensure uninterrupted satisfactory performance of
the plant and facilities by the Purchasers personnel after completion of the Defect
Liability Period and issuance of the Performance Certificate. These personnel shall be
available to be deputed to the site as and when required.
11.10 The bidder shall submit separately, as a part of his technical proposal, details of the
qualifications and experience of the personnel he proposes to provide for supervision of
operation and maintenance during the defect liability period. All costs for the bidders
personnel shall be included in the bid prices. All costs for the Purchasers personnel
during this period will be borne by the Purchaser.
11.11 The above notwithstanding, the Vendor will be required to rectify any deficiencies which
are attributable to defects in the workmanship or quality of materials.
12.0
TESTING AND
MAINTENANCE
12.1
Immediately after the erection of the equipment, the Vendor shall carry out testing and
commissioning of the equipment to demonstrate the suitability of the equipment
workmanship, and operational aspects to the requirements of the contract, to the
satisfaction of the Purchaser. This stage shall be commenced within 7 days of completion
of erection and shall precede the trial run period.
12.2
Duration of the testing & commissioning period shall not exceed 15 days. In the trial run,
the Vendor shall run the DG sets for 3 months to demonstrate satisfactory performance
to the Purchaser prior to taking over by the Purchaser.
12.3
The cost towards Vendors engineer and other operating personnel during the said period
of trial run along with cost of tools and spare parts which are required for operation and
maintenance of the equipment during the trial run period shall be borne by the Vendor
and shall be included in the Vendors price schedule.
12.4
In the event that the equipment do not satisfactorily achieve the required performance
standards during this period, the trial run period will be extended until such time as the
Vendor has satisfactorily rectified any deficiencies as may be necessary to satisfy the
performance requirements. No additional compensation will be paid to the Vendor for
such extension.
13.0
COMMISSIONING
AND
TRIAL
RUN
INCLUDING
SPARES
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DOCUMENT No
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13.1
14.0
14.1
SECTION - 4
PAGE: 10 of 11
DG SET
BIDDER shall furnish a list of essential spares with item wise prices for the equipment /
systems covered under this specification for three years operation of the DG set.
BIDDER shall also furnish a list of his recommended spare parts along with the item
wise prices. The prices of the essential and recommended spares will not be considered
in the bid evaluation. However, all start up spares as required during commissioning
and up to handing over of the plant to the PURCHASER shall be supplied by BIDDER
and cost of the same shall be included in the quoted price.
DOCUMENTS / DRAWINGS ALONG WITH OFFER
The bidder shall furnish the following minimum documents / drawings along with offer.
a. Description of the DG set with basic technical details
b. Data sheets for DG set including generator and accessories as called for in Data
Sheet B.
c. G.A. drawings & Catalogues.
d. Reference list of supplier make till date.
e. Essential spares list along with unit rate
15.0
INSPECTION AND TESTING
15.1
The DG Sets shall be subjected to Purchasers inspection and witness testing.
15.2
A mutually agreed quality assurance plan shall be developed which provides for
inspection and certification by Purchaser at specified times during the manufacture and
fabrication of such items. All costs for independent inspection or testing will be borne by
the Vendor, and the Vendor shall be fully responsible to ensure that adequate provisions
are made in his tendered rates to cover independent inspections and testing for the
equipment and plant.
16.0
TRAINING PURCHASERS
MAINTENANCE
16.1
The Vendor shall be responsible to provide practical training in all aspects of the
operation.
16.2
Maintenance and repair of the equipment and facilities to all personnel deputed by
Purchaser who will ultimately be responsible for the operation, maintenance and repair
of the equipment and its facilities.
17.0
17.1
PERSONNEL
IN
OPERATION
AND
CODES AND STANDARDS

The design, manufacture and performance of DG Sets shall comply with all currently
applicable status, regulations and safety codes in the locality where the equipment will
be installed. The equipment shall also conform to the latest applicable Indian / British /
ISSUE No: R0
DATE: 20-09-2007
DOCUMENT No
PCPL-0626-3-406-04-01
DG SET
SECTION - 4
PAGE: 11 of 11
USA standards / or equivalent international standards. Some of the relevant standards

are: -
17.2
BS 5514/ISO 3046
Specification for Reciprocating Internal Combustion

Engine (Part I To IV)
VDI 2063
Measurement and evaluation of Mechanical vibration of

reciprocating engine and compressors
BS-2613:70 / IS-4722
Rotary Electrical Machinery
In case of any contradiction between the above-mentioned standards and this technical
specification, the latter will prevail.
ISSUE No: R0
DATE: 20-09-2007
DOCUMENT No
PCPL-0626-3-406-04-01-1
DG SET
DATA SHEET
SECTION - 4
PAGE: 1 of 7
DATA SHEET A
SL #
1.0
1.1
1.2
1.3
2.0
2.1
2.2
2.3
2.4
DESCRIPTION
General
No. of DG Sets
Mode of operation
Installation
Design Considerations
Capacity (100% MCR Rating)
Over load capacity
Design ambient data for engine
a)
Ambient temp.
b)
Altitude above mean sea level
c)
Humidity
Type of fuel
2.5
Type of Engine
2.6
Engine speed
2.7
Governor type
Maximum speed not to exceed

1500 RPM
Electronic
2.8
Maximum amplitude of vibration (peak to peak)
As per VDI 2063
2.9
2.10
3.0
Noise level at a distance of 1Mt from DG set

Cooling water quality
Auxiliaries / Accessories
3.1
Lube Oil system
Required
3.2
Radiator / Heat Exchanger
Required
3.3
Intake air silencer
Required
3.4
Intake air expansion joint
Required
3.5
3.6
3.7
3.8
Exhaust gas expansion joint

Exhaust gas silencer
Insulation
Exhaust pipe with glass wool insulation with
aluminium cladding
Type of start-up
HSD Day tank ( 900 litres) with inlet and outlet
connections, filling cap and drains
Fuel oil feed / booster pumps
Complete fuel, lube oil, and water piping systems
Foundation / anchor bolts / AVMs with nuts for
all equipment
Tests
a)
Performance test to determine torque,
power, fuel consumption, etc. at 50%,
Required
Required
Required
Required
3.9
3.10
3.11
3.12
3.13
4.0
UNIT
VALUE
Nos
5
Standby duty
Indoor
kVA
%
1000
As per BS: 5514 / ISO 3046
C
M
%
dB
Refer Section-2
-do-doHigh Speed Diesel (HSD)as per
IS:1460
Stationary four stroke Vertical
75
Softened water
Electric
Required
Required
Required
Required
Required & to be witnessed
DATE: 20-09-2007
ISSUE No: R0
DOCUMENT No
PCPL-0626-3-406-04-01-1
SL #
5.0
6.0
6.1
6.2
6.3
6.4
6.5
DG SET
DATA SHEET
DESCRIPTION
75%, 100% and 110% load
b)
Over speed test
c)
Noise level
d)
Vibration
Test certificates for major components
6.6
Generator Main Parameters

Maximum continuous rating
Rated terminal voltage
Rated frequency
Rated power factor
Degree of protection of the enclosure for
alternator
Class of stator winding insulation
6.7
Class of rotor winding insulation
6.8
Class of exciter winding insulation
6.9
Excitation System
6.10
Current Transformer to be mounted on the

neutral side cable box
a)
Two nos. CTs on each phase as
shown in Drg no. PCPL-0626-4-SLD-003
b)
One no. CT in Y phase for AVR

as shown in Drg no. PCPL-0626-4-SLD003
UNIT
SECTION - 4
PAGE: 2 of 7
VALUE
Required for review by owners /

owner's representative
kVA
V
Hz
1000
415,3Phase,4 Wire
50
0.8 lag
IP23 to IEC 34.5
Class F(Temperature rise
limited to be Class B)
Self excited and self regulated /
Brushless
Ratio :1600/1-1
Metering CT
Class 0.5, 30VA
Protection CT:
5P10,15VA
Ratio :1600/1-1
Class 0.5, VA burden shall be
furnished by bidder.
DATE: 20-09-2007
ISSUE No: R0
DOCUMENT No
PCPL-0626-3-406-04-01-1
DG SET
DATA SHEET
SECTION - 4
PAGE: 3 of 7
DATA SHEET B
DATA TO BE FURNISHED ALONG WITH THE BID
SL #
DESCRIPTION
1.0
General
1.1
Name of the manufacture
1.2
Nos. required.
1.3
Mode of operation
1.4
Installation
2.0
Design Condition
2.1
Capacity (100% MCR Rating)
2.2
Over load capacity
2.3
Standard engine ISO Rating
2.4
Block Load Capability
2.5
Derating factor for site conditions
2.6
Design ambient data for engine
2.7
UNIT
VALUE
Nos
kVA
%
kWe (%)
a)
Ambient temp.
b)
Altitude above mean sea level
c)
Humidity
Fuel
a)
Type of fuel
b)
Fuel consumption
i)
At 100%
ii)
At 75%
iii)
At 50%
2.8
Type of Engine
2.9
Engine speed
2.10
Engine Configuration, Bore x Stroke
2.11
Displacement
2.12
Governor type/Make
2.13
Alternator type/Make
2.14
Maximum amplitude of vibration (peak to peak)
2.15
Noise level
dB
DATE: 20-09-2007
ISSUE No: R0
DOCUMENT No
PCPL-0626-3-406-04-01-1
DG SET
DATA SHEET
SL #
DESCRIPTION
2.16
Cooling water quality
2.17
Cooling water flow / temperature & pressure
2.18
Engine Block Design Material and type
2.19
Piston Design Material and construction
2.20
Cylinder Liner Design Material & Construction
2.21
Turbo Charger Details
2.22
Lube Priming Pump
3.0
Auxiliaries / Accessories
3.1
Lube Oil system
SECTION - 4
PAGE: 4 of 7
UNIT
3.2.1
Lube oil consumption at 100% MCR
3.2.2
First Fill of Lube Oil included in the scope
3.2.3
Fuel Filter Life
Hrs
Radiator Fan capacity
kW
3.3
3.4.1
Intake air filter type with louvers
3.4.2
Air Cleaner/ Filter Life
VALUE
Yes/No
Hrs
3.5
Intake air silencer
Yes/No
3.6
Intake air expansion joint
Yes/No
3.7
Exhaust gas expansion joint
Yes/No
3.8
Exhaust gas silencer
Yes/No
3.9
Insulation
Yes/No
3.10
Exhaust pipe with Mineral wool insulation with

aluminium cladding
Yes/No
3.11
Type of start-up
3.12
HSD Day tank with inlet and outlet connections,

filling cap and drains
Yes/No
3.13
Fuel oil feed / booster pumps
Yes/No
3.13
Complete fuel, lube oil, and water piping systems
Yes/No
3.14
Foundation / anchor bolts with nuts for all

equipment
Yes/No
3.16
Material construction for major components
Yes/No
3.17
Fuel Pump/ Injector inspection & calibration to be

carried out after
4.0
Tests
a)
Hrs
Performance test to determine torque,
DATE: 20-09-2007
ISSUE No: R0
DOCUMENT No
PCPL-0626-3-406-04-01-1
SL #
DG SET
DATA SHEET
DESCRIPTION
SECTION - 4
PAGE: 5 of 7
UNIT
power, fuel consumption, etc. at 50%,

75%, 100% and 110% load
Yes/No
b)
Over speed test
Yes/No
c)
Noise level
Yes/No
d)
Vibration
Yes/No
4.1
Test certificates for major components
5.0
Alternator Main Parameters
5.1
Make, type and model number
5.2
Maximum continuous rating
kVA
5.3
5.4
Rated stator current
Amps
5.5
Rated frequency
Hz
5.6
Rated power factor
5.7
Maximum permissible variation range in:

a)
b)
Rated frequency with / without time limits

c)
Combined permissible variation of

frequency and voltage (with characteristic
curves)
%
%
%
5.8
Synchronous speed
rpm
5.9
Number of phases
Nos.
Line terminals brought out
Nos.
Neutral terminals brought out
Nos.
a)
b)
5.10
Type of stator winding connection
5.11
Degree of protection of the enclosure for

generator.
5.12
Generator efficiency at rated power factor
5.13
VALUE
a)
100% load
b)
75% load
c)
50% load
d)
25% load
e)
110% rated capacity
Minimum guaranteed short circuit ratio

corresponding to maximum capability
DATE: 20-09-2007
ISSUE No: R0
DOCUMENT No
PCPL-0626-3-406-04-01-1
DG SET
DATA SHEET
SL #
DESCRIPTION
5.14
Designation for method of cooling as per IS/IEC

standards
6.0
Alternator Reactance
6.1
Alternator reactance's in percent at rated kV and

kVA, both saturated and unsaturated
7.0
Alternator Temperature Rises
7.1
Guaranteed temperature considering the ambient

air temperature as 45 deg. C
UNIT
a)
Stator (By resistance)
b)
Rotor (By resistance)
8.0
Alternator losses
9.0
Class of stator winding insulation
10.0
Class of rotor winding insulation
11.0
Class of exciter winding insulation
12.0
Alternator Miscellaneous Particulars
12.1
Direction of rotation of alternator as seen from

Engine end
12.2
Vibration amplitude (peak to peak)

a)
Stator frame vibration
b)
Rotor vibration
c)
Bearing vibration
Excitation System
14.0
Tests
14.1
All type and routine tests as specified
15.0
Alternator Control / Relay AMF Panel
15.1
Degree of protection for enclosure of panel
15.2
Mounting of Relays
15.3
Operating temperature range
15.5
Finish painting
VALUE
kW
13.0
15.4
SECTION - 4
PAGE: 6 of 7
External
Internal
Make of the panel
16.0
Engine Generator Control & Protection(EGCP)
16.1
Type of the electronic governor offered for the
DATE: 20-09-2007
ISSUE No: R0
DOCUMENT No
PCPL-0626-3-406-04-01-1
SL #
DG SET
DATA SHEET
DESCRIPTION
SECTION - 4
PAGE: 7 of 7
UNIT
VALUE
engine control
16.2
Type of Digital AVR with droop control offered
16.3
ENGINE Control Details
16.3.1 Engine fuel solenoid control

16.3.2 Engine pre-glow control
16.3.3 Engine starter control
16.3.5 Water temperature monitoring
16.3.6 Battery voltage monitoring
16.3.7 Speed monitoring with over speed protection
16.4
ENGINE Protection
16.4.1 Over speed

16.4.2 High/ Low Oil pressure
16.4.3 High/ Low coolant temperature
16.4.4 Start Failure
16.4.5 Battery voltage
16.5
GENERATOR Control
16.5.1
Auto Synchronisation with multiple generators and

mains
16.5.2
Manual synchronisation facility with manual

voltage and speed adjustments.
16.5.3 Dead bus closing logic

16.5.4 Base load control for optimum fuel efficiency
16.5.5 kW Droop control both for auto and manual
16.5.6 Load sharing feature for 2 units.
16.5.7 Engine speed control based on load bias
16.5.8 PF or VAR control when running on base load
16.6
GENERATOR - Protection
16.6.1 Restricted earth fault

16.6.2 Inverse time over current
16.6.3 Inverse time earth fault
DATE: 20-09-2007
ISSUE No: R0
DOCUMENT No
PCPL-0626-3-406-04-02
ACOUSTIC ENCLOSURE
SECTION - 4
PAGE: 1 of 1
1.0
SCOPE OF SUPPLY
1.1
This Specification covers the design, engineering, manufacture, testing at manufacturers

works, and delivery to site of the complete Acoustic Enclosure for the Diesel Generator
set of rating indicated at Section 3 and Data sheet - A.
2.0
EQUIPMENT TO BE SUPPLIED BY THE CONTRACTOR
2.1
The design, engineering, manufacture, testing at manufacturers works and delivery to

site of the complete Acoustic Enclosure for the above referred Diesel Generator sets.
3.0
CODES AND STANDARDS
3.1
All equipment covered under this Specification shall comply with all current statutes,
regulations and safety codes in the locality where the equipment will be installed. All
equipment shall comply in all respects with the requirements of the latest editions of
applicable Indian, American, British Codes and Standards.
4.0
SPECIFIC REQUIREMENT
4.1 The design, materials, fabrication, construction, testing and certification of the Acoustic
Enclosure shall be to applicable Standards and in compliance with the relevant statutory
requirements. The VENDOR shall supply the equipment / systems from the approved
vendors or equivalent.
4.2
The CONTRACTOR shall plan the various activities specified in the specification in
conformity with the PURCHASERS requirement and availability of the front. No extra
claim by CONTRACTOR will be entertained for non-availability of front.
4.3 CONTRACTOR shall ensure no damage to Purchasers property while executing this
contract. In the event of any damage to Purchasers property, due to CONTRACTORS
negligence the PURCHASER has to be compensated, the value of which will be
mutually discussed and agreed.
5.0
PERFORMANCE REQUIREMENTS
5.1
The performance of Acoustic Enclosure shall be as specified in Data Sheet A
6.0 GUARANTEES
6.1
TENDERER shall guarantee the Acoustic Enclosure performance parameters.
6.2
Should the performance test results deviate from the guaranteed value including the
tolerances stipulated by relevant Indian Standards, the VENDOR shall correct his
equipment at no cost to the PURCHASER, or have the option to reject the same.
DATE:20-09-2007
ISSUE No: R0
DOCUMENT No
PCPL-0626-3-406-04-02-1
ACOUSTIC ENCLOSURE
DATA SHEET
SECTION - 4
PAGE: 1 of 2
DATA SHEET-A
1
Enclosure application
Outdoor/Indoor
2
3
4
5
Enclosure panels.
Roof type
Access door(s)
Enclosure over all dimensions (desired)
mm
mm
mm
Desired sound level
Exhaust fan Capacity
Detachable type
Taper both sides
Sliding with pad locking feature
Length
*
Width
*
Height
*
75 2 dB at 1 m distance from the
enclosure.
*
HP
7.1
Motor
7.2
7.3
10
10.
Voltage/Ampere/ Frequency
Bird screen Etc.
External M.S sheet panel Thickness
(Corrugated)
Internal G.S sheet panel. Thickness
(Corrugated)
Insulation material.
Insulation density
1
10.
Insulation thickness
8
9
*
Required
mm
mm
18 G
24 G
Mineral wool
*
mm
mm
To be provided with lighting system

designed for 200LUX, complete with
MCB & RCCB protection.
Required. (Size. *)
2
Internal lighting
11
12
13
Panel openings with louvers for radiator.

Painting External
Internal paint finish
14
15
16
17
Openings on the panels.

Enclosure fixing to the floor.
No. of DG Sets to be housed in one
enclosure
Nos
Metal primer 2 coats (Including putty

work). Finish shade of RAL 7032
Metal primer 2 coats (Including putty
work). Finish shade of glossy white or
galvanised sheet finish.
Fuel piping and electrical cables to
control panels
*
Each DG Set shall have independent
enclosure
Note: * - To be furnished by the Bidder along with the Bid.

All other details shall be reviewed by Bidder and conform.
DATE: 20-09-2007
ISSUE No: R0
DOCUMENT No
PCPL-0626-3-406-04-02-1
ACOUSTIC ENCLOSURE
DATA SHEET
SECTION - 4
PAGE: 2 of 2
DATA SHEET B
Bidders shall fill in the Data Sheet-B and return with their bids.
SL# Description
1
Enclosure application
2
3
4
5
Enclosure panels.
Roof type
Access door(s)
Enclosure over all dimensions (desired)
Desired sound level
Exhaust fan Capacity
7.1
Motor
7.2
Voltage/Ampere/ Frequency
7.3
Bird screen Etc.

External M.S sheet panel Thickness
(Corrugated)
Internal G.S sheet panel. Thickness
(Corrugated)
Insulation material.
Insulation density
Insulation thickness
Panel openings with louvers for radiator.
8
9
10
11
12
13
14
14.
1
15
16
17
18
Unit
Values
mm
mm
mm
HP
mm
mm
mm
mm
Painting - External
Painting - Internal
Openings on the panels.
Enclosure fixing to the floor.
No. of DG Sets to be housed in one
enclosure
Internal lighting details
Nos
ONE
DATE: 20-09-2007
ISSUE No: R0
DOCUMENT No
PCPL-0626-3-406-04-03
SECTION - 4
PAGE: 1 of 1
ROTARY SCREW PUMP
1.0
SCOPE OF WORK AND SPECIFIC REQUIREMENTS:
.1
The design, material, construction, manufacture, inspection, testing and performance of

rotary screw pumps shall comply with all currently applicable statues, regulations and
safety codes in the locality where the equipment will be installed.
.2
The rotary screw pump shall consist of casing and rotor coupled to the driver directly or
through a reduction gearing.
.3
The screw pumps shall have rotors with opposed screws to eliminate end thrusts.
.4
The shaft shall be finished to close tolerance at the rotor, coupling and bearing diameters.
The rotor shall be firmly keyed to the shaft. The shaft shall be of sufficient size to resist
the deflection.
.5
The bearings shall be of external type. The bearings shall be of an anti-friction, heavyduty type, capable of taking the pump.
.6
Stuffing boxes shall be so designed that they can be repacked without removing any part
other than the gland.
.7
Suction and discharge connections shall be flanged if the size is 65mm or above. The
flanges shall be integral with the casing and they shall be drilled to specified standards. If
the connection size is less then 65mm, it shall be of screwed connection.
.8
The base plate shall be in one piece and it shall be made of cast iron or welded steel.
Suitable holes shall be provided for grouting and so located that the base can be grouted
in place without disturbing the pump and motor.
.9
A spring loaded relief valve shall be provided on the discharge side, set just above the
required pressure to protect each pump against excessive pressure.
DATE: 20-09-2007
ISSUE No: R0
DOCUMENT No
PCPL-0626-3-406-04-03-1
ROTARY SCREW PUMP

DATA SHEET
SECTION - 4
PAGE: 1 of 2
DATA SHEET A
Sl.
No.
Particulars
Units
Parameters
1.0
Designation
HSD
2.0
Number required
2 Nos
Refer fuel oil system flow diagram
PCPL-0626-3-SK-005
3.0
Service
Refer fuel oil system flow diagram

PCPL-0626-3-SK-005
4.0
Location
Outdoor
Liquid Data
5.0
Design viscosity at flow

temperature
6.0
Capacity
7.0
Total Dynamic head
8.0
Suction Pressure
Design and Construction

Features
9.0
Rotor type
10.0
Built-in Relief valve
Yes
11.0
Bearing Location
12.0
Material
13.0
Casing
Cast Iron as per IS: 210 GR 20 or

Fabricated Steel
14.0
Rotor
BS 970 En9 or equivalent
15.0
Shaft
BS 970 En9 Hardened and ground
16.0
Base Plate
Cast Iron as per IS: 210 or carbon steel
Note: * - To be furnished by the Bidder along with the Bid.

All other details shall be reviewed by Bidder and conform.
DATE: 20-09-2007
ISSUE No: R0
DOCUMENT No
PCPL-0626-3-406-04-03-1
ROTARY SCREW PUMP

DATA SHEET
SECTION - 4
PAGE: 2 of 2
DATA SHEET B
Sl.
No.
Particulars
1.0
Designation
2.0
Number required
3.0
Service
4.0
Location
Units
Parameters
Liquid Data
5.0
Design viscosity at flow

temperature
6.0
Capacity
7.0
Total Dynamic head
8.0
Suction Pressure
Design and Construction
Features
9.0
Rotor type
10.0
Built-in Relief valve
11.0
Bearing Location
12.0
Material
13.0
Casing
14.0
Rotor
15.0
Shaft
16.0
Base Plate
DATE: 20-09-2007
ISSUE No: R0
DOCUMENT No
PCPL-0626-3-406-04-04
1.0
ERECTION, TESTING &

COMMISSIONING OF MECHANICAL
EQUIPMENT AND SYSTEMS
SECTION - 4
PAGE: 1 of 4
Scope of Work
This specification covers the unloading of equipment and materials from Trailers/ Truck
etc, transportation of the material to storage yard/shed/erection location, erection testing
and commissioning of Mechanical equipment/systems covered under this specification.
The scope of work shall include, but not limited to the items indicated herein under 16.0.
Bidder shall quote unit rates also for the items identified therein.
2.0
Information Furnished.
The information given to Bidder in this specification is for guidance. It is therefore;
imperative that Bidder shall obtain and examine for himself all the required data,
information and particulars required for the satisfactory execution of the work under this
enquiry. The submission of tender by the Bidder implies that he has fully read the
specifications and has made himself aware of the scope and the specifications for the
work to be performed and local conditions and other features. The owner shall not,
therefore, after acceptance of the tender, pay any extra charges for any reason whatever.
3.0
Bidder to Satisfy himself of Site Conditions

Bidders are advised to inspect and examine the site and its surrounding and satisfy
themselves before submitting their tenders, the form and nature of the site, the means of
access to the site, the accommodation they may require and in general shall themselves
obtain all necessary information which may influence or effect their tender. A Bidder
shall be deemed to have full knowledge of the site, whether he inspect it or not and no
extra charge consequent on any misunderstanding or otherwise shall be allowed. Only
open storage space will be provided by the owner for storage of equipment. Contractor
shall make necessary arrangements for closed / semi- closed structures wherever
required.
4.0
No Cost Payable for Preparing Tender

The Bidder shall not be entitled to claim any costs, charges, expenses for or incidental to
in connection with preparation and submission and subsequent clarification of his tender.
5.0
Time Schedule
5.1 The work shall be executed strictly as per time schedule, which will be mutually discussed
and
agreed. The Bidder shall quote a firm price for the contract period with a grace
period of three (3) months. The period of work includes the time required for
mobilization as well as testing, rectifications, if any retesting and completion in all
respects to the entire satisfaction of the Engineer/ Owner.
5.2 A joint programme of execution of work will be prepared by the Engineer / Owner and
contractor.
DATE: 20-09-2007
ISSUE No: R0
DOCUMENT No
PCPL-0626-3-406-04-04
5.3
ERECTION, TESTING &

SECTION - 4
PAGE: 2 of 4
Weekly construction programme will be drawn up by the Engineer / Owner jointly with
the
contractor based on required programme. The contractor shall strictly adhere to
these targets/ programme by deploying adequate personnel and construction tools and
tackle in good time to achieve the targets set out in the weekly programmes / targets.
5.4 Contractor shall give every day a report on categories of labour and equipment deployed
along with
the progress of work done on previous day in the proforma prescribed by
the Engineer / Owner.
6.0
Drawings
Construction drawings will be issued to the successful contractor. The contractor shall
submit two prints each of the construction drawings marked up with as built changes.
7.0
To be Supplied by the Contractor

Supply of all necessary tools, tackles and construction equipments, man power, all
consumables, oxygen/acetylene/argon gas, steel packers, SS/Copper shims for alignment
of rotating equipment and all the necessary welding electrodes for completing the work.
8.0
Site Clearance
The contractor shall take care of cleaning the working site from time to time for easy
access to job site and also from safety point of view.
9.0
Power Supply
a. The cost towards supply of power payable to the Owner shall as decided by owner.
Which shall be deducted from the running account bills. The energy meter shall be
maintained in good working condition. In case of any out of order, the energy
consumption will be assessed by the Engineer / Owner and his decision will be
binding on the contractor.
b. Owner however, does not guarantee the supply of water and power and these do not
relieve the contractor of his responsibility of the timely completion of various works
as stipulated. As such, adequate number of diesel operated machinery such as
welding sets, pumps etc., shall be provided by the contractor as an alternative
arrangement.
10.0
Land and Labour Camp

The contractor will make his own arrangements for his labour accommodation.
DATE: 20-09-2007
ISSUE No: R0
DOCUMENT No
PCPL-0626-3-406-04-04
ERECTION, TESTING &

SECTION - 4
PAGE: 3 of 4
11.0
Putting up of Building on Project Site
11.1
The contractor shall put up temporary structures as required by him for his office,
fabrication shop and construction stores only in the area allocated to him on the project
site by owner.
11.2
No person except the authorized watchman shall be allowed to stay in the plant area /
contractors area after completion of the days job without prior written permission from
Engineer / Owner.
11.3
Safety Measures
11.3.1 Owners safety procedures/regulations shall be followed by the contractor and his
employees during execution of the work under this contract.
11.3.2 Contractor will be responsible for the safety of his personnel and property as well as the
safety of personnel and property of the owner.
12.0
Insurance
Bidder shall provide all necessary insurance for all their personnel and third party
liability insurance.
13.0
Local area lighting

Contractor shall provide local area lighting and adequate security arrangement for all
equipments/material under contractors charge.
14.0
Contractors personnel
Contractor shall provide qualified and experienced personnel for erection of equipment
covered by this contract including dedicated planning team at site and safety officers.
15.0
Responsibilities of Contractor
The contractors responsibility also covers coordination of all the works involved, site
mobilization and de-mobilization.
16.0
Equipment Weights / Price Adjustment

Contractor shall install all the equipment/systems indicated in section 3 of this
specification. However a list of major equipments/systems to be installed under this
contract are as indicated below. The unit rates for erection furnished by contractor shall
be employed. If some items are deleted from the scope of work of the contractor, the unit
rates furnished by him shall be used for price adjustment.
DATE: 20-09-2007
ISSUE No: R0
DOCUMENT No
PCPL-0626-3-406-04-04
ERECTION, TESTING &

SECTION - 4
PAGE: 4 of 4
16.1
Diesel Engine Sets and its associated auxiliary equipment/system including Air Intake
duct, Exhaust duct, Insulation etc.
16.2
Fuel Oil day tanks and its associated piping work, valves, fittings, instruments etc.
16.3
Acoustic enclosures.
16.4
Lube Oil piping and its associated valves, fitting and instrumentation.
16.5
HSD Booster pump and its associated piping, valves, fitting, instrumentation etc.
16.6
Chimney and its associated accessories.
DATE: 20-09-2007
ISSUE No: R0
DOCUMENT No
PCPL-0626-3-406-04-05
BATTERY
SECTION - 4
PAGE: 1 of 7
1. SCOPE
1.1.
This specification covers requirements of stationary lead acid storage battery complete
with battery racks inter cell and inter tier connectors and all other accessories.
1.2.
In case of conflict between any section or clause of this specification and Data Sheet-A,
the requirements of Data Sheet-A shall govern
2. CODES & STANDARDS

2.1.
The design, manufacture and performance of equipment shall comply with all currently
applicable statutes, regulations and safety codes in the locality where the equipment will
be installed. Nothing in this specification shall be construed to relieve VENDOR of this
responsibility.
2.2.
The equipment shall conform to the latest edition of standards mentioned in Data SheetA.
3. TYPE
3.1.
The battery offered shall preferably be one of the following types as mentioned in Data
sheet A.
i. Sealed Lead Acid Battery
ii. Nickel Cadmium Battery
4. FEATURES OF CONSTRUCTION
4.1.
GENERAL
4.1.1. The equipment offered shall be complete with all parts that are necessary or usual for the
efficient operation of the equipment, whether specifically mentioned or not
4.2.
SEALED LEAD ACID BATTERY
4.2.1. The sealed batteries shall be a starved electrolyte type with electrolyte immobilised in a
micro porous material to allow recombining of generated oxygen internally. The battery
shall be completely explosion resistant. Shall tolerate freezing and shall not allow gases
to escape during normal charging conditions. The battery shall not require any watering
and be maintenance free.
4.2.2. Plante' Positive Plates
The plante' positive plate shall be cast solid in pure lead in one piece and shall have
adequate mechanical strength. It shall be electrochemically formed and shall be capable
of operating under normal working condition with out buckling or cracking. Welding
together of small size lead castings or fully formed plates to form larger sizes will not be
accepted.
DATE: 20-09-2007
ISSUE No: R0
DOCUMENT No
PCPL-0626-3-406-04-05
BATTERY
SECTION - 4
PAGE: 2 of 7
4.2.3. Tubular Positive plate shall consist of suitable bar with spines cast of suitably alloyed
lead to give adequate mechanical strength. Porous, acid resistant and oxidation resistant
tubes shall be inserted one over each spine. After insertion, the tubes shall be adequately
filled and packed with active material before their lower ends are closed by a common
bar. The construction and material of the tubes shall be such as to reduce loss of active
material and to withstand normal internal stresses developed during service.
4.3.
PASTED POSITIVE PLATES
4.3.1. The pasted positive plates shall consist of either pure lead, low antimonial lead alloy or
lead calcium positive grids; having double separation with a glass wool retainer mat or
any other suitable material placed against the surface of the positive plates, for good
service life.
4.4.
NEGATIVE PLATES
The negative plates shall normally be of the box type. End negative plates, if of box type
may be of the half pasted type. Pasted plates shall have adequate mechanical strength
and shall be so designed that the active material is maintained in intimate contact with
the grid under normal working conditions.
4.5.
CONTAINERS
The containers shall be made of plastics, or fibre reinforced plastics (FRP). The
container shall be spill proof and leak proof, explosion resistant and increased safety type
enclosure.
4.6.
VENT PLUG
The vent plug shall be for safety pressure vent and of self resealing type. The Vendor
shall indicate the vent pressure value.
4.7.
SEPARATORS
The plate separators shall consist of a micro porous matrix, which shall serve as the
mobiliser for the electrolyte. The battery separator shall maintain the electrical
insulation between the plates and shall allow the electrolyte to permeate freely. The
VENDOR shall indicate the material of the separator.
4.8.
CONNECTORS AND TERMINAL POSTS

Inter cell and inter-tier connectors and terminal posts shall be of copper. Terminal posts
shall be designed to accommodate external bolted connection conveniently and
positively. Each terminal post shall have two bolt holes of the same diameter, preferably
at right angles to each other. The bottom hole shall be used to terminate the inter cell
connection. The top hole shall be left for PURCHASERS terminal connections. All the
metal parts of the terminals shall be lead coated if necessary. The VENDOR shall
indicate this in the bid. The junction between terminal posts and cover and between
cover and container shall be so sealed as to prevent any seepage of electrolyte.
4.9.
ELECTROLYTE
DATE: 20-09-2007
ISSUE No: R0
DOCUMENT No
PCPL-0626-3-406-04-05
SECTION - 4
PAGE: 3 of 7
BATTERY
The electrolyte shall be battery grade sulfuric acid conforming to latest editions of
relevant standards. The sealed battery shall be transported with the electrolyte
immobilized and fully charged.
4.10.
NICKEL-CADMIUM BATTERY
4.10.1. The battery container and lid shall be alkali resistant no-aging material with high impact
strength. It shall have smooth sides except for receptacles., hold down br, vent tubes,
name plate, latches and polarity marking.
4.10.2. The cell container shall be of high strength alkali resistant material either nickel plated
mild steel/ stainless steel or non-porous plastic as specified in Data Sheet-A
4.10.3. The connector covers shall be of hard PVC to prevent external short circuiting.
4.10.4. The venting device shall be of anti splash type and shall allow the gases to escape freely
and shall effectively prevent the electrolyte from coming out . Provisions shall be made
for drawing electrolytes samples, checking and topping of the electrolyte.
4.10.5. The electrolyte used shall be a solution of potassium hydroxide in distilled water or demineralised made up to the specific gravity at 27O C.
4.10.6. Cell Designation.
Vented Nickel-Cadmium prismatic rechargeable cells shall be designated by letter K
followed by second letter:
T
Cells with tubular plates
Cells with pocket plates
cells with sintered plates
The second letter shall be followed by a third letter:

L
For low rate of discharge (below 0.5 Cs)
For medium rate of discharge (0.5 Cs to 3.5 Cs)
For high rate of discharge (3.5 Cs to 7 Cs)
For very high rate of discharge (above 7 Cs)
4.10.7. The group of three letters shall be then followed by a group of figures indicating Amphour capacity. Cells in plastic material shall be marked with letter 'P'.
4.10.8. Separators used for the cells shall be porous alkali resistant and high insulating capacity
to avoid shorting on leakage of the current between the plates of opposite polarity. The
separator shall be dimensionally stable with out deformation at the room temperature.
4.11.
ACCESSORIES
The battery shall be complete with accessories and devices, including but not limited to
the following:
i. Battery racks
ii. Porcelain insulators, rubber pads etc.
DATE: 20-09-2007
ISSUE No: R0
DOCUMENT No
PCPL-0626-3-406-04-05
SECTION - 4
PAGE: 4 of 7
BATTERY
iii. Set of inter cell, inter-tier and inter bank connectors as required for the complete
installation.
iv. Electrolyte for first filling +10% extra in plastic bottles or drums, for Ni-Cd
battery.
v. Accessories for testing and maintenance.
a.
One - -3, 0, +3 volts Dc voltmeter with suitable leads for measuring cell
voltage.
b.
One -Hydrometer for measuring specific gravity of electrolyte in steps of

0.002.
c.
One - Filler hole thermometer fitted with plug and cap and having specific
gravity correction scale.
d.
Three -Pocket thermometers
e.
Two sets - Funnels or siphon hydrometer and plastic jugs for topping up.
f.
Two Graduated plastic level test tube for electrolyte level checking.
g.
Two PVC aprons
h.
Four- PVC GLOVES and any other protective wearing apparel to be

specified by VENDOR
i.
Two- Cell lifting straps
j.
One set Terminals and cable boxes with glands for connecting cable as
required.
k.
Spare connectors
l.
Spare vent plugs
m.
Spare nuts and bolts
n.
Suitable set of spanners
o.
PVC spill trays under the Battery cells
p.
One set - Cell topping up apparatus (for large sizes of NI-CD cells)
VENDOR shall list the items.
q.
Insulated wrencher (for sealed lead acid battery).
5. BATTERY LAYOUT
5.1.
Unless otherwise specified the battery shall be complete with battery racks and
preferably mounted in single tier arrangement. VENDOR shall furnish dimensioned
drawings of the battery layout for purchasers APPROVAL. For smaller units, utilising
sealed-in type of batteries, mounting of the battery in the same sheet metal cubicle as the
associated equipment, for instance battery charger, will also be acceptable.
DATE: 20-09-2007
ISSUE No: R0
DOCUMENT No
PCPL-0626-3-406-04-05
5.2.
BATTERY
SECTION - 4
PAGE: 5 of 7
BATTERY RACKS
Battery racks shall be constructed from good quality teakwood and painted with two
coats of approved alkali resisting paint. The construction of the racks unless otherwise
mentioned in Data Sheet-A shall be suitable for fixing to a flat concrete floor. The racks
shall be rigid, freestanding type and free from warp and twist. The completed racks shall
be suitable for being bolted end to end to form a continuous row. Insulators shall be
provided below the legs of the stands.
5.3.
VENTILATION
THE bidder shall INDICATE IN THE TENDER REQUIREMENTS OF
VENTILATION IN THE BATTERY ROOM. The battery shall operate satisfactorily
over the entire range of temperature indicated in Data Sheet without affecting its normal
life. BIDDER shall indicate the percentage reduction in battery capacity at the lowest
temperature compared to that tat standard temperature of 27O C. If any special ventilation
requirements are necessary, the same shall be indicated.
6. CAPACITY
The standard ampere-hour capacity at ten hour rate of discharge of the battery has been
based on the requirements of loads mentioned in Data Sheet-A and the minimum
ambient temperature specified. BIDDER SHALL Guarantee that the capacity of the
battery offered by him is adequate for the duty specified (all loads being co-incident
from the instant of supply failure even at the minimum ambient temperature specified in
Data Sheet-A). For lead acid battery it may be assumed that the battery is fully charged
to 2.15 V at the start of the cycle and is discharged to a voltage of 1.75 V/cell at the end
of the cycle. For Ni-Cd battery each cell at start is considered charged to 1.28 V and the
cell end voltage after discharge to be 1.1. or 1.05 V as mentioned in Data Sheet-A
7. CHARGING
7.1.
The proposed method of charging of the battery is indicated in the Data Sheet A.
7.2.
BIDDER shall state whether an equalising charge is recommended for the battery. If so,
the equalising charging voltage, current, duration and the interval between the
equalising charging shall be specified in Data Sheet-B. BIDDER SHALL also indicate
the requirements for boost charging.
8. LIFE
The BIDDER shall quote in his offer the guaranteed life of the battery when operating
under the conditions specified
DATE: 20-09-2007
ISSUE No: R0
DOCUMENT No
PCPL-0626-3-406-04-05
BATTERY
SECTION - 4
PAGE: 6 of 7
9. TESTS
9.1.
All tests shall be conducted as per the relevant standards. Tests shall include following
Type & acceptance tests:
i. Type Tests: Copy of report on type test performed at MANUFACTURERS works
shall be submitted with the bill.
ii. Acceptance Test: Performed at site after installation and commissioning of the
battery. All tests shall be witnessed by the PURCHASERS representative. Details
of tests to be performed are given below:
10. TYPE TESTS

10.1.
Type tests shall comprise o the following:

a. Visual inspection
b. Dimensional check
c. Capacity tests
d. Retention of charge test
e. Ampere-hour and watt-hour efficiency tests.
f. Endurance test
g. Life cycle test
10.2.
Type tests shall be conducted on a minimum of one sample cell typical and identical
with the cells forming the complete battery offered. However, the test cell shall not be
one of the cells offered in the battery offered.
10.3.
In applications where the first momentary discharge stated in Data Sheet-A is high and
lasts for several minutes a high discharge test shall be conducted, in addition to the
above tests, as a type test. This test shall ensure that at the end of the high discharge rate
duty, end cell voltage does not fall below 1.6 V for lead acid and 1.1/1.05 V for Ni-Cd
and the temperature rise of electrolyte shall be within 10O C.
11. ACCEPTANCE TESTS

Acceptance tests shall be conducted at site on completion of installation and
commissioning and immediately prior to putting the battery in service. These tests shall
comprise of:
a. Visual inspection
b. Dimensional check
c. Capacity test
d. Test for voltage during discharge
e. Storage test
f. Insulation resistance
DATE: 20-09-2007
ISSUE No: R0
DOCUMENT No
PCPL-0626-3-406-04-05
SECTION - 4
PAGE: 7 of 7
BATTERY
12. TEST REPORTS

A copy of routine and type test results shall be submitted for approval before the dispatch
of batteries. Specified number of bound copies of complete test results shall be furnished
with the batteries.
13. SPARE PARTS
BIDDER shall include the following items in his recommended list of spares along with
item wise unit prices:
g.
h.
i.
j.
k.
l.
m.
Inter cell connectors

Battery stand insulators and cell insulators
Nuts, bolts, washers etc.
Vent plugs cum level indicators
Complete set of spare cell (without electrolyte for Ni-Cd cell)
Battery inter row connector
Battery intercell connector
14. IDENTIFICATION
Each cell shall be marked in a permanent manner to indicate the following information:
n.
o.
p.
q.
r.
s.
Cell number
Type of positive plate
AH capacity at 10 hour rate (lead Acid) and 8 hour rate (Nickel-Cadmium).
Type of container
MANUFACTURERS name
Month and year of manufacture.
15. CO-ORDINATION WITH BATTERY CHARGER VENDOR

When battery charger is procured separately, VENDOR shall coordinate with battery
charger VENDOR in regard to layout, connections, charging voltage requirements etc.
16. TRANSPORT
The Ni-Cd battery shall be transported without electrolyte in preferably dry charged
condition. The electrolyte shall be supplied separately in non-returnable containers.
The sealed lead acid battery shall be transported with the electrolyte immobilized, sealed
and fully charged.
DATE: 20-09-2007
ISSUE No: R0
DOCUMENT No
PCPL-0626-3-406-04-05-1
BATTERY
DATA SHEET
SECTION - 4
PAGE: 1 of 4
DATA SHEET A1
Sl. NO.
1
DESCRIPTION
Type of Battery
Quantity/Application
3
4
Number of battery banks required

Number of cells in each bank in series
(Approximate)
Ambient conditions
Type of Nickel-Cadmium battery
Cell container (Ni-Cd)
i)D.C. System voltage for engine starter
system
ii)Control supply for AMF Panel
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Ampere-hour capacity of battery at 27O C.

10 hours rate to give final cell voltage of 1.75
volts/cell sealed lead acid.
Momentary load/duration
Emergency load/duration
Continuous load/duration
Sketch NO.(If any) showing load on battery
Cell voltage-initial /final
Calculated ampere hour for above duty
Specified ampere hour
Tentative size of cables to connect battery to
external circuit
Available area in battery room L X B
Layout drawing No.(if any)
Mounting arrangement
High discharge test requires
Yes/ No
Charging method proposed
REQUIREMENT
Sealed Lead Acid Plante /
Tubular
i) One No. of 24 V Supply for
engine starter system for each
DG Set
One
12 Nos for 24 V system
45OC(Ref Section-2)
NA
NA
24 V
24 V
*
*
*
*
NA
2.15V / 1.75V
*
*
*
NA
NIL
Rack
No
Float and Boost
* Data by bidder.
DATE: 20-09-2007
ISSUE No: R0
DOCUMENT No
PCPL-0626-3-406-04-05-1
BATTERY
DATA SHEET
SECTION - 4
PAGE: 2 of 4
DATA SHEET A2
APPLICABLE STANDARD
Sl. NO.
DESCRIPTION
1
Sealed lead acid
Nickel Cadmium
2
Water for storage battery
3
Synthetic separator for lead acid batteries
STANDARD
IS-8320, 1652
IS-12956
IS-6071
DATE: 20-09-2007
ISSUE No: R0
DOCUMENT No
PCPL-0626-3-406-04-05-1
BATTERY
DATA SHEET
SECTION - 4
PAGE: 3 of 4
DATA SHEET B
Sl. NO.
DESCRIPTION
1.0
a) Manufacturers Name
b) Type of battery
2.0
Standards to which battery is manufactured
3.0
Capacity
3.1
At 27 Deg. C
3.1.1
Initial
3.1.2
Rated
3.1.3
End of life
3.2
Rated capacity at minimum
Ambient temperature
3.3
Rated capacity at maximum ambient temp.
3.4
Capacity at high discharge rate 27Deg. C
3.4.1
5 minutes
3.4.2
30 minutes
3.4.3
45 minutes
3.4.4
1 hour
3.4.5
2 hour
3.4.6
3 hour
3.4.7
4 hour
3.4.8
5 hour
3.4.9
6 hour
3.4.10 7 hour
3.4.11 8 hour
3.4.12 9 hour
3.5
Maximum Momentary current 1 minute
3.6
Expected life of battery
4.0
Recommended charging rate
4.1
Float charging Voltage/
current
4.2
Trickle charging Voltage/
Current
4.3
Boost charging Voltage/
Current
4.4
Equalizing charge
a) Voltage/current
b) Duration
c) Interval between successive equalising
charges
5.0
Expected fault level at bus due to battery
UNIT
DETAILS
Ah
Ah
Ah
Ah
Ah
Ah
Ah
Ah
Ah
Ah
Ah
Ah
Ah
Ah
Ah
Ah
Ah
Ah
Amps
Years
V
A
V
A
V/A
Min.
Hrs.
kVA
DATE: 20-09-2007
ISSUE No: R0
DOCUMENT No
PCPL-0626-3-406-04-05-1
Sl. NO.
6.1
6.2
7.1
7.2
8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
9.0
9.1
9.2
10.0
10.1
10.2
11.0
12.0
12.1
12.2
13.0
14.0
15.0
BATTERY
DATA SHEET
DESCRIPTION
Total resistance of battery
Resistance of inter cell Connectors
AH efficiency at rated load
Watthour efficiency
Type of positive plate
NO. of positive plates/ cell
No. of cells required to give rate D.C.
voltage
NO. of spare cells
Whether positive plates of individual cells
are inter changeable
Whether negative plates are
interchangeable
Type of containers
Type of cell
Overall dimensions
Each cell L x W x H
Complete battery L x W x H
Weight
Each cell
Complete battery
Whether explosion vents are offered
Ventilation requirements
Cubic content of battery room
Exhaust fans
a) Number
b) Rating of each
Whether there would be any harmful effect
on the life of battery if discharged as per
load cycle specified above, after being
maintained in float charging condition
List of spare/accessories enclosed
List of deviations enclosed
SECTION - 4
PAGE: 4 of 4
UNIT
Ohms
Ohms
DETAILS
Pocket /
Sintered
YES/NO
YES/NO
mm
mm
Kg
Kg
Yes/no
M3
kW
Yes/no
Yes/no
Yes/no
DATE: 20-09-2007
ISSUE No: R0
DOCUMENT No
PCPL-0626-3-406-04-06
BATTERY CHARGER
SECTION - 4
PAGE: 1 of 7
1.0
SCOPE
1.1
This specification covers requirements of Battery Charger & DC Distribution Board

(DCDB) equipment comprising of rectifier, rectifier transformer and auxiliary
equipment.
2.0
CODES & STANDARDS
2.1
The design, manufacture and performance of equipment shall comply with all currently
applicable statutes, regulations and safety codes in the locality where the equipment will
be installed. Nothing in this specification shall be construed to relieve VENDOR of this
responsibility.
2.2
Unless otherwise specified, equipment shall conform to the latest applicable standards as
mentioned in Data Sheet-A2.
3.0
TYPE
3.1
The battery charger shall be static type preferably composed of silicon controlled
rectifiers (SCRs) connected in three-phase full wave bridge circuit. Transducer control
may be offered as an alternative for large sets if SCRs are not feasible.
3.2
The rectifier transformer shall be indoor dry type, double wound with adequate number
of primary and secondary taps.
4.0
RATING
4.1
The float charger shall be designed for supplying:

a)
The DC loads specified in Data Sheet-A.
b)
The float charging current of the battery.
4.2
The boost charger shall be designed for supplying the boost charging current of the
battery.
4.3
When a composite (float/Boost) charger is specified it shall be designed to meet the

requirements specified in Clauses 4.1 and 4.2.
4.4
It shall be the responsibility of VENDOR to co-ordinate with the battery

MANUFACTURER and ascertain the float and boost charging currents and voltages
required by the battery.
5.0
CHARGER & DCDB CUBICLE & WIRING
5.1
Cubicle accessories and wiring shall conform to the requirements as stated in the
following clauses and in the companion specification for Control Cabinets.
ISSUE No: R0
DATE: 20-09-2007
DOCUMENT No
PCPL-0626-3-406-04-06
6.0
SECTION - 4
PAGE: 2 of 7
BATTERY CHARGER
ACCESSORIES
Each battery charger shall include the following:
6.1
One (1) set - silicon controlled rectifiers connected in three phase full wave bridge circuit
with ripple filtering device.
6.2
One (1) set - double wound dry type main transformer of suitable rating with adequate
primary and secondary taps for the charger output voltage control.
6.3
One (1) set - booster transformers as required.
6.4
One (1) set - automatic voltage regulator unit (for float chargers) with manual/auto
control switch.
6.5
One (1) set - coarse and fine control knobs for manual control.
6.6
One (1) - selector switch for modes of charging i.e. float charging/boost charging. This
shall be as indicated in the diagram referred to in Data Sheet-A.
6.7
One (1) - off load tap changing switch for changing the primary taps of the transformer.
6.8
One (1) - D.C. voltmeter with MCB and selector switch for measuring the output
voltage.
6.9
One (1) - D.C. ammeter with shunt
6.10
One (1) TPN incoming MCCB unit on A.C. side of each charger along with SC, OL &
EF releases and alarm contacts.
6.11
One (1) DP MCCB on D.C. output side of each charger with SC, OL, EF and alarm
contacts.
6.12
One (1) - centre zero ammeter with shunt for battery circuit.
6.13
Two (2) sets - silicon diodes arranged in series for connection between the end cell tap
on the battery and the positive bus of charger output.
6.14
One (1) - cubicle space heater with control switch and MCB suitable for 240V AC 50
Hz. single phase supply.
6.15
One (1) - 240 V AC lamp for cubicle internal lighting.
6.16
Two (2) - On - Off switch with MCB for items 6.14 and 6.15.
6.17
Two (2) - silicon diodes in series in the float charger circuit.
7.0
INDICATION & PROTECTION

Each battery charger shall be provided with the following indication and protective
devices:
7.1
Three (3) cluster LED type indicating lamps on the AC supply of the charger.
7.2
One (1) cluster LED type indicating lamp on the DC output side.
7.3
Two (2) AC under voltage relays connected across phases on the AC supply side with
alarm contacts for annunciator.
ISSUE No: R0
DATE: 20-09-2007
DOCUMENT No
PCPL-0626-3-406-04-06
SECTION - 4
PAGE: 3 of 7
BATTERY CHARGER
7.4
Thermal overload elements on each phase of the AC contactor on the supply side with
alarm contacts for remote annunciator.
8.0
PERFORMANCE
8.1
The automatic constant voltage regulator shall regulate the DC voltage within 1% of the
set value from no load to full load under the supply voltage and frequency fluctuations of
+/- 10% and +/- 5% respectively.
8.2
The float charger shall have built-in current limiting feature to drop the output voltage on
currents more than 110% of the rated current.
8.3
Suitable ripple filtering circuits shall be provided to give a smooth DC output. The ripple
content shall be limited to less than +/- 5% on resistive load.
9.0
DCDB:
9.1
Battery charger shall include a DCDB for distribution of DC supply to various essential
loads. DCDB shall be provided with MCCB for incomer & outgoing control. The
detailed feeder ratings shall be as detailed at Data Sheet A
9.2
DCDB CONSTRUCTION DETAILS:
9.2.1
Switchgear shall be designed in such a way that all component equipment operate
satisfactorily without exceeding their respective maximum permissible temperature rises
under temperature conditions prevailing within the switchgear cubicles. Reference
ambient temperature outside the switchgear cubicles is specified in Data Sheet A.
9.2.2
Ventilating louvers are generally not preferred. If ventilating louvers are considered
essential by the Vendor, these may be provided. However, all ventilating louvers shall
be of G.I or non-ferrous metal and shall be provided with fine-screened meshes to
prevent entry of Vermin.
9.2.3
Switchgear shall be provided with two bus bars. Bus bars shall be uniform cross section
throughout the length of the switchgear and up to the incoming terminals of feeder
circuit breaker/switch.
9.2.4
Except when otherwise noted in Data Sheet-A all bus bars shall be made of high
conductivity aluminium.
9.3
All bus bars, bus taps and joints shall be using self adhesive PVC tape.
9.3.1
Positive and negative bus bars shall be completely segregated from each other by sheet
steel partition.
9.3.2
Bus bars shall be adequately supported and braced to withstand the stresses due to the
specified short circuit currents of the associated switchgear. Bus bar supports shall be
made of Hylam sheets, moulded plastic material or permali wood.
9.3.3
Separate supports shall be provided for bus bar of each polarity. If a common support is
provided for both the bus bars, anti-tracking barriers shall be provided.
ISSUE No: R0
DATE: 20-09-2007
DOCUMENT No
PCPL-0626-3-406-04-06
SECTION - 4
PAGE: 4 of 7
BATTERY CHARGER
9.3.4
Bus bar joints shall be of the bolted type complete with Belleville washer. Bus bars shall
be thoroughly cleaned at the joint locations and suitable contact grease shall be applied
just before making a joint.
10.0
MOULDED CASE CIRCUIT BREAKER
10.1
Incomer and outgoing feeder control shall be with MCCB's of suitable rating as specified
in Data Sheet-A. Moulded case circuit breakers shall comply with the requirements of
the specification.
11.0
MINIATURE CIRCUIT BREAKERS
11.1
Miniature circuit breakers shall be provided in all control circuits in place of HRC fuses.
MCB's shall be suitable for DC application and shall comply with the requirements of
the specification.
12.0
CONTROL AND SELECTOR SWITCHES

Control and selector switches shall be:
12.1
Of the rotary type with enclosed contacts
12.2
Adequately rated for the purpose intended (minimum acceptable rating is 10A)
12.3
Provided with escutcheon plates clearly marked to show the positions.
13.0
INDICATING INSTRUMENTS AND METERS
13.1
Electrical indicating instruments shall be of the taut band type with 110-mm square dial
and 240 deg scale.
13.2
Indicating instruments shall have provision for zero adjustment from outside the cover.
13.3
Instrument dials shall be parallax free with black numerals on white background dial.
14.0
INDICATING LAMPS
Indicating lamps shall be:
14.1
Of the cluster type LED type and of low watt consumption.
14.2
Provided with translucent lamp covers of colours Red, Green and Amber as
specified in Data Sheet-A Control wiring diagrams
15.0
PUSH BUTTONS
Push buttons shall be:
15.1
Of the momentary contact, push to actuator type, rated to carry 6A at 220V D.C.
ISSUE No: R0
DATE: 20-09-2007
DOCUMENT No
PCPL-0626-3-406-04-06
SECTION - 4
PAGE: 5 of 7
BATTERY CHARGER
15.2
Fitted with self reset N/O and N/C contacts
15.3
Provided with integral escutcheon plates marked with its function.
15.4
Start push button shall be green in colour.
15.5
Stop push button shall be red in colour.
15.6
All other push button shall be black in colour.
15.7
Emergency stop push button shall be of the lockable type in the pushed position and
shall be shrouded to prevent accidental contact by operating personnal.
16.0
SPACE HEATERS
Space heaters shall be:
16.1
Suitable for operation on 240 V, single phase, 50 Hz supply.
16.2
Provided with rotary type ON-OFF switches, HRC fuses on line leads and links on the
neutral leads or double pole MCBs with overload and short circuit releases on the main
side.
16.3
Provided with humidistat to control the space heater, in order to maintain switchgear
interior at a temperature 5 deg c above the ambient.
17.0
CABLE TERMINATIONS
17.1
Suitable compression type of brass cable glands mounted on a removable gland plate
shall be provided to support all power and control cables entering the switchgear. Cable
glands shall incorporate built-in facilities for earthing the wire armour of cables.
17.2
All cable cores shall be adequately supported at regular intervals inside the cable alleys
by means of suitable, rubber or PVC lined clamps, up to the respective terminal blocks.
17.3
Necessary crimping type of cable lugs for connecting the individual cores to the
respective terminals shall be provided.
18.0
INTERNAL WIRING
18.1
All wiring inside the switchgear shall be carried out with 650/1100V grade,FRLS, PVC
insulated, stranded Copper conductor wires. Minimum size of conductor for power
circuits is 6 sq. mm aluminium. Control circuits shall be wired with copper conductor
wires of at least 2.5 sq. mm size.
18.2
Engraved identification ferrules, marked to correspond with the enclosed wiring

diagrams shall be fitted to each wire. Ferrules shall be of yellow colour with black
lettering.
18.3
All wires forming part of a tripping circuit shall be provided with an additional red
ferrule marked T.
ISSUE No: R0
DATE: 20-09-2007
DOCUMENT No
PCPL-0626-3-406-04-06
SECTION - 4
PAGE: 6 of 7
BATTERY CHARGER
18.4
Spare auxiliary contacts of all equipment forming part of the switchgear shall be wired
up to the terminal blocks.
18.5
All wiring for equipment supplied by the Purchaser for which Vendor has to provide
cutouts (where indicated in the Data Sheets) shall be provided up to the terminal blocks.
18.6
Spare and unassigned modules shall be complete with internal wiring.
18.7
All wiring shall be terminated on to terminal blocks using crimping type of lugs.
19.0
TERMINAL BLOCKS
19.1
All terminal blocks (both for power and control circuits) shall be of the 650V grade stud
type, comprising finely threaded pairs of brass studs of at least 6 mm diameter, links
between each pair of studs, washers, nuts and lock nuts. The studs shall be securely
locked within the mounting base to prevent its turning. Insulated barriers shall be
provided between adjacent terminals.
19.2
All terminals for circuits with voltage exceeding 125V shall be shrouded. Terminal
blocks shall be grouped and suitably segregated depending on circuit voltage. Different
voltage groups of terminal blocks shall be segregated.
19.3
Terminal blocks shall be adequately rated to carry the current of the associated circuit.
Minimum rating of the terminal block shall be 10A
19.4
Provision shall be made to insert terminal labels between two successive insulating
barriers.
19.5
Terminals shall be numbered for identification and grouped according to function.

Engraved white-on-block labels shall be provided on the terminal blocks, describing the
function of the circuit.
19.6
Where duplication of a terminal block is necessary, it shall be achieved by solid bonding

links.
19.7
Terminal blocks for CT secondary lead wires shall be provided with short-circuiting
links and earthing facilities.
19.8
Terminal blocks shall be arranged with at least 100-mm clearance between two rows of
terminal blocks.
20.0
LABELS
20.1
All labels shall comprise white letters on a black background.
20.2
Labels shall be made of non-rusting metal or 3-ply lamicoid sheet.
20.3
Labels shall be properly fixed, with provision to prevent distortion due to expansion.
20.4
Sizes of labels and lettering are subject to Purchasers approval.
ISSUE No: R0
DATE: 20-09-2007
DOCUMENT No
PCPL-0626-3-406-04-06
BATTERY CHARGER
SECTION - 4
PAGE: 7 of 7
21.0
EARTHING
21.1
The switchgear shall be provided with an earth bus bar running along the entire length of
the board provided with stud hole at either ends to connect purchasers earth bus.
Material and size of the earth bus bar shall be as specified in Data Sheet-A.
21.2
Earth bus bars shall be supported at suitable intervals.
21.3
Positive connection between all the frames of equipment mounted in the switchboard and
earth bus bar shall be provided by using insulated copper wires/bare bus bars of cross
section equal to that of the bus bar or equal to half the size of circuit load current
carrying conductor.
21.4
All instrument and relay metallic cases shall be connected to the earth bus bar using
650/1100V grade PVC insulated 2.5 sq. mm stranded, tinned copper earthing conductor.
22.0
TESTS
22.1
FACTORY TESTS
All type and routine tests as listed in applicable standards shall be carried out at
MANUFACTURERs works.
22.2
ACCEPTANCE TEST
Routine tests as per applicable standards will also be carried out on the assembled unit at
site.
ISSUE No: R0
DATE: 20-09-2007
DOCUMENT No
PCPL-0626-3-406-04-06-1
BATTERY CHARGER
DATA SHEET
SECTION - 4
PAGE: 1 of 5
1.GENERAL PARTICULARS
DATA SHEET A1
1.1
1.2
Designation
Battery Charger with DCDB
Quantity/Application
i) One No. Battery charger for

24 V Supply for engine starter
system for each DG Set.
1.3
1.4
1.5
1.6
1.7
Type Boost / Float / Composite

DC System voltage
Location
Design Ambient Temperature
Type of mounting (floor/Pedestal/
column/wall)
Cable Entry- Top/Bottom
Glands/Conduits
Purchaser's Earthing conductor
Material
Size
Painting:
Colour
Outside
Inside
Control scheme & Bill of Material, enclosed
Yes Ref No.
Composite
24 V
Indoor
45OC
FLOOR
IP 52
2.1
Degree of enclosure protection and grade of

the cubicle.
IP class as per IS
Thickness of Sheet Steel
Cold Rolled
Hot rolled
Earthing Bus
Material
Size
Momentary
2.2
Emergency
2.3
Continuous
1.8
1.9
1.10
1.11
1.12
1.13
LOAD2. DC BUS
1.14
Top
Glands
GS
75 x 12mm
632 of IS-5
Glossy White
No, to be furnished by Vendor
Frame 2 mm ; Others 1.5 mm

NA
Copper
40 x 6
*
*
*
ISSUE No: R0
DATE: 20-09-2007
DOCUMENT No
PCPL-0626-3-406-04-06-1
PERFORMANCE4.
3. AC SYSTEM DATA
3.1
3.2
BATTERY CHARGER
DATA SHEET
SECTION - 4
PAGE: 2 of 5
Supply:
Volts
Phase
Frequency
415V
3
50Hz
Voltage
Frequency
+ /- 10%
+ /- 5%
36 MVA
Effectively
earthed
Yes
Required
240V
Yes
+ /- 2%
+ /- 3%
0.9
Variation in supply
3.3
3.4
Short circuit level

Type of earthing
3.5
3.6
3.7
4.1
4.2
4.3
4.4
Auxiliary supply if available

Control Transformer
Space Heater/Lighting Supply Voltage
Automatic voltage regulator
Voltage Regulation with AVR
Permissible harmonics at rated continuous load
Minimum permissible power factor at rated continuous load
* Data by bidder
ISSUE No: R0
DATE: 20-09-2007
DOCUMENT No
PCPL-0626-3-406-04-06-1
BATTERY CHARGER
DATA SHEET
SECTION - 4
PAGE: 3 of 5
DATA SHEET A2
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
19
20
21
APPLICABLE STANDARDS
Switchgear general requirements
IS : 4237
AC circuit breakers
IS : 2516
Factory built assemblies of SW. Gear and control gear IS : 8623
for voltages up to and including 1000V AC & 1200V
DC.
Air break switches
IS : 4064
Miniature circuit breakers
IS : 8828
Contactors
IS : 2959
Starters
IS : 8544
Control switches / push buttons
IS : 6875
Current transformers
IS : 2705
Voltage transformers
IS : 3156
Relays
IS : 3231
Indicating instruments
IS : 1248
Arrangement for busbars main connections and
IS : 5578
accessories
IS: 11353
AC electricity meters
IS : 8530
Degree of protection
IS : 2147
The performance of AC control gear equipment rated
up to 600V for use on high prospective fault current
system
Code of practice for installation and maintenance of
IS : 10118
switchgear
Climate proofing of electrical equipment
-Code of practice for phosphating iron & steel
IS : 6005
BS : 3189
Wrought aluminium & aluminium alloys for electrical IS : 5082
purposes
Control transformer for switchgear and control gear
IS : 12021
for voltage not exceeding 1000V AC
NOTE: Equivalent IEC standards are also acceptable.
ISSUE No: R0
DATE: 20-09-2007
DOCUMENT No
PCPL-0626-3-406-04-06-1
BATTERY CHARGER
DATA SHEET
SECTION - 4
PAGE: 4 of 5
DATA SHEET - B
SL.
1
2
3
4
5
6
7
DESCRIPTION
Manufacturers name
Indoor/outdoor application
Thickness of sheet steel
Degree of protection provided (as per IS:2147 or
equivalent)
Bill of material for the various equipment giving
make, type, ratings etc., enclosed
Colour of finish paint
Outside
Inside
Bus bars for power devices (when applicable)
UNIT
mm
Yes/no
a) Material
8
b) Continuous current rating

Control Wiring/Power Wiring
a) Material of conductor and size
9
10
11
12
13
14
15
16
17.1
17.2
b) Conductor- Solid/Stranded
AC input power rating of charger
a) Float mode +DC loads
b) Boost mode + DC loads
Regulation of charger
Hormonics generated by charger (THD)
Ripple content in the output
PF of the charger at rated DC load &boost charging
Efficiency of charger
Float charging transformer data
a) Type
b) Rating
Boost charging transformer data
a) Type
b) Rating
List of indications provided on charger
a)
b)
c)
DETAILS
(Insulated/Bare)
A
Cu/A1
mm2
KW
KW
%
%
List of protections provided on charger

a)
b)
c)
ISSUE No: R0
DATE: 20-09-2007
DOCUMENT No
PCPL-0626-3-406-04-06-1
SL.
18
19
20
21
BATTERY CHARGER
DATA SHEET
DESCRIPTION
UNIT
SECTION - 4
PAGE: 5 of 5
DETAILS
Dimensions and weight of transformer

Length
Width
Height
Weight
Typical GA drawings enclosed
Yes / No
List of routine tests to be done on charger
a)
b)
c)
List of type test carried on charger
a)
b)
c)
mm
mm
mm
Kgs.
ISSUE No: R0
DATE: 20-09-2007
1.0
Lumpsum price for

supply, installation,
testing
&
commissioning
of
1000kVA DG Set Sets
complete with all
accessories as per
specifications
Break-up of Prices
2.1
1000kVA DG Set
and Auxiliaries as per Sets
specifications & BOQ
2.2
Fuel Oil System as

Sets
per specifications
2.4
Acoustic Enclosures
as per specifications
DG Control & Relay
Panel (AMF Panel)
Battery & battery
Charger System as
per specifications
i) 24 V DC system
for Starter
2.6
2.7
2.8
2.9
2.10
3.0
Exhaust Stack with

supports
Design Engineering
for the package
Installation, testing &
Commissioning
Mechanical Systems
Installation, testing &
Commissioning
Electrical Systems
Spares
Sets
Sets
Sets
Sets
Lot
Lot
Lot
DATE: 20-09-2007
ISSUE No: R0
Rs.TOTAL F.O.R Destn. PRICE
UNIT F.O.R Destn. PRICE Rs.
UNIT TAXES Rs.
UNIT E.D Rs.
UNIT F & I Rs.
UNIT P & F Rs.
UNIT EX-WORKS Rs.
QTY.
2
2.0
2.5
SECTION - 5
PAGE: 1 of 1
PRICE SCHEDULE
UNIT
DESCRIPTION
SL #
DOCUMENT No
PCPL-0626-3-406-05
Rs.TOTAL F.O.R Destn. PRICE
UNIT TAXES Rs.
UNIT E.D Rs.
UNIT F & I Rs.
UNIT P & F Rs.
UNIT EX-WORKS Rs.
QTY.
UNIT F.O.R Destn. PRICE Rs.
SECTION - 5
PAGE: 2 of 1
PRICE SCHEDULE
UNIT
DESCRIPTION
SL #
DOCUMENT No
PCPL-0626-3-406-05
NOTE: BIDDERS to indicate the exact requirement of spares with suggested quantity for trouble free
operation for 3 years.
DATE: 20-09-2007
ISSUE No: R0
DOCUMENT No
PCPL-0626-3-406-06
#
Section
Remarks
SECTION - 6
PAGE : 1 of 1
DEVIATION SCHEDULE
Doc. No.
Cl.No.
Deviation
Reason/
Justification
Note: Bidders shall furnish the list of deviations if any with reasons / justification as per
the above format. In the absence of such a deviation it shall be construed that the Bidder
fully complies with the enquiry specification.
DATE: 20-09-2007
ISSUE No: R0

PCPL 0630 3 401

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ITC LIMITED,

PROJECT WEST SIDE

DIESEL GENERATOR SET

POET CONSULTANTS PVT. LTD

This specification covers the design, engineering, procurement, manufacture, inspection

ELEVATION ABOVE MEAN SEA

PLANT MAIN EARTH GRID

b. Lighting Fixtures, spring charging

AUXILIARY SUPPLY VOLTAGE

ITC Limited, ITD Pune

ITC EHS CONSTRUCTIONAL

This document defines the operations undertaken by contractors and sub-contractors on

IT IS IN A TERM OF ALL CONTRACTS BETWEEN THE CLIENT AND

ITC EHS CONSTRUCTIONAL

The passage of people and / or vehicles whether on a defined gangway or

Access for emergency apparatus such as fire fighting equipment.

Contractors and sub-contractors shall nevertheless provide adequate

Accident and Incident Reporting:

Contractors and Sub-contractors Tools and Equipment

Dust and Fume Control

Fire Hazards and Precautions

Housekeeping and hygiene go hand in hand with safe working practices.

ITC EHS CONSTRUCTIONAL

Safety Clothes and Equipment

ITC EHS CONSTRUCTIONAL

Warning Signs and Notices

ITC EHS CONSTRUCTIONAL

Electricity driven portable tools

Compressed Air Tools

Percussion Cartridge Tools

Abrasive cutting and Grinding tools

ITC EHS CONSTRUCTIONAL

Such tools shall be used for their designed purpose only.

Hoisting and Lifting

Movement of Plant and Machinery

Powered Industrial Trucks

ITC EHS CONSTRUCTIONAL

Safe working practices must be observed at all times.

It is the responsibility of the Contractor and sub-contractors staffs to use appropriate

Vehicle parking will be in designated areas only.

Smoking is NOT allowed in work areas.

No food is to be consumed or left in work areas.

Warning signs and speed restrictions must be strictly observed.

All work men shall wear helmets approved boots.

ITC EHS CONSTRUCTIONAL

All hand tools shall be of 110 Volts A/C double insulated.

Only authorised approved equipment /tools shall be used in execution of work.

Cable laying shall be carried out using roller. etc.

ITC EHS CONSTRUCTIONAL

SPECIFIC TECHNICAL REQUIREMENTS

EQUIPMENT/ SYSTEMS TO BE PROVIDED BY THE BIDDER:

Fly wheel and suitable flexible couplings.

Intake air system with air cleaner (dry type).

Water pump-centrifugal type-engine mounted.

Fuel filters and lube oil filter.

Fan (Blower type) with safety guard if required.

Electronic Governor having facility for remote control of speed (RPM).

SPECIFIC TECHNICAL REQUIREMENTS

Battery and Battery charger systems.

Throttle control lever with remote stopping (shut-off) facility.

Instrumentation system including engine and generator protection system.

Lube oil Temperature gauge.

Lube oil Pressure gauge.