Four (4) CAT 3512 B Series or latest model diesel engines coupled to alternators conforming Tier-I emission norms. Each engine should be with following specifications:
Caterpillar 12-cylinder, direct-injected, turbocharged, after cooled diesel oilfield engine; 4 cycle, 170 mm bore x 191 mm stroke (6.7 in bore x 7.5 in stroke) with separate-circuit after- cooler and optimized for low emissions. Engine rotation: standard (counter-clockwise as viewed from flywheel end). Engine Rating = 1250 to 1300 gross horse power at 1000 RPM.
EMISSION NORMS
The engine shall conform to minimum Tier-I or latest emission norms, it shall be bidder‟s endeavor to offer Caterpillar make engines only. Engine Fault Diagnostic Tools (both software as well as hardware) shall be supplied along with the unit. Bidder shall categorically confirm in the bid that the offered software is for the particular engine.
Each engine should be complete with the following:
AIR INLET SYSTEM
After cooler core, corrosion resistant Air cleaner, Heavy duty, with soot filter. Service indicators.
CONTROL SYSTEM
Caterpillar ADEM - II ECM or any advanced version as per engine design, LEFT HAND. Requires 24V DC 10-amp continuous, 20- amp intermittent, clean electrical power.
COOLING SYSTEM
In order to ensure compliance in use, optional or customer-supplied radiators must be capable of rejecting enough heat to allow proper operation at worst case site conditions, and also must supply 122 deg F (50 deg C) SCAC cooling water to the after cooler inlet, with an SCAC flow rate of at least 100 GPM (379 l/m) with an ambient temperature of 86 deg F (30 deg C) and at-site conditions (including altitude considerations). Maximum allowable SCAC flow rate is 115 GPM (435 l/m).
RADIATOR COOLED LAND BASED:
Outlet controlled thermostat and housing. Jacket water pump, gear driven. Dual outlets: 88.9 mm O.D. (3.5 in) elbow hose connections. After cooler fresh water cooling pump (SCAC), gear driven centrifugal SCAC pump circuit contains a thermostat to keep the after cooler coolant from falling below 30 deg C (85 F).
EXHAUST SYSTEM
Exhaust outlet: 292 mm I.D. (11.5 in).
12-10.5 mm dia holes EQ SP, 376 mm bolt hole dia.
Exhaust flexible fitting:
318 I.D. mm (12.5 in)
12-14 mm dia. holes EQ SP, 375 mm bolt hole dia. 306.6 mm tall with compressed gasket.
Exhaust adapter:
297 mm I.D. to 340 mm I.D. (11.7 in to 13.4 in).
12-10.5 mm dia. holes EQ SP, 376 mm bolt hole dia.
12-13.8 mm dia. holes EQ SP, 430 mm bolt hole dia.
158.5 mm tall with compressed gasket.
Weldable flange:
360 mm I.D. (14.2 in).
12-13.8 mm dia. holes EQ SP, 430 mm bolt hole dia.
17.4 mm wide with compressed gasket.
Exhaust manifolds, dry.
Dual turbochargers with w/c bearings.
12” SPARK ARRESTING MUFFLER – INDUSTRIAL GRADE:
Includes nuts, bolts, and flanges for connections.
FLYWHEELS & FLYWHEEL HOUSINGS
Analog gauges with digital display data for:
Engine oil pressure gauge.
Engine water temperature gauge.
Fuel pressure gauge.
System DC voltage gauge.
Air inlet restriction gauge.
Exhaust temperature (prior to turbochargers) gauge.
Fuel filter differential pressure gauge.
Oil filter differential pressure gauge.
Service meter (digital display only).
Tachometer (digital display only).
Instantaneous fuel consumption (digital display only).
Total fuel consumed (digital display only).
Engine start-stop (off, auto start, manual start, cooldown timer).
LUBE SYSTEM Crankcase breather Oil cooler
Oil filter.
Shallow oil pan
Oil pan drain valve, 2' NPT female connection
Lubricating oil, SAE 10W30, Caterpillar DEO (CG4) 643 L.
MOUNTING SYSTEM
Rails, mounting, floor type, 254 mm (10 in).
POWER TAKE-OFFS Accessory drive.
Lower LEFT HAND front (available for PTO usage).
Front housing, two-sided PROTECTION SYSTEM
ADEM - II ECM or any advanced version monitoring system provides engine de-ration, or shutdown strategies to protect against adverse operating conditions. Selected parameters are customer-programmable. Status available on engine- mounted instrument panel and can be broadcast
through the optional customer communications module or programmable relay control module(s).
Initially set as follows:
Safety shutoff protection, electrical: Oil pressure, water temperature, over speed, crankcase pressure, after cooler temperature. Includes air inlet shutoff, activated on over speed or emergency stop.
Alarms, electrical:
ECM voltage, oil pressure, water temperature (low and high), over speed, crankcase pressure, after cooler temperature, low water level, air inlet restriction, exhaust stack temperature, filter differential pressure (oil and fuel).
Derate, electrical:
High water temperature, crankcase pressure, after cooler temperature, air inlet restriction, altitude, exhaust temperature.
Emergency stop push button, located on instrument panel. Alarm switches (oil pressure and water temperature), for connection to alarm panel.
STARTING SYSTEM
Air starting motor, RIGHT HAND, 620 to 1034 kPa (90 to 150 psi), LEFT HAND Control Air silencer
GENERAL
Paint, Caterpillar Yellow Vibration damper and guard Lifting eyes
WITH THE FOLLOWING ACCESSORIES INCLUDED:
GOVERNOR CONVERSION:
TECHNICAL: Converts engine to direct rack controls requiring 0-200 MA DC control.
FLEXIBLE COUPLING:
Viscous damped.
Includes flywheel guard.
COUPLING HUB - 127 MM DIA MAX:
FOR USE WITH: 127 mm (5 in) diameter maximum shaft, 31.7 x 31.7 mm (1-1/4 x 1-1/4 in) key.
ACOUSTIC ENCLOSURE:
The acoustic enclosure shall be designed for minimum 25 db(A) insertion loss or for meeting the ambient noise standards, whichever is on the higher side. (As per guideline of Central Pollution Control Board, Januray 2008 (Ministry of Environment & Forests, Govt of India)
The DG set shall be provided with proper exhaust muffler with insertion loss of minimum 25 db(A) Authorised agencies for certification as per CPCB
i) Automotive Research Association of India, Pune ii) National Physical Laboratory, New Delhi
iii) Naval Science & Technology Laboratory, Visakhapatnam iv) Fluid Control Research Institute, Palghat.
v) National Aerospace Laboratory, Bangalore
COMPONENTS TO BE OFFERED WITH POWER PACK
Two (2) sets of standard tool kit as per ANNEXURE-I (indicated at the end of this section) for carrying out normal maintenance of engine should be supplied in a conventional tool box.
In addition to above, the special tools as mentioned below should be supplied along with the engine
o Alternator Alignment Tool kit with Instruction Manual - 2 Nos.
o Blow-by Measurement Tool kit - 1 No.
o Fuel Injector Timing setting tool - 1 No.
o Air Restriction Measurement tool - 1 No.
o Heavy Duty Digital Multimeter – 2 Nos.
o Lube Oil testing Kit - 2 Nos.
o Infra Red Digital Tachometer( 0 to 9999 RPM) – 2 Nos.
o Belt Tension Gauge - 2 Nos.
o Laptop (ET) for monitoring Engine Parameters. – 1 No.
o CAT battery Charger/ Charging Alternator & 24 V Battery for ECM for each unit – 1 Set
o Rechargeable Emergency lamp - 2 Nos.
Bidder has to quote the price of the tool kit and special tools separately. The cost of the tool kit and special tools will be considered for commercial evaluation.
OPERATING SITE CONDITION
The engines should be suitable for operation at the following site condition – Engine site temperature - 41Cent. (Max)
Engine site temperature - 6Cent. (Min) Maximum relative humidity at 21C – 100%
Maximum relative humidity at 35C - 95%
Maximum relative humidity at 41C - 70%
Altitude above sea level - 150 m.
Average annual rainfall - 343 cms.
NOTES FOR SECTION 13