Sanskar Genset Pvt.Ltd Paldi, Ahmedabad, Gujarat

High class sheet metal fabricated enclosure for reducing the noise level of DG set & also acts as weather proof housing. Genset will be a integral part of acoustic enclosure and whole construction will be multi-fold sheet channels & ISMC sections. Enclosure construction is fully bolted keeping in view the major service requirements all doors are provided with specially designed hinges and lockable handles, Battery, & Control Panel is housed inside the enclosure, where as Fuel tank, outside the acoustic enclosure.   -> ACCOUSTIC MATERIAL Rock wool in the form of slabs of 50 -100 mm thickness and 64 KG Metres cube density, Compressed along with 4 mm thick vinyl sheet and nonferrous sheet. The 3 mm thick Vinyl sheet is pasted on the inside of the outer wall for anti-draining effect. Non ferrous lead sheet 0.4 mm is sandwiched between Rock wool layers. Specification of Rock wool conforms to IS 8183. Further to increase the life of Acoustic material resin coated fiber glass cloth is provided on exposed surface of Rock wool slabs and the panels are supported by perforated sheets.   -> SURFACE TREATMENT Weather proof and anti-corrosion treatment provided to the entire structure i.e.2 coats of epoxy primer, after sand – blasting followed by 2 coats of epoxy paint of durability, dependability and longer life.   -> VENTILATION IBRATION ISOLATION    # The container is modular construction with the provision to assemble and       dismantle easily.    # The container is fabricated 16 / 18 SWG-CRCA-sheet. The sheet metal components       are pretreated and is P.P. based coated (inside as well outside) for long life. All       nuts and bolts, hardware are Zinc coated.    # Fuel tank provided with breather, drain plugs for draining mobile oil and diesel &       with the level Indicator.    # Fuel to be fitted from outside and has locking arrangement    # Battery is accommodated in the enclosure.    # Doors are gasketed with quality EDPN gaskets to avoid leakage of sound.    # Sound proofing of enclosure is done with high quality rock wool confirming to IS       8183 to suitable thickness and density.    # The rock wool is further covered with fibre glass cloth and perforated power coated       sheets.    # A reactive type residential silencer is provided with in the DG to control exhaust       noise.    # Specially designed attenuators are provided to control sound at air entry to the       enclosure and exit from the enclosure.    # To make the system vibration free, engine and alternator (single bearing) are       mounted on on specially designed anti-vibration pads.    # The enclosure is designed and layout of the equipment is such that there is easy       access to serviceable parts. Acoustic enclosure is designed in such a way that there are no hot pockets around engine and it is provided with suitable designed engine radiator / or additional axial flow fan and does not allow the temperature to rise more than 7 o C., above ambient temperature besides this provision are make in such a way that engine gets combustion air & cooling air within Max.+5 o C of ambient temperature. To achieve optimam output and minimum sound level from the DG set, suitable opening with acoustic hoods are provide for increasing the inflow of air required for combustion & forced ventilation. Air intake and Exhaust fans or single unit velocity Axial flow fans as per the recommendations and engine requirement are provided.    # Fan blade size with speed of 900 – 2800 RPM depending on the requirement.    # Acoustic hoods with noise splitters provided to block and reduce the sound       leakage.    # The sound control system designed to suppress the sound level to 75 db maximum       at 3 metres distance. -> SILENCER Specially designed low noise silencer is provided. Silencer & engine exhaust outlet, Connected with flexible SS below.

1.GAS ENGINE ASHOK LEYLAND LIMITED make Gas Engine : Water cooled, Electric starting, Four Stroke Multi Cylinder Gas Engine running at 1500 RPM confirming to BS:5514/ISO; 3046 Standards. -> COOLING SYSTEM      # Radiator for Naturally aspirated Engines      # Cooling water centrifugal pump      # Coolant      # By pass thermostate -> EXHAUST SYSTEM      # Exhaust gas turbocharger      # Exhaust Mainfold water cooled      # 1 No. Industrial type Silencer -> FUEL SYSTEM      # Metronic      # Spark Plugs      # Carburetor Link      # Flexible House      # Gas Regulators      # Electrical Valve -> LUB OIL SYSTEM      # Lub oil filter      # By pass filter -> AIR SYSTEM      # Air intake manifold      # Air cleaner - dry type mounted ( filter efficiency 99.9% ) -> GOVERNOR      # Electronic / Hydrulic Governing System -> STARTING SYSTEM      # Electric Starter - 12 Volts      # Battrey charging alternator -> COUPLING ARRANGEMENT      # Directly coupled      # Flywheel to suit flexible coupling      # Flywheel housing -> SAFETY CONTROLS      # High Water temperature      # Low lub oil pressure      # Engine overspeed ( optional ) -> ENGINE INSTRUMENT PANEL ENGINE MOUNTED      # Starting switch with key      # Water temperature gauge      # Lub oil pressure gauge      # Tachometer with hour meter -> MANUAL  Engine operation & maintenance manual      # Parts catalogue      # Engine maintenance schedule Warranty card -> PURCHASER WILL HAVE TO PROVIDE THE FOLLOWINGS :      # Gas scrubber with fitters      # Mechanical Valve      # Necessry piping bfor Gas inlet   2.ALTERNATOR Synchronous alternator of KIRLOSKAR / CROMPTON / STAMFORD / LEROYSOMER make rated @ 1500 RPM at 0.8 lagging PF at 415 V suitable for 50 Hz 3 phase system. The alternator shall be in SPDP enclosure, IP 23, Class H Insulation, Self excited, Self regulated, Brushless (From 75 kVA) foot mounted with single bearing design. The alternator shall confirm to IS 4722, BS 5000 and IEC 34 and shall be suitable for tropical conditions.   3.ALTERNATOR CONTROL PANEL Floor mounting type, totally enclosed, vermin proof, louvered steel fabricated SWG 14 Control panel suitable for the above Generator comprising of • Voltmeter • Ammeter • MCB / MCCB / ACB (As per the rating of DG ) • Frequency Meter • Ammeter Selector Switch • Voltmeter selector Switch • INDICATING LAMP • L1setrunning • L2 LOAD ON   4.BATTERIES & BATTERY LEADS Battery of rated A/H Capacity of STANDARD / EXIDE make to cater the electrical starting of the genset along with the battery leads.

BEARINGS      Replaceble, precision type steel backed shells with higher load bearing capacity      Superior resistance to corrosion and wear due to copper-lead formulation. Lead-tin overlay      for fast and effective break-in surface. -> CAM SHAFT      Induction hardened, alloy steel, broad lobe cam shafts precisely control valve and injector      lobes. Replaceable precision type cam bushes Hardened, roller type cam shaft followers      longer cam and follower life. -> CONNECTING RODS      I beam section, drop forged, alloy steel connecting rod with easy in-frame engine overall      capability. Rifle drilled pressure lubrication of pistion pins. -> COOLING SYSTEM      Belt driven centrifugal water pump. Large volume coolant passages provide even flow of      coolant around cylinder liners, valves and injectors . System desiged for Indian ambient      temperature. Corrosion inhibitor coolant is environment friendly, checks foaming, scaling,      rust ,corrosion . controls pH value and neutralises acids. -> COUNTER BALANCER      Crankshaft driven, Located in Oil pan. -> CRANK SHAFT      High tensile strength, vacuum degassed medium carbon alloy steel forging . Induction      hardened pins and journals for high fatigue resistance, Toughened core provides better      compressive fatigue strength.. Dynamically balance in all planes. -> CYLINDER BLOCK      Alloy cast iron with removable wet liners. Cross bolt support to main bearing cap provides      extra strength and stability. -> CYLINDER HEADS      Alloy cast iorn, stress relieved , Each head serves two cylinders.. Designed for maximum      coolant flow across the cylinder and for optimum swirl for better combustion /fuel efficiency      and emissions. Valve seat inserts are corrosion resistant. -> GEAR TRAIN      All gears are hardened helical gears driven from crank shaft and located at front the block. -> CYLINDER LINERS      Replaceable wet liners dissipate heat faster than dry liners and easily replaced without      reboring the block. -> FUEL SYSTEM      MICO / BOSH self adjusting direct injection. Mechanical governor for droop governing      characteristics. This system has high pressure in fuel lines and high injection pressure in      the cylinder for efficient fuel combustion and lesser fuel leakages. -> LUBRICATION      Efficient, forced lubricating oil system using gear pump with internally drilled passages in      cylinder block and heads to feed all bearings and other parts including piston cooling . Oil      cooler, full flow filters and by-pass filters maintain oil quality, thus maximising oil and      engine life. -> PISTONS AND PISTON PINS      Aluminium alloy with Ni-resist ring carrier piston to minimise piston ring leakages.Cam      tuned barrel shaped to compensate for thermal expansion. Piston pin ism fullfloating , solid      steel retained by snap rings. -> TURBOCHARGERS WITH AFTER COOLER      Holset turbocharger with after cooler mounted on the engine converts energy of exhaust      gases for more power , improved fuel economy, altitude compensation and lower exhaust      temperature , smoke and noise levels. -> VALVES      Chrome plated type intake and exhaust valves. Wear resistant face on exhaust valve. -> STANDARD EQUIPMENT      # Radiator with blower fan      # Coolant      # Paper element filters- Fuel Filter & Lube Oil Filter      # Flywheel housing and Flywheel      # Holset flexible coupling / Directly coupled      # Dry type air cleaners and Vaccum indicators      # Residential silencer      # Stainless steel exhaust flexible bellow      # Electric starter ( 12 V / 24 V )      # Battery charging alternator      # Local instrument panel     # Safety controls (trip) :     # High Water Temperature (HWT) Low Lube Oil Pressure (LLOP) -> OPTIONAL EQUIPMENT      # Air starter      # EFC governor      # Over speed stop      # Lube Oil and coolant heaters -> INSTRUMENT PANEL      # Lub Oil temp. gauge      # Starting switch with key      # Water Temp. gauge      # Lub oil pressure gauge      # Hour meter with RPM indicattor      # Indicating lamp, push button   2.ALTERNATOR Synchronous alternator of KIRLOSKAR / CROMPTON / STAMFORD / LEROYSOMER make rated @ 1500 RPM at 0.8 lagging PF at 415 V suitable for 50 Hz 3 phase system. The alternator shall be in SPDP enclosure, IP 23, Class H Insulation, Self excited, Self regulated, Brushless (From 75 kVA) foot mounted with single bearing design. The alternator shall confirm to IS 4722, BS 5000 and IEC 34 and shall be suitable for tropical conditions.   3.ALTERNATOR CONTROL PANEL Floor mounting type, totally enclosed, vermin proof, louvered steel fabricated SWG 14 Control panel suitable for the above Generator comprising of • Voltmeter • Ammeter • MCB / MCCB / ACB (As per the rating of DG ) • Frequency Meter • Ammeter Selector Switch • Voltmeter selector Switch • INDICATING LAMP • L1setrunning • L2 LOAD ON   4.BATTERIES & BATTERY LEADS Battery of rated A/H Capacity of STANDARD / EXIDE make to cater the electrical starting of the genset along with the battery leads.   5.FUEL TANK 8 Hours Capacity, Floor mounting type made from 14 SWG MS sheet, duly painted and fitted with inlet outlet , returns connection , air vent , drain value , Gate value , Over flow , Level guage , level indicator and Breather.   6.ARRANGEMENTS The above Engine and alternator would be Directly coupled. Both the units including the radiator / heat exchanger mounted on a rigid fabricated base frame would be of MS STEEL suitably machined to ensure perfect alignment of the engine and alternator with rigid construction to ensure minimum vibration. The base frame would be provided with lifting facilities and pre-drilled foundation holes suitable for permanent installation on pre-prepared concrete foundation.  

Radiator with Blower Fan / Vee Belt driven axial flow blower    # Flywheel to suit flexible coupling with starter ring    # Mico fuel pump with mech. Governor    # Oil bath type air cleaner    # Exhaust Silencer    # Lub Oil filter    # Fuel Oil filter    # 12V Electric starting system    # Battery charging alternator / Static Battery Charger    # ON / OFF START Key ->OPTIONAL    Lub Oil pressure gauge, Water temp. gauge

Specification For Standard Automatic Failure Panel   -> Floor Mounting , Cubicle Type Automatic Panel comprising of :     # 1 - TP Contractor with HRC Fuses for MAINS (Upto 380 KVA)     # 1 - TP Contractor with HRC Fuses & Thermal Overload Relay        for Alternator (Upto 380 KVA)     # 2 - Neutral Contactor for MAINS & ALTERNATOR     # 1 - Volt meters with Selector Switches for MAINS & ALTERNATOR     # 1 - Ammeter with Selector Switch, Frequency Meter     # 3 - Current Transformers     # 1 - Battery Charger , consisting of Transformer/Rectifier with        surge protection network DC Voltmeter, DC Ammeter Selector        Switch for Trickle, Off & Boost & Current Adjust     # 1 - Mains supply Failure Monitor (voltage sensing )     # 1 - Supply Failure Timer & Restoration Timer     # 1- Control Unit incorp. 3 impulse automatic engine start/stop and failure to sart'       lockout     # 1- Off/Manual/Auto/Test Selector Switch     # 1 - ON/OFF Circuit Switch -> LAMP INDICATION & TRIP ANNOUNCIATION SCHEME Condition                                Indication                        Trip Announciation Main ON                                           Yes                                                   - Generator ON                                   Yes                                                   - Load on Mains                                  Yes                                                   - Load on Generator                            Yes                                                   - Low Lube Oil Pressure                       Yes                                                   - High Water Temperature                   Yes                                                   - Set Fails to Start (with Alarm)           Yes                                                   - Push Buttons/ Switchesfor: Engine Start/ Stop, Alternator Contactor ON/ Off & Mains Contactor Off / AMF Test WORKING OF THE PANEL : -> AUTO MODE When the supply fails, the 'Mains supply failure Monitor' operates after preset time of approx. 10 Secs. This actuates the '3 impulse Engine Start' control unit The Control Unit gives three starting impulses with an interval of 1-5 Secs, if the engine starts at the first impulse , this unit shuts off. If not , it gives further two impulses during which time, if the engine does not start, the unit shuts off, activating the audio-visual alarm for 'Set Fails to Start'. On Starting of the engine, the alternator switch gear closes automatically after the preset time of 1-10 Secs. When the Mains Supply is restored , the 'Restoration Timer' operates and after the preset time of 10 Secs., the load is automatically transferred to the Mains, and the Generator shuts down.   -> TEST MODE By operating the 'AMF Test' Push Button, the conditions of Mains Failure are stimulated as explained in the Auto Mode above, without disturbing the supply through mains Switchgear. -> MANUAL MODE The DG Set operates as a standard manual operated set , and all its functions are carried out manually by means of 'Engine Start/Stop' and 'Alternator Contactor ON/OFF' Push Buttons.