Annexure -1

SR No Description QTY (Nos)

400 DG Synchroniation Panel (Loc: Electrical Room) : 400V,
50 Hz, 3 Ph, 4 Wire, 65kA for 1 sec.Cu. bus bar, IP 42, indoor,
floor mounted, single front, stand alone type panel with 14
gauge CRCA sheet steel enclosure Switchgear including all
control devices, micro-processor based releases, metering
devices, indicating lamps, space-heater & related accessories,
etc as per attached specification and 'Single Line Diagram for
Electrical Distribution' of this tender

Buchanan

2 No Incomer of 315A MCCB and 1 No 630A ACB 1

Tokadeh

2 No Incomer of 630A MCCB and 1 No 1000A ACB 1

Document No: Page 1 of 14

SPECIFICATION FOR DG SYNCHRONISATION PANEL

Project Name: Liberia Fuel Storage and Distribution Infrastructure.

Client: ARCELOR MITTAL

Contractor: Mahathi Infra Services Private Limited. (MISPL)

Package No.: CP014

A
Prepared by Reviewed by Approved by Reviewed by Approved by
Revision Date
(MISPL) (MISPL) (MISPL) (AML) (AML)
Document No: Page 2 of 14

CONTENTS

Serial No. Description

1.0 GENERAL

2.0 SCOPE OF SUPPLY AND SERVICES

3.0 CODES AND STANDARDS

4.0 OPERATING CONDITIONS

5.0 TECHNICAL PARAMETERS

6.0 CONTROLLER WILL BE 3 PHASE SYNCHRONIZATION

7.0 DG SUNCHRONIZATION PANEL

8.0 GENERAL REQUIREMENTS

9.0 WARRANTY

10.0 QUALITY ASSURANCE

Document No: Page 3 of 14

1.0 GENERAL

The scope of this specification is to define technical requirements of design, engineering, fabrication,
manufacture, assembly, inspection, testing, shop painting, packing, transportation, delivery, erection,
testing and Commissioning of 3 phase, 415 V, 50 Hz DG Synchronization Panel with all the
accessories which shall be installed at Arcelor Mittal Liberia Limited (AML) Buchanan and Tokadeh
Site

2.0 SCOPE OF SUPPLY AND SERVICE

2.1 SCOPE OF SUPPLY

1. Design, Engineering, Manufacture, fabrication, assembly, inspection, testing at manufacturer’s

works / test lab, shop painting, supply and delivery, properly packed, transportation and delivery,
erection, testing and commissioning of DG Synchronization Panel including all the auxiliary
equipment, hardware and accessories as specified in this specification and Annexure, Bill of
quantity
2. All relevant drawings, data and instruction manuals

2.2 SCOPE OF SERVICES

1. The scope of work shall also include, at the option of the purchaser, the services of a senior
engineer for

i. Complete checking of materials at site and advising the purchaser of any discrepancy thereof
ii. Advice on procedure of erection to be followed
iii. Supervision of erection, testing, commissioning and putting into successful commercial
operation
iv. Configuration and testing of protection relays. Vendor’s engineer shall bring the necessary test
kits

3.0 CODES AND STANDARDS

The equipment shall meet the requirements of Liberia Electricity rules. Materials, equipment and
methods used in the manufacture shall conform to the latest edition of IEC standards.

• In case of any contradiction between various referred standards / specifications and statutory
regulations for following order of priority shall governs:

o Statutory regulations
o This specification
o Codes and standards
Document No: Page 4 of 14

4.0 OPERATING CONDITIONS

Site Data

Equipments shall be suitable for operating in humid & corrosive atmosphere found in petrochemical
plants. Service conditions shall be defined as

Parameters Description
Altitude from above Sea Level Less than 1000 m from Mean Sea
Level
Design Ambient Temperature 55 °C
Annual average Rainfall 5100 mm
Ambient Temperature (Min. / Max.) 21 / 36 °C

5.0 TECHNICAL PARAMETERS

5.1 DG SYNCHRONIZING SYSTEM

DG Synchronizing System to be used to power saving and Start and Stop DG as per required load in
auto AMF function. From this system we can save fuel consumption of DG, wastage of power, DG
protection, auto load sharing. On AGC controller screen we can see the status of system as below:

• DG power, total run hour.

• DG voltage, current, frequency.
• DG load.
• BUS Voltage, Frequency.
• Alarms.
• SLD status with led indication.
• Voltage, Phase sequence and Phase angle,

If all the required data is ok then Controller will start DG otherwise it stops DG.

5.2 BRIEF TECHNICAL DESCRIPTION

DG Synchronizing Panel System to be Start DG as per required load. Basically, it can be operated by
Auto Mode and Manual Mode. As per required Load we can change Consumption mode it Night Mode
and Day Mode. In Night production is very less so we activate any one 180/250 KVA DG, but in Day
Mode first DG 180/ 250 KVA will start and if load in field is more then automatically 2nd DG 180/250
KVA will be start automatically start and sync and start load sharing with already running DG.

In Case we want to operated DG by Manual mode, in this mode you start DG one by one through push
bottom on controller and close breaker from DG controller button or from PCC panel. If you start 2nd
Document No: Page 5 of 14

DG in this mode, then at the time of breaker closing from DG controller button it will sync before
closing breaker.

5.3 FUNCTION OF DG SYNCHRONIZING PANEL

DG Sync functions can be summarized in the following way-

• Auto Mode
• Manual Mode
• Day Mode
• Night Mode

5.3.1 AUTO MODE IN DAY

• PRE-CONDITION SHOULD BE OK AS ABOVE DESCRIBED IN POINT

• If mains supply fail
• AMF activate as per day or night mode selection.
• 1st DG will start and charge the BUS.
• 2nd DG start and close 2nd DG breaker after sync.
• Continue running with load sharing until mains resume.
• If mains supply resume.
• Then DGs will stop one by one.
• All two DG breakers will open and main breaker will close and charge BUS.
• All DG will stop after cooling
• System will ready for next cycle.

5.3.2 AUTO MODE IN NIGHT

• If mains supply fail

• AMF activate DG 250 KVA
• 1st DG will start and charge the BUS.
• Continue running with load sharing until mains resume or more load require.
• If mains supply resume.
• Then DGs will stop.
• System will ready for next cycle.

5.3.3 DG SYNCHRONIZING IN MANUAL MODE:

• PRE-CONDITION SHOULD BE OK AS ABOVE DESCRIBED IN POINT

Document No: Page 6 of 14

• If mains supply fail

• AMF activate as per day or night mode selection.
• As per required load 1st DG will start by manually and charge the BUS.
• If load is more and 1st DG not full fill the load then
• 2nd DG start and close manually 2nd DG breaker after sync.
• Continue running with load sharing until mains resume or more load require.
• If mains supply resume.
• Then DGs will stop one by one manually.
• All two DG breakers will open and main breaker will close and charge BUS.
• All DG will stop after cooling
• System will ready for next cycle.

5.4 AMF SYSTEM

The abbreviation of AMF is Auto Mains failure, it means if the main supply will fail then AMF panel
will start DG but main condition is DG Sync controller should be in AUTO mode and in healthy
condition.

• DG Panel should be in power on.

• DG controllers should be in auto.
• Day or night mode should be selected.
• DG controller should be in healthy condition there should be no alarm.
• Emergency button should be release condition.
• All mobs that behind the PCC panel should be on for acceptance command from DG controllers.
• All DG should be in healthy condition and ready for receiving the command from panel
• DG panel front door should be locked for safety.

5.5 CONTROL PHILOSOPHY

5.5.1 Automatic Start & Stop of Engine

Controller Logic for Auto Synchronizing, Auto sharing & Auto Load Management including
auto start / auto stop of DG Set

The system will come in operation after sensing of grid failure initiation of DG operation from
Man machine interface to automatically control the start and stop of the engine, depending on
the predefined load setting in the controller.

In case engine does not start in the first cranking, two more auto commands will be given with
proper interval. Even then if engine fails to starts indication will appear on MMI (main machine
Document No: Page 7 of 14

interface). In the event, the engines are under loaded load sensed is capable of being catered by
less then running engines, command will be given to engine running for shortest duration at the
moment. Provision to select number of DG sets to be started at no load to cope up with sudden
load without tripping ready the DG’s.

5.5.2 Power Management Controller

The entire operation of the captive power generation system will be controlled automatically
through a controller. These controllers will be state of art equipments using latest technology
and of most rugged and reliable design. Since they shall be operating in the harsh & unfriendly
environment of DG room, they will be suitable to operate trouble free in those conditions. The
chosen equipment will be able to withstand high temperature, humidity and voltage fluctuations,
thus making it suitable for the operating conditions described above and will perform the
following functions

Tripping of less priority loads in the plant in case of under frequency of bus both in isolation as
well as synchronized mode.

Control of all the auxiliary drive of DG set will Auto Synchronizing, start / stop automatically
with proper interlock.

Controller system shall have provision to test the DG in auto mode without closing the breaker
to do the routine electrical / mechanical testing of set without interruption to power generation.

The System supplier will supply built drawing. Along with trouble shooting and operation and
maintenance guidelines.

5.6 CONTROLLER WILL HAVE THESE PROTECTIONS FOR GENERATOR.

Protection ASNI Code Protection ASNI Code

Under / Over Voltage 27P / 59P Reverse Power 32R
Under / Over Frequency 81U / 81O Voltage dependent Over Current 51 V
Short Circuit 50P / N Unbalance Voltage 47

Over Current 51 Unbalance Current 46

Under Excitation 32RV
Vector Surge 78 Over Excitation 32FV
Over Load 32 Over Speed 12
Low Battery Voltage 27 DC High Battery Voltage 59 DC
Phase Sequen Error 47 Hz / V Failure 53
Earth Fault 51N

6.0 CONTROLLER WILL BE 3 PHASE SYNCHRONIZATION

• 3 Phase Generator Voltage

• 3 Phase Bus Voltage
Document No: Page 8 of 14

6.1 AUTO MODE

6.1.1

a. System Operation

While the normal mains supply is healthy, the DG set shall be at rest and the load shall be
supplied by mains. During this period all the DG INCOMERS shall be in OPEN position.

The controller system shall monitor supply voltage on each phase. When the mains supply
fails completely or falls below set value (variable between 80% to 95% of the nominal
value) on any phase, the monitor module shall initiate start-up of diesel engine. To avoid
initiation due to momentary dips or system disturbance, a time delay adjustable between 0.5
to 5 seconds (adjustable) shall be incorporated in the start-up initiation.

A three-attempt starting facility shall be provided with the sequence 6 seconds ON 5

seconds OFF 6 seconds ON 5 seconds OFF and 6 seconds ON. At the end of the third
attempt if the engine has not been already started and built up voltage, engine shall be
locked out for start. A master timer shall be provided for the function. An audio-visual
alarm shall be given.

Suitable adjustable timers shall be incorporated which shall make it feasible to vary
independently ON-OFF setting periods from 1-10 seconds. If the alternator does not build
up voltage after the first or any start, as may, further starting attempt shall not be made and
the starting facility shall be reset.

Once engine has built up voltage, signals shall be provided to operate the alternator, mains
and bus coupler circuit breakers as per logic sequence required. The Mains supply circuit
breaker shall open before the alternator circuit breaker closes. Before giving close command
to alternator breaker, all the bus couplers shall be given close command. At this point of
time all the load shall be on one DG. System provided in the DG Synchronization control
Panel shall check and ensure that all the engine auxiliaries like cub oil pump, CT fan,
cooling water pump are running and healthy. In case of any fault in engine auxiliaries, the
system shall automatically stop the DG set and an audio-visual alarm shall be given.
Suitable inputs for overload and single phase preventor for alternator and for each of the
engine auxiliaries shall also be considered as inputs for this function.

DG Synchronization control system shall continuously monitor total load on the DG set. In
case the load on any of the DG sets is less than 60 % of the rated value, the controller shall
assess the load on the adjacent DG set. In case the summation of the loads is within 90% of
the rating of one of the DG sets, one DG set shall shut down and load shall be transferred to
the second DG set.

In case the total load on the system is not more than 90% of the full load rating of a single
DG set, the controller shall shut down due to non-availability of adequate load and will the
Document No: Page 9 of 14

load increase, the controller shall automatically start the DG set and shall isolate the
buses/loads on the Main LT panel bus.

The Automatic Load Management system shall be designed to provide optimum utilization
of the DG sets so that operation of the DG sets is need based with higher load factor on each
set. The system would therefore transfer loads from one bus to the other on the Main LT
panel with Main L.T. panel as per logic sequence required. The controller shall ensure that
that the ACB’s on the closed and opened and DG sets are started and stopped according to
the predetermined logic and interlocking scheme to provide a fail-safe system.

When the voltage in the mains get restored, its quality shall be monitored for about one
minute and if proven satisfactory, the main supply breaker shall close automatically for
retransfer of the load from Diesel engine to the main supply at LT panel. However, prior to
this operation DG incomer breakers shall open position before the mains breaker closed.

The Automatic Logic Management system shall also consider that in the eventuality of
failure of any component of the controller, adequate safeguards shall be provided in that the
system shall revert to the manual mode with visual and audible alarms. These safeguards
and the system shall be detailed in the offer.

The Logic Panel shall automatically arrange for sequential starting of DG sets to be based
on number of operating hours of each DG set so that to ensure that all DG sets are operated
as equally as possible.

In case of over load on the DG system, the logic panel shall give audio visual alarm to
enable the operators to switch off loads as required and if this is not taken care of in
predetermined time, the Logic Panel shall put the DG in shut down mode with alarm.

The DG set shall stop after idle running of one minute after restoration of main supply.

The DG set reverts to standby conditions and is ready to start will the mains supply fail
again.

b. Sequence of operation for Auto start, Auto load management & Auto Synchronizing

One failure of grid supply, DG-1 shall start automatically and close its breaker shall start
feeding the load.

On DG-1 attaining its full rated capacity, DG-2 shall start automatically.

Voltage and frequency of DG-2 shall be monitored and necessary commands shall adjust the
parameters of DG-2 with bus.

System shall also monitor the slip frequency and the beat voltage of the machine or system.
Document No: Page 10 of 14

It shall be possible to alter sequence of DG set starting through manual selectors or through
Man Machine Interface.

Active Power shall be made equal on both the machines automatically with the help of
active load balancing system through governor control.

On restoration of grid supply, DG breakers and Bus coupler breakers shall be switched off
in sequence with time delays to cover dips and grids supply breakers shall be switched On.
Dg sets shall continue to run for one-minutes after DG breaker has been switched OFF.

It shall be possible to alter crucial settings / time delays thru. Man-Machine Interface.

Controller, annunciation system, protection system and metering system shall have
compatibility for future interface with PC for graphics displays / report generation.

System shall have total manual override.

Tenderers may note that the controller controls and sequence of operation are indicative of
requirements and the controller shall not with-standing the above, be complete in all
respects to achieve the control, monitoring and operation of DG sets indicated above.

6.1.2 Manual Mode

Under manual mode it shall be possible for the operator to start up the generator set by pressing
the (START) push button.

Three attempt starting facility shall also be operative for the start-up function.

Alternator, mains and bus coupler circuit breakers ‘CLOSE’ and ‘TRIP’ operations as per logic
sequence required shall be manual by pressing the appropriate push button on the panel. Closure
shall be feasible only after alternator has built up full voltage. If the load is already on ‘MAINS’
pressure on ‘CLOSE’ button shall be ineffective.

When running under manual mode, if the mains supply has failed, the load shall automatically
get transferred to the alternator immediately overriding the stipulation of pressure on ‘CLOSE’
button.

Engine shut down, other than due to faults shall be manual by pressing a ‘STOP’ button.

6.1.3 Test Mode

When under ‘TEST’ mode pressure of ‘TEST’ button shall complete the start-up sequence
simulation and start the engine. The simulation will be that of mains failure.
Document No: Page 11 of 14

Engine-shall build up voltage but the set shall not close alternator circuit breaker when the load
is on the mains. Monitoring performance for voltage / frequency etc. will be feasible without
supply to load.

If during TEST run the power supply has failed, the load shall automatically get transferred to
alternator.

Bringing the mode selector to auto position shall shut down the sets.

7.0 DG SYNCHRONIZATION PANEL

7.1 POWER SUPPLY

1. Rated operational voltage Ue 415 V ±10%

2. Rated insulation voltage Ui 1000 V ac rms
3. Rated frequency 50 Hz (+3%, -5%)
4. Rated Normal Current Refer SLD
5. Temperature rise The maximum value of temperature shall be as per Table-2 and
Table-3 of IEC 60947-1 at the maximum specified ambient air
temperature
6. Rated short time withstand current 50 kA rms
7. Rated duration of short time with-stand 1 Sec
current
8. Rated impulse (1.2 / 50 µs) withstand 6 kV peak (as per IEC 60947-1 Table H.1)
voltage
9. Control voltage for Breaker Module Contactor Module
i. 110 Vdc/240 Vac (85% - 240 Vac ±10%
110%)
ii. Max short circuit current of
50 kA
10. Service supply for heating, lighting and 240 Vac ±10%, 50 Hz (+3%, -5%)
power sockets
11. System neutral earthing Effectively earthed
12. Number of phases Three-phase + Neutral
13. Paint shade RAL 7032 for complete panel

7.2 DG SYNCHRONIZATION PANEL DESIGN CRITERIA

1. Service 0utdoor
2. Type Metal enclosed, fully compartmentalized
3. Mounting Floor (Free standing)
4. Connections Cable entry – Bottom
5. Configuration Single front
6. Panel height Preferably <= 2500 mm
7. Working height from ground >= 300 mm and <= 1950 mm
8. Enclosure degree of protection IP 55
9. Enclosure Material CRCA sheets
10. Enclosure Sheet Thickness i. Minimum 2.0 mm for load bearing members
Document No: Page 12 of 14

ii. Minimum 1.6 mm for doors and covers

iii. Minimum 3.25 mm for integral base frame
11. Compartmental design i. Separate compartments for Bus bar, MCCB, cables, PT, LV
instruments and relays
ii. The design shall be such that the failure in one compartment does
not affect the adjacent compartments.
12. Doors and Covers i. Bolted covers for bus bar chamber and cable chamber (preferably
with captive screws)
ii. Hinged door for cable alley
iii. Non-deteriorating neoprene gaskets shall be provided for the
doors and removable covers.

7.3 NAMEPLATE AND WARNING BOARDS

1. Location of nameplates i. Panel nameplate at the front

ii. Instruments and devices nameplate at the front and rear
2. Warning symbol for dangerous voltages as On shutters and removable covers
per IS 8923
3. Danger Sign Board as per IS 2551 On all four sides of panel
4. Material, text and size Anodized aluminium, Subject to approval during detailed engineering
5. Engraving With white letters on black background

7.4 PAINTING AND TROPICAL PROTECTION

1. Surface preparation Surface shall be sand blasted, pickled and ground as required to
produce a smooth, clean surface free of scale, grease and rust
2. Painting The surface shall be given a phosphate coating followed by 2 coats of
high-quality primer. The coating shall be done electro-statically
followed by stoving
3. Tropical protection Shall have fungus protection, involving special treatment of
insulation and metal against fungus, insects and corrosion
4. Suitability i. Shall withstand heat and weather conditions.
ii. Shall not scale - off or crinkle or get removed by abrasion due to
normal handling

7.5 PACKING AND SHIPPING

1. Packing Protection Protection against corrosion, dampness, heavy rains, breakage and
vibration
2. Packing for accessories and spares Robust wooden non-returnable packing case
3. Packing Identification Label on each case i. Individual serial number
with details as listed ii. PO number (along with SAP item code, if any) and date
iii. Equipment Tag no. (if any)
iv. Manufacturer / Supplier’s name and address
v. Description and Quantity
Document No: Page 13 of 14

vi. Month and year of Manufacturing

vii. Case measurements
viii. Gross and net weights in kilograms
ix. All necessary slinging and stacking instructions
4. Improper packing The seller shall be responsible for all transit damage due to improper
packing
5. Shipping Limitations Any transport limitations such as weights, dimensions, road culverts,
overhead lines, free access etc. from the manufacturing plant to the
project site shall be informed to the purchaser well in advance.
6. Lifting lugs 4 nos. of lifting lugs shall be provided for each shipping section
7. Shipping length Shall be limited to 2700 mm

8.0 GENERAL REQUIREMENTS

8.1 COMPLETENESS OF SUPPLY

1. It is not the intent to specify completely herein all details of the equipment. Nevertheless, the
equipment shall be complete and operative in all aspects and shall conform to highest standard of
engineering, design and workmanship and be capable of performing in continuous commercial
operation up to the guarantees in a manner acceptable to the purchaser, who will interpret the
meaning of drawings and specifications and shall be entitled to reject any work or material which in
his judgment is not in full accordance therewith
2. Any material or accessory which may not have been specifically mentioned but which is necessary
or usual for satisfactory and trouble-free operation and maintenance of the equipment shall be
furnished without any extra charge.
3. The bidder shall supply all brand-new equipment and accessories as specified herein with such
modification and alteration as agreed upon in writing after mutual discussion

8.2 GUARANTEED PERFORMANCE

1. The performance figures quoted in Schedule, Technical Particulars shall be guaranteed within the
tolerance permitted by relevant standards. In case of failure of the equipment to meet the guarantee,
the equipment may be liable for rejection

8.3 DEVIATION

1. Should the Bidder wish to deviate from this specification in any way, it shall be clearly mentioned
in Schedule, Technical Deviation with reference to the respective clause of the specification
2. Unless such deviations are recorded as above and submitted with the offer, it will be taken for
granted that the offer is made in conformity with this specification in all respects
Document No: Page 14 of 14

8.4 DRAWING APPROVAL

1. Before starting manufacture of any equipment, the bidder shall have to take approval of the relevant
drawings, data sheet and Quality Assurance Plan from Purchaser in writing
2. Any manufacture done prior to the approval of drawings / data shall be rectified in accordance with
the approved drawings / data by the Bidder at his own cost and the equipment shall be supplied
within the stipulated period.

Bidder shall ensure that other necessary write-ups, curves and information required to fully describe the
equipment are submitted along with this bid.

Drawing submission shall be within 1 month from kick off meeting (KOM). Bidder shall not start
manufacturing unless manufacturing clearance is provided by Owner / Consultant in writing.

9.0 WARRANTY

Bidder shall have final and total responsibility for the design and performance of charger, battery and
DCDB supplied under this specification. The equipment and the system shall be guaranteed for troubles
free operation for a period of 12 months from the date of commissioning. Any defects discovered
during this period shall be rectified free of charge.

10.0 QUALITY ASSURANCE

Manufacturer shall follow his standard procedures for quality assurance and control. However, the
standard procedures shall be submitted to the Owner in event of order. Bidder shall submit the QAP for
Owner’s approval prior to dispatch at supplier’s works and during commissioning at site.

The procedures shall be in such a form as to clearly delineate the manufacturing sequence and major
inspection points and to reference manufacturer’s test and inspection procedures.

The Owner will inform the manufacturer as to which of the inspection points and tests will be
witnessed.