erection and commissioning procedure

Kirloskar Oil Engines Ltd.Large Engines Division

INSTALLATION & COMMISSIONING MANUAL

Chapter-1 Drawing list

LIST OF DRAWINGS FOR PROJECT EXECUTION(MECHANICAL)

SR. NO. DRAWING NO. DESCRIPTION

CIVIL DRAWINGS 1 27.827.11.0.00 POWER HOUSE & EQUIPMENT LAYOUT 2 27.827.16.0.00 DG SET FOUNDATION BLOCK

BASIC DRAWING 3 27.828.90.0.02 BASE FRAME FOR ENGINE AND ALTERNATOR

4 27.815.11.0.00 FLY WHEEL COUPLING ASSLY 5 74.225.40.0.01 LIMIT OF SUPPLY 6 AZ-12832 GA DRG. OF ALTERNATOR7 74.640.20.0.00 COUPLING

HT WATER CIRCUIT8 27.809.21.0.00 HT WATER CIRCUIT SCHEMATIC9 70.660.10.0.00 EXPANSION WATER TANK10 27.706.10.0.00 CHEMICAL MIXING TANK & PUMP

11 27.833.10.0.00 PRE HEATING MODULE 12 27.810.11.0.00 HT WATER RADIATOR

LT WATER CIRCUIT13 27.809.20.0.00 LT WATER CIRCUIT SCHEMATIC14 27.810.12.0.00 LT WATER RADIATOR

FUEL CIRCUIT15 27.809.25.0.00 FUEL CIRCUIT SCHEMATIC16 74.635.10.0.05 GA DRG. OF FUEL DAY TANK 990 LTRS.17 79.824.10.0.00 HSD DRIP TANK WITH PUMP ASSLY.18 27.692.02.0.00 FUEL FILTER COARSE19 74.649.10.0.00 FINE FUEL FILTER

LUBE OIL CIRCUIT20 27.809.22.0.00 LUBE OIL SCHEMATIC21 27.808.10.0.00 LUBE OIL COOLER

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SR. NO. DRAWING NO. DESCRIPTION

COMPRESSED AIR CIRCUIT22 27.809.23.0.00 COMPRESSED AIR CIRCUIT SCHEMATIC23 27.689.10.0.00 COMPRESSED AIR MODULE24 27.812.11.0.00 COMPRESSED AND AIR BOTTLE25 74.632.12.0.00 MOTOR DRIVEN AIR COMPRESSOR26 74.632.11.0.00 ENGINE DRIVEN AIR COMPRESSOR

CHARGE AIR EXHAUST CIRCUIT27 27.809.24.0.00 CHARGE AIR & EXHAUST SYSTEM SCHEMATIC28 27.650.01.0.03 EXHAUST SILENCER

MISCELLANCEOUS29 XI--08074--M04--01CHIMNEY30 27.809.27.0.00 LEGEND AND ABBRIVATION31 74.643.10.0.00 WORKING PLATFORM (L.H.)32 74.643.11.0.00 WORKING PLATFORM (R.H.)

33 UTILITY WATER DISTRIBUTION

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LIST OF DRAWINGS FORPROJECT EXECUTION

(ELECTRICAL)

SR. NO. DRAWING NO. DESCRIPTION1 SINGLE LINE DIAGRAM2 POWER DISTRIBUTION SCHEMATIC OF GCP CUM SYN.3 PLC WIRING SCHEMATIC OF GCP CUM SYN.PANEL4 PLC INPUT/OUTPUT LIST5 SYSTEM ARCHITECTURE OF GCP CUM SYN.PANEL6 AVR TERMINAL7 LOCAL SENSOR STAND8 MOTOR CONTROL CENTRE PANEL9 DG BREAKER10 NEUTRAL GROUND RESISTOR PANEL11 CABEL SCHEDULE12 CABEL INTERCONNECTION DETAILS13 POWER HOUSE EARTHING LAYOUT14 POWER HOUSE CABLE TREY LAYOUT16 DG OPERATION PHILOSPHY17 ALTERNATOR MANUAL WITH TEST CERTIFICATE18 TEST CERTIFICATE OF ALL PANELS

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Chapter 2 - INSTALLATIONTechnical Specifications forInstallation of DG Set Mechanica/Electrical



TECHNICAL SPECIFICATIONS FORINSTALLATION OF DG SET (MECHANICAL)

1. UNLOADING OF MATERIAL (Lifting, Leading & Installation)

We have to use proper tools, adequate manpower & arrangements to unload the materialdepending upon its size and weight to avoid damages.

For Unloading of engine, alternator and auxiliaries etc., should use hooks which are provided onit for handling with crane otherwise we have to use jacks & sleepers with wrench and wire rope.

If crane is used to unload, the capacity of crane should be twice the weight of material

Crane documents should be verified before allowing to work as per RTO.

Slings of crane should be lubricated and joints of the sling should be examined for perfect fitmentwith clamping.

While unloading the crane should be supported by jacks on both ends and tyres should be lockedat both end with some media like sleepers to avoid jerking while unloading.

NOTE : Collect a catalogue from crane manufacturer for more informations.

No material shall be slinged with any components of machineries like motors, pumps, pipesbase frame etc.

No body should step on the components to do any work while unloading, leading or at the time ofinstallation.

For each sq. mtrs. 4 persons are required for handling of material to avoid any damage tomaterial, what ever may be its weight.

All glass parts, instrumentation items, pressure gauges etc. should be handled with care andprecautions to avoid damage, no jerks & drops.

While handling the material top side mark should always be maintained at the top.

NOTE : Enquire the capacity of winch, pulleys used for leading and lifting of materials dependingupon the weight.

2. CHECKING OF LAYOUT.

Civil layout made by customer should be collected from customer and compared with KOELlayout w.r.t. dimensions, if any variation is noticed enquire with Customer.

Locate the direction of power house & co-relate with drawing, than locate foundation blocks ofengine and its auxiliaries as per drawing.

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3. CHECKING OF MATERIAL

Check the material as per packing sheets and also cross check with application code, if there isany shortage / damage, intimate to KOEL Ofiice immediately.

Examine the material for its condition frequently during the course of commissioning.

Inform shortage of material, if any in advance.

Make a chart for weekly material consumption and cross check the plan with every day actualconsumption.

Correctness of material should be checked for weekly plan.

4. PIPING NORMS

Each pipe should clearly shows the direction of flow of liquids with arrows.

If any doubt in pipe size of circuit, clarify with KOEL AE.

5. PIPING SUPPORTS

The pipe must be supported on both side of bend joints, flange joints and Auxiliaries ends within afeet.

In every 4 meters of pipeline there should be a support.

For supports use 50 x 50 x 5 angles or 100 x 50 x 5 C Channel. Use U clamps, washer and nuts forclamping the pipes with angle & channel.

All supports must be painted by BLACK paint, before clamping the pipes.

For clamps of pipes to supports, all holes on supports should be drilled and shall not be done bygas cutting.

All Supports should be horizontal.

At every 5 mtrs. length there must be flange connection except for Fuel.

All flange of pipeline should be minimum 100 mm above the trench floor and supports should be300 mm. above floor level of trench.

The vertical gaps between pipe line supports in double tier should be maintained around 300 mm.

Lower support should be both side welded in trench and above that, only one support of cantile-ver type and only one side of trench with a gap of 400 mm. from opposite side of trench.

NOTE : Ensure that the trenches are water proof before laying pipelines.

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6. WELDING

The angle between the two pieces of pipes to be welded should be chamfered.

The distance between two pipes should be half of the thickness of the pipe, which are to bewelded together.

Before starting the welding clean the edge to be welded thoroughly and make sure edges are dry.use proper flux for proper welding with correct grade of welding rods.

Properly chamfer the edges to be welded.

Remove distance piece used to maintain gap between pipes.

Root weld and brush it by wire brush before doing 2nd round i.e. there is no any red beed.

Capacity of welding machine should be as per the welding rod requirement. Keep all weldingrods packets in a dry container.

If welding rods are wet they should be kept in a oven for drying before use.Do not use sub-standard, damaged or cracked welding rods.

Standard welding rods requirement

Seamless pipe : 6013 - Advani S & 2S or equivalent of reputed make.6010 - Deep penetration rod.7018 - Super therm special

S.S. Pipe S4E 308 - 16 for ss 304 PipeS4E 308L - 16 for ss 304L Pipe

Selection of current of welding motor for different size of rods.

Size of rod Amps2.50 x 350 50 - 703.15 x 350 90 - 1104.00 x 350 110 - 1405.00 x 350 160 - 200

Welding beed should be uniform and @ 1.5 mm, above the surface of pipe. Chipping and wirebrushing should be done to take out slag, flex and burgs of welding.

If pipe size is more than 4’’ use clits in between edges of pipes to be welded to make sure bothpipes are in correct position.

Size of welding rod selection as per thickness of pipes is as below :-

Pipe Size (mm) Root Weld (mm) Main Weld (mm)15 NB 12 10/820 NB 12 10/825 NB 12 840 NB 12/10 8

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50 NB 12/10 865 NB 12/10 880 NB 12/10 8100 NB 12/10 8150 NB 10 8200 NB 10 8460 OD 10 8560 OD 10 8750 OD 10 81000 OD 10 8/6

Fillet welding should be done for the pipe to the flange and pipe to valves.

Gap between pipes and flange face should be minimum 5 mm x 45 Deg.

Pipe should be horizontal or vertical when it is welded with valve.

7. WELDING TEST

Random test of welding joints is to be done by D. P. Test (10%).

8. HYDRO TEST

Pipe should be Hydro tested at following pressure:

Pipe line PressureL. T. Water 10 barH. T. Water 10 barInjector water 10 barFuel 10 barLub Oil 10 barAir 45 bar

(The Hydro test should be carried out by pump which is to be arranged by contractor)

NOTE : The specifications of hand pump required for Hydro test are to be confirmed.

Before Hydro test all pipes should be thoroughly cleaned with wire brush chipping at flange endand by water flushing.

Any leakage found in the Hydro test should be rectified and pipe should be retested for leakage.

Put a air vent at highest point of pipe line while doing Hydrotest which should withstand therequired pressure.

After Hydro test no work should be done on the pipe line like gas cutting, drilling, welding etc.

The pressure should hold, at least for one hour without any leakage.

For exhaust and air intake ducting there is no Hydro test.

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9. ACID CLEANING.

Acid cleaning should be done immediately after Hydro test within 4 hours.

NOTE : For More details refer chapter : Chemical Cleaning Procedures for Pipes.

10. PAINTING.

Preparation of pipe surface before application of paint.

a) Remove all oil on pipe surface with the solvent.b) Removal of dirt, loose rust and loose mill scale with scraper or wire brush.c) Flame cleaning if necessary.d) Clean and dry pipe surface with cloth.e) Ensure pipes are degreased properly.

First apply red oxide or Primer.

After one day apply the 2 coats of paint on pipelines as per following colour codes.

PIPE LINE PAINTING COLOUR CODE

Sr. No. System Colour Colour shade as Per IS 5

1. L.T. Water Sea Green 2172. H.T. Water & French blue 166

Injector Water

3. Lub Oil Golden brown 4144 Fuel Post office red 5385 Air Canary yellow 3096 Exhaust Gas Silicon based heat resistance ----

Aluminium paint (upto 600 deg.C)7 Supports Bituminous Black ----

Note: Do not apply red Oxide on exhaust ducting.

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TECHNICAL SPECIFICATIONS FOR INSTALLATIONOF DG SET (ELECTRICAL)

1. INSPECTIONa) Check whether there is no damage to the panel.b) Check whether all terminal connections and numbering of ferrules are as per cable

schedule.c) Check the continuity of each terminal.d) Check for proper tightness of each connection.e) Check for proper earthing of panels.f) Check / ensure fuses provided are of correct rating.g) If any damage, faulty component found out during testing, inform to KOEL HO and ask for

replacement.h) Check whether all the live connections are properly covered with insulation and earthed.

2. GENERATOR CUM SYNCHRONISING PANELa) Check whether there is no damage to the panel .b) Check / Ensure that output of DC-DC convertor supply to panel is 24 volts.c) Switch on PLC and check / ensure its proper working functions.d) Check the input and outputs of PLC are as per requirements.e) Check all safeties by simulation method.f) Check EFMU for proper working condition by simulation method.g) Check whether there is no drop of voltage observed across hour meter connections while

hooter is on.h) Check starting of lub oil priming pump and preheating module through GCP.i) Check whether lub oil priming pump, water pump and heaters are operating as per logic

i.e. 20 min on and 15 min off. (All the three should run continuously till temp. reaches 50deg. C and then the cycle should start) .

j) Check three attempts start and starting refusal logic functions.k) Check proper operation of start, stop and emergency stop.l) Check the magnetic pickup resistance is more than 500 ohms. (as per requirement.)m) Check whether the over speed safety is operating properly by pressing test push button

on EFMUn) Check / Ensure all temperature scanners, pressure indicators etc. are showing proper

readings.o) Calibrate all pressure gauges, pressure switches and RTD’s installed on GCP & LSS and on all auxiliaries. p) Test each relay, its settings and record the same.q) Check / Ensure operation of breaker through GCP.r) Check whether excitation is not permitted without “ready for excitation” permission from

GCP.

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s) Check the following functions are OK.i) Speed raise / Lowii) Voltage raise / Lowiii) Manual / auto synchronizing.iv) Breaker closing and tripping.v) Indication for all these operations.vi) Check other functions.

3. NGR PANELa) Check whether there is no damage to the panelb) Ensure whether resistance banks are not damaged.c) Check whether required No. and proper ratio of CT’s are available.d) If possible test the ratio of CT’s by injecting primary winding.e) Check whether cables are connected to correct polarity.f) Check for proper termination / insulation of HT cables and ensure that proper type of

cable joint kit is used.g) Measure the resistance of whole bank and ensure that it is as per requirement.

4. BREAKER PANELa) Check whether there is no damage to the panel.b) Rack out the breaker and check that all components are OK.c) Grease the rack and other components, if required.d) Ensure whether breaker can not be operated in “half in position”e) Ensure proper and easy slide of breaker rack.f) Push the rack inside and check that limit switch is operating.g) Check whether auto and manual charging of spring is proper.h) Check whether breaker ON / OFF operation is proper, both by auto and manual method.i) Check for “breaker closed” indication on GCP when it is on.j) Ensure tripping of breaker during fault by simulation.k) Ensure auto closing of breaker by simulation check.

5. MCC PANELa) Check whether there is no damage to the panel .b) Check whether all OLR, Contactors and fuses fitted are of proper range.c) Check whether all switches and contactors are functioning properly.d) Check the interconnection of MCC, ECP and auxiliaries are proper.

6. EARTHING PITS AND EARTHING GRID.a) Check the earthing pit resistance is within limit (Record the same.)b) Ensure the proper connections / joint of each grid. (As per drawing)

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7. ALTERNATOR.a) Megger the windings. ( Record the same.)b) Check the continuity of windings.c) Check whether space heater is working properly.d) Check whether the diodes are OK.e) Check the Lube Oil / Greasing of bearings.f) Check the proper air gap of excitation field if it is a separate unit.g) Check the CT ratio and polarity. (If applicable)h) Check whether RTD’s are properly showing readings.

8.H.T. CABLE

a) Megger the Cable and record the same.b) Take the high potential test.c) Check for proper termination.d) Ensure whwther cable jointing is done by using std. material and correctly.

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Chapter 3 - INSTALLATIONStatutory Rules & Safety Regulations



STATUTORY RULES & SAFETY REGULATIONSThe details of statutory rules and safety regulations are followed for labour work execution

for KOEL’s erection and commissioning contractor at L&T-IOCL,Panipat Sites.

STATUTORY RULES:

01. This being a labour contract, it is obligatory for contractor’s employees under PF/ESI/WC,schemes and make compliance under various statutory acts, by contractor applicable. Itclarified that no reimbursement will be made on account of employer’s share of PF/ESI bythe company.

02. The contractor shall comply promptly with the provisions of contract labour Act and producethe Licence of the Contract Labour Act if the number of labours exceed 19 on any day duringcontract period.

03. The contractor shall bring only those labourers at the work site / premises who have beenissued gate passes / identity cards. the contractor agrees that he shall not retain the gatepasses with the labourers engaged by him to restrict unnecessary entries in the premises.The contractor also agrees to return all gate Passes / identity cards to the company as andwhen contract is over.

04. The contractor will maintain muster roll of his employees engaged in the work site / premisesand update their attendance on day to day basis this should be handedover along with astatement showing the ESI / PF contributions to be recovered from the employees, to KOEL/ Local Labour Officer as and when required.

05. The contractor will pay wages to the labourers as per rate under the minimum Wages Actnotified from time to time by the Govt. Authority.

06. The labourers engaged by the contractor will be his employees and KOEL shall be in no wayresponsible or liable for their payment of wages / salaries, bonus, gratuity and otherallowances, if any.

07. The labourers engaged by the contractor shall abide by all the disciplinary, rules & regulationslaid down by the customer / company / end user from time to time.

08. In the event of any act committed by contractor’s laboures against the interest of the company,the company reserves the right to ask the contractor to remove such labourers withoutgiving notice and contractor is bound to do so.

09. The contractor shall comply with all the rules and regulations under the various Acts applicableto the company. In case he fails to comply with the same and if the company apprehendsany breach thereto his contract is liable for termination fortwith. The company also reservesthe right to withhold the payment of the contractor.

10. The contractor shall ensure the compliance and provisions of the contract labour Act. TheMinimum Wages Act. The payment of Wages Act, The Employees Provident Fund Act, ESIAct, Factories Act, payment of Wages Act. The payment of Gratuity Act and such labourlegislation’s applicable at the relevant time.

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SAFETY REGULATIONS:

01. The company has set some safety rules to be followed by each person to be employed bythe contractor to take care of the safety of the persons, safety of the other people and toensure the safety of company’s properties. These rules are being framed by our safetydepartment and you will follow the same.

02. While working at height all labour must use P.P.E. (Personal Protective Equipments)

03. While working at the height on fragile roofs and other delicate areas special equipmentmust be used as directed by Safety Dept. Also you will take special precautions whileworking at height with open busbars open H. T. Lines etc.

04. You will make use of safety belts wherever required. The healthiness of the safety beltsshould be confirmed.

05. You will bring machines / equipment such as welding machine, drilling machine, gascutting set, rigging equipment, etc. of proper specifications and safety features. Machines/ equipments without safety features will not be permitted for use.

06. While carrying out welding / gas cutting or any other fire hazardous works, ensure thatsite is made clear of such materials which can cause fire hazard.

07. You will depute your supervisor at site to supervise your workers. No work will be permittedin the absence of your supervisor.

08. You will carry out work against this from 9.00 am to 5.00 pm and weekly work basis. Workafter 5.00 pm or on holidays should be carried out only after getting special permission,depending on the works you are working.

09. Workers possessing trade certificate for electrician should only allow to work on liveelectrical supply systems. The workers deputed by the contractor, as helper should carryout only the labour work and strictly under the supervision of contractor’s supervisor.

10. While carrying out work you will make proper provisions to take care of the safety andcompany’s machinery / property. Whenever required you will do the work after providingsuitable barricades / covers. Whenever carrying work, which is likely to lead harm toother persons, you will see that suitable sign / caution boards are displayed.

11. Whenever working in combined space you will obtained permission from safety department

12. Whenever working near LT / HT cables prior permission / clearance of concerned electricalmaintenance department should be taken.

13. All safety rules and codes as applicable to work must be followed without anyexception.

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14. All personal protective equipments (safety bolts, hand gloves, aprons, helmets, safetyshoes, safety belts, shields, goggles etc.) must be used while working at site.

15. The company may from time to time add, delete, modify or change any rule as and whenrequired.

CONTRACTORS OBLIGATIONS / LIABILITIES:

Above rules and regulations are to followed to take care of safety of persons employedby you, Other people working in the company and company’s property. These rules are to befollowed strictly and wherever in doubt you will clarify with us for the same. Any work carriedout without following above rules and regulations will be considered as illegal. The contractorshall identify the company at all times against all claims for compensation under the provisionof any law for the time being in force by or in respect of any labours employed by him incarrying out the contract and against all costs and expenditure incurred by the company inconnection therewith.

It will be contractor’s responsibility to settle all legal deals of his labourers on theirtermination and will hand over the copy of the receipt obtained from the concerned labour, infull and final settlement of the claims of whatsoever nature, to the company. In case if anylabour engaged by the contractor raises any demand after his termination or after making fulland final settlement by the contractor during the currency or after the expiry of the contract, thecontractor shall settle the same and no liability will rest upon the company.

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Chapter 4 - INSTALLATIONTools for Installation of DG Set



LIST OF TOOLS REQUIRED FORINSTALLATION OF DG SET

SR. NO. DESCRIPTION QTYA . TOOLS FOR UNLOADING AND SHIFTING OF DG SET

AND AUXILIARIES1 MECHANICAL SCREW JACK 20 TON 4 NOS2 MECHANICAL SCREW JACK 10 TON 2 NOS3 SLING / STEEL ROPE / NYLONE ROPE AS REQD4 WOODEN SLEEPER Min. 50 NOS5 CHAIN PULLEY BLOCK 20 TON 2 NOS6 CHAIN PULLEY BLOCK 5 TON 1 NO7 TARPAULIN / PLASTIC SHEET TO PROTECT EQUIPMENTS AS REQD

B GENERAL TOOLS1 DOUBLE ENDED OPEN SPANNER (10 TO 41 MM) 1 SET2 DOUBLE ENDED RING SPANNER (10 TO 32 MM) 1 SET3 BOX SPANNER 10 TO 30 MM (1/2’’ DRIVE) 1 EACH4 BOX SPANNER 30,32,36,41,46,50 & 55 MM (3/4’’ DRIVE) 1 EACH5 BOX SPANNER 60 & 65 MM (1’’ DRIVE) 1 EACH6 EXTENSION BAR 6’’ & 12’’ LONG (1/2’’ DRIVE) 1 EACH7 TOMMY BAR (1/2’’ DRIVE) 1 NO8 RATCHET (1/2’’ DRIVE) 1 NO9 EXTENSION BAR 8” & 16” LONG (3/4’’ DRIVE) 1 EACH10 TOMMY BAR (3/4’’ DRIVE) 1 NO11 RATCHET (3/4’’ DRIVE) 1 NO12 REDUCER (1.0” X 3/4’’ ) 1 NO13 REDUCER (3/4’’ X 1.0” ) 1 NO14 ALLEN KEY SET 2 MM TO 19 MM 1 EACH15 SCREW DRIVER HEAVY DUTY 2 DIFFERENT SIZE 1 EACH16 ADJUSTABLE SPANNER 8.0’’ & 12.0’’ 1 EACH17 CUTTING PLIER 8” 1 NO18 NOSE PLIER 8’’ 1 NO19 CIRCLIP PLIER 8.0” LONG (INTERNAL) 1 NO20 CIRCLIP PLIER 8.0” LONG (EXTERNAL) 1 NO21 TAP SET 10,12,16,18,20,& 24 MM 1 EACH22 TAP SET WRENCH 1 NO23 PIPE WRENCH 12”,18” & 24 “ 1 EACH24 FILE ROUGH (ROUND, HALF ROUND & FLAT) 12” LONG 1 EACH25 FILE SMOOTH (ROUND, HALF ROUND & FLAT) 12” LONG 1 EACH26 BENCH VICE (HEAVY DUTY) 1 NO27 HAMMER (SMALL & BIG) 1 EACH28 CHISEL 6” & 8” 1 EACH29 HOLE PUNCH 16,18,20,& 24 MM 1 EACH30 MALLET / PLASTIC BAR / PLASTIC HAMMER 1 NO

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31 TIN CUTTER 12” LONG 1 NO32 SINGLE ENDED OPEN SPANNER 46,50,55,60,&65 MM 1 EACH33 FLAT RING SPANNER 60 & 65 MM 1 EACH34 8 MM PIPE BENDING MACHINE FOR PR GAUGES ETC. 1 NO35 CLEANING TRAYS 2 DIFFERENT SIZE 1 EACH

C TOOLS FOR WELDING & CUTTING1 WELDING TRANSFORMER (ONLY FOR TAG WELDING) 1 NO2 WELDING RECTIFIER ROTATING 200 AMPS (FINAL WELDING) 2 NOS3 WELDING HELMET / SCREEN 3 NOS4 WELDING BRUSH, HAMMER & CHISEL 3 EACH5 RIGHT ANGLE 12” LONG 2 NOS6 GAS CUTTING TORCH WITH EXTRA NOZZLE 1 SET7 FLEX HOSE AND REGULATOR FOR SR. NO. 6 1 SET8 SPANNER FOR GAS CYLINDER 2 NOS9 ELECTRICAL ANGLE GRINDER 4.0” WHEEL DIA 2 NOS10 ELECTRICAL ANGLE GRINDER 6.0” WHEEL DIA 2 NOS11 MEASUREMENT TAPE STEEL 3 MTRS 3 NOS12 MEASUREMENT TAPE 15 MTRS 1 NOS13 WATER LEVEL MAGNETIC BASE 12” LONG 3 NOS14 6/8 MM DIA PLASTIC TUBE 20 MTRS15 25 MM DIA PLASTIC TUBE 25 MTRS16 NEEDLE PLUM 100 GM WEIGHT 3 NOS17 HACK SAW FRAME WITH BLADE 12” 2 NOS18 CENTRE PUNCH 6” LONG 1 NOS19 CHAIN PULLEY BLOCK 5 & 10 TON 1 EACH20 SLING / WIRE ROPE / ENDLESS ROPE (DIFFERENT SIZES) AS REQD21 NYLONE ROPE 1/2” AND 1.0 “ DIA 20 MTRS.22 D SHAKLES DIFFERENT SIZE AS REQD23 CROW BAR 1.0 MTR LONG 2 NOS.24 ELECTRICAL MOTOR DRIVEN PIPE LINE CUTTER WITH 1 NO

WHEEL 10 TO 12” DIA25 DRILL MACHINE WITH DRILL BITS 1 SETD PRECISION TOOLS1 DIGITAL VERNIER CALIPER (0 TO 300 MM) 1 NO2 MICRO METER OUT SIDE (0 TO 25 MM) 1 NO3 DAIL GAUGE (0.01 MM) 0 TO 10 MM TRAVEL 2 NOS4 MAGNETIC BASE FOR DAIL GAUGE 2 NOS5 STEEL SCALE 0 TO 1.0 MTRS 1 NO6 FEELER GAUGE MM (100 MM BLADE LENGTH) 1 SET7 SMALL MIRROR FOR DEFLECTION AND ALIGNMENT WORK 1 NO8 TORCH WITH CELL 1 NO9 MASTER LEVEL GAUGE 6” LONG 0.025 MM/ MTR ACCURACY 1 NO10 REAMER SET (REFER COUPLING DETAILS) 1 SET

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E TOOLS FOR HYDRO TESTING AND ACID PICKLING1 HYDRAULIC PRESSURE TESTING PUMP WITH CORRECT 1 NO

END CONNECTION AND FLEX HOSE (CAPACITY 50 BAR)2 PRESSURE GAUGE FOR HYDRO TESTING PUMP UP TO 60 BAR 1 NO3 ACID PICKLING PUMP 5.0 HP / 3.5 KW 1 NO4 ACID PICKLING TANK (CAN BE FABRICATED AT SITE) 150 LTRS 1 NO5 CHEMICALS FOR PICKLING, NEUTRALISING & PASSIVATION AS REQD

F CONSUMABLES FOR INSTALLATION (MECH)1 GRINDING WHEELS FOR 4.0” GRINDER AS REQD2 GRINDING WHEELS FOR 6.0” GRINDER AS REQD3 HACK SAW BLADES AS REQD4 GLASS FOR WELDING HELMET (WHITE) AS REQD5 GLASS FOR WELDING HELMET (BLACK) AS REQD6 WELDING BRUSH AS REQD7 WELDING RODS 2.5,3.25,4.0,5 & 6 MM (ADVANI OERLICON / ESAB) AS REQD8 LINE DORI 20 MTRS9 CHALK / PENCIL (WHITE COLOUR) AS REQD10 TEFLON TAPE AS REQD11 EMERY PAPER ROUGH 60 TO 100 NUMBER AS REQD12 EMERY PAPER MEDIUM 300 TO 400 NUMBER AS REQD13 EMERY PAPER FINE 600 NUMBER AS REQD14 GRINDING PASTE (ROUGH AND FINE BOTH) AS REQD15 EMERY STONE / HONING STICK 10 X10 X100 AS REQD16 ORDINARY GREASE AS REQD17 HAND GLOVES (CLOTH, PLASTIC & ASBESTOS ETC.) AS REQD18 M SEAL, ARALDITE & FEVIQUICK AS REQD19 CTC, PETROL & HSD FOR CLEANING AS REQD20 CLEANING CLOTH, MARKING CLOTH & BANIAN CLOTH ETC. AS REQD21 CLEANING BRUSH AS REQD22 CELLO TAPE, PERMANENT MARKER AS REQD23 SPONGE AS REQD24 RUSTOLIN AS REQD

G ELECTRICAL TOOLS1 MEGGER 500 AND 1000 V 1 NO2 TONG TESTER 0 TO 200 AMPS DIGITAL 1 NO3 MULTIMETER (DIGITAL WITH FREQ. MEASUREMENT UPTO 4 KHz) 1 NO4 LINE TESTER 2 NOS5 INSULATION PLIER 2 NOS6 SCREW DRIVER SET 1 NO7 WIRE STRIPPER 2 NOS8 CRIMPING TOOL FOR INSULATED AND NON INSULATED 1 NO

LUGS UPTO 70 SQ.MM

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9 EXTENSION BOARD WITH 15 AMPS & 5 AMPS, 5 PIN SOCKETS/ 3 NOSSWITCHES

10 SERIES LAMP 1 NO11 SOLDERING IRON, WIRE AND FLUX 1 SET12 EARTH RESISTANCE TESTER 1 NO13 ELECTRICAL HAND DRILL MACHINE UPTO 15 MM BIT 1 NO14 ELECT. DRILL MACHINE WITH MAGNETIC BASE UPTO 30 MM 1 NO15 HAND LAMP WITH GUARD AND 20 MTRS CORD 1 NO16 NUMBER AND LETTER PUNCH 1 EACH17 BLADE / CUTTER AS REQD18 IMMERSION HEATER 1 NO19 BLOWER 1 NO20 RELAY TESTING KIT 1 SET21 SET OF SPANNERS FOR DOING ALL ELECTRICAL WORK 1 SET22 PHASE SEQUENCE INDICATOR 1 NO

H CONSUMABLES FOR INSTALLATION (ELECTRICAL)1 INSULATION TAPE RED, YELLOW, BLUE & BLACK AS REQD2 BINDING TAPE AND BUTTONS (BLACK) AS REQD3 ELECTRICAL HAND GLOVES AS REQD4 CTC AS REQD5 ALUMINIUM TAGS (FOR CABLE NUMBERING) AS REQD6 CLAMPS FOR CABLE FIXING IN TRAYS AS REQD7 BITUMEN PAINT AS REQD8 FERRULES NOS 0 TO 9 T TYPE 2.5 SQ.MM AS REQD9 FERRULES NOS A TO Z T TYPE 2.5 SQ.MM AS REQD

4.4

Chapter 5 - PROCEDUREGrouting Procedure



Document no.-27.400.85.0.00

TECHNICAL NOTEGROUTING PROCEDURE

INTRODUCTION

During installation of DG set on the foundation block, grouting is carried out in order.a) To minimize heat build up on foundation block.b) To assure precise and unsurpassed contact with baseframe.c) To provide a high coefficient of friction to help maintain DG set alignment which

further reduces possible bearing or crank shaft alternator rotor damage.

Generally powdered FOSROCK GP2 is used as grouting compound which is mixed withwater along with coarse aggregates or pea gravel of size 6sq.mm. down to obtain freeflowing grout. ** Aggregates to be used only for pockets.

1) PREPARATION OF GROUT

In order to obtain optimum physical properties with grouts, precise mixing and curing ofgrout is necessary.

A) MATERIAL AND EQUIPMENT REQUIRED FOR PREPARATION OF GROUT

- FOSROCK GP2 of sufficient quantity.- Crushed aggregates or pea gravels of size 6 sq.mm. down to sufficient quantity.- A 220 lits. drum for stocking water - 4 Nos.- Buckets to carry mixed grout - 6 Nos.- Concrete mixer - tilting drum type - 2 Nos.- A water can measuring 4.5 lits. capacity.- A pan with dry FOSROCK GP2 in case of leaks.- Water bath curing compound - 2 Nos.- Hammer, Chisels, nails etc.- Wire Brush.- Sufficient length of MS plates.- Masonry tools like pan, trowel etc.

B) MIXING OF GROUT- The quantity of grout required is estimated by using the following thumb rule.

Weight of FOSROCK GP2 required = 2 x vol. of grouting space.- Place about 80% of the water required per batch inside the mixer.- Add bag by bag FOSROCK GP2 with mixer running.- Add balance about 20% water.- Add the crushed aggregates or pea gravel about 50% by wt. of FOSROCK GP2.- Mix for 5 minutes.- Unload into buckets for transporting and placing.

B.1) PRECAUTIONARY MEASURES TO BE TAKEN DURING MIXING- Do not mix anything else like sand, cement etc. to the grout.- Do not pour more that 4.3 liters of water per bag of FOSROCK GP2 for grouting pockets

and 4.5 liters. for plain grouting.- Mixed grout should be consumed within 20 minutes after mixing.

5.1




- If the ambient temperature is very high (above 40 deg.C) and humidity also is low, thegrout tends to lose moisture fast and thus fluidity is reduced. Under such circumstances,mixed grout may have to be consumed immediately after mixing.

B.2) CHECKS TO BE FOLLOWED BEFORE MIXING- Ensure the FOSROCK GP2 used is well protected from moisture and no damages have

occurred.- No Vibrators are used as a means of mixing.

2) PLACING OVER OF GROUT

C) CHECKS TO BE FOLLOWED BEFORE GROUTING

- The top surface of foundation block is plane and rigid.- The top surface of foundation and bottom surface of baseframe should be free from oil,

grease and debris.The foundation block is soaked with water for about 24 hours.

- Ensure lowering of baseframe and anchor bolts in position.- Sole plates (Reqd. if any in relation to alignment) are well levelled.- Shuttering around the sole plates with MS angle or wooden block is done.

D) GROUTING PROCEDURE- Grout the sole plates individually upto half their thicknesses.- Use mixed grout for the space in between sole plates and space around the sole plates.- Continue to grout bay after bay in both the sole plates.

E) CHECKS TO BE FOLLOWED DURING GROUTING- Pouring of grout should be continuous and from one side to avoid voids.- Check for leaks. The leakages can be avoided by applying dry FOSROCK GP2.

F) CURING OF GROUT- After 4 hours of grouting the grout becomes hard so water curing is carried out. Curing

period should be minimum 6 d

5.2




PREPARATION OF FOUNDATION BLOCK

A surcharge of 15 mm concrete is provided on the top surface of foundation block.The block surface shall be gently chipped off. There should not be any peak exceeding10 mm. The top surface of block shall be perfectly cleaned after chipping.Mark the location of chokes (MS Block) on the foundation block just below the jackingbolt location.The bearing area near the chokes to be flattened to the size 250 mm (L) x 150 mm (w).Surface shall be cleaned again.Position the chokes such that length of each block gets equally divided at the centre ofjacking hole. Chokes should be longitudinally parallel to the foundation block.The foundation block and pockets shall be soaked with water for about 24 hrs.Remove all remaining water from the pockets.Place all the foundation bolts in the pockets.Place the baseframe on minimum 200 mm height wooden sleepers and align all baseframe mounting holes with pocket centres.Clean the alternator mounting pads on the baseframe. Place the alternator on the baseframe. Loosely connect the mounting bolts with alternator.Clean baseplate bottom so that it is free from oil, debris etc. Insert foundation bolts frombottom in the baseframe. Assemble nut and washer with foundation bolt. Ensure that boltprojection is about 20 mm above nut top surface.Ensure all bolts are laying straight in the pockets. The foundation bolt should not remaininclined in the pocket.Lower the baseframe (with engine mounted on it) slowly on the choke plates and ensurethat it rests firmly on all the chokes. While lowering the base frame make sure thatadjacent jacking screws are equally loaded and foundation bolts are in perfect position.Carry out the leveling of baseframe with water level tube and level bottle. The baseframeshould be leveled within 2 mm of water level.

Note : Engine is mounted on the baseframe.

PARTIAL GROUTING OF FOUNDATION BOLTRefer specification No. 27.400.85.0.00 for preparation of grouting material andprocedure.Fill 3/4th portion of pockets by slowly pouring the mixed grout. Ensure that there is no airpocket or cavity (voids) in the pocket after poring of grout.After 4 hrs. of grouting the grout becomes hard, water curing is therefore necessary forminimum 6 days.Carry out leveling checks once again before final grouting.Carry out shuttering around the baseframe with MS angle or wooden plate.Fill remaining 1/4th portion of the pocket with mixed grout.Use pure GP2 cement for grouting the space between bottom of baseplate andfoundation block top surface. Grouting will be done such that GP2 cement is filledsurrounding the baseplate and foundation block top surface. About 150 mm wide layersurrounding the baseplate and 3/4th thickness of bottom plate of baseplate in height will

5.3




be filled up with GP2 cement. Grouting should be continuous and from one side to avoidvoids.Check for leaks. The leakage can be avoided by applying dry FOSROCK GP2.After 4 hrs of grouting the grout becomes hard therefore water curing has to be carriedout. Curing period should be minimum 6 days.During curing period, meanwhile remove shuttering and carry out cementing of portionbetween baseplate and edge of foundation block on all four sides. Provide suitable slopetowards the edge of foundation block.

TORQUING OF FOUNDATION BOLTSAfter 6 days of grouting carry out torquing as per sequence given below.

1) First apply 10 kgm torque on centrally located foundation bolt on both sides.2) Continue applying torque 10 kgm on foundation bolts starting from centrally located bolt

towards engine and alternator and simultaneously on both sides.3) Repeat procedure by increasing torque value by 10 kgm in each step till final torquing of

95 kgm is achieved.

5.4

Chapter 6 - PROCEDUREAlignment Procedure



RELATIVE POSITION OF THE SHAFTS IN THE HORIZONTAL PLANE

The measurements show that :

A axis is more at right than B one by = 9

in the plane of dial gauge C1.

B axis is more at right than A one by = 47

in the plane of dial gauge C2

Then the relative position of the shafts is as follows :

The experience shows that some erectors prefer to realize an intermediary sketch giving therelative position of the traces of the axis A and B in the planes C1 and C2 before carrying out therepresentation of the axis in the vertical plane and the horizontal plane.

With this operation the operators can probably better “figure out the axis in the space”, this inter-pretation can be considered as good as the one explained in this note.

Plane C1 Plane C2

9

axis Baxis A

47

104 - 86 2

164 - 70 2

6.3

Chapter 7- PROCEDUREChemical Cleaning Procedure for Pipe Line

INSTALLATION & COMMISSIONING MANUAL Kirloskar Oil Engines Ltd.Large Engines Division

CHEMICAL CLEANING PROCEDURE FOR PIPES

[Chemical Cleaning of the associated piping of DG set subsystem ( Material of constructioncarbon steel - seamless Tube ASTM A 106)]

1. LOOP FORMATIONThe various pipes are joined together by means of mating flanges and flexible hoses and formedinto a closed loop system alongwith the chemical circulation pump and tank.

2. PREFLUSHThe system is filled with water and leak tested, it is then continuously flushed with water into thedrain gutter. All high points if any are to be vented regularly till system is completely filled.

3. DEGREASINGThe objective of degreasing is to remove all the dirt, loose rust and mill scale so as to provide anactive surface for acidic solvent treatment.

The degreasing solvent to be used is proprietary formulation of an Alkali alongwith a Non lonicWetting Agent.

The degreasing is to be carried out for a period of 2 hrs. at a temp. of 40 Deg. C and flow velocityof 0.2 m/s.

4. FLUSHINGUse service water to flush the system till pH is neutral.

5. ACIDIC SOLVENT TREATMENTThe objective of acidic solvent treatment HCL 50% (strength 30%) + 50% water is to remove allthe rust, mill scale, welding slag and other oxide deposits. The circulation is to be carried out fora period 1-2 hrs. with help of acid circulation pump at flow velocity of 0.3 m/s.During the circula-tion hammer the pipe loop at regular interval so that welding slag,mill scale get removed.

6. DRAINING & FLUSHINGThe acidic solvent is drained and the system is flushed completely till pH is neutral.

7. ORGANIC ACID RINSEThe step involves the circulation of an ammoniated organic acid (10% Caustic Soda + Water)having an alkaline pH to remove all residual matter and neutralize the acid solvent.

The circulation of this is to be carried out for a period for 1 hr. at ambient temperature.

7.1

Chapter 7- PROCEDUREChemical Cleaning Procedure for Pipe Line

INSTALLATION & COMMISSIONING MANUAL Kirloskar Oil Engines Ltd.Large Engines Division

8. DRAINING & FLUSHINGThe solution is to be drained completely and flushed till pH is neutral.

9. PASSIVATIONThe objective of passivation is to form a protective film on the freshly cleaned surfaces. Thepassivating solution with a sodium nitrite base is circulated for 4 hrs. at ambient temp. The systemis drained and inspected.

The above procedure is carried out prior to system start up for the purpose of removing millscale, corrosion and other deposits. The operation provides a thin, uniform protective coating ofiron oxide and removes the loose material that might cause damage to systems down stream ofpiping.

7.2

Chapter 8 - KOEL’S RECOMMENDATIONSNote on Water Quality & Recommendation



QUALITY OF WATER REQUIRED TO PA6 ENGINES

The raw water available for a cooling tower, could contain following characteristics :

Hardness < 2500 mg / litAlkalimetric Content (TAC) < 400 ppmSilicon < 100 mg / litSuspended Matter < 20 mg / litChlorine < 300 mg / litSulphates < 600 ppmCa Concentration Product < 15000 (F)2

Although chemicals are available to condition such water quality, our experience in the pasthave shown that the problems occurs due to scaling / fouling and corrosion in the raw watersystem These problems occurred either due to incorrect treatment, or bad monitoring. Basedon past experience, KOEL essentially recommends softened water for use on raw watercircuit for PA6 engines, with cooling tower applications.

The softened water will have the following characteristics :

pH > 6Total hardness < 5 ppmAlkalimetic content (TAC) < 400 ppmSalinity strength < 300 ppmSuspended Matters < 20 ppm

Please note that it is impossible to one treatment procedure for water at all sites. Werecommend a pre-survey by water treatment experts from M/s Nalco or M/s Ion Exchange fortheir recommendations or economical conditioning of water.

Si suspended matter concentration, Ca concentration Chlorides + Sulphates will be decidedTOS etc. case to case basis on joint consultation with engine manufacturer & water treatmentexperts.

A comprehensive TIN will be prepared on the above subject.

Please note, the softened water outlet must be checked periodically and regularly to ascertainthe correctness of regeneration frequency.

Use of Nalco / Ion Exchange chemicals must not be avoided to use of softener.

H. T. Water :KOEL essentially recommends the use of DM water for H.T. water circuit with Nalco /Ion Exchange chemicals.

RE / RAVI / KH -1 / 5516Date : 05/06/1999

8.1




Please note DM water being corrosive in nature must not be used without chemicals in H.T.water circuit as this will cause corrosion

Before commissioning of DG set, the DM water with chemicals must be kept available soas to ensure their use of correct water quality and chemicals from first instance itself.

Also ensure availability of softened water for L.T. Circuit and suitable chemicals during startof set. Ensure the availability of the expert from the chemical supplying company (Nalco /Ion Exchange) to stabilize the water chemistry and recommend correct final dosage ofchemicals.

Maintain a log book of essential water parameters as suggested by the expert on the site.

8.2




LT , HT COOLING WATERUnsuitable water, results in scaling, pitting or corrosion. Use of very soft water should notdispense with water treatment, since water absorbs Carbon - di - Oxide which renders itcorrosive.

LT WATER SYSTEM :LT WATER system can either be.

1) Closed2) Half Open (for Stationary Plants)3) Open : With waste water and sea water. Necessary steps to be taken to avoid

corrosion, Scaling & to eliminate seaweeds & bacteria.

In open system, precautions to be taken are as follows:

1) A suction strainer should be provided and maintained in clean condition.2) Piping should be reduced so that flow rate should be maintained to avoid

temperature raise above 40 oC in order to avoid salt deposition.3) For application with sea water, pipes, Lub oil cooler and charge air cooler to be

waterproof ex. Bronze, Cupro-Nickel.

Temperature deviation between system inlet and outlet should range from 10 to 12oC at fullload.

REQUIRED WATER PROPERTIES :1) Hardness : Total hydrodynamic hardness should be minimum. Water can be

softened by using Soda.2) pH should be more than 63) Chlorine ion content should be minimum (below 100 mg/ lit)4) Salinity should be less than 200 mg / lit5) Water should be clean at filling. If required can be cleaned by adding chemicals,

further rinsing is necessary since these chemicals are acid.

NECESSITY OF WATER TREATMENT1) To avoid chemical & electrochemical corrosion from different metals which requires

basicity (pH) level to be maintained between 7.5 to 9.2) To avoid scale, liable to reduce wall heat conductivity.

TYPES OF TREATMENT

1) CHROMATE:Sodium & Potassium Chromate provides protection on Iron. Their efficiency of antiscaling

protection can be increased by addition of organic compounds. For Aluminium and coppersince, it is not compatible, it can be gained by adding Borate compound.

TIN/COOL/VMK/001-00Date : 14/04/1998

8.3




When Chromate drops below 0.5 gm/lit, it becomes dangerous. They are then capable oforiginating corrosive reaction, chromate level recommended 2.5 to 3 gm/lit. Chromate doesnot deteriorate with time.

2) BORATE - NITRITE:Mixture of sodium Borates & Nitrites with addition of organic compounds ensure efficient

antiscaling action and corrosion resistance for ferrous material. But Nitrites in alone attackon welding therefore other components like borate - benzoates are added. 3 to 5 gm / litnitric contain is recommended. Nitrite are toxic from absorption of 4 gm of pure nitrite salts.

Requirements of Additives :

1) It must prevent corrosion2) It must prevent precipitation of scaling salts.3) It should be soluble in water4) It must be compatible with anti - freeze.5) It must have suitable pH range . (Stabilising 7.5 to 9)

ENGINE REQUIREMENT DATA :

1) FOR HSD

HT cooling water temperature at engine outlet 80 to 85 oC - for non pressurised circuitHT cooling water temperature at engine outlet 95 to 100 oC - for pressurised circuitLT cooling water temperature at air cooler inlet 25 to 35 oC.

2) FOR HFO(applicable only for HFO 0

HT cooling water temperatureFor 0 to 60% MCR : Normal temperature 90 to 95 oCFor 60 to 100% MCR : Normal temperature 80 to 85 oC

LT cooling water temperatureFor 100 to 40% MCR : Normal temperature 40 to 45 oCFor 40 to 15% MCR : Normal temperature 60 to 70 oC

Injector Water Cooling : Injector Inlet temperature : 80 to 85 oCInjector Outlet Pressure : Normal 250 Kpa.

QUANTITY OF WATER IN ENGINE (lit)

No. Of Cylinders 6 8 9 12 16 18

Quantity of Water (Lit) 260 340 370 520 670 750

Nominal Recommended flow rate : 7.5 m3 / hr / cyl

8.4




A) LOW TEMPERATURE WATER FOR HT WATER COOLING AND LUBE OIL COOLING

SR PROPERTY SPEC.NO.

1. pH 7.5 to 7.82. Total hardness (ppm) 300 max3. Alkalinity (ppm) 50-1504. TSS (NTU) 25 max5. Silica (ppm) 150 max6. Chlorides (ppm) 100 max7. Iron (ppm) 3.0 max8. TDS (ppm) 1000 max

B) HIGH TEMPERATURE WATER


1. pH 7.1 to 7.82. Nitrite level (ppm) 1000-1200

C) DEMINERALISED WATER

1. Conductivity (ms / cm) 30 max2. Total Hardness (ppm) Nil3. Si O2 (ppm) 0.5 max

4. pH 8 - 9

RECOMMENDED WATER QUALITY

8.5




E) INCOMING WATER FOR CPP


1. Total hardness (ppm) 180 max2. Total Alkaline content (ppm) 400 max3. Suspended solids (ppm) 20 max4. pH 6.5 to 8.55. Chlorides, Phosphates & Sulphates (ppm) 300 max (Total)6. Chlorides (ppm) 100 max7. Turbidity (NTU) 25 max.

8.6

3 - 1

Chapter 9- KOEL’S RECOMMENDATIONSNote on Lub Oil Quality & Recommendation



LUBRICATING OIL FOR PA-6 ENGINESHigh speed diesel engine of our range needs specially tailored lub oil, catering to following

conditions:1) High firing pressure2) Mean Piston Speed3) High combustion temperature

The above factors results in high stress on mechanical components and lubricating oil

SEMT Pielstick has an elaborate approval procedure of lubricating oil for their engines. Afterthrough tests on chemical and physical characteristics of lubricating oil. It is subjected to rigerouson field trials, before a certain lubricating oil brand is approved for a specific engine series.

IMPORTANT CHARACTERISTICS OF LUBRICATING OIL :A) VISCOSITY :

To avoid metal to metal contact, it is mandatory to have stable and sufficient thick oil filmbetween cylinder liner and piston ring. Oil from this region is high temperature thereby lowerviscosity than when entering in the engine. The viscosity index expressing the temperaturedependent of the viscosity is of importance to protect engine components.Lubricating oil viscosity has been chosen as being defined by SAE 40 grade that is between 12.5to 16.3 cSt at 100 Deg C. In this range, correct lubricating oil film and flow will be made throughengine.

If the viscosity changes, film thickness and flow will trend towards the values which can bedangerous to the engine.

CAUSE OF DROP IN VISCOSITY :a) Diesel dilution coming from pump leakage (HSD)b) Unburnt diesel in fuel chamber.c) Leakages through injection pump.

CAUSE OF RAISE IN VISCOSITY :a) Oxidation,b) Presence of insolublesc) Raw Fuel Dilution

Alarm Limit : 2/3 SAE grade Variation (18%)Rejection Limit : One grade of SAE (25% variation of viscosity)B) TOTAL BASE NO (TBN) :This value defines the resistance value of lub oil against the corrosion (Mainly sulphuric, generatedfrom Sulphur in Fuel)

9.1

TIN No. : TIN/LO/VMK/001/00Date : 19/06/1999

3 - 2




Other than Sulphur, Other engine running condition have an effect on this value. A too coldwater will lead to temperature on liner walls lower than dew point of Sulphuric Acid.

CAUSE OF DROP IN TBN1) High Sulphur Content2) Bad Adjustment of HT water Circuit3) Precipitation of additives due to water presence.

LIMITS FOR TBN FOR LUB OIL :

Fuel Gas Oil Gas Oil Distillates Interediates HFO% Sulphur < 0.1 < 1 < 1.8 0.3 - 1.8 1.8 - 3.0 3 - 4 < 5Mn TBN 5 10 16 16 20 20 25 - 28

To keep cold corrosion rate low, neutralisation capacity of lub oil must be sufficiently high. ThereforeTBN 40 oil is recommended for HFO Operation.

C) WATER CONTENT :Presence of water in lub oil is the risk of major break down of engine. The water elimination

will be made by centrifuges adjusted as purifier.

Normal water content : 0.1 %Alarm Limit : 0.2 %Rejection Limit : 0.5 %

In case of excessive wear, the water content, TBN & lub oil additives must be controlled. (LubOil additives trend is to react with water and disappear with it)

CAUSES OF WATER CONTENT IN LUB OIL :a) Condensation of crankcase wall in humid and tropical zones.b) Engine Leakagesc) Leakages in lub oil coolerd) Bad running of centrifuge.

D) FLASH POINT :It is the temperature at which mist and product are ignited with a flame- hot point (In

case of engines) like cylinder and crankshaft or by flame generated by blowby owing to badtightness of rings.

Flash point for new oil : 235 to 240 Deg CAlarm Level : 50 Deg C less than new oils flash point (Higher than 190 Deg C)Rejection Limit : 150 Deg C risk of self ignition and bursting of crankcase.

9.2

3 - 3




E) DETERGENCY / DISPERSANCY :Oil has to keep clean the liners, pistons, piston Rings, and ring grooves from the

combustion products, This property is called as high temperature detergency.

After lubricating the piston and liner, oil returns to sump during which it cleans crankcase wallsconnecting rods, Crankshafts. This effect is known as low temperature detergency.

DISPERSANCY : Ability of oil to maintain in suspension all particles and unburnt componentspicked by oil in piston, liners etc. All the impurities must be transported to the purifier wheremost are removed. Dispersancy determined by visual inspection and automatic analysis of aspot.

These values allow to define if the lub oil is still capable to clean and maintain the material insuspension.

F) ANTIWEAR AND EXTREME PRESSURE:Whenever the oil film gets interrupted from or in insufficient quantity, the tribological

characteristics have to be supported by antiwear and extreme pressure additives to reduceabrasive and adhesive wear.

G) THERMAL STABILITY :Oil is exposed to long period of high temperature. Adequate thermal stability is therefore

vital.

H) OXIDATION STABILITY :Oxidation stability is required to prevent oxidation of oil due to high temperature and

oxygen surplus in blow by gases and trapped air.

I) LUBRICITY :Lubricant must be capable of covering surfaces to be protected. Therefore good

spreadablity and reliability cohesion to the mettalic surfaces are required.

J) ALKALINITY :The property permits the oil to react against corrosive wear by neutralising acidic

combustion products from fuel sulphur.

K) COMPATIBILITY WITH HEAVY FUEL :The lubricating oil and fuel should be compatible at prevailing temperature. Otherwise

plunger sticking by deposit formation in fuel pump initiated by asphanates drop out from fuelmay take place.

9.3

3 - 4




L ) ANTIFOAMING :Oil circulation in engine is continuous. During the circulation, air gets mixed with oil

intensively. Antifoaming capacity of lubricating oil should be high otherwise which is dangerousfor bearing.

FUNCTION OF LUBRICATING OIL.1) Lubrication2) Cooling3) Anticorrosion4) Antiwear

LUBRICATION SYSTEMI) BEARING LUBRICATION

Between crankshaft journal and bearing there must be an oil film of a defined thickness.By considering engine characteristics and temperature requirements, viscosity grade shouldbe selected and specified viscosity grade shall be used.

The oil is circulated in crankshaft to reach big end bearing of connecting rod. Here theoil film has to provide an oil film to resist the impact resulting from combustion pressure onpiston head.

The oil passes towards small end (through connecting rod holes) bearing of gudgeonpin where again oil film is required. A important task of lubricating oil is to cool the bearings(removing frictional heat)

II) PISTON COOLINGAfter gudgeon pin, oil enters in the interior as a coolant medium (cooling the piston

head). For this oil must have good resistance against deterioration at high temperature whichis known as ‘Oxidation Stability’.

III) OUR LUB OIL CONSUMPTION :Recommended lub oil consumption is 0.8 to 1.2 gm / kwh. optimisation of Piston ring

set, piston clearance, liner temperature and its ability to retain the shape and liner surface areprerequisites of lub oil consumption, this rate includes losses in separators / filters.

Oil change is required when lub oil consumption gets decreased. reduced oilconsumption results in stress on oil, as oil volume will be replenished to lesser degrees byfresh oil. Therefore will require frequent oil changes. It could also indicate a trend of externalcontamination etc. (Fuel dilution into lub oil or water contamination in lub oil through improper

9.4

3 - 5




centrifuge settings.)

LUB OIL PARAMETERS RECOMMENDED DURING THE ENGINE RUNNINGCONDITION :

Oil temperature at engine inlet : 59 to 61 oCFiltering : 30 µm max. and is being changed to 20 µm through main filter Glacier

for HSD and Alfa - Laval centrifuge for HFOFlow Rate : 5 m3 / Hr - for L engines

10 m3 / Hr - for V engines

VOLUME OF LUB OIL IN THE SUMP (Wet Sump)For PA6 L and PA6 V st. engines (running on HSD)No. of cylinders 6 8 9 12 16 18Max level (Lit) 660 860 960 920 1200 1340Min Level (Lit) 560 730 810 770 1000 1115Flow rate through 75 75 75 100 110 120oil pumps m3 / Hr

PE-LUBRICATION PUMP PRESSURE: 6 bar for engine and motor driven pump

Volume of lub oil in the sump of PA6V CL Engine : 7,600 Lit (Engine running on HFO withexternal / dry sump)Volume of lub oil in the sump of PA6L CL Engine : 4,200 Lit (Engine running on HFO withexternal / dry sump)

VOLUME OF LUB OIL IN THE SUMP (Wet Sump)For PA6 L CL and PA6V CL engines (running on HSD)No. of cylinders 6 8 9 12 16 18Max level (Lit) 700 910 1020 1500 1980 2200Min Level (Lit) 600 780 880 1350 1780 1980

Engine Inlet pressure : 6 to 6.5 barEngine outlet temperature : 73 oC

9.5

Chapter 10- ELECTRICAL SYSTEM Kirloskar Oil Engines Ltd.

Large Engines Division


CONTROL PANELS

Following control panels are suppliedalong with the DG set.

Generator Control Panel (GCP)

Local Sensor Stand (LSS)

Motor Control Centers (MCC)

Neutral Grounding Resistor (NGR)

Breaker Panel.

GENERATOR CUM SYNCHRONISING PANEL

Function

Synchronization, Protection, Controland Monitoring of DG SET.

FeaturesSuitable for Auto/Manual operation.

Major Components

Programmable Logic Controller.Operator Terminal (Panel View).Protection Relay.Power Meters i.e. KW, KVA, PF, A,V etc.Engine RPM Meter.Turbo charger RPM Meter.Excitation Voltmeter and Ammeter.Engine Frequency Monitoring Unit.Turbo. Frequency Monitoring Unit.Push Buttons and Selector Switches .

PROGRAMMABLE LOGIC CONTROLLER

Major ItemsCentral Processing Unit.Power Supply.Digital Input Modules.Digital Output Modules.RTD Modules .

10.1




Thermocouple Modules .Analog (4-20mA) Modules.Panel View ( HMI ).

Functions of the PLC.

Monitoring of the operating parameters.Operation logic execution.Auto synchronization and load sharing.

STARTING INTERLOCK

Manual mode

Fuel Control Handle should be unlocked.Turning Gear to be disengaged.Level of Water Expansion Tank should be more than low level.Starting Air Pressure should be more than 16 bar.No Safety Stop should be operated.DG Breaker should be in off condition.Lube Oil Priming pressure should be more than 0.5 bar.Engine should not be in running condition.

Auto mode

HT Water Engine Inlet Temp. should be more than 40 Deg.

PRE HEATING AND PRIMING MOUDLE

Ability of an engine to take the load rapidly after a standstill period depends essentially on theambient conditions.More precisely on HT water and Lube oil temperature at the time of starting.DG set is equipped with “Pre Heating and Priming” module, which maintains a reduced flow ofHT water and lube oil in the engine.This equipment allows maintaining water temp. between 40 to 50 deg. in the cylinders andcylinder heads, decreasing the lube oil viscosity and thus avoid the over pressure on starting,ensures an adequate lubrication of all the moving components.Power supply to this module is fed from alternate supply source.

MODE OF OPERATION

There are three modes to start the DG set.

Auto mode :

Start of the engine shall be through AMF operation.Engine will be start after checking the following condition.Under voltage relays on GCP/Customer panel senses the bus supply.In AMF mode, these Under voltage relays will give command for starting the DG set.

10.2




MANUAL MODE-

In Manual mode Starting of Engine, Closingof the DG Breaker manual.Closing of breaker may be Either dead bus orlive bus.

In case of live bus of closing DG Breaker canbe momentary paralleled With either of normalincomer.In this Engine starting can only be done Afterchecking all necessary process Permissive.

TEST MODE-

In Test mode operation is similar to AUTOoperationGrid supply fail signal is given to PLC by simulation.

ALTERNATORBasic Operating Principle

Exciting current Ie(dc current from AVR)flows through exciter Stator.

It induces emf in exciter rotor(3 Ph).Then It is rectified by rotating diode and field current flowsthrough main rotor winding.

The flux due to this current induces an alternating emf in main stator winding.

GENERATOR PROTECTION RELAY

Combined numerical relayFunction

REM 543 of ABB make is used for following abnormal protection conditions

-Differential-Under Voltage-Over Voltage-Under Frequency-Over Frequency-Earth Fault-Over Current etc.-Reverse Power.-Breaker trip command and Engine Stop command will execute through GPR under the aboveabnormal conditions.

10.3




AUTO SYNCHRONISATION RELAY

Function

To check following conditions for paralleloperation

FREQUENCY DIFF. WITHIN SET LIMITVOLATAGE DIFF WITHIN SET LIMIT.PHASE ANGLE DIFF. WITHIN SET LIMIT

If all above conditions are fulfilled it givesClosing command to the circuit breaker ofWhich is to be synchronized.

GOVERNOR CONTROL UNIT

Function

To control Speed/frequency of the prime mover (Engine).

AUTOMATIC VOLTAGE REGULATOR

Function :

To regulate the alternator voltage.

Operation of AVR

AVR senses the voltage signal Um from main stator and adjusts the field Current Ie, as perthe set value to regulate the stator voltage.

FREQUENCY MOINTERING UNIT

FUNCTION

Monitoring the speed of engine.It receives following inputs,24V DC supply.Magnetic RPM pickup input from pickup fitted on the Fly wheel of engineIt gives following outputs,RPM>170 (PF output) Threshold 1.RPM>300 (PF output) Threshold 2.RPM>550 (PF output) Threshold 3.RPM>700 (PF output) Threshold 4.RPM>840 (PF output) Engine over speed.Fault (PF output) Speed Sensing Failure.

10.4




Following indications are used,Thresholds i.e. TH1 to TH4, Over speed .In working order – In healthy condition, this indication should be always present. If thisindication is not there, either RPM pickup input has failed or connection to the over speedsolenoid on compressed air module is loose or broken.

Following controls are possible,

Test –This facility is to be used only when engine is in stopped condition. By pressing this button,engine RPM meter will reach up to 1000RPM and over speed solenoid valve on the airmodule is operated.

Half speed test –This facility is used to check OSPD safety when engine is running at speed of 840/2=420RPM. Bring speed about 400 RPM and press ‘Half Speed Test’ button. Slowly startincreasing the speed. When indication on RPM meter will cross 840 (actual engine speed420), OSPD safety should be operate as mentioned above.After operating above tests or in case over speed condition are rectified, press reset pushbutton.In case Engine over speed safety operates, with pressing reset button. Engine cannot bestarted again.EFMU also gives 4-20 mA output corresponding to engine speed. This output is connectedto engine RPM meter on ECP, engine RPM meter on LSS and to 4-20 mA input module ofPLC.

THERMOCOUPLE

Engine is equipped with temperature sensors, to show the temperature of exhaust gas fromthe respective cylinder heads and the temperature of turbo charger. The thermocouple isused as a sensor.

The thermocouple operates on the principle of Seebeck effect, “when two dissimilar metals/alloys are joined together to form a closed circuit and the two junctions are held at differenttemperatures, then a voltage is generated. This voltage is due to the temperature differencebetween the two junction”. The voltage generated is proportional to temperature.

The range of temperature measurement is from room temperature to 600 Deg. C, for alltypes of engines. Considering the temperature ranges & other factors like,

We uses K-type thermocouple as a sensor for exhaust gas temperature and turbo chargertemperature measurement. the typical range of K-type temperature sensor is -150 Deg. C.to 1400 Deg. C.

TEMPERATURE SENSOR RTD-PT100

10.5




DG Set is equipped with temperature sensor, to show the temperature lub oil, fuel oil, LTwater, HT water temperature, charge air cooler inlet and outlet temperature etc.

The resistance temperature detector (RTD) PT 100 is used as a sensor. The RTDoperates on the principle of change in the electrical resistance of a conductor takes placewhen there is change in temperature. The PT 100 is a positive temperaturecoefficient type RTD, means when temperature increases the resistance of theconductor also increases. The output of the PT 100 is resistance, corresponding totemperature. The PT 100 sensor consist of 3 wires at the output. At 0 deg its resistance is100 ohm,the resistance increases by 4 ohm for every increase by 10 deg.

MAGNETIC PICK UP( SPEED SENSOR )

The magnetic pickup is used to detect the speed of the prime mover. Engine FrequencyMonitoring Unit (EFMU) which is mounted in the GCP is needed to convert thepickup’s output signal to one usable by the governor amplifier. The magnetic pickupwill produce a voltage output , when any magnetic material moves through themagnetic field. Most engines have flywheels or other large gears made up ofmagnetic material ( usually iron or steel). Magnetic pickups can usually be installedwithout adding attachments to a gear or shaft. Non-magnetic materials, such asaluminum, brass and some stainless, will not excite the magnetic pickup. Anydevice which produces a dynamic discontinuity of magnetic material in the field of thepickup will produce an electrical voltage.

LOCAL SENSOR STAND

FunctionMonitoring of pressure parameters.

Features

Located near DG set for easy monitoringRemote control of engine possible.

Major ComponentsPressure Gauges.Pressure Transmitters.Push Buttons.Indicating Lamps.

10.6




INDICATIONS1. HT water Pressure 0-6 Bar (pump outlet)

2. LT water Pressure 0-6 Bar (pump outlet)

3. Lub oil Pressure 0-10 Bar (engine inlet)

4. Injector Water Pressure 0- 6 Bar

5. Fuel Pressure 0-10 Bar (engine inlet)

6. Engine Speed 0-1000 RPM

7. Local control Lamp

8. Remote control Lamp

9. Engine start permission Lamp

10. Engine trip Lamp

Switches

1) Low lube oil priming pressure switchAlarm & Start interlock

2) Low/ Very low lube oil pressure switch Alarm/Stop

3) Low HT water pressure Alarm

4) Low LT water pressure Alarm

5) Low fuel pressure switch Alarm

6) Turbocharger lube oil inlet pressure Low Alarm

MCC PANEL

Provide the supply to the auxiliaries

1. LT RADIATOR.2. HT RADIATOR.3. EMD COMPRESSOR.4. L.OIL PRIMING PUMP.5. DRIP TRANSFER PUMP.6. TURNING GEAR.7. PREHEATING HEATER.8. CHEMICAL MIXING PUMP.

10.7




BREAKER PANEL FUNCTION

Vacuum circuit breaker is used to deliver the generated output power to the consumer. MAJOR COMPONENTS VCB trolley rated for 13.1 KA. Metering / Protection CT’s and PT’s Meters, indicators

METERING DEVICE Ammeter with selector switch Voltmeter with selector switch

INDICATIONS VCB ON VCB OFF Auto trip Spring charged CONTROLS POSSIBLE Local / Remote control selection

VCB ON/OFF

10.8


Chapter 11- ELECTRICAL SYSTEMThermocouple / RTD Calibration Chat


Date :

THERMOCOUPLE CALIBRATION REPORT FORMAT

Standard Observed ReadingSr.No

Reading

Temp. oC mV. Output Temp oC mV.Output01 0 oC 002 30 oC 1.203 50 oC 2.0204 75 oC 3.05805 100 oC 4.106 150 oC 6.1407 200 oC 8.1408 300 oC 12.2109 400 oC 16.410 500 oC 20.6411 600 oC 24.9

REMARK :

11.1




TEMPERATURE V/S OUTPUTCHARACTERISTICS OF K- TYPE THERMOCOUPLE

Sr.No Temperature (oC) Output (mV)

01 - 150 - 4.92102 - 100 - 3.55303 - 50 - 1.88904 - 25 - 0.36805 0 006 10 0.39707 20 0.79808 30 1.20309 40 1.61110 50 2.02211 60 2.43612 70 2.85013 80 3.26614 90 3.68115 100 4.09516 120 4.91917 140 5.73318 160 6.53919 180 7.33820 200 8.13721 250 10.15122 300 12.20723 350 14.29224 400 16.39525 500 20.64026 600 24.90227 700 29.12828 800 33.27729 900 37.32530 1000 41.26931 1100 45.10832 1200 48.828

NOTE : Add Ambient Temperature.

11.2




TEMPERATURE V/S OUTPUTCHARACTERISTICS OF RTD PT - 100

Sr.No Temperature (oC) Output (ohm)

01 - 150 39.7102 - 100 60.2503 - 50 80.3104 - 25 90.1305 0 100.0006 10 103.9007 20 107.7908 30 111.6709 40 115.5410 50 119.4011 60 123.2412 70 127.0713 80 130.8914 90 134.7015 100 138.5016 120 146.0617 140 153.5818 160 161.0419 180 168.4620 200 175.8421 250 194.0722 300 212.0223 350 229.6724 400 247.0425 500 280.9026 600 313.5927 700 345.13

11.3



CHAPTER-12 HANDING OVER

COMMISSIONING REPORTS

ENGINE DETAILS

Engine Make :Engine Modle :Engine Sr. No. :Year of Mfg. :Speed / MHP :Firing order :Lube oil :Fuel :Direction of Rotation :

ALTERNATOR DETAILSMake :Type :Sr.No.KW :K.V.A :Voltage :Current :Speed :Duty :AVR :Year of Mfg. :Frequency :Power factor :Excitation Voltage :Excitation Current :Insulation Class :Grease type :

DE Bearing NDE Bearing

Type : Type :

KIRLOSKAR OIL ENGINES LTD. Large Engines Division

4 MW EMERGENCY DG SET COMMISSIONING REPORTSProject :PANIPAT NAPHTHA CRACKER PROJECT CAPTIVE POWER PLANTFormat No. : KOEL/L&T/EPCC-4/6556/Engine-Alter details/01

Format No. : KOEL/L&T/EPCC-4/6556/DG Base frame levelling/01

mm 0 Reference set

mm mm

mm mm

mm mm

KOEL L&T EIL

Sign:

Name:

ENGINE

ALTERNATOR

Priming Pump SideGovernor Side

Phase side NGR Side

Remarks - DG Baseframe levelling done with water tube column and reading found within limit

DG SET BASE FRAME LEVELLING


4 MW EMERGENCY DG SET COMMISSIONING REPORTProject : PANIPAT NAPHTHA CRACKER PROJECT CAPTIVE POWER PLANT

Date :

Engine No.- Alternator No.-

( B ) ( D ) ( F ) ( H )GOV SIDE LOP SIDE GOV SIDE LOP SIDE

Gauge Position

If DV OR DH IS -VE PLOT BELOW ENGINE AXIS.

LOP Side

DV DHC2 C2

KOEL L&T EILSIGN.:

NAME:

DATE:

DIAL ON ENGINE ( C1 ) DIAL ON ALTERNATOR (C2)

C1 Down C1 GOV Side

UP

Engine Axis Engine Axis

DH=F-H/2DV=C-A/ 2 DV=A-C/2DH=D-B/2 DH=B-D/2

DV=E-G/2

If Dial on Inner of C li

If Dial on Inner side of Flywheel

If Dial on outer side of Flyheel

CALCULATIONSC 1 C1

BOTTOM SIDE

(Indicator is 1/100 of millimeter )

A

D H

B FC G

EGauge PositionDial on Engine

C2

ENGINE AND ALTERNATOR ALIGNMENT

TOP SIDE TOP SIDE500 ( A ) ( E )

( C ) 500 ( G )BOTTOM SIDE


4 MW EMERGENCY DG SET COMMISSIONING REPORTSProject : PANIPAT NAPTHA CRACKER PROJECT CAPTIVE POWER PLANT

DATE-Format No. :KOEL/L&T/EPCC-4/6554/DG Alignment/01

Dial on Alternator

Format No. :KOEL/L&T/EPCC-4/6554/Web deflection/01


Coupled / Uncoupled

1 Gauge on balance weight2 Insure dial when plunger seeezess reading

increases3 Read the reading on dial( Bold & Big)

(Upper scale reading )4 1 Unit =0.01mm

Gov. Side C

1 2 3 4 5 6 7 8ABCDE

DV=[A+E/2-C]/100DH=B-D

INSTRUMENTS USED ( TYPE,MAKE,SL.NO.):

KOEL L& T EILSign :

Name :

Date:Page 1 of 1



Date :

CRANKSHAFT WEB DEFLECTION MEASUREMENT

A E

B D

LOP Side

Guage Position Cylinder No.

Format No :KOEL/L&T/EPCC-4/6554/Shim report/01 Date :


A B C D

KOEL L&T EIL

SIGN.:

NAME:

DATE:

Page 1 of 1



DG SHIM REPORT

Lube Oil Priming Pump Side

B C

Drive End side Non Drive side

A D

Governor side

Position

Shim thickness in mm

Torquing on bolts

SR.NO.1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16 Acid Water Air

17 Acid Water Air

18 Acid Water Air

19 Acid Water Air

20 Acid Water Air

Note: Confirm the Torque Values as per Drawing.


4 MW EMERGENCY DG SET COMMISSIONING REPORT

Project : PANIPAT NAPTHA CRACKER PROJECT CAPTIVE POWER PLANTFormat No. :KOEL/L&T/EPCC-4/6554/Check points/01 Date :

INSTALLATION AND COMMISSIONING CHECK POINTS

DESCRIPTIONS VALUEBase Frame to Foundation Bolts (Torque). 95 Kg.M

Base Frame to Alternator Bolts (Torque). 95 Kg.M

Base Frame to Engine Bolts (Torque). 50 Kg.M

Flywheel to Coupling Bolts (Torque). 95 Kg.M

Coupling to Alternator Bolts (Free )(Torque). 10 Kg.M + 360 Rotation

Coupling to Alternator Bolts (Dowel )(Torque). 10 Kg.M + 320 Rotation

Number punching on Coupling Bolts. Yes

Distance between Fly Wheel Face and Hub. mm

Distance between Coupling flange and Hub after spacer mm

Expansion Bellow Free gap mm

Balance Water Tank fitted at Height of mtrs.

Radiator outlet at the Height of mtrs.

Daily service Fuel tank at the Height of mtrs.

Engine Base Frame Levelling Done With Water Coulmn

Base Frame Leveling Position ok

Lub Oil Pipes cleaned with

HT Water Pipes cleaned with

LT Water Pipes cleaned with

Fuel Pipes cleaned with

Compressed Air Pipes cleaned with

LOCATION: DESIGNATION:

MAKE : TEST PRESS. :

Sr.No. : CAPACITY :

MAX. WORKING PRESS. : TESTED DATE :

Sr.No Remarks12345678

REMARKS:-

KOEL L&T EIL

SIGN.:

NAME:

DATE

Ensure right level of installation as per Approved Drg.



Project : PANIPAT NAPTHA CRACKER PROJECT CAPTIVE POWER PLANTFormat No. :KOEL/L&T/EPCC-4/6554/AIR RECIVER/01 Date :

AIR RECIVER

Installation as per Drawing

Check Points

Tight partial to secure the equipment to the foundation bolts.Ensure right name plate exist as per Approved Drg. Fittment of all gauges and instrument as per the drawing.Fittment of safety valve as per the drawing. Ensure vents and drain provided is not fouling with the foundation.

Any physical damage observed.

LOCATION:


Sr.No. : CAPACITY :

MAX. WORKING PRESS. :


910

REMARKS:-

KOEL L&T EIL

SIGN.:

NAME:

DATE

Ensure vents and drain provided is not fouling with the foundation.

Pressure test cooler element ( if applicable )Check fan louvers operation,adjust if applicable

Tight partial to secure the equipment to the foundation bolts.Ensure right name plate exist as per Approved Drg. Fan assembly alignmedCheck fan pitch angle,adjust if necessary and check blade tip clearance.

Check PointsAny physical damage observed. Installation as per DrawingEnsure right level of installation as per Approved Drg.

INSTALLATION OF LT WATER RADIATOR



Project : PANIPAT NAPTHA CRACKER PROJECT CAPTIVE POWER PLANTFormat No. :KOEL/L&T/EPCC-4/6554/LT WATER RADIATOR/01 Date :

MAKE :

Sr.No. :


8

9

10

11

12

13

141516

REMARKS:-KOEL L&T

SIGN.:

NAME:

DATE

INSTALLATION OF AIR COMPRESSOR



Project : PANIPAT NAPTHA CRACKER PROJECT CAPTIVE POWER PLANTFormat No. :KOEL/L&T/EPCC-4/6554/Compressor/01 Date :


Time setting for auto draining.

Tight partial to secure the equipment to the foundation bolts.Ensure right name plate exist as per Approved Drg. Fittment of all gauges and instrument as per the drawing.Fittment of safety valve as per the drawing.

Ensure direction of Motor.

Ensure safety valves for excess pressure by manually lifting and auto lifiting.

Ensure pressure switch for cutson/off power supply for desired pressure.Ensure time requried for filling air bottle.


Check Oil level and correct oil grade.

Check compressor rotates freely by hand and no Mechanical obstruction.

Check all electrical connection for tightness.

LOCATION:


Sr.No. : CAPACITY :

MAX. WORKING PRESS. :


910

REMARKS:-

KOEL L&T EIL

SIGN.:

NAME:

DATE


Pressure test cooler element ( if applicable )Check fan louvers operation,adjust if applicable

Tight partial to secure the equipment to the foundation bolts.Ensure right name plate exist as per Approved Drg. Fan assembly alignmedCheck fan pitch angle,adjust if necessary and check blade tip clearance.


INSTALLATION OF HT WATER RADIATOR



Project : PANIPAT NAPTHA CRACKER PROJECT CAPTIVE POWER PLANTFormat No. :KOEL/L&T/EPCC-4/6554/HT WATER RADIATOR/01 Date :

LOCATION:

MAKE : TESTED DATE :

Sr.No. :

Inlet - Outlet :

Volume V :

Design Pressure PS :

Design Temperature TS :

Test Pressure PT :

Sr.No. Remarks123

4

56

789

KOEL L&T EILSIGN.:

NAME:

DATE:


4MW EMERGENCY DG SET COMMISSIONING REPORTProject : PANIPAT NAPTHA CRACKER PROJECT CAPTIVE POWER PLANT Format No. : KOEL/L&T/EPCC-4/6554/LOC/01 Date

DESIGNATION:

Check PointsAny physical damage observed.

LUBE OIL COOLER (LOC)

Verify plate withdrawal space is adequate and unobstructed.Ensure Proper alignment of Piping and proper Torque tightening of bolts.Installation of all instruments.( Rtd,Thermometer).Check operation of Butterfly Valves.

Ensure right level of installation as per Approved Drg. Ensure Tightness of the equipment to the foundation bolts.

Ensure right name plate exist as per Approved Drg. Ensure all the cripping bolts of PHE are properly protect against rust.

Format No. : KOEL/L&T/EPCC-4/6556/Pipe hydro Test/01

CIRCUIT NAME : DRG.NO :-SYSTEM PRESSURE : TEST PRESSURE : Bar

REMARKS

KOEL L&T EILSIGN:

NAME :

DATE :

DURATION RESULTSr.No. PIPE LINE NO. FROM TO SIZE(MM/NB ) WORKING PRESSURE

TEST PRESSURE



PIPES HYDRO TEST REPORT

Format No. :: KOEL/L&T/EPCC-4/6556/Pipes Cleaning/01

CIRCUIT NAME :

DRG.NO.

Sr.No Pipe Size

Acid Solvent

Treatment ( Min.)

Organic Acid Rinse(Caustic soda+Water) (

Min.)

Flushing with

Water ( Min.)

Remarks

KOEL L&T EIL

Sign:

Name:


4EMERGENCY DG SET COMMISSIONING REPORTProject : PANIPAT NAPHTHA CRACKER PROJECT CAPTIVE POWER PLANT

Date :

PIPELINE CHEMICAL CLEANING REPORT

Line from Line to

Format No. : KOEL/L&T/EPCC-4/6556/Powerl cable Test/01

RY YB BR RE YE BE

INSTRUMENTS USED ( TYPE,MAKE,SL.NO.): ( Megger, tong tester, multimeter)

MeggerMake- Sr.No.Rating

KOEL L&T EILSIGN :

NAME :

Length Mtr IR in Megaohms M ΩSr.No. Cable Tag No. Cable Type Cable size



POWER CABLE TEST REPORT

Cable Type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

REMARKS:KOEL L&T EIL

SIGN

NAME


4 MW EMERGENCY DG SET COMMISSIONING REPORTProject : PANIPAT NAPHTHA CRACKER PROJECT CAPTIVE POWER PLANT Format No. : KOEL/L&T/EPCC-4/6556/Control cable Test/01

Sr.No. Cable Tag No. Cable size LengthIR IN -

M Ohm

Contunity check (core)

CONTROL CABLE TEST REPORT

CABLE SIZE :

TO :

Megger Tong tester Make- Make- Sr.No. Sr.No.Rating Rating

KOEL L&T EIL

HIGH VOLTAGE TEST

BETWEEN VOLTAGE APPLIED LEAKAGE CURRENT MEASURED

RED-YELLOW YELLOW-BLUE

Date:

RED-EARTH

INSULATION TEST BEFORE HV TEST WITH 5000VOLT MEGGER

FROM :

3C X 300 Sq. mm XLPE 11 KV GRADE

RED ( Y & B EARTH )

YELLOW ( B & R EARTH )

BLUE ( R & Y EARTH )

NAME :

SIGN :

INSULATION TEST AFTER HV TEST WITH 5000VOLT MEGGER

RED-EARTH YELLOW-EARTH BLUE-EARTH

RED-YELLOW YELLOW-BLUE BLUE-RED

BLUE-RED

YELLOW-EARTH BLUE-EARTH

PROPER PHASE CONNECTION :COUNTINITY CHECK : OK

ANY PHYSICAL DAMAGE :OKNO


COMMISSIONIG CHECKS FOR HT CABLE

KIRLOSKAR OIL ENGINES LIMITED Large Engines Division

4 MW EMERGENCY DG SET COMMISSIONING REPORTProject : PANIPAT NAPHTHA CRACKER PROJECT CAPTIVE POWER PLANT Format No. : KOEL/L&T/EPCC-4/6556/HT Cable/01

REMARKS : Cable is Healthy

LOCATION: GUAGE DESIGNATION:

MAKE : PRESURE SETTING. :

Sr.No. : RANGE:

TEST

REMARK

Details of Testing Instruments Used:

1. Pressure Pump:

2. Master Pressure Gauge :

KOEL L&T EIL

SIGN.:

NAME:

DATE



Project : PANIPAT NAPTHA CRACKER PROJECT CAPTIVE POWER PLANTFormat No. :KOEL/L&T/EPCC-4/6554/Pressure gauge/01 Date :

CALIBRATION / TEST REPORT OF PRESSURE GAUGE

SR.NO Observation / Reading (In Kg/cm2) RESULTMaster Pressure Gauge Testing Pressure Gauge

LOCATION: SWITCH DESIGNATION :

MAKE : PRESURE SETTING. :

Sr.No. : RANGE:

TEST

REMARK

Details of Testing Instruments Used:

1. Pressure Pump:

2. Master Pressure Gauge :

KOEL L&T EIL

SIGN.:

NAME:

DATE

CALIBRATION / TEST REPORT OF PRESSURE SWITCH



Project : PANIPAT NAPTHA CRACKER PROJECT CAPTIVE POWER PLANTFormat No. :KOEL/L&T/EPCC-4/6554/Pressure switch/01 Date :

Testing Pressure switch Operated at

Observation / Reading (In Kg/cm2)SR.NOMaster Pressure Pump Pressure

RESULT

Format No.:KOEL/L&T/EPCC-4/6556/Safety Checks/01

ALTERNATOR SR. No.:

Sr.No. SAFETY DESCRIPTION CONDITION SAFETY STATUS REMARK

1.0 GENERAL1.1 Turning Gear engaged Limit switch pressed Start interlock1.2 Speed Sensing Failure Speed signal not available Trip

1.3 Engine Over SpeedEngine rpm > 840 ( Simulation with EFMU 1/2 SPEED test )

Trip

1.4 Fuel control Handle locked Limit switch pressed Start interlock2.0 LUBE OIL CIRCUIT2.1 Low lube oil priming pressure Pressure P<0.5 Bar,RPM<170 Start interlock2.2 Low lube oil pressure Pressure P<4.5 Bar,RPM>700 Alarm2.3 Very low lube oil pressure Pressure P<3.5 Bar,RPM>700 Trip2.4 Very low lube oil pressure Pressure P<2.5 Bar,RPM>170 Trip2.5 Low T/C lub oil pressure Pressure P<1 Bar,RPM>170 Alarm2.6 High lub oil temperature Temp T>65 Deg. C Alarm2.7 Very high lub oil temperature Temp T<70 Deg. C Trip3.0 HT WATER CIRCUIT3.1 HT Water Engine inlet pressure low Pressre P<1.5 Bar, RPM>170 Alarm3.2 Low level in balance water tank ……… Alarm3.3 Very low level in balance water tank ……… Trip3.4 HT water Engine outlet temp. High Temp T > 90 Deg. C Alarm3.5 HT water Engine outlet temp. Very High Temp T > 95 Deg. C Trip4.0 LT WATER CIRCUIT4.1 LT water Engine inlet pressure low Pressure P < 1.5 Bar, RPM >170 Alarm5.0 FUEL OIL CIRCUIT5.1 Fuel oil pressure low Pressure P < 1.5 Bar, RPM >170 Alarm6.0 AIR CIRCIUT6.1 Control Air pressure low Pressure P < 7 Bar Alarm6.2 Starting air pressure low Pressure P < 16 Bar Start interlock7.0 ELECTRICAL CHECKS7.1 Emergency Stop - Local ( LSS ) By pressing Emergency switch Trip7.2 Emergency Stop - Remote ( GCP ) By pressing Emergency switch Trip7.3 Alternature fault From REM 543 Protection relay Alarm7.4 Alternator fault trip From REM 543 Protection relay Trip7.5 Alternator winding temperatur High Temp T > 110 Deg. C Alarm7.6 Alternator winding temperatur Very High Temp T > 120 Deg. C Trip7.7 Alternator Bearing temperature High Temp T > 85 Deg. C Alarm7.8 Alternator Bearing temperature Very High Temp T > 90 Deg. C Trip7.9 PLC Failure DC Supply failed Trip7.10 Breaker Close / Trip operation From TNC Status

KOEL L&T EILSIGN.:

NAME:

SAFETY CHECKS ENGINE SR. NO. :

KIRLOSKAR OIL ENGINES LIMITED LARGE ENGINE DIVISION

4 MW EMERGENCY DG SET COMMISSIONING REPORTPROJECT:PANIPAT NAPHTHA CRACKER PROJECT CAPTIVE POWER PLANT

Date:

LOCATION:

PANEL Sr. No.: MAKE:

TESTING DETAILS

DIMENSIONAL CHECK

A.PHASE REMARKS

SET OBS.RYB

B.PHASE REMARKS

SET OBS.RYB

C.CB TRIP SIGNAL

ENGINE SHUT

REMARKS

SET Observed SET Observed

Format No. : KOEL/L&T/EPCC-4/6556/GCP TEST REPORT/01 Date :

51 N ( Earth Fault ) CURRENT ( Amps.) Time Delay

51V ( Voltage Controlled Over Current ) CURRENT ( Amps.) Time Delay

Calculated ObsCB TRIP SIGNAL

ENGINE SHUT DOWN SIGNAL

CURRENT ( Amps.) CB TRIP SIGNAL

VISUAL CHECKS

LAYOUT AND BILL OF MATERAIL CHECK

REMARKSTEST RESULTS

87 DIFFERNTIAL

INSULATION RESISTANCE CHECKS WITH 500V MEGGERBETWEEN ALL CIRCUITS AND EARTH FOR 1 MINUTE.(All electronic, microprocessor based components

FUNCTIONAL / OPERATIONAL TESTS

WIRING / CONTINUTY TEST


4 MW EMERGENCY DG SET COMMISSIONING REPORTProject :PANIPAT NAPHTHA CRACKER PROJECT CAPTIVE POWER PLANT

GENERATOR CONTROL PANEL

DRG. NO.:

Generator Protection Relay, Make – ABB, Type- REM-543

D.REMARKS


E.REMARKS


F.

PHASE

CB TRIP SIGNAL


REMARKS

SET Observed SET ObservedRYB

G.REMARKS


H.REMARKS


I.CB TRIP SIGNAL


REMARKS


81O ( Over Frequency )

FREQUENCY Time Delay

FREQUENCY Time Delay CB TRIP SIGNAL

32 ( Reverse Power ) VALUE OF POWER Time Delay CB TRIP SIGNAL

81U ( Under Frequency )

59 ( Over Voltage )

VOLTAGE ( Amps.) Time Delay

46 NEGATIVE PHASE SEQUENCENEGATIVE SEQ.CURRENT

( A) Time Delay CB TRIP SIGNAL

NEGATIVE SEQ.CURRENT Time Delay CB TRIP SIGNAL27 ( Under Voltage )

REMARKS

REMARKEngine RPM meter Turbocharger RPM meter 1Turbocharger RPM meter 2

Hooter, Buzzer & Flasher

INSTRUMENTS USED ( TYPE,MAKE,SL.NO.):

Make- Make- Sr.No. Sr.No.Rating Rating

KOEL L&T EILSIGN.:

NAME:

DATE:

CONTROL FUNCTION RESULTBreaker Closing Breaker Tripping Local/Remote selectionInput/Output Logic Fault Annunciation

ITEM SR.NO. RESULTS

Mimic Display

PF meterKW meter

Hz Mete

KV meter

Ammeter DC Voltmeter DC

KVAR meterKWH meter

Output contacts

Status, Alarm & Trip Indicators Tube – light, exhaust fan and switch socket

Control Scheme

CONTROL FUNCTION OF GENERATOR PROTECTION RELAY

Testing of the Other Instruments/ components

Turbocharger Freq. Mon. unit Auxiliary Relay & MCB’s

Allen Bradley PLC systemEngine Freq. Monitoring Unit

Ammeter

Format No.: KOEL/L&T/EPCC-4/6556/Alternator/01 Date :

M/c Sr. No.: VOLTAGE :

RATING : CURRENT :

P.F. IP :

RPM : INSULATION CLASS

AVR TYPE: EXCITATION : -

FREQUENCY : AUX. EXCIT. :

A) INSULATION RESISTANCE TEST OF WINDING WITH 5000 V FOR 1 MIN.:

U1 - U2

V1 - V2

W1 - W2

B) INSULATION RESISTANCE TEST OF WINDING WITH 500 V FOR 1 MIN.:

UH12

WH12

EXCITER U - V

C) PT 100 STATOR WINDING :A1 A2 A3 A4 A5 A6

D) PT 100 BEARING :

RESISTANCE IN Ohms

RESISTANCE IN Ohms

DRIVE END NON DRIVE END

STATOR

AUX. EXCITER

INSULATION Mohms.

RESISTANCE MEASUREMENT ohms

Project : PANIPAT NAPHTHA CRACKER PROJECT CAPTIVE POWER PLANT




INSULATION Mohms.

ALTERNATOR

Page1 of 2

Project : PANIPAT NAPHTHA CRACKER PROJECT CAPTIVE POWER PLANT



E) INSULATION RESISTANCE TEST OF SPACE HEATER WITH 500 V FOR 1 MIN.:

F) DIRECTION OF ROTATION : U - V - W

G) ANY ABNORMAL SOUND OBSERVED :


MeggerMake- Sr.No.Rating

KOEL L&T EIL

NAME:

SIGN.:

DATE:

INSULATION Mohms.


AUX. EXCITER H1 - H2

Page2 of 2

SECONDERAY CURRENT :

POLARITY CHECK :


KOEL L&T EIL

NETRUAL AFTER STAR POINT

NEUTRAL POINTCORE-I

NAME :


SIGN :

ANY PHYSICAL DAMAGE :

REMARKS : CT IS HEALTHY

25 A

50 A

100 A

COUNTINITY CHECK :

RATIO CHECK

PRIMERY CURRENT APPLIED

SECONDERY CURRENT MEASURED

VA / CLASS

Sr.No.CORE-I CORE-II CORE-III

PRIMARY CURRENT :

MAKE :

COMMISSIONIG CHECKS FOR NGR CT s

LOCATION : NEUTRAL GROUNDING RESISTOR PANEL


4 MW EMERGENCY DG SET COMMISSIONING REPORTProject : PANIPAT NAPHTHA CRACKER PROJECT CAPTIVE POWER PLANT Format No. : KOEL/L&T/EPCC-4/6556/NGR CT CDate:

SECONDERAY VOLTAGE :

CORE-I CORE-II CORE-III CORE-I CORE-II CORE-III CORE-I CORE-II CORE-III


1

3

5

POLARITY CHECK :


KOEL L&T EIL

NAME :


SIGN :


REMARKS : PT IS HEALTHY

66 V

198 V

330 V

COUNTINITY CHECK :

PRIMERY VOLTAGE APPLIED

SECONDERY VOLTAGE MEASUREDR-PHASE Y-PHASE B-PHASE

VA / CLASS

RATIO CHECK

Sr.No.

R-PHASE Y-PHASE B-PHASE

PRIMARY VOLTAGE :

MAKE :

COMMISSIONIG CHECKS FOR BREAKER PT s

LOCATION : DG INCOMER BREAKER


4 MW EMERGENCY DG SET COMMISSIONING REPORTProject : PANIPAT NAPHTHA CRACKER PROJECT CAPTIVE POWER PLANT Format No. : KOEL/L&T/EPCC-4/6556/Breaker PT report/01 Date:

Format No. : KOEL/L&T/EPCC-4/6556/Breaker CT/01 Date:

SECONDERAY CURRENT :



POLARITY CHECK :


KOEL L&T EIL

COMMISSIONIG CHECKS FOR BREAKER CT s


4 MW EMERGENCY DG SET COMMISSIONING REPORTProject :PANIPAT NAPHTHA CRACKER PROJECT CAPTIVE POWER PLANT

LOCATION : DG INCOMER BREAKER

COUNTINITY CHECK :


PRIMARY CURRENT :

Y-PHASE B-PHASE

20 A

40 A

100 A

RATIO CHECK

R-PHASE Y-PHASE B-PHASEPRIMERY CURRENT APPLIED

SECONDERY CURRENT MEASURED

REMARKS : CT IS HEALTHY


SIGN :

MAKE :

Sr.No.

VA / CLASS

R-PHASE

NAME :

Format No. :KOEL/L&T/EPCC-4/6554/Baring gear/01 Date :

LOCATION: MOTOR DESIGNATION:

MOTOR Sr. No.: MAKE: TYPE:

RATING: VOLTS: AMPS:

RPM :

A) IR VALUE OF MOTOR

a) R-E / Y-E / B-E :

b) R-Y / Y-B / B-R :

B) IR VALUE OF CABLE

a) R-E / Y-E/ B-E :

b) R-Y / Y-B / B-R :

C) WINDING RESISTANCE: U1-U2 / V1-V2 / W1-W2 =

D) DIRECTION OF ROTATION :

E) FORWARD AND REVERSE OPERATION OF MOTOR :-

G) STARTING CURRENT ( AMPS) :

H) RUNNING CURRENT ON LOAD ( AMPS) :

I) ANY ABNORMAL SOUND OBSERVED :

INSTRUMENTS USED ( TYPE,MAKE,SL.NO.): Megger Tong tester / MultimeterMake- Make- Sr.No. Sr.No.Rating Rating

KOEL L&T EILSIGN.:

NAME:

DATE:

BARING GEAR


Project : PANIPAT NAPHTHA CRACKER PROJECT CAPTIVE POWER PLANT 4 MW EMERGENCY DG SET COMMISSIONING REPORT

Format No. :KOEL/L&T/EPCC-4/6554/Drip transfer/01 Date :




RPM :


a) R-E / Y-E / B-E :

b) R-Y / Y-B / B-R :


a) R-E / Y-E/ B-E :

b) R-Y / Y-B / B-R :



E) MOTOR PROTECTION RELAY SETTINGS(AMPS):-





KOEL L&T EILSIGN.:

NAME:

DATE:

DRIP TRANSFER


Project : PANIPAT NAPTHA CRACKER PROJECT CAPTIVE POWER PLANT4 MW EMERGENCY DG SET COMMISSIONING REPORT

Format No. ::KOEL/L&T/EPCC-4/6554/LOP/01 Date :




RPM :

PUMP MAKE : PUMP SR. NO.:


a) R-E / Y-E / B-E :

b) R-Y / Y-B / B-R :


a) R-E / Y-E/ B-E :

b) R-Y / Y-B / B-R :



E) MOTOR EARTHING:-





KOEL L&T EILSIGN.:

NAME:

DATE:

LUBE OIL PRIMING PUMP


Project :PANIPAT NAPTHA CRACKER PROJECT CAPTIVE POWER PLANT4 MW EMERGENCY DG SET COMMISSIONING REPORT

Format No. KOEL/L&T/EPCC-4/6554/CMT/01 Date :




RPM :


a) R-E / Y-E / B-E :

b) R-Y / Y-B / B-R :


a) R-E / Y-E/ B-E :

b) R-Y / Y-B / B-R :



E) MOTOR EARTHING:-





KOEL L&T EILSIGN.:

NAME:

DATE:

CHMICAL MIXING TANK


Project : PANIPAT NAPTHA CRACKER PROJECT CAPTIVE POWER PLANT4 MW EMERGENCY DG SET COMMISSIONING REPORT

COMPRESSOR MAKE: MODEL :CAPACITY: Fab.. No.UNIT RPM: Max. W/Pr :

MOTOR TAG NO.: MAKE:

VOLTS:

AMPS:

C) WINDING RESISTANCE : U1-U2 / U2-U3 / U3-U1

D) DIRECTION OF ROTATION FROM DRIVE END :

22 Bar ON -30Bar CUTT OFF

INSTRUMENTS USED ( TYPE,MAKE,SL.NO.): ( Megger, tong tester, multimeter)Megger Tong tester/ MultimeterMake- Make- Sr.No. Sr.No.Rating Rating

KOEL L&T EIL

SIGN.:

NAME :

a) R-E / Y-E / B-E

a) R-E / Y-E/ B-E

b) R-Y / Y-B / B-R


I) AIR FILLING TIME ( 0-30 Bar ) Min.:

J)COMPRESSOR OIL GRADE :

F) RUNNING CURRENT ON LOAD ( AMPS) :

G) ANY ABNORMAL SOUND OBSERVED :

H) PRESSURE SWITCH SETTING VALUE:

E) NO LOAD CURRENT :

b) R-Y / Y-B / B-R

RATING:


RPM :


4 MW EMERGENCY DG SET COMMISSIONING REPORTPROJRECT : PANIPAT NAPHTHA CRACKER PROJECT CAPTIVE POWER PLANT

ELECTRIC MOTOR DRIVEN AIR COMPRESSORDate :Format No. : KOEL/L&T/EPCC-4/6556/EMDAC/01

Date:




RPM :


a) R-E / Y-E / B-E

b) R-Y / Y-B / B-R


a) R-E / Y-E/ B-E

b) R-Y / Y-B / B-R


D) DIRECTION OF ROTATION FROM DRIVE END:

E) MOTOR NO LOAD CURRENT (AMPS):-

F) RUNNING CURRENT ON LOAD ( AMPS) :

G) MOTOR EARTHING

H) ANY LEKAGE/ ABNORMAL SOUND OBSERVED :


Megger Tong tester / MultimeterMake- Make- Sr.No. Sr.No.Rating Rating

KOEL L&T EIL

SIGN.:

NAME:

DATE:

PRE HEATING MOTOR

KIRLOSKAR OIL ENGINES LIMITED Large Engines division

4 MW EMERGENCY DG SET COMMISSIONING REPORTProject : PANIPAT NAPTHA CRACKER PROJECT CAPTIVE POWER PLANTFormat No. :KOEL/L&T/EPCC-4/6554/HT PUMP/01

Format No. : KOEL/L&T/EPCC-4/6554/PREHEATER/01 Date :

LOCATION: DESIGNATION:

Sr. No.: MAKE:


CONNECTION : ELEMENT CAPACITY / VOLTAGE :

A) IR VALUE OF HEATER

a) R-E / Y-E / B-E

b) R-Y / Y-B / B-R


a) R-E / Y-E/ B-E

b) R-Y / Y-B / B-R

C) HEATER RESISTANCE: U1-U2 / V1-V2 / W1-W2 =

D) HEATER EARTHING :

E) CURRENT ON LOAD ( AMPS) :

F) ANY WATER LEKAGE OBSERVED :

G) TEMPERATURE SETTING FOR HEATER


Megger Tong tester / MultimeterMake- Make- Sr.No. Sr.No.Rating Rating

KOEL L&T EIL

SIGN.:

NAME:

DATE:

KIRLOSKAR OIL ENGINES LIMITED Large Engines division

4 MW EMERGENCY DG SET COMMISSIONING REPORTProject : PANIPAT NAPTHA CRACKER PROJECT CAPTIVE POWER PLANT

PRE-HEATER

Format No. :KOEL/L&T/EPCC-4/6554/LT RADIATOR/01 Date :




RPM :


a) R-E / Y-E / B-E :

b) R-Y / Y-B / B-R :


a) R-E / Y-E/ B-E :

b) R-Y / Y-B / B-R :



E) MOTOR EARTHING:-





KOEL L&T EILSIGN.:

NAME:

DATE:

LT WATER RADIATOR



Format No. :KOEL/L&T/EPCC-4/6554/HT Radiator/01 Date :




RPM :


a) R-E / Y-E / B-E :

b) R-Y / Y-B / B-R :


a) R-E / Y-E/ B-E :

b) R-Y / Y-B / B-R :



E) MOTOR EARTHING:-





KOEL L&T EILSIGN.:

NAME:

DATE:

HT WATER RADIATOR



Format No. : KOEL/L&T/EPCC-4/6556/EDG START UP/01

Sr. No Description YES / NOA Engine and Alternator1 Engine-Alternator alignment2 Crank web deflection to check-Un-Coupled and Coupled condition..3 Safeties to be checked & ensure for correctness as per safety check

format KOEL/L&T/EPCC-4/6556/Safety Check/01 (Checksatisfactory operation by simulation and certify)

a) Overspeed safety (RPM>840) - Tripb) Turning gear engagedc) Alternator fault - Tripd) Following Alternator Protection by secondary injection method

~Differential protection~ Earth Fault protection~ Over & Under voltage protection~ Over & Under frequency protection~ Over current protection~Negative phase sequence

4 Ensure smooth turning of the gear5 Fuel handle to be zero and all indicator cocks to be open. Under this

conditions rotate engine and observe.6 Close all indicator cocks before engine starting.7 Ensure there is no fuel spillage around the DG set.8 Ensure stop lever is kept in ‘work position’ (Vertical position).9 Ensure barring gear handle is not engaged.B Instrumentaion & Electrical1 Complete erection of control panels for test2 Control cable interconnection between all the panels to complete.3 LT & HT cable laying and testing of cables like inlsulation test etc.

Megger value of insulation should be greater than 1 Mohm between2 cables, core and w.r.t earth. Test the LT cables by 500V meggerand HT cables, alternator by 5000V megger. Carry out Hypotest ofHT cables by injecting 1.2 times rated voltage for 1 min. Themegger value should be greater than 300 Mohm. Earth pitsresistance will be measured to check correctness of Pits. Theresistance of earth pits shall not be more than 2 to 3 ohm.

4 HT cable termination to alternator, NGR & DG incoming breaker.The HT cable connection will be done.

FIRST START UP CHECK SHEET FOR DG SET


4 MW EMERGENCY DG SET COMMISSIONING REPORTPROJRECT : PANIPAT NAPHTHA CRACKER PROJECT CAPTIVE POWER PLANT

Page1 of 4

5 Electrical connection of all engine, alternator mounted sensor,switches to the GCP panel.

6 Earthing conntection of control panels & equipment.7 Make initial setting of woodword governor as per the procedure

mentioned in woodword manual.8 Ensure that all the electrical wiring, connections are done properly

and live connections, parts are covered properly.9 Check control panels with respect to operational requirements.10 Ensure that all the panels, equipments are properly earthed.11 Ensure DG incoming breaker is tripping manually as well as

automatically during safety condition.12 Safeties to be checked & ensure for correctness. (Check satisfactory

operation by simulation and certify)a) Emergency STOP from LSS & GCP - Tripb) Speed sensing failure - Tripc) Starting refusald) Breaker ON / OFF tripe) Starting interlock - No trip signal on GCP I.e. safety STOPf) Starting interlock - DG incoming breaker is open

13 Ensure all instruments are calibrated at site.Test certificates fromsupplier is to be obtained.

14 Ensure the engine Selector switch on GCP is selected in AUTOmode.

15 Ensure the EDG breaker is kept in Remote.16 Ensure the DG building Air ventillation system & Air-conditioner

for the GCP room is working properly.17 Ensure no alarm is persisting on GCP; if any alarm is persisting

note and rectify accordingly.18 Ensure all protective shields and covers are mounted properly.C LT Water system1 All pressure gauges/ switches to be checked.2 All temperature gauges/ switches/ thermometers/ RTDs/

Thermocouples to be check and recorded.3 Safeties to be checked & ensure for correctness. (Check satisfactory

operation by simulation and certify)a) Low LT water pressure - Alarm (Pressure < 1.5 bar)

4 Check expansion level low alarm is not persisting on GCP as this5 Ensure L.T water expansion tank level is @ 90%.( For Radiator

operation only ).6 Ensure availability of all radiator fan.( Radiator operation only ).7 Ensure water/lub.oil LT-PHE properly line up.All requried valves

are open.D HT Water system1 All pressure gauges/ switches to be checked.2 All temperature gauges/ switches/ thermometers/ RTDs/

Thermocouples to be checked and recorded.3 Safeties to be checked & ensure for correctness. (Check satisfactory

operation by simulation and certify)

Page2 of 4

a) HT water outlet safety - Alarm at 90°C and Trip at 95°Cb) HT water expansion Tank safety - Alarm at low level and Trip at

very low level.c) Low HT water pressure - Alarm (Pressure < 1.5 bar)d) Starting interlock - HT balance water tank is full

4 PHM is line up to heat water up to given temperature.5 Ensure H.T water Expansion tank level is @ 90%.6 Ensure chemical dosing tank is ready which recommendedchemical

mixer.7 Chemical dosing tank line up upto H.T & L.T expansion tank.8 Ensure availability of all radiator fan.E Lube Oil system1 All pressure gauges/ switches to be checked.2 All temperature gauges/ switches/ thermometers/ RTDs/

Thermocouples to be checked.3 Check specifications of Lube oil - IOC - SERVO ULTRA 40 or HP -

DISOLA M 4015.( As per recommendation from KOEL ).4 Safeties to be checked & ensure for correctness. (Check satisfactory

operation by simulation and certify).a) Lube oil pressure =< 4.5 bar at RPM > 550 - Alarm.b) Lube oil pressure =< 3.5 bar at RPM > 550 - Trip.c) Lube oil pressure =< 4.5 bar at 170 > RPM > 550 - Trip.d) Ensure Lube oil priming pump is switching OFF when engine speed

raised to 170 rpm.e) Lube oil engine inlet temperature safety - Temperature - Alarm at

65°C & Trip at 70°C.f) Lube oil filter clogged - Alarm.g) Low Lube oil priming pressure - alarm (Pressure < 0.5 bar).h) Starting interlock - Lube oil priming pump is ON.i) Starting interlock - Lube oil priming pressure is greater than 0.5 bar

5 Ensure the lube oil level is between the minimum and maximummark in engine sump using dipstick.

6 Ensure lube oil filters are line up.7 Check that <<Pre-lubricating lack>> alarm not exists on GCP i.e.

engine is continuously prelubricated by pre-lubricating pump. Itshould run for every 20 seconds and stop for the next 15 seconds toobtain lubricating pressure about 0.5 bars.

8 Ensure lub. oil priming pr. Healthy indication available.F Fuel Oil System1 Fuel consumption measurement equipment to be checked.2 All pressure gauges/ switches to be checked.3 All temperature gauges/ switches/ thermometers/ RTDs/

Thermocouples to be checked.4 Ensure correct fitment and connection of all sensors/ pprobes for

accurate measurement of parameters.a) Low Fuel pressure - Alarm (Pressure < 1.5 bar)b) Checl fuel control handle locked/Unlocked as per the operation

requriement.

Page3 of 4

c) Starting interlock - Fuel control handle is released.5 Ensure cleanliness of coarse fuel filter and air filter on compressor

air module.6 Ensure the fuel day tank is 80-90 % full and fuel is properly vented

and flooded.G Compressed Air System1 All pressure gauges/ switches to be checked.2 All temperature gauges/ switches/ thermometers/ RTDs/

Thermocouples to be checked.3 Safeties to be checked & ensure for correctness. (Check satisfactory

operation by simulation and certify)a) Low overspeed air pressure - Trip (Pressure < 7 bar)b) Low starting air pressure - Alarm (Pressure < 16 bar)c) Starting interlock - Overspeed air pressure is greater than 7 bar.d) Starting interlock - Starting air pressure is greater than 19 bar.

4 Ensure motor driven compressor starts and stops at header pressure22 and 30bar respectively.

5 Ensure motor driven compressor is maintaining air bottle pressurebetween 20-30 bars.

6 Check control air pr. and starting air pressure healthiness.7 Check healthiness of diesel engine driven compressor by starting it.8 Check the healthiness of the battery of the diesel engine.9 Ensure starting air is properly line up to the engine & lub. Oil

priming pump .H Power House Ventilation System1 All pressure gauges/ switches to be checked.2 All temperature gauges/ switches/ thermometers/ RTDs/

Thermocouples to be checked.

I Charge Air and Exhaust system1 All pressure gauges/ switches to be checked.2 All temperature gauges/ switches/ thermometers/ RTDs/

Thermocouples to be checked.

Remarks:

KOEL L&T EIL

SIGN.:

NAME:

DATE:

Page4 of 4


Project : PANIPAT NAPTHA CRACKER PROJECT CAPTIVE POWER PLANT

MECHANICAL PARAMETRES SHEET-1

Time1 HOUR METER Reading2 ELECTRICAL LOAD ( MW )3 INJECTOR NOTCH4 ENGINE SPEED ( RPM )5 TURBOCHARGER -1 SPEED ( RPM )6 TURBOCHARGER -2 SPEED ( RPM )7 AMBIENT TEMPERATURE 0C8 CRANK CASE PRESSURE ( H2O ) mm.

LT WATER SYSTEM9 LT WATER PUMP OUTLET pressure Kg/cm2

10 AIR COOLER INLET TEMPERATURE 0C11 AIR COOLER OUTLET TEMPERATURE 0C12 DELTA LT ( ACROSS CAC ) 0C13 LUBE OIL COOLER OUTLET temp.OC14 RADIATOR INLET temp. OC15 RADIATOR OUTLET temp. OC16 DELTA LT ( ACROSS RADIATOR ) 0C17 BALANCE WATER TANK LEVEL mm

HT WATER SYSTEM18 HT WATER PUMP OUTLET pressure Kg/cm2

19 ENGINE INLET temp.OC20 ENGINE OUTLET temp.OC21 RADIATOR INLET temp. OC22 RADIATOR OUTLET temp. OC23 DELTA HT ( ACROSS RADIATOR ) temp. 0C24 BALANCE WATER TANK LEVEL mm

LUBE OIL SYSTEM25 ENGINE INLET pressure Kg/cm2

26 LUBE OIL pressure OF TURBOCHARGER-1 Kg/cm2

27 LUBE OIL pressure OF TURBOCHARGER-2 Kg/cm2

28 ENGINE INLET temp.OC29 LUBE OIL COOLER INLET temp.OC30 LUBE OIL COOLER OUTLET temp.OC31 DELTA LO ( ACROSS LOC )32 LUBE OIL SUMP LEVEL mm

Format No. :KOEL/L&T/EPCC-4/6554/DG PARAMETER/01

SR.NO PARAMETERS TIME AND READING

1 2 3 4

KIRLOSKAR OIL ENGINES LIMITEDLarge Engines Division

1 of 3



MECHANICAL PARAMETRES SHEET-1

TimeFUEL OIL SYSTEM

33 FUEL ENGINE OUTLET pressure Kg/cm2

34 HSD ENGINE INLET FLOWMETER reading35 HSD DUPLEX FILTER IN SERVICE ( A / B )36 HSD DAY TANK LEVEL mm37 FUEL DRIP TANK LEVEL mm

AIR SYSTEM38 CHARGE AIR COOLER INLET pressure Kg/cm2

39 CHARGE AIR COOLER OUTLET pressure Kg/cm2

40 STARTING AIR pressure Kg/cm2

41 CONTROL AIR pressure Kg/cm2

EXHAUST SYSTEM/BANK A B A B A B A B42 EXHAUST CYLINDER -1 temp OC43 EXHAUST CYLINDER -2 temp OC44 EXHAUST CYLINDER -3 temp OC45 EXHAUST CYLINDER -4 temp OC46 EXHAUST CYLINDER -5 temp OC47 EXHAUST CYLINDER -6 temp OC48 EXHAUST CYLINDER -7 temp OC49 EXHAUST CYLINDER -8 temp OC50 TURBOCHARGER INLET temp OC51 TURBOCHARGER OUTLET temp OC




1 2 3 4

2 of 3



1 2 3 4Time

1 HOUR METER Reading2 LOAD IN KW3 POWER FACTOR ( PF )4 FREQUENCY Hz ( f )5 UNIT GENERATION KWH6 ALTERNATOR AIR INLET TEMPERATURE7 ALTERNATOR AIR OUTLET TEMPERATURE

GENERATOR VOLTAGE8 PHASE RY Kv9 PHASE YB Kv10 PHASE BR Kv

GENERATOR CURRENT 11 PHASE R Amp.12 PHASE Y Amp.13 PHASE B Amp.

WINDING TEMPERATURE14 WINDING TEMPERATURE- 115 WINDING TEMPERATURE- 216 WINDING TEMPERATURE- 317 WINDING TEMPERATURE- 418 WINDING TEMPERATURE- 519 WINDING TEMPERATURE- 6

ALTERNATOR BEARING TEMPERATURE20 DRIVING END ( DE )21 NON DRIVING END ( NDE )

EXCITATION SYSTEM22 EXCITATION VOLTAGE ( V )23 EXCITATION CURRENT ( A )

ELECTRICAL PARAMETRES SHEET-2




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erection and commissioning procedure

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