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BHAGYANAGAR GAS LIMITED (A JOINT VENTURE OF HPCL & GAIL)

TECHNICAL SPECIFICATION

FOR

GAS GENERATOR SET

(50 KVA)

Tender No: BGL/113/2010-11 Description: Tender for procurement of 50 KVA Gas Engine driven Gen Sets for

Vijayawada.

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CONTENTS

SECTION NUMBER DESCRIPTION

1.0 Scope

2.0 Codes & Standards

3.0 General

4.0 Gas Engine

5.0 Lube Oil System

6.0 Engine Starting System

7.0 Air Intake And Exhaust System

8.0 Governing System

9.0 Digital Controller

10.0 ALTERNATOR (Power Output @ 0.8 Power Factor)

11.0 Performance Requirements

12.0 Gas Train

13.0 Wiring

14.0 Control System

15.0 Base Frame

16.0 AVM Pads

17.0 Packing and Despatch

18.0 Tool Kit

19.0 Tests

20.0 Drawings

21.0 Other Details

22.0 Acoustic Enclosure

23.0 Specification of Continuous On Line Gas Monitoring System

24.0 Enclosure Illumination

25.0 Skid

26.0 Painting

27.0 Data Sheets for Engine

28.0 Data Sheet for Alternator

29.0 Data Sheet of Panel & Instruments

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1.0 SCOPE This specification covers the design, engineering, manufacture, shop testing, supply, erection, testing and commissioning of 2 Nos. 415 V, 3 phase & N, 50 KVA Gas Generator Set along with all required accessories including integral AVM pads and weather and Sound proof acoustic enclosure. The rating applies for supplying continuous power at variable load for unlimited annual hours. A 10% overload is allowed for up to 1 hour in every 12 hours.

2.0 CODES AND STANDARDS The Gas Generator set with all its components shall comply with the latest applicable

standards, regulations and safety codes in the locality where the equipment shall be installed. The equipment shall comply with following British Standards, Indian Standards or equivalent British or International Standards with latest revisions.

o ISO 3046/1

o BS 5514

o AS 2789

o DIN 6271

o ISO 8528/1

o ISO 8528-5

3.0 GENERAL 3.1 The Gas Generator Set shall be outdoor type complete with suitable acoustic

enclosure, to limit noise level to 75 db (Permissible limits as per CPCB norms). The set shall consist of Gas Engine coupled to suitable alternator having self, brush less excitation system with PMG and include all necessary accessories and control panel as specified and as required.

3.2 The engine and generator shall be mounted on an integral robust fabricated steel frame with anti vibration mountings pads. No separate foundation will be provided. Required set of foundation bolts, nuts and washer etc. and set of spanner and tools shall be supplied by the bidder.

3.3 The gas genset should meet CSA, UL, NFPA or other comparable safety standards

3.4 The generator set shall be factory built and production tested.

3.5 The generator set shall be capable of taking the block loading in single step.

3.6 The generator shall have Integral vibration isolation.

3.7 The generator shall have advanced Digital Controller for the engine and alternator

combine with LED display unit for display of system parameters and fault indication of both the engine / alternator.

3.8 The generator set shall have cooling system rated for 500 C ambient temperature.

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3.9 The generator shall have a test certificate confirming the generator load parameters.

3.10 The generator shall have auto start feature with programmed cranking cycles.

3.11 The generator shall have package mounted Line Circuit breaker for protection.

3.12 The generator package shall have a gas detection alarm sensor fitted in flame proof box with controller and alarm mounted in separate compartment in the acoustic enclosure.

3.13 The generator set shall have a spark arrester and a catalytic converter fitted on it.

4.0 GAS ENGINE

4.1.1 The generator set shall be powered by proven field tested 4 stroke, naturally aspirated / turbo charged, water cooled Gas Engine suitable for operating on CNG with a power output of min. 73 BHP @ 1500 RPM along with all standard engine components and shall have following features: a. Internal Exhaust System with approved Spark Arrestor and Catalytic converter. b. The Gas Engine shall be suitable for block loading in one step and supplied with

Electronic Isochronous Governor for optimum fuel, spark performance and frequency regulation of ± 0.5 %.

c. Residential grade silencer. d. 70A / 12V Battery Charging Alternator. e. 12 V starter motor. f. High engine temperature safety & shutdown. g. Low Lube Oil Pressure safety & shutdown. h. Dry type air filter. i. Cartridge type lubrication oil filter j. The Generator set engine should be fitted with 3-way catalytic convertor capable

of reducing NOx, C0 and HC by over 70%. k. The Generator supplier should have sufficient experience with catalytic convertor

fitted gensets in India. l. The Catalytic convertor supplier or its principal must have manufacturing base in

India. m. The catalyst supplier should have its product validated by ARAI n. Catalytic convertor approved makes: a)- Johnson Mathey Brand, b) Airshield

Brand. o. Gas Engine shall be supplied with high silicone content or other improved

material pistons for durability / long life. Expected engine life without any major maintenance shall be indicated by the bidders.

p. The generator set shall have a gas train to operate at a gas pressure of 14 - 19 Kg /cm2.

q. The generator set shall be able to operate on the following gas configuration:

Sr. No. Component Mole (%)

1 Methane 93.7368

2 Ethane 1.6871

3 Propane 1.3024

4 i-Butane 0.2799

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5 n-Butane 0.3359

6 i-Pentane 0.1090

7 n-Pentane 0.0900

8 Hexane 0.3319

9 Carbon Dioxide 2.0521

10 Nitrogen 0.0750

Total 100.00

The Generator shall have fuel consumption in the range of 17 m3/hour +/- 7 % @ 100 % Load based on natural gas.

5.0 LUBE OIL SYSTEM Automatic pressure lubrication system shall be provided. Bidder shall also indicate the specific lube oil consumption and capacity of the lube oil

tank. 6.0 ENGINE STARTING SYSTEM Starting of gas engine shall be by electrical starting system. Electrical Starting System shall comprise of a starter motor, batteries, battery charger

and all the necessary instruments and accessories. Batteries, battery charger and associated panel, cabling, supporting structure etc shall be supplied by the bidder.

7.0 AIR INTAKE AND EXHAUST SYSTEM Air intake filter and silencer shall be provided. The exhaust system shall consist of an exhaust gas driven turbocharger, exhaust gas

silencer, necessary piping, adapters, accessories etc. 8.0 GOVERNING SYSTEM The Gas engine should have Electronic Isochronous governing. Governor shall be provided for keeping constant speed within permissible limits with

variable load. The governor shall be Electronic type. It shall be capable of operating on isochronous mode i.e. the speed of the engine (frequency of the generator set) shall remain constant irrespective of the load on the Gas Generator set upto 100% capacity. RPM indicator and tacho generator to trip the Gas Generator set during over speed shall also be provided.

9.0 DIGITAL CONTROLLER The Digital Controller shall be integrally mounted on generator set and shall have

automatic start function with provision for manual Start / Stop / Reset and Auto options as per technical specs / features listed below:

a. The Digital Controller shall have self diagnostics and test function.

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b. Digital Controller shall have LED to display Engine Parameters like Running Hours, Crank Cycle status, Diagnostics.

c. LED shall also display communication faults like i. High Engine Temperature, ii. Low Oil Pressure iii. Over Crank Safety iv. Over Speed v. Over Frequency vi. Over Voltage vii. Under Frequency viii. Under Voltage ix. High Battery Voltage x. Low Battery Voltage xi. Auxiliary Fault.

d. Digital Controller shall preferably have a MMI membrane keypad for configuration

and adjustment of features like i. Password protection for Menu access ii. Voltage, Gain and Speed adjustments iii. System configurations like System Voltage, Phase and iv. Frequency settings etc.

10.0 ALTERNATOR (Power output @ 0.8 Power Factor)

The alternator shall be designed for the specified rating voltage etc. and shall be Single bearing with class `H’ insulation with 130 temp rise as per NEMA MG1-1.66, IEEE & ANSI standards. The maximum power required by the alternator for the rated prime power shall be indicated.

The alternator shall be suitable for continuous operation at 415V, 3 phase, 4 wire

system, 50 Hz, 0.8 pf (lag). The Alternator should be able to take the 100 % load in single step The alternator shall have following features:

Brush less, screen protected, revolving field, self excited, self regulated through an DVR /AVR.

It should have PMG (Permanent Magnet) Excitation incorporated for block & motor Loads.

Sustained short circuit current of upto 300% of the rated current upto 10 seconds.

It should have vacuum impregnated windings with fungus resistant varnish for use in humid areas.

It should have self ventilated and drip proof construction.

It should have Superior voltage wave form from a two-thirds pitch stator & skewed rotor.

Fast Response II brushless alternator with brushless exciter for excellent load response.

+/ - 0 .25 % voltage regulation (max.)

IP:23 enclosure

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Two nos. body earthing terminals which shall be separate from the neutral terminal.

Permissible overload 10% for one hour in 12 hours of duration.

Alternator shall conform to the following standards: IS: 12065 Noise Limit IS: 12075 Vibration IS: 4722 Governing Standards IS: 4691 Enclosure Protection IS: 6362 Cooling IS: 2253 Mounting IS: 13364 Specification of Alternator coupled with IC Engines

Alternator frame and enclosure shall be made from MS or Cast Steel.

The maximum Vibration of the alternator should not be more than 4.5mm/sec (rms) at full load.

Alternator windings and AVR should be suitable for humid atmosphere as per ambient conditions mentioned in the enquiry.

All windings should be made from electrolytic grade copper of high purity.

Lifting hooks are to be provided for lifting the alternator. 11.0 PERFORMANCE REQUIREMENTS The unit shall be capable of starting from cold condition. The unit shall be capable of a peak output of 10% in excess of the rated output for a

period of one hour out of a total 12 consecutive hours of operation, without exceeding permissible temperature limits and with a fairly clear visible exhaust.

The unit shall operate up to 110% of the rated speed over the entire range of output

without undue vibration and noise. The unit shall be in accordance with Standby Rating as per ISO-3046/1, BS 5514, AS

2789 & DIN 6271 12.0 GAS TRAIN SCHEMATIC DIAGRAM

The bidder should provide gas train as per schematic diagram above.

Slam shut off valve should be provided to shut off the supply of gas in case gas pressure exceeds the specified limits.

Safety valve

Vent line

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Safety valve should be provided to pass the gas, if pressure of gas exceeds the set value of pressure.

The bidder shall provide gas meter of reputed make.

Vent line should be provided to vent the gas of pipeline of gas genset for maintenance.

The bidder may study the requirement at site and quote accordingly as per site conditions.

Any item not mentioned and required for proper functioning of the gas train shall be provided free of cost.

The gas pipeline pressure would be 4 to 19 Bar.

The bidder would be required to submit test certificate of the gas train.

The filter should be hydro tested up to 25 Bar.

13.0 WIRING

All control wiring inside the controller shall be carried out with 2.5 sq.mm 1100/650 V grade PVC insulated copper wires.

14.0 CONTROL SYSTEM

The Gas Generator set will be normally at rest when the station A.C. supply is

available from normal power source. In case of main AC power supply failure, the Gas Generator shall be started as follows.

On failure of normal station A.C. power supply, Gas Generator set shall start

automatically, if put in AMF mode. Arrangement for manual starting shall also be provided.

When Gas Generator set is running & grid power restores, the load shall be

transferred to grid manually and the Gas Generator set will stop after a preset time. Three attempt starting facility shall be provided for the Gas Generator set. In case, the

gas engine fails to start and reach rated speed within 30 seconds, it shall be disconnected and locked out automatically.

15.0 BASE FRAME

Skid mounting type base frame, fabricated from suitable size MS channel, of heavy side members and cross members, providing common bed for engine and alternator, directly coupled together. The base frame shall have provision for grouting the set on grouting bolts as well as fixing on the Anti-Vibration Mounts. Provision shall also be made in the base frame for lifting the Set.

16.0 AVM PADS

Vibration Mounting Pads, as recommended by the set manufacturer shall be supplied

with the DG set.

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17.0 PACKING AND DESPATCH

The unit shall be packed suitably to facilitate installation and transportation. During transport, care shall be taken to avoid damage to paint or accessories of the equipment if any damage is caused during transport, the vendor shall repair the same, free of cost.

18.0 TOOL KIT

Special tool kit, if any, for the Gas Generator Set shall be supplied. 19.0 TESTS

Following tests shall be carried out for the Gas Generator Set. Routine tests for engine like fuel consumption test, 24 hours running test, etc. as per

relevant Indian / International Standards. Routine tests for alternator, as per latest IS-4722 or other applicable Indian Standards,

like Insulation Resistance and High Voltage Test etc. 8 hour run test with the set completely assembled at the bidder’s test bed with full load

and 10% overload. All parameters will be recorded in presence of the customer’s representative.

Bidder shall perform the following tests at site to the satisfaction of owner, if required:

a. Automatic starting up and interlock b. Governor response c. Voltage regulator response d. Speed/voltage droop setting for parallel operation as specified.

Bidder shall submit copies of routine and type test certificates for approval in required

sets before despatch. 20.0 DRAWINGS

Bidder shall submit prints of following drawings in required sets:

a. Outline dimensional drawings with general arrangement. b. Piping flow sheets and piping layout. c. Electrical wiring and schematic diagram along with cable schedule and general

arrangement drawing for control panel. d. Foundation drawings. e. Fuel oil system with instrumentation and control with write-up. f. Lube oil system with instrumentation and control with write-up. g. Governor system and voltage regulator write-up. h. G.G. set instrumentation and control system with write-up.

One print of each of above drawing will be returned to bidder after making all

necessary corrections/ comments. Bidder shall incorporate these and send within fifteen (15) days, 5 prints of each drawing for final checking/ approval.

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The bidder shall also provide 7 sets of installation, operation, maintenance and major overhauling instruction manuals before inspection.

21.0 OTHER DETAILS:

a) All the earthing work will be in bidder’s scope. b) Power Cabling will be in bidder’s scope. c) Station Piping will be in bidder’s scope. d) All the consumables required for 1st year operation has to be included in the

Gas Genset price. e) The average running hours for one year would be 750 hours i.e. approximately

2 hours per day. f) The bidder should submit the following information along with relevant

performance rating curves and engine product catalogue: I. Gross HP developed at rated RPM. II. Deduction for fan and other ancillary equipment.

III. Net HP developed at rated RPM. IV. Specific fuel consumption at rated power as well as at 110%, 75%, 50%

and 25% of rated load. g) The generator set should be suitable for operation at the following site

conditions: Maximum Temperature : 48 DEG C Minimum Temperature : 05 DEG C Maximum Humidity at 21 DEG C : 100% Maximum Humidity at 35 DEG C : 95% Maximum Humidity at 41 DEG C : 70% Maximum Altitude above sea level : 150 Meter

22.0 ACOUSTIC ENCLOSURE:

The generator set comprising of engine coupled with alternator for each set should be placed inside an acoustic enclosure having the following salient features:

The acoustic enclosure should be of modular construction with the provision to assemble and disassemble easily at site. There should also be adequate provision of taking out the equipment for maintenance / repairing jobs and reinstalling the same after necessary corrective action.

The engine generator shall be factory enclosed in not less than a 12 gauge cold rolled steel enclosure constructed with corner posts, uprights and headers. The roof shall aid in the runoff of water and include a drip edge. The weatherproof and corrosion resistant acoustic enclosure should be duly surface treated, phosphated and finally powder coated for long lasting finish. The sheet metal components should preferably be hot dip, seven tank pretreated before powder coating with special pure polyester based powder.

The sound proofing of the enclosure should be done with self extinguishing high quality rock wool / mineral wool conforming to IS 8183. The rock wool should be further covered with fibre glass tissue and perforated sheet. The silencer must be such that sound level is 75 dbA at 1 meter from the enclosure surface.

Exhaust silencer shall be provided of the size as recommended by the manufacturer and shall attenuate the sound to the level noted above. It shall be supplied with a flexible, seamless, stainless steel exhaust connection as well as with all internal pipe work. A rain cap will be supplied to terminate the exhaust

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pipe. These components must be properly sized to assure operation with minimum back pressure and high sound when installed. The canopy should be finished in synthetic enamel paint incorporating rust inhibitors and aluminum sprayed silencers and spark arrestors to guarantee a superior and long lasting finish.

There should be carefully designed inlet and outlet baffles / attenuators with corresponding weather louvers and bird mesh allowing sufficient air flow, for the set to operate even under the harshest ambient conditions whilst maintaining specified noise levels. Suitably sized blower should be incorporated to meet total air requirement.

The temperature inside the enclosure should be suitable for human comfort. The temperature of exhaust line should not exceed the self ignition temperature of fuel gas. A high temperature trip system (to shut down the engine by cutting off fuel supply to the engine through the solenoid valve ) with variable setting connected to a thermostatically controlled blower must be provided for eliminating excessive heat dissipated by the engine within the acoustic enclosure. Suitable continuous on line Temperature Monitoring and Control System with Alarm and Shut down Mechanism should be provided.

a) When the concentration of gas inside the acoustic enclosure reaches 10 % of LEL of gas, audio visual alarm should activate and automatic preventive measure should activate to reduce the concentration of leakage gas. These preventive measures include switching on heavy duty exhaust fan to disperse leakage gas or stoppage of gas leakage itself.

b) When the concentration of gas inside the acoustic enclosure reaches 15 % of LEL of gas (or any other suitable rating), the alternator main circuit breaker should trip automatically and subsequently the engine should be shut down instantaneously by automatic device (i.e., cutting off power supply to the fuel solenoid valve.)

A separate Blower of suitable size should be provided and it will be in operation even if the thermostatically controlled blower stops / fails.

There should be a provision of emergency shutdown of the generating set (Prime Mover) from outside the enclosure.

The enclosure should be complete with power and control wiring between control panel and alternator and other components like blowers etc with proper size copper cable. The cables should be terminated using gland and tinned copper sweating sockets and run through guard pipe.

The enclosure should have the sufficient space in and around the generating set to facilitate maintenance and operation of the set.

Acoustic Enclosures base frame should incorporate necessary facilities for handling and inter location transfer through oil field trucks and its overall dimension should not exceed 9M x 2.5 M x 2.5M ( Length x Width x Height).

The control panel for the Generating set should be installed separately on the same skid in a different enclosure (which need not be acoustic). The connection from the alternator and control panel should be carried out with 3.5 core 120 sq. mm PVC insulated, PVC sheathed armoured copper cable and cable should be terminated with proper size of tinned copper sweating socket and cable glands at alternator and panel end.

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All the terminal boxes/Junction boxes etc, the battery and self starter connection terminals / and its components should be housed inside DGMS approved intrinsically safe enclosure.

23.0 SPECIFICATION OF CONTINUOUS ON LINE GAS MONITORING SYSTEM

Detector / Gas Sensor: Actual No’s of Sensors to be decided based on locations where there is possibilities of gas leakage inside the acoustic enclosure.

Type : IR (Infrared), suitable for detection of NATURAL GAS ( By Volume CH4 : 89.538 %, N2 : 1.004 %, CO2 :0.543 %, C2H6 : 4.132 %, C3H8 : 2.491 %, Others : 2.292 % )

Range: 0 to 100 % LEL Operating Temperature: 0 to 50 Deg C Display: 4 digit LCD Display Alarm Setting: Variable Shut down setting: Variable Control system: Suitable control system to be provided for alarm and safety shut down

of the engine Sensor calibration: Adjustment of Zero & Span on-site Non Intrusive one man

calibration should have facility to calibrate the instrument on spot without disconnecting from power supply by using any portable hand held intrinsically safe calibrator.

Detectors must be suitable for hazardous environment i.e., Zone 1 & Zone 2 hazardous area as per OMR, 1984. Approval for Detectors / Sensors: Valid DGMS approval certificate must be provided

with the offer. 24.0 Enclosure Illumination: A separate circuit shall be provided for lighting of the acoustic part of the enclosure. There shall be only 2 nos. FLP type, Bulk head glass fitting, 160 MLLamp, Material- LM6, 230VAC, 50 HZ, IP-65, Lamp holder Porcelain ES-27, fitted on wall of enclosure with control from non acoustic part of the enclosure. The light fitting shall be certified by CMRI for installation in above hazardous area. 3x2.5 sq mm stranded copper conductor, PVC insulated, PVC sheathed, 100v Grade, heavy duty, approved by IS-1554, Armoured cable and FLP cable glands should be used for wiring purpose inside the acoustic enclosure. Make of Luminaire: Baliga / FCG Light will be switched from one MCB, 6amp, C curve, mounted on control panel cover & have back-up HRC fuse and neutral link of 6 amp rating. Make: Legrand/ Merlin-Gerin for MCB Non Acoustic Enclosure Part: A separate circuit shall be provided for lighting of NON acoustic part of enclosure. Power for the lighting circuit shall be taken from the incoming switch in the control panel through backup HRC fuse & neutral link of 16 Amp rating. Enclosure shall have 2(Two) No’s of 1x40 Watt Tube light luminaries suspended with rigid supports from the roof or wall. These luminaries shall be wired with heavy duty PVC insulated, PVC sheathed, armoured, 3x4 sqmm stranded copper cables.

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Lights should be switched from individual 6 Amp, C curve, MCBs, mounted on the front cover of the control panel. One no. industrial type metallic plug socket of 20 Amp rating with 10 Amp SP MCB for switching shall be provided which shall be mounted on the side of the enclosure and fed from the lighting circuit. Make of Luminaire: Philips/Crompton Make of Metallic plug & socket: Legrand / Merlin Gerin Make of MCB: Legrand / Merlin Gerin. NOTE: 1. Bidders should submit layout drawing of the acoustic enclosure indicating positions of engine, alternator etc along with the wiring diagram of the package and will have to be approved by BGL before execution of the order. 2. Enclosure design should be such that for any major maintenance activities the enclosures from any side can be easily dismantled and re-erected. 3. Generating set comprising of Engine, Alternator, and other auxiliaries should be placed inside an acoustic enclosure (approved by ARAI, Pune/ NPL, New Delhi/ NSTL, Visakapatnam/ FCRI, Palghat / NAL, Bangalore) 25.0 SKID: The skid should be of oilfield type and fabricated from sufficiently strong steel section for carrying the generating set from one place to another from time to time. The engine and alternator should be unitized and mounted on the skid before dispatch. The generator housing shall be one piece and mount directly to the engine flywheel housing without bolted adopter. 26.0 PAINTING: All metal surfaces shall be thoroughly cleaned and degreased. The under surface shall be prepared by applying a coat of phosphate paint and a coat of yellow zinc chromate primer. After preparation of under surface, the panel shall be spray painted with two coats of epoxy based final paint. Panel finish shall be free from imperfections like pin holes orange peels, run off paint etc. 27.0 DATA SHEET FOR ENGINE:

MAKE : MODEL : NUMBER OF CYLINDER : ASPIRATION : COMPRESSION RATIO : SIZE (BORE & STROKE) : DISPLACEMENT : DUTY : GROSS HP AT 1500 RPM : DEDUCTION FOR FAN, ALD & TEMP. : NETT HP AVAILABLE AT 1500 RPM : SPECIFIC FUEL CONSUMPTION :

· 100% LOAD : · 75% LOAD : · 50% LOAD :

LUB OIL CONSUMPTION (LT/HR) :

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ENGINE SUMP CAPACITY : ENGINE RADIATOR : MAKE & TYPE OF GOVERNOR : LENGTH x WIDTH x HEIGHT :

28.0 DATA SHEET FOR ALTERNATOR

Make : Rated Output : Phase : Frequency : No. of Poles : RPM : Rated power factor : Conductor Material : Type : Duty : Class of insulation : Connection : Site Condition : Alternators Internal Protection (Enclosure) : Alternators Terminal Box protection : Cooling : Excitation system : Automatic Voltage Regulation : Permissible voltage variation at rated : Speed and power factor : Voltage swing (transient response) : Permissible Engine Speed variation : Permissible frequency variation at rated : Speed and power factor Period for taking load from start impulse : Motor starting ability : Overload capacity : Unbalanced current carrying capacity : Short circuit current withstand capacity : Over voltage : Mounting : Amplitude of vibration at no load :

29.0 DATA SHEET OF PANEL AND INSTRUMENTS:

1) MAIN SWITCH a) Make b) Rating c) Cat No/ Type

2) MCCB a) Make b) Rating c) Cat No/Type

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3) Earth Leakage Relay a) Make b) Range c) Cat No/Type

4) Voltage Monitoring Relay a) Make b) Range c) Cat No/Type

5) Digital RPM Meter a) Make b) Range c) Cat No.

6) COS a) Make b) Rating c) Cat No