Erection and Commissioning Procedure

Kirloskar Oil Engines Ltd.
INSTALLATION & COMMISSIONING MANUAL

Large Engines Division 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 ALTERNATOR
7 74.640.20.0.00 COUPLING
HT WATER CIRCUIT
8 27.809.21.0.00 HT WATER CIRCUIT SCHEMATIC
9 70.660.10.0.00 EXPANSION WATER TANK
10 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 CIRCUIT
13 27.809.20.0.00 LT WATER CIRCUIT SCHEMATIC
14 27.810.12.0.00 LT WATER RADIATOR
FUEL CIRCUIT
15 27.809.25.0.00 FUEL CIRCUIT SCHEMATIC
16 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 COARSE
19 74.649.10.0.00 FINE FUEL FILTER
LUBE OIL CIRCUIT

20 27.809.22.0.00 LUBE OIL SCHEMATIC
21 27.808.10.0.00 LUBE OIL COOLER
1.1
Kirloskar Oil Engines Ltd. INSTALLATION & COMMISSIONING MANUAL
COMPRESSED AIR CIRCUIT

22 27.809.23.0.00 COMPRESSED AIR CIRCUIT SCHEMATIC
23 27.689.10.0.00 COMPRESSED AIR MODULE
24 27.812.11.0.00 COMPRESSED AND AIR BOTTLE
25 74.632.12.0.00 MOTOR DRIVEN AIR COMPRESSOR
26 74.632.11.0.00 ENGINE DRIVEN AIR COMPRESSOR
CHARGE AIR EXHAUST CIRCUIT

27 27.809.24.0.00 CHARGE AIR & EXHAUST SYSTEM SCHEMATIC
28 27.650.01.0.03 EXHAUST SILENCER
MISCELLANCEOUS
29 XI--08074--M04--01CHIMNEY
30 27.809.27.0.00 LEGEND AND ABBRIVATION
31 74.643.10.0.00 WORKING PLATFORM (L.H.)
32 74.643.11.0.00 WORKING PLATFORM (R.H.)
33 UTILITY WATER DISTRIBUTION
1.2
Kirloskar Oil Engines Ltd. INSTALLATION & COMMISSIONING MANUAL
LIST OF DRAWINGS FOR

PROJECT EXECUTION
(ELECTRICAL)

1 SINGLE LINE DIAGRAM
2 POWER DISTRIBUTION SCHEMATIC OF GCP CUM SYN.
3 PLC WIRING SCHEMATIC OF GCP CUM SYN.PANEL
4 PLC INPUT/OUTPUT LIST
5 SYSTEM ARCHITECTURE OF GCP CUM SYN.PANEL
6 AVR TERMINAL
7 LOCAL SENSOR STAND
8 MOTOR CONTROL CENTRE PANEL
9 DG BREAKER
10 NEUTRAL GROUND RESISTOR PANEL
11 CABEL SCHEDULE
12 CABEL INTERCONNECTION DETAILS
13 POWER HOUSE EARTHING LAYOUT
14 POWER HOUSE CABLE TREY LAYOUT
16 DG OPERATION PHILOSPHY
17 ALTERNATOR MANUAL WITH TEST CERTIFICATE
18 TEST CERTIFICATE OF ALL PANELS
1.3
Large Engines Division Chapter 2 - INSTALLATION
Technical Specifications forInstallation of DG Set Mechanica/Electrical
TECHNICAL SPECIFICATIONS FOR

INSTALLATION OF DG SET (MECHANICAL)
1. UNLOADING OF MATERIAL (Lifting, Leading & Installation)
We have to use proper tools, adequate manpower & arrangements to unload the material
depending upon its size and weight to avoid damages.
For Unloading of engine, alternator and auxiliaries etc., should use hooks which are provided on
it 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 fitment
with clamping.
While unloading the crane should be supported by jacks on both ends and tyres should be locked
at 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, pipes
base frame etc.
No body should step on the components to do any work while unloading, leading or at the time of
installation.
For each sq. mtrs. 4 persons are required for handling of material to avoid any damage to
material, what ever may be its weight.
All glass parts, instrumentation items, pressure gauges etc. should be handled with care and
precautions 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 depending
upon the weight.
2. CHECKING OF LAYOUT.
Civil layout made by customer should be collected from customer and compared with KOEL
layout 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 of
engine and its auxiliaries as per drawing.
2.1
3. CHECKING OF MATERIAL
Check the material as per packing sheets and also cross check with application code, if there is
any 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 actual
consumption.
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 a
feet.
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 for
clamping 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 by
gas 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 be
300 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.
2.2
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 be
welded 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 welding
rods 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 Pipe
S4E 308L - 16 for ss 304L Pipe
Selection of current of welding motor for different size of rods.
Size of rod Amps

2.50 x 350 50 - 70
3.15 x 350 90 - 110
4.00 x 350 110 - 140
5.00 x 350 160 - 200
Welding beed should be uniform and @ 1.5 mm, above the surface of pipe. Chipping and wire
brushing 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 both
pipes 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 10/8
20 NB 12 10/8
25 NB 12 8
40 NB 12/10 8
2.3
50 NB 12/10 8
65 NB 12/10 8
80 NB 12/10 8
100 NB 12/10 8
150 NB 10 8
200 NB 10 8
460 OD 10 8
560 OD 10 8
750 OD 10 8
1000 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 Pressure
L. T. Water 10 bar
H. T. Water 10 bar
Injector water 10 bar
Fuel 10 bar
Lub Oil 10 bar
Air 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 end
and 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 the
required 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.
2.4
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 217
2. H.T. Water & French blue 166
Injector Water
3. Lub Oil Golden brown 414
4 Fuel Post office red 538
5 Air Canary yellow 309
6 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.
2.5
TECHNICAL SPECIFICATIONS FOR INSTALLATION

OF DG SET (ELECTRICAL)
1. INSPECTION
a) 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 PANEL

a) 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 50
deg. 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 EFMU
n) 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.
2.6
s) Check the following functions are OK.

i) Speed raise / Low
ii) Voltage raise / Low
iii) Manual / auto synchronizing.
iv) Breaker closing and tripping.
v) Indication for all these operations.
vi) Check other functions.
3. NGR PANEL
a) Check whether there is no damage to the panel
b) 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 PANEL
a) 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 PANEL
a) 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)
2.7
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.
2.8
Statutory Rules & Safety Regulations
STATUTORY RULES & SAFETY REGULATIONS

The 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. It
clarified that no reimbursement will be made on account of employer’s share of PF/ESI by
the company.
02. The contractor shall comply promptly with the provisions of contract labour Act and produce
the Licence of the Contract Labour Act if the number of labours exceed 19 on any day during
contract period.
03. The contractor shall bring only those labourers at the work site / premises who have been
issued gate passes / identity cards. the contractor agrees that he shall not retain the gate
passes 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 and
when contract is over.
04. The contractor will maintain muster roll of his employees engaged in the work site / premises
and update their attendance on day to day basis this should be handedover along with a
statement 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 Act
notified 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 way
responsible or liable for their payment of wages / salaries, bonus, gratuity and other
allowances, if any.
07. The labourers engaged by the contractor shall abide by all the disciplinary, rules & regulations
laid 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 without
giving notice and contractor is bound to do so.
09. The contractor shall comply with all the rules and regulations under the various Acts applicable
to the company. In case he fails to comply with the same and if the company apprehends
any breach thereto his contract is liable for termination fortwith. The company also reserves
the right to withhold the payment of the contractor.
10. The contractor shall ensure the compliance and provisions of the contract labour Act. The
Minimum Wages Act. The payment of Wages Act, The Employees Provident Fund Act, ESI
Act, Factories Act, payment of Wages Act. The payment of Gratuity Act and such labour
legislation’s applicable at the relevant time.
3.1
SAFETY REGULATIONS:
01. The company has set some safety rules to be followed by each person to be employed by
the contractor to take care of the safety of the persons, safety of the other people and to
ensure the safety of company’s properties. These rules are being framed by our safety
department 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 equipment
must be used as directed by Safety Dept. Also you will take special precautions while
working 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 belts
should be confirmed.
05. You will bring machines / equipment such as welding machine, drilling machine, gas
cutting 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 that
site 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 permitted
in 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. Work
after 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 live
electrical supply systems. The workers deputed by the contractor, as helper should carry
out 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 and
company’s machinery / property. Whenever required you will do the work after providing
suitable barricades / covers. Whenever carrying work, which is likely to lead harm to
other 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 electrical
maintenance department should be taken.
13. All safety rules and codes as applicable to work must be followed without any
exception.
3.2
14. All personal protective equipments (safety bolts, hand gloves, aprons, helmets, safety
shoes, 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 when
required.
CONTRACTORS OBLIGATIONS / LIABILITIES:
Above rules and regulations are to followed to take care of safety of persons employed
by you, Other people working in the company and company’s property. These rules are to be
followed strictly and wherever in doubt you will clarify with us for the same. Any work carried
out without following above rules and regulations will be considered as illegal. The contractor
shall identify the company at all times against all claims for compensation under the provision
of any law for the time being in force by or in respect of any labours employed by him in
carrying out the contract and against all costs and expenditure incurred by the company in
connection therewith.
It will be contractor’s responsibility to settle all legal deals of his labourers on their
termination and will hand over the copy of the receipt obtained from the concerned labour, in
full and final settlement of the claims of whatsoever nature, to the company. In case if any
labour engaged by the contractor raises any demand after his termination or after making full
and final settlement by the contractor during the currency or after the expiry of the contract, the
contractor shall settle the same and no liability will rest upon the company.
3.3
Tools for Installation of DG Set
LIST OF TOOLS REQUIRED FOR

INSTALLATION OF DG SET
SR. NO. DESCRIPTION QTY
A. TOOLS FOR UNLOADING AND SHIFTING OF DG SET
AND AUXILIARIES
1 MECHANICAL SCREW JACK 20 TON 4 NOS
2 MECHANICAL SCREW JACK 10 TON 2 NOS
3 SLING / STEEL ROPE / NYLONE ROPE AS REQD
4 WOODEN SLEEPER Min. 50 NOS
5 CHAIN PULLEY BLOCK 20 TON 2 NOS
6 CHAIN PULLEY BLOCK 5 TON 1 NO
7 TARPAULIN / PLASTIC SHEET TO PROTECT EQUIPMENTS AS REQD
B GENERAL TOOLS
1 DOUBLE ENDED OPEN SPANNER (10 TO 41 MM) 1 SET
2 DOUBLE ENDED RING SPANNER (10 TO 32 MM) 1 SET
3 BOX SPANNER 10 TO 30 MM (1/2’’ DRIVE) 1 EACH
4 BOX SPANNER 30,32,36,41,46,50 & 55 MM (3/4’’ DRIVE) 1 EACH
5 BOX SPANNER 60 & 65 MM (1’’ DRIVE) 1 EACH
6 EXTENSION BAR 6’’ & 12’’ LONG (1/2’’ DRIVE) 1 EACH
7 TOMMY BAR (1/2’’ DRIVE) 1 NO
8 RATCHET (1/2’’ DRIVE) 1 NO
9 EXTENSION BAR 8” & 16” LONG (3/4’’ DRIVE) 1 EACH
10 TOMMY BAR (3/4’’ DRIVE) 1 NO
11 RATCHET (3/4’’ DRIVE) 1 NO
12 REDUCER (1.0” X 3/4’’ ) 1 NO
13 REDUCER (3/4’’ X 1.0” ) 1 NO
14 ALLEN KEY SET 2 MM TO 19 MM 1 EACH
15 SCREW DRIVER HEAVY DUTY 2 DIFFERENT SIZE 1 EACH
16 ADJUSTABLE SPANNER 8.0’’ & 12.0’’ 1 EACH
17 CUTTING PLIER 8” 1 NO
18 NOSE PLIER 8’’ 1 NO
19 CIRCLIP PLIER 8.0” LONG (INTERNAL) 1 NO
20 CIRCLIP PLIER 8.0” LONG (EXTERNAL) 1 NO
21 TAP SET 10,12,16,18,20,& 24 MM 1 EACH
22 TAP SET WRENCH 1 NO
23 PIPE WRENCH 12”,18” & 24 “ 1 EACH
24 FILE ROUGH (ROUND, HALF ROUND & FLAT) 12” LONG 1 EACH
25 FILE SMOOTH (ROUND, HALF ROUND & FLAT) 12” LONG 1 EACH
26 BENCH VICE (HEAVY DUTY) 1 NO
27 HAMMER (SMALL & BIG) 1 EACH
28 CHISEL 6” & 8” 1 EACH
29 HOLE PUNCH 16,18,20,& 24 MM 1 EACH
30 MALLET / PLASTIC BAR / PLASTIC HAMMER 1 NO
4.1
31 TIN CUTTER 12” LONG 1 NO

32 SINGLE ENDED OPEN SPANNER 46,50,55,60,&65 MM 1 EACH
33 FLAT RING SPANNER 60 & 65 MM 1 EACH
34 8 MM PIPE BENDING MACHINE FOR PR GAUGES ETC. 1 NO
35 CLEANING TRAYS 2 DIFFERENT SIZE 1 EACH
C TOOLS FOR WELDING & CUTTING

1 WELDING TRANSFORMER (ONLY FOR TAG WELDING) 1 NO
2 WELDING RECTIFIER ROTATING 200 AMPS (FINAL WELDING) 2 NOS
3 WELDING HELMET / SCREEN 3 NOS
4 WELDING BRUSH, HAMMER & CHISEL 3 EACH
5 RIGHT ANGLE 12” LONG 2 NOS
6 GAS CUTTING TORCH WITH EXTRA NOZZLE 1 SET
7 FLEX HOSE AND REGULATOR FOR SR. NO. 6 1 SET
8 SPANNER FOR GAS CYLINDER 2 NOS
9 ELECTRICAL ANGLE GRINDER 4.0” WHEEL DIA 2 NOS
10 ELECTRICAL ANGLE GRINDER 6.0” WHEEL DIA 2 NOS
11 MEASUREMENT TAPE STEEL 3 MTRS 3 NOS
12 MEASUREMENT TAPE 15 MTRS 1 NOS
13 WATER LEVEL MAGNETIC BASE 12” LONG 3 NOS
14 6/8 MM DIA PLASTIC TUBE 20 MTRS
15 25 MM DIA PLASTIC TUBE 25 MTRS
16 NEEDLE PLUM 100 GM WEIGHT 3 NOS
17 HACK SAW FRAME WITH BLADE 12” 2 NOS
18 CENTRE PUNCH 6” LONG 1 NOS
19 CHAIN PULLEY BLOCK 5 & 10 TON 1 EACH
20 SLING / WIRE ROPE / ENDLESS ROPE (DIFFERENT SIZES) AS REQD
21 NYLONE ROPE 1/2” AND 1.0 “ DIA 20 MTRS.
22 D SHAKLES DIFFERENT SIZE AS REQD
23 CROW BAR 1.0 MTR LONG 2 NOS.
24 ELECTRICAL MOTOR DRIVEN PIPE LINE CUTTER WITH 1 NO
WHEEL 10 TO 12” DIA
25 DRILL MACHINE WITH DRILL BITS 1 SET
D PRECISION TOOLS
1 DIGITAL VERNIER CALIPER (0 TO 300 MM) 1 NO
2 MICRO METER OUT SIDE (0 TO 25 MM) 1 NO
3 DAIL GAUGE (0.01 MM) 0 TO 10 MM TRAVEL 2 NOS
4 MAGNETIC BASE FOR DAIL GAUGE 2 NOS
5 STEEL SCALE 0 TO 1.0 MTRS 1 NO
6 FEELER GAUGE MM (100 MM BLADE LENGTH) 1 SET
7 SMALL MIRROR FOR DEFLECTION AND ALIGNMENT WORK 1 NO
8 TORCH WITH CELL 1 NO
9 MASTER LEVEL GAUGE 6” LONG 0.025 MM/ MTR ACCURACY 1 NO
10 REAMER SET (REFER COUPLING DETAILS) 1 SET
4.2
E TOOLS FOR HYDRO TESTING AND ACID PICKLING

1 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 NO
3 ACID PICKLING PUMP 5.0 HP / 3.5 KW 1 NO
4 ACID PICKLING TANK (CAN BE FABRICATED AT SITE) 150 LTRS 1 NO
5 CHEMICALS FOR PICKLING, NEUTRALISING & PASSIVATION AS REQD
F CONSUMABLES FOR INSTALLATION (MECH)

1 GRINDING WHEELS FOR 4.0” GRINDER AS REQD
2 GRINDING WHEELS FOR 6.0” GRINDER AS REQD
3 HACK SAW BLADES AS REQD
4 GLASS FOR WELDING HELMET (WHITE) AS REQD
5 GLASS FOR WELDING HELMET (BLACK) AS REQD
6 WELDING BRUSH AS REQD
7 WELDING RODS 2.5,3.25,4.0,5 & 6 MM (ADVANI OERLICON / ESAB) AS REQD
8 LINE DORI 20 MTRS
9 CHALK / PENCIL (WHITE COLOUR) AS REQD
10 TEFLON TAPE AS REQD
11 EMERY PAPER ROUGH 60 TO 100 NUMBER AS REQD
12 EMERY PAPER MEDIUM 300 TO 400 NUMBER AS REQD
13 EMERY PAPER FINE 600 NUMBER AS REQD
14 GRINDING PASTE (ROUGH AND FINE BOTH) AS REQD
15 EMERY STONE / HONING STICK 10 X10 X100 AS REQD
16 ORDINARY GREASE AS REQD
17 HAND GLOVES (CLOTH, PLASTIC & ASBESTOS ETC.) AS REQD
18 M SEAL, ARALDITE & FEVIQUICK AS REQD
19 CTC, PETROL & HSD FOR CLEANING AS REQD
20 CLEANING CLOTH, MARKING CLOTH & BANIAN CLOTH ETC. AS REQD
21 CLEANING BRUSH AS REQD
22 CELLO TAPE, PERMANENT MARKER AS REQD
23 SPONGE AS REQD
24 RUSTOLIN AS REQD
G ELECTRICAL TOOLS
1 MEGGER 500 AND 1000 V 1 NO
2 TONG TESTER 0 TO 200 AMPS DIGITAL 1 NO
3 MULTIMETER (DIGITAL WITH FREQ. MEASUREMENT UPTO 4 KHz) 1 NO
4 LINE TESTER 2 NOS
5 INSULATION PLIER 2 NOS
6 SCREW DRIVER SET 1 NO
7 WIRE STRIPPER 2 NOS
8 CRIMPING TOOL FOR INSULATED AND NON INSULATED 1 NO
LUGS UPTO 70 SQ.MM
4.3
9 EXTENSION BOARD WITH 15 AMPS & 5 AMPS, 5 PIN SOCKETS/ 3 NOS

SWITCHES
10 SERIES LAMP 1 NO
11 SOLDERING IRON, WIRE AND FLUX 1 SET
12 EARTH RESISTANCE TESTER 1 NO
13 ELECTRICAL HAND DRILL MACHINE UPTO 15 MM BIT 1 NO
14 ELECT. DRILL MACHINE WITH MAGNETIC BASE UPTO 30 MM 1 NO
15 HAND LAMP WITH GUARD AND 20 MTRS CORD 1 NO
16 NUMBER AND LETTER PUNCH 1 EACH
17 BLADE / CUTTER AS REQD
18 IMMERSION HEATER 1 NO
19 BLOWER 1 NO
20 RELAY TESTING KIT 1 SET
21 SET OF SPANNERS FOR DOING ALL ELECTRICAL WORK 1 SET
22 PHASE SEQUENCE INDICATOR 1 NO
H CONSUMABLES FOR INSTALLATION (ELECTRICAL)

1 INSULATION TAPE RED, YELLOW, BLUE & BLACK AS REQD
2 BINDING TAPE AND BUTTONS (BLACK) AS REQD
3 ELECTRICAL HAND GLOVES AS REQD
4 CTC AS REQD
5 ALUMINIUM TAGS (FOR CABLE NUMBERING) AS REQD
6 CLAMPS FOR CABLE FIXING IN TRAYS AS REQD
7 BITUMEN PAINT AS REQD
8 FERRULES NOS 0 TO 9 T TYPE 2.5 SQ.MM AS REQD
9 FERRULES NOS A TO Z T TYPE 2.5 SQ.MM AS REQD
4.4
Large Engines Division Chapter 5 - PROCEDURE
Grouting Procedure
Document no.-27.400.85.0.00
TECHNICAL NOTE
GROUTING 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 with
water along with coarse aggregates or pea gravel of size 6sq.mm. down to obtain free
flowing 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 of
grout 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
Grouting Procedure
- If the ambient temperature is very high (above 40 deg.C) and humidity also is low, the
grout 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
Grouting Procedure
PREPARATION OF FOUNDATION BLOCK
z A surcharge of 15 mm concrete is provided on the top surface of foundation block.

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

z Refer specification No. 27.400.85.0.00 for preparation of grouting material and
procedure.
z Fill 3/4th portion of pockets by slowly pouring the mixed grout. Ensure that there is no air
pocket or cavity (voids) in the pocket after poring of grout.
z After 4 hrs. of grouting the grout becomes hard, water curing is therefore necessary for
minimum 6 days.
z Carry out leveling checks once again before final grouting.
z Carry out shuttering around the baseframe with MS angle or wooden plate.
z Fill remaining 1/4th portion of the pocket with mixed grout.
z Use pure GP2 cement for grouting the space between bottom of baseplate and
foundation block top surface. Grouting will be done such that GP2 cement is filled
surrounding the baseplate and foundation block top surface. About 150 mm wide layer
surrounding the baseplate and 3/4th thickness of bottom plate of baseplate in height will
5.3
Grouting Procedure
be filled up with GP2 cement. Grouting should be continuous and from one side to avoid
voids.
z Check for leaks. The leakage can be avoided by applying dry FOSROCK GP2.
z After 4 hrs of grouting the grout becomes hard therefore water curing has to be carried
out. Curing period should be minimum 6 days.
z During curing period, meanwhile remove shuttering and carry out cementing of portion
between baseplate and edge of foundation block on all four sides. Provide suitable slope
towards the edge of foundation block.
TORQUING OF FOUNDATION BOLTS

z After 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 - PROCEDURE
Large Engines Division
Alignment Procedure
RELATIVE POSITION OF THE SHAFTS IN THE HORIZONTAL PLANE

The measurements show that :
104 - 86
A axis is more at right than B one by 2 =9
in the plane of dial gauge C1.
164 - 70
B axis is more at right than A one by 2 = 47
in the plane of dial gauge C2
Then the relative position of the shafts is as follows :
47
axis B
axis A
Plane C1 Plane C2
The experience shows that some erectors prefer to realize an intermediary sketch giving the
relative position of the traces of the axis A and B in the planes C1 and C2 before carrying out the
representation 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.
6.3
Large Engines Division Chapter 7- PROCEDURE
Chemical Cleaning Procedure for Pipe Line
CHEMICAL CLEANING PROCEDURE FOR PIPES
[Chemical Cleaning of the associated piping of DG set subsystem ( Material of construction

carbon steel - seamless Tube ASTM A 106)]
1. LOOP FORMATION
The various pipes are joined together by means of mating flanges and flexible hoses and formed
into a closed loop system alongwith the chemical circulation pump and tank.
2. PREFLUSH
The system is filled with water and leak tested, it is then continuously flushed with water into the
drain gutter. All high points if any are to be vented regularly till system is completely filled.
3. DEGREASING
The objective of degreasing is to remove all the dirt, loose rust and mill scale so as to provide an
active surface for acidic solvent treatment.
The degreasing solvent to be used is proprietary formulation of an Alkali alongwith a Non lonic
Wetting Agent.
The degreasing is to be carried out for a period of 2 hrs. at a temp. of 40 Deg. C and flow velocity
of 0.2 m/s.
4. FLUSHING
Use service water to flush the system till pH is neutral.
5. ACIDIC SOLVENT TREATMENT

The objective of acidic solvent treatment HCL 50% (strength 30%) + 50% water is to remove all
the rust, mill scale, welding slag and other oxide deposits. The circulation is to be carried out for
a 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 & FLUSHING

The acidic solvent is drained and the system is flushed completely till pH is neutral.
7. ORGANIC ACID RINSE

The 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
Large Engines Division Chapter 7- PROCEDURE
Chemical Cleaning Procedure for Pipe Line
8. DRAINING & FLUSHING

The solution is to be drained completely and flushed till pH is neutral.
9. PASSIVATION
The objective of passivation is to form a protective film on the freshly cleaned surfaces. The
passivating solution with a sodium nitrite base is circulated for 4 hrs. at ambient temp. The system
is drained and inspected.
The above procedure is carried out prior to system start up for the purpose of removing mill
scale, corrosion and other deposits. The operation provides a thin, uniform protective coating of
iron oxide and removes the loose material that might cause damage to systems down stream of
piping.
7.2
Chapter 8 - KOEL’S RECOMMENDATIONS
Large Engines Division Note on Water Quality & Recommendation
RE / RAVI / KH -1 / 5516
Date : 05/06/1999
QUALITY OF WATER REQUIRED TO PA6 ENGINES

The raw water available for a cooling tower, could contain following characteristics :
Hardness < 2500 mg / lit

Alkalimetric Content (TAC) < 400 ppm
Silicon < 100 mg / lit
Suspended Matter < 20 mg / lit
Chlorine < 300 mg / lit
Sulphates < 600 ppm
Ca Concentration Product < 15000 (F)2
Although chemicals are available to condition such water quality, our experience in the past
have shown that the problems occurs due to scaling / fouling and corrosion in the raw water
system These problems occurred either due to incorrect treatment, or bad monitoring. Based
on past experience, KOEL essentially recommends softened water for use on raw water
circuit for PA6 engines, with cooling tower applications.
The softened water will have the following characteristics :
pH >6
Total hardness < 5 ppm
Alkalimetic content (TAC) < 400 ppm
Salinity strength < 300 ppm
Suspended Matters < 20 ppm
Please note that it is impossible to one treatment procedure for water at all sites. We
recommend a pre-survey by water treatment experts from M/s Nalco or M/s Ion Exchange for
their recommendations or economical conditioning of water.
Si suspended matter concentration, Ca concentration Chlorides + Sulphates will be decided

TOS etc. case to case basis on joint consultation with engine manufacturer & water treatment
experts.
A comprehensive TIN will be prepared on the above subject.
Please note, the softened water outlet must be checked periodically and regularly to ascertain
the 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.
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 so
as 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 start
of 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 of
chemicals.
Maintain a log book of essential water parameters as suggested by the expert on the site.
8.2
TIN/COOL/VMK/001-00
Date : 14/04/1998
LT , HT COOLING WATER
Unsuitable water, results in scaling, pitting or corrosion. Use of very soft water should not
dispense with water treatment, since water absorbs Carbon - di - Oxide which renders it
corrosive.
LT WATER SYSTEM :
LT WATER system can either be.
1) Closed
2) 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 full
load.
REQUIRED WATER PROPERTIES :

1) Hardness : Total hydrodynamic hardness should be minimum. Water can be
softened by using Soda.
2) pH should be more than 6
3) Chlorine ion content should be minimum (below 100 mg/ lit)
4) Salinity should be less than 200 mg / lit
5) 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 TREATMENT

1) 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 copper
since, it is not compatible, it can be gained by adding Borate compound.
8.3
When Chromate drops below 0.5 gm/lit, it becomes dangerous. They are then capable of
originating corrosive reaction, chromate level recommended 2.5 to 3 gm/lit. Chromate does
not 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 attack
on welding therefore other components like borate - benzoates are added. 3 to 5 gm / lit
nitric contain is recommended. Nitrite are toxic from absorption of 4 gm of pure nitrite salts.
Requirements of Additives :
1) It must prevent corrosion

2) It must prevent precipitation of scaling salts.
3) It should be soluble in water
4) 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 circuit

HT cooling water temperature at engine outlet 95 to 100 oC - for pressurised circuit
LT cooling water temperature at air cooler inlet 25 to 35 oC.
2) FOR HFO(applicable only for HFO 0
HT cooling water temperature

For 0 to 60% MCR : Normal temperature 90 to 95 oC
LT cooling water temperature

Injector Water Cooling : Injector Inlet temperature : 80 to 85 oC

Injector 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
RECOMMENDED WATER QUALITY
A) LOW TEMPERATURE WATER FOR HT WATER COOLING AND LUBE OIL COOLING
SR PROPERTY SPEC.
NO.
1. pH 7.5 to 7.8
2. Total hardness (ppm) 300 max
3. Alkalinity (ppm) 50-150
4. TSS (NTU) 25 max
5. Silica (ppm) 150 max
6. Chlorides (ppm) 100 max
7. Iron (ppm) 3.0 max
8. TDS (ppm) 1000 max
B) HIGH TEMPERATURE WATER
SR PROPERTY SPEC.
NO.
1. pH 7.1 to 7.8
2. Nitrite level (ppm) 1000-1200
C) DEMINERALISED WATER
1. Conductivity (ms / cm) 30 max

2. Total Hardness (ppm) Nil
3. Si O2 (ppm) 0.5 max
4. pH 8-9
8.5
E) INCOMING WATER FOR CPP
SR PROPERTY SPEC.
NO.

2. Total Alkaline content (ppm) 400 max
3. Suspended solids (ppm) 20 max
4. pH 6.5 to 8.5
5. Chlorides, Phosphates & Sulphates (ppm) 300 max (Total)
7. Turbidity (NTU) 25 max.
8.6
E) INCOMING WATER FOR CPP
SR PROPERTY SPEC.
NO.

2. Total Alkaline content (ppm) 400 max
3. Suspended solids (ppm) 20 max
4. pH 6.5 to 8.5
5. Chlorides, Phosphates & Sulphates (ppm) 300 max (Total)
7. Turbidity (NTU) 25 max.
8.6
Chapter 9- KOEL’S RECOMMENDATIONS
Note on Lub Oil Quality & Recommendation
TIN No. : TIN/LO/VMK/001/00

Date : 19/06/1999
LUBRICATING OIL FOR PA-6 ENGINES

High speed diesel engine of our range needs specially tailored lub oil, catering to following
conditions:
1) High firing pressure
2) Mean Piston Speed
3) 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. After
through tests on chemical and physical characteristics of lubricating oil. It is subjected to rigerous
on 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 film
between cylinder liner and piston ring. Oil from this region is high temperature thereby lower
viscosity than when entering in the engine. The viscosity index expressing the temperature
dependent 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 12.5
to 16.3 cSt at 100 Deg C. In this range, correct lubricating oil film and flow will be made through
engine.
If the viscosity changes, film thickness and flow will trend towards the values which can be
dangerous 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 insolubles
c) 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, generated
from Sulphur in Fuel)
3 - 1 9.1
Other than Sulphur, Other engine running condition have an effect on this value. A too cold
water will lead to temperature on liner walls lower than dew point of Sulphuric Acid.
CAUSE OF DROP IN TBN

1) High Sulphur Content
2) Bad Adjustment of HT water Circuit
3) 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 <5
Mn TBN 5 10 16 16 20 20 25 - 28
To keep cold corrosion rate low, neutralisation capacity of lub oil must be sufficiently high. Therefore
TBN 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. (Lub
Oil 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 Leakages
c) Leakages in lub oil cooler
d) 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 bad
tightness of rings.
Flash point for new oil : 235 to 240 Deg C
Alarm 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.
3-2 9.2
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 walls
connecting rods, Crankshafts. This effect is known as low temperature detergency.
DISPERSANCY : Ability of oil to maintain in suspension all particles and unburnt components
picked by oil in piston, liners etc. All the impurities must be transported to the purifier where
most are removed. Dispersancy determined by visual inspection and automatic analysis of a
spot.
These values allow to define if the lub oil is still capable to clean and maintain the material in
suspension.
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 reduce
abrasive 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 fuel
may take place.
3-3 9.3
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 dangerous
for bearing.
FUNCTION OF LUBRICATING OIL.

1) Lubrication
2) Cooling
3) Anticorrosion
4) Antiwear
LUBRICATION SYSTEM
I) 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 should
be selected and specified viscosity grade shall be used.
The oil is circulated in crankshaft to reach big end bearing of connecting rod. Here the
oil film has to provide an oil film to resist the impact resulting from combustion pressure on
piston head.
The oil passes towards small end (through connecting rod holes) bearing of gudgeon
pin where again oil film is required. A important task of lubricating oil is to cool the bearings
(removing frictional heat)
II) PISTON COOLING

After 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 which
is 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 are
prerequisites of lub oil consumption, this rate includes losses in separators / filters.
Oil change is required when lub oil consumption gets decreased. reduced oil
consumption results in stress on oil, as oil volume will be replenished to lesser degrees by
fresh oil. Therefore will require frequent oil changes. It could also indicate a trend of external
contamination etc. (Fuel dilution into lub oil or water contamination in lub oil through improper
3-4 9.4
centrifuge settings.)
LUB OIL PARAMETERS RECOMMENDED DURING THE ENGINE RUNNING

CONDITION :
Oil temperature at engine inlet : 59 to 61 oC

Filtering : 30 µm max. and is being changed to 20 µm through main filter Glacier
for HSD and Alfa - Laval centrifuge for HFO
Flow 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 18
Max level (Lit) 660 860 960 920 1200 1340
Min Level (Lit) 560 730 810 770 1000 1115
Flow rate through 75 75 75 100 110 120
3
oil pumps m / 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 with
external / dry sump)
Volume of lub oil in the sump of PA6L CL Engine : 4,200 Lit (Engine running on HFO with
external / 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 18
Max level (Lit) 700 910 1020 1500 1980 2200
Min Level (Lit) 600 780 880 1350 1780 1980
Engine Inlet pressure : 6 to 6.5 bar

Engine outlet temperature : 73 oC
3-5 9.5
Large Engines Division Chapter 10- ELECTRICAL SYSTEM
CONTROL PANELS
Following control panels are supplied

along 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, Control

and Monitoring of DG SET.
Features
Suitable 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 Items
Central 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 the
ambient 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 of
HT water and lube oil in the engine.
This equipment allows maintaining water temp. between 40 to 50 deg. in the cylinders and
cylinder 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, Closing

of the DG Breaker manual.
Closing of breaker may be Either dead bus or
live bus.
In case of live bus of closing DG Breaker can

be momentary paralleled With either of normal
incomer.
In this Engine starting can only be done After
checking all necessary process Permissive.
TEST MODE-
In Test mode operation is similar to AUTO

operation
Grid supply fail signal is given to PLC by simulation.
ALTERNATOR
Basic 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 flows
through main rotor winding.
The flux due to this current induces an alternating emf in main stator winding.
GENERATOR PROTECTION RELAY
Combined numerical relay

Function
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 above
abnormal conditions.
10.3
AUTO SYNCHRONISATION RELAY
Function
To check following conditions for parallel

operation
FREQUENCY DIFF. WITHIN SET LIMIT

VOLATAGE DIFF WITHIN SET LIMIT.
PHASE ANGLE DIFF. WITHIN SET LIMIT
If all above conditions are fulfilled it gives

Closing command to the circuit breaker of
Which 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 per
the 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 engine
It gives following outputs,
RPM>170 (PF output) Threshold 1.
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 this
indication is not there, either RPM pickup input has failed or connection to the over speed
solenoid 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 air
module is operated.
Half speed test –

This facility is used to check OSPD safety when engine is running at speed of 840/2=420
RPM. Bring speed about 400 RPM and press ‘Half Speed Test’ button. Slowly start
increasing the speed. When indication on RPM meter will cross 840 (actual engine speed
420), OSPD safety should be operate as mentioned above.
After operating above tests or in case over speed condition are rectified, press reset push
button.
In case Engine over speed safety operates, with pressing reset button. Engine cannot be
started again.
EFMU also gives 4-20 mA output corresponding to engine speed. This output is connected
to engine RPM meter on ECP, engine RPM meter on LSS and to 4-20 mA input module of
PLC.
THERMOCOUPLE
Engine is equipped with temperature sensors, to show the temperature of exhaust gas from
the respective cylinder heads and the temperature of turbo charger. The thermocouple is
used 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 different
temperatures, then a voltage is generated. This voltage is due to the temperature difference
between the two junction”. The voltage generated is proportional to temperature.
The range of temperature measurement is from room temperature to 600 Deg. C, for all
types of engines. Considering the temperature ranges & other factors like,
We uses K-type thermocouple as a sensor for exhaust gas temperature and turbo charger
temperature 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, LT
water, HT water temperature, charge air cooler inlet and outlet temperature etc.
The resistance temperature detector (RTD) PT 100 is used as a sensor. The RTD
operates on the principle of change in the electrical resistance of a conductor takes place
when there is change in temperature. The PT 100 is a positive temperature
coefficient type RTD, means when temperature increases the resistance of the
conductor also increases. The output of the PT 100 is resistance, corresponding to
temperature. The PT 100 sensor consist of 3 wires at the output. At 0 deg its resistance is
100 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 Frequency
Monitoring Unit (EFMU) which is mounted in the GCP is needed to convert the
pickup’s output signal to one usable by the governor amplifier. The magnetic pickup
will produce a voltage output , when any magnetic material moves through the
magnetic field. Most engines have flywheels or other large gears made up of
magnetic material ( usually iron or steel). Magnetic pickups can usually be installed
without adding attachments to a gear or shaft. Non-magnetic materials, such as
aluminum, brass and some stainless, will not excite the magnetic pickup. Any
device which produces a dynamic discontinuity of magnetic material in the field of the
pickup will produce an electrical voltage.
LOCAL SENSOR STAND
Function
Monitoring of pressure parameters.
Features
Located near DG set for easy monitoring

Remote control of engine possible.
Major Components
Pressure Gauges.
Pressure Transmitters.
Push Buttons.
Indicating Lamps.
10.6
INDICATIONS
1. 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
Thermocouple / RTD Calibration Chat
Date :
THERMOCOUPLE CALIBRATION REPORT FORMAT
Standard
Sr.No Observed Reading
Reading
Temp. oC mV. Output Temp oC mV.Output
01 0 oC 0
02 30 oC 1.2
03 50 oC 2.02
04 75 oC 3.058
05 100 oC 4.1
06 150 oC 6.14
07 200 oC 8.14
08 300 oC 12.21
09 400 oC 16.4
10 500 oC 20.64
11 600 oC 24.9
REMARK :
11.1
TEMPERATURE V/S OUTPUT

CHARACTERISTICS OF K- TYPE THERMOCOUPLE
Sr.No Temperature (oC) Output (mV)
01 - 150 - 4.921
02 - 100 - 3.553
03 - 50 - 1.889
04 - 25 - 0.368
05 0 0
06 10 0.397
07 20 0.798
08 30 1.203
09 40 1.611
10 50 2.022
11 60 2.436
12 70 2.850
13 80 3.266
14 90 3.681
15 100 4.095
16 120 4.919
17 140 5.733
18 160 6.539
19 180 7.338
20 200 8.137
21 250 10.151
22 300 12.207
23 350 14.292
24 400 16.395
25 500 20.640
26 600 24.902
27 700 29.128
28 800 33.277
29 900 37.325
30 1000 41.269
31 1100 45.108
32 1200 48.828
NOTE : Add Ambient Temperature.
11.2
TEMPERATURE V/S OUTPUT

CHARACTERISTICS OF RTD PT - 100
Sr.No Temperature (oC) Output (ohm)
01 - 150 39.71
02 - 100 60.25
03 - 50 80.31
04 - 25 90.13
05 0 100.00
06 10 103.90
07 20 107.79
08 30 111.67
09 40 115.54
10 50 119.40
11 60 123.24
12 70 127.07
13 80 130.89
14 90 134.70
15 100 138.50
16 120 146.06
17 140 153.58
18 160 161.04
19 180 168.46
20 200 175.84
21 250 194.07
22 300 212.02
23 350 229.67
24 400 247.04
25 500 280.90
26 600 313.59
27 700 345.13
11.3
Large Engines Division CHAPTER-12 HANDING OVER
COMMISSIONING REPORTS
KIRLOSKAR OIL ENGINES LTD.
4 MW EMERGENCY DG SET COMMISSIONING REPORTS

Project :PANIPAT NAPHTHA CRACKER PROJECT CAPTIVE POWER PLANT
Format No. : KOEL/L&T/EPCC-4/6556/Engine-Alter details/01
ENGINE DETAILS
Engine Make :
Engine Modle :
Engine Sr. No. :
Year of Mfg. :
Speed / MHP :
Firing order :
Lube oil :
Fuel :
Direction of Rotation :
ALTERNATOR DETAILS
Make :
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 REPORT

Project : PANIPAT NAPHTHA CRACKER PROJECT CAPTIVE POWER PLANT
Format No. : KOEL/L&T/EPCC-4/6556/DG Base frame levelling/01 Date :
DG SET BASE FRAME LEVELLING
Governor Side Priming Pump Side

mm 0 Reference set
mm mm
ENGINE
mm mm
ALTERNATOR
mm mm
Phase side NGR Side
Remarks - DG Baseframe levelling done with water tube column and reading found within limit
KOEL L&T EIL
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Project : PANIPAT NAPTHA CRACKER PROJECT CAPTIVE POWER PLANT
Format No. :KOEL/L&T/EPCC-4/6554/DG Alignment/01 DATE-
Engine No.- Alternator No.-

ENGINE AND ALTERNATOR ALIGNMENT
DIAL ON ENGINE ( C1 ) DIAL ON ALTERNATOR (C2)
TOP SIDE TOP SIDE

500 ( A ) (E)
(B) (D) (F) (H)

GOV SIDE LOP SIDE GOV SIDE LOP SIDE
(C) 500 ( G )
BOTTOM SIDE BOTTOM SIDE
(Indicator is 1/100 of millimeter )

Gauge Position Dial on Engine Gauge Position Dial on Alternator
A E
B F
C G
D H
CALCULATIONS
If Dial on outer C 1 If Dial on Inner side of C1 If Dial on C2
side of Flyheel Flywheel Inner of
DV=C-A/ 2 DV=A-C/2 C li
DV=E-G/2
DH=D-B/2 DH=B-D/2 DH=F-H/2
If DV OR DH IS -VE PLOT BELOW ENGINE AXIS.
UP LOP Side
Engine Axis Engine Axis
DV DH
C1 Down C2 C1 GOV Side C2
KOEL L&T EIL

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Format No. :KOEL/L&T/EPCC-4/6554/Web deflection/01 Date :
CRANKSHAFT WEB DEFLECTION MEASUREMENT
Coupled / Uncoupled
1 Gauge on balance weight

A E
2 Insure dial when plunger seeezess reading
increases
3 Read the reading on dial( Bold & Big)
(Upper scale reading )
B D
4 1 Unit =0.01mm
Gov. Side LOP Side

C
Cylinder No.
Guage Position
1 2 3 4 5 6 7 8
A
B
C
D
E
DV=[A+E/2-C]/100
DH=B-D
INSTRUMENTS USED ( TYPE,MAKE,SL.NO.):
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Date:
Page 1 of 1

Format No :KOEL/L&T/EPCC-4/6554/Shim report/01 Date :
DG SHIM REPORT
Lube Oil Priming Pump Side

B C
Drive End side Non Drive side
A D
Governor side
Position A B C D
Shim thickness in mm
Torquing on bolts
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Page 1 of 1

Format No. :KOEL/L&T/EPCC-4/6554/Check points/01 Date :
INSTALLATION AND COMMISSIONING CHECK POINTS
SR.NO. DESCRIPTIONS VALUE

1 Base Frame to Foundation Bolts (Torque). 95 Kg.M
2 Base Frame to Alternator Bolts (Torque). 95 Kg.M
3 Base Frame to Engine Bolts (Torque). 50 Kg.M
4 Flywheel to Coupling Bolts (Torque). 95 Kg.M
0
5 Coupling to Alternator Bolts (Free )(Torque). 10 Kg.M + 36 Rotation
0
6 Coupling to Alternator Bolts (Dowel )(Torque). 10 Kg.M + 32 Rotation
7 Number punching on Coupling Bolts. Yes
8 Distance between Fly Wheel Face and Hub. mm
9 Distance between Coupling flange and Hub after spacer mm
10 Expansion Bellow Free gap mm
11 Balance Water Tank fitted at Height of mtrs.
12 Radiator outlet at the Height of mtrs.
13 Daily service Fuel tank at the Height of mtrs.
14 Engine Base Frame Levelling Done With Water Coulmn
15 Base Frame Leveling Position ok
16 HT Water Pipes cleaned with Acid Water Air
17 LT Water Pipes cleaned with Acid Water Air
18 Fuel Pipes cleaned with Acid Water Air
19 Compressed Air Pipes cleaned with Acid Water Air
20 Lub Oil Pipes cleaned with Acid Water Air
Note: Confirm the Torque Values as per Drawing.


Format No. :KOEL/L&T/EPCC-4/6554/AIR RECIVER/01 Date :
AIR RECIVER
LOCATION: DESIGNATION:
MAKE : TEST PRESS. :
Sr.No. : CAPACITY :
MAX. WORKING PRESS. : TESTED DATE :
Sr.No Check Points Remarks

1 Any physical damage observed.
2 Installation as per Drawing
3 Ensure right level of installation as per Approved Drg.
4 Tight partial to secure the equipment to the foundation bolts.
5 Ensure right name plate exist as per Approved Drg.
6 Fittment of all gauges and instrument as per the drawing.
7 Fittment of safety valve as per the drawing.
8 Ensure vents and drain provided is not fouling with the foundation.
REMARKS:-
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DATE

Format No. :KOEL/L&T/EPCC-4/6554/LT WATER RADIATOR/01 Date :
INSTALLATION OF LT WATER RADIATOR
LOCATION:
Sr.No. : CAPACITY :
MAX. WORKING PRESS. :

6 Fan assembly alignmed
7 Check fan pitch angle,adjust if necessary and check blade tip clearance.
9 Pressure test cooler element ( if applicable )
10 Check fan louvers operation,adjust if applicable
REMARKS:-
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NAME:
DATE

Format No. :KOEL/L&T/EPCC-4/6554/Compressor/01 Date :
INSTALLATION OF AIR COMPRESSOR
MAKE :
Sr.No. :

6 Fittment of all gauges and instrument as per the drawing.
7 Fittment of safety valve as per the drawing.
9 Check Oil level and correct oil grade.
10 Check compressor rotates freely by hand and no Mechanical obstruction.
11 Check all electrical connection for tightness.
12 Ensure direction of Motor.
13 Ensure safety valves for excess pressure by manually lifting and auto lifiting.
14 Ensure pressure switch for cutson/off power supply for desired pressure.
15 Ensure time requried for filling air bottle.
16 Time setting for auto draining.
REMARKS:-
KOEL L&T
SIGN.:
NAME:
DATE

Format No. :KOEL/L&T/EPCC-4/6554/HT WATER RADIATOR/01 Date :
INSTALLATION OF HT WATER RADIATOR
LOCATION:
Sr.No. : CAPACITY :
MAX. WORKING PRESS. :

6 Fan assembly alignmed
7 Check fan pitch angle,adjust if necessary and check blade tip clearance.
9 Pressure test cooler element ( if applicable )
10 Check fan louvers operation,adjust if applicable
REMARKS:-
KOEL L&T EIL
SIGN.:
NAME:
DATE
4MW EMERGENCY DG SET COMMISSIONING REPORT

Format No. : KOEL/L&T/EPCC-4/6554/LOC/01 Date
LUBE OIL COOLER (LOC)
MAKE : TESTED DATE :
Sr.No. :
Inlet - Outlet :
Volume V :
Design Pressure PS :
Design Temperature TS :
Test Pressure PT :
Sr.No. Check Points Remarks

3 Ensure Tightness of the equipment to the foundation bolts.
Ensure all the cripping bolts of PHE are properly protect against
5 rust.
6 Verify plate withdrawal space is adequate and unobstructed.
Ensure Proper alignment of Piping and proper Torque tightening of
7 bolts.
8 Installation of all instruments.( Rtd,Thermometer).
9 Check operation of Butterfly Valves.
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Format No. : KOEL/L&T/EPCC-4/6556/Pipe hydro Test/01
PIPES HYDRO TEST REPORT

CIRCUIT NAME : DRG.NO :-
SYSTEM PRESSURE : TEST PRESSURE : Bar
WORKING TEST
Sr.No. PIPE LINE NO. FROM TO SIZE(MM/NB ) DURATION RESULT
PRESSURE PRESSURE
REMARKS
KOEL L&T EIL

SIGN:
NAME :
DATE :
4EMERGENCY DG SET COMMISSIONING REPORT

Format No. :: KOEL/L&T/EPCC-4/6556/Pipes Cleaning/01 Date :
PIPELINE CHEMICAL CLEANING REPORT
CIRCUIT NAME :
DRG.NO.
Acid Organic Acid Flushing

Pipe Solvent Rinse(Caustic with
Sr.No Line from Line to Remarks
Size Treatment soda+Water) ( Water (
( Min.) Min.) Min.)
KOEL L&T EIL
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Format No. : KOEL/L&T/EPCC-4/6556/Powerl cable Test/01
POWER CABLE TEST REPORT
IR in Megaohms M Ω
Sr.No. Cable Tag No. Cable Type Cable size Length Mtr
RY YB BR RE YE BE
INSTRUMENTS USED ( TYPE,MAKE,SL.NO.): ( Megger, tong tester, multimeter)
Megger
Make-
Sr.No.
Rating
KOEL L&T EIL

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Format No. : KOEL/L&T/EPCC-4/6556/Control cable Test/01
CONTROL CABLE TEST REPORT
IR IN -
Cable Contunity check (core)
Sr.No. Cable Tag No. Cable size Length M
Type Ohm 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
KIRLOSKAR OIL ENGINES LIMITED
Format No. : KOEL/L&T/EPCC-4/6556/HT Cable/01 Date:
COMMISSIONIG CHECKS FOR HT CABLE
CABLE SIZE : 3C X 300 Sq. mm XLPE 11 KV GRADE
FROM : TO :
INSULATION TEST BEFORE HV TEST WITH 5000VOLT MEGGER

RED-EARTH YELLOW-EARTH BLUE-EARTH
RED-YELLOW YELLOW-BLUE BLUE-RED
HIGH VOLTAGE TEST

LEAKAGE CURRENT
BETWEEN VOLTAGE APPLIED
MEASURED
RED ( Y & B EARTH )
YELLOW ( B & R EARTH )
BLUE ( R & Y EARTH )
INSULATION TEST AFTER HV TEST WITH 5000VOLT MEGGER

RED-EARTH YELLOW-EARTH BLUE-EARTH
RED-YELLOW YELLOW-BLUE BLUE-RED
COUNTINITY CHECK : OK
PROPER PHASE CONNECTION : OK
ANY PHYSICAL DAMAGE : NO
REMARKS : Cable is Healthy
Megger Tong tester

Make- Make-
Sr.No. Sr.No.
Rating Rating
KOEL L&T EIL

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Format No. :KOEL/L&T/EPCC-4/6554/Pressure gauge/01 Date :
CALIBRATION / TEST REPORT OF PRESSURE GAUGE
LOCATION: GUAGE DESIGNATION:
MAKE : PRESURE SETTING. :
Sr.No. : RANGE:
TEST
SR.NO Observation / Reading (In Kg/cm2) RESULT
Master Pressure Gauge Testing Pressure Gauge
REMARK
Details of Testing Instruments Used:
1. Pressure Pump:
2. Master Pressure Gauge :
KOEL L&T EIL
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DATE

Format No. :KOEL/L&T/EPCC-4/6554/Pressure switch/01 Date :
CALIBRATION / TEST REPORT OF PRESSURE SWITCH
LOCATION: SWITCH DESIGNATION :
MAKE : PRESURE SETTING. :
Sr.No. : RANGE:
TEST
SR.NO Observation / Reading (In Kg/cm2) RESULT
Master Pressure Pump Pressure Testing Pressure switch
Operated at
REMARK
Details of Testing Instruments Used:
1. Pressure Pump:
2. Master Pressure Gauge :
KOEL L&T EIL
SIGN.:
NAME:
DATE
LARGE ENGINE DIVISION

PROJECT:PANIPAT NAPHTHA CRACKER PROJECT CAPTIVE POWER PLANT
Format No.:KOEL/L&T/EPCC-4/6556/Safety Checks/01 Date:
ENGINE SR. NO. : ALTERNATOR SR. No.:

SAFETY CHECKS
SAFETY
Sr.No. SAFETY DESCRIPTION CONDITION REMARK
STATUS
1.0 GENERAL
1.1 Turning Gear engaged Limit switch pressed Start interlock
1.2 Speed Sensing Failure Speed signal not available Trip
Engine rpm > 840 (
1.3 Engine Over Speed Simulation with EFMU 1/2 SPEED Trip
test )
1.4 Fuel control Handle locked Limit switch pressed Start interlock
2.0 LUBE OIL CIRCUIT
2.1 Low lube oil priming pressure Pressure P<0.5 Bar,RPM<170 Start interlock
2.2 Low lube oil pressure Pressure P<4.5 Bar,RPM>700 Alarm
2.3 Very low lube oil pressure Pressure P<3.5 Bar,RPM>700 Trip
2.4 Very low lube oil pressure Pressure P<2.5 Bar,RPM>170 Trip
2.5 Low T/C lub oil pressure Pressure P<1 Bar,RPM>170 Alarm
2.6 High lub oil temperature Temp T>65 Deg. C Alarm
2.7 Very high lub oil temperature Temp T<70 Deg. C Trip
3.0 HT WATER CIRCUIT
3.1 HT Water Engine inlet pressure low Pressre P<1.5 Bar, RPM>170 Alarm
3.2 Low level in balance water tank ……… Alarm
3.3 Very low level in balance water tank ……… Trip
3.4 HT water Engine outlet temp. High Temp T > 90 Deg. C Alarm
3.5 HT water Engine outlet temp. Very High Temp T > 95 Deg. C Trip
4.0 LT WATER CIRCUIT
4.1 LT water Engine inlet pressure low Pressure P < 1.5 Bar, RPM >170 Alarm
5.0 FUEL OIL CIRCUIT
5.1 Fuel oil pressure low Pressure P < 1.5 Bar, RPM >170 Alarm
6.0 AIR CIRCIUT
6.1 Control Air pressure low Pressure P < 7 Bar Alarm
6.2 Starting air pressure low Pressure P < 16 Bar Start interlock
7.0 ELECTRICAL CHECKS
7.1 Emergency Stop - Local ( LSS ) By pressing Emergency switch Trip
7.2 Emergency Stop - Remote ( GCP ) By pressing Emergency switch Trip
7.3 Alternature fault From REM 543 Protection relay Alarm
7.4 Alternator fault trip From REM 543 Protection relay Trip
7.5 Alternator winding temperatur High Temp T > 110 Deg. C Alarm
7.6 Alternator winding temperatur Very High Temp T > 120 Deg. C Trip
7.7 Alternator Bearing temperature High Temp T > 85 Deg. C Alarm
7.8 Alternator Bearing temperature Very High Temp T > 90 Deg. C Trip
7.9 PLC Failure DC Supply failed Trip
7.10 Breaker Close / Trip operation From TNC Status
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NAME:

Format No. : KOEL/L&T/EPCC-4/6556/GCP TEST REPORT/01 Date :
GENERATOR CONTROL PANEL
LOCATION: DRG. NO.:
PANEL Sr. No.: MAKE:
TESTING DETAILS
TEST RESULTS REMARKS

VISUAL CHECKS
DIMENSIONAL CHECK
LAYOUT AND BILL OF MATERAIL
CHECK
WIRING / CONTINUTY TEST
INSULATION RESISTANCE
CHECKS WITH 500V
MEGGERBETWEEN ALL
CIRCUITS AND EARTH FOR 1
MINUTE.(All electronic,
microprocessor based components
FUNCTIONAL / OPERATIONAL
TESTS
Generator Protection Relay, Make – ABB, Type- REM-543
A. 87 DIFFERNTIAL
PHASE CURRENT ( Amps.) CB TRIP SIGNAL ENGINE SHUT REMARKS
DOWN SIGNAL
SET OBS.
R
Y
B
B. 51V ( Voltage Controlled Over Current )

PHASE CURRENT ( Amps.) Time Delay CB TRIP SIGNAL REMARKS
Calculated Obs
SET OBS.
R
Y
B
C. 51 N ( Earth Fault )
CURRENT ( Amps.) Time Delay CB TRIP ENGINE REMARKS
SIGNAL SHUT
SET Observed SET Observed
D. 46 NEGATIVE PHASE SEQUENCE
NEGATIVE SEQ.CURRENT Time Delay CB TRIP SIGNAL REMARKS
( A)
E. 27 ( Under Voltage )
NEGATIVE SEQ.CURRENT Time Delay CB TRIP SIGNAL REMARKS
F. 59 ( Over Voltage )
CB TRIP ENGINE REMARKS
SIGNAL SHUT
PHASE VOLTAGE ( Amps.) Time Delay
DOWN
SIGNAL
R
Y
B
G. 32 ( Reverse Power )
VALUE OF POWER Time Delay CB TRIP SIGNAL REMARKS
H. 81U ( Under Frequency )

FREQUENCY Time Delay CB TRIP SIGNAL REMARKS
I. 81O ( Over Frequency )

CB TRIP ENGINE REMARKS
SIGNAL SHUT
FREQUENCY Time Delay
DOWN
SIGNAL
CONTROL FUNCTION OF GENERATOR PROTECTION RELAY
CONTROL FUNCTION RESULT REMARKS

Breaker Closing
Breaker Tripping
Local/Remote selection
Input/Output Logic
Fault Annunciation
Mimic Display
Testing of the Other Instruments/ components
ITEM SR.NO. RESULTS REMARK

Engine RPM meter
Turbocharger RPM meter 1
Turbocharger RPM meter 2
Hz Mete
PF meter
KW meter
KVAR meter
KWH meter
Ammeter DC
Voltmeter DC
Ammeter
KV meter
Allen Bradley PLC system
Engine Freq. Monitoring Unit
Turbocharger Freq. Mon. unit
Auxiliary Relay & MCB’s
Status, Alarm & Trip Indicators
Tube – light, exhaust fan and switch
socket
Hooter, Buzzer & Flasher
Control Scheme
Output contacts
Make- Make-
Sr.No. Sr.No.
Rating Rating
KOEL L&T EIL

SIGN.:
NAME:
DATE:

Format No.: KOEL/L&T/EPCC-4/6556/Alternator/01 Date :
ALTERNATOR
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.:
INSULATION
RESISTANCE
Mohms.
MEASUREMENT ohms
U1 - U2
STATOR V1 - V2
W1 - W2
B) INSULATION RESISTANCE TEST OF WINDING WITH 500 V FOR 1 MIN.:
Mohms. MEASUREMENT ohms
UH12
AUX. EXCITER
WH12
EXCITER U-V
C) PT 100 STATOR WINDING :

RESISTANCE A1 A2 A3 A4 A5 A6
IN Ohms
D) PT 100 BEARING :
RESISTANCE DRIVE END NON DRIVE END
IN Ohms
Page1 of 2

E) INSULATION RESISTANCE TEST OF SPACE HEATER WITH 500 V FOR 1 MIN.:
Mohms. MEASUREMENT ohms
AUX. EXCITER H1 - H2
F) DIRECTION OF ROTATION : U-V-W
G) ANY ABNORMAL SOUND OBSERVED :
Megger
Make-
Sr.No.
Rating
KOEL L&T EIL
NAME:
SIGN.:
DATE:
Page2 of 2
Format No. : KOEL/L&T/EPCC-4/6556/NGR CT CDate:
COMMISSIONIG CHECKS FOR NGR CT s
LOCATION : NEUTRAL GROUNDING RESISTOR PANEL
MAKE :
PRIMARY CURRENT : SECONDERAY CURRENT :
NETRUAL AFTER STAR POINT

CORE-I CORE-II CORE-III
Sr.No.
VA / CLASS
RATIO CHECK
PRIMERY SECONDERY CURRENT MEASURED

CURRENT NEUTRAL POINT
APPLIED CORE-I
25 A
50 A
100 A
POLARITY CHECK :
COUNTINITY CHECK :
ANY PHYSICAL DAMAGE :
REMARKS : CT IS HEALTHY
Megger Tong tester

Make- Make-
Sr.No. Sr.No.
Rating Rating
KOEL L&T EIL

SIGN :
NAME :
Format No. : KOEL/L&T/EPCC-4/6556/Breaker PT report/01 Date:
COMMISSIONIG CHECKS FOR BREAKER PT s
LOCATION : DG INCOMER BREAKER
MAKE :
PRIMARY VOLTAGE : SECONDERAY VOLTAGE :
R-PHASE Y-PHASE B-PHASE

CORE-I CORE-II CORE-III CORE-I CORE-II CORE-III CORE-I CORE-II CORE-III
Sr.No.
VA / CLASS
RATIO CHECK
PRIMERY SECONDERY VOLTAGE MEASURED

VOLTAGE R-PHASE Y-PHASE B-PHASE
APPLIED
66 V
1
198 V
3
330 V
5
POLARITY CHECK :
COUNTINITY CHECK :
REMARKS : PT IS HEALTHY
Megger Tong tester

Make- Make-
Sr.No. Sr.No.
Rating Rating
KOEL L&T EIL

SIGN :
NAME :
Format No. : KOEL/L&T/EPCC-4/6556/Breaker CT/01 Date:
COMMISSIONIG CHECKS FOR BREAKER CT s
LOCATION : DG INCOMER BREAKER
MAKE :
PRIMARY CURRENT : SECONDERAY CURRENT :
R-PHASE Y-PHASE B-PHASE

Sr.No.
VA / CLASS
RATIO CHECK
PRIMERY SECONDERY CURRENT MEASURED

CURRENT R-PHASE Y-PHASE B-PHASE
APPLIED
20 A
40 A
100 A
POLARITY CHECK :
COUNTINITY CHECK :
REMARKS : CT IS HEALTHY
Megger Tong tester

Make- Make-
Sr.No. Sr.No.
Rating Rating
KOEL L&T EIL

SIGN :
NAME :

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

Megger Tong tester / Multimeter
Make- Make-
Sr.No. Sr.No.
Rating Rating
KOEL L&T EIL

SIGN.:
NAME:
DATE:

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

Make- Make-
Sr.No. Sr.No.
Rating Rating
KOEL L&T EIL

SIGN.:
NAME:
DATE:

Project :PANIPAT NAPTHA CRACKER PROJECT CAPTIVE POWER PLANT
Format No. ::KOEL/L&T/EPCC-4/6554/LOP/01 Date :
LUBE OIL PRIMING PUMP
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:-

Make- Make-
Sr.No. Sr.No.
Rating Rating
KOEL L&T EIL

SIGN.:
NAME:
DATE:

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

Make- Make-
Sr.No. Sr.No.
Rating Rating
KOEL L&T EIL

SIGN.:
NAME:
DATE:

PROJRECT : PANIPAT NAPHTHA CRACKER PROJECT CAPTIVE POWER PLANT
Format No. : KOEL/L&T/EPCC-4/6556/EMDAC/01 Date :
ELECTRIC MOTOR DRIVEN AIR COMPRESSOR
COMPRESSOR MAKE: MODEL :
CAPACITY: Fab.. No.
UNIT RPM: Max. W/Pr :
MOTOR TAG NO.: MAKE:
RATING: VOLTS:
RPM : AMPS:
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) WINDING RESISTANCE : U1-U2 / U2-U3 / U3-U1
D) DIRECTION OF ROTATION FROM DRIVE END :
E) NO LOAD CURRENT :
F) RUNNING CURRENT ON LOAD ( AMPS) :
G) ANY ABNORMAL SOUND OBSERVED :
H) PRESSURE SWITCH SETTING VALUE: 22 Bar ON -30Bar CUTT OFF
I) AIR FILLING TIME ( 0-30 Bar ) Min.:
J)COMPRESSOR OIL GRADE :

Megger Tong tester/ Multimeter
Make- Make-
Sr.No. Sr.No.
Rating Rating
KOEL L&T EIL
SIGN.:
NAME :
KIRLOSKAR OIL ENGINES LIMITED Large
Engines division

Format No. :KOEL/L&T/EPCC-4/6554/HT PUMP/01 Date:
PRE HEATING MOTOR
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 :


Make- Make-
Sr.No. Sr.No.
Rating Rating
KOEL L&T EIL
SIGN.:
NAME:
DATE:
Large Engines division
Format No. : KOEL/L&T/EPCC-4/6554/PREHEATER/01 Date :
PRE-HEATER
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

Make- Make-
Sr.No. Sr.No.
Rating Rating
KOEL L&T EIL
SIGN.:
NAME:
DATE:

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

Make- Make-
Sr.No. Sr.No.
Rating Rating
KOEL L&T EIL

SIGN.:
NAME:
DATE:

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

Make- Make-
Sr.No. Sr.No.
Rating Rating
KOEL L&T EIL

SIGN.:
NAME:
DATE:

PROJRECT : PANIPAT NAPHTHA CRACKER PROJECT CAPTIVE POWER PLANT
Format No. : KOEL/L&T/EPCC-4/6556/EDG START UP/01
FIRST START UP CHECK SHEET FOR DG SET
Sr. No Description YES / NO

A Engine and Alternator
1 Engine-Alternator alignment
2 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 (Check
satisfactory operation by simulation and certify)
a) Overspeed safety (RPM>840) - Trip
b) Turning gear engaged
c) Alternator fault - Trip
d) 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 gear
5 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 & Electrical
1 Complete erection of control panels for test
2 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 between
2 cables, core and w.r.t earth. Test the LT cables by 500V megger
and HT cables, alternator by 5000V megger. Carry out Hypotest of
HT cables by injecting 1.2 times rated voltage for 1 min. The
megger value should be greater than 300 Mohm. Earth pits
resistance will be measured to check correctness of Pits. The
resistance 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.
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 - Trip
b) Speed sensing failure - Trip
c) Starting refusal
d) Breaker ON / OFF trip
e) Starting interlock - No trip signal on GCP I.e. safety STOP
f) Starting interlock - DG incoming breaker is open
13 Ensure all instruments are calibrated at site.Test certificates from
supplier is to be obtained.
14 Ensure the engine Selector switch on GCP is selected in AUTO
mode.
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 system
1 All pressure gauges/ switches to be checked.
2 All temperature gauges/ switches/ thermometers/ RTDs/
Thermocouples to be check and recorded.
a) Low LT water pressure - Alarm (Pressure < 1.5 bar)
4 Check expansion level low alarm is not persisting on GCP as this
5 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 system
Thermocouples to be checked and recorded.
Page2 of 4
a) HT water outlet safety - Alarm at 90°C and Trip at 95°C
b) 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 system
Thermocouples to be checked.
3 Check specifications of Lube oil - IOC - SERVO ULTRA 40 or HP -
DISOLA M 4015.( As per recommendation from KOEL ).
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 maximum
mark 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. It
should run for every 20 seconds and stop for the next 15 seconds to
obtain lubricating pressure about 0.5 bars.
8 Ensure lub. oil priming pr. Healthy indication available.
F Fuel Oil System
1 Fuel consumption measurement equipment 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 System
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 pressure
22 and 30bar respectively.
5 Ensure motor driven compressor is maintaining air bottle pressure
between 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 System
I Charge Air and Exhaust system

Remarks:
KOEL L&T EIL
SIGN.:
NAME:
DATE:
Page4 of 4
Format No. :KOEL/L&T/EPCC-4/6554/DG PARAMETER/01
MECHANICAL PARAMETRES SHEET-1
SR. TIME AND READING

PARAMETERS
NO 1 2 3 4
Time
1 HOUR METER Reading
2 ELECTRICAL LOAD ( MW )
3 INJECTOR NOTCH
4 ENGINE SPEED ( RPM )
5 TURBOCHARGER -1 SPEED ( RPM )
6 TURBOCHARGER -2 SPEED ( RPM )
7 AMBIENT TEMPERATURE 0C
8 CRANK CASE PRESSURE ( H2O ) mm.
LT WATER SYSTEM
9 LT WATER PUMP OUTLET pressure Kg/cm 2
10 AIR COOLER INLET TEMPERATURE 0C
11 AIR COOLER OUTLET TEMPERATURE 0C
12 DELTA LT ( ACROSS CAC ) 0C
13 LUBE OIL COOLER OUTLET temp. OC
14 RADIATOR INLET temp. OC
15 RADIATOR OUTLET temp. OC
16 DELTA LT ( ACROSS RADIATOR ) 0C
17 BALANCE WATER TANK LEVEL mm
HT WATER SYSTEM
18 HT WATER PUMP OUTLET pressure Kg/cm 2
19 ENGINE INLET temp.OC
20 ENGINE OUTLET temp. OC
21 RADIATOR INLET temp. OC
22 RADIATOR OUTLET temp. OC
23 DELTA HT ( ACROSS RADIATOR ) temp. 0C
24 BALANCE WATER TANK LEVEL mm
LUBE OIL SYSTEM
25 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.OC
29 LUBE OIL COOLER INLET temp.OC
30 LUBE OIL COOLER OUTLET temp. OC
31 DELTA LO ( ACROSS LOC )
32 LUBE OIL SUMP LEVEL mm
1 of 3
MECHANICAL PARAMETRES SHEET-1
TIME AND READING

SR.NO PARAMETERS
1 2 3 4
Time
FUEL OIL SYSTEM
33 FUEL ENGINE OUTLET pressure Kg/cm2
34 HSD ENGINE INLET FLOWMETER reading
35 HSD DUPLEX FILTER IN SERVICE ( A / B )
36 HSD DAY TANK LEVEL mm
37 FUEL DRIP TANK LEVEL mm
AIR SYSTEM
38 CHARGE AIR COOLER INLET pressure Kg/cm2
2
39 CHARGE AIR COOLER OUTLET pressure Kg/cm
2
40 STARTING AIR pressure Kg/cm
2
41 CONTROL AIR pressure Kg/cm
EXHAUST SYSTEM/BANK A B A B A B A B
O
42 EXHAUST CYLINDER -1 temp C
43 EXHAUST CYLINDER -2 temp OC
50 TURBOCHARGER INLET temp OC
51 TURBOCHARGER OUTLET temp OC
2 of 3
ELECTRICAL PARAMETRES SHEET-2
TIME AND READING

SR.NO PARAMETERS
1 2 3 4
Time
1 HOUR METER Reading
2 LOAD IN KW
3 POWER FACTOR ( PF )
4 FREQUENCY Hz ( f )
5 UNIT GENERATION KWH
6 ALTERNATOR AIR INLET TEMPERATURE
7 ALTERNATOR AIR OUTLET TEMPERATURE
GENERATOR VOLTAGE
8 PHASE RY Kv
9 PHASE YB Kv
10 PHASE BR Kv
GENERATOR CURRENT
11 PHASE R Amp.
12 PHASE Y Amp.
13 PHASE B Amp.
WINDING TEMPERATURE
14 WINDING TEMPERATURE- 1
ALTERNATOR BEARING TEMPERATURE
20 DRIVING END ( DE )
21 NON DRIVING END ( NDE )
EXCITATION SYSTEM
22 EXCITATION VOLTAGE ( V )
23 EXCITATION CURRENT ( A )
3 of 3

Erection and Commissioning Procedure

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Erection and Commissioning Procedure

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Kirloskar Oil Engines Ltd.

INSTALLATION & COMMISSIONING MANUAL

LIST OF DRAWINGS FOR PROJECT EXECUTION

LUBE OIL CIRCUIT

SR. NO. DRAWING NO. DESCRIPTION

COMPRESSED AIR CIRCUIT

CHARGE AIR EXHAUST CIRCUIT

LIST OF DRAWINGS FOR

SR. NO. DRAWING NO. DESCRIPTION

TECHNICAL SPECIFICATIONS FOR

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

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

Inform shortage of material, if any in advance.

Correctness of material should be checked for weekly plan.

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

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

All Supports should be horizontal.

Seamless pipe : 6013 - Advani S & 2S or equivalent of reputed make.

Size of rod Amps

Pipe Size (mm) Root Weld (mm) Main Weld (mm)

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

Preparation of pipe surface before application of paint.

a) Remove all oil on pipe surface with the solvent.

First apply red oxide or Primer.

PIPE LINE PAINTING COLOUR CODE

Sr. No. System Colour Colour shade as

Note: Do not apply red Oxide on exhaust ducting.

TECHNICAL SPECIFICATIONS FOR INSTALLATION

2. GENERATOR CUM SYNCHRONISING PANEL

s) Check the following functions are OK.

6. EARTHING PITS AND EARTHING GRID.

a) Megger the Cable and record the same.

STATUTORY RULES & SAFETY REGULATIONS

CONTRACTORS OBLIGATIONS / LIABILITIES:

LIST OF TOOLS REQUIRED FOR

31 TIN CUTTER 12” LONG 1 NO

C TOOLS FOR WELDING & CUTTING

E TOOLS FOR HYDRO TESTING AND ACID PICKLING

F CONSUMABLES FOR INSTALLATION (MECH)

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

H CONSUMABLES FOR INSTALLATION (ELECTRICAL)

- The top surface of foundation block is plane and rigid.

PREPARATION OF FOUNDATION BLOCK

z A surcharge of 15 mm concrete is provided on the top surface of foundation block.

PARTIAL GROUTING OF FOUNDATION BOLT

TORQUING OF FOUNDATION BOLTS

RELATIVE POSITION OF THE SHAFTS IN THE HORIZONTAL PLANE

CHEMICAL CLEANING PROCEDURE FOR PIPES

[Chemical Cleaning of the associated piping of DG set subsystem ( Material of construction

5. ACIDIC SOLVENT TREATMENT

6. DRAINING & FLUSHING

7. ORGANIC ACID RINSE

8. DRAINING & FLUSHING

QUALITY OF WATER REQUIRED TO PA6 ENGINES

Hardness < 2500 mg / lit

The softened water will have the following characteristics :

Si suspended matter concentration, Ca concentration Chlorides + Sulphates will be decided

A comprehensive TIN will be prepared on the above subject.

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

1) A suction strainer should be provided and maintained in clean condition.

REQUIRED WATER PROPERTIES :

NECESSITY OF WATER TREATMENT

1) It must prevent corrosion